Mic520 525 530 e

Models MIC520, MIC525, MIC530
ClassI,Div2,Group C,D
22/03/2006 Rev. 1.2
MOTORTECH manual MIC500 series
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 batterycharging 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.
Product-information. MOTORTECH GmbH, Hogrevestrae 21-23, 29223 Celle, Germany

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All information is subject to change. We reserve the right to change technical information.
page 2
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 ............................................................................................................... 32
Ignition coils and high tension leads..................................................................................... 33
Ignition-Timing Adjustment................................................................................................... 34
Programming examples ...................................................................................................... 35
2 step adjustment.............................................................................................................. 36
Permissive Start................................................................................................................... 37
Contact Switch ..................................................................................................................... 38
Additional functions.............................................................................................................. 38
Ignition-energy levels ........................................................................................................... 38
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Cylinder-to-Cylinder timing................................................................................................... 38
Activating Cylinder-to-Cylinder timing .................................................................................. 49
Example of a 6 cylinder engine ............................................................................................ 40
Misfiring control of primary wiring......................................................................................... 40
Startup procedure ................................................................................................................ 41
Shutdown procedure ............................................................................................................ 41
Operational features ............................................................................................................ 41
Trigger-signal-check ............................................................................................................ 42
Input-signal, fault recognition ............................................................................................... 42
CHAPTER 4 PROGRAMMING ...........................................................................................................43
Short guide for every single step of programming the MIC 500 series ignition control unit .. 43
Programming the MIC500 series with a Laptop .................................................................. 45
Programming the MIC500 series with the Hand Held Programmer ..................................... 45
Programming of Parameters ............................................................................................... 48
Programmable Parameters ................................................................................................. 49
Example of Programming an MIC500 series........................................................................ 65
CHAPTER 5 MAINTENANCE AND TROUBLESHOOTING ..............................................................66
Maintenance ....................................................................................................................... 66
Faults Causes and Remedial Action .................................................................................... 67
Troubleshooting ................................................................................................................... 68
Input Fault Diagnosis ........................................................................................................... 68
Fault Detection in the low or High Voltage Ignition Circuits .................................................. 70
Self-test Function ................................................................................................................. 71
Legal Provisions .................................................................................................................................72
Copyright Regulations .......................................................................................................................73
Abridged instructions.........................................................................................................................74
PROGRAMMING OVERVIEW ............................................................................................................83

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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 3.8 Manual timing adjustment .................................................................................. 34
Figure 3.9 05 Volt Retarded Curve .................................................................................... 35
Figure 3.10 05 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 420mA limit ........................................................................ 59
Figure 4.5 Speed points BP1 to BP5.................................................................................... 62
Figure 4.6 Speed-points example ........................................................................................ 64
Figure 5.1 OscilloscopeSquare 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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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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page 6
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.
ClassI, Div2, Group C,D
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
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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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page 8
Models Available
Ignition Control Unit
06.00 520
06.00.525
06.00.530
MIC520
MIC525
MIC530
up to 8 outputs
up to 12 outputs
up to 16 outputs
Accessories
Unshielded Harnesses
Input Harnesses - length to be specified. Standard length: 160
Active pickup
06.02.501-L
06.02.502-L
Magnetic pickup
06.02.505-L
06.02.506-L
Hall-effect pick up
06.02.510-L
06.02.511-L
Input harness, active pickup

Input harness, DUAL active pickup
Input harness, magnetic pickup
Input harness, DUAL magnetic pickup
Input harness, hall-effect pick up
Input harness, DUAL hall-effect pick up
Output Harnesses - length to be specified. Standard length: 240

06.02.604-L
06.02.608-L
06.02.612-L
06.02.616-L
Output harness for MIC 520, 4 outputs


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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
95.30.511-L
Input harness, hall-effect pick up

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
95.30.616-L
Unshielded Pickups
Active pickup
06.60.023
06.60.027
Magnetic pickup
06.60.101
06.60.105
06.60.102
06.60.103
06.60.107
Hall-effect pickup
06.60.020
06.60.021
06.60.022
M12 x 1 x 100 mm Active pickup

5/8-18 UNF x 1,25 Magnetic pickup
5/8-18 UNF x 1,75 Hall-effect pickup

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page 10
Shielded Pickups
Active pickup
95.70.003-100
95.70.003-60
Magnetic pickup
95.70.001-125
95.70.001-175
95.70.001-250
95.70.001-400
95.70.001-600
Hall-effect pickup
75.70.002-175
75.70.002-250
75.70.002-450

Unshielded Pickup Leads

Active pickup
06.71.007
Magnetic pickup
06.71.001
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
95.60.020-L

Hall-effect pickup
95.60.030-L
95.60.040-L

Coils
Trigger Devices
Trigger Discs
Trigger Magnets
Trigger Pins
High Tension Leads
See Catalog

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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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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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Chapter 2
Technical Data
MIC500 series Dimensions of the Ignition Control Module
(8)
2.1
(159mm) 6,25''
(142mm) 5,59''
(178mm) 7,00''
RS-232
(196mm) 7,71''
(217,5mm) 8,56''
(77mm) 3,03''
(223,5mm) 8,79''

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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
MIC530
Input 10 pin

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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

o 2 16 cylinders for single firing and
o 2 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:
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:
Ignition coils:
min. 10 VDC
max. 32 VDC
- 40 F to 158 F
- 40 F to 212 F
- 40 C to 70 C
- 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 vibrationdamping 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.
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.
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
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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page 19
3.1
Trigger Disc Mechanical Requirements

NOTES:
1.
2.
Note direction of rotation.

Inch (mm) as specified.
Minimum
Diameter
4
(100)
INDEX
M, (360/M places)
See table
.236
(6)
see table
Configuration N (Degrees) M (Degrees) Trigger

2+1
3+1
4+1
5+1
6+1
8+1
10+1
12+1
60
180
3
40
120
4
30
90
5
20
72
6
20
60
7
15
45
9
15
36
11
Not recomended for camshaft mounting

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Camshaft Pickup
The camshaft pickup generates a square wave signal.
CAUTION!
It is essential to take account of the camshaft slope in order to prevent the
reluctor pin from striking the pickup!
In order to avoid defective signals, the mounting surface must be free of sharp
edges, holes, or other irregularities.
Preparations for Active Pickup
Prepare a massive and vibration-free mount for the active pickup unit.
The bracket must be positioned in such a way that the pickup is directed at a right angle to
the surface of the disc.
Drill and tap a hole to accept the chosen pickup.
WARNING!
Ensure that metal chips, filings, or shavings from drilling and tapping operations
do not remain in the engine!
3.2
Mounting of Camshaft Trigger Disc

Example: 4-cylinder-engine
Trigger disc with reluctor pins
(4+1 configuration)
.020
Camshaft-sensor
(active)
30
NOTE! Tightening torque for the camshaft pickup: max. 15 N m (11 lb-ft)!

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Installation of a Disc with Reluctor Pins

In order to avoid wrong signals, the mounting surface must be free of sharp edges, holes, or
other irregularities.
WARNING!
Take care to ensure that the speed pickup does not rotate with the lock nut, thereby
causing the gap to alter.
It is essential that the threaded hole be perpendicular to the surface of the ring gear!
Screw the active pickup into the tapped hole.

The pickup must point to the "A" trigger pin at a right angle.
The air gap between the tip of the reluctor pin and the surface of the pickup should be
approximately 0.02 inch / 0.5 mm.
This gap is best achieved by following these steps:
Screw in the pickup until it just makes contacts with the tip of the trigger pin.
Unscrew the pickup by a half turn counter clockwise direction.
Now tighten the lock nut, taking care to ensure that the pickup does not rotate at the same
time.
Crank the engine back and forth several times by a few degrees to make sure that the
trigger pin does not strike the pickup surface.
NOTE! Trigger Pin may be a magnet or reluctor pin!

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Mounting a Trigger Disc with Slots

3.3
Mounting a Trigger Disc with Slots
.020
CAUTION!
In order to avoid wrong signals, the mounting surface must be free of sharp
edges, holes, or other irregularities.
It is essential that the threaded hole is perpendicular to the surface of the ring
gear!
WARNING!
Take care to ensure that the speed pickup does not rotate with the lock nut,
thereby causing the gap to alter.
Screw the speed pickup into the tapped hole.

The pickup must point to the "A" trigger slot at right angles.
The air gap between the surface of the trigger disc and the nose of the pickup should be
approximately 0.02 inch / 0.5 mm.
This gap is best achieved by following these steps:
Screw in the pickup until it just makes contact with the surface of the trigger disc.
Unscrew the pickup by turn counterclockwise direction.
Now tighten the lock nut, taking care to ensure that the pickup does not rotate at the same
time.
Crank the engine back and forth several times by a few degrees to make sure that the
pickup does not strike the trigger disc.

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Passive Pickup
The flywheel pickup senses an AC signal if a passive pickup is used.
3.4
Mounting of a magnetic Pickup
30
Index
Flywheel
1:1
.025
Speed sensor

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Setting the Ignition Timing Adjustment Range and

Positioning the Trigger Disc
The maximum ignition timing range of the MIC500 series ignition control module is 38 degrees.
The maximum range is achieved with a base setting of 40 BTDC or more. Lower base settings
reduce the ignition timing range.
The base setting is the crank angle of cylinder #1, on the compression stroke, when the trigger
disk A pin is aligned with the pickup. Typically the base setting target is the most advanced
ignition timing the engine needs plus 2 or more degrees. The MIC500 series ignition control
module requires 2 degrees for computation time.
To obtain the correct base setting:
1. Bar the engine over until cylinder #1 is on compression stroke. Turn backwards to
40 BTDC or any other selected crank angle for the base setting.
2. Rotate the trigger disk on the camshaft or crankshaft to align pin A with the pickup.
3. Securely fasten the trigger disk to the camshaft or crankshaft.
4. Setting must be between 25 and 60 BTDC on cylinder #1. Be sure the range fits the
engine ignition timing requirements.
3.5
Example of Flywheel Positioning
basic setting:
40 BTDC
ignition adjustment
range:
38BTDC to TDC

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3.6
Example:
Basic Setting 40 BTDC
Example A:
Basic setting:
40 BTDC
Ignition adjustment range: 38 BTDC to TDC (38 total)
Example B:
Basic setting:
30 BTDC
Ignition adjustment range: 28 BTDC to TDC (28 total)
Example C:
Basic setting:
50 BTDC
Ignition adjustment range: 48 BTDC to 10 BTDC (38 total)
NOTE!
The system does not allow After Top Dead Center (ATDC) ignition timing.

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Wiring Requirements
General
NOTE!
Wire exposed beyond the shield must be as short as possible
MIC500 series CD Ignition System Electrical Connections and Pin Functionality
WARNING!
The engine power supply must be disconnected and safeguarded against switching
on before beginning any work on the MIC500 series. Do not make any power supply
connections into live power circuits!
Never switch on the ignition control module without the output leads connected to the unit.
An improperly installed ignition system may lead to engine damage and could pose threat of
personal injury to operators.
All components (ignition control module, ignition coils, and all lead screens) must be grounded
to ensure electromagnetic compatibility.
CAUTION!
Take care to ensure that the following minimum and maximum voltages to the MIC500
series are complied with:
Minimum 10 VDC
Maximum 32 VDC
Input voltages beyond these values might damage the MIC500 series.
NOTE!
Emergency shutdown of the MIC500 series is achieved by switching off the input
power.
Emergency shutdown devices must be rewired in order to switch off the input power.

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RS-232 Port
The MIC500 series is programmed via RS-232 using a null modem cable. Any fault indications
will be transmitted to a PC or Laptop through the RS-232 link.
Input Power
Pins A (+) and B () connect the MIC500 series to input power from an external power source.
The rated operating range is 1032 VDC. (steady state operation from 10 to 18 VDC is
allowable but may not be able to achieve 100% energy). Connect the buffered positive power
supply terminal through a 6 A Slo-Blo fuse to the harness and the reference to pin A. To
ensure proper operation, the minimum input voltage (12 V) must be maintained even under
load. The cross-section of the power supply leads must be at least 14 AWG / 2.5 mm

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Example 6-Cylinder Viewing Diagram
A (+) 24VDC
B (-) 24VDC
red
black
C (+)4-20mA
E (-)4-20mA
F Loop Power (24VDC)
green
brown
white
D A/B - START/STOP Contact
white
G (+) Pick Up Signal

H MPU Power
I (-) Pick Up
black
brown
blue
J GO/NOGO Contact
brown
fig 11a: Example 6 Cylinder

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3.7.1
MIC520 WIRING CHART

Input 10 pin
Pole
A
B
C
E
F
D
G
H
I
J
Function
+ 24Volt supply
- Ground
(+) 4 - 20 mA
(-) 4 - 20 mA
Loop Power (24 VDC)
Contact A/B or
START / STOP
(+) Pick Up Signal
MPU Power
(-) Pick Up Signal
GO / NOGO Contact
Harness
colour code
Red
Black
Green
Brown
White
White 1,5mm
Black
Brown
Blue
Brown 1,5mm
Pole
A
B
C
D
E
F
G
I
H
J
Function
Output Cylinder 1 in firing order
Shutdown lead or Panel Output
Power. Max. 20mA at 300 V Primary
Ground
Harness
colour code
Red
Yellow
Green
Brown
Blue
Orange
Purple
Grey
White
Black
NOTE!
Leads which are not connected for use must be isolated, as they could be
internally connected to a power source.

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3.7.2
MIC525 WIRING CHART

Input 10 pin
Pole
A
B
C
E
F
D
G
H
I
J
Harness colour Pole

code
A
+ 24Volt supply
Red
B
- Ground
Black
C
(+) 4 - 20 mA
Green
D
(-) 4 - 20 mA
Brown
E
Loop Power (24 VDC) White
F
Contact A/B or START
G
White 1,5mm
/ STOP
I
(+) Pick Up Signal
Black
K
MPU Power
Brown
L
(-) Pick Up Signal
Blue
M
GO / NOGO Contact Brown 1,5mm
N
Function
Function

H
Power.Max. 20 mA at 300V Primary
J Ground
Harness
colour code
Red
Yellow
Green
Brown
Blue
Orange
Purple
Grey
Pink
White/Red
White/Yellow
White/Green
White
Black
NOTE!

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3.7.3
MIC530 WIRING CHART

Input 10 pin
Pole
Function
A
B
C
E
F
+ 24Volt supply
- Ground
(+) 4 - 20 mA
(-) 4 - 20 mA
Loop Power (24 VDC)
Contact A/B or
START / STOP
(+) Pick Up Signal
MPU Power
(-) Pick Up Signal
GO / NOGO Contact
D
G
H
I
J
Harness
colour code
Red
Black
Green
Brown
White
White 1,5mm
Black
Brown
Blue
Brown 1,5mm
Pole
A
B
C
D
E
F
G
K
L
M
N
P
R
S
T
U
H
J
Function
Power.Max. 20 mA at 300V Primary
Ground
Harness
colour code
Red
Yellow
Green
Brown
Blue
Orange
Purple
Grey
Pink
White/Red
White/Yellow
White/Green
White/Black
White/Violet
White/Orange
White/Blue
White
Black
NOTE!

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Output Harness
NOTE!
Failure to correctly install the ring-type terminals will affect engine performance
and may shorten the life of the ignition system. The MIC500 series is a negative
ground system. When replacing positive ground systems by the MIC500 series,
the wiring must be altered accordingly. The ignition coils must be connected in
series in case of double-firing engines!
Route the individual primary wires to the corresponding ignition coil as indicated in the wiring
chart, taking care to avoid:
Sharp edges;
Hot manifolds;
Rotating parts that could damage the installation of the wiring.
Route the primary wires through metallic, grounded sleeves.
Trim each low voltage wire to the proper length and crimp ring-type terminals onto their free
ends.
The ring-type terminals should be suitable for 16 AWG/1.5 mm gauge wire and should have a
hole diameter of 0.2"/5mm.
Use only proper crimping tools for attaching ring-type terminals.
Use the remaining primary wire (or other wire 16 AWG/1,5 mm that is temperature resistant to
221 F/105 C and Insulation breakdown strength of 600V) along with the ring type terminals to
jumper the negative ignition coil terminals
On each engine cylinder bank, the first and last coil must be grounded to the engine block.
Glue a DIN 4844-W8 safety label the engine at a clearly visible position.
Safety Label DIN 4844 W8

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Ignition Coils and High-Tension Leads:
Securely mount each ignition coil on the engine as close to the spark plug as possible.
Avoid mounting the coils on or near hot manifolds or where ambient temperatures exceed
212 F/100 C.
Only install high-tension leads that are suitable for the application and meet the authorities
certification
Ensure that the high-tension leads are as short as possible.
Apart from the spark plug resistance, an additional resistance of 2 to 5 k must be provided in all
non-shielded high tension leads. We recommend the use of spark plug connectors with
integrated resistors.
NOTE!
On non-shielded installations we recommend spark plug connectors with integrated
resistors.

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Ignition Timing Adjustment

The MIC500 series features two stages of variable timing adjustment:
Manual adjustment (potentiometer)
420 mA analog signal (both directional)
Each method is operator-adjustable and provides up to 38 adjustment range. The resolution of
the timing setting is accurate to 0.25 crankshaft degrees.
Manual Adjustment
CAUTION!
An incorrect timing setting may lead to engine damage!
The desired timing may be precisely set by manually rotating the potentiometer.
Manual timing adjustment is possible with the engine running.
Do not apply voltage to terminals C, D, or E of the harness.
The desired timing setting may be obtained by rotating the potentiometer.

The span between the extreme CW and CCW position is max. 38 depending on the
configuration of the MIC500 series (see Setting Potentiometer Span in Chapter 4).
The potentiometer has no STOP position

3.8 Manual Timing Adjustment
Manual
Timing
adjustment
CAUTION!
When choosing the correct timing setting, it is essential to strictly adhere to the
values specified by the engine manufacturer.

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Analog Input:
The second timing control method requires a linear 4 20 mA signal, e.g. provided by a remote
potentiometer, a boost pressure sensor or a knock detection system.
By means of a steady linear 4 20 mA input signal, the timing can be shifted further towards
advanced and/or retard over a max range of 38 degrees.
Programming Examples:
3.9
4 20 mA Retarded Curve
40
4 mA
30
potentiometer setting 30 BTDC
10 RET (retarded) span
20
20 mA
0
3.10
4 20 mA Advanced Curve
40
20 mA
35
20 ADV (advanced) span
15
potentiometer setting 15 BTDC
4 mA
5
0
NOTE!
The slope of the Y-(4-20 mA) curve can be selected / programmed by the two curve end
points

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2-Step Adjustment:
A simple 2-step adjustment is possible with the aid switching contact D (10-pin Input connector to
ground). If the engine is operated, e.g. with two different grades of fuel, it is generally advisable
to alter the ignition timing when changing from one type of fuel to another.
3.11
2-Step Adjustment
F Loop Power (+24 VDC)
D programmed for A/B
Proceed as follows:
Open the switch.
Change parameter I/P for Stop to A/B. Select the required DELTA/OFFSET Angle to the main
setting, (maximum 38 crank angle) and program the unit accordingly
By manual adjustment, first set the ignition timing to the programming advanced position by
using the integrated potentiometer of the MIC500 series control unit.
Close the switch.
You may now switch between the two fixed timing settings by opening and closing the switch in
lead F of the 10-pin connector.

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3.12
Timing Offset A/B
Integrated potentiometer setting
20
5 timing offset programmed
15
Permissive Start / GO/NOGO OUTPUT

Pin J is the Permissive Start or Go/NoGo output. It is a solid-state output, capable of sinking up
to 150 mA, that should be used to enable/disable fuel flow to the engine directly or in
combination with other devices (lube oil pressure, etc.).
Anytime the ignition stops due to normal stop sequence, overspeed, or when a fault is detected,
the Permissive Start output will de-energize.
Upon start-up, the Permissive Start output will not energize until all timing signals are verified
and the ignition is starting to fire. Figure 3.13 shows a likely set up for this output.
3.13
GO / NOGO Output
for ex FUEL VALVE
24 VDC (+)
MIC 500 series

Max. 150 mA
GO / NOGO lead (J)

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Contact Switch
Pin D can be set up as a switch to select between the timing schedules A or B. It can also be
configured as an Auxiliary Shutdown Input. This needs to be programmed. The default is for Auxiliary
Shutdown.
Additional functions
Ignition Energy Levels
Depending on the gas quality and the application, it is possible to vary the available ignition energy.
You may set any value between 15 100 % (155V-300V).
Fast burning gases like propane require relatively small energy, whereas slow burning gases like
sewage gas require high energy and long spark duration.
To change the preset values proceed as follows:
Press "E"
Press "F1"
Enter new value
Press "Enter"
Press "F5" to save changes
Primary Voltage to Coil vs Energy (%)
15%
= 155V
20%
= 160V
30%
= 180V
40%
= 200V
50%
= 220V
60%
= 240V
70%
= 255V
80%
= 275V
90%
= 290V
100% = 300V
Cylinder-to-Cylinder-Timing
The Cylinder-to-Cylinder-Timing allows a change of individual cylinders to optimize ignition firing. The
ignition timing of each cylinder can be shifted by 2 from the global setting. However, you should only
use this option, if a suitable instrumentation is available to analyse the position with the most effective
compression, in order to immediately judge the result.
Activating Cylinder-to-Cylinder-Timing
NOTE!
ADV is advanced from the global setting
RET is retarded from the global setting
See sequence of connections, respectively firing order.
Press "F5" to save all cylinder adjustment values. Leave the cylinder-to-cylinder menu by pressing
ESC". Now you can disconnect the programming tool from the MIC500 series without losing any data.
The MIC500 series primary outputs do not consider the direction of rotation. Pin "A" is always the first
cylinder of the firing order, "B" is the second, "C" the third etc.
The function cylinder-to-cylinder-adjustment is started during engine operation by pressing [C] using
the programmer.
The following menu is displayed:
CYL #1 x.xx ADV / RET
F1 CHANGE
F2 NEXT
F3 PREVIOUS
F5 SAVE
value can be changed

call next ignition output
back to previous output
save
To change values proceed as follows:

[F2]
until ignition output of the cylinder, which is to be optimized, appears
[F1]
1ST TYPE IN NEW enter delta value (2ADV to 2RET)
THEN ENTER
[ENTER]
F1 ADVANCE
F2 RETARD
change to position advanced from global setting

change to position retarded from global setting
F5
save

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Example of a 6-Cylinder Engine Wiring vs No of cylinder in firing order:

3.1
Outputs of IC500
Firing order of engine
Misfiring Control of Primary Wiring:

The MIC500 series continuously checks all outputs of the unit and the connection to the ignition coils.
When calling this function by pressing "M", you get the following screen:
3.2
Normal
Outputs
M N
Miss / sec =0*
Fault: Example shows loss of one cylinder (primary wire F)

Outputs
M N
Miss / sec =15*
From this table the wiring fault can be traced through the harness output designation letter
* Misfiring per second

Error
1 = NO ERRORS
0 = ERROR
Miss/sec
= value between 0 and 255 can be programmed as maximum misfire rate

= 0 disables the function
ESC to leave this menu
WARNING!
An improperly installed ignition system may lead to engine damage and could pose
threat of personal injury to operators.
When set to 0 or 255 this feature is disabled.

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Start-Up Procedure:
Before starting the engine recheck all wire and plug connections.
Proper ignition can be verified by cranking the engine with the fuel valve closed.
Apply input power to the ignition control module and verify proper firing by checking each spark plug
lead with an inductive timing light.
Once satisfied that the ignition system is functioning properly, follow the normal engine starting
procedure.
Start the engine with the fuel valve open, increase to rated speed, and set ignition timing to exact
position.
Open switch in lead F (4-20mA Loop Power) and set proper timing by turning the external potentiometer.
When using timing schedule B for alternative timing, close contact input D and check timing.
Is the timing not as desired, you need to correct your offset timing as described in Setting offset angle
Shutdown Procedure
After shutdown, ensure that the MIC500 series is disconnected from the power supply before
unplugging any harness connector.
Operational Features
In order to ensure perfect operation of the ignition control system, observe the maintenance instructions
given in section Maintenance. The MIC500 series has several functional features to ensure proper
operation:
Trigger signal check
Input signal fault recognition
Shutdown
Manual ignition timing adjustment

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Trigger Signal Check:

The ignition control module compares the trigger-timing signal with the pin count and the firing patterns
pre-programmed. Should any discrepancy occur, the ignition control module will shut down following
one further complete revolution of the flywheel.
Input Signal Fault Recognition:

If a fault is detected in the pickup circuit during operation, the MIC500 series automatically shuts down.
The cause of the fault must be corrected before the engine can be restarted.
Control Functions
A list of the various control functions can be found in Chapter 4 Programming.

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Chapter 4
Programming
Short Guide for every Single Step of Programming the MIC500 series
Ignition Control Unit:
(1)
Sequence-Number
see configuration table
(2)
Reset BTDC
position in degrees of trigger disc basic setting. Trigger

pin / hole "A" is opposite to pickup.
(3)
Overspeed
Overspeed RPM. When reached, ignition will shut down.
(4)
Security Speed
Speed that inhibits operation of the contact switch.
(5)
MIS / SEC
Max. allowed misfiring rate. When exceeded, ignition

will shut down. To disable set to 0 or 255.
(6)
Cyl to Cyl enable

Cyl to Cyl disable
enables Cyl-to-Cyl-timing feature

disables Cyl-to-Cyl-timing feature
(7)
Contact I/P for STOP

Contact I/P for A/B
contact switch lead D of 10-pin input connector

enabled for ON/OFF of ignition.
enabled for operation with 2 timing schedules
(8)
Pot timing enable

Pot timing disable
potentiometer function enabled

potentiometer function disabled
(9)
Speed curve in A in A -enable

Speed curve in A not in A -disable
speed curve for timing curve A enabled

speed curve for timing curve A disabled
(10) 4 20 mA in A in A - enable
4 20 m A in A not in A - disable
4 20 mA analog for timing curve A enabled

4 20 mA analog for timing curve A disabled
(11) Speed curve in B in B - enable

Speed curve in B not in B disable
speed curve for timing curve B enabled

speed curve for timing curve B disabled
(12) 4 20 mA in B in B - enable
4 20 mA in B not in B - disable
4 20 mA analog for timing curve B enabled

4 20 mA analog for timing curve B disabled

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(13) Pot CCW xx.xx ADV
Potentiometer, max. angle at max. CCW position

ADV BTDC
RET most retarded (TDC)
(14) Pot CW xx.xx ADV
Potentiometer min. angle at max. CW position

ADV BTDC
RET most retarded (TDC)
(15) Max ADV A:
most advanced timing limit for timing curve A

(max. limit to advance)
(16) Max RET A:
most retarded timing limit for timing curve A

(max. limit to retard)
(17) Max ADV B:
most advanced timing limit for timing curve B

(max. limit to advance)
(18) Max RET B:
most retarded timing limit for timing curve B

(max. limit to retard)
(19) Offset
only for"2-point adjustment when (7) contact I/P is

programmed for A/B timing schedule
(20) 4 mA timing
adjustment of timing point given by analog signal

(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 signal

(input signal: 20 mA)
ADV = "x" degree advanced from potentiometer setting
RET = "x" degree retarded from potentiometer setting
(22) Default setting
Fixed value which is automatically activated when the

4-20 mA signal is lost or out of range
(23) Speed points #
number of speed points, required for speed curve

(max. 5 points possible)
(24) BP 1
speed point 1
new speed = desired speed point
angle = Advanced or retarded angle from potentiometer
setting

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BP 2
speed point 2
setting
BP3
speed point 3
setting
BP4
speed point 4
setting
BP5
speed point 5
setting
(25) End / Start
ESC quit programming mode
Programming the MIC500 series with a Laptop

The scope of supply includes a CD disk and an interface cable. The software is designed for
WINDOWS. Install the software on your laptop according to the instructions attached to it.
When using a laptop, please note that all capital letters in this manual have to be entered as such
letters. That means you have to use the [SHIFT]-key and the appropriate key for the letter.
[F10] is used to quit program,reset supply and follow engine starting procedure

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Programming the MIC500 series with the Hand-Held Programmer

06.05.001-110VAC or 06.05.008 - 240 VAC
Before the first use the hand-held programmer has to be configured.
Switch on the programmer.
Press [Shift] + [CTRL] + [F1] at the same time.
The first parameter will be displayed.
Baud = 9600, press [F1] to continue in lines until "9600" is displayed.

[F2] next
Data Bits = 7, press [F1] to continue in lines until "7" is displayed.
[F2] next
Parity = ignore, press [F1] to continue in lines until "ignore" is displayed
[F2] next
Display Pe enabled, press [F1] to continue in lines until "enabled" is displayed
[F2] next
Repeat = fast, press [F1] to continue in lines until "fast" is displayed
[F2] next
Echo disabled, press [F1] to continue in lines until "disabled" is displayed
[F2] next
Handshake disabled, press [F1] to continue in lines until "disabled" is displayed
[F2] next
Self-Test disabled, press [F1] to continue in lines until "disabled" is displayed
[F2] next
Power Save enabled, press [F1] to continue in lines until "enabled" is displayed
[F2] next
[F5] Save
Now, the hand-held programmer is ready for use.
NOTE!
When programming with the hand-held programmer only capital letters are possible.
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General Programming Commands

Commands:
[F1]: Change Parameter
[F2]: Next
[F3]: Previous
[F4]: Help
[F5]: Save
Sub Menus:
[C]: Cyl. to Cyl. menu
[E]: Energy level menu
[H]: Hours and Software Rev. no.
[M]: Misfires and Misses/sec
[S]: Self-test
Main Screen:
RPM:
speed
4 20 mA:
analog input signal
SPARK:
00,00
ignition timing
ENERGY LEVEL : 100 %
energy in %
STATUS:
ignition status
READY

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Programming the Control Unit in General

Prior to operating the MIC500 series it has to be configured in regards to engine and application.
Programming carried out using:
Laptop
call for software CD
PDA WIN CE
call for software CD
Hand held programmer (06.05.001 / 06.05.008)
The connection is established via a serial computer interface and a cable to the RS232 port of
the MIC500 series control unit.
NOTE!
The MIC500 series may only be programmed by trained personnel. A password is required,
which you kindly ask for at your MOTORTECH Distributor. In case of access to programming,
please proceed as follows:
Switch on voltage supply to the MIC500 series, connect the MIC500 series to the computer and start the
terminal software.
The main screen is shown.
Press [ESC] If the engine is already in operation, the ignition module cannot switch to the
programming mode.
Now, you will be prompted to enter your PASSWORD.
Enter password and press [Enter] to reach programming level. The first parameter is displayed.
(If password is unknown, call your nearest Distributor).
General information for setting parameters:

[F1]
change parameter and confirm with[Enter].Every parameter change has to be saved with[F5]
[F2]
next parameter
[F3]
previous parameter
[F4]
help for current parameter
[F5]
save parameter
[ESC]
quit programming level and start MIC500 series
([F10] quit program, reset supply voltage and follow engine starting procedure only used in Comupter
Software )
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After setting MIC500 series parameters, we recommend to separate supply voltage in order to reset
the MIC500 series.
If voltage supply is disconnected for 20 seconds, it is ensured that all possible faults are reset.
Programming the MIC500 series Controller

The MIC500 series has 24 programmable parameters, which have to be set before operation.
Connect the hand-held programmer or your PC / Laptop to the RS232 port of the MIC500 series.
Switch on 12 / 24 V supply voltage to control unit
Press [Shift] and [ESC] at the same time. A message is displayed.
Enter PASSWORD
Press [Enter]. The first parameter is displayed.
If you press [F1], you can enter a new parameter by using the figure keys. Confirm with [Enter]. Every
single changed parameter has to be saved with [F5].
[F2] scrolls ahead to next parameter
[F3] scrolls back to previous parameter
[F4] brings up a short clarification to the current parameter

To quit the parameter menu press [Shift] and [ESC] at the same time.
1.
Programmable Parameters:
Sequence Number
See configuration table for appropriate sequence no.
[F1] or [F2] scrolls through sequence table
[F1] enter sequence no. and press [Enter] [F5] [F2].
[F4] shows the selected sequence no. and the firing pattern
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MIC500series Sequence Table

MIC500
SEQ
NO. OF
OUTPUTS
1
2
3
4
5
6
7
8
9
10
11
12
13
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
2
3
3
6
6
6
2
4
4
8
8
8
8
8
5
5
10
12
12
12
12
6
3
4
6
7
7
8
8
8
16
16
16
16
4
10
5
12
12
12
12
16
12
12
16
16
12
16
16
12
12
12
12
TRIGGER
FIRING
DISC
DEGREES
2+1
3+1
3+1
3+1
3+1
3+1
4+1
4+1
4+1
4+1
4+1
4+1
4+1
4+1
5+1
5+1
5+1
6+1
6+1
6+1
6+1
6+1
6+1
6+1
6+1
7+1
7+1
8+1
8+1
8+1
8+1
8+1
8+1
8+1
8+1
10+1
10+1
12+1
12+1
12+1
12+1
8+1
6+1
6+1
8+1
8+1
6+1
8+1
8+1
6+1
6+1
6+1
6+1
360-360
240-240
120-120
50-70
30-90
90-30
90-90
180-180
90-90
20-70
60-30
45-45
30-60
60-120
72-72
144-144
54-90
30-90
40-80
48-72
56-64
120-120
60-180
120-60
60-60
102,8-102,8
51,43-51,43
90-90
45-45
45-45
10-35
21-24
22,5
30-60
90-90
36
72
50-70
55-65
60-90
75-45
20-70
90-30
42-78
60-30
45-45
60-60
50-40
40-50
50-70
55-65
75-45
45-75
DISC
LOCATION
CAM
CAM
CRANK
CRANK
CRANK
CRANK
CRANK
CAM
CRANK
CRANK
CRANK
CRANK
CRANK
CAM
CRANK
CAM
CAM
CAM
CAM
CAM
CAM
CAM
CRANK
CRANK
CRANK
CAM
CRANK
CAM
CRANK
CRANK
CRANK
CRANK
CRANK
CAM
CRANK
CRANK
CRANK
CAM
CAM
CAM
CAM
CAM
CAM
CAM
CAM
CAM
CAM
CAM
CAM
CAM
CAM
CAM
CAM
Uneven Wiring
A-B-E
A-C-D-F
A-C-E-G-L-N-R-T
A-E-L-T
A-C-E-G-K

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MIC520
MIC520
MIC530
MIC530
MIC530
page 51
2.
Basic Settings (Position of Reset Signal)
NOTE!
The MIC500 series is programmed in a way that the top dead center (TDC) is at 0.
Ignition timing before top dead center (BTDC) are named "Degrees Before Top Dead
Center".
Ignition timing after top dead center (ATDC) are named "Degrees After Top Dead Center".
The basic setting of the trigger disc or the trigger pins / holes may be between 50 BTDC to 25 BTDC.
The MIC500 series program allows electronical compensation of mistakes made when setting the
trigger points.
We recommend the index position to be at 40 BTDC, this allows a timing span from 38 BTDC to 0
BTDC
For final adjustment, start the engine, set the ignition timing point to the point specified by the engine
manufacturer by using a timing light. If done, read timing information on the main screen display.
Correction of Reset Position

If the value is higher than the actual angle set by timing light, the difference in degrees has to be added
to the "reset position" programmed. If the value is lower than the actual angle set by timing light, the
difference in degrees has to be deducted from the "reset position" programmed.
To make the changes, stop the engine, enter the programming mode (password protected) and change
the value by pressing [F1]. Enter new value, press [Enter] and save with [F5]. Quit programming mode
with [ESC].

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page 52
3.
Overspeed Limit
Press [F1], enter desired speed for limit, then press [Enter], [F5] and finally [F2].
WARNING!
The ignition will be shutdown if overspeed limit is reached!
4.
Security Speed
The MIC500 series offers the "Security Speed" as a programmable feature. The desired speed is set by
pressing [F1], [(value)], [ENTER] and [F5]. Valid settings reach from 0 to speed limit ("overspeed rpm").
The "Security Speed" is the speed that may affect the operation of contact D. Contact D enables or
disables the primary outputs. The Security Speed determines if the outputs are enabled or if the engine
speed must go to zero RPM first. If the ignition is firing and the contact is closed and opened below the
security speed, the primary outputs will be enabled. With the ignition firing above the security speed, if
the contact is closed and then opened, it is necessary to wait for 0 RPM. If the contact is closed when
the engine speed goes above the security speed, (the ignition is not firing), opening the contact will
enable the primary outputs.
5.
Misfiring Rate
The control unit checks every output connection between the control unit and ignition coil. Damaged
leads cause misfiring. Here, you can enter a maximum frequency. If this value is exceeded, the ignition
will shut down.
To disable, set misfire rate to 0 or 255.
Example: At 1500 rpm every cylinder fires 12.5 times per second.
6.
Cylinder-to-Cylinder Timing (Toggle with [F1])
MIC500 series units are equipped with Cylinder-to-Cylinder-timing adjustment capability. This allows
individual fine-tuning of the ignition timing for each cylinder.
[F1] ENABLE
[F2] DISABLE
[F5]
activate
deactivate
save

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7.
Function of Contact Lead D of 10-Pole Input Connector
The contact lead D allows the choice between 2 functions:

CONTACT I/P FOR STOP A/B
F1 CONTACT FOR STOP
Ignition can be STARTED and STOPPED via this dry contact lead
F2 CONTACT FOR A/B
Switching this lead allows shifting between 2 timing schedules; the offset
between A and B can be programmed. It is possible to have a speed and
analog curve enabled or disabled for both A and B schedules.
8.
Activating Potentiometer
The integrated potentiometer of the MIC500 series can be disabled after making the settings, in order to
lock this feature for the operator.
POT TIMING ENABLED / DISABLED
F1
ENABLE
activated
DISABLE
deactivated
F5
save
9.
Speed Curve in Timing Schedule A
The MIC500 series offers programming of a speed curve / speed ramp. That means, depending on the
actual engine speed certain timing is chosen. This aims at reaching optimal gas combustion and
inproved starting
SPEED CURVE IN A / NOT IN A
F1
ENABLE
activated / function is used
DISABLE
deactivated / function is not used
F5
save

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10. Analog Input Signal for Timing Schedule A

Additionally to the potentiometer adjustment and the speed curve it is possible to change the ignition
timing by using the analog input signal.
Example:
A knock monitoring system can change the ignition timing linear. In that case the knock monitoring
system sends the analog output signal 4 20 mA to the ignition system depending on the level of
engine knocking.
4 20 mA IN A / NOT IN A
F1
ENABLE
DISABLE
F5

save
11. Speed Curve in Timing Schedule B

It is possible to program a different speed curve / speed ramp for timing schedule B. This different
ignition timing is given depending on actual engine speed.
By setting a speed dependent ignition timing an optimal gas combustion can be achieved.
SPEED CURVE IN B / NOT IN B
F1
ENABLE
DISABLE
F5
save
12. Analog Input Signal for Timing Schedule B

Additionally to the potentiometer adjustment and the speed curve it is possible to change the ignition
timing by using the analog input signal.
Example:
A knock monitoring system can change the ignition timing linear. In that case the knock monitoring
system sends the analog output signal 4 20 mA to the ignition system depending on the level of
engine knocking.
4 20 mA IN B / NOT IN B
F1
ENABLE
DISABLE
F5

save

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13. Setting the Potentiometer Span - CCW Position

The left electrical limit (ccw) of the potentiometer can be set as timing angle.
POT CCW x.xx ADV
F1
1ST TYPE NEW
F1: ADVANCE
F2: RETARD
F5
enter value
BTDC (before top dead center)
most retarded (TDC)
save
14. Setting Potentiometer Span CW Position

The right electrical limit (cw) of the potentiometer can be set as timing angle.
POT CW x.xx ADV
F1
1ST TYPE NEW
F1: ADVANCE
F2: RETARD
F5
4.2
enter value
most retarded (TDC)
save
Potentiometer Span CW Position
Ignition timing
25
20
CCW-position
Potentiometer-span
CW-position
10
50
500
1000
1500
RPM

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15. Timing Schedule A Limit of max. Advanced Ignition

In order to avoid engine damage by addition of the various ignition relevant parameters, it is possible to
set a maximum ignition limit.
MAX ADV IN A: xx.xx ADV

F1
1ST TYPE NEW:
THEN ENTER
F1: ADVANCE
F2: RETARD
F5
enter value
press [ENTER]
most retarded (TDC)
save
16. Timing Schedule A Limit of max. Retarded Ignition

set a minimum ignition limit.
MAX RET IN A: xx.xx ADV
F1
1ST TYPE NEW:
THEN ENTER
F1: ADVANCE
F2: RETARD
F5
enter value
press [ENTER]
most retarded (TDC)
save
Note!
The maximum advanced and retarded limit restricts any ignition-curve to this
point. Ensure that limits do not interfere with potentiometer and speed curve
settings.

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4.3
Ignition Limits
Ignition timing
25
MAX limit
20
MIN limit
50
500
1000
1500
RPM
17. Timing Schedule B Limit of max. Advanced Ignition

set a maximum ignition limit.
MAX ADV IN B: xx.xx ADV
F1
1ST TYPE NEW:
THEN ENTER
F1: ADVANCE
F2: RETARD
F5
enter value
press [ENTER]
most retarded (TDC)
save

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18. Timing Schedule B Limit of max. Retarded Ignition

set a minimum ignition limit.
MAX RET IN B: xx.xx ADV
F1
1ST TYPE NEW:
THEN ENTER
F1: ADVANCE
F2: RETARD
F5
enter value
press [ENTER]
most retarded (TDC)
save
19. Setting Offset Angle

When activating the pot A / B function, for Contact D you can setting schedule B by programming the
offset angle (40 advance to 40 retard) to timing schedule A.
20. Analog Input Signal 4 mA-Limit

Direction of rotation direction and span, direct or indirect effect of the 4 20 mA signal can be
programmed with end points retarded or advanced. The 4 20 mA signal (advance or retard) will be
added to or deducted from the potentiometer and speed curve (if activated).
The value of change has to be entered as a figure in degrees when the 4 mA-signal is received.
4 mA TIMING x.xx ADV
1ST TYPE NEW
ENTER
F1: ADVANCE
F2: RETARD
F5
enter value
advance (addition to existing curve)
retard (deduction from existing curve)
save

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21. Analog Input Signal 20 mA-Limit

Rotation Direction of and span, direct or indirect effect of the 4 20 mA signal can be programmed with
end points retarded or advanced. The 4 20 mA signal (advance or retard) will be added to or
deducted from the potentiometer and speed curve (if activated).
The value of change has to be entered as a figure in degrees when the 20 mA-signal is received.
20 mA TIMING x.xx ADV
1ST TYPE NEW
ENTER
F1: ADVANCE
F2: RETARD
F5
4.4
enter value
advance (addition existing curve)
retard (deduction from existing curve)
save
Analog Input Signal 20 mA-Limit
Ignition Timing
25
20
= 4 mA input
4 20 mA adjustment range
= 20 mA input
10
50
500
1000
1500
RPM

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Ignition Timing
25
= 4 mA input
4 20 mA adjustment range
20
= 20 mA input
10
50
500
1000
1500
RPM
22. Default Setting

The default setting is a fixed value which is automatically activated when the 4-20 mA signal is lost or
out of range
DFLT 4-20MA:
X,XX
F1
1ST TYPE NEW:
ENTER WHEN DONE:
F1 ADVANCE
F2 RETARD
ENTER WHEN DONE:
F5
ADV/RET
Type new
press[ENTER]
add
deduct
press[ENTER]
SAVE

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23. Speed Points

For programming a speed dependent curve a max. of 5 speed points can be set. The speed curve
should be worked out before you start programming the data!
SPEED POINTS:
1ST TYPE NEW:
ENTER WHEN DONE
F5
x
enter value (1 to 5)
press [ENTER]
save
24. Setting the Speed Points BP1 to BP5

Setting the speed points always requires a speed and a degree value. The degree value will be added
to (ADV) or deducted from (RET) the potentiometer curve, which is always 0 (zero).
BP1: x.xx ADV
NEW SPEED
ENTER WHEN DONE
F1: ADVANCE
F2: RETARD
enter speed
press [ENTER]
add
deduct
Follow these instructions for the remaining speed points.

Example:
A typical speed curve of an engine (generator operation) with a speed curve to influence the start-up
procedure positively:
When the engine is not running the ignition timing is equal to the potentiometer setting. Thus the ignition
timing can also be checked with the programmer or a laptop when the engine is out of operation. If the
engine is started the ignition timing will be reduced and increased again from 50 revolutions until it
reaches the preset value at 1000 revolutions.
SPEED POINTS:
BP1:
F5
BP2:
F5
BP3:
3
0
0 ADV
number of speed points

speed
angle
50
speed
10 RET angle
1000
0 ADV
speed
angle
F5
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4.5
Speed Points BP1 to BP5
Ignition Timing
25
20
BP1
BP3
Potentiometer Setting
10
BP2
50
500
1000
1500
RPM

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Example of Programming the Timing Curves

Potentiometer in A:
enabled
Speed curve in A:
enabled
4- 20 mA analog input:
enabled
Potentiometer CCW:
22ADV
Potentiometer CW:
18ADV
Max. advance:
25ADV
Max. retard:
5ADV
4 20 mA Signal - 4 mA:
0 RET
4 20 mA Signal - 20 mA:
5 RET
Default:
4 RET
Number of speed points:
BP1:
0 RPM
0ADV
BP2:
50 RPM
15 RET
BP3:
1000 RPM
0ADV
See diagram on next page

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4.6
Example of a Timing Curve

Overspeed
Crank
Max
25
Pot CCW
22
Potentiometer
BP3
BP1
20
and 4mA Level
18
Pot CW
Default Level
15
20 mA
Speed curve
10
Min
BP2
TDC
0
50
1000

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1500
1800
RPM
page 65
Enter your Programmed Data here:

3.3
Crank
35
30
25
20
15
10
5
TDC
0
50
1000

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1500
page 66
RPM
1800
Chapter 5
Maintenance and Troubleshooting
Maintenance
WARNING! HIGH VOLTAGE!
DANGER TO LIFE!
Switch off the engine and disconnect the power supply before commencing any
installation work! An improperly installed ignition system may lead to engine
damage and could pose threat of personal injury to operators.
The MIC500 series ignition control module is designed as maintenance-free unit with a long service life.
The remaining parts of the ignition control system should be serviced as follows:
The pickups might need to be replaced if they operate under extreme thermal conditions
(> 165 F, 90 C)
All control system cables should be carefully examined for signs of damage and replaced if necessary.
All plug connections should be checked to ensure that they are in a serviceable condition.
The spark plugs should be serviced according to the specifications of the spark plug and engine
manufacturer.

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Faults, Causes and Remedial Action

The MIC500 series includes an LED, which indicates faults by flashing once or several times.
How to interprete the LED flashes:
Flashing
System Status
Possible Problem
Continuous flashing:
normal operation with

Ignition firing
none
(1x) One flash:
normal READY mode, 0 RPM none
(1x) One flash:
no pickup signal
or ignition not released
defective pickup, incorrect wiring of

pickup or ignition has not been released
(2x) Two flashes:
bad pickup signal
pickup failure, sequence no. does not

match timing disk or improperly machined
or damaged timing disk
(3x) Three flashes:
engine speed too slow
too slow cranking speed / check

sequence number and timing disk
contact D has not been opened
(4x) Four flashes:
engine overspeed
overspeed limit exceeded
(5x) Five flashes:
low supply voltage
defective supply/battery or undersized wire
(6x) Six flashes:
programming mode
ignition in programming mode when engine

was cranked or Misfire rate exceeded
(6x) Six flashes:
configuration error
incorrect parameters programmed, bad

data identified in non-volatile memory, bad
pickup signal at > 200 RPM or security
NOTE! After an automatic engine shutdown caused by a fault the power supply
to the MIC500 series has to be disconnected and reconnected.
The LED will flash one time only. This is normal, the engine can be restarted.

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Troubleshooting
The ignition system comprises of the following components, which have to be taken into consideration
when searching for faults:
Ignition control module
Harness
Ignition coils
High-tension leads
Ground leads
Spark plugs
Shutdown equipment
Most ignition system failures occur outside the ignition control module. The cause may lie in any one of
the above components or in the connections between them.
The following troubleshooting guide is divided into three sections:
Input fault diagnosis
Troubleshooting in low or high voltage circuits
Ignition control module self-test function
Input Fault Diagnosis:

If a fault is detected in the inputs to the MIC500 series, the ignition control module will automatically shut
down the ignition. Input faults, which might cause shutdown, are:
Open circuit or short-circuit to ground in the input power circuit
Open circuit or short-circuit to ground in the engine starting circuit
Loss of input power or supply voltage too low

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Power Supply Circuit:
WARNING!
Supply voltages below the specified values will impair the operation of the ignition
control module and may cause the engine to stall. Supply voltages above the specified
values could damage the ignition control module.
The following minimum and maximum input voltages must be maintained:
10 / 32 VDC supply voltage
Minimum 10 VDC
Maximum 32 VDC
WARNING!
Input voltages outside these values may damage the MIC500 series.
If damping of the supply voltage is suspected, verify with a voltmeter. Check the START/STOP circuit for
any opens, shorts or accidental connections to ground.
Faulty Pickup Signal:

If a timing signal fault is detected during operation, the ignition control module automatically shuts down
the ignition. Such a fault could result from the failure of a pickup, an open, short-circuited or grounded
connection to a pickup, or a physical change in the characteristics of a pickup.
Proceed as follows:
Crank the engine with the fuel valve closed and check all signals at the pickup connectors using an
oscilloscope.
Verify minimum signal to be 2.5 V peak to peak

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5.1
Oscilloscope Square Wave signal
Oscilloscope display: Typical signal of a 24 V. Reset signal supplied by a trigger disc (appears as double
signal)
Active Sensor
Hall Effect Sensor
NOTE!
If active sensor is used, the appropriate pick up lead has 2 LEDs
The colours indicate the following:
Green:
Power supply connected
Orange:
Trigger signal
Fault Detection in the Low and High Voltage Ignition Circuits:

Track the ignition circuit current flow if the engine is missing on one or more cylinders, but not
completely dead.
Apply an inductive timing light to the high-tension leads to determine which cylinder is not firing.
WARNING!
The brightness of the firing indicator bulb is not a measure of the actual strength of the
respective output signal; it only reflects the voltage required by the spark plug
itself.
Determine which lead in the harness is connected to the malfunctioning cylinder.
Stop the engine and unplug the output harness connector from the ignition control module.
Use an ohmmeter with a scale of R x 1.
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Self-test Function
WARNING!
Do not crank the engine while the self-test is active!
The ignition control module features a unique self-diagnostic test function which allows verification of the
input, output, primary harness / ground circuits, and ignition coil integrity for all cylinders. This test can
be performed "on engine".
Performance of Self-test:
Switch on the power supply.
Connect the hand-held programmer / laptop to the MIC500 series via the RS232 interface.
Start the program.
Key [S] will start the self-test. Pressing key [S] once more will stop the self-test.
All pre-selected outputs will be fired one after the other within 1/10-second intervals. On connector pin H
you can measure the output voltage on the primary side and the waveform. Output harness and ignition
circuit can be checked by measuring voltage on the output terminals.
Check all high-tension leads with a timing light. Constant flashing frequency indicates proper function.

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Legal Provisions
Liability Clause
The sole purpose of this manual is to present our products. It does not contain any instructions or
guidance for use. All specifications and statements contained in this manual only serve to describe the
product. They do not constitute any legal declarations of or concerning guaranteed properties or
characteristics, or the suitability thereof for particular or assumed intended use, even though the manner
in which this manual is presented might appear to give this impression. They are subject without
exception to the applications-specific testing by the user in any given case.
The products presented in this manual are subject to technical alteration or further development without
notice, including modifications in compliance with changing standards, norms and regulations.
Only individual contractual agreements and agreed specifications, drawings and other data shall be
binding. We and those acting on our behalf accept no liability for the statements and specifications
contained in this manual insofar as this is legally permissible. No persons shall be entitled to make
statements different to the above without our written permission.
All rights reserved by MOTORTECH GmbH.

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page 73
Copyright Regulations
This manual was prepared by
MOTORTECH GmbH
Hogrevestr. 21-23
D-29223 Celle
All rights reserved. Extracts from this manual shall also constitute independent items of intellectual work.
This manual or extracts therefrom must not be reproduced in any form (printing, photocopying, microfilm
or any other method) or (using electronic equipment) processed, duplicated or distributed without the
prior written consent of MOTORTECH GmbH.
As an exception to the foregoing, customers of MOTORTECH GmbH shall be permitted to reproduce
this manual or extracts therefrom provided that the following conditions are complied with:
All extracts from this manual must be clearly marked and must include a detailed source of reference as
well as the MOTORTECH GmbH copyright "Copyright MOTORTECH GmbH Celle, Germany 2004".
If this manual or an extract therefrom constitutes the part of a new document to be handed over to a
third party, a complete copy of this new document must be sent to MOTORTECH GmbH for reference,
hereupon the right of ownership shall automatically be transferred to the latter.
The liability clause contained in this manual as well as this provision must be transferred.
Copyright MOTORTECH GmbH Celle, Germany 2005

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Abridged Instructions
WARNING!
An improperly installed ignition system may lead to engine damage and could pose
threat of injury to operators!
Wiring Example 6-Cylinder Engine
A (+) 24VDC
red
B (-) 24VDC
black
C (+)4-20mA
green
E (-)4-20mA
brown
F Loop Power (24VDC)
white
D A/B - START/STOP Contact
white
G (+) Pick Up Signal
black
H MPU Power
brown
blue
(-) Pick Up
J GO/NOGO Contact
brown
fig 11a: Example 6 Cylinder

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Timing Adjustment
Manual Adjustment:
WARNING!
An incorrect timing setting may lead to engine damage!
NOTE
When choosing the correct timing setting, it is essential to strictly adhere to the
values specified by the engine manufacturer.
Manual
Timing
Adjustment

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2-Point Adjustment:
A simple 2-point adjustment is possible with the aid of the analog input. If the engine is operated, e.g.
with two different grades of fuel, it is generally advisable to alter the ignition timing when changing from
one type of fuel to another.
F Loop Power (+24VDC)
D programmed for A/B
2-Point Adjustment

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page 77

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page 78

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page 79

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page 80

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page 81
0
.2
AX
Flywheel in
position
40 BTDC
Pickup
Index
A
8x4
5 ( =
360
B
)
F
E
Reset / Index Position

The Index position should be
less than 1/2 the distance between
the last and first trigger event.
(application)
(tolerances)
DIN ISO 2768-m
copyright according to DIN 34

all rigths reserved
for this drawing
(surface)
DIN ISO
1302
date
name
edited 02.09.2003 WEINGARTZ
appro. 02.09.2003
scale
(weight)
(material, semi-finished product)
(raw part-no.)
(model- or swage-no.)

8 + 1 Disc
page
1
pages
rev.
change
date
name origin
replacement for

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replacement for
page 82
.
MAX
15
Index
Pickup
Flywheel in
position
40 BTDC
A
B
L
30
D
I
E
H

The Index position should be
less than 1/2 the distance between
the last and first trigger event.
(application)
(tolerances)
copyright according to DIN 34

all rigths reserved
for this drawing
(surface)
date
name
edited 11.07.2005 WEINGARTZ
appro. 11.07.2005
scale
(weight)
(material, semi-finished product)
(raw part-no.)
(model- or swage-no.)

12 + 1 Disc
page
1
pages
rev.
change
date
name origin
replacement for

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replacement for
page 83
Programming Overview
Here, you can enter the values you programmed. The figures behind the descriptions refer to the
programming short guide,
Customer
Part no ignition
controller
Engine type / model
Engine serial number
Software Revision:
Number of cylinders
Ignition timing point
(1) Firing pattern = sequence-no.

(2) Reset position BTDC
Nominal:
Actual:
(3) Overspeed
(4) Security speed
(5) Misfire rate
(6) Cyl-to-cyl-timing
(7) Contact I/P D STOP
Enabled
START / STOP
Disabled
ON/OFF ignition
2-timing operation
Timing A/B
(8) Potentiometer function
Enabled
Disabled
(9) Speed curve timing schedule A
Enabled
Disabled
(10) 4 20 mA in A
Enabled
Disabled
(11) Speed curve timing schedule B
Enabled
Disabled
(12) 4 20 mA in B
Enabled
Disabled
(13) Potentiometer max. angle limit left (CCW):
ADV BTDC:
(14) Potentiometer max. angle limit right (CW):
ADV BTDC:
(15) Most advanced timing limit for schedule A:
ADV BTDC:
(16) Most retarded timing limit for schedule A:
ADV BTDC:

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(17) Most advanced timing limit for schedule B:
ADV BTDC:
(18) Most retarded timing limit for schedule B:
ADV BTDC:
(19) Offset angle for timing schedule B:
ADV =
degree advanced
RET =
degree retarded
(20) Adjustment of timing point given by analog signal, input signal: 4 mA:
ADV =
degree advanced
RET =
degree retarded
(21) Adjustment of timing point given by analog signal, input signal: 20 mA:
ADV =
degree advanced
RET =
degree retarded
RET =
degree retarded
(22) Default 4 20 mA
ADV =
degree advanced
(23) Number of speed points required for speed curve (max. 5 points):
(24) Speed points
BP1
BP2
BP3
BP4
BP5
+ADV/-RET
+ADV/-RET
+ADV/-RET
+ADV/-RET
+ADV/-RET
Speed
(+ADV/-RET)

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Additional Functions:
[Shift] + [E]
energy (15 % - 100 %):
[Shift] + [H]
operating hours
Date:
op. hours:
[Shift] + [C]: Cylinder to Cylinder Adjustment

Ignition output:
Firing order
Change
(+) ADV
(-) RET
[Shift] + S
self test
[Shift] + M
misfirings / sec
[Shift] + R
reset error
_________________________
_______________________________________
Date
Signature
Primary Voltage to Coil vs Energy level programmed

15%
20%
30%
40%
50%
60%
70%
80%
90%
100%
=
=
=
=
=
=
=
=
=
=
155V
160V
180V
200V
220V
240V
255V
275V
290V
300V

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Models MIC520, MIC525, MIC530

MOTORTECH manual MIC500 series

CAUTION!indicates a potentially hazardous situation which, if not

NOTE!provides other helpful information that does not fall under

Product-information. MOTORTECH GmbH, Hogrevestrae 21-23, 29223 Celle, Germany

MOTORTECH manual MIC500 series

MOTORTECH manual MIC500 series

Product-information. MOTORTECH GmbH, Hogrevestrae 21-23, 29223 Celle, Germany

MOTORTECH manual MIC500 series

Illustrations and Tables

Product-information. MOTORTECH GmbH, Hogrevestrae 21-23, 29223 Celle, Germany

MOTORTECH manual MIC500 series

Electrostatic Discharge Awareness

Product-information. MOTORTECH GmbH, Hogrevestrae 21-23, 29223 Celle, Germany

MOTORTECH manual MIC500 series

ClassI, Div2, Group C,D

MOTORTECH manual MIC500 series

Disposal of the Ignition Control System

Product-information. MOTORTECH GmbH, Hogrevestrae 21-23, 29223 Celle, Germany

MOTORTECH manual MIC500 series

Input harness, active pickup

Output Harnesses - length to be specified. Standard length: 240

Output harness for MIC 520, 4 outputs

Product-information. MOTORTECH GmbH, Hogrevestrae 21-23, 29223 Celle, Germany

MOTORTECH manual MIC500 series

Input harness, hall-effect pick up

Output Harnesses - length to be specified. Standard length: 80; 160

M12 x 1 x 100 mm Active pickup

Product-information. MOTORTECH GmbH, Hogrevestrae 21-23, 29223 Celle, Germany

MOTORTECH manual MIC500 series

M12 x 1 x 100 mm Active pickup

Unshielded Pickup Leads

Pickup lead 400, 90 connector

Shielded Pickup Leads lengths to be specified

Pickup lead, 90 connector

Pickup lead, 180 connector

Pickup lead, 180 connector

Product-information. MOTORTECH GmbH, Hogrevestrae 21-23, 29223 Celle, Germany

MOTORTECH manual MIC500 series

Ignition coils and boots

Low-voltage circuit leads

The harness must be removed.

Safety devices must not be disassembled or inactivated.

Always ensure that the engine room is properly ventilated!

Product-information. MOTORTECH GmbH, Hogrevestrae 21-23, 29223 Celle, Germany

MOTORTECH manual MIC500 series

Product-information. MOTORTECH GmbH, Hogrevestrae 21-23, 29223 Celle, Germany

MOTORTECH manual MIC500 series

Product-information. MOTORTECH GmbH, Hogrevestrae 21-23, 29223 Celle, Germany

MOTORTECH manual MIC500 series

MIC500 series Vibration Mounts and Ground Strap

MIC500 series Connector Arrangement

Output 10 pole socket

Output 14 pole socket

Output 19 pole socket

Product-information. MOTORTECH GmbH, Hogrevestrae 21-23, 29223 Celle, Germany

MOTORTECH manual MIC500 series