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Woodward 8904-922
Product Name: IC-922 Ignition Controller with ServLink
Product Overview: The IC-922 is a capacitive-discharge ignition system controller belonging to Woodward’s IC-920/IC-922 family. It is designed for spark-ignited engines in gas compression, power generation, and other industrial applications. The IC-922 delivers “Big Strike” high energy for up to 20 ignition coils (24 optional), making it ideal for high-BMEP or misfire-prone engines that require very high ignition energy for stable combustion under lean-burn or other misfire-prone conditions.
Detailed content
Technical Specifications:
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Adjustable stored energy: up to 340 mJ
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Supported ignition coils: up to 20 (24 optional)
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Input voltage range: 18 to 32 Vdc (steady state); 10 to 32 Vdc transient (for less than 1 minute)
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Average current draw: 10 A maximum
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Peak current draw: 30 A at 100% energy
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Engine speed limits: 4-stroke up to 1,800 rpm with 20 outputs (1,500 rpm with 24 outputs); 2-stroke up to 900 rpm with 20 outputs (750 rpm with 24 outputs)
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Cylinder configuration: configurable from 2 to 20 (or 24) cylinders
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Timing sensors: crankshaft position, camshaft position, engine speed
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Timing control input: two manual timing potentiometers, 4–20 mA signal, 0–5 Vdc signal, or 5-point speed curve
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Communication: RS-232 ServLink interface with Windows®-based service tool; Modbus RTU; J1939 CAN; CANopen
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CPU: 16-bit CPU with sensor signal conditioning
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High voltage power supply: four capacitive-discharge power supplies, charging to a maximum of 300 V
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Energy adjustment range: 100 V (10% energy) to 300 V (100% energy), independently controlled per bank
Functional Features:
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Ultra-high energy output (up to 340 mJ) for high-BMEP and misfire-prone engines
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User-adjustable spark energy for optimized spark plug life
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Advanced diagnostics with continuous ignition system monitoring
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Fault severity-based shutdown or alarm with information transmitted via serial port to PC
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Programmable overspeed shutdown setpoint
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On-site programmable — no factory re-programming required
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16-bit CPU with sensor signal conditioning
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Independent energy level control per power supply bank
Material & Construction: Industrial-grade electronic controller housed in a robust enclosure suitable for harsh industrial environments, with circular connectors for odd/even bank cylinder outputs and power input.
Application Scenarios:
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Spark-ignited industrial gas engines
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Gas compression stations
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Electric power generation
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Lean-burn and high-BMEP engine applications
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Engines prone to misfire requiring high-energy ignition
Working Principle: The IC-922 determines the firing cylinder and timing based on signals from three sensors (crankshaft position, camshaft position, and engine speed). The 16-bit CPU commands the capacitive-discharge power supplies to charge to the configured voltage (up to 300 V). When the timing point is reached, the energy is discharged through the corresponding ignition coil primary winding to create the spark. Energy levels are user-adjustable to balance ignition performance and spark plug life. Continuous monitoring of all timing sensors and primary ignition circuits allows the controller to detect faults and trigger alarms or shutdowns based on fault severity.
Installation Requirements: Install per Woodward Manual 26263. Provide input power wiring with a low-resistance harness — use a 12 A slow-blow fuse in each power line near the power supply. Each input power line must be fused. Observe maximum wiring length vs. wire size tables in the manual. Connect the odd bank via 17-pin circular connector. Ensure proper grounding and shielding for RS-232 ServLink and CAN communications.
Usage Notes: At input voltages below 18 V, 100% energy setpoint may not be achieved. The peak current draw of 30 A occurs at 100% energy. A separate combustion fault shutdown device should be used in the system to detect misfires resulting from any primary wiring fault. Primary wiring carries high voltage (up to 300 V) and high pulsating currents — handle with appropriate insulation and clearance. Program and configure using the Windows®-based service tool via the RS-232 ServLink interface.
