Page 1: ...VariFuel3 Air Gas Mixer Assembly Instructions P N 01 50 031 2022 A EN Rev 09 2022 A...
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: ...sal 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 15 4 1 3 Warning Notices on the...
Page 4: ...4 Adjust Fuel Ring 39 7 5 Customer Service Information 41 7 6 Returning Equipment for Repair Inspection 41 7 7 Instructions for Packaging the Equipment 41 8 Maintenance 42 8 1 Maintenance Instruction...
Page 5: ...of gas engines 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...
Page 6: ...ms are used in the assembly instructions Abb Term Description Explanation CE Conformit Europ enne Conformity with EU directives Mark based on EU legislation for certain products in conjunc tion with p...
Page 7: ...he 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 O...
Page 8: ...materials 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 c...
Page 9: ...s and with due regard to relevant ESD standards It must be installed into a con trol cabinet and it must comply with the ESD standard IEC 61340 5 1 Damage caused by electrostatic discharge is not cove...
Page 10: ...per Storage Clean the VariFuel3 gas mixer before storing Store the VariFuel3 gas mixer in a dry and clean place on even ground For storage place the VariFuel3 upright on the flat support surface on th...
Page 11: ...h relevant regulations In the VariFuel3 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 noz...
Page 12: ...motor and a drive belt The stepper motor of the VariFuel3 is controlled by a stepper motor driver This can process the signals of a master control Connections All VariFuel3 gas mixers also have the f...
Page 13: ...sture content or foreign materials in the gas such as tar Mixing the air and fuel with the VariFuel3 must be done with the same pressure therefore it is necessary to use a balance or a zero pressure r...
Page 14: ...3 stepper motor driver Master control VariFuel3 gas mixer Flywheel ITB throttle with integrated stepper motor Magnetic pickup SC100 speed controller Engine Impulse line Air Air filter Gas Ball valve G...
Page 15: ...of Conformity are enclosed with your product 4 1 2 Mechanical Data The devices of VariFuel3 series have the following mechanical characteristics Feature Value Dimensions See chapter Overview Drawings...
Page 16: ...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 17: ...Mixer 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 furthe...
Page 18: ...ailed layout can be found in the subse quent section Dimensions Pos Description Stepper motor Gas connection here closed with a cover Gauge port for gas pressure measurement at the gas inlet by a pres...
Page 19: ...4 Product Description Rev 09 2022 19 Dimensions Series 140 80 VariFuel3...
Page 20: ...4 Product Description 20 Rev 09 2022 Series 200 120 VariFuel3...
Page 21: ...per motor of the VariFuel3 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 H E...
Page 22: ...se bipolar Maximum phase current 2 8 A Recommended 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 a...
Page 23: ...nt ESD standards It must be installed into a con trol cabinet and it must comply with the ESD standard IEC 61340 5 1 Damage caused by electrostatic discharge is not covered by warranty Scope of Supply...
Page 24: ...and are specified in more detail in the following Install flow body Install VariFuel3 into intake section air and gas inlet plus mixture outlet Connect stepper motor driver For optimum performance acc...
Page 25: ...5 Installation Instructions Rev 09 2022 25 Connection Example Pos Description Impulse line connection Impulse line Balance Zero pressure regulator Gas...
Page 26: ...access must be provided at the VariFuel3 on the air inlet Illustration example Proceed as follows 1 A label is enclosed with the flow body Stick this label onto the field Label Flow Body Size of the...
Page 27: ...must be observed during installation The VariFuel3 must be mounted tension free i e all bores of the flanges must be aligned with the housing bores For the mixture outlet consider the additional dept...
Page 28: ...r fingers may get stuck For this reason under no circumstances should you reach into the openings and gaps of the VariFuel3 gas mixer when connecting the lines Air inlet Hose connection e g with clamp...
Page 29: ...es 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 VariFuel3 out of the con trol area observe the followi...
Page 30: ...nected to the air inlet of the VariFuel3 via the impulse line connection of the VariFuel3 Also adjust the balance zero pressure regulator in such a way that the balance zero pressure regulator equaliz...
Page 31: ...ching the mixture At the gauge port of the VariFuel3 an underpressure greater than 30 mbar is measured In this case it is necessary to increase the air supply This can be achieved based on the follow...
Page 32: ...VariFuel3 air gas mixer The tools are supplied with brief operating instructions which must be taken into account dur ing use 7 2 Possible Faults Explosion hazard If the system is not entirely tight...
Page 33: ...3 stepper motor driver via the MICT After wards if necessary adjust the fuel ring see Adjust Fuel Ring on page 39 Stepper motor driver is unsuitable Use a compatible stepper motor driver Wiring of ste...
Page 34: ...39 POWER LED of the step per motor driver does not light up although it is connected to the sup ply voltage Stepper motor driver is defective Replace the stepper motor driver Stepper motor does not mo...
Page 35: ...ate with the stepper motor and the respective O ring from the housing of the VariFuel3 3 Disconnect the toothed pulley from the shaft of the stepper motor 4 Remove the adapter plate from the stepper m...
Page 36: ...e adapter plate to the stepper motor and place the toothed pulley on the shaft Observe alignment of the adapter plate and the stepper motor Align the adapter plate as shown in the illustrations When a...
Page 37: ...et head cap screw M4x16 to the shaft of the stepper motor Do not tighten the screw Do not tighten the hexagon socket head cap screw M4x16 The toothed pulley must be rotatably mounted on the shaft to a...
Page 38: ...the hexagon socket head cap screw M6x16 The stepper motor has to remain movable to enable the correct belt tension to be set 10 Tighten the drive belt with the VariFuel Adjustment Tool for Belt Tensi...
Page 39: ...ring can lead to leakage of the VariFuel3 and there is a risk of explosion when put back into operation Replace a dirty O ring Use only O rings from MOTORTECH part of MOTORTECH repair kits 3 In the up...
Page 40: ...VariFuel Locking Tool for Toothed Pulley as described in the locking tool in structions for use Use a tightening torque of 2 5 Nm 1 9 lb ft Conduct in the event of an error message If you move the st...
Page 41: ...tomer Service Information on page 41 From him you will receive all the information you need to process your order quickly and smoothly For return shipment also observe the instruc tions in the section...
Page 42: ...fatigue e g cracks MOTORTECH offers cleaning for this purpose send in your gas mixer see Returning Equip ment for Repair Inspection on page 41 All maintenance works which require opening the VariFuel...
Page 43: ...sal 10 E Encoder 21 22 Errors 32 F Flow body Install 24 Fuel ring Adjust 39 Fuel value 13 Function 11 M Mechanical data 15 MOTORTECH Contact 41 P Part number 17 R Repair 41 Return shipment 41 S Scope...
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