EC12

Engine Control
System
Igniter Module

User Manual
1525-PS-0001
Issue 03
Gill Instruments Ltd
Saltmarsh Park,
67 Gosport Street,
Lymington, Hampshire,
SO41 9EG, UK

Tel: +44 1590 613500

Fax: +44 1590 613555
Email: [email protected]
Website: www.gill.co.uk
Gill Instruments Ltd

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1. INTRODUCTION…………………………………………..……………..…………………..….3
2. Features…………………………………………………………………………………………....3
3. INSTALLATION………………………………………………………………………………....4
3.1. General Information……..……………………………...………………………………….....4
3.1.1 Igniter Installation and location………………………………………….…………….4
3.1.2 Ignition Coil location…………………………………………………………….…….4
3.1.3 Wiring Harness…………………………………………………………………….…..4
3.1.4 HT Lead recommendations…..………………………………………………….…….5
3.1.5 Timing Disc and Engine Position Sensor installation….……………………….……..5
3.1.5.1 Installing the Timing Disc…………………………………………………………5
3.1.5.2 Dual Timing Disc installation……………...……………………………………...5
3.1.5.3 Inductive Engine Position Sensors………………….……………………………..6
3.1.5.4 Hall-effect Engine Position Sensors……………….………………………………6
3.1.5.5 Single / Dual Timing Disc options……………….………………………….……..6
3.1.6 Igniter L.E.D. display….…………...………………………………………………….7
3.2. SparkZ GUI Software Installation…………………………...……………………….…….…8
3.2.1 Communications software……………………………………………………………..8
3.2.2 Minimum requirements………………………………………………………….…….8
3.2.3 Installing the new GillShell software………………………………………………….8
3.2.4 Running the SparkZ GUI program…………………………………………………….9
3.2.5 The SparkZ GUI Configuration Facility…………………………………………….…9
3.2.6 The SparkZ GUI “Monitor” Screen………………………………………..………....10
3.2.7 The SparkZ “Ignition Control Maps” Screen………………………………………...11
3.2.8 The SparkZ “Diagnostics” Screen…………………………………………...……….12
4. Controlled Shutdown / Power relay Control……………………………………………….……13
5. The SPARKZ HELP DIRECTORY…………………………………………………………......14
5.1 The SparkZ Help Directory Contents…………………………………………………..…….14
6. WIRING DIAGRAM (Igniter Connector Pin-out arrangement)……………………….…….…15
Appendix 1 – EC12 Wiring Diagram………………………………..…………….………….……16
Appendix 2 – Wiring Diagram for Dual Pickup Sensor operation…………………..……………..17
Appendix 3 – EC12 Igniter Assembly………………………………………………..…………...18
Appendix 4 – Standard Gill Timing Disc and Sensor Installation……………………..…………...19

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1. INTRODUCTION
The Gill EC12 Engine Control System is primarily targeted at diesel to gas engine conversions (non-
wasted spark) with up to 12 cylinders, static and non static, vehicles, gensets, compressors etc.

The EC12 System consists of the following components:

Igniter module;

Wiring harness;

Ignition coils;

Engine Position Sensor;

Timing Disc;

Programming Software;

And this Operating Manual, which refers to the EC12 Igniter Module only.

2. FEATURES
Twelve coil drive outputs which permit the following configurations:

2,3,4,5,6,8,10 and 12 cylinder operation with one coil per cylinder.

Programmable ignition control maps.

Ignition suppression and fuel cut off on over-rev.
Digital input or analogue input (e.g. over temperature).
Programmable ignition and fuel cut off rpm limits.
Programmable global timing retard / map bank select for dual fuel operation.
Programmable Timing Correction for EPS positioning errors.
Speed output signal.
Operates with TPS or MAP sensor.
Optional Controlled shutdown on ignition off.
Built-in diagnostic LED lamps.
Timing disk to Pickup gap Monitor
Spark voltage and duration Monitor
Malfunction Indicator Lamp output.
Progressive rpm limiting.
Programmable nominal dwell times.
Dwell period versus Battery voltage compensation.
Operates with universal timing disc geometry.
Operates with crank / cam sensor configurations.
Can be configured for alternative Timing Discs and Engine Position Sensors.
Controlled access SparkZ GUI software.
Interfaces to Gill Knock and Air/Fuel Control Modules.
Canbus communication availability.
Operates with Gill SM60 or SM100 ignition coils.

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3. INSTALLATION
Prior to installing the EC12 system, please ensure that all relevant components have been supplied,
especially that the correct number of ignition coils and the correct timing disc is present.

3.1 General Information

The EC12 can be configured for 2,3,4,5,6,8,10 and 12 cylinder engines: this is a programmable
option as the same standard Gill timing disc is used for all configurations. Specific firing patterns
and Timing discs can be accommodated – refer to Gill Instruments Ltd for advice.

On the wiring diagram the coils are numbered in EC12 firing order, NOT the engine firing order.
Ensure the coil HT leads are wired to the correct cylinders in the correct firing order.

3.1.1 Igniter Installation and location

It is strongly advised to mount the Igniter away from sources of heat and excessive vibration for
optimum reliability.
If installed in the engine compartment, mount the igniter low down and away from exhaust pipes and
hot air from radiators.
If the Igniter is to be installed remote from the engine, and therefore the ignition coils, ensure the
wiring harness is of sufficient length – please contact Gill Instruments if an extended wiring harness
is required.

Note: the Igniter is designed for NEGATIVE EARTH battery operation only.

Gill Instruments recommends a torque setting of 11.0Nm (8.0 lbf. ft) for the fixing bolts.

3.1.2 Ignition Coil location

Ensure that the coils are securely mounted and that the mounting flanges are not stressed. Keep the
coils away from direct contact with the engine cylinder head or exhaust manifold, preferably using
rubber mountings for resistance to any vibration-induced damage.
The coils should be installed as close as practicable to the engine to avoid long HT cable length.

Gill Instruments recommends a torque setting of 8.0Nm (5.5 lbf.ft) for the fixing bolts and a
maximum of 2Nm (1.5 lbf.ft) for the brass low-tension terminal nuts.
Always use a 5mm ring termination for wiring to these terminals and fit the supplied spring washers.

Important Note:
It is most important that the coil low-tension connection polarity is correct or premature coil
failure could result.
Coils will withstand only short periods of operation with reversed LT connections. Gill advises
that this warning be included in your engine service literature.

The centre low-tension terminal on SM100 coils MUST be securely connected to an engine
ground or premature coil failure will occur.

3.1.3 Wiring Harness

Ensure that the wiring is correctly fitted into the Igniter connector header (see the Wiring Diagram in
the Manual Appendix for details).
Also ensure that the wiring loom is suitably clipped along its length for security.
Avoid installing the wiring loom too close to the Ignition coils to ensure freedom from any possible
electrical interference effects.

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3.1.4 HT Lead recommendations

Gill recommends the use of spark plugs with a built in interference suppressor and carbon core HT
leads with suitable coil and spark plug caps. It is preferable to maintain the same length of HT lead
to each spark plug with this type of lead as their resistance varies with length.

Do not exceed a total nominal resistance of 20kohm (plug plus cap plus lead).
It is the responsibility of the user to choose the correct types of spark plugs, caps and HT leads in
order to meet EMC (interference) emission regulations.

3.1.5 Timing Disc and EPS installation

The correct installation of the Timing Disc and Engine Position Sensor (EPS) is critical for reliable
operation of the Gill EC12 Igniter.
Refer to the Manual Appendix for the Timing Disc and Engine Position Sensor Drawing.

3.1.5.1 Installing the Timing Disc

The standard configuration for the EC12 timing disc is for it to be fitted to the camshaft or other half
crankshaft speed shaft.
The disc should normally rotate anti-clockwise in the direction of the arrow; for clockwise rotation
reverse the disc so the arrow is on the inner face.

To time the system, set the engine to TDC on cylinder 1 (firing) then align the scribed TDC line on
the disc with the centre of the Engine Position Sensor “pin”.
The clearance between the EPS and timing disc (for the standard Gill 90mm (3½”) disc) should be
set as follows:
For the Standard Gill Inductive Pickup: - 1.5mm to 2.0mm, ideally 2.0 mm (0.080”).
For the Gill Threaded Inductive pickup: - 0.5mm to 1.00mm, ideally 0.75mm (0.030”).
For the Gill Push-in Inductive pickup: - 0.5mm to 1.00mm, ideally 0.75mm (0.030”).

It is essential that both radial and sideways run out of the disc is less than 0.2mm each way and the
total of sideways run out and end float must not exceed 0.5mm with the Engine Position Sensor
mounted centrally to the timing disc as shown in drawing 1470 -K -014 (Appendix 4).
The timing disc is supplied as standard with a centre-mounting hole of 10mm diameter.

The disc should be securely fitted to the mounting shaft, if necessary using additional means of
ensuring it cannot move, e.g. keyway or dowelling accordingly.
Gill Instruments recommends a torque setting of 11.0Nm (8.0 lbf.ft) for the fixing bolts.

Contact Gill Instruments for advice on non-standard disc designs.

3.1.5.2 Dual Timing Disc Installation

Where an installation uses a crankshaft mounted (Primary) timing disc in conjunction with a
camshaft mounted (Secondary) timing disc, the installation requirements are as above.

Where the Primary and / or Secondary Engine Position Sensors are Hall-effect type, the sensor
manufacturer’s specifications for disc vane clearance and alignment must be adhered to.

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3.1.5.3 Installing the Engine Position Sensor

3.1.5.4 Inductive Engine Position Sensors

The standard Gill Engine Position Sensor (EPS) is a conventional inductive unit.
It is polarity sensitive; if connected in reverse the engine may not run at all, or if it does, it will
experience substantial timing errors and is likely to misfire.
Refer to the drawing 1470-K-014 (Appendix 4) for the correct alignment with the timing disc and
the disc “pegs”.

It is important to mount the EPS rigidly so that it cannot be affected by vibration, to ensure reliable
performance of the Ignition system
The wires from the EPS must be run close together, but should not be run with other wiring over
large distances. Screened twisted pair wiring is recommended for lengths over 2 metres.
Gill Instruments does not recommend sensor cable lengths over 5 metres.

3.1.5.5 Hall effect Engine Position Sensors

Where the Engine Position Sensor is of the Hall-effect type the sensor manufacturer’s specifications
for sensor mounting, disc clearance and alignment must be adhered to.
The wiring arrangement for Hall effect sensors is shown in Appendix 2.

Contact Gill Instruments for advice on alternative Engine Position Sensors.

3.1.5.6 Dual Timing Disc operation

The GS8 will operate with the following Engine Position Sensor arrangements to provide normal
“non-wasted spark” operation:

1. Camshaft disc, Inductive sensor

2. Camshaft disc, Hall-effect sensor
3. Crankshaft disc, Inductive sensor + camshaft disc, Hall-effect sensor
4. Crankshaft disc, Hall-effect sensor + camshaft disc, Hall-effect sensor

The wiring for Dual Timing Disc operation is shown in Appendix 2.

For “wasted spark” operation the following arrangements are available:

1. Crankshaft disc, Inductive sensor

2. Crankshaft disc, Hall-effect sensor

(Note; Gill do not recommend the use of “wasted spark” operation on gaseous-fuelled engines)

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IGNITER LED DISPLAY

The LED display next to the Igniter 36 way connector shows the following information:

Left –
This LED will flash once every few seconds to indicate that there is power to the Igniter.
1 flash every 3 seconds shows the Igniter is in Standby Mode
If this is not occurring, there is no power to the Igniter.
1 flash every second shows the igniter is Enabled and in Operating Mode.

Centre –
This LED will remain lit when the Igniter has successfully synchronised to the timing disc.
If at any time this LED is not lit it indicates that the igniter has not received adequate signals from
the Engine Position Sensor.
If at any time this LED is lit with the Igniter powered up but with the engine stopped, the Igniter
processor has been corrupted and has reverted to the factory default configuration (8 cylinder
operation using a 24-2 peg timing disc).
Contact Gill Instruments for advice.

Right –
This LED indicates that there is Igniter microprocessor activity.
When the Spark Gap Monitor feature is enabled this LED will go out if the reported spark voltage or
duration values are outside the specified limits. Clicking on the “Reset status flags” button will
relight the LED.

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3.2 SPARKZ GUI SOFTWARE INSTALLATION

This topic covers programming requirements and steps involved to install and run the SparkZ
Graphical User Interface (GUI) software.

3.2.1 Communications Software

The system is supplied with a Windows based GillShell CD, which includes SparkZ Graphical
User Interface software, designed to run on an IBM PC or equivalent.
According to the specification required, SparkZ can enable the user to adjust the timing curve and
other programmable information within the igniter and also to download operational information
from the igniter.

A 9 way D type connector is fitted in the wiring loom. This should be connected to the COM 1 or
COM 2 port of the user’s PC (via a standard comms cable – not supplied).

3.2.2 Minimum requirements

Processor 133 MHz or higher

RAM 32Mb minimum
Hard disc 16Mb free space (minimum)
CD drive Must be fitted
Floppy disc Must be fitted
Display VGA or higher
Mouse Must be fitted
Keyboard Must be fitted
Serial port Must be fitted (COM1 & COM2 supported)
Operating systems Windows 95, Windows NT or Windows 98, Windows 2000,
Windows XP

3.2.3 INSTALLING THE NEW GILLSHELL SOFTWARE

1. Follow normal Windows procedure to remove any existing Gill Digital Ignition System software
- (Start – Settings – Control Panel – Add / Remove programs).
2. Load the GillShell Installation CD into the PC. If the program does not auto-install then:
3. Click on Start – Run – Browse – locate the “GillShell” CD icon and click on it.
4. Click on the Setup icon that appears in the window. Click on Open, and then click on OK.
5. Follow the Wizard Instructions.

NOW INSTALL THE ‘SPARKZ GUI CONFIGURATION’ DISC

After installing the GillShell software, the SparkZ “GUI CONFIGURATION” disc should be installed
as necessary.

1. Load the 1.44MB floppy disc into the PC.

2. Click on Start – Run – Browse – locate the “31/2” floppy” disc icon and click on it.
3. Click on the Setup.exe. icon that appears in the window. Click on Open, and then on OK.
4. Follow the Wizard instructions.

When an Engine Control Module or Igniter is connected to the PC, GillShell will detect which
type of Gill Module is present and automatically run the appropriate software.

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3.2.4 Running the SparkZ GUI

Click on Start – Programs – GillShell, and click on the SparkZ tab to run the program.
Alternatively, “Drag and Drop” the SparkZ tab to create a desktop icon ‘shortcut’ on your PC
desktop as required.
Then double click on this SparkZ GUI icon ‘shortcut’ to run the program.

Note: It is not necessary to connect the igniter to be able to run the SparkZ GUI software program.
This is to enable users to familiarise themselves with the operation and programming procedures
before installing and programming the system.

We also recommend you read the SparkZ GUI Help Directory to familiarise yourself with the
SparkZ GUI software and the Igniter's features and functionality.

3.2.5 SparkZ GUI Configuration Facility

The SparkZ GUI works with what are called “GUI Configuration Files” (“GCF”), that are
preprogrammed by Gill Instruments and supplied on a 1.44MB floppy disc.

If no GCF is installed, then the SparkZ GUI is “read only” with only Monitoring and “Image”
download capability.

The SparkZ GUI can be modified for the available Igniter programmability to suit the requirements
of the Engine / Installation Manufacturer (“The Customer”)
This means that the Manufacturer can have all the programming features relevant to their
requirements whereas their Field Engineers or End Users can be limited to a “Read Only” capability,
for example.
This ensures that the Ignition system’s parameters can only be altered or modified by the Engine /
Installation Manufacturer or their Authorised Agents.

Each customer has a unique “Customer Identification Number” associated with these “GCF” files.
This means that only Gill Instruments or the Customer can access the relevant SparkZ GUI
programmability for their Ignition systems.
The Customer Identification Number is displayed on the SparkZ GUI “Monitor Screen” page.

The SparkZ GUI will then operate according to the GCF configuration supplied.

Contact Gill Instruments for further information on the GUI Configuration facility.

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3.2.6 The SparkZ Monitor Screen

When the SparkZ GUI software program is opened, the above screen will appear after a few
moments. Note the command line at the bottom of the screen identifies if there is communication
with the Igniter.
If there is a communication problem with the Igniter, follow the Command line instruction to select
the Comms tab and select the alternative Comms Port.

The Tabs "Re-Synch" and "Link Mode" only function when an Igniter is present and connected.

Note: The “Advanced” tab at the bottom of the screen is only displayed, with the required
programming facilities, according to the GUI Configuration Disc supplied.

Refer to the SparkZ GUI Help Directory for the list of programmable Igniter functions.

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3.2.7 The SparkZ Ignition Control Maps Screen

Refer to the SparkZ GUI Help Directory for advice on using the Ignition Control Maps Screen.

Ignition Control (Timing curve) maps can be always be downloaded into an EC12 igniter, but
Timing curve adjustment is only available according to the GUI Configuration Disc supplied.

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3.2.8 The SparkZ Diagnostics Screen

Diagnostics Parameters Panel

The readings displayed in this Panel are generated by the Igniter from various inputs.

Load sensor (%) A value related to the output from a Throttle Position or MAP sensor.
Battery (V) A value related to the power supply voltage.
On Peg A reading of the timing disc pegs used for igniter processing.
Off Peg A reading of the timing disc pegs used for igniter processing.
Speed (rpm) The rpm value generated by the Igniter.
Ign. Angle (deg) The calculated ignition advance angle.
Crank peg on Cam synch This shows which primary timing disc peg is used when the
secondary timing disc signal is received, in dual timing disc operating mode.
Int.Temp (deg C) The actual internal temperature of the Igniter module.
It must not exceed 85 deg C.

This information is primarily for Gill Instruments use only.

“Status / Fault” panel

The Status / Fault check boxes display, if ticked, possible errors reported by the Igniter.
When running a Data Log (see “Data Logging” below), the information is stored as a code number.

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“Data Logging” panel

Running a Data Log will assist in locating a possible ignition system malfunction on an engine.

To run a Data Log, click on the Data Logging panel “Start” button, name and select a suitable
location for the resulting data log file, click on the “save” button and the Data Log run will start.

Click on the “stop” button to end the Data Log run.

The Data Log file can be then be retrieved from the chosen location and forwarded to Gill
Instruments for analysis as required.
A “Configuration Snapshot” should also be forwarded at the same time (see below).

“Primary Disc Position” panel

This reports the position of the Primary Timing Disc as configured in the Igniter; either on the
Camshaft or the Crankshaft.

“Configuration snapshot” panel

When an igniter configuration is being developed, a “snapshot” can be taken of the igniter settings.
Click on the “Save” button, name and save the file accordingly and forward to Gill Instruments for
confirmation as to its suitability for an installation.

4. CONTROLLED SHUTDOWN / POWER RELAY CONTROL

For both of these facilities the Enable (Pin 11) Black / Red wire is connected via a switch to the
Battery supply voltage.

4.1 CONTROLLED SHUTDOWN

Controlled Shutdown Operation provides the facility of turning off the fuel valve a pre-programmed
time (“purge” time) before the sparks are cut, the igniter then reverting to a low power “standby”
mode.
If, for example, the “Purge time” is set to 5 seconds, then when the supply voltage is removed from
Enable, Pin 11, the fuel valve is shut 5 seconds before sparks are cut. This ensures no un-burnt fuel
remains in the engine manifolds, thus avoiding potential backfiring and the risk of engine damage.

4.2 POWER RELAY CONTROL

This facility allows control of a main power relay, connected between Pin 32 and the battery +
supply voltage – to allow the power to be removed from loads controlled by the Igniter (e.g. coils,
fuel valve) when the Igniter itself is in standby mode.
This is to ensure safety when the Igniter is in the permanently powered mode (pin 1 permanently
connected to the battery + supply)

To enable both of the above facilities, the Igniter requires programming accordingly (refer to
Gill Instruments for advice).

REFER TO THE EC12 WIRING DIAGRAM IN BOTH CASES

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5. THE SPARKZ GUI HELP DIRECTORY

5.1 SparkZ GUI Help Directory Contents

The Contents list displays all the Help files associated with the operation of the Gill EC12 Igniter.
It is strongly recommended that you read through all the Topics to thoroughly familiarise yourself
with the features and functions of the Igniter and it's associated components.
The main screens are divided into separate operating "Panels" to simplify access to the relevant Help
pages.
Click on the Menu 'Help' Tab on any screen to access the Help page for that screen.

Right clicking on a drop-down Tab, Information Panel Tab, or underlined Topic heading will access
the associated Help page.

Introduction
Installation
Igniter LED Display,
Monitor Screen
Monitor Screen Tabs
Imaging
Comms
Igniter Information Panel
Variable Parameters Panel
Set Up Parameters Panel
Ignition Maps
Ignition Maps Tabs
Load Map Table
Ignition Maps Information Panel
Diagnostics Screen
Diagnostic Parameters Panel
Diagnostic Status / fault Panel
Data Logging Panel
Controlled Shutdown
Wiring Details (Igniter connector pinout arrangement)

(Note: When the GillShell GUI software has been installed, the SparkZ Help Directory can be
accessed by clicking on Start – Programs – GillShell and then select the SparkZ Help Directory Tab.
This will enable the use of the facility without having to run the SparkZ GUI program.)

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6. WIRING DIAGRAM (Igniter Connector Pinout Arrangement)

Note that Pin 1 is located at the bottom right hand side of the Igniter connector (when viewed from the front).
Pins are numbered right to left in each row.

Pin Wire Colour Description Comment

1 White / Red Battery +ve Permanent power in (+31V maximum)

2 Black / White Battery –ve 0V (power ground)
3 Black / White Battery –ve 0V (power ground)
4 Black / Green Sensor Supply +5 Volt DC for sensors (e.g. load, Hall)
5 Black / Yellow Sensor Ground 0V for sensors and switches
6 Black Pickup Ground Inductive Pickup -
7 Red Pickup Input Inductive Pickup +
8 Hall sensor 2 Secondary disc Hall sensor input
9 Red / Green Global Retard / Map Set Switch to ground to activate
10 Hall sensor 1 Primary disc Hall sensor input
11 Black / Red System Enable Igniter Enable Supply (See note below)
12 Green / Red Ignition Inhibit Switch to ground to activate
13 Orange Coil A
14 Violet Coil G
15 Brown Coil B
16 Green Coil H
17 Yellow Coil C
18 Orange / Black Coil I
19 Spare
20 Analogue Input Temperature Sensor (Thermistor input)
21 Yellow / Red Load Sensor TPS or MAP sensor signal input
22 Spare
23 White RS232 TX
24 Red / Blue RS232 RX
25 Grey Coil D
26 Yellow / Black Coil J
27 Pink Coil E
28 Grey / Black Coil K
29 Blue Coil F
30 Pink / Black Coil L
31 M.I.L Malfunction Indicator lamp
32 Violet / Red Power relay
33 Brown / Yellow Fuel Valve
34 White / Violet Speed signal e.g.Tachometer
35 CAN CANbus communications
36 CAN CANbus communications

IMPORTANT NOTE:

Pin 11 System Enable – This MUST be connected to the DC power supply if the engine is NOT
wired for Controlled Shutdown.

Pins 31, 32, 33 and 34 should have their loads connected between the connector pin and V+ supply voltage.

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Appendix 1 – Wiring Diagram

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Appendix 2 – Wiring for Dual Pickup operation

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Appendix 3 - EC12 Igniter Assembly

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Appendix 4 – Standard Gill Timing Disc

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