ataengine-altronic

7/29/2019 ataengine-altronic

1/12

ALTRONIC IGNITION SYSTEMSFOR INDUSTRIAL ENGINES




2/12

CONTENTS

Altronic Ignition Systems Overview and Guide

Contents and Introduction ............................................................................................2

Application Guide ..........................................................................................................3

Solid-State/Mechanical Ignition Systems

Theory and Overview ....................................................................................................4

Altronic I, II, III, and V .................................................................................................... 5

Disc-Triggered Digital Ignition Systems


CD1, CD200, DISN .........................................................................................................7

Crankshaft-Referenced Digital Ignition Systems


CPU-95, CPU-2000 ........................................................................................................9

Ignition Coils .............................................................................................................10

Flashguard Spark Plugs and Secondary Leads,

24V Alternator Systems................................................................................. 11

Sales/Service Contacts ........................................................................Back Cover

ALTRONIC IGNITION SYSTEMS

Pushing the Performance Envelope:Altronic Ignition Systems and Accessories

Girard, Ohio-based Altronic, Inc. has spent much of the last 40years dening and redening the state-of-the-art when it comes toignition systems and accessories for industrial natural gas-fueledengines. As a result of this constant attention to product developmentand manufacturing excellence, engine manufacturers and end usersalike from around the world continue to turn to Altronic rst for technically-advanced, high-quality ignition systems and components.

Browsing through these pages will give you a good overview of

both the evolution of the Altronic ignition and ignition accessory productline, as well as a good idea about the system options available for yourspecic make and model of engine. For additional details, please referto the Ignition System Application Guide on page 3 which outlinesboth the recommended and optional ignition systems for all of themajor industrial engine lines. Your local authorized Altronic Distributorand Dealer, Regional Manager, and Altronic factory sales and servicecontacts listed on the back cover of this catalog are also available toaddress specic application questions.

2

Altronic, Inc. Only


3/12

ALTRONICIGNITIO

NSYSTEMSAPPL

ICATIONGUIDE


4/12

CERTIFIEDCLASS 1, DIV. 2, GROUP D

Description and features:

Alternator powered

Capacitor discharge ignition

Replaces magneto, breaker points and impulse coupling

High output at engine cranking RPM

Extended spark plug life

Easy to service with plug-in modules

Altronic solid-state ignition systems consist of a self-poweredignition unit, a wiring harness and an appropriate number ofignition coils. Operating power is provided by a self-contained,multi-pole permanent magnet alternator that charges an energystorage capacitor. Pick-up coils, triggered magnetically, providethe timing pulses to discharge the capacitor in timed sequence.These low-tension discharges are routed by a distribution system,composed of a rotating magnet and solid state switching com-ponents, to the ignition coil of the proper cylinder. Electronics aremounted on easy to replace plug-in modules.

Drive couplings are furnished in synthetic elastomer materialsfor low wear and long life. They also serve to dampen part of theengine drive train vibration. Combined with the smooth rotationalcycle of the Altronic alternator, these features contribute to thelong mechanical life designed into Altronic solid-state systems.

SOLID-STATE/MECHANICAL IGNITION SYSTEMS


5/12

ALTRONIC I FOR SMALL 1-6 CYLINDER IN-LINEAND 1-3 CYLINDER HORIZONTAL ENGINES

Altronic I, rst introduced in 1966, brought the advantages ofcapacitor discharge ignition to industrial gas engines. It consists of asmall permanent magnet alternator with a plug-in electronic module

attached. Timing is set by one or more remote mounted pick-up sens-ing magnets referenced to the engine crankshaft. On horizontal en-gines, these are typically mounted on the ywheel; on in-line engines,a magnet disc is used. The alternator performs no timing function andcan thus be either belt- or coupling-driven. The only moving part is

the alternators sealed, underloaded ball bearing.

Over 60,000 Altronic I systems have been sold. The systems sim-

plicity and long record of eld reliability have made it the ignition of

choice for operators of low-horsepower industrial engines.

ALTRONIC IIFOR LARGE GAS ENGINES 3-20 CYLINDERS

Altronic II provides a self-powered, capacitor discharge systemfor large-bore, slow-speed gas engines. With four different internalgear ratios, base or ange mounting, and three drive coupling choic-es, Altronic II can be readily specied to replace most older magnetoor breaker-point ignition systems. Altronic II can be used on engines

with either one or two spark plugs per cylinder.

With an operating base of thousands of units, Altronic II has aproven record for reliability. Users can also easily upgrade to the

Altronic II-CPU system while retaining the Altronic II alternator section

to supply system power requirements.

ALTRONIC IIIFOR MEDIUM-SIZED ENGINES 2-16 CYLINDERS

With over 40,000 units in the eld, Altronic III has become theindustry standard system for medium-sized stationary gas engines.

Altronic III is offered with seven mounting variations and six internalgear ratios to t virtually any application in its class. Three types ofelectronic timing control are also offered: dual timing settings, timingvs. RPM and timing vs. 4-20 milliamp signal. Ease of service is as-

sured by the replaceable back cover, which contains all the systemelectronics.

Other options include a choice of standard or long spark duration

coils in both unshielded and shielded versions. Altronic III can alsobe upgraded to the benets of crankshaft-referenced, electronically-

controlled timing refer to the Altronic III-CPU system.

ALTRONIC VFOR SMALL 1-6 CYLINDER IN-LINE ENGINES

Altronic V offers the same design features, installation ease,dependability and serviceability that are built into Altronic III, but in asmaller package. Six mounting variations and a dual-position elec-tronic timing option are additional features.

Altronic V affords small engine users a cost-effective replacement forobsolete and maintenance-intensive breaker-point magneto systems.

SOLID-STATE/MECHANICAL IGNITION SYSTEMS


6/12

Description and features:

Single pickup operation

Precision-machined timing disc accurate to 0.1 degree

Incremented manual timing switches for known adjustments

LED diagnostics for power, pickup, application faults

Suitable for lean-burn engines

12-24 Vdc powered

Full output at engine cranking RPM

The Altronic DISC-TRIGGERED digital ignition systems consist ofan ignition unit, a magnetic or Hall-effect pickup, a timing discmounted to the engine crankshaft or camshaft, wiring harnesses,and an appropriate number of ignition coils. These systems employ aCYLINDER POSITION SENSING design,typically using a single pickup and onetrigger event per cylinder, which may bederived from an Altronic timing disc or

holes/protrusions in the engine ywheel orcamshaft gear. The pickup and timing discprovide accurate timing reference signalsto the ignition unit, which calculates thecorrect ignition timing point. The systemsfeature high-energy, capacitor-dischargeoutput supplying over 40KV with sparkduration up to 600 microseconds.

These innovative and reliable systemscan be applied to a variety of engines, in-cluding heavy-duty vehicular applicationsas well as engines incorporating lean-burntechnology. Timing discs are manufac-

tured to an accuracy of 0.1 degree, thuseliminating variations caused by drillingtiming holes in the eld.

CERTIFIEDCLASS 1, DIV. 2, GROUP DNOTE: Hazardous area certicationsdo not include the CD1 or non-shieldedCD200 systems.

DISC-TRIGGERED DIGITAL IGNITION SYSTEMS


7/12

CD1/CD200 FAMILY

FOR SMALL ENGINES TO 8-CYLINDERSThe Altronic CD1 Digital Ignition System has been developed for

application on small, stationary industrial engines up to 8 cylinders. This

moderately-priced, easily installed system utilizes a low-cost magneticpickup sensing drilled holes (usually in the engine ywheel) to determine

the angular position of the crankshaft. LED indicators give diagnosticsignals regarding input power, the pickup signal, and correct ignition unitoperation. Individual coils or economical multi-cylinder coil modules canbe used in conjunction with the CD1 system.

Beyond the CD1, substantial capability for this same class/size ofindustrial gas engine is avaliable in the CD200 Universal Small EngineDigital Ignition System. These innovative designs employ microproces-

sor technology and are fully congurable for a range of suitable 1-8cylinder engine models and ring patterns. While utilizing thesame single pickup arrangement employed in the CD1 system, theCD200 features complete application exibility through the use of

an advanced, ModBus RTU-driven, Windows-based terminalprogram. Performance enhancement features resident in the CD200include adjustable output energy and automatic timing adjustmentcurves. Diagnostics associated with system operation, as well as theprimary and secondary discharge functions, are communicated via on-

board LEDs as well as through the terminal program. Integral overspeedshutdown protection is also included.

Two versions of the CD200 system are available. The standard CD200

systems (791070-X) are used with unshielded system componentsand ignition coils. For applications requiring service in hazardous areas(Class I, Division 2, Groups C and D), a special, CSA-certied series ofCD200 systems is available (791080-X). This latter version utilizes shielded

primary input and output harnesses as well as CSA-certied ignition coils

(shielded and integral-style). Both the unshielded and CSA-certied ver-sions are available in 6 and 8-output congurations.

DISN 800C/801C/801M

FOR MEDIUM-SIZED INDUSTRIAL ENGINESThe DISN is a full-featured industrial ignition system for small- to

medium-sized stationary engines up to 16 cylinders. The DISN system isintended for compression-stroke ring and usually uses a single pickup

sensing, precision-machined timing disc rotating at engine camshaftspeed. If crankshaft-referenced timing is desired, two pickups are used:one sensing ring magnets placed in the engine ywheel and the secondsensing a single index magnet rotating at camshaft speed.

Three basic series are available: 800C, 801C and 801M. All offer upto eight ring patterns in a common unit and are available in 8, 12 or16-output models, each with multiple applications. The DISN systems

also incorporate four advanced timing control options: manual 16-position timing switch, one-step timing change, remote potentiometertiming control or control from a 4-20 milliamp analog signal. Three LEDdiagnostic indicators give an instant indication of the basic incoming

power and pickup signals. The new cast housing offers superiorprotection in harsh environments.

The DISN 801C series offers offset timing programmed in selected

cylinders (for use with detonation detection systems) and two levels ofspark energy. The 801M version is for engines with 4-12 cylinders anduses more economical connectors, pickups and triggering components.

DISC-TRIGGERED DIGITAL IGNITION SYSTEMS


8/12

CERTIFIEDCLASS 1, DIV. 2, GROUP D

T he Altronic CPU CRANKSHAFT-REFERENCED systems consist ofan ignition unit, two magnetic pickups and cables, a primary wiringharness and an ignition coil for each spark plug. These systems employa CONTINUOUS CRANKSHAFT SENSING design. One magnetic pickupinputs signals from the engine ring-gear or holes drilled in the ywheel;the second pickup senses a revolution/reset event giving precise information onthe location of the crankshaft. On 4-cycle

engines, a reference signal at enginecamshaft speed is used to determine thecompression cycle. A replaceable memorychip, programmed with the enginesapplication data, operates with the CPUsdigital circuitry to output precise ringpulses to the ignition coils.

The Altronic CPU systems eliminate allmechanical wearing parts gears, chains,couplings, etc. Ignition timing is precise inall cylinders due to crankshaft-referencedtiming. All CPU systems feature manualtiming adjustment, one-step timing capabil-

ity and electronic timing control from a 4-20milliamp signal.

CPU-95 and CPU-2000 are second-gen-eration, microprocessor-based crankshaft-referenced systems that add comprehensivedisplay and diagnostic capabilities seenext page.

Description and features: Common unit with replaceable, programmed EPROM

Stable, crankshaft-referenced timing

Multiple electronic timing modes

Custom timing curves available Incremented manual timing switches for known adjustments

High-energy, capacitor discharge ignition

Suitable for lean-burn engines

CRANKSHAFT-REFERENCED DIGITAL IGNITION SYSTEMS


9/12

ALTRONIC CPU-95 FOR MEDIUM STATIONARY ENGINESThe Altronic CPU-95 is a DC-powered, capacitive discharge digital igni-

tion system for medium-sized industrial gas engines to 20 cylinders.

The Display Module, typically mounted in the engine control panel,

gives the user convenient access to critical operating information such asignition system mode, engine speed, system diagnostics and setup func-tions, and the value of the 420mA signal being used for automatic timingcontrol and the timing of the ignition system.

State-of-the-art combustion enhancement tools, including multistrike(two full-energy spark events), and automatic spark energy adjustment

(incrementally raising required spark energy) help to minimize misre andthus improve fuel economy and reduce exhaust emissions. Individual cylin-der timing control strategies can also be incorporated.

Proprietary diagnostic capabilities for monitoring the system, as wellas the primary and secondary discharge diagnostic functions, are built intothe CPU-95. These patented diagnostics offer users a means of continually

monitoring spark plug wear and combustion stability without the addition

of special ignition coils or high voltage probes.Special CPU-95 models:CPU-95C Developed for use on SI Controller-equipped Caterpillar3500-series engines, the CPU-95C system replaces both the existing

Altronic III unit and AIB box. Its installation allows for full access to thecritical operational and diagnostic information and enhanced sparkcharacteristic control resident in standard CPU-95 systems.

CPU-95 VariSpark The CPU-95 VariSpark system is aninnovative CPU-95 variant which utilizes capacitive-discharge ignitiontechnology to deliver a long-duration spark typical of an inductive igni-tion system. This model is of particular interest to operators of

large bore, low-BMEP engines that exhibit ignitability or combustionstability problems.

ALTRONIC CPU-2000 FOR LARGE STATIONARY ENGINESThe DC-powered CPU-2000 system is designed for application on

all large-bore stationary gas engines and can accommodate virtually any

engine ring pattern. A single, universal CPU-2000 Logic Module canbe used in conjunction with either a 16 or a 32-output Ignition OutputModule thus minimizing the number and variety of ignition components.A simple terminal program allows one unit to t all applications, and a eld-

replaceable memory minimizes overall engine downtime in the event thatthe ignition system requires replacement.

This second-generation digital crankshaft-referenced system alsointegrates sophisticated combustion enhancement tools, and communi-

cations capabilities. The quad-strike function (four full-energy strikes),present in the CPU-2000, has been proven highly effective in ignitinglean mixtures for lower exhaust emissions, as well as for improved fueleconomy on engines that suffer from poor air/fuel mixing and scavenging.An on-board RS-485 serial port with MODBUS capability for integrationinto planned or existing control systems is also available.

Comprehensive system diagnostics, with primary and secondarydischarge monitoring functions, are built into the CPU-2000 DiagnosticModule. This innovative diagnostic method patented by Altronic requires noadditional probes or special ignition coils, yet offers users effective tools for

monitoring spark plug wear and other ignition or combustion abnormalities.This spark demand monitoring capability can be used to automatically raisethe delivered energy as the spark plugs wear calling for higher voltage.

CRANKSHAFT-REFERENCED DIGITAL IGNITION SYSTEMS


10/12

IGNITION COILS

The ignition coil is a nal and most critical component in the ignition sys-tem performance chain. Available in several electrical and physical congura-tions, Altronic coils are produced in a new, state-of-the-art facility the mostadvanced in the world dedicated solely to industrial engine ignition coils. The

plant incorporates advanced, customized equipment and manufacturing pro-cesses to assure consistent, high quality production of high voltage coils acomponent very sensitive to process variations.

For optimum performance and reliability, the ignition coil must be properlymatched to the ignition system output characteristics. Despite look-alike ap-pearance, other sources of coils simply are not the same internally, and dontoffer comparable output and quality.

A variety of coils are offered to meet application requirements (see chartfor variations):

Unshielded Round Case Coils The standard of unshielded coils, the

well-known Altronic blue, red and black variations are used in applicationsnot requiring hazardous area certications.

Unshielded Square Case Coils An alternative to the round case de-sign, these coils have extended spark duration.

Flange Mount Coils The same internal structure as the unshielded coilpackaged in the convenient 3-bolt ange mount conguration. Flangemount coils are designed to mount to the valve covers on a number ofpopular, modern gas engines.

Shielded Coils Shielded versions are encased in stainless steel hous-ings and are CSA-certied for Class I, Division 2, Group D areas. Steel

shell primary connectors are used to take the rough handling of industrialmarket applications.

Integral Coils Designed to mount directly to special threaded spark

plugs, integral coils have stainless steel housings and are CSA-certied forClass I, Division 2, Group D areas. Steel shell primary connectors are used

to take the rough handling of industrial market applications.

Note: To maintain the CSA system certifcation, all coils (shielded or

integral types) and all primary and secondary components must be

CSA-certifed Altronic parts.

0

IGNITION SYSTEM ACCESSORIES


11/12

24 VDC ALTERNATOR POWER PACKAGESThe alternator power packages are designed to deliver up to 70 watts

of DC power to users wishing to operate the latest DC-powered ignitionsystems, instrumentation, and control products, on installations lackingaccess to electrical service. To promote easy eld retrot, the alterna-tor units are designed to mate directly to various ange-mount magnetodrive congurations. A belt-driven version is also available.

Two variations of the power package system are offered:

Version I Consists of an alternator, voltage regulator, battery packand cable. This system can furnish up to 4 amps at 24 Vdc for power-ing ignition, instrumentation and controls.

Version II Consists of an alternator, voltage regulator and cableoptimized to make a self-powered ignition system for the AltronicCPU-90 or DISN. No battery is used with the Version II system.

FLASHGUARD, SHIELDED, and SAFE-T-LEAD

SPARK PLUG LEADSAltronic offers a complete line of universal and custom Flashguard

spark plug leads. These premium secondary leads are designed with a

5,000-ohm integral resistor and with tight-tting silicone or Teon bootsfor reduced emitted RFI, minimized ashover, and improved spark plug life.

For those operating in Division 2 hazardous areas, Altronic offerstwo certied secondary lead styles designed for use with shielded sparkplugs. The traditional braided stainless-steel lead is certied as safe for

use in Class I, Division 2, Group D hazardous areas. As an alternative, theAltronic Safe-T-Lead is a non-metallic lead designed for use in con-junction with shielded ignition coils and spark plugs, but eliminates thecorrosion and spark plug life issues associated with traditional metallic

leads. The non-metallic nature of the Safe-T-Lead lead also enables theuser to employ traditional diagnostic tools such as an ignition timing lightin troubleshooting the ignition system and the engine.

See the Altronic Industrial Spark Plug and Ignition Accessories cata-

log for further details.

FLASHGUARD SPARK PLUGSAltronic offers a series of high quality spark plugs engineered and

manufactured specically for use in stationary gas engines. Incorporat-

ing a number of unique design elements, the Altronic Flashguard sparkplugs are available with both massive and precious metal electrodes(including an iridium/platinum model), in 14mm, 18mm, and 7/8"-18 sizes,and in both shielded and unshielded congurations. All Flashguardspark plugs feature an extended ceramic insulator and proprietary nose

cone design for maximum ashover resistance, and a high ohmic internalresistor for reduced RFI and improved spark plug service life.

See the Altronic Industrial Spark Plug and Ignition AccessoriesCatalog for further technical and application details.

IGNITION SYSTEM ACCESSORIES


12/12

F AIS C 07 Alt i I 2007

Frank BalkGeneral Manager

[email protected]

Tjeerd Van Eif

International Area Manager,Europe

[email protected]

Pavel PavlovArea Manager, Russia and CIS

[email protected]

SALES/SERVICE CONTACTS

David BellVice President

Aftermarket Sales and Service

[email protected]

Keith BrooksVice President

OEM Sales

[email protected]

Matt DonhamOEM Sales Representative

[email protected]

Sandy WinansInside Sales Representative

[email protected]

Tom SmithDirector of Service Operations

[email protected]

Paul McHenrySenior Technical Service Engineer

[email protected]

Rich HallTechnical Support Representative

[email protected]

Chuck CooperTechnical and Marketing

Communications Manager

[email protected]

Pam BrooksAdministrative Assistant

[email protected]

Altronic, Inc.

712 Trumbull AvenueGirard, Ohio 44420

P: (330) 545-9768

F: (330) 545-9005

[email protected]

Altronic Europe

De Tienden 50A5674 TB Nuenen

The Netherlands

P: 011-31-40-2906270

F: 011-31-40-2838990

[email protected]

ataengine-altronic

Documents