685

685 MALLORY | Alldatasheet

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HYFIRE® VI SERIES OF ELECTRONIC IGNITION CONTROLS HYFIRE® VI Ignition System Part No. 685, Advanced HYFIRE® VI Ignition System Part No. 6851, Basic For applications triggered by points, Mallory Electronic Ignition Distributor (all models), original equipment electronic ignition amplifi ers and magnetic trigger pulses (magnetic pickup distributor or crank trigger ignition). Optional adapters are available for easy connection to early model Delco/GM HEI Systems, late model GM HEI/EST Systems, Ford TFI Systems, and OEM magnetic pickup (non-computer; Ford DuraSpark, GM HEI and Mopar/Chrysler Electronic Systems). NOTE: Mallory HYFIRE ® VI Electronic Ignition Controls are not compatible with distributorless systems or positive ground applications. The RPM Limiter in the HYFIRE ® VI (Part No. 685) will not work properly with odd- fi re or semi-even fi re V6 applications. Parts included in this kit: 1 HYFIRE ® VI Electronic Ignition Control - Part No. 685 or 6851 1 Ignition Control Harness - Part No. 29348 2 Terminal Connectors - Part No. 450

1 Bypass Connector

4 Cable Ties

2 Spade Terminals

8 Ring Terminals, 1/4”

1 Ring Terminal, 3/8”

5 Spade Receptacle Terminals

4 10-32 Nuts with Lockwashers INSTALLATION INSTRUCTIONS FORM 1478 (REV. D) 09/2008 WARNING: DO NOT USE NON-SUPPRESSOR SPARK PLUG WIRES WITH THE HYFIRE® VI IGNITION CONTROL. KEEP ALL IGNITION SYSTEM WIRES AS FAR FROM SPARK PLUG WIRES AS POSSIBLE. External RPM Limiters Mallory PRO TACH Ford DuraSpark Systems (non-computer type, Early Model GM HEI Systems (non-computer type, Mopar/Chrysler Corp. Electronic Systems Mallory Electronic Ignition, UNILITE ® Distributors, Magnetic Breakerless Distributors or Electronic For OEM Electronic Systems with modules/ampli fi ers Magnetic Pickup Trigger Pulses (magnetic RPM Limiter Operation – HYFIRE ® VI Ignition System

CONTENTS

The HYFIRE® VI Ignition System Part Nos. 685 and 6851 are not for marine use. The RPM limiter in the HYFIRE® VI is not recommended as an engine speed governor. The use of the RPM limiters is not recommended for applications equipped with a catalytic converter. Similarly, forcing engine RPM past the RPM limiter continuously for long sustained intervals can cause fuel build up in the exhaust system that may adversely affect your application. The RPM limiting systems will not work properly with odd-fi re V6 applications. Ignition Ballast Resistor / Loom Resistance Wire The performance of the HYFIRE ® VI is not affected by the presence of the factory ignition resistors or ignition ballast resistors in the wire from the ignition switch. Standard Ignition Bypass (Bypass Connector) The Bypass Connector (supplied) fi ts into the Ignition Control Harness to convert back to stan- dard ignition. If you use the Bypass Connector, use ignition ballast resistors designed for your vehicle’s distributor and coil (see diagrams for more information). This bypass method does not work with magnetic pickup distributor or crank trigger ignition. Racing Applications: It is not necessary to install ignition ballast resistors. However, do not use the Bypass Connector until the ignition ballast resistors are installed in the wire from the ignition switch. Ignition Coils The HYFIRE® VI Electronic Ignition Controls are designed to work with most original equipment ignition coils. For optimum performance use the Mallory PROMASTER® Coil Part No. 29440 (up to 7,500 RPM) or Part No. 29625 (up to 10,000 RPM). Fuel Injection Some fuel injection systems need a voltage spike signal from the ignition coil before they will operate properly. This signal changes once HYFIRE ® VI Electronic Ignition Controls are installed. The Mallory Fuel Injection and Tachometer Adapters Part Nos. 29074 and 29078 supply the proper signal to the vehicle computer to operate the fuel injection system. Installation procedure and diagrams are supplied with these adapters. Spark Plug Wires YOU MUST USE suppression type (carbon core, spiral core, suppression core) spark plug wire. We recommend spiral core ignition wire, such as Mallory PRO SIDEWINDER ® Ignition Wire. Suppression type spark plug wires prevent false triggering and possible premature ignition or accessory failures. DO NOT USE solid core (copper core; stainless steel core) spark plug wire with any electronic ignition system or accessory. Spark Plug Gaps For street applications, use your engine manufacturer’s specifi cations. For racing applications, start with your engine manufacturer’s specifi cations, then experiment with, and closely monitor, various gaps to achieve maximum performance. Electric Welding Unplug the Ignition Control Harness from the HYFIRE® VI Electronic Ignition Control and un- plug any distributor harnesses (if possible) before any welding is done on the vehicle. External RPM Limiters Mallory Proportional RPM Limiter Part Nos. 641-4, 641-6, 641-8, 642, 643 and 644 WILL NOT function with the HYFIRE ® VI Electronic Ignition Controls. Mallory PRO TACH® I, IV and VI The RPM needle and shift light will work with the HYFIRE® VI. However, the tach’s proportional controller that limits RPM WILL NOT function with the HYFIRE® VI. Turn the LIMIT RPM knob slightly past 11,000 to prevent the limiter from interfering with the tach’s other functions. See Optional Ignition Accessories for more information. MOUNTING PROCEDURE Step 1 Disconnect the battery (–) cable to cut power to the system. Computerized vehicles: Discon- nect the battery (–) cable and let the vehicle sit overnight before proceeding. This allows the computer to calibrate for the new ignition. Step 2 Select a convenient location to mount the HYFIRE® VI Electronic Ignition Control. Keep the unit away from hot engine components or extreme heat such as the exhaust system and manifolds. Also, keep it away from moving devices, such as fans, belts and linkages. The location must be dry. Moisture will damage components inside the unit. Step 3 Choose one mounting method listed below for mounting the HYFIRE ® VI Electronic Ignition Control (3a, 3b, or 3c). (3a) Mounting to a fl at surface

• Center punch the mounting pattern on the mounting surface using the housing holes to mark locations for drilling mounting holes. Drill holes using a 7/32” drill bit.
• Hold the HYFIRE ® VI Electronic Ignition Control in position over the mounting holes.
• From the backside of the mounting surface, insert the 10-32 screws with lock washers through the mounting holes and attach with the 10-32 nuts supplied. (3c) Mounting to a fl at surface with shock mounts (available separately, PN 29069)
• Center punch the mounting pattern on the mounting surface using the housing holes to mark locations for drilling mounting holes. Drill holes using a 7/32” drill bit.
• Install the shock mounts into the side fl anges of the HYFIRE® VI and tighten nuts. Hold the unit in position where it will be mounted.
• From the backside of the mounting surface, insert the 10-32 nuts with lock washers onto the shock mount studs. Tighten each nut until snug. FIGURE 1

Connecting to Ford DuraSpark Systems (non-computer type) using Adapter PART NO. 29039 and Harness PART NO. 29040 for OEM magnetic pickup Refer to Figure 8 while performing the following steps. Connecting Adapter PART NO. 29039:

• Disconnect all connectors at the ignition module, ignition coil and distributor. Remove the ignition module. Remove the distributor and coil harnesses.
• Connect the Adapter ORANGE WIRE to the distributor plug’s ORANGE WIRE.
• Connect the Adapter YELLOW WIRE to the distributor plug’s PURPLE WIRE.
• Connect the other Adapter female socket to the vehicle’s matching male socket. (The matching male socket was originally connected the ignition module.) Connecting the Harness PART NO. 29040:
• Connect the HYFIRE ® VI Electronic Ignition Control’s SMALL GREEN WIRE to the Harness RED WIRE.
• Connect the HYFIRE ® VI Electronic Ignition Control’s SMALL BLACK WIRE to the Harness BLACK WIRE.
• Connect the mating plug of the Harness to the mating plug of the Adapter Part No. 29039 from the distributor. Connecting the Ignition Control Harness:
• Route the Ignition Control Harness to the coil so that its wires do not make contact with extreme heat, sharp objects or moving devises such as fans, belts and linkages.
• Crimp the Ignition Control Harness RED WIRE to the slice connector on the Adapter Part No. 29039 female socket.
• Crimp a spade receptacle terminal on the Ignition Control Harness YELLOW WIRE. Connect the YELLOW WIRE to the ignition coil (+) terminal. DO NOT allow any wire except the YELLOW WIRE to make contact with the coil (+) terminal.
• Crimp a spade receptacle terminal on the Ignition Control Harness BLACK WIRE. Connect the BLACK WIRE to the ignition coil (–) terminal.
• NOTE: Do not connect the GREEN WIRE of the Ignition Control Harness to anything. Tape the end of the wire to insulate it.
• Go to Step 3, page 9. Connecting to Early Model GM HEI Systems (non-computer type) using Adapter PART NO. 29043 and Harness PART NO. 29040 for OEM magnetic pick-up. Refer to Figures 11 and 12 while performing the following steps. Connecting Adapter PART NO. 29043: For coil-in-cap distributors only
• Disconnect the (RED or PINK) BAT PLUG/wire from the distributor cap.
• Disconnect the tachometer wire from the TACH terminal on the distributor cap.
• Disconnect the distributor plug from the distributor cap. For coil-in-cap distributors and external coil
• Remove the distributor cap.
• Disconnect the pickup plug from the ignition module.
• Remove the ignition module, radio noise fi lter/capacitor and distributor plug harness.
• Slide the Adapter ORANGE and YELLOW WIRES through the grommet (supplied).
• Connect the Adapter ORANGE WIRE to the pickup plug’s WHITE WIRE.
• Connect the Adapter YELLOW WIRE to the pickup plug’s GREEN WIRE.
• Position the grommet into the slot on the edge of the distributor housing. Use cable ties and 8-32 screws to hold wires in place.
• Install the distributor cap. Connecting the Harness PART NO. 29040:
• Connect the HYFIRE ® VI Electronic Ignition Control’s SMALL GREEN WIRE to the Harness RED WIRE.
• Connect the HYFIRE ® VI Electronic Ignition Control’s SMALL BLACK WIRE to the Harness BLACK WIRE.
• Connect the mating plug of the Harness to the mating plug of the Adapter Part No. 29043 from the distributor. Connecting the Ignition Control Harness:
• Route the Ignition Control Harness to the coil so that its wires do not make contact with extreme heat, sharp objects or moving devises such as fans, belts and linkages.
• Crimp a spade terminal on the Ignition Control Harness RED WIRE. For coil-in-cap distributors only Refer to Figure 10 while performing the following steps.
• Connect the BAT PLUG/wire to the RED WIRE.
• Crimp the YELLOW WIRE to the YELLOW WIRE of the Adapter Part No. 29043 3-pin connector.
• Crimp the BLACK WIRE to the BROWN WIRE of the Adapter Part No. 29043 3-pin connector.
• Plug the Adapter Part No. 29043 3-pin connector into the distributor cap.
• Note: DO NOT connect the GREEN WIRE of the Ignition Control Harness to anything. Tape the end of it to insulate it.
• Go to Step 3, page 9. For external coil only Refer to Figure 11 while performing the following steps. (Replace the words “spade receptacle terminal” with “ring terminal” when aftermarket coils with post type terminals are used.)
• Disconnect the BAT wire from the ignition coil BAT/(+) terminal. Connect the BAT wire to the RED WIRE.
• Disconnect the tachometer wire from the ignition coil TACH/(–) terminal.
• Crimp a spade receptacle terminal on the Ignition Control Harness YELLOW WIRE. Connect the YELLOW WIRE to the ignition coil BAT/(+) terminal. DO NOT allow any wire except the YELLOW WIRE to make contact with the ignition coil BAT/(+) terminal.
• Crimp a spade receptacle terminal on the Ignition Control Harness BLACK WIRE. Connect the BLACK WIRE to the ignition coil BAT/(–) terminal.
• Discard the adapter plug with the yellow and brown wires from the Adapter PART NO. 29043. It is not used on external ignition coil HEI systems.
• Note: DO NOT connect the GREEN WIRE of the Ignition Control Harness to anything. Tape the end of it to insulate it.
• Go to Step 3, page 9. Connecting to Mopar/Chrysler Electronic Systems (non-computer type) using Harness PART NO. 29040 for OEM magnetic pickup Refer to Figure 12 while performing the following steps.
• Disconnect all connectors at the ignition module, ignition coil and distributor. Remove the ignition module. Take notice of a DARK GREEN/RED WIRE connected to the ignition ballast resistor. Remove the distributor and coil harnesses. Connecting the Harness PART NO. 29040:
• Connect the HYFIRE ® VI Electronic Ignition Control’s SMALL GREEN WIRE to the Harness RED WIRE.
• Connect the HYFIRE ® VI Electronic Ignition Control’s SMALL BLACK WIRE to the Harness BLACK WIRE.
• Connect the mating plug of the Harness to the distributor plug. Connecting the Ignition Control Harness:
• Route the Ignition Control Harness to the ignition coil so that its wires do not make contact with extreme heat, sharp objects or moving devices such as fans, belts and linkages.
• Connect the RED WIRE to the terminal on the ignition ballast resistor that previously had the DARK GREEN/RED WIRE connected to it (or to a 12-volt wire from the ignition switch). NOTE: The RED WIRE must get voltage when the ignition switch is in the START and RUN positions.
• Connect the YELLOW WIRE to the ignition coil (+) terminal. DO NOT allow any wire except the YELLOW WIRE to make contact with the ignition coil (+) terminal.
• Connect the BLACK WIRE to the ignition coil (–) terminal.
• DO NOT connect the GREEN WIRE of the Ignition Control Harness to anything. Tape the end of it to insulate it.
• Go to Step 3, page 9.

Top Panel Operation and Features Mallory HYFIRE® VI 685 CD Ignition System The Mallory HYFIRE® VI 685 ignition system has a number of features that are set up by using the top panel display and switches. Here is a list of the different features (or modes): Mode 1 – This is the normal engine protection RPM limit. It is active if no other RPM limit is selected. The range of this limiter is 1000 to 12800 in steps of 100 RPM. Mode 2 – This is the auxiliary RPM limiter, and it is activated when 12 volts is applied to the ORANGE wire coming out of the end panel. The range is the same as the Mode 1 RPM limiter. This RPML will over-ride the Mode 1 RPML when it is active. Mode 3 – This is a selectable high-speed timing retard. It is selected when the YELLOW wire coming out of the end panel has 12 volts applied. The range is 1 to 15 degrees in .1 degree steps. Mode 4 – Start retard value. This amount of retard is applied whenever the engine RPM is below 500. The range is .1 to 10 degrees in .1 degree steps. Modes 5 and 6 – These two control the built-in RPM activated “window” switch. Mode 5 sets the RPM where the switch activates, and mode 6 sets the RPM where the switch de-activates. This is useful if, for example, you want to have your nitrous system only work within a certain RPM range. The output wire for the RPM switch is the VIOLET wire coming out of the end panel. It is connected to ground when the switch is active, and has a maximum current rating of 10 amps. NOTE: The RPM range for this switch is 1000 to 12, 8000 and the off RPM (mode 6) must be at least 100 RPM higher than the on RPM (mode 5). Mode 7 – Tach test. This feature allows you to check the accuracy of your tachometer and any accessories connected to the tach output terminal. It also will activate the built-in RPM switch in the Hy fi re. To use the tach test feature, turn the ignition switch on without starting the engine. Select mode 7. Turn the ignition switch off brie fl y, then back on again. The HYFIRE ® will be generating a signal at the tach output terminal at the RPM displayed on the top panel. You can use the UP and DOWN arrow keys to change the RPM to the desired value. To return to normal operation, select mode 1. Turn the ignition switch off. The next time the ignition switch is turned on, the HYFIRE ® will be out of the tach test mode. Mode 8 – Boost timing retard degrees per PSI of boost. If you have an optional MAP sensor connected, the HYFIRE® 685 will retard the timing as the boost pressure increases. Mode 8 tells the system how many degrees to retard the timing for each pound of boost. The MAP sensor plugs into the 3 wire connector that comes out of the front panel. If you don’t have a MAP sensor installed, this function has no effect. Mode 9 – Cylinder number select. Set this to however many cylinders your engine has. The range is 3 to 12, even-fi re ONLY! Mode A – MAP sensor select. There are two MAP sensors available that are compatible with the HYFIRE ® 685. One is a 2 Bar sensor (Accel P/N 74776), which is good for about

15 PSI of boost, and the other is a 3 Bar sensor (Accel P/N 74777), good for about 30 PSI

of boost. Use mode A to tell the HYFIRE ® 685 which sensor you are using. If you don’t have a MAP sensor installed, this function has no effect. To use the boost retard feature, you must use the Mallory P/N 29785 harness and appropriate MAP sensor, as referenced above. Both the harness and the MAP sensors are available separately. BYPASS CONNECTOR The Bypass Connector (standard ignition bypass) fi ts into the mating plug of the Ignition Control Harness to convert back to standard ignition. If you use the Bypass Connector, use ignition ballast resistors designed for the particular distributor and coil in the wire from the ignition switch. DO NOT put the Bypass Connector into the mating plug of a Mallory HYFIRE ® VI RPM Limiting Adapter, or Single or Multi Stage High Speed Retard. DO NOT put the Bypass Connector into the mating plug of a Mallory Electronic Advance Computer or Remote Timing Control. Use the Power Plug to convert back to standard ignition. Also, if you are using a Mallory Fuel Injection/Tachometer Adapter (Part No. 29074), disconnect it (and its diode if used) as part of converting back to standard ignition. The Bypass Connector (standard ignition bypass method to convert back to standard ignition) does not work with magnetic pickup distributors or crank trigger ignition. FIGURE 20 MODE MODEVALUE MICROPROCESSOR CONTROLLED CD IGNITION SYSTEM A. MAP SENSOR 9. CYLINDER NUMBER 8. BOOST DEG/PSI 7. TACH TEST 6. RPM SWITCH HIGH 5. RPM SWITCH LOW 4. START RETARD 3. SELECTABLE RETARD 2. AUX RPML 1. MAIN RPML PART No. 685 RR® PUSH THESE TO RAISE OR LOWER THE SELECTED MODE VALUE THIS WILL BLINK DURING CRANKING IF THE TRIGGER SIGNAL IS PRESENT PUSH THIS BUTTON TO SELECT THE MODE FIGURE 19

MALLORY IS A DVIISION OF PRESTOLITE PERFORMANCE CLEVELAND, OHIO (216) 688-8300 FAX (216) 688-8306 www.malloryperformance.com FORM 1478 (REV. D) 09/2008 X100X10006 4 CYL PART No. 6851 RPM MICROPROCESSOR CONTROLLED CD IGNITION SYSTEM RR® HYFIRE® 6851 IGNITION SYSTEM The Mallory HYFIRE ® 6851 ignition system has the same basic connections as the 685 ignition system. However, the only accessory included is an RPM activated switch. This RPM switch is controlled by two rotary DIP switches that are located behind an access plate on the top of the unit (see the illustration below). Loosen the two screws to gain access to the switches. You can select 4 or 6 cylinder operation, and an RPM switch value from 1000 to 9900 RPM. Use a small screwdriver or similar to select 4 or 6 cylinder mode, if desired. If both these switches are off, the unit is in 8 cylinder mode. Use a screwdriver to set the 1000 RPM and 100 RPM switches to the desired setting. When you reach this RPM, the violet wire coming out of the end panel will be connected to ground (10 amp maximum). OPTIONAL IGNITION ACCESSORIES Multi Stage High Speed Retard – Part No. 618-3 This is a fi nger tip adjustable 3-stage timing retard control with an adjustment range for the first and second stage of 0°-15° and a range of 0°- 20° for the third stage. Each succeeding stage overrides the previous stage to allow you to reduce (or add) ignition timing on a succeeding stage. This retard is designed to be easily added to the HYFIRE ® VI Electronic Ignition Control. Mallory Electronic Advance Computer – Part Nos. 600-04, 600-06 and 600-08 This is a user programmable advance curve system using a CMOS microprocessor for advance calculations. This allows you to select from 256 different advance curve combinations! It is designed with matching mating plugs so it can to be added between the HYFIRE ® VI Electronic Ignition Control and the Ignition Control Harness. Mallory Remote Timing Control – Part No. 631 Mallory’s Remote Timing Control allows you to change the ignition timing as you drive for maximum performance, for better fuel economy or to avoid engine knock. NOTE: The accessories listed above will not work properly with odd- fi re V6 applications or point trigger distributors. They are not designed for marine use. Mallory Fuel Injection and Tachometer Adapter – Part No. 29074 and 29078 Some applications with fuel injection or a tachometer need a voltage spike signal from the negative side of the coil before they will operate properly. This signal changes once the HYFIRE ® VI Electronic Ignition Control is installed. Mallory’s adapter provides the proper signal to trigger most fuel injection systems and voltage/current triggered tachometers. FIGURE 21