Motortech MIC500 User manual

MIC500 –
IGNITION CONTROLLER
OPERATING MANUAL
MOTORTECH I
g
nition Controllers
P/N 01.10.0
3
0-EN
|
Rev. 01/201
5

Copyright
© Copyright 2015 MOTORTECH GmbH. All rights reserved.
Distribution and reproduction of this publication or parts thereof, regardless of the specific
purpose and form, are not permissible without express written approval by MOTORTECH.
Information contained in this publication may be changed without prior notice.
Trademarks
All trademarks and logos displayed or used in this publication are the property of the respective
entitled person.

Rev. 01/2015 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 Special Safety Instructions for the Device ...............................................................11
2.4 Proper Disposal.................................................................................................... 13
3 Intended Use ............................................................................................................. 14
3.1 Functional Description .......................................................................................... 14
3.2 Applications......................................................................................................... 14
4 Product Description ................................................................................................... 15
4.1 Product Overview.................................................................................................. 15
4.2 Technical Data...................................................................................................... 16
4.2.1 Certifications..................................................................................................... 16
4.2.2 Mechanical Data................................................................................................20
4.2.3 Warning Notices on the Device ...........................................................................20
4.2.4 Product Identification – Labeling on the Device ...................................................20
4.2.5 Electrical Data ................................................................................................... 21
4.2.6 Interfaces .........................................................................................................22
4.2.7 Requirements for External Equipment .................................................................22
4.2.8 Overview Drawings ............................................................................................23
5 Installation Instructions............................................................................................ 26
5.1 Unpacking............................................................................................................26
5.2 Determine the Installation Location of the Pickup and the Trigger Disc .....................26
5.3 Installation of the Ignition Controller ..................................................................... 27
6 Wiring of the Device.................................................................................................. 28
6.1 Input and Output Wiring on the Controller ..............................................................28
6.1.1 Input and Output Connector – P/N 06.00.507, P/N 06.00.508 ...............................29
6.1.2 Input and Output Connector – P/N 06.00.510.......................................................30
6.1.3 Input and Output Connector – P/N 06.00.511 .......................................................32
6.1.4 Input and Output Connector – P/N 06.00.513.......................................................34
6.1.5 Input and Output Connector – P/N 06.00.514.......................................................36
TABLE
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F
CO
NTENT
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TABLE OF CONTENTS
4 Rev. 01/2015
6.1.6 Input and Output Connector – P/N 06.00.515-6 and -8 .........................................38
6.1.7 Input and Output Connector – P/N 06.00.516.......................................................40
6.1.8 Input and Output Connector – P/N 06.00.517....................................................... 42
6.1.9 Input and Output Connector – P/N 06.00.520 ......................................................44
6.1.10 Input and Output Connector – P/N 06.00.525.....................................................46
6.1.11 Input and Output Connector – P/N 06.00.530 .....................................................48
6.1.12 Input and Output Connector – P/N 06.00.550..................................................... 50
6.1.13 Input Wiring – Power Supply ............................................................................. 52
6.1.14 Input Wiring – 4-20 mA Input ............................................................................ 53
6.1.15 Input Wiring – Pickup ....................................................................................... 54
6.1.16 Wiring – Digital Input, Go/NoGo ........................................................................ 56
7 Functions ................................................................................................................... 57
7.1 Monitoring of Pickup Signal................................................................................... 57
7.2 Go/NoGo ............................................................................................................. 57
7.3 Remote-Controlled Ignition Release ....................................................................... 58
7.4 Schedules A/B ..................................................................................................... 59
7.5 Timing Correction .................................................................................................60
7.5.1 Manual Timing Correction ................................................................................... 61
7.5.2 Analog Current Input – 4-20 mA ..........................................................................62
7.5.3 Speed Curve......................................................................................................62
7.5.4 Cylinder-to-Cylinder Alignment ........................................................................... 62
7.6 Misfire Detection..................................................................................................62
7.7 Ignition Energy ..................................................................................................... 63
8 Adjustments ..............................................................................................................64
8.1 Ignition Control ....................................................................................................64
8.1.1 System Requirements Ignition Control.................................................................64
8.1.2 Installing Ignition Control...................................................................................64
8.1.3 Starting Ignition Control..................................................................................... 67
8.1.4 Menu Bar and Buttons........................................................................................68
8.2 Hand-Held Programmer ........................................................................................69
8.2.1 RS232 Interface Adjustments .............................................................................69
8.2.2 Switching on the Hand-Held Programmer............................................................ 70
8.2.3 Keys of the Control Panel ....................................................................................71
8.3 Conventions Used in the Following ........................................................................ 72
8.4 Main View............................................................................................................ 73
8.5 Parameterization Level ......................................................................................... 75
8.5.1 General Operation of the Parameterization Level ................................................. 75

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8.5.2 Brief Overview of Parameters ............................................................................. 78
8.5.3 Set Sequence Number .......................................................................................80
8.5.4 Set Reset Position .............................................................................................84
8.5.5 Set Overspeed...................................................................................................84
8.5.6 Set Security Speed ............................................................................................85
8.5.7 Set Misfire Rate .................................................................................................86
8.5.8 Activate Cylinder-to-Cylinder Alignment.............................................................. 87
8.5.9 Select Function for Digital Input..........................................................................87
8.5.10 Activate Potentiometer .....................................................................................88
8.5.11 Activate Functions for Schedules A and B ...........................................................89
8.5.12 Set Potentiometer Limits .................................................................................. 91
8.5.13 Set Ignition Timing Limits .................................................................................93
8.5.14 Set Timing Offset for Schedule B ....................................................................... 95
8.5.15 Set Limits for 4-20 mA Input..............................................................................95
8.5.16 Set Speed Curve .............................................................................................. 97
8.5.17 Configuration Example ................................................................................... 100
8.6 Additional Functions .......................................................................................... 102
8.6.1 Set Ignition Energy .......................................................................................... 102
8.6.2 Information View............................................................................................. 103
8.6.3 Cylinder-to-Cylinder Alignment ........................................................................ 103
8.6.4 Self Test ......................................................................................................... 105
8.6.5 Misfire Detection............................................................................................. 107
8.7 Programming Overview....................................................................................... 107
9 Operation ................................................................................................................ 110
9.1 Start-up ..............................................................................................................110
9.2 Shutdown ...........................................................................................................110
10 Errors...................................................................................................................... 111
10.1 Possible Faults................................................................................................... 111
10.2 Causes of Faults................................................................................................. 111
10.2.1 Overspeed ...................................................................................................... 111
10.2.2 Misfire Detection (Primary) .............................................................................. 111
10.2.3 Pickup Input Errors..........................................................................................112
10.2.4 Insufficient Power Supply ................................................................................112
10.2.5 Exiting Error Status .........................................................................................112
10.3 Troubleshooting and Eliminating Errors...............................................................113
10.3.1 Message and Error Overview ............................................................................113
10.3.2 Testing Supply Voltage....................................................................................114

TABLE OF CONTENTS
6 Rev. 01/2015
10.3.3 Testing Pickup Signal......................................................................................114
10.3.4 Running a Self Test .........................................................................................116
10.3.5 Customer Service Information .......................................................................... 117
10.3.6 Returning Equipment for Repair / Inspection .................................................... 117
10.3.7 Instructions for Packaging the Equipment.........................................................118
11 Maintenance........................................................................................................... 119
11.1 Maintenance Instructions....................................................................................119
11.2 Spare Parts and Accessories ...............................................................................119
12 Index ..................................................................................................................... 120

Rev. 01/2015 7
Read through this operating manual carefully before use and become familiar with the machine.
Installation and start-up should not be carried out before reading and understanding this
document. Keep this manual readily available so that you can reference it as needed.
1.1 What Is the Purpose of this Operating Manual?
This manual serves as an aid for the installation and operation of the product and supports the
technical staff with all operating and maintenance tasks to be performed. 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 set-up,
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. 01/2015
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
ATDC After Top Dead Center After top dead center
BTDC Before Top Dead
Center
Before top dead
center
CE Conformité
Européenne
Conformity with EU
directives
Mark based on EU legislation
for certain products in
conjunction with product safety
°crank-
shaft
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 Direct current
EMC Electromagnetic
Compatibility
Compatibility of electrical or
electronic equipment items
with their surroundings
LED Light Emitting Diode Light emitting diode Light emitting electronic semi-
conductor
POT Potentiometer Continuously adjustable
potential divider
PWR Power Output / current Operating voltage
RET Retard Retarded with respect
to the top dead center
Indicates the direction for
timing

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Abb. Term Description Explanation
RPM Revolutions Per
Minute
Revolutions per
minute
Unit for speed
TDC Top Dead Center

10 Rev. 01/2015
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 damages 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 power supply and secured against unintentional
restarting.
–Perform only such maintenance and repair work as is described in this operating manual,
and follow the instructions given while working. For maintenance of the equipment, only use
spare parts supplied by MOTORTECH. 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

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–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 lead to an explosion
hazard. 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.
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.
2.3 Special Safety Instructions for the Device
Danger to life! Hazardous residual voltage!
A dangerous level of residual voltage is present in the ignition system for up
to three minutes after stopping the ignition. Do not touch any components
of the ignition kit during this time.
Explosion hazard!
When the system is powered up, do not remove any connectors unless the
system is not located in a potentially explosive atmosphere.

2 SAFETY INSTRUCTIONS
12 Rev. 01/2015
Explosion hazard!
The replacement of parts or assemblies can impair compliance with CSA
Class I, Division 2 (Group C, D), T4.
Explosion hazard!
Never remove the equipment while the device is connected to a power
source unless the system is not located in an explosive environment.
Risk of burning!
The surfaces of the system may heat up to high temperatures.
Operational safety!
All connector screws and screw joints must be adequately tightened.
Compliance with the following tightening torques is mandatory:
–RS232 connection: 1 Nm (0.7 lb-ft)
–Connection plug 6-pole, 7-pole, 10-pole: 2.6 Nm (1.9 lb-ft)
–Connection plug 14-pole, 19-pole: 5 Nm (3.7 lb-ft)
Explosion hazard!
Never remove the cover for timing adjustment and the RS232 interface,
unless the system is not located in an explosive environment.

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Risk of damage!
Magnetic fields and heat occur when welding, which may damage or
destroy the MIC500. Therefore, pay attention to the following when
welding:
–Disconnect all electrical connections to the MIC500 prior to welding.
–Protect the MIC500 against direct contact with the welding unit and
magnetic fields, sparks and liquid metal.
2.4 Proper Disposal
After the expiration of its service life, MOTORTECH equipment can be disposed of with other
commercial waste, or it may be returned to MOTORTECH. We will ensure its environmentally
friendly disposal.

14 Rev. 01/2015
3.1 Functional Description
The devices of the MIC500 series are microprocessor-controlled condenser discharge ignition
systems, which provide the ignition energy for gas engines with up to 16 cylinders.
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 MIC500 series use information supplied by the pickup to precisely
determine the correct timing for the respective outputs. An event type N+1 trigger disc serves as
transmitter.
The timing is influenced by various inputs made either automatically or manually. This can be
implemented with the installed manual potentiometer, an analog input signal (4-20 mA) or a
configurable speed curve.
By checking the information received, the ignition controllers continuously monitor the system
status of the pickup and the correct operation of the primary ignition circuit during operation.
Depending on the severity of an error that is detected, the devices will shut down immediately or
warn the operator by a flashing LED.
To protect the engine, the ignition controllers additionally have an adjustable overspeed shut-
off.
3.2 Applications
Depending on the device type, the ignition controllers of the MIC500 series are designed for
specific 2- or 4-stroke gas engines. Depending on the device type, there are between 2 to max.
16 ignition outputs available.
The ignition controllers supply the energy output required for the corresponding ignition coils of
the gas engines and can supply signals for peripheral devices. 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

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4.1 Product Overview
The following properties of the devices from the MIC500 series differ as follows:
Device type Number of outputs Test port /
monitor voltage Voltage for pickup
P/N 06.00.507 830 V DC 24VDC
P/N 06.00.508 8 30 V DC 24 V DC
P/N 06.00.510 16 30 V DC 24VDC
P/N 06.00.511 16 30VDC 24VDC
P/N 06.00.513 8 300 V DC 8VDC
P/N 06.00.514 16 30 V DC 8 V DC
P/N 06.00.515-6 8 (programmed on 6) 300 V DC 8VDC
P/N 06.00.515-8 8 300 V DC 8 V DC
P/N 06.00.516 16 (programmed on 12) 300 V DC 8VDC
P/N 06.00.517 16 300 V DC 8 V DC
P/N 06.00.520 8 300 V DC 24VDC
P/N 06.00.525 12 300 V DC 24 V DC
P/N 06.00.530 16 300 V DC 24VDC
P/N 06.00.550 8 30VDC 24VDC
4
PRODUCT DESCRIPTION

4 PRODUCT DESCRIPTION
16 Rev. 01/2015
4.2 Technical Data
4.2.1 Certifications
The ignition controllers of the MIC500 series with the test mark are certified as per the
following CSA standards:
CSA
–Class I, Division 2, Group C and D, T4
–CSA Std C22.2 No. 142-M1987 (Reaffirmed 2004)
–CSA Std C22.2 No. 213-M1987 (Reaffirmed 2004)
The ignition controllers of the MIC500 series are additionally certified as per the following
directives/regulations:
CE
–EMC Directive 2004/108/EC
–Limits as per DIN EN 55011:2011
–Immunity for industrial environments as per DIN EN 61000-6-2:2006-03
–Emission standard for industrial environments as per DIN EN 61000-6-4:2007-09
–Low Voltage Directive 2006/95/EC
–Low voltage switchgear – General rules as per DIN EN 60947-1:2007

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4 PRODUCT DESCRIPTION
18 Rev. 01/2015

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DECLARATION OF CONFORMITY
The Company: MOTORTECH GmbH
Hogrevestrasse 21 - 23
29223 Celle
declares that the products: Ignition controller MIC500
Intended purpose: to be used on gas-Otto-engines
complies with the provisions of the following EC Directives:
EMC Directive 2004/108/EC
Low Voltage Directive 2006/95/EC
under consideration of following standards:
DIN EN 55011-2011
DIN EN 61000-6-2-2006:03
DIN EN 61000-6-4-2007:09
DIN EN 60947-1 : 2007
The marking of the product is: P/N 06.00.5x
x
This declaration is submitted by:
Name: Florian Virchow
Professional status: Managing Director
Celle, 13.07.2011
City, date
legally binding signature

4 PRODUCT DESCRIPTION
20 Rev. 01/2015
4.2.2 Mechanical Data
The devices of the MIC500 series have the following mechanical characteristics:
Feature Value
Dimensions see chapter Overview Drawings on page 23
Weight 2.1 kg (4.7 lbs)
Shape of device see chapter Overview Drawings on page 23
Climatic environmental
conditions
-40°Cto+70°C(-40°Fto+158°F)
4.2.3 Warning Notices on the Device
EXPLOSION HAZARD! Do not open cover for timing adjustment and RS232 interface unless area is
known to be non-hazardous.
WARNING! Read and understand the installation and operating manual prior to installing or
making any adjustments.
EXPLOSION HAZARD! Do not disconnect while circuit is live unless area is known to be non-
hazardous. For wiring details please refer to the operating manual.
CAUTION! Do not pressure wash this ignition module. Damage to electronic components may
result.
4.2.4 Product Identification – Labeling on the Device
The necessary numbers for unique product identification are on the device:
–P/N: Product number of the ignition controller
–S/N: Serial number of the ignition controller