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Ignition Systems

for Industrial Engines


Altronic Ignition Systems

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


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

CD1, CD200, CD200D, DISN............................................................................ 7

Crankshaft-Referenced Digital Ignition Systems


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

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

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

Flashguard® Spark Plugs and Secondary Leads,


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

Pushing the Performance Envelope: Altronic Ignition Systems and Accessories


Girard, Ohio-based Altronic, Inc. has spent much of the last 40 Browsing through these pages will give you a good overview of
years defining and redefining the state-of-the-art when it comes both the evolution of the Altronic ignition and ignition accessory
to ignition systems and accessories for industrial natural gas- product line, as well as a good idea about the system options
fueled engines. As a result of this constant attention to product available for your specific make and model of engine.
development and manufacturing excellence, engine manufactu-
rers 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, INC 2009 2
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Altronic Ignition Systems Application Guide

No. CD1 CPU- CPU- No. CD1 CPU- CPU-


Engine Manufacturer I III V DISN Engine Manufacturer I III V DISN
Cyls. CD200 95 2000 Cyls. CD200 95 2000

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

GUASCOR 6-16 O R R CERTIFIED FOR USE IN


HAZARDOUS LOCATIONS
HERCULES (WHITE) 4-6 O O R NOTE: Most, but not all, Altronic ignition

INGERSOLL RAND 1-2 R systems and accessories in this catalog


are CSA certified and compliant with the
4-16 O O R R appropriate CE/ATEX regulations. Check
each product listing for certification and
INTERNATIONAL 4-6 O R
hazardous area classification.
IVECO 6-12 R R

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© ALTRONIC, INC 2009 3
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Solid-State/Mechanical Systems

Altronic solid-state ignition systems con-


sist of a self-powered ignition unit, a wir-
ing harness and an appropriate number of
ignition coils. Operating power is provided
by a self-contained, multi-pole perma­
nent 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, com-
posed 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 synthetic
CLASS 1, DIV. 2,
elastomer materials for low wear and long GROUP D
life. They also serve to dampen part of
the engine drive train vibration. Com- Application Data
bined with the smooth rotational cycle IGNITION SYSTEM POWER SOURCE CYLINDERS APPLICATIONS
Small in-line engines
of the Altronic alternator, these features Altronic I Self-powered 1-6
Horizontal 1-3 cyl. engines
contribute to the long mechanical life de- Altronic II Self-powered 3-20 Large bore, slow speed engines
signed into Altronic solid-state systems. Altronic III Self-powered 2-16 Medium-sized industrial engines
Small in-line engines
„„ Alternator powered Altronic V Self-powered 1-6
Horizontal 1-3 cyl. engines

„„ Capacitor discharge ignition


„„ Replaces magneto, breaker points TYPICAL CYLINDER BORE SIZE (MM)

and impulse coupling 100 125 150 175 200 225 250 275 300 325 350 375 400 425

„„ High output at engine cranking RPM Altronic I *


Altronic II
„„ Extended spark life
Altronic III
„„ Easy to service with plug-in modules
Altronic V *
* Also applies to larger bore, horizontal 1-3 cylinder engines

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© ALTRONIC, INC 2009 4
AIS-C 9-09
Solid-State/Mechanical Systems

Altronic I for Small Engines, able back cover, which contains all the
1-6 cylinder In-Line and system electronics.
1-3 cylinder Horizontal Other options include a choice of stan-
Altronic I, first introduced in 1966, dard or long spark duration coils in both
brought the advantages of capacitor dis- unshielded and shielded versions. Altronic
charge ignition to industrial gas engines. III can also be upgraded to the benefits
It consists of a small permanent magnet of crankshaft-referenced, electronically-
breaker-point ignition systems. Altronic
alternator with a plug-in electronic controlled timing — refer to the Altronic
II can be used on engines with either
module attached. Timing is set by one or III-CPU system.
one or two spark plugs per cylinder.
more remote mounted pick-up sensing
With an operating base of thousands of
magnets refer- Altronic V for Small In-Line Engines,
units, Altronic II has a proven record for
enced to the en- 1-6 cylinder
reliability. Users can also easily upgrade
gine crankshaft. Altronic V offers the same design fea-
to the Altronic II-CPU system while re-
On horizontal tures, installation ease, depend­ability
taining the Altronic II alternator section
engines, these
to supply system power requirements.
are typically
mounted on
the flywheel; Altronic III for Medium-Sized Engines,
on in-line engines, a magnet disc is 2-16 cylinders
used. The alternator performs no timing With over 40,000 units in the field,
function and can thus be either belt- or Altronic III has become the industry
coupling-driven. The only moving part is standard system for medium-sized
the alternator’s sealed, underloaded ball stationary gas engines. Altronic III is of-
bearing. fered with seven mounting variations and and serviceability that are built into
Over 60,000 Altronic I systems have six internal gear ratios to fit virtually any Altronic III, but in a smaller package. Six
been sold. The system’s simplicity and mounting variations and a dual-position
long record of field reliability have made electronic timing option are additional
it the ignition of choice for operators of features.
low-horsepower industrial engines. Altronic V affords small engine users a
cost-effective replacement for obsolete
Altronic II for Large Gas Engines, and maintenance-intensive breaker-point
3-20 cylinders magneto systems.

Altronic II provides a self-powered, ca-


pacitor discharge system for large-bore,
application in its class. Three types of
slow-speed gas engines. With four dif-
electronic timing control are also offered:
ferent internal gear ratios, base or flange
dual timing settings, timing vs. RPM and
mounting, and three drive coupling
timing vs. 4-20 milliamp signal. Ease
choices, Altronic II can be readily speci-
of service is assured by the replace-
fied to replace most older magneto or

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© ALTRONIC, INC 2009 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 ap-
propriate number of ignition coils. These
systems employ a cylinder position sens-
ing 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 refer-
ence 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
CERTIFIED
be applied to a variety of engines, includ-
CLASS 1, DIV. 2,
ing heavy-duty vehicular applications as GROUP D
well as engines incorporating lean-burn NOTE: Hazardous
area certifications
technology. Timing discs are manufac-
do not include the
tured to an accuracy of 0.1 degree, thus CD1 or non-shielded
eliminating variations caused by drilling CD200 systems.

timing holes in the field.


Application Data
„„ Single pickup operation
IGNITION SYSTEM POWER SOURCE CYLINDERS SPECIAL FEATURES
„„ Precision-machined timing disc
12-24Vdc or Universal, low cost CD200 system available in shielded
accurate to 0.1 degree CD1/CD200 1-8
DC alternator and CSA certified versions

„„ Incremental manual timing switches 12-24Vdc or


CD200D 4-16 General purpose, unshielded industrial system
for known adjustments DC alternator
12-24Vdc or
„„ LED diagnostics for power, pickup, DISN 800C
DC alternator
4-16 Unshielded or shielded industrial system, CSA certified
application faults
„„ Suitable for lean-burn engines TYPICAL CYLINDER BORE SIZE (MM)
„„ 12-24Vdc powered 100 125 150 175 200 225 250 275 300 325 350 375 400 425

„„ Full output at engine cranking RPM CD1/CD200


CD200D
DISN 800C

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© ALTRONIC, INC 2009 6
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Disc-Triggered Digital Ignition Systems

CD1/CD200 Family for flexibility through the use of an advanced, It is also capable of accepting an engine
Small Engines to 8-cylinders ModBus RTU-driven, Windows™-based position signal from either a magnetic
The Altronic CD1 Digital Ignition System terminal program. Performance enhance- or Hall-effect pickup. The CD200D is
has been developed for application on ment features resident in the CD200 designed as the successor to the widely-
small, stationary industrial engines up include adjustable output energy and used Altronic DISN system.
to 8 cylinders. This moderately-priced, automatic timing adjustment curves.
DISN 800C for Medium-Sized
easily installed system utilizes a low- Diagnostics associated with system opera-
Industrial Engines
cost magnetic pickup sensing drilled tion, as well as the primary and secondary
The DISN is a full-featured industrial
holes (usually in the engine flywheel) to discharge functions, are communicated
ignition system for small- to medium-sized
determine the angular position of the via on-board LEDs as well as through
stationary engines up to 16 cylinders. The
crankshaft. LED indicators give diagnos- the terminal program. Integral overspeed
DISN system is intended for compression-
tic signals regarding input power, the shutdown protection is also included.
stroke firing
pickup signal, and correct ignition unit
and usually
operation. Individual coils or economical Two versions of the CD200 system are
uses a single
multi-cylinder coil modules can be used available. The standard CD200 systems
pickup sens-
in conjunction with the CD1 system. (791070-X) are used with unshielded
ing, precision-
system components and ignition coils. For
machined
Beyond the CD1, substantial capabil- applications requiring service in hazard-
timing disc
ity for this same class/ ous areas (Class I, Division 2, Groups C
rotating at
size of industrial gas and D), a special, CSA-certified series of
engine cam-
engine is avaliable in CD200 systems is available (791080-X).
shaft speed.
the CD200 Universal This latter version utilizes shielded pri-
If crankshaft-referenced timing is desired,
Small Engine Digital Ignition mary input and output harnesses as well
two pickups are used: one sensing firing
System. These innova- as CSA-certified ignition coils (shielded
magnets placed in the engine flywheel and
tive designs employ and integral-style). Both the unshielded
the second sensing a single index magnet
micropro- and CSA-certified versions are available
rotating at camshaft speed. DISN offers
cessor in 6 and 8-output configurations.
up to eight firing patterns in a common
tech-
unit and is available in 8, 12 or 16-output
nology CD200D
models, each with multiple applications.
and The Altronic CD200D is suitable for both
The DISN systems also incorporate four
are unshielded and shielded systems on en-
advanced timing control options: manual
fully config- gines up to 16-cylinders. Housed in the
16-position timing switch, one-step timing
urable for a traditional DISN enclosure, this advanced
change, remote potentiometer timing con-
range of suitable digital ignition system incorporates all of
trol or control from a 4-20 milliamp analog
1-8 cylinder engine the same capabilities and functionality
signal. Three LED diagnostic indicators
models and firing patterns. resident in the standard CD200 prod-
give an instant indication of the basic
While using the same single pickup ar- uct, including adjustable output energy,
incoming power and pickup signals. The
rangement employed in the CD1 system, primary and secondary discharge diagnos-
cast housing offers superior protection in
the CD200 features complete application tics, automatic timing adjustment curves,
harsh environments.
and ModBus RTU communications.

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© ALTRONIC, INC 2009 7
AIS-C 9-09
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 con-
tinuous 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 infor-
mation on the location of the crankshaft.
On 4-cycle engines, a reference signal at
engine camshaft speed is used to deter-
mine the compression cycle. A replace-
able memory chip, programmed with the
engine’s application data, operates with
the CPU’s digital circuitry to output pre-
cise firing pulses to the ignition coils.
Altronic CPU systems eliminate mechani-
cal wearing parts — gears, chains, cou-
plings, etc. Ignition timing is precise in
all cylinders due to crankshaft-referenced
timing. All CPU systems feature manual
timing adjustment, one-step timing capa-
bility and electronic timing control from a CERTIFIED
CLASS 1, DIV. 2,
4-20 milliamp signal.
GROUP D
„„ Single pickup operation
„„ Precision-machined timing disc Application Data
accurate to 0.1 degree IGNITION SYSTEM POWER SOURCE CYLINDERS SPECIAL FEATURES
„„ Incremental manual timing switches CPU-95
12-24Vdc or
3-18
Adds display of operational and primary/secondary
DC alternator diagnostic features
for known adjustments
Adds operational and diagnostic displays:
„„ LED diagnostics for power, pickup, CPU-2000 24Vdc 3-30
multi-strike feature
application faults
„„ Suitable for lean-burn engines TYPICAL CYLINDER BORE SIZE (MM)
„„ 12-24Vdc powered 100 125 150 175 200 225 250 275 300 325 350 375 400 425

„„ Full output at engine cranking RPM CPU-95


CPU-2000

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© ALTRONIC, INC 2009 8
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Crankshaft-Referenced Digital Ignition Systems

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

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© ALTRONIC, INC 2009 9
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Ignition System Accessories

Ignition Coils Flange Mount Coils Integral Coils


The ignition coil is a final and most The same internal structure as Designed to mount directly
critical component in the ignition system the unshielded coil pack- to special threaded spark
performance chain. Available in several aged in the convenient plugs, integral coils have
electrical and physical configurations, Al- 3-bolt flange mount stainless steel housings
tronic coils are produced in a new, state- configuration. Flange and are CSA-certified
of-the-art facility — the most advanced mount coils are designed for Class I, Division
in the world dedicated solely to industrial to mount to the valve covers on a number 2, Group D areas.
engine ignition coils. The plant incorpo- of popular, modern gas engines. Steel shell primary
rates advanced, customized equipment connectors are used
Shielded Coils
and manufacturing processes to assure to take the rough handling of industrial
Shielded versions are encased in stainless
consistent, high quality production of market applications.
steel housings and are CSA-
high voltage coils — a component very Note: To maintain the CSA system cer-
certified for Class I, Division
sensitive to process variations. tification, all coils (shielded or integral
2, Group D areas. Steel
For optimum performance and reliabil- types) and all primary and secondary
shell primary connectors
ity, the ignition coil must be properly components must be CSA-certified Al-
are used to take the
matched to the ignition system output tronic parts.
rough handling of in-
characteristics. Despite look-alike appear-
dustrial market applications.
ance, other sources of coils simply are
not the same internally, and don’t offer
comparable output and quality. A variety
of coils are offered to meet application
requirements. ALTRONIC I, III, V ALTRONIC II
CD1, CD200 II-CPU
COIL TYPE DURATION
Unshielded Round Case Coils CPU-90/95 CPU-2000
DISN D.I.S.
The standard for unshielded Standard 501061 —
Unshielded, round case
coils, the well-known Extended 591010 291001
Extended 591040 —
Altronic blue, red and Unshielded, square case
Extended 591050* —
black variations are used Standard 591018 —
Flange, 3-bolt
Extended 591012 —
in applications not requiring
Standard 501061-S —
hazardous area certifications. Shielded
Extended 591010-S 291001-S

Unshielded Square Case Coils Integral, 1"-20 x 5.6" 591007 591008


13/16"-20 x 6.1" 591011A —
Standard
An alternative to the round 13/16”-20 x 10.8” 591011B —
13/16”-20 x 11.3” 591011C —
case design, these coils
have extended spark
duration.

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© ALTRONIC, INC 2009 10
AIS-C 9-09
Ignition System Accessories

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

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© ALTRONIC, INC 2009 11
AIS-C 9-09
Altronic Inc – 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 INC ALTRONIC EUROPE BV Form AIS-C 9-09


712 Trumbull Avenue De Tienden 50A
Girard, Ohio 44420 USA 5674 TB Nuenen
P: 330-545-4045 The Netherlands
F: 330-545-9005 P: 011-31-40-2906270
F: 011-31-40-2838990

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