Itm Accutek III User manual

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SECTION 1
INTRODUCTION
Thank you for purchasing the ACCUTEK III Capacitive Discharge
IgnitionAnalyser. The ACCUTEK III works with most ignition systems
and their components to bring you reliable and accurate test information
on component integrity and function.
Listed below are some features of the ACCUTEK III analyser:
•Full ignition diagnosis - on both shielded and unshielded systems
•Microprocessor based - allowing full diagnostic flexibility.
•Backlit liquid crystal display simplifies operator use
•Compatible with Altronic®, Bosch®, Fairbanks Morse (Holley)®
and most other capacitive discharge ignition systems
•Rugged high impact case designed for field use
•High quality circuit design produces meaningful, reliable test data
•Low battery indicator with user replaceable cells (4 AA)
•Fully protected inputs and outputs
•Small, hand held design
The intention of this manual is to guide the user through a logical trou-
bleshooting procedure to determine the integrity of the ignition system
under test.
These trademarks are the registered
trademarks for their respective companies.
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NOTICE
The ACCUTEK III analyser and information in this document are sub-
ject to change in order to improve reliability, design, or function without
prior notice. Information or descriptions in this manual do not represent
a commitment on the part of this company.
In no event will Innovative Technical Solutions Inc. be liable for
direct, indirect, special or consequential damages arising out of the use
of these products or documentation, even if advised of the possibility of
such damages.
No part of this manual may be reproduced or transmitted by any means
or in any form without the prior written permission of Innovative
Technical Solutions Inc.
CONTENTS
Section 1 Introduction
Section 2 Safety
Using the ACCUTEK III
Section 3 D.C. Power Supply
Section 4 Ignition Coils
Section 5 Secondary Leads and Extensions
Section 6 Wiring Harness
Section 7 LeakageTesting (primary wiring insulator integrity)
Section 8 Testing Instruments
Section 9 Peak Voltage
Section 10 Transfer
Section 11 Energy
Section 12 Missing Pulse
Section 13 Maintenance, Battery Replacement
Section 14 Warranty
Section 15 Ignition Coil Resistance Specifications
Section 16 Product Specifications
Section 17 Accessories
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SECTION 2
SAFETY
Please take the time to carefully read this users manual. It
will assist you in fully utilizing the features of the
ACCUTEK III in a safe and effective manner.
The ACCUTEK III has the potential to deliver high voltage
and can produce much higher voltages when connected to other devices
(eg. ignition coils).
This device utilizes storage capacitors and can hold a charge for an
extended period of time - even if the power switch is in the OFF posi-
tion.
This manual has been published for negative ground systems. Leads
must be reversed when testing positive ground systems.
Purge all fuel from the engine before performing any static engine tests.
As with any electrical device, caution must be observed when using this
product.
Multi-strike ignition systems must be operated in single strike mode
when testing with the ACCUTEK III.
DO NOT USE IN AN EXPLOSIVE ATMOSPHERE
No tests should be performed with the ACCUTEK III unless the opera-
tor is fully capable of protecting himself from electrical shock.
Do not exceed the input or output specifications of the ACCUTEK III.
Should any assistance be required in the safe operation of the
ACCUTEK III, please contact:
INNOVATIVE TECHNICAL SOLUTIONS INC.
7127 18 St. S.E. Calgary, Alberta T2C 1K2
Ph [phone] • Fax [phone]
www.intechnical.com
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USING THE ACCUTEK III
Section 3
D.C. Power Supply
Power supply stability can be detrimental to proper operation of any
D.C. powered equipment. Most manufacturers will supply a maximum
amount of power supply instability (referred to as peak to peak noise)
for their equipment. Exceeding these recommendations will result in
unpredictable operation and possible failure of the equipment.
D.C. power stability MUST be established before any other tests are
performed on an inoperative or erratic D.C. powered device such as
an ignition module.
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•Please refer to the ignition manufacturer’s guidelines for min/max
D.C. levels and maximum peak to peak noise for the ignition sys-
tem that you are testing.
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Section 4
Ignition Coils
The ACCUTEK III is designed to test most industrial ignition coils by
discharging a storage capacitor at 1.0 Hz across the primary side of the
ignition coil. The voltage stored on this capacitor is user adjustable from
approximately 100 V.D.C. to approximately 350 V.D.C. This allows the
operator to evaluate the characteristics of most industrial ignition coils.
Ignition Coils - General Notes
When inspecting ignition coils, the ignition coil should be checked for
the following:
•Evidence of physical damage which could hinder the ignition coil
from performing in both its physical and environmental surround-
ings, eg. distorted case, cracked housing, damaged connector, dam-
aged threads, etc.
•Close evaluation of the primary connector, locating pin, connector
pins, connector threads, secondary threads, epoxy, teflon, or ceram-
ic insulator condition, secondary tower/spring, etc.
•Ignition coil manufacturers typically specify an operating temper-
ature of approx. 200 deg. F (93 deg. C) for ignition coils. Therefore
check ignition coil operating temperatures.
•If corona action (viewed as corrosive erosion) is present on the sec-
ondary tower, the corrosion must be removed and if damage has
occurred to the spring, it should be replaced. If the erosion has
damaged the secondary tower, the ignition coil should be replaced.
CAUTION REFER TO SECTION 2.
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The following procedure on resistance testing applies to both shielded
and unshielded ignition coils.
4.1 Resistance Test
Ignition coil primary resistance tests are usually measured between ter-
minals “A” and “B” on a shielded ignition coil or (+) and (-) on an
unshielded ignition coil. Ignition coil secondary resistance is usually
measured from the secondary tower to the (-) or “B” terminal. If in
doubt please check with the ignition coil manufacturer.
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•Connect the ignition coil to the multi-meter/ohmmeter using the
appropriate cables and switch positions (refer to the manufacturer’s
operators manual for further instructions). The meter will now dis-
play the measured resistance. These results can be compared to
manufacturer’s data (section 15) to determine if the coil is within
specs.
VERY IMPORTANT, PLEASE READ CAREFULLY
The information below deals with negative ground systems. Always
observe ignition coil polarity before connecting the ACCUTEK III to
ignition coils.
4.2 Firing Unshielded ignition coils
Note: A shock hazard exists if the following procedure is not
followed carefully.
4.21 All tests must be performed in a nonhazardous area and on an
electrically conductive surface.
4.22 A lead from the ACCUTEK III “COMMON” output, igni-
tion coil negative, and one side of the spark gap, must be con-
nected to the conductive surface - this will ensure that the
spark energy will be able to return to the tester.
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4.23 Place the ignition coil on the conductive surface. Supply a
suitable spark gap for the ignition coil to fire (approximately
0.5”). Be sure to connect the ground side of the spark gap and
ignition coil negative terminal to the conductive surface.
KEEP ALL PARTS OF YOUR BODY AWAY
FROM THE IGNITION COIL WHEN YOU
ARE FIRING THE IGNITION COIL.
ALLOWING AN UNSHIELDED COIL TO FIRE AN
EXCESSIVELY LARGE GAP COULD SHOCK YOU AND
MAY CAUSE DAMAGE TO THE IGNITION TESTER.
4.24 Place the TEST switch to the COIL/IGN position and place
the MEASUREMENT switch to the PEAKVOLTS position.
4.25 Turn the ACCUTEK III on and depress PUSH TO TEST
switch.
4.26 Set voltage to be delivered to the ignition coil by adjusting
the VOLT SET potentiometer.
DO NOT EXCEED IGNITION COIL
MANUFACTURER’S INPUT VOLTAGE
4.27 Connect the leads from the HV-TEST and COMMON out-
puts of the ACCUTEK III to the primary side of the ignition
coil while observing proper polarity.
4.28 Place the MEASUREMENT switch to the TRANSFER posi-
tion and depress the PUSH TO TEST switch.
The ignition coil should now be firing at 1.0 times per second across
the spark gap. The LCD will be displaying (in microseconds) how
long the ACCUTEK III is delivering energy to the ignition coil. This
LCD reading should be noted and compared against similar ignition
coils.
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When placed in the ENERGY position, a calculated value of pulse
amplitude and duration supplied to the ignition coil from the ACCUTEK
III will be displayed on the LCD (see ENERGY).
ENERGY and TRANSFER readings will increase as voltage supplied
to the ignition coil under test is increased.
Ignition coils with display readings above or below normal may also
have low or no secondary voltage output. If the operation of the ignition
coil is questionable, compare results to a known good ignition coil. If
tests are being performed on the engine, ensure that the area is non-haz-
ardous and that all the fuel has been purged from the engine. Disconnect
the wiring from the ignition source, consider the engine as the conduc-
tive surface and follow the above instructions (Refer to 4.21 to 4.28).
4.3 Testing Shielded Ignition Coils
Before proceeding, please perform resistance tests. (Refer to 4.1)
While there is a risk of electrical shock when firing a shielded ignition
coil, the high voltage generated by the ignition coil should go to ground
within the metal can surrounding the ignition coil.
DO NOT TEST COILS IN HAZARDOUS AREAS.
To minimize potential electrical shock, only test leads supplied by I.T.S.
should be used to test shielded and unshielded ignition coils.
•Place the ignition coil so that the secondary tower is at a comfort-
able viewing angle.
•Follow steps 4.21 to 4.28
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Note how the spark travels from the secondary tower to ground. In
many cases, when the ignition coil integrity has been compromised, the
spark will consistently go to ground through a hole or crack in the sec-
ondary insulating material which may be virtually impossible to see
under normal operation but becomes very evident in this type of test.
In other cases, there will be some foreign contaminant on the high volt-
age insulator allowing the secondary high voltage spark to “travel”
along the insulator with little or no resistance - allowing a portion of the
intended insulator to become partially or completely inefficient. These
problems may disappear with new plugs and light engine loads but tend
to resurface with increased ignition demands.
Typically, TRANSFER readings are very consistent when testing iden-
tical ignition coils (same manufacturer and model). TRANSFER read-
ings are usually between 20 to 50 microseconds for standard duration
coils and somewhat longer for long duration coils (due to the higher coil
primary resistance). ENERGY readings are a product of selected volt-
age and measured TRANSFER results.
An LCD display of “LLL” or a reading that is considerably lower than
that of other similar ignition coils could indicate a defective ignition
coil.
An LCD display of “HHH” or a reading higher than that of other
similar ignition coils could indicate high resistance or a defective
ignition coil.
When firing ignition coils, a displayed reading of HHH will force the
internal oscillator to shut down for safety precautions. Oscillator
output can be re-established by turning the TEST switch from the
COIL/IGN position to any other position and then returning it back
to the COIL/IGN position.
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