Motortech ICT User manual

IGNITION COIL TESTER
OPERATING MANUAL
TOOLS & TEST EQUIPMENT FOR IGNITION SYSTEMS
P/N 01.10.00
3
|
Rev. 0
3
/2010

Copyright
© Copyright 2010 Motortech GmbH. All rights reserved.
Distribution and reproduction of this publication or parts thereof, regardless of the specific
purpose and form, are not permissible without express written approval by Motortech.
Information contained in this publication may be changed without prior notice.
Trademarks
All trademarks and logos displayed or used in this publication are the property of the respective
entitled party.

Rev. 03/2010 3
1 General information .....................................................................................................4
1.1 What is the purpose of this operating manual?..........................................................4
1.2 Who is this manual targeted to?...............................................................................4
1.3 Which symbols are used in the operating manual? ....................................................4
1.4 What abbreviations / acronyms are used in the operating manual? ............................5
2 Safety instructions ..................................................................................................... 6
2.1 General safety instructions......................................................................................6
2.2 Electrostatic discharge hazards............................................................................... 7
2.3 Special Safety Instructions for the Device ................................................................ 7
2.4 Proper disposal......................................................................................................8
3 Intended Use .............................................................................................................. 9
3.1 Function Description ...............................................................................................9
3.2 Application Range ..................................................................................................9
4 Product Description ................................................................................................... 10
4.1 Technical Data ...................................................................................................... 10
4.2 Overview.............................................................................................................. 12
5 Operation .................................................................................................................. 14
5.1 Start-up................................................................................................................ 14
5.2 Overview Ignition Coil Data ................................................................................... 14
5.3 Test Implementation Summary .............................................................................. 16
5.4 Evaluation of the Test Results................................................................................20
5.5 Testing of Caterpillar Coils ....................................................................................22
6 Maintenance............................................................................................................. 26
6.1 Spare Parts and Accessories..................................................................................26
6.2 Customer service information ...............................................................................26
6.3 Returning equipment for repair / inspection...........................................................26
6.4 Instructions for packaging the equipment .............................................................. 27
TABLE
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4 Rev. 03/2010
Prior to use, read this operating manual carefully and familiarize yourself with the product. The
installation and start-up should not be performed without reading and understanding this
document. Keep this manual readily available so that you can reference it as needed.
1.1 What is the purpose of this operating manual?
This manual serves as an aid for the installation and operation of the product and supports the
technical staff with all operating and maintenance tasks to be performed. Furthermore, this
manual is aimed at preventing dangers to life and health of the user and third parties.
1.2 Who is this manual targeted to?
The operating manual provides a code of conduct for personnel tasked with the set-up,
operation, maintenance, and repair of gas engines. A certain level of technical knowledge with
respect to the operation of gas engines and basic knowledge of electronic ignition systems are
prerequisite. Persons who are merely authorized to operate the gas engine shall be trained by
the operating company and shall be expressly instructed concerning potential hazards.
1.3 Which symbols are used in the operating manual?
The following symbols are used in this manual and shall be observed:
Example
This symbol marks examples that illustrate the necessary steps and
techniques for you. Furthermore, the examples provide you with
supplemental information to increase your knowledge.
Notice
This symbol marks important information for the operator. Follow these
instructions. Additionally, this symbol is used for overviews that provide
you with a summary of the required work steps.
Warning
This symbol indicates warnings of potential risks of property damage or
health hazards. Read these warning notices carefully and take the stated
safety precautions.
1 GENERAL INFORMATION

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Danger
This symbol warns of danger to life, especially due to high voltage. Read
these warning notices carefully and take the stated safety precautions.
1.4 What abbreviations / acronyms are used in the operating manual?
In the manual or the user interface, the following abbreviations / acronyms are used.
Abb. Term Description Explanation
AC Alternating Current Alternating current
DC Direct Current Direct current
EMC Electromagnetic
compatibility Compatibility of electrical or electronic equipment items
with their surroundings.
HV High Voltage High voltage

6 Rev. 03/2010
2.1 General safety instructions
The following safety instructions must be observed in the environment in which the equipment is
operated.
High voltage! Danger to life!
While the engine is running, especially the area around the ignition system
holds the risk of danger to life due to high voltage. Therefore, the following
parts must not be touched or pulled off:
–ignition coils and boots
–wires of the high voltage circuit
–connectors of the input / output wiring
–pickups and their wiring
Motortech equipment is manufactured as per the state of the art and therefore safe and reliable
to operate. Nonetheless, the equipment may cause danger or damage if the following
instructions are disregarded:
–The gas engine must be operated by trained and authorized personnel, only.
–Operate the equipment only within the parameters specified in the technical data.
–Use the equipment correctly and for its intended use only.
–Never apply force.
–For all work such as installation, conversion, adaptation, maintenance, and repair, all
equipment must be disconnected from the mains and secured against unintentional
reactivation.
–Perform only such maintenance and repair work as is described in this operating manual,
and follow the instructions described while working. For maintenance of the equipment,
only use spare parts supplied by Motortech. Further work must only be performed by
personnel authorized by Motortech. Non-compliance with the instructions will void any
warranties for the proper function of the equipment as well as the responsibility for the
validity of the certifications.
–Safety devices must not be dismounted or disabled.
–Avoid all activities that can impair the function of the equipment.
–Operate the equipment only while it is in proper condition.
–Investigate all changes detected while operating the gas engine or ignition system.
–Ensure compliance with all directives and regulations applicable to the operation of your
system, including such not expressly stated herein.
–Always ensure adequate ventilation of the engine compartment.
–Ensure a safe position at the gas engine.
2 SAFETY INSTRUCTIONS

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2.2 Electrostatic discharge hazards
Electronic equipment is sensitive to static electricity. To protect these components from damage
caused by static electricity, special precautions must be taken to minimize or prevent
electrostatic discharge.
Observe these safety precautions while you work with the equipment or in its vicinity.
–Before performing maintenance or repair work, ensure that the static electricity inherent to
your body is discharged.
–Do not wear clothing made from synthetic materials to prevent static electricity from
building up. Your clothing should therefore be made of cotton or cotton mix materials.
–Keep plastics such as vinyl and styrofoam materials as far away from the control system, the
modules, and the work environment as possible.
–Do not remove the circuit boards from the housing of the device.
2.3 Special Safety Instructions for the Device
High voltage! Danger to life!
During the coil tests (as soon as the Ignition button is pressed), the
following parts must not be touched, as they may be live with high voltages
of up to 40,000 V.
–high tension lead
–ignition coil
–metal parts of the spark gap
–metal tip of the grounding probe
High voltage! Danger to life!
Before each measurement, ensure that the tester is properly grounded. Use
the green-yellow cable with the alligator clip for this purpose. Without
proper grounding, high voltages of up to 40,000 V can occur.
Explosion hazard!
As the tests using the ignition coil tester produce open ignition sparks,
such tests must never be performed in potentially explosive atmospheres.

2 SAFETY INSTRUCTIONS
8 Rev. 03/2010
Risk of destruction and injury
Actuate the ignition switch only if an ignition coil is correctly connected.
Otherwise, the ignition system may be damaged. In addition, a voltage of
between 200 and 300 V is applied across the ignition terminal, which can
result in injuries.
Risk of destruction
Ignition coils and spark gaps can produce major electrical and
electromagnetic interference (EMC), which can destroy other electronic
devices. It must therefore be ensured that a distance of min. 2 m from other
electronic equipment is observed during tests with the ignition coil tester.
Health hazard
Prolonged operation of the spark gaps produces ozone, which is a health
hazard at high concentrations. Operate the spark gap only for short periods
of time and ensure adequate ventilation.
Danger to persons with pacemakers!
The limits for effects on pacemakers can be exceeded by electromagnetic
pulses in the cables connected to the ignition system. Persons with
pacemakers must therefore not be present in the vicinity of the ignition
system being operated. Mark the operating location of the ignition system
with the corresponding standardized warning symbol.
2.4 Proper disposal
After expiration of its service life, Motortech equipment can be disposed of with other
commercial waste, or it may be returned to Motortech. We will then ensure the environmentally
friendly disposal thereof.

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3.1 Function Description
With the ignition coil tester, you can perform and analyse function tests on ignition coils for gas
engines. Aside from the ignition unit, the kit comprises connection leads and adapters for a
variety of common ignition coil types.
With a grounding probe, the insulation of the coils can be checked for defects. This way, you can
detect even cracks that are invisible to the naked eye. In addition, you can verify the values for
the secondary voltage and the spark duration with an oscilloscpe. The oscilloscope is not
included in the delivery scope of the ignition coil tester.
3.2 Application Range
The ignition coil tester is designed for performing function tests on the ignition coil types listed
in the section
Technical Data . The connection data of the respective ignition coil must be taken
into account for all tests.
Any use other than the one described in the operating manual shall be considered improper use
and will result in the voiding of all warranties.
3
INTENDED USE

10 Rev. 03/2010
4.1 Technical Data
The ignition coil tester has the following technical characteristics:
Property Value
Supply voltage 110 bis 230 V AC
Primary voltage adjustable with potentiometer from 0 to 300 V
Division ratio of measuring
outputs
Primary voltage 10:1
Secondary voltage 1000:1
Temperature max. -40° C to +70° C
Humidity max. 85% without condensation
The following ignition coil types can be tested with the optionally available adapter kits:
Caterpillar coils Altronic standard coils European coils
A
dapter kit: 06.98.054-1
A
dapter kit: 06.98.054-2
A
dapter kit: 06.98.054-3
Consisting of: Consisting of: Consisting of:
A
dapter: 06.98.057-1
A
dapter: 06.98.057-2
A
dapter: 06.98.057-3
Cable: 06.70.192-1 Cable: 06.70.192-2 Cable: 06.70.192-2
4
PRODUCT DESCRIPTION