MFE_30_Documentation_12-9-13.pdf

POC:

Warren Eastham

Engineer, NSWC PCD warren.eastham@navy.mil

850-636-6497

Multifuel Engine (MFE) – 30 HP Modifications Overview

09 DEC 2013

mailto:warren.eastham@navy.mil

Base Motor – Evinrude Etec 30 MFE Model E30MRL

• Multifuel Capable

– Gasoline, kerosene, JP-4, JP-5, JP-8, Jet A and Jet B

• 160 lbs

• Rope Start

Modifications to Evinrude Etec 30 MFE

1. Submersible wiring harness

2. Submersible Engine Management Module (EMM)

3. Potted sensors/components with waterproof connectors

4. Waterproofing adaptor for throttle position sensor

(TPS)

5. Throttle spring return

6. Improved fuel select switch design

7. Head dewatering valves with external actuators

8. Parylene coated stator, flywheel, and oil pump (for corrosion resistance)

9. Relocated ignition coil

Submersible Wiring Harness

Problem:

Solution:

• Stock Evinrude Etec 30 MFE wiring harness is not submersible

• Uses “splash proof,” rather than waterproof connectors

Submersible harness manufactured by vendor to NSWC PCD specs

Submersible Wiring Harness

• Harness manufactured by Chenega

Manufacturing Services, LLC to NSWC PCD specs

• Utilizes Seacon waterproof connectors for sensors and components

• Utilizes Souriau connectors for ECU and stator

• All wiring encapsulated in waterproof casing and shrink boots

• Harness Part #: 1000100-3

8 7

11 12

LEGEND

1. EMM Connector

2. Crank Position

3. Throttle Position

4. Air Temp

5. Cyl Head Temp

6. Ground 1

7. Low Oil Switch

8. Neutral Switch

9. Stop Switch

10. Fuel Select Switch

11. Diagnostic

12. System Check

13. High Press Fuel Pump

14. Fuel INJ (Bottom)

15. Fuel INJ (Top)

16. Ground 2

17. Oil Injector

18. IGN Coil (Bottom)

19. IGN Coil (Top)

Submersible Wiring Harness

Part #: 1000100-3

Submersible Engine Management Module

(EMM)

• OEM EMM uses a soft potting material that is splash proof but not submersible

• OEM EMM’s connector is not waterproof

Problem:

Solution: • EMM modified by potting on both sides with submersible potting material

• Two Souriau waterproof connectors were adapted to OEM connector and then sealed with potting material

Submersible EMM Wires from Souriau connectors attached to original connector and potted into place

Polyurethane potting material

Polyurethane potting material

Connects to Stator

Connects to Wiring Harness

Sensors & Components

Solution:

• Stock Etec 30 MFE uses many electrical sensors and components that are monitored or controlled by the EMM

• These components are not submersible, and do not utilize waterproof connectors

• All sensors and components were modified by vendor to NSWC PCD specs

• Sensors/components waterproofed

• Waterproof connectors added

Submersible Components Kit Part # 1000101-SET

Component Qty Evinrude Part # (for unmodified part)

Chenega Part # (for potted part with waterproof connector)

Air Temp Sensor 1 3010673 1000101-1

Throttle Position Sensor 1 5006484 1000101-2

Crank Position Sensor 1 0587014 1000101-3

Engine Temperature Sensor 1 3010674 1000101-4

Ignition Coil 2 0586980 1000101-5

Stator 1 0586918 1000101-6

Fuel Vapor Separator & Pump

1 5007896 1000101-7

Fuel Injector 2 5008837 1000101-8

Oil Pump 1 5007898 1000101-9

Neutral Switch 1 0586780 1000101-10

Stop Switch 1 0586792 1000101-11

Oil Level Switch 1 0352874 1000101-12

Fuel Select Switch 1 * 1000101-13

* NSWC PCD designed, manufactured part 10

Air Temp Sensor 1000101-1

Throttle Position Sensor (TPS) 1000101-2

Potted Sensor/Components with Waterproof Connectors

Crank Position Sensor 1000101-3

Engine Temp Sensor 1000101-4 11

Potted Sensor/Components with Waterproof Connectors

Ignition Coil (2 per motor) 1000101-5

Stator 1000101-6

Fuel Vapor Separator & Pump 1000101-7

Fuel Injector (2 per motor) 1000101-8

Oil Pump 1000101-9

Neutral Switch 1000101-10

Stop Switch 1000101-11

Oil Level Switch 1000101-12 13

Fuel Select Switch - Improved 1000101-13

Fuel Select Switch – OEM Style 1000101-14 Replaced By: 1000101-13

Throttle Position Sensor (TPS) Waterproofing Adaptor

Factory TPS consists of two moving parts – is vulnerable to water intrusion

Problem:

Solution: A waterproof adaptor was designed and produced to seal the TPS

TPS Waterproofing Adaptor

TPS

TPS Waterproofing Adaptor

Throttle Return Spring

• The TPS waterproofing adaptor is sealed with O-rings

• The added friction can make the throttle “stick” above idle when the hand throttle is in the idle position

Problem:

Solution: • A supplemental throttle return spring was added

• It ensures the throttle returns to idle when the hand throttle is in the idle position

Throttle Return Spring

Installed

Return Spring Assembly

Improved Fuel Select Switch

• Factory MFE fuel select switch has three problems:

– It is push-pull button that can easily be inadvertently actuated

– It is difficult/impossible to use with a gloved hand

– It is nearly impossible to see switch position in low light

Problem:

Solution:

• New fuel select switch designed and produced by NSWC PCD

– Addresses all shortcomings of factory switch

– Mounts in the same location, with no modifications to the motor or cowling

Aluminum Mounting Plate – When installed, the plate locks into the geometry of the cowling. This makes it possible to mount switch without modifying the stock motor cowlings

Switch works using a potted magnet and magnetic reed switch

– Totally Waterproof

Seacon Connector

Fuel Select Switch

Switch locks in two positions:

• Pointing Left = Heavy Fuel

• Pointing Right = Gasoline

Head Dewatering Valves & Actuators

Solution:

• During submersion, water gets trapped above pistons in combustion chamber

• Traditionally, this water has to be slowly squeezed past the piston rings during dewatering

• This increases dewatering time/effort and can result in pull rope breakage

• Dewatering valve installed on each cylinder head

• External actuators added so user can open/close the valves with cowling on

Dewatering Valves External Acuators Installed 23

Head Dewatering Valve Actuators

• Push IN to Dewater

• Valves close automatically when RPM’s increase above idle

Parylene coated stator, flywheel, and oil pump

• Parylene is a room temperature, vapor-deposition coating

• Often used to waterproof electronics

• Intended to reduce corrosion and prolong the life of parts

Relocated Ignition Coil

Solution:

• Lower Ignition Coil blocks field access to bottom sparkplug

• Also blocks path for lower head dewatering valve actuator

• Bracket created to relocate coil to a different location

• No mods to engine block needed

Relocated Coil Bracket

Relocated Coil

Original Ignition Cable can still be used

Bottom Valve and Sparkplug Unobstructed 27

Supplemental Documents

• Harness & Components Parts List.xlsx

• MFE 30 Dewatering Procedure.docx