MOTORTECH Ignition Controllers MIC3 MOTORTECH IGNITION CONTROLLER MIC4 MOTORTECH IGNITION CONTROLLER MIC5 MOTORTECH IGNITION CONTROLLER REV. 09/2014 06/2013 MIC Series reliable efficient worldwide 1
MIC Series MOTORTECH Ignition Controllers MOTORTECH has developed into one of the leading manufacturers of ignition controllers in the global market for industrial gas engines. The MOTORTECH ignition controller series now provides solutions for virtually all gas types and engine sizes. Cooperation with leading engine manufacturers, packagers and operators has resulted in specific designs of equipment. The result is the ability to maintain ideal engine performance across a variety of applications. As the Biogas market continues to grow the need to ignite various gasses like mine gas and drilling gas effectively grows. MOTORTECH meets these needs by offering products that provide increased ignition energy, long duration spark control while maintaining precise ignition timing. Efficiency and device availability drive MOTORTECH to devote its efforts to peak technology for the future. 2
MIC3 MOTORTECH IGNITION CONTROLLER MIC4 MOTORTECH IGNITION CONTROLLER MIC5 MOTORTECH IGNITION CONTROLLER Characteristics MIC Series General For 2- and 4-stroke enginers Ignition technology pulse width modulated Technical restriction to 6000 rpm Max. trigger impulses 16 + 1 or 500 teeth on the flywheel CSA certified (Class I, Div. 2, Group C, D; T4) Technical data & functions Ignition timing to 0.1 crankshaft Magnetic, Hall effect- or inductive pickup Control of ignition timing optional by - potentiometer - Speed curve - 0 20 ma analog input - 0 10 V analog input Control of the ignition energy by the patented MOST (MOTORTECH Output Stage Technology) Ignition sequence in device programmable Safety shutdown during overspeed Access control via password Programmable spark duration Ignition energy regulation 2 programmable speed curves with max. 8 speed points (speed/ignition timing) Diagnosis memory System status display Error memory Ignition diagnosis Runtime data Alarm and error messages Data logging Primary, secondary misfire recognition Individual cylinder voltage calculation (kv) Interfaces CAN Bus 2.0b interface (CANopen-/SAE J1939 protocol) RS485 interface (Modbus RTU) USB 2.0-interface Inputs Digital ignition impulse input (start/stop) configurable digital input (GPI) Digital input for parameter set conversion (schedule A/B) Outputs 1 angle-dependent synchronization output (ASO), e.g. to connect a detonation control system (e.g. DetCon) or for injection systems 1 multi-function output (GPO) Ignition confirmation (Go/NoGo) Configuration With the assistance of the graphic user interface MICT (MOTORTECH Integrated Configuration Tool, see page 10) 3
System Overview MIC Series 1 DetCon20 MOTORTECH DETONATION CONTROL SYSTEM PowerView3 MOTORTECH ENGINE INFORMATION MONITOR MIC MOTORTECH IGNITION CONTROLLER C D CAN CAN 0 5 V/4 20 ma 24 VDC Power Supply 6 A 3 4 5 V 2 X Z 3 4 3 1) 7 W B Y 8 1) In combination with the MIC3 only a crank shaft sensor is possible. 4
Legend Neccessary components 1 MIC Ignition Controller 2 Pickup cable* 3 Pickup* 4 Trigger pins/magnets alternative 5 Trigger disc alternative Trigger drive 6 Output cable harness* 7 Ignition coil* 8 1 Primary cable/ignition lead per ignition coil Accessories A Junction box B AlphaRail-/ LiteRail ignition wiring rail* System enhancement C DetCon20 Detonation contoller D PowerView3 HMI module Description V Camshaft W Crankshaft X Engine Y Cylinder Z Harness to connect the ignition wiring rails and the junction box * Shielded and unshielded versions available. Common versions for pickup arrangement Pickup arrangement with 3 pickups in 4 stroke engines 1) Reset (crankshaft) Magnetic pickup (holes, pins, teeth, screws) 2) Speed (crankshaft) Magnetic pickup (holes, pins, teeth, screws) 3) Camshaft Hall effect pickup (magnets) alternative 3) Camshaft Inductive pickup (Pins, screws, grooves) Pickup arrangement with 1 with pickup in four stroke engines 1) Camshaft Hall effect pickup (disc with magnets) alternative 1) Camshaft Inductive pickup (disk with pins, screws, grooves) Pickup arrangement with 2 pickup in 2 stroke engines 1) Reset Magnetic pickup (holes, pins, teeth, screws) 2) Speed (crankshaft) Magnetic pickup (holes, pins, teeth, screws) 5
Technical Data MIC Series Feature MIC3 series MIC4 series MIC5 series Max. number ignition outputs 6/12 8/16 20 General Max. number pickups 1, 2 1, 2, 3 1, 2, 3 Voltage supply 10 32 VDC 10 32 VDC 18 32 VDC permitted ambient temperature 40 C to +60 C 40 C to +60 C (LD) 40 C to +70 C (HD) 40 C to +60 C Max. primary voltage 250 VDC 250 VDC 250 VDC Power Max. ignition energy 200 mj (300 mj boost for start phase) 300 mj (500 mj boost for start phase) 500 mj (700 mj boost for start phase) Max. programmable spark duration 100 700 µsec 100 1000 µsec 100 1500 µsec Available housing versions 1) Light Duty (LD) Panel Mount (PM), Light Duty (LD), Heavy Duty (HD) Heavy Duty (HD) Dimensions 250 mm x 240 mm x 89.5 mm 304 mm x 240 mm x 97.5 mm (LD) 371 mm x 240 mm x 114.5 mm Protection class IP54 IP20, IP54, IP65 IP65 Housing Engine installation not permitted not permitted not permitted Potentiometer number for manual speed adjustment Input cabling O 2 (continuously variable) 2 (continuously variable) 35-pin, pin (MIL) Multi-point connector (Optional 2 MIL Version) Multi-point connector Output cabling 17-pin, socket (MIL) 17-pin, socket (MIL) 35-pin, socket (MIL) Status LEDs number 5 6 6 6 1) Please contact your MOTORTECH partner for information on the availability of housing versions
Possible MIC4 housing versions Housing version LD (Light Duty)* Standard configuration for applications in direct vicinity of gas engines in protected environment. The electronic system is integrated in a solid aluminum housing. 17 pole military style connector (socket) for 8 and 16 outputs Plug connectors for input wiring Optional 2 MIL version for fast installation For ambient temperatures from -40 C to +60 C (-40 F to +140 F) Protection rating IP54 CSA Class I, Division 2, Group C, D; T4 304 mm x 240 mm x 97.5 mm (L x B x H) Optionally as 2-MIL version Housing version PM (Panel Mount switch cabinet installation)* Device configuration for assembly in control panels. Equipped with plug connectors for simple integration into the wiring system. Plug connectors for input and output wiring (8 and 16 outputs) For ambient temperatures from -20 C to +50 C (-4 F to +122 F) Protection rating IP20 CSA Class I, Division 2, Group C, D; T4 (within a control panel) 304 mm x 240 mm x 114.5 mm (L x B x H) Back Housing version HD (Heavy Duty)* When it s time to really get down to business. The Heavy Duty housing is 100 % reliable whether in hot desert sand or perpetual ice! 17 pole military style connector (socket) for 8 and 16 outputs Plug connectors for input wiring Optional as 2 MIL version for fast installation For ambient temperatures from -40 C to +70 C (-40 F to +158 F) Integrated cooling element for optimal heat dissipation Protection rating IP65 CSA Class I, Division 2, Group C, D; T4 304 x 240 x 114.5 mm (L x B x H) * ATEX versions available. 7
MOTORTECH Output Stage Technology Patented Technology for MIC3/MIC4/MIC5* MOST MOTORTECH OUTPUT STAGE TECHNOLOGY Efficiency-enhanced engines, highly compressed mixtures, as well as the use of a great variety of gas types are putting greater demands on the entire ignition system, including: reliable ignition even with weak or fluctuating calorific values of the gas compliance with the strictest emission regulations eliminates knocking and misfiring reduction of maintenance through longer spark plug runtimes These requirements can only be met by precision ignition behavior and efficient control of the ignition spark. MOTORTECH Output Stage Technology* (MOST) was developed by MOTORTECH for this. MOST works with the following principles: adjustable ignition spark duration with different available ignition voltages constant spark intensity via adjusted ignition spark duration 200 to 700 mj of primary energy (device dependent) are available Settings for MOST in MICT The settings for MOST are made using the MICT configuration software. On the configuration side Timing Schedule A/B Energy, you can define different values for the spark duration, spark intensity, breakdown voltage and energy limit for the start phase and normal operation. That way starting difficulties of the engine can be caught. Different energy settings for the two schedules A and B support, for example, optimally matched two gas operations. The settings are dependent on the ignition coils that are used, among other things. They must be suitable for MOST and set correctly on the configuration side Engine Ignition Coils. To optimize the energy settings for an engine, the ignition behavior must be observed and analyzed (misfiring, knock behavior, emission values, etc.). The secondary side diagnosis with MICT, among other things, can help here. *Patent No.: US 8,893,692 BS. 8
The graphic compares the behavior of a conventional capacitor discharge ignition system (CDI) and ignition system with MOST. Capacitor discharge ignition system (CDI) The red curve shows that a high peak current is reached during ignition. Afterwards, the current decreases sharply. To achieve longer spark duration, the energy supply must be increased. The result of this is a higher peak current. Ignition system with MOST The blue curve shows that a lower peak current is reached during ignition with MOST. The current remains at a constant level until the energy supply ends. Thereafter, the current drops. In this case as well, more energy is supplied for a longer spark duration, however the peak current is not increased in the process. 100 Capacitor Discharge Ignition System (CDI) MOTORTECH Output Stage Technology (MOST) Secondary Current [ma] 50 variable variable 100 200 300 400 500 600 700 800 Spark Duration [µs] 9
MICT MOTORTECH Integrated Configuration Tool The MICT2.0 is the graphic user interface for the controllers of the MIC3, MIC4 und MIC5 series. Configurations can be performed and the operating data of the engine seen and adjusted using a laptop. Language selectable (German/English/Chinese) Compatible with Microsoft Windows XP/Vista/7 Print function of a runtime data snapshop for external problem analysis, etc. MICT MOTORTECH INTEGRATED CONFIGURATION TOOL Context-independent online help Different access levels to avoid unintended incorrect entries Example pages configuration Parameter set The database included provides engine information such as ignition order, ignition sequence, number of ignition coils per cylinder and typical number of teeth on the flywheel for easy engine configuration. Other configurations can be entered manually. Engine selection and user-defined cabling When selecting an engine from the engine database, user-defined direct cabling can also be configured. As a result it is possible to define the orientation of the cable tracks mounted on the engine and define the output cable harness in the ignition controller. 10
Parameter set The MIC ignition controllers offer two parameter sets for the inputs needed to calculate ignition timing, which for example can be used for two-gas engine operation. In addition, the parameter sets can be represented graphically. Parameter set Presentation of the configuration Graphic presentation of parameter sets A and B facilitates rapid visual checking of the values configured. Parameter set Energy settings The ignition spark duration and ignition spark intensity can be set at different ignition voltages with the assistance of the extended energy settings for the start-up phase and normal operation of the engine. 11
Example pages run time data Overview You can see the most important current run time data such as speed, ignition timing or system status at a glance in the overview presentation. Breakdown voltage The MICT provides a lot of current and detailed information on the status of every single ignition output. Important data is optically processed, ensuring that irregularities show up immediately; e.g. the secondary voltage is in addition shown as a bar diagram and the type of a misfire is symbolized by a warning light. Warning, error and alarm list The MICT shows a summary of all information, warnings, errors and alarms in a list. Apart from the alarm list and detailed reports, the precise date and time at which a report was included in the list is shown in addition to the operating hours. 12
Ignition timing On the left side of the display you see all values and settings that influence the ignition timing. In addition the values are shown and presented as a bar diagram on the right that are pending on the three inputs (potentiometer, analog current and voltage input) and in this way lead to the changes in ignition timing indicated. The value for the speed curve is shown by curve progression set in the configuration. Diagnosis The status display indicates the current error handling condition of the device for CAN bus communication. Example pages self-test Self-test You can carry out a self-test via the MICT to check the sequence of the cabling and connection between the outputs of the ignition controller to the spark plugs. 13
Components for MIC Ignition Systems High Tension Leads for NON Shielded Applications PolyMot patented spark plug leads are the most reliable high tension leads in the industry. Made from a combination of Ceramic, Teflon and Silicone they transfer nearly any rate of high energy spark from the coil to the spark plug. Variations for nearly all engine models in combination to spark plugs are available. Extended Spark Plugs For engine applications equipped with extreme tight spark plug well, conventional ignition leads show its limits. The solution is specially designed spark plugs with extended metal housing. XTLPlugs are manufactured with an integrated 7 mm spark plug lead, which allows a direct connection to an externally mounted ignition coil. It can be ordered with different barrel and lead lengths, different lead outputs from the barrel and a wide range of ignition coil connectors. XTL-Plugs are designed for unshielded applications and offer long runtimes. Industrial Spark Plugs Today the industrial gas engine market requests Platinum and Iridium tip electrodes for long spark plug life. High energy coils Ignition coils are becoming steadily more important in modern ignition systems. MOTORTECH provides high energy coils adjusted to controllers. New modern design Use of high quality materials Ideal for the ignition of alternative fuels like biogas Compatible with MOST MOT- Coils MOTORTECH IGNITION COILS 14
MOTORTECH LiteRail Wiring Systems The MOTORTECH LiteRail system aluminium profile is delivered pre-assembled for your engine design. Appropriate and pre-fitted ignition coils and the cabling needed via an exchangeable cable distributor simplify the assembly and exchangeability in the event of service. The MOTORTECH Lite Rail is available as a compound system with the MIC3, MIC4 and MIC5. Lite Rail cabling tracks are only available for use in rooms not at risk of explosion (non CSA). DetCon20 MOTORTECH DETONATION CONTROL SYSTEM DetCon20 The DetCon20 control unit offers full protection for gas, diesel and dual fuel engines from 2 to 20 cylinders. Microprocessor controlled, it will detect any detonation in the early stage and will send an analog signal (4-20mA/0-5V) out to the ignition system to retard in a linear function. If detonation cannot be cured a signal will be sent for load reduction and finally an engine STOP signal. CAN Bus interface included. PowerView3 HMI-Module PowerView3 is a compact and flexible HMI module (Human-Machine-Interface) for visualization and operation of MOTORTECHs new generation control units. On more than 25 screens the 7 color display supports the full visualization of the most important operating data of ignition and detonation control as well as the adjustment of various parameters. Error diagnostics can be executed easily on-site without requiring a laptop. The touchscreen guarantees an intuitive navigation through different display pages and menus. The relevant operating data can be easily recorded and stored via USB mass storage device or SD card. The visualization functions have to be activated for every single device. Additional activations or firmware updates are possible at any time. Magnetic Pickup (MPU) Reliable design in a variety of different lengths. Available in standard or CSA certified versions. Hall-Effect Pickup High temperature resistant pickup. Triggers off any magnet. Available in standard or CSA certified versions and both possible polarities. Inductive Pickup Small sensor (M12 thread) for use in applications where there is not much available installation space. It can operate in oil. High temperature resistance. Available in standard or CSA certified versions. 15
We aim at your problems! Regardless of which part of the globe we need to travel to. We know that the stakes are high, and therefore we outperform the others. That is because we want everything to run smoothly at your site, everywhere and at any time. This is entirely in keeping up with our motto: Let us drop everything and work on your problem! Distribution partner for DENSO spark plugs MOTORTECH GmbH Hogrevestr. 21-23 29223 Celle, Germany Phone: +49 5141 93 99 0 Fax: +49 5141 93 99 99 www.motortech.de motortech@motortech.de Headquarter Office Sales Partner MOTORTECH Americas, LLC 1400 Dealers Avenue, Suite A New Orleans, LA 70123 Phone: +1 504 355 4212 Fax: +1 504 355 4217 www.motortechamericas.com info@motortechamericas.com Distributed by: Copyright The copyright for all materials used in this MOTORTECH publication is reserved. Any kind of duplication or use of objects such as pictures or texts in other electronic or printed publications without approval by MOTORTECH is not permitted. 16 P/N 01.15.025-EN Rev.08/2015 MOTORTECH SalesFlyer MIC Series Trademark Information MOTORTECH products and the MOTORTECH logo are registered and/or common law trademarks of MOTOR- TECH Holding GmbH. All OEM names and part numbers shown are for reference purposes only. All trademarks, logos and symbols used or shown in this MOTORTECH publication are exclusive objects to the right of their owners and are used for reference purposes only.