Elektronik Sachse ZDG 3.23 - User Manual

1
ELEKTRONIK
SACHSE
Elektronik Sachse GmbH & Co. KG
Installation Manual
Digital Ignition ZDG 3.23 (Moto Guzzi
Ducati Alternator)
Item: Z59-D
Contents
1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 General Notes / Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Function
T he d i g it a l i gn iti on k it ZDG3 r ep l aces o ri g i na l e l ec tr on i c i gn iti on un it s as we ll as o l d po i n t s
including the weights advancer or manual advance wires.
Func ti on : Pe r r e v o l u ti on o f t he c r anksha ft s t a rti ng fr om T D C , t he momen t a ry pe ri phe r a l
speed i s de t e r m i ned and b y t h i s means , t he ti me up t o i gn iti on i s ca l cu l a t ed . Because t he
pe ri phe r a l speed v a ri es subs t an ti a lly du ri ng acce l e r a ti on , t h i s l ong measu r emen t i s se l ec t ed
in order to determine a relatively exact measurement.
The computation of ignition timing is divided into 4 ranges:
Range
Function
0 – 400 rpm Starting range, ignition always at TDC
400 – 1000 rpm Idling range, 2° to 8° advanced ignition, depending on curve selection
1000 – 6200 rpm Partial load range, the spark advance adjustment occurs here
6200 – 12000 rpm Maximum load range, constant maximum advanced ignition, depend-
ing on curve selection

Summary

Digital Ignition Functionality

Mounting the Ignition Kit

Pickup Installation and Alignment

Steps for installing the pickup plate, aligning magnets, and ensuring proper fit with the cover.

Cable Routing and Grommet Fitting

Procedure for routing the pickup cable through the generator cover grommet.

Electrical Connections Guide

System Settings and Configuration

Sector Disk and LED Adjustment

Procedure for adjusting the sector disk using the LED for accurate ignition timing.

Securing Screws and Timing Verification

Instructions for securing adjustment screws and verifying ignition timing with a lamp.

DIP Switch 1: Rev Limiter

Configuration of the rev limiter using DIP switch 1 (up/down settings).

DIP Switch 2: Tachometer Frequency

Setting DIP switch 2 for electronic tachometer frequency (crankshaft/camshaft).

Ignition Curve Selection

Selecting ignition curves (0-9) using the rotary dial for engine performance tuning.

General Notes and Troubleshooting

Engine Starting Issues

Troubleshooting steps for engines that do not start or backfire.

Irregular Engine Performance

Diagnosing and resolving intermittent engine cutouts due to ignition resets or poor connections.

Overview

1. Function Description
2. Installation and Mounting
3. Electrical Connections
4. Settings
5. DIP Switches and Rotary Switch
6. General Notes / Troubleshooting
7. Contact Information

The Elektronik Sachse GmbH & Co. KG Digital Ignition ZDG 3.23 (Moto Guzzi Ducati Alternator), item Z59-D, is a digital ignition kit designed to replace original electronic ignition units, as well as older points systems, including weights advancers or manual advance wires.

Function Description

The ZDG3 digital ignition system operates by determining the momentary peripheral speed per revolution of the crankshaft, starting from Top Dead Center (TDC). This information is then used to calculate the precise time for ignition. To ensure accuracy, especially during acceleration when peripheral speed can vary significantly, a longer measurement period is employed.

The ignition timing computation is divided into four distinct ranges:

• 0-400 rpm (Starting Range): Ignition consistently occurs at TDC.
• 400-1000 rpm (Idling Range): The ignition is advanced by 2° to 8°, with the specific advance depending on the selected curve.
• 1000-6200 rpm (Partial Load Range): This is where the spark advance adjustment takes place.
• 6200-12000 rpm (Maximum Load Range): The ignition maintains a constant maximum advanced setting, again dependent on the chosen curve.

Installation and Mounting

The mounting process involves several steps to ensure proper alignment and connection of the pickup and magnetic disk.

1. Pickup Mounting Position: The pickup's mounting position is determined by the stator's installation and connection. Two of the three M5-stator screws are removed and replaced with supplied threaded bolts and washers.
2. Rotor and Driver Sleeve: The central nut is removed from the rotor, and the driver sleeve is screwed back on, but only tightened slightly at this stage.
3. Pickup Plate and Magnetic Disk: The pickup plate is then fitted onto the threaded bolts. The magnetic disk is pushed onto the driver until its magnets are at the same height as the sensors.
4. Driver Adjustment: If the driver overlaps, it must be reduced (e.g., by filing, grinding, or lathing) to allow the generator cover to fit as closely as possible. Once everything fits, the driver can be fully tightened.
5. Cable Routing: The pickup cable can be routed through the rubber grommet using patience and talcum powder. Alternatively, an additional groove for the pickup lead (with a provided grommet) may need to be made into the generator cover next to the existing grommet.
6. Pickup Connection: The pickup is connected according to the provided diagram.

Electrical Connections

Careful attention to wire cross-sections and connections is crucial for optimal performance and safety.

• Ground Cable: The ground cable's wire cross-section should be at least 1.5 mm² and kept as short as possible.
• Other Cables: The wire cross-section for all other cables should not be below 0.5 mm².
• Pickup Lead: The pickup lead should not be shortened.
• Wire End Ferrules: Insulated wire end ferrules must be used on all other cables.

The ignition circuit diagram for breaker points replacement shows connections for:

• +12V ignition (rechts/right and links/left)
• Pickup
• Electronic rev counter

For Motoplat replacement, the connections are:

1. Ignition coil cylinder left
2. Ground
3. Pickup lead, brown
4. Pickup lead, green
5. Pickup lead, yellow
6. Pickup lead, white
7. Output for electronic tachometer
8. +12 supply voltage, switched
9. Ground (same as #2)
10. Ignition coil cylinder right

Settings

Accurate adjustment of the ignition system is vital for proper engine operation.

1. TDC Position: Bring the right piston to the TDC position.
2. Disk Rotation: Rotate the disk in the direction of rotation until the 'S'-marked magnet is close to the sensor, ensuring the magnets are approximately at the same height as the sensor.
3. Ignition Switch: Turn on the ignition switch.
4. LED Indication: Continue rotating the disk. The LED near the sensor should light up when the 'S'-marking passes the sensor (red arrow). Note that LEDs might already be indicating at power-on.
5. 'N'-Marking Adjustment: Slowly rotate the disk to the 'N'-marking until the LED switches off. This indicates the correct position, and the disk can then be tightened with the set screws. This adjustment must be made very accurately.
6. LED Reset: The LED cannot be switched on by turning back the disk. To reset, the ignition must be switched off/on, or the disk must be turned back to the 'S'-marked magnet.
7. Set Screw Security: If the engine is running, secure the set screws with medium-strength thread locker.
8. Timing Check: If possible, check the timing with a timing lamp.

DIP Switches and Rotary Switch

The ignition box features DIP switches and a rotary dial for various settings.

• DIP Switch No. 1 (Rev Limiter Setting): Located on the left side of the ignition box, this switch controls the rev limiter.
  • Up: 8600 rpm
  • Down: 7800 rpm
• DIP Switch No. 2 (Frequency Setting): Located next to DIP switch No. 1, this switch adjusts the frequency for the electronic tachometer connected to #7. If no electronic tachometer is connected, this switch can be ignored.
  • Up: Crankshaft frequency selection
  • Down: Camshaft frequency selection
• Rotary Dial (Ignition Curves): The ignition curves are set using the rotary dial on the left side of the box, to the right of the DIP switches.
  • Curve No. 0 (Test Mode): In this mode, the box continually fires without the engine running. This allows for testing the installation of the unit and coils, but it does not test the pickup.
  • Rotary Switch Settings 1-9: These correspond to different ignition curves, which are graphically represented in the manual, showing Advance/° versus RPM.

General Notes / Troubleshooting

• Spark Plugs: Only use interference-free caps for spark plugs. NGK caps with 5 kΩ internal resistance are recommended.
• Engine Doesn't Start / Kicks Back: If the engine fails to start or kicks back, the ignition coils may be mixed up. Swap the ignition cables leading to the spark plugs or reconnect the external ignition coils. A general rule is that each time a piston reaches TDC, the corresponding plug must spark.
  • To check cable connections and supply voltage, turn the rotary switch to '0'. The spark plugs should fire continually.
  • If the rotary switch is then turned to a level (1-9), the timing can be checked with a strobe by activating the starter (without plugs in the cylinders).
  • If the engine doesn't start with a slowly turning starter, the battery voltage may be falling below the minimum supply voltage for the ignition (approximately 7 V).
• Irregular Engine Cutouts: If the engine occasionally suspends for 2-3 seconds while driving and then resumes normal operation, it indicates that the ignition has been reset. This can be caused by:
  • A defective cap or a loose ignition cable in the coil or cap.
  • Most commonly, a bad contact in the operating voltage supply (e.g., kill switch, starter lock, fuse holder, terminals).
  • Troubleshooting Steps:
    • Connect a cable directly from the ignition coils and the ignition box to the positive terminal of the battery.
    • Connect a second cable from the negative terminal of the battery to the ignition box (ensuring a secure ground connection).
    • If the engine runs well after these direct connections, the issue likely lies in the wiring harness. Unlike contact breakers, which are less sensitive to short power interruptions, electronics are more sensitive to even brief (milliseconds) supply voltage breaks.

Contact Information

Elektronik Sachse GmbH & Co. KG Kloster-Oeseder-Weg 37 49176 Hilter Germany Phone: +49 (0) 5409 9069826 Email: info@elektronik-sachse.de

Elektronik Sachse ZDG 3.23 Specifications