PRODUCT INFORMACTION INDEX DATE

Dep. 8
IT-G-A-33-003e D April 2009

DISN 800 ELECTRONIC IGNITION SYSTEM

1. INTRODUCTION
An ignition system is a device which controls and manages the firing of the air-fuel mixture in the combustion
chamber. Firing must be accurately coordinated with the engine rotation and the movement of the different
cylinder valves.

The electronic ignition system on GUASCOR FGLD engines consists of the following components:

- DISN 800 ignition unit

- Position pickup
- Coils
- Spark plugs
- Low voltage (primary) wiring
- High voltage (secondary) wiring

2. DISN 800 IGNITION UNIT

DISN 800 electronic ignition unit is a programmable static system that generates the firing signal sequence and
distributes it to the different cylinders through the primary (low voltage) wiring, coils, secondary (high voltage) wiring
and spark plugs. This unit operates on a 24 Vdc power supply or battery and synchronises the firing signal
sequence for each cylinder according to the engine rotation reference given by the position pickup.

Since it is programmable, the ignition unit is usable with different types of engines, subject to adjusting the cylinder
number, firing sequence and intervals and advance ignition with two selectors.

ANALOG TIMING APPLICATION

TIMING SWITCH SWITCH
CONTROL

15 0 1 A
14 2 H B
13 3
12 4 G C
11 5
10 6 F D
9 8 7 E

Fig. 1 - DISN 800 unit setup controls

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 PRODUCT INFORMACTION INDEX DATE
Dep. 8
IT-G-A-33-003e D April 2009

DISN 800 ELECTRONIC IGNITION SYSTEM

2.1. Position Pickup

The DISN800 ignition unit needs to know the engine crankshaft or camshaft position at all times to be able to
synchronise the cylinders firing signal sequence (timing control) at the right moment.

For this purpose, the engines incorporate a set of magnet discs on the camshaft driving gear, angularly
distributed at fixed intervals, and one extra disc that determines the "reset" in each combustion cycle.

A Hall-effect pickup sensor lying opposite the magnet discs detects their presence and transmits the relevant
position control signals to the ignition unit.

Fig. 2 – Basic diagram of an ignition system with DISN 800 unit

2.2. Operation

The DISN 800 ignition control unit is designed to operate on a 12 to 24Vdc voltage supplied by a battery or power
supply (5A).

The required operating voltage is at least 8Vdc on starting and 12-28V during operation. Average current intake
depends on the operating speed and number of outputs according to the following equation:

(nr. of outputs x rpm/2)/10000 (for 24 Vdc)

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 PRODUCT INFORMACTION INDEX DATE
Dep. 8
IT-G-A-33-003e D April 2009

DISN 800 ELECTRONIC IGNITION SYSTEM

WARNING

Although the device includes internal protection fuses, it is advisable to insert two external 10A fuses near the
power supply, in order to protect the engine and the electrics of the building or place of installation.

The unit receives data signals from the pickup for synchronising the engine position with the ignition signals. The
ignition disc, rotating at the same speed as the camshaft, is the only moving part of the system and it carries the
magnets for indexing the cylinders position according to the crankshaft rotation. Moreover, the ignition disc has an
extra "resetting" magnet for restarting the successive entire combustion cycles.

The unit loads the primary condensers by means of the main power supply and releases the accumulated energy
through switches to the coils at the adequate time in tune with the firing sequence. A high voltage is induced by
the coils in the secondary winding, which alters the potential at the spark plug electrodes to a sufficient extent for
breaking the dielectric and producing the ignition spark.

The ignition unit has two manual selector switches:

- A "Timing Switch" serves to set advance ignition in relation to the top dead centre of each cylinder in
conformity with the engine specifications and application.

- An "Application Switch" permits pre-defining the engine type, i.e. number of cylinders and firing order.

Likewise, the unit has one (“Timing Control”) connector for using a 4-20mA analog input to determine the engine's
advance ignition. This option is active only if the “Timing Control” connector's pin "E" is live. Otherwise, the unit
works with the advance as defined by the manual timing switch.

WARNING

Set the “Application Switch” carefully to avoid problems before starting the engine and do not change the setting
while the engine is running.

Do not change the “Timing Switch” settings sharply when the engine is running on load.

NOTE

There are two optional ways of stopping ignition:

- cutting off power to the unit, or

- connecting the “G” terminal to the engine ground.

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Dep. 8
IT-G-A-33-003e D April 2009

DISN 800 ELECTRONIC IGNITION SYSTEM

The unit has a normally closed contact on the main connector (pin “D”), whose status changes in the event of a
pickup failure o if one of the outputs fails. Moreover, there are three LEDs on the front panel of the unit, which
provide information on the system's condition:

- Application. When on, this LED indicates an error in the selection of the engine type and/or the reference
magnets on the disc, or a failure of the unit.

- Pickup. If on, with the engine running, the LED denotes a failure of the pickup signal
(sensor, cable, gap).

- Power. If this LED is off, the power supply to the unit is failing.

GUASCOR gas engines' ignition system with DISN800 electronic unit comprises the following parts:

1- Pickup A- 3-pin Connector (for pickup)

2- Control Disc B- 6-pin Connector (pickup + 24 Vdc + alarm)
3- Pickup cable C- 10/19-pin Connector (ignition signals)
4- Ignition Unit D- 5-pin Connector (“Timing Control”)
5- Primary (low voltage) wiring S1- Timing Switch
6- Coils S2- Application Switch
7- Secondary (high voltage) wiring S2- Application Switch
8- Spark plugs
9- 10A fuse

Camshaft

24 VDC

Fig. 3 – General diagram of FGLD 180 engine's ignition system

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 PRODUCT INFORMACTION INDEX DATE
Dep. 8
IT-G-A-33-003e D April 2009

DISN 800 ELECTRONIC IGNITION SYSTEM

NOTA

The earth wire of the ignition unit must establish an effective electric
contact of the module with the engine through its support.
2
Minimum size = 10 mm

Fig. 4 – Earth connection diagram

According to the number of outputs available, there are two types of ignition units. The following table shows
GUASCOR references for these units, with regard to the Application Switch identifier for the different types of
engines.

DISN Unit Engine Application Switch Timing Switch

76.64.098 FGLD180 C Acc. to application
76.64.098 FGLD240 D Acc. to application
76.64.029 FGLD360 C Acc. to application
76.64.029 FGLD480 D Acc. to application

Fig. 5 – References of DISN unit for GUASCOR FGLD engines

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 PRODUCT INFORMACTION INDEX DATE
Dep. 8
IT-G-A-33-003e D April 2009

DISN 800 ELECTRONIC IGNITION SYSTEM

3. CHECKING IGNITION TIMING

To verify that the real ignition timing of the engine, at rated speed, matches the programmed settings, follow the
procedure described below:

- Remove the cover from the flywheel housing's inspection hole.

- Feed a light strobe with 12 VDC, by connecting the clips.

- Clamp the third clip to the wire of the coil of cylinder #1.

- Direct the light strobe through the flywheel housing hole to the adjusting rule fitted to the flywheel and read the
timing value indicated by the index.

1 INDEX
2 ADJUSTING RULE

Fig. 6 - Reading of Ignition Point

- Compare actual advance ignition with the values specified for the engine and application concerned, and
adjust as and when necessary.

Engine A.Switch Firing Order

FG 180 C
1-5-6-3-2-4
FGLD 180 C
FG 240 D
1-4-2-6-8-5-7-3
FGLD 240 D
FGLD 360 C 1-8-5-10-3-7-6-11-2-9-4-12
FGLD 480 D 1-12-4-10-2-14-6-16-8-13-5-15-7-11-3-9
Fig. 7 – Applications Table

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