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Summary of Contents for Motortech VariFuel2-TEM
- Page 1 VariFuel2-TEM – Air/Gas Mixer Assembly Instructions P/N 01.50.030-2023-A-EN | Rev. 02/2023 (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.
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Page 3: Table Of Contents
5.2 Assembly ......................20 5.2.1 Dismount Original Gas Mixer ................22 5.2.2 Install Flow Body ....................23 5.2.3 Install VariFuel2-TEM into Intake Section ............. 25 5.2.4 Connect TEM-EVO System ................. 27 ® 6 Operation ......................... 28 ... - Page 4 Table of Contents 7.4 Customer Service Information ................36 7.5 Returning Equipment for Repair / Inspection ............36 7.6 Instructions for Packaging the Equipment .............. 36 8 Maintenance ......................37 8.1 Maintenance Instructions ..................37 ...
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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 Operational safety! Contaminated gas can lead to blocking of the fuel ring and thus can cause the gas engine to stop. Examine the VariFuel2-TEM regularly for contamina- tion as a part of the regular maintenance intervals customary for your sys- tem.
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Page 10: Proper Transport
Transport the VariFuel2-TEM to the installation site unopened in its original carton. 2.5 Proper Storage Clean the VariFuel2-TEM gas mixer before storing. Store the VariFuel2-TEM gas mixer in the original packaging in a dry and clean place on even ground. -
Page 11: Intended Use
In the VariFuel2-TEM, 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 openings of the fuel ring are adjusted by a stepper motor and a drive belt . The stepper motor of the VariFuel2-TEM is controlled by the superordinate TEM-EVO system. For ® this purpose a proximity sensor integrated in the VariFuel2-TEM indicates the closed position of the fuel ring to the TEM-EVO system. ® Connections All VariFuel2-TEM gas mixers also have the following connections: –...
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Page 13: Applications
Mixing the air and fuel with the VariFuel2-TEM must be done with the same pressure, therefore it is necessary to use a balance or a zero pressure regulator within the gas train. - Page 14 3 Intended Use System Overview (Example) TEM-EVO system Ball valve ® Turbocharger Gas filter Multifunctional rail Double safety valve Proximity sensor Balance/Zero pressure regulator Stepper motor Air filter Impulse line VariFuel2-TEM air/gas mixer Rev. 02/2023...
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Page 15: Product Description
4.1 Technical Data 4.1.1 Certifications Machinery Directive – The VariFuel2-TEM 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 Symbol on Stepper Motor Warning of hot surface 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. -
Page 17: Overview Drawings
4 Product Description 4.1.5 Overview Drawings Components The following drawing shows an example of a VariFuel2-TEM series 200-120. The exact position of the individual parts varies with other series. A detailed layout can be found in the subsequent section Dimensions. - Page 18 4 Product Description Dimensions Series 200-120 VariFuel2-TEM Rev. 02/2023...
- Page 19 4 Product Description Series 250-150 VariFuel2-TEM Rev. 02/2023...
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Page 20: Installation Instructions
The balance or zero pressure regulator must be con- nected to the impulse line connection of the VariFuel2-TEM and it must be installed in the gas train at a suitable position before the gas inlet of the VariFuel2-TEM. - Page 21 5 Installation Instructions Connection Example Pos. Description Impulse line connection Impulse line Balance/Zero pressure regulator Rev. 02/2023...
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Page 22: Dismount Original Gas Mixer
However, leave the connec- tion cable connected to the relevant connection on the gas engine, as the proximity sensor of the VariFuel2-TEM gas mixer will be connected to this cable after the installation of the VariFuel2-TEM. -
Page 23: 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-TEM, observe the following guide- lines: –... - Page 24 5 Installation Instructions To install or replace the flow body, free access must be provided at the VariFuel2-TEM 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 Flow Body Size of the VariFuel2-TEM nameplate.
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Page 25: Install Varifuel2-Tem Into Intake Section
Flow bodies made of thermoplastic material: 3 Nm (2.2 lb-ft) 5.2.3 Install VariFuel2-TEM into Intake Section The mounting position of the VariFuel2-TEM gas mixer is arbitrary. For mounting, use the four threaded holes and the flat surface on the bottom side of the device. - Page 26 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-TEM gas mixer when connecting the lines. – Air inlet Series 200-120: Hose connection Series 250-150: Flange connection Rev.
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Page 27: Connect Tem-Evo System
Gauge port Connection for the measuring lead of a pressure gauge to measure the gas pressure at the gas inlet of the VariFuel2-TEM. The connection is suitable for hoses with an inner diameter of 8 mm (0.31"). 5.2.4 Connect TEM-EVO System ®... -
Page 28: Operation
Basic Settings of the System With an ideal design, the VariFuel2-TEM 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 at nominal load. - Page 29 The nominal output is reached by enriching the mixture. – At the gauge port of the VariFuel2-TEM, 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- ing measures: –...
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Page 30: Errors
– VariFuel Locking Tool for Toothed Pulley With this tool, you lock the toothed pulley of a VariFuel2-TEM gas mixer to tighten or loosen the hexagon socket head cap screw with which the toothed pulley is attached to the shaft. - Page 31 In case of questions, please contact your MOTORTECH contact person. Fuel ring is dirty. Fuel ring does not The VariFuel2-TEM must be cleaned move. and wearing parts must be replaced if necessary. In case of questions, please contact your MOTORTECH contact person.
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Page 32: Fix Shaft
Dismounting Explosion hazard! A dirty O-ring can lead to leakage of the VariFuel2-TEM, 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). - Page 33 7 Errors 5. Loosen the set screw from the shaft. Installation Moisten the set screw with medium strength thread lock fluid. 2. Replace the shaft on the axle 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 34 M4x16 to the shaft of the stepper motor. To tighten the hexagon socket head cap screw, use the VariFuel Locking Tool for Toothed Pulley and a hex key SW3. Proceed as described in the instructions for use of the locking tool. 7. Insert the O-ring into the housing of the VariFuel2-TEM. Rev. 02/2023...
- Page 35 7 Errors 8. Insert the stepper motor into the housing of the VariFuel2-TEM so that the drive belt lies on the toothed pulley, and then attach the stepper motor with the hexagon socket head cap screws M6x16 of the adapter plate to the VariFuel2-TEM.
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Page 36: Customer Service Information
(all other matters) 7.5 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 36). From him you will receive all the information you need to process your order quickly and smoothly. -
Page 37: Maintenance
MOTORTECH. – Dirty seals (e.g. flat gaskets, O-rings) can lead to leakage of the VariFuel2-TEM. When re- placing seals, only use clean seals from MOTORTECH (part of MOTORTECH repair kits). –... -
Page 38: Index
Start-up ............ 28 Flow body Install ............20 Fuel value ............13 Function ............11 M Maintenance ..........37 Mechanical data..........15 MOTORTECH Contact ............. 36 O Original gas mixer Dismounting ..........22 P Part number ..........16 Proximity sensor Connect ............ - Page 39 Rev. 02/2023...
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