Installation Instructions: CD200D Digital Ignition System Form CD200D II 4-17

Installation Instructions
CD200D Digital Ignition System
Form CD200D II 4-17

1.0 DESCRIPTION WARNING: DEVIATION FROM THESE
INSTRUCTIONS MAY LEAD TO IM-
1.1 This manual provides installation and operating instructions for the Altronic PROPER OPERATION OF THE MACHINE
CD200D ignition system. It is recommended that the user read this manual in WHICH COULD CAUSE PERSONAL
its entirety before commencing operations. INJURY TO OPERATORS OR OTHER
NEARBY PERSONNEL.
1.2 The Altronic CD200D ignition system consists of these basic components:
■ CD200D Unit - 791090-x or CD200D Unit - 791090-xR (See FIG. 1)
■ Magnetic Pickup Sensor or Hall-effect pickup (one per system)
■ Input Harness (one per system, specific to pickup type)
■ Output Harness (one per system) NOTE: If possible, keep the original
■ Ignition coils (one per cylinder) shipping container. If future
transportation or storage is necessary,
1.3 The system requires a battery or a suitable power supply with a nominal 12 Vdc this container will provide the
or 24 Vdc (see FIG. 2). The CD200D unit steps up the DC supply voltage optimum protection.
to charge an energy storage capacitor and contains a microprocessor and
solid-state switching devices to release the stored energy to the ignition coils
in programmed, timed sequence according to the application. Holes (one per
cylinder) in a special timing disc signal the position of the engine crankshaft to
the electronic circuitry in the CD200D unit. One additional hole trails after the
last cylinder hole; this is the index signal that another revolution has started.
An Altronic manufactured magnet disc should be used when employing a Hall-
effect pickup. Ignition timing may be varied by means of a manual switch, an
analog timing signal and/or engine RPM.
1.4 The CD200D system can operate as a single-firing or double-firing (firing on ex-
haust stroke) system up to sixteen (16) cylinders. These instructions detail 8-, NOTE: Please see Addendum CD200D
12-, and 16-cylinder, single-firing applications using CD200D units 791090-8, R II 4-17 for instruction details when
791090-12, 791090-16, 791090-8R, 791090-12R, 791090-16R. using CD200D units 791090-8R,
791090-12R, 791090-16R.
1.5 As shipped from the factory, the CD200D is in the auto-detect mode and is set
up for a trigger disc running at camshaft speed (see SECTION 9.5). The setup is
programmable by the use of the PC compatible CD200D terminal program (see
FIG. 9) provided on a CD delivered with the unit. The programming of the unit is
done via the RS-485 Modbus compatible communications port.
2.0 CD200D UNIT

2.1 Select a location for the CD200D unit that will be at least 24 inches (600mm)
away from the ignition coils and spark plug leads. In addition, the mounting
location must be relatively cool, preferably one benefitting from the engine fan
stream (if any); the outside case temperature of the CD200D unit should not
exceed 185°F. (85°C.) in continuous operation.
2.2 Secure the CD200D unit to a suitable mounting bracket with four ¼-inch
(6 mm) screws. Refer to FIG. 1 for CD200D unit dimensions.
3.0 PICKUP SENSOR – CAMSHAFT DISC

3.1 MAGNETIC Pickup – A disc with the appropriate hole pattern must be
prepared for mounting at CAMSHAFT speed. The disc must be of magnetic
material and 4.0" (100mm) diameter or larger. FIG. 3 details the hole spacing
depending on the number of engine cylinders. Note the direction of rotation
of the disc. The angular spacing is extremely important as this establishes the
basic timing accuracy of the system.
3.2 Locate a suitable mounting position for the pickup sensor in order to sense the NOTE: Some MAN engines have a
holes in the rotating disc. Secure the pickup to a rigid bracket or surface. See 12 mm thread port; use Altronic
FIG. 3 for the dimensions of the ¾"-16 pickup sensors. pickup 791041-3.
CD200D II 4-17 All rights reserved © ALTRONIC, LLC 2017 2

3.3 Set the engine with no. 1 cylinder in the most advanced timing position. Not-
ing the direction of rotation, set the drilled disc opposite the pickup in the
position shown in FIG. 3. Some 12- and 16-cyclinder engines may require line NOTE: Keep the pickup
up on a different cylinder, typically the second cylinder in the firing order. sensor wires at least 2" (50 mm)
away from the coil primary wires and
3.4 Adjust the tightening nut holding the pickup sensor to maintain an air gap as at least 8" (200 mm) away from the
specified below: spark plug leads.
■ For 3/4" magnetic pickups 791015-1 and 791016-2, the gap shall
be set to .020" ± .005" (0.50mm ± 0.12mm).
■ For magnetic pickups 791035-2 and 791041-3 (12mm thread),
the gap shall be set to .014" ± .004" (0.35mm ± 0.10mm).
The center of the pickup face must line up with the center of each drilled hole
as the disc rotates.
3.5 Plug the 2-pin pickup connector fully into the mating connector of the
CD200D wiring harness.
3.6 ALTERNATIVE HALL EFFECT Pickup AND MAGNET DISC – On 4-cycle

engines, the disc mounts to the camshaft or other shaft operating at one-half
engine speed. On 2-cycle engines, the disc mounts to the engine crankshaft.
3.7 Set the engine with no. 1 cylinder 2.0 crankshaft degrees, 4-cycle or 1.0
degree, 2-cycle ahead of the most advanced desired timing point on the NOTE: On certain 12- and 16-cylinder
compression stroke. This is the point where the Hall-effect pickup must line- engines, a cylinder other than no. 1
up with the edge of the magnet next to the “x” on the O.D. of the disc. When (typically the second cylinder in the
mounting the magnet disc, be sure to observe the rotation indication marked firing order) must be used when lining
on the disc. up the disc and pickup.
3.8 Mount the Hall-effect pickup sensor, FIG. 4, securely to a rigid bracket or
surface to maintain an air gap not exceeding .040" (1.0mm). The center of the
pickup face must also line up with the center of the disc as it rotates.
3.9 Plug the cable for the pickup into the 6-pin connector of the CD200D unit;
the 3-pin connector end plugs into the Hall-effect pickup.
4.0 IGNITION COILS

4.1 USE ONLY THE ALTRONIC COILS INDICATED HERE:
■ UNSHIELDED: 501061, 591010, 591040
■ FLANGE: 591012, 591018
■ SHIELDED: 501061-S, 591010-S
■ INTEGRAL: 591007, 591011A, 591011B
4.2 Mount the ignition coils as close to the spark plugs as possible keeping the
high-tension lead length to a minimum but also keeping temperatures below
200°F. (95°C.) during operation.

5.0 PRIMARY WIRING WARNING: THE HOOKUP SHOWN IS
FOR THE MOST COMMON ENGINE FIR-
5.1 The CD200D system requires a battery or other DC power source providing ING ORDER. CONNECT TO THE IGNITION
12-30Vdc for running and a minimum of 8 volts for engine starting. Refer to COILS ACCORDING TO THE ACTUAL
FIG. 2 for details of the connection to the DC power source. ENGINE FIRING ORDER.
5.2 Primary wiring hookup is shown in the wiring diagram template – FIGS. 5 or 6.
Use the table below to record the actual firing order and wiring.
791090-8 or A B C D E F K L
791090-8R
Engine Cyl. No.
See section 9.21 for details on

programming the slave firing angle and
791090-12 or A B C D E F K L M N P R for special wiring instructions.
791090-12R
Engine Cyl. No.

791090-16 or A B C D E F K L M N P R S T U V
791090-16R
Engine Cyl. No.

The common coil ground lead on all units is the J harness lead.
5.3 All connections at unshielded coils should be made using ring-type terminals
specified for 16 AWG (1.5 sq. mm) wire and #10 (5mm) stud size. Terminals NOTE: Keep the primary wiring at least
should either be soldered to the wire or attached with an appropriate staking 2" (50mm) away from the spark plug
tool. Protect primary wiring from physical damage, vibration and temperatures leads.
in excess of 200°F. (95°C.).
5.4 For details of the hookup for the analog timing signal, see FIG. 7.
6.0 SHUTDOWN WIRING NOTE: Do NOT run the input power line
through a series of normally closed
6.1 The CD200D system is shut-off by interrupting the DC power to the unit; use switches.
a switch or relay with contacts rated 24Vdc, 10 amps - refer to FIG. 2.
6.2 The CD200D can also be shutdown by using the G-lead of the output harness.
To shutdown the unit, connect the G-lead of the output harness to ground. The NOTE: The CD200D should not be
CD200D will draw about 0.1 ampere from the power source when shutdown,
used to power ignition-powered panel
see FIG. 5 or 6.
instruments.
7.0 SECONDARY WIRING

NOTE: The use of resistance spark
7.1 With unshielded coils, spark plug leads should be fabricated from 7mm, silicone plug cable or individual 5,000 ohm
insulated, ignition cable with suitable terminals and silicone spark plug boot. resistors (mounted either at the spark
plug or coil) is recommended.
7.2 Keep spark plug leads as short as possible and at least 2" (50mm) away
from any grounded engine part. In deep spark plug wells, use rigid, insulated
extenders projecting out of the well.
7.3 The use of a clear, silicone grease (such as Dow Corning DC-4, G.E. G-623
or GC Electronics Z5) is recommended for all high-tension connections and
boots. This material helps seal out moisture and prevent corrosion from atmo-
spheric sources.

8.0 OPERATION NOTE: On the first start-up after system
installation, verify correct ignition
8.1 IGNITION DELAY: timing by cranking the engine with the
On cranking, there will be a delay of two disc revolutions—after the power is ON fuel supply shut off.
and the engine begins rotating—before the CD200D unit commences outputs to
the ignition coils. This delay is to allow identification of the pickup index hole to
insure proper synchronization with the engine. A greater delay of more revolutions
to allow for engine purging can be added to the programming. See section 9.10. NOTE: DO NOT switch from position
7 to 0, or 0 to 7 while the engine is
8.2 MANUAL TIMING SWITCH: running. The large timing change may
The CD200D unit has a TIMING switch located under a white plastic cap at cause the engine to shutdown or be
the end of the case. Using a timing light, set the timing to the desired position damaged.
with the engine running at NORMAL OPERATING SPEED. Replace the white
cap over the timing switch once the proper timing is set. Switch position 7
gives the most advanced timing. The timing retards approximately one (1)
engine degree for each switch position as the switch is moved to position 6, 5, NOTE: The analog timing retard is
4, 3, 2, 1, 0. Switch position 0 is full retard. Larger timing changes per switch added to the retard established by the
position can be programmed. See section 9.15. manual timing switch (see section 8.2
and FIG. 9).
8.3 ANALOG TIMING ADJUSTMENT: (REFER TO FIG. 7)
The CD200D unit provides for analog timing adjustment in two ways:
■ 0-1,000 ohm potentiometer connected between terminals E
and F of the input harness. NOTE: When checked at different
■ 4-20 mA signal applied to leads F and G of the input harness. speeds, timing will vary in accordance
with the programmed RPM curve
8.4 RPM BASED TIMING CURVE: indicated.
The CD200D unit is shipped with an RPM-based timing curve (default pro-
gramming) providing a 6-degree advance as the engine speed increases from
0 to 600 RPM (FIG. 7). This timing change is in addition to changes made
with the manual switch (section 8.2) or the analog timing input (section 8.3).
9.0 CUSTOMIZING THE CD200D UNIT

9.1 TERMINAL PROGRAM SETUP:
The CD200D is designed to be programmed by a Personal Computer via the
RS-485 Modbus communications link. See FIG. 8 for the proper hookup. The
CD200D unit case must be securely grounded prior to programming.
The Terminal Program is included on the CD-ROM supplied with each CD200D
unit. The first time that the terminal software is used on a PC, the Communica-
tions Port settings must be configured in order to establish communications.
After loading the Terminal Program from the CD-ROM, click on the Connection
icon on the upper tool bar. The Connection Setup window will appear. The port
being selected for use with the CD200D should also be set for 9600 baud, no
parity, 200 ms time out (8 data bits and 1 stop bit). The PC will now be set to
communicate with the CD200D. Set the ID# for the CD200D to 01.
9.2 PROGRAMMING CUSTOM VALUES:

NOTE: In order to program the values,
A variety of numeric parameters can be entered by the user for customized
applications or the unit can be left at the factory default settings. Changes to the CD200D must be powered. Care
numeric values are made by placing the cursor in the appropriate box and typ- should be taken in changing entries
ing in the new value. When the new numeric value is first typed, it appears in when the engine is operational to
red text on the PC screen. The values appearing in red have not yet been sent avoid unstable or dangerous operating
to the CD200D unit, but are being stored on the PC until being sent. Hitting conditions.
the Enter key sends the selection to the CD200D. The entered value turns
green on the PC display, indicating that the new value has been successfully
communicated to the CD200D and stored.
9.3 SELECTING OPTIONAL FEATURES:

Other OFF/ON programming selections are made by activating or deactivating
a blue status flag on the PC screen. When the mouse pointer is located over
the status flag, a double-left click activates the status flag and makes it ap-
pear to be “ON” or glowing on the PC screen, a double-right click deactivates
the feature and the status flag.

9.4 Pickup TYPE SELECTION:
OFF/ON programming selection to enable the use of a Hall-effect pickup. NOTE: Pickup type selection is critical
Requires proper harness. and must be properly configured to
match the pickup type in use.
9.5 DISC TYPE SETTING:
This numeric entry configures the Disc Type (number of holes or protrusions)
on the timing disc, excluding the index. This number is normally equal to the
number of cylinders on the engine for a camshaft mounted disc when the
engine is even firing, and half the number of cylinders when it is odd-firing
and requires the programming of a “slave angle”. 4-cycle crankshaft mounted
discs or holes in a flywheel can only be used on even firing applications and
cannot be used with “slave angles”. This value is used to test for the correct
disc and scales the rpm measurement and ignition timing angles to the spe- NOTE: Conversion from some DISN
cific disc chosen. Default setting = (0+1). applications will require a new disc
with half the number of cylinders if
Entering a value of Zero (0+1), places the ignition in auto detect mode. In
slave angles are required!
auto detect mode, the ignition will automatically scale rpm measurement and
ignition timing angles to the disc pattern observed.
9.6 Test Disc Flag:

When this status flag is ON, the CD200D will test for a match of the incom- NOTE: The disc test for a specific
ing signal pattern observed by the CD200D to the Disc Type specified. When number of pulses is not performed in
enabled, this test is performed after synchronization to the disc pattern and auto detection mode (0 entry for Disc
before initiating firings. When the pattern does not match the setting, the Type Setting – section 9.5).
ignition will not fire and the diagnostic LED on the unit will signal the error by
turning off until rotation stops. Once the ignition is firing, the disc pattern will
be monitored continuously and, if an error is detected, the unit will stop firing
and the alarm output switch will open. Firings will be inhibited and the output
switch will remain off for 5 seconds after input signals cease.
If the shutdown lead is grounded after the unit is firing, the firings will stop, the
output switch will open and remain open for 5 seconds after rotation stops.
The diagnostic LED on the unit will turn off until rotation stops. After rotation
stops it will blink the appropriate signal, see section 11.2. Default setting = OFF.
9.7 On Crank Flag:

When this status flag is ON, the ignition scales rpm measurement and timing
angles for a signal pattern coming from a crankshaft-mounted disc. When this
status flag is OFF, the ignition scales rpm measurement and timing angles for
a signal pattern from a camshaft mounted disc. Default setting = OFF.
9.8 Line Up Angle:

This numeric entry has no impact on actual engine timing and is only used as
a reference to calculate the spark timing number for display in the Terminal
Software. When the pickup is aligned with the first hole or protrusion on the
timing disc, the Line Up Angle is the angular position of the crankshaft with
respect to TDC of the first cylinder in the firing order. Entry range is 0 to 100
engine degrees BTDC. This value will need to be fine-tuned to provide an ac-
curate display of timing. Default setting = 40.0 degrees BTDC.
9.9 Insertion Retard Setting:

This numeric entry configures the minimum internal electronic input signal
delay. Entry range is 2.0 to 25.5 degrees of engine retard. Default setting =
2.0 degrees.
9.10 Purge Delay Setting:

This numeric entry configures the number of disc rotations (engine cycles) fol-
lowing successful synchronization to delay before ignition outputs begin. Entry
range is 0 to 255 cycles. Default setting = 0.
9.11 Overspeed Setting:

This numeric entry configures the engine rpm at which the ignition will stop
firing outputs due to an overspeed condition. The overspeed condition also
turns off the alarm output switch. When rotation has fully stopped, the LED on
the CD200D unit will blink the appropriate code and the alarm output switch
is restored to normal (closed). Default setting = 2200 RPM.

9.12 Run Speed Setting:
This numeric entry configures the transition speed from crank to run. This set-
ting also determines the transition of the diagnostic LED on the CD200D from
crank to run modes. Default setting = 500 RPM.
9.13 Low Voltage Setting:

This numeric entry configures the threshold for the low voltage diagnostic of
the DC input voltage to the CD200D. If the DC voltage decreases to this set-
ting, the diagnostic LED on the CD200D will blink the appropriate code. The
CD200D will continue to try to fire outputs regardless of the voltage. Default
setting = 6 volts.
9.14 Enable LED Diagnostics Flag:

When this LED status flag is activated, the blink code diagnostics for primary
and secondary outputs are enabled. Default setting is ON.
9.15 Switch CAL:

These numeric entries configure the timing retard for each position of the
manual timing switch on the CD200D case. Entry range is 0 to 25.5 degrees
of engine retard. The active entry is indicated in blue. Default setting is 7-6-5-
4-3-2-1. If two degrees change per switch position is desired, enter 14-12-10-
8-6-4-2.
9.16 Loop CAL:

These numeric entries configure the interpolated lookup table for the ignition
retard versus the analog current loop input signal. This allows the operator to
create custom spark timing maps versus the current loop input signal. Entry
range is 0 to 25.5 degrees of engine retard. The active entries are indicated
in blue. Default sequence is 0 degrees retard at 4mA, 16 degrees retard at
20mA.
9.17 RPM CAL:

These numeric entries configure the interpolated lookup table for retard versus
the engine speed. This allows the operator to create custom spark timing maps
versus engine rpm. Entry range is 0 to 25.5 degrees of engine retard. The
active entries are indicated in blue. Default sequence is 6 degrees retard at 0
RPM, decreasing to 0 degrees retard at 600 RPM.
9.18 Enable Slave Firing Flag:

When this LED status flag is activated, the ignition will generate a second
slave firing for each (x+1) reference pulse. For a (6+1) disc pattern, the igni-
tion will fire 12 outputs when this flag is activated, and 6 outputs when this
flag is not activated. Modification of this flag through the Terminal Program
requires that the engine be stopped and the G-lead be grounded.
9.19 SLAVE FIRING ANGLE SETTING:

This numeric entry configures the angle of the slave firing relative to the stan-
dard firings that are generated for each (x+1) reference pulse. Entry range is
25.0° to 60.0° which is used to set the slave firing angle on a 12 or 16-cylin-
der, 4-cycle engine. The slave angle must be the smaller of the two angles that
define the engine firing pattern. For example, firing patterns of either 30°–60°
or 60°–30° would require the slave angle be entered as “30”. Modification of NOTE: All 16-cylinder applications
this value through the Terminal Program requires that the engine be stopped must be slave-firing patterns utilizing
and the G1 lead be grounded.
an 8+1 disc.
Common slave-firing patterns:
NO. Engine SECT. 9.5 SECT. 9.20 IN FIRING ORDER,

CYLS. Firing DISC SLAVE OUTPUT A
Angle SETTING ANGLE CONNECTS TO:
8 60°–120° 4+1 60° First cylinder

8 120°–60° 4+1 60° Second cylinder
10 54°–90° 5+1 54° First cylinder

NO. Engine SECT. 9.5 SECT. 9.20 IN FIRING ORDER,
CYLS. Firing DISC SLAVE OUTPUT A
Angle SETTING ANGLE CONNECTS TO:

12 30°–90° 6+1 30° First cylinder
12 40°–80° 6+1 40° First cylinder
12 50°–70° 6+1 50° First cylinder
12 55°–65° 6+1 55° First cylinder
12 60°–even 6+1 60° First cylinder
16 30°–60° 8+1 30° First cylinder
16 45°–even 8+1 45° First cylinder
9.20 Cylinder CAL:

These numeric entries configure the amount of individual offset timing retard
NOTE: Please see page 28 (Addendum)
added to the global timing for each individual output. This feature can be used
to map an evenly spaced timing disc to an odd firing angle engine pattern. En- for further details of CD200D Unit -
try range is 0 to 50 degrees of engine retard. Default settings are 0. Contact 791090-xR.
the factory for further details of this feature.
9.21 Energy Flags:

Select one of four output energy settings for the CD200D:
NOTE: Please see page 28 (Addendum)
Bit 1 OFF Bit 0 OFF Vcap = 150 volts for further details of CD200D Unit -
Bit 1 OFF Bit 0 ON Vcap = 160 volts 791090-xR.
Bit 1 ON Bit 0 OFF Vcap = 170 volts
Bit 1 ON Bit 0 ON Vcap = 180 volts
Default setting is 160 volts at the capacitor. This voltage can only be mea-
sured using a device with an input impedance of 1 megaohm or higher with no
other device connected.
10.0 PC TERMINAL DISPLAY FUNCTIONS

10.1 Engine Speed:
Indicates current speed of the engine in RPM based on disc signal.
10.2 Spark Timing:

Indicates the global spark timing of the engine in degrees before TDC. This
number is the LINE UP ANGLE setting less the TOTAL RETARD. Slight dif-
ferences between this number and the timing reading obtained with a timing
light may occur since the LINE UP ANGLE entered may differ slightly from the
actual angular position of the engine when the input pulse event is received by
the CD200D. In this event, the Spark Timing number should be made to agree
with the timing light by changing the LINE UP ANGLE entry.
10.3 Switch Position:

Indicates the current position of the manual timing switch on the CD200D case.
10.4 Loop Input:

Indicates the value of the external input current loop.
10.5 Observed Disc:

Indicates the number of input events (timing holes, protrusions or magnets) be-
ing recognized by the CD200D unit on the timing disc input signal at this time.

10.6 Insertion Retard:
Indicates the amount of electronic insertion retard at this time.
10.7 Switch Retard:

Indicates the amount of timing retard being added by the current timing switch
position at this time.
10.8 Loop Retard:

Indicates the actual amount of timing retard added from the current loop
versus retard lookup table curve at this time.
10.9 RPM Retard:

Indicates the actual amount of timing retard being added by the RPM versus
retard lookup table curve at this time.
10.10 TOTAL Retard:

Indicates the total global timing retard at this time. This number is the sum of NOTE: Please see page 29 (Addendum)
the Insertion Retard, Switch Retard, Loop Retard and RPM Retard. for further details of CD200D Unit -
791090-xR.
10.11 Counter:
Indicates the number of disc rotations (engine cycles) registered since the
engine was last started.
10.12 Purge Counter:

During a startup, indicates the number of purge cycles remaining before the
outputs are activated.
10.13 Supply Voltage:

Indicates the measured DC voltage supply level to the CD200D.
10.14 Spark Ref. (A, B, C, etc.):

Indicates the current spark reference number for each cylinder.
10.15 Syncing:
When red, indicates that engine rotation has been sensed and the synchroni-
zation process is taking place.
10.16 Insync1:
When red, indicates that the index input has been recognized once.
10.17 Insync2:
When red, indicates that the index has been recognized a second time and the
ignition is ready to proceed.
10.18 Purging:
When red, indicates that synchronization has been completed and the purge
cycle countdown is taking place.
10.19 Trying:
When red, indicates that the CD200D is trying to fire outputs, but a proper
primary discharge event has not yet occurred.
10.20 Firing:
When red, indicates that CD200D is successfully firing primary outputs.
10.21 LOCKOUT:
When red, indicates that firings are locked out until engine rotation has ceased
for a minimum of 5 seconds.
10.22 Cranking:
When red, indicates engine rotation below the Run Speed setting.
10.23 Running:
When red, indicates engine rotation above the Run Speed setting.

10.24 Disc Error:
When red, indicates that the Test Disc status flag is activated and the timing
disc pattern being sensed did not match the DISC TYPE selected.
10.25 G-Lead:
When red, indicates that the G-lead is grounded.
10.26 Remote:
When red, indicates a remote serial shutdown command is active.
10.27 SD-Lead:
When red, indicates that a shutdown has occurred which was the result of a
grounded G-lead condition.
10.28 SD-Remote:
When red, indicates that a shutdown has occurred as a result of a remote se-
rial shutdown command.
10.29 SD-Overspeed:
When red, indicates that a shutdown has occurred as a result of the engine
reaching the Overspeed setting.
10.30 Wdog1:
When red, indicates that the microprocessor has re-booted since the ignition
has been powered-up.
10.31 Wdog2:
When red, indicates that the microprocessor is currently re-booting. Disregard
the first blink when first connecting.
10.32 ChkSum:
When red, indicates a software checksum failure of the unit’s firmware.
10.33 Low Volt:

When red, indicates that the input DC voltage is at or below the Low Voltage
setting input.
10.34 No Charge:
When red, indicates that the primary storage capacitor has failed to charge
properly within the last ~2 seconds.
10.35 Primary Open:

When red, indicates that an open primary condition has been detected within
the last ~2 seconds.
10.36 Primary Short:

When red, indicates that a shorted primary condition has been detected within
the last ~2 seconds.
10.37 Secondary Open:

When red, indicates that an open secondary condition has been detected
within the last ~2 seconds.
10.38 Cranks Log:

Indicates the total number of crank attempts seen by the CD200D.
10.39 Starts Log:

Indicates the total number of successful starts seen by the CD200D as de-
fined by the Run Speed setting input.
10.40 Cycle Log:

Total number of engine cycles seen by the CD200D.
10.41 Cold Boot Log:

Indicates the number of times the input DC voltage has been cycled to zero.
10.42 Warm Boot Log:

Indicates the number of times the microprocessor has restarted without a
complete loss of power.
10.43 Graphic Display:

The CD200D Terminal Software provides a real time graphic display of the
secondary diagnostic numbers, global engine timing (y-axis/10) and engine
speed (y-axis x 10).
11.0 CD200D UNIT LED DIAGNOSTIC BLINK CODES

11.1 CD200D IGNITION BLINK CODES:
Whenever the LED Diags status flag is enabled (blue) by using the CD200D
Terminal Software, the blinking pattern of the LED on the side of the CD200D
case can be used to interpret the general status of the CD200D diagnostics
without the use of the Terminal Software. Within each group of conditions
described below, the possible diagnostic states are listed according to their
number of blinks. The LED is ON for about 2 seconds between each blink
sequence and the blinks occur evenly spaced at a faster rate.
11.2 LED SIGNALS WITH THE ENGINE STOPPED:

ON – Steady = READY (new power up or last start attempt aborted)
ON – 1 Blink – ON = FIRED LAST TIME ROTATING (stopped due to stall)
ON – 2 Blink – ON = SHUTDOWN (By grounding G-LEAD when running)
ON – 3 Blink – ON = SHUTDOWN (By Remote Serial Request when running)
ON – 4 Blink – ON = SHUTDOWN (By Overspeed when running)
ON – 5 Blink – ON = WRONG DISK PATTERN
ON – 6 Blink – ON = LOW SUPPLY VOLTAGE (Below Threshold when running)
11.3 LED SIGNALS WITH ENGINE CRANKING:

Rotating, and still below running RPM.
ON/OFF/ON/OFF = PURGING (off first input pulse, toggles each revolution of purge)
ON – Steady = FIRING NORMALLY (RPM below running set point value)
OFF = WRONG DISC PATTERN DETECTED
11.4 LED SIGNALS WITH ENGINE RUNNING:

When firing, and above run speed.
ON – Steady = FIRING NORMALLY (No Diagnostics to Report)

ON – 1 Blink – ON = OPEN SECONDARY ALARM
ON – 2 Blink – ON = PRIMARY SHORT ALARM
ON – 3 Blink – ON = PRIMARY OPEN ALARM
ON – 4 Blink – ON = NO CHARGE ALARM
ON – 6 Blink – ON = LOW SUPPLY VOLTAGE

12.0 RS-485 COMMUNICATIONS, MODBUS RTU
12.1 The CD200D is compliant to the Modicon Modbus RTU standard. Maximum
WARNING: Writable Modbus registers
number of registers that can be read at one time is limited to 32. Maximum
number of booleans that can be read at one time is limited to 256. All com- such as ‘0XXXX’ and ‘4XXXX’ directly
munications are 8 data bits, no parity, 1 stop bit. The baud rate is 9600. The reference the CD200D non-volatile
MODBUS address list follows: memory. Non-volatile memory has a
useful life of ~100,000 Write/Erase
12.2 24 READ-ONLY STATUS BITS cycles. Any device writing to these reg-
READABLE IN MULTIPLES OF 8 BITS isters must take care to not exceed the
STARTING AT 8-BIT BOUNDARIES maximum number of Write/Erase cycles.
ADDRESS FUNCTION
10001 Syncing
10002 InSync1
10003 InSync2
10004 Purging
10005 Trying
10006 Firing
10007 LockOut
10008 FIRED
10009 Cranking
10010 Running
10011 Wrong Disk
10012 GLead Shutdown Grounded
10013 Remote Shutdown Present
10014 GLead Shutdown Logged
10015 Remote Shutdown Logged
10016 Overspeed Shutdown Logged
10017 WDOG1 Reset Latched

10018 WDOG2 Reset Event
10019 CheckSum Error
10020 LOW Supply Voltage
10021 No Charge
10022 Open Primary
10023 Shorted Primary
10024 Open Secondary

12.3 READ ONLY STATUS REGISTERS
ADDRESS FUNCTION
30001 Input Bit Mirror 10016–10001
30005 RPM
30006 Timing xxx.xDEG signed
30007 Switch Position 1–8
30008 Current Loop Input xx.xmA
30009 Disk Observed X+1
30010 Insertion Retard xxx.xDeg
30011 Switch Retard xxx.xDeg
30012 Loop Retard xxx.xDeg
30013 RPM Retard xxx.xDeg
30014 Total Retard xxx.xDeg
30015 Cycle Counter HI
30016 Cycle Counter LO
30017 Supply Voltage xx.xVolts
30018 Spark Ref. Num. Output A
30019 Spark Ref. Num. Output B
30020 Spark Ref. Num. Output C
30021 Spark Ref. Num. Output D
30022 Spark Ref. Num. Output E
30023 Spark Ref. Num. Output F
30024 Spark Ref. Num. Output K
30025 Spark Ref. Num. Output L
30026 Spark Ref. Num. Output M
30027 Spark Ref. Num. Output N
30028 Spark Ref. Num. Output P
30029 Spark Ref. Num. Output R
30030 Spark Ref. Num. Output S
30031 Spark Ref. Num. Output T
30032 Spark Ref. Num. Output U
30033 Spark Ref. Num. Output V
30034 Purge Delay Index Down Counter
30035 Distributor MUX code 0–15
30036 KEYCOMMAND
30037 Period Predivider
30038 Period MS16BITS
30039 Period LS16BITS
30040 FireStat:DelayStat

12.4 8 READ/WRITE CONFIGURATION BITS
SUPPORTS WRITE SINGLE ONLY
READABLE IN MULTIPLES OF 8 BITS
STARTING AT 8 BIT BOUNDARIES
ADDRESS FUNCTION NOTE: Please see page 29 (Addendum)

00001 DISK ON CAM=0 CRANK=1 for further details of 0XXXX Registers for
CD200D Unit - 791090-xR.
00002 TEST FOR PROPER DISK YES=1
00003 ENABLE SECONDARY DIAGS YES=1
00004 ENERGY BIT0 00=~160 01=~170
00005 ENERGY BIT1 10=~180 11=~190
00006 SLAVE
00007 reserved
00008 OFF = MAGNETIC Pickup ON = HALL-EFFECT Pickup
12.5 4 READ/WRITE REGISTERS MIRROR COIL BITS
ADDRESS FUNCTION NOTE: Please see pages 29 through 31

40001 REG40001=CoilBits 00016-00001 (Addendum) for further details of 4XXXX
Registers for CD200D Unit - 791090-xR.
40002 REG40002=CoilBits 00032-00017
40003 REG40003=CoilBits 00048-00033
40004 REG40004=CoilBits 00064-00049
12.6 8 READ/WRITE REGISTERS REGARDING APPLICATION
ADDRESS FUNCTION
40005 Disk+1 2,3,4,5,6,7,8,9,10,12
40006 Disk Lineup to TDC xx.x DEG
40007 Insertion Ret MIN=2.0 DEG xx.x
40008 Purge Delay Cycles 0-255
40009 RPM Over Speed Setpoint
40010 RPM Crank to Run Threshold
40011 Low Supply Voltage Limit xx.xV
40012 SLAVE ANGLE xx.x DEG
12.7 12 READ/WRITE REGISTERS FOR CYLINDER RET. TABLE
ADDRESS FUNCTION
40017 OUTPUT A EXTRA RETARD DEG
40018 OUTPUT B EXTRA RETARD DEG
40019 OUTPUT C EXTRA RETARD DEG
40020 OUTPUT D EXTRA RETARD DEG
40021 OUTPUT E EXTRA RETARD DEG
40022 OUTPUT F EXTRA RETARD DEG
40023 OUTPUT K EXTRA RETARD DEG
40024 OUTPUT L EXTRA RETARD DEG
40025 OUTPUT M EXTRA RETARD DEG

ADDRESS FUNCTION
40026 OUTPUT N EXTRA RETARD DEG
40027 OUTPUT P EXTRA RETARD DEG
40028 OUTPUT R EXTRA RETARD DEG
40029 OUTPUT S EXTRA RETARD DEG
40030 OUTPUT T EXTRA RETARD DEG
40031 OUTPUT U EXTRA RETARD DEG
40032 OUTPUT V EXTRA RETARD DEG
12.8 8 READ/WRITE REGISTERS FOR TIMING SWITCH RET. TABLE
ADDRESS FUNCTION
40033 TIMING SWITCH POS 0 DEG
12.9 21 READ/WRITE REGISTERS FOR LOOP RET. TABLE
ADDRESS FUNCTION
40049 LOOP RET MAP 0mA 0.00V DEG

12.10 31 READ/WRITE REGISTERS FOR RPM RET. TABLE
ADDRESS FUNCTION
40070 RPM RET MAP 0000 RPM DEG
12.11 7 READ/WRITE MISC. REGISTERS
ADDRESS FUNCTION
40122 Crank Counter
40123 Start Counter
40124 Cycle Counter HIGH
40125 Cycle Counter LOW
40126 REG40005 MSB=BAUD LSB=NODEID fixed 9600n81:node1
40127 Cold Boot (powerup) Count
40128 Warm Boot ( reset ) Count

FIGURE 1 — CD200D DIMENSIONS & SPECIFICATIONS
158.8 180.0
6.25 7.12
196.3
7.73
224.8
8.85
14-PIN 19-PIN
14-PIN CONNECTOR
CONN. PIN PCB HOLE
A MPA
B MPB OPERATING TEMPERATURE: -40 C TO +85 C
C 485 + STORAGE TEMPERATURE: -40 C TO +105 C
D FLT
E +5V INPUT VOLTAGE: 12 TO 30 VDC
F 4-20 IN OUTPUT VOLTAGE: 160 VDC NOM.

G 4-20 -
H 485 -
I N/C
J N/C
K +24
L HEA
M HEB
N HEC

STARTING: 8 VDC MINIMUM
D.C. POWER SOURCE
RUNNING: 12-30 VDC
REGULATOR
BAT.
+ CD200D UNIT
ALTERNATOR
-
WIRE SIZE: 16 GA. (1.5 SQ. mm) MIN.
SWITCH
BAT. CHARGER BAT. RATING:
CD200D II 4-17 All rights reserved © ALTRONIC, LLC 2017

10 AMP MIN.
+
FUSE RATING:
FIGURE 2 — CD200D OPERATING VOLTAGE REQUIREMENT
-
10 AMP
18
CD200D IGNITION
POWER SUPPLY
-
NOTE: CD200D HOUSING MUST BE
GROUNDED TO POWER SUPPLY
POWER SUPPLY SPECS: 25 AMP PEAK PULSES, 5 AMP CONTINUOUS.
NEGATIVE AND ENGINE BLOCK.
AVERAGE CURRENT = I AV
CD200D UNIT GENERAL EXAMPLE:
NOTE: FORMULA 16-CYL. ENGINE, 1800 RPM
1. INFORMATION IS PER ONE (1) CD200D SYSTEM. I = N x RPM 8 x 1800 = 2.88 AMPS
AV
I AV
FOR MULTIPLE SYSTEMS, MULTIPLY REQUIREMENTS 12VDC UNIT 5,000 5,000
BY NUMBER OF SYSTEMS.
I AV = N x RPM I AV 8 x 1800 = 1.44 AMPS
24VDC UNIT 10,000 10,000
2. POWER SUPPLY NEGATIVE MUST BE
GROUNDED TO ENGINE BLOCK.
N = NO. FIRINGS PER ENGINE REVOLUTION.
FIGURE 3 — CD200D MAGNETIC PICKUP AND DISC HOLE DETAIL

FIGURE 4 — CD200D PICKUP AND DISC INSTALLATION

FIGURE 5 — CD200D WIRING DIAGRAM TEMPLATE FOR SINGLE-FIRING SYSTEM WITH MAGNETIC PICKUP
INDEX
GND
J
SLAVE
V
DISC
10+1
12+1
2+1
3+1
4+1
5+1
6+1
7+1
8+1
9+1
U
-16
T
S
R
P
-12
N
M
L
K
F
E
-8
D
C
B
A
PRIMARY PIN
CYLINDER
IGNITION
ANGLE
PART NO.
CD200D
791090

FIGURE 6 — CD200D WIRING DIAGRAM TEMPLATE FOR SINGLE-FIRING SYSTEM WITH HALL EFFECT PICKUP
INDEX
GND
J
SLAVE
V
DISC
10+1
12+1
2+1
3+1
4+1
5+1
6+1
7+1
8+1
9+1
U
-16
T
S
R
P
-12
N
M
L
K
F
E
-8
D
C
B
A
PRIMARY PIN
CYLINDER
IGNITION
ANGLE
PART NO.
CD200D
791090

FIGURE 7 — CD200D HOOK-UP FOR ANALOG TIMING SIGNAL

FIGURE 8 — PC TO CD200D

FIGURE 9 — CD200D TERMINAL PROGRAM SCREEN – VERSION 1.0 - 5.0
NOTE: This CD200D TERMINAL PROGRAM is compatible with CD200D Unit - 791090-x.

FIGURE 10 — CD200D TERMINAL PROGRAM SCREEN – VERSION 5.1 ONWARD
NOTE: This CD200D TERMINAL PROGRAM is compatible with CD200D Unit - 791090-x.

FIGURE 11 — CD200D (Remote Control) TERMINAL PROGRAM SCREEN – VERSION 1.0 ONWARD
NOTE: This CD200D (Remote Control) TERMINAL PROGRAM is compatible with CD200D Unit - 791090-xR.

Installation Instructions – Addendum
This addendum provides installation and operating instructions specific to the Altronic
CD200D Unit – 791090-xR ignition system. It is intended as supplemental informa-
tion to the CD200D Installation Instructions.
(Section 9)
Remote (RMT) Engine Control Configuration (green background entries in CD200D
Unit - 791090-xR Modbus Terminal Program).
CD200D Unit – 791090-xR was designed to extend the life of EEPROM for Remote
Control Operations. By introducing RAM only (RMT) Registers for Remote Engine
Control Systems, every write to these registers are not committed to EEPROM. On
Power up initialization and on Engine stops, these Remote control registers (TABLE
12.11 and 12.12) are properly pre-loaded from Default control registers (TABLE
12.7). These Remote control registers are also purposely grouped together for conve-
nient single READ/ WRITE from and to Remote Engine Control Systems.
Default Engine Control Configuration (orange background entries in CD200D Unit -

791090-xR Modbus Terminal Program).
To maintain the same Engine Control configurations at startup, 3 Default Engine Con-
trol registers are committed to EEPROM every write. Frequent write to these entries
are not recommended due to EEPROM write cycle wear.
9.20 Engine Control Energy Selection
9.20.1 RMT Energy (RAM ONLY):

Default Energy (section 9.20.2) is pre-loaded to this RMT Energy on initializa-
tion and on engine stop.
There are four RMT Energy settings for CD200D Unit - 791090-xR
Energy 0 Vcap = 150 volts
This voltage can only be measured using device with an input impedance of 1
megaohm or higher with no other device connected.
9.20.2 Default Energy:

This Default Energy Selection resides in NON-VOLATILE memory section.
Frequent write to this Default Energy Selection is not recommended due to
memory wear out.
9.21 Engine Control Global Retard
9.21.1 RMT Global (RAM ONLY):

Default Global Retard (section 9.21.2) is pre-loaded to this RMT Global Retard
on initialization and on engine stop.
9.21.2 Default Global:

This Default Global Retard resides in NON-VOLATILE memory section. Fre-
quent write to this Default Global Retard is not recommended due to memory
wear out.
9.22 Engine Control Individual Retard
9.22.1 RMT Cylinder CAL (RAM ONLY):

These numeric entries configure the amount of individual offset timing retard
added to the global timing for each individual output. Entry range is 0 to 50
degrees of engine retard (May be less for Slave pattern applications). Upon
Power on Initialization and on Engine Stops, all entries in this RMT Cylinder
CAL array are pre-loaded with the Default Indv Retard (section 9.22.2).
9.22.2 Default Indv:

This Default Indv Retard resides in NON-VOLATILE memory section. Frequent
write to this Default Indv Retard is not recommended due to memory wear out.
CD200D II 4-17 Addendum 28

All rights reserved © ALTRONIC, LLC 2017
(Section 10)
10.10 Total Retard:
Indicates the total global timing retard at this time. This number is the sum
of the Insertion Retard, Switch Retard, Loop Retard, RPM Retard, and RMT
Global Retard (section 9.21.1).
(Section 12)
12.4 8 READ/WRITE CONFIGURATION BITS SUPPORTS WRITE SINGLE ONLY
READABLE IN MULTIPLES OF 8 BITS STARTING AT 8 BIT BOUNDARIES
ADDRESSES FUNCTION
00001 DISK ON CAM=0 CRANK=1
00002 TEST FOR PROPER DISK YES=1
00003 ENABLE SECONDARY DIAGS YES=1
00004*** reserved
00005*** reserved
00006 SLAVE
00007 reserved
00008 OFF = MAGNETIC Pickup ON = HALL-EFFECT Pickup
NOTE: READ/WRITE Functionality of Energy BIT 0 and BIT 1 in Standard

CD200D - 791090-x is replaced by READ/WRITE functionality of RMT Energy
Selection in CD200D Unit – 791090-xR (Remote Control) (TABLE 12.11)
12.5 4 READ/WRITE REGISTERS MIRROR COIL BITS
ADDRESSES FUNCTION
40001 REG40001=CoilBits 00016-00001
40002 REG40002=CoilBits 00032-00017
40003 REG40003=CoilBits 00048-00033
40004 REG40004=CoilBits 00064-00049
12.6 8 READ/WRITE REGISTERS REGARDING APPLICATION
ADDRESSES FUNCTION
40005 Disk+1 2,3,4,5,6,7,8,9,10,12
40006 Disk Lineup to TDC xx.x DEG
40007 Insertion Ret MIN=2.0 DEG
40008 Purge Delay Cycles 0-255
40009 RPM Over Speed Setpoint
40010 RPM Crank to Run Threshold
40011 Low Supply Voltage Limit
40012 SLAVE ANGLE xx.x DEG
12.7 3 READ/WRITE DEFAULT GLOBAL REGISTERS FOR ENGINE CONTROL

SYSTEM TABLE **
ADDRESSES FUNCTION
40014 Default Global Energy 0,1,2,3
40015 Default Global Timing Retard
40016 Default Individual Retard

12.8 8 READ/WRITE REGISTERS FOR TIMING SWITCH RET. TABLE *
ADDRESSES FUNCTION
12.9 21 READ/WRITE REGISTERS FOR LOOP RET. TABLE *

ADDRESSES FUNCTION

12.10 31 READ/WRITE REGISTERS FOR RPM RET. TABLE *
ADDRESSES FUNCTION

12.11 2 READ/WRITE REMOTE CONTROL REGISTERS FOR
ENGINE CONTROL SYSTEM TABLE (RAM ONLY) **
ADDRESSES FUNCTION
40101 Remote Cont Energy 3,2,1,0 RAM
40102 Remote Cont Global Ret Deg RAM
12.12 12 READ/WRITE REMOTE CONTROL REGISTERS FOR

CYLINDER RET. TABLE (RAM ONLY) **
ADDRESSES FUNCTION
40103 OUTPUT A (01) Indv Ret Deg RAM
40104 OUTPUT B (02) Indv Ret Deg RAM
40105 OUTPUT C (03) Indv Ret Deg RAM
40106 OUTPUT D (04) Indv Ret Deg RAM
40107 OUTPUT E (05) Indv Ret Deg RAM
40108 OUTPUT F (06) Indv Ret Deg RAM
40109 OUTPUT K (07) Indv Ret Deg RAM
40110 OUTPUT L (08) Indv Ret Deg RAM
40111 OUTPUT M (09) Indv Ret Deg RAM
40112 OUTPUT N (10) Indv Ret Deg RAM
40113 OUTPUT P (11) Indv Ret Deg RAM
40114 OUTPUT R (12) Indv Ret Deg RAM
40115 OUTPUT S (13) Indv Ret Deg RAM
40116 OUTPUT T (14) Indv Ret Deg RAM
40117 OUTPUT U (15) Indv Ret Deg RAM
40118 OUTPUT V (16) Indv Ret Deg RAM
12.13 7 READ/WRITE MISC. REGISTERS

ADDRESSES FUNCTION
40122 Crank Counter
40123 Start Counter
40124 Cycle Counter HIGH
40125 Cycle Counter LOW
REG40005 MSB=BAUD LSB=NODEID fixed
40126
9600n81:node1
40127 Cold Boot (powerup) Count
40128 Warm Boot ( reset ) Count
* Registers reordered
** New registers
*** Registers removed


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Installation Instructions

CD200D Digital Ignition System

Form CD200D II 4-17

2.0 CD200D UNIT

3.0 PICKUP SENSOR – CAMSHAFT DISC

CD200D II 4-17 All rights reserved © ALTRONIC, LLC 2017 2

3.6 ALTERNATIVE HALL EFFECT Pickup AND MAGNET DISC – On 4-cycle

4.0 IGNITION COILS

CD200D II 4-17 All rights reserved © ALTRONIC, LLC 2017 3

7.0 SECONDARY WIRING

CD200D II 4-17 All rights reserved © ALTRONIC, LLC 2017 4

9.0 CUSTOMIZING THE CD200D UNIT

9.2 PROGRAMMING CUSTOM VALUES:

9.3 SELECTING OPTIONAL FEATURES:

CD200D II 4-17 All rights reserved © ALTRONIC, LLC 2017 5

9.6 Test Disc Flag:

9.7 On Crank Flag:

9.8 Line Up Angle:

9.9 Insertion Retard Setting:

9.10 Purge Delay Setting:

9.11 Overspeed Setting:

CD200D II 4-17 All rights reserved © ALTRONIC, LLC 2017 6

9.13 Low Voltage Setting:

9.14 Enable LED Diagnostics Flag:

9.15 Switch CAL:

9.16 Loop CAL:

9.17 RPM CAL:

9.18 Enable Slave Firing Flag:

9.19 SLAVE FIRING ANGLE SETTING:

NO. Engine SECT. 9.5 SECT. 9.20 IN FIRING ORDER,

8 60°–120° 4+1 60° First cylinder

CD200D II 4-17 All rights reserved © ALTRONIC, LLC 2017 7

10 90°–54° 5+1 54° Second cylinder

9.20 Cylinder CAL:

9.21 Energy Flags:

10.0 PC TERMINAL DISPLAY FUNCTIONS

10.2 Spark Timing:

10.3 Switch Position:

10.4 Loop Input:

10.5 Observed Disc:

CD200D II 4-17 All rights reserved © ALTRONIC, LLC 2017 8

10.7 Switch Retard:

10.8 Loop Retard:

10.9 RPM Retard:

10.10 TOTAL Retard:

10.12 Purge Counter:

10.13 Supply Voltage:

10.14 Spark Ref. (A, B, C, etc.):

CD200D II 4-17 All rights reserved © ALTRONIC, LLC 2017 9

10.33 Low Volt:

10.35 Primary Open:

10.36 Primary Short:

10.37 Secondary Open:

10.38 Cranks Log:

10.39 Starts Log:

10.40 Cycle Log:

10.41 Cold Boot Log:

10.42 Warm Boot Log:

CD200D II 4-17 All rights reserved © ALTRONIC, LLC 2017 10