CPU-95 OI 4-08

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OPERATING INSTRUCTIONS

CPU-95DIGITAL IGNITION SYSTEMMODELS 791950-8/16/18, 791952-18, 791958-16

DEVIATION FROM THESE INSTRUCTIONS MAY LEAD TO IMPROPER OP-

ERATION OF THE MACHINE WHICH COULD CAUSE PERSONAL INJURYTO OPERATORS OR OTHER NEARBY PERSONNEL.WARNING:

www.altronicinc.com

FORM CPU-95 OI 4-08

www.altronicinc.com 1

DEVIATION FROM THESE INSTRUCTIONS MAY LEAD TO IMPROPER

ENGINE OPERATION WHICH COULD CAUSE PERSONAL INJURY TOOPERATORS OR OTHER NEARBY PERSONNEL.WARNING:

1.0 OVERVIEW

1.1 The Altronic CPU-95Digital Ignition system has been designed forapplication on natural gas fueled engines. This system is eld-programmable and offers a variety of advanced control, emissionsreduction, primary and spark diagnostics, self diagnostics, se-rial communications and engine protection features. The systemconsists of two main parts: an engine mounted Ignition Module(791950-8/16/18, 791952-18 OR 791958-16) and an optional user inter-face Display Module (791902-1 OR 791908-1).

1.2 This document provides instructions and descriptions to be usedin the operation of the ignition system, and does not cover physicalinstallation. Reference the installation instructions, form CPU-95 II,for instructions regarding installation and mounting.

NOTE: These instructions

pertain to CPU-95 systems

equipped with rmware

release 4.0, dated 01/01/99

and later. The rmware dates

can be displayed from the

home screen by pressing

DIAG and then ENTER.

The date of the installed

rmware is viewed:

Top line (LOGIC) applies

to the output module

rmware date.

Lower line (DISPLAY)

applies to the display

module rmware date.

THE IGN ITIO N SYST EM MUST B E CONF IGURE D PRIOR T OUSE ON AN ENGINE. REFER TO SECTION 9.7 TO VIEW THECURRENT CONFIGURATION. REFERENCE FORM CPU-95 PIFOR INSTRUCTIONS DESCRIBING HOW TO CONFIGURE THEIGNITION SYSTEM. VERIFY EEPROM PROGRAMMING PRIORTO STA RTIN G ENGI NE.

WARNING:

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FORM CPU-95 OI 4-082

CPU-95 DIGITAL IGNITION SYSTEM

NOTE: If possible, keep the

original shipping container.

If future transportation or

storage is necessary, this

container will provide the

optimum protection.

2.0 IGNITION MODULE OUTPUT SWITCHES, LED INDICATORS AND CONTROL INPUT2.1 Three output switches in the Ignition Module provide a means of

communicating the current ignition status to other systems. Theseswitches have isolated outputs and share one common return path

which is not referenced to engine or power ground. They will be inthe open condition when the unit is unpowered. A typical applica-tion would be as a relay or solenoid coil driver.

FIRE-CONFIRM OUTsitch: closed hen the inition is rin or trin to re. Coulde used as a sinal to the control sstem to turn fuel on.

FAULT OUTsitch: closed to sinal that the inition has no dianostic faults hichould result in a self-shutdon. Upon detectin a fault that ould result in a self-shutdon of the inition, this sitch ill open. Could e used as a sinal to the con -trol sstem to turn fuel off.

ALARM OUTsitch: closed to sinal that no unacnoleded faults or arnins arepresent. Upon detection of a dianostic fault or arnin, this sitch ill open. This

output is desined to control an alarm indicator or soundin device.

2.2 Four red LED indicators are provided inside the ignition unit fortroubleshooting purposes:

POWER LED:on to indicate that the unit has poer and the microprocessor isrunnin. The Poer LED ashes to indicate that the unit has poer ut is notoperatin correctl. The Poer LED is off to indicate that the unit has no poer.

TX LED: ashes to indicate that the inition unit is transmittin on the RS-485 serial lin.

RX LED:ashes to indicate that the inition unit is receivin on the RS-485serial lin.

ALARM LED:turns on to indicate that a arnin or fault is present. TheALARM LED ashes hen an acnoleded arnin is present.

2.3 One RS-485 serial communications port is provided within the Ig-nition Module. This port is normally used for communication tothe optional Display Module. A PC (personal computer) or a PLC(programmable logic controller) can be connected to the RS-485portto perform remote monitoring or control functions. The IgnitionModule can be operated in a stand-alone mode, but diagnostic andcontrol features would not be accessible. This port is also used tocongure the ignition system for its application using a PC and theCPU-95PC terminal software.

2.4 One digital input is provided inside the ignition system (MISC. INPUT).This logic level input is active when shorted to ground, and is used

to control any combination of the following features: one-step re-tard, spark energy level or multi-strike option. These features areenabled based on the special features conguration settings as de-scribed in the programming instructions, FORM CPU-95 PI.

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3.0 DISPLAY MODULE USER INTERFACE AND INPUTS

3.1 DISPLAY MODULE:serves as the user interface for the CPU-95ignitionsystem. An RS-485two wire serial communications format is usedto connect the Display Module to the Ignition Module. This linkcommunicates between the modules using a proprietary protocol.

3.2 LCD DISPLAY: An alphanumeric 16-character x 2-line back-lit LCDdisplay is used to provide output to the user. A sealed membranekeypad is used to accept user input. The LCD display and the key-pad function together to provide an interactive user interface whichprompts the user as different functions are selected. SEE FIGURE 1for a description of the keypad.

3.3 All actions and adjustments are immediate and are performed onan incremental basis using up and down arrow keys. All keypadadjustments, except individual offset timing adjustments are per-formed directly in non-volatile EEPROM memory. This EEPROMmemory retains previous settings even after an engine shutdown,

or an ignition power down.

3.4 Capital letters are used on the LCD display screen to designate anactive selection while lower case letters are used to indicate otherpossible options.

3.5 The Display Module includes an isolated current loop input whichcan be congured to control spark timing. Reference the program-ming instructions, FORM CPU-95 PI.

3.6 One logic level digital input (MISC. INPUT)is available at the DisplayModule which can be used in the same fashion as the input of theIgnition Module. If either input is shorted to ground, then the MISC.

INPUTfunctions are active.

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4.0 UNDERSTANDING THE HOME SCREEN

4.1 A series of HOMEscreens are used to describe the current status ofthe ignition system. The LCD display always reverts back to one ofthe home screens after a keypad operation is completed or timesout. The HOMEscreen is designed to display the most critical operat-

ing parameters on one screen.

4.2 All of the HOMEscreens provide a status word in the upper left cor-ner, the engine speed (xxxx rpm)in the upper right corner, the currentloop (xx.x mA)in the lower left corner and the global ignition timing(xx.xBtdc or xx.xAtdc)in the lower right corner.

4.3 The READYmessage is displayed when the ignition is ready for theengine to crank for starting.

READY 0rpm

15.0mA 10.0Btdc

4.4 Once the engine begins turning, the SYNCINGmessage is displayedwhile the ignition system veries signals from the engine pickups.

SYNCING 155rpm

15.0mA 10.0Btdc

4.5 The FIRING message is displayed when the ignition begins ring.Additional data is provided on this screen to describe the selectedmode of operation for the ignition. The energy mode (E1,E2,E3) andthe single-strike/multi-strike type (S or M)are described in the mid-

dle of the upper line in small characters.

FIRING E1S1000rpm

15.0mA 10.0Btdc

4.6 The STALLEDmessage is displayed when a loss of rotation is detectedafter the ignition is ring and neither a SHUTDOWNor FAULThas oc-curred. This signies that the engine has stopped without any de-tected cause from the ignition system.

STALLED 0rpm

15.0mA 10.0Btdc

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4.7 The WARNINGmessage will supersede all of the above home screensif a diagnostic warning condition is present. When a diagnostic

warning exists, aVIEW DIAGNOSTICSmessage will ash on the bottomline of the display. The Ignition Module will continue to operateunder a warning condition while alerting the operator of a poten-tial problem in several ways: by turning on the Alarm LED in the

Ignition Module and by changing the state of the Alarm Out switch(switch opens). The Display Module will display the Warning mes-sage. The various types of diagnostic warnings are described inSECTION 10.0.

WARNING 1000rpm

15.0mA 10.0Btdc

WARNING 1000rpm

VIEW DIAGNOSTICS

4.8 The FAULTmessage will supersede all of the above home screens ifa diagnostic fault condition is present. When a diagnostic fault ex-ists, aVIEW DIAGNOSTICSmessage will ash on the bottom line of thedisplay. The ignition system will stop operating under a fault condi-tion and will alert the operator to the problem in several ways: bychanging the state of the Fire Conrm Out switch (switch opens),

by turning on the alarm LED inside the Ignition Module, by chang-ing the state of the Alarm Out switch (switch opens), by changingthe state of the Fault Out switch (switch opens), and by displayingthe Fault message. The various types of diagnostic faults are de-scribed inSECTION 10.0.

FAULT 0rpm

15.0mA 10.0Btdc

FAULT 0rpm

VIEW DIAGNOSTICS

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4.9 The SHUTDOWN screen will supersede all other home displays if thelogic level shutdown input of the Ignition Module or the G-Lead ofthe output primary connector is grounded or was previously ground-ed and the engine has not stopped rotating. This screen indicates thatthe ignition is not ring because a shutdown input was triggered toshutdown the engine. If a diagnostic fault or warning exists while the

ignition is in shutdown, aVIEW DIAGNOSTICSmessage will ash on thebottom line of the display. The Fire Conrm Out switch will changestate (switch opens) and the other outputs will function as describedabove based on the existence of faults or warnings.

SHUTDOWN 0rpm

15.0mA 10.0Btdc

SHUTDOWN 0rpm

VIEW DIAGNOSTICS

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5.0 ADJUSTING GLOBAL RETARD

5.1 Global retard is an adjustment affecting the timing of all cylin-ders equally. This adjustment can be equated to the manual timingswitch of the Altronic CPU-90 system. Adjustments made as de-scribed below will be in effect until another adjustment is made.

5.2 To adjust global retard:

FROM PRESS

FIRING E1S1000rpm

15.0mA 10.0Btdc

TIMING

THEN AT PRESS

=GLOBAL(ENGINE)

=CYLINDER(INDV)

THEN AT PRESS

= ADJUST RETARD

= SELECT MODE

THEN AT NOTE: Resultant timing shown on bottom line.

MANUAL RET 10.5

Esc 10.0Btdc

PRESS TO PRESS TO PRESS TO PRESS TOINCREASE DECREASE EXITRETARD RETARD

ESC

5.3 The increment of timing change is dependent on the number ofholes or teeth being sensed. The minimum timing change is denedas follows.

If N < 270, then Increment = 45/N derees

If N 270, then timin increment is 90/N derees, here N = no. of holes or teeth.

5.4 Global spark timing is determined based on the sum of severalspark retard components which include manual retard, currentloop retard, rpm retard, and one step retard. The range of total re -tard is limited to 255 X TIMING INCREMENT. When the sum of all retardcomponents reaches 255 X TIMING INCREMENT, the actual timing will

be at the retard limit.

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6.0 SELECTION OF GLOBAL TIMING MODES

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

FROM PRESS

FIRING E1S1000rpm15.0mA 10.0Btdc

TIMING

THEN AT PRESS

=GLOBAL(ENGINE)

=CYLINDER(INDV)

THEN AT PRESS

= ADJUST RETARD

= SELECT MODE

6.2 The rst mode selection can enable or disable the pre-conguredretard curve controlled by the 4-20 mAcurrent loop input. The choic-es are ONor OFF, with the active selection displayed in capital letters.

A PC is required to congure the 4-20 mAcurve; reference the pro-gramming instructions, form CPU-95 PI. When the 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 thelower case a.

AT NOTE: Displa shos Current loop ON.

CURRENT LOOP RET

ON/offNext Esc

TO TO FOR TOTURN TURN NEXT EXITON OFF OPTION

NEXT

ESC

6.3 The Next mode selection can enable or disable the pre-conguredretard curve controlled internally by engine RPM. To congure theRPM retard curve, reference form CPU-95 PI.

AT THE NOTE: DisplaNEXT shows RPMOPTION Map OFF.SCREEN

RPM RETARD MAP

ON/offNext Esc

TO TO FOR TOTURN TURN NEXT EXITON OFF OPTION

NEXT

ESC

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6.4 The NEXTmode selection can increase or decrease the one-step retardvalue. The rst screen below is displayed when one-step retard isboth congured and is active. The second screen below is displayedwhen the one-step retard is congured but not active. The defaultconguration 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 theone-step retard feature is not congured. The actual engine timingis displayed on this screen so the effect of 1 step retard can be seenduring adjustments (if the Misc Input terminal is grounded).

AT THE NOTE: Upper caseNEXT 1 STEP RET = on.OPTIONSCREEN

1 STEP RET 10.0

Esc 0.0Btdc

OR NOTE: Lower case 1 step retard = off.

1 step ret 10.0

Esc 0.0Btdc

OR NOTE: 1 Step Retard not conured.

ONE-STEP FEATURE

NOT PRESENT Next

TO TO TO GO TOINCREASE DECREASE BACK TO EXIT FIRST

NEXT

ESC

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7.0 ADJUSTING INDIVIDUAL OFFSETS7.1 The timing of individual cylinders can be offset by up to 3degrees of

advance or retard from the global timing of the engine. Adjustmentsmade as described below should be considered temporary. The ig-nition will revert back to the values saved in EEPROM memory on

every reset, start or power-up. To save temporary adjustments toEEPROM memorySEE SECTION 8.0.

7.2 Enter the individual timing adjustment menu as described below.

FROM PRESS

FIRING E1S1000rpm

15.0mA 10.0Btdc

TIMING

THEN AT PRESS

=GLOBAL(ENGINE)

=CYLINDER(INDV)

THEN AT PRESS

= ADJUST RETARD

= SELECT MODE

7.3 The individual timing adjustment screen identies the primary out-put to be adjusted, and the degrees of offset in use for the output.

THEN AT NOTE: 2.5 degrees advance for output A.

output A.

CYL A 2.5ADV

Esc Next

TO TO TO TOADVANCE RETARD SELEC T EXIT NEXT

CYL.

NEXT

ESC

7.4 The output identication characters will be provided as follows:

IGNITION MODULE 791950-8/16 OR 791958-16: A B C D E F K L M N P R S T U V

IGNITION MODULE 791950-18 OR 791952-18: A B C D E F G H K G R P 1 L M N P R S T U V G R P 2

This identication is the CPU-95 output harness identication;match-up to the engine ring order to determine the engine cylin-der number.

NOTE: In applications with

narrow ring angles, theadjustment range may be

limited.

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8.0 INDIVIDUAL CYLINDER OFFSET MODES

8.1 Two additional functions with regard to individual cylinder timingoffsets are provided. These functions can be accessed from the indi -

vidual timing mode menu which can be entered as described below.

FROM PRESS

FIRING E1S1000rpm15.0mA 10.0Btdc

TIMING

THEN AT PRESS

=GLOBAL(ENGINE)

=CYLINDER(INDV)

THEN AT PRESS

= ADJUST RETARD

= SELECT MODE

8.2 The rst function is used to save the current (temporary) individualoffsets to EEPROM memory. When this is done, the ignition will loadthese offset settings every time the engine starts or reset is pressed.REFERENCE SECTION 7.0to adjust individual (temporary) offsets.

AT THEFIRSTOPTIONSCREEN

SAVE CYL OFFSETS

NEXT or ENTER

PRESS TO PRESS TO PRESS PRESS TOSAVE FOR NEXT EXITOFFSETS OPTION

ENTER

NEXT

ESC

8.3 The NEXTmode function can be used to reset all cylinder offset val-ues back to zero (both temporary memory and EEPROM memory).

AT THENEXTOPTIONSCREEN

RESET OFFSETS =0

ENTER OR NEXT

PRESS TO PRESS TO PRESS PRESS TORESET FOR NEXT EXITOFFSETS OPTION

ENTER

NEXT

ESC

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9.0 SETUP CONTROL OPTIONS

9.1 Additional control settings and display features can be accessed un-der the setup menu. Changes made under the Setup menu are storedin EEPROM and remain xed until changed again. The Setup menucan be entered as described below.

FROM PRESS

FIRING E1S1000rpm

15.0mA 10.0Btdc

SETUP

9.2 The rst setup screen permits the operator to enable or disable theMulti-Strike feature.

Note 1: A special feature can e selected durin conuration to force Multi-Strieto e active elo 250 rpm, or hen the Misc. Input is rounded.

This feature is not active in a standard conuration.

Note 2: The Multi-Strie feature is automaticall turned off aove 1050 rpm.

Note 3: The use of Multi-Strie rins ma tend to accelerate spar plu electrode

erosion.Note 4: The Multi-Strie feature res the spar plu 2 times per event (~1100usec apart).

Note 5: ON 791958-16 UNIT ONLY: The Multi-Strie feature is replaced the VariSpar lon duration (~2000 usec) spar.

AT MULTI STRIKE

on/OFFNext Esc

TO TO FOR TOTURN TURN NEXT EXIT

ON OFF OPTIONMULTI

MULTI

NEXT

ESC

9.3 The next setup screen permits the operator to select one of three igni-tion energy levels (E1,E2,E3). The energy levels are 75 millijoules (E1), 100millijoules (E2), 125 millijoules (E3).

Note 1: A special feature can e selected durin conuration to use the maximumener level elo 250 rpm, or hen the Misc Input is rounded.

This feature is not active in a standard conuration.

Note 2: The ener is automaticall limited to E2 hen Multi-Strie is active.

Note 3: The use of hiher spar ener ma tend to accelerate spar plu electrodeerosion.

AT NOTE: Ener levelE1 is displaed.

output A.

OUTPUT ENERGYEsc E1/e2/e3

TO TO FOR TOINCREASE DECREASE NEXT EXIT OPTION

NEXT

ESC

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9.4 The next setup screen is used to adjust the engine overspeed set-point. The setpoint can be adjusted in increments of 10 rpmto a max-imum of 2550 rpm.

AT

output A.

ADJUST OVERSPEED

Esc 2000 RPM


NEXT

ESC

9.5 The next setup screen is used to specify the exact position of the re-set pin. Both the reset position and the engine timing are displayed.

Adjustments are made here to make the displayed timing match theactual spark timing as veried with a timing light. This adjustmenteffects the displayed timing but does NOTchange the actual timing

of the rings.

AT

output A.

RESET PIN> 30.5

Esc 10.5Btdc


NEXT

ESC

9.6 The next setup screen is used to enable or disable VALUE PROTECTIONof all user values in the EEPROM memory. When protection is on,

none of the EEPROM settings under the Setup or Timing menuscan be changed. This feature can be used to provide limited protec-tion from random changes by inexperienced operators.

AT

output A.

VALUE PROTECTION

on/OFFNext Esc

TO TURN TO TURN FOR TOON PRO- OFF PRO- NEXT EXITTECTION TECTION OPTION

NEXT

ESC

NOTE: Adjustment of this

parameter should be done

while individual cylinder off-

sets are all at zero.

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FOR DISPLAY MODULE P/N 791908-1 ONLY:The VALUE PROTECTIONcan bePASSWORDprotected. The password PROTECTION LOCKis enabled whenprogramming options from the 791908-1PC terminal program. Seethe Programming Instructions, FORM CPU-95 PI for details. Whenpassword protection is enabled the following menu appears insteadof the VALUE PROTECTIONmenu.

PROTECTION LOCK

***** Next Esc

To enter the password press, use the function keys F1, F2, F3, F4whereF1=1, F2=2, F3=3, F4=4where the number entered is equal to the userassigned ve digit password. After the last digit of the proper pass-

word is entered, theVALUE PROTECTIONmenu shown above will appear.If the password is not known, press the ESCkey to exit or the NEXTkey to go on to the VIEW IGNITION SETUPmenu.

9.7 The next setup screen can be used to view the conguration com-ments which describe the conguration of the ignition system.There are a total of 8 screens which can be rotated to the displayusing the NEXTkey.

ATVIEW IGN. CONFIG

Next Esc Enter

PRESS TO PRESS TO PRESS TO PRESS TOVIEW GO TO EXITCONFIG NEXTENTER

NEXT

ESC

The conguration screens are shown starting on the next page.

NOTE: Because EEPROMS

can be recongured (using

a PC and Altronics con-

guration software), these

comments should be viewed

to identify and verify the

conguration settings of the

ignition prior to operation.

Refer to the programming

instructions, form CPU-95

PI, for further information on

conguration.

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The folloin tpes of screens can e vieed pressin ENTER to start and NEXT to advance.

FIRING PATTERN CODE: (H4A360.FS100)

SPECIAL FEATURE CODE: (#001) (1STEP DEFAULT)

IGNITION MODULE TYPE: (PART NUMBER)

DATE CONFIGURED: (01-22-07)

TIME CONFIGURED: (12:00)

CONFIGURED BY: (USER NAME)

TERMINAL VERSION #: (V1.00)

CURRENT LOOP CURVE DESCRIPTION

AT 4 MA 0 RETARD

AT 20 MA 24 RETARD

USER SPECIFIED DESCRIPTION

RPM RETARD CURVE DESCRIPTIONRETARD 10 BELOW 100 RPM

RAMP TO 0 AT 200 RPM

USER SPECIFIED DESCRIPTION

LOCATION: USER SPECIFIED DESCRIPTION

ENGINE NUMBER OR DESCRIPTIONUSER SPECIFIED DESCRIPTION

SPECIAL USER COMMENTS AREA #1 USER SPECIFIED COMMENTS

SPECIAL USER COMMENTS AREA #2 USER SPECIFIED COMMENTS

ROTATION CONTINUES AGAIN THROUGH THE 8CONFIGURATION COMMENT SCREENS.

ESC. TO EXIT TO HOME SCREEN.

H4A360.FS100#001

UNIT 791950-16 NEXT

01-22-07 12:00

By:Joe v1.00 NEXT

LOOP RETARD: 24

4/20ma 0/24ret NEXT

RPM RETARD: YES

Ramp10/0 100/200 NEXT

LOCATION: ALT.

GIRARD OHIO USA NEXT

ENGINE#: 8G825

Number 4 USA-GAS NEXT

USER

COMMENTS #1 NEXT

USER

COMMENTS #2 NEXT

H4A360.FS100#001

UNIT 791950-160 NEXT

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BREAKDOWN OF FIRING PATTERN CODE:

H REPRESENTS THE NUMbER OF OUTPUTS USED, IN THIS CASE 8 (F =6, L = 12, ETC.)

4 REPRESENTS THE CYCLE TYPE OF THE ENGINE

2 = TwO-CyCLE

4 = FOUR-CyCLE

A REPRESENTS THE ALTRONIC PATTERN CODE (SEE FORM CPU-95 AL)

360 REPRESENTS THE NUMBER OF GEAR TEETH OR HOLES TO BE SENSED

F REPRESENTS A DESIGNATOR FOR CPU-95 VERSION 1

S 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 = 0 AT 4MA / 8 AT 20MA

N = SPECIAL NON-STANDARD TIMING CURVE VS. CURRENT OR RPM, NON-FACTORY PROGRAMMED

S = SPECIAL NON-STANDARD TIMINg CURVE VS. CURRENT OR RPM, FACTORy PROGRAMMED

X = NO CURRENT LOOP CURVE

100 REPRESENTS THE SPECIAL VERSION NUMBER (ONLY EXISTS FOR TYPES N AND S)

#001 REPRESENTS THE SPECIAL FEATURE CODE

(TOTAL SUM OF ALL SELECTED OPTIONS; 001=DEFAULT) 064 = FORCE MULTI-STRIkE wHEN RPM IS LESS THAN 250

032 = FORCE MAX ENERgy wHEN RPM IS LESS THAN 250

016 = USE 1 STEP RETARD wHEN RPM IS LESS THAN 250

004 = FORCE MULTI-STRIkE wHEN MISC INPUT IS gROUNDED

002 = FORCE MAX ENERgy wHEN MISC INPUT IS gROUNDED

001 = USE 1 STEP RETARD WHEN MISC INPUT IS GROUNDED

NOTE: This number must be

selected and properly docu-

mented by the originator.

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9.8 The last setup screen permits the operator to enter an ignition testmode. This test mode can re all outputs in rotation, or individualoutputs at a slow rate. This feature can be used to troubleshoot pri-mary wiring and Output Module operation. Test mode will termi-nate if rotation of the engine is sensed. Diagnostic features do notfunction while in test mode.

ATRUN TEST MODE

Next Esc Enter

PRESS FOR PRESS TO PRESS PRESS TOTEST MODE FOR NEXT EXIT

OPTIONENTER

NEXT

ESC

THE OPERATOR MUST FULLY PURGE THE ENGINE OF COM-BUSTIBLE MIXTURES PRIOR TO SELECTING THE TEST MODEOPERATION. PRESSING THE ENTER KEY AGAIN IS A CONFIRMA-

TION OF THIS ACTION.

WARNING:

THENBEFORESTARTINGTEST MODE

IS ENGINE PURGED

Esc Enter

PRESS TO PRESS TO PRESS TOVERIFY EXITPURGED

ENTER

NEXT

Then the test mode screen indicates that the ignition is ring and

permits the operator to select the output to be red.

ATTest-Mode ALL

Esc

PRESS TO PRESS TO PRESS TO PRESS TOSELECT SELECT EXITPREVIOUS NEXTOUTPUT

OUTPUT

ESC

Test-Mode selection rotates as described below.

MODEL # ROTATION SEQUENCE

791950-8: ALL, A, B, C, D, E, F, K, L

791950-16, 791958-16: ALL, A, B, C, D, E, F, K, L, M, N, P, R, S, T, U, V, ALL

791950-18: ALL, A, B, C, D, E, F, G, H, K, L, M, N, P, R, S, T, U, V, ALL

791952-18: ALL (Individual output test mode not availale.)

NOTE: 791908-1 Display

Module only: The Test-Mode

is enabled by the user dur-

ing initial setup of display

module from PC terminal

program. See form CPU-95 PI

for details.

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10.0CPU-95 DIAGNOSTICS

10.1 A diagnostic fault represents the most severe classication of prob-lems. The presence of a diagnostic fault will inhibit the ignitionfrom ring. When a fault is detected several things will occur:

Inition ill stop rin.

Fire Conrm Out sitch ill open.

Fault Out sitch ill open.

Alarm Out sitch ill open.

Alarm LED in the inition unit ill turn on.

Home status ill read FAULT, and the ottom line ill ash VIEwDIAGNOSTICS.

FAULT 0rpm

VIEW DIAGNOSTICS

10.2 A diagnostic warning represents the least severe classication of prob-lems. The ignition will continue to re in the presence of a diagnostic

warning. When a warning is detected, several things will occur:

Alarm Out sitch ill open.

Alarm LED in the inition unit ill turn on.

Home status ill read wARNINg, and the ottom line ill ash VIEwDIAGNOSTICS.

WARNING 300rpm

VIEW DIAGNOSTICS

10.3 If the Alarm Out switch is being used to turn on an audible alarm orasher, the user can acknowledge the alarm as described below.

PRESS

ALARM

ACK

Acknowledgment of the alarm results in the following until a resetis commanded or until another fault or warning may occur.

Alarm Out sitch ill return to its closed position.

Alarm LED ill ash to indicate that an alarm is present ut acnoleded.

NOTE: Diagnostic FAULTS

will supersede diagnostic

WARNINGS.

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

FROM THE PRESSHOMESCREEN

FAULT 0rpm

VIEW DIAGNOSTICS

DIAG

Then from the diagnostic description screens use the following keys.

PRESS TO OR PRESS PRESS TOVIEW NEXT TO VIEW EXIT

NEXTDIAG

NEXT

ESC

10.5 Diagnostic Fault screens, in order of display priority:

when zero ear-tooth pulses areseen eteen to reset pulses.

when too man ear-tooth pulsesare seen ithout a reset pulse.

when there are no Hall-effectpicup pulses or hen the pic-ups are not snchronized.

when too man or too fe ear-tooth pulses are seen eteenreset pulses.

The received numer of pulses isdisplaed.

when the enine speed exceedsthe overspeed setpoint.

Maximum oserved speed is alsodisplaed.

when the chec-sum of micro-processor rmare cannot everied.

Unit requires service.

GT PICK-UP FAULT

MISSING PULSES

RS PICK-UP FAULT

MISSING PULSES

HE PICK-UP FAULT

MISSING//NO-SYNC

RING-GEAR FAULT

352 TEETH READ

ENGINE OVERSPEED

1023 RPM

BOTTOM BOARD uP

CHECKSUM FAILED

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10.6 Diagnostic Warning screens, in order of display priority:

This screen indicates that the current-loop has deviated out-side the limits of2 mA and 22 mA. The current loop follos the conured curve hich is speci -ed from 0-25 mA. This dianostic is active onl if the current loop retard is on.

This screen indicates that at some point no loop data as received from theDispla Module. In this condition, the timin for 0 mA is used. This test is ac -tive onl if the current loop retard is on.

This screen indicates that the rin pattern conuration data saved inEEPROM memor is incorrect or incomplete. The EEPROM memor must ereprorammed or replaced.

This screen indicates that dianostics have identied an open circuit on theprimar output pin A. Normall indicates fault irin or a failed coil.

This screen indicates that dianostics have identied a short circuit condition

on the primar output pin b. This ould normall indicate a coil is misired,or the primar ire is shorted.

This screen indicates that the dianostics have identied a lo spar demandcondition on the plu at the C coil. This is often caused a shorted spar

plu or shorted secondar ire.

This screen indicates that the dianostics have identied a hih spar de-mand condition on the spar plu at the D coil. This is often caused ornspar plus.

This screen indicates that the dianostics have identied a no spar conditionon the plu at the E coil. No spar occurred since the demand as reaterthan the output capailit of the coil.

This screen indicates that the dianostics have detected a condition here

the averae value of output F is sinicantl loer than the averae of all theactive outputs on the enine.

This screen indicates that the dianostics have detected a condition herethe averae value of output k is sinicantl hiher than the averae of allthe active outputs on the enine.

CURRENT LOOP

OUT OF RANGE

DISPLAY BOARD

DATA INTERRUPTED

EEPROM MEMORY

CHECKSUM FAILED

PRIMARY OPEN

A

PRIMARY SHORT

B

LO SPARK VOLT.

C

HI SPARK VOLT.

D

NO SEC. SPARK

E

LO FROM ENGINE F

HI FROM ENGINE

K

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10.7 After all of the diagnostics have been read, the user can reset thewarnings and faults by pressing the reset key as pictured below.

PRESS PRESSTO EXIT

ESC

Reset

Pressing the reset key performs all of the following actions:

Clears all dianostic arnins from memor.

Clears all dianostic faults from memor.

Clears a latched shutdon condition hen the input is no lonerrounded.

Causes temporar clinder timin offsets to e overritten fromEEPROM memor

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11.0 UNDERSTANDING AND USING THE SECONDARY SPARKDIAGNOSTICS

11.1. The spark reference number is a unitless number which correlateswith voltage demand at the spark plug and is calculated for every r-ing of each cylinder. As the voltage increases, the reference number

also increases. The number is non-linear and will increase faster athigher voltages (aove 20V). The usefulness of the number lies not inits absolute value, but rather in how the number changes over timeas the spark plugs erode. With a little experience, the engine opera-tor will be able to tell when spark plugs require changing. Abnormalconditions in the ignition system, such as open or short circuits inthe primary and secondary wiring, can also be detected.

11.2 The reference cylinder spark data number can be viewed separate-ly for each ignition output (cylinder) in two ways, and compared tothe average of the entire engine:

INSTANTANEOUSvalue: shon in ( )

CYLINDER AVERAGEvalue: CAVgFROM THE PRESSHOME SCREEN TO VIEW DISPLAY

FIRING E1S1000rpm

15.0mA 10.0Btdc SCREENF1

CYLINDER CYLINDERDESIGNATOR AVERAGE VALUEINSTANTANEOUS AVERAGE VALUE

CYL A 115 CAVG

(112) 116 EAVG

PRESS PRESS PRESS PRESSTO VIEW TO VIEW TO VIEW TO

NEXT OFFSET NEXT EXITCYLINDER

F1 ADJ. F4 CYLINDERNEXT

ESC

ON THE 791908-1 DISPLAY MODULE ONLY:Press F2for Bar Graph displayof Spark number.


CYL A 115 CAVG

L|||||||| H

PRESS PRESS PRESS PRESS

TO VIEW TO VIEW TO VIEW TONEXT OFFSET NEXT EXITCYLINDER

F1 ADJ.

F4 CYLINDER

NEXT

ESC

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11.3 The offset adjustment screen (F4) permits the operator to adjust anoffset to the spark reference number ( 15 counts)to compensate forminor variations in reference numbers between individual coils ofthe same type and voltage demand. To initialize all offset values tozero from this screen, press RESET.

FROM THE PRESSHOME TO VIEWSCREEN DISPLAY

FIRING E1S1000rpm

15.0mA 10.0Btdc SCREENF1


CYL A1 115 CAVG

+ 0 116 EAVG

PRESS PRESS PRESS TO VIEW TO VIEW TO NEXT NEXT EXIT

CYLINDER

F4 CYLINDER

NEXT

ESC

PRESS PRESSTO VIEW TO ZEROBASE ALLDISPLAY

F1 OFFSETS

Reset

11.4 The spark reference number is used in conjunction with compara-tive thresholds to set diagnostic codes for several different ignitionsystem and spark plug conditions. When a threshold is violatedtwice in a row, the corresponding diagnostic ag is set for the ap-propriate cylinder. The diagnostic ags are latching and will existuntil the unit is restarted or until a reset or power-down occurs.

Open Primar CAVg < 1

Shorted Primar CAVg < 50

Lo Spar Voltae CAVg < user prorammale threshold (tp. 100)

Hih Spar Voltae CAVg > user prorammale threshold (tp. 180), also Forces E2

No Secondar Spar CAVg > user prorammale threshold (tp. 250), also Forces E3

Lo From Enine (EAVg - CAVg) > user prorammale threshold (tp. 20)

Hih From Enine (CAVg - EAVg) > user prorammale threshold (tp. 20)

NOTE: Improper use of this

feature may limit the effec-

tiveness of the diagnostic

system and result in spark

reference numbers that

mask real or create false

problems.

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11.5The spark reference number is also used to automatically changespark energy for different ignition system conditions. The minimumenergy setting is selected under the Setup Menu(SEE SECTION 9.3).En-ergy will automatically be adjusted in response to the engine aver-age spark reference number (EAVG)based on four individual thresh-olds listed below. Additionally, spark energy will automatically be

increased when a High Spark Voltage or No Secondary Spark warn-ing exists for any cylinder.

Auto Enale E2 EAVg > user prorammale threshold (tpical 200)

Auto Disale E2 EAVg < user prorammale threshold (tpical 190)

Auto Enale E3 EAVg > user prorammale threshold (tpical 205)

Auto Disale E3 EAVg < user prorammale threshold (tpical 195)

11.6 The above user programmable thresholds need to be adjusted basedon the type of coil being used and on the operating characteristics(specically, voltage demand) of the engine. There are known dif-ferences between various types of Altronic coils, and slight varia-

tions are normal between coils of the same type. In order to maxi-mize the usefulness of the cylinder spark reference number, it isrecommended that all coils be of the same type and vintage(production date). This will aid greatly in detecting variations inone cylinder vs. the general trend in the engine. The typical rangesto be expected in normal operation with new spark plugs are:

Older 501061 (lue) coils: 70 to 90

Current 501061 (lue) coils: 90 to 120

Current 591010 (red) coils: 120 to 140

Current 501061-S (shielded lue) coils: 110 to 130

Current 591007 / 591011A / 591011b coils: 70 to 90

11.7 The indicated thresholds were designed to be adjustable so that theuser can customize these diagnostics to t the specic needs of eachengine. It will take some testing and adjustment to obtain thresholdsthat optimize the use of these features. For maximum benet, thespark reference number for each cylinder should be recorded at nor-mal operating load with new spark plugs installed and then moni-tored over a period of time for changes. The HI SPARK VOLTAGEalarmlevel should be set (typically) at 180 initially and can be adjusted asexperience dictates. A gradual increase in the spark reference num-

ber is expected over time as the spark plug electrodes erode.

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11.8 In addition to energy control and the diagnostic ags, the referencenumbers can also be used for predictive purposes:

A. As the numbers increase toward the preset HI SPARK VOLTAGEthreshold(SEE SECTION 12.3), the operator knows that a changeof spark plugs should be scheduled. With this information, thisfunction can be determined on an actual need basis rather than

a predetermined schedule. Also, unexpected engine misring orshutdowns can be avoided by tracking the reference numbers ona routine basis.

B. The reference numbers can provide an early warning of a dif-ference in operation in a given cylinder(s). A reading higher (orlower) than the other cylinders, when such a difference is notnormally present, tells the operator of a potential problem; thisallows further troubleshooting and evaluation to take place be-fore an unexpected operational problem develops. (SEE SECTION12.5, 12.6.)

11.9 Other Information regarding the spark reference number:

A. The spark energy setting has only a small effect on the referencenumber if the spark plug res correctly. Therefore, the high andlow voltage thresholds should hold across the energy settingsif the spark plugs continue to re correctly. On the other hand,a worn plug may not re consistently on energy setting E1but

will on energy setting E2; in this case there will be a signicantdifference in the reference number when the energy setting ischanged. Operators may be able to increase spark plug life byoperating initially with new spark plugs on E1energy setting anduse the HI SPARK VOLTAGE alarm as an indicator to manually in-crease the energy progressively to E3.

B. The spark reference number is designed to work with one coilper output. Where two coils are connected to the same primarylead, the number will tend to be an average of the conditions atthe two spark plugs. While some of the benets of the spark ref-erence number can still be realized, the usefulness of the num-

ber in detecting deviations between cylinders (alarm levels) willbe reduced.

NOTE:See Section 11.5for

automatic system adjust-

ment of ignition energy.

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12.0 THRESHOLD ADJUSTMENT SCREENS

12.1 Nine threshold adjustment screens enable the operator to calibratethresholds used to diagnose potential ignition problems and control ig-nition energy based on the spark reference numbers. All of the thresh-old screens have the same button functions as described with the rst

threshold screen. All thresholds are accessed under the F2key.

FROM PRESS TO VIEW 1ST THRESHOLD

FIRING E1S1000rpm

15.0mA 10.0Btdc SCREEN

F2

12.2 If the CAVGreference number of a cylinder is below the LOW SPARK

VOLTAGEthreshold, a diagnostic warning for that cylinder will occur.This test will identify a low voltage demand condition which mayresult from a shorted coil, secondary lead or spark plug. To disablediagnostic, set value to zero.

LO SPARK VOLTAGE

THRESHOLD< 100

PRESS TO PRESS TO PRESS TO VIEW NEXT VIEW NEXT EXIT THRESHOLD THRESHOLDF2

NEXT

ESC

PRESS TO PRESS TOINCREASE DECREASETHRESHOLD THRESHOLD

12.3 If the CAVGreference number of a cylinder is above the HIGH SPARK

VOLTAGEthreshold, a diagnostic warning for that cylinder will occur.When a high spark warning is present, the ignition energy will au-tomatically be increased to at least E2. This test will identify a high

voltage demand condition which may result, for example, from wornspark plugs or poor air-fuel ratio control. To disable, set to 255.

HI SPARK VOLTAGE

THRESHOLD >150

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12.4 If the CAVGreference number of a cylinder is above the NO SECONDARYSPARKthreshold, a diagnostic warning for that cylinder will occur.

When a no secondary spark warning is present, the ignition energywill automatically be increased to E3as long as the system is not inmulti-strike mode. This test will identify cylinder rings that do notresult in a spark an open circuit condition at the secondary of the

coil resulting from a worn spark plug, or a disconnected or failedsecondary wire. To disable, set to 255.

NO SEC. SPARK

THRESHOLD >250

12.5 If the difference between EAVGand CAVGreference numbers is great-er than the LOW FROM ENGINEthreshold, a diagnostic warning for thatcylinder will occur. This test will identify a cylinder whose voltagedemand is too far below the average engine voltage demand.

Default = 60

LO FROM ENGINE

THRESHOLD > 60

12.6 If the difference between CAVGand EAVGreference numbers is greaterthan the HIGH FROM ENGINEthreshold, a diagnostic warning for thatcylinder will occur. This test will identify a cylinder whose voltagedemand is too far above the average engine voltage demand.

Default = 60

HI FROM ENGINE

THRESHOLD > 60

12.7 If the EAVG reference number is greater than the EAVG E2 ENABLEthreshold, the energy will be increased to at least E2. This featurecan be used to automatically increase the spark energy as the volt-age demand of the engine increases.

Default = 200

EAVG E2 ENABLE

THRESHOLD >200

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12.8 If the energy is at level E2and if the base energy setting under theSETUPkey is E1, then the EAVG E2 DISABLEthreshold setting is used toautomatically decrease the energy from E2.

Default = 190

EAVG E2 DISABLE

THRESHOLD 205

12.10If the energy is at E3and if the base energy setting under the SETUPkey is not E3, then the EAVG E3 DISABLEthreshold setting is used to au-tomatically decrease the energy from E3. NOTE:This threshold must

be at least 2counts below the enable threshold (SECTION 12.9).

Default = 195

EAVG E3 DISABLE

THRESHOLD >195

NOTE: This threshold must

be at least 2 counts below

the enable threshold.

See section 12.7.

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13.0 SPECIAL INSTRUCTIONS FOR 791908-1 DISPLAY MODULE ONLY

13.1 The 791908-1 Display Module incorporates data logging and a half du-plex RS-485port which is Modbus RTU slave compliant. The protocolused follows the Modicon Modbus RTU standard. A complete listing

of the Modbus register addresses is included on the CPU-95terminalprogram CD, along with a PC based Modbus compatible monitoringprogram which can be used to access the ignition data remotely.

13.2 The auxiliary communications port conguration must be set tomatch the values expected by the Modbus master. This is done inthe 791908-1Display Module via the AUX PORT SETUPmenu which ap-pears immediately after the RUN TEST MODEmenu under the SETUPmenu. (SEE SECTION 9.8).

AUX PORT SETUP

Next Esc Enter

PRESS TO PRESS TOSETUP PORT EXIT

ENTER

ESC

AUX PORT NODE ID

1

PRESS PRESS TOARROWS TO CONTINUE

SET NODE

NEXT

AUX PORT MODE

ModbusRTU96008n1

PRESS TO PRESS TOARROWS TO EXITSET MODE

ESC

Supported aud rates are 300, 600, 1200, 2400, 4800, 9600, 19200, 38400.

Supported parit selections are n (none), o(odd), e(even).

Supported data it format is 8 ith 1 stop it.

In order to simplify troubleshooting of the Modbus connection, anAUX PORTdiagnostic menu is provided. To access this menu, pressthe DIAGkey when viewing any of theAUX PORTsetup screens above.

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PRESS TOVIEW DIAGS.

DIAG

MODBUS ERROR

NONE

PRESS TORETURN TOPREVIOUSMENU

NEXT

ERROR LIST: CRC Checsum on incomin data invalid

INVALID ADDRESS Received data contained invalid address

INVALID DATA LEN Received data as the ron lenth

REC bUF OVF Incomin data reater than 256 tes

UkN FN Unnon function called

NONE No errors since last reset

PRESS TO PRESS TOCLEAR EXITERROR

Reset

ESC

13.3 The 791908-1 Display Module supports data logging of the infor-mation normally available from the display of the CPU-95. The unitretains 100 datalogs which are stored in a FIFO (rst in, rst out)manner. When 100logs are stored, the oldest log is purged and thenewest added. The oldest data is stored as LOG NO. 100and the new-

est as NO. 1; there is also a copy of the current values available asDATALOG 0. The datalogs can be accessed by the special PC terminalprogram supplied with the unit or by a special Modbus commandsent by the User supplied PLC or computer system. More detailedinformation is provided on the terminal CD.

The DATALOG SETUPmenu appears after the AUX PORT SETUPmenu. Ifdatalogs are not being used, press the NEXTkey to proceed to theBARGRAPH SETUPmenu.

DATALOG SETUP

Next Esc Enter

PRESS TO PRESS TOSET SEECURRENT BARGRAPHMONTH

ENTER

SETUP

NEXT

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CURRENT DATE

0122/2007

ARROWS TO PRESS TO

SET MONTH SET DAY

ENTER

CURRENT DATE

0122/2007

ARROWS TO PRESS TOSET DAY SET YEAR

ENTER

CURRENT DATE

01/222007

ARROWS TO PRESS TOSET YEAR SET

CURRENT TIME

NEXT

CURRENT TIME

0801:00

ARROWS TO PRESS TOSET HOUR SET

MINUTE

ENTER

CURRENT TIME

0801:00

ARROWS TO PRESS TOSET MINUTE SET

DATALOG INTERVAL

NEXT

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DATALOG INTERVAL

5min.

ARROWS TO PRESS TOSET SET

INTERVAL DATALOG RETENTION

NEXT

DATALOG POWERUP

RETAIN/erase

ARROWS TO PRESS TOSET SETRETENTION DATALOG

STOP

NEXT

LOG AFTER STOP?

yes/NO

ARROWS TO PRESS TOSET STOP SET

TIMING TRACKER

ESC

It is possible to setup the system so that any change to the ignitiontiming will trigger a datalog event (an exception report). Exceptionreports are automatically generated for alarms or shutdowns.

TRACK TIMING?

yes/NO

ARROWS TO PRESS TOSET OPTION RETURN TO

DATE MENU

NEXT

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13.4 The Bargraph displaySEE SECTION 11.2of the spark reference num-ber on Display Module 791908-1can be scaled by changing the LOWand HIGHendpoints of the bargraph. A smaller range between end-points increases the resolution of the Bargraph.

BARGRAPH SETUP

Next Esc Enter

PRESS TO PRESS TOSET RETURN TOBARGRAPH OTHERENDPOINTS

ENTER

MENUS

NEXT

BARGRAPH LIMIT

LOW 100

PRESS PRESS TOARROWS CONTINUESET LOW

NEXT

BARGRAPH LIMIT

HIGH 150

PRESS PRESS TOARROWS RETURNSET NODE HOME

ESC

The Bargraph LOW LIMITis adjustable from 0 to the value set for theLOW SPARK threshold alarm SEE SECTION 12.2 for details. The Bar-graph HIGH LIMITis adjustable from the value set for the HIGH SPARKthreshold to 255SEE SECTION 12.3for details.

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