Motortech SparkScan1 User manual

SparkScan1 –
High Voltage Clamp
Operating Manual
P/N 01.10.019-2023-A-EN | Rev. 02/2023 (A)

Original instructions
© Copyright 2023 MOTORTECH GmbH. All rights reserved.
MOTORTECH products and the MOTORTECH logo are registered and/or common law trademarks
of the MOTORTECH GmbH. All further trademarks and logos displayed or used in this publication
are the property of the respective entitled person and are used for reference purposes only.
Information contained in this publication may be changed without prior notice.

Rev. 02/2023 3
1 General Information .....................................................................................................5
1.1 What Is the Purpose of this Operating Manual? ......................................................... 5
1.2 Who Is this Operating Manual Targeted to?...............................................................5
1.3 Which Symbols Are Used in the Operating Manual?...................................................5
1.4 Which Abbreviations/Acronyms Are Used in the Operating Manual?...........................6
2 Safety Instructions ......................................................................................................7
2.1 General Safety Instructions ..................................................................................... 7
2.2 Electrostatic Discharge Hazards ..............................................................................8
2.3 Special Safety Instructions for the Device ................................................................9
2.4 Proper Disposal.................................................................................................... 10
3 Intended Use ............................................................................................................. 11
3.1 Functional Description ...........................................................................................11
3.2 Application ...........................................................................................................11
4 Product Description ................................................................................................... 12
4.1 Technical Data ...................................................................................................... 12
4.1.1 Certifications ..................................................................................................... 12
4.1.2 Mechanical Data ................................................................................................ 12
4.1.3 Warning Notices on the Device............................................................................ 12
4.1.4 Product Identification – Labeling on the Device.................................................... 13
4.1.5 Electrical Data.................................................................................................... 13
4.1.6 Overview ........................................................................................................... 14
5 Operation .................................................................................................................. 15
5.1 Unpacking............................................................................................................ 15
5.2 Measuring High Voltage........................................................................................ 15
5.3 Evaluation of Measuring Results............................................................................ 19
6 Errors ........................................................................................................................22
6.1 Possible Faults .....................................................................................................22
6.2 Customer Service Information ...............................................................................22
6.3 Returning Equipment for Repair / Inspection ..........................................................22
6.4 Instructions for Packaging the Equipment ..............................................................22
7 Maintenance ..............................................................................................................23
7.1 Cleaning...............................................................................................................23
7.2 Spare Parts and Accessories ................................................................................. 23
Table of Contents

Table of Contents
4 Rev. 02/2023
8 Index.........................................................................................................................24

Rev. 02/2023 5
Read through this operating manual carefully before use and become familiar with the product.
Installation and start-up should not be carried out before reading and understanding this docu-
ment. 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 Operating Manual Targeted to?
The operating manual provides a code of conduct for personnel tasked with the setup, opera-
tion, 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 neces-
sary. Persons who are only authorized to operate the gas engine shall be trained by the operat-
ing 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 must be observed:
Example
This symbol indicates examples, which point out necessary handling steps
and techniques. In addition, you receive additional information from the
examples, which will increase your knowledge.
Notice
This symbol indicates important notices for the user. Follow these. In addi-
tion, this symbol is used for overviews that give you a summary of the
necessary work steps.
Warning
This symbol indicates warnings for possible risks of property damage or
risks to health. Read these warning notices carefully and take the men-
tioned precautionary measures.
1 General Information

1 General Information
6 Rev. 02/2023
Danger
This symbol indicates warnings for danger to life, especially due to high
voltage. Read these warning notices carefully and take the mentioned
precautionary measures.
1.4 Which Abbreviations/Acronyms Are Used in the Operating Manual?
The following abbreviations/acronyms are used in the operating manual.
Abb. Term Description Explanation
BNC Bayonet Neill Concel-
man
Special design of coaxial con-
nectors
CE Conformité Euro-
péenne
Conformity with EU
legislation
Mark based on EU legislation
for certain products in conjunc-
tion with product safety
UKCA UK Conformity As-
sessed
Conformity with Brit-
ish legislation
Mark based on British legisla-
tion for certain products in
conjunction with product safety

Rev. 02/2023 7
2.1 General Safety Instructions
The following safety instructions must be followed in the area in which the device is operated:
High voltage! Danger to life!
While the engine is running, there is danger to life through high voltage
particularly in the area of the ignition system. The following parts should
therefore not be touched or removed unless explicitly stated otherwise:
–Ignition coils and caps
–Wires of the high voltage circuit
–In- and output wiring of the ignition controller
–Pickups and their wiring
Danger to persons with implanted cardiac devices!
Electromagnetic impulses in the wiring of the ignition system may exceed
the permissible limits of active implanted cardiac devices such as pace-
makers or defibrillators. Persons with cardiac devices must therefore not be
present in the vicinity of the ignition system being operated. Mark the oper-
ating location of the ignition system with the corresponding standardized
warning symbol.
MOTORTECH equipment is manufactured as state of the art and therefore safe and reliable to
operate. Nevertheless the equipment can cause risks or damage can occur, if the following
instructions are not complied with:
–The gas engine must only be operated by trained and authorized personnel.
–Observe all safety instructions of the system and all safety instructions of the system oper-
ator.
–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 reacti-
vation.
–Perform only such maintenance and repair work as is described in this operating manual,
and follow the instructions given while working.
–Only use spare parts supplied by MOTORTECH for the maintenance of the device.
2 Safety Instructions

2 Safety Instructions
8 Rev. 02/2023
–Further work must only be performed by personnel authorized by MOTORTECH. Non-compli-
ance 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 laws, directives, and regulations applicable to the operation of
your system, including such not expressly stated herein.
–If the system is not entirely tight and sealed, gas may escape and result in explosion hazard.
The inhalation of gas can also lead to death or severe health damages. Therefore, upon com-
pletion of all assembly works, always check the system's tightness.
–Always ensure adequate ventilation of the engine compartment.
–Ensure a safe position at the gas engine.
–There is a risk of burning on hot surfaces. It is imperative that you avoid contact with hot
spots and wear safety gloves.
–Personal protective equipment (PPE), e.g. safety shoes and gloves, must be worn during all
work on the gas engine.
–Noise from the system can cause permanent or temporary damage to your hearing. Wear
suitable hearing protection at the system.
–Your behavior can reduce possible residual risks to a minimum. Observe responsible han-
dling of the gas engine and the gas-carrying system.
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 electro-
static 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 build-
ing 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 equipment as
possible.
–Do not remove the circuit boards from the housing of the device.

2 Safety Instructions
Rev. 02/2023 9
2.3 Special Safety Instructions for the Device
High voltage! Danger to life!
While the engine is running, there is danger to life through high voltage
particularly in the area of the ignition system. Do not touch the spark plug
leads, ignition coils, and spark plugs with your hands while the engine is
running. You can safely touch the grounded SparkScan1 high voltage clamp
even when the engine is running.
High voltage! Danger to life!
Without proper grounding of the SparkScan1 high voltage clamp, life-threat-
ening high voltage can occur. For your own safety, observe the following:
–Ensure at all times that the SparkScan1 is properly grounded to the
engine via the grounding cable.
–If the grounding of the SparkScan1 comes loose during measuring (e.g.
by tripping over the grounding cable), do not touch the measuring
clamp and the cables of the SparkScan1 or the BNC connector of the
SparkView. Switch off the engine, and when the ignition is inactive, re-
store proper grounding before proceeding with measuring.
High voltage! Danger to life!
In a wet environment and when the products are wet, there is a danger to
life from high voltage with the SparkView high voltage indicator and Spark-
Scan1 high voltage clamp. Likewise, wetness can destroy the products.
Therefore, use the products only in dry condition in a dry environment.
High voltage! Danger to life!
If the SparkView high voltage indicator or the SparkScan1 high voltage
clamp show any visible signs of damage in particular to cables and con-
nectors, there is danger to life through high voltage and the measurements
may be faulty. In such a case, refrain from using the respective product
under any circumstances.
Risk of injury!
There is a risk of crushing in the area of the clamp. Be sure to keep fingers
or other body parts away from the clamping surfaces.

2 Safety Instructions
10 Rev. 02/2023
Risk of injury!
To avoid injuring yourself, be careful not to trip over the cables of the Spark-
Scan1 high voltage clamp.
Risk of damage!
Hot engine parts can damage the cables of the SparkScan1 high voltage
clamp or the SparkView high voltage indicator. Avoid contact of the prod-
ucts with hot spots. Do not use damaged products.
Special Safety Instructions for the SparkView High Voltage Indicator
Risk of destruction!
Excess voltage may destroy or damage the SparkView high voltage indica-
tor. Stop the measurement immediately if continuously values above 25 kV
(set measuring range up to 25 kV) or above 50 kV (set measuring range up
to 50 kV) are measured.
Risk of destruction!
When the battery compartment is open, moisture and dirt may get into the
SparkView high voltage indicator and destroy it. You should therefore only
use the device with the battery compartment cover firmly screwed shut.
Risk of destruction! Operational safety!
Third-party products can destroy the SparkView high voltage indicator and
lead to incorrect measurement results. Operate the SparkView solely with
the MOTORTECH SparkScan1 high voltage clamp, with high-quality MOTOR-
TECH BNC cables and with MOTORTECH ignition coils featuring a BNC diag-
nostic interface.
2.4 Proper Disposal
For the proper disposal of MOTORTECH equipment, observe the information provided at
www.motortech.de.

Rev. 02/2023 11
3.1 Functional Description
The SparkScan1 high voltage clamp offers the opportunity to measure the high voltage require-
ments and the spark duration of the spark plugs. From the measured values you can draw con-
clusions about the condition of the ignition system and of the spark plugs.
The capacitive measuring process can be used for preventive maintenance or for supportive
analysis in the event of a problem. Regular measurements can thus also contribute to reducing
maintenance costs. The measuring results are displayed via an oscilloscope or the SparkView
high voltage indicator from MOTORTECH.
3.2 Application
The SparkScan1 high voltage clamp is designed exclusively for short-term measurements under
full load on unshielded MOTORTECH high voltage spark plug leads with a maximum diameter of
7 mm (0.27").
In addition to the high voltage clamp SparkScan1, a SparkView high voltage indicator from
MOTORTECH (length of SparkScan1 signal line max. 3 m / 118") or an oscilloscope is required for
measuring. The SparkScan1 high voltage clamp must only be used with the specified devices
under the specified conditions.
The SparkScan1 high voltage clamp must only be used by qualified personnel (see section Who
Is this Operating Manual Targeted to? on page 5).
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

12 Rev. 02/2023
4.1 Technical Data
4.1.1 Certifications
The SparkScan1 high voltage clamp is certified as follows: CE, UKCA
The certificates can be obtained on request from your MOTORTECH contact person (see section
Customer Service Information on page 22).
4.1.2 Mechanical Data
The SparkScan1 high voltage clamp has the following mechanical characteristics:
Feature Value
Dimensions high voltage clamp 169 mm x 64 mm x 90 mm (6.66" x 2.52" x 3.55")
(length x width x height)
Available lengths coaxial and
grounding cable
2 m (80"), 5 m (200"), 10 m (400")
Shape of device See section Overvie
w
on page 14
Mechanical environmental
conditions
Pollution degree: 1
Climatic environmental
conditions
–20 °C (–4 °F) to +70 °C (+158 °F)
Max. 80 % relative humidity without condensation
Up to 2,000 m (6,561') above sea level
4.1.3 Warning Notices on the Device
Warning Notice on the Clamping Handle of the High Voltage Clamp
Warning! Before use read and understand the operating manual. Always ground before use.
Warning Symbols on the Clamping Handle of the High Voltage Clamp
Warning of a hazardous point
Read operating manual
4 Product Description

4 Product Description
Rev. 02/2023 13
Warning Notice on the Wrap-Around Label of the BNC Connector
Length of coaxial cable 2 m (80"):
WARNING! Only for use with SparkView high voltage indicator or an oscilloscope.
Length of coaxial cable 5 m (200") and 10 m (400"):
WARNING! Only for use with an oscilloscope.
4.1.4 Product Identification – Labeling on the Device
The necessary numbers for product identification are on the device:
Illustration example
Abb. Meaning
P/N Part number of high voltage clamp
PC Production code
4.1.5 Electrical Data
The SparkScan1 high voltage clamp has the following electrical characteristics:
Feature Value
Measuring range 5 kV to 50 kV (in operation)
Tolerance Up to 20 kV: +/– 1 kV
At higher voltages: +/– 2 kV
Voltage ratio 1000:1
Maximum diameter of
MOTORTECH spark plug lead
7 mm (0.27")

4 Product Description
14 Rev. 02/2023
4.1.6 Overview
Pos. Designation
Clamp body, in the form of a clamping handle
Coaxial cable
Grounding cable
Ground terminal (alternative design as eyelet)
BNC connector

Rev. 02/2023 15
5.1 Unpacking
Unpack the inductive high voltage clamp, taking care not to damage it, and ensure that the
operating manual is always near to the device and is easily accessible. Check the contents for
completeness and verify that the equipment meets your application requirements.
5.2 Measuring High Voltage
High voltage! Danger to life!
While the engine is running, there is danger to life through high voltage
particularly in the area of the ignition system. Do not touch the spark plug
leads, ignition coils, and spark plugs with your hands while the engine is
running. You can safely touch the grounded SparkScan1 high voltage clamp
even when the engine is running.
High voltage! Danger to life!
In a wet environment and when the products are wet, there is a danger to
life from high voltage with the SparkView high voltage indicator and Spark-
Scan1 high voltage clamp. Likewise, wetness can destroy the products.
Therefore, use the products only in dry condition in a dry environment.
Operational safety!
Additionally follow the instructions in the manual of the SparkView high
voltage indicator and of the oscilloscope in order to guarantee the safe
operation of the SparkScan1 high voltage clamp.
Risk of injury!
There is a risk of crushing in the area of the clamp. Be sure to keep fingers
or other body parts away from the clamping surfaces.
Risk of injury!
To avoid injuring yourself, be careful not to trip over the cables of the Spark-
Scan1 high voltage clamp.
5 Operation

5 Operation
16 Rev. 02/2023
The SparkView high voltage indicator is only suitable for measurements taken with the Spar-
kScan1 with two meter (80") long coaxial cable.
Damages to the SparkScan1 high voltage clamp including its cables may result in danger to life
through high voltage and the measurements may be faulty. Before each use, visually inspect the
SparkScan1 to make sure it is not damaged, otherwise do not use the SparkScan1. If you have
any questions on the safe operation and measurement accuracy of your SparkScan1, contact
your MOTORTECH contact person (see section Customer Service Information on page 22).
Prepare for measuring as follows:
1. Adjust the oscilloscope or the SparkView high voltage indicator from MOTORTECH for the
measuring process. Further details about adjustments can be found in the operating manual
of the corresponding device.
High voltage! Danger to life!
Without proper grounding of the SparkScan1 high voltage clamp, life-threat-
ening high voltage can occur. For your own safety, observe the following:
–Ensure at all times that the SparkScan1 is properly grounded to the
engine via the grounding cable.
–If the grounding of the SparkScan1 comes loose during measuring (e.g.
by tripping over the grounding cable), do not touch the measuring
clamp and the cables of the SparkScan1 or the BNC connector of the
SparkView. Switch off the engine, and when the ignition is inactive, re-
store proper grounding before proceeding with measuring.
High voltage! Danger to life!
If the insulation of the ignition components is insufficient or damaged,
there is a danger to life through high voltage due to leaping sparks and the
measurements may be faulty.
Stop the measurement immediately if sparks leap. Switch off the engine
and do not proceed with the measurement until you are sure that the igni-
tion components are sufficiently insulated.
Risk of damage!
Hot engine parts can damage the cables of the SparkScan1 high voltage
clamp or the SparkView high voltage indicator. Avoid contact of the prod-
ucts with hot spots. Do not use damaged products.

5 Operation
Rev. 02/2023 17
2. Ground the high voltage clamp at a suitable location on the engine that provides a safe
electrical connection to ground. Depending on the design of the grounding cable, use the
grounding clamp (see photo) or the eyelet for this purpose. For the design with eyelet, make
sure that the eyelet is securely fastened to the grounding point.
3. Connect the coaxial cable with the aid of the BNC connector to an oscilloscope or to the
SparkView high voltage indicator from MOTORTECH.
4. Clamp the high voltage clamp as far away as possible from the ignition coil and with suffi-
cient distance to the spark plug to an unshielded spark plug lead from MOTORTECH without
touching the spark plug lead, the ignition coil, or the spark plug with your hands.
Maximum diameter of spark plug leads
For a reliable measurement it is necessary for the contact surfaces to be
touching each other. This is only guaranteed for MOTORTECH spark plug
leads up to a maximum diameter of 7 mm (0.27").

5 Operation
18 Rev. 02/2023
▸The test setup looks like this:
Pos. Designation
Ignition coil
Spark plug
High voltage clamp
Grounding
Oscilloscope / SparkView
▸You can read out or record the measured values from the oscilloscope or the SparkView.

5 Operation
Rev. 02/2023 19
Risk of damage!
The SparkScan1 high voltage clamp is designed for short-term measuring of
high voltages under full load and must not remain on the spark plug lead
permanently. Otherwise, the spark plug lead may be damaged.
5.3 Evaluation of Measuring Results
This section contains some typical results from measurements taken with the inductive high
voltage clamp and an oscilloscope. The important factors include both the voltage and spark
duration as well as a clean curve. In order to be able to draw reliable conclusions about the
condition of your ignition system, please also read the operating manuals for the engine, the
ignition system and the oscilloscope used.
Typical Curve for an Intact Ignition System
–Measurement with ignition coil connected:

5 Operation
20 Rev. 02/2023
–Measurement without spark plug connected (open circuit):