biggest PITA being dust contamination (my fix for that later). Overall it has been a good upgrade.
A concern is the End of Life announcement due to retirement at PowerARC. It's been a good run
for them over 25 years as a boutique. Now, no spare parts? Not entirely! I'll get to that.
I've reached a good understanding of the versions, components, reverse engineered the interfaces
to the various Coils, module capabilities, and I have some spare parts for self sufficiency.
So what's my motive? So I can support myself! Also to get the info out, it may be helpful for others.
** If you see anything incorrect or have additional information please PM me or respond **
A little history on the versions, to understand the differences, weaknesses, and improvements.
PinzSSI 1.0 introduced 2013 (1.x version a couple of years later not sure if a 1.1 or 1.2).
> 1.0 is the only module version that can drive the primary Coil winding DIRECTLY. The A/B outputs
can sink several amps to ground acting as ePoints such as a Pertronix ignitor.
> The Coil pack used is a 3.0 Ohm primary, and not likely to fail. If coil does fail, a replacement MUST
have a primary winding no less than 3.0 Ohms or the module will overheat. These high resistance
Quad packs are VERY hard to find.
> A possible alternative is a pair of 3.0 Ohm wasted spark Harley coils.
> If you have a 1.0 version it has a relay on the Coil board to switch power ON to the Coil and module
via lower 12V battery. The Coil has a 3-pin connector connecting back to the module via the harness.
** IMPORTANT Note: 1.0 Coil Pack will NOT work on any PinzSSI version other than 1.0.
Only a Wasted spark Coil pack with a 3.0 Ohm primary can work on 1.0
A more modern Coil pack with built in Igniters will NOT work on 1.0.
This image is a PowerARC ignition for a VW introduced before the Pinz. Same Coil used.
- PowerARC VW.jpg (32.03 KiB) Viewed 428 times
> The module changed to IDS CD-Series. Coil outputs are "Triggers" and cannot directly drive the
primary winding of a Coil. Current sink is limited ~10 ma (measured).
> This is a good change REDUCING drive current reduces power dissipation and increased reliability.
Total current consumption of the 1.x module is ~40 ma (measured).
> 1.x Coil is used from 1.x on through 3.0. This is a CUSTOMIZED coil pack to maintain compatibility
with the module signalling levels. Coil includes a terminal board embedded in the connector housing.
Board includes circuitry to drive the primary windings AND maintain module compatibility.
> Speculation why the Coil changed was a lack of available high impedance Quad packs.
Industry moved to higher voltage output but lower impedance primaries, ~0.5 Ohm EXCEEDS module
capability. A likely generic Coil used is IGN-4 tower pack common for Megaspark applications.
> Power delivery changed; Coil power direct from the bottom battery, module power from the switched
24V Carb solenoids BUT with a 300 Ohm resistor in series to drop the voltage to 12V for the module.
** IMPORTANT Note: There is NO off-the-shelf Coil Pack replacement without modification.
This image curtsy of PinsSSI installation manual, shows Coil pack with ckt board modification.
- CoilPack2.jpg (26.26 KiB) Viewed 428 times
Weakness for both 1.0 and 1.x is power delivery. Both are sensitive to 24V Battery health. Several cases
where a Pinz would not start when cranking due to voltage drop. Taking power from the bottom battery
also results in unbalanced charging. Although a fix is/was new batteries a recommended improvement is
to incorporate a 24V->12V DC/DC converter as per version 2.0.
PinzSSI 2.0 introduced 2018 (possibly earlier?).
> Same Coil pack and controller as 1.x
> Voltage delivery major improvement using an Eaton DC/DC converter. This converter has a control
input that will turn ON/OFF a 12V output with a switched 24V source. These converters are expensive
but designed for commercial vehicle applications, very rugged and reliable.
PinzSSI 3.0 introduced 2020
> Same Coil pack as 1.x and 2.0
> Same power delivery as 2.0
> Different module, CD-LM series, functionally the same as IDS CD-series. Static timing LED on top of
Optics tower. Shorter engine block "stem" length as this module is considerably thinner. I suspect this
version removed the Coil drivers making a thinner module profile possible and less expensive.
> Module enclosure improved to help reduce dust ingress with a screen seal but not hermetic.
** IMPORTANT Note: Modules are not interchangeable IDS-CD versus CD-LM due to different thickness
resulting in their own unique Engine block stems. It may be possible to shim up a
CD-LM to get the optical disk to position properly in a 2.0 stem.
PinzSSI 4.0 introduced 2022
> Same module as 3.0
> Same power delivery as 2.0 and 3.0 (a lower max current Easton DC/DC but sufficient).
> Same module enclosure as 3.0
> Different Coil, modified pair of wasted spark, each with two HV terminals. Similar approach to adapt
to module using a terminal board (+12V, GND, Trig) embedded in connector housing. Board circuitry is
simple, this "smart" coil has built in driver (Mazda Protege 1999-2003 wasted spark Coil).
> Speculation why the coil change -- to consolidate part types. This coil was used broadly across many
PowerARC options, for 2, 4, 6, and 8 cylinder use cases, with 1 or more of the same coil.
The weakest link with the 4.0 version is the "Mazda" coil pack. This was not a good choice IMHO.
Image shows one removed Mazda type coil pack with embedded circuit board.
- MazdaCoilPack.jpg (20.44 KiB) Viewed 428 times
the other HV terminal, horizontal, connects to a second spark plug with a cable. PowerARC re-purposed
the coils by removing the stem and connecting a boot/cable to that terminal -- a spring is necessary
for electrical connection. Also there is the additional embedding circuit board for compatibility.
There is evidence of "failed" 4.0 units. One potential issue is the propensity for the HV cable with a
right-angle boot to pop off the "stem" terminal. Now running on two cylinders it can result in
"un-clamped" overvoltage which could lead to a stressed igniter. What causes the cable to pop off is
the Spring being too long, over compressed internally, resulting in a force pushing it off.
** IMPORTANT Note:
Make sure the Spring for the vertical HV terminal extends no more than 3/8" beyond the end of the
right-angled boot! Use a small Zip tie at the base to secure.
Although there is no fundamental reason why the Mazda coil isn't reliable with good HV connections.
** Tips, Tricks, Lessons learned **
Module reliability: If you are having a problem with your PinzSSI, it is NOT likely to be the module.
Other than 1.0, these modules are low current, low power dissipation and all Solid state. Check first:
> Power and Ground connections, you may need to dig into the split loom checking connections.
> If a 1.0/1.x version check your battery health.
> Dust ingress effecting the optical path -- a much bigger issue than you may think.
> Slipped timing due to a loose Engine block stem or timing disk.
> Fouled plugs or a disconnected or loose HV terminal.
> Bad Coil pack.
One of these issues is going to be your problem BEFORE a bad module. However, if you have an
opportunity to pick up a spare Module GRAB it. Just make sure it was programmed for a Pinz and
the different module versions are not swapable across Engine block stems.
Coil Packs: Several versions, limited cross compatibility, no simple path forward.
Other than 1.0 with the restriction of 3.0 Ohm minimum primary winding (Harley wasted spark
coil) all other versions require modification for module compatibility. Coil packs used from 1.x, to 3.0
are the same and swappable. Coil pack for 4.0 is unique and if used on a non 4.0 version that module
should be re-programmed for that Coil type (MC2) for it's Dwell timing requirement.
Adapter for Coil pack options: Beyond 1.0, are a few reasons why PowerARC decided to put an adapter
in a Coil pack rather than modify the modules. The question its can an adapter be built allowing
off-the-shelf Coil packs -- YES, and it's relatively simple. I do have one that works. I have moved toward
a VW style quad pack, Herko, Huco, Bosch and other sources are readily available. Building a breadboard
is not the hard part, getting a circuit board fab'd and packaging it up is the challenge. I plan on doing
this eventually -- a winter project.
Dusty roads: Several known cases of poor performance to engine won't run due to dust.
If you wheel where there is dust, and have had no issues -- consider your on borrowed time.
If dust gets inside the optical path it can severely effect either the Trigger or RPM sense. This will
result in extremely poor running or not able to run at all. Version 3.0 attempted to address this
issue with tighter sealing and a screen -- although an improvement IMHO it's not sufficient.
My solution is MERV 16 Air Filter material https://www.amazon.com/dp/B089MDPCV8?re ... in_title_1
Cut a 11" diameter circle out of the MERV material, center on top of the module cover then drape over
the cover with the smooth surface facing inside, then Zip tie at the base. This stops dust down to
micron sized particles and has solved this problem for me.
Eaton DCDC: If you are running a 1.0 or 1.x, do yourself a favor and upgrade the power delivery. This
does involve digging into the wire harness and finding a place to install the converter. But the result
is a more reliable running and starting system. It also stops de-balancing the charging of the batteries.
I recommend using the Eaton 21010C10 10A converter. Sources are,
www.ase-supply.com
www.powRparts.com
I know this was a VERY LONG posting. But there's a lot that transpired and subtle details and changes.
I figure those who read this are running PinzSSI's and this might help you out in a pinch.