IC‐920 / IC‐922 Ignition Controllers with ServLink
Applications The IC-920 and IC-922 are state-of-the-art capacitive- discharge ignition system controllers especially designed for spark-ignited engines used in gas compression, electric power generation, and other industrial applications. User-adjustable The IC-920 controller provides standard-strike energy for up energy levels for to 20 ignition coils, with an option for up to 24 coils available. precise spark control and The IC-922 controller provides “big-strike” energy for up to 20 (or optionally 24) coils. The big-strike capability is well optimum plug life suited for high-BMEP or other engines that are prone to misfire. Ultra-high energy Description available—170 mJ (IC-920) or 340 mJ The IC-920 and IC-922 are ultra-high-energy ignition system (IC-922)—assures controllers featuring user-controlled energy levels, advanced diagnostics, and an RS-232 ServLink interface for easy outstanding programming with a Windows®-based service tool. combustion The controller system consists of a 16-bit CPU, sensor signal User-program- conditioning circuitry, a high-voltage power supply. and 20 (or optionally 24) outputs. The system can be configured from two mable for any cylinders to 20 (or 24) cylinders. industrial gas The unit software can be configured for any type of industrial engine. There is never a engine requirement for factory reprogramming of software. All user programming/configuring is accomplished via a Windows-based computer program. Individual cylinder timing control The IC-920/IC-922 uses information provided by three timing sensors (position of crankshaft and camshaft and speed of the engine) to precisely determine when and which cylinder RS-232 ServLink should fire. interface for easy The ignition timing of the engine is controlled by operator inputs, such as two manual timing programming with potentiometers, a 4–20 mA signal, a 0–5 Vdc signal, or a five-point speed curve. Windows®-based Engine operators can adjust spark energy levels for precise spark control and to optimize spark plug life. And to assure good combustion in lean-burn and other misfire-prone service tool applications, the IC-920 and IC-922 controllers are capable of providing very high levels of energy output. The single-strike IC-920 controller is adjustable up to 170 mJ of stored energy, the big-strike IC-922 model is adjustable up to 340 mJ of stored energy. While the IC-920/IC-922 is operating, the unit continuously monitors the status of the ignition system by verifying proper information from all timing sensors and proper operation of the primary ignition circuit. Depending on the severity of the fault, the unit will either shut down or warn the operator. In both cases, a message is transmitted via a serial link to a PC. Some faults are also annunciated via an auxiliary output. In addition to protecting the engine from ignition faults, the IC-920/IC-922 also has a user- programmable overspeed set-point shutdown. The 20-cylinder versions are suitable for four-stroke engines having rated speeds up to 1800 rpm, and two-stroke engines rated up to 900 rpm. The 24-cylinder versions are suitable for 1500 rpm (four-stroke) or 750 rpm (two-stroke) operation. Woodward 03331 p.2
Features The IC-920/-922 is a versatile ignition control that is user configurable for a variety of engine installations. A single IC-920/-922 ignition control can be configured to fit numerous engine makes, models, and sizes. The IC-920 family of ignition controls derive their power from a 24 Vdc battery power distribution system with a steady state range of 18–32 Vdc. The IC-920 family accepts three magnetic pick-up signals. Typically two of the sensors are variable reluctance type (passive), and the third sensor is an active proximity or Hall effect sensor. These pick-up sensors indicate the position of the camshaft, the position of the crankshaft, and the speed of the engine. Using pre-programmed timing sequences, the CPU in the IC-920 family controls the ignition timing of up to 24 ignition outputs. The ignition outputs are connected to the primary windings of industry- standard CD ignition coils. The IC-920 family ignition drivers are designed to work with industrial engines that require between 2 and 24 separate CD ignition coil outputs. A CD ignition coil output is intended to connect to the primary side of a CD ignition coil. The firing sequences are user programmable. Energy Control: Spark energy levels of the IC-920/IC-922 are adjustable, allowing the user to obtain optimum spark duration while maximizing spark plug life. Energy settings are easily increased as needed to compensate for normal spark plug wear. With the IC-920 platform, the capacitively stored primary energy can be adjusted from 20 to 170 mJ in 10 mJ steps. To provide “big strike” capability, the IC-922 platform incorporates two power output boards—a main power board and a secondary board that drives a second spark at an optimized time delay from the main board spark. The main and delay power boards each have a stored energy range of 20 to 170 mJ. The IC-922 software configures both the main and delay boards to the same energy level. With the combined boards, the capacitively stored primary energy can be adjusted from 40 to 340 mJ in 20 mJ steps. Ultra-High Available Energy Levels: The IC-920 is capable of delivering up to 170 mJ of energy, and the IC-922 is capable of delivering up to 340 mJ of energy. This ultra-high available energy provides a number of benefits to engine operation, including a reduced ignition delay that provides for improved and more consistent combustion, particularly at lean conditions. The ultra-high energy capability also contributes to outstanding brake specific energy consumption characteristics at lean operating conditions.
Spark Energy Affects on Ignition Delay Brake Specific Energy Consumption
17.0 7300 16.5 7200 16.0 7100 BSEC (BTU/bhp-hr)
15.5 Ignition Delay
7000 15.0 Typical Ignition System 6900 Typical Ignition System 14.5 14.0 6800 13.5 Woodward Ultra-High 6700 13.0 Woodward Ultra-High 12.5 Energy Ignition System 6600 Energy Ignition System 12.0 6500 0.33 0.34 0.35 0.36 0.37 0.38 0.39 0.4 0.41 0.42 0.330 0.340 0.350 0.360 0.370 0.380 0.390 0.400 0.410 0.420 Equivalence Ratio Equivalence Ratio (exhaust)
Timing Control: Ignition timing of the IC-920 family can be biased (advanced or retarded) in real time based on a potentiometer setting, a 4–20 mA or 0–5 Vdc signal, or a 5-point speed map. The speed map allows the ignition timing to be varied relative to the CPU-calculated engine speed. The global timing can be set for a maximum span of 60° crankshaft. The most advanced timing is limited to 10° less than the distance from the reset location to cylinder one. Universal timing limit values are programmed for the earliest (most advanced) and latest (most retarded) timing points. The universal timing limits override any combination of the timing variation inputs that exceed these limits. Individual Cylinder Timing Offsets: Because of the unique circumstances for each engine configuration, the IC-920/-922 allows run-time energy adjustment for each (odd and even) primary output. It is possible to adjust the individual cylinders within a range of +/- 3° crankshaft. Annunciation: The 92X family ignition controllers contain three discrete outputs that can be used within an engine system to communicate fault or abnormal conditions. Faults sensed by the 92X design can be communicated via the discrete outputs. A PC-based service tool is used to retrieve the precise reason for the discrete output annunciation. Woodward 03331 p.3 Engine Control and Safety: The IC-920 family also has built-in ancillary functions that include a programmable overspeed shutdown, hour meter, and a speed switch output. The IC-920/-922 has built-in features that protect the engine if any malfunction related to the ignition system is detected: Overspeed protection Permissive start output Auxiliary shutdown input Misfire rate protection Timing sensor fault detection Alarm output ServLink Communications: The RS-232 ServLink communications interface allows the setting of numerous parameters. Number of cylinders Firing sequence Number of teeth of the flywheel ring gear Position of the trigger source for the first cylinder Overspeed setpoint Primary misfire limit Speed for the security speed function Limit values for the earliest and latest timing points. Schedules A and B both have a maximum advance and retarded setting Setting range for the potentiometers Enabling of the speed curve timing Speed and timing for each of the five speed points Enabling of the 4–20 mA or 0–5 Vdc timing adjustment The 4–20 mA signal has three timing settings: 20 mA timing, 4 mA timing, and a default timing for <1 mA signal. The 0–5 Vdc signal has two timing setting: 0 Volt timing and 5 Volt timing Speed trip levels and hysteresis Global energy and Energy level alarms ServLink Display: It is possible to display the following information on the ServLink communications interface: Status line display—indicates communication mode, firing, warnings Timing Individual cylinder misfire Misfire rate Run/Stop discrete input signal status 4–20 mA input level 0–5 Vdc input level Energy levels for each cylinder Operating hours and software version Individual Cylinder timing adjustments Service Tool: The IC-900 series ignition service tool is a Windows-based software tool that is used to configure, monitor, and troubleshoot an IC-920/-922 ignition system. It runs on a personal computer and communicates with the IC-920/-922 ignition control through a serial connection. The IC-900 series service tool software can be downloaded free from the Woodward website at www.woodward.com/software/software.cfm, under Ignition System Tools. All configuration settings are shown in an intuitive graphical interface format. Configuration, for initial setup or replacement, is a straightforward process. Settings can be saved directly into the IC-920/-922 EEPROM or to a file. Settings from a file can be loaded into the IC-920/-922 ignition control for quickly configuring ignition controls for all like engines within a manufacturing facility, a plant, or a system. Diagnostic LEDs: Eight LEDs on the IC-92x products provide the following functionality: Name Function Color I/O Pin Trigger Indicates presence of signal on trigger input. amber Trigger Input Reset Indicates presence of signal on reset input. Flashes during normal amber Reset Input operation. Cam Indicates presence of signal on cam input. Flashes during normal amber Cam Input operation. Power Indicates presence of 24V power. green Input Power Permissive Start Illuminated LED indicates that ignition is firing. green Permissive Start Discrete Output Speed Trip #1 Illuminated LED indicates that the Speed Trip #1 discrete output is amber Speed Trip #1 Discrete energized. Output Alarm Output - Illuminated LED indicates that the Alarm Output - Trip #2 is amber Alarm Output - Trip #2 Trip #2 energized Discrete Output System General system health indicator. amber NA Woodward d 03331 p.4
Speecification ns Technical Manual 26263 Envirronmental Spe ecification Opperating Temp. –40 to +700 °C Storage Temp. –40 to +855 °C CE Compliant Low Voltagge Directive ATEX Dire ective (Zone 2) EMC Direc ctive: Complian nce to 89/336/E EEC Immunity: EN 61000-6-2, Generic Stand dards—Immun nity for Industria al Environmentt Emissions: EN 61000-4-2 2, Generic Stan ndards—Emisssions for Industtrial Environme ent Ingreess Protection n The ICC-920 family has been qualifiied to IP-54 ratting for dust an nd water ingress. Inputt Power Requiirements Input Voltagge Range 18 to 32 Vdc Steady S State Trransient Voltag ge Range* 10 to 32 Vdc (ffor less than 1 minute) Average Current Draw IC-920: 5 A ma ax IC-922: 10 A max m Peak Current Draw 3 A @ 100% energy 30 Current Draww Equation IC-920: A = (rppm * outputs) / (stroke * 1800)) IC-922: A = (rppm * outputs) / (stroke * 900) Notes 1. Average current is depe endent on the number of cylin nders, input poower, energy level, and engine e speed. 2. Peak currrent is depend dent only on energy level, 100 0% energy = 25 5 A peak. Dime ensions IC-920: 13.5 in. Hig gh x 10.0 in. Wide W x 5.35 in. Deep D (343 x 25 54 x 136 mm) IC-922: 17.5 in. Hig gh x 14.0 in. Wide W x 8.35 in. Deep D (445 x 35 56 x 212 mm) Vibraation and Shoc ck Tests The ICC-920 family iss designed for skid s mount ope eration. Humiidity Test The ICC-920 family has been qualifiied to Woodwa ard H2 humidityy test procedurre called out in procedure 4-0 04-6230 (5 cycles, 60 ºC, 95%). Crank king Waveform m The IC-920 family is designed forr operation on a 24 V batteryy power distrib w a steady state variation of 18–32 bution system with Vdc. However, the units will be capable of gene erating spark output o in the presence p of the e cranking wavveform specifie ed in SAE J1113 3/11 test pulse 4 (June 1995)). Safetty Certificationn All moodels of the IC-92x family aree certified for use in Class I, Division D 2, Grouups A, B, C, & D and Ordinarry Locations pe er CSA for Canada. Accu uracy The IC-920 I family timing t accurac cy is ±0.17° crrankshaft at ra ated engine sp peed up to 180 00 rpm (four-sttroke) or 900 rpm (two- strokee). A deviation of ±1.0° crankkshaft is not bee exceeded thrroughout the en ntire speed ran nge (50–2200 rpm). r In the evvent that a trigge er signal coincid des simultaneo ously with the output o of a firing g pulse, an acccuracy of ±0.17 7 ° crankshaft is maintained. In the e case that twoo outputs fire siimultaneously due d to the setttings of individu ual timing, the firing point of the t even cylind ders (bank two) may m deviate by ±0.32° crank kshaft from the e nominal value. The odd cyylinders (bank one) will exhib bit the ±0.17° crankshaft c accurracy as previouusly stated.
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