SECTION 2.10 IGNITION SYSTEM DESCRIPTION CEC IGNITION MODULE SYSTEM MAGNETO IGNITION SYSTEM

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1 SECTION 2.10 SYSTEM DESCRIPTION CEC SYSTEM The Custom Engine Control (CEC) Ignition Module is located on the engine's left side (see Figure and Figure ). The CEC Ignition Module system consists of the following engine mounted components: Ignition Module Hall-effect pickup Timing magnets Ignition coils High tension leads Spark plugs Wiring harnesses Engine driven generator (if equipped) JUNCTION BOX Figure F18/H24 CEC Ignition Module System HALL-EFFECT PICKUP JUNCTION BOX Figure L36/P48 CEC Ignition Module System MAGNETO SYSTEM The magneto includes pulse activated solid state electronic components. Electrical energy is stored in the internal storage capacitors. Silicon controlled rectifiers (SCR) function as switches to release the stored energy to the transformer coils. The breakerless (capacitor discharge) magneto ignition system consists of the following engine mounted components: Magneto Magneto ON/OFF switch Ignition coils (one per cylinder) High tension wires (secondary) Spark plugs Wiring harness The magneto (if equipped) is located on the engine's left side (see Figure ). FORM 6284 Third Edition

2 SYSTEM DESCRIPTION MAGNETO COILS The remote mounted ignition coils produce a high energy, long duration spark, which provides consistent cylinder firing. These coils are located on mounting brackets on top of the intake manifolds (see Figure and Figure ). HIGH TENSION LEAD COIL Figure Magneto Ignition SYSTEM COMPONENT DESCRIPTION CEC The Ignition Module is powered by 24 volts DC. The module steps up the DC supply voltage to charge an energy storage capacitor. The microcircuit logic and SCR switching devices release the stored energy to the ignition coils firing the appropriate spark plug (see Figure ). CEC HALL-EFFECT PICKUP The Hall-effect pickup senses each magnet as it passes and trips the logic circuit to fire. The pickup is located above the barring device in the gear housing. CEC TIMING MAGNETS The timing magnets are mounted in the left bank camshaft gear which rotates at half engine speed. The L36 gear contains a magnet for each cylinder. The P48 uses one magnet for every two firing cylinders. Both engines use an additional indexing magnet to reset the microcircuit logic. HIGH TENSION LEADS The standard high tension leads route the ignition secondary current from the ignition coils to the spark plugs. WIRING HARNESS A wiring harness is used to connect the Ignition Module or magneto primary wiring to the ignition coils. The wiring harness uses solderless connectors on the coil terminals and a multiple pin connector at the Ignition Module connection. SPARK PLUG CSA COIL Figure Standard Ignition Coil HIGH TENSION LEAD Figure CSA Flange Mounted Ignition Coil SPARK PLUGS The spark plugs are housed within the cylinder head and fire the air/fuel mixture in the combustion chamber (see Figure ) FORM 6284 Third Edition

3 SYSTEM DESCRIPTION SPARK PLUG ACCESS TUBE ROCKER COVER SWITCH Figure CSA Stop Switch CYLINDER HEAD SHIELDED SWITCH Figure Spark Plug Installation HAZARDOUS LOCATION SYSTEM (CSA APPROVED) COMPONENT DESCRIPTION (OPTIONAL) This ignition system is designed to meet the hazardous location requirements for explosion proof systems. The shielded ignition system consists of the following components: CEC Ignition Module (standard) CEC Hall-effect pickup (standard) Ignition switch (explosion-proof) Shielded spark plug Junction box (explosion-proof) Integral ignition coil Primary wiring Secondary wiring Timing light hookup SWITCH The shielded Run/Stop switch is mounted on the left side of the engine. The switch contacts are isolated from the atmosphere. The push/pull Run/Stop switch is used for both normal and emergency shutdowns (see Figure and Figure ). Figure CEC Ignition Module Shielded Ignition The F18/H24 shielded magneto ignition system uses a toggle for the Run/Stop switch (see Figure ). SHIELDED SWITCH Figure F18/H24 Magneto Shielded Ignition Switch FORM 6284 Third Edition

4 SYSTEM DESCRIPTION SHIELDED COIL This coil is assembled to a special rocker cover. This coil contains a similar style of primary and secondary windings as a standard coil (see Figure ). CSA COIL HIGH TENSION LEAD Figure CSA Flange Mounted Ignition Coil SHIELDED SPARK PLUG A standard spark plug is used with the flange mounted ignition coil. PRIMARY WIRING The wiring that connects the Ignition Module or magneto to the junction boxes is housed within conduits. Junction boxes are used at each cylinder to provide the connections to the ignition coils (see Figure ). POLARITY Observe correct polarity when connecting CAUTION power to the Ignition Module. Failure to correctly connect the power supply may damage the Ignition Module. The system is designed to deliver negative voltage to the spark plug center electrode. If improper wiring causes positive voltage to be delivered to the plug, the voltage required to jump the gap may be increased as much as 45%. If the ignition system cannot deliver the increased voltage requirement, the plug will not fire. Fouling or missing will occur. The center electrode normally runs at a higher temperature than the shell electrodes. The hotter center electrode is better able to discharge a spark than the colder one. If the polarity is correct, the wear will take place on the center electrode rather than the side electrode. CEC GENERATOR SYSTEM DESCRIPTION The optional CEC generator system supplies voltage to the CEC Ignition Module as well as being compatible with future CEC module components. The CEC generator supplies AC power to the voltage regulator (see Figure ). CEC GENERATOR DRIVE UNIT # 1 CYLINDER JUNCTION BOX Figure Shielded Wiring Harness Conduit SECONDARY WIRING The wiring that connects the junction boxes to the coils is housed within a steel braided wire. Figure CEC Generator The voltage regulator converts and regulates the power to a nominal 24 VDC (30.0 volts VDC maximum open circuit) (see Figure ) FORM 6284 Third Edition

5 SYSTEM DESCRIPTION VOLTAGE REGULATOR The KDM does not have all the same capabilities of the CEC Detonation Sensing Module (DSM), though it works with some of the same technologies. OPERATOR INTERFACE The KDM is equipped with a light (LED) on the front panel that informs site personnel of system status (see Figure ). The light is on when the KDM is powered and functioning properly with the knock sensors connected. The light is off when there is a fault or there is no power to the KDM. Figure CEC Generator Voltage Regulator The CEC Type I generator is equipped with a battery and has some power above the Ignition Module requirements to supply future CEC module needs. The battery is mounted off the engine. The CEC Type II generator is not equipped with a battery and is used to power only the CEC Ignition Module. CEC KNOCK DETECTION SYSTEM F18/H24 ONLY SYSTEM DESCRIPTION In order to detect detonation or knock, Waukesha Engine has developed a CEC Knock Detection Module (KDM) system for VGF F18/H24 GL, GLD, and GSID engines (see Figure ). The KDM system protects Waukesha VGF spark ignited gas engines from catastrophic damage due to detonation. STATUS LED Figure Knock Detection Module COMPONENTS The KDM system includes the KDM module, two knock sensors (see Figure ), and harnesses that may vary depending on the application. KDM SENSOR KNOCK DETECTION Figure KDM Knock Sensor Installation Figure Knock Detection Module System NOTE: For maximum engine protection, the KDM system must be connected to a safety shutdown. FORM 6284 Third Edition

6 SYSTEM DESCRIPTION SYSTEMS SERVED The KDM was designed to operate with the CEC Ignition Module or Altronic III Magneto. The KDM uses the G-lead and the positive lead of #1 coil of these systems to determine the number of cylinders and engine speed. NOTE: Refer to Form 6285, KDM Custom Engine Control Knock Detection Module Installation, Operation, And Maintenance Manual, for further information. CEC DETONATION SENSING L36/P48 Detonation is the autoignition of end gas that has not been consumed in normal flame-front reaction in a combustion chamber. When this happens in a combustion chamber of an engine, two pressure waves, created by the two flame-fronts, slam against the cylinder walls and cause an audible ping or knock known as detonation. Avoiding detonation conditions is critical since detonation is normally detrimental to engine components. To prevent detonation from occurring, Waukesha Engine has developed an electronic CEC Detonation Sensing Module (DSM) system (see Figure ). The DSM protects Waukesha spark ignited gas engines from damage due to detonation. The DSM and its related systems must function with a CEC Ignition Module with a 14 pin DSM expansion port (see Figure ). The DSM system also includes a Waukesha designed filter, a detonation sensor mounted between every two engine cylinders (see Figure ), and a number of interconnecting cables and harnesses that may vary depending on the application. Run the AutoCal program after doing any CAUTION repair or replacement of cylinder heads, gaskets, liners, pistons, or knock sensors. The DSM Auto- Cal program automatically establishes detonation levels so that the DSM system can operate properly. Failure to run the AutoCal program could result in poor engine performance and engine damage. See the DSM manual for the AutoCal programming steps (Form 6268 for DSM Interface Program version 5.3C; Form 6278 for DSM Interface Program version 6.0 series). CONTROL Figure DSM Control Module And Filter DSM FILTER Figure Ignition Module With Expansion Port DSM SENSOR POWER ALARM SHUTDOWN DSM EXPANSION PORT Figure DSM Knock Sensor Installation FORM 6284 Third Edition