Motortech MIC-Marine User manual

MIC6 – Ignition Controller
Operating Manual
P/N 01.10.026-EN | Rev. 09/2019

Original instructions
Copyright
© Copyright 2019 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.
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.

Rev. 09/2019 3
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
1.4 Which Abbreviations/Acronyms Are Used in the Operating Manual?...........................9
2 Safety Instructions .................................................................................................... 11
2.1 General Safety Instructions ....................................................................................11
2.2 Electrostatic Discharge Hazards ............................................................................ 12
2.3 Information on Electric Isolation............................................................................ 13
2.4 Special Safety Instructions for the Device .............................................................. 15
2.5 Proper Disposal.................................................................................................... 16
3 Intended Use ............................................................................................................. 17
3.1 Functional Description .......................................................................................... 17
3.2 Applications......................................................................................................... 17
4 Product Description ...................................................................................................18
4.1 Technical Data ...................................................................................................... 18
4.1.1 Certifications ..................................................................................................... 18
4.1.2 Mechanical Data ................................................................................................20
4.1.3 Warning Notices on the Device............................................................................ 21
4.1.4 Product Identification – Labeling on the Device....................................................22
4.1.5 Electrical Data....................................................................................................23
4.1.6 Interfaces..........................................................................................................26
4.1.7 Requirements for External Equipment ..................................................................26
4.1.8 Overview Drawings ............................................................................................ 27
4.1.9 LED Functions ....................................................................................................29
5 Installation Instructions.............................................................................................32
5.1 Unpacking............................................................................................................ 32
5.2 Installation of the Ignition Controller ..................................................................... 33
5.2.1 Installation of the Vibration Dampers ..................................................................34
5.2.2 Installation of the Ground Strap..........................................................................36
5.3 Determine the Installation Location of the Pickup ...................................................36
6 Wiring of the Device...................................................................................................37
6.1 Input and Output Wiring on the Controller .............................................................. 37
6.1.1 Input Wiring....................................................................................................... 37
6.1.2 Input Wiring – Power Supply...............................................................................40
Table of Contents

Table of Contents
4 Rev. 09/2019
6.1.3 Input Wiring – Pickups .......................................................................................42
6.1.4 Input Wiring – Timing and Safety Devices ............................................................ 45
6.1.5 Output Wiring – Binary Outputs (Go/NoGo, GPO, ASO) .........................................48
6.1.6 Wiring – PowerView3 .........................................................................................49
6.1.7 Output Wiring – CAN Bus Interface .......................................................................51
6.1.8 Output Wiring – RS485 Interface......................................................................... 53
6.2 Ignition Coil Wiring............................................................................................... 55
6.2.1 Ignition Coil Wiring for a 35-Pole Connector ......................................................... 56
6.2.2 Ignition Coil Wiring for 17- and 14-Pole Connectors .............................................. 57
6.2.3 Straight Order Wiring of the Ignition Outputs ...................................................... 58
6.2.4 Straight Order Wiring of the Ignition Outputs – Overview ..................................... 59
7 Functions.................................................................................................................. 60
7.1 Redundant Pickup System .....................................................................................60
7.2 Pickup Sensitivity.................................................................................................60
7.3 Monitoring of Pickup Signals.................................................................................60
7.4 Go/NoGo.............................................................................................................. 61
7.5 Ignition Timing Adjustment ................................................................................... 61
7.5.1 Analog Inputs .................................................................................................... 63
7.5.2 Cylinder-to-Cylinder Alignment ...........................................................................64
7.5.3 Speed Curve ...................................................................................................... 65
7.5.4 Ignition Timing Correction ..................................................................................65
7.6 Firing Angles ........................................................................................................ 65
7.7 HV-Power Supply Error Monitoring ......................................................................... 65
7.8 Output Monitoring................................................................................................ 65
7.9 Schedules A/B .....................................................................................................66
7.10 Alarms ...............................................................................................................66
7.11 GPO: General Purpose Outputs............................................................................. 67
7.12 ASO: Auxiliary Synchronization Outputs ............................................................... 67
7.13 Ignition Energy....................................................................................................69
7.14 Access Control ....................................................................................................69
8 Settings via the MICT................................................................................................. 71
8.1 MICT System Requirements....................................................................................71
8.2 MICT Installation...................................................................................................71
8.3 Access Levels in the MICT ..................................................................................... 72
8.4 Configuration Pages (Overview) ............................................................................ 73
8.5 Menu Bar and Toolbar........................................................................................... 74
8.6 Online Update Settings ........................................................................................ 77

Table of Contents
Rev. 09/2019 5
8.7 Self Test...............................................................................................................78
8.8 Pickup Trace ........................................................................................................ 79
8.9 Access Control for MIC6........................................................................................82
8.9.1 Enable/Disable Access Control ...........................................................................82
8.9.2 Login/Logout ....................................................................................................83
8.9.3 Changing the PIN...............................................................................................83
8.9.4 Reset all PINs ....................................................................................................84
8.10 Working with Configurations ...............................................................................84
8.10.1 Create, Open, Save...........................................................................................85
8.10.2 Upload, Download ........................................................................................... 87
8.10.3 Compatibility Information................................................................................. 87
8.11 Configuration......................................................................................................88
8.11.1 Engine – Parameters.........................................................................................89
8.11.2 Engine – Cylinder Names ..................................................................................92
8.11.3 Engine – Ignition Outputs .................................................................................93
8.11.4 Engine – Ignition Coils...................................................................................... 95
8.11.5 Engine – Speed Settings ................................................................................... 97
8.11.6 Engine – Pickups – General...............................................................................98
8.11.7 Engine – Pickups – Inputs ............................................................................... 100
8.11.8 Timing – Analog Inputs................................................................................... 103
8.11.9 Timing – Schedule A/B – General .................................................................... 104
8.11.10 Timing – Schedule A/B – Energy .................................................................... 106
8.11.11 Timing – Miscellaneous ................................................................................. 107
8.11.12 Inputs/Outputs – Alarms............................................................................... 108
8.11.13 Inputs/Outputs – ASO1, ASO2 (Auxiliary Synchronization Outputs)...................110
8.11.14 Inputs/Outputs – Inputs.................................................................................112
8.11.15 Miscellaneous – Communication ....................................................................113
8.11.16 Miscellaneous – Information ..........................................................................115
8.12 Runtime Data.....................................................................................................116
8.12.1 Runtime Data – Overview ................................................................................. 117
8.12.2 Runtime Data – Timing ................................................................................... 120
8.12.3 Runtime Data – Ignition...................................................................................121
8.12.4 Runtime Data – Bank A and B.......................................................................... 122
8.12.5 Runtime Data – States.................................................................................... 124
8.12.6 Runtime Data – Message Log...........................................................................131
8.12.6.1 Information................................................................................................. 133
8.12.6.2 Warnings.....................................................................................................135
8.12.6.3 Alarms ....................................................................................................... 136
8.12.6.4 Failure.........................................................................................................137

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6 Rev. 09/2019
8.12.7 Runtime Data – Diagnostics.............................................................................141
8.12.8 Runtime Data – Temperatures ........................................................................ 143
8.12.9 Runtime Data – Information............................................................................ 144
8.13 Log ...................................................................................................................145
8.14 Runtime Adjustments........................................................................................ 146
8.14.1 Runtime Adjustments – Reset ..........................................................................147
8.14.2 Runtime Adjustments – Timing ....................................................................... 148
8.14.3 Runtime Adjustments – Energy ....................................................................... 149
8.14.4 Runtime Adjustments – Secondary Voltage Estimation Calibration.....................150
8.14.5 Runtime Adjustments – Secondary Short Calibration......................................... 151
8.15 Cylinder Individual Offsets .................................................................................152
8.16 Schedule Curve .................................................................................................154
8.16.1 Schedule Curve – Simulation ...........................................................................154
8.16.2 Schedule Curve – Runtime Values....................................................................156
8.17 Coils .................................................................................................................157
8.17.1 General...........................................................................................................158
8.17.2 Min. Energy Limit Curve .................................................................................. 160
9 Operation ................................................................................................................ 161
9.1 Start-up ..............................................................................................................161
9.2 Shutdown ...........................................................................................................161
9.3 Firmware Update ................................................................................................ 162
10 Errors..................................................................................................................... 166
10.1 Possible Faults.................................................................................................. 166
10.2 Causes of Faults ............................................................................................... 166
10.2.1 Overspeed ..................................................................................................... 166
10.2.2 Output Error Detection ................................................................................... 166
10.2.3 Misfire Detection (Primary) ..............................................................................167
10.2.4 Pickup Input Errors..........................................................................................167
10.2.5 Acknowledging Faults .................................................................................... 168
10.3 Troubleshooting ............................................................................................... 168
10.3.1 Running a Self Test......................................................................................... 168
10.3.2 Customer Service Information......................................................................... 168
10.3.3 Returning Equipment for Repair/Inspection ..................................................... 169
10.3.4 Instructions for Packaging the Equipment........................................................ 169

Table of Contents
Rev. 09/2019 7
11 Maintenance........................................................................................................... 170
11.1 Maintenance Instructions................................................................................... 170
11.2 Spare Parts and Accessories .............................................................................. 170
12 Index ......................................................................................................................171

8 Rev. 09/2019
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. Furthermore, this
manual is aimed at preventing dangers to life and health of the user and third parties.
1.2 Who Is this Operating Manual Targeted to?
The operating manual provides a code of conduct for personnel tasked with the setup,
operation, maintenance, and repair of gas engines. A certain level of technical knowledge with
respect to the operation of gas engines and basic knowledge of electronic ignition systems are
necessary. Persons who are only authorized to operate the gas engine shall be trained by the
operating company and shall be expressly instructed concerning potential hazards.
1.3 Which Symbols Are Used in the Operating Manual?
The following symbols are used in this manual and must be observed:
Example
This symbol indicates examples, which point out necessary handling steps
and techniques. In addition, you receive additional information from the
examples, which will increase your knowledge.
Notice
This symbol indicates important notices for the user. Follow these. In
addition, this symbol is used for overviews that give you a summary of the
necessary work steps.
Warning
This symbol indicates warnings for possible risks of property damage or
risks to health. Read these warning notices carefully and take the
mentioned precautionary measures.
1 General Information

1 General Information
Rev. 09/2019 9
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. Term Description Explanation
ADV Advance Advanced with
respect to top dead
center
Indicates the direction for
timing
ASO Auxiliary
Synchronization
Output
Output for synchronizing the
MIC6 and other controllers
ATDC After Top Dead Center
BTDC Before Top Dead
Center
CAN bus Controller Area
Network bus
Bus for control
devices / networks
Asynchronous serial
connection system for linking
control units
CE Conformité
Européenne
Conformity with EU
directives
Mark based on EU legislation
for certain products in
conjunction with product safety
CPU Central Processing
Unit
°crankshaft Degree crankshaft Unit for the rotation angle of
the crankshaft
CSA Canadian Standards
Association
Organization that defines
standards, inspects products
for safety compliance, and
issues pertinent certifications.
DC Direct Current
DetCon Detonation Control
System Serves to prevent major engine damage that can be caused by
knocking combustion.

1 General Information
10 Rev. 09/2019
Abb. Term Description Explanation
EMI Electromagnetic
Interference
EMC Electromagnetic
Compatibility
Compatibility of electrical or
electronic equipment items
with their surroundings
GPI General Purpose Input Multi-purpose input
GPO General Purpose
Output
Multi-purpose
output
HV High Voltage
ISO International
Organization for
Standardization
LED Light Emitting Diode Light emitting electronic
semiconductor
MIC MOTORTECH Ignition
Controller
MICT MOTORTECH
Integrated
Configuration Tool
Software for the configuration
of the MIC6
MOSFET Metal Oxide
Semiconductor Field-
Effect Transistor
Semiconductor component
RET Retard Retarded with
respect to the top
dead center
Indicates the direction for
timing
RS485/
TIA485
Recommended
Standard 485/
Telecommunications
Industry Association
485
Industrial standard for a
physical interface for
asynchronous serial data
transfer
TDC Top Dead Center
USB Universal Serial Bus Serial connection system to
link a computer to external
devices

Rev. 09/2019 11
2.1 General Safety Instructions
The following safety instructions must be followed in the area in which the device is operated:
High voltage! Danger to life!
While the engine is running, the area around the ignition system especially
holds the risk of danger due to high voltage. The following parts should
therefore not be touched or removed unless explicitly stated otherwise:
–Ignition coils and caps
–Wires of the high voltage circuit
–In- and output wiring of the ignition controller
–Pickups and their wiring
Danger to persons with pacemakers!
Electromagnetic impulses in the wiring of the ignition system may exceed
the permissible limits of pacemakers. Persons with pacemakers must
therefore not be present in the vicinity of the ignition system being
operated. 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:
–The gas engine must only be operated by trained and authorized personnel.
–Operate the equipment only within the parameters specified in the technical data.
–Use the equipment correctly and for its intended use only.
–Never apply force.
–For all work such as installation, conversion, adaptation, maintenance, and repair, all
equipment must be disconnected from the mains and secured against unintentional
reactivation.
–Perform only such maintenance and repair work as is described in this operating manual,
and follow the instructions given while working.
–Only use spare parts supplied by MOTORTECH for the maintenance of the device.
–Further work must only be performed by personnel authorized by MOTORTECH. Non-
compliance with the instructions will void any warranties for the proper function of the
equipment as well as the responsibility for the validity of the certifications.
–Safety devices must not be dismounted or disabled.
–Avoid all activities that can impair the function of the equipment.
2 Safety Instructions

2 Safety Instructions
12 Rev. 09/2019
–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.
–If the system is not entirely tight and sealed, gas may escape and result in explosion hazard.
The inhalation of gas can also lead to death or severe health damages. Therefore, upon
completion of all assembly works, always check the system's tightness.
–Always ensure adequate ventilation of the engine compartment.
–Ensure a safe position at the gas engine.
–There is a risk of burning on hot surfaces. Allow the engine to cool down before starting any
work.
–Personal protective equipment (PPE), e.g. safety shoes and gloves, must be worn during all
work on the engine.
–Your behavior can reduce possible residual risks to a minimum. Observe responsible
handling of the gas engine and the gas-carrying system.
2.2 Electrostatic Discharge Hazards
Electronic equipment is sensitive to static electricity. To protect these components from damage
caused by static electricity, special precautions must be taken to minimize or prevent
electrostatic discharge.
Observe these safety precautions while you work with the equipment or in its vicinity.
–Before performing maintenance or repair work, ensure that the static electricity inherent to
your body is discharged.
–Do not wear clothing made from synthetic materials to prevent static electricity from
building up. Your clothing should therefore be made of cotton or cotton mix materials.
–Keep plastics such as vinyl and Styrofoam materials as far away from the control system, the
modules, and the work environment as possible.
–Do not remove the circuit boards from the housing of the device.

2 Safety Instructions
Rev. 09/2019 13
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)
–Unwanted leakage currents
Therefore, earth potential and the negative pole of the power supply of all devices in the electric
assembly that provide the option, should be connected separately. If possible, the negative pole
of the power supply should only be connected to earth potential at one point in the entire
system.
Wiring Example
Device with
shielded wires
Device featuring
protection class II

2 Safety Instructions
14 Rev. 09/2019
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. Due to impedance (resistance R > ) of the loop, low-
frequency interference currents can lead to an unwanted voltage drop in the
signal path.
Device 1 Device 2
Ground loop

2 Safety Instructions
Rev. 09/2019 15
2.4 Special Safety Instructions for the Device
Danger to life! Hazardous residual voltage!
After stopping the ignition, there is dangerous residual voltage for up to
three minutes in the ignition system. Do not touch any components of the
ignition kit during this time.
Explosion hazard!
If the system is located in a hazardous area, never open the device (e. g. by
opening the service screw or removing covers). There is a risk of explosion.
Explosion hazard!
The replacement of parts or assemblies can impair compliance with CSA
Class I, Division 2 (Group C, D), T3C.
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.
Explosion hazard!
Do not remove or replace the fuse while the equipment is live.

2 Safety Instructions
16 Rev. 09/2019
Risk of burning!
The surfaces of the system may heat up to high temperatures.
Operational safety!
All connector screws and screw joints must be adequately tightened. Refer
to the section Mechanical Data on page 20.
Operational safety!
The proper functioning of the device is only guaranteed if the device is
operated within the permissible supply voltage range. Therefore, use a
power supply in accordance with the specifications in the operating
manual.
Risk of destruction!
Magnetic fields and heat occur when welding, which may damage or
destroy the MIC6. Therefore, pay attention to the following when welding:
–Disconnect all electrical connections to the MIC6 prior to welding.
–Protect the MIC6 against direct contact with the welding unit and
magnetic fields, sparks and liquid metal.
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.

Rev. 09/2019 17
3.1 Functional Description
The devices of the MIC6 series are microprocessor controlled ignition systems, each consisting
of a board with a 32 bit main processor (CPU).
Please note that the manufacturer is not required to implement configurations of the ignition
controller for specific engines, and that devices may be delivered without pertinent
configuration.
The ignition controllers of the MIC6 series use information supplied by the pickups to precisely
determine the correct timing for the respective outputs. The pickups can be assigned to two
redundant sets of pickups depending on the device version. The ignition timing is influenced by
various inputs. This can be implemented using analog input signals, a speed characteristic, or
using a serial interface (USB, CAN bus, RS485).
During operation, the ignition controllers continuously monitor the system status of all installed
pickups and the correct operation of the primary ignition circuit by checking the information
received.
Depending on the severity of an error that is detected, the device will shut down immediately or
warn the operator. A corresponding message can be viewed on a connected computer.
To protect the engine, the ignition controllers additionally have an adjustable overspeed shut-
off.
3.2 Applications
The ignition controllers of the MIC6 series are designed for specific 2- or 4-stroke gas engines.
From 1 to max. 24 ignition outputs are available. The device variants are intended for the
following use:
–MIC6: stationary gas engines
–MIC6-Marine: gas engines on ships
The ignition controllers supply the energy required for the corresponding ignition coils of the
gas engines and can supply signals for peripheral equipment.
Any use other than the one described in the operating manual shall be considered improper use
and will result in the voiding of all warranties.
3 Intended Use

18 Rev. 09/2019
4.1 Technical Data
4.1.1 Certifications
The ignition controllers of the MIC6 series are certified as per the following
directives/regulations:
CE
–EMC Directive 2014/30/EU
–EN 61326-1:2013 – Electrical equipment for measurement, control and laboratory use.
EMC requirements. General requirements
–EN 55011:2009 + A1:2010 – Industrial, scientific and medical equipment. Radio-
frequency disturbance characteristics. Limits and methods of measurement
–EN 61000-6-2:2005 – Electromagnetic compatibility (EMC). Generic standards. Immunity
for industrial environments
–EN 61000-6-4:2007 + A1:2011 – Electromagnetic compatibility (EMC). Generic standards.
Emission standard for industrial environments
–Low Voltage Directive 2014/35/EU
–EN 61010-1:2010 – Safety requirements for electrical equipment for measurement,
control, and laboratory use. General requirements
–EN 60529:1991 + A1:2000 + A2:2013 – Degrees of protection provided by enclosures (IP
Code)
–RoHS Directive 2011/65/EU
CSA
–CSA Std C22.2 No. 0 -10
–CSA Std C22.2 No. 142-M1987 (R 2004)
–CSA Std C22.2 No. 213-M1987 (R 2004)
–ANSI/ISA 12.12.01, Ed. 1 (2007)
–UL Std No. 916, Ed. 3 (1998)
4 Product Description

4 Product Description
Rev. 09/2019 19
Further Approvals for Ignition Controller of the MIC6-Marine Series
Lloyd's Register (LR)
DNV GL
Bureau Veritas (BV)
American Bureau of Shipping (ABS)
The certificates are included on the storage device enclosed with device.

4 Product Description
20 Rev. 09/2019
4.1.2 Mechanical Data
The MIC6 has the following mechanical characteristics.
Feature Value
Dimensions 391 mm x 240 mm x 114 mm (15.39" x 9.45" x 4.48")
(length x width x height) including connectors
MIC6-Marine:
Width x height including wire rope dampers:
311 mm x 149 mm (12.22" x 5.85")
Weight 6 kg (13.2 lbs)
Shape of device See chapter Overview Drawings on page 27
Mechanical environmental
conditions
The housing is resistant to general atmospheric
contaminations.
Resistant to gas engine lubricants.
Protection class: I
Protection: IP 69
The specified protection classes and types are only
guaranteed if all external wiring connections are made in
accordance with the connector specification, all covers and
seals are installed as intended and the following tightening
torques are observed:
–All M4 bolts: 0.8 Nm to 1 Nm (0.6 lb-ft to 0.7 lb-ft)
–Service screw: 2.5 Nm to 3 Nm (1.9 lb-ft to 2.2 lb-ft)
Always use a new seal when installing the service cover.
Climatic environmental
conditions
Housing surface temperature:
–40 °C to +60 °C (–40 °F to +140 °F)
Max. 95 % humidity without condensation
up to 3,000 m (9,842') above sea level
Permissible vibration
conditions
MIC6-Marine:
–2 Hz to 25 Hz with a maximum vibration displacement of
1.6 mm (0.06")
–25 Hz to 1,000 Hz with a constant acceleration of 4g
MIC6:
–2 Hz to 12.4 Hz with a maximum vibration displacement
of 1.6 mm (0.06")
–12.4 Hz to 1,000 Hz with a constant acceleration of 1g