ALTRONIC®, INC.

712 TRUMBULL AVENUE

GIRARD, OHIO 44420

ALTRONIC II-CPU IGNITION SYSTEM INSTALLATION INSTRUCTIONS

DC POWERED, "D" SERIES FORM DC-CPU II 6-88

WARNING: AN IMPROPERLY INSTALLED OR OPERATING IGNITION SYSTEM MAY LEAD TO

IMPROPER ENGINE OPERATION WHICH CONSEQUENTLY COULD POSE TilE TIIREAT
OF PERSONAL INJURY TO OPERATORS OR OTIIER NEARBY PERSONNEL.

1.0 DESCRIPTION

1.1 The Altronic II-CPU, DC-powered ignition system is a microcircuit-based,

capacitor discharge system applicable to slow and medium speed, high BMEP
engines. The system features crankshaft-triggered timing accuracy and the
capability to vary timing electronically by several means, including an
external 4-20 rna. control signal. There are no wearing rotating parts added
to the engine in the DC-powered CPU system. The system consists of a
specially-designed DC power converter unit (see section 13.1), a CPU control
unit, a wiring harness, (2) magnetic pick-ups and cables, a Hall-effect pick-up
and trigger magnet ( 4-cycle engines only), and an ignition coil for each
spark plug; see drawing 209 060A for a total system overview.

1. 2 For non-hazardous operations there is an unshielded epoxy coil 291 001. For
hazardous area operations, shielded primary cable assemblies are available
for connection to one of two optional shielded coil series - 291 001-S or
591 008. NOTE: Use only the above Altronic coils with the Altronic II-CPU
ignition system.

2.0 MOUNTING THE 24VDC CONVERTER UNIT

2.1 Select a mounting location meeting the following requirements:

- Located within 12 ft. of the CPU unit; the converter may be located on
or off the engine.
- The front panel door of the converter unit should be easily accessible
and free to swing open.
- Select a location where the maximum ambient temperature does not exceed
150°F. (65°C.).

2. 2 The converter unit should be fastened securely to a rigid bracket using the
shock mounts provided.

3.0 MOUNTING THE ALTRONIC II-CPU CONTROL UNIT

3.1 Select a mounting location meeting the following requirements (refer to drawing
209 060A):
- Located within 12 ft. of the 24 VDC converter unit.
- Located within 7 ft. of the primary junction box.
- The front panel door of the control unit should be easily accessible and
free to swing open.
- Select a location where the maximum ambient temperature does not exceed
150°F. (65°C.).

3. 2 The control box should be fastened securely to a rigid engine bracket using
the shock mounts provided.
4.0 MOUNTING FLYWHEEL GEAR / DRILLING FLYWHEEL HOLES

4.1 The Al tronic II -CPU system requires a source of angular position pulses from
the engine crankshaft. This can be a flywheel ring gear, a separately provided
gear or specially drilled holes in the flywheel. The source of position
pulses must meet the following requirements:
- Must be ferrous material
- Diameter of 18" or greater
- No. of teeth or holes of 180 or greater
- Maximum runout referenced to the pick-up of .007"
Refer to drawings 209 060A, 209 102 and 209 103 for further details.

5.0 MOUNTING THE MAGNETIC PICK-UPS

5.1 The system requires two magnetic pick-up signals: the angular position pulses
from the gear or drilled holes and a reset pulse near the most advanced firing
position desired for no. 1 cylinder. The pick-ups must be mounted to rigid
brackets to maintain an air gap of .015" ± .005" with respect to the rotating
gear or flywheel. It is also important for maximum signal efficiency that
the centerline of the pick-up pass through the center of the rotating part
- see drawing 209 102.

6.0 MOUNTING THE FLYWHEEL RESET PIN

6.1 Set the engine with no. 1 cylinder six (6) degrees ahead of the most advanced
firing point. Mark a point on the flywheel directly opposite the pole piece
of the reset magnetic pick-up; then rotate the engine to a position convenient
for drilling and tapping the flywheel at the point marked above. The reset
pin should be made from a steel (magnetic) 1/4"-20 bolt or stud. See drawing
209 102 for details.

6. 2 Rotate the engine to the original set point and adjust the air gap between
the end of the reset pin and the magnetic pick-up at . 010" using a feeler
gauge.

7.0 MOUNTING THE CYCLE TRIGGER (4-CYCLE ENGINE ONLY)

7.1 The trigger magnet 720 002 must be mounted on the engine camshaft or other
accessory drive operating at camshaft speed. An 8mm tapped hole 1/2" (12.7mm)
deep is required - see drawing 720 002 for details. The magnet MUST rotate
on a diameter NOT EXCEEDING 6 inches (150mm).

7. 2 Set the engine on the COMPRESSION stroke of no. 1 cylinder with the reset
pin DIRECTLY OPPOSITE the reset pick-up. The Hall-effect pick-up (591 014-2)
must be mounted DIRECTLY OPPOSITE the trigger magnet (720 002) coincident
with the reset pick-up and pin being lined-up - refer to drawing 209 060A.
NOTE: The Hall-effect signal and the reset pick-up signal must occur at
the same time for the system to function.
The Hall-effect pick-up dimensions are shown on drawing 591 014.

7.3 The air gap between the Hall-effect pick-up and trigger magnet must not exceed
.040" (l.Omm).
8.0 24VDC CONVERTER UNIT WIRING

8.1 It is necessary to fabricate two w1r1ng conduits; use 1/2" conduit (rigid
or flexible) for mechanical and shock-hazard protection:
- RIGHT-HAND ENTRY - Two leads from a source (preferably non-interruptible)
of 20-28 VDC (nominal 24 VDC), 2 amps minimum. The negative of the 24
VDC supply MUST be common with engine ground.
- LEFT-HAND ENTRY - Two leads leading from the converter unit to the Altronic
II-CPU control unit - see drawing 209 061A for details.
CAUTION: These leads carry 400 VDC and are a shock hazard. Do not handle
these wires while the system is powered.

8. 2 Provision must be made to interrupt the 24 VDC supply to stop the ignition
system output. Use a switch rated for 24 VDC, 10 amps; refer to drawing
209 060A.

9.0 CPU CONTROL UNIT WIRING

9.1 RIGHT-HAND ENTRY - A conduit containing the two 400 VDC output leads from
the 24 VDC converter unit must be run to the right-hand entry in the bottom
access plate of the CPU control unit. Connect as shown on drawing 209 061A.
The entry hole is sized for a 1/2"-14 NPT male conduit fitting.

9.2 CENTER ENTRY - Run a separate conduit for the two (2) magnetic pick-up cable
assemblies. These should enter through the center entry in the CPU box and
terminate as shown on drawing 209 061A. The entry hole is sized for a 1/2"-14
NPT male conduit fitting. 4-CYCLE ENGINE ONLY: The cable from the Hall-effect
pick-up also enters through the center hole and connects as shown on drawing
209 061A.

9. 3 LEFT-HAND ENTRY - A separate conduit must be used to the left-hand entry

for all connections to the left-hand, 12-position terminal strip in the CPU
box. Use 24AWG, UL style 1015 wire for all these connections; this wire
is available from Altronic under part no. 603 102 (black) or 603 103 (white).
A. Terminals 1-4 are used for the 4-20 rna timing control connections. The
4-20 rna loop connects to terminals 1 and 2; the 12-24 VDC supply voltage
is connected to terminals 3 and 4. See drawings 209 104B and 209 llO.
NOTE: Terminals 2 and 4 MUST BE common negative supply.
B. Terminals 5 and 6 are used for the one-step timing adjustment if used;
see drawings 209 061A and 209 109.
C. If used, the fault output leads connect to terminals 10 and 11; see drawing
209 111 and section 14.2 for details.
10.0 PRIMARY WIRING (REFER TO WIRING DIAGRAMS 209 10SA/209 106A)

10.1 The main wiring harness (293 023-X, 293 026-X, or 293 027 -X) connects the
CPU control unit to the engine junction box. Refer to drawing 509 025 if
it is desired to shorten the conduit length of the harness. Insert the
connector into the Altronic II-CPU control unit and tighten hand tight;
then carefully tighten an additional one-sixth turn with a wrench.

10.2 Write in the engine firing order below the applicable CPU control unit:
281 508-X A- B- C - D- E - F - G- H
ENGINE:
281 512-X A- B- C - D- E - F - G- H- J - K- L - M
ENGINE:
281 516-X A - B - C - D - E - F - G - H - J - K - L - M- R - S - T - U
ENGINE:
281 520-X Al-A2-Bl-B2-Cl-C2-Dl-D2-El-E2-Fl-F2-Gl-G2-Hl-H2-Jl-J2-Kl-K2
ENGINE:

10.3 Connect the harness leads in the junction box in accordance with the engine's
firing order. The leads from the junction box corresponding to the above
system outputs connect to the ignition coil negative(-) terminals. The
"P" lead and the common coil ground lead(s) connecting the positive (+)
terminals of the ignition coils must be grounded to the engine in the junction
box. On V-engines, run a separate common ground lead for each bank. All
primary wiring should be protected from physical damage and vibration. Refer
to wiring diagrams 209 105A (unshielded) or 209 106A (shielded) for general
details.

10.4 Primary wire should be no. 16 gauge stranded, tinned copper wire. The
insulation should have a minimum thickness of .016" and be rated 105°C.
or higher. Irradiated PVC or polyolefin insulations are recommended.
Altronic primary wire no. 503 188 meets these specifications.

10.5 If two ignition coils per cylinder connected to a common output are used,
use parallel wiring as shown on the wiring diagrams 209 105A and 209 106A.

11.0 SHUTDOWN WIRING

11.1 To shut-off the DC powered ignition system, the 24 VDC supply to the converter
unit must be interrupted. Use a switch rated 24 VDC, 5 amps. Refer to
drawing 209 060A for details.

11. 2 DO NOT ground leads "N" or "V" to stop the ignition with a DC power source.
This can cause component failure in the DC converter and/or the CPU control
unit.
12.0 SECONDARY WIRING

12.1 Mount the ignition coils as close as possible to the engine spark plugs
consistent with a secure mounting and avoidance of temperatures in excess
of 185°F.

12.2 The spark plug leads should be fabricated from 7rnrn, silicone insulated,
tinned copper conductor with sui table terminals and a silicone spark plug
boot. Keep spark plug leads as short as possible and in all cases not longer
than 18 inches. Spark plug leads should be kept at Jeast 2 inches away
from any grounded engine part. In deep spark plug wells, use rigid, insulated
extenders projecting out of the well.

12.3 The use of a clear, silicone grease (such as Dow Corning DC-200) is
recommended for all high-tension connections and boots. This material helps
seal out moisture and prevent corrosion from atmospheric sources.

13.0 OPERATION (Refer to drawing 209 107A)

13.1 The 24 VDC converter provides the power for the basic system operation. The
Al tronic converter is a special design that outputs a regulated 400 VDC
to the energy storage capacitors and contains special circuitry limiting
the output after each firing to insure proper SCR turn-off.
NOTE: During each start-up, it is necessary to turn off the 24 VDC power
to the converter unit. Re-apply power approximately four seconds
prior to the point in the engine start-up sequence when ignition
is desired.
On 4-cycle engines, a Hall-effect pick-up senses a trigger magnet mounted
on the engine camshaft to determine whether the flywheel is on the compression
or exhaust stroke.

13.2 The CPU Control Unit consists of power conditioning circuitry for the logic
circuit and memory, and an electronic distribution circuit. The system
operates with two magnetic pick-up inputs. One counts the teeth on a
crankshaft-mounted gear or holes drilled in the flywheel; the other provides
a reset pulse once per engine revolution. Two counts are provided for each
gear tooth or flywheel hole. Thus the degree separation from one count
to the next is 360/2N, where N = no. of teeth or holes. This value is called
a TOOTH DEGREE.
Examples: No. of teeth 180
TOOTH DEGREE 360/2xl80 1.0 engine degree
No. of teeth 230
TOOTH DEGREE 360/2x230 = 0.78 engine degree
The TOOTH DEGREE is the basic unit of timing adjustabili ty or change in
the system. As ignition timing is varied on an operating engine, it will
vary one TOOTH DEGREE at a time; no finer increment is possible. Therefore,
a minimum of 180 interruptions (teeth or holes) is recommended.
13.3 All timing adjustments are made by delaying (retarding) the spark output
a given number of TOOTH DEGREES. There are three ways to vary ignition
timing with the DC-CPU system; all are through connections and/or switches
in the CPU control unit (refer to drawing 209 108A):
- MANUAL SETTING (SWl) - This subtracts TOOTH DEGREES (0-15) from the reset
pin position to determine the maximum advance timing point in operation.
- ONE-STEP SETTING (SW2) - This sets another retard amount in TOOTH DEGREES
(0-15) that can be switched in through the use of external contacts (see
drawing 209 109).
- 4-20 MA ADJUSTMENT (SW3) - Open position allows influence of the 4-20
ma. control loop signal; closed position deletes any effect from the loop
signal. The system reads 11 4 ma. 11 as no retard, 11 20 ma. 11 as full retard
and is linear in between. The standard ranges of the system are 24 engine
degrees (code C), 36 engine degrees (code B) and 48 engine degrees (code
A); the timing range code is the last letter in the Memory Code Part No.
- see section 13.4. Drawing 209 110 shows the timing curve vs. milliamp
(ma.) signal input and the wiring hook-up.

13.4 The system memory chip contains the specific information for any particular
engine application. This includes no. of cylinders, 2 or 4-cycle, engine
firing pattern in degrees, no. of teeth or holes being sensed, and timing
range on the 4-20 ma. loop control. The Memory Code Part No. is written
on the large memory integrated circuit chip in the CPU Control Unit. See
form All-CPU AL for the Memory Code Part No. to be sure the system program
meets the application requirements. To order a spare memory chip, order
part no. 601 507 (memory code).

14.0 INDICATION OF CURRENT LOOP OPERATION

14.1 The logic board on the cover of the CPU control unit has a LED indicator
light for current loop operation. The light should be on if the system
is on current loop operation; if not, check connections 1 through 4 and
the external loop circuits.

14.2 The system also has a normally-closed, solid state fault-output switch
available at terminals 10 and 11 in the CPU control unit; this automatically
opens if the 4-20 ma. control loop or the loop power supply is lost. The
internal switch has a rating of 30 VDC, 250 ma. Terminals 10 and ll in
the CPU control unit may be connected to an external alarm or shutdown device;
a typical hook-up using a relay is shown on drawing 209 111.
NOTE: Terminal 11 must be the negative supply; it is electrically common
with terminals 2 and 4 - see drawing 209 111.
15.0 TROUBLESHOOTING GUIDE

PROBLEM TEST PROCEDURE TEST RESULT CORRECTIVE ACTION

Ignition not Measure voltage at Below 30 YDC See checklist #1

firing on any CPU unit "N" pin. 30-150 YDC Check cranking RPM
cylinder. Above 150 YDC See checklist #2

Ignition mis- Check primary with Primary firing Check spark plug,
firing on one oscilloscope or coil or plug lead.
cylinder only timing light
No primary firing See checklist #3

Ignition tim- Check timing on All incorrect by See checklist #4

ing steady but several cylinders same amount
incorrect on each bank
Incorrect by vary- See checklist #5
ing amounts

Ignition tim- Put SW3 in closed Timing OK 4-20 rna signal is

ing varies position problem

Timing still Check gap and align-

varies ment of gear-tooth
(or hole) pick-up
Checklist #1
1. Disconnect the primary harness. If val tage is now OK, problem is the CPU
control unit (distributor board).
2. I f val tage is still low with harness disconnected, unplug the 6-posi tion
plug (right side) inside the CPU control unit. Measure voltage at the
6-position connector: (+) to "A" pin, (-) to "B" pin; if voltage OK, problem
is the CPU control unit (distributor board).
3. If voltage is still low, problem is in the DC converter unit.

Checklist #2
1. Check primary ground connections and coil grounds.
2. Check air gap (.015") and alignment vs. interrupting element on both magnetic
pick-ups.
3. Check continuity of magnetic pick-up connections. Unplug the 5-position
plug (middle) inside the CPU control unit. Measure resistance across the
two pairs of magnetic pick-up leads; 1,100 ohms is the correct reading.
4. On 4-cycle engines, check that the Hall-effect pick-up and its triggering
magnet are exactly lined-up when the reset pin exactly lines up with the
reset magnetic pick-up on the compression stroke of no. 1 cylinder.
5. If all above checks are OK and system still does not fire, problem is in
the CPU control unit.

Checklist #3
1. Check all primary w1r1ng and connections for continuity and/or shorts to
ground. NOTE: Do not apply a megger or other high voltage tester without
first disconnecting the main harness from the CPU control unit.
2. If above appears OK, problem is most likely in CPU control unit (distributor
board).

Checklist #4
1. Attempt to remedy by changing position of manual timing switch SWl - see
drawing 209 108A.
2. If timing still is incorrect, check for proper position of reset pin; see
section 6.0.

Checklist #5
1. Check firing order of engine vs. CPU firing order (A-B-C-etc.).
2. Check memory code no. vs. application - see section 13.4.
 201 602

\ I TAP 5/8-18
I I / F O R PICKUP D
- __ _j ____ ~--
f~~AIR
11
1
I
\v, ~ I
~~59~PTIMUM rLYWHEEL
D
R
.015"J~~ \_:~,
GEAR WHEEL
180 TIEETH MIN. I l
TI
I
\
:V4"
I
CHANNEL

I , i RESET
PICKUP
I ~ PROJECTION
W/NUT
I

i \ i 1-.Lo·-
I \ : MIN.

I I i FLYWHEEL AND PROJECTION

~
FLYWHEEL
ORIENTATION (EDGE VIEW)
i
1
/l \ AIR GAP GRIND AWAY BDL T HEAD
I
2" MIN. RECOMMENDED~ i
I _j /iN~~RESET
J

:1\ \
I :::::--------- .015" OPTIMUM

PROJECTION
TAP 5/8-18 &_
~~~~87~,
V
RESET PROJECTION
WITH 1/4-20 JAM NUT
f MATIERIAL SHOI'fN DASHED-
(USING 1/4-20 BOLT)

lr"
ANGLE STOCK (TYP 2) FOR PICKUP
1
1

,..j,
I
I "''
ENGI!:!E_ BEDPLA_!~ _ _ _ _ _ _ c~~-:::::!'_~=~=:::::::~#=J'
II
3/8" THICK
MOUNTING PLATE
gvgo·
o @ _j
r
111
SOL T INTO STEEL OR
ANCHOR TO CONCRETIE
(TYP 4)
u a:

PATH OF ROTATION IS
PERPENDICULAR TO FLAT OF STUD
•J=131
.75
["iJ
L_
NOTE:
VISUAL PROPORA TION OF THIS ILLUSTRATION EDGE VIEW RESET PROJECTION
WILL CHANGE WITH VARIATIONS IN GEAR AND
FLYWHEEL SIZE AND RELATIONSHIP.
L-------""1"--~R~~EV~I..i:SiJ;I,\;;O~N~S~==~-------i <EXCEPT
TOLERANCES
AS NlTED> AL TRDNIC INC.
NO. DATE BY DESCRIPTION

L_3:__j___27:_1~8~-~90~~WTP~~R:.:,ED~R~A~W~N__:O~N~C.:,AD~;_U~P...':D:::Ac:_TE:,:D:.......__ _ _ _ _ _ _-j'":~~"X"--
.XX -
•.00!5
:1:.010
TITLE pICKUP MDUNTI NG DETAIL
4

t_s~------4---~------------------------------------i----~oc~~~&arnne~v~~llt~~T~r--li11~_;9 ~8~4~
DR•WN IY DA sc•L£ NONE PART NUMBER

~6~---------l----lf.---------------------------------------1"'"TERIAL APPRIJVED BY 209 102

7
 £'0l 60Z

PROCEDURE FOR DRILLING

FLYWHEEL LAYOUT
360 HOLES IN ENGINE FLYWHEEL

MARK "A" AND MEASURE DRILLING DETAIL

CIRCUMFERENCE A-A
=
=
c::>
c::>
c::> ~FLYWHEEL
0

···0···
0
MEASURE 1/2A-A
AND MARK "B"
NOTE: A-B - B- A
0
¢ Gv BAR HOLES

,.,, "'"" -~- "" D

···0·· "C"
"D"
MEASURE 1/2A-B
AND MARK "c"
MEASURE AND MARK
"D" IN THE SAME MANNER

MEASURE 1/2A-C
~~~---';.:;--"~
I
1--
!
1"
MIN.
-.J.- MIN.-
1"
r-
RESET PROJECTION

;\D
AND MARK "E"
" 0 " "A" "H" MEASURE AND MARK
"B" "F", "G", AND "H" IN THE SAME MANNER 2I 3 N
... "N" ~(;1/3"N"
t-- DISTANCE
NOTE: CONFIRM INTERVALS BETWEEN SO I nMING
"F" "E" MARKS ARE NOW EQUAL. MIN. I I , HOLES
"N" = A TO E
"C"
-r 'f~~g ~

MEASURE THE LENGTH A-E. DIVIDE

I
O I I
BY 45, AND BEGINNING 'MTH "A"
MARK OFF INTERVALS OF THIS
"A" LENGTH TO "E". COUNTING "A"
AND "E" THERE SHOULD BE 46 MARKS. NOTE: IF 2/3 "N" WORKS OUT TO BE BETWEEN STANDARD
DRILL SIZES - USE NEXT SIZE LARGER.
E"
SAME
DO REMAINING 7 SECTIONS IN1r
THEMANNER. ~TH:E:...--------~~~~m~----------,~~:::;;T----:7':::'~::~;::--;--;:::-----,
REVISIONS TOLERANCES
NO. DATE BY DESCRIPTION
AL TRDNIC INC. CEXCEPT AS I«JTED)

I 10 19 90 WTP REDRAWN ON CAD; UPDATED DECIMH.. TITLE

.XXX - .t.005
.XX - ±.010 FL Y\./HEEL HOLE DRILLING
2 3 12 91 WTP UPDATED
F'RACTJDNoiL.
3 DRA'WN JY SCAL£
DA NONE PART NUMBER
CHECKED BY DATE
4 5 29 85
5
HAT ERIAL
APPROVED BY 209 103
 \1090 602

NOTE• REQUIRED ONLY

fOR 4-CYCLE ENGINES CABLE - 593 052-X

6
(n)

l !
SPARK PLUG-
HALL-EffECT
(
.040'
MAXl
CYCLE SENSOR
591 014-2
HIGH TENSION -
LEAD Jf~~
~ f----0>
rJj
~
(----'

CAA~lJ
COIL- 1---

MOUNTED
MAGNET n n JJ
lq
720 002

J,mcn"
~
IGNITION TIMING CONTROL BOX
HALL-EFfECT PICK-UP TO , - - - PER 209 108A. 209 109,
LINE -UP IJITH MAGNET COINCIDENT
IJITH RESET PICK-UP LINED-UP
IJITH RESET PIN ON COMPRESSION
STROKE Of Ill CYLINDER
AND 209 110.
293 023-X HARNESS 1
b_
AL TRONIC II - CPU
IGNITION UNIT

281 SXX-2 o----- AL TRONIC II - CPU

24 VOLT D.C. CONVERTER

~ 281 550-2
NON-INTERRUPTIBLE
24VDC 2 AMP.
POIJER SUPPLY
DRILLED HOLE
OR GEAR TOOTH
MAG. PICK-UP
691 118-X
RESET
MAG. PICK -UP
~ 691 118-X LJ ~
T IGNITION POIJER - 400V DC T ~
MAX. AIR GAP IGNITION SIJITCH
<BOTH PICK-UPS>• CABLE - 693 104-X CLOSE TO RUN
.015' OPEN TO STOP
SIJITCH RATING• 24VDC, SA
CABLE - 693 104-X
NOTE• DO NOT GROUND
SYSTEM 'N' OR 'V' LEAD
TO STOP IGNITION.

REVISIONS TOLERANCES
NO. DATE BY DESCRIPTION
<EXCEPT AI NJTElD AL TRONIC INC.
1 llECIJW.. TITLE
.XXX - :t.005 DC POIJERED
2 .XX - t.OlO AL TRONIC II CPU LAYOUT
r!IACTIDNAL
3 IRA\r'H IY $CIU
IJTP NONE PART NUMBER
0£0CED JY 111\T£
4 6-7 88
5
""TERIN..
lol'l'ltiJVO IY 209 060A
 1;;;1190 602

281 5XX-2
CPU II UNIT
+ + +
;~ a~ ~BU
I I I

BUH ...... ;~ ..
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a ~~ ~! ~j ~ ~+ ~ @§ 1 I

9~;~! ~~Ui;
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TIMING CD<TI!Q. !PI'UTS
u ~~~~'
PlCK-tPS
123456719101112 A I S A I S£DCIA
OUTPUT
281 550-2
TO COIL DC CONVERTER
000000000000 00001l fl>00001l -
/~~~~~'~l
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ii!~5 =f~
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riELD 'WIRING HUST : - ; ~ $1 1--- l
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~ ~
!0!5 TYPE 'WIRE IN
SEPERATE CONDUIT
A'WAY rROM ALL OTHER
, [c ....
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'WIRING.
,,~----
0
> ""...
>
NOTE• THE riRST rll\R (
TERMINALS MUST BE :i ""z ""z (\J

~ +
I 1!1 1!1
CONNECTED 'WHEN USING
THE 4-20 "" TIHING
LOOP - SEE CHART
I o">
-w
... "' 593 052-24
HARNESS
z

I
I
MC<
Cl'<t
"'I
I I
NOTE:
THE NEGATIVE OF THE 24VDC
SUPPLY MUST BE COMMON \liTH

I TO MAG
PICKUPS
I I \liRE TO BE 16 GA.
ENGINE GROUND.

NOTE: AL TRONIC 503 188 OR EQUIVALENT NON-INTERRUPTIBLE

TERMINALS 2, 4, AND II ARE ' - - - - + 24VDC

ELECTRICALLY COMMON.
GND
TO HALL
EFFECT PICKUP J_
7

REVISIONS TOLERANCES
NO. DATE BY DESCRIPTION
CEXIXPT .. ICJTDD AL TRONIC INC.
I DECIMAL TITLE
.XXX - :t,OOS
2 .XX - t.O!O CPU II AND DC CONVERTER \./IRING
rRACTJQo!AL
3 DRA\IN JY $CAL£
\ITP NONE PART NUMBER
O£Ck£D 1Y ""T£
4 6-17-88
5
~'T[RlAL.
APPROVED IY 209 061A
 \iSO L 60Z

GROUND HOOK-UP DETAIL:

JUNCTION BOX
COIL POSITIVE TERMINAL TO N
MOUNTING BRACKET CONNECTION
"N" AND "I( LEADS ARE NOT CONNECTED
AT BOTH ENDS OF EACH BANK.

USE HOOK-UP SHOWN FOR

TWO COILS PER CYLJNDER

JUNCTION
BOX

SPARK PLUG

SPARK PLUG LEAD

COIL 291 001

NOTE:
CPU UNIT MUST
BE GROUNDED
USE PARALLEL HOOK-UP
SHOWN FOR TWO COILS
SEPARATE GROUNDS
PER CYLJNDER.
IN JUNCTION BOX
AS SHOWN.

L--~----~--~--~R~E~~~S~I~O~N~S~~~-------------trrum~~
(IJ<CU'TMNOlEI>) AL TRONIC INC.
BY DESCRIPTION

nnE WIRING DIAGRAM - UNSHIELDED

~~--------~--~---------------------------------------L--------~~~~n~~~iru••~~r-~6~-~6~-~8~8~~
ORA.., BY WTP SICA!.£ NONE PART NUMBER

L-~----------+--4-----------------------·-----------------JWA~~ ~~===o~~.=y~--~----~~~~209 105A

 V90 l 60l

+ CLASS I, GROUP D, DIV. 2 RATED SYSTEM.

UNSHIELDED SPARK PLUG AND LEAD MAY BE
USED 'M-iERE SUCH RATING IS NOT REQUIRED.

.AJNCTION BOX

N
"N" AND "V" LEADS ARE NOT CONNECTED

FLEXIBLE SHIELDED""'\
OR RIGID COIL \
CONDUIT 291 001-S IGNITION COILS:
291 001-S
591 008

.AJNCTION
BOX

SHIELDED PRIMARY LEAD TWO COILS PER

593 022. 593 027 C'l'UNDER SHOWN
ABOVE AND BELOW.

INTEGRAL
COIL
591 008

USE PARAU.EL HOOK-UP

NOTE: SHOWN FOR TWO COILS
SEPARATE GROUNDS PER C'l'UNDER.
CPU UNIT MUST IN JUNCTION BOX
BE GROUNDED

_..
AS SHOWN.

NO.
REVISIONS
DESCRIPTION
TOlERANCES_, ALTRONIC INC.
DATE BY
1 ll£CIMAL
6-15-88 DEB DELETED GROUND NOTE .XXX- :t.005 TITLE
.XX - :t.010 WIRING DIAGRAM - SHIELDED
2 2-2-89 WTP REMOVED "N" LEAD FROM JUNCTION BOX; ADDED CPU NOTE
F'RAC11CNIL
3 ORA~ BY SCAI£
2-14-89 WTP APPEARANCE OF COILS AND SPARK PLUGS CHANGED WTP NONE PART NUMBER
O<Ea<ED BY DAlE
4 6-6-88
5
IIAmiiiL
N't'ROI'EDBY 209 106A
 VLOL 60Z

CPU CONTROL UNIT

IF-:,:::------------------~
+
o-
241/DC
24VDC
CONVERTER
I 1
1-----:::----...__-1
I
PO\\£R DC- r-----~
I l MEt.IORY I ----ll I

i ~;~~OR i!
SUPPLY LOW
o-

! ~' i i "'~,~~OW'
'------'

I i
~"
t.IAGNET AT ~
CAt.ASHAFT
SPEED PICK-UP
I l I
I I ~~
I I I '" ,,_ I

I ! ;, l '" I,
RESET
PULSE ~ 4-20mA
Tlt.IING Tlt.IING
PULSES '------ SIGNAL
(OPTlONAL)
___./._
STEP Tlt.IING
SWITCH

!...._ IGNITlON COILS

(ONE PER SPARK PLUG)

TOI.£RAHCES
(b<IPTAS..,) ALTRONIC INC.
OEOUAL TITLE
.XXX - ,o.oo5
.XX - ±.010 DC-CPU BLOCK DIAGRAM
REVISIONS
FRAC'r.ONAL
NO. DATE BY DESCRIPTlON DRAYIN BY SCN..£
WTP NONE PART NUMBER
OfEO<ED BY OAlt
MATDtiAL 6 7 88
2 APPI\0\tD BY 209 107A
 \1801 602

~r-
f-

0 0 0 1-

l€lO!Y PliO 6111 :507 1-

INSTALL MEMORY TIMING SIJITCH SIJ1

~o~
f-- Is"' 2l CHIP AS SHO\IN1
r-- f- MANUAL TIMING ADJUSTMENT USED TO SET THE FULL ADVANCE TIMING POSITION

~
1:1'£ ST[P

II
D
RETARD S\IITCH OF THE SYSTEM. POSITION 0 IS MIN. RETARDJ POSITION F IS MAX. RETARD.
OaHIN RETARD
f- EACH ADDITIONAL SIJITCH POSITION RETARDS THE TIMING BY ONE TOOTH DEGREE.
f•HAX RETAAD

~ TIMING SIJITCH SIJ2

~MNI.IH.. TtMING
AD.JUSTMENT
- ONE -STEP TIMING CHANGE CONTROLLED BY EXTERNAL CONTACTS CONNECTED BETIJEEN
~ SWITCH TERMINALS 5 AND 6 <SEE DRAIJING 209 104A>. THE EXTERNAL CONTACTS ARE NORMALLY
O.MIN RETARD
f•MAX RETARD
f- CLOSED AND ARE OPENED TO ENABLE ADDITIONAL RETARD SET BY SIJ2.
POSITION 0 IS MIN. RETARDJ POSITION F IS MAX. RETARD. EACH ADDITIONAL SIJITCH
POSITION ADDS AN ADDITIONAL TOOTH DEGREE TO THE ONE-STEP TIMING CHANGE.

TIMING SIJITCH SIJ3

ON ISIJ 3 - CURRENT LOOP SIJ!TCH I CONTROLS IJHETHER EXTERNAL 4-20MA CONTROL LOOP SIGNAL IS ACTIVE OR NOT.
LOOP SIGNAL AND POIJER ARE CONNECTED TO TERMINALS 1-4 <SEE DRAIJING 209 104A).
III£H IH IJ< POSITillN <HAHIILE I J ' l @
I~ ENABLES 4-20~A CU~RLNT
LOOP TIMING CONTROL
0 OPEN POSITION OF SIJ3 ALLOIJS THE INFLUENCE OF THE 4-20MA LOOPJ CLOSED POSITION
DELETES ANY INFLUENCE FROM THE LOOP. 4MA IS MIN. RETARD, 20MA IS MAX. RETARD.

I 0
I~
ICURRENT LOOP INDICA TOR I NOTES•
INDICA TIJ! 'IJI' <WMHiil - CU!II!liT llD' llf'U1 IS 'V AILAIU I1R USE.
DllliCATTR 'IJT' - L.llll [J" LIIP P!MJI [R LIIP DI'U1 Sl<lOL <HIW • 1-SVl.
1) SIJITCH SIJ! IS ALIJAYS OPERATIONAL. SIJITCHES SIJ2 AND SIJ3,
'--
IJHEN ACTIVATED, PROVIDE FOR ADDITIONAL RETARD CAPABILITY.
ASSEHBL 'r' PIN f- TOTAL RETARD = RETARD SIJ1 + RETARD SIJ2 + RETARD SIJ3.
272 502
'D' SERIES 2)
ITEST POINTSIR£1lUTRES CDNNECTIR PliO 0!0< OIJ ON SIJ1 AND SIJ2, POSITIONS A-F REPRESENT 10-15 <TOOTH DEGREES OF RETARD>.
0 I ABCX'!'Z
SII SERVICE IHSTRUCTIONS
0
f-

1-

lr

REVISIONS TDLERANCCS
NO. DATE BY DESCRIPTION
CDCCD-T AS NOT£D) AL TRONIC INC.
l DEC!IW.. TITLE
.XXX - :t.QOS CPU II CONTROL UNIT
2 .XX - :1.010 TIMING SIJITCHES
fltACTWfriii'L
J IRA\IN IY SC\1..£
IJTP .8 PART NUMBER
4 CHE:OC£DIY DArt:
S-31-88
5
MATERIAL
APPROVED IY 209 108A
 TE..IIW. 8l0Cl
U CPU COKT1IIll .. IT

11£611££5
0 ---~1 ~~AID
I
...1..
T
11'£11 - RETAIID
III'OITMT:
AS IIETE..IIED
-~·
SEPARATE
COIIDUIT
IT 5112 POSITIOII
II TlllllH 11£611££5
RETAIID

.----,
: l.,~ :
- 24 All& WIRE
TTPE Ul 1015
I -~ I DR EQUIY.
I I
,____ _1
ISOLATED
( DRT COlTACT I
DEY ICE

I.E. PII[Ssua£ SIIITCII

liJI>.SIIITOI
RELAY
m.
fOLI.AANCitS """Ta:........ Do"·AWN TlltACilD ICHICIUD:.oi: •• G ... IlJ"'"""0V£ DATE
o-¥:~:'i.t:,!,',~: 11

1 5 - .30 - 8 5
.xxx - ±.cos~l-:==~-+--l_::_:__Ai::iR<»:iiC~;;!,c;-...1.---~--SCM:i"'"-~
SPI!CII"IED
... ,. ..... u.s ALTRONIC, tnc. scALE
.xx - ::.010
GIRARD (YOUNGSTOWN) • OHIO
NAME PAftT NO.
1----+--1
TIMING CURVE
ONE -STEP
209109
 OLL 60Z:

2-WIRE TRANSMITTER I CPU CONTROL UNIT

12 - POSITlON STRIP
EXAMPLE: ROSEMONT, FOXBORO

I<~ oo96 ~
24' RANGE 48' RANGE
+ - IW
25' 50' + Or>----+-•
24' 48'
\l.)
20'
I 40'
12-24 VDC
SUPPLY

·0

DEGREES
OF 15'
I
l7 3D'
IGNITION
RETARD
FROM
MANUAL
TIMING
1D' 7 20'
3-WIRE TRANSMITTER
EXAMPLE: ALTRONIC 1201P,
1301P, 1501P, EPC
I 1
lo <:> <;>
CPU CONTROL UNIT
12 - 'POSITlON STRIP
2 3 4
9
5
o o
6

I
POSITION

IW
v
5' 1D'
+ OUT
+oo----4\~~~----------~
12-24 VDC
a· r.!l a· SUPPLY
IT
3 4 5 1D 15 2D 25 30 ·0
I
I CONTROL LOOP CURRENT (mA)
FAULT
LEVEL NOTE:
I 1. LOOP INPUT IMPEDANCE: 25D OHMS ±1%
POWER REQUIREMENT: 12-24 VDC, SOmA
TIMING REMAINS AT
LAST VAUD READING
2. TERMINALS 2 AND 4 ARE ELECTRICALLY
BEFORE LOSS OF LOOP.
COMMON NEGATIVE.

3. FIELD WIRING MUST BE 24 AWG UL STYLE

1D15 TYPE WIRE IN SEPARATE CONDUIT
AWAY FROM ALL OTHER WIRING.

REVISIONS TOLERANCES
NO. DATE BY DESCRIPTION
(DCIPT AS NOTED) ALTRONIC INC.
1 2-7-86 UPDATE D£011"'-
.XXX- ±.005
·nnLE
.. )()( - ±.010 TIMING CURVE +-20m A
2 5 31 88 WTP REVISED INPUT CIRCUIT; REDRAWN ON CAD
f'OACTlOH ....
3 DRAM! BY SCN..t:

I.IAttRIAL.
Qti:CI(EJ) BY

Al'f'IOO',ED BY
DA
OAn: , NONE
7 85
PART NUMBER

209 110
5
 111 602

NOTESI
I. TERMINALS 10 AND 11 ARE CLOSED IN A RUN CONDITION
'WHICH ENERGIZES EXTERNAL RELAY. Ir 4 TO 20""' SIGNAL
TERMINAL STRIP IN CPU II rAILS, THE EXTERNAL RELAY DROPS OUT OPENING TERMINALS
5 AND 6 TO INITAT£ THE RETARD SET ON S'W 2. OTHER
CONTACTS ARE r~ ALARM. ETC.
r---e-------------, 2. TERMINALS 2. 4, AND 11 ARE ELECTRICALLY COHHON
I I I AND ARE CONNECTED TO PO'WER SUPPLY NEGATIVE.

0000®0000®®®
+ -
I

(-)

24 VDC
r-
I
I
I
I
-
-- 1------,
0
Cl
I
I
I
I
-=>-
0
N/C CONTACTS TO ANNUNCIATOR OR OTHER ALARM
CN/0 ALSO AVAILABLE>

I 0 I
I I

i I
L_ -- ----
<:> I

l 1- ~ DPDT RELAY - JOVDC, 2501'1A MAXIMUM COIL VOL TAG£ AND CURRENT
CSHO'WN IN RUN CONDITION>

R_EVISIDNS
PC). DollIT IY OCSCRIPTI~
.,.,.,., .........
TCLERNIC[S
AL TRONIC INC .
I IEI:DW. TITLE
.)00( - ..- AUTO RETARD ON LOSS
2 .XX - *-010 or LOOP - CPU II
,_.,......_ _...,...,
5
3
4 ....__ IHI:ICD l'f

--.urr
'WTP
. ,.
ICIU NON£
5-24-88
PART -KR

209 111
 gzo 6os;

TO SHORTEN HARNESS
1. LOOSEN AND DISENGAGE NUT (2) AND REMOVE CONDUIT (1)
COMPLETELY FROM CONNECTOR AND HARNESS ASSEMBLY (3).

2. REMOVE ITEMS (5), (4), AND (2) IN THAT ORDER FROM CONDUIT (1).
NOTE THREADS ON (5).

3. CUT CONDUIT TO LENGTH WITH HACKSAW AND DRESS WITH FILE TO

INSURE A CLEAN, SQUARE END. REMOVE FILINGS FROM INSIDE CONDUIT.

4. REINSTALL ITEMS (2). (4), AND (5) IN THAT ORDER.

5. INSTALL REASSEMBLED CONDUIT INTO (3) AND TIGHTEN (2).

REVISIONS TOLERANCES
NO. OATE BY DESCRIPTION
(EXCEPT AS NOTED) AL TRONIC INC.
DECIMAL
3-14-92 WTP REDRAWN ON CAD .XXX - ±.005
TITLE SHIELDED HARNESS
.XX - ±.010 CONDUIT LENGTH ADJUSTMENT
F"RACllONAL.
DRAWN BY sc.LE
DWA NONE PART NUMBER
CHECKED BY DATE
4 5-28-85
5
MATERIAL
APPROVED BY 509 025
 -/710 16S

·_B_.Ot~O:. :'b:!~:. :o;:O00 ... - -• ~

2
__
~ 20,3 ....
;:_'_ IOSL·3P CONNECTOR

"L''~ .o 5 ,, 44,s ....,

LAPPROX.
CONNECTOR
CLEARANCE
NOTE~
I. N-POLE OF MAGNET I.IUSr FACf
SENSING END WITH AIR GAP OF
.030/040" ( ,76/ 1,0}
2 CENTERLINE OF MAGNET's ROTAr!ON
MUST RUN THROUGH CENTERLINE
OF PICKUP,

(OL&RANCII:S MATII:RIAl. OftAWN DATI!.

UNLESS
OTHI:ItWISI:
SpoECIP'IIlD OWA 1-26-88
.xxx - ±.oos
ANALYSIS
.xx - ±.010
OF
GIRARD (YOUNGSTOWN). OHIO
FULL
ALT II NAME

CPU HALL EFFECT 5910/4

PICKUP SALES DWG.
,.w auo-••
,,... 720 002 -

NORTH POLE

~----3/-8. HEX

~ -··
I .3 94 I · 31 ~

C 10>

.709
(18>
(8)

REF'~

l TE1.EJW«:ES I
AL TRDNIC INC.
-