Altronic VariSpark CPU-XL Operating Instructions Manual Download Page 7

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CPU-XL VariSpark IOM 07-21

Point-to-point connections of the system.

Junction Terminal ID

on Label inside

Junction/Diagnostic

Module

Cable to

Output

Module

Output Module

Harness to EZRail

Connector Pin

Cyl. Position, counting

from end away from 19-pin

connector

Rail

Designator

Rail 1 Terminal 1

Out 1 Pin A

Connector a Pin A

1 Far end of engine

Rail 1 Terminal 2

Out 1 Pin B

Connector a Pin B

Rail 1 Terminal 3

Out 1 Pin C

Connector a Pin C

Rail 1 Terminal 4

Out 1 Pin D

Connector a Pin D

Rail 1 Terminal 5

Out 1 Pin E

Connector a Pin E

Junction

Terminal ID

on Label

Cable to

Output

Module Wire

Output Module

Harness to EZRail

Connector Pin

Rail Position, counting

from end away from 19-pin

connector

Rail

Designator

Rail 2 Terminal 6

Out 1 Pin F

Connector b Pin E

Rail 2 Terminal 7

Out 1 Pin G

Connector b Pin D

Rail 2 Terminal 8

Out 1 Pin H

Connector b Pin C

Rail 2 Terminal 9

Out 1 Pin J

Connector b Pin B

Rail 2 Terminal 10

Out 1 Pin K

Connector b Pin A

1 Far end of engine

Junction

Terminal ID

on Label

Cable to

Output

Module Wire

Output Module

Harness to EZRail

Connector Pin

Rail Position, counting

from end away from 19-pin

connector

Rail

Designator

Rail 4 Terminal 1

Out 2 Pin K

Connector b Pin A

1 Far end of engine

Rail 4 Terminal 2

Out 2 Pin J

Connector b Pin B

Rail 4 Terminal 3

Out 2 Pin H

Connector b Pin C

Rail 4 Terminal 4

Out 2 Pin G

Connector b Pin D

Rail 4 Terminal 5

Out 2 Pin F

Connector b Pin E

Junction

Terminal ID

on Label

Cable to

Output

Module Wire

Output Module

Harness to EZRail

Connector Pin

Rail Position, counting

from end away from 19-pin

connector

Rail

Designator

Rail 3 Terminal 6

Out 2 Pin E

Connector a Pin E

Rail 3 Terminal 7

Out 2 Pin D

Connector a Pin D

Rail 3 Terminal 8

Out 2 Pin C

Connector a Pin C

Rail 3 Terminal 9

Out 2 Pin B

Connector a Pin B

Rail 3 Terminal 10

Out 2 Pin A

Connector a Pin A

1 Far end of engine

(1)

(2)

(3)

(4)

Summary of Contents for VariSpark CPU-XL

Page 1: ...Operating Instructions CPU XL VariSpark Digital Ignition System with Enhanced Display Form CPU XL VariSpark IOM 07 21...

Page 2: ...dule replaces the traditional on engine junction box and serves several purposes The Junction Diagnostic Module wiring is used to determine which cylinder is fired for each output event of the Logic D...

Page 3: ...Figure 4 for physical dimension details Select a mounting location meeting the following requirements n Within 20 ft 6m of the Output Modules n The front panel door of the Junction Diagnostic Module...

Page 4: ...source is recommended 10 3 Power wiring and signal wiring must be in separate conduits and conduit entries into the Logic Display Module to avoid undesired electrical interaction All conduit entries...

Page 5: ...om all other terminals refer to Figures 11 and 15 D MISC INPUT terminal 11 Provides for control of various user selected features This input is normally open connect to engine ground to activate the s...

Page 6: ...be identified Each rail connects to one connector of an Output Module using the harness provided 12 6 The Junction Diagnostic Module wiring is is used to determine which cylinder is fired for each ou...

Page 7: ...Terminal 8 Out 1 Pin H Connector b Pin C 3 Rail 2 Terminal 9 Out 1 Pin J Connector b Pin B 2 Rail 2 Terminal 10 Out 1 Pin K Connector b Pin A 1 Far end of engine Junction Terminal ID on Label Cable t...

Page 8: ...is no traditional primary wiring required for the use of the CPU XL ignition system All of the necessary primary wiring is supplied pre configured inside the flexible conduit harnesses and the ignitio...

Page 9: ...tains a PC based Modbus compatible monitoring program which can be used to access the ignition data remotely 17 2 Logic Display Module serves as the user interface for the CPU XL VariSpark ignition sy...

Page 10: ...ed while the ignition system verifies signals from the engine pickups After the ignition system has synchronized with the engine the system displays TRYING This message means that the system has begun...

Page 11: ...c Display Module will display the WARNING message The various types of diagnostic warnings are described in section 25 6 19 7 The FAULT message will supersede all of the above home screens if a diagno...

Page 12: ...tic fault or warning exists while the ignition is in shutdown a Press DIAG message will appear on the display The Fire Confirm Out switch will change state switch opens and the other outputs will func...

Page 13: ...TURE CODE 001 1STEPDEFAULT IGNITION MODULE TYPE P A R T NUMBER NEXT LOCATION USER SPECIFIED DESCRIPTION NEXT DATE CONFIGURED 05 16 12 TIME CONFIGURED 10 07 CONFIGURED BY HD3 TERMINAL VERSION v1 00 NEX...

Page 14: ...FIED COMMENTS NEXT PRESS NEXT TO RETURN TO HOME SCREEN NEXT PRESS ESC FROM ANY SCREEN TO RETURN TO HOME SCREEN ESC NOTE Because EEPROMS can be reconfigured using a PC and Altronic s configuration soft...

Page 15: ...NSED L REPRESENTS A DESIGNATOR FOR CPU XL VARISPARK VERSION 1 C REPRESENTS THE CURRENT LOOP RETARD CURVE TYPE A 0 AT 4MA 48 AT 20MA B 0 AT 4MA 36 AT 20MA C 0 AT 4MA 24 AT 20MA D 0 AT 4MA 16 AT 20MA E...

Page 16: ...This adjustment can be equated to the manual timing switch of the Altronic CPU XL VariSpark system Adjustments made as described below will be in effect until another adjustment is made 20 2 To adjust...

Page 17: ...on the sum of several spark retard components which include manual retard current loop retard RPM retard and 1 step retard The range of total retard is limited to 255 X timing increment When the sum o...

Page 18: ...he current loop is on the current loop value is displayed xx x mA with the A capitalized When the current loop is off the value is displayed xx x ma with the lower case a AT NOTE DISPLAY SHOWS CURRENT...

Page 19: ...e default configuration selects 1 step retard to be controlled by the Misc Input terminal The additional retard would be implemented when the input is grounded The third screen below is displayed when...

Page 20: ...ies the primary output to be adjusted and the degrees of offset in use for the output THEN AT NOTE 0 0 degrees advance for output A TO ADJUST TO SELECT TO SELECT INDIVIDUALCYL NEXT PREVIOUS TIMING CYL...

Page 21: ...mode menu which can be entered as described below FROM PRESS TIMING THEN AT PRESS THEN AT PRESS 23 2 The first function is used to save the current temporary individual offsets to EEPROM memory When t...

Page 22: ...OPTION SCREEN PRESS TO PRESS PRESS TO RESET FOR NEXT EXIT OFFSETS OPTION ENTER NEXT ESC 23 4 The next screen allows all temporary cylinder timing to be reloaded from the EEPROM PRESS TO PRESS TO RETUR...

Page 23: ...maximum of 1275 rpm AT TO TO FOR TO INCREASE DECREASE NEXT EXIT OPTION NEXT ESC 24 3 The next setup screen is used to specify the exact position of the reset pin Both the reset position and the engine...

Page 24: ...OTECTION can be password protected The password PROTECTION LOCK is enabled under the programming options from the PC terminal program See the Programming Instructions form CPU XL VariSpark PI for deta...

Page 25: ...indicates that the ignition is firing and permits the operator to select the output to be fired AT PRESS TO PRESS TO PRESS TO SELECT SELECT EXIT PREVIOUS THE NEXT OUTPUT OUTPUT ESC Test Mode selection...

Page 26: ...following baud rates 9600 19200 38400 57600 115200 Always no parity 8 data bits and 1 stop bit N81 The USB port has the following modes TERMINAL MODBUS RTU and DEBUG The TERMINAL mode is for future us...

Page 27: ...otation number The second log set contains 512 snapshots of the system configuration and the average ignition values This log set is accessed with an index of 0 511 with 0 being the most recent snapsh...

Page 28: ...24 11 The CYLINDER LABELS menu allows the user to associate two alphanumeric cylinder designators with the output lead on the CPU XL VariSpark AT PRESS TO PRESS TO PRESS TO ACCESS GO TO THE EXIT THEME...

Page 29: ...t Module Rails 3 and 4 correspond to the lower and upper rails of the second right Output Module This is required in order to be able to correlate cylinder diagnostic information with the actual physi...

Page 30: ...DONE ON A RUNNING ENGINE SEE BELOW AT ENTER ESC PRESS TO CONTINUE PRESS TO RETURN TO PREVIOUS SCREEN The system has the ability to attempt to automatically detect and or verify the connections while...

Page 31: ...p up the message OR The system can also automatically detect the fire order FROM PRESS PRESS TO CONTINUE It will then detect and verify the fire order If the detection fails it will display the follow...

Page 32: ...unit will turn on n Home status will read FAULT and the bottom line will read PRESS DIAG n LCD backlight turns red 25 2 A diagnostic warning represents the least severe classification of problems The...

Page 33: ...4 When a fault or warning is present the operator can display the actual cause of the diagnostic as depicted below FROM THE PRESS HOME SCREEN DIAG Then from the diagnostic description screens use the...

Page 34: ...the EEPROM memory must be replaced When the programming stored in the Ignition processor is corrupted This indicates that the Ignition processor must be replaced When the voltage supplied to the left...

Page 35: ...s active only if the current loop retard is on This screen indicates that the firing pattern configuration data saved in EEPROM memory is incorrect or incomplete The EEPROM memory must be reprogrammed...

Page 36: ...nders 1R 2R and 4R This can be caused by a shorted spark plug faulty coil or opened spark plug lead This screen indicates that diagnostics have detected a condition where the output of the master coil...

Page 37: ...ent loop spark number control has deviated outside the limits of 2mA and 22mA The current loop follows the configured curve which is specified from 4 20mA This diagnostic is active only if the 4 20mA...

Page 38: ...nd 3 25 7 After all of the diagnostics have been read the user can reset the warnings and faults by pressing the reset key from the HOME SCREEN as pictured below PRESS OR PRESS THEN TO EXIT TO GO TO P...

Page 39: ...figuration and operation 26 2 Analog Data screen FROM PRESS THEN OR ThisscreendisplaystheactualvoltagevaluesreadfromtheJunction Diagnostic Moduleaswell asthecurrent loopsinboth theRPMretardcurrentloop...

Page 40: ...er and software version The first screen shows the information for the display unit PRESS TO GO TO PRESS TO GO TO ATTACHEDMODULES HOME SCREEN SCREEN 26 5 Attached Modules screen This screen displays t...

Page 41: ...rcuits in the primary and secondary wiring can also be detected 27 2 The reference cylinder spark data number can be viewed separately for each ignition output cylinder in two ways and compared to the...

Page 42: ...ISTS TOTOGGLEBETWEEN TO RESET THE DIAGNOSTICOFFSETFORTHEMASTERAND DIAGNOSTIC SLAVECOIL OTHERWISE ADVANCETONEXT OFFSET FOR THE CYLINDER IN FIRING ORDER F4 COIL TO ZERO RESET 27 4 All thresholds are use...

Page 43: ...flags the reference numbers can also be used for predictive purposes A As the numbers increase toward the preset HI SPARK VOLTAGE threshold the operator knows that a change of spark plugs should be s...

Page 44: ...cylinder will occur This test will identify a low voltage demand condition which may result from a shorted coil secondary lead or spark plug To disable diagnostic set value to zero PRESS TOVIEW PRESS...

Page 45: ...demand Default 15 28 5 If the difference between CAVG and EAVG reference numbers is greater than the HI FROM ENGINE threshold a diagnostic warning for that cylinder will occur This test will identify...

Page 46: ...relation to the EAVG engine average PRESS TO TOGGLE PRESS TO BETWEEN OUTPUT INCREASE LEAD AND CYLINDER DECREASE LABEL THE ZOOM PRESS TO INCREMENT PRESS TO ACCESS THE THE COIL BEING CURRENT SELECTED VI...

Page 47: ...S TO GO TO PRESS TO ADVANCE TO PREVIOUS CYLINDER THE NEXT CYLINDER SETUP NEXT PRESS TO ACCESS THE PRESS TO VIEW THE GRAPH IN SECTION 29 2 CURRENT SELECTED CYLINDER F3 F1 PRESS TO ADJUST THE PRESS TO A...

Page 48: ...ED CURRENTSELECTED CYLINDERSPARKOFFSET CYLINDERTIMING OFFSET PRESSTOCLEARERROR PRESS TO EXIT COUNTS PRESS TO CHANGE THE LAYOUT OF THE GRAPH 29 5 In addition to short and long term spark demand graphs...

Page 49: ...nutes Pressing ENTER will toggle the arrows in the upper left hand corner of the graph and change the role of the up and down arrow keys n When the arrows are left right using the up down arrow keys w...

Page 50: ...eft hand corner of the graph and change the role of the up and down arrow keys n When the arrows are left right using the up down arrow keys will shift the time period being displayed to view data ear...

Page 51: ...he backup and program functions the configuration of one component can be backed up and restored from the other in the event that one becomes corrupted FROM PRESS AUTO PRESS TO PRESS TO PRESS TO SELEC...

Page 52: ...hase of the backup is to read the ignition eeprom contents PRESS TO ABORT ESC The second phase is to read the ignition again for verification PRESS TO ABORT ESC After reading and verifying the content...

Page 53: ...or via USB from a computer without a RS 485 card Refer to programming instructions CPU XL VariSpark PI The user must first confirm the program option FROM PRESS AUTO THEN THEN ENTER PRESS TO PRESS TO...

Page 54: ...C LLC 2021 54 The Logic Display Module now writes the eeprom contents of the CPU XL VariSpark ignition Next the Logic Display Module will read back what was written for verification With verification...

Page 55: ...sing the backup and program functions the configuration of one component can be backed up and restored from the other in the event that one becomes corrupted FROM PRESS NEXT THEN ENTER The Logic Displ...

Page 56: ...complete the ignition will be reset Done PRESS TO EXIT ESC 30 4 Restoring the CPU XL Configuration from the ignition image FROM PRESS NEXT THEN UP THEN ENTER NOTE After the CPU XL ignition image has b...

Page 57: ...IC LLC 2021 57 The Logic Display Module will read the configuration from the ignition EEPROM Next theLogic DisplayModulewillreadbackwhatwaswrittentoverifythatitiscorrect With verification complete the...

Page 58: ...D style spark discharges This profile optimizes the advantages of a multi strike approach as it maintains the desired peak pressure angle after top dead center TDC Doing so ensures optimum engine perf...

Page 59: ...cs of the spark profile shown in section 31 5 but with lower applied energy 31 7 SPARK 7 A multi strike profile incorporating three 3 independent spark discharges with each featuring longer duration a...

Page 60: ...isc Input is activated connected to ground The selectable range for Misc in Spk Number is 0 8 When set to zero this feature is disabled and will not override the active spark number TOADJUST TOADVANCE...

Page 61: ...BER selection will be de asserted The Enable and Disable thresholds create a hysteresis pair to add stability to the HI EAVG SPARK request function TOADJUST TOADVANCE TOGOBACK THEVALUE TOTHENEXT TOTHE...

Page 62: ...NUMBER selection will be disabled The coil with the highest COV is compared against this threshold The Enable and Disable thresholds create a hysteresis pair to add stability to the HI COV SPARK reque...

Page 63: ...the 4 20mA signal is within the limit range of 2 22mA If the current is outside of the range a warning is asserted TOADJUST TOADVANCE TOGOBACK THEVALUE TOTHENEXT TOTHE MENU HOME SCREEN ESC 4 20mA Cur...

Page 64: ...04 Alarm LED REG10005 2K ROM MAP ENABLED REG10006 SKIP CONTROL internal REG10007 CMDPAGE2 internal REG10008 TWO CYCLE REG10009 IGN SHUTDOWN FLAG REG10010 IGN WARNING FLAG REG10011 IGN FAULT FLAG REG10...

Page 65: ...1M REG10102 HIGH FROM ENGINE AVG 1M REG10103 LOW FROM ENGINE AVG 1M REG10104 HIGH COV 1M REG10105 PRIMARY OPEN 1S REG10106 Spare 1S REG10107 LOW VOLTAGE 1S Register Label REG10108 HIGH VOLTAGE 1S REG...

Page 66: ...AVG 9M REG10232 HIGH COV 9M REG10233 NO PRIMARY CURRENT 9S REG10234 spare 9S REG10235 LOW VOLTAGE 9S REG10236 HIGH VOLTAGE 9S Register Label REG10151 LOW FROM ENGINE AVG 4M REG10152 HIGH COV 4M REG101...

Page 67: ...275 LOW VOLTAGE 12M REG10276 HIGH VOLTAGE 12M REG10277 NO SECONDARY SPARK 12M REG10278 HIGH FROM ENGINE AVG 12M REG10279 LOW FROM ENGINE AVG 12M Register Label REG10280 HIGH COV 12M REG10281 NO PRIMAR...

Page 68: ...IGH VOLTAGE 20M REG10405 NO SECONDARY SPARK 20M REG10406 HIGH FROM ENGINE AVG 20M REG10407 LOW FROM ENGINE AVG 20M REG10408 HIGH COV 20M Register Label REG10323 LOW VOLTAGE 15M REG10324 HIGH VOLTAGE 1...

Page 69: ...MARY OPEN ACK D Register Label REG10458 spare ACK D REG10459 LOW VOLTAGE ACK D REG10460 HIGH VOLTAGE ACK D REG10461 NO SECONDARY SPARK ACK D REG10462 HIGH FROM ENGINE AVG ACK D REG10463 LOW FROM ENGIN...

Page 70: ...RETARD SETTING deg 10 REG30029 ANALOG RETARD FROM TBL deg 10 REG30030 RPM RETARD FROM TBL deg 10 REG30031 SERIAL RETARD deg 10 REG30032 REF ANGLE OF RESET PIN deg 10 REG30033 MAX INDIVIDUAL OFFSET de...

Page 71: ...9M REG30072 COIL AVG 19S REG30073 COIL AVG 20M REG30074 COIL AVG 20S REG30075 COV 1M REG30076 COV 1S REG30077 COV 2M REG30078 COV 2S REG30079 COV 3M REG30080 COV 3S Register Label REG30081 COV 4M REG3...

Page 72: ...SEEN COIL 6M REG30206 MAXIMUM SEEN COIL 6S REG30207 MAXIMUM SEEN COIL 7M REG30208 MAXIMUM SEEN COIL 7S REG30209 MAXIMUM SEEN COIL 8M REG30210 MAXIMUM SEEN COIL 8S Register Label REG30125 FIRE DELAY C...

Page 73: ...4 InStat 049 064 REG30245 InStat 065 080 REG30246 InStat 081 096 REG30247 InStat 097 112 REG30248 InStat 113 128 REG30249 InStat 129 144 REG30250 InStat 145 160 REG30251 InStat 161 176 REG30252 InStat...

Page 74: ...G30375 Label87 REG30376 Label88 REG30377 Label89 REG30378 Label90 REG30379 Label91 REG30380 Label92 REG30381 Label93 REG30382 Label94 Register Label REG30297 Label09 REG30298 Label10 REG30299 Label11...

Page 75: ...ry 10001 10008 etc A single Boolean read from registers 00001 to 00064 can be made which will return all 64 values as a group of 8 bytes These registers also support an Altronic custom function 101 wh...

Page 76: ...L 6 INDEP 0 REG00047 CYL 7 INDEP 0 REG00048 CYL 8 INDEP 0 REG00049 CYL 9 INDEP 0 REG00050 CYL 10 INDEP 0 REG00051 CYL 11 INDEP 0 REG00052 CYL 12 INDEP 0 REG00053 CYL 13 INDEP 0 REG00054 CYL 14 INDEP 0...

Page 77: ...0 65535 0 REG40010 CYL TIM OFF 7 deg 10 0 65535 0 REG40011 CYL TIM OFF 8 deg 10 0 65535 0 REG40012 CYL TIM OFF 9 deg 10 0 65535 0 REG40013 CYL TIM OFF 10 deg 10 0 65535 0 REG40014 CYL TIM OFF 11 deg...

Page 78: ...REG40059 COIL DIAG OFF 6M deg 10 0 30 15 REG40060 COIL DIAG OFF 6S deg 10 0 30 15 REG40061 COIL DIAG OFF 7M deg 10 0 30 15 REG40062 COIL DIAG OFF 7S deg 10 0 30 15 REG40063 COIL DIAG OFF 8M deg 10 0 3...

Page 79: ...REG40102 CYL LABEL 14 0 65535 14162 REG40103 CYL LABEL 15 0 65535 14412 REG40104 CYL LABEL 16 0 65535 14418 REG40105 CYL LABEL 17 0 65535 14668 REG40106 CYL LABEL 18 0 65535 14674 REG40107 CYL LABEL...

Page 80: ...REG40145 Spk Select Cal low volt 0 65535 0 REG40146 Spk Select Cal hi AD 0 65535 16368 REG40147 Spk Select Cal hi volt 0 65535 250 REG40148 Low Output Module Thresh 100 0 65535 1500 REG40149 Hi Output...

Page 81: ...unction code received in the query is not an allowable action for the slave 02 ILLEGAL DATA ADDRESS The data address received in the query is not an allowable address for the slave This may also occur...

Page 82: ...RE 4 CPU XL VARISPARK JUNCTION DIAGNOSTIC MODULE MOUNTING DIMENSIONS FIGURE 5 PICKUP MOUNTING DETAIL FIGURE 6 FLYWHEEL HOLE DRILLING FIGURE 7 MAGNET ASSEMBLY FIGURE 8 MAGNET ASSEMBLY FIGURE 9 MAGNET A...

Page 83: ...D E F G H J K A B C D E E D C B A K J H G F E D C B A V10 60 1R 2 274 2R 8 204 3R 6 X X X X X 132 4R 4 348 5R 10 A B C D E E D C B A 1L 2L 3L 4L 5L 1R 2R 3R 4R 5R A B C D E E D C B A Rail 1 Rail 2 Rai...

Page 85: ...6 24 7 73 6 25 4 45 FIGURE 3 CPU XL VARISPARK OUTPUT MODULE MOUNTING DIMENSIONS FIGURE 4 CPU XL VARISPARK JUNCTION DIAGNOSTIC MODULE MOUNTING DIMENSIONS 17 PIN INPUT 19 PIN FROM JUNCTION DIAGNOSTIC M...

Page 97: ...l rights reserved ALTRONIC LLC 2021 97 FIGURE 16 DC POWER HOOKUP POWER SUPPLY REGULATOR ALTERNATOR BATTERY BATTERY D C POWER SOURCE POWER SUPPLY SPEC SEE CHART BELOW B A 20 AMP FUSE RATING 20 AMP MIN...

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