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Electronic Ignition
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Introduction

THERE is an Electronic Ignition sold by Le Galet which may be reliable and suitable for the VeloSoleX S 3800. Alternatively, for those of you who wish to build my CDI (Capacitor Discharge Ignition) system, I am including the details below.


Computer Simulation

FOR those who wish to view a Computer Simulation of my CDI (Capacitor Discharge Ignition) system, I am including the schematic diagram CDI.SCH (for personal use only):

Capacitor Discharge Ignition

and CDI.CIR for the program TopSPICE (PSPICE):

TopSPICE Simulation of CDI (CAPACITOR DISCHARGE IGNITION)

.PARAM RPM=2500
.PARAM Vpeak=290
.PARAM Freq={RPM/60*2}
.PARAM Period={1/(RPM/60)}
.PARAM Open={Period/8}
.PARAM Duration={Period*0.275}
VEXCITER 0 VM SIN (0
{Vpeak} {Freq})
VTRIG VT 0 PULSE (1 0
{Open} 1nS 1nS {Duration} {Period} 0)
RTEST VT 0 10MEG               
;Return path

R1 2 CB 22K                    ;CURRENT-LIMITING RESISTOR
R2 3 GATE 220R                 
;CURRENT-LIMITING RESISTOR
R3 GATE 0 470R                 
;TO PREVENT FALSE TRIGGERING OF SCR
C1 CB 3 22nF                   
;GATE TRIGGER CAPACITOR
C2 GATE 0 10nF                 
;TO PREVENT FALSE TRIGGERING OF SCR
C3 VCHARGE PRI 0.47uF          
;MAIN DISCHARGE CAPACITOR
D1 1 VCHARGE D1N4007           
;POSITIVE CYCLE DIODE
D2 2 1 D1N4007                 
;NEGATIVE CYCLE DIODE
D3 0 GATE D1N4007              
;FAST-CHARGE DIODE FOR C1
D4 PRI 0 DP600J                
;DISSIPATION DIODE
XEXCOIL VM 1 XEXCITER          ;EXCITER COIL (9 x 250t = 2250t)
XDIAC1 CB 0 XBR100             
;BR100 (DB3) 32V 2A DIAC
XSCR1 VCHARGE GATE 0 XTIC106M  
;SCR TIC106M A G K - 600V 4A
S1 CB 0 VT 0 SW                
;CONTACT BREAKER

XIGNCOIL PRI 0 SEC 0 XIGNITIONCOIL;IGNITION COIL +PRI GND +SEC GND
RLEAD SEC 4 1R                 ;
HT LEAD RESISTANCE
LLEAD 4 5 25uH                 ;
HT LEAD INDUCTANCE
CLEAD 5 0 70pF                 ;
HT LEAD CAPACITANCE

XSPARKPLUG SPARK 0 XNGKBPR4HS  ;NGK BPR4HS SPARK PLUG
RPLUG 5 6 5K                   
;SPARK PLUG RESISTANCE
LPLUG 6 SPARK 10nH             
;SPARK PLUG INDUCTANCE
CPLUG SPARK 0 100pF            
;SPARK PLUG CAPACITANCE

#AUTOPLOT 1 V(VM)
#AUTOPLOT 2 {1-V(VT)}
#AUTOPLOT 3 V(CB)
#AUTOPLOT 4 V(GATE)
#AUTOPLOT 5 V(VCHARGE)
#AUTOPLOT 6 V(SEC)

.TRAN 0.5mS 40mS 0mS 0.5mS
.SAVE

.MODEL D1N4007 D               ;1N4007 1000V 1A Silicon Rectifier Diode
+IS=1.19449e-08 RS=0.00284884 N=1.19832 EG=1.3
+XTI=0.5 BV=630 IBV=0.0001 CJO=3.13475e-10
+VJ=1.00996 M=0.459839 FC=0.5 TT=2.04804e-06
+KF=0 AF=1

.MODEL DP600J D                ;P600J 600V 6A Silicon Rectifier Diode
+IS=1.19449e-08 RS=0.00284884 N=1.19832 EG=1.3
+XTI=0.5 BV=630 IBV=0.0001 CJO=3.13475e-10
+VJ=1.00996 M=0.459839 FC=0.5 TT=2.04804e-06
+KF=0 AF=1

.SUBCKT XBR100 1 2             ;BR100 (DB3) 32V 2A DIAC
RS 1 N006 10
RV N002 N004 225K              
;Vbrkdwn = 32V (RV changes it)
R1 N006 N002 10K               
;Sets Ibo to 60uA
R2 N004 2 10K                  ;Sets Ibo to 60uA
Q4 N002 N005 2 0 PNP
Q2 N004 N003 N006 0 PNP
Q1 N003 N004 2 0 NPN
Q3 N005 N002 N006 0 NPN
D5 N002 N005 D
D6 N004 N003 D
.MODEL NPN NPN(BF=20 TF=5u)
.MODEL PNP PNP(BF=2 TF=5u)
.MODEL D D
.ENDS XBR100

.SUBCKT XTIC106M   1 2 3       ;SCR TIC106M A G K - 600V 4A
QP  6 4 1  QPOUT
QN  4 6 5  QNOUT
RF  6 4    133MEG
RR  1 4    88.9MEG
RGK 6 5    1.12K
RG  2 6    46.2
RK  3 5    16.2M
DF  6 4    DZF
DR  1 4    DZR
DGK 6 5    DZGK
.MODEL DZF   D (IS=1.6F IBV=900N BV=600 RS=20MEG)
.MODEL DZR   D (IS=1.6F IBV=900N BV=800)
.MODEL DZGK  D (IS=1.6F IBV=900N BV=6)
.MODEL QPOUT PNP (IS=1.6P BF=1 CJE=418P)
.MODEL QNOUT NPN (IS=1.6P BF=100 RC=65M
+ CJE=418P CJC=83.7P TF=214N TR=68U)
.ENDS XTIC106M

.SUBCKT XEXCITER 1 2           ;EXCITER COIL (9 x 250t = 2250t)
RL1 1 3 105R                   
;Primary DC Resistance
L1 3 2 418mH                   
;Primary Inductance
CL1 1 2 100pF                  
;Primary Capacitance
.ENDS XEXCITER

.SUBCKT XIGNITIONCOIL 1 2 3 4  ;IGNITION COIL +PRI GND +SEC GND
.PARAM RSEC=6270 LLEAK=282uH RPRI=1.5R CINTWIND=50pF TNRATIO=91.2
RS 6 3
{RSEC}
E3 5 4 VALUE
{V(7,2)*TNRATIO}
LL 8 7
{LLEAK}
CSP 1 3
{CINTWIND}
VM 5 6 DC 0
.PARAM LCORE=3.43MH FEDDY=5.05KHZ
E2 13 0 VALUE
{V(8,2)/V(12,0)}
E1 12 0 TABLE
{ABS(I(V1))}
+ (0,1) (.5,1) (.75,.993) (1.25,.892)
+ (1.75,.856) (2.25,.856) (2.75,.793)
+  (3.25,.772) (3.75,.735) (4.25,.674)
+ (4.75,.634) (5.25,.569) (5.75,.535)
G2 8 11 14 0 1
C1 15 14
{LCORE}
V1 11 2 DC 0
G1 0 14 13 0 1
R2 0 14 100MEG
R1 0 15
{1/(6.283*FEDDY*LCORE)}
R3 2 8 100MEG
G3 7 2 VALUE
{I(VM)*TNRATIO}
RP 1 8
{RPRI}
.ENDS XIGNITIONCOIL

.SUBCKT XNGKBPR4HS 1 2         ;NGK BPR4HS SPARK PLUG
.MODEL D1N4148 D(Is=2.682n N=1.836 Rs=.5664 Xti=3 Eg=1.11 Cjo=4p
+ M=.3333 Vj=.5 Fc=.5 Bv=100 Ibv=100u Tt=11.54n)
.PARAM VGLOW=1500 VARC=150 ISUS=2mA VBRKDWN=12000 IARC=200mA
D3 10 11 DZARC
SWSARC 3 10 9 0 SWARC
.MODEL SWARC VSWITCH Roff=50MEG Ron=5R Voff=0V Von=10V
RT1 7 0 50R
DT2 8 9 D1N4148
.MODEL DZGLOW D (BV={VGLOW} IS=1uA RS=5R IBV=10uA)
EBRKDWNCTRL 6 0 VALUE
{IF(ABS(V(1,2))>VBRKDWN|ABS(I(VSENSE))>ISUS,12,0)}
.MODEL DZARC D (BV={VARC} IS=1uA RS=5R IBV=10uA)
D4 5 11 DZARC
EARC_CTRL 8 0 VALUE
{IF(ABS(I(VSENSE))>IARC,12,0)}
D2 5 4 DZGLOW
VSENSE 5 2 DC 0
CT2 9 0 0.1uF
RT2 9 0 50R
CT1 7 0 0.25uF
SWSBV 1 3 7 0 SW_SPK
.MODEL SW_SPK VSWITCH Roff=50MEG Ron=5R Voff=0V Von=10V
D1 3 4 DZGLOW
DT1 6 7 D1N4148
.ENDS XNGKBPR4HS

.END

The graph below shows the voltages in the circuit (WITH SPARK PLUG FITTED):


CDI Graph


Circuit Operation

THE circuit operation is as follows:

  1. The Exciter Coil produces an AC voltage VM of between 70V peak (at 600 RPM) to about 300V peak (at 2500 RPM).
  2. On the positive half-cycle, C3 charges via D1 and D5 to the peak voltage.
  3. Approximately in the middle of the negative half-cycle the Contact Breaker S1 opens and C1 charges quickly via D2, R1, R2 and D3.
  4. After about 60uS, voltage CB reaches 32V and XDIAC1 fires discharging C1 as a positive current pulse into the GATE of XSCR1 via current-limiting resistor R2.
  5. XSCR1 fires causing C3 to discharge into the Primary Winding (PRI) of the Ignition Coil.
  6. The voltage of C3 applied to the Primary Winding is stepped up to between 6.5KV (at 600 RPM) to 27KV (at 2500 RPM) in the Secondary Winding (by transformer action) which fires the Spark Plug. 6KV is considered the minimum voltage to fire a plug reliably within the Combustion Chamber. In the graph above, the spark plug has fired and the ionising current pulls the Secondary Voltage down to around to 2KV for about 130uS.
  7. As the Primary Voltage swings positive, D4 conducts until all the energy in the Ignition Coil has dissipated. The current in D4 can peak at 10A but its surge current (IFSM) is rated at 400A so it is not a problem.
  8. C3 charges again on the next positive half-cycle and the sequence repeats.

 NOTES:

  • Any CDI Ignition Coil can be substituted for the Yamaha YZ50 coil.
  • There is no need for two Exciter Coils in this design (most designs use a low-RPM and a high-RPM coil), as the standard VeloSoleX S 3800 does not rev over 6000 RPM.
  • An old VeloSoleX Magneto Coil can be stripped down and used to make the Exciter Coil. The coil must be wound slowly and carefully, using a proper coil-winding machine or using a hand-operated home-made one. The turns must lie perfectly side by side otherwise by the 5th layer or so, you will end up with kinks and the possibility of voltage breakdown.
  • Solder two long 6A insulated wires to the two ends of the Enamelled Copper Wire. Coat the complete assembly with High-Temperature Epoxy Resin and allow to harden.
  • The electronics and ignition coil should be mounted in an aluminium box using a suitable insulator to mount the SCR to the inside of the box and using Heat-Transfer Compound if necessary. The box should be mounted away from heat, preferably on the left-hand fork leg.
  • The voltage on C3 can reach 400 - 500V DC! Therefore make sure you use proper high-voltage electronic assembly techniques. I will be producing a PCB template shortly.

 

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Copyright 2008 BRIAN'S VELOSOLEX. All rights reserved. This is a personal website containing information for and by VeloSoleX enthusiasts. It is not intended to replace any official information and whilst every effort is made to ensure the accuracy of all published information no guarantee is offered nor liability accepted for any loss or damage that may arise from any errors or omissions.