Motortech VariFuel2 Assembly Instructions Manual
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Motortech VariFuel2 Assembly Instructions Manual

Air/gas mixer
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VariFuel2/2+ – Air/Gas Mixer
Assembly Instructions
P/N 01.10.001-EN | Rev. 09/2020

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Summary of Contents for Motortech VariFuel2

  • Page 1 VariFuel2/2+ – Air/Gas Mixer Assembly Instructions P/N 01.10.001-EN | Rev. 09/2020...
  • Page 2 MOTORTECH products and the MOTORTECH 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 are used for reference purposes only.

  • Page 3: Table Of Contents

    5.1 Unpacking ......................28   5.2 Assembly ......................29   5.2.1 Install Flow Body ....................31   5.2.2 Install VariFuel2/2+ into Intake Section .............. 33   5.2.3 Connect Stepper Motor Driver ................35   6 Operation ........................36   6.1 Start-up ....................... 36  ...
  • Page 4 Table of Contents   7.3 Fix Shaft ......................41   7.4 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  ...

  • Page 5: General Information

    1 General Information Prior to use, read these assembly instructions carefully and familiarize yourself with the pro- duct. Installation and start-up should not be carried out before reading and understanding this document. Keep these assembly instructions readily available so that you can reference them as needed.

  • Page 6: Which Abbreviations/Acronyms Are Used In The Assembly Instructions

    1 General Information Danger This symbol indicates warnings for danger to life, especially due to high voltage. Read these warning notices carefully and take the mentioned precautionary measures. 1.4 Which Abbreviations/Acronyms Are Used in the Assembly Instructions? The following abbreviations/acronyms are used in the assembly instructions: Abb.

  • Page 7: Safety Instructions

    2 Safety Instructions 2.1 General Safety Instructions MOTORTECH equipment is manufactured as state of the art and therefore safe and reliable to operate. Nevertheless the equipment can cause risks or damage can occur, if the following instructions are not complied with: –...

  • Page 8: Electrostatic Discharge Hazards

    2 Safety Instructions 2.2 Electrostatic Discharge Hazards Electronic equipment is sensitive to static electricity. To protect these components from damage caused by static electricity, special precautions must be taken to minimize or prevent electro- static discharge. Observe these safety precautions while you work with the equipment or in its vicinity. –...
  • Page 9 Contaminated gas can lead to blocking of the fuel ring and thus can cause the gas engine to stop. Examine the VariFuel2/2+ regularly for contamination as a part of the regu- lar maintenance intervals customary for your system. Use clean gas preferably.

  • Page 10: Proper Transport

    Transport the VariFuel2/2+ to the installation site 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 VariFuel2/2+ upright on the flat support surface on the underside of the device.

  • Page 11: Intended Use

    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 nozzle.
  • Page 12 The fuel (gas) is guided into the nozzle using the adjustable rectangular openings in a fuel ring , which are wedge-shaped in the VariFuel2+. The openings of the fuel ring are adjusted by a stepper motor and a drive belt .

  • Page 13: Applications

    The VariFuel2/2+ can mix up to two gases with air. For lean gas applications (such as wood or landfill gas) with a V-engine, it is possible to interconnect two VariFuel2/2+ to achieve the desired mixing ratio.
  • Page 14 3 Intended Use System Overview (Example) VariStep3 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 filter Ball valve Gas filter Double safety valve Balance/Zero pressure regulator...

  • Page 15: Product Description

    – EN 61000- 6- 2 – Electromagnetic compatibility (EMC) - Part 6- 2: Generic standards - Immunity for industrial environments The Declaration of Incorporation and the EU Declaration of Conformity of your VariFuel2/2+ are enclosed with your product. Rev. 09/2020...

  • Page 16: Mechanical Data

    Shape of device See chapter Overview Drawings on page 19 Climatic environmental VariFuel2: –10 °C to +80 °C (+14 °F to +176 °F) conditions 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: –...

  • Page 17: Warning Notices On The Device

    4 Product Description 4.1.3 Warning Notices on the Device 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 stepper motor card. Do not use stepper motor to lift or carry the device.

  • Page 18: Product Identification - Labeling On The Device

    4 Product Description 4.1.4 Product Identification – Labeling on the Device The necessary numbers for unique product identification are on the device: Nameplate Air/Gas Mixer on Upper Part of Housing Abb. Meaning Part number of the air/gas mixer Serial number of the air/gas mixer The field Label Flow Body Size is reserved for the label that comes with the flow body.

  • Page 19: Overview Drawings

    4 Product Description 4.1.5 Overview Drawings Components The following drawing shows an example of a VariFuel2 series 200-120. The exact position of the individual parts varies slightly with other series. A detailed layout can be found in the subse- quent section Dimensions.
  • Page 20 4 Product Description Dimensions Series 100-60 VariFuel2, VariFuel2+ Rev. 09/2020...
  • Page 21 4 Product Description Series 140-80 VariFuel2, VariFuel2+ Rev. 09/2020...
  • Page 22 4 Product Description Series 200-120 VariFuel2, VariFuel2+ Rev. 09/2020...
  • Page 23 4 Product Description Series 250-150 VariFuel2, VariFuel2+ Rev. 09/2020...
  • Page 24 4 Product Description Series 300-190 VariFuel2, VariFuel2+ Rev. 09/2020...
  • Page 25 4 Product Description Series 350-225 VariFuel2, VariFuel2+ *for eye bolt DIN 580 Rev. 09/2020...

  • Page 26: Pole Connector Stepper Motor / Encoder

    4 Product Description 4.1.6 Pole Connector Stepper Motor / Encoder The connector on the stepper motor of the VariFuel2/2+ gas mixer is assigned as follows: Description Description Stepper motor phase A1 Encoder B Stepper motor phase A2 Encoder I (index)

  • Page 27: Digression: Direct Control Of Stepper Motor

    4 Product Description 4.1.7 Digression: Direct Control of Stepper Motor In the standard application, the stepper motor of the VariFuel2/2+ gas mixer is driven by the VariStep3 stepper motor driver. For example, if you want to implement a direct activation from a master control, you receive the technical details for activation of the stepper motor in the fol- lowing section.

  • Page 28: Installation Instructions

    ESD standard IEC 61340-5-1:2016. Damage caused by electrostatic discharge is not covered by warranty. Scope of Supply The scope of supply of the VariFuel2/2+ air/gas mixer consists of the following components: – VariFuel2/2+ air/gas mixer –...

  • Page 29: Assembly

    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 Rev. 09/2020...
  • Page 30 The balance or zero pressure regulator must be connected to the impulse line connection of the VariFuel2/2+ and it must be installed in the gas train at a suitable position before the gas inlet of the VariFuel2/2+.

  • Page 31: Install Flow Body

    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 operation of the VariFuel2/2+, observe the following guide- lines: –...
  • Page 32 5 Installation Instructions To install or replace the flow body, free access must be provided at the VariFuel2/2+ both on the air inlet and on the mixture outlet. Proceed as follows: Illustration example A label is enclosed with the flow body. Stick this label onto the field Label Flow Body Size of the VariFuel2/2+ nameplate.

  • Page 33: Install Varifuel2/2+ Into Intake Section

    – For the mixture outlet, consider the additional depth of the engine-specific mounting flange. – With series 300 and 350, you can mount ring eyelets for lifting the VariFuel2/2+ into the provided threaded holes, if necessary. – For the air inlet, gas inlet and mixture outlet, use only galvanized hexagon bolts.
  • Page 34 Risk of injury! When connecting the cables, your 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 clamp, seal and counter flange) –...

  • Page 35: Connect Stepper Motor Driver

    Gauge port Connection for the measuring lead of a pressure gauge to measure the gas pressure at the gas inlet of the VariFuel2/2+ (thread size G1/8). The connection is suitable for hoses with an inner diameter of 8 mm (0.31").

  • Page 36: Operation

    Basic Settings of the System With an ideal design, the VariFuel2/2+ gas mixer is operated in a range between 15 % and 80 % of the fuel ring’s opening. In this way the prescribed emission values should be complied with nominal load.
  • Page 37 The nominal output is reached by enriching the mixture. – At the gauge port of the VariFuel2/2+, 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 fol- lowing measures: –...

  • Page 38: Errors

    – VariFuel Locking Tool for Toothed Pulley With this tool, you lock the toothed pulley of a VariFuel2/2+ gas mixer to tighten or loosen the hexagon socket head cap screw with which the toothed pulley is attached to the shaft.
  • Page 39 Disassemble and clean the Vari- move. Fuel2/2+ and replace all wearing parts. For this operation, you need special repair kits from MOTORTECH. Influence of master control Check the master control. Shaft has loosened from Tighten the shaft with the set screw the stepper motor.
  • Page 40 How- ever, the location of the movement is wrong. Traverse range of the A wrong VariFuel2/2+ is Configure your VariStep3 stepper fuel ring is too configured in the stepper motor driver via the MICT. Afterwards small/too big.

  • Page 41: Fix Shaft

    All graphics used in this section represent an example of a VariFuel2/2+ series 200-120. To fix the shaft between stepper motor and VariFuel2/2+, the stepper motor must be completely dismounted. The explosion view provides information on how the stepper motor has been in- stalled.
  • Page 42 7 Errors Installation Moisten the set screw with thread lock fluid. 2. Replace the shaft on the axis of the stepper motor and tighten the set screw with the torque stated in the following drawing. Alignment and positioning of the shaft Observe the following while positioning the shaft.
  • Page 43 Do not tighten the hexagon socket head cap screw M4x16 . The toothed pulley must be rotatably mounted on the shaft to allow the fuel ring to be adjusted. 8. Insert the O-ring into the housing of the VariFuel2/2+. Rev. 09/2020...

  • Page 44: Adjust 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 ring as follows: Stop the gas supply.
  • Page 45 7 Errors 4. If not already done, connect the stepper motor to the VariStep3 stepper motor driver. For this purpose, read the VariStep3 operating manual. 5. Move the stepper motor into the closed position. 6. Rotate the reference scale of the fuel ring into the lateral inspection window of the Vari- Fuel2/2+ by moving the fuel ring via the VariFuel locking tool that has been inserted into the toothed pulley in step 3.

  • Page 46: Customer Service Information

    7.6 Returning Equipment for Repair / Inspection To return the device for repair and inspection, obtain a return form from your MOTORTECH con- tact person (see Customer Service Information on page 46). After you have completely filled out the return form and returned it to MOTORTECH, MOTORTECH will send you back the return form and a delivery note with RMA number specified.

  • Page 47: Maintenance

    MOTORTECH. – Dirty seals (e.g. flat gaskets, O-rings) can lead to leakage of the VariFuel2/2+. When replac- ing seals, only use clean seals from MOTORTECH (part of MOTORTECH repair kits).

  • Page 48: Index

    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 ...........
  • Page 49 Rev. 09/2020...

This manual is also suitable for:

Varifuel2+

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