DOKUMENTATION PROJEKT HAUS ADEN (ENTWURF)COMPACT PRODUCT GUIDE

2014

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HIGH QUALITY PARTS AND ACCESSORIES FOR GAS ENGINES

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IGNITION CONTROLLER

MOTORTECH has devolved its new ignition con-troller platform which is designed to meet the special needs of cutting edge industrial gas engines. Gas engines with up to 20 cylinders can be controlled efficiently and reliably.High adjustable ignition energies (MOST), accurate spark timing and diversified online diagnostics help to improve engine effici-ency, spark plug lifetime and availability of the equipment under the strictest emission regulations. The controller is fully customer configurable via Laptop.

• Adjustablesparkdurationandintensity• Constantsparkintensityviaadjusted

duration• 200to500mJprimaryenergy• Ignitiondiagnostics

(primary and secondary)• Faultmemorywithtrenddata• IntegratedCANopenandModbusRTU

interface• EasyaccessperUSBport

(Fulltechnicaldataandinformationatwww.motortech.de)

MOTORTECH IGNITION CONTROLLERMIC4

MOTORTECH IGNITION CONTROLLERMIC5

• Highperformanceignitioncon-troller with 24 ignition outputs for use with slow, medium and fast spinning industrial gas engines

• Automaticcontrolofsparkduration(ASC)

• Variousdiagnosticandconfigu-ration options

MOTORTECH IGNITION CONTROLLERMIC850

MOTORTECH IGNITION CONTROLLERMIC3

The new MOTORTECH Ignition Controller Platform

MIC3 MIC4 MIC5

Primary Energy 200mJ 300mJ 500mJ

Start-UpBoost 300mJ 500mJ 700mJ

Ignition Outputs 6 / 12 8 / 16 20

Pickups 1 or 2 1, 2 or 3 1, 2 or 3

Housing Styles

Panel Mount (IP20) X

LightDuty(IP54) X X

HeavyDuty(IP65) X X

MOTORTECH ENGINE INFORMATION MONITORPowerView3

PowerView3 – HMI MODUL

CompletevisualizationofMIC3/MIC4/MIC5operating data, inclusive error diagnostic, via optionally available HMI module (Human-Ma-chine-Interface). The touchscreen guarantees an intuitive navigation through different display pages and menus.

NEW

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IGNITION COILS

Standard Ignition CoilsStandard unshielded epoxy coils for non-shieldedapplications.Availableindifferent colors and variations to replace any existing coil.

"High Performance" Ignition CoilsIgnition coils are becoming more and more importantin modern, up to date ignition systems. MOTORTECH made it its business to develop a series of new high performance ignition coilsproduced in the German facility:• Useofhigh-qualitymaterial• Ideallysuitedforignitionof

alternative fuels such as biogas• ApplicableforASC–Automatic

Spark Control of MOTORTECH ignition controller

• MOST(06.50.104,06.50.105)• ASC(06.50.100,06.50.102)

Shielded Ignition CoilsCoils are encapsulated in a steel housingwithweldedlidsandmeetCSAClassI;Division2;GroupDrequirementsforha-zardous areas. Canned coils are available with standard and extended duration characteristics.Standardly available with 3-pin primaryand 3/4“ spark plug lead connector(interchangeablewithALTRONIC® coils).Alsoavailablewithamorerigid2-pinpri-mary and a 1“ spark plug lead connector.

Integral Ignition CoilsCoils designed to mount directly to dualthreaded spark plugs. Top cover hasaspecialSAFETY-DESIGNtopreventthe coil body from blowing out of theshellwhensparkplugsleak.Availablewith standard, but also with long sparkduration. Capable of providing doublethe amount of energy to the spark plug.Can be ordered in various length from 6” to14.5”!PerfectforapplicationsliketheWAUKESHAVHPseries.MeetCSAClassI, Division 2, Group D environment.

FlangeIgnitionCoilsSame winding configuration as in the standard epoxy coils but molded to a 3-hole steel flange. This allows installation directly on the valve cover.Flangeignitioncoilswiththesamewindingconfigurationsarealso available as version with diagnostic interface. This enables the possibility to measure the high voltage via MOTORTECHSparkViewor digital oscilloscope.

The rising demand for specialized ignition coils has led MOTORTECH to the decision to design a new series of igni-tion coils, specially made for use with CATERPILLAR®seriesG3400,G3500andG3600 gas engines.

• SupportsCATERPILLAR® ignition systems• Spark plug extensions made of high qua-

lity Teflon® for high dielectric strength

• Innovativespring-loadedsecondaryterminal for a secure connection with the spark plug (patented design)

• Improvedconstructionwithoutmetalring

• Automatedseriesproductionwithhighquality standard

• VersionsforCSAapplications

ThealternativeforCATERPILLAR® Gas Engines

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IGNITIONSYSTEMS

Wiring RailsMade from stainless steel profile, foam filled for long life and designedtolast.Availableas:

• IgnitionforstandardorCSAcertifiedapplications• Detonationcontroll• Temperaturemonitoring

IgnitionKitsComplete ignition kits designed to easily fit particular engines. The kits are availa-ble complete with rails, pre-made prima-ry wire harness, ignition coils, ignition controller, pickup and corresponding brackets.Plugandplay!

MOTORTECH IGNITION RAIL SYSTEMAlphaRail

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IGNITIONTRIGGERARRANGEMENTS

MagneticPickup(MPU)Reliable design in a variety of differentlengths.AvailableinstandardorCSAcertified versions.

Hall Effect Pickup High temperature resistant pickup.Triggersoffanymagnet.AvailableinstandardorCSAcertifiedversionsandboth possible polarities.

Inductive PickupSmall sensor (M12 thread) for use inapplications where there is not muchavailable installation space. It can ope-rate in oil. High temperature resistance.AvailableinstandardorCSAcertifiedversions.

TriggerDiscsavailableinallVariations• Withmagnets• Withsteelinserts• ForWAUKESHA®VGF,VHP

and CATERPILLAR® applications

Trigger Magnets and Reluctor PinsPrecision made to ensure accurate trigger impulses on flywheel or camshaftreferenced igni-tion systems.

Forapplicationswhereaccesstothecamshaft is difficult and no trigger disc can be mounted, this trigger device (figu-re 1) is an easy and reliable mechanical solution. Mounted to the position of the former ignition magneto or other drive shafts, it will sense all necessary trigger signals. The heavy duty bearings and smartdesignofferhighreliability! Alsoavailableareotherenginespecific solutionsforCATERPILLAR® (figure 2), WHITESUPERIOR®(figure3),MAN® (figure 4) etc.

MOTORTECH TRIGGERING DEVICESTriDev

3 4

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INDUSTRIALSPARKPLUGS

Industrial Spark PlugsToday the industrial gas engine market requests Platinum andIridiumtipelectrodesforlongsparkpluglife.Available:

ExtendedBarrelSparkPlugsForspecialapplicationsthereisarequestforlongsparkplugstoreachdowntothebottomofthesparkplugwell.Availab-le with aircraft style thread for high tension lead connection or with a female thread to accept an integral coil. Plugs are availablewithJ-typeandX-typegroundelectrodeconfiguration.CenterandgroundelectrodesareequippedwithIridium(J-type)orNickel/Aluminumtipsforlongsparkpluglife(X-type).

The “S2-Type” has a 3/4” male

thread and is used to be called the AIRCRAFTSTYLEspark plug. This

spark plug is desi-gned to connect to

a shielded spark plug lead.

The “DCP-Type” has afemale thread to ad-

apt to a short integral ignition coil.

This combination is popular in some

applications where customers have

made bad experi-ences with shielded

spark plug leads.

The “C-Type” is an extended barrel

plug that has a con-ventional ceramic

insulator on the top end. This allows the

use of a standard spark plug boot.

Preferable a connec-tor that includes a 5KOhmresistortosuppresstheRFI.

J-Type− Iridium X-Type −Nickel/Aluminum

MOTORTECH Extended Spark PlugsXT-Plugs

MOTORTECH Extended Spark PlugsXTL-PlugsForengineapplicationsequippedwithextreme tight spark plug well, conventi-onal ignition leads show its limits. The solution are specially designed spark plugs with extended metal housing. XTL-Plugs are manufactured with an integra-ted 7 mm spark plug lead, which allows a direct connection to an externally mounted ignition coil. Can be ordered with different barrel and lead lengths, different lead outputs from the barrel and a wide range of ignition coil connec-tors. XTL-Plugs are designed for unshiel-ded applications and offer long runtimes.

MOTORTECHMBP1800BridgePlugTheMBP1800BridgePlugisahighperfor-mance and extremely durable spark plug for usewithgasenginesthathaveahighBMEP(> 20 bar). It uses an innovative, highly solid electrode design, thus granting three times longerlifetimesthananytraditionalJ-gap spark plug can do.

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HIGHTTENSIONLEADS

Shielded High Tension LeadsAvailableinconventionalorMotBluesstyle to replace any product in the market. TheMotBluessparkplugwireisa MOTORTECH development with a special multilayer design to ensure that no humi-dity can be trapped in the lead.

High Tension Leads for NON ShieldedApplicationsPolyMot® patented spark plug leads arethe most reliable high tension leads inthe industry. Made from a combination ofCeramic, Teflon® and Silicone they trans-fer nearly any rate of high energy sparkfromthecoiltothesparkplug.Variationsfor nearly all engine models in combina-tion to spark plugs are available.

Spark Plug Extensions

In applications where ignition coils aremounted right on top of the valvecover, a spark plug extension is required.PolyMot® Extensions outlast any OEMproduct. Made from a combinationof Ceramic, Teflon® and Silicone, thepatented design increases availability ofequipment.

CATERPILLAR® Ignition Coil RepairKitsImprove the OEM coil product by using amore reliable Teflon® extension. Coupled with a unique and patented designstainless steel terminal it eliminates theuse of the metal ring and all electricalpunctures through the extension.• RepairkitsforG3400&G3500coils

(mounted under the valve cover)• ExtensionforG3600Ademcoil

Shielded Primary LeadsMOTORTECH primary leads are available as standard version or in new style that is produced with a special multilayer wire. The new primary leads offer a significant higher flexibility than conventional leads, shielded with braided steel, while being highly resistant to all kinds of environmental conditions. Primary leads are available with rigid terminations in several different configurations with durable 90° and 180° 2-pole and 3-pole connectors.

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IGNITION TOOLS

ExtendedBarrelSparkPlugSocketsInstalling spark plugs can be a pain.The extended barrel spark plug so-cket (available up to 36” length) has strong magnets incorpora-ted that hold the spark plug when being installed in a deep spark plug well.

The high voltage clamp SparkScan1 iscoupledtoaSparkVieworadigi-tal scope and allows the operator to measure real time data from his spark plug lead (conventional spark plug wire 0,28”) to analyze cylinder malfunctio-ning.Aservicetoolthatsavestimeandmoney.

Ignition Coil TesterThis test equipment is designed to offerservice companies a professional tool totest all different kinds of coils that areused by engine manufacturers or after-marketcompanies.AbuiltinCDignition,high voltage clamp and a spark gap allowrealistic testing.

Adaptor-Kits

When using the MOTORTECH ignition coil tester the adaptor kits need to be spe-cified.Forallcommoncoiltypesspecialadaptors are already included. The figure shows adaptor and lead kit for the test of CATERPILLAR®G3400andG3500Coils.

The newly developed handheld device monitors the high voltage required by the spark plugs while the engine is running. The condition of the spark plugs and the time at which they need to be replaced can be determined with the SparkScan1 highvoltageclamporwithaBNCcable.

Oscilloscope not in scope of delivery.

The ScopeLite timing light can take an impulse through shielded pri-mary and secondary ignition leads. UniqueLEDdesign.

MOTORTECH IGNITION ACCESSORIESSparkScan1

MOTORTECH HIGH VOLTAGE INDICATORSparkView

MOTORTECH TIMING LIGHTScopeLite

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DETONATIONCONTROL

The DetCon20 control unit offers full protection for gas, diesel and dual fuel engines from 2 to 20 cylinders. Microprocessor controlled, it will detect any detonation in the early stage and will send an analog signal (4-20mA/0-5V)outtotheignitionsystemtoretardinalinearfunction.If detonation cannot be cured a signal will be send for load reduction andfinallyanengineSTOPsignal.CANBusinterfaceincluded.

KnockSensorCan be installed on any cylinder headbolt or stud as the sensor is smaller than1.5”india.Itmeasuresthecombustionsignal and transfers it to the controller.

DetCon20SoftwareThe DetCon20 comes with a WIN basedsoftware package that allows the operatorto analyze all data in real time on his PC.

ALL-IN-ONEisacompletegasenginemanagement system (upper controller).It allows you to monitor, control,regulate and protect your entire system.This controller will open new costreduction possibilities in the servicesector, thanks to the remote data access and long distance data transmis-sionfeatures.Allsystemparameters,performance and historical data can betransfered via modem, internet or SMS.These features will significantly increa-se your customer´s system availability.

ALL-IN-ONEFeatures:• Mainsmonitoringandprotection• Import/exportcontrol• 3operationmodes:island,standby (emergency) or parallel to mains• ForwardandReversesynchronization without interruptions• Generatormonitoring(U,I,cosφ, T)• Enginemonitoring(P,T,p,min-1,etc.)• LeanBurncontrol• Speedmeasurementandcontrol• CANBusInterface• Extendableupto32modules

• Binaryinput(statusLEDonboard)• Binaryoutput(statusLEDonboard)• Analoginput(mA,PT100,NiCr-Ni,etc.)• Analogoutput(mA,V)• Alarmlistrecordsandhistorialdata• 7levelsofpasswordprotection• Remotecontrolviamodem,internet, GMS connection• SMS, e-mail, and warning call service

MOTORTECH GAS ENGINE MANAGEMENTALL-IN-ONE

MOTORTECH DETONATION CONTROL SYSTEMDetCon20

PowerView3forDetCon20ThePowerVIew3HMImodulesupportsthe full visualization of the most impor-tant operating and trend data like knocking intensity for each cylinder or the current analog output signal levels.

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GASREGULATION

TheVariFuel2isahightechvariableVenturitypemixerthatcanconstantlyadjust to any fuel changes andallows the engine to operate at its mostefficient point. Series 100, 140, 200 and250availableforawiderangeofengines.Coupled to a lambda controller (lean

burn or stoichiometric) it will beregulating the mixture precisely.Verypopularinbiogasapplicationswhere the calorific value of fuel canconstantly change.

Oxygen SensorsAvarietyofoxygensensorsareavailable.Including versions to replace CATERPILLAR® OEM sensors.

VariFuel2–Accessories

TheEmCon5isaleanburnengineemission controller. Cost effective andno need for a separate oxygen sensor.Comes with Software package and iscapable of data logging.

New stepper motor card − developed and manufactured by MOTORTECH• Guaranteestheidealcontrolofthevarious typesofVariFuel2air/fuelratiomixers• Precisemixeradjustmentdueto micro step operation• IntegratedCANopenand ModbusRTUinterface• EasyaccessviaUSBinterface• ConfigurationviaMICTsoftware• SealedtoIP20

MOTORTECH INTEGRATED CONFIGURATION TOOLMICT

Throttles with integrated Stepper MotorThe throttles are equipped with an inte-grated stepper motor, eliminating linkage components.Allmovingpartsaremadeofstainless steel to survive in the harshest environments including H2S.

VariStepMOTORTECH STEPPER MOTOR CARD

MOTORTECH LEAN-BURN EMISSION CONTROLLEREmCon5

MOTORTECH AIR/FUEL RATIO MIXERVariFuel2

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These bypass filters with stainless steel filter elements clean coolant liquids of any deposits. Elements can be washed and do not need to be disposed. Increases wa-ter pump life, cylinder head efficiency and equipment availability. Reduces service and maintenance cost.Filterelementsavailablein50micron(standard)and25micron(optional)rating.

GASENGINEACCESSORIES

Custom made stainless steel lube oil filters. Over 800 different filters –alltoyourexactspecifications.Allfiltersare100%stainlesssteelconstruction.Filtersareavailableinratingsof3to400micronabsolute.Standardsealbuna„N“-Viton,Siliconeetc.–optional.

Features

• Cleanable• Consistent• Environmentallyfriendly• Reducehazardouscontaminants• Highpayback• Directreplacement

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CUSTOM MADE STAINLESS STEEL FILTERSLubeOilFilter

MOTORTECH CUSTOM MADE STAINLESS STEEL FILTERSCoolantFilter

• Greaterfluidflow• Extendsmaintenanceintervals• Improvesperformance• Providespredictivetool• Reducesinventory• Extendsequipmentlife

MOTORTECH OIL LEVEL CONTROLLER

OLC

Oil level monitoring, oil refill, and even an automated oil change–inotherwords,thecompletemanagementoftheoilcycle–canberealizedinacompletelyreliablemannerwithMOTORTECH‘sOLCoillevelcontroller.Availableasvariantwithfloat switches or with analog level sensor.

Advantages for Users

• Eliminationofregularmonitoringoftheoillevel• Operationisnotinterruptedformonitoringtheoillevel• Operating errors are avoided, no overfilling/lack of oil• Automatedoilchangepossible• Lessworkforstaff,increaseinoperationalsafety• Visualsurveillanceoftheoillevelduringoperation

is possible • Remotemonitoringfromacentrallocation

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When things get hot our Service Team is at your site quickly.

Distribution partner for DENSO spark plugs

Regardless of which part of the globe we need to travel to.

We know that the stakes are high, and therefore we outperform the others. That is because we want every-thing to run smoothly at your site, everywhere and at any time.

This is entirely in keeping up with our motto: Letusdropeverythingandworkonyourproblem!

Distributed by:

Office

Sales Partner

Headquarter

MOTORTECH GmbHHogrevestr. 21-2329223 CellePhone: +49514193990Fax: +495141939999www.motortech.demotortech@motortech.de

MOTORTECH Americas, LLC1400DealersAvenue,SuiteANewOrleans,LA70123Phone: +15043554212Fax: +15043554217www.motortechamericas.cominfo@motortechamericas.com

P/N 01.00.003-EN | MOTORTECH Compact Product Guide

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Trademark Information

AllOEMnamesandpartnumbersshownareforreferencepurposesonly.Alltrademarks,logosandsymbolsusedor shown in this MOTORTECH publication are exclusive objects to the right of their owners and are used for reference purposes only.