Motortech MIC500 Operating Manual
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Motortech MIC500 Operating Manual

Ignition controller
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MIC500 –
IGNITION CONTROLLER
OPERATING MANUAL
MOTORTECH Ignition Controllers
P/N 01.10.030-EN | Rev. 01/2015

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Summary of Contents for Motortech MIC500

  • Page 1 MIC500 – IGNITION CONTROLLER OPERATING MANUAL MOTORTECH Ignition Controllers P/N 01.10.030-EN | Rev. 01/2015...
  • Page 2 © Copyright 2015 MOTORTECH GmbH. All rights reserved. Distribution and reproduction of this publication or parts thereof, regardless of the specific purpose and form, are not permissible without express written approval by MOTORTECH. Information contained in this publication may be changed without prior notice.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS   1 General Information ..................... 7   1.1 What Is the Purpose of this Operating Manual? ............7   1.2 Who Is this Operating Manual Targeted to? ............... 7   1.3 Which Symbols Are Used in the Operating Manual? ........... 7  ...
  • Page 4 TABLE OF CONTENTS   6.1.6 Input and Output Connector – P/N 06.00.515-6 and -8 ......... 38   6.1.7 Input and Output Connector – P/N 06.00.516 ............40   6.1.8 Input and Output Connector – P/N 06.00.517 ............42   6.1.9 Input and Output Connector – P/N 06.00.520 ............44  ...
  • Page 5   8.5.2 Brief Overview of Parameters ................78   8.5.3 Set Sequence Number ..................80   8.5.4 Set Reset Position ..................... 84   8.5.5 Set Overspeed ....................84   8.5.6 Set Security Speed .................... 85   8.5.7 Set Misfire Rate ....................86  ...
  • Page 6 TABLE OF CONTENTS   10.3.3 Testing Pickup Signal ..................114   10.3.4 Running a Self Test ..................116   10.3.5 Customer Service Information ................117   10.3.6 Returning Equipment for Repair / Inspection ............ 117   10.3.7 Instructions for Packaging the Equipment ............118  ...

  • Page 7: General Information

    1 GENERAL INFORMATION Read through this operating manual carefully before use and become familiar with the machine. Installation and start-up should not be carried out before reading and understanding this document. Keep this manual readily available so that you can reference it as needed. 1.1 What Is the Purpose of this Operating Manual? This manual serves as an aid for the installation and operation of the product and supports the technical staff with all operating and maintenance tasks to be performed.

  • Page 8: Which Abbreviations/Acronyms Are Used In The Operating Manual

    1 GENERAL INFORMATION Danger This symbol indicates warnings for danger to life, especially due to high voltage. Read these warning notices carefully and take the mentioned precautionary measures. 1.4 Which Abbreviations/Acronyms Are Used in the Operating Manual? In the manual or the user interface, the following abbreviations / acronyms are used: Abb.
  • Page 9 Abb. Term Description Explanation Revolutions Per Revolutions per Unit for speed Minute minute Top Dead Center Rev. 01/2015...

  • Page 10: Safety Instructions

    Mark the operating location of the ignition system with the corresponding standardized warning symbol. MOTORTECH equipment is manufactured as state of the art and therefore safe and reliable to operate. Nevertheless the equipment can cause risks or damages can occur, if the following instructions are not complied with: –...

  • Page 11: Electrostatic Discharge Hazards

    – Operate the equipment only while it is in proper condition. – Investigate all changes detected while operating the gas engine or ignition system. – Ensure compliance with all laws, directives and regulations applicable to the operation of your system, including such not expressly stated herein. –...
  • Page 12 2 SAFETY INSTRUCTIONS Explosion hazard! The replacement of parts or assemblies can impair compliance with CSA Class I, Division 2 (Group C, D), T4. Explosion hazard! Never remove the equipment while the device is connected to a power source unless the system is not located in an explosive environment. Risk of burning! The surfaces of the system may heat up to high temperatures.

  • Page 13: Proper Disposal

    2.4 Proper Disposal After the expiration of its service life, MOTORTECH equipment can be disposed of with other commercial waste, or it may be returned to MOTORTECH. We will ensure its environmentally friendly disposal.

  • Page 14: Intended Use

    The ignition controllers of the MIC500 series use information supplied by the pickup to precisely determine the correct timing for the respective outputs. An event type N+1 trigger disc serves as transmitter.

  • Page 15: Product Description

    4 PRODUCT DESCRIPTION 4.1 Product Overview The following properties of the devices from the MIC500 series differ as follows: Test port / Device type Number of outputs Voltage for pickup monitor voltage P/N 06.00.507 30 V DC 24 V DC P/N 06.00.508...

  • Page 16: Technical Data

    Class I, Division 2, Group C and D, T4 – CSA Std C22.2 No. 142-M1987 (Reaffirmed 2004) – CSA Std C22.2 No. 213-M1987 (Reaffirmed 2004) The ignition controllers of the MIC500 series are additionally certified as per the following directives/regulations: – EMC Directive 2004/108/EC –...
  • Page 17 Rev. 01/2015...
  • Page 18 4 PRODUCT DESCRIPTION Rev. 01/2015...
  • Page 19 The Company: MOTORTECH GmbH Hogrevestrasse 21 - 23 29223 Celle declares that the products: Ignition controller MIC500 Intended purpose: to be used on gas-Otto-engines complies with the provisions of the following EC Directives: EMC Directive 2004/108/EC Low Voltage Directive 2006/95/EC...

  • Page 20: Mechanical Data

    4 PRODUCT DESCRIPTION 4.2.2 Mechanical Data The devices of the MIC500 series have the following mechanical characteristics: Feature Value Dimensions see chapter Overview Drawings on page 23 Weight 2.1 kg (4.7 lbs) Shape of device see chapter Overview Drawings on page 23 Climatic environmental -40 °C to +70 °C (-40 °F to +158 °F)

  • Page 21: Electrical Data

    Depending on device type (see Input and Output Wiring on the Controller on page 28) Electrical Data for Inputs and Outputs The inputs and outputs of the MIC500 ignition controllers have the following electrical data: Inputs and outputs Values 4-20 mA input...

  • Page 22: Interfaces

    Baud rate: 9,600, data bits: 8, stop bit: 1, parity: none – Plug connection: D-SUB, 9-pole – Maximum lead length: 5 m 4.2.7 Requirements for External Equipment External equipment shall fulfill the input and output specifications of the MIC500. Rev. 01/2015...

  • Page 23: Overview Drawings

    4.2.8 Overview Drawings P/N 06.00.507, P/N 06.00.508: P/N 06.00.511, P/N 06.00.520, P/N 06.00.525, P/N 06.00.530, P/N 06.00.550: Rev. 01/2015...
  • Page 24 4 PRODUCT DESCRIPTION P/N 06.00.513, P/N 06.00.514, P/N 06.00.515-6 and -8, P/N 06.00.516, P/N 06.00.517: All device types: Rev. 01/2015...
  • Page 25 Device Components Pos. Labeling Description Function RS232 connection Connection of the ignition controller to a computer or a hand-held programmer for configuration and status monitoring (see Adjustments on page 64). Timing adjustment potentiometer Potentiometer for manual timing adjustment (see Manual Timing Correction on page 61).

  • Page 26: Installation Instructions

    Check the contents for completeness and verify that the device type meets your application requirements. Scope of Supply The scope of supply of the MIC500 ignition controllers consists of the following components: – Ignition controller MIC500 –...

  • Page 27: Installation Of The Ignition Controller

    The device must not be installed directly on or at the engine, as vibration and heat may cause damage to electronic components. The installation of the MIC500 ignition controller is implemented on a fixed bracket or a wall near the engine. Always use the included vibration dampers and the ground strap. The...

  • Page 28: Wiring Of The Device

    6 WIRING OF THE DEVICE 6.1 Input and Output Wiring on the Controller Operational safety! All connector screws and screw joints must be adequately tightened. Compliance with the following tightening torques is mandatory: – RS232 connection: 1 Nm (0.7 lb-ft) –...

  • Page 29: Input And Output Connector - P/N 06.00.507, P/N 06.00.508

    6.1.1 Input and Output Connector – P/N 06.00.507, P/N 06.00.508 Input and output connector: left side of device, 23-pole, connector Pin assignment Ignition output D Ignition output C Ignition output B Ignition output A Switch Go/NoGo Not used (+) 4-20 mA Pickup signal Ignition output E Ground...

  • Page 30: Input And Output Connector - P/N 06.00.510

    6 WIRING OF THE DEVICE 6.1.2 Input and Output Connector – P/N 06.00.510 Input connector: left front, 6-pole, socket Pole Pole assignment Pickup signal Supply voltage pickup (24 V DC) Pickup ground Switch Go/NoGo (+) Supply voltage (-) Supply voltage right side of device, 10-pole, socket Pole Pole assignment...
  • Page 31 Pole Pole assignment Not used Not used Not used Output connector: right front, 19-pole, socket Pole Pole assignment Ignition output A Ignition output B Ignition output C Ignition output D Ignition output E Ignition output F Measuring lead (1:1) Measuring lead (1:10) Ground Ignition output K Ignition output L...

  • Page 32: Input And Output Connector - P/N 06.00.511

    6 WIRING OF THE DEVICE 6.1.3 Input and Output Connector – P/N 06.00.511 Input connector: left front, 10-pole, socket Pole Pole assignment (+) Supply voltage (-) Supply voltage (+) 4-20 mA Digital input (Switch A/B or Switch Start/Stop) (-) 4-20 mA 4-20 mA PWR Pickup signal Supply voltage pickup (24 V DC)
  • Page 33 Output connector: right front, 19-pole, socket Pole Pole assignment Ignition output A Ignition output B Ignition output C Ignition output D Ignition output E Ignition output F Measuring lead (1:1) Measuring lead (1:10) Ground Ignition output K Ignition output L Ignition output M Ignition output N Ignition output P...

  • Page 34: Input And Output Connector - P/N 06.00.513

    6 WIRING OF THE DEVICE 6.1.4 Input and Output Connector – P/N 06.00.513 Input connector: left front, 6-pole, connector Pin assignment Pickup signal Supply voltage pickup (8 V DC) Pickup ground Switch Go/NoGo (+) Supply voltage (-) Supply voltage right side of device, 10-pole, socket Pole Pole assignment Not used...
  • Page 35 Pole Pole assignment Not used Not used Not used Output connector: right front, 10-pole, connector Pin assignment Ignition output A Ignition output B Ignition output C Ignition output D Ignition output E Ignition output F Measuring lead (1:1) Ignition output K Ignition output L Ground No digital input at P/N 06.00.513...

  • Page 36: Input And Output Connector - P/N 06.00.514

    6 WIRING OF THE DEVICE 6.1.5 Input and Output Connector – P/N 06.00.514 Input connector: left front, 6-pole, connector Pin assignment Pickup signal Supply voltage pickup (8 V DC) Pickup ground Switch Go/NoGo (+) Supply voltage (-) Supply voltage right side of device, 10-pole, connector Pin assignment Not used Not used...
  • Page 37 Pin assignment Not used Not used Not used Output connector: right front, 19-pole, connector Pin assignment Ignition output A Ignition output B Ignition output C Ignition output D Ignition output E Ignition output F Measuring lead (1:1) Measuring lead (1:10) Ground Ignition output K Ignition output L...

  • Page 38: Input And Output Connector - P/N 06.00.515-6 And -8

    6 WIRING OF THE DEVICE 6.1.6 Input and Output Connector – P/N 06.00.515-6 and -8 Input connector: left front, 7-pole, connector Pin assignment Pickup signal Supply voltage pickup (8 V DC) Pickup ground Digital input (Switch A/B or Switch Start/Stop) (+) Supply voltage (-) Supply voltage Switch Go/NoGo...
  • Page 39 Pole Pole assignment Not used Not used Not used Output connector: right front, 10-pole, connector Pin assignment Ignition output A Ignition output B Ignition output C Ignition output D Ignition output E Ignition output F Measuring lead (1:1) Ignition output K Ignition output L Ground Rev.

  • Page 40: Input And Output Connector - P/N 06.00.516

    6 WIRING OF THE DEVICE 6.1.7 Input and Output Connector – P/N 06.00.516 Input connector: left front, 7-pole, connector Pin assignment Pickup signal Supply voltage pickup (8 V DC) Pickup ground Digital input (Switch A/B or Switch Start/Stop) (+) Supply voltage (-) Supply voltage Switch Go/NoGo right side of device, 10-pole, connector...
  • Page 41 Pin assignment Not used Not used Not used Output connector: right front, 19-pole, connector Pin assignment Ignition output A Ignition output B Ignition output C Ignition output D Ignition output E Ignition output F Measuring lead (1:1) Not used Ground Ignition output K Ignition output L Ignition output M...

  • Page 42: Input And Output Connector - P/N 06.00.520

    6 WIRING OF THE DEVICE 6.1.8 Input and Output Connector – P/N 06.00.517 Input connector: left front, 7-pole, connector Pin assignment Pickup signal Supply voltage pickup (8 V DC) Pickup ground Digital input (Switch A/B or Switch Start/Stop) (+) Supply voltage (-) Supply voltage Switch Go/NoGo right side of device, 10-pole, connector...
  • Page 43 Pin assignment Not used Not used Not used Output connector: right front, 19-pole, connector Pin assignment Ignition output V Ignition output A Ignition output B Ignition output C Ignition output D Ignition output E Measuring lead (1:1) Not used Ground Ignition output F Ignition output K Ignition output L...

  • Page 44: Input And Output Connector - P/N 06.00.525

    6 WIRING OF THE DEVICE 6.1.9 Input and Output Connector – P/N 06.00.520 Input connector: left front, 10-pole, connector Pin assignment (+) Supply voltage (-) Supply voltage (+) 4-20 mA Digital input (Switch A/B or Switch Start/Stop) (-) 4-20 mA 4-20 mA PWR Pickup signal Supply voltage pickup (24 V DC)
  • Page 45 Output connector: right front, 10-pole, socket Pole Pole assignment Ignition output A Ignition output B Ignition output C Ignition output D Ignition output E Ignition output F Ignition output K Measuring lead (1:1) Ignition output L Ground Rev. 01/2015...

  • Page 46: Input And Output Connector - P/N 06.00.530

    6 WIRING OF THE DEVICE 6.1.10 Input and Output Connector – P/N 06.00.525 Input connector: left front, 10-pole, connector Pin assignment (+) Supply voltage (-) Supply voltage (+) 4-20 mA Digital input (Switch A/B or Switch Start/Stop) (-) 4-20 mA 4-20 mA PWR Pickup signal Supply voltage pickup (24 V DC)
  • Page 47 Output connector: right front, 14-pole, socket Pole Pole assignment Ignition output A Ignition output B Ignition output C Ignition output D Ignition output E Ignition output F Ignition output K Measuring lead (1:1) Ignition output L Ground Ignition output M Ignition output N Ignition output P Ignition output R...

  • Page 48: Input And Output Connector - P/N 06.00.550

    6 WIRING OF THE DEVICE 6.1.11 Input and Output Connector – P/N 06.00.530 Input connector: left front, 10-pole, connector Pin assignment (+) Supply voltage (-) Supply voltage (+) 4-20 mA Digital input (Switch A/B or Switch Start/Stop) (-) 4-20 mA 4-20 mA PWR Pickup signal Supply voltage pickup (24 V DC)
  • Page 49 Output connector: right front, 19-pole, socket Pole Pole assignment Ignition output A Ignition output B Ignition output C Ignition output D Ignition output E Ignition output F Ignition output K Measuring lead (1:1) Ground Ignition output L Ignition output M Ignition output N Ignition output P Ignition output R...
  • Page 50 6 WIRING OF THE DEVICE 6.1.12 Input and Output Connector – P/N 06.00.550 Input connector: right front, 14-pole, socket Pole Pole assignment Pickup signal Pickup ground Not used Not used Not used (+) 4-20 mA (-) 4-20 mA Switch Go/NoGo Supply voltage pickup (24 V DC) Digital input (Switch A/B or Switch Start/Stop) (+) Supply voltage...
  • Page 51 Output connector: left front, 10-pole, socket Pole Pole assignment Ignition output A Ignition output B Ignition output C Ignition output D Ignition output E Ignition output F Ignition output K Ignition output L Ground Measuring lead (1:1) Rev. 01/2015...

  • Page 52: Input Wiring - Power Supply

    6 WIRING OF THE DEVICE 6.1.13 Input Wiring – Power Supply Variations Battery Generator Control Unit Power Supply Battery Charger Rev. 01/2015...

  • Page 53: Input Wiring - 4-20 Ma Input

    Four-wire transmitter Auxiliary supply voltage for the 4-20 mA input Via the 4-20 mA PWR terminal, the MIC500 series provides an auxiliary supply voltage for the 4-20 mA input. If using current transmitters, the 4-20 mA PWR terminal is used for Loop Power.

  • Page 54: Input Wiring - Pickup

    Connect passive (magnetic) pickup with plus to PU Signal and with minus to PU Com. The recommended distance to the triggering is 0.75 mm to 1 mm (0.03" to 0.04") for MOTORTECH pickups. Please note that additional fine-tuning is required for every pickup position due to the different conditions of the engines.
  • Page 55 One revolution of the pickup changes the distance as follows: Thread Change in distance 1 revolution ≙ 1 mm (0.04'') M12x1 1 revolution ≙ 1.41 mm (0.05'') 5/8"-18 UNF 1 revolution ≙ 1.59 mm (0.06'') 3/4"-16 UNF For problems with the pickup signal, see section Pickup Input Errors on page 112. Auxiliary pickup supply voltage Depending on the device type, the terminal PU Power provides an auxiliary supply voltage of 8 V DC or 24 V DC for the pickup.

  • Page 56: Wiring - Digital Input, Go/Nogo

    6 WIRING OF THE DEVICE 6.1.16 Wiring – Digital Input, Go/NoGo The function of the digital input (Switch Start/Stop or Switch A/B) is specified via the parameterization of the ignition controller (see Select Function for Digital Input on page 87). Digital input Function Switch Start/Stop open...

  • Page 57: Functions

    7.1 Monitoring of Pickup Signal The MIC500 monitors the pickup signal. Possible errors are indicated on the device by the LED. For further information on errors, please refer to the overview in section Message and Error Overview on page 113.

  • Page 58: Remote-Controlled Ignition Release

    With this device type, schedule A settings are applied solely for ignition timing configuration. Via the digital input, the ignition of the MIC500 ignition controller can be switched on and off by a master control. In order to use this function, the digital input must be set to the function Switch Start/Stop. In this mode, the ignition controller applies solely the settings from schedule A.

  • Page 59: Schedules A/B

    (Switch A/B, Switch Start/Stop) as described in this operating manual. With this device type, schedule A settings are applied solely for ignition timing configuration. The MIC500 ignition controllers offer two separate schedules with the following setting options: – Timing limits –...

  • Page 60: Timing Correction

    Potentiometer Per schedule: 4-20 mA input Speed curve Schedule B: Ignition timing offset Per cylinder: Cylinder-to-cylinder alignment Limited by the min./max. ignition timing per schedule With MIC500 ignition controllers, the maximum adjustment range for ignition timing is 38°. Rev. 01/2015...

  • Page 61: Manual Timing Correction

    Reinsert the cover after every ignition timing adjustment made using the potentiometer. The ignition controllers of the MIC500 series include a permanently installed overwind-protected potentiometer (Timing Adjustment) for manually adjusting the timing point. The maximum adjustment range is defined by the user through the corresponding limits.

  • Page 62: Analog Current Input - 4-20 Ma

    7.5.3 Speed Curve To optimize the ignition, for example, during the start phase of the engine, a speed curve can be defined for the MIC500 ignition controllers. To create this curve, up to five adjustable speed points are available. To configure the speed curve, see sections Activate Functions for Schedules A and B on page 89 and Set Speed Curve on page 97.

  • Page 63: Ignition Energy

    7.7 Ignition Energy Depending on the gas quality and the application, it is possible to vary the available ignition energy. In a range between 15 % to 100 %, any value can be selected. Fast-igniting gases such as propane require relatively small levels of energy, whereby poorly igniting gases such as landfill gas require lots of energy to ignite.

  • Page 64: Adjustments

    An incorrect configuration can result in damage to the engine. Before using the MIC500 series ignition controller, all parameters relevant to the engine and the application must be configured. This parameterization can be carried out via a computer (PC/laptop) using Ignition Control software.
  • Page 65 Proceed as follows: Select a location for saving Ignition Control on the hard disk of your computer, e.g. by creating a file folder with the name Ignition Control. 2. From the subdirectory MIC software\WIN2000-NT-XP on the supplied storage device, copy the file IC.exe to the location you selected on the hard disk of your computer.
  • Page 66 8 ADJUSTMENTS 7. Read through the information carefully and confirm with OK. ▸ The main view is displayed. 8. If you are not using COM1 for the connection between the ignition controller and your computer, and there are no status values displayed on the left of the main view (RPM, 4-20, SPARK etc.), adapt Ignition Control to the relevant communication interface via the menu item Config ->...

  • Page 67: Starting Ignition Control

    ▸ After correctly selecting the port, you will see status values on the left side of the main view. Ignition Control is installed and ready for operation. ▸ If there are still no status values displayed on the left side of the main view, check the cable connection between the ignition controller and the computer (see step 4), ensure that the ignition controller is ready for operation (see step 5) as well as the selected communication interface (see step 8).

  • Page 68: Menu Bar And Buttons

    8 ADJUSTMENTS 8.1.4 Menu Bar and Buttons Menu Bar The following functions are available to you via the entries in the menu bar: Menu Function Finishes Ignition Control. File -> Exit Opens the Configuration window for the configuration of Config -> RS232 the RS232 interface.

  • Page 69: Hand-Held Programmer

    8.2 Hand-Held Programmer 8.2.1 RS232 Interface Adjustments If you wish to program the MIC500 ignition controller from the optionally available hand-held programmer, the RS232 interface of the hand-held programmer must be configured to correspond to the RS232 interface of the MIC500.

  • Page 70: Switching On The Hand-Held Programmer

    1 Nm (0.7 lb-ft). To switch the hand-held programmer on, proceed as follows: Connect the hand-held programmer to the MIC500 ignition controller via the RS232 connector. 2. Ensure that the ignition controller is connected to the power supply and that the status LED on the ignition controller is flashing every 2 seconds for the device to be ready for operation.

  • Page 71: Keys Of The Control Panel

    8.2.3 Keys of the Control Panel The following table gives an overview of the keys on the control panel and their functions. Function [ON/OFF] On/Off key Key for switching the hand-held programmer on and off [F1] to [F5] Function keys Depending on the opened view, the function keys are assigned differently.

  • Page 72: Conventions Used In The Following

    8 ADJUSTMENTS 8.3 Conventions Used in the Following In the subsequent sections, the views that allow you to enter settings or provide you with information will be explained. Therefore, the following conventions apply: Key Combinations – The keys to be pressed on the computer keyboard or the hand-held programmer are shown in square brackets, e.

  • Page 73: Main View

    Ignition Control software is started or when the hand-held programmer is switched on – when leaving other views including the parameterization level by pressing [Esc] In the main view, you receive the following information on the current status of the MIC500 ignition controller: – RPM: current engine speed –...
  • Page 74 8 ADJUSTMENTS Following statuses are possible: – READY The ignition controller is ready for operation. – FIRING The ignition controller is firing. – NO MPU No input signal detected. – TOO SLOW The speed is too slow (less than 60 crankshaft revolutions or 30 camshaft revolutions).

  • Page 75: Parameterization Level

    4. In order to open the parameterization level, press the [Esc] key from the main view. ▸ You are requested to enter your password. Password for the parameterization level The password required for access to the parameterization level is obtained from your MOTORTECH contact person (see Customer Service Information on page 117). Rev. 01/2015...
  • Page 76 5. Enter your password and confirm it by pressing the [Enter] button. ▸ After correctly entering the password, the window changes to parameter view. The MIC500 ignition controller is now in programming mode (status LED on device flashes 6 times). The parameter SEQ. NUMBER is displayed. Navigating Through the Parameters...
  • Page 77 [F5] prior to exiting. 2. From the parameter view, press [Esc] to return to the main view. ▸ The MIC500 ignition controller exits the programming mode and is ready for operation (LED flashes briefly every 2 seconds). Using the Help Function Via the help function, further information is available for every shown parameter.

  • Page 78: Brief Overview Of Parameters

    8 ADJUSTMENTS 8.5.2 Brief Overview of Parameters In the following table, you will find a brief overview of the ignition controller's configurable parameters. For more detailed information about the individual parameters, see the corresponding sections. Display of parameters The parameters indicated with a star (*) are dependent on the settings of other parameters and are not shown in specific instances.
  • Page 79 Parameter Function Configuration SPEED CURVE A Activate or deactivate the speed curve see Activate for schedule A Functions for Schedules A and B 4-20 A 4-20 mA input for activating or on page 89 deactivating schedule A SPEED CURVE B Activate or deactivate the speed curve for schedule B 4-20 B...

  • Page 80: Set Sequence Number

    8 ADJUSTMENTS 8.5.3 Set Sequence Number Operational safety! Please ensure that the set sequence number of the MIC500 ignition controller corresponds to your engine. An incorrect configuration can result in damage to the engine. The sequence number (SEQ. NUMBER) reflects the engine's configuration. The following application properties can be set with the sequence number: –...
  • Page 81 Seq. Number of Ignition Trigger Trigger disc Ignition output Strokes outputs offset mounting location 360-360 2 + 1 Camshaft 4-stroke 240-240 3 + 1 Camshaft A-B-C 4-stroke 120-120 3 + 1 Crankshaft A-B-C 2-stroke 50-70 3 + 1 Crankshaft A-B-C-D-E-F 2-stroke 30-90 3 + 1...
  • Page 82 8 ADJUSTMENTS Seq. Number of Ignition Trigger Trigger disc Ignition output Strokes outputs offset mounting location 45-45 8 + 1 Crankshaft A-B-C-D-E-F-K-L 2-stroke 45-45 8 + 1 Crankshaft A-C-E-K-M-P-S-U 2-stroke 10-35 8 + 1 Crankshaft A-B-C-D-E-F-K-L-M- 2-stroke N-P-R-S-T-U-V 21-24 8 + 1 Crankshaft A-B-C-D-E-F-K-L-M- 2-stroke...
  • Page 83 Seq. Number of Ignition Trigger Trigger disc Ignition output Strokes outputs offset mounting location 50-40 8 + 1 Camshaft A-B-C-D-E-F-K-L-M- 4-stroke N-P-R-S-T-U-V 40-50 8 + 1 Camshaft A-B-C-D-E-F-K-L-M- 4-stroke N-P-R-S-T-U-V 50-70 6 + 1 Camshaft A-B-C-D-E-F-K-L-M- 4-stroke N-P-R 55-65 6 + 1 Camshaft A-B-C-D-E-F-K-L-M- 4-stroke...

  • Page 84: Set Reset Position

    8 ADJUSTMENTS 8.5.4 Set Reset Position With the RESET BTDC parameter, you define the angular position of the reset signal from the upper dead center of the first cylinder. All other cylinders are assessed based on this value. If there is a difference between the actual and the displayed timing, adjust this value accordingly. Value range: –...

  • Page 85: Set Security Speed

    Proceed as follows: Open parameterization level -> [F2] to OVERSPEED -> [F1] -> Enter overspeed -> [Enter] -> [F5] 8.5.6 Set Security Speed With the SECURITY SPEED parameter, you can specify the speed value for the security speed. Below this speed, the ignition can be switched on or off via the digital input if set to function Switch Start/Stop (see Select Function for Digital Input on page 87).

  • Page 86: Set Misfire Rate

    8 ADJUSTMENTS 8.5.7 Set Misfire Rate Deactivate misfire monitoring For sequences 22, 23, 29, 34 and 36, it is necessary to set the MISFIRE RATE to  via Ignition Control, which deactivates misfire monitoring. With the MISFIRE RATE parameter, you can specify the permissible misfires per second (primary side, open circuit) across all outputs.

  • Page 87: Activate Cylinder-To-Cylinder Alignment

    8.5.8 Activate Cylinder-to-Cylinder Alignment With the CYL TO CYL parameter, you can activate the cylinder-to-cylinder alignment. This optimizes the ignition timing of the individual cylinders based on your specifications. Ignition timing optimization is carried out in a separate view outside the parameterization level. See section Cylinder-to-Cylinder Alignment on page 103.

  • Page 88: Activate Potentiometer

    8 ADJUSTMENTS Proceed as follows: Open parameterization level -> [F2] to CONTACT I/P -> [F1] -> Set with [F1] to FOR STOP or with [F2] to FOR A/B -> [F5] 8.5.10 Activate Potentiometer Explosion hazard! Never remove the cover for timing adjustment, unless the system is not located in an explosive environment.

  • Page 89: Activate Functions For Schedules A And B

    Proceed as follows: Open parameterization level -> [F2] to POT TIMING -> [F1] -> Set with [F1] to ENABLE or with [F2] to DISABLE -> [F5] 8.5.11 Activate Functions for Schedules A and B No digital input at P/N 06.00.513 The device type P/N 06.00.513 is designed as a replacement for the ignition controller Caterpillar®...
  • Page 90 8 ADJUSTMENTS Proceed as follows: Activate Speed Curve for Schedule A Open parameterization level -> [F2] to SPEED CURVE IN A/NOT IN A -> [F1] -> Set with [F1] to IN A or with [F2] to NOT IN A -> [F5] Activate 4-20 mA Input for Schedule A Open parameterization level ->...

  • Page 91: Set Potentiometer Limits

    Activate 4-20 mA Input for Schedule B Open parameterization level -> [F2] to 4-20 IN B/NOT IN B-> [F1] -> Set with [F1] to IN B or with [F2] to NOT IN B -> [F5] 8.5.12 Set Potentiometer Limits Explosion hazard! Never remove the cover for timing adjustment, unless the system is not located in an explosive environment.
  • Page 92 8 ADJUSTMENTS Proceed as follows: Define Left Potentiometer Stop Open parameterization level -> [F2] to POT CCW -> [F1] -> Enter left potentiometer stop -> [Enter] -> [F5] Define Right Potentiometer Stop Open parameterization level -> [F2] to POT CCW -> [F1] -> Enter right potentiometer stop ->...

  • Page 93: Set Ignition Timing Limits

    8.5.13 Set Ignition Timing Limits To prevent engine damage caused by the addition of various parameters in the ignition timing adjustment, you can set limits which may not be exceeded for ignition timing. MAX ADV indicates the earliest possible firing time, MAX RET the latest possible firing time. Ignition timing adjustments which extend beyond these limits will only be applied up to the set limit.
  • Page 94 8 ADJUSTMENTS Set Latest Ignition Timing for Schedule A Open parameterization level -> [F2] to MAX RET A -> [F1] -> Enter latest ignition timing -> [Enter] -> [F5] Set Earliest Ignition Timing for Schedule B Open parameterization level -> [F2] to MAX ADV B ->...

  • Page 95: Set Timing Offset For Schedule B

    8.5.14 Set Timing Offset for Schedule B With the B OFFSET parameter, you can set an ignition timing offset to offset the ignition timing for active schedule B (= digital input is closed) in addition to all other timing adjustments. This function is only available if the digital input is set to the Switch A/B function, and therefore switching between both schedules is enabled (see Select Function for Digital Input on page 87).
  • Page 96 8 ADJUSTMENTS Proceed as follows: Enter Ignition Timing Adjustment at 4 mA Open parameterization level -> [F2] to 4mA TIMING -> [F1] -> Enter ignition timing adjustment -> [Enter] -> Select [F1] for ADVANCE or [F2] for RETARD -> [F5] Enter Ignition Timing Adjustment at 20 mA Open parameterization level ->...

  • Page 97: Set Speed Curve

    Configuration examples Characteristic 4-20 mA – ignition timing adjustment towards retard BTDC Parameterization 4mA TIMING: 0.00 ADV 20mA TIMING: 15.00 RET 15° retarded ignition if timing is at 30° BTDC Characteristic 4-20 mA – ignition timing adjustment towards advance BTDC Parameterization 4mA TIMING: 0.00 ADV 20mA TIMING: 15.00 ADV...
  • Page 98 8 ADJUSTMENTS Value ranges: – # SPEED POINTS: 0 to 5, whole numbers If you enter the value  for the # SPEED POINTS parameter, then there is no speed ▸ curve activated and therefore no speed points can be configured. –...
  • Page 99 Speed Curve Example of a typical speed curve for an engine in generator mode, for which the speed curve is intended to positively impact the start performance of the engine: If the engine is not running, the timing is equivalent to the potentiometer setting, as in example 20°...

  • Page 100: Configuration Example

    8 ADJUSTMENTS 8.5.17 Configuration Example The following configuration example serves to demonstrate the functionality of the MIC500 ignition controller and the effect of the individual parameter settings. Sample Values Parameter Value Parameter Value Parameter Value RESET BTDC 30° POT CW 18°...
  • Page 101 Schedule B Schedule B is active if the digital input is closed. The possible timing settings are limited with MAX ADV B and MAX RET B to values between 23° BTDC and 3° BTDC. Because the B OFFSET parameter is set to 2° later, the setting ranges of the potentiometer, the 4-20 mA input, including the fail value and the speed curve are shifted based on this value.

  • Page 102: Additional Functions

    8 ADJUSTMENTS 8.6 Additional Functions Outside the parameterization level, you can call the following additional functions, which are explained in the following sections: – Set ignition energy – Information view (operating hours, software revision) – Cylinder-to-cylinder alignment – Self test –...

  • Page 103: Information View

    8.6.2 Information View In this view, you will see information on the MIC500 ignition controller. Activate View – Computer: [Shift]+[H] – Hand-held programmer: [H] Displayed Values – HOURS: Hours of operation of the ignition controller – CHECKSUM: Internal checksum of the ignition controller (relevant in some service instances) –...
  • Page 104 8 ADJUSTMENTS Value range: – 2.00 ADV (advance) to 2.00 RET (retard) with up to two decimal places ▸ Enter decimal places with a period as the delimiter, e.g. 35.55. Activate View – Computer: [Shift]+[C] – Hand-held programmer: [C] Displayed Values –...

  • Page 105: Self Test

    If you conduct a self test, ensure that the following conditions are met in order to avoid equipment damage or personal injury: – The MIC500 ignition controller may not be located in a potentially explosive area. – The gas supply must be switched off.
  • Page 106 8 ADJUSTMENTS Start Self Test – Computer: [Shift]+[S]: – Hand-held programmer: [S] ▸ The ignition controller begins the self test immediately. Displayed Values – HOURS: Hours of operation of the ignition controller – Column of figures below HOURS: Display of ignition outputs. All outputs that are functioning properly are indicated as 1.

  • Page 107: Misfire Detection

    8.6.5 Misfire Detection In this view, the current status of the misfire detection is displayed. Activate View – Computer: [Shift]+[M] – Hand-held programmer: [M] Displayed Values – OUTPUTS Display of ignition outputs and their status. All outputs that are functioning properly are indicated as 1.
  • Page 108 8 ADJUSTMENTS Programming Overview Customer: P/N Ignition controller: P/N Ignition system: Engine type: Engine serial number: Software revision: Number of cylinders: Ignition timing:* *Caution! The ignition timing must be adjusted to the respective application prior to start-up. SEQ. NUMBER RESET BTDC OVERSPEED SECURITY SPEED MISFIRE RATE...
  • Page 109 B OFFSET ° ADV/RET only if 7 set to FOR A/B 4mA TIMING ° ADV/RET only if 10 or 12 enabled 20mA TIMING ° ADV/RET only if 10 or 12 enabled DFLT 4-20 ° ADV/RET only if 10 or 12 enabled # SPEED POINTS only if 9 or 11 enabled SPEED...

  • Page 110: Operation

    9.1 Start-up Before you start up the MIC500 ignition controller, take note of the following: – Does the ignition sequence fit the engine? If you are unsure, contact MOTORTECH or the corresponding engine manufacturer. – Ensure that the firing order of the engine and/or the wiring of the output cable harness are carried out correctly.

  • Page 111: Errors

    10 ERRORS 10.1 Possible Faults The MIC500 ignition controllers include several safety functions that can shut down the engine in case of fault: – Overspeed protection – External shutdown contact (if digital input is set to function Switch Start/Stop) –...

  • Page 112: Pickup Input Errors

    – Distance of the pickup incorrect – Dirt on the pickup 10.2.4 Insufficient Power Supply An error has occurred in the power supply to the MIC500. Potential causes: – The size of the power supply is too small – Low battery –...

  • Page 113: Troubleshooting And Eliminating Errors

    10.3 Troubleshooting and Eliminating Errors 10.3.1 Message and Error Overview The following errors and notifications are indicated on the device by an LED. The flash signals have the following meaning: LED Signals in Fault-free Operation Flash signal Description Slow flashing (every 2 seconds) Ready for operation Fast flashing (every 0.6 seconds) Normal operation with ignition...

  • Page 114: Testing Supply Voltage

    10 ERRORS Flash signal Description Potential causes Flashes six times Misfire rate exceeded on the – Defect in the output wiring supply side – Ignition coil defective Ignition controller waiting for – In Switch Start/Stop mode: standstill Start/Stop input closed due to speed exceeding security speed, ignition release blocked until engine standstill...
  • Page 115 Ideal pickup signal sequence – with a magnetic sensor: – with an inductive sensor: – with a Hall effect sensor: Rev. 01/2015...

  • Page 116: Running A Self Test

    If you conduct a self test, ensure that the following conditions are met in order to avoid equipment damage or personal injury: – The MIC500 ignition controller may not be located in a potentially explosive area. – The gas supply must be switched off.

  • Page 117: Customer Service Information

    +49 5141 93 99 0 Fax: +49 5141 93 99 99 Email: service@motortech.de 10.3.6 Returning Equipment for Repair / Inspection To return the device for repair and inspection, obtain a return form and return number from MOTORTECH. Fill out the return form completely. The completely filled out return form guarantees fast, uncomplicated processing of your repair order.

  • Page 118: Instructions For Packaging The Equipment

    10 ERRORS Send the device and the return form to one of the two addresses below or to the nearest MOTORTECH representative: MOTORTECH GmbH MOTORTECH Americas, LLC Hogrevestr. 21-23 1400 Dealers Avenue, Suite A 29223 Celle New Orleans, LA 70123...

  • Page 119: Maintenance

    Use only a damp cloth to clean the ignition controller. Do not use a high-pressure device or similar. 11.2 Spare Parts and Accessories For spare parts and accessories for MIC500 ignition systems, please refer to our current product guide, which is available for download at www.motortech.de. Rev. 01/2015...

  • Page 120: Index

    12 INDEX 4  Dimensions ..........20, 23 Disposal ............13 4-20 mA input Activate ............ 89 E  Current value ..........73 Electrostatics ..........11 Function ........... 62 Energy Limits ............95 Current value ........73, 102 Wiring ............53 Function ............ 63 A ...
  • Page 121 Maintenance ..........119 P/N 06.00.520 .......... 44 Menu bar P/N 06.00.525 .......... 46 Ignition Control .........68 P/N 06.00.530 .......... 48 MIC500 P/N 06.00.550 ........... 50 Application range ........14 Outputs Cleaning ..........119 Electrical data ..........21 Dimensions ......... 20, 23 Overspeed Disposal ............
  • Page 122 12 INDEX Schedule P  Function ............ 59 Parameter Limits ............93 4-20 mA input ........89, 95 Setting ..........87, 89 Activate ............ 75 Scope of supply ..........26 B Offset ............ 95 Security speed Configuration example ......100 Setting ............85 Cylinder-to-cylinder alignment ....
  • Page 123 W  Weight ............20 Wiring 4-20 mA input ..........53 Digital input ..........56 Go/NoGo output ........56 Pickup............54 Power supply ..........52 Switch A/B ..........56 Switch Start/Stop ........56 Rev. 01/2015...
  • Page 124 Original MOTORTECH Accessories for Stationary Gas Engines As a supplier, MOTORTECH develops, produces and distributes accessories as well as spare and wearing parts for nearly all kinds of stationary gas engines worldwide: Ignition control and monitoring, industrial spark plugs and high tension leads, wiring systems and gas regulation –...

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