®

Upgrade Kits
For WAUKESHA® VHP G/GU/GSI/GL
12 Cylinder Engines

GAS ENGINE TECHNOLOGY

reliable ∙ efficient ∙ worldwide
1
 Ignition and Detonation Control Upgrade Kits

1
CAN
C
For WAUKESHA VHP G/GU/GSI/GL ®

12 Cylinder Engines CAN

Upgrade your workhorse to the latest

Systems and Accessories 0 to 5 V / 4 to 20 mA
D

MOTORTECHʼs ignition and detonation control upgrade kits are

specially designed for a complete and simple conversion of
Power Supply 24 VDC
WAUKESHA® VHP series gas engines. Prefabricated and prewired
components make the conversion easier and reduce costs based on
engine downtime.
Donʼt go Low-Tech and take the risk of engine down time because TORTECH
MO
of failing equipment. Eliminate the need for constant rewiring,
connector exchanges or straightening out weak and bent aluminum UPGRADE
wiring rails. 2 5
IT E M
Upgrade your engine to the latest systems and increase
reliability and efficiency. A

Z
Benefits
■■ Kits include all necessary components for a
successful ignition or detonation control upgrade 6 3
■■ Available in different versions for unshielded or
shielded applications 6
■■ Prefabricated components guarantee easy V 4
installation
■■ High quality materials and design last longer
■■ Upgrade kits can be extended individually

Sample System Overview – Ignition Control X

B
Necessary Components System Enhancement
1 MIC4 ignition controller C PowerView3 –
2 Pickup lead* HMI module
D DetCon20 –
3 1 Hall effect pickup*
Detonation controller
4 Trigger disc and hub
5 Output harness* Description
6 Ignition coil* V Camshaft W
7 1 Primary lead/PolyMot™ W Crankshaft
spark plug lead per ignition coil*
X Engine
Accessories Y Cylinder
Z Harness to connect the
A Junction box 7 7
ignition wiring rails
B AlphaRail ignition wiring rail Y
and the junction box

* Shielded and unshielded versions depending on upgrade kit.

2
 Ignition Control Upgrade Kit Components
®

MIC4 Ignition Controller

Efficiency-enhanced engines, stricter emission regulations, highly compressed
mixtures, as well as the use of a great variety of gas types are putting even greater
demands on the entire ignition system. Based on the MOTORTECH ignition controller
platform, the MIC4 series fulfills these greater demands.
With 300 mJ primary energy, the MIC4 series provides a reliable combustion on
engines up to 16 cylinders even with weakest or fluctuating caloric values of the gas.
Next to high variable ignition energy (MOST – MOTORTECH Output Stage Technology*)
an 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.

■■ Adjustable spark duration ■■ Ignition diagnostics

and intensity (primary and secondary)
■■ Constant spark intensity via ■■ Fault memory with trend data
adjusted duration ■■ Integrated CANopen and Modbus
■■ Patented technology (MOST*) RTU interface
■■ 300 mJ primary energy ■■ Easy access per USB port
(500 mJ boost for start phase)

*Patent No.: US 8,893,692 B2

Ignition coils
Special high performance ignition coils are designed for use with latest technologies
of MOTORTECH ignition controllers (MOST). Different designs are available either for
direct rail mounting in combination with spark plug leads or as integral ignition coil to
allow installation directly on the spark plug.

AlphaRail Wiring Rail System for Ignition and Detonation Control

MOTORTECH stainless steel, vibration resistant rail assembly will withstand any harsh
environment commonly found in the oil & gas industry. The proven design is made for
engine manufacturers and the global aftermarket. Do not go Low-Tech and take the risk
of engine down time because of equipment being under repair. Eliminate the need for
constant rewiring, connector exchanges or straightening out weak and bent aluminum
wiring rails.

■■ Made of stainless steel

■■ Rigid military style connectors
■■ Rails are filled with special foam to ensure that all wires are separated from ground
and will not vibrate
■■ Water proof design – built to last in uncovered environment
■■ Wiring rails can be used for shielded and unshielded applications
■■ Due to base rail structure easy for stocking
■■ Quick service access with quick-disconnect connections

3
 Shielded Ignition Control Upgrade Kit

SHIELDED

With MIC4 Series Ignition Controller

For WAUKESHA® VHP G/ GU/ GSI 12 Cylinder Engines

Upgrade kit contains:

■■ MIC4 series ignition controller 1 with 16 outputs and
MIC4 1
patented MOTORTECH Output Stage Technology (MOST*)
■■ 1 pickup arrangement (Hall effect 2 ) incl. shielded pickup
5
lead 3 , trigger disc and hub 4
■■ Output wiring 5 and junction box 6 with fittings to 3
connect ignition controller and wiring rails (flex conduit 5
2
has to be ordered separately or supplied by customer) 4
■■ AlphaRail wiring rails 7 with hardware kit 6
7
■■ New Flex Style primary leads for connection of wiring
8 8
rails and integral ignition coils
9
■■ High energy integral ignition coils 9 (fat design)

Ordering Information

P/N Description Required Qty

95.75.120-12 Shielded ignition control upgrade kit for WAUKESHA® VHP G/ GU/ GSI 12 cylinder engines 1 pc

Ordering Information – Optional Parts

P/N Description Required Qty
ICPB812 ICP spark plug, M18x1.5, 0.500 in thread reach, J-type (Ir/Ir) 12 pcs
06.05.085 PowerView3 HMI module 1 pc
alternative
PowerView3 HMI module, built into stainless steel enclosure 1 pc
06.05.185
alternative
PowerView3 HMI module, built into steel enclosure with sight window 1 pc
06.05.187
06.05.086-F PowerView3 activation code for MIC4 visualization 1 pc
15.07.112 Flex conduit, 1/2 in, black, for wiring of junction box to wiring rails 30 ft
15.07.134 Flex conduit, 3/4 in, black, for wiring of ignition controller to junction box 15 ft

Ordering Information – Tools and Accessories

P/N Description Required Qty
06.98.100-200 ScopeLite LED timing light 1 pc
07.99.022-2-18 Magnetic spark plug socket, 18 in length, HEX 15/16 in, 1/2 in drive 1 pc
44.01.023 Spark plug cleaning kit 1 pc

*Patent No.: US 8,893,692 B2

4
 Unshielded Ignition Control Upgrade Kit
®

UNSHIELDED

With MIC4 Series Ignition Controller

For WAUKESHA® VHP G/GU/GSI 12 Cylinder Engines

Upgrade kit contains:

■■ MIC4 series ignition controller 1 with 16 outputs and
patented MOTORTECH Output Stage Technology (MOST*) MIC4 1

■■ 1 pickup arrangement (Hall effect 2 ) incl. pickup lead 3 ,

5
trigger disc and hub 4
■■ Output wiring 5 and junction box 6 with fittings to 3
connect ignition controller and wiring rails 5
2
■■ AlphaRail wiring rails 7 with hardware kit 4 9
8
■■ Primary lead and mounting kits 8 for connection of 6
7
wiring rails and ignition coils
■■ High energy ignition coils 9 10
■■ PolyMot™ spark plug leads 10

Ordering Information

P/N Description Required Qty

77.75.120-12 Unshielded ignition control upgrade kit for WAUKESHA® VHP G/ GU/ GSI 12 cylinder engines 1 pc

Ordering Information – Optional Parts

P/N Description Required Qty
B8124 MHP spark plug, M18x1.5, 0.500 in thread reach, J-type (Ir/Ir) 12 pcs
alternative
DENSO® spark plug, M18x1.5, 0.500 in thread reach, J-type (Ir/Pt) 12 pcs
GT3-1
06.05.085 PowerView3 HMI module 1 pc
alternative
PowerView3 HMI module, built into stainless steel enclosure 1 pc
06.05.185
alternative
PowerView3 HMI module, built into steel enclosure with sight window 1 pc
06.05.187
06.05.086-F PowerView3 activation code for MIC4 visualization 1 pc

Ordering Information – Tools and Accessories

P/N Description Required Qty
06.90.099-100 SparkView high voltage indicator with SparkScan1 high voltage clamp 1 pc
06.98.100-200 ScopeLite LED timing light 1 pc
07.99.022-3-18 Magnetic spark plug socket, 18 in length, HEX 7/8 in, 1/2 in drive 1 pc
44.01.023 Spark plug cleaning kit 1 pc
06.84.040-100 Silicone seal rings for PolyMot™ spark plug leads, pack of 100 pcs 1 pc

5
 Shielded Ignition Wiring Rail Upgrade Kit

SHIELDED

For use with existing WAUKESHA® CEC Ignition Controller

For WAUKESHA® VHP G/GU/GSI 12 Cylinder Engines

Upgrade kit contains:

■■ Output wiring 2 and junction box 3 with fittings to
CEC 1
connect existing CEC ignition controller 1 and wiring rails
(flex conduit has to be ordered separately or supplied by
customer) 2
■■ AlphaRail wiring rails 4 with hardware kit
■■ New Flex Style primary leads 5 for connection of wiring 2
rails and integral ignition coils
■■ Integral ignition coils 6 (fat design) to work with 3
4
CEC Spark Reference System
5
6

1 CEC ignition controller, input wiring and pickup

not included in scope of supply.
Ordering Information

P/N Description Required Qty

95.75.121-12 Shielded ignition wiring rail upgrade kit for WAUKESHA® VHP G/ GU/ GSI 12 cylinder engines 1 pc

Ordering Information – Optional Parts

P/N Description Required Qty
ICPB812 ICP spark plug, M18x1.5, 0.500 in thread reach, J-type (Ir/Ir) 12 pcs
15.07.112 Flex conduit, 1/2 in, black, for wiring of junction box to wiring rails 30 ft
15.07.134 Flex conduit, 3/4 in, black, for wiring of ignition controller to junction box 15 ft

Ordering Information – Tools and Accessories

P/N Description Required Qty
06.98.100-200 ScopeLite LED timing light 1 pc
07.99.022-2-18 Magnetic spark plug socket, 18 in length, HEX 15/16 in, 1/2 in drive 1 pc
44.01.023 Spark plug cleaning kit 1 pc

6
 Unshielded Ignition Wiring Rail Upgrade Kit
®

UNSHIELDED

For use with existing WAUKESHA® CEC Ignition Controller

For WAUKESHA® VHP G/GU/GSI 12 Cylinder Engines

Upgrade kit contains:

■■ Output wiring 2 and junction box 3 with fittings to CEC 1
connect existing CEC ignition controller 1 and wiring rails
■■ AlphaRail wiring rails 4 with hardware kit
■■ Primary lead and mounting kits 5 for connection of wiring 2
rails and ignition coils
■■ Ignition coils 6 to work with CEC Spark Reference System 2
6
■■ PolyMot™ spark plug leads 7 5
3
4

1 CEC ignition controller, input wiring and pickup

not included in scope of supply.
Ordering Information

P/N Description Required Qty

77.75.121-12 Unshielded ignition wiring rail upgrade kit for WAUKESHA® VHP G/ GU/ GSI 12 cylinder engines 1 pc

Ordering Information – Optional Parts

P/N Description Required Qty
B8124 MHP spark plug, M18x1.5, 0.500 in thread reach, J-type (Ir/Ir) 12 pcs
alternative
DENSO® spark plug, M18x1.5, 0.500 in thread reach, J-type (Ir/Pt) 12 pcs
GT3-1

Ordering Information – Tools and Accessories

P/N Description Required Qty
06.90.099-100 SparkView high voltage indicator with SparkScan1 high voltage clamp 1 pc
06.98.100-200 ScopeLite LED timing light 1 pc
07.99.022-3-18 Magnetic spark plug socket, 18 in length, HEX 7/8 in, 1/2 in drive 1 pc
44.01.023 Spark plug cleaning kit 1 pc
06.84.040-100 Silicone seal rings for PolyMot™ spark plug leads, pack of 100 pcs 1 pc

7
 Detonation Control Upgrade Kit Components

CAN
B
1
Detonation Control Upgrade for CAN

WAUKESHA® VHP Series Gas Engines

Next to the ignition system, MOTORTECH also offers 0 to 5 V / 4 to 20 mA
complete system upgrades for detonation control. C
Prefabricated and prewired components make the
conversion easier and reduce costs based on engine
Z
downtime.

Upgrade your engine and increase availability of the

equipment!
X Y
TORTECH
MO

UPGRADE
IT E M

DetCon20 Control Unit

The gas engine operators are calling for increased power
output from their engines. More load means higher tem-
A
peratures, pressures and tougher operation. This mostly
ends in catastrophic engine damages due to detonation
or pre-ignition.

As MOTORTECH has proven for years, detonation can

be detected professionally with the DetCon20. Single
cylinder sensors constantly monitor the sound level of
the combustion chamber. Once the controller detects
soft detonation on one of the sensors (this is a specific
stage before real detonation occurs), several steps will
take place:

■■ Alarm signal turns on 2 3

■■ Ignition retard by 0 to 5 V or 4 to 20 mA analog output
■■ If this action does not cure the detonation, the load
reduction output will be activated. Sample System Overview – Detonation Control
■■ If the load drop does not stop the engine from Necessary Components System Enhancement
detonating the engine STOP output will be activated.
1 DetCon20 control unit* BPowerView3 – HMI module
2 Detonation sensor lead CMIC4 – Ignition controller
3 Detonation sensor Description

Accessories
X Engine
Y Cylinder
A AlphaRail detonation
Z Harness to connect the
wiring rail
Detonation Sensor detonation wiring rails and the
control unit
Installed on the cylinder head screw it measures the
* Shielded and unshielded versions available.
detonation signal and transfers it to the controller.

8
 Detonation Control Upgrade Kit
®

With DetCon20 Detonation Controller

For WAUKESHA® VHP G/GU/GSI/GL 12 Cylinder Engines

Upgrade kit contains:

■■ DetCon20 detonation controller 1 with 20 inputs, CSA
certified (has to be installed in CSA approved control panel
or enclosure), IP20
■■ Harnesses to connect detonation controller and DetCon 1
wiring rails 2
■■ AlphaRail wiring rails 3 with hardware kit 2

■■ Leads for connection of wiring rails and

detonation sensors 4
3
■■ Detonation sensors 5 to monitor each 4
cylinder individually 5

For use in hazardous and non-hazardous environments.

Ordering Information

P/N Description Required Qty

43.00.421-12 Detonation control upgrade kit for WAUKESHA® VHP G/ GU/ GSI/ GL 12 cylinder engines 1 pc

Ordering Information – Optional Parts

P/N Description Required Qty
06.05.085 1) PowerView3 HMI module 1 pc
06.05.087-F PowerView3 activation code for DetCon20 visualization 1 pc
43.20.002 2)
Ignition sensor unit 1 pc
169994B-DS Cylinder head screw, VHP series, prepared for detonation sensor 12 pcs
1)
If HMI module is already ordered with ignition upgrade kit, it is only necessary to order the activation code for DetCon20 visualization.
2)
Ignition sensor unit only needs to be ordered separately when WAUKESHA® CEC or ALTRONIC® CPU95 ignition controller is used with DetCon20.

9
 Optional Parts

Ignition and Detonation Control Visualization

The operating data of the MIC4 series ignition controller and
PowerView3 MOTORTECH ENGINE INFORMATION MONITOR
DetCon20 controller will be completely visualized via HMI
module (Human Machine Interface). The overview screen
shows the relevant ignition information as engine speed,
ignition timing and status of pickups, ignition outputs or
active parameter set or detonation control information as
engine knocking, knock intensity and status for activated load
reduction or emergency shutdown of engine.

The PowerView3 also allows justification of various ignition

parameters such as ignition timing and energy. Functions as
the self-test for error diagnostics can also be executed via
HMI module. The control keys guarantee simple navigation
through different display pages and menus. All in all the
PowerView3 HMI module is also able to provide error
diagnostics on-site without requiring a laptop!

General Features
■■ Visualization of ignition and ■■ For assembly in control panels
detonation control via CAN bus ■■ Day and night mode
■■ Access control ■■ CSA® certified (Class I, Division 2, Group C, D; T4)
■■ Display of CAN connection status
■■ Several display configurations
(languages, date, display calibration, etc.)

MIC Overview Ignition DetCon Overview Knocking Intensity

■■ Status displays (pickup, ignition ■■ Displays the estimated ignition ■■ Status displays (engine knocking, ■■ Display of knocking intensity for
outputs, ignition enabled, system voltage for each individual active load reduction, emergency each cylinder
status, schedule) cylinder shutdown, signal errors) – Green: The detonation control
■■ Displays the current engine ■■ Display of current and past ■■ Displays the analog output does not register any excessive
speed misfires of each individual signal strength knocking intensity
cylinder ■■ Displays the knocking intensity – Yellow: Detonation control
■■ Shows the current global ignition reduces knocking
timing in ° crankshaft in percent
– Red: Critical engine state
■■ Displays the previous operating ■■ Display of sensor errors
■■ Additional status display for
hours of the spark plugs sensor errors at the cylinder

10
 Optional Parts
®

ICP-Plugs MHP-Plugs
For shielded applications where integral ignition coils are MHP spark plugs are designed to meet the requirements,
used, MOTORTECH manufactures the dual threaded spark both of modern and common engine developments and
plugs. The J-type electrode design and use of higher erosion reliably deliver highest voltages and thus a strong spark down
resistance materials ensure better combustion particularly on into the combustion chamber. The J-type electrode design
lean burn gas engines and longest service life. The top thread with IRIDIUM alloy discs on center and ground electrode
for ignition coil connection with full 6 threads meets the CSA provides reliable combustion and increased spark plug life
requirements. For years these plugs have been successfully and helps to reduce service costs due less spark plug
operated worldwide. changes.

Tools and Accessories

SparkView Scopelite Spark Plug Extended Barrel

High Voltage Indicator Timing Light Cleaning Kit Magnetic Spark Plug
The SparkView is a handheld The self-powered ScopeLite Apart from readjusting the Sockets
device developed by is designed to work with fully electrode gap, the spark MOTORTECH offers a
MOTORTECH that can shielded ignition systems. A plug should also be freed complete range of extended
monitor the high voltage special clamp picks up the from deposits and residues barrel magnetic spark plug
required by the spark plug small trigger signal through that have formed during sockets in various lengths
while the engine is running. the braid of shielded spark operation. By using the for all types of HEX.
The condition of the spark plug leads. The signal is MOTORTECH spark plug Integrated strong magnets
plugs and the time at which processed by the timing cleaning kit these impurities hold the spark plug
they need to be replaced light and via LED technology can be removed easily and securely in any position,
can be determined with the a sequence of flashes is gently in the electrode area which guarantees an easy
SparkScan1 high voltage generated. and on the thread within a assembly and disassembly
clamp or with a BNC cable. regular maintenance inter- work especially on large
val. This will increase spark engines with deep spark
plug service life and cut plug wells.
maintenance costs.

11
 ®

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MOTORTECH GmbH MOTORTECH Americas, LLC MOTORTECH Shanghai Co. Ldt.

Hogrevestr. 21-23 1400 Dealers Avenue, Suite A Room 1018 Enterprise Square,
29223 Celle New Orleans, LA 70123 No. 228 Meiyuan Road,
Germany USA Zhabei District, 200070 Shanghai
Phone: +
49 (5141) 93 99 0 Phone: +1 (504) 355 4212 China
Fax: +49 (5141) 93 99 99 Fax: +1 (504) 355 4217 Phone: +86 (21) 6380 7338
www.motortech.de www.motortechamericas.com www.motortechshanghai.com
[email protected] [email protected] [email protected]

P/N 01.15.035-EN | Rev. 07/2018 | Upgrade Kits for WAUKESHA® VHP G/GU/GSI 12 Cylinder Engines

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