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MOTORTECH GmbH
MOTORTECH Product Guide 2013

MOTORTECH Product Guide 2013

Product catalog summary

Introduction
MOTORTECH's 2013 Product Guide emphasizes innovation and efficiency in gas engine accessories and systems, focusing on enhancing engine performance and reducing emissions through research and development.

Key Sections

Ignition Controllers: Includes MIC5 and MIC4 series with high energy and precise timing, configurable via laptop, featuring ignition diagnostics and CANopen interfaces.
Ignition Coils: Offers various styles and conversion kits for optimal engine performance.
Triggering Systems: Ensures accurate ignition timing with pickups, leads, and trigger devices.
High Tension Leads and Accessories: Provides shielded and unshielded leads, terminal kits, and extensions for different spark plug types.
Gas Engine Management: Systems like ALL-IN-ONE and DetCon20 for comprehensive engine monitoring and control.
Sensor Systems: Includes sensor harnesses, oxygen sensors, and thermocouples for accurate diagnostics.
Gas Regulation: Products like VariFuel2 and EmCon5 for precise gas flow control.
Gas Engine Accessories: Liquid level controllers, coolant filters, and cleaning stations to maintain efficiency.

Innovative Design and Products
MOTORTECH uses advanced technologies like 3D-CAD and CNC machining for product development and manufacturing, ensuring state-of-the-art engines.

Quality Assurance
ISO 9001 certified, MOTORTECH focuses on quality and safety, maintaining a zero-failure strategy and comprehensive safety management system.

Service and Support
Offers extensive maintenance, repair, and on-site services globally, with customer training and a large inventory for quick parts delivery.

Conclusion
MOTORTECH positions itself as a leader in gas engine accessories, focusing on innovation, quality, and comprehensive customer support.

Technical Specifications and Features
Details a dbus RTU interface with USB access, supply voltage range of 10 to 32 VDC, 8 or 16 ignition outputs, and primary voltage of 250 VDC with 300 mJ primary energy. Features 0.1° crankshaft accuracy, timing control via potentiometer, speed curve, and analog inputs, and energy control through MOTORTECH Output Stage Technology (MOST).

Ignition Diagnostic and Interfaces
Provides runtime data, alarm and error messages, data logging, and misfire detection. Interfaces include CAN Bus 2.0b, RS485, and USB 1.1.

Configuration and Hardware
Fully customizable via laptop using MICT software, with different housing styles and coil driver boards for 8 or 16 ignition outputs.

Pickup Arrangements and Accessories
Details pickup arrangements for 4-stroke and 2-stroke engines, including magnetic, hall-effect, and inductive pickups.

System Enhancement and Additional Modules
Enhancements include DetCon20 detonation controller and PowerView3 HMI module for visualizing operating data and parameter adjustments.

Housing Styles and Protection Ratings
Describes Light Duty, Panel Mount, and Heavy Duty housing styles with specific protection ratings and temperature ranges.

MICT – MOTORTECH Integrated Configuration Tool
Provides a graphical user interface for configuration, engine information, and diagnostics, supporting multiple languages and print functions.

MIC850 Series – Ignition Controllers
Offers high ignition energy, accurate spark timing, and online diagnostics, configurable via PC with a built-in keyboard and optional graphical display.

Ignition Timing Adjustment
Outlines the process for adjusting ignition timing using the MIC850 controller, with adjustments via analog input or speed curve.

Engine Parameters
MICT engine library stores data for various engine manufacturers, aiding in system configuration and reducing errors.

Parameter Sets
MIC850 offers two parameter sets for calculating engine ignition timing, suitable for operations with varying gas qualities.

Pickup Arrangements
Details configurations for 1-3 pickup systems, including magnetic and Hall-Effect pickups for different engine types.

Required Accessories
Lists essential components such as the MIC850 ignition controller, output harness, pickups, trigger pins, magnets, and ignition coils.

MIC500 Series
Describes the MIC500 ignition system, a cost-effective, programmable unit for small to midsize engines.

Technical Data and Features
MIC500 operates on 10 to 30 VDC, with a primary voltage of 300 VDC and ignition energy of 180 mJ, supporting 2 to 16 ignition outputs.

Ignition Coils
MOTORTECH designs specialized ignition coils for various applications, including lean burn gas engines and high voltage systems.

Specifications
Lists part numbers for ignition coils, detailing color, primary and high voltage termination, polarity, and equivalent models.

Procedures and Compatibility
MOTORTECH ignition coils are compatible with ALTRONIC® and CATERPILLAR® systems, with cross-reference charts for replacement products.

Accessories and Kits
Various accessories such as repair kits, spark plug extensions, and boots are available for different ignition coil models.

Innovations
Introduces the SparkView, a handheld device for monitoring high voltage traces, allowing real-time spark plug condition measurement.

Recommendations
Suggests using specific ignition coils and accessories for optimal performance and safety, emphasizing correct boots and terminals.

Trigger Discs and Magnets
Specifications for trigger discs with magnets compatible with WAUKESHA® engines, including part numbers and equivalent references.

Accessories for Trigger Discs
Includes hubs, trigger magnets, and reluctor pins for WAUKESHA® engines.

High Tension Leads and Accessories
Highlights PolyMot™ style leads for reliability and patented design, available in various lengths and configurations.

Installation Tools and Accessories
Tools for installing reluctor pins and grommets for WAUKESHA® engines, along with silicone seal rings and flange kits.

Specifications and Compatibility
Detailed specifications for high tension leads, including part numbers, engine compatibility, lengths, resistance values, and connection types.

High Tension Leads and Accessories

Specifications:
Available in standard lengths with ceramic terminals featuring a HEX-nut on the spark plug side.

Terminal Kits for Shielded High Tension Leads:
Available in various styles, including MOT-Blues, ALTRONIC®, and MOTORTECH, designed to fit specific spark plug and ignition coil configurations.

Terminal Kits for Non-Shielded High Tension Leads:
Available in ALTRONIC® and BENDIX® styles, including components like boots, nuts, studs, O-rings, insulators, and gaskets.

Primary Leads:
Shielded primary leads meet CSA Class I, Division 2, Group D requirements, designed for harsh environments.

New Style Shielded Primary Leads:
Compliant with CSA standards, featuring fine bare copper wire, PVC/Nylon insulation, aluminum-plated foil, and tinned copper braid.

Conventional Shielded Primary Leads:
Available for MOTORTECH AlphaRail wiring rails, with options for cross-wired primary leads for positive grounded ignition systems.

Conclusion:
Provides detailed specifications and configurations for high tension leads and accessories, catering to various ignition systems and environmental conditions.

Overview: Detailed specifications and descriptions of ignition system components, including pole sockets, primary leads, shielded cable assemblies, spark plug extensions, and repair kits.

Specifications: Lists standard braid and lead lengths, with options for custom lengths.

Components:

Pole Sockets: Includes MIL Style 3 pole sockets with 90° and 180° configurations.
Primary Leads: Detailed for different engine models, including WAUKESHA®, CUMMINS®, and MOTORTECH applications.
Shielded Cable Assemblies: Descriptions include MIL Style sockets with various wire configurations.
Spark Plug Extensions: MOTORTECH's PolyMot™ style extensions are highlighted for their unique design and advantages over OEM products.
Repair Kits: Available for CATERPILLAR® and MOTORTECH ignition coils, with detailed sub-component listings.

Wiring Rail Systems: MOTORTECH's AlphaRail system is described as a robust solution for ignition control, featuring stainless steel construction, vibration resistance, and waterproof design.

Key Features:

High-quality materials and construction for durability in harsh environments.
Customizable lengths and configurations to fit specific applications.
Innovative designs to enhance performance and reliability.

Overview: Detailed information on ignition system tools and spark plugs, focusing on the ScopeLite timing light, MOTORTECH spark plugs, and DENSO spark plugs.

ScopeLite Timing Light: A self-powered LED timing light for fully shielded ignition systems, with automatic shut-off and adjustable sensitivity.

Tools and Test Equipment: Lists various tools for ignition systems, including high tension lead removal tools, timing lights, and installation tools.

MOTORTECH Spark Plugs: Offers extended barrel spark plugs with improved reliability and longer run times, available in different styles and materials.

DENSO Spark Plugs: Highlights Double Iridium spark plugs for durability and reduced maintenance, especially in biogas engines.

Key Specifications and Recommendations: Includes conversion tables, recommended tightening torques, and part numbers for ordering.

Overview: Detailed technical specifications and features of DENSO's Iridium Saver spark plugs and MOTORTECH Gas Engine Management system.

Specifications:

Iridium Alloy: Enhances wear resistance, offering longer service intervals.
360° Laser Welding: Ensures secure welding of the Iridium tip.
Cross Groove Design: Improves sparking performance and reduces voltage dispersion.

Installation and Maintenance:

Thread and Hex Sizes: Various specifications for M14 and M18 spark plugs.
Cleaning and Maintenance Tools: Includes spark plug cleaning kits and gap setting tools.

Gas Engine Management System:

All-In-One Controller: Integrates multiple functions for monitoring, controlling, and protecting gensets.
Features: Includes built-in synchronizing, load sharing, and air-fuel-ratio functions.
Protections: Comprehensive protection features including overcurrent and overload protections.

Key Benefits:

Enhanced durability and performance of spark plugs.
Comprehensive control and protection for gas engines with the MOTORTECH system.

Overview: Detailed information on components and systems related to gas engine management, focusing on control units, sensors, and wiring systems.

Key Sections:

InteliMains and Circuit Breakers: Outlines functionalities including import/export, load sharing, and grid monitoring.
Engine Management (ECU): Details on engine management functions such as speed measurement/control and engine monitoring.
ALL-IN-ONE Controllers: Descriptions of various controllers and their functionalities.
Detonation Control System (DetCon20): Explains the system for detecting and mitigating engine detonation.
AlphaRail Wiring System: Described as a robust wiring solution for detonation and temperature control.
Sensor Systems: Highlights the importance of reliable sensors for modern engine control systems.

Critical Information:

Detonation Control: The DetCon20 system is crucial for preventing engine damage due to detonation.
Wiring Rail System: The AlphaRail system is designed to withstand harsh environments.
Controller Compatibility: Various controllers and modules are compatible with specific engine types.

Overview
Detailed information on sensor harnesses and related components for MAN® and LIEBHERR® gas engines, as well as various sensors and gas regulation systems.

Sensor Harnesses for MAN® Gas Engines
Pre-configured sensor harnesses for different MAN® gas engine models, designed to be temperature-resistant and flexible.

Sensor Harnesses for LIEBHERR® Gas Engines
Customized harnesses for each engine type, including sensors for pressure, temperature, and speed control.

Oxygen Sensors
Offers both shielded and unshielded oxygen sensors, designed to withstand high temperatures.

MAP and MAT Sensors
Lists various sensors essential for monitoring and controlling engine performance.

Thermocouples
Provided for temperature control in various gas engines.

Gas Regulation Systems
Highlights the VariFuel2 air/fuel ratio mixer for adjusting fuel mixtures in gas engines.

Conclusion
Comprehensive guide to MOTORTECH's offerings for sensor harnesses, sensors, and gas regulation systems.

Gas Regulation Systems

VariFuel2 Air/Fuel Ratio Mixer
Details components and specifications for the VariFuel2 mixer, including gas inlet flanges and signal multipliers.

VariStep Stepper Motor Card
Designed for precise control of VariFuel2 mixers, with features like microstep operation and error message memory.

EmCon5 Lean-Burn Emission Controller
Manages emissions for gas engine co-generation units without requiring an oxygen sensor.

Throttles for Engines
Describes various throttle options for naturally aspirated and turbocharged engines.

Gas Safety and Control Systems
Provides customized engineering and production services for gas safety and control systems.

Gas Engine Accessories
Offers accessories like the Liquid Level Controller for monitoring oil, water, or coolant levels.

Overview: Detailed information on coolant and lube oil filters, including specifications for various applications.

Coolant Filters:

Function: Prevent corrosion, inhibit scale deposits, and ensure efficient thermal load dissipation.
Specifications: Categorized by application and temperature range.
Part Numbers: Provided for different filter sizes and micron ratings.

Lube Oil Filters:

Construction: Made from 100% stainless steel, cleanable, and environmentally friendly.
Applications: Compatible with major engine brands.
Specifications: Available in various sizes and configurations.

Ultrasonic Cleaning Stations:

Features: Offer powerful ultrasonic cleaning and environmentally safe aqueous cleaning.
Components: Include an ultrasonic cleaner, soak tank, backwash cabinet, and drying cabinet.

Accessories:

Additional Items: Pressure gauges, grommet seals, and seal kits available to complement the filters and cleaning stations.

Catalog excerpts

SENSOR SYSTEMS SPARK PLUGS IGNITION SYSTEMS

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COPYRIGHT The copyright for any material used in the MOTORTECH publications is reserved. Any duplication or use of objects such as pictures or texts in other electronics or printed publications is not permitted without MOTORTECH's agreement. TRADEMARK INFORMATION MOTORTECH is not a part of nor affiliated with ALTRONIC®, CATERPILLAR®, CUMMINS®, WAUKESHA®. All OEM names and part numbers shown are for reference purpose only. All trademarks, logos, and symbols used or shown in the MOTORTECH publications are exclusive objects to the right of their owners and are used for reference purpose only.

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TABLE OF CONTENTS 90 MOTORTECH AlphaRail − Wiring Rail System 92 Wiring Rail Kits 94 Ignition Kits TOOLS AND TEST EQUIPMENT IGNITION COILS 30 NEW MOTORTECH Style 31 MOTORTECH Style 31 ALTRONIC® Style 32 CATERPILLAR® Style 33 Conversion Kits 34 Accessories 36 Flange Versions 38 Externally Mounted 39 Integral Standard Versions 40 Integral High Energy Versions 100 SparkView 101 SparkScan1 102 Ignition Coil Tester 104 Ignition Pickup Simulator 105 ScopeLite 106 Tools and Workshop Equipment SPARK PLUGS AND ACCESSORIES 110 MOTORTECH XT-Plugs 112 MOTORTECH XTL-Plugs 116 MOTORTECH MPC Spark Plugs 116...

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MOTORTECH − WE UPGRADE GAS ENGINES 4 For those who fail to advance from what they have already achieved are quickly overtaken by the ever-changing demands of the market. This is why it pays to be innovative. At MOTORTECH we have been working hard to meet the needs of our customers for almost 25 years. We always strive to be one decisive step ahead of the rest! This is how we have proven ourselves worthy of being your qualified partner for stationary gas engines. Therefore, it should come as no surprise that MOTORTECH places high value in innovation, in research and in development. With over 200...

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• Equipment for all kinds of stationary gas engines • Development of hardware and software solutions • Design and production of innovative system solutions and individual solutions • Delivery and maintenance of ignition and control systems • Extensive test procedures to assure highest levels of product safety • Comprehensive technical support • From problem analysis to new design • Fastest possible delivery of gas engine accessories and replacement parts of all kinds • Specialists in electronic controls and for gas engines used for CHP and compressor drives • Installation and on-site repair –...

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INNOVATIVE DESIGN AND PRODUCTS Innovative Design TAKE ADVANTAGE OF 25 YEARS OF EXPERIENCE! 6 We develop innovative hardware and software solutions for engine management that will keep your gas engine state-of-the-art for years to come. Our microprocessor-controlled ignition, anti-knock control, temperature monitoring and CHP control (Combined Heat and Power) for gas engines exceed the most stringent future requirements. This includes interactive functions for all devices – like the integration of TFT touch screens via CAN BUS interfaces that enable fast data exchange and visualization of important...

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At MOTORTECH special emphasis is put on quality and safety, because neither you nor we can afford defects. That is why our entire company is DIN ISO 9001 certified. Additionally, MOTORTECH has passed the certification audit of the strictest automotive standard ISO TS 16949/2002 (similar to QS 9000) in 2004. In conjunction with ISO 9001, this certificate specifies Quality Management System requirements for development, production and any applicable assembly and maintenance of the specific products. Safety Management System "We live quality!" − That is also reflected in our high work safety standards....

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MAINTENANCE, REPAIR, ON-SITE SERVICE Service Team WHEN THINGS GET HOT OUR SERVICE TEAM IS AT YOUR SITE QUICKLY! 8 Take advantage of MOTORTECH’s many years of technical expertise in maintenance, repair and service. Our team participates in an ongoing training program and is familiar with the technical and maintenance procedures of all commonly used systems. Our technicians will perform know how repairs using the latest test instruments and tools, either at your company site or at our own workshops, even on products that we did not produce. Furthermore, to assure you with the best possible delivery...

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COMPLETE SERVICE MOTORTECH’s customer-focused know-how can provide support and consultation for your new developments, project planning, and problem analyses. Moreover, we are ready to assist you with advice and service at anytime. Just give us a call! You can be sure that our team will find an optimal solution for your particular problem area. Warehousing To assure you the best possible delivery anywhere in the world, MOTORTECH maintains an extensive inventory of parts and finished goods. Optimized orderprocessing and select global logistics partners deliver even the smallest of parts via a...

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IGNITION CONTROLLERS Years ago, MOTORTECH has made the decision to become a key player in design and manufacturing of ignition controls for the Global Industrial Gas Engine Business. A large engineering staff develops hard and software platforms. Test facilities were put in place to stress our hardware by temperature, heat and vibration. Cooperation with engine manufacturers, packagers and end users have led to specific designs and arrangements that will ensure the best performance of the rotating equipment. The new engine regulations and the growing biogas market, the developing mine gas industry...

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IGNITION CONTROLLERS MOTORTECH IGNITION CONTROLLER MIC5 Series Ignition Controllers The latest MOTORTECH development convinces with a future oriented electronical concept for more power and a significantly higher degree of efficiency. High ignition energy, accurate spark timing and diversified online diagnostics help to improve engine efficiency, spark plug life and availability of the equipment under the strictest emission regulations. The controller is fully customer configurable via Laptop. ∙ 20 ignition output channels ∙ Constant spark intensity via adjusted duration ∙ 500 mJ primary energy...

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