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--- documents:ngi-5000-logic:ngi5000installation [2023/02/26 13:37]
rocky [7.2 ]
+++ documents:ngi-5000-logic:ngi5000installation [2023/02/28 02:33] (current)
rocky [1.1 OVERVIEW]
@@ Line 1: / Line 1: @@
+{{ :documents:ngi-5000-logic:ngi-5000-persp_a_4k8bit_white.png?1200 |}}
 ===== Installation Instructions =====
@@ Line 5: / Line 9: @@
 ==== - OVERVIEW ====
-The NGI-5000 Logic Module is designed to be a drop in, plug and play replacement for the CPU-2000 Logic Module. It comes with two screens hosting information that is exported using the highly advanced Altronic Web Interface (AWI). One screen offers a touch interface for interacting with the module, while the other holds static information for quick viewing. Each screen is independent and uses only HDMI and USB for its interface to the rest of the system. A separate interface is used to program the engine application information, this uses web technology and does not require a separate terminal program to be downloaded.
+The NGI-5000 Logic Module Legacy Mode is designed to be a drop in, plug and play replacement for the CPU-2000 Logic Module. It comes with two screens hosting information that is exported using the highly advanced Altronic Web Interface (AWI). One screen (bottom) offers a touch interface for interacting with the system, while the other holds static information for quick viewing. Each screen is independent and uses only HDMI and USB for its interface to the overall application. A separate interface is used to program the engine configuration information, this uses web technology and does not require a separate terminal program to be downloaded.
-Internally there is an ethernet backbone, and 485 two wire MODBUS for communications. To power the communications, the displays, and all of the expandability a System On Module (SOM) is used with high end computing power. In additional to the SOM a time critical and high specification microcontroller is used to interface with the input signals and drive the rest of ignition system.
+Internally there is an ethernet backbone, and RS485 two wire MODBUS for communications. To power the communications, the displays, and all of the expandability, a System On Module (SOM) is used with high end computing power. In additional to the SOM a time critical and high specification microcontroller is used to interface with the input signals and drive the rest of ignition system.
+Since the NGI-5000 Logic Module Legacy Mode is very straight forward, and can be deployed in all CPU-2000 instances, the majority of this document covers CPU-2000 component installation to limit the necessity to go back to the CPU-2000 literature.
@@ Line 14: / Line 20: @@
 ===== - MOUNTING THE NGI-5000 LOGIC MODULE  =====
-==== - ====
 The NGI-5000 Logic Module is preferably panel-mounted off the engine in such a manner
 as to minimize exposure to vibration. Refer to drawing 299 103 for physical dimension
 details.
-==== - ====
+----
 The Logic Module should be mounted within 50 feet (15 m) of the Output Module which is
 to be mounted on the engine.
-==== - ====
+----
 Operating temperature range is -40°F. to 158°F. (-40°C. to 70°C.). Humidity specification is
 -95%, non-condensing. Housed in a NEMA 4 enclosure, the CPU-2000 Logic Module is
@@ Line 33: / Line 40: @@
 ===== - MOUNTING FLYWHEEL GEAR/DRILLING FLYWHEEL HOLES =====
-==== - ====
 The Altronic NGI-5000 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:
+holes in the flywheel. The source of position pulses must meet the following requirements:\\
-- Must be ferrous material
+  * Must be ferrous material
-- Diameter of 18" or greater
+  * Diameter of 18" or greater
-- No. of teeth or holes of 180 or greater
+  * No. of teeth or holes of 180 or greater
-- Maximum run-out referenced to the pickup of .007''
+  * Maximum run-out referenced to the pickup of .007''
 Refer to drawings [[documents:ngi-5000-logic:ngi5000installation#Pickup Mounting|209 102A]] and 209 103 for further details.
@@ Line 47: / Line 53: @@
 ===== - MOUNTING THE MAGNETIC PICKUPS =====
-==== - ====
 The system requires two magnetic pickup signals: the angular position pulses from the
 gear or drilled holes and a reset pulse near the most advanced firing position desired for
@@ Line 57: / Line 62: @@
 ===== - MOUNTING THE FLYWHEEL RESET PIN =====
-==== - ====
+----
 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 pickup;
@@ Line 64: / Line 71: @@
 stud. See drawing  [[documents:ngi-5000-logic:ngi5000installation#Pickup Mounting|209 102A]] for details.
-==== - ====
+----
 Rotate the engine to the original set point and adjust the air gap between the end of the
 reset pin and the magnetic pickup at .01 O" using a feeler gauge.
@@ Line 70: / Line 78: @@
 ===== - MOUNTING THE CYCLE TRIGGER (4-CYCLE ENGINE ONLY) =====
-==== - ====
+----
 The trigger magnet (260604, 260605 or 720002) must be mounted on the engine camshaft
 or other accessory drive operating at camshaft speed. An M8 (8 mm) tapped hole, 0.5
@@ Line 78: / Line 87: @@
 - 15 inches (375 mm) for magnet 260604 or 260605.
-==== - ====
+----
 Set the engine on the COMPRESSION stroke of no. 1 cylinder with the reset pin DIRECTLY
 OPPOSITE the reset pickup. The Hall-effect pickup ( [[documents:ngi-5000-logic:ngi5000installation#Hall Effect Pickup Dimensions|591014]]-x) must be mounted
@@ Line 90: / Line 100: @@
 ===== - LOGIC MODULE ELECTRICAL HOOK-UP =====
-==== - ====
+----
-The power connections to the CPU-2000 must be in accordance with the National
-Electrical Code or other applicable country code. The CPU-2000 is suitable for installation
+The power connections to the NGI-5000 Legacy Logic Module must be in accordance with the National
+Electrical Code or other applicable country code. The NGI-5000 Logic Module is suitable for installation
 in Class I, Division 2, Group D locations.
-==== - ====
+----
-The Logic Module must have its own 24 Vdc power connection. Although the device has
-internal protective fuses (3 amp), an external fuse near the power source is recommended.
+The Logic Module must have its own 24 Vdc power connection. An external fuse near the power source is recommended for a power consumption of up to 5A max.
 See section 13.0 for other details regarding powering the CPU-2000 system.
-==== - ====
+----
 Power wiring and signal (transducers) wiring must be in separate conduits and conduit
 entries into the Logic Module to avoid undesired electrical interaction. All conduit entries
@@ Line 110: / Line 123: @@
 LEFT CONDUIT ENTRY Control inputs, serial communications, and alarm outputs
-==== - ====
+----
 RIGHT ENTRY: Input power supply wires (16 AWG minimum) should enter the right
 conduit entry and connect to the 24 Vdc supply terminals of terminal block. The interface
 cable 293030-xx connecting the Logic Module with eitherthe Diagnostic or Output Module
-also enters through the right conduit entry. Refer to drawings 209 078 and 299 104 for
+also enters through the right conduit entry. Refer to drawings [[documents:ngi-5000-logic:ngi5000installation#Wiring Diagram|209078]] and 299 104 for
 connection details.
 CAUTION: Do not mistake the brown (pin "D") and light brown (pin "S") wires.
-==== - ====
+----
 Run a separate conduit for the two (2) magnetic pickup cable
 assemblies. These should enter through the center entry in the CPU box and terminate
@@ Line 125: / Line 141: @@
 center entry and connects as shown.
-==== - ====
+----
 LEFT ENTRY: A separate conduit must be used to the left-hand entry for all connections
 to the user interface terminal strips in the Logic Module. Use 24 AWG, UL style 1015 wire
@@ Line 138: / Line 156: @@
 common rail COMMON OUT (terminal 8). The switches are rated 75 mA@ 100 Vdc.
 These output switches are electrically isolated from all other terminals. The
-recommended hook-up is shown on drawing 209 078. For operational details, refer
+recommended hook-up is shown on drawing [[documents:ngi-5000-logic:ngi5000installation#Wiring Diagram|209078]]. For operational details, refer
 to the CPU-2000 Operating Instructions, form CPU-2000 01.
 C. 4-20 MA TIMING CONTROL INPUT: The 4-20 mA timing control loop connects to
 terminals 9( +) and 10(-). This input is electrically isolated from all other terminals;
-refer to drawings 209 078 and 209 079.
+refer to drawings [[documents:ngi-5000-logic:ngi5000installation#Wiring Diagram|209078]] and 209 079.
 D. MISC INPUT (terminal 11): Provides for control of various user selected features.
 This input is normally open; connect to engine ground to activate the selected feature
@@ Line 151: / Line 169: @@
 ===== - DC POWER HOOKUP -293030-XX: CABLE ======
-==== - ====
+----
 The power connections to the CPU-2000 must be in accordance with the National
 Electrical Code or other applicable country code. The CPU-2000 is suitable for installation
 in Class I, Division 2, Group D locations.
-==== - ====
+----
 It is necessary to split the control cable and power leads of the 293030 cable in an engine
 mounted junction box or conduit tee. This box should be separate from the main junction
@@ Line 169: / Line 191: @@
 to either the Diagnostic or Logic Module.
-==== - ====
+----
 The CPU-2000 system can be powered in one of the following ways:
 A. 24 volt battery with charger.
@@ Line 177: / Line 201: @@
 require a separate dedicated power supply for the CPU-2000.
-==== - ====
+----
 IMPORTANT: For proper operation of the CPU-2000 system, voltage and current supplied
 must be sufficient during all selected modes of operation. Drawing 209 120 provides these
@@ Line 183: / Line 209: @@
 . CURRENT DRAW PER SYSTEM - formula varies depending on number of outputs
 used, engine cycle and RPM, and the use of the multi-strike feature.
-. MINIMUM WIRE GAUGE REQUIREMENTS - Chart 1 of drawing 209 120 gives the
+. MINIMUM WIRE GAUGE REQUIREMENTS - Chart 1 of drawing [[documents:ngi-5000-logic:ngi5000installation#Power Hookup|209120]] gives the
 requirement vs. the length of run between the power source and the CPU-2000
 Output Module.
 . MULTIPLE ENGINE INSTALLATIONS - Multiply current required per system by the
 number of engines. Where more than one engine is powered from a common power
-source, see Chart 2 of drawing 209 120 for the minimum wire size required.
+source, see Chart 2 of drawing  [[documents:ngi-5000-logic:ngi5000installation#Power Hookup|209120]] for the minimum wire size required.
 ===== - PRIMARY WIRING =====
-==== - ====
+----
 The main wiring harness (293023-x, 293026-x, or 293027-x) connects the Output Module
-to the engine junction box. Refer to drawing 509 025 if it is desired to shorten the conduit
+to the engine junction box. Refer to drawing [[documents:ngi-5000-logic:ngi5000installation#Conduit Length Adjustment|509025]] if it is desired to shorten the conduit
 length of the harness. Insert the connector into the Altronic CPU-2000 Output Module
 receptacle and tighten hand-tight; then carefully tighten an additional one-sixth turn with
@@ Line 200: / Line 228: @@
 Referring to applicable drawing 209 118 or 209 119, write in the engine firing order below:
-==== - ====
+----
 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
@@ Line 207: / Line 237: @@
 in the junction box. On V-engines, run a separate common ground lead for each bank.
 Separate ground connections in the junction box are recommended. Refer to wiring
-diagrams 209 105A (unshielded) or 209 106A (shielded) for general details.
+diagrams [[documents:ngi-5000-logic:ngi5000installation#Wiring Diagram Unshielded|209105A]] (unshielded) or [[documents:ngi-5000-logic:ngi5000installation#Wiring Diagram Shielded|209106A]] (shielded) for general details.
+----
-==== - ====
  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
@@ Line 215: / Line 247: @@
 specifications. All primary wiring should be protected from physical damage and vibration.
-==== - ====
+----
  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.
+WIRING as shown on the wiring diagrams [[documents:ngi-5000-logic:ngi5000installation#Wiring Diagram Unshielded|209105A]] and [[documents:ngi-5000-logic:ngi5000installation#Wiring Diagram Shielded|209106A]].
+----
-==== - ====
 All unused primary wires should be individually taped so that they are insulated from
 ground and each other. The unused primary wires can then be tie-wrapped together for
@@ Line 225: / Line 261: @@
 ===== - SHUTDOWN WIRING =====
- ==== - ====
+----
 To shut-off the DC-powered CPU-2000 system, a special input (SHUTDOWN INPUT -
 terminal 4) in the Logic Module is provided. This input is open for normal operation and
 is connected to engine ground to initiate an ignition shutdown. Use a switch rated 24 Vdc,
-.5 amps. Refer to section 9.6A. and drawing 209 078 for details.
+.5 amps. Refer to section 9.6A. and drawing [[documents:ngi-5000-logic:ngi5000installation#Wiring Diagram|209078]] for details.
+----
-==== - ====
 DO NOT ground leads "N" or "V" to stop the ignition with the CPU-2000 system. This can
 cause component failure in the Output Module. These leads are provided to power
@@ Line 238: / Line 278: @@
 ===== - SECONDARY WIRING =====
-==== - ====
+----
 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 (85°C.).
-==== - ====
+----
 The spark plug leads should be fabricated from silicone insulated 7 mm cable with suitable
 terminals and silicone spark plug boots. The use of leads with resistor spark plug boots
@@ Line 253: / Line 296: @@
 well.
-==== - ====
+----
 The use of a clear, silicone grease (such as Dow Corning DC-4, G.E. G-623 or GC
 Electronics ZS) is recommended for all high-tension connections and boots. This material