Product Manual 26205 (Revision B) : IC-100 CD Ignition System

Product Manual 26205
(Revision B)
Original Instructions
IC-100 CD Ignition System
Installation and Operation Manual

This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
 DANGER—Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
DEFINITIONS  WARNING—Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
 CAUTION—Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
 NOTICE—Indicates a hazard that could result in property damage only (including
damage to the control).
 IMPORTANT—Designates an operating tip or maintenance suggestion.
The engine, turbine, or other type of prime mover should be equipped with an
overspeed shutdown device to protect against runaway or damage to the prime
mover with possible personal injury, loss of life, or property damage.
The overspeed shutdown device must be totally independent of the prime mover
control system. An overtemperature or overpressure shutdown device may also
be needed for safety, as appropriate.
Read this entire manual and all other publications pertaining to the work to be performed before
installing, operating, or servicing this equipment. Practice all plant and safety instructions and
precautions. Failure to follow instructions can cause personal injury and/or property damage.
This publication may have been revised or updated since this copy was produced. To verify that
you have the latest revision, be sure to check the publications page on the Woodward website:
www.woodward.com/publications
The current revision and distribution restriction of all publications are shown in manual 26311.
The latest version of most publications is available on the publications page. If your publication is
not there, please contact your customer service representative to get the latest copy.
Any unauthorized modifications to or use of this equipment outside its specified mechanical,
electrical, or other operating limits may cause personal injury and/or property damage, including
damage to the equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or
"negligence" within the meaning of the product warranty thereby excluding warranty coverage
for any resulting damage, and (ii) invalidate product certifications or listings.
To prevent damage to a control system that uses an alternator or battery-charging

device, make sure the charging device is turned off before disconnecting the battery
from the system.
To prevent damage to electronic components caused by improper handling, read

and observe the precautions in Woodward manual 82715, Guide for Handling and
Protection of Electronic Controls, Printed Circuit Boards, and Modules.
Revisions—Text changes are indicated by a black line alongside the text.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken.
Copyright © Woodward 2003
All Rights Reserved
Manual 26205 IC-100 CD Ignition System
Contents
ELECTROSTATIC DISCHARGE AWARENESS ..................................................III

CHAPTER 1. GENERAL INFORMATION ........................................................... 1
Introduction .............................................................................................................1
Operational Features ..............................................................................................1
Limitations ..............................................................................................................1
CHAPTER 2. IC-100 IGNITION SYSTEM INSTALLATION .................................. 3
Unpacking ...............................................................................................................3
Safety......................................................................................................................3
Installation ..............................................................................................................4
Setting the Ignition Timing Adjustment Range and Positioning the Trigger Disc .12
Disposal of the Ignition Control System ...............................................................14
Wiring Requirements ............................................................................................14
CHAPTER 3. OPERATION ........................................................................... 23
Programming the IC-100 with a Laptop................................................................23
Programming the IC-100 with the Hand Held Programmer .................................23
IC-100 Programming Overview ............................................................................24
Additional Functions .............................................................................................37
Initial Start-up Procedure ......................................................................................38
CHAPTER 4. MAINTENANCE AND TROUBLESHOOTING ................................. 40
Maintenance .........................................................................................................40
Faults and Troubleshooting ..................................................................................40
CHAPTER 5. PRODUCT SUPPORT AND SERVICE OPTIONS ........................... 45
Product Support Options ......................................................................................45
Product Service Options .......................................................................................45
Returning Equipment for Repair ...........................................................................46
Replacement Parts ...............................................................................................46
Engineering Services............................................................................................47
Contacting Woodward’s Support Organization ....................................................47
Technical Assistance ............................................................................................48
APPENDIX. PROGRAMMING OVERVIEW....................................................... 49
DECLARATIONS ......................................................................................... 52
IC–100 CONTROL SPECIFICATIONS ........................................................... 53
Woodward i
IC-100 CD Ignition System Manual 26205
Illustrations and Tables
Figure 2-1. IC-100 Outline Drawing ........................................................................6

Figure 2-2. Trigger Disc Mechanical Requirements ...............................................7
Figure 2-3. Mounting of Camshaft Trigger Disc .....................................................8
Figure 2-4. Mounting a Trigger Disc with Slots ....................................................10
Figure 2-5. Mounting of Flywheel Pickup .............................................................12
Figure 2-6. Example of Positioning of Flywheel ...................................................13
Figure 2-7. IC-100 Wiring Diagram.......................................................................16
Figure 2-8. 0–5 Volt Retarded Curve ...................................................................17
Figure 2-9. 0–5 Volt Advanced Curve ..................................................................18
Figure 2-10. Two-point Adjustment ......................................................................18
Figure 2-11. Potentiometer Setting.......................................................................19
Figure 2-12. GO/NOGO Output ............................................................................19
Figure 4-1. Oscilloscope—Square Wave Signal ..................................................42
Table 2-1. Input Wiring with Passive Pickup ........................................................20

Table 2-2. Input Wiring with Active Pickup ...........................................................21
Table 2-3. Cylinder Output Pin-out .......................................................................21
Table 2-4. Ignition Firing Order.............................................................................22
Table 4-1. LED Flash Codes ................................................................................40
ii Woodward
Electrostatic Discharge Awareness

All electronic equipment is static-sensitive, some components more than others.
To protect these components from static damage, you must take special
precautions to minimize or eliminate electrostatic discharges.
Follow these precautions when working with or near the control.
1. Before doing maintenance on the electronic control, discharge the static

electricity on your body to ground by touching and holding a grounded metal
object (pipes, cabinets, equipment, etc.).
2. Avoid the build-up of static electricity on your body by not wearing clothing
made of synthetic materials. Wear cotton or cotton-blend materials as much
as possible because these do not store static electric charges as much as
synthetics.
3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam

cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or
folders, plastic bottles, and plastic ash trays) away from the control, the
modules, and the work area as much as possible.
4. Do not remove the printed circuit board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:
 Do not touch any part of the PCB except the edges.
 Do not touch the electrical conductors, the connectors, or the

components with conductive devices or with your hands.
 When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.
To prevent damage to electronic components caused by improper

handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.
Woodward iii
iv Woodward
Chapter 1.
General Information
Introduction
The IC-100 is a microprocessor-controlled, capacitive spark discharge ignition
system capable of supplying ignition energy for certain two- or four-stroke gas
engines with one to eight cylinders (single-firing) or two to 16 cylinders (double
firing).
The number of cylinders and the corresponding firing pattern, as well as the
trigger disc configuration, are programmed individually.
Integral to the IC-100 is one adjustment potentiometer. This has a programmable

maximum span of 38°. Additional methods of adjustment are by means of an
integral speed curve and a linear 0–5 V analog signal. A two-stage adjustment is
also possible with the aid of the analog signal and the use of an external
potentiometer.
The IC-100 is capable of firing up to eight cylinders with either one or two spark
plugs per cylinder. In the case of two spark plugs per cylinder, the corresponding
ignition coils must be wired in series.
A cam or crankshaft trigger disc is used to provide relative position reference.

This information is sent to a microprocessor that controls the ignition system.
Thus, the system is alerted whenever a new cycle has begun.
The IC-100 is intended for use in non-hazardous locations.
Operational Features
In order to ensure perfect operation of the ignition control system, observe the
maintenance instructions given in Chapter 4.
The IC-100 has several functional features to ensure proper operation:

 trigger signal check
 input signal fault recognition
 shutdown
 manual ignition timing adjustment
Limitations
The IC-100 ignition control system provides ignition energy for one to eight or two
to 16-cylinder gas engines. Trigger disc configurations are listed in Chapter 2.
The IC-100 is intended only for use on the engines listed in the configuration
table (see Chapter 3). It also needs to be programmed to comply with the
appropriate engine.
Woodward 1
The IC-100 is designed for continuous operation in conditions of a still air
environment with a maximum ambient temperature of 55 °C (which corresponds
to a 70 °C maximum case temperature). Certain applications and operating
conditions may require cooling the IC-100 to ensure long-term reliable operation.
The interval between plug firings is the primary factor in determining the
maximum allowed ambient temperature. Firing interval is determined by the
following formula:
S * 30000 * D
time[ ms ] 
RPM * C
where:
S=2 for a two-stroke engine
S=4 for a four-stroke engine
D=1 for single firing engines (typical)
D=2 for double firing engines (two cylinders fired at once)
C is the number of cylinders
RPM is the crankshaft steady state engine speed
At firing intervals less than 8.33 milliseconds, check the case temperature of the
IC-100. The temperature should be measured at the far end of the box, which is
opposite the side with the connectors. If it exceeds 70 °C, some means of
reducing the case temperature is required. Forced air-flow or mounting to a heat
sink can accomplish this. Temperature should be measured for two hours to
ensure that thermal stability is achieved before taking a measurement.
2 Woodward
Chapter 2.
IC-100 Ignition System Installation
Unpacking
Check the shipping container for evidence of mishandling during shipping.
Carefully remove the IC-100 from the shipping container. Check the hardware for
evidence of damage during shipping. Notify the shipper and Woodward if
shipping damage is found.
Safety
The operator of the equipment must ensure:
 That all persons concerned with the installation, maintenance, and repair of
the IC-100 ignition control system have entirely read and completely
understood this operating manual.
 That all persons authorized to operate the gas engine have received
detailed instruction and have been warned about possible dangers.
In no case should the following parts of the ignition control system

be touched, removed, or disconnected while the engine is running:
 ignition coils and caps
 high tension leads
 low voltage circuit leads
 harness connectors
The IC-100 ignition control system design conforms to high technology principles
and is operationally safe. The equipment may suffer damage or pose the threat
of injury if the following safety precautions are not observed. Only trained and
authorized personnel must operate the gas engine.
 Before commencing any work involving the installation, operation, resetting,

matching, maintenance, or repair of the ignition control system, the
equipment must be disconnected from the power supply and safeguarded
against switching on the power.
 The harness must be removed.
 Safety devices must not be disassembled or inactivated.
 Avoid all work that might impair the function of the ignition control system.
 Only operate the ignition control system provided it is in perfect condition,

and inform all concerned personnel of any modifications which have been
made to the gas engine or the ignition control system.
 Ensure that you observe all the rules and regulations pertaining to your
equipment, including those that are not explicitly stated here.
 Always ensure that the engine room is properly ventilated!
Woodward 3
 Ensure that you maintain a safe distance from the gas engine and the
ignition control system.
Switch off the engine; disconnect the power supply, and lock out
both before commencing any installation work.
Make sure that the system was programmed for your engine before
attempting to operate the IC-100 ignition system. An improperly
installed or programmed system may lead to engine damage and
could pose threat of personal injury to operators.
Installation
Read this section carefully before assembling the components!
A complete ignition system consists of:

 The IC-100 ignition control module
 Ignition coils (one per cylinder minimum)
 Protection cap for ignition coil, high tension side
 Protection cap for ignition coil, low tension side
 Input/output harness
 A speed pickup for the flywheel trigger disc or an active pickup for the
camshaft trigger disc
 A trigger disc
 High tension leads, customized
Before commencing with the final assembly, it is advisable to carefully consider

the mounting locations of the individual components. A good choice of mounting
locations ensures proper operation of the entire ignition system.
Ignition Control Module

Considerations for IC-100 mounting location:
 Specified environmental limits
 Temperature
 Vibration
 Cable length to
 Power supply
 Pickup units
 The distance between the ignition control module and the pickup unit
should not exceed 6 m (20 ft).
 Away from high voltage or high current devices or high electromagnetic
radiation (EMC) sources
 Clearance for cables
Never do any welding work on the engine or chassis when the

ignition control module is mounted on the engine or connected to
the chassis. This could destroy the ignition control module!
4 Woodward
 Mount the ignition control module in such a way that the cable harness may
be easily routed downwards.
 Mount the ignition control module on a secure bracket near the engine using
vibration-damping mounts.
 The ignition control module must be grounded to the engine through the
mounting hardware or a very short strap (25x76 mm/1x3” braid).
 The ignition control module should be mounted in the cooling fan air-stream
if practical.
Mount the IC-100 using the bolt pattern shown in Figure 2-1. Do not
mount the IC-100 directly on the engine. The IC-100 must be mounted
in an off-engine location, avoiding excessive vibration and heat.
Trigger Disc
Depending on the engine design, there are two possibilities to trigger the ignition:
 Trigger disc mounted on crankshaft. This location is required for 2-stroke
engines (double firing on 4-stroke engines; ignition fires on compression and
exhaust stroke). The magnetic disc is equipped with a certain number of
holes, slots, or magnets. This disc may use a passive or active pickup
unit.
 Trigger disc mounted on camshaft. This location is recommended for 4-
stroke engines (single firing, ignition fires on compression stroke only). The
non-magnetic disc is equipped with a specified number of magnets or holes.
Using a disc with holes or pins for the camshaft requires an active pickup
unit.
The crankshaft and camshaft pickup should be mounted at a convenient position

providing easy access for maintenance.
A massive and vibration-free bracket must be prepared for mounting the pickup.
2-Stroke and Double-Firing 4-Stroke Engines

Mount the trigger disc on the flywheel, pulley disc, or vibration damper. The
trigger disc must rotate at crankshaft speed.
Ensure that the trigger disc is perfectly centered!
Instead of using a disc, holes can be drilled into the flywheel. For the basic
setting, outlined in Figure 2-6, the hole, slot or pin "A" has to be opposite the
pickup mounting hole.
For engine timing see “Setting the Ignition Timing Adjustment Range” later in this
chapter.
Woodward 5
Figure 2-1. IC-100 Outline Drawing
6 Woodward
Single-Firing 4-Stroke Engines

Mount the trigger disc on the camshaft or any drive running at one-half engine
speed.
For the basic setting outlined in Figure 2-6, the hole, slot, or pin “A” has to be
opposite the pickup mounting hole.
For engine timing see “Setting the Ignition Timing Adjustment Range” later in this
chapter.
Figure 2-2. Trigger Disc Mechanical Requirements
Woodward 7
Camshaft Pickup
The camshaft pickup generates a square wave signal.
It is essential to take account of the camshaft slope in order to

prevent the reluctor pin from striking the pickup!
In order to avoid defective signals, the mounting surface must be

free of sharp edges, holes, or other irregularities.
Preparations for Active Pickup

 Prepare a massive and vibration-free mount for the active pickup unit.
 The bracket must be positioned in such a way that the pickup is directed at
a right angle to the surface of the disc.
 Drill and tap a hole to accept the chosen pickup.
Ensure that metal chips, filings, or shavings from drilling and tapping
operations do not remain in the engine!
Example: 4-cylinder-engine
trigger disc with reluctor pins
(4+1 configuration)
(active)
Figure 2-3. Mounting of Camshaft Trigger Disc
8 Woodward
Installation of a Disc with Reluctor Pins
Tightening torque for the camshaft pickup: max. 15 Nm (11 lb-ft)!
In order to avoid defective signals, the mounting surface must be free of sharp
edges, holes, or other irregularities.
Take care to ensure that the speed pickup unit does not rotate with
the lock nut, thereby causing the gap to alter.
It is essential that the threaded hole be perpendicular to the surface

of the ring gear!
 Screw the active pickup into the tapped hole.

 The pickup must point to the "A" reluctor pin at a right angle.
 The air gap between the tip of the reluctor pin and the surface of the pickup
should be approximately 0.5 mm (0.02 inch).
 This gap is best achieved by following these steps:
 screw in the pickup until it just makes contacts with the tip of the reluctor
pin;
 unscrew the pickup by a half turn counterclockwise direction.
 Now tighten the lock nut, taking care to ensure that the pickup does not
rotate at the same time.
 Crank the engine back and forth several times by a few degrees to make
sure that the reluctor pin does not strike the pickup surface.
Mounting a Trigger Disc with Slots
Tightening torque for active pickup: max. 15 Nm (11 lb-ft)!
Woodward 9
Example 6-cylinder-engine
trigger disc with slots
(6+1 configuration)
Figure 2-4. Mounting a Trigger Disc with Slots
In order to avoid defective signals, the mounting surface must be

free of sharp edges, holes, or other irregularities.
It is essential that the threaded hole is perpendicular to the surface

of the ring gear!
Take care to ensure that the speed pickup does not rotate with the
lock nut, thereby causing the gap to alter.
 Screw the speed pickup into the tapped hole.

 The pickup must point to the "A" reluctor pin at right angles.
 The air gap between the surface of the trigger disc and the surface of the
pickup should be approximately 0.5 mm (0.02 inch).
 This gap is best achieved by following these steps:
 screw in the pickup until it just makes contact with the surface of the
trigger disc;
 unscrew the pickup by ½ turn counterclockwise direction.
10 Woodward
 Now tighten the lock nut, taking care to ensure that the pickup does not
rotate at the same time.
 Crank the engine back and forth several times by a few degrees to make
sure that the pickup does not strike the trigger disc.
Flywheel Pickup
The flywheel pickup senses an ac signal if a passive pickup is used.
Mounting Location
A massive and vibration-free bracket must be prepared for the speed pickup.
Preparations
 Drill and tap a hole to accept the magnetic pickup.

This hole must be drilled in such a way that the pickup is directed towards
the surface of the trigger disc at right angle.
Ensure that metal chips, filings, or shavings from drilling and tapping
operations do not remain in the engine!
It is essential that the threaded hole be perpendicular to the surface

of the ring gear!
Installation
 Screw the pickup into the threaded hole.

The pickup must be precisely directed towards the center of the flywheel.
The gap between its surface and the surface of the trigger disc must be
approximately 0.6 mm (0.02 inch).
This gap is best achieved by screwing in the pickup unit until it just makes
contact with the top of the trigger disc or flywheel, then unscrewing it one-
half turn counterclockwise.
 Fix the pickup in place by means of the lock nut.
 Slowly crank the engine a full rotation to ensure that the disc does not strike
the pickup.
Woodward 11
(passive)
Figure 2-5. Mounting of Flywheel Pickup
Setting the Ignition Timing Adjustment Range and

Positioning the Trigger Disc
The maximum ignition timing range of the IC-100 ignition control module is 38
degrees. The minimum ignition timing range is 23 degrees. The maximum range
is achieved with a base setting of 40º BTDC or more. Lower base settings reduce
the ignition timing range.
The base setting is the crank angle of cylinder #1, on the compression stroke,
when the trigger disc “A” pin is aligned with the pickup. Typically the base setting
target is the most advanced ignition timing the engine needs plus 2 or more
degrees. The IC-100 ignition control module requires 2 degrees for computation
time.
To obtain the correct base setting:

1. Bar the engine over until cylinder #1 is on the compression stroke and at the
correct crank angle for the base setting.
2. Rotate the trigger disc on the camshaft or crankshaft to align pin “A” with the
pickup.
3. Securely fasten the trigger disc to the camshaft or crankshaft.
4. Setting must be between 25º and 60º BTDC on cylinder #1. Be sure the
range fits the engine ignition timing requirements.
12 Woodward
40° 38°
basic setting: 40° BTDC adjustment-

range
ignition adjustment
range: 38° BTDC to
0°
0° BTDC
flywheel
Figure 2-6. Example of Positioning of Flywheel
o
40
TDC
The maximum advance for the ignition timing (º BTDC) is the base setting minus
a 2 degree computation time. Maximum advance is limited to 58º BTDC.
Maximum retard is limited to 0.0º BTDC.
Example A:
Basic setting: 40° BTDC
Ignition adjustment range: 38° BTDC to 0° BTDC ( 38°)
Example B:
Ignition adjustment range: 28° BTDC to 0° BTDC ( 28°)
Woodward 13
Example C:
Ignition adjustment range: 48° BTDC to 10° BTDC 38°)
The system does not allow After Top Dead Center (ATDC) ignition
timing.
Disposal of the Ignition Control System

The IC-100 is comprised of only a small amount of surplus refuse that may be
disposed of in the usual manner as industrial waste.
Wiring Requirements
General
This symbol identifies earth ground. It is to be used to connect the IC-

100 to earth ground.
This symbol identifies chassis ground. This terminal is to be used for

cable shield or for connecting the cable gland plates to the chassis.
To maintain compliance with CE marking requirements, the EMC

directive requires that all shields be connected to the terminals provided in the
IC-100 according to the wiring diagram as in Figure 2-7. In addition, the IC-100
must be connected to earth ground (engine) through the mounting hardware or a
very short strap (25x76 mm/1x3” braid).
Wire exposed beyond the shield must be as short as possible.
IC-100 CD Ignition System Electrical Connections and Pin

Functionality
The engine power supply must be disconnected and safeguarded

against switching on before beginning any work on the IC-100. Do
not make any power supply connections into live power circuits!
Never switch on the ignition control module without the output leads
connected to the unit.
An improperly installed ignition system may lead to engine damage

and could pose threat of personal injury to operators.
All components (ignition control module, ignition coils, and all lead
screens) must be grounded to ensure electromagnetic compatibility.
14 Woodward
Take care to ensure that the following minimum and maximum

voltages to the IC-100 are complied with:
 Minimum 10 Vdc
 Maximum 32 Vdc
Input voltages beyond these values might damage the IC-100.
Shutdown of the IC-100 is achieved by switching off the input power.

Emergency shutdown devices must be rewired in order to switch off
the input power.
The IC-100 CD ignition system offers the option of RS-232 or CANBus

communication. All input power, various I/O, and ignition coil output connection
are made through a 23 socket-pin plug connector.
RS-232 Port
The IC-100 may programmed via RS-232 using a null modem cable. Any fault
indications will be transmitted to a PC/laptop through the RS-232 link.
CANBus
There are two modes for the CANBus: display (read only) and control
(read/write). The write mode is enabled with the RS-232 programming mode
“CAN BUS ENABLED”. For instructions on how to operate in this mode, please
contact the factory (see chapter 5 for instructions). With both modes, once the
CANBus has active communication, the ESC key on the RS-232 does not work.
This is to prevent conflicts between the CANBus writing configuration and that of
the RS-232 port. This is important to remember if using the D-1 display to
monitor the cylinder energy because you cannot exit the cylinder-to-cylinder
adjustment or the energy screen using the ESC key.
In order for the CANBus to function properly, the correct CAN ID must be used.
With the D-1 display, this number is 2. Please read the D-1 Display manual, if
you require more information on its operation.
Input Power
Pins 13(+) and 12(–) connect the IC-100 to input power from an external power
source. The rated operating range is 18–32 Vdc (steady state operation from 10
to 18 Vdc is allowable but may not be able to achieve 100% energy). Connect
the buffered positive power supply terminal through a 5 A Slo-Blo fuse to pin 13
of the harness and the reference to pin 12. To ensure proper operation, the
minimum input voltage (18 V) must be maintained even under load. The cross-
section of the power supply leads must be at least 2.5 mm² (14 AWG).
Woodward 15
Figure 2-7. IC-100 Wiring Diagram
16 Woodward
Ignition Timing Adjustment

The IC-100 features two stages of variable timing adjustment:
 manual adjustment (potentiometer)
 0–5 V analog signal
Pins 6(+), 20(–), and 21(+5 V) are used to receive a linear 0–5 Vdc signal for
timing control.
Each method is operator-adjustable and provides up to 38° adjustment range.

The resolution of the timing setting is accurate to 0.25° crankshaft degrees.
Manual Adjustment
An incorrect timing setting may lead to engine damage!
The desired timing may be precisely set by manually rotating the potentiometer.
Manual timing adjustment is possible with the engine running.
 Do not apply voltage to terminals 6, 20, or 21 of the harness.
 The desired timing setting may be obtained by rotating the potentiometer.
The span between the extreme right and left position is max. 38° depending
on the configuration of the IC-100 (see Setting Potentiometer Span in
Chapter 3).
When choosing the correct timing setting, it is essential to strictly

adhere to the values specified by the engine manufacturer.
Analog Input
The second timing control method requires a linear 0–5 Vdc signal (for example,
provided by a remote potentiometer or a boost pressure sensor).
By means of a steady 5 Vdc output and the linear 0–5 Vdc input signal, the
timing is shifted further towards retard over a range of max. 35 degrees. This
depends on the configuration of the IC-100 (See Analog Input Signal – 5V Limit
in Chapter 3).
Timing Examples
"A" Trigger
40°
0V
30° pot setting 30° BTDC
10° retarded span
20° 5V
0°
Figure 2-8. 0–5 Volt Retarded Curve
Woodward 17
"A" Trigger
40°
5V
35°
20° advanced span
15° pot setting 15° BTDC

0V
5°
0°
Figure 2-9. 0–5 Volt Advanced Curve
Two-point Adjustment
A simple two-point adjustment is possible with the aid of the analog input. For
example, if the engine is operated with two different grades of fuel, it is generally
advisable to alter the ignition timing when changing from one type of fuel to
another.
21
0 – 5 V=(+)
5 k
6
20
Ground
External potentiometer: 5 k, 10-turn
Figure 2-10. Two-point Adjustment
Proceed as follows:
The potentiometer must be installed in a shielded housing. If an input

lead is required, this must also be screened. Maximum cable length:
10 m (33 ft)!
 Wire-pins 21, 6, and 20 of the harness as shown in the Figure 3-3.

 Open the switch.
 By manual adjustment, first set the ignition timing to the most advanced
position by using the integrated potentiometer of the IC-100.
 Close the switch.
 Adjust the external potentiometer (0–5 Vdc) until the desired timing setting is
obtained.
 You may now switch between the two fixed timing settings by opening and
closing the switch in lead 6.
18 Woodward
integrated potentiometer setting

28°
external potentiometer setting (0–5 Vdc)

20°
Figure 2-11. Potentiometer Setting
Permissive Start
Pin 5 is the Permissive Start or Go/No Go output. It is a solid-state output,
capable of sinking 150 mA, that should be used to enable/disable fuel flow to the
engine directly or in combination with other devices (lube oil pressure, etc.).
Anytime the ignition stops due to normal stop sequence, over speed, or when a
fault is detected, the Permissive Start output will de-energize. Upon start-up, the
Permissive Start output will not energize until all timing signals are verified and
the ignition is starting to fire. Figure 2-12 shows a likely set up for this output.
Figure 2-12. GO/NOGO Output
Contact Switch
Pin 19 can be set up as a switch between the timing schedules A or B. It can
also be configured as an Auxiliary Shutdown Input. This needs to be
programmed using the RS-232. The default is for Auxiliary Shutdown.
Woodward 19
Auxiliary Shutdown Input
The IC-100 provides a low voltage, low current means of shutting down the
ignition system using a PLC or similar device. If the contact switch is tied to
ground, the ignition outputs will not fire. If the contact is tied to ground above the
security speed (above cranking speed, but below idle), it is necessary for the rpm
to go to zero before the outputs will fire. If the contact is open below the security
speed, the ignition will fire immediately if the trigger, reset, and cam signals are
correct.
Do not use the Auxiliary Shutdown input as a primary shutdown

device. Be sure to have a separate and independent shutdown
device.
Timing Schedules A or B
Two different timing schedules can be programmed to be accepted by the IC-
100. The contact switch is then configured to select between the two schedules.
It is possible to change timing schedules while running.
Monitor
Pin 11 is a voltage output of the voltage present at the internal capacitor used to
ignite the coils. The ratio is a function of the impedance of the meter. For a 10
MΩ meter impedance, the ratio is 9.23:1; and for a 1 MΩ, it is 10.2:1.
Trigger
Pins 7(+), and 22(–) are for the trigger timing signal. The ignition control module
compares the trigger timing signal with the preprogrammed pin count and the
firing patterns. Should any discrepancy occur, the ignition control module will
shut down following one further complete revolution of the flywheel.
Pickup Signal Input

Pins 8(+), and 23(–) are used to receive either an active or passive pickup
signal. Pin 14(active pickup power) also provides power to the active pickup
unit equal to 1 V less than the power provided to the input terminals (pins 13 &
12). Pin 15 can be used for the shield of this input. See Tables 2-1 and 2-2 for
recommended connections.
connector pole function
8 passive pickup (+)

23 passive pickup (–)
chassis ground shielding
21 5 Vdc output
6 analog input
20 (–) signal ground
19 contact switch
5 permissive start
13 input power dc (+)
12 input power dc (–)
Table 2-1. Input Wiring with Passive Pickup
20 Woodward
connector pole function
14 active pickup power

8 active pickup (+)
23 active pickup (–)
chassis ground shielding
21 5 Vdc output
6 analog input (+)
20 (–) signal ground
19 contact switch
5 permissive start
13 input power dc (+)

12 input power dc (–)
Table 2-2. Input Wiring with Active Pickup
Ignition Coils Output Leads

The IC-100 ignition control system provides ignition energy for one to eight or two
to 16-cylinder gas engines. The corresponding pin number for each cylinder in
firing order is given in Table 2-3. Please note that pin 10 is used for the
return/ground reference.
Ignition Module Firing Order

connector 4 3 2 1 9 16 17 18 10
pin ground
function 1 2 3 4 5 6 7 8
(cylinder) IFO IFO IFO IFO IFO IFO IFO
Engine Firing Order
IFO = in firing order
Table 2-3. Cylinder Output Pin-out
Failure to correctly install the ring-type terminals will affect engine

performance and may shorten the life of the ignition system.
The IC-100 is a negative ground system. When replacing positive

ground systems by the IC-100, the wiring must be altered
accordingly.
The ignition coils must be connected in series in case of double-

firing engines!
Additional Considerations
 Route the individual primary wires to the corresponding ignition coil as

indicated in the wiring chart, taking care to avoid:
sharp edges
hot manifolds
rotating parts that could damage the installation of the wiring
 Route the primary wires through metallic, grounded sleeves.
 Trim each low voltage wire to the proper length, and crimp ring-type
terminals onto their free ends.
Woodward 21
 The ring-type terminals should be suitable for 1.5 mm² (16 AWG) wire and
should have a hole diameter of 5 mm (0.2 inch).
 Use only proper crimping tools for attaching ring-type terminals.
 Use the remaining primary wire or other wire (1.5 mm², temperature
resistance: up to 125 °C/257 °F; insulation breakdown strength: min. 600 V)
along with the ring-type terminals to jumper the negative ignition coil
terminals.
On each engine cylinder bank, the first and last coil must be grounded to the
engine block.
Starting with cylinder 1, enter the engine firing order in Table 2-4 below. Always
refer to the engine manufacturer's specifications for the correct firing order.
Output Wiring
Connector Pole Function
4 cylinder 1
3
2
enter firing order here

1
9
16
17
18
10 ground
11 measuring output
Table 2-4. Ignition Firing Order
Spark plugs should be replaced for optimum ignition performance.

Always follow the manufacturer's recommended gap setting and
installation procedures.
If reusing high tension leads, make sure that they are free of breaks,
cracks, oil contamination, or burns. Connectors must be clean and
seat firmly.
Ignition Coils and High Tension Leads
HIGH VOLTAGE—Do not remove spark plug caps when the engine is
running.
 Securely mount each ignition coil on the engine as close to the spark plug
as possible.
 Avoid mounting the coils on or near hot manifolds or where ambient
temperatures exceed 100 °C (212 °F).
 Ensure that the high tension leads are as short as possible.
Spark plug leads with integrated resistors (5 kΩ typical) are

recommended.
22 Woodward
Chapter 3.
Operation
Programming the IC-100 with a Laptop

In order to program the IC-100, it is necessary to download the “Ignition System
tools” from www.woodward.com/ic/software. The software is designed for
DOS. Install the software on your laptop according to the instructions.
When using a laptop, please note that commands are case-sensitive (capital
letters must be entered as capitals, using the [SHIFT]-key).
Programming the IC-100 with the Hand Held

Programmer
Any hand held programmer needs to have the serial port configured for the
following:
 Baud rate = 9600
 Data bits = 7
 No parity
The following instructions are unique for use only with the 9420-0006
hand held programmer.
Before first use, the hand held programmer must be configured.

 Switch on the programmer.
 Press [SHIFT] + [CTRL] + [F1] at the same time.
 The first parameter will be displayed.
Baud = 9600, press [F1] to continue in lines until "9600" is displayed.

[F2] next
Data Bits = 7, press [F1] to continue in lines until "7" is displayed.

[F2] next
Parity = ignore, press [F1] to continue in lines until "ignore" is displayed.

[F2] next
Display Pre enabled, press [F1] to continue in lines until "enabled" is displayed.
[F2] next
Repeat = fast, press [F1] to continue in lines until "fast" is displayed.

[F2] next
Echo disabled, press [F1] to continue in lines until "disabled" is displayed.

[F2] next
Handshake disabled, press [F1] to continue in lines until "disabled" is displayed.

[F2] next
Self Test disabled, press [F1] to continue in lines until "disabled" is displayed.
[F2] next
Woodward 23
Power Save enabled, press [F1] ton continue in lines until "enabled" is displayed.
[F2] next
[F5] Save
Now, the hand held programmer is ready for use. When programming with the
hand held programmer, only capital letters are possible.
IC-100 Programming Overview

The following is a brief overview of the different screens available on an IC-100.
A more detailed description follows under “Programmable parameters”.
(1) SEQ. Number See Configuration Table 3-1 in this chapter.

Default is 23.
(2) Reset BTDC Position in crank angle degrees of trigger disc

basic setting. Trigger pin / hole "A" is opposite to
pickup. Default is 25.
(3) Overspeed Overspeed value in rpm. When reached, ignition

will shut down. Default is 2200.
(4) Security Speed Speed that inhibits operation of the contact

switch. Default is 350.
(5) MISFIRE RATE Max. allowed misfiring rate. When exceeded,

ignition will shut down. Default is 0.
(6) CAN ID # The range is from 1 to 31. Default is 2.
(7) CANBus enable CANBus function activated (R/W mode).

CANBus disable CANBus function deactivated (Read only). This is
the default.
(8) cyl to cyl enable Enables cyl-to-cyl timing. This is the default.
cyl to cyl disable Disables cyl-to-cyl timing.
(9) contact I/P – for stop Contact switch provides ON/OFF functionality
(timing schedule A only). This is the default.
contact I/P – for A/B Contact switch provides timing schedule
selection (timing schedule A or B)
(10) Pot timing – enable Potentiometer function activated. This is the

default.
Pot timing – disable Potentiometer function deactivated.
(11) speed curve in A – in A –

enable Speed curve for timing schedule A activated.
speed curve in A – not in A –
disable Speed curve for timing schedule A deactivated.
This is the default.
(12) 0 – 5 V in A – in A - enable 0–5 V analog for timing schedule A activated.

0 – 5 V in A – not in A - disable 0–5 V analog for timing schedule A deactivated.
1
(13) speed curve in B – in B –
enable Speed curve for timing schedule B activated.
speed curve in B – not in B –
disable Speed curve for timing schedule B deactivated.
24 Woodward
1
(14) 0 – 5 V in B – in B - enable 0–5 V analog for timing schedule B activated.
0 – 5 V in B – not in B - disable 0–5 V analog for timing schedule B deactivated.
(15) Pot CCW xx.xx ADV Crank angle degrees at CCW position. The
default is 0 degrees.
(16) Pot CW xx.xx ADV Crank angle degrees at CW position. The default
is 10 degrees.
(17) max ADV A: Most advanced timing point for timing schedule A
(max. limit to advance). The default is 10
degrees.
(18) max RET A: Most retarded timing point for timing schedule A
(max. limit of retard). The default is 10 degrees.
1
(19) max ADV B: Most advanced timing point for timing schedule B
(max. limit to advance). The default is 10
degrees.
1
(20) max RET B: Most retarded timing point for timing schedule B
(max. limit of retard). The default is 10 degrees.
(21) 0 V timing Crank angle degrees offset applied to

potentiometer setting for 0V input. The default is
10 degrees.
ADV = "x" degree advanced from potentiometer
setting.
RET = "x" degree retarded from potentiometer
setting.
(22) 5 V timing Crank angle degrees offset applied to

potentiometer setting for 5V input. The default is
10 degrees.
ADV = "x" degree advanced from potentiometer
setting.
RET = "x" degree retarded from potentiometer
setting.
(23) speed points # Number of speed points, required for speed

curve (max. 5 points possible). The default is 2.
(24) BP 1 Speed point 1

new speed = engine speed (default is 100)
angle = advanced or retarded from potentiometer
setting (default is 0)
BP 2 Speed point 2
BP3 Speed point 3

BP4 Speed point 4

1
—Not visible if (9) “contact I/P — for stop” is selected.
Woodward 25
BP5 Speed point 5
new speed = new engine speed (default is 1800)
(25) End / Start ESC – quit programming mode
Function Key Overview

The Main Screen will contain the following information:
RPM :0 speed
0–5V :0 analog input signal
SPARK : 00,00 ignition timing
ENERGY LEVEL :100% energy in %
STATUS: READY ignition status
The following menus may be accessed while the engine is running except self test
[S]:
[C] : cyl. to cyl. menu
[E] : energy level menu
[H] : for Rev, Hours and software rev. no.
[M] : actual misfires and miss/sec
[S] : self test
Sub Menus:
[F1] : Change Parameter
[F2] : Next
[F3] : Previous
[F4] : Help
[F5] : Save
The engine must be stopped to access any other menus!
Programming of Parameters
Prior to operating the IC-100, it must be configured in regards to engine and
application. Programming is done by computer software or the handheld. The
connection is established via a serial computer interface and a cable to the RS-
232 port of the IC-100.
The IC-100 should only be programmed by trained personnel.
If access to programming is needed, proceed as follows:

 Switch on voltage supply to the IC-100, connect the IC-100 to the hand held
or the computer and start the terminal software.
 The main screen is displayed.
 Press [H] to obtain the engine hours.
 Press [ESC]—If the engine is already in operation, the ignition module
cannot switch to the programming mode.
 Enter password which is the number of hours +10. For example, if the
number of hours displayed when [H] was pressed was 2, the password
would be 12.
 Press [Enter] to reach programming level. The first parameter is displayed.
 General information for setting parameters:
[F1] change parameter and confirm with [Enter]. Every parameter change
has to be saved with [F5]
[F2] scrolls ahead to the next parameter
[F3] scrolls back to the previous parameter
26 Woodward
[F4] displays a short clarification of the current parameter
[F5] save parameter
[ESC] quit programming level and start IC-100
[F10] quit program (PC only)
Hit [ESC] to exit programming mode before exiting [F10] the DOS
program for PC only OR disconnect the hand held.
After setting IC-100 parameters, we recommend switching off the supply voltage
in order to reset the IC-100. If the CANBus is activated, the supply voltage must
be switched off, since the ignition will be started in a different mode. Leave the
supply voltage off for at least 20 seconds to ensure that all possible faults are
reset.
All programmable parameters must be set according to the engine application

before operation.
Some of the submenus are available when engine is running:

[C] : cyl. to cyl. menu
[E] : energy level menu
[H] : for Rev, Hours and software rev. no.
[M] : actual misfires and miss/sec
Programmable Parameters
(1) SEQ. Number
IC-100 Sequence Table
Sequence No. of Magnet Firing Disc Unit Firing
No. Outputs Disc Degrees Location Order
1 2 2+1 360-360 cam A-B
2 3 3+1 240-240 cam A-B-C
3 3 3+1 120-120 crank A-B-C
4 6 3+1 50-70 crank A-B-C-D-E-F
5 6 3+1 30-90 crank A-B-C-D-E-F
6 6 3+1 90-30 crank A-B-C-D-E-F
7 2 4+1 90-90 crank A-B
8 4 4+1 180-180 cam A-B-C-D
9 4 4+1 90-90 crank A-B-C-D
10 8 4+1 20-70 crank A-B-C-D-E-F-G-H
11 8 4+1 60-30 crank A-B-C-D-E-F-G-H
12 8 4+1 45-45 crank A-B-C-D-E-F-G-H
13 8 4+1 30-60 crank A-B-C-D-E-F-G-H
14 5 5+1 72-72 crank A-B-C-D-E
15 5 5+1 144-144 cam A-B-C-D-E
16 6 6+1 120-120 cam A-B-C-D-E-F

17 3* 6+1 60-180 crank A-B-E
18 4* 6+1 120-60 crank A-C-D-F
19 6 6+1 60-60 crank A-B-C-D-E-F
20 7 7+1 102.8-102.8 cam A-B-C-D-E-F-G

21 7 7+1 51.43-51.43 crank A-B-C-D-E-F-G
22 8 8+1 90-90 cam A-B-C-D-E-F-G-H
23 8 8+1 45-45 crank A-B-C-D-E-F-G-H
24 2* 6+1 360-360 cam A-D
25 3* 6+1 240-240 cam A-C-E
26 4* 6+1 180-180 cam A-D-E-H
27 8 6+1 120-60 cam A-B-C-D-E-F-G-H
Woodward 27
*NOTE—Firing order/sequence. Rev 2.46 (and higher) allows adjustment of 6 outputs for
cylinder-to-cylinder timing in the RS-232 menu and the CANBus.
Sequence 26 allows all 8 outputs to be adjusted.
All outputs in the firing order are displayed. Make sure to match the output letter in the
table above to the output that is being adjusted.
Letters are used instead of numbers for the firing order: A is the first in the firing order,
followed by B, C, D, E, F, G, H.
[F1] enter sequence no. and press [Enter]

[F5] to save
[F2] to advance to the next screen
If the sequence table is not available, press:
[F4] shows the selected sequence number and the firing pattern. Press <U> or
<D> to scroll through the sequence table.
(2) Reset BTDC

The reset BTDC parameter is the basic setting of the IC-100. The basic setting of
the trigger disc or the trigger pins / holes may be between 25° and 60°. The
IC-100 program allows electronic compensation of the trigger points. For more
information see Chapter 2 (Setting the Ignition Timing Adjustment Range). For
final adjustment follow the start up procedure later in this chapter.
(3) Overspeed
Press [F1], enter desired speed in RPM for limit, then press [Enter].
[F5] to save
The engine should be equipped with an overspeed shutdown device

to protect against runaway or damage to the prime mover with
possible personal injury, loss of life, or property damage.
The overspeed shutdown device must be totally independent of the

prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.
The ignition will be shut down if the overspeed limit is reached!
Power must be cycled to the IC-100 after an overspeed shutdown condition to

clear the fault.
(4) Security Speed (start-up speed)

This is essentially a programmable ‘Run’ speed setting that controls the
operation of the Contact Switch input. Security Speed is rendered inoperable
when the Contact Switch input is not connected or is not configured as a “Stop”
Contact (see ‘Contact I/P’ programming).
The Stop Contact enables or disables the primary outputs.

 Below the Security Speed but above 30 rpm (approx.), the primary outputs
will fire or stop firing each time the Stop Contact is opened (ungrounded) or
closed (grounded).
 Above the Security Speed the primary outputs will stop firing when the Stop
Contact is closed and will not fire again until the engine has come to a full
stop (zero rpm is sensed) and the engine is re-started.
28 Woodward
 Above the Security Speed the primary outputs will fire if the Stop Contact
was closed and is opened for the first time. This allows engine starting when
the Security Speed is set below cranking speed.
Typically the Security Speed is set above cranking speed and below minimum or
idle speed.
Programming Sequence:
1. Press F1 to change security speed or F2 to skip.
2. Enter security speed, then press ENTER.
3. Press F5 to save.
4. Press F2 to program next parameter.
Range: Valid from 0 rpm to ‘overspeed’ rpm setting.
(5) Misfire Rate

The number of misses per second that is permissible before the engine shuts
down due to misfire rate exceeded. To disable, set misfire rate to zero or 255.
The most sensitive setting is 1. Please note that damaged leads may cause
misfires.
1. Press F1 to change misfire rate or F2 to skip.
2. Enter misfire rate, then press ENTER.
3. Press F5 to save.
4. Press F2 to program next parameter.
Disabling this function may cause personal injury or engine damage.
(6) CAN-ID #
Specify desired CANBus protocol. The default is 2 which allows communication
with a D1 display.
[F1]
CAN ID #
1ST TYPE NEW: Please enter “2”.
ENTER WHEN DONE Press [Enter]
[F5] to save
(7) CAN BUS ENABLED / DISABLED

The CANBus function should only be activated if an engine management system
controls the ignition timing via CANBus.
[F1]
ENABLED activated
DISABLED deactivated
[F5] to save
Contact the factory for the CANBus communication protocol.
(8) Cylinder-to-Cylinder Timing (toggle with [F1])

IC-100 units are equipped with cylinder-to-cylinder timing adjustment capability.
This allows fine tuning of each cylinder ignition timing, individually. See Chapter 3
(Additional Functions).
[F1] ENABLE activate

[F2] DISABLE deactivate
[F5] save
Woodward 29
(9) Function of Contact Lead 19
Contact lead 19 allows choice between two functions:
CONTACT I/P FOR STOP A/B

F1
F1 CONTACT FOR STOP Ignition can be STOPPED and STARTED via
this lead
F2 CONTACT FOR A/B Switching this lead allows shifting between 2

timing schedules, A or B. A or B can have
different timing for the potentiometer and 0–5
Volt. It is possible to have a speed curve
enabled or disabled for both A and B schedules.
(10)Activating Potentiometer
The integrated potentiometer of the IC-100 can be disabled after making the
settings, in order to lock this feature for the operator.
POT TIMING ENABLED / DISABLED

F1
ENABLE activated
DISABLE deactivated
F5 save
(11) Speed Curve in Timing Schedule A

The IC-100 offers programming of a speed curve / speed ramp. That means,
depending on the actual engine speed, a certain timing is chosen. This aims at
reaching optimal gas combustion.
SPEED CURVE IN A / NOT IN A

F1
ENABLE activated / function is used
DISABLE deactivated / function is not used
F5 save
(12) Analog Input Signal for Timing Schedule A

In addition to the potentiometer adjustment and the speed curve, it is possible to
change the ignition timing by using the analog input signal.
Example:
A knock monitoring system can change the ignition timing linear. In that case the
knock monitoring system sends the analog output signal 0–5 Vdc to the ignition
system depending on the level of engine knocking.
0 – 5 V IN A / NOT IN A
F1
F5 save
30 Woodward
(13) Speed Curve in Timing Schedule B
It is possible to program a different speed curve / speed ramp for timing schedule
B. Thus a different ignition timing is given depending on actual engine speed.
By setting a speed dependent ignition timing an optimal gas combustion can be

achieved.
SPEED CURVE IN B / NOT IN B

F1
F5 save
(14) Analog Input Signal for Timing Schedule B

Additionally to the potentiometer adjustment and the speed curve it is possible to
change the ignition timing by using the analog input signal.
Example:
A knock monitoring system can change the ignition timing linear. In that case the
knock monitoring system sends the analog output signal 0–5 Vdc to the ignition
system depending on the level of engine knocking.
0 – 5 V IN B / NOT IN B
F1
F5 save
(15) Setting the Potentiometer Span—CCW Position

The left limit (CCW) of the potentiometer can be set as timing angle.
POT CCW x.xx ADV

F1
1ST TYPE NEW enter value
F1: ADVANCE BTDC (before top dead center)
F2: RETARD most retarded (0.00°)
F5 save
(16) Setting Potentiometer Span—CW Position

The right limit (CW) of the potentiometer can be set as timing angle.
POT CW x.xx ADV

F1
F5 save
Woodward 31
Ignition Timing
25°
20°
CCW position
potentiometer-span
10° CW position
50 500 1000 1500 RPM
(17) Timing Schedule A—Maximum Limit of Advanced Ignition

In order to avoid engine damage by addition of the various ignition relevant
parameters, it is possible to set a maximum ignition limit.
MAX ADV IN A: xx.xx ADV

F1
1ST TYPE NEW: enter value
THEN ENTER press [ENTER]
F5 save
(18) Timing Schedule A—Maximum Limit Retarded Ignition

In order to avoid engine damage by addition of the various ignition relevant
parameters, it is possible to set a minimum ignition limit.
MIN ADV IN A: xx.xx ADV

F1
THEN ENTER press [ENTER]
F5 save
Ignition Timing
25° MAX limit
20°
10° MIN limit
50 500 1000 1500 RPM
32 Woodward
(19) Analog Input Signal—0 Volt Limit
Rotation direction and span, direct or indirect effect of the 0–5 Volt signal can be
programmed with end points retarded or advanced. The 0–5 Volt signal (advance
or retard) will be added to or deducted from the potentiometer and speed curve
(if activated).
The value of change has to be entered as a figure in degrees when the 0 Volt
signal is received.
0V TIMING x.xx ADV

ENTER
F1: ADVANCE advance (addition to existing curve)
F2: RETARD retard (deduction from existing curve)
F5 save
(20) Analog Input Signal—5 Volt Limit

Rotation direction and span, direct or indirect effect of the 0–5 Volt signal can be
programmed with end points retarded or advanced. The 0–5 Volt signal (advance
or retard) will be added to or deducted from the potentiometer and speed curve
(if activated).
The value of change has to be entered as a figure in degrees when the 5 Volt
signal is received.
5V TIMING x.xx ADV

ENTER
F1: ADVANCE advance (addition existing curve)
F2: RETARD retard (deduction from existing curve)
F5 save
Ignition Timing
25°
20°
= 0 Volt value pot setting
0 – 5 Volt adjustment range
= 5 Volt value pot setting
10°
50 500 1000 1500 RPM
Woodward 33
Ignition Timing
25° = 5 Volt value pot setting

0 – 5 Volt adjustment range
20° = 0 Volt value pot setting
10°
50 500 1000 1500 RPM
(21) Speed Points

For programming a speed dependent curve max. speed of 5 points can be set.
The speed curve should be worked out before you start programming the data!
SPEED POINTS: x
ENTER WHEN DONE press [ENTER]
F5 save
(22) Setting Speed Points BP1 to BP5

Setting the speed points always requires a speed and a degree value. The
degree value will be added to (ADV) or deducted from (RET) the potentiometer
curve which is always 0 (zero).
BP1: x.xx ADV

NEW SPEED enter speed
ENTER WHEN DONE press [ENTER]
F1: ADVANCE add
F2: RETARD deduct
Follow these instructions for the remaining speed points.
Example of a typical speed curve of an engine (generator operation) with a

speed curve to influence the start-up procedure positively:
When the engine is not running, the ignition timing is equal to the potentiometer
setting. Thus the ignition timing can also be checked with the programmer or a
laptop when the engine is out of operation. Even if the engine is started the
ignition timing will be reduced and increased again from 50 revolutions until it
reaches the preset value at 1000 revolutions.
SPEED POINTS :3 number of speed points

BP1 :0 speed
0 ADV angle
F5
BP2 : 50 speed
10 RET angle
F5
BP3 : 1000 speed
0 ADV angle
F5
34 Woodward
Ignition Timing
25°
20°
BP1
BP3
10°
BP2
50 500 1000 1500 RPM
Example of Programming an IC-100

Potentiometer A : enabled
speed curve A : enabled
0 – 5 V analog input : enabled
Potentiometer CCW : 22° ADV
Potentiometer CW : 18° ADV
max. advance : 25° ADV
max. retard : 5° ADV
0 – 5 Volt Signal - 0 Volt : 0° RET
0 – 5 Volt Signal - 5 Volt : 5° RET
number of speed points : 3
BP1 : 0 RPM
0° RET
BP2 : 50 RPM
15° RET
BP3 : 1000 RPM
0° RET
Woodward 35
Enter your programmed data here:
°crank
35°
30°
25°
20°
15°
10°
5°
TDC
0 50 1000 1500 1800 RPM
36 Woodward
Additional Functions
Ignition Energy Levels
Depending on the gas quality and the application, it is possible to vary the
available ignition energy.
You may set any value between 20–100%.
Fast-burning gases like propane require relatively small energy, whereas slow-
burning gases like sewage gas require high energy, to ignite the gas.
To change the preset values proceed as follows:

 press "E"
 press "F1"
 enter new value
 press "Enter"
 press "F5" to save changes
Cylinder-to-Cylinder Timing
The cylinder-to-cylinder timing allows changing the adjustment for single
cylinders, to optimize ignition firing.
The ignition timing of each cylinder can be shifted by ±2° from the global setting.
However, you should use this option only if suitable instrumentation is available
to analyze the position with the most effective compression, in order to
immediately judge the result.
Activating Cylinder-to-Cylinder-Timing
ADV is ° advanced from the global setting.

RET is ° retarded from the global setting.
See Table 2-4, Ignition Firing Order, for sequence of connections and
firing order.
Press "F5" to save all cylinder adjustment values. Leave the cylinder-
to-cylinder menu by pressing “ESC". Now you can disconnect the
programmer from the IC-100 without losing any data.
The IC-100 primary outputs do not consider the direction of rotation.

Pin "4" is always the first cylinder of the firing order, "3" is the
second, "2" the third, etc. (see Table 2-4).
To activate cylinder-to-cylinder timing, proceed as follows. The function cylinder-

to-cylinder-adjustment is started during engine operation by pressing [C] using
the programmer.
Woodward 37
The following menu is displayed:
CYL #1 x.xx ADV / RET

F1 CHANGE value can be changed
F2 NEXT call next ignition output
F3 PREVIOUS back to previous output
F5 SAVE save
To change values proceed as follows:
[F2] until ignition output of the cylinder, which is to be

optimized, appears
[F1]
1ST TYPE IN NEW enter delta value (max. 2°)
THEN ENTER
[ENTER]
F1 ADVANCE change to position advanced from global setting

F2 RETARD change to position retarded from global setting
F5 save
Initial Start-up Procedure

I. Before applying power to the IC-100, check and verify the following:
1. Fuel valve is shut off.
2. The firing interval (sequence number) is correct for the engine type. If you
are not sure, contact your engine manufacturer.
3. Cylinder firing order is known and the ignition coils are wired to the correct
outputs in accordance with the Cylinder Output Pin-out Table 2-3.
4. Timing sensor is properly gapped and tightened.
5. Timing sensor is wired in accordance with Table 2-1 or Table 2-2.
II. Apply power to the IC-100 (fuel valve still in the off position):
1. Check and verify that the IC-100 is programmed correctly.
2. Perform the normal engine start-up procedure (prelube, etc.), except that the
fuel must remain OFF.
3. With a timing light connected to the #1 cylinder, verify that the cylinder is
firing within ±2 degrees of the programmed setting. If not, refer to Chapter 4.
4. Check all remaining cylinders for proper timing. If not correct, stop the engine
and recheck wiring and sequence number for correctness.
5. Disengage the starter. Continue with step III if no problems are encountered.
38 Woodward
III. Set the fuel valve to its normal position.
1. Follow the normal starting procedure and start the engine.
2. If the engine fails to start, refer to Chapter 4.
3. If the engine starts, re-verify timing of #1 cylinder.
4. Increase engine speed to normal operating speed.
5. Check timing of #1 cylinder and compare measured timing to the displayed
timing (PC/laptop with monitor program or hand held terminal is required).
6. If the IC-100 displayed value is too high, the programmed reset position
(Reset BTDC parameter)needs to be reduced by the difference.
Example:
If the IC-100 monitor is displaying 22.0° BTDC and the actual measured
timing is 20.5° BTDC, the programmed reset position will have to be
reduced by 1.5 degrees (22–20.5). So, if the programmed reset position
(Reset BTDC parameter) is 50 degrees Adv., the programmed reset position
will have to be changed to 48.5 degrees Adv.
If the IC-100 displayed value is too low compared to the measured timing,
the programmed reset position will have to be increased by the difference.
7. If necessary, stop the engine using the normal shutdown procedure and
change the programmed reset position (Reset BTDC parameter).
8. Re-start the engine and verify that the #1 cylinder is firing at the correct
position.
9. Check all remaining cylinders for proper timing. If not correct, stop the engine
immediately and recheck wiring and sequence number for correctness.
Woodward 39
Chapter 4.
Maintenance and Troubleshooting
Maintenance
Switch off the engine and disconnect the power supply before
commencing any installation work!

The IC-100 ignition control module is not intended for repair by the end user. See
Chapter 5 for service options.
The remaining parts of the ignition control system should be serviced as follows:
 The pickups might need to be replaced if they operate under extreme
thermal conditions (> 90 °C/194 °F).
 All control system cables should be carefully examined for signs of damage
and replaced if necessary.
 All plug connections should be checked to ensure that they are in a
serviceable condition.
 The spark plugs should be serviced according to the specifications of the
spark plug and engine manufacturer.
Faults and Troubleshooting

The IC-100 includes an LED, which indicates faults by flashing once or several
times.
flashing system status possible problem

continuous flashing normal operation with ignition none
firing
1 flash normal READY mode, 0 rpm none
1 flash no pickup signal defective pickup or incorrect wiring
of pickup
2 flashes bad pickup signal sequence number does not match
timing
3 flashes engine speed too low increase cranking speed / check
sequence number and timing disc
4 flashes engine overspeed engine overspeed or set point too
low
5 flashes low supply voltage defective supply/battery or
undersized wire
6 flashes programming mode none
6 flashes configuration error incorrect parameters programmed,
bad data identified in non-volatile
memory, bad pickup signal at >
200 rpm
Table 4-1. LED Flash Codes
40 Woodward
The ignition system is comprised of the following components that have to be
taken into consideration when searching for faults:
 ignition control module
 harness
 ignition coils
 high tension leads
 ground leads
 spark plugs
 shutdown equipment
Most ignition system failures occur outside the ignition control module. The cause
may lie in any one of the above components or in the connections between them.
The following troubleshooting guide is divided into three sections:

 input fault diagnosis
 low or high voltage ignition circuits
 ignition control module self test function
Input Fault Diagnosis

If a fault is detected in the inputs to the IC-100, the ignition control module will
automatically shut down the ignition. The cause of the fault must be corrected
before the engine can be restarted.
Input faults which might cause shutdown are:

 open circuit or short-circuit to ground in the input power circuit
 open circuit or short-circuit to ground in the engine starting circuit
 loss of input power or supply voltage too low
Power supply circuit:
Supply voltages below the specified values will impair the operation
of the ignition control module and may cause the engine to stall.
Supply voltages above the specified values could damage the
ignition control module.
The following minimum and maximum input voltages must be

maintained:
Minimum 10 Vdc
Maximum 32 Vdc
Input voltages outside these values may damage the IC-100.
If damping of the supply voltage is suspected, verify with a voltmeter. Check the
start/stop circuit for any opens, shorts or accidental connections to ground.
Faulty pickup signal:

If a timing signal fault is detected during operation, the ignition control module
automatically shuts down the ignition. Such a fault could result from the failure of
a pickup, an open, short-circuited, or grounded connection to a pickup, or a
physical change in the characteristics of a passive trigger.
Proceed as follows:
 Crank the engine with the fuel valve closed and check all signals at the
pickup connectors using an oscilloscope.
 Verify minimum 2.5 V square wave signal.
Woodward 41
Figure 4-1. Oscilloscope—Square Wave Signal
Two LEDs are installed in the connector cap of the reset pickup. The
colors indicate the following:
green—power supply connected
orange—trigger signal
Low or High Voltage Ignition Circuits
 Track the ignition circuit current flow if the engine is missing on one or more
cylinders, but not completely dead.
 Apply an inductive timing light to the high tension leads to determine which
cylinder is not firing.
The brightness of the firing indicator bulb is not a measure of the

actual strength of the respective output signal; it only reflects the
voltage required by the spark plug itself.
Determine which lead in the harness is connected to the malfunctioning cylinder.

 Stop the engine and unplug the output harness connector from the ignition
control module.
 Use an ohmmeter with a scale of R x 1.
 Connect one ohmmeter probe to the harness connector pin of the
malfunctioning cylinder and the other to the engine ground.
 Read the measured resistance.
The resistance on the low voltage side should lie within the values specified
below.
If this is the case, the low voltage ignition circuit is not the cause of the fault.
42 Woodward
primary secondary
ignition coil resistance resistance (HV)
9100.0002 1.10—1.45 Ω 10.70—11.80 kΩ
9100.0001 0.60—0.80 Ω 7.50—9.50 kΩ
All ohmmeters have a certain error margin which may lie between 3
and 5%.
If lower values are measured, this indicates that the low voltage supply lead to
the ignition coil is grounded or the ignition coil low voltage winding is short-
circuited.
If higher values than those listed above are measured, this indicates poor
connections, a fault in the ignition coil low voltage winding, or a poor engine
ground.
 To locate this fault, the harness ring-type connectors must be disconnected
from the ignition coil.
 Connect one ohmmeter probe to the negative terminal of the ignition coil
and the other to the engine ground.
Resistance within the values specified above:

Fault in the harness lead or harness plug connector.
Resistance outside the values specified above:

Defective ignition coil or poor ground connection.
If you have still not located the fault, proceed as follows:

 Connect one ohmmeter probe to the positive terminal and the other to the
negative terminal of the ignition coil.

Poor ground connection.

Defective ignition coil.
If you still have not located the fault, proceed as follows:

 Disconnect the output harness from the ignition control module!
 Remove the spark plug cap from the spark plug. Do not yet remove the
ignition coil.
 Select the R x 100 or R x 1000 scale and connect the ohmmeter probes
between the spark plug cap and ground.
 The resistance on the high voltage side of the ignition coil should be within
the values specified above.

Defective spark plug or defective ignition control module.

Defective spark plug lead or ignition coil, or poor ground connection.
Woodward 43
 Disconnect the spark plug lead from the ignition coil.
 Measure the resistance between the ignition coil high voltage output and the
engine ground. The resistance on the high voltage side should lie within the
values specified above.
If your spark plug boots have integrated resistance, you must

subtract this resistance from your measured values!

Defective spark plug lead or spark plug boot.

Defective ignition coil or poor ground connection.

 Connect one ohmmeter probe to the ignition coil high voltage output and the
other to the ignition coil ground terminal. The measured resistance should
lie within the values specified above.

Defective ground connection.

Defective ignition coil.
Ignition Control Module Self Test Function
It is critical that the fuel to the engine be shut off and the engine
purged of any fuel gas before starting the self-test. Failure to do this
could result in personal injury or damage to equipment.
HIGH VOLTAGE—Warn all personnel to avoid contact with the

ignition coils or primary and secondary wiring before starting the
self-test. Failure to avoid contact could result in personal injury.
Do not crank the engine while the self-test is active!
The self-test feature of the IC-100 allows the operator/mechanic to conduct

performance checks on the wiring to the coil, the ignition coil, high tension leads,
and spark plugs by discharging the energy stored in the high voltage capacitor
into each coil in successive order. The IC-100 will “fire” a cylinder every
0.1.second. The energy delivered to each coil is fixed at 70%.
On this screen, you must enter the password to enable the self-test. Pressing “S”
(upper case) from the main screen starts the self-test feature. Pressing “S”
(upper case) again from the main screen stops the self-test feature. While in self-
test, proper performance of each cylinder can be checked using standard
troubleshooting tools (timing light, voltmeter, etc.).
44 Woodward
Chapter 5.
Product Support and Service Options
Product Support Options

If you are experiencing problems with the installation, or unsatisfactory
performance of a Woodward product, the following options are available:
1. Consult the troubleshooting guide in the manual.
2. Contact the OE Manufacturer or Packager of your system.
3. Contact the Woodward Business Partner serving your area.
4. Contact Woodward technical assistance via email
(EngineHelpDesk@Woodward.com) with detailed information on the
product, application, and symptoms. Your email will be forwarded to an
appropriate expert on the product and application to respond by telephone
or return email.
5. If the issue cannot be resolved, you can select a further course of action to
pursue based on the available services listed in this chapter.
OEM or Packager Support: Many Woodward controls and control devices are
installed into the equipment system and programmed by an Original Equipment
Manufacturer (OEM) or Equipment Packager at their factory. In some cases, the
programming is password-protected by the OEM or packager, and they are the best
source for product service and support. Warranty service for Woodward products
shipped with an equipment system should also be handled through the OEM or
Packager. Please review your equipment system documentation for details.
Woodward Business Partner Support: Woodward works with and supports a

global network of independent business partners whose mission is to serve the
users of Woodward controls, as described here:
 A Full-Service Distributor has the primary responsibility for sales, service,
system integration solutions, technical desk support, and aftermarket
marketing of standard Woodward products within a specific geographic area
and market segment.
 An Authorized Independent Service Facility (AISF) provides authorized
service that includes repairs, repair parts, and warranty service on
Woodward's behalf. Service (not new unit sales) is an AISF's primary
mission.
 A Recognized Engine Retrofitter (RER) is an independent company that
does retrofits and upgrades on reciprocating gas engines and dual-fuel
conversions, and can provide the full line of Woodward systems and
components for the retrofits and overhauls, emission compliance upgrades,
long term service contracts, emergency repairs, etc.
A current list of Woodward Business Partners is available at

www.woodward.com/directory.
Product Service Options

Depending on the type of product, the following options for servicing Woodward
products may be available through your local Full-Service Distributor or the OEM
or Packager of the equipment system.
 Replacement/Exchange (24-hour service)
 Flat Rate Repair
 Flat Rate Remanufacture
Woodward 45
Replacement/Exchange: Replacement/Exchange is a premium program
designed for the user who is in need of immediate service. It allows you to
request and receive a like-new replacement unit in minimum time (usually within
24 hours of the request), providing a suitable unit is available at the time of the
request, thereby minimizing costly downtime.
This option allows you to call your Full-Service Distributor in the event of an
unexpected outage, or in advance of a scheduled outage, to request a
replacement control unit. If the unit is available at the time of the call, it can
usually be shipped out within 24 hours. You replace your field control unit with
the like-new replacement and return the field unit to the Full-Service Distributor.
Flat Rate Repair: Flat Rate Repair is available for many of the standard
mechanical products and some of the electronic products in the field. This
program offers you repair service for your products with the advantage of
knowing in advance what the cost will be.
Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat
Rate Repair option, with the exception that the unit will be returned to you in “like-
new” condition. This option is applicable to mechanical products only.
Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned for repair,
please contact your Full-Service Distributor in advance to obtain Return
Authorization and shipping instructions.
When shipping the item(s), attach a tag with the following information:
 return number;
 name and location where the control is installed;
 name and phone number of contact person;
 complete Woodward part number(s) and serial number(s);
 description of the problem;
 instructions describing the desired type of repair.
Packing a Control
Use the following materials when returning a complete control:
 protective caps on any connectors;
 antistatic protective bags on all electronic modules;
 packing materials that will not damage the surface of the unit;
 at least 100 mm (4 inches) of tightly packed, industry-approved packing
material;
 a packing carton with double walls;
 a strong tape around the outside of the carton for increased strength.
To prevent damage to electronic components caused by improper

handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.
Replacement Parts
When ordering replacement parts for controls, include the following information:
 the part number(s) (XXXX-XXXX) that is on the enclosure nameplate;
 the unit serial number, which is also on the nameplate.
46 Woodward
Engineering Services
Woodward’s Full-Service Distributors offer various Engineering Services for our
products. For these services, you can contact the Distributor by telephone or by
email.
 Technical Support
 Product Training
 Field Service
Technical Support is available from your equipment system supplier, your local
Full-Service Distributor, or from many of Woodward’s worldwide locations,
depending upon the product and application. This service can assist you with
technical questions or problem solving during the normal business hours of the
Woodward location you contact.
Product Training is available as standard classes at many Distributor locations.

Customized classes are also available, which can be tailored to your needs and
held at one of our Distributor locations or at your site. This training, conducted by
experienced personnel, will assure that you will be able to maintain system
reliability and availability.
Field Service engineering on-site support is available, depending on the product

and location, from one of our Full-Service Distributors. The field engineers are
experienced both on Woodward products as well as on much of the non-
Woodward equipment with which our products interface.
For information on these services, please contact one of the Full-Service

Distributors listed at www.woodward.com/directory.
Contacting Woodward’s Support Organization

For the name of your nearest Woodward Full-Service Distributor or service
facility, please consult our worldwide directory published at
www.woodward.com/directory.
You can also contact the Woodward Customer Service Department at one of the
following Woodward facilities to obtain the address and phone number of the
nearest facility at which you can obtain information and service.
Products Used In Products Used In Products Used In

Electrical Power Systems Engine Systems Industrial Turbomachinery
Systems
Facility---------------- Phone Number Facility---------------- Phone Number Facility---------------- Phone Number
Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800
China ----------- +86 (512) 6762 6727 China ----------- +86 (512) 6762 6727 China ----------- +86 (512) 6762 6727
Germany: Germany------- +49 (711) 78954-510 India --------------- +91 (129) 4097100
Kempen ---- +49 (0) 21 52 14 51 India --------------- +91 (129) 4097100 Japan -------------- +81 (43) 213-2191
Stuttgart-- +49 (711) 78954-510 Japan -------------- +81 (43) 213-2191 Korea -------------- +82 (51) 636-7080
India --------------- +91 (129) 4097100 Korea -------------- +82 (51) 636-7080 The Netherlands - +31 (23) 5661111
Japan -------------- +81 (43) 213-2191 The Netherlands - +31 (23) 5661111 Poland--------------- +48 12 295 13 00
Korea -------------- +82 (51) 636-7080 United States ---- +1 (970) 482-5811 United States ---- +1 (970) 482-5811
Poland--------------- +48 12 295 13 00
United States ---- +1 (970) 482-5811
For the most current product support and contact information, please visit our
website directory at www.woodward.com/directory.
Woodward 47
Technical Assistance
If you need to contact technical assistance, you will need to provide the following information.
Please write it down here before contacting the Engine OEM, the Packager, a Woodward
Business Partner, or the Woodward factory:
General
Your Name
Site Location
Phone Number
Fax Number
Prime Mover Information

Manufacturer
Engine Model Number
Number of Cylinders
Type of Fuel (gas, gaseous, diesel,
dual-fuel, etc.)
Power Output Rating
Application (power generation, marine,
etc.)
Control/Governor Information
Control/Governor #1
Woodward Part Number & Rev. Letter
Control Description or Governor Type
Serial Number
Control/Governor #2
Serial Number
Control/Governor #3
Serial Number
Symptoms
Description
If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written down and with you at the time of the call.
48 Woodward
Appendix.
Programming Overview
Here is a good place to enter the values you programmed.

Customer
Engine Type / Model
Engine Serial Number
Number of Cylinders
Ignition Timing Point
(1) firing pattern = sequence-no.
(2) reset position BTDC nominal: actual:
(3) overspeed
(4) security speed (max. starting speed)
(5) misfire rate
(6) CAN ID
(7) CANBus enabled disabled
(8) cyl-to-cyl timing enabled disabled
(9) contact switch 19 enabled for: ON/OFF ignition

2-potentiometer operation
(10) potentiometer function enabled disabled
(11) speed curve potentiometer A enabled disabled
(12) 0 – 5 V in A enabled disabled
(13) speed curve potentiometer B enabled disabled
(14) 0 – 5 V in B enabled disabled
(15) potentiometer max. angle stop left ADV – BTDC: RET – ATDC:
(CCW):
(16) potentiometer max. angle stop right ADV – BTDC: RET – ATDC:
(CW):
(17) most advanced timing point for
potentiometer A:
(18) most retarded timing point for
potentiometer A:
(19) most advanced timing point for
potentiometer B:
(20) most retarded timing point for
potentiometer B:
Woodward 49
(22) adjustment of timing point given by analog signal, input signal: 5 Volt:
ADV = degree advanced RET = degree retarded
(23) number of speed points required for speed curve (max. 5 points):
(24) speed points

BP1 BP2 BP3 BP4 BP5
speed
retard angle
Additional functions:
[Shift] + [E] energy (10 % - 100 %):
[Shift] + [H] operating hours Date: op. hours:
[Shift] + [C]: cylinder – cylinder adjustment
ignition output: 4 3 2 1 9 16 17 18 10
firing order ground
change
(+) ADV
(–) RET
_________________________ _____________________________________
Date Signature
50 Woodward
Woodward 51
Declarations
IC–100 Control Specifications
Power Consumption 24 V operation: 18–32 Vdc (2.2 A max.)
10–18 Vdc (3.5 A max) steady state operation is allowable but may not be
able to achieve 100% energy.
Average current is dependent on the number of cylinders, input power,
energy level, and engine speed.
Peak current is dependent only on energy level; 100% energy = 20 A peak
Trigger Input Variable reluctance (passive) +2 Vdc min., 80 V p-p max, 10 Hz to 10 kHz
Sensor Inputs 0–5 V sensors
Permissive Start (solid-state output) Open collector (NPN) 60 V max., 150 mA max
Communications Ports CAN, RS-232
Maximum Case Temperature 70 °C (158 °F) [see Chapter 1 for details]
Ambient Operating Temperature –40 to +55 °C (–40 to +131 °F)
Storage Temperature –40 to +85 °C (–40 to +185 °F)
Mechanical Vibration SV2: 4g, 5–2000 Hz and RV1: 8.2 Grms, 10–2000 Hz
Mechanical Shock MS1: 40g peak, 11 ms sawtooth
Air Quality Pollution Degree II
Installation Overvoltage Category II
Ingress Protection IP40
Regulatory Compliance
European Compliance for CE Mark:
EMC Directive Declared to 2004/108/EC COUNCIL DIRECTIVE of 15 December 2004 on
the approximation of the laws of the member states relating to
electromagnetic compatibility.
Low Voltage Directive Declared to the 2006/95/EC COUNCIL DIRECTIVE of 12 December 2006
on the harmonization of the laws of the Member States relating to electrical
equipment designed for use within certain voltage limits.
We appreciate your comments about the content of our publications.
Send comments to: icinfo@woodward.com
Please reference publication 26205B.
PO Box 1519, Fort Collins CO 80522-1519, USA

1000 East Drake Road, Fort Collins CO 80525, USA
Phone +1 (970) 482-5811  Fax +1 (970) 498-3058
Email and Website—www.woodward.com
Woodward has company-owned plants, subsidiaries, and branches,

as well as authorized distributors and other authorized service and sales facilities throughout the world.
Complete address / phone / fax / email information for all locations is available on our website.
2012/8/Colorado

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Product Manual 26205

IC-100 CD Ignition System

Installation and Operation Manual

To prevent damage to a control system that uses an alternator or battery-charging

To prevent damage to electronic components caused by improper handling, read

Revisions—Text changes are indicated by a black line alongside the text.

ELECTROSTATIC DISCHARGE AWARENESS ..................................................III

Illustrations and Tables

Figure 2-1. IC-100 Outline Drawing ........................................................................6

Table 2-1. Input Wiring with Passive Pickup ........................................................20

Electrostatic Discharge Awareness

Follow these precautions when working with or near the control.

1. Before doing maintenance on the electronic control, discharge the static

3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam

 Do not touch any part of the PCB except the edges.

 Do not touch the electrical conductors, the connectors, or the

To prevent damage to electronic components caused by improper

Integral to the IC-100 is one adjustment potentiometer. This has a programmable

A cam or crankshaft trigger disc is used to provide relative position reference.

The IC-100 is intended for use in non-hazardous locations.

The IC-100 has several functional features to ensure proper operation:

In no case should the following parts of the ignition control system

 Before commencing any work involving the installation, operation, resetting,

 The harness must be removed.

 Safety devices must not be disassembled or inactivated.

 Only operate the ignition control system provided it is in perfect condition,

 Always ensure that the engine room is properly ventilated!

Read this section carefully before assembling the components!

A complete ignition system consists of:

Before commencing with the final assembly, it is advisable to carefully consider

Ignition Control Module

Never do any welding work on the engine or chassis when the

The crankshaft and camshaft pickup should be mounted at a convenient position

2-Stroke and Double-Firing 4-Stroke Engines

Ensure that the trigger disc is perfectly centered!

Figure 2-1. IC-100 Outline Drawing

Single-Firing 4-Stroke Engines

Ensure that the trigger disc is perfectly centered!

Figure 2-2. Trigger Disc Mechanical Requirements

It is essential to take account of the camshaft slope in order to

In order to avoid defective signals, the mounting surface must be

Preparations for Active Pickup

Figure 2-3. Mounting of Camshaft Trigger Disc

Installation of a Disc with Reluctor Pins

It is essential that the threaded hole be perpendicular to the surface

 Screw the active pickup into the tapped hole.

Mounting a Trigger Disc with Slots

Tightening torque for active pickup: max. 15 Nm (11 lb-ft)!

Figure 2-4. Mounting a Trigger Disc with Slots

In order to avoid defective signals, the mounting surface must be

It is essential that the threaded hole is perpendicular to the surface

 Screw the speed pickup into the tapped hole.

 Drill and tap a hole to accept the magnetic pickup.

It is essential that the threaded hole be perpendicular to the surface

 Screw the pickup into the threaded hole.

Figure 2-5. Mounting of Flywheel Pickup

Setting the Ignition Timing Adjustment Range and