INSTRUCTION MANUAL
Transcription
INSTRUCTION MANUAL
INSTRUCTION MANUAL Rev. 1.1 ISGI002 BIGAS INTERNATIONAL AUTOGAS SYSTEMS S.r.l. Sede legale: Via A. De Gaspari, 31 Stabilimento: Via P. Nenni, 40 50019 Sesto Fiorentino Firenze ITALY Tel. 0554211275-0554201432 Fax 0554215977 http: www.bigas.it e-mail [email protected] Realizzazione: Ufficio Tecnico Bigas 2003 ISGI001 Index ! Required connection pag. 5-12 ! Simplified calibration instruction pag. 13-30 ! Point by point calibration instruction pag. 31-56 ! Appendix pag. 57-76 - SGIS general diagram - Modification of the lambda probe connections - General diagram for 4 cylinder engine - General diagram for 4 cylinder engine Boxer - General diagram for 5 cylinder engine - General diagram for 6 cylinder engine - General diagram for 6 cylinder engine double reducer - General diagram for 6 cylinder engine V type - General diagram for 6 cylinder engine V type double reducer - General diagram for 8 cylinder engine - 2 rail juction diagram - Water sector diagram for 2 reducer - LPG sector for 2 reducer - Rail assembly diagram - Schema di colleg. PLUG-Cilindro generale distributore - Multiplier-Amplifier for 8 cylinders AEB387 - Multiplier-Amplifier for 8 cylinders AEB388 - Signal duplicator for 8 cylinders AEB386 - Plugs: electrics signals Pag. 3 - 88 pag. 59 pag. 60 pag. 61 pag. 62 pag. 63 pag. 64 pag. 65 pag. 66 pag. 67 pag. 68 pag. 69 pag. 70 pag. 71 pag. 72 pag. 73 pag. 74 pag. 75 pag. 76 pag. 77 Pag. 4 - 88 Required connections Pag. 5 - 88 Pag. 6 - 88 Required connections Computer connections IMPORTANT Switch off the computer before making any connections. Plug the serial cable (supplied as standard equipment) into the serial port of the computer. Plug the hardware key into the parallel port of the computer. Pag. 7 - 88 Plugs: electric signal Required connections Control box connections - phase 1 PLUG DRIVER PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 COLOR BLACK\WHITE RED\WHITE WHITE\BLUE WHITE\BROWN BLACK WHITE BLACK\WHITE BLACK\BLUE RED RED RED RED RED SIGNALS IMPULSE IMPULSE IMPULSE IMPULSE 0V IMPULSE IMPULSE 12 V (GAS WORKING) 12 V (GAS WORKING) 12 V (GAS WORKING) 12 V (GAS WORKING) 12 V (GAS WORKING) BLACK\GREEN BLACK\BROWN IMPULSE IMPULSE Before and after Gas commutation Impulse in phasis at injection 14 12 Volts(V) Volts(V) 10 8 6 4 Connect the female connector of the control box to the male connector of the pressure sensor. 2 time(t) 0 time(t) SEGNALE SU: 1-2-3-4-7-8-15-16 SEGNALE SU: 9-10-11-12-13 NOTE:_______________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ Pag. 8 - 88 Pag. 81 - 88 Plugs: electric signal Required connections Control box connections - phase 2 GREY PLUG PIN A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B3 B4 B5 B6 B7 B8 C1 C2 C3 C4 C5 C6 C7 C8 COLOR WHITE\RED BLACK\WHITE NOT UTLIZZATED BLUE\YELLOW (BLACK COVER) NOT UTLIZZATED BLACK\BROWN BLACK\GREY BLACK\GREEN WHITE\BLUE RED RED NOT UTLIZZATED NOT UTLIZZATED BLACK\WHITE BLACK\VIOLA RED WHITE\BROWN RED RED NOT UTLIZZATED NOT UTLIZZATED BLACK\BLUE WHITE BLACK SIGNALS IMPULSE IMPULSE 2 0V IMPULSE OXIGEN SENSOR BANK 2 IMPULSE IMPULSE 12 V (GAS WORKING) 12 V (GAS WORKING) IMPULSE OXIGEN SENSOR BANK 2 12 V (GAS WORKING) IMPULSE 12 V (GAS WORKING) 12 V (GAS WORKING) IMPULSE 0V Before and after Gas commutation Impulse in phasis at injection 14 12 Volts(V) Volts(V) 10 8 6 Connect the female connector of the pressure sensor to the male connector of the serial cable. 4 2 0 time(t) time(t) SIGNALS OVER: A1-A2-A6-A8-B1-B6-C1C6 SIGNALS OVER: C2-C3-B2-B3-B8 NOTE:_______________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ Pag. 80 - 88 Pag. 9 di 88 Plugs: electric signal Required connections Connecting the pressure sensor PLUG FLUEL INJECTION 1 PIN A1 A2 A3 A4 A5 B1 B2 B3 B4 B5 COLOR BLACK\BLUE BLACK\ RED BLACK\GREEN BLACK\YELLOW NOT UTILIZZATED BLUE RED GREEN YELLOW WHITE\RED SIGNALS 12 V (GAS WORKING) 12 V (GAS WORKING) 12 V (GAS WORKING) 12 V (GAS WORKING) IMPULSE IMPULSE IMPULSE IMPULSE 12 V PLUG PRESSURE SENSOR 3 PIN 1 2 3 4 COLOR BLACK ORANGE\BLACK YELLOW\RED RED\BLACK 2 Disconnect the hose from the connector of rail (1). Insert the connector between rail and hose (2). Connect to the pressure sensor (3) Pag. 10 - 88 Pag. 79 - 88 SIGNALS 12 V 2,4 V 0,45 V 5V Plugs: electric signal Required connections Final checks GREY PLUG Before configuring the vehicle, check that the MAP and the pressure stabilizer hose are correctly connected. PIN A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B3 B4 B5 B6 B7 B8 C1 C2 C3 C4 C5 C6 C7 C8 COLOR RED WHITE\BLACK WHITE\RED BLUE YELLOW YELLOW\BLACK WHITE\RED NOT UTILIZZATED RED WHITE\MBROWN WHITE\BLUE BLACK\BLUE BLACK\GREEN YELLOW\RED ORANGE\BLACK BLACK RED RED BLACK\RED RED GREEN RED\BLACK BLACK NOT UTILIZZATED SIGNALS 12 V (GAS WORKING) IMPULSE IMPULSE 12 V (GAS WORKING) 12 V (GAS WORKING) IMPULSE 12 V 12 V (GAS WORKING) IMPULSE IMPULSE IMPULSE IMPULSE 0,45 V 2,4 V 0V 12 V (GAS WORKING) 12 V (GAS WORKING) IMPULSE 12 V (GAS WORKING) 12 V (GAS WORKING) 5V 0V Pressure Stabilizer Connection MAP Connection Before and after Gas commutation Impulse in phasis at injection 14 12 Volts(V) Volts(V) 10 8 6 4 2 0 time(t) time(t) IMPORTANT SIGNALSOVER : A2-A3-A6-B2-B3-B4-B5-C3 SIGNALS OVER: A1-B1-C1-C2 NOTE:_______________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ Pag. 78 - 88 In order to ensure best system operation, we recommend taking the two depressions by perforating in two points adjacent to the manifold, as close as possible to the throttle valve casing. Pag. 11 - 88 Plugs: electric signal Required connections BLACK PLUG PIN A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B3 B4 B5 B6 COLOR RED RED RED BROWN NOT UTILIZZATED BLACK BROWN GREEN BLACK BLACK BLACK ORANGE BLACK\BLUE BLUE\YELLOW B7 B8 C1 C2 C3 C4 C5 C6 C7 C8 PINK\BLACK PINK BLUE PURPLE BLUE GREY WHITE GREEN BLACK RED\BLACK SIGNALS 12 V (SWITCHED IGNITION) 12 V (BATTERY) 5V 5V 0V TACHOMETER NOT UTILIZZATED 0V 0V 0V TEMPERATUR SENSOR DON’T CONNECT FROM 0 TO 5 V T.P.S. SENSOR 5V 5V 12 V (GAS WORKING) 4,2 V OXIGEN SENSOR BANK 1 GAS LEVEL SENSOR GAS LEVEL SENSOR 0V 12 V DIAGNOSIS PLUG PIN 4 5 6 7 8 COLOR GREEN PINK\BLACK BLACK RED\BLACK PINK SIGNALS NOT UTILIZZATED 5V 0V 12 V 5V COLOR RED BROWN BLACK BLUE SIGNALS 5V 5V 0V 4,2 SWITCH IMPORTANT NOTICE For good operation of the SGIS system, use spark plugs with internal resistors; we recommend NGK, BERU. Check the engine-battery-body ground connections; if unsure of efficiency, reinforce with a cable of minimum 5 mm section. It is important that the engine hood be well-grounded; if necessary, install an additional cable of minimum 3 mm section. Pag. 12 - 88 PIN 1 2 3 4 NOTE:_______________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ Pag. 77 - 88 Pag. 76 - 88 THE CONNECTION SHOWN HERE IS USED IN THE CASE OF A 3-SIGNAL COIL (FOR EXAMPLE, FOR 6-CYLINDER ENGINES WITH D.I.S. IGNITION), AND MAY REPLACE THE 388. THE AEB386 SIGNAL DUPLICATOR IS USED WHEN THE SIGNAL TO THE NEGATIVE OF THE IGNITION COIL IS THE DUAL-SIGNAL (D.I.S.) TYPE: DESCRIPTION (AEB386 SIGNAL DUPLICATOR) ASSEMBLY DIAGRAM CONNECT THE BROWN WIRE TO THE CONTROL BOX Signal duplicator for 8 cylinders AEB386 Simplified Calibration Manual by Displacement Pag. 13 - 88 Pag. 14 - 88 Pag. 75 - 88 IF RPM’S ENGINE CHANGES CONTINUOUSLY AND THE ENGINE RUNS ALTERNATE, TRY TO INSERT ONE 1000 OHM RESISTOR FOR EACH OF TWO BROWN WIRES. THE AEB 388 RPM MULTIPLIER IS USED WHEN THE SIGNAL TO THE NEGATIVE OF THE IGNITION COIL IS OF THE FOLLOWING TYPE: DESCRIPTION (AEB388 MULTIPLIER-AMPLIFIER) FOR 8 CYLINDERS ENGINE ASSEMBLY DIAGRAM CONNECT BOTH WIRES TO THE BROWN WIRE OF THE CONTROL BOX Multiplier - Amplifier for 8 cylinders AEB388 Multiplier - Amplifier for 8 cylinders AEB387 CONNECT BOTH WIRE OF THE CONTROL BOX - Before beginning configuration of the control box, check that all the cable connections are correct and that the hardware key is inserted in the computer. Click the “Sequential GIS” icon on the Windows desktop to launch the SGIS software. (AEB387 RPM MULTIPLIER-AMPLIFIER) FOR 8 CYLINDERS ENGINE Pag. 74 - 88 Vehicle configuration is performed in two phases. The first phase provides for entering the technical data for the vehicle; the second phase comprises actual calibration of the vehicle. IF RPM’S ENGINE CHANGES CONTINUOUSLY AND THE ENGINE RUNS ALTERNATE, TRY TO INSERT ONE 1000 OHM RESISTOR FOR EACH OF TWO BROWN WIRES. THE AEB 387 RPM MULTIPLIER-AMPLIFIER IS USED WHEN THE IGNITION SIGNAL ON THE COILS IS THE SQUARE WAVE TYPE, AS SHOWN IN THE EXAMPLE. INTRODUCTION DESCRIPTION ASSEMBLY DIAGRAM Simplified calibration instruction To access the first phase, click: “VEHICLE CONFIGURATION” Pag. 15 - 88 Distributor plug connections diagram Simplified calibration instruction D Plug C Plug B Plug E Plug G F Plug Plug C Plug B Plug 6C “V” Distributor F G E Plug Plug Plug Plug A 4C Distributor Plug First firing engine cylinder A E First firing engine cylinder Plug D C B Plug Plug A G F E C B H G A 5C Distributor Plug Plug Plug Plug Plug 6C Distributor Plug Plug Plug Plug First firing engine cylinder First firing engine cylinder H C Plug B Plug A D Plug Plug 8C “V” Distributor Plug First firing engine cylinder F E D B A C Plug Plug Plug 8C. Distributor Plug Plug Plug Distributor plug connections diagram First firing engine cylinder Pag. 16 - 88 Pag. 73 - 88 BANK 1 In particular, should the RPM value not be similar to that given by the vehicle engine speed indicator: - shift the RPM signal pickup point - if unsure of the specific connection, try all the leads to the engine ECU comb one by one until the monitor displays the correct value; - or connect the special AEB adapters to the ignition coil. BANK 2 Before continuing, check that the TPS, MAP, RPM, LAMBDA, TEMPERATURE, PRESSURE, and LEVEL values are correctly detected. BANK 1 IMPORTANT BANK 2 Plug GAS change-over Rail assembly diagram Simplified calibration instruction GAS change-over 1 2 3 4 5 6 Air Manifold THE GAS PIPES BETWEEN THE RAIL AND THE COLLECTOR MAY BE OF DIFFERENT LENGTHS. Nozzle Gas GAS SGIS ECU DESCRIPTION ASSEMBLY DIAGRAM 7 Pag. 72 - 88 1 Select the RPM signal type 2 Enter the number of engine cylinders 3 Enter fuel switching mode. 4 IEnter the RPM value for switchover to gas fueling. 5 Enter the RPM value for engine speed limiter cut-in. 6 Enter the minimum pressure reducer temperature value for fuel switchover. (We recommend temperature = 25°C) 7 Enter the gasoline-to-gas fuel switchover delay time, in seconds. (We recommend leaving the value = 0) Pag. 17 - 88 Simplified calibration instruction LPG sector for 2 reducer Collegamento parallelo di 2 distributori Lambda - Press F2 to access the lambda probe configuration menu UNION 1/8 DM.8 1 2 3 2 Enter the number of lambda probes connected to the GIS (This value is always = 1 for 4-cylinder engines). When the no. 2 lambda probe is inserted, two lambda value report boxes will be shown on the display. The left-hand box corresponds to the first block (1). 3 Enter the lambda probe reading time delay, in seconds (We recommend an initial setting = 10 and then measuring the lambda probe response time after starting the engine in the gasoline operation mode. 4 If necessary in order to adapt the lambda signal value (in Volts) to the standard sensors value, enter the lambda probe ground reference value (in Volts) when lean mixture is detected (We recommend leaving the setting = 0, at least initially). Pag. 18 - 88 PIPE DM.8 COUPLING ¼ DM.8 COUPLING ¼ UNION TEE ¼ DM.6 * PIPE DM.6 Select the lambda probe output signal on the basis of the value shown in the box during gasoline-fueled operation. (REDUCER JUNCTIONS) 1 ASSEMBLY DIAGRAM 4 Pag. 71 - 88 Water sector diagram for 2 reducer Simplified calibration instruction TPS - Press F3 to access the TPS configuration menu. 1 2 3 4 (WATER CIRCUIT) WATER OUTLET UNION TEES * WATER INLET ASSEMBLY DIAGRAM 5 Pag. 70 - 88 1 Select the type of TPS installed on the vehicle, with reference to (Straight 0-12Volt Inverted 12-0Volt) the value shown in the box. In the case of a single TPS switch, connect the linear TPS lead of the GIS to it and enter the values in this box. 2 Indicate whether or not an additional TPS switch (besides linear TPS) is installed on the vehicle, and if so, the type. 3 Select this option if a Drive by wire system is installed on the vehicle. (Option not currently available) 4 Select to manually adjust the TPS. (We recommend not selecting this option, at least initially) 5 Enter the TPS hysteresis value (in Volts) for more uniform operation of cut-off and fuel enrichment. (We recommend not changing this value initially and in any case, when stepping up the value, to proceed by 0.01 V intervals) * Pag. 19 - 88 2 Rail juction diagram Simplified calibration instruction Emulation - Press F4 to access the lambda probe emulation configuration menu. BIGAS GAS INLET FROM REDUCER N°2 BIGAS GAS INLET FROM REDUCER N°1 Pag. 20 - 88 After having completed calibration of each single distributor with the pressure tester, connect the distributors using the union for that purpose (see diagram). DESCRIPTION CONNECTION UNION FOR PRESSURE STABILIZATION Select the lambda probe emulation type from among the available options. This information is provided on the technical information card specific to each vehicle. (DISTRIBUTOR JUNCTIONS) 1 ASSEMBLY DIAGRAM 1 Pag. 69 - 88 General diagram for 8 cylinder engine Simplified calibration instruction CUT-OFF - Press F5 to access the CUT-OFF configuration menu. 1 2 3 4 * * 1 Select the CUT-OFF type. (For reduced fuel consumption and faster return to idle select CUT-OFF COMPLETE) 2 Enter the RPMs for end of CUT-OFF. (We recommend values from 1400 to 1600 rpm) 3 Enter the CUT-OFF start delay time, in seconds. This value affects driving quality (smoothness). (We recommend not changing the preset value, at least initially) 4 Enter the CUT-OFF stop delay time, in seconds. This value affects driving quality (smoothness. (We recommend not changing the preset value, at least initially) Important: if injection sequence is unknown or in absence of electronic sequential injection, connect the blue-yellow wire to the engine ground or to the negative pole of ignition coil (for tradional type with distributor ignition). Pag. 68 - 88 Pag. 21 - 88 General diagram for 6 cylinder engine V type double reducer Simplified calibration instruction GAS level - Press F6 to access the gas fuel level configuration menu. 1 2 * 1 Select the gas fuel level sensor type. (For other types of sensors, use AEB adapters) 2 Select this option to activate switchover to gasoline fueling with a low gas bottle level (We recommend not using this option) Basic vehicle configuration ends here. Click the “X” in the top right corner of the window to return to the main menu. * Pag. 22 - 88 Important: if injection sequence is unknown or in absence of electronic sequential injection, connect the blue-yellow wire to the engine ground or to the negative pole of ignition coil (for tradional type with distributor ignition). Pag. 67 - 88 General diagram for 6 cylinder engine V type Simplified calibration instruction * - To access the second phase, click: “CALIBRATION” * Important: if injection sequence is unknown or in absence of electronic sequential injection, connect the blue-yellow wire to the engine ground or to the negative pole of ignition coil (for tradional type with distributor ignition). Pag. 66 - 88 Pag. 23 - 88 General diagram for 6 cylinder engine double reducer Simplified calibration instruction Select type of fuel Set vehicle 1 WARNING If you continue you risk to eliminate the Carburation current parameters EXIT 1 To continue, enter the requested data and click OK to continue. * IMPORTANT The carburetion curves currently available refer 1200 - 1400 1600 - 1800 - 2000 - 3000 - 4000 - 5000 cc engines for LPG and 1600 for methane fuel. Important: For intermediate cylinder capacities, select the closest approximation. * Pag. 24 - 88 Important: if injection sequence is unknown or in absence of electronic sequential injection, connect the blue-yellow wire to the engine ground or to the negative pole of ignition coil (for tradional type with distributor ignition). Pag. 65 - 88 General diagram for 6 cylinder engine Simplified calibration instruction Pressure 2 Wait for the reducer temperature to overcome ok then switch to gas 1 * * EXIT 1 Switch over from gasoline to gas fuel and leave the engine idling. 2 Use an Allen wrench to adjust the reducer pressure to a value between 0.92 e 0.98 bar (green-colored area on dial). A few seconds after pressure stabilizes, the message screen will read “ENTER”: press the “ENTER” key on the computer keyboard to start the calibration-at-idle phase. Important: if injection sequence is unknown or in absence of electronic sequential injection, connect the blue-yellow wire to the engine ground or to the negative pole of ignition coil (for tradional type with distributor ignition). Pag. 64 - 88 Pag. 25 - 88 General diagram for 5 cylinder engine Simplified calibration instruction Pressure Calibration idling 1 * 1 Wait until the blue calibration bar moves all the way to the right. If calibration is successful, the window shown below will open. * Pag. 26 - 88 Important: if injection sequence is unknown or in absence of electronic sequential injection, connect the blue-yellow wire to the engine ground or to the negative pole of ignition coil (for tradional type with distributor ignition). Pag. 63 - 88 General diagram for 4 cylinder engine Boxer Simplified calibration instruction Pressure Set the engine to approx 2000 REVS * 1 Calibrating out of idling 1 Accelerate the engine to 2000 RPM and hold engine speed constant +/- 50 RPM. Wait until the blue calibration bar moves all the way to the right. If calibration is successful, the window shown below will open. Calibration ended successfully EXIT * Important: if injection sequence is unknown or in absence of electronic sequential injection, connect the blue-yellow wire to the engine ground or to the negative pole of ignition coil (for tradional type with distributor ignition). Pag. 62 - 88 Calibration is now correctly completed. Press “ESC” to return to the main menu. Pag. 27 - 88 General diagram for 4 cylinder engine Simplified calibration instruction * We recommend saving the configuration after the vehicle has been calibrated. To save the current configuration, click “ SAVE CURRENT CONFIGURATION” and follow the instructions given on the screen. 1 1 Enter the filename in the space for that purpose and click OK Pag. 28 - 88 * Important: if injection sequence is unknown or in absence of electronic sequential injection, connect the blue-yellow wire to the engine ground or to the negative pole of ignition coil (for tradional type with distributor ignition). Pag. 61 - 88 MAKE THIS MODIFICATION IF THE SGIS SOFTWARE READS THE LAMBDA PROBE SIGNAL INCORRECTLY. DESCRIPTION Pag. 60 - 88 IMPORTANT !!! SWITCH GAS ON ENGINE GROWND DOUBLE EXCHANGE RELAY A.E.B. RL32A THE MODIFICATION HAS TO BE APPLIED ONLY IF TENSION FOUND ON THE BLACK WIRE OF THE LAMBDA SENSOR IS BETWEEN 0,7 E 1,5 VOLTS. PRE-CATALYTIC OXIGEN BLACK WHITE GREY (MODIFICATION OF THE LAMBDA PROBE CONNECTIONS) ASSEMBLY DIAGRAM Modification of the lambda probe connections Istruzione di taratura semplificata To load a new configuration, click: “LOAD NEW CONFIGURATION”. Select a filename from the list and click OK. ATTENTION! Once OK has been clicked, the software will proceed with programming the control box for the selected configuration. Pag. 29 - 88 Pag. 30 - 88 1) Indicator-ready switch 2) AEB control box E13-67R-010157 BIGAS trade name 3) Connection for computer or tester 4) System protection fuses 5) Battery 6) Ignition coil 7) Petrol (gasoline) injectors 8) Gas injectors, E2067R-010494 9) Gasoline injectors cutoff 10) LPG tank 11) On-off solenoid valve, E20-67R-010389 12) Class 1/2A reducer-vaporizer “E20-67R-010493” 13) Acceleration sensor (TPS) 14) Lambda probe 15) Connection for engine speed indicator DESCRIPTION 11 12 4 13 5 1 (SYSTEM DESCRIPTION) ASSEMBLY DIAGRAM 14 15 10 2 4 6 8 3 7 9 SGIS General diagram Pag. 59 - 88 Point by point calibration instruction manual Pag. 58 - 88 Pag. 31 - 88 APPENDIX Pag. 32 - 88 Pag. 57 - 88 Point by point calibration instruction - Before beginning configuration of the control box, check that all the cable connections are correct and that the hardware key is inserted in the computer. - Double-click the “Sequential GIS” icon on the Windows desktop to launch the software. INTRODUCTION Vehicle configuration is performed in two phases. The first phase consists of entering the technical data for the vehicle. The second consists of actual calibration of the vehicle. To access the first phase, click on: “ VEHICLE CONFIGURATION” Pag. 56 - 88 Pag. 33 - 88 Point by point calibration instruction Point by point calibration instruction GAS change-over IMPORTANT NOTICE To load a new configuration, click: “LOAD NEW CONFIGURATION”. Before proceeding with calibration, check that the TPS, MAP, RPM, LAMBDA, TEMPERATURE, PRESSURE, and LEVEL values have been correctly detected. Select a name from the list and press OK. In particular, should the RPM value not be similar to that given by the vehicle engine speed indicator: - shift the RPM signal pickup point. - if unsure of the specific connection, try all the leads to the engine ECU comb one by one until the monitor displays the correct value. - if these steps still do not solve the problem, connect the special AEB adapters to the ignition coil. Pag. 34 - 88 IMPORTANT! Once OK has been pressed, the software will program the control box with the selected configuration. Pag. 55 - 88 Point by point calibration instruction Point by point calibration instruction GAS change-over 1 2 3 4 5 6 7 We recommend saving the configuration once the automobile has been fully tuned. To save the current configuration, click: “ SAVE CURRENT CONFIGURATION” and follow the instructions. 1 Select the RPM signal type (Standard>5 Volt Weak<5 Volt). 2 Enter the number of engine cylinders. 3 Enter fuel switching mode (for vehicles with unstable TPS signals, select switching in acceleration and do not use the CUT-OFF). 4 Enter the RPM value for switchover to gas fueling. 5 Enter the RPM value for engine speed limiter cut-in 6 Enter the minimum pressure reducer temperature value for fuel switchover (We recommend temperature = 25°C). 7 Enter the gasoline-to-gas fuel switchover delay time, in seconds (We recommend leaving the value = 0). 1 1 Enter a filename in the space for that purpose and click OK. If the configuration is an improvement of an existing map, overwrite the old map by saving with the same filename. Pag. 54 - 88 Pag. 35 - 88 Point by point calibration instruction Point by point calibration instruction Lambda - Press F2 to access lambda probe configuration. 1 2 3 4 1 Select the lambda probe output signal on the basis of the value shown in the box during gasoline-fueled operation. * 2 Enter the number of lambda probes connected to the GIS (This value is always = 1 for 4-cylinder engines). When the no. 2 lambda probe is inserted, two lambda value report boxes will be shown on the display. The left-hand box corresponds to the first block (1). 3 Enter the lambda probe reading time delay, in seconds (We recommend an initial setting = 10 and then measuring the lambda probe response time after starting the engine in the gasoline operation mode. 4 If necessary in order to adapt the lambda signal value (in Volts) to the standard sensors value, enter the lambda probe ground reference value (in Volts) when lean mixture is detected (We recommend leaving the setting = 0, at least initially). Pag. 36 - 88 Screen displaying the acquired map curves. The map may be modified from this screen as well. With the mouse, scroll to the desired line and left-click. Then move the mouse cursor to the value to be modified; hold down the left mouse button and move down or up to the desired value. Pag. 53 - 88 Point by point calibration instruction Point by point calibration instruction Miscellaneous TPS - Press F9 to access “Miscellaneous” - Press F3 to access TPS configuration. 1 2 3 4 5 * SECOND PHASE OF MAPPING - Always make use of the controlled return to idle function (zeroing of the correction when decelerating below the 1000 RPM threshold); it is possible to maintain a small correction of +10 -10 (+1% -1% on the map). - Use the idle lock function if it is not possible to otherwise stabilize the idle (the corrector never goes below zero). Pag. 52 - 88 1 Select the type of TPS installed on the vehicle, with reference to (Direct 0-12 Volt, Inverted 12-0 Volt). the value shown in the box In the case of a single TPS switch, connect the linear TPS lead of the GIS to it and enter the values in this box. 2 Indicate whether or not an additional TPS switch (besides linear TPS) is installed on the vehicle, and if so, the type. 3 Select this option if a drive-by-wire system is installed on the vehicle (Option not currently available). 4 Enter the TPS hysteresis value (in Volts) for more uniform operation of cut-off and fuel enrichment (We recommend not changing this value initially and in any case, when stepping up the value, to proceed by 0.01 V intervals). 5 If the GIS software does not automatically detect the minimum value of the TPS signal, select this option to manually set the TPS (We recommend not selecting this option, initially). When the TPS signal is stable, the value in Volts displayed on the screen will be shown in red with the accelerator not pressed (idle speed); the color of the value display must change to blue when the engine is accelerated slightly. * Pag. 37 - 88 Point by point calibration instruction Point by point calibration instruction Emulation Enrichment - Press F4 to access lambda probe emulation configuration. - Press F8 to access the “Enrichment” window. 1 SECOND PHASE OF MAPPING 1 Select the lambda probe emulation type from among the available options. This information is provided on the technical information card specific to each vehicle or is available from the supplier's technical service. For FEEDBACK emulation see the next page. Pag. 38 - 88 - To reduce the acceleration response delay, select a value of up to 40 (4% enrichment on the map); this solution slightly increases LPG consumption. - For methane gas use, we recommend negative values to -40 (-4% on the map). Pag. 51 - 88 Point by point calibration instruction Point by point calibration instruction Correct Map Correct Map - FEEDBACK System SECOND PHASE OF MAPPING - Again with the engine in neutral gear, accelerate brusquely. If the engine speed (RPM) does not increase uniformly, select cells as shown in the figure. Press ENTER/RETURN; in the “Modify Map Values” window, use the “Percentage” option to modify the values by making small corrections, positive if the mixture is lean and negative if the mixture is rich. Pag. 50 - 88 FEEDBACK MAPPING (for automobiles for which there exists no specific OBD emulator; e.g., Citroen and Peugeot) - Emulation with the FEEDBACK system is performed as outlined below. - Once system installation is completed (with the automobile in the gasoline operation mode), the next step is to acquire about 40 points distributed over the entire map. To acquire a point, simply position the dot on the cell; as soon as the lambda probe begins to oscillate between red and green, press SPACE to acquire the value. Once point acquisition is completed, click “Download Road-Acquired Map”. In the gasoline fuel mode, proceed at a steady speed to various points on the map and check that the gasoline correction value (on the lower right of the display) remains within a maximum value range of +/- 100. If so, the map is good; contrariwise, any chosen point may be precisely corrected, taking the gasoline correction value as the point value. Example: if at a given point on the map we see a gasoline correction value of 350, use the mouse to light the correction window and enter a value of -35%. When gasoline mapping is completed, it is possible to go on to GAS mapping by setting “Lambda emulation” on the FEEDBACK screen. Pag. 39 - 88 Point by point calibration instruction Point by point calibration instruction CUT-OFF Correct Map - Press F5 to access CUT-OFF configuration. 1 2 3 4 1 Select the CUT-OFF type (For reduced fuel consumption and faster return to idle select COMPLETE CUTOFF. SECOND PHASE OF MAPPING 3 Enter the CUT-OFF start delay time, in seconds. This value affects driving quality (smoothness) (We recommend not changing the preset value, at least initially). - Again with the engine idling, modify the cells adjacent to the red reference point in such a manner as to obtain more similar values. This modification will result in greater engine stability at idling speed. In this phase, work in such a manner as to bring the correction close to zero, with a temperature of about 70°. - For example: maintain a time interval of between 0.4 and 0.8 between one line of the map and the next. 4 Enter the CUT-OFF stop delay time, in seconds. This value affects driving quality (smoothness) and idling stability (We recommend selecting values in the 0.04 to 0.48 range). Between one RPM line and the next in the interval between 500 and 1500 RPM, up to a MAP value of 1.08, maintain a time interval between 0.1 and 0.2. 2 Enter the RPM for end of CUT-OFF (We recommend values from 1400 to 1600 RPM). If the engine stalls upon return to idle speed, use only lean mixture or no CUT-OFF. Pag. 40 - 88 Pag. 49 - 88 Point by point calibration instruction Point by point calibration instruction Correct Map GAS level - Press F6 to access gas fuel-level sensor configuration. 1 A 2 SECOND PHASE OF MAPPING - With the automobile in neutral gear and the engine idling (and the air conditioner off), use the SHIFT and ARROW keys to select the first line of the map; press ENTER/RETURN to open the “Modify Map Values” window. Select the “Absolute” option and enter a value very similar to that of the cell above the red reference point at idle (in this case, cell “A”). - For example: if the stored cell “A” value is 4.14, we will enter a value of 4.00; this modification will improve the return to idling speed at the end of cutoff and reduce the delay in acceleration during gear change. 1 Select the gas fuel level sensor type. (For other types of sensors, use AEB adapters). 2 Select this option to activate switchover to gasoline fueling with a low gas bottle level (We recommend not making use of this option). Basic vehicle configuration ends here. Click the “X” in the top right corner of the active window to return to the main menu. Pag. 48 - 88 Pag. 41 - 88 Point by point calibration instruction Point by point calibration instruction Correct Map Correct Map - Press F7 to access mapping. A The operations for performing mapping of the SGIS control box are outlined below. - In order to make use of probe emulation with gasoline feedback, the gasoline map must be created before switching over to GAS fueling. - Start the automobile and switch to GAS fueling when the temperature exceeds 60°. - With the vehicle idling, use the SHIFT and ARROW keys to highlight the map cells around the red reference point. - Check the A correction value. If this value oscillates between +/- 40 and the lambda probe displayed on the screen changes color continually between red and green (lambda control condition 1.00), press the BACKSPACE key to acquire the datum (if the datum is successfully acquired the cell under the dot will turn white) and go on to recording the next point. - If the A correction value oscillates between 200 and 100, press the ENTER/RETURN key to open the “Modify Map Values” window, select the “Percentage” option and enter a value of -5. Press OK. At this point the highlighted values will change and the correction will oscillate between 150 and 50. Repeat the operation until the correction oscillates within the +/- 40 range and the lambda probe displayed on the screen changes color continually between red and green (lambda control condition 1.00). Press the BACKSPACE key to acquire the datum and go on to recording the next point. - If the A correction value oscillates between +200 and +100, press the ENTER/RETURN key to open the “Modify Map Values” window, select the “Percentage” option and enter a value of +5. Press OK. At this point the highlighted values will change and the correction will oscillate between +150 and +50. Repeat the operation until the correction oscillates within the +/- 40 range and the lambda probe displayed on the screen changes color continually between red and green (lambda control condition 1.00). Press the BACKSPACE key to acquire the datum and go on to recording the next point. Pag. 42 - 88 INSERTION OF THE ACQUIRED DATA - With the automobile in neutral gear and the engine idling, press the “Download Road-Acquired Map” button. Several seconds later the curves of the map thus obtained will be displayed. Calibration is now terminated; to obtain even more precise values, repeat the operations relative to registration of the five points (use of a greater number of points can improve the precision of the map). The first phase of mapping is thus concluded. The second phase consists of manual modification of certain map values. N.B. We recommend saving the first part of the procedure under the name of the automobile. In case of errors in the second phase it will thus be possible to restore the values without having to repeat the road test. Pag. 47 - 88 Point by point calibration instruction Point by point calibration instruction Correct Map Correct Map A A RECORDING THE FIFTH POINT - In second gear, using both the accelerator and the brake, run the engine at a steady speed of about 3000 RPM. Use the SHIFT and ARROW keys to highlight the map cells around the red reference point. - Check the A correction value. If this value oscillates between +/- 100 and the lambda probe displayed on the screen changes color continually between red and green (lambda control condition 1.00), press the BACKSPACE key to acquire the datum and go on to recording the next point. - If the A correction value oscillates between 200 and 100, press the ENTER/RETURN key to open the “Modify Map Values” window, select the “Percentage” option and enter a value of -5. Press OK. At this point the highlighted values will change and the correction will oscillate between 150 and 50. Repeat the operation until the correction oscillates within the +/- 100 range and the lambda probe displayed on the screen changes color continually between red and green (lambda control condition 1.00). Press the BACKSPACE key to acquire the datum and go on to recording the next point. - If the A correction value oscillates between +200 and +100, press the ENTER/RETURN key to open the “Modify Map Values” window, select the “Percentage” option and enter a value of +5. Press OK. At this point the highlighted values will change and the correction will oscillate between +150 and +50. Repeat the operation until the correction oscillates within the +/- 100 range and the lambda probe displayed on the screen changes color continually between red and green (lambda control condition 1.00). Press the BACKSPACE key to acquire the datum and go on to recording the next point. Pag. 46 - 88 RECORDING THE SECOND POINT - In neutral gear, accelerate the engine to a steady speed of about 4500 RPM. Use the SHIFT and ARROW keys to highlight the map cells around the red reference point. - Check the A correction value. If this value oscillates between +/- 100 and the lambda probe displayed on the screen changes color continually between red and green (lambda control condition 1.00), press the BACKSPACE key to acquire the datum and go on to recording the next point. - If the A correction value oscillates between 200 and 100, press the ENTER/RETURN key to open the “Modify Map Values” window, select the “Percentage” option and enter a value of -5. Press OK. At this point the highlighted values will change and the correction will oscillate between 150 and 50. Repeat the operation until the correction oscillates within the +/- 100 range and the lambda probe displayed on the screen changes color continually between red and green (lambda control condition 1.00). Press the BACKSPACE key to acquire the datum and go on to recording the next point. - If the A correction value oscillates between +200 and +100, press the ENTER/RETURN key to open the “Modify Map Values” window, select the “Percentage” option and enter a value of +5. Press OK. At this point the highlighted values will change and the correction will oscillate between +150 and +50. Repeat the operation until the correction oscillates within the +/- 100 range and the lambda probe displayed on the screen changes color continually between red and green (lambda control condition 1.00). Press the BACKSPACE key to acquire the datum and go on to recording the next point. Pag. 43 - 88 Point by point calibration instruction Point by point calibration instruction Correct Map Correct Map A A RECORDING THE THIRD POINT RECORDING THE FOURTH POINT - In second gear, using both the accelerator and the brake, run the engine at a steady speed of about 1000-1500 RPM. Use the SHIFT and ARROW keys to highlight the map cells around the red reference point. - Check the A correction value. If this value oscillates between +/- 100 and the lambda probe displayed on the screen changes color continually between red and green (lambda control condition 1.00), press the BACKSPACE key to acquire the datum and go on to recording the next point. - In second gear, using both the accelerator and the brake, run the engine at a steady speed of about 4500 RPM. Use the SHIFT and ARROW keys to highlight the map cells around the red reference point. - Check the A correction value. If this value oscillates between +/- 100 and the lambda probe displayed on the screen changes color continually between red and green (lambda control condition 1.00), press the BACKSPACE key to acquire the datum and go on to recording the next point. - If the A correction value oscillates between 200 and 100, press the ENTER/RETURN key to open the “Modify Map Values” window, select the “Percentage” option and enter a value of -5. Press OK. At this point the highlighted values will change and the correction will oscillate between 150 and 50. Repeat the operation until the correction oscillates within the +/- 100 range and the lambda probe displayed on the screen changes color continually between red and green (lambda control condition 1.00). Press the BACKSPACE key to acquire the datum and go on to recording the next point. - If the A correction value oscillates between 200 and 100, press the ENTER/RETURN key to open the “Modify Map Values” window, select the “Percentage” option and enter a value of -5. Press OK. At this point the highlighted values will change and the correction will oscillate between 150 and 50. Repeat the operation until the correction oscillates within the +/- 100 range and the lambda probe displayed on the screen changes color continually between red and green (lambda control condition 1.00). Press the BACKSPACE key to acquire the datum and go on to recording the next point. - If the A correction value oscillates between +200 and +100, press the ENTER/RETURN key to open the “Modify Map Values” window, select the “Percentage” option and enter a value of +5. Press OK. At this point the highlighted values will change and the correction will oscillate between +150 and +50. Repeat the operation until the correction oscillates within the +/- 100 range and the lambda probe displayed on the screen changes color continually between red and green (lambda control condition 1.00). Press the BACKSPACE key to acquire the datum and go on to recording the next point. - If the A correction value oscillates between +200 and +100, press the ENTER/RETURN key to open the “Modify Map Values” window, select the “Percentage” option and enter a value of +5. Press OK. At this point the highlighted values will change and the correction will oscillate between +150 and +50. Repeat the operation until the correction oscillates within the +/- 100 range and the lambda probe displayed on the screen changes color continually between red and green (lambda control condition 1.00). Press the BACKSPACE key to acquire the datum and go on to recording the next point. Pag. 44 - 88 Pag. 45 - 88