The IntelliSpark Ignition System is a capacitive discharge, low-tension ignition system designed to provide precise spark timing, which enhances fuel economy, load balance, and ignition stability in engines. The system is controlled by a 16-bit microcontroller, offering a flexible solution for various ignition needs.
Function Description:
The core function of the IntelliSpark system is to manage and deliver ignition sparks to engine cylinders. It achieves this through a capacitive discharge mechanism, ensuring consistent and powerful sparks. A key feature is its patented spark plug demand voltage measurement, available with IntelliSpark smart coils. This allows the system to:
- Measure the demand on each cylinder's spark plug for diagnostic purposes.
- Utilize the measured demand for automatic energy control, optimizing spark energy delivery.
- Employ the measured demand in a unique camless crank method to determine the compression stroke, eliminating the need for a camshaft sensor in certain configurations.
The system operates in different modes:
- Cranking Mode: During engine startup, the system counts flywheel gear teeth (PIPs) and, if within specification, activates the Ign On Relay to begin firing coils. For 4-stroke engines, it also detects the CAMREF signal. In camless operation, it distinguishes stroke sequences during the initial test firings.
- Normal Run Mode: Once the engine RPM exceeds a predefined Crank/Run RPM, the system transitions to normal run mode. In this mode, it uses tighter tolerances for PIP counts and continuously monitors engine parameters.
- Automatic Energy Control: In "Auto" mode, the system adjusts the tank voltage to provide just enough energy to fire all plugs, minimizing plug erosion and extending operating hours. As plugs age and kV demand increases, the tank voltage and energy gauge will rise to meet the demand, providing an indication of plug wear. In "Manual" mode, tank voltage and energy remain at user-programmed levels.
Important Technical Specifications:
- Power Supply: The system operates on 12/24V DC. It requires a few seconds after power-up to become ready for firing.
- Minimum RPM for Firing: 30 RPM.
- Timing: The system can display and adjust timing in degrees (e.g., 10.0 Deg Sch:A).
- Tank Voltage: Displays the current tank voltage (e.g., 239.3 VDC).
- Energy Level: Shows the percentage of energy available (e.g., 78% Energy).
- Firmware Version: Displayed on the Main Menu (e.g., IS F/W Ver: 4.07).
- Cylinder Support: Available in 16/8 series, supporting up to 16 cylinders.
Usage Features:
The IntelliSpark system features a user-friendly display with several interactive pages:
- Main Menu: The initial screen after power-up, displaying "Initializing..." for about 8 seconds while establishing communication with the controller. It provides access to:
- Operator Page: The primary operational screen.
- Off-Line Diag: For diagnostic testing when the system is in Standby Mode.
- System Setup: For programming and configuration (requires passcode).
- Help Menu: Provides general help topics.
- Also displays day/date, clock, and firmware versions.
- Operator Page: Shows real-time engine status during cranking and running.
- Displays PIPs counted, current RPM, timing, overspeed trip setting.
- Indicates the status of Ign On Relay, Alarm Relay, Shut/Dn Relay, and Ignition Enable.
- Shows Tank Voltage and % Max Energy.
- Spark kV Page: Offers unique insights into ignition system operation.
- Displays actual spark gap breakdown voltage (kV values) for each cylinder.
- Shows the maximum available kV and the engine's average kV.
- Provides diagnostic information for each cylinder, including:
- Open primary wire
- Shorted primary wire
- Open or disconnected plug wire
- Allows selection between "Auto" and "Man" (Manual) energy modes.
- Engine View Page: Presents an engine block view with color-coded cylinders.
- Cylinders are color-coded: green for normal kV, yellow for kV near available limit, and red for diagnostic faults.
- Displays firing order, RPM, and timing parameters.
- Indicates the wire color of the primary lead for each cylinder, aiding in wiring.
- Diagnostic Log Page: Records and displays any faults that have occurred.
- Shows three possible diagnostic conditions for each cylinder: Open Secondary, Open Primary, and Short Primary.
- A red square indicates the last fault event for a cylinder, remaining red until "Clear Log" is pressed.
- Faults are registered only if they occur for two out of three consecutive revolutions to prevent false reporting.
- Data Page: Displays a set of operational variables, including:
- PIPs Counted and PIPs Programmed.
- Cam Lead, Cam Trail, Cam Ref Pol, Cam Ref (grayed out in camless modes).
- Tank 1 and Tank 2 VDC.
- Coil Type.
- Power-Applied timer (stops after 48 hours).
- View/Edit Setpoint Page: Allows observation and modification of operating parameters (requires passcode).
- Tank Volts Setpoint: Sets the desired tank voltage.
- Timing Adjust: Allows adjustment of timing by +/- 3 degrees.
- 1/Rev Position: Specifies where the 1/REV signal occurs, aligning displayed timing with a timing light.
- Changes can be saved to non-volatile memory, but saving during run mode requires the engine to be shut down first.
- Factory Setpoints Page: Accessible via a "More" button on the View/Edit Setpoints page (after passcode).
- KV Scale Factor: Affects kV measurement.
- KV Comparator Ref: Affects kV measurement.
- Shutdowns and Alarms Page: Displays shutdown events and alarms.
- Active Shutdown: Shows current shutdown status (e.g., "No Shutdowns," "Normal Shutdown," or specific fault messages like overspeed or signal loss).
- Last Shutdown: Records the date and time of the last shutdown.
- Alarms: Includes ignition diagnostics, 4/20 mA input errors, PIP count issues, etc.
- Alarm Relay activates when an alarm occurs, and an LED indicator turns red.
- Options to: Leave Alarm Relay on, Acknowledge Alarm (turns off relay but alarm remains posted), or Clear Alarm (requires source of alarm to be fixed).
- Cam Score Page: Used when camless methods are employed (e.g., for 16-cylinder engines).
- Displays time delay values for each cylinder across multiple revolutions (e.g., REV #1, REV #2, etc.).
- Helps distinguish compression strokes based on higher time delay values.
- Shows "Total Score Obtained" and "Min Score Needed," indicating the system's confidence in identifying strokes.
- Can reveal non-uniform plug gaps based on variations in time delay values.
Maintenance Features:
- Diagnostic Log: Helps identify intermittent problems by recording fault events, even if they occurred only once since the last clearing.
- Spark kV Page Diagnostics: Provides immediate feedback on open/shorted primary wires or open/disconnected plug wires, indicating potential issues that require inspection.
- Automatic Energy Control: In "Auto" mode, the energy gauge can serve as an indicator for plug wear. If energy exceeds 95%, it may suggest that plugs are nearing their end of life and require replacement or regapping.
- Power-Applied Timer: Useful for troubleshooting unattended shutdowns, indicating how long the unit has been powered.
- Clear Log/Clear Alarm Buttons: Allow users to reset fault indicators and alarm states after addressing the underlying issues.
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