mic520_525_530_series_en-rev1_8

MOTORTECH GmbH I Hogrevestrae 21-23 I 29223 Celle I Germany Phone: +49-5141 93990 I Fax: +49-5141 939999 I [email protected] I www.motortech.de

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

Models MIC520, MIC525, MIC530 21.10.2009 Rev. 1.8

ClassI,Div2,Group C,D



WARNING! Read this entire manual and all other publications pertaining to the work to be performed before installing, operating, or servicing this equipment. Practice all plant and safety instructions and precautions. Failure to follow instructions can cause personal injury and/or property damage.

The engine should be equipped with an overspeed shutdown device to protect against runaway or damage to the engine with possible personal injury or loss of life, or property damage

CAUTION! To prevent damage to a control system that uses an alternator or battery-charging device, make sure the charging device is turned off before disconnecting the battery from the system.

Electronic controls contain static-sensitive parts. Observe the following precautions to prevent damage to these parts. Discharge body static before handling the control (with power to the control turned off, contact a grounded surface and maintain contact while handling the control).

IMPORTANT DEFINITIONS

WARNING!indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION!indicates a potentially hazardous situation which, if not avoided, could result in damage to equipment.

NOTE!provides other helpful information that does not fall under the warning or caution categories.



Contents

ELECTROSTATIC DISCHARGE AWARENESS ...............................................................................6

CHAPTER 1 GENERAL INFORMATION ............................................................................................7

Introduction .......................................................................................................................... 7 Operational Features ........................................................................................................... 7 Limitations ........................................................................................................................... 8 Disposal of the Ignition Control System .............................................................................. 8 Models available .................................................................................................................. 9 Accessories ......................................................................................................................... 9 Unpacking ............................................................................................................................ 12 Safety ................................................................................................................................... 12

CHAPTER 2 Technical Data ..............................................................................................................14

CHAPTER 3 MIC500 series IGNITIONSYSTEM INSTALLATION ...................................................17

Installation ........................................................................................................................... 17 Ignition Control Module ........................................................................................................ 17 Trigger Disc ........................................................................................................................ 18 Camshaft Pickup .................................................................................................................. 21 Installation of a Disc with Reluctor Pins .............................................................................. 22 Mounting a Trigger Disc with Slots ...................................................................................... 23 Passive Pickup .................................................................................................................... 24 Setting the Ignition Timing Adjustment Range and Positioning the Trigger Disc .................. 25 Wiring Requirements ........................................................................................................... 27 General ............................................................................................................................... 27 MIC500 series CD Ignition System Electrical Connections and Pin Functionality ............... 27 RS-232 Port ........................................................................................................................ 28 Input Power ......................................................................................................................... 28 Output Harnessing ............................................................................................................... 34 Ignition coils and high tension leads ..................................................................................... 35 Ignition-Timing Adjustment ................................................................................................... 36 Programming examples ...................................................................................................... 37 2 step adjustment .............................................................................................................. 38 Permissive Start ................................................................................................................... 39 Contact Switch ..................................................................................................................... 40 Additional functions .............................................................................................................. 40 Ignition-energy levels ........................................................................................................... 40



Cylinder-to-Cylinder timing ................................................................................................... 38 Activating Cylinder-to-Cylinder timing .................................................................................. 40 Example of a 6 cylinder engine ............................................................................................ 41 Misfiring control of primary wiring ......................................................................................... 42 Startup procedure ................................................................................................................ 42 Shutdown procedure ............................................................................................................ 43 Operational features ............................................................................................................ 43 Trigger-signal-check ............................................................................................................ 43 Input-signal, fault recognition ............................................................................................... 44

CHAPTER 4 PROGRAMMING ...........................................................................................................45

Short guide for every single step of programming the MIC 500 series ignition control unit .. 45 Programming the MIC500 series with a Laptop .................................................................. 48 Programming the MIC500 series with the Hand Held Programmer ..................................... 48 Programming of Parameters ............................................................................................... 50 Programmable Parameters ................................................................................................. 51 Example of Programming an MIC500 series ........................................................................ 65

CHAPTER 5 MAINTENANCE AND TROUBLESHOOTING ..............................................................68

Maintenance ....................................................................................................................... 68 Faults Causes and Remedial Action .................................................................................... 69 Troubleshooting ................................................................................................................... 70 Input Fault Diagnosis ........................................................................................................... 70 Fault Detection in the low or High Voltage Ignition Circuits .................................................. 72 Self-test Function ................................................................................................................. 73

Legal Provisions .................................................................................................................................74

Copyright Regulations .......................................................................................................................75

Abridged instructions .........................................................................................................................76

PROGRAMMING OVERVIEW ............................................................................................................86



Illustrations and Tables

Figure 2.1 MIC500 series dimensions of the ignition control module........................................... 14 Figure 2.2 MIC500 series vibration-mounts and Ground-strap ...........................................................15 Figure 2.3 MIC500 series connectors .................................................................................................15 Figure 2.4 MIC500 series electrical data .............................................................................................16 Figure 3.1 Trigger disc mechanical requirements ..............................................................................20 Figure 3.2 Mounting of Camshaft Trigger Disc ..................................................................... 21 Figure 3.3 Mounting of a Trigger Disc with Slots .................................................................. 23 Figure 3.4 Mounting of a Passive Pickup ............................................................................................24 Figure 3.5 Example of Flywheel Positioning ......................................................................... 25 Figure 3.6 Basic Setting 40 BTDC ...................................................................................... 26 Figure 3.7.1 MIC520 series Wiring Chart ............................................................................. 29 Figure 3.7.2 MIC525 series Wiring Chart ............................................................................. 30 Figure 3.7.3 MIC530 series Wiring Chart ............................................................................. 31 Figure 3.8 Manual timing adjustment .................................................................................. 34 Figure 3.9 05 Volt Retarded Curve .................................................................................... 35 Figure 3.10 05 Volt Advanced Curve ................................................................................ 35 Figure 3.11 Two-step Adjustment ....................................................................................... 36 Figure 3.12 Timing offset .................................................................................................... 37 Figure 3.13 GO/NOGO output ............................................................................................. 37 Figure 4.1 MIC500 series Sequence Tables ........................................................................ 51 Figure 4.2 Potentiometer span CW position ...................................................................... 55 Figure 4.3 Maximum limit retarded ignition........................................................................... 58 Figure 4.4 Analog input signal 420mA limit ........................................................................ 59 Figure 4.5 Speed points BP1 to BP5 .................................................................................... 62 Figure 4.6 Speed-points example ........................................................................................ 64 Figure 5.1 OscilloscopeSquare Wave Signal ................................................................... 70

Table 3.1 Example of a six cylinder engine ......................................................................... 40 Table 3.2 Misfiring control ................................................................................................... 40 Table 3.3 Programmed data ............................................................................................... 65



Electrostatic Discharge Awareness

All electronic equipment is static-sensitive, some components more than others. To protect these components from static damage, you must take special precautions to minimize or eliminate electrostatic discharges.



Chapter 1 General Information

Introduction

The MIC500 series is a microprocessor-controlled, capacitive discharge ignition system capable of supplying ignition energy for certain two- or four-stroke gas engines with two(2) to sixteen(16) cylinders (single-firing) or two(2) to sixteen(16) cylinders (double firing).

The number of cylinders and the corresponding firing pattern, as well as the trigger disc configuration, are programmed individually.

Integral to the MIC500 series is one timing adjustment potentiometer. This has a programmable ignition span of maximum 38 crankshaft degrees. Additional methods of adjustment are by means of an integral speed curve and a linear 4-20 ma analog signal. A two-stage adjustment is also possible with the aid of the analog signal and the use of an external potentiometer.

The MIC500 series is capable of firing up to sixteen cylinders with either one or two spark plugs per cylinder. In the case of two spark plugs per cylinder, the corresponding ignition coils must be wired in series.

A cam or crankshaft trigger disc is used to provide relative position reference. This information is sent to a microprocessor that controls the ignition timing. Thus, the system is alerted whenever a new cycle has begun.

The MIC500 series is CSA certified for use in hazardous locations.

Operational Features

In order to ensure perfect operation of the ignition control system, observe the maintenance instructions given in Chapter 4.

The MIC500 series has several functional features to ensure proper operation: Trigger signal check Input signal fault recognition Shutdown Manual ignition timing adjustment

ClassI, Div2, Group C,D



Limitations

The MIC500 series ignition control system provides ignition energy for two to 16-cylinder gas engines. Trigger disc configurations are listed in Chapter 2.

The MIC500 series is intended only for use on the engines listed in the configuration table (see Chapter 3). It also needs to be programmed to comply with the appropriate engine.

Disposal of the Ignition Control System

The MIC500 series is comprised of only a small amount of surplus refuse that may be disposed of in the usual manner as industrial waste.



Models Available

Ignition Control Unit

06.00 520 MIC520 up to 8 outputs 06.00.525 MIC525 up to 12 outputs 06.00.530 MIC530 up to 16 outputs

Accessories

Unshielded Harnesses

Input Harnesses - length to be specified. Standard length: 160

Active pickup 06.02.501-L Input harness, active pickup 06.02.502-L Input harness, DUAL active pickup Magnetic pickup 06.02.505-L Input harness, magnetic pickup 06.02.506-L Input harness, DUAL magnetic pickup Hall-effect pick up 06.02.510-L Input harness, hall-effect pick up 06.02.511-L Input harness, DUAL hall-effect pick up

Output Harnesses - length to be specified. Standard length: 240

06.02.604-L Output harness for MIC 520, 4 outputs 06.02.608-L Output harness for MIC 520, 8 outputs 06.02.612-L Output harness for MIC 525, 12 outputs 06.02.616-L Output harness for MIC 530, 16 outputs



Shielded Harnesses

Input Harnesses - length to be specified. Standard length: 80 Active pickup 95.30.501-L Input harness, active pickup 95.30.502-L Input harness, DUAL active pickup Magnetic pickup 95.30.505-L Input harness, magnetic pickup 95.30.506-L Input harness, DUAL magnetic pickup

Hall-effect pick up 95.30.510-L Input harness, hall-effect pick up 95.30.511-L Input harness, DUAL hall-effect pick up

Output Harnesses - length to be specified. Standard length: 80; 160 95.30.608-L Output harness, conduit, MIC520 95.30.612-L Output harness, conduit, MIC525 95.30.616-L Output harness, conduit, MIC530

Unshielded Pickups

Magnetic pickup 66.60.001-125 5/8-18 UNF x 1.25 Magnetic pickup 66.60.001-175 5/8-18 UNF x 1.75 Magnetic pickup 66.60.001-250 5/8-18 UNF x 2.50 Magnetic pickup 66.60.001-400 5/8-18 UNF x 4.00 Magnetic pickup 66.60.001-600 5/8-18 UNF x 6.00 Magnetic pickup Hall-effect pickup 66.60.002-175 5/8-18 UNF x 1.75 Hall-effect pickup 66.60.002-250 5/8-18 UNF x 2.50 Hall-effect pickup 66.60.002-450 5/8-18 UNF x 4.50 Hall-effect pickup Active pickup 66.60.003-60 M12 x 1 x 60 mm Active pickup 66.60.003-100 M12 x 1 x 100 mm Active pickup



Shielded Pickups Magnetic pickup 95.70.001-125 5/8-18 UNF x 1.25 Magnetic pickup 95.70.001-175 5/8-18 UNF x 1.75 Magnetic pickup 95.70.001-250 5/8-18 UNF x 2.50 Magnetic pickup 95.70.001-400 5/8-18 UNF x 4.00 Magnetic pickup 95.70.001-600 5/8-18 UNF x 6.00 Magnetic pickup Hall-effect pickup 95.70.002-175 5/8-18 UNF x 1.75 Hall-effect pickup 95.70.002-250 5/8-18 UNF x 2.50 Hall-effect pickup 95.70.002-450 5/8-18 UNF x 4.50 Hall-effect pickup Active pickup 95.70.003-60 M12 x 1 x 60 mm Active pickup 95.70.003-100 M12 x 1 x 100 mm Active pickup

Unshielded Pickup Leads Active pickup 06.71.007 Pickup lead 400, 90 connector Magnetic pickup 06.71.001 Pickup lead 400, 90 connector Hall-effect pickup 06.71.002 Pickup lead 400, 90 connector

Shielded Pickup Leads lengths to be specified Active pickup 95.60.050-L Pickup lead, 90 connector

Magnetic pickup 95.60.010-L Pickup lead, 180 connector 95.60.020-L Pickup lead, 90 connector

Hall-effect pickup 95.60.030-L Pickup lead, 180 connector 95.60.040-L Pickup lead, 90 connector

Coils Trigger Devices Trigger Discs Trigger Magnets Trigger Pins High Tension Leads

See Catalog



Unpacking Check the shipping container for evidence of mishandling during shipping. Carefully remove the MIC500 series from the shipping container. Check the hardware for evidence of damage during shipping.

Safety The operator of the equipment must ensure:

That all persons concerned with the installation, maintenance, and repair of the MIC500 series ignition control system have entirely read and completely understood this operating manual.

That all persons authorized to operate the gas engine have received detailed instruction and have been warned about possible dangers.

WARNING!

In no case should the following parts of the ignition control system be touched, removed, or disconnected while the engine is running:

Ignition coils and boots

High-tension leads

Low-voltage circuit leads

Harness connectors

The MIC500 series ignition control system design conforms to high technology principles and is operationally safe. The equipment may suffer damage or pose the threat of injury if the following safety precautions are not observed. Only trained and authorized personnel must operate the gas engine.

Before commencing any work involving the installation, operation, resetting, matching, maintenance, or repair of the ignition control system, the equipment must be disconnected from the power supply and safeguarded against switching on the power.

The harness must be removed.

Safety devices must not be disassembled or inactivated.

Avoid all work that might impair the function of the ignition control system.

Only operate the ignition control system provided if it is in perfect condition, and inform all concerned personnel 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, including those that 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.



WARNING! Switch off the engine; disconnect the power supply, and lock out both before commencing any installation work.

Make sure that the system was programmed for your engine before attempting to operate the MIC500 series ignition system. An improperly installed or programmed system may lead to engine damage and could pose threat of personal injury to operators. Ensure that ignition timing is set to engine manufactures recommendation and that is actually checked with a timing light.



Chapter 2

Technical Data

2.1 MIC500 series Dimensions of the Ignition Control Module

(159

mm) 6,25''

(178

mm) 7,00''

(142mm) 5,59

''

(8)

(223,5mm) 8,79''

(196mm) 7,71''

(217,5mm) 8,56''

RS-2

32

(77mm) 3,03''



2.2 MIC500 series Vibration Mounts and Ground Strap

2.3 MIC500 series Connector Arrangement MIC520

Input 10 pin Output 10 pole socket

MIC525


MIC530




2.4 MIC500 series Electrical Data

WARNING! The MIC500series accepts 12 V to 24 VDC and automatically recognizes the selected supply voltage. The supply voltage must be maintained within the following limits: 10 VDC minimum 32 VDC maximum A supply voltage below 10 VDC will impair the operation of the ignition control module. Voltages above 32 VDC could damage the ignition control module.

16 ignition outputs for engines with o 2 16 cylinders for single firing and o 2 16 cylinders for double firing

Two selectable ignition timings

Suitable for 2- and 4-stroke engines

12 V and 24 VDC supply voltage

voltage limits: min. 10 VDC max. 32 VDC

20 A peak current

3,5 A average current consumption

100 300 V primary voltage (Programmable energy)

Max. 50 KV secondary voltage

Max. 600 msec spark duration at 20 KV (depends on selected coil)

Negative grounded

Temperature range: Control module: - 40 F to 158 F - 40 C to 70 C Ignition coils: - 40 F to 212 F - 40 C to 100 C



Chapter 3 Installation

CAUTION! Read this section carefully before assembling the components!

Installation

A complete ignition system consists of: The MIC500 series ignition control module Input harness Output harness Ignition coils (one per cylinder / two per cylinder) High tension leads A speed pickup for the flywheel trigger disc or an active or hall-effect pickup for the

camshaft trigger disc A pick up lead A trigger disk, magnets or pins

Before commencing with the final assembly, it is advisable to carefully consider the mounting locations of the individual components. A good choice of mounting locations ensures proper operation of the entire ignition system.

Ignition Control Module

Considerations for MIC500 series mounting location: Specified environmental limits

Temperature Vibration

Cable length to Power supply Pickup units The distance between the ignition control module and the pickup unit should not exceed 30 ft / 10 m. Away from high voltage or high current devices or high electromagnetic radiation RFI/EMC sources Clearance for cables



CAUTION! Never do any welding work on the engine or chassis when the ignition control module is mounted on the engine or connected to the chassis. This could destroy the ignition control module!

Mount the ignition control module in such a way that the cable harness may be easily routed downwards.

Mount the ignition control module on a secure bracket near the engine using the vibration-damping mounts supplied with the unit.

The ignition control module must be grounded to the engine through the mounting hardware by use of the ground strap supplied with the unit.

The ignition control module should be mounted in cool location free of vibration.

____________________________________________________________________________

Trigger Disc

Depending on the engine design, there are four possibilities to trigger the ignition:

A Trigger disc mounted on crankshaft. This location is required for 2-stroke engines (double firing on 4-stroke engines; ignition fires on compression and exhaust stroke). The magnetic disc is equipped with a certain number of holes, slots, or magnets. This disc may use a passive or active pickup unit.

B Trigger disc mounted on camshaft. This location is recommended for 4-stroke engines (single firing, ignition fires on compression stroke only). The non-magnetic disc is equipped with a specified number of magnets or holes. Using a disc with holes or pins for the camshaft requires an active or hall effect pickup.

C Trigger disc with 2 to 8 magnets or pins mounted on the flywheel and an additional disc with a single INDEX magnet or pin mounted on the camshaft

Note: Both pickups need to have the same configuration: Hall effect or active pickup

D If a trigger disc cannot be mounted easily, use a trigger device that is mounted to the former magneto drive and has a built in timing disc

The crankshaft and camshaft pickup should be mounted at a convenient position providing easy access for maintenance.

A massive and vibration-free bracket must be prepared for mounting the pickup.



2-Stroke and Double-Firing 4-Stroke Engines Mount the trigger disc on the flywheel, pulley disc, or vibration damper. The trigger disk must rotate at crankshaft speed.

CAUTION! Ensure that the trigger disc is perfectly centered!

Instead of using a disc, holes can be drilled into the flywheel. For the basic setting, outlined in Figure 2-6, the hole, slot or pin "A" has to be opposite the pickup-mounting hole.

For engine timing see Setting the Ignition Timing Adjustment Range later in this chapter.

Single-Firing 4-Stroke Engines Mount the trigger disc on the camshaft or any drive running at one-half engine speed.

For the basic setting outlined in Figure 3.1, the hole, slot, or pin A has to be opposite the pickup-mounting hole.

For engine timing see Setting the Ignition Timing Adjustment Range later in this chapter.

CAUTION! Ensure that the trigger disc is perfectly centered!



3.1 Trigger Disc Mechanical Requirements

Configuration N (Degrees) M (Degrees) Trigger2+1 60 180 33+1 40 120 44+1 30 90 55+1 20 72 66+1 20 60 78+1 15 45 910+1 15 36 1112+1 Not recomended for camshaft mounting

NOTES: 1. Note direction of rotation. 2. Inch (mm) as specified.

Minimum Diameter

4 (100)

M, (360/M places) See table

.236 (6)

see table

INDEX



Camshaft Pickup

The camshaft pickup generates a square wave signal.

CAUTION! It is essential to take account of the camshaft slope in order to prevent the reluctor pin from striking the pickup!

In order to avoid defective signals, the mounting surface must be free of sharp edges, holes, or other irregularities.

Preparations for Active Pickup Prepare a massive and vibration-free mount for the active pickup unit. The bracket must be positioned in such a way that the pickup is directed at a right angle to

the surface of the disc. Drill and tap a hole to accept the chosen pickup.

WARNING! Ensure that metal chips, filings, or shavings from drilling and tapping operations do not remain in the engine!

3.2 Mounting of Camshaft Trigger Disc

NOTE! Tightening torque for the camshaft pickup: max. 15 N m (11 lb-ft)!



Installation of a Disc with Reluctor Pins

In order to avoid wrong signals, the mounting surface must be free of sharp edges, holes, or other irregularities.

WARNING! Take care to ensure that the speed pickup does not rotate with the lock nut, thereby causing the gap to alter.

It is essential that the threaded hole be perpendicular to the surface of the ring gear!

Screw the active pickup into the tapped hole. The pickup must point to the "A" trigger pin at a right angle. The air gap between the tip of the reluctor pin and the surface of the pickup should be

approximately 0.03 inch / 0.75 mm. This gap is best achieved by following these steps:

Screw in the pickup until it just makes contacts with the tip of the trigger pin. Unscrew the pickup by a turn counter clockwise direction.

Now tighten the lock nut, taking care to ensure that the pickup does not rotate at the same time.

Crank the engine back and forth several times by a few degrees to make sure that the trigger pin does not strike the pickup surface.

NOTE! Trigger Pin may be a magnet or reluctor pin!



Mounting a Trigger Disc with Slots

3.3 Mounting a Trigger Disc with Slots

CAUTION! In order to avoid wrong signals, the mounting surface must be free of sharp edges, holes, or other irregularities.

It is essential that the threaded hole is perpendicular to the surface of the ring gear!

WARNING! Take care to ensure that the speed pickup does not rotate with the lock nut, thereby causing the gap to alter.

Screw the speed pickup into the tapped hole. The pickup must point to the "A" trigger slot at right angles. The air gap between the surface of the trigger disc and the nose of the pickup should be

approximately 0.03 inch / 0.75 mm. This gap is best achieved by following these steps:

Screw in the pickup until it just makes contact with the surface of the trigger disc. Unscrew the pickup by turn counterclockwise direction.

Now tighten the lock nut, taking care to ensure that the pickup does not rotate at the same time.

Crank the engine back and forth several times by a few degrees to make sure that the pickup does not strike the trigger disc.



Passive Pickup

The flywheel pickup senses an AC signal if a passive pickup is used.

3.4 Mounting of a magnetic Pickup

Speed sensor

Index

Flywheel 1:1

30

.025



Setting the Ignition Timing Adjustment Range and positioning the Trigger Disc

The maximum ignition timing range of the MIC500 series ignition control module is 38 degrees. The maximum range is achieved with a base setting of 40 BTDC or more. Lower base settings reduce the ignition timing range.

The base setting is the crank angle of cylinder #1, on the compression stroke, when the trigger disk A pin is aligned with the pickup. Typically the base setting target is the most advanced ignition timing the engine needs plus 2 or more degrees. The MIC500 series ignition control module requires 2 degrees for computation time.

To obtain the correct base setting: 1. Bar the engine over until cylinder #1 is on compression stroke. Turn backwards to

40 BTDC or any other selected crank angle for the base setting. 2. Rotate the trigger disk on the camshaft or crankshaft to align pin A with the pickup. 3. Securely fasten the trigger disk to the camshaft or crankshaft. 4. Setting must be between 25 and 60 BTDC on cylinder #1. Be sure the range fits the

engine ignition timing requirements.

3.5 Example of Flywheel Positioning

basic setting: 40 BTDC

ignition adjustment range: 38BTDC to TDC



3.6 Example: Basic Setting 40 BTDC

Example A: Basic setting: 40 BTDC Ignition adjustment range: 38 BTDC to TDC (38 total)

Example B: Basic setting: 30 BTDC Ignition adjustment range: 28 BTDC to TDC (28 total)

Example C: Basic setting: 50 BTDC Ignition adjustment range: 48 BTDC to 10 BTDC (38 total)

NOTE! The system does not allow After Top Dead Center (ATDC) ignition timing.



Wiring Requirements General

NOTE! Wire exposed beyond the shield must be as short as possible

MIC500 series CD Ignition System Electrical Connections and Pin Functionality

WARNING! The engine power supply must be disconnected and safeguarded against switching on before beginning any work on the MIC500 series. Do not make any power supply connections into live power circuits!

Never switch on the ignition control module without the output leads connected to the unit.

An improperly installed ignition system may lead to engine damage and could pose threat of personal injury to operators.

All components (ignition control module, ignition coils, and all lead screens) must be grounded to ensure electromagnetic compatibility.

CAUTION! Take care to ensure that the following minimum and maximum voltages to the MIC500 series are complied with:

Minimum 10 VDC Maximum 32 VDC

Input voltages beyond these values might damage the MIC500 series.

NOTE! Emergency shutdown of the MIC500 series is achieved by switching off the input power. Emergency shutdown devices must be rewired in order to switch off the input power.



RS-232 Port

The MIC500 series is programmed via RS-232 using a null modem cable. Any fault indications will be transmitted to a PC or Laptop through the RS-232 link.

Input Power

Pins A (+) and B () connect the MIC500 series to input power from an external power source. The rated operating range is 1032 VDC. (steady state operation from 10 to 18 VDC is allowable but may not be able to achieve 100% energy). Connect the buffered positive power supply terminal through a 6 A Slo-Blo fuse to the harness and the reference to pin A. To ensure proper operation, the minimum input voltage (12 V) must be maintained even under load. The cross-section of the power supply leads must be at least 14 AWG / 2.5 mm



Example 6-Cylinder Viewing Diagram

10 Socket

W ir ing D iag ram : Contact +4-20mA/-4-20mA and Loop P ower (24VDC)

- Shield

E brown

C green

F white

loop power (24VDC)

+ 4-20mA

- 4-20mA

TWO WIRE TRANSMITTER

10 Socket

W ir ing D iag ram : Contact +4-20mA/-4-20mA and Loop Power (24VD C)

- Shield

loop power (24VDC)

+ 4-20mA

- 4-20mA

FOUR WIRE TRANSMITTER

- V- I+ I

+ V

E brown

C green

F white

10 Socket

IGNITION Start

IGNITION Stop

W ir ing D iag ram : Contact Start/Stop

10 Socket

IGNITION Schedule A

IGNITION Schedule B

W ir ing D iag ram : Contact Schedu le A/B

D white D white

10 Socket

W ir ing D iag ram : Power Supp ly

A (+) 24 VDC

B (-) 24 VDC

6A SLO BLO

Fuse

A red

B black6A SLO BLO

Fuse



10 Socket

GO / NOGO OUTPUT / ALERT RELAY

(+) 24 VDC

W ir ing D iag ram : Go/NoGo Ou tput

J brown

A

B C

D

EF

Reset

(+) PICK UP SIGNAL

8-24 VDC Pick up Power

(-) PICK UP SIGNAL

W ir ing D iag ram : Hall E ffect S ensor

10 SOCKET

G white

H brown

I green

A

B C

D

EF

Reset

(+) PICK UP SIGNAL

PICK UP (24 VDC + SUPPLY)

(-) PICK UP SIGNAL

10 SOCKET

W ir ing D iag ram : In duct iv e Sensor

G black

H brown

I blue



3.7.1 MIC520 WIRING CHART


NOTE! Leads which are not connected for use must be isolated, as they could be internally connected to a power source.

Pole Function Harness colour code

A + 24Volt supply RedB - Ground BlackC (+) 4 - 20 mA GreenE (-) 4 - 20 mA BrownF Loop Power (24 VDC) WhiteD Contact A/B or START / STOP White 1,5mmG (+) Pick Up Signal BlackH MPU Power BrownI (-) Pick Up Signal BlueJ GO / NOGO Contact Brown 1,5mm


A Output Cylinder 1 in firing order RedB Output Cylinder 2 in firing order YellowC Output Cylinder 3 in firing order GreenD Output Cylinder 4 in firing order BrownE Output Cylinder 5 in firing order BlueF Output Cylinder 6 in firing order OrangeG Output Cylinder 7 in firing order PurpleI Output Cylinder 8 in firing order Grey

H Shutdown lead or Panel Output Power. Max. 20mA at 300 V Primary White

J Ground Black









A Output Cylinder 1 in firing order RedB Output Cylinder 2 in firing order YellowC Output Cylinder 3 in firing order GreenD Output Cylinder 4 in firing order BrownE Output Cylinder 5 in firing order BlueF Output Cylinder 6 in firing order OrangeG Output Cylinder 7 in firing order PurpleI Output Cylinder 8 in firing order GreyK Output Cylinder 9 in firing order PinkL Output Cylinder 10 in firing order White/RedM Output Cylinder 11 in firing order White/YellowN Output Cylinder 12 in firing order White/Green

H Shutdown lead or Panel Output Power.Max. 20 mA at 300V Primary White

J Ground Black









A Output Cylinder 1 in firing order RedB Output Cylinder 2 in firing order YellowC Output Cylinder 3 in firing order GreenD Output Cylinder 4 in firing order BrownE Output Cylinder 5 in firing order BlueF Output Cylinder 6 in firing order OrangeG Output Cylinder 7 in firing order PurpleK Output Cylinder 8 in firing order GreyL Output Cylinder 9 in firing order PinkM Output Cylinder 10 in firing order White/RedN Output Cylinder 11 in firing order White/YellowP Output Cylinder 12 in firing order White/GreenR Output Cylinder 13 in firing order White/BlackS Output Cylinder 14 in firing order White/VioletT Output Cylinder 15 in firing order White/OrangeU Output Cylinder 16 in firing order White/Blue

H Shutdown lead or Panel Output Power.Max. 20 mA at 300V Primary White

J Ground Black



Output Harness

NOTE! Failure to correctly install the ring-type terminals will affect engine performance and may shorten the life of the ignition system. The MIC500 series is a negative ground system. When replacing positive ground systems by the MIC500 series, the wiring must be altered accordingly. The ignition coils must be connected in series in case of double-firing engines!

Route the individual primary wires to the corresponding ignition coil as indicated in the wiring chart, taking care to avoid: Sharp edges; Hot manifolds; Rotating parts that could damage the installation of the wiring.

Route the primary wires through metallic, grounded sleeves.

Trim each low voltage wire to the proper length and crimp ring-type terminals onto their free ends. The ring-type terminals should be suitable for 16 AWG/1.5 mm gauge wire and should have a hole diameter of 0.2"/5mm.

Use only proper crimping tools for attaching ring-type terminals.

Use the remaining primary wire (or other wire 16 AWG/1,5 mm that is temperature resistant to 221 F/105 C and Insulation breakdown strength of 600V) along with the ring type terminals to jumper the negative ignition coil terminals

On each engine cylinder bank, the first and last coil must be grounded to the engine block. Glue a DIN 4844-W8 safety label the engine at a clearly visible position.

Safety Label DIN 4844 W8



Ignition Coils and High-Tension Leads:

Securely mount each ignition coil on the engine as close to the spark plug as possible.

Avoid mounting the coils on or near hot manifolds or where ambient temperatures exceed 212 F/100 C.

Only install high-tension leads that are suitable for the application and meet the authorities certification

Ensure that the high-tension leads are as short as possible.

Apart from the spark plug resistance, an additional resistance of 2 to 5 k must be provided in all non-shielded high tension leads. We recommend the use of spark plug connectors with integrated resistors.

NOTE! On non-shielded installations we recommend spark plug connectors with integrated resistors.



Ignition Timing Adjustment

The MIC500 series features two stages of variable timing adjustment: Manual adjustment (potentiometer) 420 mA analog signal (both directional)

Each method is operator-adjustable and provides up to 38 adjustment range. The resolution of the timing setting is accurate to 0.25 crankshaft degrees.

Manual Adjustment

CAUTION! An incorrect timing setting may lead to engine damage!

The desired timing may be precisely set by manually rotating the potentiometer. Manual timing adjustment is possible with the engine running. Do not apply voltage to terminals C, D, or E of the harness. The desired timing setting may be obtained by rotating the potentiometer.

The span between the extreme CW and CCW position is max. 38 depending on the configuration of the MIC500 series (see Setting Potentiometer Span in Chapter 4).

The potentiometer has no STOP position

3.8 Manual Timing Adjustment

Manual Timing adjustment

CAUTION! When choosing the correct timing setting, it is essential to strictly adhere to the values specified by the engine manufacturer.



Analog Input:

The second timing control method requires a linear 4 20 mA signal, e.g. provided by a remote potentiometer, a boost pressure sensor or a knock detection system.

By means of a steady linear 4 20 mA input signal, the timing can be shifted further towards advanced and/or retard over a max range of 38 degrees.

Programming Examples:

3.9 4 20 mA Retarded Curve

40 4 mA 30 potentiometer setting 30 BTDC

10 RET (retarded) span 20 20 mA

0

3.10 4 20 mA Advanced Curve

40 20 mA 35 20 ADV (advanced) span

15 potentiometer setting 15 BTDC 4 mA 5 0

NOTE! The slope of the Y-(4-20 mA) curve can be selected / programmed by the two curve end points



2-Step Adjustment:

A simple 2-step adjustment is possible with the aid switching contact D (10-pin Input connector to ground). If the engine is operated, e.g. with two different grades of fuel, it is generally advisable to alter the ignition timing when changing from one type of fuel to another.

3.11 2-Step Adjustment

Proceed as follows:

Open the switch. Change parameter I/P for Stop to A/B. Select the required DELTA/OFFSET Angle to the main setting, (maximum 38 crank angle) and program the unit accordingly By manual adjustment, first set the ignition timing to the programming advanced position by using the integrated potentiometer of the MIC500 series control unit.

Close the switch.

You may now switch between the two fixed timing settings by opening and closing the switch in lead F of the 10-pin connector.

Minus 24 VDC

D programmed for A/B



3.12 Timing Offset A/B

Integrated potentiometer setting

20

5 timing offset programmed 15

Permissive Start / GO/NOGO OUTPUT

Pin J is the Permissive Start or Go/NoGo output. It is a solid-state output, capable of sinking up to 150 mA, that should be used to enable/disable fuel flow to the engine directly or in combination with other devices (lube oil pressure, etc.). Anytime the ignition stops due to normal stop sequence, overspeed, or when a fault is detected, the Permissive Start output will de-energize. Upon start-up, the Permissive Start output will not energize until all timing signals are verified and the ignition is starting to fire. Figure 3.13 shows a likely set up for this output.

3.13 GO / NOGO Output

24 VDC (+)

MIC 500 series

Max. 150 mA GO / NOGO lead (J)

for

ex

FUEL

VA

LVE



Contact Switch

Pin D can be set up as a switch to select between the timing schedules A or B. It can also be configured as an Auxiliary Shutdown Input. This needs to be programmed. The default is for Auxiliary Shutdown.

Additional functions

Ignition Energy Levels

Depending on the gas quality and the application, it is possible to vary the available ignition energy. You may set any value between 15 100 % (155V-300V). Fast burning gases like propane require relatively small energy, whereas slow burning gases like sewage gas require high energy and long spark duration.

To change the preset values proceed as follows: Press "E" Press "F1" Enter new value Press "Enter" Press "F5" to save changes

Primary Voltage to Coil vs Energy (%) 15% = 155V 20% = 160V 30% = 180V 40% = 200V 50% = 220V 60% = 240V 70% = 255V 80% = 275V 90% = 290V 100% = 300V

Cylinder-to-Cylinder-Timing

The Cylinder-to-Cylinder-Timing allows a change of individual cylinders to optimize ignition firing. The ignition timing of each cylinder can be shifted by 2 from the global setting. However, you should only use this option, if a suitable instrumentation is available to analyse the position with the most effective compression, in order to immediately judge the result.



Activating Cylinder-to-Cylinder-Timing

NOTE! ADV is advanced from the global setting RET is retarded from the global setting

See sequence of connections, respectively firing order.

Press "F5" to save all cylinder adjustment values. Leave the cylinder-to-cylinder menu by pressing ESC". Now you can disconnect the programming tool from the MIC500 series without losing any data. The MIC500 series primary outputs do not consider the direction of rotation. Pin "A" is always the first cylinder of the firing order, "B" is the second, "C" the third etc.

The function cylinder-to-cylinder-adjustment is started during engine operation by pressing [C] using the programmer.

The following menu is displayed:

CYL #1 x.xx ADV / RET F1 CHANGE value can be changed F2 NEXT call next ignition output F3 PREVIOUS back to previous output F5 SAVE save

To change values proceed as follows:

[F2] until ignition output of the cylinder, which is to be optimized, appears

[F1] 1ST TYPE IN NEW enter delta value (2ADV to 2RET) THEN ENTER

[ENTER]

F1 ADVANCE change to position advanced from global setting F2 RETARD change to position retarded from global setting

F5 save



Example of a 6-Cylinder Engine Wiring vs No of cylinder in firing order: 3.1

Outputs of IC500 A B C D E F

Firing order of engine 1 5 3 6 2 4

Misfiring Control of Primary Wiring:

The MIC500 series continuously checks all outputs of the unit and the connection to the ignition coils. When calling this function by pressing "M", you get the following screen: 3.2 Normal

Outputs A B C D E F G K L M N P R S T U

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Miss / sec =0*

Fault: Example shows loss of one cylinder (primary wire F) Outputs A B C D E F G K L M N P R S T U

1 1 1 1 1 0 1 1 1 1 1 1 1 1 1 1 Miss / sec =15*

From this table the wiring fault can be traced through the harness output designation letter * Misfiring per second

Error 1 = NO ERRORS 0 = ERROR

Miss/sec = value between 0 and 255 can be programmed as maximum misfire rate = 0 disables the function

ESC to leave this menu

WARNING! An improperly installed ignition system may lead to engine damage and could pose threat of personal injury to operators. When set to 0 or 255 this feature is disabled.

CAUTION! When using the Shutdown lead (Panel Power Output) the Misfire Control should be disable by setting the Misfire rate to zero.



Start-Up Procedure:

Before starting the engine recheck all wire and plug connections.

Proper ignition can be verified by cranking the engine with the fuel valve closed.

Apply input power to the ignition control module and verify proper firing by checking each spark plug lead with an inductive timing light.

Once satisfied that the ignition system is functioning properly, follow the normal engine starting procedure.

Start the engine with the fuel valve open, increase to rated speed, and set ignition timing to exact position.

Open switch in lead F (4-20mA Loop Power) and set proper timing by turning the external potentiometer.

When using timing schedule B for alternative timing, close contact input D and check timing.

Is the timing not as desired, you need to correct your offset timing as described in Setting offset angle

Shutdown Procedure

After shutdown, ensure that the MIC500 series is disconnected from the power supply before unplugging any harness connector.

Operational Features

In order to ensure perfect operation of the ignition control system, observe the maintenance instructions given in section Maintenance. The MIC500 series has several functional features to ensure proper operation:

Trigger signal check

Input signal fault recognition

Shutdown

Manual ignition timing adjustment



Trigger Signal Check:

The ignition control module compares the trigger-timing signal with the pin count and the firing patterns pre-programmed. Should any discrepancy occur, the ignition control module will shut down following one further complete revolution of the flywheel.

Input Signal Fault Recognition:

If a fault is detected in the pickup circuit during operation, the MIC500 series automatically shuts down. The cause of the fault must be corrected before the engine can be restarted.

Control Functions

A list of the various control functions can be found in Chapter 4 Programming.



Chapter 4 Programming

Short Guide for every Single Step of Programming the MIC500 series Ignition Control Unit:

(1) Sequence-Number see configuration table

(2) Reset BTDC position in degrees of trigger disc basic setting. Trigger pin / hole "A" is opposite to pickup.

(3) Overspeed Overspeed RPM. When reached, ignition will shut down.

(4) Security Speed Speed that inhibits operation of the contact switch.

(5) MIS / SEC Max. allowed misfiring rate. When exceeded, ignition will shut down. To disable set to 0 or 255.

(6) Cyl to Cyl enable enables Cyl-to-Cyl-timing feature Cyl to Cyl disable disables Cyl-to-Cyl-timing feature

(7) Contact I/P for STOP contact switch lead D of 10-pin input connector enabled for ON/OFF of ignition.

Contact I/P for A/B enabled for operation with 2 timing schedules

(8) Pot timing enable potentiometer function enabled Pot timing disable potentiometer function disabled

(9) Speed curve in A in A -enable speed curve for timing curve A enabled Speed curve in A not in A -disable speed curve for timing curve A disabled

(10) 4 20 mA in A in A - enable 4 20 mA analog for timing curve A enabled 4 20 m A in A not in A - disable 4 20 mA analog for timing curve A disabled

(11) Speed curve in B in B - enable speed curve for timing curve B enabled Speed curve in B not in B disable speed curve for timing curve B disabled

(12) 4 20 mA in B in B - enable 4 20 mA analog for timing curve B enabled 4 20 mA in B not in B - disable 4 20 mA analog for timing curve B disabled



(13) Pot CCW xx.xx ADV Potentiometer, max. angle at max. CCW position ADV BTDC RET most retarded (TDC)

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

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

(16) Max RET A: most retarded timing limit for timing curve A (max. limit to retard)

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

(18) Max RET B: most retarded timing limit for timing curve B (max. limit to retard)

(19) Offset only for"2-point adjustment when (7) contact I/P is programmed for A/B timing schedule

(20) 4 mA timing adjustment of timing point given by analog signal (input signal:4 mA)

ADV = "x" degree advanced from potentiometer setting RET = "x" degree retarded from potentiometer setting

(21) 20 mA timing adjustment of timing point given by analog signal (input signal: 20 mA)

ADV = "x" degree advanced from potentiometer setting RET = "x" degree retarded from potentiometer setting

(22) Default setting Fixed value which is automatically activated when the 4-20 mA signal is lost or out of range

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

(24) BP 1 speed point 1 new speed = desired speed point angle = Advanced or retarded angle from potentiometer setting



BP 2 speed point 2 new speed = desired speed point angle = Advanced or retarded angle from potentiometer setting

BP3 speed point 3 new speed = desired speed point angle = Advanced or retarded angle from potentiometer setting



(25) End / Start ESC quit programming mode

Programming the MIC500 series with a Laptop

The scope of supply includes a CD disk and an interface cable. The software is designed for WINDOWS. Install the software on your laptop according to the instructions attached to it.

When using a laptop, please note that all capital letters in this manual have to be entered as such letters. That means you have to use the [SHIFT]-key and the appropriate key for the letter.

[F10] is used to quit program,reset supply and follow engine starting procedure



Programming the MIC500 series with the Hand-Held Programmer 06.05.001-110VAC or 06.05.008 - 240 VAC

Before the first use the hand-held programmer has to be configured.

Switch on the programmer.

Press [Shift] + [CTRL] + [F1] at the same time.

The first parameter will be displayed.

Baud = 9600, press [F1] to continue in lines until "9600" is displayed. [F2] next

Data Bits = 7, press [F1] to continue in lines until "7" is displayed. [F2] next

Parity = ignore, press [F1] to continue in lines until "ignore" is displayed [F2] next

Display Pe enabled, press [F1] to continue in lines until "enabled" is displayed [F2] next

Repeat = fast, press [F1] to continue in lines until "fast" is displayed [F2] next

Echo disabled, press [F1] to continue in lines until "disabled" is displayed [F2] next

Handshake disabled, press [F1] to continue in lines until "disabled" is displayed [F2] next

Self-Test disabled, press [F1] to continue in lines until "disabled" is displayed [F2] next

Power Save enabled, press [F1] to continue in lines until "enabled" is displayed [F2] next

[F5] Save

Now the hand-held programmer is ready for use. NOTE!



When programming with the hand-held programmer only capital letters are possible.

General Programming Commands

Commands:

[F1]: Change Parameter

[F2]: Next

[F3]: Previous

[F4]: Help

[F5]: Save

Sub Menus:

[C]: Cyl. to Cyl. menu

[E]: Energy level menu

[H]: Hours and Software Rev. no.

[M]: Misfires and Misses/sec

[S]: Self-test

Main Screen:

RPM: 0 speed

4 20 mA: 0 analog input signal

SPARK: 00,00 ignition timing

ENERGY LEVEL : 100 % energy in %

STATUS: READY ignition status



Programming the Control Unit in General

Prior to operating the MIC500 series it has to be configured in regards to engine and application. Programming carried out using: Laptop call for software CD PDA WIN CE call for software CD Hand held programmer (06.05.001 / 06.05.008)

The connection is established via a serial computer interface and a cable to the RS232 port of the MIC500 series control unit.

NOTE! The MIC500 series may only be programmed by trained personnel. A password is required, which you kindly ask for at your MOTORTECH Distributor. In case of access to programming, please proceed as follows:

Switch on voltage supply to the MIC500 series, connect the MIC500 series to the computer and start the terminal software.

The main screen is shown.

Press [ESC] If the engine is already in operation, the ignition module cannot switch to the programming mode.

Now you will be prompted to enter your PASSWORD.

Enter password and press [Enter] to reach programming level. The first parameter is displayed. (If password is unknown, call your nearest Distributor).

General information for setting parameters:

[F1] change parameter and confirm with[Enter].Every parameter change has to be saved with[F5]

[F2] next parameter

[F3] previous parameter

[F4] help for current parameter

[F5] save parameter

[ESC] quit programming level and start MIC500 series

([F10] quit program, reset supply voltage and follow engine starting procedureonly used in



Comupter Software )

After setting MIC500 series parameters, we recommend to separate supply voltage in order to reset the MIC500 series.

If voltage supply is disconnected for 20 seconds, it is ensured that all possible faults are reset.

Programming the MIC500 Series Controller

The MIC500 series has 24 programmable parameters, which have to be set before operation.

Connect the hand-held programmer or your PC / Laptop to the RS232 port of the MIC500 series.

Switch on 12 / 24 V supply voltage to control unit

Press [Shift] and [ESC] at the same time. A message is displayed.

Enter PASSWORD

Press [Enter]. The first parameter is displayed.

If you press [F1], you can enter a new parameter by using the figure keys. Confirm with [Enter]. Every single changed parameter has to be saved with [F5].

[F2] scrolls ahead to next parameter

[F3] scrolls back to previous parameter

[F4] brings up a short clarification to the current parameter

To quit the parameter menu press [Shift] and [ESC] at the same time.

1. Programmable Parameters:

Sequence Number

See configuration table for appropriate sequence no.

[F1] or [F2] scrolls through sequence table

[F1] enter sequence no. and press [Enter] [F5] [F2].

[F4] shows the selected sequence no. and the firing pattern



MIC500series Sequence Table

MIC500 SEQ

NO. OF OUTPUTS

TRIGGER DISC

FIRING DEGREES

DISC LOCATION Uneven Wiring

1 2 2+1 360-360 CAM2 3 3+1 240-240 CAM3 3 3+1 120-120 CRANK4 6 3+1 50-70 CRANK5 6 3+1 30-90 CRANK6 6 3+1 90-30 CRANK7 2 4+1 90-90 CRANK8 4 4+1 180-180 CAM9 4 4+1 90-90 CRANK

10 8 4+1 20-70 CRANK11 8 4+1 60-30 CRANK12 8 4+1 45-45 CRANK13 13

8 8

4+1 4+1

30-60 60-120

CRANK CAM

14 5 5+1 72-72 CRANK15 5 5+1 144-144 CAM16 10 5+1 54-90 CAM17 12 6+1 30-90 CAM18 12 6+1 40-80 CAM19 12 6+1 48-72 CAM20 12 6+1 56-64 CAM21 6 6+1 120-120 CAM22 3 6+1 60-180 CRANK A-B-E MIC52023 4 6+1 120-60 CRANK A-C-D-F MIC52024 6 6+1 60-60 CRANK25 7 7+1 102,8-102,8 CAM26 7 7+1 51,43-51,43 CRANK27 8 8+1 90-90 CAM28 8 8+1 45-45 CRANK29 8 8+1 45-45 CRANK A-C-E-G-L-N-R-T MIC53030 16 8+1 10-35 CRANK31 16 8+1 21-24 CRANK32 16 8+1 22,5 CRANK33 16 8+1 30-60 CAM34 4 8+1 90-90 CRANK A-E-L-T MIC53035 10 10+1 36 CRANK36 5 10+1 72 CRANK A-C-E-G-K MIC53037 12 12+1 50-70 CAM38 12 12+1 55-65 CAM39 12 12+1 60-90 CAM40 12 12+1 75-45 CAM41 16 8+1 20-70 CAM42 12 6+1 90-30 CAM43 12 6+1 42-78 CAM44 16 8+1 60-30 CAM45 16 8+1 45-45 CAM46 12 6+1 60-60 CAM47 16 8+1 50-40 CAM48 16 8+1 40-50 CAM49 12 6+1 50-70 CAM50 12 6+1 55-65 CAM51 12 6+1 75-45 CAM52 12 6+1 45-75 CAM



2. Basic Settings (Position of Reset Signal)

NOTE! The MIC500 series is programmed in a way that the top dead center (TDC) is at 0. Ignition timing before top dead center (BTDC) are named "Degrees Before Top Dead Center". Ignition timing after top dead center (ATDC) are named "Degrees After Top Dead Center".

The basic setting of the trigger disc or the trigger pins / holes may be between 50 BTDC to 25 BTDC. The MIC500 series program allows electronical compensation of mistakes made when setting the trigger points. We recommend the index position to be at 40 BTDC, this allows a timing span from 38 BTDC to 0 BTDC

For final adjustment, start the engine, set the ignition timing point to the point specified by the engine manufacturer by using a timing light. If done, read timing information on the main screen display.

Correction of Reset Position

If the value is higher than the actual angle set by timing light, the difference in degrees has to be added to the "reset position" programmed. If the value is lower than the actual angle set by timing light, the difference in degrees has to be deducted from the "reset position" programmed.

To make the changes, stop the engine, enter the programming mode (password protected) and change the value by pressing [F1]. Enter new value, press [Enter] and save with [F5]. Quit programming mode with [ESC].



3. Overspeed Limit

Press [F1], enter desired speed for limit, then press [Enter], [F5] and finally [F2].

WARNING! The ignition will be shutdown if overspeed limit is reached!

4. Security Speed

The MIC500 series offers the "Security Speed" as a programmable feature. The desired speed is set by pressing [F1], [(value)], [ENTER] and [F5]. Valid settings reach from 0 to speed limit ("overspeed rpm").

The "Security Speed" is the speed that may affect the operation of contact D. Contact D enables or disables the primary outputs. The Security Speed determines if the outputs are enabled or if the engine speed must go to zero RPM first. If the ignition is firing and the contact is closed and opened below the security speed, the primary outputs will be enabled. With the ignition firing above the security speed, if the contact is closed and then opened, it is necessary to wait for 0 RPM. If the contact is closed when the engine speed goes above the security speed, (the ignition is not firing), opening the contact will enable the primary outputs.

5. Misfiring Rate

The control unit checks every output connection between the control unit and ignition coil. Damaged leads cause misfiring. Here, you can enter a maximum frequency. If this value is exceeded, the ignition will shut down. To disable, set misfire rate to 0 or 255.

Example: At 1500 rpm every cylinder fires 12.5 times per second.

CAUTION! When using the Shutdown lead (Panel Power Output) the Misfire Control should be disable by setting the Misfire rate to zero.

6. Cylinder-to-Cylinder Timing (Toggle with [F1])

MIC500 series units are equipped with Cylinder-to-Cylinder-timing adjustment capability. This allows individual fine-tuning of the ignition timing for each cylinder.

[F1] ENABLE activate [F2] DISABLE deactivate [F5] save



7. Function of Contact Lead D of 10-Pole Input Connector

The contact lead D allows the choice between 2 functions:

CONTACT I/P FOR STOP A/B

F1 CONTACT FOR STOP Ignition can be STARTED and STOPPED via this dry contact lead

F2 CONTACT FOR A/B Switching this lead allows shifting between 2 timing schedules; the offset between A and B can be programmed. It is possible to have a speed and analog curve enabled or disabled for both A and B schedules.

8. Activating Potentiometer

The integrated potentiometer of the MIC500 series can be disabled after making the settings, in order to lock this feature for the operator.

POT TIMING ENABLED / DISABLED F1 ENABLE activated DISABLE deactivated F5 save

9. Speed Curve in Timing Schedule A

The MIC500 series offers programming of a speed curve / speed ramp. That means, depending on the actual engine speed certain timing is chosen. This aims at reaching optimal gas combustion and inproved starting

SPEED CURVE IN A / NOT IN A F1 ENABLE activated / function is used DISABLE deactivated / function is not used F5 save



10. Analog Input Signal for Timing Schedule A

Additionally to the potentiometer adjustment and the speed curve it is possible to change the ignition timing by using the analog input signal.

Example: A knock monitoring system can change the ignition timing linear. In that case the knock monitoring system sends the analog output signal 4 20 mA to the ignition system depending on the level of engine knocking.

4 20 mA IN A / NOT IN A F1 ENABLE activated / function is used DISABLE deactivated / function is not used F5 save

11. Speed Curve in Timing Schedule B

It is possible to program a different speed curve / speed ramp for timing schedule B. This different ignition timing is given depending on actual engine speed. By setting a speed dependent ignition timing an optimal gas combustion can be achieved.

SPEED CURVE IN B / NOT IN B F1 ENABLE activated / function is used DISABLE deactivated / function is not used F5 save

12. Analog Input Signal for Timing Schedule B

Additionally to the potentiometer adjustment and the speed curve it is possible to change the ignition timing by using the analog input signal.

Example: A knock monitoring system can change the ignition timing linear. In that case the knock monitoring system sends the analog output signal 4 20 mA to the ignition system depending on the level of engine knocking.

4 20 mA IN B / NOT IN B F1 ENABLE activated / function is used DISABLE deactivated / function is not used F5 save



13. Setting the Potentiometer Span - CCW Position

The left electrical limit (ccw) of the potentiometer can be set as timing angle.

POT CCW x.xx ADV F1 1ST TYPE NEW enter value F1: ADVANCE BTDC (before top dead center) F2: RETARD most retarded (TDC) F5 save

14. Setting Potentiometer Span CW Position

The right electrical limit (cw) of the potentiometer can be set as timing angle.

POT CW x.xx ADV F1 1ST TYPE NEW enter value F1: ADVANCE BTDC (before top dead center) F2: RETARD most retarded (TDC) F5 save

4.2 Potentiometer Span CW Position

Ignition timing

25

20 CCW-position

CW-position 10

50 500 1000 1500 RPM

Potentiometer-span



15. Timing Schedule A Limit of max. Advanced Ignition

In order to avoid engine damage by addition of the various ignition relevant parameters, it is possible to set a maximum ignition limit.

MAX ADV IN A: xx.xx ADV F1 1ST TYPE NEW: enter value THEN ENTER press [ENTER] F1: ADVANCE BTDC (before top dead center) F2: RETARD most retarded (TDC) F5 save

16. Timing Schedule A Limit of max. Retarded Ignition

In order to avoid engine damage by addition of the various ignition relevant parameters, it is possible to set a minimum ignition limit.

MAX RET IN A: xx.xx ADV F1 1ST TYPE NEW: enter value THEN ENTER press [ENTER] F1: ADVANCE BTDC (before top dead center) F2: RETARD most retarded (TDC) F5 save

Note! The maximum advanced and retarded limit restricts any ignition-curve to this point. Ensure that limits do not interfere with potentiometer and speed curve settings.



4.3 Ignition Limits

Ignition timing

25 MAX limit

20

5 MIN limit

50 500 1000 1500 RPM

17. Timing Schedule B Limit of max. Advanced Ignition

In order to avoid engine damage by addition of the various ignition relevant parameters, it is possible to set a maximum ignition limit.

MAX ADV IN B: xx.xx ADV F1 1ST TYPE NEW: enter value THEN ENTER press [ENTER] F1: ADVANCE BTDC (before top dead center) F2: RETARD most retarded (TDC) F5 save



18. Timing Schedule B Limit of max. Retarded Ignition

In order to avoid engine damage by addition of the various ignition relevant parameters, it is possible to set a minimum ignition limit.

MAX RET IN B: xx.xx ADV F1 1ST TYPE NEW: enter value THEN ENTER press [ENTER] F1: ADVANCE BTDC (before top dead center) F2: RETARD mo

mic520_525_530_series_en-rev1_8

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