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    90 views44 pages

    Tomasetto Multivalve Model AT 02 - PDF Free Download PDF

    Uploaded by

    Ilayaraja Boopathy

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    © All Rights Reserved
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    lA f TOMASETTO ACHILLE components for PG & CNG systems Tomasetto Multivalve Model AT 02 Lam gE somssero meses { 0 la f TOMASETTO ACHILLE ‘components for LPG & CNG systems TOMASETTO ACHILLE 59.8. Vad Poors, 4753 | We 39.0662826 | nfeotoraetiocom | the/CF.\mO931330245-REA. 281289 Nncmii 36020categno vp naia | rxe30.0110620367 | wntonamtocom |W Rep ngs VEO91330285 Cap. sex 1000000 ei la 4 TOMASETTO ACHILLE components for LPG & CNG systems Indice Multivalve description Multivalve function description... a) 80% fill imiter system .. b) Electronic level indicator: ¢) Pressure reliof valve (PRV) ... d) Pressure reliof device (PRD)... e) Shut-off solenoid valve f) 9) h) Excess flow valve ) Non-return valve ... ) Manual tap... Installation Instructions Troubleshooting . oe " a) b) OO) a) °) f) 9) h) ) d ) m) ”) 0) Multivaive model and size check... a Tank integrity check and overall dimensions check Multivalve integrity check and 80% system check. Installation of multi-valve in a cylindrical tank Installation of multi-valve in 0°, 30° and 90° cylindrical tanks... Installation of multi-valve in a toroidal tank Installation of multi-valve in 30° and 37°toroidal tanks Installation of multi-valve in 0 *toroidal tank Sotup of the inlet and outlet fittings. ‘Checks to be performed on the tank after installation on the vehicle.. Fittings tightening and electrical wire connection. Final Checks wn. Remote filing point TOMASETTO ACHILLE Sp.A. Via del Progreso, 4753 36020 Castegnero (Va Calibration of the level sensor . el 139.0440.638326 x +30-0048-620367 info@tomssetto.com Pag. 3.4144 Pla /C 00931330245 - REA. 261289 Nag impose 00031330248 - Cap. Soc. 1.000.000 euro la 4 TOMASETTO ACHILLE components for LPG & CNG systems Multivalve description ‘The Tomasetto multivalve model ATO2 is a component for LPG gas systems designed according to the UN ECE R01 67 Regulation and approved by the Ministry of Transport of the Czech Republic with approval number E8-67R013018. ‘The Tomasetto multivalve model ATO2 is a multifunction device to be installed on automotive LPG tanks and ‘equipped with the following accessories: a) 80% fill imiter valve; b) level indicator; c) Pressure Relief Valve (PRV); d) Pressure Relief Device (PRD); €) Shut-off solenoid valve: ) Excess flow valve; 4g) Non-return valve; h) Manual tap PRET ec Se, og tea fj Via del Progresso, 4753 | fe. +30-0442.638326 | infoOtomasetiocem | Pva//C.F G0031330245 - REA, 281289 36020 CastegneraVpitala | Fax +30-0442-620367 | winwtcmasettocam | N* Rag inpreze VO003139024S - Cap, Soc. 1.000.000 eu 1h f TOMASETTO ACHILLE components for LPG & CNG systems DESCRIPTION OF THE DEVICES a) 80% fill limiter system The 80% fil miter is a safety device aimed to close the filing valve when the 80% of the tank capacity is reached, by using a float, a rod and a special mechanism with a rotating cam Float postion at 80% b) Electronic level indicator The level indicator should be chosen according to the adopted ECU system ¢) Pressure relief valve (PRV) The PRV is a safety device aimed to limit the maximum pressure inside the tank to 2.7 + 0.1 MPa. ‘The PRV is a valve with a retaining spring allowing, i verpressure, the discharge of the LPG from the tank in vapor phase Safty vawo in close conditions Salaty valve in open condition: TOMASETTO ACHILLE SpA. Pag. 8 di44 la 4 TOMASETTO ACHILLE components for LPG & CNG systems d) Pressure relief device (PRD) The PRD is a safety device equipped with a thermo fuse element which melts at a pre-set temperature of 120°C # 10°C. In case of fire, the fuse melts and opens @ hole for the fast release of the LPG from the tank, preventing the risk of an explosion Fuse element Fuse in conditions of normal operation Hole opened by fuse metting Fuse in open conditions e) Shut-off solenoid valve This device is aimed stop the gas flow when one of the following conditions occurs: the engine is switched off or is working in petrol and the electric supply to the solenoid is switched off; in this condition, a spring inside the solenoid valve maintains the moving core in the closing position; while switching to LPG, the electric supply to the solenoid is switched on and the solenoid generates a magnetic field that attracts the plunger, allowing the opening of the multivaive hole and, consequently, the LPG flow. Electrovalve in cut of position Electrovave in open positon Patents ce. con eeite i 8 Via del Progresso, 47453, Tel. +30.0444.638226 | info@tomasettocom | Plva/C.F Wl00931330245 - REA. 281289 36020 Castegnero (v0 tala | Fan +30.0842620967 | wwwwtamacettocem | NP Rag Imprese VO0O31330248 - Cap Soc. 1.00000 euro la 4 TOMASETTO ACHILLE components for LPG & CNG systems f) Excess flow valve ‘The excess flow valve is located in the withdrawal circuit , upstream the solenoid valve and is aimed to block the flow of LPG in the event of an accidental breakage of the LPG piping After its intervention, for the automatic resetting of the valve, a residual flow is allowed. Excess flow valve position with the engine switched off Excess flow valve in working position Excess flow valve in close position GED vomssrT0 mises Z Pag. 7 di44 Via del Progreso, 4753 fel. +39.0848:698326 | infoGtomacettocom | Flva/C. MOO931220248 - REA, 261200 36020 CastegneraVpitala | Fax +30-0442-620367 | winwtcmasettocam | N* Rag inpreze VO003139024S - Cap, Soc. 1.000.000 eu la 4 TOMASETTO ACHILLE components for LPG & CNG systems 9) Non-return valve at the inlet The non-return device is equipped with a double safety system: the first non-return valve is integrated in the 80% filing limiter, the second device is located in the inlet fiting ‘These devices are aimed to avoid the back flow of gas from the tank toward the outlet of the filing device non-return valves in close position non-return valves during filling operation h) Manual vaive ‘The manual valve intercepts the outlet gas circuit upstream of the solenoid valve and is aimed to the maintenance of the solenoid valve. Manual valve in open postion Manual valve in close position Pawnee sats Pag. 8 di44 20285 - REA. 281289 wwtomasetocom | N* Rag imprese 00831330285 - Cap. Soc. 1.000.000 euro 1h f TOMASETTO ACHILLE components for LPG & CNG systems Installation instructions For a correct installation, all the operations must be performed according to the requirements of the ECE RO1 ONU67 Regulation, Part | and Part |! The use of the multivalve is limited to that specified in the UN ECE 67R01 Regulation fS TOMASETTO ACHILE SpA. Pag. 9144 % la 4 TOMASETTO ACHILLE components for LPG & CNG systems a) Multivalve model and size checks The correspondence between the type and the size of the tank marked on the multi-valve has to be verified with the information indicated on the marking plate of the tank. Figure 1: Muttvalve size Figure 2: LPG tank size TOMASETTO ACHILLE SpA. Pag. 10144 Via del Progreso, 4753 info@tomseetocom | Pha/CEV REA. 261209 36020 Castegnero (Va vwwntomasetocom | N° Reg npree 00031330245 - Cap, Soc. 1.000.000 eu iv la 4 TOMASETTO ACHILLE components for LPG & CNG systems b) Tank integrity and overall dimension checks The angular error of the screws threaded holes of the flange must not exceed + 2 ° The tank must be placed in a horizontal position. For a correct installation, it is warmly suggested to tighten two screws on the two opposite holes as shown in figure 3. The inclination of the ring with respect to the horizontal plane has to be measured as shown in Figure 3, Figure 3: measuring method of the angular error ofthe flange In the toroidal tanks, the inclination of the flange has to be checked with a goniometer in order to verify whether it is one as per the requirements: 0°, 30 * or 37° £37" Toroidal tank ann ems sc A ag 11a fj Via del Progreso, 4753 sso oan eae Jtomaatioc | ha/CF WOO0B1330245 -REA, 201280 1h f TOMASETTO ACHILLE components for LPG & CNG systems The seat ring has to be clean and any remaining paint has to be removed, taking care to not create planarity error, dents or scratches that might affect the sealing. The inside part of the tank has to be cleaned from any welding or sanding residue and empty from any trace of water (see figure 4). Figure 4: Removing of the paint from the eeat ring of the tank If necessary, residual paint from the screw threaded holes MS has to be removed, as well as any burr or debris created by this operation (see figute 5). Figure 5: Removing of the paint from the screw threaded holes Pag. 12.4144 | N* Rag nprece W00031320245 - Cap, Soc. 1.000.000 eu la 4 TOMASETTO ACHILLE components for LPG & CNG systems c) Integrity checks of the multivalve The muttivalve has to be without damages due to improper handling. Warning! Handle the multivalve grabbing it from the multivalve body. Do not grab the multivalve in different ways, Figure 6: Handling methods The correct movement of the float rod has to be checked by rotating it as shown in Figure 7. i Figure 7: float rod test GE rouse nomisse pee. 13444 i Via del Progresso, 47/53 39.0444-6383 foBtomasetto,con P) 30245 - REA. 281289 la 4 TOMASETTO ACHILLE components for LPG & CNG systems d) Installation of a multivalve in a cylindrical tank For cylindrical tanks located inside the vehicle, the multi-valve must be installed together with the gas tight housing. Lay out for 0° and 30° cylindrical tanks Figure 8: Assembly lay out for 0° and 30° cylindrical tanks Lay out for 90° cylindrical tanks: Main axis of the tank Figure 9: Assembly ay out for 80° cylindrical tanks GES rouse somizses. A Vial ree, 4783 wi sanousaens | nletomattocon | fia WOH3122025- RA. 281209 , ear Casegpe tata | fa 20- 040862267 | wont ca Pag. 14.4144 Rag inprese 00031330248 - Cap Soc. 1.000.000 euro la 4 TOMASETTO ACHILLE components for LPG & CNG systems For 90° cylindrical tanks with diameter smaller than 270 mm, a special gas tight housing has to be used as shown in figure 1: Via del Progreso, 47853 Tek +39-0142.638226 | info@tomacttocam | Plva/C.F V0931390245 - REA. 281289 36020 Castegnero (v0 tala | Fan +30.0842620967 | wwwwtamacettocem | NP Rag Imprese VO0O31330248 - Cap Soc. 1.00000 euro C& TOMASETTO ACHILLE Sp.A. Pag. 15.4144 u la 4 TOMASETTO ACHILLE components for LPG & CNG systems @) Assembly instructions for 0°, 30° and 90° cylindrical tanks: Placement of the O-ring gasket in the ring of the tank; Figure 11: Placement ofthe O-ing gasket Placement of the gas-tight housing (Figure 12); Figure 12: Positioning of the gas tight housing Inserting of the float rod and of the withdrawal pipe in the tank (Figure 13); Figure 13: Insert the loat and the withdrawal pipe in the tank TOMASETTO ACHILLE SpA. Pag. 16144 36020 Castegnero (Va ox +39-0440-630267 | wwiomasettocem | N* Reg nprese VO0231330245 -Cap. Soc 1.000.000 eu i. 1h f TOMASETTO ACHILLE components for LPG & CNG systems Removal ofthe coil with a 7mm wrench and fixing ofthe 6 flange screws (sequence explained in figure 14) Fixing torque to be 3.5 +/- 0.5 Nm ing: avoid tod Do not remove during ‘Screws fixing lay out sequence components during installation installation Figure 14: operation sequence for screws fixing 80% system correct functioning verification: this check has to be performed by rotating the tank along its axis and by checking the correct indication of the level sensor (Figure 15). Warning: According to the ECE 67 R01 Regulation, Part Il paragraph 17.6.3.1 “The automatic filling level limiter shall be suitable for the fuel container it is fitted to and shall be installed in the appropriate position to ensure that the container cannot be filled to more than 80%” Figure 18: 80% system check TOMASETTO ACHILLE SpA. Pag. 17144 36020 Castegnero (Va ox +30-0442-620367 | wirwtcmasettocam | N* Rag inpeze VO003139024S - Cap, Soc. 1.000.000 eu la 4 TOMASETTO ACHILLE ‘components for LPG & CNG systems f)_ Installation of multivalve in a toroidal tank In 0°, 30° and 37° toroidal tank the assembly position of multivalve changes as shown in the following pictures. Figure 17: Muttivaive lay out assembly for 30° and 37” toroidal tank version Via del Progreso, 47853 Tek +39-0142.638226 | info@tomacttocam | Plva/C.F V0931390245 - REA. 281289 36020 Castegnero (v0 tala | Fan +30.0842620967 | wwwwtamacettocem | NP Rag Imprese VO0O31330248 - Cap Soc. 1.00000 euro C& TOMASETTO ACHILLE Sp.A. Pag. 18 di 44 u la 4 TOMASETTO ACHILLE components for LPG & CNG systems 4) Installation of the multivaive in 30° and 37° toroidal tanks: Inserting of the float rod and of the withdrawal pipe in the tank (Figure 18). Do not force the components of multivalve during the assembly operation, Figure 18: Inserting of the float red, of the withdrawal pipe and of the plastic pipe in the 30° and 37° toroidal tank Warning. To avoid damages to the plastic pipe and guarantee the correct working of the 80% system, the plastic pipe must not be assembled in the tank as show! \S Pees roanerro pom TOMASETTO ACHILE Sp. Pog, 21 4144 3 : 5-REA i Vie de ogee i 36020 CasegneraVDitala | Fax vwwntomasetocom | N° Reg npree 00031330245 - Cap, Soc. 1.000.000 eu iv la 4 TOMASETTO ACHILLE components for LPG & CNG systems h) Installation of the multivalve in 0° toroidal tanks In the 0 * toroidal tanks, the multivaive is protected by a plastic protection to prevent damage during use. Inserting ofthe float rod and of the PRV with¢rawal pipe in the plastic ring and clamping (figure 21). Figura 21 Inserting of the float rod and of the withdrawal pipe in the tank (figure 22). D sssembly of Figure 22: Inserting of the lost rod, ofthe withdrawal pipe and of the plastic pipe inthe 0° toroidal tank Pag. 22 di 44 20285 - REA. 281289 wwtomasetocom | N* Rag imprese 00831330285 - Cap. Soc. 1.000.000 euro se TOMASETTO ACHILE Sp. Via de oreo, 4753 36020 Casegreto aa la 4 TOMASETTO ACHILLE components for LPG & CNG systems Warnin damages to the plastic pipe and guarantee the correct working of the 80 system, the plast the tank as shown in figures below Removal of the coil with a 7mm wrench and fixing of the 6 flange screws (sequence explained in figure 23) Fixing torque to be 3.5 +/- 0.5 Nm. Warning: during the coil assembly operation, insert the gasket and plastic cap to increase the coil protection, to prevent damages caused by water and debris. Fixing screw of call ZOO somsero semursoa ag 200144 1h f TOMASETTO ACHILLE components for LPG & CNG systems 80% system correct functioning verification: this check has to be performed by rotating the tank and by checking the correct indication of the level sensor (Figure 24) Warning: According to the ECE 67 R01 Regulation, Part ll paragraph 17.6.3.1 “The automatic filling level limiter shall be suitable for the fuel container it is fitted to and shall be installed in the appropriate position to ensure that the container cannot be filled to more than 80%” Figure 24: 80% system check (FR 1merosomsso ag.a4aea la 4 TOMASETTO ACHILLE components for LPG & CNG systems i) Inlet and outlet fittings setup NOTE: the inlet and outlet fittings preparing is warmly recommended before proceeding with the installation of the tank on the vehicle WARNING! DO NOT FIX THE INLET AND OUTLET CONNECTIONS IF THE MULTIVALVE IS NOT FIXED ‘ON THE TANK BUNG - OUTLET FITTING Inserting of the nut and of the ferrule on the copper pipe. Copper pipe Manual connection of the nut, ferrule and copper pipe to the multivalve outlet fitting Figure 25: outet fiting manual connection Pees roanerro pom

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