Motortech MIC100 User manual

MIC100 – Ignition Controller
Operating Manual
P/N 01.10.044-EN | Rev. 05/2020

Original instructions
© Copyright 2020 MOTORTECH GmbH. All rights reserved.
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 and are used for reference purposes only.
Information contained in this publication may be changed without prior notice.

Rev. 05/2020 3
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
1.4 Which Abbreviations/Acronyms Are Used in the Operating Manual?...........................8
2 Safety Instructions .................................................................................................... 10
2.1 General Safety Instructions ................................................................................... 10
2.2 Electrostatic Discharge Hazards .............................................................................11
2.3 Information on Electric Isolation............................................................................ 12
2.4 Special Safety Instructions for the Device .............................................................. 13
2.5 Proper Disposal.................................................................................................... 15
3 Intended Use ............................................................................................................. 16
3.1 Functional Description .......................................................................................... 16
3.2 Applications......................................................................................................... 16
4 Product Description ................................................................................................... 17
4.1 Technical Data ...................................................................................................... 17
4.1.1 Certifications ..................................................................................................... 17
4.1.2 Mechanical Data ................................................................................................ 18
4.1.3 Warning Notices on the Device............................................................................ 19
4.1.4 Product Identification – Labeling on the Device....................................................20
4.1.5 Electrical Data.................................................................................................... 21
4.1.6 Interfaces.......................................................................................................... 23
4.1.7 Requirements for External Equipment ..................................................................23
4.1.8 Overview Drawings ............................................................................................24
4.1.9 LED Functions .................................................................................................... 25
5 Installation Instructions............................................................................................ 28
5.1 Unpacking............................................................................................................28
5.2 Installation of the Ignition Controller .....................................................................28
5.2.1 Installation of the Ignition Controller...................................................................29
5.2.2 Installation of the Ground Strap..........................................................................29
5.3 Determine the Installation Location of the Pickup ...................................................30
6 Wiring of the Device................................................................................................... 31
6.1 Input and Output Wiring on the Controller .............................................................. 31
6.1.1 Input Wiring – Power Supply ............................................................................... 33
6.1.2 Input Wiring – Pickup......................................................................................... 35
Table of Contents

Table of Contents
4 Rev. 05/2020
6.1.3 Input Wiring – Timing and Safety Devices ............................................................ 36
6.1.4 Output Wiring – Binary Outputs (Go/NoGo, ASO) ................................................. 39
6.1.5 Output Wiring – CAN Bus Interface ...................................................................... 41
6.2 Ignition Coil Wiring............................................................................................... 43
6.2.1 Straight Order Wiring of the Ignition Outputs....................................................... 45
6.2.2 Straight Order Wiring of the Ignition Outputs – Overview .....................................46
7 Functions ...................................................................................................................47
7.1 Pickup Sensitivity ................................................................................................. 47
7.2 Monitoring of Pickup Signals................................................................................. 47
7.3 Go/NoGo.............................................................................................................. 47
7.4 Ignition Timing Adjustment ...................................................................................48
7.4.1 Analog Current Input ..........................................................................................49
7.4.2 Speed Curve.......................................................................................................51
7.4.3 Ignition Timing Correction ...................................................................................51
7.5 Firing Angles .........................................................................................................51
7.6 Output Monitoring.................................................................................................51
7.7 ASO: Auxiliary Synchronization Output ...................................................................51
7.8 Ignition Energy......................................................................................................51
7.9 Access Control ..................................................................................................... 52
8 Settings via the MICT.................................................................................................54
8.1 MICT System Requirements ................................................................................... 54
8.2 MICT Installation.................................................................................................. 54
8.3 Access Levels in the MICT ..................................................................................... 55
8.4 Configuration Pages (Overview) ............................................................................ 56
8.5 Menu Bar and Toolbar........................................................................................... 57
8.6 Online Update Settings ........................................................................................60
8.7 Self Test .............................................................................................................. 61
8.8 Access Control for MIC100 ....................................................................................62
8.8.1 Enable/Disable Access Control...........................................................................62
8.8.2 Login/Logout .................................................................................................... 63
8.8.3 Changing the PIN .............................................................................................. 63
8.8.4 Reset all PINs....................................................................................................64
8.9 Working with Configurations.................................................................................64
8.9.1 Create, Open, Save ............................................................................................ 65
8.9.2 Upload, Download.............................................................................................66
8.9.3 Compatibility Information .................................................................................. 67
8.10 Configuration .....................................................................................................68

Table of Contents
Rev. 05/2020 5
8.10.1 Engine – Parameters ........................................................................................69
8.10.2 Engine – Ignition Outputs................................................................................. 72
8.10.3 Engine – Ignition Coils ..................................................................................... 73
8.10.4 Engine – Speed Settings .................................................................................. 74
8.10.5 Engine – Pickups – General .............................................................................. 75
8.10.6 Engine – Pickups – Inputs ................................................................................ 77
8.10.7 Timing – Analog Inputs.....................................................................................80
8.10.8 Timing – Schedule A – General ......................................................................... 81
8.10.9 Timing – Schedule A – Energy...........................................................................82
8.10.10 Miscellaneous – Communication.....................................................................83
8.10.11 Miscellaneous – Information ...........................................................................84
8.11 Runtime Data ......................................................................................................85
8.11.1 Runtime Data – Overview ..................................................................................86
8.11.2 Runtime Data – Timing......................................................................................88
8.11.3 Runtime Data – Bank A .....................................................................................89
8.11.4 Runtime Data – States ......................................................................................90
8.11.5 Runtime Data – Message Log ............................................................................90
8.11.6 Runtime Data – Diagnostics .............................................................................. 91
8.11.7 Runtime Data – Temperatures ...........................................................................92
8.11.8 Runtime Data – Information ..............................................................................93
8.12 Log ....................................................................................................................94
8.13 Runtime Adjustments.......................................................................................... 95
8.13.1 Runtime Adjustments – Reset............................................................................ 95
8.13.2 Runtime Adjustments – Timing .........................................................................96
8.13.3 Runtime Adjustments – Energy Limit .................................................................96
8.14 Schedule Curve................................................................................................... 97
8.14.1 Schedule Curve – Simulation ............................................................................ 97
8.14.2 Schedule Curve – Runtime Values .....................................................................98
8.15 Coils ..................................................................................................................99
8.15.1 General.......................................................................................................... 100
9 Operation ................................................................................................................ 102
9.1 Start-up ............................................................................................................. 102
9.2 Shutdown .......................................................................................................... 102
9.3 Firmware Update ................................................................................................ 102
10 Errors..................................................................................................................... 107
10.1 Possible Faults.................................................................................................. 107
10.2 Causes of Faults................................................................................................ 107

Table of Contents
6 Rev. 05/2020
10.2.1 Overspeed ......................................................................................................107
10.2.2 Output Error Detection ....................................................................................107
10.2.3 Misfire Detection (Primary) ............................................................................. 108
10.2.4 Pickup Input Errors......................................................................................... 108
10.2.5 Acknowledging Faults .................................................................................... 108
10.3 Customer Service Information............................................................................ 108
10.4 Returning Equipment for Repair/Inspection ........................................................ 109
10.5 Instructions for Packaging the Equipment........................................................... 109
11 Maintenance........................................................................................................... 110
11.1 Maintenance Instructions....................................................................................110
11.2 Spare Parts and Accessories ...............................................................................110
12 Index ...................................................................................................................... 111

Rev. 05/2020 7
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
8 Rev. 05/2020
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
MIC100 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
Rev. 05/2020 9
Abb. Term Description Explanation
EMI Electromagnetic
Interference
EMC Electromagnetic
Compatibility
Compatibility of electrical or
electronic equipment items
with their surroundings
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 MIC100
PG Panzergewinde Panzer Screw
Thread
Screw thread type for cable
screw connections
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

10 Rev. 05/2020
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.
–Observe all safety instructions of the system and all safety instructions of the system
operator.
–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.
2 Safety Instructions

2 Safety Instructions
Rev. 05/2020 11
–Safety devices must not be dismounted or disabled.
–Avoid all activities that can impair the function of the equipment.
–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.
–Noise from the system can cause permanent or temporary damage to your hearing. Wear
suitable hearing protection at the system.
–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 equipment as
possible.
–Do not remove the circuit boards from the housing of the device.

2 Safety Instructions
12 Rev. 05/2020
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
Rev. 05/2020 13
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
2.4 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). There is a risk of explosion.

2 Safety Instructions
14 Rev. 05/2020
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.
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.
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.

2 Safety Instructions
Rev. 05/2020 15
Risk of destruction!
Magnetic fields and heat occur when welding, which may damage or
destroy the MIC100. Therefore, pay attention to the following when welding:
–Disconnect all electrical connections to the MIC100 prior to welding.
–Protect the MIC100 against direct contact with the welding unit and
magnetic fields, sparks and liquid metal.
Danger of interference with radio reception!
The device is not intended for use in residential areas and cannot ensure
adequate protection of radio reception in such environments.
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.

16 Rev. 05/2020
3.1 Functional Description
The devices of the MIC100 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 generally 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 MIC100 series use information supplied by the pickup to precisely
determine the correct timing for the respective outputs. The ignition timing is influenced by
various inputs. This can be implemented using analog input signal, a speed characteristic, or
using a serial interface (CAN bus).
By checking the information received, the ignition controllers continuously monitor the system
status of the installed pickup and the correct operation of the primary ignition circuit during
operation.
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 MIC100 series are designed for specific 2- or 4-stroke gas engines.
From 1 to max. 8 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.
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

Rev. 05/2020 17
4.1 Technical Data
4.1.1 Certifications
The ignition controllers of the MIC100 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 61000-6-2:2005 + AC: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
–EN 55011:2009 + A1:2010 – Industrial, scientific and medical equipment. Radio-frequency
disturbance characteristics. Limits and methods of measurement
–Group1, Class A
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 + AC:2016-12 + AC:2019-02 – Degrees of protection
provided by enclosures (IP Code)
RoHS Directive 2011/65/EU
4 Product Description

4 Product Description
18 Rev. 05/2020
4.1.2 Mechanical Data
The MIC100 has the following mechanical characteristics.
Feature Value
Dimensions 232 mm x 190 mm x 55.5 mm (9.1" x 7.5" x 2.2")
(length x width x height)
Weight 1.6 kg ( 3.5 lbs)
Shape of device See chapter Overview Drawings on page 24
Mechanical environmental
conditions
The housing is resistant to general atmospheric
contaminations.
Resistant to gas engine lubricants and cooling water.
Protection class: I
Protection: IP69k
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:
–Service screw: 2.5 Nm to 3 Nm (1.9 lb-ft to 2.2 lb-ft)
The device must not be opened except via the service
screw.
Climatic environmental
conditions
Housing surface temperature: –40 °C to +70 °C
(–40 °F to +158 °F)
Max. 85 % humidity without condensation up to 3,000 m
(9,842') above sea level
Permissible vibration
conditions
–2 Hz to 20.85 Hz with a maximum vibration
displacement of 1.6 mm (0.06")
–20.85 Hz to 1,000 Hz with a constant acceleration of
4g

4 Product Description
Rev. 05/2020 19
4.1.3 Warning Notices on the Device
Validity of warning notices on device
The warning notices on the device are valid for the MIC100 and all
components connected to it.
Warning notice on the device German translation French translation
WARNING! Read and
understand the installation
and operating manual prior to
installing or making any
adjustments.
WARNUNG! Lesen und ver-
stehen Sie die Installations-
und Betriebsanleitung vor der
Installation und bevor Ein-
stellungen vorgenommen
werden.
ATTENTION! Avant d’installer
ou d’effectuer une
modification, lisez et
comprenez le manuel
d’utilisation et d’installation.
EXPLOSION HAZARD! Do not
disconnect while circuit is
live unless area is known to
be non-hazardous. For wiring
details refer to the operating
manual.
EXPLOSIONSGEFAHR! Keine
Verbindungen lösen, solange
der Stromkreis aktiv ist,
außer das Umfeld wird als
nicht explosionsgefährdet
eingestuft. Hinweise zur
Verkabelung finden Sie in der
Betriebsanleitung.
RISQUE D‘EXPLOSION! Ne
débranchez pas lorsque le
circuit est sous tension sauf
si la zone est connue pour
être non dangereuse. Pour
plus de détails de câblage,
veuillez consulter le manuel
d´utilisation.
CAUTION! Do not pressure
wash this ignition module.
Damage to electronic
components may result.
ACHTUNG! Die Zündsteue-
rungseinheit nicht mit
Hochdruck reinigen. Es
könnte zu Schäden an den
elektronischen Bauteilen
führen.
ATTENTION! Ne pas laver cette
boîte de contrôle en utilisant
un jet sous pression. Les
composants électriques
peuvent être endommagés.
Warning Symbol on Device
Warning of hot surface

4 Product Description
20 Rev. 05/2020
4.1.4 Product Identification – Labeling on the Device
The necessary numbers for unique product identification are on the device:
–Part number of the ignition controller (P/N)
–Arrangement number of the ignition controller (A/N)
–Revision number of the ignition controller indicating its precise construction status (R/N)
–Serial number of the ignition controller (S/N)