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Motortech VARIFUEL2, Assembly Instructions Manual

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Motortech VARIFUEL2 Assembly Instructions Manual Download Page 29

5 Installation Instructions 

 

Rev. 09/2020 

29 

5.2 

 

Assembly 

   

 

Risk of destruction! 

The stepper motor of the VariFuel is not suitable for carrying or lifting a gas 
mixer. There is a danger that the stepper motor could break, and if the gas 
mixer were to fall, it could result in injury or property damage. 

Always carry or lift the gas mixer by its exterior housing. 

   

The following steps must always be carried out and are specified in more detail in the following: 

–

 

Install flow body 

–

 

Install VariFuel2/2+ into intake section (air and gas inlet plus mixture outlet) 

–

 

Connect stepper motor driver 

Summary of Contents for VARIFUEL2

Page 1: ...VariFuel2 2 Air Gas Mixer Assembly Instructions P N 01 10 001 EN Rev 09 2020...

Page 2: ...CH logo are registered and or common law trademarks of the MOTORTECH GmbH All further trademarks and logos displayed or used in this publication are the property of the respective entitled person and...

Page 3: ...10 3 Intended Use 11 3 1 Functional Description 11 3 2 Applications 13 4 Product Description 15 4 1 Technical Data 15 4 1 1 Certifications 15 4 1 2 Mechanical Data 16 4 1 3 Warning Notices on the Dev...

Page 4: ...4 Adjust Fuel Ring 44 7 5 Customer Service Information 46 7 6 Returning Equipment for Repair Inspection 46 7 7 Instructions for Packaging the Equipment 46 8 Maintenance 47 8 1 Maintenance Instruction...

Page 5: ...s A certain level of technical knowledge with respect to the operation of gas engines and basic knowledge of the electronic components used are necessary Persons who are only authorized to operate the...

Page 6: ...nformit Europ enne Conformity with EU directives Mark based on EU legislation for certain products in conjunc tion with product safety CPR Counts Per Revolution Unit for the resolution of en coders EM...

Page 7: ...the equipment as well as the responsibility for the validity of the certifications Safety devices must not be dismounted or disabled Avoid all activities that can impair the function of the equipment...

Page 8: ...aterials as far away from the equipment as possible Do not remove the circuit boards from the housing of the device 2 3 Special Safety Instructions for the Device Gas Danger to life Leaking gas may ca...

Page 9: ...talled by specialized personnel who has been trained in handling ESD sensitive components and with due regard to relevant ESD standards It must be installed into a con trol cabinet and it must comply...

Page 10: ...unopened in its original carton 2 5 Proper Storage Clean the VariFuel2 2 gas mixer before storing Store the VariFuel2 2 gas mixer in a dry and clean place on even ground For storage place the VariFuel...

Page 11: ...h relevant regulations In the VariFuel2 2 gas and air are mixed based on the Venturi principle Based on the suction pressure of the engine the air is sucked in through the air inlet into the Venturi n...

Page 12: ...sted by a stepper motor and a drive belt The stepper motor of the VariFuel2 2 is controlled by a stepper motor driver This can process the signals of a master control Connections All VariFuel2 2 gas m...

Page 13: ...estrictions in the case of excessive moisture content or foreign materials in the gas such as tar Mixing the air and fuel with the VariFuel2 2 must be done with the same pressure therefore it is neces...

Page 14: ...stepper motor driver Master control VariFuel2 2 gas mixer Flywheel ITB throttle with integrated stepper motor Magnetic pickup SC100 speed controller Engine Impulse line Air Air filter Gas Ball valve...

Page 15: ...s were considered EN ISO 12100 Safety of machinery General principles for design Risk assessment and risk reduction EN 60204 1 Safety of machinery Electrical equipment of machines Part 1 General requi...

Page 16: ...nmental conditions VariFuel2 10 C to 80 C 14 F to 176 F VariFuel2 40 C to 80 C 40 F to 176 F Max humidity without condensation up to 2 000 m 6 561 above sea level 85 at 80 C 176 F 60 at 40 C 40 F Air...

Page 17: ...e Warning on Removable Gas Inlet Cover Don t touch inside Warning Symbol on Stepper Motor Warning of hot surface Warning Notice on Stepper Motor CAUTION Stepper motor rev B only for use with VariStep...

Page 18: ...er Part of Housing Abb Meaning P N Part number of the air gas mixer S N Serial number of the air gas mixer The field Label Flow Body Size is reserved for the label that comes with the flow body For fu...

Page 19: ...layout can be found in the subse quent section Dimensions Pos Description Stepper motor Gas connection here closed with a cover Gauge port G1 8 for gas pressure measurement at the gas inlet by a pres...

Page 20: ...4 Product Description 20 Rev 09 2020 Dimensions Series 100 60 VariFuel2 VariFuel2...

Page 21: ...4 Product Description Rev 09 2020 21 Series 140 80 VariFuel2 VariFuel2...

Page 22: ...4 Product Description 22 Rev 09 2020 Series 200 120 VariFuel2 VariFuel2...

Page 23: ...4 Product Description Rev 09 2020 23 Series 250 150 VariFuel2 VariFuel2...

Page 24: ...4 Product Description 24 Rev 09 2020 Series 300 190 VariFuel2 VariFuel2...

Page 25: ...4 Product Description Rev 09 2020 25 Series 350 225 VariFuel2 VariFuel2 for eye bolt DIN 580...

Page 26: ...epper motor of the VariFuel2 2 gas mixer is assigned as follows Pin Description Pin Description A Stepper motor phase A1 F Encoder B B Stepper motor phase A2 G Encoder I index C Stepper motor phase B1...

Page 27: ...ecommended current 1 4 A full step operation mode 2 A microstep operation mode Step width 0 9 Recommended control 1 16 microstep operation mode Holding torque at maximum phase current 1 75 Nm 15 49 lb...

Page 28: ...standards It must be installed into a con trol cabinet and it must comply with the ESD standard IEC 61340 5 1 2016 Damage caused by electrostatic discharge is not covered by warranty Scope of Supply...

Page 29: ...e stepper motor could break and if the gas mixer were to fall it could result in injury or property damage Always carry or lift the gas mixer by its exterior housing The following steps must always be...

Page 30: ...rate the VariFuel2 2 gas mixer with a balance or zero pressure regulator The balance or zero pressure regulator must be connected to the impulse line connection of the VariFuel2 2 and it must be insta...

Page 31: ...o longer be securely tightened If the flow body were to fall apart due to the use of a no longer securable nut parts of the system will be destroyed and it could cause an explosion For the safe operat...

Page 32: ...ded at the VariFuel2 2 both on the air inlet and on the mixture outlet Proceed as follows Illustration example 1 A label is enclosed with the flow body Stick this label onto the field Label Flow Body...

Page 33: ...For mounting use the four threaded holes and the flat surface on the bottom side of the device The following must be observed during installation The VariFuel2 2 must be mounted tension free i e all b...

Page 34: ...r fingers may get stuck For this reason under no circumstances should you reach into the openings and gaps of the VariFuel2 2 gas mixer when connecting the lines Air inlet Hose connection e g with cla...

Page 35: ...uitable for hoses with an inner diameter of 8 mm 0 31 5 2 3 Connect Stepper Motor Driver Risk of destruction To rule out the possibility of moving the connected VariFuel2 2 out of the control area obs...

Page 36: ...m performance according to its design it is important that air pressure and gas pressure are equal so that the gas is sucked in by the Venturi effect alone Therefore operate the VariFuel2 2 gas mixer...

Page 37: ...Reach Nominal Power With the prescribed emissions the engine does not reach its nominal output The following scenarios might be possible Scenario 1 The opening of the fuel ring is in the range between...

Page 38: ...part of the VariFuel2 2 housing VariFuel Adjustment Tool for Belt Tension The VariFuel Adjustment Tool for Belt Tension is ideal for adjusting the tension of the drive belt of a VariFuel2 2 air gas mi...

Page 39: ...roperly sealed Stepper motor is defective Replace the stepper motor For this operation you need special repair kits from MOTORTECH Stepper motor driver is in error mode Confirm all error messages Step...

Page 40: ...motor driver Configure your VariStep3 stepper motor driver via the MICT Afterwards if necessary adjust the fuel ring see Adjust Fuel Ring on page 44 Fuel ring scale is not in the inspection window Hom...

Page 41: ...or has been in stalled Dismounting 1 Remove the inspection window in the upper part of the housing with the VariFuel Tool for Inspection Window For this purpose read the instructions of the VariFuel T...

Page 42: ...Alignment and positioning of the shaft Observe the following while positioning the shaft The drill hole in the shaft must be aligned with the flattening of the axle The shaft must be 1 mm from the ste...

Page 43: ...the stepper motor connection plug Align the stepper motor so that you can connect the wiring harness optimally to the stepper motor 7 Attach the toothed pulley with the washer and the hexagon socket h...

Page 44: ...ustment of the fuel ring see Adjust Fuel Ring on page 44 7 4 Adjust Fuel Ring In order to adjust the fuel ring the VariFuel2 2 must be connected with the VariStep3 stepper motor driver Adjust the fuel...

Page 45: ...usting keep the locking tool inserted in the toothed pulley 7 Fasten the toothed pulley to the shaft with the hexagon socket head cap screw M4x16 a hex key SW3 and the VariFuel Locking Tool for Toothe...

Page 46: ...note to the packaging so that it is clearly visible from the outside This will ensure a speedy and smooth processing of your repair order Send the device with delivery note and return form to one of t...

Page 47: ...atigue e g cracks MOTORTECH offers cleaning for this purpose send in your gas mixer see Returning Equip ment for Repair Inspection on page 46 All maintenance works which require opening the VariFuel2...

Page 48: ...Errors 38 F Flow body Install 29 Fuel ring Adjust 44 Fuel value 13 Function 11 M Mechanical data 16 MOTORTECH Address 46 Mounting 29 P Part number 18 R Regulations 15 Repair 46 Return shipment 46 S Sc...

Page 49: ...Rev 09 2020 49...

Page 50: ......

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