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REV.

06/

2013

REV.

09/

2014

MOTORTECH Ignition Controllers

MOTORTECH IGNITION CONTROLLERMIC4

MOTORTECH IGNITION CONTROLLERMIC5

MOTORTECH IGNITION CONTROLLERMIC3

MIC Seriesreliable ∙ efficient ∙ worldwide

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MOTORTECH has developed into one of the leading manufacturers of ignition control-lers in the global market for industrial gas engines. The MOTORTECH ignition controller series now provides solutions for virtually all gas types and engine sizes.

Cooperation with leading engine manufacturers, packagers and operators has resulted in specific designs of equipment. The result is the ability to maintain ideal engine per-formance across a variety of applications. As the Biogas market continues to grow the need to ignite various gasses like mine gas and drilling gas effectively grows. MOTORTECH meets these needs by offering products that provide increased ignition energy, long duration spark control while maintaining precise ignition timing.

Efficiency and device availability drive MOTORTECH to devote its efforts to peak technology for the future.

MIC Series –MOTORTECH Ignition Controllers

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MOTORTECH IGNITION CONTROLLERMIC3

MOTORTECH IGNITION CONTROLLERMIC4

MOTORTECH IGNITION CONTROLLERMIC5

Characteristics MIC SeriesGeneral• For 2- and 4-stroke enginers• Ignition technology pulse width

modulated • Technical restriction to 6000 rpm• Max. trigger impulses 16 + 1 or 500

teeth on the flywheel• CSA certified

(Class I, Div. 2, Group C, D; T4)

Technical data & functions• Ignition timing to 0.1° crankshaft• Magnetic, Hall effect- or

inductive pickup• Control of ignition timing optional by- potentiometer- Speed curve- 0–20 mA analog input- 0–10 V analog input• Control of the ignition energy by the

patented MOST (MOTORTECH Output Stage Technology)

• Ignition sequence in device programmable

• Safety shutdown during overspeed• Access control via password• Programmable spark duration

• Ignition energy regulation• 2 programmable speed curves

with max. 8 speed points (speed/ignition timing)

• Diagnosis memory• System status display• Error memory

Ignition diagnosis• Runtime data• Alarm and error messages• Data logging• Primary, secondary misfire

recognition• Individual cylinder voltage

calculation (kV)

Interfaces• CAN Bus 2.0b interface

(CANopen-/SAE J1939 protocol)• RS485 interface (Modbus RTU)• USB 2.0-interface

Inputs• Digital ignition impulse input

(start/stop)• configurable digital input (GPI)

• Digital input for parameter set conversion (schedule A/B)

Outputs• 1 angle-dependent synchronization

output (ASO), e.g. to connect a detonation control system (e.g. DetCon) or for injection systems

• 1 multi-function output (GPO)• Ignition confirmation (Go/NoGo)

Configuration• With the assistance of the graphic

user interface MICT (MOTORTECH Integrated Configuration Tool, see page 10)

System Overview MIC Series

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1) In combination with the MIC3 only a crank shaft sensor is possible.

0–5 V/4–20 mA

A

Z

B

X

1

MOTORTECH DETONATION CONTROL SYSTEMDetCon20

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MOTORTECH ENGINE INFORMATION MONITORPowerView3

MOTORTECH IGNITION CONTROLLERMIC

CAN CAN

24 VDC Power Supply

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3

3

8

DDC

V5

34

W

7

Y

1)

Pickup arrangementwith 3 pickups in 4 stroke engines

1) Reset (crankshaft) Magnetic pickup (holes, pins, teeth, screws)2) Speed (crankshaft) Magnetic pickup (holes, pins, teeth, screws)3) Camshaft Hall effect pickup (magnets)

alternative3) Camshaft Inductive pickup(Pins, screws, grooves)

Pickup arrangementwith 1 with pickup in four stroke engines 1) Camshaft Hall effect pickup (disc with magnets)

alternative1) Camshaft Inductive pickup (disk with pins, screws, grooves)

Pickup arrangement with 2 pickup in 2 stroke engines1) Reset Magnetic pickup (holes, pins, teeth, screws)2) Speed (crankshaft) Magnetic pickup (holes, pins, teeth, screws)

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Legend

Common versions for pickup arrangement

Neccessary components

1 MIC Ignition Controller2 Pickup cable*3 Pickup*4 Trigger pins/magnets

alternative5 Trigger disc

alternative Trigger drive6 Output cable harness*7 Ignition coil*

8 1 Primary cable/ignition lead per ignition coil

Accessories

A Junction boxB AlphaRail-/ LiteRail – ignition wiring rail*

System enhancementC DetCon20 – Detonation contoller D PowerView3 – HMI module

DescriptionV CamshaftW CrankshaftX EngineY CylinderZ Harness to connect the

ignition wiring rails and the junction box * Shielded and unshielded versions available.

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Technical Data MIC Series

1) Please contact your MOTORTECH partner for information on the availability of housing versions

Gene

ral

Feature MIC3 series MIC4 series MIC5 series

Max. number ignition outputs 6/12 8/16 20

Max. number pickups 1, 2 1, 2, 3 1, 2, 3

Voltage supply 10 – 32 VDC 10 – 32 VDC 18 – 32 VDC

permitted ambient temperature –40 °C to +60 °C –40 °C to +60 °C (LD) –40 °C to +70 °C (HD) –40 °C to +60 °C

Pow

er

Max. primary voltage 250 VDC 250 VDC 250 VDC

Max. ignition energy 200 mJ (300 mJ boost for start phase)

300 mJ (500 mJ boost for start phase)

500 mJ (700 mJ boost for start phase)

Max. programmable spark duration 100–700 µsec 100–1000 µsec 100–1500 µsec

Hous

ing

Available housing versions1) Light Duty (LD) Panel Mount (PM), Light Duty (LD), Heavy Duty (HD) Heavy Duty (HD)

Dimensions 250 mm x 240 mm x 89.5 mm 304 mm x 240 mm x 97.5 mm (LD) 371 mm x 240 mm x 114.5 mm

Protection class IP54 IP20, IP54, IP65 IP65

Engine installation not permitted not permitted not permitted

Potentiometer number for manu-al speed adjustment O 2 (continuously variable) 2 (continuously variable)

Input cabling 35-pin, pin (MIL)Multi-point connector(Optional 2 MIL Version) Multi-point connector

Output cabling 17-pin, socket (MIL) 17-pin, socket (MIL) 35-pin, socket (MIL)

Status LEDs number 5 6 6

Possible MIC4 housing versions

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Housing version “LD” (Light Duty)*Standard configuration for applications in direct vicinity of gas engines in protected environment. The electronic system is integrated in a solid aluminum housing.• 17 pole military style connector (socket) for 8 and 16 outputs• Plug connectors for input wiring Optional 2 MIL version for fast installation• For ambient temperatures from -40 °C to +60 °C (-40 °F to +140 °F)• Protection rating IP54• CSA Class I, Division 2, Group C, D; T4• 304 mm x 240 mm x 97.5 mm (L x B x H)

Housing version “HD” (Heavy Duty)*When it‘s time to really get down to business. The Heavy Duty housing is 100 % reliable whether in hot desert sand or perpetual ice!• 17 pole military style connector (socket) for 8 and 16 outputs• Plug connectors for input wiring Optional as 2 MIL version for fast installation• For ambient temperatures from -40° C to +70° C (-40° F to +158° F)• Integrated cooling element for optimal heat dissipation• Protection rating IP65• CSA Class I, Division 2, Group C, D; T4• 304 x 240 x 114.5 mm (L x B x H)Back

Housing version “PM” (Panel Mount – switch cabinet installation)*Device configuration for assembly in control panels. Equipped with plug connectors for simple integration into the wiring system.• Plug connectors for input and output wiring (8 and 16 outputs)• For ambient temperatures from -20° C to +50° C (-4° F to +122° F)• Protection rating IP20• CSA Class I, Division 2, Group C, D; T4 (within a control panel)• 304 mm x 240 mm x 114.5 mm (L x B x H)

Optionally as 2-MIL version

* ATEX versions available.

Efficiency-enhanced engines, highly compressed mixtures, as well as the use of a great variety of gas types are putting greater demands on the entire ignition system, including:

• reliable ignition even with weak or fluctuating calorific values of the gas

• compliance with the strictest emission regulations

• eliminates knocking and misfiring

• reduction of maintenance through longer spark plug runtimes

These requirements can only be met by precision ignition behavior and efficient control of the ignition spark. MOTORTECH Output Stage Technology* (MOST) was developed by MOTORTECH for this.

MOST works with the following principles:

• adjustable ignition spark duration with different available ignition voltages

• constant spark intensity via adjusted ignition spark duration

• 200 to 700 mJ of primary energy (device dependent) are available

MOTORTECH OUTPUT STAGE TECHNOLOGYMOST

MOTORTECH Output Stage TechnologyPatented Technology for MIC3/MIC4/MIC5*

Settings for MOST in MICTThe settings for MOST are made using the MICT configurationsoftware. On the configuration side Timing – ScheduleA/B – Energy, you can define different values for the sparkduration, spark intensity, breakdown voltage and energy limitfor the start phase and normal operation. That way startingdifficulties of the engine can be caught. Different energysettings for the two schedules A and B support, for example,optimally matched two gas operations. The settings aredependent on the ignition coils that are used, among otherthings. They must be suitable for MOST and set correctly onthe configuration side Engine – Ignition Coils. To optimize theenergy settings for an engine, the ignition behavior must beobserved and analyzed (misfiring, knock behavior, emissionvalues, etc.). The secondary side diagnosis with MICT, amongother things, can help here.

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*Patent No.: US 8,893,692 BS.

50

100

100 200 300 400 500 600 700 800

Spark Duration [µs]

Seco

ndar

y Cu

rrent

[mA]

variable

variable

Capacitor Discharge Ignition System (CDI)

MOTORTECH Output Stage Technology (MOST)

Capacitor discharge ignition system (CDI)The red curve shows that a high peak current is reached during ignition. Afterwards, the current decreases sharply. To achieve longer spark duration, the energy supply must be increased. The result of this is a higher peak current.

Ignition system with MOSTThe blue curve shows that a lower peak current is reached during ignition with MOST. The current remains at a constant level until the energy supply ends. Thereafter, the current drops. In this case as well, more energy is supplied for a longer spark duration, however the peak current is not increased in the process.

The graphic compares the behavior of a conventional capacitor discharge ignition system (CDI) and ignition system with MOST.

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The MICT2.0 is the graphic user interface for the controllers of the MIC3, MIC4 und MIC5 series. Configurations can be performed and the operating data of the engine seen and adjusted using a laptop.

• Language selectable (German/English/Chinese)• Compatible with Microsoft Windows XP/Vista/7• Print function of a runtime data snapshop for external

problem analysis, etc.

• Context-independent online help• Different access levels to avoid unintended incorrect entries

MICT – MOTORTECH Integrated Configuration Tool

Example pages – configuration

MOTORTECH INTEGRATED CONFIGURATION TOOLMICT

Parameter setThe database included provides engine information such as ignition order, ignition sequence, number of ignition coils per cylinder and typical number of teeth on the flywheel for easy engine configuration. Other configurations can be entered manually.

Engine selection and user-defined cabling

When selecting an engine from the engine database, user-defined direct cabling can also be configured. As a result it is possible to define the orientation of the cable tracks mounted on the engine and define the output cable harness in the ignition controller.

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Parameter setThe MIC ignition controllers offer two parameter sets for the inputs needed to calculate ignition timing, which for example can be used for two-gas engine operation. In addition, the parameter sets can be represented graphically.

Parameter set – Presentation of the configurationGraphic presentation of parameter sets A and B facilitates rapid visual checking of the values configured.

Parameter set – Energy settingsThe ignition spark duration and ignition spark intensity can be set at different ignition voltages with the assistance of the extended energy settings for the start-up phase and normal operation of the engine.

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Example pages – run time dataOverviewYou can see the most important current run time data such as speed, ignition timing or system status at a glance in the over-view presentation.

Breakdown voltageThe MICT provides a lot of current and detailed information on the status of every single ignition output. Important data is optically processed, ensuring that irregularities show up immediately; e.g. the secondary voltage is in addition shown as a bar diagram and the type of a misfire is symbolized by a warning light.

Warning, error and alarm list

The MICT shows a summary of all information, warnings, errors and alarms in a list. Apart from the alarm list and detailed re-ports, the precise date and time at which a report was included in the list is shown in addition to the operating hours.

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Ignition timingOn the left side of the display you see all values and settings that influence the ignition timing. In addition the values are shown and presented as a bar diagram on the right that are pending on the three inputs (potentiometer, analog current and voltage input) and in this way lead to the changes in ignition timing indicated. The value for the speed curve is shown by curve progression set in the configuration.

Diagnosis The status display indicates the current error handling condi-tion of the device for CAN bus communication.

Self-test

You can carry out a self-test via the MICT to check the sequence of the cabling and connection between the outputs of the igniti-on controller to the spark plugs.

Example pages – self-test

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Components for MIC Ignition Systems

MOTORTECH IGNITION COILSMOT- Coils

High energy coilsIgnition coils are becoming steadily more important in modern ignition systems. MOTORTECH provides high energy coils adjusted to controllers. • New modern design• Use of high quality materials• Ideal for the ignition of alternative

fuels like biogas• Compatible with MOST

High Tension Leads for NON Shielded ApplicationsPolyMot® patented spark plug leads are the most reliable high tension leads in the industry. Made from a combination of Ceramic, Teflon® and Silicone they transfer nearly any rate of high energy spark from the coil to the spark plug. Variations for nearly all engine models in combination to spark plugs are available.

Extended Spark PlugsFor engine applications equipped withextreme tight spark plug well, conven-tional ignition leads show its limits. The solution is specially designed spark plugs with extended metal housing. XTLPlugs are manufactured with an integrated 7 mm spark plug lead, which allows a direct connection to an externally mounted ignition coil. It can be ordered with different barrel and lead lengths, different lead out-puts from the barrel and a wide range of ignition coil connectors. XTL-Plugs are designed for unshielded applica-tions and offer long runtimes.

Industrial Spark PlugsToday the industrial gas engine market requests Platinum andIridium tip electrodes for long spark plug life.

DetCon20The DetCon20 control unit offers full protection for gas, diesel and dualfuel engines from 2 to 20 cylinders. Microprocessor controlled, it willdetect any detonation in the early stage and will send an analog signal(4-20mA/0-5V) out to the ignition system to retard in a linear function.If detonation cannot be cured a signal will be sent for load reductionand finally an engine STOP signal. CAN Bus interface included.

MOTORTECH DETONATION CONTROL SYSTEMDetCon20

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Magnetic Pickup (MPU)Reliable design in a variety of differentlengths. Available in standard or CSAcertified versions.

Hall-Effect PickupHigh temperature resistant pickup.Triggers off any magnet. Available instandard or CSA certified versions andboth possible polarities.

Inductive PickupSmall sensor (M12 thread) for use inapplications where there is not muchavailable installation space. It can operate in oil. High temperature resi-stance. Available in standard or CSA certified versions.

PowerView3 – HMI-ModulePowerView3 is a compact and flexible HMI module (Human-Machine-Inter-face) for visualization and operation of MOTORTECHs new generation con-trol units. On more than 25 screens the 7” color display supports the full visualization of the most important operating data of ignition and deto-nation control as well as the adjust-ment of various parameters. Error diagnostics can be executed easily on-site without requiring a laptop. The touchscreen guarantees an intuitive navigation through different display pages and menus. The relevant ope-rating data can be easily recorded and stored via USB mass storage device or SD card. The visualization functions have to be activated for every single device. Additional activations or firmware updates are possible at any time.

MOTORTECH LiteRail Wiring SystemsThe MOTORTECH LiteRail system aluminium profile is delivered pre-assembled for your engine design. Appropriate and pre-fitted ignition coils and the cabling needed via an exchangeable cable distributor simplify the assembly and exchangeability in the event of service. The MOTORTECH Lite Rail is availab-le as a compound system with the MIC3, MIC4 and MIC5.

Lite Rail cabling tracks are only available foruse in rooms not at risk of explosion (non CSA).

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MOTORTECH GmbHHogrevestr. 21-2329223 Celle, GermanyPhone: +49 5141 93 99 0Fax: +49 5141 93 99 99www.motortech.demotortech@motortech.de

MOTORTECH Americas, LLC1400 Dealers Avenue, Suite ANew Orleans, LA 70123Phone: +1 504 355 4212Fax: +1 504 355 4217 www.motortechamericas.cominfo@motortechamericas.com

OfficeSales Partner

Headquarter

We aim at your problems!

Distribution partner for DENSO spark plugs

Regardless of which part of the globe we need to travel to.We know that the stakes are high, and therefore we outperform the others. That is because we want every-thing to run smoothly at your site, everywhere and at any time.This is entirely in keeping up with our motto: Let us drop everything and work on your problem!

Distributed by:CopyrightThe copyright for all materials used in this MOTORTECH publication is reserved. Any kind of duplication or use of objects such as pictures or texts in other electronic or printed publications without approval by MOTORTECH is not permitted.

Trademark Information

MOTORTECH products and the MOTORTECH logo are registered and/or common law trademarks of MOTOR-TECH Holding GmbH.

All OEM names and part numbers shown are for reference purposes only. All trademarks, logos and symbols used or shown in this MOTORTECH publication are exclusive objects to the right of their owners and are used for reference purposes only.P/N 01.15.025-EN | Rev.08/2015 | MOTORTECH SalesFlyer MIC Series

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