CPU-95EVS Enhanced VariSpark

CPU-95EVS Enhanced VariSpark
CPU-95EVS Enhanced VariSpark®
Digital Ignition System
for Industrial Engines
Features
Users can select from one of six VariSpark
Serial Communications to PC or
Engine Management System
What is VariSpark® and how is it implemented in the CPU-95EVS system?
spark energy profiles embedded within
All system features, display data, and confi-
VariSpark represents a wholesale depar-
the system to insure maximized improved
guration inputs are accessible via an integral
ture from traditional CD ignition sys-
engine performance and combustion stabi-
RS-485 serial port enabling simultaneous
tems—a system that discharges a storage
lity, ignition of lean mixtures for emissions
use of both the system display and a supervi-
capacitor through the ignition coil during
reduction or improved starting and loading
sory control system utilizing ModBus RTU.
firing. VariSpark technology utilizes a
VariSpark® Spark Profile Control
specialized power supply and high speed
characteristics. Profiles can be changed
via the keypad, Modbus, or the miscel-
System Configuration
switching technology to positively control
laneous input switch while the engine is
Engine-specific configuration parameters
the delivered spark energy. This provides
running to suit varying operating needs.
(engine firing pattern, gear teeth, timing
the capacity to independently control
control map) are contained in a plug-in
spark intensity and duration—in many
memory (EEPROM) which can be moved
cases delivering energy orders of magnitu-
Large, backlit, graphical display indicates
the following operating parameters:
to a spare unit if necessary. The memory
de higher than any other ignition tech-
can be configured in the shop or on loca-
nology. The impact on engine operation:
„„ System status and mode
tion using a personal computer connected
assured combustion of leaner mixtures,
„„ Selected VariSpark® profile
to the serial port.
the ability to operate at higher efficienci-
Comprehensive Display Capability
es, and extended service intervals.
„„ Global timing (in degrees BTDC)
„„ Individual cylinder timing
Diagnostics, Testing, Shutdown
Capabilities
Accessing one of the six VariSpark spark
Advanced and patented diagnostics, self-
can be accomplished from the system key-
„„ Engine speed (in RPM)
test, and alarm/shutdown capabilities are
pad, via Modbus, and/or through the use
„„ Engine overspeed setpoint
included with each CPU-95EVS system:
of the Miscellaneous Input Switch. This
„„ Diagnostic messages
„„ Primary and secondary discharge
faults identified as to cylinder
„„ Value of timing control signal (4-20mA)
„„ Relative spark plug voltage indication
by cylinder
profiles embedded within the CPU-95EVS
allows for the use of the single and doublestrike configurations that are part of the
Ignition Timing Control Modes
„„ Status of system pickups
standard CPU-95 system for lower demand
Local and remote control of ignition ti-
„„ Test firing of selected cylinder(s) (optional)
operating conditions, and for the use of
„„ Overspeed condition
more current intensive, longer-duration
„„ Alarm and shutdown outputs
profiles when proper combustion is more
ming (global or individual cylinder) allows
engine starting and running performance
to be optimized.
„„ One-step timing change vs. input
signal or RPM
Retrofit Existing Altronic III, III-CPU,
CPU-90, and CPU-95 Systems
„„ Keypad control via display module
Retaining many system components ma-
„„ Terminal program control via serial port
kes conversion to the CPU-95EVS simple
„„ Analog 4 to 20mA control
and cost-effective.
difficult—lean operation, light load, etc.
100mA/Div
200µs/Div
„„ Timing control vs. RPM
E1 SS (RED): Emulates SS mode of standard CPU-95.
E3 SS (BLUE): 5x the energy of single spark.
Overview
„„ Incorporates Altronic-patented VariSpark
spark current control technology to assure
combustion in lean operating environments, on engines with poorly mixed air/
fuel charges, under light load, and on
low-btu fuel applications
„„ A simple, cost-effective system upgrade
for existing CPU-90/95 systems – All
system accessories including the
primary harness, coils, secondary leads,
pickups, and pickup cables are retained
spark voltage demand by cylinder on both
pickups and cables, a primary wiring
an immediate and long-term basis.
harness, and an ignition coil for each spark
plug. A system Display Module, typically
Patented CPU-95EVS diagnostics and
used (but not required), is also available.
prognostics (predictive diagnostics) super-
A Hall-effect pickup and cable, as well as
vise all ignition system-related functions.
a magnet turning at camshaft-speed are
The secondary analysis capabilities detect
utilized on 4-cycle applications only.
shorted spark plugs and leads, as well
as spark plugs that exhibit high voltage
demand or are not firing at all. A display
„„ Delivers full-time system, primary
discharge, and secondary discharge
diagnostics (patented)
of the relative voltage demand of each
„„ Features an advanced, user-friendly
Display Module to adjust all critical
operating parameters and to access all
system and spark diagnostics
Module and pickup operation, timing input,
„„ Class I, Div 2, Group C and D certified
The Altronic CPU-95EVS is a microprocessor-based digital ignition system
designed for application to mediumrange industrial gas engines. Advantages
include the patented VariSpark spark
®
energy control system, a full-featured user
display and interface, advanced timing
adjustment options, serial communications, and state-of-the-art diagnostics.
Full access to all CPU-95EVS operating
data and control functionality is available through an advanced, user-friendly
Display Module as well as via a PC operating the provided CPU-95EVS Terminal
Program. Both options display essential
engine and ignition data such as RPM, timing angle, VariSpark® spark profile, and
spark plug is provided, allowing spark plug
changes to be predicted and scheduled.
and primary output functions are also monitored for operation within preset limits.
The CPU-95EVS system is shop- or fieldconfigurable. Using the standard Terminal
Program and the CPU-95 Display Module,
the user has the added flexibility and convenience associated with a USB-based
connection to the system for programming. Operation of the Display Module
also enables the user to download and
retain the ignition operating parameters
(firing code, number of monitored gear
teeth, 4-20mA or RPM control loop, etc.)
from the connected Ignition Module.
Should the ignition module ever require
replacement, the Display Module can then
simply upload the correct ignition operating
parameters into the new unit without need
for a laptop, the Terminal Program, or the
services of an instrumentation technician.
Operation
The diagram at right illustrates how
these components are integrated into an
operating system. To insure that the spark
is delivered at precisely the right moment
for each engine cylinder on each revolution, the CPU-95EVS determines the position of the engine crankshaft through the
use of a magnetic pickup sensing starting
ring gear teeth or holes drilled into the
flywheel allowing precise determination
of crankshaft angular position in real
time. Matching that to a pre-programmed
system memory, the CPU-95EVS system
can achieve extremely high ignition timing accuracy. A second, flywheel-based
magnetic pickup, is used to generate
a once per crankshaft revolution reset
pulse. Four-cycle applications also utilize
a Hall-effect pickup sensing a magnet
turning at camshaft speed to determine
the compression cycle of the engine.
The CPU-95EVS Ignition Module is
typically mounted on or near the engine.
The associated Power Supply Module
accepts 24VDC and provides a185 VDC
Components
output The Ignition Module accepts and
ments and overspeed setpoint. Extensive
Each CPU-95EVS system is composed of
engine-based pickups and any control
spark reference number graphing and
the VariSpark® Ignition Module, a VariS-
data being brought into the system
trending is included to support analysis of
park Power Supply Module, two magnetic
through the CPU-95EVS Display Module,
diagnostic messages, along with global
and individual cylinder timing adjust-
®
processes the input data derived from the
Terminal Program, or engine management
of ignition-related problems, a suite of
These powerful, non-intrusive diagnos-
system. This control information, inclu-
comprehensive, easy-to-use, troubleshoo-
tics are unique in the industry for their
ding timing adjustments and VariSpark
ting diagnostics have been developed and
reliability and the fact that they do not
spark profile selections influences both
imbedded into the CPU-95 system. The
require a special ignition coil, any add-on
the moment at which the spark is deli-
goal of these diagnostics is simple: redu-
probes or clamps, or any other special
vered and the important characteristics
ce engine downtime and all of the costs
equipment. Instead, Altronic primary and
of that spark. A 4-20mA timing control
associated with it.
secondary diagnostics utilize standard
input from a supervisory control system
ignition coils (typically the same ignition
or an instrument monitoring a specific
CPU-95 diagnostics are split into two
coil that is on the engine during a retrofit)
operating parameter (such as fuel mani-
separate groups. System diagnostics are
in assessing secondary voltage demand.
fold pressure or air manifold temperature)
those that relate primarily to the operati-
This valuable capability assists users in
is also available as an additional means
on of the ignition system itself or to the
determining the proper point at which to
of optimizing performance.
inputs into the system (pickups, control
change their spark plugs, in troubleshoo-
inputs, etc.). The second group encom-
ting problematic primary and secondary
passes Altronic’s patented primary and
connections, and in detecting combustion
secondary discharge diagnostics (U.S.
anomalies in the cylinder (such as air/fuel
Patent No. 5,623,209).
ratio or imbalance conditions).
Diagnostics
To assist operators of gas engines in properly locating and diagnosing the source
H
I
G
CPU-95EVS Ignition System
P/N
WARNING: KEEP COVER TIGHT
WHILE CIRCUITS ARE LIVE.
A
AVERTISSEMENT: GARDER LE
COUVERCLE BIEN FERMÉ
LORSQUE LES.
S/N
C
RATED: 20–32Vdc, 5A MAX.
MAXIMUM AMBIENT TEMPERATURE: +85° CELSIUS
WARNING: EXPLOSION HAZARD. DO NOT CONNECT
OR DISCONNECT UNLESS POWER HAS BEEN REMOVED
OR AREA IS KNOWN TO BE NONHAZARDOUS.
SUBSTITUTION OF COMPONENTS MAY IMPAIR
SUITABILITY FOR DIV 2
MUST BE INSTALLED PER FORM CPU-95EVS II
INSTALLÉ CONFORMÉMANT CPU-95EVS II
ALTRONIC, LLC GIRARD, OHIO USA U.S. PATENT NO. 5,623,209
F
B
D
E
CPU-95EVS Display Module
Display Module capabilities also include
an on- board data logging function which
retains up to one-hundred (100) date
and time- stamped records of the Spark
Reference Number for each output which
have been recorded at user-adjustable
intervals. These records are stored in a
rolling “first in-first out” fashion and are
User can monitor spark reference numbers individually and
simultaneously.
For users integrating their CPU-95EVS
is damaged or requires replacement.
system into an existing or planned
supervisory control or remote monitoring
The larger system display allows for the
system, Altronic offers its Display Module
simultaneous display of large amounts
(791909-1).
of information, and the ability to “map”
the CPU-95EVS Ignition Outputs to the
In addition to incorporating a Modbus
appropriate cylinder designation. Thus,
RTU-enabled serial port for communica-
the user retains indication of the appro-
tion with a remote monitoring system or
priate CPU-95EVS output (A, B, C, etc.)
local controller, the CPU-95EVS Display
while also getting diagnostic indications
Module also supports USB connectivity to
in terms of the on-engine cylinder refe-
a PC and the associated CPU-95 Terminal
rence (5L, 3R, #6, etc.). Advanced spark
Program. An innovative ignition memory
reference number graphing is also made
“cloning” system allows this advanced
possible by the incorporation of the lar-
Module to upload the ignition system
ger display (see sample displays above).
configuration file (number of cylinders,
“Live” and data log-based XY graphing of
firing pattern, number of monitored gear
the monitored Spark Reference Number
teeth, 4-20mA or RPM curve, etc.) from
for a given cylinder and “at-a-glance”
a connected Ignition Module, retain it
indication of the relative value of the
indefinitely in its own memory, and—wit-
Spark Reference Number across all
hout need of a laptop—to download that
cylinders gives the user unparalleled ac-
memory information to a new Ignition Mo-
cess and convenience in ignition system
dule in the event that the existing module
troubleshooting and monitoring.
accessible for download via the Display
Module for offline trending and analysis.
„„ Larger display for greater single-screen
access to operating, diagnostic, and
setup data
„„ Features an integral graphing and
data-logging capability for convenient
spark reference number analysis
„„ Allows for display mapping of individual outputs (Output A = Cylinder 1L,
Output B = Cylinder 1 R, etc.)
„„ Incorporates a unique uploaddownload capability to assist users
in configuring a new or replacement
CPU-95 Ignition Module without need
of a laptop
„„ On-board USB connectivity and a
Modbus RTU-capable serial port are
included for simple connection to a
PC for continuous monitoring and/or
automation system integration
„„ Password protection of key operating
characteristics including overspeed
setpoint, spark configuration, and
diagnostic thresholds
Specifications
Dimensions
Input Signals:
Magnetic pickups, (1) ring gear teeth or drilled holes
(1) reset (1/engine revolution)
Hall-effect for compression stroke reference (4-cycle only)
Display Module
6.50
Control Inputs: Shutdown input, “G-Lead“
Timing Control Inputs: Manual (display module keypad)
Analog (4-20mA control signal)
Digital (RS-485 serial data)
6.50
Output:
47kV maximum output voltage
Control Outputs:
Normal fire confirm
Solid State, NC switches Alarm fault
Shutdown fault
Communications:
RS-485 serial, USB, Modbus RTU (Enhanced Display Only)
6.00
1.25
2.19
.203 DIA.
(TYP 4)
Display:
Alphanumeric, backlit
Power Rqmt: 24VDC, 1–20 amps typ. (varies by application)
NOTE: On many applications, power can be supplied by engine-driven Altronic 24Vdc alternator; see form ALT.
6.00
5.50
Temperature:
-40°F to +158°F (-40°C to +70°C)
Ordering Information
CPU-95EVS VariSpark Ignition System
5.50
®
791963-16A
791963-16A-SS
791911-1
791909-1
CPU-95EVS with Enhanced Display
CPU-95EVS with stainless steel enclosure
Power Supply Module, VariSpark
Display Module
Power Supply Module
7.43
188.6
6.50
165
Ignition Module
6.31
160.3
6.97
177
7.43
188.6
6.50
165
.25
6.4
4.66
103.3
712 Trumbull Avenue / Girard, Ohio 44420 USA
P: 330-545-9768 F: 330-545-3231
www.altronic-llc.com
Form CPU-95EVS 9-14 ©2013 Altronic. LLC
4.81
122.3
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