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Ignition Systems

for Industrial Engines


Altronic Ignition Systems

CONTENTS

Altronic Ignition Systems Overview and Guide


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

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

Solid-State/Mechanical Ignition Systems


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

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

Disc-Triggered Digital Ignition Systems


Theory and Overview......................................................................................... 6

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

Crankshaft-Referenced Digital Ignition Systems


Theory and Overview......................................................................................... 8

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

Crankshaft-Referenced, Directed Energy Digital Ignition Systems


CPU-XL VariSpark........................................................................................... 10

Ignition Coils.................................................................................................... 12

Conversion Kits for Caterpillar Engines.......................................................... 14

Flashguard® Spark Plugs & Secondary Leads, 24V Alternator Systems....... 15

Pushing the Performance Envelope: Altronic Ignition Systems and Accessories


Girard, Ohio-based Altronic, LLC has spent much of the last Browsing through these pages will give you a good overview of
40 years defining and redefining the state-of-the-art when it both the evolution of the Altronic ignition and ignition accessory
comes to ignition systems and accessories for industrial natural product line, as well as a good idea about the system options
gas-fueled engines. As a result of this constant attention to available for your specific make and model of engine.
product development and manufacturing excellence, engine
manufacturers and end users alike from around the world
continue to turn to Altronic first for technically-advanced, high-
quality ignition systems and components.

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© ALTRONIC, LLC 2012 2
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Altronic Ignition Systems Application Guide

CPU- CPU-
2000 2000
No. ALT. ALT. ALT. CD1 DISN CPU- CPU- No. ALT. ALT. ALT. CD1 CD200 CPU- CPU-
Engine Manufacturer Cyls. I III V CD200 CD200 95 XL Engine Manufacturer Cyls. I III V CD200 DISN 95 XL

AJAX 1-2 R O O JENBACHER 6-8 O O R R

3 R R O O 12-16 O R R

4 R O O 18-20 O R

ALCO 6-16 O R KUBOTA 1 R

ALLIS-CHALMERS 4-6 O R LISTER 2-3 R R

ARIEL 1-2 R O LORAIN 1 R

ARROW 1 R LUFKIN 2 R O

2 R O MAN 6-12 R R

BELL 1 R MAN
6-18 O R
(BRONS-CROSSLEY)
BUDA 6-8 O R
M.E.P. 4-12 O O R O
CATERPILLAR 4-6 O O O R R R
MINNEAPOLIS-MOLINE 4-6 O O R
8-16 O R R
MITSUBISHI 6-18 R R
CHICAGO PNEUMATIC 8-10 R
MWM (DEUZ) 6-16 O R
CLARK 1-2 R
NIIGATA 6-18 R
3-8 O O R R
NORDBERG 6-16 R
10-12 O R
OILWELL (WHITE) 1-2 R
16-20 R
PERKINS 6-16 R
CLIMAX 6-12 O R
ROLLS-ROYCE (BERGEN) 6-18 R
CONTINENTAL 3-6 O O R
ROILINE 6-12 O R
CONTINENTAL-EMSCO 1-2 R O
RUSTON 6-12 R O
COOPER-BESSEMER 1-2 R
SACM 6-16 O R
3-8 O O R R
SCANIA 6 R R
10-12 O R
SUPERIOR 6-16 O O R O
16-20 R
VALMET (SISU) 3-6 R R
CUMMINS 4-6 O O O R R
WAUKESHA 4-6 O R R O
12-16 O R R
6-16 O R R
DE LAVAL 6-16 R
WORTHINGTON 3-10 O O R
DEUTZ 2-6 O O R R
12-20 R
8-16 O R
R = Recommended system for application. O = Optional system for application.
DORMAN 3-6 R O R

6-16 O R

FAIRBANKS MORSE 1 R

FORD 4-6 O R

8 R O

GEMINI 1-2 R CERTIFIED FOR USE IN


HAZARDOUS LOCATIONS
GUASCOR 6-16 O R R NOTE: Most, but not all, Altronic ignition
systems and accessories in this catalog
HERCULES (WHITE) 4-6 O O R
are CSA certified and compliant with the
INGERSOLL RAND 1-2 R appropriate CE/ATEX regulations. Check
each product listing for certification and
4-16 O O R R hazardous area classification.

INTERNATIONAL 4-6 O R

IVECO 6-12 R R

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© ALTRONIC, LLC 2012 3
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Solid-State/Mechanical Systems

Altronic solid-state ignition systems


consist of a self-powered ignition unit,
a wiring harness and an appropriate
number of ignition coils. Operating power
is provided by a self-contained, multi-
pole perma­nent magnet alternator that
charges an energy storage capacitor.
Pick­-up coils, triggered magnetically,
provide the 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
components, to the ignition coil of the
proper cylinder. Electronics are mounted
on easy to replace plug-in modules.
CERTIFIED
Drive couplings are furnished in
CLASS 1, DIV. 2,
synthetic elastomer materials for low GROUP D
wear and long life. They also serve to
dampen part of the engine drive train Application Data
vibration. Combined with the smooth IGNITION SYSTEM POWER SOURCE CYLINDERS APPLICATIONS
Small in-line engines
rotational cycle of the Altronic alternator, Altronic I Self-powered 1-6
Horizontal 1-3 cyl. engines
these features contribute to the long Altronic II Self-powered 3-20 Large bore, slow speed engines
mechanical life designed into Altronic Altronic III Self-powered 2-16 Medium-sized industrial engines

solid-state systems. Altronic V Self-powered 1-6


Small in-line engines
Horizontal 1-3 cyl. engines

„„ Alternator powered
TYPICAL CYLINDER BORE SIZE (MM)
„„ Capacitor discharge ignition
100 125 150 175 200 225 250 275 300 325 350 375 400 425

„„ Replaces magneto, breaker points Altronic I *


and impulse coupling Altronic II
Altronic III
„„ High output at engine cranking RPM
Altronic V *
„„ Extended spark life * Also applies to larger bore, horizontal 1-3 cylinder engines

„„ Easy to service with plug-in modules

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© ALTRONIC, LLC 2012 4
AIS-C 3-12
Solid-State/Mechanical Systems

Altronic I for Small Engines, vs. RPM and timing vs. 4-20 milliamp
1-6 cylinder In-Line and signal. Ease of service is assured by the
1-3 cylinder Horizontal replaceable back cover, which contains

Altronic I, first introduced in 1966, all the system electronics.

brought the advantages of capacitor Other options include a choice of standard


discharge ignition to industrial gas or long spark duration coils in both
engines. It consists of a small permanent unshielded and shielded versions. Altronic
older magneto or breaker-point ignition
magnet alternator with a plug-in III can also be upgraded to the benefits
systems. Altronic II can be used on
electronic module attached. Timing is set of crankshaft-referenced, electronically-
engines with either one or two spark
by one or more remote mounted pick-up controlled timing — refer to the Altronic
plugs per cylinder.
sensing magnets III-CPU system.
With an operating base of thousands of
referenced
units, Altronic II has a proven record
to the engine Altronic V for Small In-Line Engines,
for reliability. Users can also easily
crankshaft. 1-6 cylinder
upgrade to the Altronic II-CPU system
On horizontal Altronic V offers the same design
while retaining the Altronic II alternator
engines, these features, installation ease, depend­ability
section to supply system power
are typically
requirements.
mounted on the
flywheel; on in-line engines, a magnet
disc is used. The alternator performs Altronic III for Medium-Sized Engines,
no timing function and can thus be 2-16 cylinders
either belt- or coupling-driven. The only With over 40,000 units in the field,
moving part is the alternator’s sealed, Altronic III has become the industry
underloaded ball bearing. standard system for medium-sized
Over 60,000 Altronic I systems have stationary gas engines. Altronic III is
been sold. The system’s simplicity and
long record of field reliability have made and serviceability that are built into
it the ignition of choice for operators of Altronic III, but in a smaller package. Six
low-horsepower industrial engines. mounting variations and a dual-position
electronic timing option are additional
Altronic II for Large Gas Engines, features.

3-20 cylinders Altronic V affords small engine users a

Altronic II provides a self-powered, cost-effective replacement for obsolete

capacitor discharge system for large- and maintenance-intensive breaker-point


offered with seven mounting variations magneto systems.
bore, slow-speed gas engines. With
and six internal gear ratios to fit virtually
four different internal gear ratios,
any application in its class. Three types
base or flange mounting, and three
of electronic timing control are also
drive coupling choices, Altronic II can
offered: dual timing settings, timing
be readily specified to replace most

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© ALTRONIC, LLC 2012 5
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Disc-Triggered Digital Ignition Systems
The Altronic disc-triggered digital ignition
systems consist of an ignition unit, a
magnetic or Hall-effect pickup, a timing
disc mounted to the engine crankshaft
or camshaft, wiring harnesses, and an
appropriate number of ignition coils.
These systems employ a cylinder position
sensing design, typically using a single
pickup and one trigger event per cylinder,
which may be derived from an Altronic
timing disc or holes/protrusions in the
engine flywheel or camshaft gear. The
pickup and timing disc provide accurate
timing reference signals to the ignition
unit, which calculates the correct ignition
timing point. The systems feature
high-energy, capacitor-discharge output
supplying over 40KV with spark duration
up to 600 microseconds.
These innovative and reliable systems
can be applied to a variety of engines, CERTIFIED
CLASS 1, DIV. 2,
including heavy-duty vehicular
GROUP D
applications as well as engines NOTE: Hazardous
incorporating lean-burn technology. area certifications
do not include the
Timing discs are manufactured to an
CD1 or non-shielded
accuracy of 0.1 degree, thus eliminating CD200 systems.
variations caused by drilling timing holes
in the field. Application Data
IGNITION SYSTEM POWER SOURCE CYLINDERS SPECIAL FEATURES
„„ Single pickup operation
12-24Vdc or Universal, low cost CD200 system available in shielded
CD1 1-8
„„ Precision-machined timing disc DC alternator and CSA certified versions

accurate to 0.1 degree CD200


12-24Vdc or
1-16 Unshielded or shielded industrial system, CSA certified
DC alternator
„„ Incremental manual timing switches 12-24Vdc or
DISN 800C 4-16 Unshielded or shielded industrial system, CSA certified
for known adjustments DC alternator

„„ LED diagnostics for power, pickup,


TYPICAL CYLINDER BORE SIZE (MM)
application faults
100 125 150 175 200 225 250 275 300 325 350 375 400 425

„„ Suitable for lean-burn engines CD1


CD200
„„ 12-24Vdc powered
DISN 800C
„„ Full output at engine cranking RPM

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© ALTRONIC, LLC 2012 6
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Disc-Triggered Digital Ignition Systems
CD1 for Small Engines to 8-cylinders the CD200-90 fulfills the same role with DISN 800C for Medium-Sized
The Altronic CD1 Digital Ignition System respect to the widely-used DISN800C Industrial Engines
has been developed for application on system. The DISN is a full-featured industrial
small, stationary industrial engines up to ignition system for small- to medium-sized
8 cylinders. This moderately- The CD200 family features complete stationary engines up to 16 cylinders. The
priced, easily installed application flexibility through the use DISN system is intended for compression-
system utilizes a low- of an advanced, ModBus RTU-driven, stroke firing and usually uses a single
cost magnetic Windows™-based terminal program. Per- pickup sensing, precision-machined
pickup sensing formance enhancement features resident timing disc rotating at engine camshaft
drilled holes in these systems include adjustable out- speed. If crankshaft-referenced timing is
(usually in the put energy and automatic timing adjust- desired, two pickups are used: one sens-
engine flywheel) ment curves. Diagnostics associated with ing firing magnets placed in the engine
to determine the system operation, as well as the primary flywheel and the second
angular position of the and secondary discharge functions, are sensing a single index
crankshaft. LED indicators give diagnos- communicated via on-board LEDs and magnet rotating
tic signals regarding input power, the a powerful PC-based terminal program. at camshaft
pickup signal, and correct ignition unit Integral overspeed shutdown protection is speed. DISN
operation. Individual ignition coils are also included. offers up to
used with the CD1 system. eight firing patterns
A full assortment of unshielded and in a common unit
CD200 for Small shielded harnesses, and other accessories, and is available in
and Medium- is available. 8, 12 or 16-output
Sized Industrial models, each with multiple applications.
Engines CD200-70 CD200-80 CD200-90 The DISN systems also incorporate four
The Altronic CD200 Cylinder advanced timing control options: manual
1-8 1-8 6-16
Range
family is a micro- 16-position timing switch, one-step timing
CSA
processor- No Yes Yes
Certified change, remote potentiometer timing con-
based Signal MPU MPU
MPU or trol or control from a 4-20 milliamp analog
Hall-effect
series signal. Three LED diagnostic indicators
Same as Same as Same as
Mounting
with CD1 CD1 DISN give an instant indication of the basic
three incoming power and pickup signals. The
vari- cast housing offers superior protection in
ations harsh environments.
providing
substan-
tial additional
features over the base
CD1 and the older DISN800C products.
The CD200-70 and -80 are designed
as successors to the CD1 model, while

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© ALTRONIC, LLC 2012 7
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Crankshaft-Referenced Digital Ignition Systems

The Altronic CPU crankshaft-referenced


systems consist of an ignition unit,
two magnetic pickups and cables, a
primary wiring harness and an ignition
coil for each spark plug. They employ a
continuous crankshaft-sensing design.
One magnetic pickup inputs signals
from the engine ring-gear or holes drilled
in the flywheel; the second pickup
senses a revolution/reset event giving
precise information on the location of
the crankshaft. On 4-cycle engines, a
reference signal at engine camshaft speed
is used to determine the compression
cycle. A replaceable memory chip,
programmed with the engine’s application
data, operates with the CPU’s digital
circuitry to output precise firing pulses to
the ignition coils.
Altronic CPU systems eliminate
mechanical wearing parts — gears,
chains, couplings, etc. Ignition timing is
precise in all cylinders due to crankshaft-
referenced timing. All CPU systems
feature manual timing adjustment, CERTIFIED
CLASS 1, DIV. 2,
one-step timing capability and electronic
GROUP D
timing control from a 4-20 milliamp
signal. Application Data
„„ Single pickup operation IGNITION SYSTEM POWER SOURCE CYLINDERS SPECIAL FEATURES
24Vdc or Adds display of operational and primary/secondary
„„ Precision-machined timing disc CPU-95 3-18
DC alternator diagnostic features
accurate to 0.1 degree Adds operational and diagnostic displays:
CPU-2000 24Vdc 3-30
multi-strike feature
„„ Incremental manual timing switches
for known adjustments
TYPICAL CYLINDER BORE SIZE (MM)
„„ LED diagnostics for power, pickup, 100 125 150 175 200 225 250 275 300 325 350 375 400 425

application faults CPU-95


CPU-2000
„„ Suitable for lean-burn engines

„„ 12-24Vdc powered

„„ Full output at engine cranking RPM

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© ALTRONIC, LLC 2012 8
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Crankshaft-Referenced Digital Ignition Systems

Altronic CPU-95 for Medium without the addition of special ignition This second-generation digital crankshaft-
Stationary Engines coils or high voltage probes. Special CPU- referenced system also integrates
The Altronic CPU-95 is a DC-powered, 95 models: sophisticated combustion enhancement
capacitive discharge digital ignition „„ CPU-95C — Developed for use on tools and communications capabilities.
system for medium-sized industrial gas SI Controller-equipped Caterpillar The quad-strike function (four full-
engines to 20 cylinders. The Display 3500-series engines, the CPU-95C energy strikes), present in the CPU-
Module, typically mounted in the engine system replaces both the existing 2000, is highly effective in igniting lean
control panel, gives the user convenient Altronic III unit and AIB box. Its mixtures for lower exhaust emissions,
access to critical operating information installation allows for full access to and improved fuel economy on engines
such as ignition system mode, engine the critical operational and diagnostic that suffer from poor air/fuel mixing
speed, system diagnostics and setup information and enhanced spark and scavenging. An on-board RS-485
functions, and the value of the 4–20mA characteristic control resident in serial port with MODBUS capability
signal being used for automatic timing standard CPU-95 systems. for integration into planned or existing
control and the timing of the ignition control systems is also available.
„„ CPU-95 VariSpark™ — an innovative
system. State-of-the-art combustion variant which uses capacitive- Comprehensive system diagnostics,
enhancement tools, including multistrike discharge ignition technology to with primary and secondary discharge
(two full-energy spark events), and deliver a long-duration spark, typical monitoring functions, are built into the
automatic spark energy adjustment of an inductive ignition system. This CPU-2000 Diagnostic Module. This
(incrementally raising required spark model is of particular interest to innovative diagnostic method patented
energy) help to operators of large bore, low-BMEP by Altronic requires no additional probes
minimize misfire engines that exhibit ignitability or or special ignition coils, yet offers users
and thus improve combustion stability problems. effective tools for monitoring spark plug
fuel economy wear and other ignition or combustion
and reduce Altronic CPU-2000 for Large abnormalities. This spark demand
exhaust Stationary Engines monitoring capability can be used to
emissions. The DC-powered CPU-2000 system is automatically raise the delivered energy
Individual designed for application on all large- as the spark plugs wear calling for higher
cylinder bore stationary gas engines and can voltage.
timing control accommodate virtually any engine firing
strategies pattern. A single, universal CPU-2000
can also be Logic Module can be used in conjunction
incorporated. with either a 16 or a 32-output Ignition
Proprietary diagnostic capabilities Output Module thus minimizing
for monitoring the system, as well as the number and variety of ignition
the primary and secondary discharge components. A simple terminal program
diagnostic functions, are built into the allows one unit to fit all applications, and
CPU-95. These patented diagnostics offer a field-replaceable memory minimizes
users a means of continually monitoring overall engine downtime in the event that
spark plug wear and combustion stability the ignition system requires replacement.

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© ALTRONIC, LLC 2012 9
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Crankshaft-Referenced Directed Energy Digital Ignition Systems
The capacity of a conventional is discharged into the ignition coil/ including the traditional peak of current
capacitive-discharge (CD) ignition spark plug during each spark event. This registered during the breakdown phase
system to deliver voltage and current to allows for a specified, pre-fabricated and a general decline in the delivered
the spark plug and air/fuel mixture has spark profile—inclusive of both delivered current through the duration portion of
traditionally been governed by the design voltage and current, as well as multiple the spark event. Through a modulation of
of the ignition system and the associated strikes. The result: delivered energy the applied spark energy, the realizable
ignition coil (transformer). The standard (voltage, current, and number of strikes) spark voltage can reach 50,000 volts
CD ignition system uses a capacitor to the air/fuel mixture in the cylinder that and the delivered energy per spark
charged to full voltage. When triggered, assures combustion. event can reach as high as twenty times
it is fully discharged during each spark that provided in a conventional spark.
event. This spark is characterized by a VOLTAGE The concept of “shaping the spark” to
peak of both voltage and current during dynamically optimize the performance
the breakdown phase with both declining of the engine and to provide combustion
through the ionization, duration, and assurance for fuel economy, emissions,
ring-down phases. and operating reliability is a reality.
CURRENT Multiple strikes of varying duration, single

VOLTAGE strikes with escalating current, long


The above diagram illustrates that the duration single strikes and combinations
rules associated with a CD spark no longer of all of the above are made possible by
apply with a Directed Energy System— the Directed Energy technology.

CURRENT
CPU-XL VariSpark System Diagram

The above diagram depicts a conventional


CD spark breakdown event. A duration
of approximately 300µsec is determined
largely by the coil characteristics. The
energy in the ring-out pattern following
the breakdown phase represents lost
energy. If additional energy is supplied
from the ignition driver in the form of a
higher primary voltage, some additional
duration is achieved but the conversion
efficiency is increasingly lower.

A Directed Energy System takes a


different approach. Instead of fully
discharging the (very large) capacitor, a
measured amount of current and voltage

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© ALTRONIC, LLC 2012 10
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CPU-XL VariSpark Advanced Digital Ignition System

The Altronic CPU-XL VariSpark is a ary voltage and current delivered to the „„ Innovative and patented (U.S.
24-VDC-powered digital ignition system spark plug and air/fuel mixture can be Patent 7,401,603) Directed Energy
for large gas engines and integral com- matched—and dynamically adjusted—to spark control capability optimizes
pressors. It combines the reliability and meet the operating requirements and performance on emissions-controlled
operating simplicity of first- and second- conditions of the engine, thus assuring engines as well as on applications
generation ignition systems such as the combustion. Supported by Altronic’s dis- experiencing wide variations in
II-CPU and CPU-2000, with Altronic’s charge diagnostics, the CPU-XL VariSpark operating and ambient conditions
newly-patented spark control capability system delivers an unparalleled combina- „„ Incorporates an engine-specific
and system diagnostics. tion of features and capabilities. ignition coil/EZRail system rail
for cost-effective installation and
Combustion assurance across a wide To insure a high level of convenience and operation
range of operating and in-cylinder a minimum level of new product training,
„„ Comprehensive system and spark
conditions is the goal of the CPU-XL the operating philosophy and functional-
discharge diagnostics help to insure
system. The CPU-XL system stretches ity is very similar to other Altronic digital
the swift identification of operating
the envelope of successful operation, ignitions, including the CPU-2000. The
issues and to minimize associated
allowing combustion to take place under CPU-XL VariSpark incorporates modular
engine downtime
difficult circumstances, such as operating system construction, including standard
near the lean misfire limit for emissions, system harnesses with a unique ignition „„ System timing, spark profile, and
under lighter loads, or on engines that coil/EZRail combination. The availability access to all other system options
mix the air/fuel charge poorly. This is of all of these components as purchased and diagnostics are available from the
possible through the introduction of a parts limits on-engine fabrication and al- system keypad and graphical display,
controllable, selectable spark profile, lows for simpler system troubleshooting. as well as remotely via Modbus RTU
optimized for those conditions, a Directed communications
Energy spark. By choosing one of eight „„ State-of-the-art, crankshaft-referenced
waveforms, including several which can digital ignition system for natural-gas
deliver secondary current levels as much fueled integral compressor engines
as twenty times that of a conventional
„„ CSA-certified for Class I, Division 2,
capacitive discharge spark, the second-
Groups C & D hazardous areas

Combustion Assurance for:


„„ IMPROVED FUEL PERFORMANCE

„„ IMPROVED EMISSIONS

„„ IMPROVED RELIABILITY

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© ALTRONIC, LLC 2012 11
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Ignition System Accessories

Ignition Coils
The ignition coil supplies the high voltage
spark, and is therefore one of the most
critical components in the ignition system
performance chain. Available in several
electrical and physical configurations,
Altronic ignition coils are designed
and produced in a new, state-of-the-
art manufacturing facility in Ohio—the
most advanced in the world dedicated
to production for use exclusively on
stationary industrial engine applications.

To insure optimum performance,


reliability, and service life, the ignition
coil must be designed and matched for
State-of-the-art coil production facility
use with the selected ignition system.
Despite look-alike appearance, non-
Altronic coils do not deliver the same
performance or reliability.

Unshielded Round Case Coils Primary winding Secondary winding Secondary winding Coil assembly
The standard for unshielded
coils, the well-known
Altronic blue, red and
black variations are
used in applications not
requiring hazardous area Coil assembly Coil assembly Coil assembly Baking eliminates moisture

certifications.

Unshielded Square Case Coils


An alternative to the round
case design, these coils
have extended spark Sealing with epoxy Curing in the oven Testing and validation Finished coils
duration.

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© ALTRONIC, LLC 2012 12
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Ignition System Accessories

Flange Mount Coils Integral Coils Variable Duration/Directed Energy Coils


The same internal structure Designed to mount directly Altronic’s directed energy ignition
as the unshielded coil to special threaded spark systems—including the CPU-XL
packaged in the convenient plugs, integral coils have VariSpark system—incorporate a
3-bolt flange mount stainless steel housings revolutionary ignition coil design and
configuration. Flange and are CSA-certified for technology. These rail-mounted, state-
mount coils are Class I, Division 2, Group of-the-art devices are certified for use in
designed to mount to D areas. Steel shell Class I, Division 2 hazardous areas, as
the valve covers on a primary connectors are well as in unrated environments. When
number of popular, modern gas engines. used to take the rough used in conjunction with their associated
handling of industrial ignition system, they are capable of
Shielded Coils
market applications. delivering unprecedented ignition energy
Shielded versions are encased in
levels to the spark plug/air-fuel mixture.
stainless steel housings and Note: To maintain the CSA system
are CSA-certified for Class I, certification, all coils (shielded or
Division 2, Group D areas. integral types) and all primary and
Steel shell primary secondary components must be CSA-
connectors are used to certified Altronic parts.
take the rough handling
of industrial market
applications.

ALTRONIC I, III, V ALTRONIC II


ALTRONIC
CD1, CD200 II-CPU
COIL TYPE DURATION CPU-XL
CPU-90/95 CPU-2000
VARISPARK
DISN D.I.S.
Standard 501061 — —
Unshielded, round case
Extended 591010 291001 —
Extended 591040 — —
Unshielded, square case
Extended 591050 — —
Standard 591018 — —
Flange, 3-bolt
Extended 591012 — —
Standard 501061-S — —
Shielded Extended 591010-S 291001-S —
Variable — — 591401-1
Integral, 1"-20 x 5.6" 591007 591008 —
13/16"-20 x 6.1" 591011A — —
Standard
13/16”-20 x 10.8” 591011B — —
13/16”-20 x 11.3” 591011C — —

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© ALTRONIC, LLC 2012 13
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Retrofit Ignition/Control Package for Caterpillar® 3500 Engine

Many operators of the Caterpillar 3500 A retrofit of an SI-equipped engine „„ Pre-engineered, engine-specific
engine seek a cost-effective means of replaces the existing Altronic III, Altronic ignition and control system solution
upgrading their legacy SI and EIS ignition Interface Box (AIB), and SI panel with for legacy Caterpillar® 3500-series
and control systems with an Altronic-based the new hardware set—inclusive of new engines equipped with the SI or EIS
ignition and instrumentation solution. harnesses and an EZRail junction box. All ignition systems
This need has been driven by a desire existing ignition coils, valve covers, and
„„ Incorporates custom ignition and
for standardization with other Altronic- secondary components are retained.
detonation sensor harnesses for simple
equipped engines, improved access to
system installation and service
operating information and diagnostics, While the electronic hardware package
„„ Delivers expanded user access to
cost-effective access to service parts, and is identical for retrofitting an EIS-
system diagnostics and configuration
long-term product support. equipped engine, the retrofit requires the
replacement of the existing valve covers, „„ Assured future upgrade path and
Altronic has developed an integrated, secondary hardware, and ignition coils with system support from Altronic and its
pre-engineered solution using proven those components used in the SI-based Aftermarket Distributor organization
off-the-shelf components and a number of solution. „„ Hazardous area certified for Class I,
products specific to 3500-series engines. Division 2, Groups C and D
Available either as individual components, Theory of Operation
as part of a stand-alone Altronic Controls The Altronic SI/EIS Ignition System
FLANGE IGNITION COIL DETONATION
SENSOR

panel, or as part of a larger panel Retrofit Package is specifically designed


incorporating additional functionality, this to emulate the control parameters of the
package is designed with variants for each existing ignition/control system. This is
engine model—8, 12, and 16-cylinder accomplished by biasing the ignition
configurations—to provide a maximum timing vs. engine RPM (internal to the
level of added capability and operating CPU-95), as well as air manifold pressure
reliability, while minimizing installation (AMP), and the DET-1600 detonation
costs and associated downtime. These control. These latter two inputs (AMP
systems feature the standard CPU-95 and detonation) are used as inputs into
ignition system and all of its performance the DSG-1682DUPS and produce a
IGNITION JUNCTION-BOX

and diagnostic features, the Altronic DET- scheduled/integrated 4-20mA output as


1600 for advanced detonation and misfire an additional timing control input to the CONTROL PANEL
IGNITION PRIMARY
HARNESS

control, and a DSG-1682DUPS Digital CPU-95 system. All of the associated


Setpoint Gauge to assist in effectively RPM switch points, pressure setpoints, IGN. FIRING
CPU-95 IGNITION
MODULE DETONATION
ALARM POWER
SENSOR HARNESS

emulating the configuration and function and detonation control parameters can be
FAULT

of the existing OEM systems. Engine- reproduced in the new system from the
specific harnesses are provided for the OEM data. Alternative control strategies,
ignition system and for the accelerometers however, are available to the customer to
installed on each power cylinder, along further optimize the performance of their
with an EZRail junction module. specific application.

All rights reserved


© ALTRONIC, LLC 2012 14
AIS-C 3-12
Ignition System Accessories

FLASHGUARD®, Shielded, and FLASHGUARD® Spark Plugs 24VDC Alternator Power Packages
Altronic offers a series of high The alternator power packages are
Safe-T-Lead™ Spark Plug Leads
quality spark plugs engineered and designed to deliver up to 70 watts of
Altronic offers a complete line of
manufactured specifically for use in DC power to users wishing to operate
universal and custom Flashguard® spark
stationary gas engines. Incorporating the latest DC-powered ignition systems,
plug leads. These premium secondary
a number of unique design elements, instrumentation, and control products, on
leads are designed with a 5,000-ohm
the Altronic Flashguard spark plugs
®
installations lacking access to electrical
integral resistor and with tight-fitting
are available with both massive and service. To promote easy field retrofit,
silicone or Teflon® boots for reduced
precious metal electrodes (including the alternator units are designed to mate
emitted RFI, minimized flashover, and
an iridium/platinum model), in 14mm, directly to various flange-mount magneto
improved spark plug life.
18mm, and 7/8"-18 sizes, and in both drive configurations. A belt-driven version
For those operating in Division 2
shielded and unshielded configurations. is also available.
hazardous areas, Altronic offers two
All Flashguard® spark plugs feature Two variations of the power package sys-
certified secondary lead styles designed
an extended ceramic insulator and tem are offered:
for use with shielded spark plugs. The
proprietary nose cone design for
traditional braided stainless-steel lead „„ Version I — Consists of an alternator,
maximum flashover resistance, and a high
is certified as safe for use in Class I, voltage regulator, battery pack and
ohmic internal resistor for reduced RFI
Division 2, Group D hazardous areas. As cable. This system can furnish up
and improved spark plug service life.
an alternative, the Altronic Safe-T-Lead™ to 4 amps at 24Vdc for powering
is a non-metallic lead designed for use See the Altronic Ignition Accessories ignition, instrumentation and
in conjunction with shielded ignition Catalog for further technical and controls.
coils and spark plugs, but eliminates application details.
„„ Version II — Consists of an alternator,
the corrosion and spark plug life issues
voltage regulator and cable optimized
associated with traditional metallic leads.
to make a self-powered ignition
The non-metallic nature of the Safe-T-
system for the Altronic CPU-90 or
Lead™ lead also enables the user to
DISN. No battery is used with the
employ traditional diagnostic tools such
Version II system.
as an ignition timing light in
troubleshooting the ignition
system and the engine.
See the Altronic
Industrial Spark
Plug and Ignition
Accessories
catalog for
further
details.

All rights reserved


© ALTRONIC, LLC 2012 15
AIS-C 3-12
Altronic, LLC – A Member of
the HOERBIGER Group

The HOERBIGER Group

HOERBIGER Compression Technology is a business unit of HOERBIGER Holding AG,


Zug / Switzerland. HOERBIGER is active throughout the world as a leading player in the fields
of compression technology, automation technology and drive technology. Its 6,400 employees
achieve sales of around 1 billion Euro. The focal points of its business activities include key
components and services for compressors, gas engines and turbomachines, hydraulic systems and
piezo technology for vehicles and machine tools, as well as components and systems for shift and
clutch operations in vehicle drive trains of all kinds. Through innovations in attractive technological
niche markets, the HOERBIGER Group sets standards and delivers cutting-edge solutions for the
benefit of its customers.

ALTRONIC, LLC Form AIS-C 3-12


712 Trumbull Avenue
Girard, Ohio 44420 USA
P: 330-545-9768
F: 330-545-3231
www.altronic-llc.com