Download Digital Ignition ZDG3 for Aermacchi - Elektronik-Sachse-Shop

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Digital Ignition ZDG3
Fitting instructions digital ignition ZDG3 for Aermacchi
1.
2.
3.
4.
5.
Function
Fitting
Electrical connection
Adjustments
General
Volker Sachse • Lerchenweg 12 • D32312 Lübbecke • 0049 5741/61188 • [email protected]
Fitting instructions digital ignition ZDG3 for Aermacchi
1. Function - 2. Fitting - 3. Electrical connection - 4.Adjustment - 5. General
The digital ignition ZDG3 consists of following components:
- light-barrier printed circuit board
- corresponding mechanical components
- the ignition box
and replaces contact breaker plate and advance unit.
Function: per revolution of the crankshaft starting from TDC, the momentary peripheral speed is determined
and by this means, the time up to ignition is calculated. Because the peripheral speed varies substantially
during acceleration, this long measurement is selected in order to determine a relatively exact measurement.
The following computation of ignition timing is divided into 4 ranges:
1. 0-400 rpm
2. 400-1000 rpm
3. 1000-6200 rpm
4. 6200-10000 rpm
Starting range, ignition always at TDC
Idling range, 2° to 8° advanced ignition, depending on curve selection
Partial load range, the spark advance adjustment occurs here
maximum load range, constant 30° to 39° advanced ignition, depending
on curve selection
As opposed to the original ignition system, ignition now takes place at each revolution of the crankshaft, thus
also during the exhaust stroke.
ignition box
pulse disc and light-barrier printed circuit board
The measuring happens by opto-electronic parts - light barriers - because only light barriers produces an
always same, speed-independent precise signal and therefore all computations can be made more
accurately.
If the engine stops, the ignition current will be switched off after 3 sec. to protect the ignition coils.
9 ignition curves are available:
Fitting instructions digital ignition ZDG3 for Aermacchi
1. Function - 2. Fitting - 3. Electrical connection - 4. Adjustment - 5. General
Remove the contact breaker plate and the mechanical
advance unit and fit the driver. Then fasten the printed circuit
board. Finally put the lightdisk onto the driver but don't tight
the set-screws yet.
The attachment of the ignition box takes place by the provided velcro strip on a suitable surface, which
should not be in the splash-water range.
The original ignition coil can be used further.
In case of an exchange nearly all types of new or used ignition coils can be used, which corresponds to a
primary resistance of 2.5 - 6 Ohms.
Fitting instructions digital ignition ZDG3 for Aermacchi
1. Function - 2. Fitting - 3. Electrical Connections - 4. Adjustments - 5. General
connection schema
Connection allocation of the system plug
1
nc
2
ground, earth
3
brown, ground (Pickup)
4
nc
5
yellow, light barrier (Pickup)
6
white, +5V (Pickup)
7
tachometer output
8
+12V (or +6V) (Supply voltage from the ignition switch)
9
ground, earth
10
ignition coil
(Make sure of a good contact to the frame
or battery!!)
The conductor cross-section of
the earth cable should amount
to 1,5-2,5 mm2 and schould be
kept as short as possible.
The conductor cross-section of
the other cables should not be
below 0,75 mm2.
Always use end splices!
0
Fitting instructions for digital ignition ZDG3 (Aermacchi 350)
1. Function - 2. Fitting - 3. Electrical connections - 4. Adjustments - 5. General
Attention! Remove the spark plug caps before
adjusting the light disc!
First the piston must be brought on TDC.
Now rotate the light disk precisely into position as shown in the picture.
The position is correct when the LED (yellow circle) toggles. Now
tighten the grub screws evenly (ensure that the light disk is in the centre
of the light-barrier!) and push the spark plug caps. The bike is ready to
start.
The switches can be found at the front of the ignition box:
switch adjustment
rotary switch
dip switch
(curve selectionl)
overspeed protection at 7900 rpm
1-9
curves 1-9
1
(switch down)
or at 9800 rpm (switch up)
rev. counter frequency
0
test mode, continuous firing
2
(switch up >> fout =crankshaft
switch down >> fout=camshaft )
Fitting instructions for digital ignition ZDG3 (Aermacchi 350)
1. Function - 2.Fitting - 3. Electrical connection - 4. Adjustment - 5. General
Only use an interference-free cap for the spark plug!
(recommended NGK caps with 5kOhm internal resistance)
Malfunction sources :
Unstable ignition timing :
At some stroboscope lamps the ignition point suddenly oscillates around 4-6°. In this case the lamp once
reacts to the ignition spark starting, another time to the burning end of the spark. If possible readjust the
sensitivity of the lamp.
Doesn't start :
You can check the function of the ignition by unscrewing the spark plugs, leaving them in the plugs, connect
to ground and by slowly kicking you can see or hear the sparks.
To check the cable connecting and the supply voltage put the rotary switch to '0'. Now the spark plugs must
fire continually.
Irregular engine cutouts:
If sometimes the engine suspends while driving for 2-3 seconds and keeps running thereafter completely
normally that means that the ignition has been reset. The cause for it can be a defective cap or a loose
ignition cable in the coil or cap. But in most cases a bad contact in the operating voltage supply (starter lock,
fuse holder etc.) causes tis effect. For a test you can put a cable directly from the ignition coils and the
ignition box to the positive terminal of the battery. Also put a second cable from the negative terminal of the
battery to the ignition box (secure ground connection). If the engine is running well now you can assume an
error in the wiring harness.
With contact brakers such a bad contact is not noticeable, because a short break for a few milliseconds of
the supply voltage does't matter, electronics in contrast are more sensitively.
Volker Sachse
motorcycle electronics
Lerchenweg 12
32312 Luebbecke
Germany
Tel. 0049 5741/61188
Mobil: 0049 160/9414 2224
[email protected]
www.elektronik-sachse.de