Motortech ITB 50 Series User manual

ITB – Throttle with Integrated
Stepper Motor
P/N 30.43. xxx
Assembly Instructions
P/N 01.50.034 | Rev. 06/2022

Original assembly instructions
© Copyright 2022 MOTORTECH GmbH. All rights reserved.
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.
Information contained in this publication may be changed without prior notice.

Rev. 06/2022 3
1 General Information .....................................................................................................4
1.1 What Is the Purpose of these Assembly Instructions?.................................................4
1.2 Who Are these Assembly Instructions Targeted to?....................................................4
1.3 What Symbols Are Used in the Assembly Instructions? ..............................................4
1.4 Which Abbreviations/Acronyms Are Used in the Operating Manual?...........................5
2 Safety Instructions ..................................................................................................... 6
2.1 Proper Disposal ......................................................................................................6
3 Intended Use ...............................................................................................................7
3.1 Functional Description ............................................................................................ 7
3.2 Applications...........................................................................................................8
4 Product Description .................................................................................................... 9
4.1 Technical Data ........................................................................................................9
4.2 Warning Notices on the Device .............................................................................. 10
4.3 Product Identification – Labeling on the Device .......................................................11
4.4 Digression: Control of the Stepper Motor ............................................................... 12
4.5 Overview Drawings ............................................................................................... 12
4.5.1 50 Series ........................................................................................................... 13
4.5.2 100 Series ......................................................................................................... 15
4.5.3 140 Series ......................................................................................................... 17
4.5.4 150 Series ......................................................................................................... 19
4.5.5 200 Series......................................................................................................... 21
5 Wiring of the Device ...................................................................................................23
5.1 Connector Stepper Motor / Encoder ....................................................................... 23
6 Assembly Instructions ...............................................................................................24
6.1 Unpacking............................................................................................................24
6.2 Mounting the Device.............................................................................................24
6.3 Connecting the Device ..........................................................................................26
7 Errors.........................................................................................................................27
8 Maintenance............................................................................................................. 28
8.1 Customer Service Information ...............................................................................28
8.2 Returning Equipment for Repair / Inspection ..........................................................28
8.3 Instructions for Packaging the Equipment ..............................................................28
8.4 Spare Parts and Accessories .................................................................................28
Table of Contents

4 Rev. 06/2022
Prior to use, read these assembly instructions carefully and familiarize yourself with the
product. 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.
1.1 What Is the Purpose of these Assembly Instructions?
This installation instruction serves as an aid for the installation of the product and supports the
technical staff with all maintenance tasks to be performed. Furthermore, this instruction is
aimed at preventing dangers to life and health of the user and third parties.
1.2 Who Are these Assembly Instructions Targeted to?
This assembly instructions provide a code of conduct for personnel tasked with the setup,
operation, maintenance, and repair of stationary engines. A certain level of technical knowledge
with respect to the operation of stationary engines and basic knowledge of the electronic
components used are necessary. Persons who are only authorized to operate the stationary
engine shall be trained by the operating company and shall be expressly instructed concerning
potential hazards.
1.3 What Symbols Are Used in the Assembly Instructions?
The following symbols are used in these instructions and must be observed:
Example
This symbol indicates examples, which point out necessary handling steps
and techniques. In addition, you receive additional information from the
examples, which will increase your knowledge.
Notice
This symbol indicates important notices for the user. Follow these. In
addition, this symbol is used for overviews that give you a summary of the
necessary work steps.
Warning
This symbol indicates warnings for possible risks of property damage or
risks to health. Read these warning notices carefully and take the
mentioned precautionary measures.
1 General Information

1 General Information
Rev. 06/2022 5
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 Operating Manual?
The following abbreviations/acronyms are used in the assembly instructions.
Abb. Term Description Explanation
CPR Counts Per Revolution Counter results per
revolution
Unit for the resolution of
encoders
HT High temperature Device version designed for
higher temperatures of the
media flowing through.
ITB Integrated Throttle
Body
Throttle with
integrated stepper
motor
MICT MOTORTECH
Integrated
Configuration Tool
Configuration software for
MOTORTECH control units
USB Universal Serial Bus Serial connection system to
link a computer to external
devices

6 Rev. 06/2022
The device is operated on a stationary engine. Please follow therefore all safety instructions of
the equipment manufacturers, especially with regards to sections under high voltage. All work
must be performed by trained and authorized personnel only.
Risk of injury!
Turn off the engine prior to assembly and secure it from re-starting in order
to avoid damage or injury.
Risk of injury and destruction
The engine must be equipped with an independent emergency shutdown
switch to avoid overspeed, which can cause destruction and/or injury.
Risk of burning!
The surfaces of the system may heat up to high temperatures.
2.1 Proper Disposal
For the proper disposal of MOTORTECH devices, observe the information provided at
www.motortech.de .
2 Safety Instructions

Rev. 06/2022 7
3.1 Functional Description
The ITB throttle controls the supply of the gas-/air mixture to the gas engine. The integrated
stepper motor evaluates signals from a VariStep stepper motor driver and implements them in
changing the opening of the throttle. The speed and power of the engine are regulated in this
way.
System Overview (Example)
VariStep3 stepper motor driver Master control
VariFuel gas mixer Flywheel
ITB throttle with integrated stepper motor Magnetic pickup
SC100 speed controller Engine
Impulse line
Air Air filter
Gas Ball valve
Gas filter
Double safety valve
Balance/Zero pressure regulator
3 Intended Use

3 Intended Use
8 Rev. 06/2022
3.2 Applications
The ITB throttles are suitable for use on stationary gas engines. Series with different valve
diameters are available for different gases and performance classes. A high temperature version
(HT) can be used for operation in front of the intercooler. These permit a temperature of the
medium flowing through of up to +200 °C (+392 °F).
Any use other than the one described in the assembly instructions shall be considered improper
use and will result in the voiding of all warranties.

Rev. 06/2022 9
4.1 Technical Data
The throttles have the following technical properties:
Feature Value
Dimensions See chapter Overview Drawings on page 12
Weight See following table.
Shape of device See chapter Overview Drawings on page 12
Maximum rotation angle of the throttle
body
80°
Chemical resistance Water, oil, gaseous fuels
Absolute pressure 4.5 bar (65 psi)
Maximum temperature of media flowing
through
+125 °C (+257 °F) (standard version)
+200 °C (+392 °F) (HT version)
Connection stepper motor 10-pole military style connector
Climatic environmental conditions –20 °C to +85 °C (–4 °F to +185 °F)
max. 95% humidity without condensation
Weight
The weight depends on the type, series and diameter of the throttle.
Series Diameter of the throttle body Type Weight
50 series 42 mm (1.65") Standard 2.1 kg (4.63 lbs)
42 mm (1.65") HT 2.2 kg (4.85 lbs)
100 series 60 mm (2.36") Standard 2.5 kg (5.51 lbs)
60 mm (2.36") HT 2.6 kg (5.73 lbs)
68 mm (2.68") Standard 2.6 kg (5.73 lbs)
68 mm (2.68") HT 2.7 kg (5.95 lbs)
140 series 75 mm (2.95") Standard 3.8 kg (8.38 lbs)
75 mm (2.95") HT 3.9 kg (8.60 lbs)
80 mm (3.15") Standard 3.7 kg (8.16 lbs)
80 mm (3.15") HT 3.8 kg (8.38 lbs)
85 mm (3.35") Standard 3.6 kg (7.94 lbs)
85 mm (3.35") HT 3.7 kg (8.16 lbs)
4 Product Description

4 Product Description
10 Rev. 06/2022
Series Diameter of the throttle body Type Weight
150 series 90 mm (3.54") Standard 7.0 kg (15.43 lbs)
90 mm (3.54") HT 7.2 kg (15.87 lbs)
100 mm (3.94") Standard 6.8 kg (14.99 lbs)
100 mm (3.94") HT 6.9 kg (15.21 lbs)
200 series 100 mm (3.94") Standard 8.4 kg (15.52 lbs)
100 mm (3.94") HT 8.5 kg (18.74 lbs)
105 mm (4.13") Standard 8.1 kg (17.86 lbs)
105 mm (4.13") HT 8.2 kg (18.10 lbs)
110 mm (4.33") Standard 7.8 kg (17.20 lbs)
110 mm (4.33") HT 7.9 kg (17.42 lbs)
115 mm (4.53") Standard 7.5 kg (16.53 lbs)
115 mm (4.53") HT 7.6 kg (16.76 lbs)
120 mm (4.72") Standard 7.2 kg (15.87 lbs)
120 mm (4.72") HT 7.3 kg (16.09 lbs)
125 mm (4.92'') Standard 6.9 kg (15.21 lbs)
125 mm (4.92'') HT 7.0 kg (15.43 lbs)
4.2 Warning Notices on the Device
The following labels are located on the stepper motor:
English warning notice German translation
CAUTION! Stepper motor rev. B only for
use with VariStep stepper motor drivers.
Do not use stepper motor to lift or carry
the device.
VORSICHT! Schrittmotor Rev. B nur mit VariStep-
Schrittmotorsteuerungen verwenden.
Den Schrittmotor nicht zum Tragen oder Heben
des Gerätes benutzen.
Warning Symbol on Stepper Motor
Warning of hot surface

4 Product Description
Rev. 06/2022 11
4.3 Product Identification – Labeling on the Device
The necessary numbers for unique product identification are on the device:
Nameplate ITB on the Throttle Body
Abb. Meaning
P/N ITB part number
S/N ITB serial number
Stepper Motor Nameplate
Abb. Meaning
P/N Part number of the stepper motor
PC Production code
REV. Revision of the stepper motor

4 Product Description
12 Rev. 06/2022
4.4 Digression: Control of the Stepper Motor
In the standard application, the stepper motor of the throttle is driven by the VariStep 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 following section.
Technical Data of Stepper Motors
Feature 50, 100, 140 series 150, 200 series
Design 2-phase, bipolar 2-phase, bipolar
Maximum phase
current
2.8 A 6.3 A
Recommended
current
2 A (full step operation mode)
2.8 A (microstep operation mode)
2.8 A (full step operation mode)
4 A (microstep operation mode)
Step width 0.9° 1.8°
Recommended
control
1/16 microstep operation mode 1/16 microstep operation mode
Technical Data of the Encoder
Feature Values for all series
Operating voltage 5 V
Type Incremental, quadrature signal
Signal form A, B, index; TTL-compatible
Resolution 4,096 CPR
Index position Throttle is completely closed
You can find the assignment of the connectors on the stepper motor and encoder in the section
Connector Stepper Motor/Encoder on page 23.
4.5 Overview Drawings
Take military style connector into account
During planning of the installation, consider the dimensions of the military
style connector on the harness (about 75 mm (2.95") on the 90° connector).

4 Product Description
Rev. 06/2022 13
4.5.1 50 Series
Standard diameter of the throttle (D): 42 mm (1.65")
possible diameters of the throttle: 41 mm (1.61") to 44 mm (1.73")
P/N 30.43.055-D and P/N 30.43.055-D-HT also correspond to the following drawings, but without
the gasket (O-ring, 56.75 mm x 3.53 mm [2.23" x 0.14"]) and the groove required for it.
Standard version (P/N 30.43.050-D)

4 Product Description
14 Rev. 06/2022
HT versions (P/N 30.43.050-D- HT)

4 Product Description
Rev. 06/2022 15
4.5.2 100 Series
Standard diameters of the throttle (D): 60 mm (2.36"), 68 mm (2.68")
possible diameters of the throttle: 48 mm (1.89") to 68 mm (2.68")
P/N 30.43.105-D and P/N 30.43.105-D-HT also correspond to the following drawings, but without
the gasket (O-ring, 82.14 mm x 3.53 mm [3.23"x 0.14"]) and the groove required for it.
Standard version

4 Product Description
16 Rev. 06/2022
HT version

4 Product Description
Rev. 06/2022 17
4.5.3 140 Series
Standard diameters of the throttle (D): 75 mm (2.95"), 80 mm (3.15"), 85 mm (3.35")
possible diameters of the throttle: 73 mm (2.8) to 85 mm (3.35")
P/N 30.43.145-D and P/N 30.43.145-D-HT also correspond to the following drawings, but without
the gasket (O-ring, 98.02 mm x 3.53 mm [3.86"x 0.14"]) and the groove required for it.
Standard version

4 Product Description
18 Rev. 06/2022
HT version

4 Product Description
Rev. 06/2022 19
4.5.4 150 Series
Standard diameters of the throttle (D): 90 mm (3.54"), 100 mm (3.94")
possible diameters of the throttle: 82 mm (3.23") to 104 mm (4.09")
P/N 30.43.155-D and P/N 30.43.155-D-HT also correspond to the following drawings, but without
the gasket (O-ring, 116 mm x 3 mm [4.57"x 0.12"]) and the groove required for it.
Standard version

4 Product Description
20 Rev. 06/2022
HT version