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Summary of Contents for Motortech ICT
- Page 1 IGNITION COIL TESTER OPERATING MANUAL TOOLS & TEST EQUIPMENT FOR IGNITION SYSTEMS P/N 01.10.003 | Rev. 03/2010...
- Page 2 © 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS 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 ... -
Page 4: General Information
1 GENERAL INFORMATION 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. -
Page 5: What Abbreviations / Acronyms Are Used In The Operating Manual
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. -
Page 6: Safety Instructions
/ 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: –... -
Page 7: Electrostatic Discharge Hazards
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. –... -
Page 8: Proper Disposal
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. Rev. 03/2010... -
Page 9: Intended Use
3 INTENDED USE 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. -
Page 10: Product Description
4 PRODUCT DESCRIPTION 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 Primary voltage 10:1 outputs Secondary voltage 1000:1 Temperature... - Page 11 Flanged coil Integral coils (external) Adapter kit: 06.98.054-4 Adapter kit: 06.98.054-5 Consisting of: Consisting of: Adapter: 06.98.057-4 Adapter: 06.98.057-5 Cable (3-pin, neg. ground): 06.70.192-4 Cable (2-pin, neg. ground): 06.70.192-3 Cable (3-pin., pos. ground): 06.70.192-4-X Cable (3-pin, neg. ground): 06.70.192-4 Cable (3-pin, pos. ground): 06.70.192-4-X Integral coils (internal thread) Shielded ignition coils...
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Page 12: Overview
4 PRODUCT DESCRIPTION 4.2 Overview Item No. Description Test adapters for different ignition coil types Grounding probe for surface scan Voltage supply (110 to 230 V) Measuring output (high voltage) Measuring output (primary voltage) Spark gap Button for ignition Potentiometer for adjusting primary voltage Adapter mount for ignition coil to be tested Primary voltage terminal for ignition coil Main switch for test system... - Page 13 Ground connections Item No. Description Ground connection of grounding probe Ground connection for grounding the entire test system Ground connection for grounding the coil Rev. 03/2010...
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Page 14: Operation
5 OPERATION 5.1 Start-up To start up the ignition coil tester and prepare it for testing, proceed as follows: Connect the equipment to the voltage supply using the enclosed cable. Ground 2. Ground the kit by connecting the green-yellow cable to the jack and placing the alligator clip on an object suitable for grounding (e.g. - Page 15 Adapter Coil Type Part Number max. Primary Voltage [V] 06.98.057-7 Shielded Coils (ext.) 95.08.003 95.09.053 95.09.054 95.09.055 95.09.005 Measurands at 10 kV The following table shows measurands and open measured secondary voltage for the coil types listed that should be achieved at a secondary voltage of 10 kV: max.
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Page 16: Test Implementation Summary
5 OPERATION Measurands at 15 kV The following table shows measurands that should be achieved by the coil types listed at a secondary voltage of 15 kV: max. Primary Secondary Spark Duration Coil Type Part Number Voltage [V] Voltage [kV] [μs] Altronic 06.50.053A... - Page 17 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. Risk of destruction When adjusting the primary voltage, ensure that the max.
- Page 18 5 OPERATION 5. Ground the coil at the shielding or the mount for the coiled cord connected to the terminal To Coil Shield as applicable for the respective coil type. 6. Rotate the potentiometer to the left-hand stop so that no primary voltage is applied across the coil upon start-up.
- Page 19 9. First, check the insulation by moving the grounding probe closely along the insulation Ignition surface while holding down the button. If there is a spark discharge, the insulation is defective at the respective location, and you must discontinue use of the ignition coil. If no spark discharge is visible, you can proceed with the subsequent tests.
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Page 20: Evaluation Of The Test Results
5 OPERATION High voltage! Danger of electrocution! Until the test system is fully discharged, high voltages may still occur. For this reason, perform the discharge as described in the above step before you remove the coil. 5.4 Evaluation of the Test Results Measuring accuracy The measuring set-up offers an accuracy level of±... - Page 21 Measuring the spark duration The coil is intact and attains the full spark The coil is defective and does not attain the duration. full spark duration. Other defect cases When the secondary voltage is measured (spark gap, max. distance), e.g. the following defect cases may occur.
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Page 22: Testing Of Caterpillar Coils
5 OPERATION 5.5 Testing of Caterpillar Coils Caterpillar coils are exposed to greater thermal loads during operation on the engine. It is therefore recommended to test the coils while hot. An example of the complete test sequence is shown in the following: Check the coil for cracks. - Page 23 7. Place the coil on the corresponding adapter. 8. Connect the grounding cable to the shielding of the coil. Test 9. Perform the tests following the detailed instructions described in section Implementation Summary on page 16. 10. If the coil passed the test as GO, a second test is performed at a higher coil temperature. Rev.
- Page 24 5 OPERATION 11. Remove the coil from the test kit. 12. Thoroughly clean the entire coil using a cleaning agent containing an oil solvent. This is absolutely necessary to ensure that the generation of harmful gases is minimised as the coil heats up. 13.
- Page 25 15. If the coil passes this test with GO, as well, you can continue using it after fitting it with a new Teflon jacket and a new terminal (repair set). Rev. 03/2010...
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Page 26: Maintenance
– Instructions concerning the desired type of repair/inspection Providing this information will ensure the speedy and smooth processing of your repair order. Send the equipment to one of the two addresses below, or to the nearest Motortech representative: Motortech GmbH... -
Page 27: Instructions For Packaging The Equipment
6.4 Instructions for packaging the equipment For return shipment, equipment should be packaged as follows: – Use packaging material that does not damage the equipment surfaces. – Wrap the equipment with sturdy materials and stabilize it inside the packaging. – Use sturdy adhesive film to seal the packaging. - Page 28 Original MOTORTECH Accessories for Stationary Gas Engines As a supplier, MOTORTECH develops, manufactures and distributes accessories as well as spare and wearing parts for nearly all kind of stationary gas engines worldwide: Ignition control and monitoring, industrial spark plugs and high tension leads, wiring systems and gas regulation - from detonation to speed control and complete gas engine management.
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