LPG STARTBOX. Instruction Manual. Rempel Power Systems GmbH

Transcription

1 LPG STARTBOX Rempel Power Systems GmbH

2 Content Installation Guidelines... 2 Layout... 2 Getting started (Learning mode)... 3 Operating mode... 5 Switch positions... 6 Programming mode (Firmware update)... 7 Factory settings... 7 Contact... 8 Page 1

3 Installation Guidelines First connect the cables according to following instructions. Please ensure, that the ignition is turned off! Generally no electric lines of the vehicle or autogas system are cut! Connect all lines in parallel. The polarity of the individual sensors are automatically detected by the LPG-Startbox. That allows the disconnection of the box from the connector at any time without affecting the electronics. The values learned by the LPG-Startbox are not lost in doing so! Layout Pin 1 Red Battery (Plus) Pin 7 Brown Battery (Minus) Pin 2 Red/white Output for the relays control Pin 3 Green Temperature sensor autogas Pin 9 Green Temperature sensor autogas Pin 4 Yellow Temperature sensor engine Pin 10 Yellow Temperature sensor engine Pin 5 Grey Signal autogas injector cylinder 1 Pin 8 White Switched line from magnetic shut-off valve on evaporator or before Pin Pin Pin It is mandatory to connect the white cable to the in-line cable of the magnetic valve. Most autogas systems are operated with +12V. However there are installations (e.g. BRC SQ56 and older...), which must be permanently (with ignition on) supplied to +12V. On these installations the white cable must be connected to the negative line. Page 2

4 Getting started (learning mode) An 8-pin dip switch and the power LEDs are located below the display of the LPG- Startbox. Please open the cover. 1. Disconnect the LPG-Startbox from the plug and then switch on the ignition (don t start the engine). 2. Switch dip switch 1 to ON. (Dip switch 2-8 off) 3. Connect plug. Automatic verification of the temperature sensors is running: a. The LED flashes blue 1x per second: The LPG-Startbox has detected the temperature sensors correctly. Proceed to step 4. b. The LED flashes red 1x per second: Check the gas temperature sensor resp. cabling. c. The LED flashes red 2x per second: Check the engine temperature sensor resp. cabling. d. The LED flashes red 3x per second: Check the gas and engine temperature sensor resp. cabling. 4. Start the engine and turn on the autogas system. Automatic detection of autogas system/switching to autogas is running: a. The LED flashes blue 2x per second: The LPG-Startbox has correctly detected the switching to autogas. Proceed to step 5. b. The LED flashes alternately red/white: The LPG-Startbox has not detected the switching to autogas. Possible cause: Magnetic valve not connected properly (white cable).!!attention!! It is mandatory to connect the white cable to the in-line cable of the magnetic valve. Most autogas systems are operated with +12V. However there are installations (e.g. BRC SQ56 and older...), which must be permanently (with ignition on) supplied to +12V. On these installations the white cable must be connected to the negative line. c. The LED flashes red permanently: Internal error. Disconnect the box from the connecting plug and start over from step 1. Please contact RPS in case the error occurs again. Page 3

5 5. Heat up the vehicle to approximately C (176 F-194 F). Switch the dip switch 2 to ON, when this temperature is reached. a. The LED flashes blue rapidly: The new characteristics are being calculated and saved. Do not interrupt this process! b. The LED flashes blue permanently: Characteristics calculation successful. Turn off ALL dip switches. Step 6 can be repeated at any time, if a new (higher or lower) temperature is to be learned. Proceed to step 7. c. The LED flashes yellow permanently: The temperature is not learned, since the temperature difference (min. 10 C) between autogas system on and the status dip switch 2 on is not sufficient. Turn off dip switch 2 and turn it back on after a while. With dip switch 2 in addition it is possible to save the current status even with a too low temperature difference. (Not recommended!) d. The LED flashes red permanently: Internal error. Disconnect the box from the connecting plug and start over from step 1. Please contact RPS in case the error occurs again. 6. Exit the learning procedure by switching dip switch 1 to OFF. The LPG-Startbox is in operating mode now and flashes green permanently. 7. Turn off the autogas system and ignition. Page 4

6 Operating mode The operating mode is automatically active, when dip switch 1 and 8 are switched OFF. The LPG-Startbox is set to following statuses: 1. The LED is turned off: The LPG-Startbox is in sleep mode and waits for ignition on. 2. The LED flashes green 1x per second: The LPG-Startbox has detected the ignition and initiates the starting procedure of the autogas system. 3. The LED flashes green 2x per second: Engine runs on autogas. The cold start is now being adjusted in autogas mode. 4. The LED flashes green: The LPG-Startbox is in sleep mode. No regulation necessary, since engine is warm already. 5. The LED flashes alternately red/white: The autogas system runs, but was not detected. Check correct connection of white cable to Startbox (Pin8). Please repeat the learning procedure. If problem persists in operating mode, please contact RPS. Note to cold start Since the engine control units can react at different paces to the changed injection, at some models it may happen at cold start in the switch over phase from gasoline to autogas that the engine softly switches only at higher rotational speed (ca. 3-5 seconds) and does not turn off. The dip switch 2, 3, 4 offer additional options to optimize the transition from gasoline to autogas. (See description function dip switches). With dip switch 6 the ON and OFF behavior of the autogas heater, which is additionally available can be varied. If the dip switch 6 is in OFF position the heater is only activated during the emulation process. If the dip switch 6 is in ON position, the autogas heater is permanently connected to the autogas system. Page 5

7 Switch positions Charact. DIP4 DIP3 DIP2 0 OFF OFF OFF DIP8 DIP1 1 OFF OFF ON 2 OFF ON OFF 3 OFF ON ON 4 ON OFF OFF 5 ON OFF ON 6 ON ON OFF 7 ON ON ON NO OFF Characteristic curves of the LPG-Startbox Temperature Time Page 6

8 Programming mode (Firmware update) Copy new software on the LPG-Startbox. Please proceed as follows: 1. Disconnect the LPG-Startbox from the connecting plug and only switch the dip switch 8 to ON. 2. Use our PC connector for your computer and connect both devices. 3. The LED flashes yellow permanently. 4. Use the available download software for transferring the available firmware. Additional information on the installation and programming procedure can be found on 5. Disconnect the LPG-Startbox from the computer resp. PC connector after successful copying of the data. 6. Switch the dip switch 8 to OFF. Learned characteristics remain generally. However the learning mode can be repeated as often as desired. 7. Connect the LPG-Startbox with the connecting plug. Factory settings To reset to factory settings. ATTENTION: All learned characteristics are being deleted! The learning mode must be repeated afterwards. 1. Switch the dip switch 1 and 6 beneath the display of the LPG-Startbox to ON. 2. Connect the plug. 3. The LED flashes yellow for ca. 5 sec: If not the LPG-Startbox requires a firmware update from Device is being reset to factory settings. Don t interrupt this process! 4. The LED flashes yellow permanently: All saved values are now reset to factory settings. Switch dip switch 6 to OFF and disconnect the plug from the box afterwards. Page 7

9 Contact Rempel Power Systems GmbH CEO: Viktor Rempel Hauptstrasse Twiste Phone: +49 (0) Fax: +49 (0) info@lpg-startbox.com Website: Page 8