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Vogels Autogas Systems VGI Hardware Manual

System Description and Installation

VGI Technical Manual 2014-01-14.pdf

Pagina 44 van 44

ECE: ECE-R 115 Fuel system: LPG/CNG
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ANNEX 2A
ARRANGEMENT OF THE LPG RETROFIT SYSTEM TYPE APPROVAL MARK

         The above plate, with approval mark and some technical information on the retrofit system,
                                          has to be fixed permanently on the body of the vehicle.
                                                                       -------------------------

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         Copyright

�

2013: Issue : VGI

The Netherlands 2014-01-13 ( Vogels Autogas)

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Summary of Contents for VGI

Page 1: ...HARDWARE MANUAL LPG Engine kit VGI Vogels Autogas Systems Ekkersrijt 3016 5692 CA Son The Netherlands Email info vogelsautogas nl Online www vogelsautogas com ...

Page 2: ...TURE SENSOR 18 1 11 PRESSURE MAP SENSOR AEB025 19 1 11 1 MAP sensor installation instructions 19 1 12 GAS ECU 20 1 12 1 ECU Landi LRE184 LRE188 21 1 12 1 1 Electrical Connection Survey Landi Omegas 4 Cyl ECU 22 1 12 1 2 Cable and Pin out information for Landi ECU 4 cyl 23 1 12 1 3 Cable and Pin out information for Landi ECU 8 cyl 24 1 12 2 ECU VGI 4 Cyl AEB2001NC OBD 25 1 12 2 1 PIN OUT ECU VGI 4 ...

Page 3: ...TRODUCTION 42 2 2 MAINTENANCE 42 Error codes and diagnostic check 42 External check 42 Filter unit maintenance 42 System pressure check and adjustment 43 2 3 RECOMMENDATIONS 43 2 4 IN CASE OF ACCIDENT 43 2 5 ARRANGEMENT OF THE LPG RETROFIT SYSTEM TYPE APPROVAL MARK 43 This document is called VGI Components and Installation Manual 02 pdf ...

Page 4: ...gas injection signal is called the slave system principle Moreover the VGI system works according the same cylinder principle which means that the gas injection signal is based upon the petrol injection signal of the very same cylinder and rotation of the engine So no delay which can cause any control frequency degreasing will occur So is the gas injection signal for cylindernr 1 based upon the pe...

Page 5: ...as Moreover it s being used for the correction of the fuel differences in cold engine conditions The temperature signal can be taken from a temperature sensor that is to be placed in a water hose or from the original engine temperature sensor Gas pressure signal By an increasing absolute gas pressure the density of the gas will increase as well and so will the energy value per volume unit To compe...

Page 6: ...f cylinder A corresponds with gas injector A Tank solenoid signal This signal opens or closes the solenoid valve on the outlet of the LPG tank so LPG can or cannot run to the pressure regulator Gas solenoid valve This signal opens or closes the solenoid valve on the inlet of pressure regulator so LPG can or cannot run into the pressure regulator and the rest of the system Serial communication with...

Page 7: ...Peak and Hold petrol injectors Resistance of injector is less than 6 Ohm Direct injection engines Use a special version of VGI Remarks regarding all gas containing components Fix all components in the engine compartment according the specific installation manual of that particular vehicle Fix the components using the brackets coming with the kit on to solids parts of the vehicle or directly on to ...

Page 8: ... by Luccio Engineering Legenda 1 LPG inlet 2 14 mm hose between pressure regulator and gasfilter 3 14 mm hose between gasfilter and injectorrail 4 6 mm hose between injectorrail and nozzle in inlet manifold 5 MAP connection 6 Overpressure connection The hose has to finish outside of the enige compartment R 67 01 Gas hose installation instructions Avoid gas hoses to run closely to heat sources Avoi...

Page 9: ...n the pressure present in the inlet manifold for normally aspirated vehicles Technical specifications Weight 840 g Working pressure 0 95 bar 95 kPa rel Nominal operating flow rate 30 Kg h Working temperature 20 to 120 C Safety valve calibration pressure 3 5 bar 350 kPa Type approval R67 E13 67R 010056 Shut off valve specifications Type MED Type 71 Coil tension 12V DC Power of coil 11W Normally Clo...

Page 10: ... Second stage operating pressure 1 0 bar 100 kPa rel Nominal flow volume 40 Nm3 h Working temperature 20 to 120 C Pressure relief flow valve 4 5 bar 450 kPa Homologation LPG No E13 67R 010025 Shut off valve specifications Type MED Type 71 Coil tension 12V DC Power of coil 11W Normally Closed Homologation LPG No E4 67R 0193001 The IG1 pressure reducer is available in 3 versions IG1 Normal until eng...

Page 11: ...e in liquid state to reducer is 3 000 Kpa 30 bar In regulation chamber pressure is reduced to 140 Kpa 1 4 bar relative by a regulation device formed by a spring and the diaphragm that is hooked to the closing valve direct plunger Also when is gasified the gas which is in the chamber is 100 gaseous state that is which comes out through the hose toward the injectors rail Specifications Nominal opera...

Page 12: ...icated The coolant nipples on the pressure regulator can be turned to ensure proper routing of the coolant hoses Secure the coolant hoses using the supplied hose clamps The other ends of the coolant hoses are connected parallel to the heater hoses by means of T pieces Ensure there are no kinks in the coolant hoses Proper and even heat exchange is necessary in order to allow the LPG to evaporate In...

Page 13: ...f filtration 10 micron Maximum working pressure 3 bar LPG type approval N E13 67R 010278 class 2A Filter unit installation instructions Place the filter unit as close as possible to the injector rail and not too far from the reducer The maximum length of the tube between reducer and filter is 70 cm while that between the filter unit and injector rail is 25 cm Avoid the gas tubes passing close to t...

Page 14: ...ecifications Weight 4 cylinders 850 g Injectors per rail 2 3 or 4 Response time 1 7 ms 0 2 Working temperature 40 to 120 C Maximum working pressure 3 bar Injector approval N E13 67R 010234 Injectors rail approval N E13 67R 010233 Driving method Peak and Hold The injector comes in three different sizes depending on the power of the engine and number of cylinders Ne can recognize the injectorsize fr...

Page 15: ...m Below 2600 cc Ø 2 4 mm Up 2600 to 3000 cc Ø 2 6 mm Up 3000 to 3500 cc Ø 2 8 mm Up 3500 to 4000 cc Ø 3 0 mm Over 4000 cc ATTENTION 3 0 diameter nozzles have a larger O ring do not mix with others The AEB injectorrail is available with 2 3 or 4 injectors in one complete rail The oulet nozzle is exchangeable and is available in different diameters which makes the rail adjustable for the required po...

Page 16: ...sor NTC type Working temperature 40 C 120 C Maximum service pressure 4 5 bar Opening time 1 7 1 8 ms 1bar 13 5V Closing time 0 9 1 0 ms 1bar 13 5V Coil resistance 2 5 0 1Ω 20 C Current control Peak and hold The Valtek Type 34 injectorrail is available with 2 3 or 4 injectors in one complete rail The oulet nozzle is exchangeable and is available in different diameters which makes the rail adjustabl...

Page 17: ...ce the tubes with the 6 mm interior Ø on the injector output to connect the injector with the nozzle placed on the inlet manifold see Chapter that describes the nozzle There is a tight correlation between the location of the injector rail and the nozzles Place the injector rail close to the inlet manifold in such a way that the connection tubes can be as short as possible and so that the nozzles c...

Page 18: ...will be made Apply grease to the point of the drill bit so as to avoid spreading swarf then drill using a 5 mm bit if the suction manifold is made of aluminum alloy In the case that the inlet manifold is plastic use a 4 8 mm bit During drilling it is important to keep the drill in a perpendicular position with respect to the surface to be drilled Tap a thread with a male M6x1 Carefully clean the i...

Page 19: ...he inlet manifold ensuring that the gasket is not damaged and take note of any components and connections Determine the position of the vacuum connection that will be made in accordance with the specific installation instructions If not explicitly specified in the installation instructions personally determine an easily accessible connection point preferably just behind the throttle valve First de...

Page 20: ...ensor e Selected fuel type 3 Controlling of flow valves 4 Controlling of gas injectors 5 Deactivation of petrol injectors 6 Serial communication with the selector switch 7 LPG level indication 8 Controlling of buzzer 9 System monitoring and diagnosis 10 Communication with interface software PC The firmware software strategy memory and the configuration memory can both be reprogrammed This means th...

Page 21: ...Connector 56 pin 3 Homologation identification 4 ECU Type identification Specifications Product name Landi Omegas 4 cyl LRE184 Supply voltage 8 to 16 V Max current 15 A Flash memory 128 kb Processor speed PLL 50 Mhz Analogue input signals 12 items Digital input signals 10 items Injector outputs 3 up to 4 Coil drivers 2 pcs Homologation LPG No E3 67R 016002 or E3 67R 016017 Specifications Product n...

Page 22: ...ruption connectors and gas injector connectors in the same order The connectors for petrol injector interruption of the first cylinder are marked with A cylinders 2 3 and 4 must be deactivated according to the order of the wire harness The connector also marked with A is used for the gas injector of the same first cylinder The following gas injectors are connected to connectors B C and D respectiv...

Page 23: ...42 Grey 0 75 mm 105ºC Purple 0 75 mm 105ºC Black 1 mm 105ºC Brown 0 75 mm 105ºC F E D C Pink Black 0 5 mm 105ºC Red White 0 5 mm 105ºC Pink 0 5 mm 105ºC Black 0 5 mm 105ºC Red Black 2 0 mm 105ºC Black 2 5 mm 105ºC Red Black 2 0 mm 105ºC 53 B A MAP signal Petrol Inj 1 Interruption ECU side Petrol Inj 1 Interruption Inj side Petrol Inj 2 Interruption Inj side Petrol Inj 3 Interruption Inj side Petro...

Page 24: ... Black 0 75 mm 105ºC 52 F E D Pink Black 0 5 mm 105ºC Red White 0 5 mm 105ºC Pink 0 5 mm 105ºC Black 0 5 mm 105ºC Red Black 2 0 mm 105ºC Black 2 5 mm 105ºC B Red Black 2 0 mm 105ºC 51 C A Logic Ground Gas Pressure sensor 5V supply pressure sensor GND pressure sensor Gas temperature Serial communication switch Switch Power supply switch GND switch 1 4 3 2 3 1 4 2 4 3 2 1 3 1 2 4 Gas Injector 3 12V ...

Page 25: ...em age automatic adaptation to the different gas qualities available on the market more information available to the installer regarding vehicle function which makes tuning the system easier Specifications Homologation LPG No E13 67R 010157 Supply voltage Vbatt 10 16V Operating temperature 40 120 C Current absorption with the actuators disabled Imax 0 5A Current absorption in the standby mode Ista...

Page 26: ...Vogels Autogas Systems VGI Hardware Manual System Description and Installation VGI Technical Manual 2014 01 14 pdf Pagina 26 van 44 1 12 2 1 PIN OUT ECU VGI 4 Cyl AEB2001NC ...

Page 27: ...Vogels Autogas Systems VGI Hardware Manual System Description and Installation VGI Technical Manual 2014 01 14 pdf Pagina 27 van 44 1 12 2 2 Electrical Connections ECU VGI 4 cyl AEB2001NC ...

Page 28: ...stem age automatic adaptation to the different gas qualities available on the market more information available to the installer regarding vehicle function which makes tuning the system easier Specifications Homologation LPG No E13 67R 016019 Supply voltage Vbatt 10 16V Operating temperature 40 120 C Current absorption with the actuators disabled Imax 0 5A Current absorption in the standby mode Is...

Page 29: ...f diagnosis data 1J Transmission of diagnosis data 2J Diagnostics negative 1K Power supply Gas injector N 1 2K Power supply Gas injector N 2 1L Tank solenoid positive 2L Tank solenoid negative 1M Regulator solenoid positive 2M Regulator solenoid negative 3A Injector B 3 cut out ECU side 4A Injector B 3 cut out INJ side 3B ENGINE RPM signal 4B Injector B 2 cut out INJ side 3C Temperature signal 4C ...

Page 30: ...Vogels Autogas Systems VGI Hardware Manual System Description and Installation VGI Technical Manual 2014 01 14 pdf Pagina 30 van 44 ...

Page 31: ...qualities available on the market more information available to the installer regarding vehicle function which makes tuning the system easier Legend 1 Fixation points 2 Connector 56 Pins 3 ECU Type identification 4 ECU Type identification Specifications Homologation LPG No E3 67R 016019 Supply voltage Vbatt 10 16V Operating temperature 40 120 C Current absorption with the actuators disabled Imax 0...

Page 32: ...Vogels Autogas Systems VGI Hardware Manual System Description and Installation VGI Technical Manual 2014 01 14 pdf Pagina 32 van 44 1 12 4 1 PIN OUT ECU VGI 8 Cyl AEB2568D ...

Page 33: ...Vogels Autogas Systems VGI Hardware Manual System Description and Installation VGI Technical Manual 2014 01 14 pdf Pagina 33 van 44 1 12 4 2 Electrical Connections ECU VGI 8 cyl AEB2568D ...

Page 34: ...ified in the specific vehicle installation instructions It can be mounted directly on the body or by means of a support Keep the gas system ECU as far away as possible from heat sources such as the exhaust radiator etc and protect it from splashes Bear in mind that the connector must be attachable and detachable Attach the connector by pressing it on with pushed out lock tab Then push in the conne...

Page 35: ...nd attach the Eurogas Omegas wire harness carefully using binding strips All of this is essential for providing access to components during maintenance work Wire to wire connections should be soldered and well isolated to prefend corrosion in a later stage Wire to contacts and terminal connections be soldered and well isolated to prefend corrosion in a later stage Use a shrink sleeve on connection...

Page 36: ...nectors and needs to be soldered to the injection wires of the car Bosch Japan Standard Pin Nr 1 Positive Pin Nr 2 Negative also called Pulse Inverted Pin Nr 2 Positive Pin Nr 1 Negative also called Pulse How to know if a connection is Standard or Inverted To identify which of the two wires is positive do the following Detach all the connectors from the injectors Set a multimeter to measure DC vol...

Page 37: ...rs where other types of connectors are used on the injectors or where it is impossible to access the injectors original connectors To install this type of wiring cut the negative wires of the petrol injectors in the order indicated in the figure The connection direction is very important The BLACK striped wires should be installed towards the petrol ECU and the others toward the injectors The WHIT...

Page 38: ...ector rail 6 Cylinder line First 3 cylinder engine 1 use first cutting wiring and first gasinjector rail Last 3 cylinders engine 2 use second cutting wire and second gasinjector rail V6 Bank 1 Left engine 1 use first cutting wiring and first gasinjector rail Bank 2 Right engine 2 use second cutting wiring and second gasinjector rail V8 Bank 1 Left engine 1 use first cutting wiring and first gasinj...

Page 39: ...Vogels Autogas Systems VGI Hardware Manual System Description and Installation VGI Technical Manual 2014 01 14 pdf Pagina 39 van 44 ...

Page 40: ...ntrol unit can be monitered using the special software for connecting the GAS control unit to the PC such as Carburetion calibrators Fast Fuel Trim and Slow Fuel Trim Voltage on the rear lambda probe Connect a OBD2 scantool to the car and check the type of connection If the tester reads connection types 1 2 or 3 proceed by following the diagram in figure 1 If the tester reads connection types 6 7 ...

Page 41: ...tank 1 green LED tank 2 green LEDs tank 3 green LEDs tank 4 green LEDs full tank 5 The red LED indicates the reserve tank function The fuel selector switch is connected to the wire harness via a 4 pin connector located at the rear of the switch The switch and the ECU use serial communication for exchanging information about the fuel selection fuel level tank level and possible error codes in the s...

Page 42: ...he Software Manual for connection related information and how to use the interface software Check whether error codes are present in the system Even if the system has not been changed back to petrol and the selector switch does not provide a warning an error code may be present nevertheless This depends on the type of error code Resolve the problem that causes this error code Consult the fault tab...

Page 43: ...he tank capacity to not damage the good functioning of the petrol pump LPG has a particular smell so that it is simple to identify leaks in case of gas leaks it is necessary to switch off the engine switch off the light dashboard change over petrol the switch indicator do not smoke verify that there are no ignition source near the vehicle When the LPG smell disappears isolate the tank Now it is po...

Page 44: ... 44 van 44 ECE ECE R 115 Fuel system LPG CNG ANNEX 2A ARRANGEMENT OF THE LPG RETROFIT SYSTEM TYPE APPROVAL MARK The above plate with approval mark and some technical information on the retrofit system has to be fixed permanently on the body of the vehicle Copyright 2013 Issue VGI The Netherlands 2014 01 13 Vogels Autogas ...

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