Motortech MIC500 User manual

MOTORTECH GmbH I Hogrevestraße 21-23 I 29223 Celle I Germany
Phone: [phone] I Fax: [phone] I Motorte[email protected] I www.motortech.de
All information is subject to change. We reserve the right to change technical information.
Models MIC520, MIC525, MIC530
21.10.2009 Rev. 1.8
ClassI,Div2,Group C,D

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MOTORTECH GmbH I Hogrevestraße 21-23 I 29223 Celle I Germany
Phone: [phone] I Fax: [phone] I Motorte[email protected] I www.motortech.de
All information is subject to change. We reserve the right to change technical information.
WARNING!
Read this entire manual and all other publications pertaining to the work to be
performed before installing, operating, or servicing this equipment. Practice all
plant and safety instructions and precautions. Failure to follow instructions can
cause personal injury and/or property damage.
The engine should be equipped with an overspeed shutdown device to protect
against runaway or damage to the engine with possible personal injury or loss
of life, or property damage
CAUTION!
To prevent damage to a control system that uses an alternator or battery-
charging device, make sure the charging device is turned off before
disconnecting the battery from the system.
Electronic controls contain static-sensitive parts. Observe the following
precautions to prevent damage to these parts.
Discharge body static before handling the control (with power to the control
turned off, contact a grounded surface and maintain contact while handling the
control).
IMPORTANT DEFINITIONS
WARNING!—indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION!—indicates a potentially hazardous situation which, if not
avoided, could result in damage to equipment.
NOTE!—provides other helpful information that does not fall under
the warning or caution categories.

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Phone: [phone] I Fax: [phone] I Motorte[email protected] I www.motortech.de
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Contents
ELECTROSTATIC DISCHARGE AWARENESS ...............................................................................6
CHAPTER 1 GENERAL INFORMATION ............................................................................................7
Introduction .......................................................................................................................... 7
Operational Features ........................................................................................................... 7
Limitations ........................................................................................................................... 8
Disposal of the Ignition Control System .............................................................................. 8
Models available .................................................................................................................. 9
Accessories ......................................................................................................................... 9
Unpacking............................................................................................................................ 12
Safety................................................................................................................................... 12
CHAPTER 2 Technical Data ..............................................................................................................14
CHAPTER 3 MIC500 series IGNITIONSYSTEM INSTALLATION ...................................................17
Installation ........................................................................................................................... 17
Ignition Control Module ........................................................................................................ 17
Trigger Disc ........................................................................................................................ 18
Camshaft Pickup.................................................................................................................. 21
Installation of a Disc with Reluctor Pins .............................................................................. 22
Mounting a Trigger Disc with Slots ...................................................................................... 23
Passive Pickup .................................................................................................................... 24
Setting the Ignition Timing Adjustment Range and Positioning the Trigger Disc .................. 25
Wiring Requirements ........................................................................................................... 27
General ............................................................................................................................... 27
MIC500 series CD Ignition System Electrical Connections and Pin Functionality ............... 27
RS-232 Port ........................................................................................................................ 28
Input Power ......................................................................................................................... 28
Output Harnessing ............................................................................................................... 34
Ignition coils and high tension leads..................................................................................... 35
Ignition-Timing Adjustment................................................................................................... 36
Programming examples ...................................................................................................... 37
2 – step adjustment.............................................................................................................. 38
Permissive Start................................................................................................................... 39
Contact Switch ..................................................................................................................... 40
Additional functions.............................................................................................................. 40
Ignition-energy levels ........................................................................................................... 40

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Cylinder-to-Cylinder timing................................................................................................... 38
Activating Cylinder-to-Cylinder timing .................................................................................. 40
Example of a 6 cylinder engine ............................................................................................ 41
Misfiring control of primary wiring......................................................................................... 42
Startup procedure ................................................................................................................ 42
Shutdown procedure............................................................................................................ 43
Operational features ............................................................................................................ 43
Trigger-signal-check ............................................................................................................ 43
Input-signal, fault recognition ............................................................................................... 44
CHAPTER 4 PROGRAMMING ...........................................................................................................45
Short guide for every single step of programming the MIC 500 series ignition control unit .. 45
Programming the MIC500 series with a Laptop .................................................................. 48
Programming the MIC500 series with the Hand Held Programmer ..................................... 48
Programming of Parameters ............................................................................................... 50
Programmable Parameters ................................................................................................. 51
Example of Programming an MIC500 series........................................................................ 65
CHAPTER 5 MAINTENANCE AND TROUBLESHOOTING ..............................................................68
Maintenance ....................................................................................................................... 68
Faults Causes and Remedial Action .................................................................................... 69
Troubleshooting ................................................................................................................... 70
Input Fault Diagnosis ........................................................................................................... 70
Fault Detection in the low or High Voltage Ignition Circuits .................................................. 72
Self-test Function ................................................................................................................. 73
Legal Provisions .................................................................................................................................74
Copyright Regulations .......................................................................................................................75
Abridged instructions.........................................................................................................................76
PROGRAMMING OVERVIEW ............................................................................................................86

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Illustrations and Tables
Figure 2.1 MIC500 series dimensions of the ignition control module ........................................... 14
Figure 2.2 MIC500 series vibration-mounts and Ground-strap........................................................... 15
Figure 2.3 MIC500 series connectors ................................................................................................. 15
Figure 2.4 MIC500 series electrical data............................................................................................. 16
Figure 3.1 Trigger disc mechanical requirements .............................................................................. 20
Figure 3.2 Mounting of Camshaft Trigger Disc..................................................................... 21
Figure 3.3 Mounting of a Trigger Disc with Slots.................................................................. 23
Figure 3.4 Mounting of a Passive Pickup............................................................................................ 24
Figure 3.5 Example of Flywheel Positioning......................................................................... 25
Figure 3.6 Basic Setting 40°BTDC...................................................................................... 26
Figure 3.7.1 MIC520 series Wiring Chart ............................................................................. 29
Figure 3.7.2 MIC525 series Wiring Chart ............................................................................. 30
Figure 3.7.3 MIC530 series Wiring Chart ............................................................................. 31
Figure 3.8 Manual timing adjustment .................................................................................. 34
Figure 3.9 0–5 Volt Retarded Curve .................................................................................... 35
Figure 3.10 0–5 Volt Advanced Curve ................................................................................ 35
Figure 3.11 Two-step Adjustment ....................................................................................... 36
Figure 3.12 Timing offset .................................................................................................... 37
Figure 3.13 GO/NOGO output ............................................................................................. 37
Figure 4.1 MIC500 series Sequence Tables ........................................................................ 51
Figure 4.2 Potentiometer span – CW position...................................................................... 55
Figure 4.3 Maximum limit retarded ignition........................................................................... 58
Figure 4.4 Analog input signal 4–20mA limit ........................................................................ 59
Figure 4.5 Speed points BP1 to BP5.................................................................................... 62
Figure 4.6 Speed-points example ........................................................................................ 64
Figure 5.1 Oscilloscope—Square Wave Signal ................................................................... 70
Table 3.1 Example of a six cylinder engine ......................................................................... 40
Table 3.2 Misfiring control ................................................................................................... 40
Table 3.3 Programmed data ............................................................................................... 65

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MOTORTECH GmbH I Hogrevestraße 21-23 I 29223 Celle I Germany
Phone: [phone] I Fax: [phone] I Motorte[email protected] I www.motortech.de
All information is subject to change. We reserve the right to change technical information.
Electrostatic Discharge Awareness
All electronic equipment is static-sensitive, some components more than others.
To protect these components from static damage, you must take special precautions to
minimize or eliminate electrostatic discharges.

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Phone: [phone] I Fax: [phone] I Motorte[email protected] I www.motortech.de
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Chapter 1
General Information
Introduction
The MIC500 series is a microprocessor-controlled, capacitive discharge ignition system capable
of supplying ignition energy for certain two- or four-stroke gas engines with two(2) to sixteen(16)
cylinders (single-firing) or two(2) to sixteen(16) cylinders (double firing).
The number of cylinders and the corresponding firing pattern, as well as the trigger disc
configuration, are programmed individually.
Integral to the MIC500 series is one timing adjustment potentiometer. This has a programmable
ignition span of maximum 38° crankshaft degrees. Additional methods of adjustment are by
means of an integral speed curve and a linear 4-20 ma analog signal. A two-stage adjustment is
also possible with the aid of the analog signal and the use of an external potentiometer.
The MIC500 series is capable of firing up to sixteen cylinders with either one or two spark plugs
per cylinder. In the case of two spark plugs per cylinder, the corresponding ignition coils must
be wired in series.
A cam or crankshaft trigger disc is used to provide relative position reference. This information
is sent to a microprocessor that controls the ignition timing. Thus, the system is alerted
whenever a new cycle has begun.
The MIC500 series is CSA certified for use in hazardous locations.
Operational Features
In order to ensure perfect operation of the ignition control system, observe the maintenance
instructions given in Chapter 4.
The MIC500 series has several functional features to ensure proper operation:
• Trigger signal check
• Input signal fault recognition
• Shutdown
• Manual ignition timing adjustment
ClassI, Div2, Group C,D

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MOTORTECH GmbH I Hogrevestraße 21-23 I 29223 Celle I Germany
Phone: [phone] I Fax: [phone] I Motorte[email protected] I www.motortech.de
All information is subject to change. We reserve the right to change technical information.
Limitations
The MIC500 series ignition control system provides ignition energy for two to 16-cylinder gas
engines. Trigger disc configurations are listed in Chapter 2.
The MIC500 series is intended only for use on the engines listed in the configuration table (see
Chapter 3). It also needs to be programmed to comply with the appropriate engine.
Disposal of the Ignition Control System
The MIC500 series is comprised of only a small amount of surplus refuse that may be disposed
of in the usual manner as industrial waste.

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MOTORTECH GmbH I Hogrevestraße 21-23 I 29223 Celle I Germany
Phone: [phone] I Fax: [phone] I Motorte[email protected] I www.motortech.de
All information is subject to change. We reserve the right to change technical information.
Models Available
Ignition Control Unit
06.00 520 MIC520 up to 8 outputs
06.00.525 MIC525 up to 12 outputs
06.00.530 MIC530 up to 16 outputs
Accessories
Unshielded Harnesses
Input Harnesses - length to be specified. Standard length: 160”
Active pickup
06.02.501-L Input harness, active pickup
06.02.502-L Input harness, DUAL active pickup
Magnetic pickup
06.02.505-L Input harness, magnetic pickup
06.02.506-L Input harness, DUAL magnetic pickup
Hall-effect pick up
06.02.510-L Input harness, hall-effect pick up
06.02.511-L Input harness, DUAL hall-effect pick up
Output Harnesses - length to be specified. Standard length: 240”
06.02.604-L Output harness for MIC 520, 4 outputs
06.02.608-L Output harness for MIC 520, 8 outputs
06.02.612-L Output harness for MIC 525, 12 outputs
06.02.616-L Output harness for MIC 530, 16 outputs

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MOTORTECH GmbH I Hogrevestraße 21-23 I 29223 Celle I Germany
Phone: [phone] I Fax: [phone] I Motorte[email protected] I www.motortech.de
All information is subject to change. We reserve the right to change technical information.
Shielded Harnesses
Input Harnesses - length to be specified. Standard length: 80”
Active pickup
95.30.501-L Input harness, active pickup
95.30.502-L Input harness, DUAL active pickup
Magnetic pickup
95.30.505-L Input harness, magnetic pickup
95.30.506-L Input harness, DUAL magnetic pickup
Hall-effect pick up
95.30.510-L Input harness, hall-effect pick up
95.30.511-L Input harness, DUAL hall-effect pick up
Output Harnesses - length to be specified. Standard length: 80”; 160”
95.30.608-L Output harness, conduit, MIC520
95.30.612-L Output harness, conduit, MIC525
95.30.616-L Output harness, conduit, MIC530
Unshielded Pickups
Magnetic pickup
66.60.001-125 5/8’’-18 UNF x 1.25’’ Magnetic pickup
66.60.001-175 5/8’’-18 UNF x 1.75’’ Magnetic pickup
66.60.001-250 5/8’’-18 UNF x 2.50’’ Magnetic pickup
66.60.001-400 5/8’’-18 UNF x 4.00’’ Magnetic pickup
66.60.001-600 5/8’’-18 UNF x 6.00’’ Magnetic pickup
Hall-effect pickup
66.60.002-175 5/8’’-18 UNF x 1.75’’ Hall-effect pickup
66.60.002-250 5/8’’-18 UNF x 2.50’’ Hall-effect pickup
66.60.002-450 5/8’’-18 UNF x 4.50’’ Hall-effect pickup
Active pickup
66.60.003-60 M12 x 1 x 60 mm Active pickup
66.60.003-100 M12 x 1 x 100 mm Active pickup

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MOTORTECH GmbH I Hogrevestraße 21-23 I 29223 Celle I Germany
Phone: [phone] I Fax: [phone] I Motorte[email protected] I www.motortech.de
All information is subject to change. We reserve the right to change technical information.
Shielded Pickups
Magnetic pickup
95.70.001-125 5/8’’-18 UNF x 1.25’’ Magnetic pickup
95.70.001-175 5/8’’-18 UNF x 1.75’’ Magnetic pickup
95.70.001-250 5/8’’-18 UNF x 2.50’’ Magnetic pickup
95.70.001-400 5/8’’-18 UNF x 4.00’’ Magnetic pickup
95.70.001-600 5/8’’-18 UNF x 6.00’’ Magnetic pickup
Hall-effect pickup
95.70.002-175 5/8’’-18 UNF x 1.75’’ Hall-effect pickup
95.70.002-250 5/8’’-18 UNF x 2.50’’ Hall-effect pickup
95.70.002-450 5/8’’-18 UNF x 4.50’’ Hall-effect pickup
Active pickup
95.70.003-60 M12 x 1 x 60 mm Active pickup
95.70.003-100 M12 x 1 x 100 mm Active pickup
Unshielded Pickup Leads
Active pickup
06.71.007 Pickup lead 400’’, 90°connector
Magnetic pickup
06.71.001 Pickup lead 400’’, 90°connector
Hall-effect pickup
06.71.002 Pickup lead 400’’, 90°connector
Shielded Pickup Leads – lengths to be specified
Active pickup
95.60.050-L Pickup lead, 90°connector
Magnetic pickup
95.60.010-L Pickup lead, 180°connector
95.60.020-L Pickup lead, 90°connector
Hall-effect pickup
95.60.030-L Pickup lead, 180°connector
95.60.040-L Pickup lead, 90°connector
Coils
Trigger Devices
Trigger Discs
Trigger Magnets
Trigger Pins
High Tension Leads
See Catalog

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MOTORTECH GmbH I Hogrevestraße 21-23 I 29223 Celle I Germany
Phone: [phone] I Fax: [phone] I Motorte[email protected] I www.motortech.de
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Unpacking
Check the shipping container for evidence of mishandling during shipping. Carefully remove the
MIC500 series from the shipping container. Check the hardware for evidence of damage during
shipping.
Safety
The operator of the equipment must ensure:
• That all persons concerned with the installation, maintenance, and repair of the MIC500
series ignition control system have entirely read and completely understood this operating
manual.
• That all persons authorized to operate the gas engine have received detailed instruction
and have been warned about possible dangers.
WARNING!
In no case should the following parts of the ignition control system be touched,
removed, or disconnected while the engine is running:
• Ignition coils and boots
• High-tension leads
• Low-voltage circuit leads
• Harness connectors
The MIC500 series ignition control system design conforms to high technology principles and is
operationally safe. The equipment may suffer damage or pose the threat of injury if the following
safety precautions are not observed. Only trained and authorized personnel must operate the
gas engine.
• Before commencing any work involving the installation, operation, resetting, matching,
maintenance, or repair of the ignition control system, the equipment must be disconnected
from the power supply and safeguarded against switching on the power.
• The harness must be removed.
• Safety devices must not be disassembled or inactivated.
• Avoid all work that might impair the function of the ignition control system.
• Only operate the ignition control system provided if it is in perfect condition, and inform all
concerned personnel of any modifications which have been made to the gas engine or the
ignition control system.
• Ensure that you observe all the rules and regulations pertaining to your equipment,
including those that are not explicitly stated here.
• Always ensure that the engine room is properly ventilated!
• Ensure that you maintain a safe distance from the gas engine and the ignition control
system.

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MOTORTECH GmbH I Hogrevestraße 21-23 I 29223 Celle I Germany
Phone: [phone] I Fax: [phone] I Motorte[email protected] I www.motortech.de
All information is subject to change. We reserve the right to change technical information.
WARNING!
Switch off the engine; disconnect the power supply, and lock out both before
commencing any installation work.
Make sure that the system was programmed for your engine before attempting to
operate the MIC500 series ignition system. An improperly installed or programmed
system may lead to engine damage and could pose threat of personal injury to
operators.
Ensure that ignition timing is set to engine manufactures recommendation and that is
actually checked with a timing light.

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Phone: [phone] I Fax: [phone] I Motorte[email protected] I www.motortech.de
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Chapter 2
Technical Data
2.1 MIC500 series Dimensions of the Ignition Control Module
(159mm) 6,25'' (178mm) 7,00''
(142mm) 5,59''
(Ø8)
(223,5mm) 8,79''
(196mm) 7,71''
(217,5mm) 8,56''
RS-232
(77mm) 3,03''

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2.2 MIC500 series Vibration Mounts and Ground Strap
2.3 MIC500 series Connector Arrangement
MIC520
Input 10 pin Output 10 pole socket
MIC525
Input 10 pin Output 14 pole socket
MIC530
Input 10 pin Output 19 pole socket

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2.4 MIC500 series Electrical Data
WARNING!
The MIC500series accepts 12 V to 24 VDC and automatically recognizes the
selected supply voltage. The supply voltage must be maintained within the
following limits:
10 VDC minimum
32 VDC maximum
A supply voltage below 10 VDC will impair the operation of the ignition control
module. Voltages above 32 VDC could damage the ignition control module.
•16 ignition outputs for engines with
o2 – 16 cylinders for single firing and
o2 – 16 cylinders for double firing
•Two selectable ignition timings
•Suitable for 2- and 4-stroke engines
•12 V and 24 VDC supply voltage
•voltage limits: min. 10 VDC
max. 32 VDC
•20 A peak current
•3,5 A average current consumption
•100 – 300 V primary voltage (Programmable energy)
•Max. 50 KV secondary voltage
•Max. 600 msec spark duration at 20 KV (depends on selected coil)
•Negative grounded
•Temperature range:
•Control module: - 40°F to 158°F - 40°C to 70°C
•Ignition coils: - 40°F to 212°F - 40°C to 100°C

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Chapter 3
Installation
CAUTION!
Read this section carefully before assembling the components!
Installation
A complete ignition system consists of:
• The MIC500 series ignition control module
• Input harness
• Output harness
• Ignition coils (one per cylinder / two per cylinder)
• High tension leads
• A speed pickup for the flywheel trigger disc or an active or hall-effect pickup for the
camshaft trigger disc
• A pick up lead
• A trigger disk, magnets or pins
Before commencing with the final assembly, it is advisable to carefully consider the mounting
locations of the individual components. A good choice of mounting locations ensures proper
operation of the entire ignition system.
Ignition Control Module
Considerations for MIC500 series mounting location:
• Specified environmental limits
Temperature
Vibration
• Cable length to
Power supply
Pickup units
The distance between the ignition control module and the pickup unit should not
exceed 30 ft / 10 m.
Away from high voltage or high current devices or high electromagnetic radiation
RFI/EMC sources
Clearance for cables

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CAUTION!
Never do any welding work on the engine or chassis when the ignition control
module is mounted on the engine or connected to the chassis. This could
destroy the ignition control module!
• Mount the ignition control module in such a way that the cable harness may be
easily routed downwards.
• Mount the ignition control module on a secure bracket near the engine using the vibration-
damping mounts supplied with the unit.
• The ignition control module must be grounded to the engine through the mounting
hardware by use of the ground strap supplied with the unit.
• The ignition control module should be mounted in cool location free of vibration.
____________________________________________________________________________
Trigger Disc
Depending on the engine design, there are four possibilities to trigger the ignition:
A Trigger disc mounted on crankshaft. This location is required for 2-stroke engines (double
firing on 4-stroke engines; ignition fires on compression and exhaust stroke). The magnetic
disc is equipped with a certain number of holes, slots, or magnets. This disc may use a
passive or active pickup unit.
B Trigger disc mounted on camshaft. This location is recommended for 4-stroke engines
(single firing, ignition fires on compression stroke only). The non-magnetic disc is equipped
with a specified number of magnets or holes. Using a disc with holes or pins for the
camshaft requires an active or hall effect pickup.
C Trigger disc with 2 to 8 magnets or pins mounted on the flywheel and an additional disc
with a single INDEX magnet or pin mounted on the camshaft
Note: Both pickups need to have the same configuration: Hall effect or active pickup
D If a trigger disc cannot be mounted easily, use a trigger device that is mounted to the
former magneto drive and has a built in timing disc
The crankshaft and camshaft pickup should be mounted at a convenient position providing easy
access for maintenance.
A massive and vibration-free bracket must be prepared for mounting the pickup.

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2-Stroke and Double-Firing 4-Stroke Engines
Mount the trigger disc on the flywheel, pulley disc, or vibration damper. The trigger disk must
rotate at crankshaft speed.
CAUTION!
Ensure that the trigger disc is perfectly centered!
Instead of using a disc, holes can be drilled into the flywheel. For the basic setting,
outlined in Figure 2-6, the hole, slot or pin "A" has to be opposite the pickup-mounting hole.
For engine timing see “Setting the Ignition Timing Adjustment Range” later in this chapter.
Single-Firing 4-Stroke Engines
Mount the trigger disc on the camshaft or any drive running at one-half engine speed.
For the basic setting outlined in Figure 3.1, the hole, slot, or pin “A” has to be opposite the
pickup-mounting hole.
For engine timing see “Setting the Ignition Timing Adjustment Range” later in this chapter.
CAUTION!
Ensure that the trigger disc is perfectly centered!

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3.1 Trigger Disc Mechanical Requirements
Configuration
N (Degrees)
M (Degrees)
Trigger
2+1 60 180 3
3+1 40 120 4
4+1 30 90 5
5+1 20 72 6
6+1 20 60 7
8+1 15 45 9
10+1 15 36 11
12+1
Not recomended for camshaft mounting
NOTES:
1. Note direction of rotation.
2. Inch (mm) as specified.
Minimum
Diameter
4”
(100)
M, (360/M places)
See table
.236”
(6)
see table
INDEX