Motortech MIC5 Operating Manual
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Motortech MIC5 Operating Manual

Ignition controller
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MIC5 – Ignition Controller
Operating Manual
P/N 01.10.023-EN | Rev. 03/2019

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Summary of Contents for Motortech MIC5

  • Page 1 MIC5 – Ignition Controller Operating Manual P/N 01.10.023-EN | Rev. 03/2019...
  • Page 2 Information contained in this publication may be changed without prior notice. Trademarks MOTORTECH products and the MOTORTECH logo are registered and/or common law trademarks of the MOTORTECH GmbH. All further trademarks and logos displayed or used in this publication are the property of the respective entitled person.

  • Page 3: Table Of Contents

    Table of Contents   1 General Information ....................8   1.1 What Is the Purpose of this Operating Manual? ............8   1.2 Who Is this Operating Manual Targeted to? ............... 8   1.3 Which Symbols Are Used in the Operating Manual? ........... 8  ...
  • Page 4 Table of Contents   6.1.3 Input Wiring – Pickups ..................41   6.1.4 Input Wiring – Timing and Safety Devices ............43   6.1.5 Output Wiring – Binary Outputs (Go/NoGo, GPO, ASO) ......... 46   6.1.6 Wiring – PowerView3 ..................47  ...
  • Page 5 Table of Contents   8.7 Self Test....................... 77   8.8 Pickup Trace ......................78   8.9 Access Control for MIC5 ..................81   8.9.1 Enable/Disable Access Control ................81   8.9.2 Login/Logout ....................82   8.9.3 Changing the PIN ....................82  ...
  • Page 6 Table of Contents   8.12.7 Runtime Data – Diagnostics ................138   8.12.8 Runtime Data – Temperatures ................ 140   8.12.9 Runtime Data – Information ................141   8.13 Log ........................142   8.14 Runtime Adjustments ..................143   8.14.1 Runtime Adjustments – Reset ................. 144  ...
  • Page 7 Table of Contents   11 Maintenance ......................167   11.1 Maintenance Instructions ................... 167   11.2 Spare Parts and Accessories ................167   12 Index ........................168 Rev. 03/2019...

  • Page 8: General Information

    1 General Information Read through this operating manual carefully before use and become familiar with the product. 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 9: Which Abbreviations/Acronyms Are Used In The Operating Manual

    Advanced with respect Indicates the direction for to top dead center timing Auxiliary Output for synchronizing the Synchronization Output MIC5 and other controllers ATDC After Top Dead Center BTDC Before Top Dead Center CAN bus Controller Area Network Bus for control...
  • Page 10 Light Emitting Diode Light emitting electronic semiconductor MOTORTECH Ignition Controller MICT MOTORTECH Integrated Software for the Configuration Tool configuration of the MIC5 MOSFET Metal Oxide Semiconductor component Semiconductor Field-Effect Transistor Panzergewinde Panzer screw thread Screw thread type for cable screw connections...

  • Page 11: 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 damage can occur, if the following instructions are not complied with: –...

  • Page 12: Electrostatic Discharge Hazards

    2 Safety Instructions – 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 13: Information On Electric Isolation

    2 Safety Instructions 2.3 Information on Electric Isolation If ground and earth potential are not properly isolated, the following problems as well as others can occur: Electromagnetic interferences (e.g. ground loops) – Signal corruption (e.g. of the analog voltage signal) –...

  • Page 14: Special Safety Instructions For The Device

    2 Safety Instructions Occurrence of ground loops The devices shown in the following image do not feature the possibility to connect the earth potential and the negative pole of the power supply separated from each other. How ground loops are created. A ground loop is a ground connection of an electric wiring assembly that is closed as a loop.
  • Page 15 2 Safety Instructions Explosion hazard! Do not disconnect any connectors while the system is live. If the system is located in a hazardous area, there is a risk of explosion. Explosion hazard! Never remove the equipment while the unit is connected to a power source. If the system is located in a hazardous area, there is a risk of explosion.

  • Page 16: Proper Disposal

    2.5 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 17: Intended Use

    3.2 Applications The ignition controllers of the MIC5 series are designed for specific 2- or 4-stroke gas engines. From 1 to max. 20 ignition outputs are available. The ignition controllers supply the energy required for the corresponding ignition coils of the gas engines and can supply signals for peripheral equipment.

  • Page 18: Product Description

    4 Product Description 4.1 Technical Data 4.1.1 Certifications The ignition controllers of the MIC5 series are certified as per the following directives/regulations: – EMC Directive 2014/30/EU – EN 61326-1:2013 – Electrical equipment for measurement, control and laboratory use. EMC requirements. General requirements –...

  • Page 19: Mechanical Data

    4 Product Description 4.1.2 Mechanical Data The MIC5 has the following mechanical characteristics. Feature Value Dimensions MIC5: 360.3 mm x 240 mm x 114.5 mm (14.19" x 9.45" x 4.51") (length x width x height) MIC5-SE: 304 mm x 240 mm x 95.5 mm (11.97" x 9.45" x 3.76")

  • Page 20: Warning Notices On The Device

    (6,562') above sea level 4.1.3 Warning Notices on the Device Validity of warning notices on device The warning notices on the device are valid for the MIC5 and all components connected to it. Warning notice on the device German translation...

  • Page 21: Product Identification - Labeling On The Device

    Arrangement number of the ignition controller (A/N) – Serial number of the ignition controller (S/N) – Example MIC5 4.1.5 Electrical Data The MIC5 has the following electrical characteristics. Feature Value Power consumption MIC5: max. 240 W at 24 V MIC5-SE: max.
  • Page 22 4 Product Description Feature Value Number of outputs MIC5: 20 outputs MIC5-SE: 8 outputs Firing Angles The size of the firing angle depends on the max. overspeed. The smallest firing angle per output bank can be calculated using the following formula:...
  • Page 23 4 Product Description Estimation of Current Requirements These current values are based on a nominal speed of 1800 rpm and 500 mJ energy MIC5: Outputs Voltage Required current Voltage Required current 24 V 16 V* 24 V 16 V* 11 A...
  • Page 24 For a pickup output impedance of 120 Ω to 10 kΩ, the pickups connected to the MIC5 may not have a higher voltage than ±40 V and the connected power may not exceed 1 W.

  • Page 25: Interfaces

    4 Product Description Frequency of the pickups The frequency of the pickup is calculated as per the following formula. 4.1.6 Interfaces Depending on the device version, the following interfaces are available: USB Interface – Compatible with USB 2.0 The Connector B version is only suitable for temporary data exchange and not for a –...

  • Page 26: Requirements For External Equipment

    4 Product Description 4.1.7 Requirements for External Equipment External equipment shall fulfill the input and output specifications of the MIC5. Rev. 03/2019...

  • Page 27: Overview Drawings

    4 Product Description 4.1.8 Overview Drawings Standard Version of MIC5 with Service Cover Devices without a service cover have an input connector at the front of the device. Rev. 03/2019...
  • Page 28 4 Product Description Rev. 03/2019...
  • Page 29 4 Product Description MIC5-SE Rev. 03/2019...

  • Page 30: Leds And Connections

    4 Product Description 4.1.9 LEDs and Connections LEDs on the MIC5 Labeling Function Status LED flashes green when the device is running with no errors. If an error occurs, the LED is red, for a warning it is yellow. Firing LED lights up when the ignition is active (exception: during the self test).
  • Page 31 4 Product Description Labeling Function Power Connection for the supply voltage (see Input Wiring – Power Supply on page 39) USB connection for connecting to the PC Button acknowledges errors, warnings and alarms or triggers a reset of the ignition controller. Please refer also to the notice below.

  • Page 32: Installation Instructions

    Operating manual 5.2 Installation of the Ignition Controller The installation of the MIC5 ignition controller is implemented on a fixed bracket e. g. on a wall near the engine. Use the included rubber vibration dampers and the ground strap. The...

  • Page 33: Installation Of The Vibration Dampers

    5 Installation Instructions 5.2.1 Installation of the Vibration Dampers There are two options for using the vibration dampers from the MIC5's scope of supply. The hole patterns can be found in section Overview Drawings on page 27. Option A Fasten the four vibration dampers to the selected installation location.

  • Page 34: Installation Of The Ground Strap

    Fasten the four vibration dampers the MIC5. Use four screws M8x16 , four rim lock washers M8 and four washers 2. Fasten the MIC5 to the selected installation location using the vibration dampers. Use four washers M8 and four lock nuts ▸...

  • Page 35: Determine The Installation Location Of The Pickup

    5 Installation Instructions 5.3 Determine the Installation Location of the Pickup Set the positions of the pickups depending on engine type and application. All angle reference information is based on: TDC 1st cylinder / compression cycle The installation location for the pickups must have adequate mechanical strength and must not exceed the specified temperature ranges.

  • Page 36: 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. Refer to the section Mechanical Data on page 19. After the service cover on the device has been opened, e.g. to complete the wiring, it must be refitted so that it is in the same alignment as it was prior to opening.

  • Page 37: Input Wiring

    6 Wiring of the Device 6.1.1 Input Wiring For the standard MIC5 version, the connections for the input wiring are located on the connector strip below the service cover (see LEDs and Connections on page 30). The wiring to the connector strips is fed through the PG screw joints at the device front.
  • Page 38 6 Wiring of the Device Pin designation Connection no. on connector strip 35-pole connector Pickup 3 Power – Signal – – Shield – CAN Display – – – Shield – Shield Go/NoGo + Binary Output Go/NoGo – GPO + GPO – ASO + ASO –...

  • Page 39: Input Wiring - Power Supply

    Design of power supply For the power supply, an overcurrent protection mechanism must be set up with a circuit breaker (MIC5: 20 A DC, MIC5-SE: 16 A DC can both be set with tripping characteristic B), which allows switching off. When selecting the circuit breaker, the conditions of the installation site and the ambient temperature must be considered.
  • Page 40 6 Wiring of the Device L ≙ 24 V DC (nominal voltage) Variations Battery Generator Control unit Power supply Battery Charger Rev. 03/2019...

  • Page 41: Input Wiring - Pickups

    Crankshaft (Reset) Crankshaft 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 42 6 Wiring of the Device 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 Allocation of the Wire Colors (Example Configuration) Camshaft...

  • Page 43: Input Wiring - Timing And Safety Devices

    6 Wiring of the Device Adjusting the pickup sensitivity Depending on the type of impulse source (interference), it may be necessary to increase the pickup sensitivity to ensure that the resultant signal strength is sufficient for reliable operation. You can make these adjustments in the MICT.
  • Page 44 6 Wiring of the Device Two-Wire Transmitter Four-Wire Transmitter Auxiliary analog input supply voltage An auxiliary supply voltage for the analog inputs can be configured using the MICT. The voltage can be set in the range of 5 to 24 V and is made available on the connection Analog Power.
  • Page 45 6 Wiring of the Device Wiring MIC5 ignition controller and DetCon detonation control system The following diagram shows an example of the wiring of a MIC5 ignition controller with a DetCon detonation control system in cases where the analog current signal (4-20 mA) at the output I out is to be used for the ignition timing adjustment.

  • Page 46: Output Wiring - Binary Outputs (Go/Nogo, Gpo, Aso)

    6 Wiring of the Device 6.1.5 Output Wiring – Binary Outputs (Go/NoGo, GPO, ASO) Example Configuration *) DetCon or other external device (for wiring of the DetCon, see following example) K1 = Go/NoGo relay K2 = GPO relay L ≙ 7 V DC to 32 V DC (L ≙...

  • Page 47: Wiring - Powerview3

    As shown in the following illustration, you can connect the PowerView3 directly to the MOTORTECH ignition controller using the CAN cable delivered with the PowerView3. To do so, you need to insert the connector in the CAN interface on the PowerView3. On the ignition controller, connect the color-coded conductors of the CAN cable to the correct CAN interface connections.
  • Page 48 PowerView3 Power Supply via the Ignition Controller If you use a MOTORTECH ignition controller with a service cover and connector strip, you have the option of supplying power to the PowerView3 via the ignition controller. A special connector is included in the PowerView3's scope of supply.

  • Page 49: Output Wiring - Can Bus Interface

    6 Wiring of the Device 5. From the PowerView3 power supply cable, plug the L– wire (white) into contact . For plugging into the contact, use a wire end ferrule provided with the PowerView3. 6. From the PowerView3 power supply cable, plug the L+ wire (brown) into contact .
  • Page 50 ® If you require information on the CANopen ® protocol, contact your MOTORTECH contact person. CAN bus wiring Note the following when connecting the CAN bus: Each bus end must be fitted with a terminating resistor of 120 Ω (see –...

  • Page 51: Output Wiring - Rs485 Interface

    6 Wiring of the Device 6.1.8 Output Wiring – RS485 Interface The RS485 interface can be wired as two-wire or four-wire wiring and twisted cables must be used. With both variants the load resistance (R =120 Ω) is the characteristic impedance of the cable.
  • Page 52 6 Wiring of the Device Connection on the Ignition Controller Wiring of the RS485 interface Follow these instructions for the RS485 interface wiring: Max. 32 devices can be connected to a bus. – The maximum wire length is 100 m (328') depending on the transfer –...

  • Page 53: Ignition Coil Wiring

    (see section Engine – Parameters on page 88). Conductor cross-section for primary wiring If you do not use a harness manufactured by MOTORTECH, the primary wiring must have a conductor cross-section of 1.5 mm². Rev. 03/2019...

  • Page 54: Ignition Coil Wiring For A 35-Pole Connector

    6 Wiring of the Device 6.2.1 Ignition Coil Wiring for a 35-Pole Connector The table shows the pole assignments for the output connector. 35-pole output connector (outside view) Pole Output Pole Output Output A1 Output A6 Output B1 Output B6 Output A2 Output A7 Output B2...

  • Page 55: Ignition Coil Wiring 17-Pole And 14-Pole Connector

    6 Wiring of the Device 6.2.2 Ignition Coil Wiring 17-Pole and 14-Pole Connector The table shows the pole assignments for the output connector. 17-pole output connector and 14-pole output connector (MIC5, outside view) The MIC5-SE has only one 17-pole output connector. Pole...

  • Page 56: Straight Order Wiring Of The Ignition Outputs

    You can use straight order wiring, if: Wiring takes place via a corresponding MOTORTECH wiring harness and a MOTORTECH – wiring rail. The harness is marked with the following information: PLEASE NOTE! The firing order needs to be configured directly in the ignition controller.

  • Page 57: Straight Order Wiring Of The Ignition Outputs - Overview

    6 Wiring of the Device 6.2.4 Straight Order Wiring of the Ignition Outputs – Overview MIC5 The following table contains the allocation of the MIC5 outputs to the cylinders. Output In-line engine V-engine Connector* Coil** Connector* Coil** Output A1 Output B1...
  • Page 58 6 Wiring of the Device MIC5-SE The following table contains the allocation of the MIC5-SE outputs to the cylinders. Output In-line engine V-engine Connector* Coil** Connector* Coil** Output A1 Output A2 Output A3 Output A4 Output A5 Output A6 Output A7...

  • Page 59: Functions

    Pickups on page 96. 7.2 Monitoring of Pickup Signals The MIC5 monitors the pickup signals. Any other errors are displayed in the MICT. For more information on the errors, please refer to the overview in the section entitled Pickup Input Errors on page 164.

  • Page 60: Ignition Timing Adjustment

    7 Functions Use master control The outputs of the MIC5 are not SIL compliant. Therefore, always use an additional master control for safety-critical applications. 7.4 Ignition Timing Adjustment The ignition controller has several functions for the timing correction. Influences on ignition timing Be aware that the actual timing of the engine can also be influenced by external signals (e.g., analog current or voltage input).
  • Page 61 7 Functions Per schedule: Base Timing Speed Curve Analog Voltage Input Analog Current Input Potentiometer Global: Ignition Timing Correction Per cylinder: Cylinder Individual Limited by the Offset min./max. cylinder individual offset Limited by the min./max. Timing Rev. 03/2019...

  • Page 62: Manual Timing Correction

    7 Functions 7.4.1 Manual Timing Correction The ignition controllers of the MIC5 series include two permanently installed overwind-protected potentiometers for manually correcting the ignition timing. The max. range is defined with the corresponding limits that are set by the user. Potentiometer A adjusts the ignition timing of schedule A and potentiometer B adjusts the igniting timing of schedule B.
  • Page 63 7 Functions Configuration examples In this example the analog inputs are configured in the Timing – Analog Inputs window as follows: – Input current: 4-20 mA – Input voltage: 0-5 V Characteristic 4-20 mA / 0-5 V – Ignition timing adjustment toward retarded.

  • Page 64: Cylinder-To-Cylinder Alignment

    7.4.4 Speed Curve To optimize the ignition, for example, during the start phase of the engine, a speed curve can be defined for the MIC5 ignition controllers. To create this curve, up to eight adjustable speed points are available. You can configure the speed curve with the MICT. Refer to the section Timing – Schedule A/B –...

  • Page 65: Output Monitoring

    7 Functions 7.7 Output Monitoring Electronic switches are used for the ignition outputs of the MIC5 ignition controller If one of these switches is defective, this would lead to a primary short or a primary open output. This can cause problems when operating the engine or can damage the engine. The function of the outputs is therefore monitored and errors that occur are displayed in the runtime data in the MICT or can be transmitted via field buses.

  • Page 66: Gpo: General Purpose Output

    Inputs/Outputs – Alarms on page 106. 7.11 ASO: Auxiliary Synchronization Output The ASO is an output of the MIC5 for synchronizing the MIC5 ignition controller and a connected control unit. The possible applications include detonation control, valve control, and fuel injection control.
  • Page 67 The ASO signal generated by the MIC5 increases by 2° each time before the ignition signal from Low to High, as can be seen in the schematic drawing. This edge is analyzed by the valve controller as the active edge.

  • Page 68: Ignition Energy

    MIC5. Although he has the full authorization set in the MICT, he is prompted to log in with the PIN for the Level 3 (Master) on the MIC5. A variety of functions are at your disposal in the four operating levels of the MIC5 . The figure below illustrates this:...
  • Page 69 7 Functions The following functions are available on the different levels: – Level 0 (Read Only) Enables read-only access for all users. – Level 1 (Operator) The user can operate the Alarm Commands, Error Commands, and the Misfire Counter on this level.

  • Page 70: Settings Via The Mict

    8 Settings via the MICT MICT is an abbreviation for MOTORTECH Integrated Configuration Tool. With the MICT, you can configure your ignition controller, and you can view and adjust the operating data of your engine. When working with the MICT, you can press the F1 key at any time to access context- sensitive help.

  • Page 71: Access Levels In The Mict

    8.3 Access Levels in the MICT You can open the MICT on your PC via Start -> Programs -> MOTORTECH -> MICT 2.x.x -> MICT 2.x.x. After opening the MICT, select the access level for which you have clearance. The access level controls the options you have at your disposal in the MICT.

  • Page 72: Configuration Pages (Overview)

    8 Settings via the MICT 8.4 Configuration Pages (Overview) The configuration pages are divided into the following sections: Item no. Area Menu bar Toolbar Navigation bar Configuration section Status bar The functions in the menu bar, navigation bar and the toolbar as well as the configuration section will be described in the following.

  • Page 73: Menu Bar And Toolbar

    – – Indication of the access level of the user in the MICT Indication of the operating level for the MIC5 if access control has been activated and the – user has logged on with a PIN. Indication of the MICT program version –...
  • Page 74 8 Settings via the MICT Symbol Menu Function Prints the current configuration. File -> Print Prints the configuration to a PDF file. File -> Print To PDF File Opens a print preview of the configuration. File -> Print Preview Exits the MICT. File ->...
  • Page 75 Acknowledge operational error running. (Keyboard shortcut: Strg+R) The setup for the access control to the MIC5 is Device -> Access Control described in a separate section. Please read the section Access Control for MIC5 on page 81.

  • Page 76: Online Update Settings

    Perform regular online updates MOTORTECH is constantly expanding its databases. Perform regular online updates to make optimal use of the opportunities that the MIC5 provides. The MICT uses data from an engine database and a coil database for the configuration. Such data can be updated with automatic online updates.

  • Page 77: Self Test

    8 Settings via the MICT – Show Log With this button, you can open a window in which the online updates performed are logged. – Update Now With this button, you manually start an online update. 8.7 Self Test Operational safety! If you carry out a self test, it is essential for the gas supply to be switched off and no more residual gas is left in the combustion chamber.

  • Page 78: Pickup Trace

    8 Settings via the MICT – Active The self test is running. – Ready The ignition controller is ready and the self test can be started. You have the following options: Cycles – Determine whether the self test should run unlimited or be terminated after a defined number of cycles.
  • Page 79 8 Settings via the MICT Pickup trace Example of a pickup trace for a configuration with three pickups: – Pickup input 1 (cam): Single event from the camshaft – Pickup input 2 (reset): Single event from the crankshaft Pickup input 3 (trigger): –...
  • Page 80 8 Settings via the MICT There are the following options for the display of the pickup signals: – Zoom In/Out Using the mouse scroll wheel you can zoom in and out of the displayed record range. Alternatively you can also use the plus and minus keys on the keyboard. With the zoom function, you can e.g.

  • Page 81: Access Control For Mic5

    MICT. If the configuration of the pickup inputs is not valid (e.g. three signals from the same shaft), no signals are recorded. 8.9 Access Control for MIC5 If the access control to the MIC5 is activated, access to the following areas is possible with a PIN only: Runtime Adjustment (Reset, timing, energy, secondary voltage estimation calibration and –...

  • Page 82: Login/Logout

    8 Settings via the MICT To enable or disable the access control, proceed as follows: Open the input dialog via Device -> Access Control -> Enable or Disable access control. 2. Enter the PIN for the level Master (Level 3). 3.

  • Page 83: Working With Configurations

    In the menu bar, select the entry Device -> Access Control -> Get reset all PINs request key to open a window with the same name. 2. Send the request key with the serial number to your service contact person at MOTORTECH (refer to Customer Service Information on page 165). This key is valid only for the respective controller and only for a certain amount of time.

  • Page 84: Create, Open, Save

    8 Settings via the MICT 8.10.1 Create, Open, Save Click on the symbol to create a new configuration and select the corresponding device type. The device type corresponds to the first five digits of the arrangement number, which you can find on a label on your device. Click on the symbol to open a saved configuration.

  • Page 85: Upload, Download

    If applicable, the MICT first establishes a connection to the MIC5 connected. Click on the symbol to download the configuration set in the MICT to the MIC5. This function can only be executed while the ignition is not active. This action overwrites the existing configuration on the device.

  • Page 86: Compatibility Information

    MICT's configuration views. 8.10.3 Compatibility Information If you upload a configuration from the MIC5 to the MICT that does not correspond to the status of your MICT, or if you open this type of configuration in the MICT, the following situations may occur: –...

  • Page 87: Configuration

    8 Settings via the MICT 8.11 Configuration The window opens after you select the device type for a new configuration or an existing configuration or have uploaded one from the ignition controller. You can make changes to the configuration by selecting an entry from the navigation bar. The corresponding configuration data are then displayed in the configuration section and can be processed.

  • Page 88: Engine - Parameters

    8 Settings via the MICT 8.11.1 Engine – Parameters Engine Selection The MICT holds an engine database with data from various manufacturers and model series. Select the desired engine manufacturer, series, and type by clicking on the corresponding fields. Rev. 03/2019...
  • Page 89 You can use straight order wiring, if: – Wiring takes place via a corresponding MOTORTECH wiring harness and a MOTORTECH wiring rail. The harness is marked with the following information: PLEASE NOTE! The firing order needs to be configured directly in the ignition controller. The ignition coils on the wiring rail are marked with Connector Pin 1 to Connector Pin X.
  • Page 90 8 Settings via the MICT Engine database MOTORTECH does not assume liability for the information in the engine database. Please contact MOTORTECH if discrepancies are found. New Engine Configuration Staff with the authorization for the Advanced Service level additionally has the option for entering the engine data manually, i.e., without selecting entries from the engine database.

  • Page 91: Engine - Cylinder Names

    8 Settings via the MICT 8.11.2 Engine – Cylinder Names To facilitate the allocation of the cylinders during the configuration of the ignition outputs, you can individually name each cylinder. The schematic representation of the plan view of the selected engine supports you in this. Enter the following settings: Enable Cylinder Names –...

  • Page 92: Engine - Ignition Outputs

    8 Settings via the MICT – Cylinder Names Enter a name for the respective cylinder. – currently not used Show banks in reverse order – currently not used 8.11.3 Engine – Ignition Outputs Make adjustments to the following settings as needed: –...
  • Page 93 8 Settings via the MICT – Column: Output Select the number of the respective output. – Column: Angle Enter the firing angle for each output. Default Application If you select from the engine database, the data stored for the selected configuration are displayed.

  • Page 94: Engine - Ignition Coils

    Different coil types must not be mixed and also no equivalent or replacement types may be used. If a coil type used is not in the drop-down list, then the MIC5 is currently not used.
  • Page 95 8 Settings via the MICT Secondary Diagnostics Enabled The secondary diagnosis can be deactivated and activated for ignition coils that support this function. If the ignition coil does not support this function, the secondary voltage estimation calibration and the of the secondary short calibration are not available. Secondary Voltage Estimation Calibration A correction value without units can be set for the secondary voltage estimation for every configured output to increase the accuracy of the secondary voltage estimation for each...

  • Page 96: Engine - Pickups

    8 Settings via the MICT 8.11.5 Engine – Pickups Active pickups Check when using active pickups that the auxiliary supply voltage is configured for your application. Pickup Setup Information The settings made in the section Pickup Setup were summarized once again in the section Pickup Setup Information.
  • Page 97 8 Settings via the MICT Pickup Setup Enter the following settings in this section: – Predefined Setup Select the pickup configuration suitable for your application from the list. The configurations available for selection depend on the previously entered settings. Index/Reset Position –...
  • Page 98 8 Settings via the MICT – Type You can select the type of events that will occur on this input for each pickup input. Type and number of events are defined by the discs or ring gears used. If you decide not to use a pickup input, select the entry None from the list.
  • Page 99 8 Settings via the MICT – Active/Passive Select the pickup to be used from the pre-defined pick list: Passive passive pickup Active (low) active pickup with high level as quiescent level Active (high) active pickup with low level as quiescent level –...

  • Page 100: Timing - Analog Inputs

    Max. Power-on Speed Enter the maximum permitted start speed at which the MIC5 starts sending ignition pulses. A value of 6000 rpm is set as the default value: The MIC5 can be activated at the starter speed and immediately send ignition pulses.
  • Page 101 8 Settings via the MICT Analog Inputs Base Settings The ignition timing adjustment can be made using two analog input signals, which can be set within the following limits: – Analog current signal: 0-20 mA Analog voltage signal: 0-10 V –...

  • Page 102: Timing - Schedule A/B - General

    8.11.7 Timing – Schedule A/B – General Schedule A General Settings The MIC5 offers two schedules for implementing the necessary settings for the timing of the engine. The schedules A and B can be used for dual fuel operation, for example. The system switches between the schedules via the input Schedule A/B.
  • Page 103 8 Settings via the MICT Base Timing Enter the timing specified by the engine manufacturer. This point must be within the limits entered and is a static portion of the global timing. Potentiometer Function The checkbox enables and disables the potentiometer function for manually adjusting the global timing by the respective stops of the potentiometer set, depending on the direction of rotation.

  • Page 104: Timing - Schedule A/B - Energy

    8 Settings via the MICT 8.11.8 Timing – Schedule A/B – Energy You can make different energy settings for the start phase and normal operation. Start Phase Set the start phase of your engine. To do this you can enter a Speed Limit, a Time Limit or both. If you enter values for both criteria, both values must also be exceeded, so that the ignition controller classifies the start phase as ended and sets the values for normal operation.

  • Page 105: Timing - Miscellaneous

    8 Settings via the MICT Energy Limit You can use the field Energy Limit to limit the output energy made available by the ignition controller. If the set output energy is no longer sufficient to reach the set energy values (spark duration, spark intensity, max.

  • Page 106: Inputs/Outputs - Alarms

    If the specified ignition timing adjustment is larger than the given value, it is divided among several cycles. 8.11.10 Inputs/Outputs – Alarms The MIC5 ignition controllers include a total of 16 configurable alarms that can be allocated to the general purpose outputs. Description –...
  • Page 107 8 Settings via the MICT – Spark plug operating hours above threshold / below threshold – Warning active – Error active – Temperature above threshold / below threshold – Analog voltage input over threshold / under threshold – Analog current input over threshold / under threshold –...

  • Page 108: Inputs/Outputs - Aso1 (Auxiliary Synchronization Output)

    8 Settings via the MICT – Outputs Activate the checkbox GPO1, so that the general purpose output is activated when the alarm is triggered. – GPO Settings Configure the general purpose output as normally closed or normally open. 8.11.11 Inputs/Outputs – ASO1 (Auxiliary Synchronization Output) With the auxiliary synchronization output, freely definable impulses depending on the angle of the crankshaft can be generated.
  • Page 109 8 Settings via the MICT – Angle Reference Select from the Angle Reference drop-down list whether the angle shall be based on the absolute angle of the crankshaft or the actual angle depending on global timing. Then, enter the trigger angle for each impulse and the length of the impulse in μs. This setting also determines when ASO signals are generated.

  • Page 110: Inputs/Outputs - Inputs

    8 Settings via the MICT ASO signals depending on the ignition release The setting in the drop down list Angle Reference determines when ASO signals are generated: – Actual Angles Depending on Global Timing ASO pulses are only transmitted if ignition is active, indicated by the green status display Firing Active in the window Runtime Data –...

  • Page 111: Miscellaneous - Communication

    8 Settings via the MICT Various functions can be selected for the general purpose input GPI1: – Disabled The input GPI1 will not be used. – CAN reset (1 s pulse), device reset (5 s pulse) This feature allows (e.g. a master control) to trigger a CAN reset and/or a device reset externally using a high impulse.
  • Page 112 8 Settings via the MICT Clicking on the CAN checkbox enables or disables the CAN interface on the device. – ALL-IN-ONE (J1939)/J1939/CANopen Select the desired protocol, depending on whether you want to set the communication for the ALL-IN-ONE or for another device. For example, for a connection to the PowerView3, select CANopen.

  • Page 113: Miscellaneous - Information

    8 Settings via the MICT Information on protocols Please contact your MOTORTECH contact person if you require more information on the CANopen, J1939 and Modbus protocols. 8.11.14 Miscellaneous – Information This configuration page can be viewed by all users, but changes can only be made with authorization for the Service access level.

  • Page 114: Runtime Data

    8 Settings via the MICT Site and Module In this section, enter information on the system and the module for which the configuration will be used. Service Contact In this section, individual contact data can be saved that can be called up and displayed via MICT.

  • Page 115: Runtime Data - Overview

    8 Settings via the MICT 8.12.1 Runtime Data – Overview In this screen, you can find the following information: – Speed Indicator (analog) – Red pointer Displays the current registered speed – Yellow pointer Displays the maximum registered speed since last starting the engine –...
  • Page 116 8 Settings via the MICT – Operating Hours – Spark Plugs Indicates the current operating hours of the spark plugs – Engine Indication of current operating hours of the engine Device State – The status of the device is shown by the following status displays: Device status Description Idle...
  • Page 117 Displays the misfire rate for all the ignition outputs for the past 32 cycles. – The number of misfires per second are calculated by the MIC5 as follows: 2-stroke engine: Number of currently misfiring outputs x RPM / 60 4-stroke engine: Number of currently misfiring outputs x RPM / 60 / 2...

  • Page 118: Runtime Data - Timing

    8 Settings via the MICT 8.12.2 Runtime Data – Timing In this view, the system displays all values and settings in the left hand section that influence the timing. On the right, the current input values (e. g. potentiometer, analog current and voltage input), leading to the displayed timing adjustment, are displayed numerically and in bar charts.

  • Page 119: Runtime Data - Ignition

    8 Settings via the MICT 8.12.3 Runtime Data – Ignition The following information is provided: – Column: Output Designation of the output Column: Cylinder – If cylinder names are assigned, these are displayed. Column: Estimated Secondary Voltage [kV] – Secondary voltage determined by the ignition controller of the respective output. The secondary voltage is used to determine deviations between the individual outputs.

  • Page 120: Runtime Data - Bank A And B

    The coil data version configured in the MIC5 is displayed under the ignition runtime data. 8.12.4 Runtime Data – Bank A and B The following information is provided: –...
  • Page 121 8 Settings via the MICT – Column: Min. Spark Duration Minimum spark duration of the outputs – Column: Energy Output Current energy release of the output Columns: Misfire – Status display for the different types of misfires (primary, secondary, open, short circuit). In case of misfire, the respective status display turns red, otherwise it is gray.

  • Page 122: Runtime Data - States

    8 Settings via the MICT 8.12.5 Runtime Data – States Status messages are listed in the States view. The following information is provided: – Operating Hours Operating hours counter reading at the time of message Time – Date and time of the message (see following information box) Status Message –...
  • Page 123 8 Settings via the MICT Date and time of ignition controller The date and time can be individually configured for each ignition controller and saved in the device. The device does not adjust automatically for daylight savings time. Hence, deviations may occur between the device time and the time on the computer used to access the device.
  • Page 124 The current sensor of output bank name failed. Restart name failed. the ignition controller. If the error occurs again after restarting the device, please contact MOTORTECH. Cylinder individual timing limited The cylinder-individual offset has reached the set limit to range timing 1 .. timing 2 (Timing 1 ...
  • Page 125 Anumber/Bnumber. Anumber/Bnumber was detected. Restart the ignition controller. If the error occurs again after restarting the device, please contact MOTORTECH. Power output (x W) exceeded error The power output (x W) exceeded failure threshold (y W) at threshold limit (y W) at a supply a supply voltage of z V.
  • Page 126 8 Settings via the MICT Status message Description PUnumber: Faulty Signal. Signal The pickup (PUnumber) is supplying a faulty signal. period (x, events counted y) is too Signal period (x, events counted y) is too small compared small compared to previous signal to previous signal period (z).
  • Page 127 8 Settings via the MICT Status message Description PUnumber: Number of events (x) For the pickup (PUnumber) the number of events (x) counted on pickup input counted on pickup input number does not the match the PUnumber does not the match the expected value (y).

  • Page 128: Runtime Data - Message Log

    Temperature sensor failed. The temperature sensor has failed. Restart the ignition controller. If the error occurs again after restarting the device, please contact MOTORTECH. 8.12.6 Runtime Data – Message Log Rev. 03/2019...
  • Page 129 8 Settings via the MICT In the view Message Log, information, warnings, errors and alarms are listed. Information, warnings and errors are specified by the ignition controller, while alarms can be freely configured using the MICT. Refer to the section Inputs/Outputs – Alarms on page 106. Errors and appropriately configured alarms shut down the engine.

  • Page 130: Information

    MIC5 on page 81). All access control PINs reset. All PINs for access control were reset (see Access Control for MIC5 on page 81). CAN interface CANnumber entered The CAN interface CANnumber has entered Bus off state bus off state.
  • Page 131 Failed to change PIN of access Failed to change PIN of access control level "number" (see control level "number". Access Control for MIC5 on page 81). Failed to disable access control. The access control could not be disabled (see Access Control for MIC5 on page 81).
  • Page 132 PIN of access control level PIN of access control level "number" changed (see Access "number" changed. Control for MIC5 on page 81). Self test denied because no The self test could not be carried out because no outputs outputs are configured.

  • Page 133: Warnings

    General warning number. General warning number. An undefined warning has occurred. If this occurs repeatedly, please contact MOTORTECH. Incompatible coil parameters Incompatible coil parameters received. The secondary received, secondary voltage voltage diagnostics have been disabled. This message diagnostics disabled.

  • Page 134: Alarms

    Critical error x (y). If the error occurs again after restarting the device, please contact MOTORTECH. Current sensor of output bank The current sensor of output bank name failed. Restart name failed. the ignition controller. If the error occurs again after restarting the device, please contact MOTORTECH. Rev. 03/2019...
  • Page 135 General error number. General error number. An undefined error has occurred. Restart the ignition controller. If the error occurs again after restarting the device, please contact MOTORTECH. General error in pickup General error in pickup pre-processing on pickup input pre-processing on pickup input PUnumber.
  • Page 136 Anumber/Bnumber. Anumber/Bnumber was detected. Restart the ignition controller. If the error occurs again after restarting the device, please contact MOTORTECH. Power output (x W) exceeded error The power output (x W) exceeded failure threshold (y W) threshold limit (y W) at a supply at a supply voltage of z V.
  • Page 137 Temperature sensor of controller The temperature sensor of controller board failed. Restart board failed. the ignition controller. If the error occurs again after restarting the device, please contact MOTORTECH. Temperature sensor of output The temperature sensor of output board failed. Restart board failed.

  • Page 138: Runtime Data - Diagnostics

    8 Settings via the MICT 8.12.7 Runtime Data – Diagnostics The following information is provided: – CAN State The status display indicates the current error handling status of the device for the CAN bus communication: – Error Active The device is in normal status of the bus communication. If an error occurs in the communication, the device sends an active Error Flag.
  • Page 139 8 Settings via the MICT – Controller Board – Supply Voltage Current voltage supply of the controller board. – Pickup Input Pre-Trigger Voltage Current pre-trigger voltage for the pickup inputs (refer to Engine – Pickups on page 96). During operation the pre-trigger voltage for passive pickups is increased depending on the speed, so that the ignition controller is less prone to interferences.

  • Page 140: Runtime Data - Temperatures

    8 Settings via the MICT 8.12.8 Runtime Data – Temperatures In the window you receive an overview of the temperatures of the controller board and the output board. The maximum and minimum values are reset at each new start of the ignition controller.

  • Page 141: Runtime Data - Information

    In this view, you can find an overview of the device and version data. If problems arise, you can print the current runtime data and send them to the MOTORTECH Service Department by fax or as a PDF file by email. For fast support, we will then immediately have all required information.

  • Page 142: Log

    If the function is active, the view panel focuses on the latest message. – Log level The selection of the log level is specified by MOTORTECH if needed. Write log to file – This checkbox activates or deactivates, respectively, the saving of the logged data in a selected file.

  • Page 143: Runtime Adjustments

    Runtime adjustments are implemented directly All runtime adjustments are implemented directly without requiring the input to be confirmed and are retained even in the case of a MIC5 restart. Changes that have been saved in the device configuration are only displayed after re-uploading the device configuration in the MICT's main window.

  • Page 144: Runtime Adjustments - Reset

    8 Settings via the MICT 8.14.1 Runtime Adjustments – Reset The index/reset position can be corrected by 5 °crankshaft (advanced/retarded) while the device is being operated. The correction is made with the buttons: 0.1 ADV/RET – in 0.1° increments to advance or retard 0.5 ADV/RET –...

  • Page 145: Runtime Adjustments - Timing

    8 Settings via the MICT 8.14.2 Runtime Adjustments – Timing The global ignition timing position can be corrected by 50 °crankshaft (advanced/retarded) while the device is being operated. The correction is made with the buttons: 0.1 ADV/RET – in 0.1° increments to advance or retard 0.5 ADV/RET –...

  • Page 146: Runtime Adjustments - Energy

    8 Settings via the MICT 8.14.3 Runtime Adjustments – Energy The energy settings can be separately adjusted for both schedules. Changes are implemented immediately and stored in the configuration provided in the device. Spark Duration – +/- 1 μs lengthen or shorten in microsecond increments –...

  • Page 147: Runtime Adjustments - Secondary Voltage Estimation Calibration

    8 Settings via the MICT 8.14.4 Runtime Adjustments – Secondary Voltage Estimation Calibration The secondary voltage estimation can be calibrated in this window when using ignition coils that support this function: A correction value without units can be set for the secondary voltage estimation for every output to increase the accuracy of the secondary voltage estimation for each individual cylinder.

  • Page 148: Runtime Adjustments - Secondary Short Calibration

    8 Settings via the MICT 8.14.5 Runtime Adjustments – Secondary Short Calibration The starting voltage and sensitivity for the secondary short-circuit detection can be adjusted. Changes are implemented immediately and stored in the configuration provided in the device. Secondary Short Enable Voltage [kV] Set the necessary average ignition voltage required to activate the secondary short-circuit monitoring: –...

  • Page 149: Cylinder Individual Offsets

    8 Settings via the MICT Adjust the sensitivity of the short-circuit monitoring If a short-circuit is misdiagnosed at a sensitivity of 1.00, the sensitivity must be set to 1.02. If a short-circuit is not detected at a sensitivity of 1.00, the sensitivity must be set to 0.98.
  • Page 150 8 Settings via the MICT Immediate execution of the changes Please note that changes made to the timing point are executed immediately at the next firing of the corresponding cylinder. The maximum performed change per cycle is however limited by the corresponding setting in the configuration.

  • Page 151: Schedule Curve

    8 Settings via the MICT 8.16 Schedule Curve Click on the symbol to open the window Schedule. 8.16.1 Schedule Curve – Simulation The schedule curve visualizes the configurations of the schedules and simulates the influence of the inputs via the speed range. With the optional input fields, you can switch between schedule A and B.
  • Page 152 8 Settings via the MICT – Analog Current Input Simulation of the analog current input – Control button for adjustments between the configured values (e.g. 0 mA and 20 mA) – Field for manual input of the desired value in mA –...

  • Page 153: Schedule Curve - Runtime Values

    8 Settings via the MICT 8.16.2 Schedule Curve – Runtime Values If the checkbox Simulation is unchecked, the Schedule curve window switches to the current runtime data. The following information is provided: – Schedule Displays the currently selected schedule. Left column: Potentiometer, Analog Current Input, Analog Voltage Input –...

  • Page 154: Coils

    8 Settings via the MICT 8.17 Coils The MICT has a database with technical information on MOTORTECH ignition coils. Open the database as follows: Tools -> Coils You have the option of storing and printing information on the ignition coils present in the database.

  • Page 155: General

    8 Settings via the MICT 8.17.1 General Details The following information is provided: – Name Coil name – Coil Type ID Used to clearly identify the ignition coil Data Version – Shows data version of the ignition coil selected in the database. The data version of the ignition coil configured in the ignition controller is displayed in the runtime data in the view Ignition (refer to Runtime Data –...
  • Page 156 8 Settings via the MICT Coil Parameters The following information is provided: – Max. Breakdown Voltage [kV] Displays the permitted value range for the maximum breakdown voltage in kV. The maximum breakdown voltage is configured in the view Ignition Timing – Schedule A/B – Energy (refer to Timing –...

  • Page 157: Min. Energy Limit Curve

    8 Settings via the MICT 8.17.2 Min. Energy Limit Curve Min. Energy Limit Curve The curve provides information on the energy in mJ necessary to achieve a certain maximum breakdown voltage in kV. The two vertical bars show the breakdown voltage area, in kV, in which a secondary diagnosis is possible.

  • Page 158: Operation

    9 Operation 9.1 Start-up Before you start up the MIC5 ignition controller, take note of the following: Were the correct engine, ignition sequence, and output configuration selected? 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 –...

  • Page 159: Firmware Update

    Directly from the storage device: Start the exe file in subdirectory Drivers (e.g. CDM v2.10.00 WHQL Certified.exe). ▸ The MOTORTECH Flash Tool is set up. You can now connect your computer to the ignition controller via the USB interface. Rev. 03/2019...
  • Page 160 9 Operation Menu Bar and Toolbar After launching the MOTORTECH Flash Tool, the following functions are available to you via the icons on the toolbar and the entries in the menu bar: Symbol Menu Function Opens a firmware file. File -> Open Exits the program.
  • Page 161 3. In the Status section under Device, check if your device has been recognized properly. ▸ If the MOTORTECH Flash Tool does not recognize a device that is connected to your PC via the USB interface, you can usually still carry out a firmware update. To do so, observe the instructions in the information windows of the MOTORTECH Flash Tool for the following steps.
  • Page 162 9 Operation Help with connection problems If a correctly connected device is not found during the automatic search, this can, for example, be because too many communication interfaces are assigned and must be checked. In this case, an interface from the drop- down list Port in the area Connection can be selected and thus specified.

  • Page 163: Errors

    10 Errors 10.1 Possible Faults The MIC5 ignition controllers include several safety functions that can shut down the engine in case of fault: Overspeed protection – External shut-down contact (Start/Stop) – – Misfire detection (primary) – Internal failure of the high voltage supply –...

  • Page 164: Pickup Input Errors

    10 Errors 10.2.4 Pickup Input Errors Faulty input signals from the pickups are detected. Potential Causes – Number of teeth on the flywheel does not match the set number. – Damage to or uneven running of trigger disc – Interference in the wiring of the pickup –...

  • Page 165: Troubleshooting

    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...

  • Page 166: Instructions For Packaging The Equipment

    10 Errors 10.3.4 Instructions for Packaging the Equipment For return shipment, equipment should be packaged as follows: Use packaging material that does not damage the equipment surfaces. – Wrap the equipment with sturdy materials and stabilize it inside the packaging. –...

  • Page 167: Maintenance

    Service screw: 2.5 Nm to 3 Nm (1.9 lb-ft to 2.2 lb-ft) 11.2 Spare Parts and Accessories For spare parts and accessories for MIC5 ignition systems, please refer to our current product guide, which is available for download on the Internet at www.motortech.de.

  • Page 168: Index

    12 Index Cylinder name ..........91 A  Access Control D  Activate ............ 81 Declaration of conformity ....... 18 Device ............81 Device Advanced service Dimension ..........27 Access level ..........71 Disposal ........... 16 Alarm Electrical data ........... 21 Acknowledge ...........128 Installation ..........
  • Page 169 Ignition coils Overview ..........120 Setting ............94 MOTORTECH Wiring ............53 Address ........... 165 Ignition controller MOTORTECH Integrated Configuration Tool Dimension ..........27 Access level ..........71 Disposal ............ 16 Design ............72 Electrical data ........... 21 Installation ..........70 Installation ..........
  • Page 170 12 Index Safety Instructions ......... 11 P  Secondary voltage Parameter settings (schedule) Secondary short detection ....... 148 Function ........... 65 Secondary voltage estimation ....147 Representation ........153 Security speed Setting ..........102, 104 Setting ............96 Simulation ..........151 Self Test ..........
  • Page 171 12 Index T  Temperature Board ............140 Timing Base ..........115, 118 Global ..........115, 118 Limits............102 Overview ..........118 Setting ............ 145 Timing correction Current value ..........118 Function ............ 64 Timing setup Wiring ............43 U  Update Process sequence ........159 Connection ..........

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Mic5-seMic3+Mic4

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