ALTRONIC CPU-2000 OPERATING INSTRUCTIONS

IGNITION SYSTEM FORM CPU-2000 OI 8-02

WARNING: DEVIATION FROM THESE INSTALLATION INSTRUCTIONS MAY LEAD TO

IMPROPER ENGINE OPERATION WHICH COULD CAUSE PERSONAL INJURY TO
OPERATORS OR OTHER NEARBY PERSONNEL.

NOTE: THESE INSTRUCTIONS COVER FIRMWARE VERSIONS 2.0 AND 2.1.

1.0 OVERVIEW

1.1 The Altronic CPU-2000 Digital Ignition system has been designed for application on large,
natural gas fueled engines and integral compressors. This system is field-programmable and
offers a variety of advanced control, emissions reduction, diagnostic, monitoring and engine
protection features. The system consists of two main parts: a user interface Logic Module
and an engine mounted Output Module.

1.2 This document provides instructions and descriptions to be used in the operation of the
ignition system, and does not cover physical installation. Reference form CPU-2000 II for
instructions regarding installation and mounting.

WARNING: THE IGNITION SYSTEM MUST BE CONFIGURED PRIOR TO USE ON AN ENGINE.

REFER TO SECTION 9.7 TO VIEW THE CURRENT CONFIGURATION.

THESE INSTRUCTIONS COVER FIRMWARE VERSIONS 2.0 AND 2.1. REFERENCE FORM

CPU-2000 PI FOR INSTRUCTIONS DESCRIBING HOW TO CONFIGURE THE IGNITION

SYSTEM. VERIFY EEPROM PROGRAMMING PRIOR TO STARTING ENGINE.

2.0 THE LOGIC MODULE USER INTERFACE

2.1 An alphanumeric 16-character x 2-line back-lit LCD display is used to provide output to the
user. A sealed membrane keypad is used to accept user input. The LCD display and the key­
pad function together to provide an interactive user interface which prompts the user as
different functions are selected.

2.2 Two LED indicators are also provided on the front panel. The Power (green) LED is
illuminated when the logic module is powered and operating. The Alarm (yellow) LED is
illuminated when a fault or ignition warning, or a diagnostic warning is present. The Alarm
LED flashes when an alarm condition has been acknowledged.

2.3 Inside the Logic Module, three additional red LED’s are provided for troubleshooting.

-1­
3.0 DESCRIPTION OF OUTPUT SWITCHES

3.1 Three output switches provide a means of communicating the current ignition status to other
systems. These switches have isolated outputs and share one common return path which
is not referenced to engine or power ground. They will be in the open condition when the unit
is unpowered. A typical application would be as a relay or solenoid coil driver.
- The FIRE-CONFIRM OUT switch is closed to signal that the ignition is running with no
faults or ignition warnings. Warnings identified by the Diagnostic Module do not effect this
output. Note: Switch is not opened for warnings with firmware version 2.1.
- The SHUTDOWN OUT switch is closed to signal that the ignition has detected no faults
which would result in a self shutdown. Upon detecting a fault that would result in a self­
shutdown of the ignition, this switch will open.
- The ALARM OUT switch is closed to signal that no un-acknowledged faults or warnings
are present. Upon detection of a fault, ignition warning or a diagnostic warning, this switch
will open. This output is designed to control an alarm indicator or sounding device.

4.0 UNDERSTANDING THE HOME SCREEN

4.1 A series of "home" screens are used to describe the current status of the ignition system. The
LCD display always reverts back to one of the home screens after a keypad operation is
completed or times out. The home screen is designed to display the most critical operating
parameters on one screen.

4.2 All of the home screens provide a status word in the upper left corner, the engine speed (xxxx
rpm) in the upper right corner, the current loop (xx.x mA) in the lower left corner and the
global ignition timing (xx.xoBTDC or xx.xoATDC) in the lower right corner.

4.3 The READY message is displayed when the ignition is ready for the engine to crank for
starting.

READY 0rpm
15.0mA 10.0oBtdc

4.4 Once the engine begins turning, the SYNCING message is displayed while the ignition system
verifies signals from the engine pickups.

SYNCING 155rpm
15.0mA 10.0oBtdc

-2­
4.5 The FIRING message is displayed when the ignition begins firing. Additional data is provided
on this screen to describe the selected mode of operation for the ignition. The energy mode
(E1,E2,E3) and the single-strike / multi-strike type (S or M) are described in the middle of the
upper line in small characters.

FIRING E1S 300rpm

15.0mA 10.0oBtdc

4.6 The STALLED message is displayed when a loss of rotation is detected after the ignition is
firing and neither a SHUTDOWN or FAULT has occurred. This signifies that the engine has
stopped without any detected cause from the ignition system.

STALLED 0rpm
15.0mA 10.0oBtdc

4.7 The WARNING message will supersede all of the above home screens if an ignition warning
or diagnostic warning condition is present. When any warning exists, a VIEW DIAGNOSTICS
message will flash on the bottom line of the display. The ignition system will continue to
operate under a warning condition, while alerting the operator of a potential problem in several
ways: by turning on the front panel Alarm LED, by changing the state of the Alarm Out switch
(switch opens), and by displaying the Warning message. Note: Firmware version 2.0 and
earlier also will open the Fire Confirm Out switch for ignition warnings. The various types of
diagnostic warnings are described in section 10.0.

WARNING E1S 300rpm WARNING E1S 300rpm

15.0mA 10.0oBtdc VIEW DIAGNOSTICS

4.8 The FAULT message will supersede all of the above home screens if a diagnostic fault
condition is present. When a diagnostic fault exists, a VIEW DIAGNOSTICS message will
flash on the bottom line of the display. The ignition system will stop operating under a fault
condition, and will alert the operator to the problem in five ways: by turning on the front panel
Alarm LED, by changing the state of the Fire Confirm Out switch (switch opens), by changing
the state of the Alarm Out switch (switch opens), by changing the state of the Shutdown Out
switch (switch opens), and by displaying the Fault message. The various types of diagnostic
faults are described in section 10.0.

FAULT 0rpm FAULT 0rpm

VIEW DIAGNOSTICS 15.0mA 10.0oBtdc

-3­
4.9 The SHUTDOWN screen will supersede all other home displays if the shutdown input is
grounded or if the shutdown input was grounded and the engine has not stopped rotating.
This screen indicates that the ignition is not firing because the shutdown input was activated
to shutdown the engine. The Fire Confirm Out switch will change state (switch opens) and
the other outputs will function as described above based on the existence of faults or
warnings. If a fault or warning exists while the ignition is in shutdown, a VIEW DIAGNOSTICS
messag e will flash on the bottom line of the display.

SHUTDOWN 0rpm SHUTDOWN 0rpm

VIEW DIAGNOSTICS 15.0mA 10.0oBtdc

5.0 ADJUSTING GLOBAL RETARD

5.1 Global retard is an adjustment affecting the timing of all cylinders equally. This adjustment
can be equated to the manual timing switch of the Altronic II-CPU system. Adjustments
made as described below will be in effect until another adjustment is made.

5.2 To adjust global retard:

from press
FIRING E1S 300rpm TIMING
15.0mA 10.0·Btdc

then at press
Q=GLOBAL(ENGINE)
!=CYLINDER(INDV) [ Q
then at press
Q= ADJUST RETARD
!= SELECT MODE [ Q
then at NOTE: Display also includes re sultant timing.
MANUAL RET 10.5·
Q! Esc 12.0·Btdc

press press press

to
increase [ Q to
decrease [ ! to e xit
ESC

5.3 The increment of timing change is dependent on the number of holes or teeth being sensed.
The minimum timing change is equal to "90/N" where N = no. of holes or teeth. EXAMPLE:
For 360 holes, the minimum timing change increment is 90/360 = 0.25 degrees.

-4­
6.0 SELECTION OF GLOBAL TIMING MODES

6.1 Several options exist with regard to global timing modes. Once the global timing mode menu
is entered as described below, the status of each option can be viewed and changed.

from press
FIRING E1S 300rpm TIMING
15.0mA 10.0·Btdc

then at press
Q=GLOBAL(ENGINE)
!=CYLINDER(INDV) [ Q
then at press
Q= ADJUST RETARD
!= SELECT MODE [ !
6.2 The first mode selection can enable or disable the pre-configured retard curve controlled by
the 4-20 mA current loop input. The choices are ON and OFF, with the active selection
displayed in capital letters. To configure the 4-20 mA curve, reference form CPU-2000 PI.
When the current loop is on, the home screen displays the current loop value (xx.x mA).
When the current loop is off, the display reads (xx.x ma).

at NOTE: Display shows Current loop ON.

CURRENT LOOP RET
QON/off!Next Esc

press press press press

to turn on

[ Q to turn off
[ ! for next
option
NEXT
to e xit
ESC

6.3 The Next mode selection can enable or disable the pre-configured retard curve controlled
internally by engine RPM. To configure the RPM retard curve, reference form CPU-2000 PI.

at the next NOTE: Display shows RPM Map OFF.

option screen RPM RETARD MAP
Qon/OFF!Next Esc

press press press press

to turn on
[ Q to turn off
[ ! for next
option
NEXT
to e xit
ESC

-5­
6.4 The Next mode selection can enable or disable the additional retard value controlled by the
serial port. To use this option reference form CPU-2000 PI.

at the next NOTE: Display shows Serial retard OFF.

option screen SERIAL/DSM RET
Qon/OFF!Next Esc

press press press press

to turn on

[ Q to turn off
[ ! for next
option
NEXT
to e xit
ESC

6.5 The Next mode selection can increase or decrease the one-step retard value. The first
screen below is displayed when 1 step retard is both configured and is active. The second
screen below is displayed when the 1 step retard is configured but not active. The default
configuration selects one 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 the one-step retard feature is not configured. The actual engine timing is
displayed on this screen so the effect of 1 step retard can be seen during adjustments (if the
Misc Input terminal is grounded).

at the next NOTE: 1 Step Retard is active.

option screen 1 STEP RET 10.0·
Q!Esc 0.0·Btdc

or NOTE: 1 Step Retard not active.

1 step ret 10.0·
Q!Esc 10.0·Btdc

or NOTE: 1 Step Retard not configured.

ONE-STEP FEATURE
NOT PRESENT Next

press press press to press

to
increase [ Q to
decrease [ ! go back
to first
option
NEXT
to e xit
ESC

-6­
7.0 ADJUSTING INDIVIDUAL OFFSETS

7.1 The timing of individual cylinders can be offset by up to 3 degrees of advance or retard.
Adjustments made as described below should be considered temporary. The ignition will
revert back to the values saved in EEPROM memory on every start or power-up. To save
temporary adjustments to EEPROM memory see section 8.0.

7.2 Enter the individual timing adjustment menu as described below.

from press
FIRING E1S 300rpm TIMING
15.0mA 10.0·Btdc

then at press
Q=GLOBAL(ENGINE)
!=CYLINDER(INDV) [ !
then at press
Q= ADJUST OFFSET
!= SELECT MODE [ Q
7.3 The individual timing adjustment screen identifies the primary output(s) to be adjusted, and
the degrees of offset in use for the output(s). In some cases, two outputs are controlled
together.

then at NOTE: 2.5 degrees advance for output A.

CYL A 2.5·ADV
Q! Esc Next

press press press to press

to
advance [ Q to
retard [ ! select
nex t cyl.
NEXT
to e xit
ESC

7.4 The output identification characters will be provided as follows:

A B C D for Output Module 291116-1 with 1 output per cylinder.

A,B C,D E,F G,H for Output Module 291116-1 with 2 outputs per cylinder.

A1 A2 B1 B2 for Output Module 291132-1 with 1 output per cylinder.

A12 B12 C12 D12 for Output Module 291132-1 with 2 outputs per cylinder.

A12 B12 C12 D12 for Output Module 291132-2 with 2 outputs per cylinder.

-7­
8.0 INDIVIDUAL CYLINDER OFFSET MODES

8.1 Two additional functions with regard to individual cylinder timing offsets are provided. These
functions can be accessed from the individual timing mode menu which can be entered as
described below.

from press
FIRING E1S 300rpm TIMING
15.0mA 10.0·Btdc

then at press
Q=GLOBAL(ENGINE)
!=CYLINDER(INDV) [ !
then at press
Q= ADJUST RETARD
!= SELECT MODE [ !
8.2 The first function can be used to save the current (temporary) individual offsets to EEPROM
memory. When this is done, the ignition will load these new offset settings every time the
engine starts.

at the first
option screen SAVE CYL OFFSETS
[ENTER OR NEXT

press press press

to save for next to e xit
offs ets
ENTER
option
NEXT ESC

8.3 The NEXT mode function can be used to reset all cylinder timing offset values back to zero
(both temporary memory and EEPROM memory).

at the second
option screen RESET OFFSETS =0
[ENTER OR NEXT

press press press

to reset for first to e xit
offs ets
ENTER
option
NEXT ESC

-8­
9.0 SETUP CONTROL OPTIONS

9.1 Additional control settings and display features can be accessed under the setup menu.
Changes made under the Setup menu are stored in EEPROM and remain fixed until changed
again. The Setup menu can be entered as described below.

from press
FIRING E1S 300rpm SETUP
15.0mA 10.0·Btdc

9.2 The first setup screen permits the operator to enable or disable the Multi-Strike feature.
Note 1: One of two special features can be selected during configuration to force Multi-
Strike to be active below 200 rpm, or when the Misc Input is grounded. This
feature is not active in a standard configuration.
Note 2: The Multi-Strike feature is automatically turned off above 500 rpm.
(750 rpm for firmware version 2.1)
Note 3: The use of Multi-Strike firings may tend to accelerate spark plug electrode erosion.

at
MULTI STRIKE
Qon/OFF!Next Esc

press press press press

to turn on
m ulti [ Q to turn off
m ulti [ ! for next
option
NEXT
to e xit
ESC

-9­
9.3 The next setup screen permits the operator to select from one of three ignition energy levels
(E1,E2,E3). The energy levels are 125 millijoules (E1), 150 millijoules (E2), 185 millijoules
(E3).
Note 1: One of two special features can be selected during config uration to use the
maximum energy level below 200 rpm, or when the Misc Input is grounded. This
feature is not active in a standard configuration.
Note 2: The energy is automatically limited to E2 when Multi-Strike is active.
Note 3: The use of higher spark energy may tend to accelerate spark plug electrode
erosion.
Note 4: Energy control features available with the optional Diagnostic Module may be
configured to automatically select the energy level (to a level different than selected
here) based on secondary spark data.

at Note: Energy level E1 is displayed

OUTPUT ENERGY
Q!Esc E1/e2/e3

press press press press

to

increase [ Q to
decrease [ ! for next
option
NEXT
to e xit
ESC

9.4 The next setup screen is used to adjust the engine overspeed setpoint. The setpoint can be
adjusted in increments of 5 rpm to a maximum of 1275 rpm.

at
ADJUST OVERSPEED
Q![Esc 1000 RPM

press press press press

to
increase [ Q to
decrease [ ! for next
option
NEXT
to e xit
ESC

-10­
9.5 The next setup screen is used to specify the exact position of the reset pin. Both the reset
position and the engine timing are displayed. Adjustments are made here to make the
displayed timing match the actual spark timing as verified with a timing light. This adjustment
effects the displayed timing but does NOT change the actual timing of the firings.
NOTE: Adjustment of this parameter should be done while individual cylinder offsets are
all at zero.

at
RESET PIN> 30.5·
Q!Esc 10.5·Btdc

press press press press

to
increase [ Q to
decrease [ ! for next
option
NEXT
to e xit
ESC

9.6 The next setup screen is used to enable or disable VALUE PROTECTION of all user values
in the EEPROM memory. When protection is on, none of the EEPROM settings under the
Setup or Timing menus can be changed. This feature can be used to provide limited
protection from random changes by inexperienced operators.

at
VALUE PROTECTION
Qon/OFF!Next Esc

press press press press

to turn on
protection [ Q to turn off
protection [ ! for next
option
NEXT
to e xit
ESC

9.7 The next setup screen can be used to view the configuration comments which describe the
configuration of the ignition system. There are a total of 8 screens which can be rotated to
the display using the NEXT key.
NOTE: Because EEPROMS can be reconfigured (using a PC and Altronic's configuration
software), these comments should be viewed to identify and verify the configuration
settings of the ignition prior to operation. Refer to form CPU-2000 PI for further
information on configuration.

at
VIEW IGN. CONFIG
Next Esc Enter

press press press

to view to go to to e xit
co nf ig
ENTER
next
NEXT ESC
option
The configuration screens are shown starting on the next page.

-11­
The following types of screens can be viewed by pressing enter to start and next to advance.

-Firing pattern code: (F2A360.HC100)

-Special Feature code: (#00 1) (1step defa ult) F2A360.HS100#001 NEXT
-Engine Type: (2c yc) (6c yl)
-Output Module Type: (16o ut)
2cyc. 6cyl.16out

-Date Configured: (01-01-95)

-Time Configured: (001) 01-01-95 12:00 NEXT
-Configured By: (User Name)
By:Joe Lepley

-Current loop Curve Description

at 4 mA 0o retard LOOP RETARD: 24 NEXT
at 20 mA 24o retard
User specified description
4/20ma 0/24ret

-RPM Retard Curve Description

retard 10o below 100 rpm RPM RETARD: YES NEXT
ramp to 0o at 200 rpm
User specified description
Ramp10/0 100/200

-Location:

User specified description

LOCATION: ALT. NEXT
GIRARD OHIO USA

-Engine Num ber or Description

User specified description ENGINE#: TLA6 NEXT
Number 4 USA-GAS

-Special user comm ents area #1

Use r spe cified c om m ents USER NEXT
COMMENTS #1

-Special user comm ents area #2

Use r spe cified c om m ents USER NEXT
COMMENTS #2

-Rotation continues again through the 8

configuration comment screens. F2A360.HS100#001 NEXT
ESC. To exit to home screen.
2cyc. 6cyl.16out

-12­
MEMORY PART NO. CODE: Example: F2A360.HS012#005

DESIGNATOR DESCRIPTION
F Letter in alphabet corresponding to no. of engine cylinders:
C=3, D=4, E=5, F=6, G=7, H=8, I=9, J=10, L=12, N=14, P=16,
R=18, T=20, X=24, Z=32
2 Engine stroke-cycle:
2 = 2-cycle
4 = 4-c ycle
6 = 2-cycle with two outputs for each cylinder/2nd plug cutout feature
8 = 4-cycle with two outputs for each cylinder/2nd plug cutout feature
A Altronic firing pattern code:
A = even firing pattern, Other letters = odd firing pattern
360 No. of sensed teeth or holes:
360 = 360 ho les or teeth
H Mem ory series code:
H = CPU-2000
S Timing curve code:
A = 48 degree retard for 4-20 mA input, 3 degrees retard default timing
B = 36 degree retard for 4-20 mA input, 3 degrees retard default timing
C = 24 degree retard for 4-20 mA input, 3 degrees retard default timing
N = special range vs. 4-20 mA or RPM, non-factory programmed
S = special range vs. 4-20 mA or RPM, factory programm ed
X = no timing curve programm ed
012 Special timing curve version no. (only for types N and S)
Note: Th is num ber m ust be selected an d docum ented by the originator.
#005 Feature co de (add nu m bers cho sen; only one choice perm itted per feature):
001 = 1-step retard when misc. input is grounded
016 = 1-step retard when rpm is less than 200
002 = Max. energy when misc. input is grounded
032 = Max. energy when rpm is less than 200
004 = Extended firing when misc. input is grounded
064 = Extended firing when rpm is less than 200
008 = Fire 2nd plug only when misc. input is grounded
128 = Fire 2nd plug only when rpm is less than 200
Exam ple: 005 = feature 001 + feature 004.

-13­
9.8 The CPU-2000 running firmware version 2.1 includes this screen which used to view and
select 1 of 25 communications parameter options which include the standard Intel 9-bit
programming protocol and 24 additional ModBus RTU modes. ModBus RTU configurations
include 3 parity modes (even odd, none) and 8 baud rates (300, 600, 1200, 2400, 4800, 9600,
19200, 38400). Display screens are formatted as depicted below. Firmware versions 2.0 and
earlier support only the Intel 9-BIT mode, which is used in all versions to program the system.

SERIAL PORT Q! SERIAL PORT Q!

Intel 9-BIT 9600 ModBusRTU 300e81

SERIAL PORT Q! SERIAL PORT Q!

ModBusRTU9600o81 ModBusRTU38.4n81

9.9 The Altronic CPU-2000 running firmware version 2.1 includes this screen used to view and
select the communication ID-Code or Node-ID. The keypad can be used to select the ID-
Code in the range of (0 to 255). Suitable ID-Codes for ModBus are (1 to 247), while suitable
ID-Codes for the standard Intel 9-bit communication format are (1 to 254).

CPU2000 COM PORT

IDCODE = 1 Q!

-14­
9.10 The next setup screen permits the operator to enter an ignition test mode. This test mode
can fire all outputs in rotation, or individual outputs at a slow rate. This feature can be used
to troubleshoot primary wiring and output module operation. Test mode will terminate if
rotation of the engine is sensed.

at
RUN TEST MODE
Next Esc Enter

press press press

for test for next to e xit
mode
ENTER
option
NEXT ESC

WARNING: The operator MUST fully purge the engine of combustible mixtures prior to
selecting the test mode operation. Pressing the enter key again is a
confirmation of this action.

then before
starting test IS ENGINE PURGED
mode
Esc Enter

press
press
to v er ify
to e xit
purged

ENTER ESC
mode

Then the test mode screen indicates that the ignition is firing and permits the operator to
select the output to be fired.

at
Test-Mode ALL [[
[Q ! Esc

press press press

to select
output [ Q to se lect
output [ ! to e xit
ESC

Test-Mode selection rotates as described below.

AL L,A,B ,C,D ,E,F ,G,H ,J,K,L ,M,R ,S,T ,U,A LL,A ,B,C ,D..... for Output M odule 29111 6-1

AL L,A1 ,A2,B 1,B2 ,C1 ,C2 ,D1 ,D2 ,E1,E 2,F1 ,F2,G 1,G 2..... for Output M odules 2911 32-1 and -2

-15­
9.11 The next setup screen is used to enable or disable the expanded secondary diagnostic
features available with the optional CPU-2000 Diagnostic Module.
NOTE 1: hen "OFF" is selected this will be the last setup screen.
NOTE 2: When "ON" is selected and the Diagnostic Module is not connected, an
ignition warning will be flagged.
NOTE 3: Pressing the "RESET" key from this screen will re-initialize all Diagnostic
Module settings to their default values (required upon installation).

at
DIAG MODULE ENAB
Qon/OFF!Next Esc

press press press press

to turn on

[ Q to turn off
[ ! for next
screen
NEXT
to e xit
ESC

9.12 WITH OPTIONAL DIAGNOSTIC MODULE ONLY: The next screen is used to select the
counter frequency of the optional Diagnostic Module monitor circuit. Low frequency is the
default setting which is recommended when one coil is connected to each output. The high
frequency setting can be used to obt ain more resolution in the diag nositic number when two
coils in parallel are connected to each primary output. NOTE: The secondary diagnostic
features are designed for use with Atlronic coils 291001 and 291001-S; do not use other
types of coils.

at Default is LOW
DIAG COUNT FREQ
Qhi/LO![Next Esc

press press press press

to select

hi freq [ Q to select
low freq [ ! for next
screen
NEXT
to e xit
ESC

9.13 WITH OPTIONAL DIAGNOSTIC MODULE ONLY: The next screen is used to select the
RPM at which to permit the update of the MIN/MAX historical cylinder data array. This
feature is provided to avoid the update of the MIN/MAX values when the engine is running
below normal loaded conditions.

at Default is 250 RPM

UPDATE MIN/MAX
Q! Esc > 250 RPM

press press press press

to select
hi freq [ Q to select
low freq [ ! for next
screen
NEXT
to e xit
ESC

-16­
10.0 CPU-2000 DIAGNOSTICS

10.1 A diagnostic fault respresents the most severe classification of problems. The presence of
a diagnostic fault will inhibit the ignition from firing. When a fault is detected several things
will occur:
- The ignition will stop firing
- The Shutdown Out switch will open.
- The Fire Confirm Out switch will open.
- The Alarm Out switch will open.
- The Alarm LED on the front panel will turn on.
- The home status will read FAULT, and the bottom line will flash VIEW DIAGNOSTICS.
Diagnostic FAULTS will supersede diagnostic WARNINGS.

FAULT 0rpm
VIEW DIAGNOSTICS

10.2 A warning represents the least severe classification of problems. The ignition will continue
to fire in the presence of any warning. The list of warnings is expanded to include coil
primary and secondary diagnostics when the Diagnostic Module is present. NOTE: These
additional primary and secondary warnings do not operate the Fire Confirm Out Switch.
When a warning is detected, several things will occur:
- The Alarm Out switch will open.
- The Alarm LED on the front panel will turn on.
- The Fire Confirm Out switch will open (firmware versions 2.0 and earlier only).
- The home status will read WARNING, and the bottom line will flash VIEW DIAGNOSTICS.

WARNING 300rpm
VIEW DIAGNOSTICS

10.3 If the Alarm Out switch is being used to turn on an audible alarm or flasher, the user can
acknowledge the alarm to silence the alarm. After viewing faults or warnings, the user would
then reset and re-arm the ignition system after the faults or warnings have been addressed.
press pres s to
ALARM
Reset
Ignition
Reset
ACK

Acknowledgement of alarms (ALARM ACK) causes the Alarm Out switch to return to its
closed position; the Alarm LED will flash as a visual reminder that the alarm had occurred.
Resetting the system (Reset) returns all indicated fault and warning indicators and outputs
to the normal condition, resets temporary timing offset values, and re-arms the ignition to
begin firing if faults are no longer present.

-17­
10.4 When a warning or fault is present, the operator can display the actual cause of the
diagnostic as depicted below.

F rom the hom e press

Screen FAULT 0rpm to view
DIAG
diags.
VIEW DIAGNOSTICS

Then from the diagnostic description screens use the following keys.

press or press press

to view to view to exit
next diag. DIAG next diag.
NEXT ESC

10.5 Diagnostic fault screens in order of display priority are described below.

W hen zero gear-tooth pulses are seen

between two reset pulses. GT PICK-UP FAULT
MISSING PULSES

W hen too many gear-tooth pulses are seen

without a reset pulse. RS PICK-UP FAULT
MISSING PULSES

W hen there are no Hall-effect pickup pulses

or when the pick-ups are not synchronized. HE PICK-UP FAULT
MISSING//NO-SYNC

W hen too many or too few gear-tooth pulses

are seen between reset pulses. RING-GEAR FAULT
The received number of pulses is displayed.
352 TEETH READ

W hen the engine speed exceeds the

overspeed setpoint. ENGINE OVERSPEED
Maximum observed speed is also displayed.
1023 RPM

W hen the check-sum of m icroprocessor

firmware cannot be verified. BOTTOM BOARD uP
Unit requires service.
CHECKSUM FAILED

-18­
10.6 The basic ignition diagnostic warning screens in order of display priority are described below.

This screen indicates that the A SIDE capacitor

was not fully charged when a firing occurred. LO OUTPUT VOLTS
This affects outputs A,C,E,etc. (16-output) or
A1,B1,C 1,etc. (32-o utpu t).
ON A SIDE

This screen indicates that the B SIDE capacitor

was not fully charged when a firing occurred. LO OUTPUT VOLTS
This affects outputs B,D,F,etc. (16-output) or
A2,B2,C 2,etc. (32-output).
ON B SIDE

This screen indicates that output pins “A” & “S”

of connector 1 have prim ary fau lts. T his would PRIMARY FAULT 1
normally indicate faulty wiring or a bad coil, but
may also indicate an Output Module problem.
A S

This screen indicates that output pin “B” of

prim ary conne ctor 2 has a prim ary fau lt. PRIMARY FAULT 2
Only 32-output Module 291132-1 has two
con nec tors.
B

This screen indicates that the current-loop has

deviated outside the limits of 2 mA and 22 mA. CURRENT LOOP
W hen this diagnostic is present, the current loop
continues to follow the configured current loop
OUT OF RANGE
curve which can be specified from 0 to 25 mA.

Note: Timing defaults to a programmable setting; see form CPU-2000 PI.

This diagnostic feature is not active when the current loop retard is turned off.
This screen indicates that at some point the
display board of the Logic Module was not DISPLAY BOARD
running correctly. Temporary values for cylinder
offsets would be lost if this message appeared;
WAS NOT RUNNING
the va lues from EEPR OM wou ld be u sed .

This scre en indicates that the firing pattern

configuration data s aved in EEP ROM m em ory is EEPROM MEMORY
incorrect or incom plete. The EEP RO M m em ory
must be reprogramm ed or replaced.
CHECKSUM FAILED

This screen indicates that the ignition system is

expecting but cannot detect the diagnostic module. DIAG MODULE
If the diagnostic module is not connected, select
diag module “off” from the appropriate setup screen.
NOT DETECTED

-19­
11.0 DIAGNOSTIC WARNING SCREENS WITH OPTIONAL DIAGNOSTIC MODULE

11.1 The additional diagnostic warning screens provided by the Diagnostic Module are described
below in the order of display priority. The second row of each display identifies which output
has flagged the warning. The number "1" or "2" on the far right of upper row describes
which connector caused the warning in the case of a 32-output unit 291132-1 or 291132-2.
No number is shown for 16-output unit 291116-1.

T his sc reen ind ica tes tha t the Dia gn os tic M od ule
has identified an open circuit on the primary PRIMARY OPEN 1
ou tpu t pin “C ” of co nn ec tor “1" . This wo uld
no rm ally in dic ate fau lty wir ing or a faile d c oil.
C

T his sc reen ind ica tes tha t the Dia gn os tic M od ule
has identified a short circuit condition on the PRIMARY SHORT
prim ary ou tpu t pin “D ”. T his wo uld no rm ally
ind ica te a m is-wir ed co il or a sh orted prim ary.
D

T his sc reen ind ica tes tha t the Dia gn os tic M od ule
has identifed a low spark demand condition on LO SPARK VOLT.
the plu g a t the “E ” coil. T his is o fte n c au se d b y a
shorted spark plug or shorted secondary wire.
E

T his sc reen ind ica tes tha t the Dia gn os tic M od ule
has identified a high spark demand condition on HI SPARK VOLT.
the spark plug at the “F” coil. This is often caused
by worn spark plugs.
F

T his sc reen ind ica tes tha t the Dia gn os tic M od ule
has identified a no spark condition on the plug at NO SEC. SPARK
the “G” coil. No spark occurs when the sparkplug
de m an d e xc ee ds the ou tpu t ca pa bility o f th e c oil.
G

T his sc reen ind ica tes tha t the Dia gn os tic M od ule
has detected that the average value of output “H” LO FROM ENGINE
is significantly lower than the average of all the
active outputs on the engine or connector group.
H

T his sc reen ind ica tes tha t the Dia gn os tic M od ule
has detected that the average value of output “J” HI FROM ENGINE
is significantly higher than avera ge of all the active
outputs on the engine or connector group.
J

T his sc reen ind ica tes tha t the Dia gn os tic M od ule
ha s d ete cte d th at o utp ut “ K” of c on ne cto r “2 " is HI VARIATION 2
firing w ith sign ificant c ycle to c ycle var iation.
K

-20­
12.0 DATA DISPLAY SCREENS WITH OPTIONAL DIAGNOSTIC MODULE

12.1 Spark reference data display screens, bargraph screens and the offset adjustment screen
are included with the optional Diagnostic Module. The "F1", "F2", "F3" and DSM keys are
used to access and switch between these screens as described below.
NOTE: Bargraph screens ONLY exist in firmware version 2.1.

12.2 Three bargraph screens showing the relationship between the spark reference numbers of
the ignition system on a global basis are available. These bargraphs provide a quick overview
of each cylinder’s respective value relative to the other cylinders.
The first bargraph displays the spark reference number of each ignition output in terms of its
relative magnitude. The spark reference number is scaled between the low and high alarm
values. The cylinders represented by outputs with the tallest vertical bars have the highest
voltage demand.

from
FIRING E1S 300rpm
15.0mA 10.0·Btdc

pres s to
view 1st iii1 1i1i1i!i1i1
bargraph DSM
screen
ABCDEFGHJKLMRSTU

The second bargraph screen shows the difference between the spark reference number for
each ignition output and the engine or group average. Scaling for this graph is determined
by high and low from engine alarm values. The engine or group average is shown as a single
narrow line across the middle of the character field. Bars extend up or down from narrow line
to indicate relative deviation plus or minus of each cylinder from the engine or group average.

pres s to
view 2nd -.-.1.-...-!..-.
bargraph DSM
screen
ABCDEFGHJKLMRSTU

The third bargraph shows the relative magnitude of the Coefficient of Variation in voltage
demand from cycle to cycle for each ignition output. The tallest vertical bars are the outputs
with the greatest variation in voltage demand.

pres s to
view 3rd . .=. ... !.. .
bargraph DSM
screen
ABCDEFGHJKLMRSTU

-21­
12.3 The first numeric display screen (F1) provides the cylinder average spark reference number
"CAVG" which indicates the relative voltage demand of each cylinder. The average spark
reference number for the entire engine "EAVG" is designed to make the comparison of a
cylinder value to the overall engine value as convenient as possible. The "COV" number
(coefficient of variation) is the result of a proprietary calculation which indicates the cycle-to­
cycle variation of the reference numbers for each cylinder. This value increases as variation
between firings of a given cylinder increases.

from pres s to
FIRING E1S 300rpm view 1st
display F1
15.0mA 10.0·Btdc screen

Cylinder Designator Cylinder Average Value

CYL A1 132 CAVG
COV 9 125 EAVG
Coefficient of Variation Engine Average Value

pres s to pres s to pres s to

view next view next view next
cylinder F1 cylinder
NEXT cylinder ESC

pres s to pres s to pres s to

view 2 nd view the view the
display F2 offset adj F3 bargraph
DSM
screen screen screen

NOTE: Systems with firmware version 2.1 and a 32-output unit with memory engine cycle
code “6" or “8" (2 individual outputs per cylinder) will have connector group averages
displayed as shown below.

Cylinder Designator Cylinder Average Value

CYL A1 132 CAVG
COV 9 125 1AVG
Coefficient of Variation Connector 1 Group Avg.

Cylinder Designator Cylinder Average Value

CYL A2 114 CAVG
COV 2 115 2AVG
Coefficient of Variation Connector 2 Group Avg.

-22­
12.4 The second display screen (F2) provides the unfiltered, instantaneous spark reference
number "INST". Also included is the historical range of the cylinder average displayed as
"MIN" and "MAX". The MAX number is updated only when the CAVG number increases
above the old MAX value. The MIN number is updated only when the CAVG number
decreases below the old MIN value. Updates to MIN and MAX are restricted when the
MIN/MAX rpm threshold is not satisfied. After initialization, the MIN and MAX values will
display "###" until they are updated. Press "Reset" while at the second display screen to
reinitialize the MIN and MAX values.
NOTE: This second display screen cannot be accessed directly from the home screen.

Cylinder Designator Instantaneous Value

CYL A1 132 INST
MIN 120 142 MAX
Minimum Cylinder Value Maximum Cylinder Value

pres s to pres s to pr e s s
v iew next view next to e xit
c y linde r F2 c y linde r
NEXT ESC

pres s to pres s to pres s to pres s to

view the
v iew 1st view the zer o m in

bargrap h

DSM display F1 off set ad j F3 and max

Reset
s c ree n scree n v alues

12.5 The spark reference number which shows the relative voltage demand of each cylinder can
be viewed in a horizontal bargraph format. The bargraph is proportionately scaled between
the low and high spark voltage alarm values. For example, the end of the bar will be halfway
across the lower part of the display when the spark reference number is halfway between the
low and high setpoints. This screen gives the user an overview of the current voltage
demand of each cylinder relative to the low and high voltage alarm settings and a visualization
of the stability of that voltage demand over time.

Cylinder Designator
CYL A 132 INST
Low Voltage Value
L H

pres s to pres s to pr e s s
v iew next view next to e xit
c y linde r
DSM c y linde r
NEXT ESC

pres s to pres s to pres s to pres s to

v iew 1 st
v iew 2 nd view the zer o m in

display
F1 display F2 off set ad j F3 and max

Reset
scree n
s c ree n scree n v alues

-23­
12.6 The offset adjustment screen (F3) permits the operator to use an offset adjustment to the
spark reference number (+/- 15 counts) to compensate for minor variations in reference
numbers between individual coils of the same type and voltage demand. To initialize all offset
values to zero from this screen, press "Reset".
NOTE: Improper use of this feature may limit the effectiveness of the diagnostic system and
result in spark reference numbers that mask, or create false, problems.

From pres s to
FIRING E1S 300rpm view
offset F3
15.0mA 10.0·Btdc adj.

Cylinder Designator Cylinder Average Value

CYL A1 132 CAVG
+ 0 Q! 125 EAVG Engine (EAVG) or Group
Cylinder Offset Value (1AVG, 2AVG) Average

pres s to pres s to press

view next view next to e xit
cylinder F3 cylinder
NEXT ESC

pres s to pres s to pres s to pres s to

view the
view 1st view 2nd zer o a ll
bargraph
DSM display F1 display F2 offs ets
Reset
screen screen

13.0 THRESHOLD ADJUSTMENT SCREENS WITH OPTIONAL DIAGNOSTIC MODULE

13.1 Ten threshold adjustment screens enable the operator to calibrate thresholds used to
diagnose potential ignition problems and control ignition energy based on the spark reference
numbers. All of the threshold screens have the same button functions as described with the
first threshold screen.

From pres s to
FIRING E1S 300rpm view 1st
thr es ho ld F2
15.0mA 10.0·Btdc screen

-24­
13.2 If the CAVG reference number of a cylinder is below the "LOW SPARK VOLTAGE" threshold,
a diagnostic warning for that cylinder will occur. This test will identify a low voltage demand
condition which may result from a shorted coil secondary lead or spark plug.

Default = 50
LO SPARK VOLT.
Q!THRESHOLD < 50

pres s to pres s to press

view next view next to e xit
thr es ho ld F2 thr es ho ld
NEXT ESC

pres s to pres s to

increase

thr es ho ld [ Q decrease
thr es ho ld [ !
13.3 If the CAVG reference number of a cylinder is above the “HIGH SPARK VOLTAGE”
threshold, a diagnostic warning for that cylinder will occur. When a high spark warning is
present, the ignition energy will automatically be increased to at least E2. This test will
identify a high voltage demand condition which may result, for example, from worn spark
plugs or poor air-fuel ratio control.

Default =220
HI SPARK VOLT.
Q!THRESHOLD >220

NOTE: Applications using firmware version 2.1 and a 32-output unit with memory engine
cycle code “6" or “8" will have a separate threshold for each connector group.
Group threshold adjust screens will appear as below.

LO SPARK VOLT. 1 LO SPARK VOLT. 2

Q!THRESHOLD < 50 Q!THRESHOLD < 50

HI SPARK VOLT. 1 HI SPARK VOLT. 2

Q!THRESHOLD >220 Q!THRESHOLD >220

-25­
13.4 If the CAVG reference number of a cylinder is above the "NO SECONDARY SPARK"
threshold, a diagnostic warning for that cylinder will occur. When a no secondary spark
warning is present, the ignition energy will automatically be increased to E3 as long as the
system is not in multi-strike mode. This test will identify cylinder firings that do not result in
a spark - an open circuit condition at the secondary of the coil. This may result from a worn
spark plug, or a disconnected or failed secondary wire.

Default = 250
NO SEC. SPARK
Q!THRESHOLD >250

13.5 If the difference between EAVG and CAVG reference numbers is greater than the "LOW
FROM ENGINE" or “LOW FROM GROUP 1 or 2" threshold, a diagnostic warning for that
cylinder will occur. This test will identify a cylinder whose voltage demand is too far below the
average engine or connector group voltage demand.

Default = 60
LO FROM ENGINE
Q!THRESHOLD > 60

LO FROM ENGINE 1 LO FROM ENGINE 2

Q!THRESHOLD > 60 Q!THRESHOLD > 60

13.6 If the difference between CAVG and EAVG reference numbers is greater than the "HIGH
FROM ENGINE" or “HIGH FROM GROUP 1 or 2" threshold, a diagnostic warning for that
cylinder will occur. This test will identify a cylinder whose voltage demand is too far above
the average engine voltage demand.

Default = 60
HI FROM ENGINE
Q!THRESHOLD > 60

HI FROM ENGINE 1 HI FROM ENGINE 2

Q!THRESHOLD > 60 Q!THRESHOLD > 60

-26­
13.7 If the COV reference number is greater than the "HIGH VARIATION" threshold, a diagnostic
warning for that cylinder will occur. This test will identify a cylinder whose cycle-to-cycle
voltage demand has become erratic.

Default = 40
HIGH VARIATION
Q!THRESHOLD > 40

13.8 If the EAVG reference number is greater than the "EAVG E2 Enable" threshold, the energy
will be increased to at least E2. This feature can be used to automatically increase the spark
energy as the voltage demand of the engine increases.

Default = 200
EAVG E2 ENABLE
Q!THRESHOLD >200

13.9 If the energy is at level E2 and if the base energy setting under the "Setup" key is E1, then
the "EAVG E2 Disable" threshold setting can be used to automatically decrease the energy
level to E1.
NOTE: The setting of this threshold must be at least 2 lower than the E2 Enable Threshold
(section 13.8).

Default = 190
EAVG E2 DISABLE
Q!THRESHOLD <190

13.10 If the EAVG reference number is greater than the "EAVG E3 Enable" threshold, the energy
will be increased to level E3 if multi-strike is not active. This feature can be used to further
automatically increase the spark energy as the voltage demand of the engine increases.

Default = 205
EAVG E3 ENABLE
Q!THRESHOLD >205

-27­
13.11 If the energy is at E3 and if the base energy setting under the “Setup” key is not E3, then the
"EAVG E3 Disable" threshold setting can be used to automatically decrease the energy
level to E2.
NOTE: The setting of this threshold must be at least 2 lower than the E3 Enable Threshold
(section 13.10).

Default = 195
EAVG E3 DISABLE
Q!THRESHOLD >195

NOTE: Applications using firmware version 2.1 and a 32-output unit with memory engine
cycle code “6" or “8" will use the larger of the two group average values ( 1AVG or
2AVG ) in place of EAVG when comparing to the energy thresholds.

14.0 UNDERSTANDING AND USING THE SECONDARY SPARK DIAGNOSTICS

14.1 The spark reference number is a unitless number which correlates with voltage demand at
the spark plug and is calculated for every firing of each cylinder. As the voltage increases,
the reference number also increases. The number is non-linear and will increase faster at
higher voltages (above 20kV). The usefulness of the number lies not in its absolute value,
but rather in how the number changes over time as the spark plugs erode. W ith a little
experience, the engine operator will be able to tell when spark plugs require changing.
Abnormal conditions in the ignition system, such as open or short circuits in the primary and
secondary wiring, can also be detected.

14.2 The following spark reference numbers are available in the CPU-2000 system:
INSTANTANEOUS (INST): The numbers read back from the system in real time.
VARIATION (COV): The variation in values for the cylinder being viewed.
CYL. AVERAGE (CAVG): The average value for the cylinder being viewed.
MINIMUM VALUE (MIN): The minimum CAVG value since the last time reset.
MAXIMUM VALUE (MAX): The maximum CAVG value since the last time reset.
NOTE: The above values are available on a per cylinder (or per coil/spark plug) basis.
ENG. AVERAGE (EAVG): The average value for all cylinders of the engine.
or
GROUP AVERAGE (1AVG): The average value for all outputs of connector group 1.
GROUP AVERAGE (2AVG): The average value for all outputs of connector group 2.
NOTE: The (EAVG) average value indicates the average conditions of the entire engine.
Applications using firmware version 2.1 and a 32-output unit with memory engine
cycle code “6" or “8" will display the group average value corresponding to the
connector number 1 or 2.

-28­
14.3 The spark reference number will have a characteristic range depending on the type of coil
used. There are known differences between the various types of Altronic coils, and slight
variations are normal between coils of the same type. In order to maximize the usefulness
of the cylinder spark reference number, it is recommended that all coils be of the same type
and vintage (production date). The typical ranges to be expected in normal operation with
new spark plugs are:

CONFIGURATION
COIL and NO. PER OUTPUT RANGE FREQUENCY
(see section 9.10)
Cu rren t 291 001 coil (1/o utpu t) 095 - 125 LO
Cu rren t 291 001 coil (2/o utpu t) 135 - 175 HI
Cu rren t 291 001 -S c oil (1/ou tput) 100 - 130 LO
Cu rren t 291 001 -S c oil (1/ou tput) 140 - 185 HI
Cu rren t 591 008 coil (1/o utpu t) 120 - 155 HI
Cu rren t 591 008 coil (2/o utpu t) 085 - 110 HI

14.4 In addition to the diagnostic flags covered in section 13.0, the spark reference numbers can
also be used for predictive purposes:
A. As the numbers increase toward the preset HI SPARK VOLTAGE threshold (see section
13.3), the operator knows that a change of spark plugs should be scheduled. With this
information, spark plug replacement can be determined on an actual need basis rather
than a predetermined schedule. Also, unexpected engine misfiring or shutdowns can
be avoided by tracking the reference numbers on a routine basis.
B. The reference numbers can provide an early warning of a difference in operation in a
given cylinder(s). A reading higher or lower than other cylinders (see sections 13.5 and
13.6) tells the operator of a potential problem. This allows further troubleshooting and
evaluation to take place before an unexpected operational problem develops.

14.5 The spark energy setting has only a small effect on the spark reference number if the spark
plug fires correctly. Therefore, the high and low voltage thresholds should hold across energy
setting changes if the spark plugs continue to fire normally. On the other hand, a worn plug
may not fire consistently on energy setting E1 but will on energy setting E2; in this case there
will be a significant difference in the reference number when the energy setting is changed.

14.6 Operators may be able to increase spark plug life by using the automatic energy adjustment
feature of the CPU-2000 system. In this mode, the system uses the spark reference numbers
to establish the lowest required energy level to minimize spark plug erosion rates. To use this
feature, the basic setup energy (section 9.3) should be set to E1. Then see sections 13.8
through 13.11 for setting the Enable and Disable thresholds for energy levels E2 and E3.

14.7 The secondary spark diagnostics will operate with either one or two coils connected to each
system output lead. Optimum operation is obtained when only one coil is connected to each
output lead; in this case, only one spark plug condition effects the spark reference number
for that output. When two coils are wired in parallel to a common output lead, the spark
reference number will tend to be an average of the condit ion at the two spark plugs. W hile
deviations between cylinders will be somewhat harder to detect, most of the benefits of the
spark reference number can still be realized.

-29­