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Updated May, 2012
INSTALLATIONINSTALLATIONINSTALLATIONINSTALLATIONMANUALMANUALMANUALMANUALFor the CNG Sequential Injection System(Can be taken as reference for LPG also)
This is an electronically controlled Gas Sequential Injection System. It can be installed in nearly any petrolfuel injection vehicles, in particular in all last-generation catalytic fuel injection vehicles. The system is amulti-point sequential injection system, 100% “follower” and where no OBD emulation device is required. Itis available both for the LPG and the CNG versions.
Gas is injected through the injector rail directly into the manifold near the intake valves, thus achieving anoptimal fuel mixture and improving gas exhausts level. The gas injection timing is directly driven by theoriginal petrol signal.
The Gas Sequential Injection system is composed of the following items: an ElectronicElectronicElectronicElectronic ControlControlControlControl UnitUnitUnitUnit, amicro-micro-micro-micro- SwitchSwitchSwitchSwitch, a GasGasGasGas PressurePressurePressurePressure RegulatorRegulatorRegulatorRegulator, a GASGASGASGAS InjectorInjectorInjectorInjector RailRailRailRail.
PicturePicturePicturePicture 1111 – CNG Sequential Injection System
- Always disconnect the Battery when installing the Gas system.
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- Never place the 15 Amp fuse in fuse housing until the system is fully installed.- Place the ECU and all cables far from heat sources and far from high voltage sources (such as battery cables,spark plugs, coils, etc.).- Place the ECU in vertical position with connectors above.- Solder and insulate all electrical connections.- Use only gas hoses specific for CNG.- Keep all Gas hoses as short as possible.- All hoses connecting the Gas injectors to the Manifold MUST have the same length.- Check the system for GAS leakage after completing the installation.
The wiring of the Sequential Injection System, is composed of 3 wire bundles:- TheTheTheThe GREYGREYGREYGREY wiring includes all the same connections required for every type of car, i.e. 3, 4, 5, 6, 8 cylinderscars;- TheTheTheThe BLACKBLACKBLACKBLACK wiring differs in two versions in accordance with the number of cylinders of the engine:* BlackBlackBlackBlack wiringwiringwiringwiring 4444 cylinderscylinderscylinderscylinders, to be used for vehicles until 4 cylinders;* BlackBlackBlackBlack wiringwiringwiringwiring 6&86&86&86&8 cylinderscylinderscylinderscylinders, to be used for vehicles until 6&8 cylinders
- WiringWiringWiringWiring forforforfor thethethethe socketssocketssocketssockets.Available in three versions:* Injectors with Bosh type connectors;* Bosh* Injectors with Japan type connectors;* Injectors without connectors also known as Universal type connectors.
Should the provided connectors are not compatible with the original ones of the vehicles, it is suggested to cutthe connectors and connect the wires, by welding.
The wire controlling the Petrol injectors have a different color on every cylinder, therefore, it is good practiceto check the polarity by using a multimeter. Once checked solder the wire ends and pay attention to the colorof each wire and their related sequence.
Should a mistake happen and the wrong signal be taken from the wrong wire, the following information willnot be displayed in your PC, that is; “Time of injection Petrol”, “RPM number” and “Status of the Injectors”.This information is present when viewing the screen “MONITOR”. Should this occur, check all wires andrepeat the above mentioned operation.
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PicturePicturePicturePicture 2222 – The GREY wiring
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PicturePicturePicturePicture 3333 – The BLACK 4 cylinders wiring
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PicturePicturePicturePicture 4444 – The BLACK 6 cylinders engine wiring
PicturePicturePicturePicture 6666– The cylinders sockets
IMPORTANT NOTE: When performing an installation on a 6 cylinders engine, it is recommended not toconnect the injector socket indicated with the number “C3”.
The +12 volt is taken from C4 (our reference as the 4th cylinder) having wire color YELLOW,
The Injectors Rail should be installed as follows: connect the Rail outlets with the respective petrol injectorconnection, therefore follow the correct firing sequence of the engine: cable “R1” to the cylinder Nr. “1”, cable“R2” to cylinder Nr. “2”, “R3” to the cylinder Nr. “3”, cable “R4” to cylinder Nr. “4” This device should beinstalled in the engine compartment, away from heat sources and protected from water or humidity.
The hoses connecting the injectors rail to the manifold must have the same length and will be as short aspossible.
In the case of installation of a 3 or a 6 cylinders engine the following is recommended:
Important note: should you use a 4 way injector on a 3 or 6 cylinder engine we recommend NOT to connectthe injector socket C3 and on rail R3.
Note: The first rail will be connected with the grey cables to be connected with the cable N2 and which runs
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the first group of cylinders ( N1 ); the second rail is to be connected with the cable N5 which runs the secondgroup of cylinders (N4 / N6 ).
Recommended injector rail nozzlenozzlenozzlenozzle sizesizesizesize ((((unit: mm) taken into consideration the Number of cylinders and theengine power, can be viewed here bellow:
(If for LPG, the nozzle size may be 0.2 mm less.)Important:Important:Important:Important:The above mentioned size chart, are the result of various data gathered in the laboratory. The nozzle size couldvary in accordance to the quality of the CNG. Therefore, it is recommended to verify the good performance ofthe engine during calibration by road testing the car, and change nozzles or enlarge size by a drill if needed.
(The regulator we use now is different with the one shown above but similar, no problem to take it asreference.)- The outlet pressure of the reducer can be trimmed by acting on the screw placed on centre top of the frontcover. By turning the screw clockwise the pressure is decreased and by turning counter clockwise the pressureis increased.
- It is recommended that the outlet pressure of the reducer is trimmed as per the table here bellow
EngineEngineEngineEngine SizeSizeSizeSize IfIfIfIf :::: MapMapMapMap PressurePressurePressurePressure ThenThenThenThen :::: ReducerReducerReducerReducer PressurePressurePressurePressureUp to 140 Hp 30KPa 80 - 90KPa
Up to 210 Hp 35KPa 90 - 110KPa
- The reducer can be installed in any position but it is recommended that the coil of the lock off is positionedupward. None the less, the reducer must be secured by fitting on to the bracket.
- It is not a good practice to connect the water circuit in series to the water flow, if set in series the water flowwill be limited to the engine and may create damage. Therefore, always fit the reducer in parallel to the waterflow and always bellow the radiator’s water level.
- The NTC or temperature sensor is fitted to the side of the alloy block of the reducer. When screwing thesensor take care and DO NOT apply excessive torque. The only function of the sensor is to measure thetemperature of the reducer. Always use the NTC provided with the given ECU and connect as per themanufacturer instruction.
- In the case the reducer is placed in a “big” size engine it is recommended to use an oversize CNG lock offand a steel pipe having 8x1mm in size.
- Connect the vacuum port placed on the side of the top cover of the front part of the reducer to the pressuresensor or ECU as recommended by the manufacturer or follow the indications provided in the “MAP SENSORCONNECTION SCHEME”.
The sequential injection system uses a gas pressure sensor to assure a good performance of the engine and toallow the best possible carburetion of the engines. The sensor is to be connected, using a rubber hose to theGas injector rail, to the manifold and to the vacuum port located on the cover of our reducer.
This device allows measures the following signals:- The MAP value (MAP: Manifold Absolute Pressure)- The gas pressure inside the injector Rail
With this system it’s possible to make use of different types of level sensor, it is simple and easy to use, simpleselect the right sensor type from the screen “GeneralGeneralGeneralGeneral SetupSetupSetupSetup” and then selecting “LevelLevelLevelLevel SensorSensorSensorSensor TypeTypeTypeType”.
Go to “GeneralGeneralGeneralGeneral SetupSetupSetupSetup” screen and click on “SetSetSetSet SwitchSwitchSwitchSwitch LevelsLevelsLevelsLevels”, open the window with manual regulation ofthe levels limits. We can select two types of data input:
SIMPLESIMPLESIMPLESIMPLE: normally used for the LPG. Hold the multivalve in your hand with the level sensor connectedcorrectly. Move the float to the desired level and click on the arrow next to the level you wish to set. Doing this,we’ll decide at which exact LPG level will the led light up (When red light shown on the micro-switch, itmeans LPG is going to use out, it’s time to refill the tank with LPG).
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ADVANCEDADVANCEDADVANCEDADVANCED: Normally used for the CNG. Select the 4 desired Voltage levels at which the exact CNGpressure will the led light up. Click on SEND to save all chosen values.
- Select “GENERALGENERALGENERALGENERALSETUPSETUPSETUPSETUP”- SETUPSETUPSETUPSETUP SWITCHINGSWITCHINGSWITCHINGSWITCHING, this function is used to select the way to switch from Petrol to Gas. Normally weadvise to switch in Deceleration when using manual gears and Acceleration with automatic gear box and fullgroup
- Select the “MAPMAPMAPMAPTHRESHOLDTHRESHOLDTHRESHOLDTHRESHOLD” or leave as per our suggestion (Best).
- “THRESHOLDTHRESHOLDTHRESHOLDTHRESHOLD PRESSUREPRESSUREPRESSUREPRESSURE VALUEVALUEVALUEVALUE” This value will be selected to modify the pressure value in which
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the switching will happen, (keep as per suggested by the manufacturer but change if required).
- “AUTOMATICAUTOMATICAUTOMATICAUTOMATIC SWITCHINGSWITCHINGSWITCHINGSWITCHING TOTOTOTO PETROLPETROLPETROLPETROL” When “ActivatingActivatingActivatingActivating” this function, the system willautomatically switch to Petrol when the gas tank is empty. If activated select a value between 10KPa and20KPa. Default value is 20KPa.
- “MINMINMINMIN TEMPERATURETEMPERATURETEMPERATURETEMPERATURE OFOFOFOF VAPORIZERVAPORIZERVAPORIZERVAPORIZER” Keep the temperature “Switching to GAS” at 36°C in coldclimates and no less than 32°C on hot climates.
- AUTOMATICAUTOMATICAUTOMATICAUTOMATIC SWITCHINGSWITCHINGSWITCHINGSWITCHING TOTOTOTO PETROLPETROLPETROLPETROL, If activated the system will automatically switch the systemback to Petrol in the event of low temperatures within the reducer. This phenomenon can happen duringnormal and when having a vapor lock in the water system or in case of low water level in the radiator. Ifactivated select a temperature value between 6°C to 10°C.
- LEVELLEVELLEVELLEVELSENSORSENSORSENSORSENSOR TYPETYPETYPETYPE. Select the level sensor type in accordance to the sensor type, or signal used.
- SETSETSETSET FUELFUELFUELFUEL LEVELSLEVELSLEVELSLEVELS: Click on this function in order to modify the level ranges of the level sensor. Thisfunction will allow you to set and personalized level thresholds. For more details see the installation manual orAnnex B here included.
- SOUNDSOUNDSOUNDSOUND: Click on this function to activate the beeper or the talking kit (optional to be ordered separately andcould be programmed with different languages)
- You can decide to return to petrol when the vehicle is working at idle and/or at high RPM. When it happenthe display inside the driver's cabin will always indicate running on Gas, without any variation.
- When the engine is working at idle, the vehicle could run:* TOTOTOTOGASGASGASGAS: normally to GAS;* REENTERREENTERREENTERREENTER TOTOTOTO PETROLPETROLPETROLPETROL: the vehicle changes over to petrol as soon as it’s under the set engine rpm;* TOTOTOTO PETROLPETROLPETROLPETROL: The vehicle switches over to petrol after 3 seconds that the rpm are below the set ones;* The vehicle automatically switches over to Petrol as soon as the engine rpm exceed the set re-turn values.
If this function is selected, it consents to modify the configuration of the system during certain situations,allowing the automatic switching from Petrol to Gas or from Gas to petrol automatically at a given RPM,temperature or Time of injection.
WORKINGWORKINGWORKINGWORKINGATATATAT IDLE:IDLE:IDLE:IDLE:- When selecting TOTOTOTOGASGASGASGAS, the engine will work on GAS at idle.- When selecting RERERERE ENTERENTERENTERENTER TOTOTOTO PETROLPETROLPETROLPETROL, a small window with an RMP will pop up and you must selectan RMP setting. Basically, when reaching the selected RPM limit the engine will run on Petrol and it willautomatically switch to GAS mode once accelerating over the selected RPM setting.- When selecting TOTOTOTO PETROLPETROLPETROLPETROL, same as RERERERE ENTERENTERENTERENTER TOTOTOTO PETROLPETROLPETROLPETROL, but it will switch to Petrol after idlingfor some seconds.
NOTE: This operation is done and managed by the gas ECU, no action is required by the driver.
WORKINGWORKINGWORKINGWORKINGATATATATHIGHHIGHHIGHHIGH RPM:RPM:RPM:RPM:- When selecting TO GAS, the engine will work on GAS at all high RPM range.- When selecting TO PETROL, and after selecting the limit of RPM and the Injection time, the LGC ECU willallow the engine to work on Petrol and will automatically come back to GAS when at lower than selectedvalues.
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Other Options: QUICKQUICKQUICKQUICK GASGASGASGAS CHANGECHANGECHANGECHANGE OVEROVEROVEROVER WITHWITHWITHWITH WARMWARMWARMWARM ENGINEENGINEENGINEENGINE, if activated the engine willchange over to Gas soon after ignition, provided it reach set Pressure in the system and there is a suitableswitching temperature.
EXTERNALEXTERNALEXTERNALEXTERNALEMULATOREMULATOREMULATOREMULATOR: to be used only with the 5, 6 and 8 cylinder model
TIMETIMETIMETIME OFOFOFOFOVERLAPOVERLAPOVERLAPOVERLAP: is used to select the time of overlap by using the two fuels (Petrol 68mode.
RETURNRETURNRETURNRETURNTOTOTOTOGENERALGENERALGENERALGENERALSETUPSETUPSETUPSETUP clicking here you will return to GENERALGENERALGENERALGENERALSETUPSETUPSETUPSETUP....
- “ENGINEENGINEENGINEENGINE DATADATADATADATA”; Always input the vehicle engine data. The information is VERY important and it issimple to insert.
- “PARAMETERSPARAMETERSPARAMETERSPARAMETERS OFOFOFOF INJECTIONINJECTIONINJECTIONINJECTION”: BeforeBeforeBeforeBefore proceeding with the “PROGRAMMING IDLE”, make sure toselect the correct “TYPETYPETYPETYPE OFOFOFOF INJECTORINJECTORINJECTORINJECTOR”.
- “MINIMALMINIMALMINIMALMINIMAL IMPULSEIMPULSEIMPULSEIMPULSE”: Select an impulse of 2.0ms when using Matrix rails and 3,4ms when using 3.0Ohms rails.
- Select “PROGRAPROGRAPROGRAPROGRAMMINGMMINGMMINGMMING IDLEIDLEIDLEIDLE” and follow the indications. NOTE: DURING THIS PROCEDURE DONOT ACTIVATE THE “MAP CORRECTOR” OR THE “SET MAPPING”.
- After PROGRAMMING IDLE is completed, you can adjust the system by making small corrections on theCONSTANTCONSTANTCONSTANTCONSTANTATATATAT IDLEIDLEIDLEIDLE for idle and CONSTANTCONSTANTCONSTANTCONSTANTATATATAT HIGHHIGHHIGHHIGH RPMRPMRPMRPM for accelerations.
- In case accelerations are not satisfactory, ACTIVATE the MAPMAPMAPMAPCORRECTORCORRECTORCORRECTORCORRECTORThe MAP CORRECTOR works just like a BOOSTER. It works just for a few milliseconds only duringacceleration. Always select the smallest number (1) to work, then next number ex. 1, 2, 3 etc…until reachingthe desired acceleration output. On each number change stop the car and make your acceleration test on eachacceleration.
- “SETSETSETSET MAPPINGMAPPINGMAPPINGMAPPING”, this function is used only for emissions tests or in very rare situations in which the carneeds to be mapped. See Annex C for details.
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MAPPINGMAPPINGMAPPINGMAPPING If activated it allows the change of the time of injection at any given RPM in function to thepressure MAP. This function is to be used with CARE and ATTENTION.* Absolute Values: It modify a fuel gas injection value as a net value in the selected MAP-RPM area.* Relative: The selected value will add or subtract from a base value in the selected MAP-RPM area.
In this area we can manage every and each single injector and can be done as follows:
- Activating the Gas Injector will start working or Deactivating the petrol injector will start working
The percentage given will give the option to increase or decrease the opening gas time of the gas nozzle for thegiven cylinder.
Chapter 13 SETUP LAMBDA
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- This section of the Software is useful when performing emission tests. We advise not to make use of it forevery day application, unless required. Reason is, that in time, the lambdas will become slow or die off. Whenthis happen the system will no longer work on gas unless this function will be deactivated or a new lambda isused. This function allows you to make a better control of the exhaust gasses.
- If in need, then make sure to connect Lambda Nr. 1.
- Activate the Fast Lambda corrector by clicking and selecting a value from 1 to 16. The values are from 1 lessimportant to 16 most important.
- The slow lambda can be activated as well, and is referred to the average calculation of a “X” number ofcycles. Basically works on its average.
- Click on SETUP LAMBDA for the programming process and acquisition of the same.
- LAMBDA PROBE it allows to fix the vehicle’s lambda signal.
- LAMBDA THRESHOLD it fixes the medium value of the Lambda Probe signal.
- SLOW LAMBDA CORRECTOR this parameter can be activated only if lambda is connected, will correctthe Gas air fuel ratio utilizing and ideal average of the Lambda signal.
- FAST LAMBDA CORRECTOR this parameter, if selected and if the lambda is connected, will allow tocorrect the fuel-air ratio utilizing the instant value provided by the system.
- LAMBDA MAPPING THRESHOLD it allows the emulation of the lambda signal, if connected thru the
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signal wire. It works in function of the engine RPM and the MAP of the engine.
- HIGH EMULATION VALUE allows to fix in mVolts the maximum value of the emulated signal.
- LOW EMULATION VALUE allows to fix in mVolts the minimal value of the emulated signal.
- LAMBDA SETUP is an automatic procedure to acquire the lambda type signal, provided that lambda probeis connected
Note: If is necessary to utilize the LAMBDA CORRECTORS it is a must to connect the lambda 1 to the ECUwiring as indicated here bellow :
1. It may happen the vehicle cannot be trimmed by the automatic programming mode. This situation mayhappen when the engine is unstable at idle or when the A/C is on or when the vent goes on very often. In suchcases, follow the listed steps to trim manually.
2. “ENGINEENGINEENGINEENGINE DATADATADATADATA”: Always input the vehicle engine data. The information is VERY important and it issimple to insert.
3. “PARAMETERSPARAMETERSPARAMETERSPARAMETERS OFOFOFOF INJECTIONINJECTIONINJECTIONINJECTION””””: BeforeBeforeBeforeBefore proceeding with the “PRPGRAPRPGRAPRPGRAPRPGRAMMINGMMINGMMINGMMING IDLEIDLEIDLEIDLE” (TrimmingTrimmingTrimmingTrimmingIdleIdleIdleIdle), make sure to select the correct “TYPETYPETYPETYPE OFOFOFOF INJECTORINJECTORINJECTORINJECTOR”.
4. “MINIMALMINIMALMINIMALMINIMAL IMPULSEIMPULSEIMPULSEIMPULSE”: Select an impulse of 2.0ms when using Matrix rails and 3.4ms when using 3.0Ohms rails.
5. VERYVERYVERYVERY IMPORTANTIMPORTANTIMPORTANTIMPORTANT:::: Write down the TIMETIMETIMETIME OFOFOFOF INJECTIONINJECTIONINJECTIONINJECTION OFOFOFOF PETROLPETROLPETROLPETROL
(((( )))) when the engine is RUNNING ON PETROL.
6. Select “TYPETYPETYPETYPE OFOFOFOF INJECTORSINJECTORSINJECTORSINJECTORS” click on “PPPPRRRROGRAOGRAOGRAOGRAMMINGMMINGMMINGMMING IDLEIDLEIDLEIDLE”, select “suggested values”. Writedown the suggested values related to the ENGINEENGINEENGINEENGINE CONSTANTCONSTANTCONSTANTCONSTANT and the OFFSET INJECTOR. Once writtenthe values exit the procedure.
7. Set in the written values in the area of the CONSTANTCONSTANTCONSTANTCONSTANT ENGINEENGINEENGINEENGINE and the OFFSETOFFSETOFFSETOFFSET INJ.INJ.INJ.INJ. VALUESVALUESVALUESVALUES givenon point 14.6.
8. Click on the Lo. Gas Logo located on left bottom side once the reducer temperature reaches 65°.
9. Change the OFFSETOFFSETOFFSETOFFSET INJECTIONINJECTIONINJECTIONINJECTION VALUESVALUESVALUESVALUES (at IDLE), by viewing the lambda on “MONITOR”--see iffuel air ration is rich or lean, and modify accordingly. Then change the ENGINE CONSTANT (at high RPM),by viewing the lambda on “MONITOR” --see if fuel air ration is rich or lean, and modify accordingly. Followthis process until the “TIMETIMETIMETIME OFOFOFOF INJECTIONINJECTIONINJECTIONINJECTION of PETROLPETROLPETROLPETROL” WHENWHENWHENWHEN RUNNINGRUNNINGRUNNINGRUNNING ONONONON PETROLPETROLPETROLPETROL as per point14.5 is the same or near to the TIMETIMETIMETIME OFOFOFOF INJECTIONINJECTIONINJECTIONINJECTION OFOFOFOF PETROLPETROLPETROLPETROLWHENWHENWHENWHEN VEHICLEVEHICLEVEHICLEVEHICLE ISISISIS RUNNINGRUNNINGRUNNINGRUNNING ONONONONGASGASGASGAS.
ANNEXANNEXANNEXANNEXAAAASETSETSETSET THETHETHETHE PORTPORTPORTPORTCOMCOMCOMCOM1. Go to the Control Panel2. Select “System”3. Select “Hardware”4. Select “Management Peripheral”5. Open PORT (COM&LPT)6. See the port used may be from 1 to 97. Go to the Mach Pro and enter into UTILITY set the PORT COM found in point 6.8. Now the PC should connect, but wait a few moments after inserting the new Port Com.