System Overview Dimensions Specifications

Display Module Input Signals: • VariSpark™ Option

6.50
6.50
Magnetic pickups (2) • ModBus Communications
6.00
1 - ring gear teeth or drilled holes NEW FEATURES: • Dual Serial Ports
6.00 .203 DIA.
(TYP 4)
.203 DIA.
1 - reset (1/engine revolution) • Data-logging Capability
(TYP 4)
Hall-effect pickup for compression stroke reference (4-cycle applications only) • 8-Output Model
Control Inputs (ground to activate): CPU-95 with
Shutdown
Feature control (timing, energy, double-strike, VariSpark™) VariSpark™ Option
6.00 6.50
6.00 6.50
Timing Control Inputs: ADVANCED DIGITAL IGNITION SYSTEM
Manual (display module keypad)
Analog (4-20mA control signal) FOR INDUSTRIAL ENGINES
Digital (RS-485 serial data)
Ignition Output: • Microprocessor-based, crankshaft-referenced digital ignition
2.19
2.19
47kV maximum output voltage system for medium-sized natural gas-fueled engines
1.25
1.25 300–600 microseconds duration (791950/952/955) • Optimizes engine combustion and performance and
1000–2000 microseconds duration with VariSpark™ option (791958) maximizes spark plug life
Control Outputs (solid state, N.C. switches): • New VariSpark™ option with up to 2000 microsecond spark
Normal fire confirm duration combines the best features of capacitor discharge
Alarm fault and inductive ignition to enhance engine performance
Shutdown fault • Comprehensive primary and secondary diagnostics and
prognostics minimize engine down time
Communications:
RS-485 serial • Intuitive, “user-friendly” display/interface offers easy access
(Single or dual port display modules available) to critical information and the ability to make virtually all
system adjustments
Display: • Optional new enhanced Display Module with dual serial
Alphanumeric, 2 lines x 16 characters, backlit ports, ModBus protocol, analog bar-graph displays, and
Ignition Module Power Requirements: diagnostic data-logging.
9.90
9.90
24VDC, 1–8 amps typ. (varies by application) • Simple and cost-effective to retrofit for users of
NOTE: On many applications, power can be supplied by engine-driven Altronic III, III-CPU, and CPU-90
6.00
6.00
Altronic 24 Vdc alternator; see form ALT.
The Altronic CPU-95 is a 24 Vdc-powered, microprocessor-based
Temperature
digital ignition system designed for application to medium-range
-40° F. to +158° F. / -40° C. to +70° C.
industrial gas engines. Operational advantages include a full-
featured user display and interface, spark characteristic control,
Ordering Information advanced timing adjustment options, serial communications, and
System Components CPU-95 IGNITION MODULE – 1 per system
state-of-the-art diagnostics.
Each CPU-95 system is composed of the Ignition Module, two per crankshaft revolution reset pulse. Four-cycle applica- Full access to all CPU-95 operating data and control options are
8.75
8.75 9.75
9.75 791950-8 Ignition Module, 8 outputs, standard
magnetic pickups and cables, a primary wiring harness, and an tions also utilize a Hall-effect pickup sensing a magnet available through a “user friendly” system display module as well as via
791950-16 Ignition Module, 16 outputs, standard a PC operating a Windows™-based terminal program. Both options
ignition coil for each spark plug. A system Display Module, turning at camshaft speed to determine the compression
791950-18 Ignition Module, 18 outputs, standard display essential engine and ignition data such as RPM, timing angle,
typically used (but not required), is also available. A Hall-effect cycle of the engine.
pickup and cable, as well as a magnet turning at camshaft- 791952-18 Ignition Module, 18 outputs, dual capacitor spark energy level, and diagnostic messages, as well as offer user
The CPU-95 Ignition Module is typically mounted on or 791952-20 Ignition Module, 20 outputs, dual capacitor control of setup selections such as global and individual cylinder
speed are utilized on 4-cycle applications only.
near the engine. This 24-VDC-powered module accepts 791955-16 Ignition Module, 16 outputs, Caterpillar G3500 low emissions engines timing, energy level, double strike or extended spark duration
and processes the input data derived from the engine-
System Operation based pickups and any control data being brought into
791958-16 Ignition Module, 16 outputs, VariSpark™ extended spark duration (VariSpark™), and overspeed setpoint.
6.25
6.25
Patented CPU-95 diagnostics and prognostics (predictive diagnos-
The diagram above illustrates how these components are the system through the CPU-95 Display Module, Termi- CPU-95 DISPLAY MODULE – 1 per system
integrated into an operating system. To insure that the spark nal Program, or engine management system (see review tics) supervise all ignition system-related functions. The secondary
USE WITH IGNITION MODULE analysis capabilities detect shorted spark plugs and leads, as well as
is delivered at precisely the right moment for each engine to left). This control information, including timing adjust-
PART NO. DESCRIPTION 791950-xx spark plugs that exhibit high voltage demand or are not firing at all. A
cylinder on each revolution, the CPU-95 determines the ments, spark energy control, and multi-strike or extended 791952-18
position of the engine crankshaft through the use of a duration (VariSpark™) directly influences both the moment 791958-16 791952-20 791955-16 display of the relative voltage demand of each spark plug is provided,
magnetic pickup sensing starting ring gear teeth or holes at which the spark is delivered and the important charac- 791902-1 Display Module, standard X allowing spark plug changes to be predicted and scheduled. Module
drilled into the flywheel allowing precise determination of teristics of that spark. A 4-20mA timing control input from 791902-1S Display Module, no test X
and pickup operation, timing input, and primary output functions are
crankshaft angular position in real time. Matching that to a a supervisory control system or an instrument monitoring also monitored for operation within preset limits.
791902-2 Display Module, Cat G3500 X
pre-programmed system memory, the CPU-95 system can a specific operating parameter (such as fuel manifold The CPU-95 system is shop or field configured via the CPU-95 Output
791908-1 Display Module, enhanced X X
achieve extremely high ignition timing accuracy. A second, pressure or air manifold temperature) is also available as Module serial port using a personal computer and the Altronic CPU-95
flywheel-based magnetic pickup, is used to generate a once an additional means of optimizing performance. See CPU-95 AL Application Information for further details. Terminal Software.
712 TRUMBULL AVE / GIRARD, OH 44420 CERTIFIED
(330) 545-9768 / Fax: (330) 545-9005 CLASS I, DIVISION 2, GROUPS C and D
www.altronicinc.com E-mail: sales@altronicinc.com
Form CPU-95 1-02 ©2002 Altronic, Inc.
System Features Display Options CPU-95 System Diagnostics Special CPU-95 Systems
Comprehensive Display Capability The CPU-95 Ignition Module is designed to operate in conjunction with a To assist operators of gas engines in properly locating and not require a special ignition coil, any add-on probes or clamps, or VariSpark™ Option the fast rise time and high available voltage (up to 47kV)
Two-line, alphanumeric, backlit display variety of display/control options through its integral RS-485 communica- diagnosing the source of ignition-related problems, a suite of any other special equipment. Instead, Altronic primary and characteristic of capacitive discharge ignition systems,
indicates the following operating parameters: comprehensive, easy-to-use, troubleshooting diagnostics have secondary diagnostics utilize standard ignition coils (typically the VariSpark™ (patent pending) provides the user with a with the ultra-long spark duration previously found only in
tion port. This facilitates the application of CPU-95 systems to gas
• System status and mode been developed and imbedded into the CPU-95 system. The goal same ignition coil that is on the engine during a retrofit) in assessing switchable option to choose between an ultra-long spark inductive ignition systems. This allows the CPU-95 with
engines operating at varying stages of automation and sophistication.
• Ignition energy level, mode and number of strikes of these diagnostics is simple: reduce engine downtime and all of secondary voltage demand. This valuable capability assists users in duration mode to overcome poor in-cylinder mixing VariSpark™ to improve combustion and stability in
• Global timing (in degrees BTDC) the costs associated with it. determining the proper point at which to change their spark plugs, conditions, and a conventional shorter duration spark for
• Individual cylinder timing Display Module in troubleshooting problematic primary and secondary connec- maximum spark plug life. The new VariSpark™ combines
engines with poor air/fuel mixtures, such as large slow-
• Value of timing control signal (4-20mA) CPU-95 diagnostics are split into two separate groups. System tions, and in detecting combustion anomalies in the cylinder (such speed, low BMEP engines, or high speed engines
• Relative spark plug voltage indication by cylinder The CPU-95 Display Module, typically diagnostics are those that relate primarily to the operation of the as air/fuel ratio or imbalance conditions). The secondary diagnostic operating at “off-load” or idle conditions, while still
• Engine speed (in RPM) mounted in an engine control panel or other ignition system itself or to the inputs into the system (pickups, functions also assist the user selecting the appropriate point at STANDARD DURATION maximizing spark plug life by firing partially-fouled plugs
400 µSEC
• Engine overspeed setpoint enclosure off the engine, offers users control inputs, etc.). The second group encompasses Altronic’s which to manually or automatically adjust the delivered spark and wide spark plug gaps.
• Diagnostic messages comprehensive display and control function- patented primary and secondary discharge diagnostics (U.S. energy (there are three levels available) to assure maximum spark
ality. It features a two-line, backlit, alphanu- Patent No. 5,623,209). These powerful, non-intrusive diagnostics are plug life and reliable combustion.
Spark Characteristic Control unique in the industry for their reliability and the fact that they do EXTENDED DURATION
CPU-95 System for SI-Controller-equipped
meric display, in conjunction with a front- 2000 µSEC
For improved engine performance and
accessible, sealed membrane keypad and
Caterpillar 3500-Series Engines
combustion stability, ignition of lean mixtures
for emissions reduction or improved starting gives users access to critical operating, This custom CPU-95 is designed to replace the Altronic III
and loading characteristics: setup, and diagnostic information. An Typical System Diagnostics Patented Primary and Secondary and AIB Interface Box used on SI-Controller-equipped
• Double-striking mode (selectable ON/OFF) optional dual-port Display Module features a Discharge Diagnostics INDUCTIVE IGNITION DURATION
2000 µSEC Caterpillar 3508, 3512, and 3516 gas engines. It eliminates all
• VariSpark™ mode (selectable ON/OFF – second serial port for additional automation ignition-related moving parts (and the maintenance associ-
VariSpark™ model only) requirements, as well as other system ated with them) and offers users access to all the diagnos-
• Manual or automatic ignition energy level enhancements (see discussion to right). 0 1000 2000 3000 tics and spark characteristic control functionality resident in
control (3 levels) MICROSECONDS
standard CPU-95 systems.
Ignition Timing Control Modes Engine overspeed has been reached with the maximum observed speed Indicates the CPU-95 has detected an open circuit on output “A”; usually
Local and remote control of ignition timing
(global or individual cylinder) allows engine A typical running message: displayed. the result of faulty wiring or a failed coil.

starting and running performance to be

optimized.
• One-step timing change vs. input signal or RPM Enhanced CPU-95 Display Module
• Keypad control via display module
• Terminal program control via serial port Indicative of a condition where an incorrect number of gear tooth pulses have A short circuit condition detected on output “B”; may be the result of an
(791908-1)
• Analog 4 to 20 mA control been received between reset events. Often the result of an improperly improperly wired coil or a short to ground inside the conduit.
• Timing control vs. RPM gapped magnetic pickup or a damaged ring gear. • ModBus protocol support
Serial Communications to PC or
Engine Management System • A second serial port for continuous monitor-
All system features, display data, and configu- ing or automation system integration
ration inputs are accessible via an integral A low voltage demand condition on output “C”; typically indicates a
RS-485 serial port. A new, dual port display This diagnostic is flagged when zero gear tooth pulses are seen between shorted spark plug or secondary wire. • Unique digital and analog bar-graph display
module enables simultaneous use of both the two reset pulses. An open, shorted, or damaged magnetic pickup cable is and datalogging of Spark Reference Numbers
system display, and a supervisory control typically the source of this fault. for each ignition output
system utilizing ModBus RTU.
System Configuration Terminal Program • Password protection of key operating
Engine-specific configuration parameters are The CPU-95 Terminal Programs can be operated via the Ignition characteristics, including overspeed set-
contained in a plug-in memory (EEPROM) A high voltage demand condition detected on output “D”; generally points, spark characteristics, and diagnostic
Module’s serial port or through the second serial port located on the encountered when spark plugs become worn and require replacement.
which can be moved to a spare unit if neces- thresholds
sary. The memory can be configured in the enhanced CPU-95 Display Module. This Windows™-based software Diagnostic faulted when too many gear tooth pulses are received without
package duplicates the display and detection of a reset pulse. An open, shorted, or damaged magnetic pickup
shop or on location using a personal com- cable is also typically the source of this fault. For users seeking a higher level of functionality or looking
puter connected to the serial port. control capabilities of the Display
• Engine firing pattern Module on a compatible Personal to integrate their CPU-95 ignition system into an existing or
• Number of gear teeth or flywheel holes sensed Computer. The Terminal Program also planned supervisory control system, Altronic now offers an
No secondary spark on output “E”; indicates disconnected secondary lead Enhanced Display Module (791908-1).
• Timing control vs. 4-20mA and RPM enables a user to reconfigure the or voltage demand exceeding the coil’s output.
Diagnostics, Testing, Shutdown Capabilities engine specific data (firing pattern, This module incorporates a second and analog bar-graph display of each
number of holes or teeth, and timing No Hall-effect pickup (4-cycle indicator) signal has been detected or it is
Advanced and patented diagnostics, self-test, improperly synchronized with the reset pickup.
RS-485 serial port for downstream cylinder’s respective Spark Refer-
and alarm/shutdown capabilities are included control curves) in the field, as well as connection to an engine manage- ence Number (describing that
with each CPU-95 system: to simultaneously monitor all primary ment, control, or monitoring system cylinder’s voltage demand), the user
• Primary and secondary discharge faults and secondary discharge diagnostics for Typical digital/analog bar-graph display
and supports the ModBus RTU of monitored Spark Reference Number. can quickly determine where each
identified as to cylinder (see inset at right) each engine power cylinder. Output “F” is indicating that its monitored spark voltage demand is dramati-
cally lower than the average of the other cylinders. This indicates potentially protocol. All critical operating output is operating in the range
• Status of system pickups
• Verification of number of teeth/holes an overly rich air/fuel mixture, a short in the secondary wiring, or perhaps parameters such as engine overspeed setpoint, energy between the low and high spark demand setpoints.
• Test firing of selected cylinder(s) (optional) Engine Management System The expected 4-20mA control signal used for timing control is either below an improperly gapped spark plug. level, number of strikes (or long duration strike), and all Added capabilities also include an innovative datalogging
2mA or above 22mA. Annunciated when timing control loop is either not user-adjustable spark diagnostic thresholds are protected function which stores up to 100 date- and time-stamped
• Overspeed condition For OEM or highly-automated applications, the CPU-95 Ignition Module’s present or out of range.
• Alarm and shutdown outputs by a password-based security system embedded in this records of the Spark Reference Number for each output
RS-485 port can be directly connected to an engine management system enhanced display. which have been recorded at user-selectable intervals.
Retrofit Existing Altronic III, or other high-level control system for direct control of all ignition system These records are stored in a rolling “first in – first out”
III-CPU, CPU-90 Systems functions and access to all diagnostics. This full-featured Display Module is ideal for those closely
Retaining many system components makes A higher spark voltage demand than that seen in the other engine power fashion (whereby the newest record replaces the oldest)
monitoring spark voltage demand as a means of deter-
conversion to the CPU-95 simple and cost-effective. cylinders has been detected on output “K”. This may also be related to air/ and are accessible via the appropriate Display Module
fuel ratio or the condition of the secondary wiring and/or spark plugs. mining the end of useful spark plug life or for anomalies in
serial port for offline trending and analysis.
operation or combustion. Incorporating both a numerical
System Features Display Options CPU-95 System Diagnostics Special CPU-95 Systems
Comprehensive Display Capability The CPU-95 Ignition Module is designed to operate in conjunction with a To assist operators of gas engines in properly locating and not require a special ignition coil, any add-on probes or clamps, or VariSpark™ Option the fast rise time and high available voltage (up to 47kV)
Two-line, alphanumeric, backlit display variety of display/control options through its integral RS-485 communica- diagnosing the source of ignition-related problems, a suite of any other special equipment. Instead, Altronic primary and characteristic of capacitive discharge ignition systems,
indicates the following operating parameters: comprehensive, easy-to-use, troubleshooting diagnostics have secondary diagnostics utilize standard ignition coils (typically the VariSpark™ (patent pending) provides the user with a with the ultra-long spark duration previously found only in
tion port. This facilitates the application of CPU-95 systems to gas
• System status and mode been developed and imbedded into the CPU-95 system. The goal same ignition coil that is on the engine during a retrofit) in assessing switchable option to choose between an ultra-long spark inductive ignition systems. This allows the CPU-95 with
engines operating at varying stages of automation and sophistication.
• Ignition energy level, mode and number of strikes of these diagnostics is simple: reduce engine downtime and all of secondary voltage demand. This valuable capability assists users in duration mode to overcome poor in-cylinder mixing VariSpark™ to improve combustion and stability in
• Global timing (in degrees BTDC) the costs associated with it. determining the proper point at which to change their spark plugs, conditions, and a conventional shorter duration spark for
• Individual cylinder timing Display Module in troubleshooting problematic primary and secondary connec- maximum spark plug life. The new VariSpark™ combines
engines with poor air/fuel mixtures, such as large slow-
• Value of timing control signal (4-20mA) CPU-95 diagnostics are split into two separate groups. System tions, and in detecting combustion anomalies in the cylinder (such speed, low BMEP engines, or high speed engines
• Relative spark plug voltage indication by cylinder The CPU-95 Display Module, typically diagnostics are those that relate primarily to the operation of the as air/fuel ratio or imbalance conditions). The secondary diagnostic operating at “off-load” or idle conditions, while still
• Engine speed (in RPM) mounted in an engine control panel or other ignition system itself or to the inputs into the system (pickups, functions also assist the user selecting the appropriate point at STANDARD DURATION maximizing spark plug life by firing partially-fouled plugs
400 µSEC
• Engine overspeed setpoint enclosure off the engine, offers users control inputs, etc.). The second group encompasses Altronic’s which to manually or automatically adjust the delivered spark and wide spark plug gaps.
• Diagnostic messages comprehensive display and control function- patented primary and secondary discharge diagnostics (U.S. energy (there are three levels available) to assure maximum spark
ality. It features a two-line, backlit, alphanu- Patent No. 5,623,209). These powerful, non-intrusive diagnostics are plug life and reliable combustion.
Spark Characteristic Control unique in the industry for their reliability and the fact that they do EXTENDED DURATION
CPU-95 System for SI-Controller-equipped
meric display, in conjunction with a front- 2000 µSEC
For improved engine performance and
accessible, sealed membrane keypad and
Caterpillar 3500-Series Engines
combustion stability, ignition of lean mixtures
for emissions reduction or improved starting gives users access to critical operating, This custom CPU-95 is designed to replace the Altronic III
and loading characteristics: setup, and diagnostic information. An Typical System Diagnostics Patented Primary and Secondary and AIB Interface Box used on SI-Controller-equipped
• Double-striking mode (selectable ON/OFF) optional dual-port Display Module features a Discharge Diagnostics INDUCTIVE IGNITION DURATION
2000 µSEC Caterpillar 3508, 3512, and 3516 gas engines. It eliminates all
• VariSpark™ mode (selectable ON/OFF – second serial port for additional automation ignition-related moving parts (and the maintenance associ-
VariSpark™ model only) requirements, as well as other system ated with them) and offers users access to all the diagnos-
• Manual or automatic ignition energy level enhancements (see discussion to right). 0 1000 2000 3000 tics and spark characteristic control functionality resident in
control (3 levels) MICROSECONDS
standard CPU-95 systems.
Ignition Timing Control Modes Engine overspeed has been reached with the maximum observed speed Indicates the CPU-95 has detected an open circuit on output “A”; usually
Local and remote control of ignition timing
(global or individual cylinder) allows engine A typical running message: displayed. the result of faulty wiring or a failed coil.

starting and running performance to be

optimized.
• One-step timing change vs. input signal or RPM Enhanced CPU-95 Display Module
• Keypad control via display module
• Terminal program control via serial port Indicative of a condition where an incorrect number of gear tooth pulses have A short circuit condition detected on output “B”; may be the result of an
(791908-1)
• Analog 4 to 20 mA control been received between reset events. Often the result of an improperly improperly wired coil or a short to ground inside the conduit.
• Timing control vs. RPM gapped magnetic pickup or a damaged ring gear. • ModBus protocol support
Serial Communications to PC or
Engine Management System • A second serial port for continuous monitor-
All system features, display data, and configu- ing or automation system integration
ration inputs are accessible via an integral A low voltage demand condition on output “C”; typically indicates a
RS-485 serial port. A new, dual port display This diagnostic is flagged when zero gear tooth pulses are seen between shorted spark plug or secondary wire. • Unique digital and analog bar-graph display
module enables simultaneous use of both the two reset pulses. An open, shorted, or damaged magnetic pickup cable is and datalogging of Spark Reference Numbers
system display, and a supervisory control typically the source of this fault. for each ignition output
system utilizing ModBus RTU.
System Configuration Terminal Program • Password protection of key operating
Engine-specific configuration parameters are The CPU-95 Terminal Programs can be operated via the Ignition characteristics, including overspeed set-
contained in a plug-in memory (EEPROM) A high voltage demand condition detected on output “D”; generally points, spark characteristics, and diagnostic
Module’s serial port or through the second serial port located on the encountered when spark plugs become worn and require replacement.
which can be moved to a spare unit if neces- thresholds
sary. The memory can be configured in the enhanced CPU-95 Display Module. This Windows™-based software Diagnostic faulted when too many gear tooth pulses are received without
package duplicates the display and detection of a reset pulse. An open, shorted, or damaged magnetic pickup
shop or on location using a personal com- cable is also typically the source of this fault. For users seeking a higher level of functionality or looking
puter connected to the serial port. control capabilities of the Display
• Engine firing pattern Module on a compatible Personal to integrate their CPU-95 ignition system into an existing or
• Number of gear teeth or flywheel holes sensed Computer. The Terminal Program also planned supervisory control system, Altronic now offers an
No secondary spark on output “E”; indicates disconnected secondary lead Enhanced Display Module (791908-1).
• Timing control vs. 4-20mA and RPM enables a user to reconfigure the or voltage demand exceeding the coil’s output.
Diagnostics, Testing, Shutdown Capabilities engine specific data (firing pattern, This module incorporates a second and analog bar-graph display of each
number of holes or teeth, and timing No Hall-effect pickup (4-cycle indicator) signal has been detected or it is
Advanced and patented diagnostics, self-test, improperly synchronized with the reset pickup.
RS-485 serial port for downstream cylinder’s respective Spark Refer-
and alarm/shutdown capabilities are included control curves) in the field, as well as connection to an engine manage- ence Number (describing that
with each CPU-95 system: to simultaneously monitor all primary ment, control, or monitoring system cylinder’s voltage demand), the user
• Primary and secondary discharge faults and secondary discharge diagnostics for Typical digital/analog bar-graph display
and supports the ModBus RTU of monitored Spark Reference Number. can quickly determine where each
identified as to cylinder (see inset at right) each engine power cylinder. Output “F” is indicating that its monitored spark voltage demand is dramati-
cally lower than the average of the other cylinders. This indicates potentially protocol. All critical operating output is operating in the range
• Status of system pickups
• Verification of number of teeth/holes an overly rich air/fuel mixture, a short in the secondary wiring, or perhaps parameters such as engine overspeed setpoint, energy between the low and high spark demand setpoints.
• Test firing of selected cylinder(s) (optional) Engine Management System The expected 4-20mA control signal used for timing control is either below an improperly gapped spark plug. level, number of strikes (or long duration strike), and all Added capabilities also include an innovative datalogging
2mA or above 22mA. Annunciated when timing control loop is either not user-adjustable spark diagnostic thresholds are protected function which stores up to 100 date- and time-stamped
• Overspeed condition For OEM or highly-automated applications, the CPU-95 Ignition Module’s present or out of range.
• Alarm and shutdown outputs by a password-based security system embedded in this records of the Spark Reference Number for each output
RS-485 port can be directly connected to an engine management system enhanced display. which have been recorded at user-selectable intervals.
Retrofit Existing Altronic III, or other high-level control system for direct control of all ignition system These records are stored in a rolling “first in – first out”
III-CPU, CPU-90 Systems functions and access to all diagnostics. This full-featured Display Module is ideal for those closely
Retaining many system components makes A higher spark voltage demand than that seen in the other engine power fashion (whereby the newest record replaces the oldest)
monitoring spark voltage demand as a means of deter-
conversion to the CPU-95 simple and cost-effective. cylinders has been detected on output “K”. This may also be related to air/ and are accessible via the appropriate Display Module
fuel ratio or the condition of the secondary wiring and/or spark plugs. mining the end of useful spark plug life or for anomalies in
serial port for offline trending and analysis.
operation or combustion. Incorporating both a numerical
System Features Display Options CPU-95 System Diagnostics Special CPU-95 Systems
Comprehensive Display Capability The CPU-95 Ignition Module is designed to operate in conjunction with a To assist operators of gas engines in properly locating and not require a special ignition coil, any add-on probes or clamps, or VariSpark™ Option the fast rise time and high available voltage (up to 47kV)
Two-line, alphanumeric, backlit display variety of display/control options through its integral RS-485 communica- diagnosing the source of ignition-related problems, a suite of any other special equipment. Instead, Altronic primary and characteristic of capacitive discharge ignition systems,
indicates the following operating parameters: comprehensive, easy-to-use, troubleshooting diagnostics have secondary diagnostics utilize standard ignition coils (typically the VariSpark™ (patent pending) provides the user with a with the ultra-long spark duration previously found only in
tion port. This facilitates the application of CPU-95 systems to gas
• System status and mode been developed and imbedded into the CPU-95 system. The goal same ignition coil that is on the engine during a retrofit) in assessing switchable option to choose between an ultra-long spark inductive ignition systems. This allows the CPU-95 with
engines operating at varying stages of automation and sophistication.
• Ignition energy level, mode and number of strikes of these diagnostics is simple: reduce engine downtime and all of secondary voltage demand. This valuable capability assists users in duration mode to overcome poor in-cylinder mixing VariSpark™ to improve combustion and stability in
• Global timing (in degrees BTDC) the costs associated with it. determining the proper point at which to change their spark plugs, conditions, and a conventional shorter duration spark for
• Individual cylinder timing Display Module in troubleshooting problematic primary and secondary connec- maximum spark plug life. The new VariSpark™ combines
engines with poor air/fuel mixtures, such as large slow-
• Value of timing control signal (4-20mA) CPU-95 diagnostics are split into two separate groups. System tions, and in detecting combustion anomalies in the cylinder (such speed, low BMEP engines, or high speed engines
• Relative spark plug voltage indication by cylinder The CPU-95 Display Module, typically diagnostics are those that relate primarily to the operation of the as air/fuel ratio or imbalance conditions). The secondary diagnostic operating at “off-load” or idle conditions, while still
• Engine speed (in RPM) mounted in an engine control panel or other ignition system itself or to the inputs into the system (pickups, functions also assist the user selecting the appropriate point at STANDARD DURATION maximizing spark plug life by firing partially-fouled plugs
400 µSEC
• Engine overspeed setpoint enclosure off the engine, offers users control inputs, etc.). The second group encompasses Altronic’s which to manually or automatically adjust the delivered spark and wide spark plug gaps.
• Diagnostic messages comprehensive display and control function- patented primary and secondary discharge diagnostics (U.S. energy (there are three levels available) to assure maximum spark
ality. It features a two-line, backlit, alphanu- Patent No. 5,623,209). These powerful, non-intrusive diagnostics are plug life and reliable combustion.
Spark Characteristic Control unique in the industry for their reliability and the fact that they do EXTENDED DURATION
CPU-95 System for SI-Controller-equipped
meric display, in conjunction with a front- 2000 µSEC
For improved engine performance and
accessible, sealed membrane keypad and
Caterpillar 3500-Series Engines
combustion stability, ignition of lean mixtures
for emissions reduction or improved starting gives users access to critical operating, This custom CPU-95 is designed to replace the Altronic III
and loading characteristics: setup, and diagnostic information. An Typical System Diagnostics Patented Primary and Secondary and AIB Interface Box used on SI-Controller-equipped
• Double-striking mode (selectable ON/OFF) optional dual-port Display Module features a Discharge Diagnostics INDUCTIVE IGNITION DURATION
2000 µSEC Caterpillar 3508, 3512, and 3516 gas engines. It eliminates all
• VariSpark™ mode (selectable ON/OFF – second serial port for additional automation ignition-related moving parts (and the maintenance associ-
VariSpark™ model only) requirements, as well as other system ated with them) and offers users access to all the diagnos-
• Manual or automatic ignition energy level enhancements (see discussion to right). 0 1000 2000 3000 tics and spark characteristic control functionality resident in
control (3 levels) MICROSECONDS
standard CPU-95 systems.
Ignition Timing Control Modes Engine overspeed has been reached with the maximum observed speed Indicates the CPU-95 has detected an open circuit on output “A”; usually
Local and remote control of ignition timing
(global or individual cylinder) allows engine A typical running message: displayed. the result of faulty wiring or a failed coil.

starting and running performance to be

optimized.
• One-step timing change vs. input signal or RPM Enhanced CPU-95 Display Module
• Keypad control via display module
• Terminal program control via serial port Indicative of a condition where an incorrect number of gear tooth pulses have A short circuit condition detected on output “B”; may be the result of an
(791908-1)
• Analog 4 to 20 mA control been received between reset events. Often the result of an improperly improperly wired coil or a short to ground inside the conduit.
• Timing control vs. RPM gapped magnetic pickup or a damaged ring gear. • ModBus protocol support
Serial Communications to PC or
Engine Management System • A second serial port for continuous monitor-
All system features, display data, and configu- ing or automation system integration
ration inputs are accessible via an integral A low voltage demand condition on output “C”; typically indicates a
RS-485 serial port. A new, dual port display This diagnostic is flagged when zero gear tooth pulses are seen between shorted spark plug or secondary wire. • Unique digital and analog bar-graph display
module enables simultaneous use of both the two reset pulses. An open, shorted, or damaged magnetic pickup cable is and datalogging of Spark Reference Numbers
system display, and a supervisory control typically the source of this fault. for each ignition output
system utilizing ModBus RTU.
System Configuration Terminal Program • Password protection of key operating
Engine-specific configuration parameters are The CPU-95 Terminal Programs can be operated via the Ignition characteristics, including overspeed set-
contained in a plug-in memory (EEPROM) A high voltage demand condition detected on output “D”; generally points, spark characteristics, and diagnostic
Module’s serial port or through the second serial port located on the encountered when spark plugs become worn and require replacement.
which can be moved to a spare unit if neces- thresholds
sary. The memory can be configured in the enhanced CPU-95 Display Module. This Windows™-based software Diagnostic faulted when too many gear tooth pulses are received without
package duplicates the display and detection of a reset pulse. An open, shorted, or damaged magnetic pickup
shop or on location using a personal com- cable is also typically the source of this fault. For users seeking a higher level of functionality or looking
puter connected to the serial port. control capabilities of the Display
• Engine firing pattern Module on a compatible Personal to integrate their CPU-95 ignition system into an existing or
• Number of gear teeth or flywheel holes sensed Computer. The Terminal Program also planned supervisory control system, Altronic now offers an
No secondary spark on output “E”; indicates disconnected secondary lead Enhanced Display Module (791908-1).
• Timing control vs. 4-20mA and RPM enables a user to reconfigure the or voltage demand exceeding the coil’s output.
Diagnostics, Testing, Shutdown Capabilities engine specific data (firing pattern, This module incorporates a second and analog bar-graph display of each
number of holes or teeth, and timing No Hall-effect pickup (4-cycle indicator) signal has been detected or it is
Advanced and patented diagnostics, self-test, improperly synchronized with the reset pickup.
RS-485 serial port for downstream cylinder’s respective Spark Refer-
and alarm/shutdown capabilities are included control curves) in the field, as well as connection to an engine manage- ence Number (describing that
with each CPU-95 system: to simultaneously monitor all primary ment, control, or monitoring system cylinder’s voltage demand), the user
• Primary and secondary discharge faults and secondary discharge diagnostics for Typical digital/analog bar-graph display
and supports the ModBus RTU of monitored Spark Reference Number. can quickly determine where each
identified as to cylinder (see inset at right) each engine power cylinder. Output “F” is indicating that its monitored spark voltage demand is dramati-
cally lower than the average of the other cylinders. This indicates potentially protocol. All critical operating output is operating in the range
• Status of system pickups
• Verification of number of teeth/holes an overly rich air/fuel mixture, a short in the secondary wiring, or perhaps parameters such as engine overspeed setpoint, energy between the low and high spark demand setpoints.
• Test firing of selected cylinder(s) (optional) Engine Management System The expected 4-20mA control signal used for timing control is either below an improperly gapped spark plug. level, number of strikes (or long duration strike), and all Added capabilities also include an innovative datalogging
2mA or above 22mA. Annunciated when timing control loop is either not user-adjustable spark diagnostic thresholds are protected function which stores up to 100 date- and time-stamped
• Overspeed condition For OEM or highly-automated applications, the CPU-95 Ignition Module’s present or out of range.
• Alarm and shutdown outputs by a password-based security system embedded in this records of the Spark Reference Number for each output
RS-485 port can be directly connected to an engine management system enhanced display. which have been recorded at user-selectable intervals.
Retrofit Existing Altronic III, or other high-level control system for direct control of all ignition system These records are stored in a rolling “first in – first out”
III-CPU, CPU-90 Systems functions and access to all diagnostics. This full-featured Display Module is ideal for those closely
Retaining many system components makes A higher spark voltage demand than that seen in the other engine power fashion (whereby the newest record replaces the oldest)
monitoring spark voltage demand as a means of deter-
conversion to the CPU-95 simple and cost-effective. cylinders has been detected on output “K”. This may also be related to air/ and are accessible via the appropriate Display Module
fuel ratio or the condition of the secondary wiring and/or spark plugs. mining the end of useful spark plug life or for anomalies in
serial port for offline trending and analysis.
operation or combustion. Incorporating both a numerical
System Overview Dimensions Specifications
Display Module Input Signals: • VariSpark™ Option
6.50
6.50
Magnetic pickups (2) • ModBus Communications
6.00
1 - ring gear teeth or drilled holes NEW FEATURES: • Dual Serial Ports
6.00 .203 DIA.
(TYP 4)
.203 DIA.
1 - reset (1/engine revolution) • Data-logging Capability
(TYP 4)
Hall-effect pickup for compression stroke reference (4-cycle applications only) • 8-Output Model
Control Inputs (ground to activate): CPU-95 with
Shutdown
Feature control (timing, energy, double-strike, VariSpark™) VariSpark™ Option
6.00 6.50
6.00 6.50
Timing Control Inputs: ADVANCED DIGITAL IGNITION SYSTEM
Manual (display module keypad)
Analog (4-20mA control signal) FOR INDUSTRIAL ENGINES
Digital (RS-485 serial data)
Ignition Output: • Microprocessor-based, crankshaft-referenced digital ignition
2.19
2.19
47kV maximum output voltage system for medium-sized natural gas-fueled engines
1.25
1.25 300–600 microseconds duration (791950/952/955) • Optimizes engine combustion and performance and
1000–2000 microseconds duration with VariSpark™ option (791958) maximizes spark plug life
Control Outputs (solid state, N.C. switches): • New VariSpark™ option with up to 2000 microsecond spark
Normal fire confirm duration combines the best features of capacitor discharge
Alarm fault and inductive ignition to enhance engine performance
Shutdown fault • Comprehensive primary and secondary diagnostics and
prognostics minimize engine down time
Communications:
RS-485 serial • Intuitive, “user-friendly” display/interface offers easy access
(Single or dual port display modules available) to critical information and the ability to make virtually all
system adjustments
Display: • Optional new enhanced Display Module with dual serial
Alphanumeric, 2 lines x 16 characters, backlit ports, ModBus protocol, analog bar-graph displays, and
Ignition Module Power Requirements: diagnostic data-logging.
9.90
9.90
24VDC, 1–8 amps typ. (varies by application) • Simple and cost-effective to retrofit for users of
NOTE: On many applications, power can be supplied by engine-driven Altronic III, III-CPU, and CPU-90
6.00
6.00
Altronic 24 Vdc alternator; see form ALT.
The Altronic CPU-95 is a 24 Vdc-powered, microprocessor-based
Temperature
digital ignition system designed for application to medium-range
-40° F. to +158° F. / -40° C. to +70° C.
industrial gas engines. Operational advantages include a full-
featured user display and interface, spark characteristic control,
Ordering Information advanced timing adjustment options, serial communications, and
System Components CPU-95 IGNITION MODULE – 1 per system
state-of-the-art diagnostics.
Each CPU-95 system is composed of the Ignition Module, two per crankshaft revolution reset pulse. Four-cycle applica- Full access to all CPU-95 operating data and control options are
8.75
8.75 9.75
9.75 791950-8 Ignition Module, 8 outputs, standard
magnetic pickups and cables, a primary wiring harness, and an tions also utilize a Hall-effect pickup sensing a magnet available through a “user friendly” system display module as well as via
791950-16 Ignition Module, 16 outputs, standard a PC operating a Windows™-based terminal program. Both options
ignition coil for each spark plug. A system Display Module, turning at camshaft speed to determine the compression
791950-18 Ignition Module, 18 outputs, standard display essential engine and ignition data such as RPM, timing angle,
typically used (but not required), is also available. A Hall-effect cycle of the engine.
pickup and cable, as well as a magnet turning at camshaft- 791952-18 Ignition Module, 18 outputs, dual capacitor spark energy level, and diagnostic messages, as well as offer user
The CPU-95 Ignition Module is typically mounted on or 791952-20 Ignition Module, 20 outputs, dual capacitor control of setup selections such as global and individual cylinder
speed are utilized on 4-cycle applications only.
near the engine. This 24-VDC-powered module accepts 791955-16 Ignition Module, 16 outputs, Caterpillar G3500 low emissions engines timing, energy level, double strike or extended spark duration
and processes the input data derived from the engine-
System Operation based pickups and any control data being brought into
791958-16 Ignition Module, 16 outputs, VariSpark™ extended spark duration (VariSpark™), and overspeed setpoint.
6.25
6.25
Patented CPU-95 diagnostics and prognostics (predictive diagnos-
The diagram above illustrates how these components are the system through the CPU-95 Display Module, Termi- CPU-95 DISPLAY MODULE – 1 per system
integrated into an operating system. To insure that the spark nal Program, or engine management system (see review tics) supervise all ignition system-related functions. The secondary
USE WITH IGNITION MODULE analysis capabilities detect shorted spark plugs and leads, as well as
is delivered at precisely the right moment for each engine to left). This control information, including timing adjust-
PART NO. DESCRIPTION 791950-xx spark plugs that exhibit high voltage demand or are not firing at all. A
cylinder on each revolution, the CPU-95 determines the ments, spark energy control, and multi-strike or extended 791952-18
position of the engine crankshaft through the use of a duration (VariSpark™) directly influences both the moment 791958-16 791952-20 791955-16 display of the relative voltage demand of each spark plug is provided,
magnetic pickup sensing starting ring gear teeth or holes at which the spark is delivered and the important charac- 791902-1 Display Module, standard X allowing spark plug changes to be predicted and scheduled. Module
drilled into the flywheel allowing precise determination of teristics of that spark. A 4-20mA timing control input from 791902-1S Display Module, no test X
and pickup operation, timing input, and primary output functions are
crankshaft angular position in real time. Matching that to a a supervisory control system or an instrument monitoring also monitored for operation within preset limits.
791902-2 Display Module, Cat G3500 X
pre-programmed system memory, the CPU-95 system can a specific operating parameter (such as fuel manifold The CPU-95 system is shop or field configured via the CPU-95 Output
791908-1 Display Module, enhanced X X
achieve extremely high ignition timing accuracy. A second, pressure or air manifold temperature) is also available as Module serial port using a personal computer and the Altronic CPU-95
flywheel-based magnetic pickup, is used to generate a once an additional means of optimizing performance. See CPU-95 AL Application Information for further details. Terminal Software.
712 TRUMBULL AVE / GIRARD, OH 44420 CERTIFIED
(330) 545-9768 / Fax: (330) 545-9005 CLASS I, DIVISION 2, GROUPS C and D
www.altronicinc.com E-mail: sales@altronicinc.com
Form CPU-95 1-02 ©2002 Altronic, Inc.
System Overview Dimensions Specifications
Display Module Input Signals: • VariSpark™ Option
6.50
6.50
Magnetic pickups (2) • ModBus Communications
6.00
1 - ring gear teeth or drilled holes NEW FEATURES: • Dual Serial Ports
6.00 .203 DIA.
(TYP 4)
.203 DIA.
1 - reset (1/engine revolution) • Data-logging Capability
(TYP 4)
Hall-effect pickup for compression stroke reference (4-cycle applications only) • 8-Output Model
Control Inputs (ground to activate): CPU-95 with
Shutdown
Feature control (timing, energy, double-strike, VariSpark™) VariSpark™ Option
6.00 6.50
6.00 6.50
Timing Control Inputs: ADVANCED DIGITAL IGNITION SYSTEM
Manual (display module keypad)
Analog (4-20mA control signal) FOR INDUSTRIAL ENGINES
Digital (RS-485 serial data)
Ignition Output: • Microprocessor-based, crankshaft-referenced digital ignition
2.19
2.19
47kV maximum output voltage system for medium-sized natural gas-fueled engines
1.25
1.25 300–600 microseconds duration (791950/952/955) • Optimizes engine combustion and performance and
1000–2000 microseconds duration with VariSpark™ option (791958) maximizes spark plug life
Control Outputs (solid state, N.C. switches): • New VariSpark™ option with up to 2000 microsecond spark
Normal fire confirm duration combines the best features of capacitor discharge
Alarm fault and inductive ignition to enhance engine performance
Shutdown fault • Comprehensive primary and secondary diagnostics and
prognostics minimize engine down time
Communications:
RS-485 serial • Intuitive, “user-friendly” display/interface offers easy access
(Single or dual port display modules available) to critical information and the ability to make virtually all
system adjustments
Display: • Optional new enhanced Display Module with dual serial
Alphanumeric, 2 lines x 16 characters, backlit ports, ModBus protocol, analog bar-graph displays, and
Ignition Module Power Requirements: diagnostic data-logging.
9.90
9.90
24VDC, 1–8 amps typ. (varies by application) • Simple and cost-effective to retrofit for users of
NOTE: On many applications, power can be supplied by engine-driven Altronic III, III-CPU, and CPU-90
6.00
6.00
Altronic 24 Vdc alternator; see form ALT.
The Altronic CPU-95 is a 24 Vdc-powered, microprocessor-based
Temperature
digital ignition system designed for application to medium-range
-40° F. to +158° F. / -40° C. to +70° C.
industrial gas engines. Operational advantages include a full-
featured user display and interface, spark characteristic control,
Ordering Information advanced timing adjustment options, serial communications, and
System Components CPU-95 IGNITION MODULE – 1 per system
state-of-the-art diagnostics.
Each CPU-95 system is composed of the Ignition Module, two per crankshaft revolution reset pulse. Four-cycle applica- Full access to all CPU-95 operating data and control options are
8.75
8.75 9.75
9.75 791950-8 Ignition Module, 8 outputs, standard
magnetic pickups and cables, a primary wiring harness, and an tions also utilize a Hall-effect pickup sensing a magnet available through a “user friendly” system display module as well as via
791950-16 Ignition Module, 16 outputs, standard a PC operating a Windows™-based terminal program. Both options
ignition coil for each spark plug. A system Display Module, turning at camshaft speed to determine the compression
791950-18 Ignition Module, 18 outputs, standard display essential engine and ignition data such as RPM, timing angle,
typically used (but not required), is also available. A Hall-effect cycle of the engine.
pickup and cable, as well as a magnet turning at camshaft- 791952-18 Ignition Module, 18 outputs, dual capacitor spark energy level, and diagnostic messages, as well as offer user
The CPU-95 Ignition Module is typically mounted on or 791952-20 Ignition Module, 20 outputs, dual capacitor control of setup selections such as global and individual cylinder
speed are utilized on 4-cycle applications only.
near the engine. This 24-VDC-powered module accepts 791955-16 Ignition Module, 16 outputs, Caterpillar G3500 low emissions engines timing, energy level, double strike or extended spark duration
and processes the input data derived from the engine-
System Operation based pickups and any control data being brought into
791958-16 Ignition Module, 16 outputs, VariSpark™ extended spark duration (VariSpark™), and overspeed setpoint.
6.25
6.25
Patented CPU-95 diagnostics and prognostics (predictive diagnos-
The diagram above illustrates how these components are the system through the CPU-95 Display Module, Termi- CPU-95 DISPLAY MODULE – 1 per system
integrated into an operating system. To insure that the spark nal Program, or engine management system (see review tics) supervise all ignition system-related functions. The secondary
USE WITH IGNITION MODULE analysis capabilities detect shorted spark plugs and leads, as well as
is delivered at precisely the right moment for each engine to left). This control information, including timing adjust-
PART NO. DESCRIPTION 791950-xx spark plugs that exhibit high voltage demand or are not firing at all. A
cylinder on each revolution, the CPU-95 determines the ments, spark energy control, and multi-strike or extended 791952-18
position of the engine crankshaft through the use of a duration (VariSpark™) directly influences both the moment 791958-16 791952-20 791955-16 display of the relative voltage demand of each spark plug is provided,
magnetic pickup sensing starting ring gear teeth or holes at which the spark is delivered and the important charac- 791902-1 Display Module, standard X allowing spark plug changes to be predicted and scheduled. Module
drilled into the flywheel allowing precise determination of teristics of that spark. A 4-20mA timing control input from 791902-1S Display Module, no test X
and pickup operation, timing input, and primary output functions are
crankshaft angular position in real time. Matching that to a a supervisory control system or an instrument monitoring also monitored for operation within preset limits.
791902-2 Display Module, Cat G3500 X
pre-programmed system memory, the CPU-95 system can a specific operating parameter (such as fuel manifold The CPU-95 system is shop or field configured via the CPU-95 Output
791908-1 Display Module, enhanced X X
achieve extremely high ignition timing accuracy. A second, pressure or air manifold temperature) is also available as Module serial port using a personal computer and the Altronic CPU-95
flywheel-based magnetic pickup, is used to generate a once an additional means of optimizing performance. See CPU-95 AL Application Information for further details. Terminal Software.
712 TRUMBULL AVE / GIRARD, OH 44420 CERTIFIED
(330) 545-9768 / Fax: (330) 545-9005 CLASS I, DIVISION 2, GROUPS C and D
www.altronicinc.com E-mail: sales@altronicinc.com
Form CPU-95 1-02 ©2002 Altronic, Inc.