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MIC500CEC Ignition Upgrade Kit

Installation Instructions
6 Cylinder P/N 75.30.112
12 Cylinder P/N 75.30.113

MOTORTECH GmbH I Hogrevestr. 21-23 I 29223 Celle I Phone: +49 5141 9399 0 I Fax: +49 5141 9399 99
www.motortech.de I motortech@motortech.de
All information is subject to change. We reserve the right to change technical information.

0 1 . Contents
02. Contents of the 6 cylinder kit ...................................................................... 3
03. Contents of the 12 cylinder kit .................................................................... 3
04. General remarks and notes on safety ........................................................ 4
05. Disassembly of the governor housing ........................................................ 5
06. Pickup installation ....................................................................................... 7
07. Trigger disc installation ............................................................................. 09
08. Assembly of the governor housing ........................................................... 13
09. Ignition wiring ............................................................................................ 15
8 cylinder wiring diagram with Murphy gas valves ........................................................... 16
6 cylinder wiring diagram without Murphy gas valves ...................................................... 17
12 cylinder wiring diagram with Murphy gas valves ......................................................... 18
16 cylinder wiring diagram without Murphy gas valves .................................................... 19
Wiring colour code ......................................................................................................... 20

10. Installation of the MIC500CEC control unit .............................................. 22


11. Final wiring ................................................................................................ 24
12. Programming ............................................................................................ 26
Programming chart for 6 cylinder engines ...................................................................... 27
Programming chart for 12 cylinder engines .................................................................... 28

Page 2
MOTORTECH GmbH I Hogrevestr. 21-23 I 29223 Celle I Phone: +49 5141 9399 0 I Fax: +49 5141 9399 99
www.motortech.de I motortech@motortech.de
All information is subject to change. We reserve the right to change technical information.

02. Contents of the 6 cylinder kit


MOTORTECH P/N
06.00.515
64.20.047
06.80.072
75.90.014
75.90.015
75.90.037
75.90.033
06.31.034
06.20.025
06.60.021
75.92.001
06.31.037
06.31.035
75.92.002
75.92.003
06.20.027
75.92.004

Quantity
1
2
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Description
MIC500CEC Ignition Unit
Mounting Bracket
Vibration Dampers
Cap Screw
Spring Washer
Cap Screw
Washer
Input Harness
Magnetic Disc
Hall-Effect Pickup
Roll Pin Magnetic disc
Adaptor Harness 6 Cyl. (Option A)
Output Harness 6 Cyl. (Option B)
Cover Plate, Drive Housing
Gasket Cover Plate
Nut for Timing Disc
Gasket, Governor Housing

03. Contents of the 12 cylinder kit


MOTORTECH P/N
06.00.515
64.20.048
06.80.072
75.90.014
75.90.015
75.90.037
75.90.033
06.31.034
06.20.026
06.60.021
75.92.001
06.31.038
06.31.036
75.92.002
75.92.003
06.20.027
75.92.004

Quantity
1
2
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Description
MIC500CEC Ignition Unit
Mounting Bracket
Vibration Dampers
Cap Screw
Spring Washer
Cap Screw
Washer
Input Harness
Magnetic Disc
Hall-Effect PU
Roll Pin, Magnetic Disc
Adaptor Harness 12 Cyl. (Option A)
Output Harness 12 Cyl. (Option B)
Cover Plate, Drive Housing
Gasket Cover Plate
Nut for Timing Disc
Gasket, Governor Housing

Page 3
MOTORTECH GmbH I Hogrevestr. 21-23 I 29223 Celle I Phone: +49 5141 9399 0 I Fax: +49 5141 9399 99
www.motortech.de I motortech@motortech.de
All information is subject to change. We reserve the right to change technical information.

04. General remarks and notes on safety


To whom is this manual addressed?
This manual is a practical instruction guide issued by the manufacturer, to all persons involved
with the installation.
Persons who are only authorized to operate gas engines must receive proper instructions from
the operator and must be explicitly warned about the possible dangers.
What is the purpose of this operating manual?
With the aid of this operating manual, trained personnel are in a position to perform all installation work.
This manual also provides assistance to gas engine design engineers.
Moreover, the manual is intended to avoid the threat of fatal injury or impaired health to the
operator or a third party, which cannot be totally ruled out as far as equipment design is concerned.
What must the operator pay attention to?
The operator of the equipment must ensure,
that all persons concerned with the installation of the MIC500CEC ignition control system have
read and understood this manual from beginning to end.
that all persons authorized to operate the gas engine have received detailed instruction and
have been warned about possible dangers.
What has to be commenced before any work?
The MIC500CEC ignition control system has been designed in compliance with state-of-the-art
technology and is operationally safe. The equipment may pose the threat of injury or suffer damage, if the following safety precautions are not observed. The gas engine must only be operated by
trained and authorized personnel.
Before commencing any work involving the installation, operation, resetting, matching, maintenance and repair of the ignition control system, the engine must be shut off and the equipment
must be disconnected from the power supply and safeguarded against switching on the power.
Only operate the ignition control system provided it is in perfect condition, and inform your superior 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 which 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.

Page 4
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www.motortech.de I motortech@motortech.de
All information is subject to change. We reserve the right to change technical information.

05. Disassembly of the


governor housing
Step 1:
Remove the cover of the governor
drive housing.

Attention! The governor drive housing is


filled with lube oil.

Step 2:
Remove the used gasket and dispose it.

Note! Do NOT
re-use the gasket!

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Step 3:
Remove the lock nut from accessory
drive shaft.

Step 4:
Remove the oil slinger.
Lock nut and oil slinger are not required any longer.

Page 6
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All information is subject to change. We reserve the right to change technical information.

06. Pickup installation


If your governor drive housing has
already a pickup hole (sealed with a
screw plug) go on to Step 1b.
Step 1a:
To install the pickup, drill a 9/16 hole
in the governor drive housing and tap
to 5/8 - 18 NC.
Line the drill bit up with centerline of
accessory drive shaft and 4.10 back
from the face of the housing.
Continue at Step 2.

Attention! To prevent
damaging the governor drive gear when
drilling, use a 4 fluted
drill bit.

Note! Particular care


must be taken to ensure the centerline of
the hole is perpendicular to the centerline of
the accessory drive
shaft.

Note! All metal chips


from drilling have to be
removed lest they will
interfere the pickups
function.

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Step 1b:
Remove the screw plug on the top of
the governor drive housing.

Step 2:
Install the hall-effect pickup so that you
can see its tip inside the governor
drive housing.

Attention! Do not
screw in the pickup
too deep. Otherwise it
will be damaged while
installing the trigger
disc!

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All information is subject to change. We reserve the right to change technical information.

07. Trigger disc installation


Step 1:
Crank the engine manually to TDC
(Top Dead Center) cylinder number
1R (right).

Step 2:
Remove spark plug lead on cylinder
number 1R.

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All information is subject to change. We reserve the right to change technical information.

Step 3:
Remove spark plug and install
Top Dead Center (TDC) measuring
adaptor.

Step 4:
Check the correct crank shaft position of cylinder 1R at TDC by cranking the engine back and forth until
pressure indicating float reaches
highest position.

This tool is available under


MOTORTECH P/N 06.98.009

Page 10
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Indicator float

Step 5:
Crank engine clockwise (CW) to position cylinder 1R at 40 BTDC.

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All information is subject to change. We reserve the right to change technical information.

Step 4:
In place of the oil slinger, install magnetic disc (watch rotation mark on
disc) and secure with provided lock
nut. Align the leading edge of the first
firing magnet (marked X) with the
centerline of the pickup.

Note! Timing disc is


marked with arrow for
correct rotation.

Step 5:
Torque the timing disc lock nut to
150-160 ft.lb. (203-217 Nm)

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All information is subject to change. We reserve the right to change technical information.

08. Assembly of the governor housing


Step 1:
Adjust the gap of the pickup and
magnet disc to .040.060
0.010

Attention! Contact
between pickup and
disc can cause failure
of these components
and loss of ignition!

Step 2:
Clean the surface of the governor
drive housing to allow for proper installation of new gasket.

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Step 3:
Apply sealing compound to the governor drive cover.
Stick the new gasket to the cover.

Step 4:
Install the governor drive cover.

Page 14
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www.motortech.de I motortech@motortech.de
All information is subject to change. We reserve the right to change technical information.

09. Ignition wiring


There are two options for wiring available:
A Adaptor harness
6 Cylinder P/N 06.31.037
12 Cylinder P/N 06.31.038
The ignition kit includes an adaptor
harness that allows to continue the
use of the old ignition coil wiring.
Connect the old existing harness to
the one end of the adaptor harness
and the other end to the MIC500CEC
unit.

B New wiring harness


6 Cylinder P/N 06.31.035
12 Cylinder P/N 06.31.036
If the existing wiring harness is worn
out a new wiring is recommended.
Remove all old wiring and wire the
engine according to attached wiring
diagrams.

Page 15
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www.motortech.de I motortech@motortech.de
All information is subject to change. We reserve the right to change technical information.

8 cylinder wiring diagram with Murphy gas valves

Page 16
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www.motortech.de I motortech@motortech.de
All information is subject to change. We reserve the right to change technical information.

6 cylinder wiring diagram without Murphy gas valves

Page 17
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www.motortech.de I motortech@motortech.de
All information is subject to change. We reserve the right to change technical information.

12 cylinder wiring diagram with Murphy gas valves

Page 18
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www.motortech.de I motortech@motortech.de
All information is subject to change. We reserve the right to change technical information.

16 cylinder wiring diagram without Murphy gas valves

Page 19
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www.motortech.de I motortech@motortech.de
All information is subject to change. We reserve the right to change technical information.

Wiring colour code


Colour

Output

Cylinder

Red ............ A ............ 1st Cylinder to fire


Yellow ........ B ............ 2nd Cylinder to fire
Green ......... C ............ 3rd Cylinder to fire
Brown ........ D ............ 4th Cylinder to fire
Blue ........... E ............ 5th Cylinder to fire
Orange ....... F ............. 6th Cylinder to fire
Purple ........ K ............ 7th Cylinder to fire
Grey ........... L ............. 8th Cylinder to fire
Pink ........... M ............ 9th Cylinder to fire
White / ....... N .......... 10th Cylinder to fire
Red
White / ....... P ........... 11th Cylinder to fire
Yellow
White / ....... R .......... 12th Cylinder to fire
Green
White / ....... S .......... 13th Cylinder to fire
Orange
White / ....... T ........... 14th Cylinder to fire
Blue
White / ....... U .......... 15th Cylinder to fire
Black
White / ....... V .......... 16th Cylinder to fire
Purple
Black ......... J ................. Ground lead
Not wired ... H ................ Monitor lead

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All information is subject to change. We reserve the right to change technical information.

Attention! Before cutting wire double check


wire colour code with
appropriate number of
cylinder.

It is recommended to use a wire protection hose when installing the ignition wiring

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www.motortech.de I motortech@motortech.de
All information is subject to change. We reserve the right to change technical information.

10. Installation of the


MIC500CEC
control unit

Attention! It is recommended to install the


control unit on locations off the engine
to prevent damages
from temperature and
vibrations.
If the control unit installation
on engine is preferred please proceed as follows.

Step 1:
Mount the ignition controller on the
brackets by use of vibration dampers.
Step 2:
Install the ground strap.

Attention! If you do
not install the ground
strap it may result in
risk of life by high voltage and the damage
of equipment.

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All information is subject to change. We reserve the right to change technical information.

Step 3:
Mount the brackets on the engine using the existing threaded holes.

MIC500CEC unit installed.

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All information is subject to change. We reserve the right to change technical information.

11. Final wiring

Step 1:
Connect the pickup lead of the input
connector to the hall-effect pickup.

Attention! Do not
bundle ignition wiring
and pickup wiring together. Maintain a
minimum separation
of 1 (25 mm).

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All information is subject to change. We reserve the right to change technical information.

Step 2:
Connect the pickup lead assembly
and the ignition harness to the
MIC500CEC with its provided military style plugs.

Step 3:
Remove magneto and install cover
plate with above shown gasket.

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All information is subject to change. We reserve the right to change technical information.

12. Programming
Read attached ignition manual carefully.
Program the controller according to
the attached programming chart.

Attention! Incorrectly
programmed ignition
may result in risk of life
and the damage of
equipment.

Page 26
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www.motortech.de I motortech@motortech.de
All information is subject to change. We reserve the right to change technical information.

Programming chart for 6 cylinder engines


(1) firing pattern = sequence-no.

21 (6 Cylinder)

(2) reset position BTDC

nominal: 40 BTDC actual:

(3) overspeed

1350 RPM

(4) security speed (max. starting speed)

400 RPM

(5) misfire rate

15

(6) cyl-to-cyl-timing

enabled

(7) contact I/P D

STOP

disabled

ON/OFF ignition
2-potentiometer operation

A/B
(8) potentiometer function

enabled

disabled

(9) speed curve potentiometer A

enabled

disabled

(10) 4 20 mA in A

enabled

disabled

(11) speed curve potentiometer B

enabled

disabled

(12) 4 20 mA in B

enabled

disabled

(13) potentiometer max. angle stop left (CCW):


(C

ADV BTDC:

30 ADV

(14) potentiometer max. angle stop right (CW):


(CW)

ADV BTDC:

15 ADV

(15) most advanced timing point for potentiometer A:

ADV BTDC:

30 ADV

(16) most retarded timing point for potentiometer A:

ADV BTDC:

15 ADV

additional functions:
[Shift] + [E]

energy (15 % - 100 %):

80%

[Shift] + [H]

operating hours / software rev.

op. hours:

software rev.:

[Shift] + [C]: cylinder cylinder adjustment


ignition output:

firing order
change
(+) ADV
(-) RET

[Shift] + S

self test

[Shift] + M

misfirings / sec

[Shift] + R

reset error

Page 27
MOTORTECH GmbH I Hogrevestr. 21-23 I 29223 Celle I Phone: +49 5141 9399 0 I Fax: +49 5141 9399 99
www.motortech.de I motortech@motortech.de
All information is subject to change. We reserve the right to change technical information.

Programming chart for 12 cylinder engines


(1) firing pattern = sequence-no.

39 (12 Cylinder)

(2) reset position BTDC

nominal: 40 BTDC actual:

(3) overspeed

1350 RPM

(4) security speed (max. starting speed)

400 RPM

(5) misfire rate

15

(6) cyl-to-cyl-timing

enabled

(7) contact I/P D

STOP

disabled

ON/OFF ignition
2-potentiometer operation

A/B
(8) potentiometer function

enabled

disabled

(9) speed curve potentiometer A

enabled

disabled

(10) 4 20 mA in A

enabled

disabled

(11) speed curve potentiometer B

enabled

disabled

(12) 4 20 mA in B

enabled

disabled

(13) potentiometer max. angle stop left (CCW):


(C

ADV BTDC:

30 ADV

(14) potentiometer max. angle stop right (CW):


(CW)

ADV BTDC:

15 ADV

(15) most advanced timing point for potentiometer A:

ADV BTDC:

30 ADV

(16) most retarded timing point for potentiometer A:

ADV BTDC:

15 ADV

additional functions:
[Shift] + [E]

energy (15 % - 100 %):

80%

[Shift] + [H]

operating hours / software rev.

op. hours:

software rev.:

[Shift] + [C]: cylinder cylinder adjustment


ignition output:

firing order
change
(+) ADV
(-) RET

[Shift] + S

self test

[Shift] + M

misfirings / sec

[Shift] + R

reset error

Page 28
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(1)

Sequence-Number ............................ See pages 28 and 29.

(2)

Reset BTDC ...................................... Position in degrees of trigger disc basic setting.


Trigger pin / hole A is opposite to pickup.

(3)

Overspeed ........................................ Over speed value. When reached, ignition will shut
down.

(4)

Security Speed .................................. The speed that controls the operation of contact A.
Contact A enables or disables the primary outputs.
The Security Speed determines whether the engine
speed must go to zero after contact A is closed (to
ground) or if the primary outputs can be enabled
with the engine stopping.If the ignition is firing and
the speed goes above the security speed if contact
A is closed, it is necessary to wait for 0 RPM before
the primary outputs will be enabled. If the speed
stays below the security speed, and contact A goes
from closed to open, the primary outputs will be
enabled and the ignition will start firing again.

(5)

MIS / SEC ......................................... Max. allowed misfiring rate. When exceeded,


ignition will shut down.

(6)

cyl to cyl enable.................................. enables cyl-to-cyl-timing


cyl to cyl disable ................................. disables cyl-to-cyl-timing

(7)

contact I/P for stop .......................... contact switch lead D of 10-pin connector activated
for ON/OFF of ignition.
contact I/P for A/B ........................... activated for operation with 2 timing schedules

(8)

Pot timing enable ............................ potentiometer function activated


Pot timing disable ........................... potentiometer function deactivated

(9)

speed curve in A in A - enable ......... speed curve for timing curve A activated
speed curve in A not in A - disable ... speed curve for timing curve A deactivated

(10) 4 20 mA in A in A - enable............. 4 20 mA analog for timing curve A activated


4 20 mA in A not in A - disable ...... 4 20 mA analog for timing curve A deactivated
(11) speed curve in B in B - enable ........ speed curve for timing curve B activated
speed curve in B not in B - disable .. speed curve for timing curve B deactivated
(12) 4 20 mA in B in B - enable ............ 4 20 mA analog for timing curve B activated
4 20 mA in B not in B - disable ..... 4 20 mA analog for timing curve B deactivated
(13) Pot CCW xx.xx ADV .......................... Potentiometer, max. angle at max. CCW position
ADV BTDC .................................... RET most retarded (0.00)

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(14) Pot CW xx.xx ADV ............................. Potentiometer min. angle at max. CW position
ADV BTDC .................................... RET most retarded (0.00)
(15) max ADV A: ....................................... most advanced timing point for timing curve A (max.
limit to advance)
(16) max RET A: ....................................... most retarded timing point for timing curve A (max.
limit of retard)
(17) max ADV B: ....................................... most advanced timing point for timing curve B (max.
limit to advance)
(18) max RET B: ....................................... most retarded timing point for timing curve B (max.
limit of retard)
(19) Offset ................................................. only for 2-point adjustment to program a second
curve B (see 6.3.1)
(20) 4 mA timing ....................................... adjustment of timing point given by analog singal
(input signal: 4 mA)
ADV = x degree advanced from potentiometer
setting
RET = x degree retarded from potentiometer
setting
(21) 20 mA timing ..................................... adjustment of timing point given by analog singal
(input signal: 20 mA)
ADV = x degree advanced from potentiometer
setting
RET = x degree retarded from potentiometer
setting
(22) speed points # ................................... number of speed points, required for speed curve
(max. 5 points possible)
(23) BP 1 .................................................. speed point 1: - new speed = engine speed
- angle = retard angle
BP 2 .................................................. speed point 2: - new speed = engine speed
- angle = retard angle
BP3 ................................................... speed point 3: - new speed = engine speed
- angle = retard angle
BP4 ................................................... speed point 4: - new speed = engine speed
- angle = retard angle
BP5 ................................................... speed point 5: - new speed = new engine speed
- angle = retard angle
(24) End / Start .......................................... ESC quit programming mode

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www.motortech.de I motortech@motortech.de
All information is subject to change. We reserve the right to change technical information.