Installation and operating manual Electronic
Contents
1. version feature l l l RC i 1x0 RC i 2x0 RC i 4x0 number of cylinders 1 2 3 amp 4 max speed rpm 30000 accuracy of speed measurement 1 25 C power supply 4 12v detectable pulse width of 0 8 2 2ms receiver signal min signal level of receiver signal 1 6V warn threshold for low voltage main 4 9 9V battery its shutdown threshold for low voltage 4 9 9V main battery warn threshold tar low voltage 2 9 9V receiver battery warn threshold for low voltage l 1 2 9 9V receiver battery reverse polarity protection with fuse 3A 5A 10A current consumption D 7500rpm 0 5A 10A 2 0A energy 2 6V 15000rpm 1 0A 2 0A 4 1A current consumption a 7500rpm 0 4A 20 7A 1 4A energy 2 9V 15000rpm 0 77A 1 3 A 2 7A current consumption P 15000rpm 0 5A 1 1A 2 2A energy 2 12V 30000rpm 1 1A 2 2A 4 4A dimensions mm without flange 82x42 82x42 82x82 dimensions mm with flange 110x 42 110x 42 110 x 82 height mm 18 18 18 100 x 72 hole pattern mm 100 x 32 100 x 32 100 x 36 weight g 100 110 195 CE for multiple cylinders versions and high speed gt 20000rpm the supply should be min 9V current consumption has a strong dependency on ignition coil spark plug an wiring cross section D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the res2. ANRANAAAANAANARAAAARSAAAARAS CANAAN OANA x X Na gt Tnn NAA sensor SO Sor X Ro aN KO Mass ce n nectio a Om SOLLLLELLLLELISELLILELLSL LLL SLLSLLSSE wee to engine housing min 1 5mm2 ony important gt insulate non used cables with insulating tape gt elongate cables only with min 1 5mm cables D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 11 POWER SPARK RC i xxx Connection of ignition coil The POWER SPARK conducts the ignition pulse via the white or yellow cable to the ignition coil s ground connection The ground connection of the ignition coil must not have an electric contact to the engine housing contrary to the original application Furthermore it has to be insulated to avoid accidental touching LLLLLLL T ground connection of ignition coil must not have contact to engine housing must be insulated to avoid accidental touching high voltage Modification of ignition coil Proposal on application of an insulating bushing that is available as accessories item nr IB 1 original state ignition coil with electrically conductive metal bushing 1 gt drilled out bushing use drill with 6 2mm gt 3 connection of white yellow cable with eye 4 insu
3. Installation and operating manual Electronic ignition system POWER H SPARK Versions cylinder RC i 100 RC i 120 e 2 cylinders RC i 200 RC i 220 twin 180 ignition offset e 3 amp 4 cylinders RC i 400 RC i 420 double twin 180 ignition offset included e POWER SPARK e speed sensor e magnet for speed sensor e 2x bushings for speed sensor e programming magnet e installation and operating instructions POWER SPARK RC i xxx Dear customer thank you for your purchase Please read the following instructions carefully so you wouldnt have any difficulties to install and operate the POWER SPARK We wish you a successful installation and much pleasure using the POWER SPARK Ids as ese ts that ds or ker proper We are always interested in improvements and look forward to your feedback Please contact tne systeme Dipl Ing T Niedermayer Alemannenstr 7 D 73457 Essingen GERMANY technology novelties engineering Tel 49 7365 9191 41 email info power spark de web www power spark de 1 Onlv receiver contral versians RC i x x 2 anlv multinle evlinders versians RC i 2xx f amp RC i 4xx POWER SPARK RC i xxx Features General e micro controlled high precision electronic ignition system e constant spark energy in the complete speed range spark energy independent from supply voltage integrated voltage booster compensates voltage swing 2 digit brilliant re
4. 25mm 35mm 29 5mm flywheel flywheel HINT For fine adjustment use menu control sensor p 30 in the configuration menu D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 8 POWER SPARK RC i xxx Connections grey cables POWER SPARK RC receiver S Co x lt E os ren Lt Ii O IILI O X only RC receiver control versions RC i x2x only multiple cylinders versions RC i 2 xx Pin assignment of POWER SPARK cables he red Wa black _ pink pink Wa white SX yellow length color Function cross section red supply 4 12V 1 mm use fuse value see p 43 black supply earth 1 mm pink supply ignition coil 1 1 mm pink supply ignition coil 2 1 mm white supply ignition coil 1 1 mm yellow supply ignition coil 2 1 mm Pin assignment of RC receiver cable color Function cross section 25 cm 25 cm 35 cm 35 cm 35 cm 35 cm length white voltage receiver 3 12V green receiver signal servosignal brown voltage receiver earth white 0 14 mm 0 14 mm 0 14 mm brown D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the re
5. hi flashes for 3sec 13a if the upper limit hi should be changed gt actuate magnetic element gt input as described in point 12 13b if the upper limit hi should not be changed gt wait until the new values are displayed in this example 14 display shows the new values of the lower and upper limit here for example lo 25 hi 78 I aii ot Ti Ti II gt gt gt 15 Display indicates that the new values are stored 16 POWER SPARK returns to the normal operation mode display of engine speed and ignition standby 17 gt reset POWER SPARK therefore disconnect and reconnect power supply o PLEASE NOTE e To deactivate the receiver signal supervision o set the upper or lower threshold to no e To activate the receiver signal supervision o set the upper and lower threshold to valid values D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 41 POWER SPARK RC i xxx DIAGNOSTICS MENU b e Voltage monitoring activation and adjustment of warning or shutdown thresholds for supervision of main or receiver battery voltage The following e
6. see d the magnet in the flywheel and the speed sensor element have to be at the same level see c d The exact adjustment can be made with the help of two 0 5mm holes in the area of the speed sensor s sensitive element you can find the sensitive element in the middle of the connecting line between the two holes the speed sensor s flattened side faces the flywheel see d set the air gap between the speed sensor and the flywheel between 0 5mm 1 5mm see d magnet gt place the magnet 3mm length 4mm into the flywheel in a way that it passes the speed sensor in direction of rotation 65 before reaching the top dead center a b For checking the sensor angle use the menu CS p 30 and correct it with menu SA p 29 that the surface of the magnet is located max 1mm under the surface of the flywheel d that it is permanently fixed for example use instant adhesive The polarity of the magnet can be ignored D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 7 POWER SPARK RC i xxx Detail description of magnet and speed sensor e Presentation a b cylinder 1 is on top dead center sensor sensor sensing element magnet flywheel flywheel rotation left reverse direction rotation right normal
7. 6 gt actuate magnetic element display shows the current speed values n and the 7 current angle values one after another i i no gt Wo gt N1 gt Wi M gt Wo h3 gt W3 The POWER SPARK has a two digit LED display This is why the display of speed values occurs by sequentially displaying the figures The display shows the speed figures one after another here for example n 12500rpm 7a display I display of pre ignition angle here for example w gt 15 7b a 11 D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 23 POWER SPARK RC i xxx CONFIGURATION MENU TIP For a faster adjustment of the parameters the display of the values can be interrupted gt wait until any angle will be displayed for example wo gt actuate magnetic element display shows 1 i an information that the proper programming can start and inputs from the user are expected adjustable parameters flash one after another for 3sec Wo gt 01 gt Wi M gt Wo gt N gt W3 10 gt actuate magnetic element to select the parameter for modifying Example the angle wo is
8. are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 34 POWER SPARK RC i xxx DIAGNOSTICS MENU DIAGNOSTICS MENU wl at General The POWER SPARK provides several diagnostic functions to increase the reliability of the system e If the monitored voltage falls below the adjusted warning threshold ignition failures will be systematically generated starting from the half maximum allowed engine speed gt engine splutters to inform the user of a weak battery adjustment of speed in menu item nl p 26 e If the monitored voltage falls below the switch off threshold the engine will be shut down for safety for example cable break of power supply on the RC receiver e When receiving an illegal signal from the RC receiver the engine will be shut down f e in case of failure of radio transmission A warning or shutdown is only triggered after a defined time see table on page 37 when the monitored parameters have exceeded or under run the permissible range of values The warning or shutdown criteria are explained in the respective menus descriptions The diagnostic menu can only be selected when the engine halts It includes the menu items ee e 1 a Supervision of receiver signal i gt engine shutdown activation and adjustment of the valid receiver signal range b Warning threshold receiver battery gt engine splutters at nL 2 a
9. in direction of rotation until the 7 display shows ii The sensor magnet of the flywheel is detected by I i speed sensor g gt turn back flywheel until only the first decimal point is shown 2 gt repeat step 7 to proceed in this way adjust an 9 angle of 75 between top dead center and trigger point 10 after making the adjustment gt actuate magnetic element T ll POWER SPARK returns to normal operation mode a display of engine speed and ignition standby Litt D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 30 POWER SPARK RC i xxx CONFIGURATION MENU g Factory reset reset POWER SPARK to default settings The POWER SPARK can be reset in the initial state with default values at any time WARNING all stored settings get lost nr action display 1 4 gt select configuration menu i 5 gt wait until Fr flashes 6 gt actuate magnetic element 7 7 Fr flashes again for 3sec 8 gt within this time actuate magnetic element l 7 9 Fr flashes again for 3sec a 10 gt within this time actuate magnetic element i ll display confirms the initialization with the factory TOY setting
10. mechanical components We are not responsible for consequential damages as a result of improper engine adjustments 2 WeT Bese 8 ee ee ae ne a W3 OS es C ziri Gaba ao ae Te eS er en 5 Soe ES x lt 1 1 I Cc I j ED N o D in l Wepre O e eg ree ra TOD Wo Fa aie pete tases setae oes No Ny No Ng speed The speed values n can be adjusted in 100rpm steps the pre ignition angles in 1 steps restrictions e m gt m gt n gt No e n Ny ny lt 30000 e W3 W2 W1 Wo lt 39 D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 22 POWER SPARK RC i xxx CONFIGURATION MENU Adjustment of the custom ignition map The adjustment of the custom ignition map is basically more complex than other menu adjustments Before starting please collect experience with the operation concept in other menu adjustments Change primarily only few parameters and check the adjusted values possibly note the values down In the following example the current ignition angle and speed pairs shall be unchanged only angle w shall be changed to 13 and speed n to 21500 rpm nr action display 1 4 gt select configuration menu i a 5 gt wait until Cc flashes ae a
11. multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 33 POWER SPARK RC i xxx STATUS MENU 6 display shows the figures of speed one after another i for example 2 5 6 5 4 a 7 POWER SPARK returns to the normal operation rir mode display of engine speed and ignition standby oft b Display of actual main battery voltage Ub U battery nr action display 1 4 gt select status menu l i i 5 gt wait until Ub flashes Pit gt actuate magnetic element tt 6 display shows the actual battery voltage _ C for example 5 6 vVolt rat 7 POWER SPARK returns to the normal operation rir i mode display of engine speed and ignition standby imt Il c Display of actual receiver battery voltage sUr U receiver nr action display rill 1 4 gt select status menu rill 5 gt wait until Ur flashes II gt actuate magnetic element Il 6 display shows the actual receiver battery voltage iit for example 4 9 volt l l 7 POWER SPARK returns to the normal operation irs mode display of engine speed and ignition standby P t Il D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks
12. POWER SPARK RC i xxx Overview configuration menu configuration menu CO ignition map individual display engine speed selection of pre programmed ignition map C c0 gt c1 gt c8 h c adjustment of angle amp speed pairs for custom map C custom valid value 0 n1 1 gt n2 gt gt 3 ea adjustment of engine speed limit n Limit 0 5 gt 0 9 gt 0 9 valid value 1000 59900 selection of ignition energy ignition Energy 1 2 3 adjustment of speed sensor angle sensor angle 4 9 gt 0 9 valid value 40 99 check position of speed sensor Control Sensor load default values Factory reset Fr possibly store data Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 17 POWER SPARK RC i xxx Overview status and diagnostics menu confirmation with prog magiiel diagnostics menu display of the maximum achieved engine speed n highest maximum voltage of main battery voltage of receiver battery
13. POWER SPARK RC i xxx CONFIGURATION MENU e Sensor angle l l compensation of mechanical displacement of speed sensor lt 75 gt A small angular offset between the ideal trigger of the speed sensor 75 before top dead center and the current value can be adjusted by setting the actual angle value between the speed sensor and the sensor magnet e Mark the angle between the trigger point of the speed sensor and the top dead center using menu CS see next page If you adjust angle values less than the nominal 75 the available computing time of the microcontroller will be shorter For example an adjustment of the sensor angle to 70 limits the use of high pre ignition angles 35 to engine speeds lt 26500rpm nr action display 1 4 gt select configuration menu i Mi 5 gt wait until SA flashes a 6 gt actuate magnetic element i 7 display shows the current sensor angle value L for example 75 l wl adjustable values of the tens flash one after another g for 3 sec 4 7 is gt wait until the desired figure flashes for example 6 it gt actuate magnetic element adjustable values of the unit position flash one after g another for 3 sec 4 7 ar gt wait until the desired figure flashes for example 6 l l ee gt actuate magnetic element 10 display shows the new s
14. ctivation and adjustment of warning threshold for supervision of receiver battery voltage c Shutdown threshold receiver battery gt engine shutdown activation and adjustment of shutdown threshold for supervision of receiver battery voltage d Warning threshold main battery gt engine splutters at nL 2 activation and adjustment of warning threshold for supervision of main battery voltage e Shutdown threshold main battery gt engine shutdown activation and adjustment of shutdown threshold for supervision of main battery voltage D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 35 POWER SPARK RC i xxx DIAGNOSTICS MENU selection of diagnostic menu nr action display 1 POWER SPARK in normal operation mode gt actuate magnetic element 2 by approaching the programming magnet to the LILI housing near the magnet sensitive element pri remove after display shows N 3 after 3sec the right figure d flashes Sy during this time gt actuate magnetic element ist l 3b by approaching the programming magnet to the LICI housing near the magnet sensitive element remove after display shows 4 Diagnostic menu will be selected l i mi D Only receiver c
15. d page 25 POWER SPARK RC i xxx CONFIGURATION MENU c Speed limit l adjustment of engine speed limit engine splutters factory setting np lt 59900rpm gt The engine can be protected against too high speeds with adjusting a speed limit If the engine speed exceeds the adjusted speed limit for at least 0 4sec the ignition will be interrupted the engine splutters The speed limit can be adjusted exactly to 100rpm If this safety function is not needed a speed limit value higher than the maximum engine speed should be programmed For example speed limit of 21500 rpm shall be adjusted nr action display 1 4 gt select configuration menu 7 5 gt wait until nL flashes sy i 6 gt actuate magnetic element Mi i display shows the current speed limit by displaying 7 the figures of the speed one after another i display scheme see section b point 7a la for example 2 0 0 0 0 display shows i i an information that the proper 8 programming can start and inputs from the user are I l expected 9 adjustable values of the ten thousands flash one after ra another for 3 sec 0 5 Lol gt wait until the desired figure flashes 10 for example 2 m gt actuate magnetic element ll adjustable values of the thousands flash one after vy another for 3sec 0 9 Sn gt wait
16. d gt during this time determine the lower and upper signal value of the receiver signal by moving the gaspoti in the end positions on the remote controller gt choose the values for the receiver signal supervision thoroughly see introductory text 10 The selectable parameters flash one after another for 3 sec lo lower limit hi higher limit lo hi mo a FA FF y A N DS 11 gt actuate magnetic element to select parameter for modifying here the lower limit lo is selected 12 Adjustable values flash one after another for 3sec no 0 9 D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 40 POWER SPARK RC i xxx DIAGNOSTICS MENU 12a To disable this diagnostic function gt actuate magnetic element 12b To enable this diagnostic function gt wait until the desired figure of the tens flashes for example 2 gt actuate magnetic element adjustable values of the unit position flash one after another for 3sec 0 9 gt wait until the desired figure flashes for example 5 gt actuate magnetic element 13 The remaining selectable parameter upper limit
17. d LED display simple installation and programming numerous possibilities to customize red anodized waterproof aluminum housing speed up to 30000rpm with one or more cylinders display of the actual engine speed ignition starts at a minimum engine speed safe start up separate ignition endstages gt low power consumption when using multiple cylinder S because additional cylinders ignite separately and not parallel to the first one e no need of an additional battery pack ignition system can be powered from the receiver battery pack min 4 batt 4 8V adjustment possibilities e 9 pre programmed ignition maps e application of custom ignition map e adjustable speed sensor angle mechanical sensor offset e adjustable ignition energy 3 steps diagnosis features e display of maximum engine speed and battery voltage e supervision of main battery voltage e low voltage warning generation of ignition misses e engine stops if low voltage detected e supervision of receiver battery voltage supervision of receiver servo signal e free definable supervision window gt engine stops if FAILSAFE signal is detected e killswitch functionality D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 2 POWER SPARK RC i xxx Backfitting an engine
18. display engine speed display of actual voltage of main battery U battery display of actual voltage of receiver battery U receiver Y only versions RC i x2x diagnostics menu supervision of rS receiver signal warn threshold rL receiver battery adjustment of valid receiver signal receiver signal adjustment of warn threshold voltage receiver low no 2 9 H 0 9 adjustment of shutdown threshold voltage receiver dead nob 2 9 H 0 9 adjustment of warn threshold voltage battery low nop 4 9 gt 0 9 adjustment of shutdown threshold voltage battery dead no 4 9 gt 0 9 possibly store data D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 18 shutdown thres r d receiver battery warn threshold main battery shutdown thres main battery display engine speed POWER SPARK RC i xxx CONFIGURATION MENU Programming CONFIGURATION MENU D The configuration menu includes the following menu items a ignition map menu selection of one of nine pre programmed ignitio
19. djustment to the engine you can use an individual created map The individual ignition map can be activated by choosing map 0 in the ignition map menu The adjustment of the individual ignition map is described in the next section Ss pre ignition angle 0 see individual map 17 0 25 3000 25 6000 30 22000 25 similar Zenoah 2 0 25 3000 20 6000 25 22000 20 3 0 25 3000 20 6000 25 22000 25 4 0 25 3000 20 6000 25 22000 30 5 0 25 3000 20 6000 25 22000 35 6 0 30 3000 20 6000 30 22000 25 7 0 30 3000 20 6000 30 22000 30 8 0 30 3000 20 6000 30 22000 35 9 0 30 3000 20 6000 30 22000 39 D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 20 POWER SPARK RC i xxx CONFIGURATION MENU Selection of a pre programmed ignition map example ignition map 4 shall be selected nr action display 1 4 gt select configuration menu i i 5 gt wait until C flashes o 6 gt actuate magnetic element 7 display shows the current ignition map l for example map 1 adjustable values fla
20. e approached along the bottom side position b see figure If there is few space the programming magnet can also be approached vertically to the magnetic sensitive element c Approach the magnet vertical from the left side to the bottom left corner d Alternatively approach the magnet vertical from the bottom to the bottom left corner of the POWER SPARK Symbolic II display 1 2 LI gt no input expected ANAS SS display 1 2 flashing gt user input expected aN NI ZFF FFFA S e ww display 1 2 1 flashing 2 not flashing gt user input expected YIII FIFI D OAS OAS display modified values are stored aN aN ANAS ANAS acceptable range of values 0 to 9 gt action of operator required D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 14 POWER SPARK RC i xxx Menu structure The operation of the POWER SPARK results by selection of the desired set or displayed parameters by approaching and removing the programming magnet The parameters are arranged in three main menu groups e configuration menu Co o engine adjustments that are changed rarely e status menu IIlI o displays actual values e diagnostics menu dd o modifying o
21. e ignition is deactivated gt to continue operation the voltage supply of the POWER SPARK has to be interrupted and reapplied reset D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 37 POWER SPARK RC i xxx DIAGNOSTICS MENU e o e e 1 a Supervision of receiver signal activation and adjustment of the valid receiver signal range l The POWER SPARK can monitor the signal of a radio control receiver If the received signal is above or below the adjusted threshold values for more than 2 sec the engine is shut down An appropriate signal for the supervision can be the gas signal to accelerate slow down reverse Alternatively any signal can be used for example steering signal or a signal that is exclusively reserved for supervision shutdown sequence of programming The POWER SPARK displays the adjusted values afterwards it displays the actual measured value of the receiver signal for 10 seconds Following the thresholds can be modified in the last step the new values are confirmed Within this time window the display shows the actual signal value of the receiver The nominal receiver signal range can be determined by moving the gas poti at the remote control To avoid an unintended shutdown of the engine caused by this dia
22. e plus cable of the POWER SPARK accessories SI 3 SI 5 Si 10 gt fuse 3A for versions RC i 1 xx fuse 5A 10A for versions RC i 2xx RC I 4xx establish a ground connection from the engine to the battery minus with a cable of at least 1 5mm cross section D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 6 POWER SPARK RC i xxx Installation of speed sensor A precise ignition to the right time assumes the correct assembly of the speed sensor to the engine The magnet and the speed sensor have to be installed in a way that during a rotation the speed sensor is triggered by the magnet 75 before reaching the top dead center As the sensing magnet is surrounded by a magnetic stray field the speed sensor will be triggered about 10 before passing the magnet mechanically For this reason the sensing magnet must pass the speed sensor 65 before the top dead center The value of the stray magnetic field about 10 applies to the shown geometry see illustration When installing the magnet on an increased radius the pre triggering of the speed sensor decreases Speed sensor gt Install speed sensor at an adequate place to the engine Assemble the speed sensor with M3 screws For protecting the strip conductors put the provided bushings under the screws
23. elected angle value D Ci here 69 lal l 11 display indicates that the new value is stored 12 POWER SPARK returns to the normal operation TE mode display of engine speed and ignition standby Tab mml D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 29 POWER SPARK RC i xxx CONFIGURATION MENU f Check sensor check mechanical position of speed sensor The speed sensor has to be positioned in a way that it is triggered by the sensor magnet 75 before reaching the top dead center With the help of this menu the adjustment can be done easily gt see also page 7 and page 29 If there is no further mechanical correction possible measure the actual triggering angle for example mark flywheel at the triggering point and at the top dead center with a pen and measure this angle o adjust the angle value in menu point SA page 29 Important Please note the constraints when adjusting the value of the sensor angle nr action display 1 4 gt select configuration menu i 7 gt wait until CS flashes O 5 I I gt actuate magnetic element i l 6 display shows permanently the first decimal point gt turn flywheel
24. f diagnostic parameters A parameter can be modified by the following procedure e select the according main menu the adjustable menu items flash one after another for 3sec e confirm the desired menu item by approaching and removing the programming magnet for confirmation the display shows additionally e display shows the actual value of the parameter e selection of values by the user adjustable values flash one after another for 3sec e confirm the desired menu item by approaching and removing the programming magnet possibly several times e display shows the new modified values e POWER SPARK returns to the normal operation mode display of engine speed Annotations e the configuration menu can only be activated when the POWER SPARK is turned on e the status and diagnostic menus can be called only when the engine is not running e the POWER SPARK returns to the normal operation mode display of engine speed and ignition standby if no confirmation happens during the changing displays of the individual menu items e if no confirmation with the programming magnet happens during the change of any value the prior values will be retained D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 15 POWER SPARK RC i xxx Example The preset ign
25. gnostic function a tolerance up to about 5 10 should be added respectively subtracted to the nominal values In the following example a signal range from 28 73 was determined To avoid an unintended shutdown of the POWER SPARK a tolerance value was added to the upper signal value respectively subtracted from the lower signal value gt The thresholds 25 and 78 have been chosen receiver signal measured signal range 3 25 signal range 78 tolerance Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 38 POWER SPARK RC i xxx DIAGNOSTICS MENU FAILSAFE and KillSwitch functions e FAILSAFE The POWER SPARK can react with an engine shutdown to a FAILSAFE signal of the remote control system o To enable this functionality a FAILSAFE signal value outside the programmed threshold values of the POWER SPARK has to be programmed to the remote control system FAILSAFE FAILSAFE signal value signal range 73 signal value 25 signalrange tolerance 78 e KILLSWITCH The POWER SPARK can act as a KillSwitch and shut down the engine when a specific value of the receiver signal is reached o Adjust the according threshold of the receiver signal to a value within the signal range of the desired shutdown criteria o Exam
26. gt actuate magnetic element 21 adjustable values of the hundreds flash one after another for 3sec 0 9 22 gt wait until the desired figure flashes for example 5 gt actuate magnetic element 23 the remaining adjustable parameters flash one after another for 3sec W2 gt N3 W3 24 gt wait until w had flashed 25a The error message EE will be shown if wrong values are entered The values before modification are retained 25b 6 display shows the new or retained speed values n and angle values one after another no gt Woy Wi gt M gt W2 gt h3 gt W3 also described in 7 26 If all values are entered correctly and the described requirements are fulfilled the values will be stored Display indicates that the new values are stored on POWER SPARK returns to the normal operation mode display of engine speed and ignition standby Please note After changing a parameter of the individual ignition map the individual map must be activated again e Therefore select the ignition map menu C and adjust individual map CO see page 20 D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepte
27. ition map 2 shall be selected e the ignition map can be adjusted in the menu item ignition map menu contained in configuration menu nr action display 1 4 gt select configuration menu see page 19 B 71 selectable menu items flash one after the other see N 5 configuration menu gt wait until C flashes gt actuate magnetic element 6 by approaching the programming magnet to the O _ housing near the magnet sensitive element l remove after display shows 7 display shows current ignition map O here ignition map 1 i 8 adjustable values flash one after another for 3sec 9 gt wait until 2 flashes S gt actuate magnetic element 10 by approaching the programming magnet to the rr 7 housing near the magnet sensitive element l la remove after display shows ll display shows the new selected ignition map w 7 ignition map 2 Le 12 display indicates that new values are stored POWER SPARK returns to the normal operation gt 13 mode i i display of engine speed and ignition standby D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 16
28. ition of the air fuel mixture however the POWER SPARK consumes more electric power To extend the operating time of the battery the ignition energy should be chosen not higher than needed for a smooth engine running To improve the startup behavior the highest ignition energy is used between speed no and nj Adjustment possibilities e setting 1 low ignition energy e setting 2 medium ignition energy factory setting e setting 3 high ignition energy nr action display 1 4 gt select configuration menu ee wre FFA 5 gt wait until IE flashes 6 gt actuate magnetic element ii display shows the current ignition energy _ TI for example 2 adjustable values flash one after another for 3 sec m Z gt wait until the desired value flashes 9 for example 3 Z gt actuate magnetic element 5 display shows the new selected ignition energy _ I 10 I TI here 3 l 11 display indicates that the new value is stored 12 POWER SPARK returns to the normal operation mir a mode display of engine speed and ignition standby oot D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 28
29. lation bushing access 5 grommet 6 screw M4 gt 7 insulate the electrically conductive components for example with silicone or adhesive tape D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 12 POWER SPARK RC i xxx Programming essentials General To make the programming as simple as possible the POWER SPARK can be programmed with the provided programming magnet In the left bottom corner there is a magnetic sensitive element that can be triggered by approaching the programming magnet magnet POWER SPARK cables magnetic sensitive element rA a 5 T o TT By approaching the programming magnet parallel to the left side of the POWER SPARK sideways or from top position a in a distance of less than 10 mm the magnetic sensitive element is triggered The POWER SPARK confirms the activation and shows additional to the active display D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 13 POWER SPARK RC i xxx gt After that confirmation remove the magnet Alternatively the programming magnet can b
30. n maps b ignition map individual configuration of one custom ignition map c speed limit adjustment of engine speed limit engine sputters d ignition energy selection of ignition energy e sensor angle compensation of mechanical displacement of speed sensor f check sensor check mechanical position of speed sensor g factory reset reset POWER SPARK to default settings The configuration menu contains engine parameters which shouldnt be manipulated thoughtless To avoid an unintended changing the configuration menu can be called only in the following way nr action display 1 gt interrupt voltage supply of POWER SPARK 2 gt approach programming magnet to the housing near the magnet sensitive element 3 gt turn on voltage supply J Zi 4 gt remove programming magnet 71 D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 19 POWER SPARK RC i xxx CONFIGURATION MENU a ignition map menu A Sia selection of one of nine pre programmed ignition maps factory setting map lt 1 gt To enable a quick initial operation of the engine the POWER SPARK contains nine pre programmed ignition maps They serve as basic adjustment and starting point for a further optimization For a specific a
31. only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 32 POWER SPARK RC i xxx STATUS MENU STATUS MENU i i i The status menu can only be selected when the engine halts It includes the menu items a maximum engine speed nh display of maximum achieved engine speed b voltage of main battery Ub display of actual main battery voltage c voltage of receiver battery sUr display of actual receiver battery voltage selection of status menu nr action display 1 POWER SPARK in normal operation mode gt i i gt actuate magnetic element 2 by approaching the programming magnet to the i i i i housing near the magnet sensitive element 3 after 3sec the right figure d flashes IIi gt wait 3 sec to get to the status menu LES the selectable menu items flash one after the other for 4 3sec in the order oy Ps nh y Ub ES Ur a Display of maximum achieved engine speed nh n highest gt value will be erased when removing the power supply gt value is averaged over a period of 0 8sec nr action display 1 4 gt select status menu 5 gt wait until nh flashes a gt actuate magnetic element PAT D Only receiver control versions RC i x2x only
32. ons and errors excepted page 5 POWER SPARK RC i xxx Assembly of the POWER SPARK Please note the following points when installing the POWER SPARK e mechanic installation O the housing of the POWER SPARK can get hot when running the engine with high speeds over a long period gt do not install heat sensitive components near the POWER SPARK gt make heat dissipation possible don t cover gt install in an adequate distance to the engine install at a place with low vibration choose the position so that the display of the POWER SPARK can be read easily choose the position that the magnetic sensitive element for programming the POWER SPARK is accessible see programming ensure a robust mechanical installation of the POWERSPARK for example with special brackets for laminating accessories assembly set item nr EB 1 the dimensions of the POWER SPARK and the distances of the fastening bores shows the scale on page 43 e electric installation O O engines with more than one cylinder and engine speeds exceeding 20000rpm need battery packs with minimum 9V supply voltage keep the supply cables red amp black as short as possible keep the cables to the ignition coils as short as possible don t place the cables to the ignition coils near signal cables for example the cables to the servos place the signal cable to the speed sensor and to the RC receiver in an adequate distance to the ignition coils fuse th
33. ontrol versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 36 POWER SPARK RC i xxx Shutdown criteria and display of diagnostic response DIAGNOSTICS MENU parameter condition result display 3 1 battery voltage engine splutters rican falls below warn reaching half _ 8 ceria cee threshold for maximum Bots ecelver patery minimum 5sec allowed speed battery voltage rd receiver dead falls cee e amp shutdown threshold donies engine shutdown a gy Pee NEE DAURI for minimum 3s battery voltage engine splutters 66 e falls below warn reaching half ys ee alice threshold for maximum it y minimum 5sec allowed speed battery voltage bd battery dead falls NG amp N N shutdown threshold engine shutdown gs main battery shutdown thres for minimum 5sec rS receiver signal supervision of receiver signal receiver signal out of the adjusted range for minimum 2sec engine shutdown gt The valid input values of the shutdown or warning thresholds and the receiver signal shows the table technical data last page PLEASE NOTE e After triggering a diagnostic function shutdown of engine o the display shows the failure o th
34. pective owners 2010 6 tne systeme Modifications and errors excepted page 43
35. ple engine should shut down by actuating backwards A signal range of 28 70 was determined by pressing the gas poti accelerate forward on the remote A signal range of 70 75 was determined by pressing the gas poti slow down reverse on the remote gt The upper threshold of the receiver signal supervision should be selected in a way that it is not reached unintended or by too small tolerances gt here chosen 73 KILLSWITCH GD signal value KILLSWITCH signal value signal range 25 _ signalrange tolerance 78 D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 39 POWER SPARK RC i xxx DIAGNOSTICS MENU Programming In the following example the limits 15 and 78 are selected the lower limit should be changed to the value 25 the upper limit should not be changed nr action gt select diagnostic menu gt wait until rS flashes gt actuate magnetic element display shows the actual values of the lower and upper limit here for example lo 15 hi 78 I o re Hi ICI m m m gt gt gt in the following 10 seconds the actual value of the receiver signal is displaye
36. rrect positioning and connection of cables is essential for long term error free function of the POWER SPARK The connector plugs of the sensor cable have adjustments please notice that and plug in the connector very carefully to avoid damage of pins Install the cables in zero potential state disconnect all battery packs Do not locate the cables near sharp edges or hot or moving parts so that they cannot be damaged To connect the cables use only suitable connectors Make sure that the cables have a good contact and that the conductive parts of the connector cannot be touched when connected Install the cables especially the sensor cable and the cable to the RC receiver as far as possible from the ignition coils to avoid interference To avoid short circuit or damages of components isolate non used cables with insulating band or insulating screw joints If possible install the plug in connectors at a suitable place where no splash water or other liquids like petrol or oil can reach them and keep care that they cannot detach from their place use tape or cable binders Please ask an expert if you have problems with the installation We are not responsible for consequential damages by installing and using the POWER SPARK D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modificati
37. s 12 display indicates that the values are stored Bs is 13 POWER SPARK returns to the normal operation DiI mode display of engine speed and ignition standby Tab mml 14 gt reset POWER SPARK therefore disconnect and reconnect power supply gt The next page shows the values of the default setting D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 31 POWER SPARK RC i xxx CONFIGURATION MENU default setting main menu menu parameter value I I i aa 1 om a ignition map 0 9 configuration Z ya lt Me Seve values of a it individual ignition map ipl _ Ci 1 75 i sensor angle 40 99 I limi 59900 7 engine speed limit 0 59900 ii ioniti 2 IIZ ignition energy 1 3 E receiver signal no Ial I l djo supervision no 0 99 warn threshold diagnostic _ no iI D low voltage menu l 1 no 2 9 9 receiver battery shutdown threshold low voltage P o lD Sf no 2 9 9 receiver battery warn threshold a low voltage lal la no 4 9 9 main battery shutdown threshold _ l It oe tl ease no 4 9 9 main battery D Only receiver control versions RC i x2x
38. selected for modifying 11 adjustable values of the tens flash one after another for 3 sec 0 3 12 gt wait until the desired figure flashes for example 1 gt actuate magnetic element 13 adjustable values of the unit position flash one after another for 3 sec 0 9 a wee ree pA 5 VSL USS 4 14 gt wait until the desired figure flashes for example 3 gt actuate magnetic element 15 the remaining adjustable parameters flash one after another for 3 sec N1 gt Wi gt M gt W2 gt h gt W3 16 gt actuate magnetic element to select the parameter for modifying Example the speed n2 is selected for modifying 17 adjustable values of the ten thousands flash one after another for 3sec 0 2 18 gt wait until the desired figure flashes for example 2 gt actuate magnetic element D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 24 POWER SPARK RC i xxx CONFIGURATION MENU 19 adjustable values of the thousands flash one after another for 3sec 0 9 wes eee A 6 HSL FIE Gq gt gt 20 gt wait until the desired figure flashes for example 1
39. sh one after another for 3sec Sy 8 Il 3 0 9 ia gt wait until the desired map flashes I 3 8 9 66 Sa for example map 4 E 10 gt actuate magnetic element li 11 display shows the new selected map map 4 12 display indicates that new values are stored ssw POWER SPARK returns to the normal operation 13 mode i i display of engine speed and ignition standby e Please note The pre programmed maps represent only a starting point or are derived from customer s experiences Each engine has to be adjusted specifically depending of use We apologize for any inconvenience that we cannot be responsible for consequential damages by installing the pre programmed E ignition maps D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 21 POWER SPARK RC i xxx CONFIGURATION MENU b ignition map individual A gt p configuration of one custom ignition map An individual created ignition map can be programmed with four pre ignition angle and speed pairs The value of the speed no cannot be modified it is set constantly to Orpm The creation of an individual map should result on experience with a pre programmed map Wrong adjustments can have negative effects on engine smoothness responding behavior or also on
40. spective owners pe 2010 6 tne systeme Modifications and errors excepted 21 cm 21 cm 21 cm page 9 POWER SPARK RC i xxx Connecting diagram 1 exemplary for POWER SPARK RC 1 220 e shared battery pack accu for receiver and POWER SPARK Lip accu t 2 E a K E Seg Sk S S S Ko ny RC i 220 S connector SA AAAAKARARAAAARAAS CNAPENAAAAAAAAARARARAAAANAAS NAAAAAAANAAAANAAAAAAAAAAAAARANAAAANAAAAAAAAA ER i EEE ANIA x SOR CAAA kf N N AS gt Skea oO om Y 5 SOOO sensor Sag Bo N i3 5 SN A ma lt red pink tt a mass Co nne ct io n Om FILLLLLISLLLLLLLLILLLLILALL ILLL LILLIE A to engine housing min 1 5mm engine important insulate non used cables with insulating tape gt elongate cables only with min 1 5mm cables D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 10 POWER SPARK RC i xxx Connecting diagram 2 exemplary for POWER SPARK RC 1 220 e separate battery packs for receiver and POWER SPARK mass connection Mm established between batteries POWER SPARK INN NYY YYYY YYYY YV KYYYYKYKKK NK NKKEKK NNS Samm EEEE S oe a SAA RC i 220 aw
41. the respective owners 2010 6 tne systeme Modifications and errors excepted page 3 POWER SPARK RC i xxx Quick way to success The POWER SPARK has a lot of adjustment possibilities and functions To ensure a fast assembly and initial startup please act according to the following checklist Assembly o attend safety and assembly instructions p 05 o assemble POWER SPARK p 06 o assemble magnet of speed sensor into new flywheel p 07 if own flywheel is used o assemble speed sensor to engine p 07 o perform wiring p 10 11 Programming o check mechanical position of speed sensor p 30 o possibly adjust sensor angle of speed sensor p 29 o choose ignition map p 20 Initial startup o adjust speed limit p 27 o start engine and perform a test run o possibly choose another ignition map p 20 o activate monitoring functions p 35 D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 4 POWER SPARK RC i xxx Safety and installation instructions Please read the following instructions carefully Please work carefully Do not pull on cables or cable connections Improper cable connections may result in cable fires by reason of short circuits Improper cable installations or cable connections may result in malfunction or damages to the components Co
42. until the desired figure flashes 12 for example 1 gt actuate magnetic element D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 26 POWER SPARK RC i xxx CONFIGURATION MENU 13 adjustable values of the hundreds flash one after TN another for 3sec 0 9 i gt wait until the desired figure flashes 14 for example 5 ia gt actuate magnetic element 15 for confirmation the adjusted speed is shown i i display shows the new speed limit by displaying the 16 figures of the speed one after another m for example 2 1 5 0 0 17 Display indicates that the new values are stored mo POWER SPARK returns to the normal operation 5 18 mode i i display of engine speed and ignition standby D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 27 POWER SPARK RC i xxx CONFIGURATION MENU d Ignition energy selection of ignition energy lt 2 gt The ignition energy of the POWER SPARK can be adapted to the engine The stronger the spark is the safer is the ign
43. with magnetic ignition system The POWER SPARK ignition was designed in a way that the original magneto ignition can be replaced with few modifications This installation and operating instruction describes the modifications using the example of the ZENOAH 260 PUM engine The modifications of other engines can be done in the same way deviations can result in the geometry of the flywheel the fitting of the speed sensor etc Advantages of the POWER SPARK Elimination of red primary ignition coil and flywheel with integrated magnets e smoother engine running since the unsymmetrical magnetic brake torque for generating the ignition spark is eliminated e allows the assembly of compact engines with more cylinders because the prime ignition coils are inapplicable Replacement of the original flywheel with integrated magnets e flywheel with increased inertia can be used accessories increased engine smoothness gt reduced idle speeds possible The original secondary ignition coil s are used furthermore e Instead of the red primary ignition coil the POWER SPARK is connected to the secondary ignition coil gt high voltage circuit only between secondary ignition coil and spark plug gt no high voltage at POWER SPARK e secondary ignition coil s do not have to be mounted to the engine D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of
44. xample shows exemplarily the deactivation activation of the warning threshold for monitoring the voltage of the main battery The adjustments of the other thresholds are identical nr action display l l 1 4 gt select diagnostic menu TIT 5 gt wait until bl flashes ba 6 gt actuate magnetic element o l 7 display shows actual voltage value IL for example 4 5 I l g adjustable values flash one after another for 3sec er no 0 9 Bos as To disable this diagnostic function 8a a gt actuate magnetic element wie To enable this diagnostic function Sb gt wait until the desired figure of the tens flashes sa for example 4 i gt actuate magnetic element gt wait until the desired figure of the unit position a 9 flashes for example 0 a gt actuate magnetic element a 10 display shows the new voltage values Limi here 4 0 i 11 Display indicates that the new value is stored 12 POWER SPARK returns to normal operation mode II display of engine speed and ignition standby lal lal D Only receiver control versions RC i x2x only multiple cylinders versions RC i 2xx amp RC i 4xx All trademarks are industrial property of the respective owners 2010 6 tne systeme Modifications and errors excepted page 42 POWER SPARK RC i xxx Technical data
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