Motortech VariFuel2-TEM User manual

VariFuel2-TEM – Air/Gas Mixer
Assembly Instructions
P/N 01.50.030-2023-A-EN | Rev. 02/2023 (A)

Original assembly instructions
© Copyright 2023 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. 02/2023 3
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
1.4 Which Abbreviations/Acronyms Are Used in the Assembly Instructions?.....................6
2 Safety Instructions ......................................................................................................7
2.1 General Safety Instructions ..................................................................................... 7
2.2 Electrostatic Discharge Hazards ..............................................................................8
2.3 Special Safety Instructions for the Device ................................................................8
2.4 Proper Transport .................................................................................................. 10
2.5 Proper Storage ..................................................................................................... 10
2.6 Proper Disposal.................................................................................................... 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 Device............................................................................ 16
4.1.4 Product Identification – Labeling on the Device.................................................... 16
4.1.5 Overview Drawings............................................................................................. 17
5 Installation Instructions.............................................................................................20
5.1 Unpacking............................................................................................................20
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
6.1 Start-up ...............................................................................................................28
7 Errors.........................................................................................................................30
7.1 Special Tools for Troubleshooting ..........................................................................30
7.2 Possible Faults .....................................................................................................30
7.3 Fix Shaft............................................................................................................... 32
Table of Contents

Table of Contents
4 Rev. 02/2023
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
8.2 Spare Parts and Accessories ................................................................................. 37
9 Index ........................................................................................................................ 38

Rev. 02/2023 5
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.
1.1 What Is the Purpose of these Assembly Instructions?
These assembly instructions serve as an aid for the installation and operation of the product and
support the technical staff with all operating and maintenance tasks to be performed. Further-
more, these instructions are aimed at preventing dangers to life and health of the user and third
parties.
1.2 Who Are these Assembly Instructions Targeted to?
These assembly instructions provide a code of conduct for personnel tasked with the setup,
operation, maintenance, and repair 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 to operate the gas 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 addi-
tion, 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 men-
tioned precautionary measures.
1 General Information

1 General Information
6 Rev. 02/2023
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. Term Description Explanation
CE Conformité
Européenne
Conformity with EU
legislation
Mark based on EU legislation
for certain products in conjunc-
tion with product safety
ESD Electrostatic
Discharge
LNG Liquefied Natural Gas Natural gas liquefied by cooling
LPG Liquefied Petroleum
Gas
Petroleum gas liquefied by
cooling and compressing

Rev. 02/2023 7
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:
–The gas engine must only be operated by trained and authorized personnel.
–Observe all safety instructions of the system and all safety instructions of the system oper-
ator.
–Operate the equipment only within the parameters specified in the technical data.
–Use the equipment correctly and for its intended use only.
–Never apply force.
–For all work such as installation, conversion, adaptation, maintenance, and repair, all equip-
ment must be disconnected from the mains and secured against unintentional reactivation.
–Perform only such maintenance and repair work as is described in these assembly instruc-
tions, and follow the instructions given while working.
–Only use spare parts supplied by MOTORTECH for the maintenance of the device.
–Further work must only be performed by personnel authorized by MOTORTECH. Non-compli-
ance with the instructions will void any warranties for the proper function of the 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.
–Operate the equipment only while it is in proper condition.
–Investigate all changes that occur during operation of the gas engine or electronic engine
control.
–Ensure compliance with all laws, directives, and regulations applicable to the operation of
your system, including such not expressly stated herein.
–If the system is not entirely tight and sealed, gas may escape and result in explosion hazard.
The inhalation of gas can also lead to death or severe health damages. Therefore, upon
completion of all assembly works, always check the system's tightness.
–Always ensure adequate ventilation of the engine compartment.
–Ensure a safe position at the gas engine.
–There is a risk of burning on hot surfaces. Allow the gas engine to cool down before starting
any work.
–Personal protective equipment (PPE), e.g. safety shoes and gloves, must be worn during all
work on the gas engine.
–Noise from the system can cause permanent or temporary damage to your hearing. Wear
suitable hearing protection at the system.
–Your behavior can reduce possible residual risks to a minimum. Observe responsible han-
dling of the gas engine and the gas-carrying system.
2 Safety Instructions

2 Safety Instructions
8 Rev. 02/2023
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.
–Before performing maintenance or repair work, ensure that the static electricity inherent to
your body is discharged.
–Do not wear clothing made from synthetic materials to prevent static electricity from build-
ing up. Your clothing should therefore be made of cotton or cotton mix materials.
–Keep plastics such as vinyl and Styrofoam 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 cause death or serious health damage if inhaled. Upon
completion of all assembly works, always check the system's tightness.
When operating a VariFuel gas mixer, make sure that the gauge port is
closed.
All works involving gas-carrying parts must be executed by trained person-
nel only.
Explosion hazard!
If the system is not entirely tight and sealed, gas may escape and result in
explosion hazard. Upon completion of all assembly works, always check the
system's tightness.
All works involving gas-carrying parts must be executed by trained person-
nel only.
Explosion hazard!
Do not disconnect any connectors while the system is live. If the system is
located in a hazardous area, there is a risk of explosion.

2 Safety Instructions
Rev. 02/2023 9
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 VariFuel2-TEM regularly for contamina-
tion as a part of the regular maintenance intervals customary for your sys-
tem. Use clean gas preferably.
Risk of burning!
The surfaces of the system may heat up to high temperatures.
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.
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.

2 Safety Instructions
10 Rev. 02/2023
2.4 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.
2.6 Proper Disposal
For the proper disposal of MOTORTECH equipment, observe the information provided at
www.motortech.de.