Digital Ignition ZDG3

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1 Digital Ignition ZDG3 Fitting instructions for digital ignition ZDG3 for Moto Guzzi available for Bosch, Ducati or Saprisa alternators 1. Function 2. Fitting 3. Electrical connection 4. Adjustments 5. General Volker Sachse Lerchenweg 12 D32312 Lübbecke /61188

2 Fitting instructions digital ignition ZDG3 for Moto Guzzi 1. Function - 2. Fitting - 3. Electrical connection - 4.Adjustment - 5. General The digital ignition ZDG3 consists of the following components: - light-barrier printed circuit board - corresponding mechanical parts - the ignition box By the assembly at the crankshaft the distributor with the contact breakers or Motoplat pickups becomes redundant. Function: per revolution of the crankshaft starting from TDC, the momentary peripheral speed is determined and by this means, the time up to ignition is calculated. Because the peripheral speed varies substantially during acceleration, this long measurement is selected in order to determine a relatively exact measurement. The following computation of ignition timing is divided into 4 ranges: rpm Starting range, ignition always at TDC rpm Idling range, 2 to 8 advanced ignition, depending on curve selection rpm Partial load range, the spark advance adjustment occurs here rpm maximum load range, constant 30 to 34 advanced ignition, depending on curve selection As opposed to the original ignition system, ignition now takes place at each revolution of the crankshaft, thus also during the exhaust stroke. That is because of the fact that at the crankshaft between work and exhaust stroke cannot be differentiated. ignition box pulse disc and tappet light-barrier printed circuit board The measuring happens by opto-electronic parts - light barriers - because only light barriers produces an always same, speed-independent precise signal and therefore all computations can be made more accurately. Unlike other ignition systems, here each cylinder has a self-sufficient ignition, i.e. two micro-controllers for two cylinders, thus two light-barriers. This has the advantage that the advanced ignition is precisely computed for each cylinder. Thus, this ignition can also be used with one-cylinder models, by leaving one channel unconnected. If the engine stops, the ignition current will be switched off after 3 sec. to protect the ignition coils. 9 ignition curves are available: (No. 6 and 7 foe double ignition )

3 Fitting instructions digital ignition ZDG3 for Moto Guzzi 1. Function - 2.Fitting - 3. Electrical connection - 4. Adjustment - 5. General DUCATI-Alternator: BOSCH-Alternator: First remove the generator cover and the bottom and left-hand (in driving direction) stator screws. Screw the two M5-screws with washers into the threaded bolts and also the threaded rods on the other side. In this way the rods can be installed surely. After the tighten of the threaded bolts remove the screws again. Next, remove the middle screw of the rotor. If necessary block the crankshaft by placing a large screwdriver through the ignition inspection opening of the gearbox. Then fit the driver with the screw (without washer) again. Next fit the pulse disc onto the driver. The grub screws should not yet be tightened. Finally, fit the pickup PCB (printed circuit board) to the threaded bolts by means of the two M5 screws. Ensure that the pulse disc is the center of the light-barrier. With a little patience and talcum powder the Pickup cable can be pushed also through the rubber sleeve. Otherwise an additional groove must be made next to the rubber sleeve for the pickup-cable seal-ring on the generator cover. When fitting the generator cover, two 6mm washers must be

4 placed on each of the four screws between the cover and ring to ensure that the pulse disc does not scrape the cover. Usually only one is necessary, but this should be checked in each individual case. Tip: this distance can be tested by placing a little plasticine or putty on the pulse disc.

5 Fitting instructions digital ignition ZDG3 for Moto Guzzi 1. Function - 2. Fitting - 3. Electrical connection - 4. Adjustment - 5. General Ignition circuit diagram, Motoplat replacement The conductor crosssection of the ground wire should amount to 1,5-2,5 mm2 and schould be kept as short as possible. The conductor crosssection of the other cables should not be below 0,75 mm2. Always use end splices! Ignition circuit diagram, contact breaker replacement Connection allocation of the system plug 1 ignition coil for left-hand cylinder 2 ground (ensure good contact to the frame!) 3 brown, ground (Pickup) 4 green, barrier P2 (l.h. cylinder) (Pickup) 5 yellow, barrier P1 (r.h. cylinder) (Pickup) 6 white, +5V (Pickup) 7 connector for the electronic rev. counter (if used) The original ignition coils can be used further, but when new ones will be mounted the only technical requirement is a primary resistance of 2,5-8 Ohm (measured between the connectors) Double ignition coils 2,5-3,5 Ohm

6 8 +12V (12V supply voltage from the ignition switch, e.g. ignition coil 15 or +) 9 ground 10 ignition coil for right-hand cylinder

7 Fitting instructions digital ignition ZDG3 for Moto Guzzi 1. Function - 2. Fitting - 3. Electrical connection - 4. Adjustment - 5. General Attention! Remove the spark plug caps before adjusting the pulse disc! First, bring the right piston to TDC (D marking on the flywheel). Now rotate the pulse disc precisely into the position as shown in the picture. The position is correct when the LED (red circle) toggles. Now tighten the grub screws evenly and replace the spark plug caps. The bike is ready to start. Finally, check the ignition timing with a timing light and if necessary, correct the position of the pulse disc. Ensure that the pulse disc is in the centre of the lightbarrier! The switches can be found at the front of the ignition box: switch adjustment rotary switch (curve selectionl) 1-9 curves test mode, continuous firing 2 DIP switch overspeed protection at 7900 rpm (switch down) or at 9800 rpm (switch up) rev. counter frequency (switch up >> fout =crankshaft switch down >> fout=camshaft )

8 Fitting instructions digital ignition ZDG3 for Moto Guzzi 1. Function - 2.Fitting - 3. Electrical connection - 4. Adjustment - 5. General Only use interference-free spark plug caps! (recommended NGK caps with 5kOhm internal resistance) Malfunction sources : Unstable ignition timing : At some stroboscope lamps the ignition point suddenly oscillates around 4-6. In this case the lamp once reacts to the ignition spark starting, another time to the burning end of the spark. If possible readjust the sensitivity of the lamp or take another timing lamp. Doesn't start : If the engine should not start, or the starting procedure is suddenly strangled, then the ignition coils are mixed up. If so, swap the ignition cables which lead to the spark plugs or reconnect the ignition coils. You can check the function of the ignition by unscrewing the spark plugs, leaving them in the plugs and connect to ground. Now start the engine with an attached timing lamp and check the ignition timing. Because of the missing spark plugs the engine runs fast enough to see a stable ignition at TDC. To check the cable connecting and the supply voltage put the rotary switch to '0'. Now the spark plugs must fire continually. If the engine should not start with slowly turning starter, probably the battery voltage falls under the minimum supply voltage of the ignition (approx. 7V). Sporadic engine cutout : If sometimes the engine suspends for 2-3 seconds while driving and keeps running thereafter normally that means that the ignition has been reset. The causes of this malfunktion could be a broken spark plug connector or a loose ignition cable. But in most cases a bad connection to the operating voltage supply causes this effect (starter lock, fuse holder etc.). For testing you can connect a wire directly from the ignition box power supply to the positive terminal of the battery. If the ignition now runs perfect, you've got an malfunction in the wiring harness. With points such a malfunction is not noticeable, because a short break of the power supply doesn't matter. In contrast electronics are very sensitive to weak power supplies. Volker Sachse Motorcycle Electronics Lerchenweg Luebbecke Germany Tel /61188 Mobil: / info@elektronik-sachse.de

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11 Fitting instructions digital ignition ZDG3 for Moto Guzzi 1. Function - 2.Fitting - 3. Electrical connection - 4. Adjustment - 5. General DUCATI-Alternator: First remove the generator cover and the central nut of the rotor. Then srew the driver onto the thread. Tighten the driver with a screw driver through the boreholes. In case of M16 thread use also the big washer. Next remove the bottom and left-hand (in driving direction) stator screws. Screw the two M5-screws with washers into the threaded bolts and also the threaded rods into the other side. In this way the rods can be installed surely. After the tighten of the threaded bolts remove the M5-screws again. Next fit the pulse disc onto the driver. The grub screws should not yet be tightened. Finally, fit the pickup PCB (printed circuit board) to the threaded bolts by means of the two M5 screws. Ensure that the pulse disc is the center of the light-barrier.

12 With a little patience and talcum powder the Pickup cable can be pushed also through the rubber sleeve. Otherwise an additional groove must be made next to the rubber sleeve for the pickup-cable seal-ring on the generator cover. The alternator cover should be set on distance with washers or nuts. The right distance should be checked in each individual case. Tip: this distance can be tested by placing a little plasticine or putty on the pulse disc.

13 Fitting instructions for digital ignition ZDG3 for BMW 1. Function - 2. Mounting - 3. Electr. connection (6V coils/di) - 4. Electr. connection (12V coils) - 4. Adjustment - 5. General electrical connection with two 6V coils (original equipment) electrical connection with a double ignition coil

14 1 not connected Connection allocation of the system plug 2 ground (Make sure of a good contact to the frame!!) 3 brown, ground (Pickup) 4 not connected 5 yellow, light barrier (Pickup) 6 white, +5V (Pickup) 7 tachometer output 8 +12V (Supply voltage from the ignition switch) The conductor cross-section of the ground wire should amount to 1,5-2,5 mm2 and schould be kept as short as possible. The conductor cross-section of the other cables should not be below 0,75 mm2. Always use end splices! 9 ground 10 ignition coil

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