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INSTALLATION INSTRUCTIONS
WARNING:
.0 DESCRIPTION
.
This manual provides installation and operating instructions for the
Altronic CD200 ignition system. It is recommended that the user
read this manual in its entirety before commencing operations.
.2
The Altronic CD200 ignition system consists of these basic components:
•
Cd200 Unit - 791070-x or 791080-x
•
Magnetic Pickup Sensor (one per system)
•
Input Harness (one per system)
•
Output Harness (one or two per system)
•
Ignition Coils (one per cylinder)
.3
The system requires a battery or a suitable power supply
with a nominal 12 Vdc or 24 Vdc
unit steps up the DC supply voltage to charge an en-
ergy storage capacitor and contains a microproces-
sor and solid-state switching devices to release the
stored energy to the ignition coils in programmed,
timed sequence according to the application. Holes
(one per cylinder) in a special timing disc signal the
position of the engine crankshaft to the electronic
circuitry in the CD200 unit. One additional hole trails
after the last cylinder hole; this is the index signal that
another revolution has started. Ignition timing may be
varied by means of a manual switch, an analog timing signal
and/or engine RPM.
.4
The CD200 system can operate as a single-firing or double-firing
(firing on exhaust stroke) system up to twelve (12) cylinders. These
instructions detail 4-, 6-, 8-, 10- and 12-cylinder, single-firing ap-
plications using CD200 units 791070-6, 791070-8, 791070-12, and
791080-6, 791080-8.
.5
As shipped from the factory, the CD200 is in the auto-detect mode
and is set up for a trigger disc running at camshaft speed
TION
9.4). The setup is programmable by the use of the PC compatible
CD200 terminal program
with the unit. The programming of the unit is done via the RS-485
Modbus compatible communications port.
DEVIATION FROM THESE INSTRUCTIONS MAY LEAD TO
IMPROPER OPERATION OF THE MACHINE WHICH COULD
CAUSE PERSONAL INJURY TO OPERATORS OR OTHER
NEARBY PERSONNEL.
(see FIG. 1 and FIG. 2)
(see FIG.
3). The CD200
(FIGS. 14 & 15)
provided on a CD delivered
ALTRONIC CD200
IGNITION SYSTEM
FORM CD200 II 5-07
(see SEC-
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Table of Contents
Related Manuals for Altronics CD200
Summary of Contents for Altronics CD200
- Page 1 (firing on exhaust stroke) system up to twelve (12) cylinders. These instructions detail 4-, 6-, 8-, 10- and 12-cylinder, single-firing ap- plications using CD200 units 791070-6, 791070-8, 791070-12, and 791080-6, 791080-8. As shipped from the factory, the CD200 is in the auto-detect mode (see SEC- and is set up for a trigger disc running at camshaft speed TION 9.4). The setup is programmable by the use of the PC compatible (FIGS.
- Page 2 INSTALLATION INSTRUCTIONS 2.0 CD200 UNIT Select a location for the CD200 unit that will be at least 24 inches (600 mm) away from the ignition coils and spark plug leads. In ad- dition, the mounting location must be relatively cool, preferably one benefitting from the engine fan stream (if any); the outside case...
- Page 3 200°F. (95°C.) during operation. 5.0 PRIMARY WIRING The CD200 system requires a battery or other DC power source providing 12-28 Vdc for running and a minimum of 8 volts for en- FIG. 3 gine starting.
- Page 4 CD200 unit. 6.0 SHUTDOWN WIRING The CD200 system is shut-off by interrupting the DC power to the unit; use a switch or relay with contacts rated 24 VDC, 10 amps - NOTE: Do NOT run the input FIG.
- Page 5 On cranking, there will be a delay of two disc revolutions—after the after system installation, power is ON and the engine begins rotating—before the CD200 unit commences outputs to the ignition coils. This delay is to allow iden- verify correct ignition timing...
- Page 6 The Connection Setup window will appear. The port being selected for use with the CD200 should also be set for 9600 baud, gramming of unit 791070-12. no parity, 200 ms time out (8 data bits and 1 stop bit). The PC will now be set to communicate with the CD200. Set the ID# for the...
- Page 7 ALTRONIC CD200 IGNITION SYSTEM TEST DISC FLAG: When this status flag is ON, the CD200 will test for a match of the in- NOTE: The disc test for a coming signal pattern observed by the CD200 to the Disc Type speci- specific number of pulses is fied. When enabled, this test is performed after synchronization to not performed in auto detec- the disc pattern and before initiating firings. When the pattern does not match the setting, the ignition will not fire and the diagnostic...
- Page 8 RUN SPEED SETTING: This numeric entry configures the transition speed from crank to run. This setting also determines the transition of the diagnostic LED on the CD200 from crank to run modes. Default setting = 500 RPM. 9.2 LOW VOLTAGE SETTING: This numeric entry configures the threshold for the low voltage di- agnostic of the DC input voltage to the CD200. If the DC voltage de- creases to this setting, the diagnostic LED on the CD200 will blink the appropriate code. The CD200 will continue to try to fire outputs regardless of the voltage. Default setting = 6 volts. 9.3 ENABLE LED DIAGNOSTICS FLAG: When this LED status flag is activated, the blink code diagnostics for primary and secondary outputs are enabled. Default setting is ON.
- Page 9 ALTRONIC CD200 IGNITION SYSTEM 9.8 ENERGY FLAGS: Select one of four output energy settings for the CD200: Bit 1 OFF Bit 0 OFF Vcap = 150 volts Bit 1 OFF Bit 0 ON Vcap = 160 volts Bit 1 ON...
- Page 10 TDC. This number is the LINE UP ANGLE setting less the TOTAL RETARD. Slight differences between this number and the timing reading obtained with a timing light may occur since the LINE UP ANGLE entered may differ slightly from the actual angular position of the engine when the input pulse event is received by the CD200. In this event, the Spark Timing number should be made to agree with the timing light by changing the LINE UP ANGLE entry. 0.3 SWITCH POSITION: Indicates the current position of the manual timing switch on the CD200 case.
- Page 11 During a startup, indicates the number of purge cycles remaining before the outputs are activated. 0.3 SUPPLY VOLTAGE: Indicates the measured DC voltage supply level to the CD200. 0.4 SPARK REF. (A, B, C, ETC.): Indicates the current spark reference number for each cylinder.
- Page 12 0.37 SECONDARY OPEN: When red, indicates that an open secondary condition has been de- tected within the last ~2 seconds. 0.38 CRANKS LOG: Indicates the total number of crank attempts seen by the CD200. 0.39 STARTS LOG: Indicates the total number of successful starts seen by the CD200 as defined by the Run Speed setting input. 0.40 CYCLE LOG: Total number of engine cycles seen by the CD200.
- Page 13 CD200 IGNITION BLINK CODES: Whenever the LED Diags status flag is enabled (blue) by using the CD200 Terminal Software, the blinking pattern of the LED on the side of the CD200 case can be used to interpret the general status of the CD200 diagnostics without the use of the Terminal Software. Within each group of conditions described below, the possible di- agnostic states are listed according to their number of blinks. The LED is ON for about 2 seconds between each blink sequence and the blinks occur evenly spaced at a faster rate.
- Page 14 3.0 RS-485 COMMUNICATIONS, MODBUS RTU 3. The CD200 is compliant to the Modicon Modbus RTU standard. Maximum number of registers that can be read at one time is limit- ed to 32. Maximum number of booleans that can be read at one time is limited to 256.
- Page 15 ALTRONIC CD200 IGNITION SYSTEM 3.3 READ ONLY STATUS REGISTERS ADDRESS FUNCTION 30001 Input Bit Mirror 10016–10001 30002 Input Bit Mirror 10032–10017 30003 Input Bit Mirror 10048–10033 30004 Input Bit Mirror 10064–10049 30005 30006 Timing xxx.xDEG signed 30007 Switch Position 1–8...
- Page 16 Disk Lineup to TDC xx.x DEG 40007 Insertion Ret MIN=2.0 DEG xx.x 40008 Purge Delay Cycles 0-255 40009 RPM Over Speed Setpoint 40010 RPM Crank to Run Threshold 40011 Low Supply Voltage Limit xx.xV 40012 SLAVE ANGLE xx.x DEG FORM CD200 II 5-07...
- Page 17 ALTRONIC CD200 IGNITION SYSTEM 3.7 12 READ/WRITE REGISTERS FOR CYLINDER RET. TABLE ADDRESS FUNCTION 40017 OUTPUT 1 EXTRA RETARD 40018 OUTPUT 2 EXTRA RETARD 40019 OUTPUT 3 EXTRA RETARD 40020 OUTPUT 4 EXTRA RETARD 40021 OUTPUT 5 EXTRA RETARD 40022...
- Page 18 LOOP RET MAP 15mA 3.75V 40065 LOOP RET MAP 16mA 4.00V DEG 40066 LOOP RET MAP 17mA 4.25V 40067 LOOP RET MAP 18mA 4.50V DEG 40068 LOOP RET MAP 19mA 4.75V 40069 LOOP RET MAP 20mA 5.00V DEG FORM CD200 II 5-07...
- Page 19 ALTRONIC CD200 IGNITION SYSTEM 3.0 31 READ/WRITE REGISTERS FOR RPM RET. TABLE ADDRESS FUNCTION 40070 RPM RET MAP 0000 RPM 40071 RPM RET MAP 0100 RPM 40072 RPM RET MAP 0200 RPM 40073 RPM RET MAP 0300 RPM 40074 RPM RET MAP 0400 RPM...
- Page 20 7 READ/WRITE MISC. REGISTERS ADDRESS FUNCTION 40122 Crank Counter 40123 Start Counter 40124 Cycle Counter HIGH 40125 Cycle Counter LOW 40126 REG40005 MSB=BAUD LSB=NODEID fixed 9600n81:node1 40127 Cold Boot (powerup) Count 40128 Warm Boot ( reset ) Count FORM CD200 II 5-07...
- Page 21 ALTRONIC CD200 IGNITION SYSTEM FIG. DIMENSIONS AND SPECIFICATIONS, 79070-X www.altronicinc.com...
- Page 22 INSTALLATION INSTRUCTIONS FIG. 2 DIMENSIONS AND SPECIFICATIONS, 79080-X FORM CD200 II 5-07...
- Page 23 ALTRONIC CD200 IGNITION SYSTEM FIG. 3 DC POWER HOOKUP www.altronicinc.com...
- Page 24 INSTALLATION INSTRUCTIONS FIG. 4 PICKUP AND DISC HOLE DETAIL FORM CD200 II 5-07...
- Page 25 ALTRONIC CD200 IGNITION SYSTEM FIG. 5 WIRING: 4-CYLINDER ENGINES www.altronicinc.com...
- Page 26 INSTALLATION INSTRUCTIONS FIG. 6 WIRING: 6-CYLINDER ENGINES FORM CD200 II 5-07...
- Page 27 ALTRONIC CD200 IGNITION SYSTEM FIG. 7 WIRING: 8-CYLINDER ENGINES www.altronicinc.com...
- Page 28 INSTALLATION INSTRUCTIONS FIG. 8 WIRING: 2-CYLINDER MAN 2842 LE FORM CD200 II 5-07...
- Page 29 ALTRONIC CD200 IGNITION SYSTEM FIG. 9 WIRING: 2-CYLINDER MAN 2842 LE — USING CAMSHAFT GEAR www.altronicinc.com...
- Page 30 INSTALLATION INSTRUCTIONS FIG. 0 79070-2 WITH FIRST ENGINE FIRING ANGLE ≤ 60° FORM CD200 II 5-07...
- Page 31 ALTRONIC CD200 IGNITION SYSTEM FIG. 79070-2 WITH FIRST ENGINE FIRING ANGLE > 60° www.altronicinc.com...
- Page 32 INSTALLATION INSTRUCTIONS FIG. 2 HOOK-UP FOR ANALOG TIMING SIGNAL FORM CD200 II 5-07...
- Page 33 ALTRONIC CD200 IGNITION SYSTEM FIG. 3 PC TO CD200 www.altronicinc.com...
- Page 34 INSTALLATION INSTRUCTIONS FIG. 4 TERMINAL PROGRAM: 4-, 6-, 8-CYLINDER ENGINES FORM CD200 II 5-07...
- Page 35 ALTRONIC CD200 IGNITION SYSTEM FIG. 5 TERMINAL PROGRAM: 2-CYLINDER ENGINES www.altronicinc.com...
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