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Motortech VariFuel3 140-80 Series Assembly Instructions Manual

Air/gas mixer
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VariFuel3 – Air/Gas Mixer
Assembly Instructions
P/N 01.50.031-2022-A-EN | Rev. 09/2022 (A)

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Summary of Contents for Motortech VariFuel3 140-80 Series

  • Page 1 VariFuel3 – Air/Gas Mixer Assembly Instructions P/N 01.50.031-2022-A-EN | Rev. 09/2022 (A)
  • 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

    Table of Contents   1 General Information ..................... 5   1.1 What Is the Purpose of these Assembly Instructions? ..........5   1.2 Who Are these Assembly Instructions Targeted to? ............ 5   1.3 What Symbols Are Used in the Assembly Instructions? ..........5  ...
  • Page 4 Table of Contents   7.3 Fix Shaft ......................34   7.4 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  ...

  • Page 5: General Information

    1 General Information Prior to use, read these assembly instructions carefully and familiarize yourself with the prod- uct. 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 2 Safety Instructions Operational safety! All screws of the connectors must be adequately tightened. Operational safety! Contaminated gas can lead to blocking of the fuel ring and thus can cause the gas engine to stop. Examine the VariFuel3 regularly for contamination as a part of the regular maintenance intervals customary for your system.

  • Page 10: Proper Transport

    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 the underside of the device. 2.6 Proper Disposal For the proper disposal of MOTORTECH equipment, observe the information provided at www.motortech.de. Rev. 09/2022...

  • Page 11: Intended Use

    3 Intended Use 3.1 Functional Description All graphics used in this section represent an example of a VariFuel3 series 200-120. Basic Design The main task of the gas mixer is it to mix the fuel (gas) and the air so that an optimal combus- tion is ensured within the gas engine.
  • Page 12 3 Intended Use Mixture Control The fuel (gas) is guided into the nozzle using the adjustable wedge-shaped openings in a fuel ring . The openings of the fuel ring are adjusted by a stepper motor and a drive belt . The stepper motor of the VariFuel3 is controlled by a stepper motor driver.

  • Page 13: Applications

    3 Intended Use 3.2 Applications Danger of interference with radio reception! The device is not intended for use in residential areas and cannot ensure adequate protection of radio reception in such environments. All VariFuel3 air/gas mixers are designed for use with gas-powered Otto engines. The following substances are approved as fuels: –...
  • Page 14 3 Intended Use System Overview (Example) VariStep3 stepper motor driver Master control VariFuel3 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 Rev.

  • Page 15: Product Description

    4 Product Description 4.1 Technical Data 4.1.1 Certifications Machinery Directive – The VariFuel3 air/gas mixer is a partly completed machinery pursuant to Article 2g of the EC Machinery Directive. – The partly completed machinery must not be put into service until the final machinery into which the product is to be incorporated has been declared in conformity with the provisions of the Machinery Directive.

  • Page 16: 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 17: 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 Mixer 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 18: Overview Drawings

    4 Product Description 4.1.5 Overview Drawings Components The following drawing shows an example of a VariFuel3 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. Pos.
  • Page 19 4 Product Description Dimensions Series 140-80 VariFuel3 Rev. 09/2022...
  • Page 20 4 Product Description Series 200-120 VariFuel3 Rev. 09/2022...

  • Page 21: Connector Stepper Motor / Encoder

    4 Product Description 4.1.6 Connector Stepper Motor / Encoder The connector on the stepper motor of the VariFuel3 gas mixer is assigned as follows: Description Description Stepper motor phase A1 Encoder B Stepper motor phase A2 Encoder I (index) Stepper motor phase B1 Encoder shield Stepper motor phase B2 Encoder 5 V supply voltage...

  • Page 22: 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 VariFuel3 gas mixer is driven by the Vari- Step3 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 23: Installation Instructions

    5 Installation Instructions 5.1 Unpacking Unpack the device, taking care not to damage it, and ensure that the assembly instructions are always stored with the device and are easily accessible. Check the contents for completeness and verify that the device type meets your application requirements. Risk of destruction due to electrostatic discharge! The VariStep3 stepper motor driver may only be installed by specialized personnel who has been trained in handling ESD sensitive components and...

  • Page 24: Assembly

    5 Installation Instructions 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.
  • Page 25 5 Installation Instructions Connection Example Pos. Description Impulse line connection Impulse line Balance/Zero pressure regulator Rev. 09/2022...

  • Page 26: Install Flow Body

    5 Installation Instructions 5.2.1 Install Flow Body To install or replace the flow body, free access must be provided at the VariFuel3 on the air inlet. Illustration example Proceed as follows: A label is enclosed with the flow body. Stick this label onto the field Label Flow Body Size of the VariFuel3 nameplate.

  • Page 27: Install Varifuel3 Into Intake Section

    5 Installation Instructions 2. On the air intake side, slide the flow body onto the center of the outlet nozzle as far as it will go. 3. Moisten the countersunk screw with thread lock fluid. 4. Fix the flow body on the central nozzle ring by inserting the countersunk screw into the flow body as far as it will go and then tightening it firmly.
  • Page 28 5 Installation Instructions Generally, you need to connect the following ports: Illustration example Explosion hazard! If the system is not entirely tight and sealed, the combustible gas mixture may escape and result in an explosion hazard. Therefore, all ports and connections must be gas-tight.

  • Page 29: Connect Stepper Motor Driver

    5 Installation Instructions – Mixture outlet Connection via a bolt hole circle for engine specific mounting flange (available with clamp, seal and counter flange) – Impulse line connection Connection for the impulse line of the balance or zero pressure regulator for connection to the air inlet of the VariFuel3 (cutting-ring connection).

  • Page 30: Operation

    – MOTORTECH recommends to start with an opening of the fuel ring of 30 % to 35 %. If the engine does not start, open the fuel ring in steps of 1 to 2 %. –...
  • Page 31 Check air filter for dirt or excessive back pressure. Clean or replace air filter if necessary. – Check underpressure in the air intake line (standard value: –5 mbar to –25 mbar) – Install a smaller flow body. To do so, please contact MOTORTECH (see Customer Service Information on page 41). Scenario 2: –...

  • Page 32: Errors

    7 Errors 7.1 Special Tools for Troubleshooting Special tools have been developed at MOTORTECH which are needed to carry out certain work safely and conveniently for the maintenance and repair of VariFuel3 gas mixers. The following tools can be obtained from MOTORTECH: –...
  • Page 33 Disassemble and clean the VariFuel3 move. and replace all wearing parts. For this operation, you need special repair kits from MOTORTECH. Impact from master control Check the master control. Shaft has loosened from Tighten the shaft with the set screw the stepper motor.

  • Page 34: Fix Shaft

    7 Errors Problem Possible cause Solution Traverse range of the A wrong VariFuel3 is con- Configure your VariStep3 stepper fuel ring is too small/ figured in the stepper motor motor driver via the MICT. After- too big. driver. wards, if necessary, adjust the fuel ring (see Adjust Fuel Ring on page 39).
  • Page 35 Dirty O-rings can lead to leakage of the VariFuel3, and there is a risk of explosion when put back into operation. Replace dirty O-rings. Use only O-rings from MOTORTECH (part of MOTORTECH repair kits). Remove the inspection window in the upper part of the housing and the respective O-ring with the VariFuel Tool for Inspection Window.
  • Page 36 7 Errors 4. Press the shaft seal ring with the flat side first into the adapter plate. 5. Moisten the hexagon socket head cap screws M5x12 with thread lock fluid. 6. Screw the adapter plate to the stepper motor and place the toothed pulley on the shaft.
  • Page 37 7 Errors 7. Attach the toothed pulley with the washer and the hexagon socket 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 .
  • Page 38 7 Errors 9. Attach the stepper motor with the hexagon socket head cap screws M6x16 of the adapter plate to the VariFuel3. Do not tighten the screws Do not tighten the hexagon socket head cap screw M6x16 . The stepper motor has to remain movable to enable the correct belt tension to be set.

  • Page 39: Adjust Fuel Ring

    A dirty O-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 upper part of the housing, loosen the toothed pulley with the VariFuel Locking Tool for Toothed Pulley and a hex key SW3.
  • Page 40 7 Errors 6. Rotate the reference scale of the fuel ring into the lateral inspection window of the VariFuel3 by moving the fuel ring via the VariFuel locking tool that has been inserted into the toothed pulley in step 3. Adjust the closed position of the fuel ring in this way so that the reference marking points to the uppermost line of the reference scale.

  • Page 41: Customer Service Information

    (all other matters) 7.6 Returning Equipment for Repair / Inspection To return the device for repair and inspection, first consult your MOTORTECH contact person (see Customer Service Information on page 41). From him you will receive all the information you need to process your order quickly and smoothly.

  • Page 42: Maintenance

    MOTORTECH (part of MOTORTECH repair kits). – Spare parts (e.g. drive belt, fuel ring) are available from MOTORTECH as repair kits. Always use these repair kits, otherwise a proper functionality cannot be guaranteed. –...

  • Page 43: Index

    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 of supply ..........23 Serial number ..........

This manual is also suitable for:

Varifuel3 200-120 series

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