MANSI CLS Series LPG/CNG Closed Loop System with Harness and Actuator Motor

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1 MANSI CLS Series LPG/CNG Closed Loop System with Harness and Actuator Motor ratio(afr) is efficiently controlled to minimize emissions, maximize efficiency and improve mileage. This product features extremely rugged and compact construction. Made out of heat resistant material, these AFR controllers are suitable for use in engine compartment and weatherproof casing and seals and multilayer conformally coated electronics ensures superior performance in harsh conditions. Features include mixture type indicator lights that indicate whether the instantaneous air-fuel mixture is lean, rich or stochiometric. Models can be chosen for mounting under dashboard or inside engine compartment. Features Compact Size: x x mm (LxWxH). Optimal control. Low cost. Rugged, discrete through hole components only. Weatherproof construction. Rugged wiring harness. Choice of models for mounting under dashboard or inside engine compartment. RoHS compliant. Application Description MANSI CLS Series closed loop system optimally controls LPG/CNG supply to the air-fuel mixer depending on value of exhaust lambda. The air fuel LPG/CNG Vehicles OEM fitment and after market conversion kits For use with Single wire Lambda sensors Technical Overview Operating Voltage Range: 7.5V to 18V DC (Note: Customized design available for vehicles with 24V battery) Operating Temperature Range: -40 C to +125 C Maximum Operating Humidity: 95 %RH Vehicle Suitability: Any vehicle operating on 12V battery Harness cable length: 1.5m Standards: Follows UNECE Regulations 67, 110 and 114

2 Ordering Information Shown below is ordering code chart with example: CLS-AERNWB. RoHS compliance certificate is available on request. HARNESS WIRE COLORS (OPTIONAL) MODEL ELECTRONIC COMPONENTS MOUNTING +12V BATTERY GND LAMBDA SIGNAL GAS CLS - A D R N W B N = BROWN R = RED O = ORANGE Y = YELLOW G = GREEN B = BLUE P = PURPLE K = BLACK A = GRAY W = WHITE D = UNDER DASHBOARD E = INSIDE ENGINE COMPARTMENT A = PREMIUM GRADE E = ECONOMY GRADE M = MILITARY GRADE GRADES BASED ON STATISTICAL LIFE. Figure 1: CLS Series Ordering Information CLS Series 2

3 Technical Specifications Available upon request. CLS Series 3

4 Installation Installation by trained personnel only. Incorrect or loose connections can cause permanent damage to the device and voids all warranty. Do not use this device with 24V battery. Do not install the unit near sources of excessive heat, possible water infiltration or high voltage wires Do not touch any electrical terminal on the device during installation. Harness plug must be inserted into the device only after all wiring connections are performed and double checked. Do not touch any electrical terminal while the device is operating. Inductive kicks on valve coils poses risk of electrical shock. Do not touch insulation of high voltage spark plug cables while the engine is running. Follow common safety rules of automotive repair during installation. CLS Series 4

5 Step 1: Open package Package contains one device one wiring harness one user s manual one linear actuator one self tapping screw one 5A blade fuse and fuse holder Step 2: Perform wiring Perform wiring as shown in the schematic below. Connect the GAS wire to changeover switch s GAS and the GND to a reliable vehicle ground. Make sure that all copper conductors are well twisted and connected using crimp type lugs (avoid doing wire wraps). All wires should be correctly connected to their designated terminals as shown in figure below and all connections should be double checked for correctness. RED YLW GRN FUSE 5A + - MANSI Closed Loop System for LPG/CNG Vehicles BATTERY MANSI CLS CLOSED LOOP SYSTEM +12 BATTERY GAS LAMBDA SENSOR GND STEPPER MOTOR STEPPER MOTOR GAS SOLENOID LAMBDA SENSOR Figure 2: CLS Series Wiring Schematic Step 3: Mount Device Connect the device to the harness. The YELLOW light goes on for 1 second and then goes off. During this phase the control unit resets and the actuator plunger is positioned at about half way along its stroke. Mount the device under dashboard (models CLS-xD) or inside engine compartment (models CLS-xE) using self tapping screws. Do not install the control unit near sources of excessive heat, possible water infiltration or high voltage wires. Step 4: Train and Test Start the vehicle in PETROL mode and wait for a few minutes so that the lambda sensor begins to heat up and work. With the vehicle on PETROL the 3 lights stay off. CLS Series 5

6 Switch the vehicle over to GAS and take the engine up to 3500 rpm; if the lambda sensor is warm the YELLOW light will stay on and the GREEN light and the RED light will flash alternately. In this condition the control unit corrects carburation and, at the same time, seeks the optimal position of the stepper motor. If the frequency of the movements is sufficiently high, the system learns the carburation and visualizes this condition by flashing one of the 3 lights for about 5 seconds: YELLOW light flashing quickly for 5 seconds. This condition indicates that the control unit has learned the carburation and the whole system is working correctly. From this moment on, the 3 lights will display the carburation of the vehicle. RED light flashing quickly for 5 seconds. This condition indicates that the control unit has learned the carburation but that it is tendentially RICH and the motor is running very CLOSED. It is necessary to draw more air to the engine, opening any throttles or the diameter of the mixer diffuser. From this moment on, the 3 lights will display the carburation of the vehicle. GREEN light flashing quickly for 5 seconds. This condition indicates that the control unit has learned the carburation but that it is tendentially LEAN and the motor is running very OPEN. It is necessary to draw less air to the engine, throttling the intake or reducing the diameter of the mixer diffuser or widening the holes of the diffuser. From this moment on the 3 lights will display the carburation of the vehicle. NOTE 1: After a modification to the mixer or to the supply system, the battery wire must be detached for at least half a minute to permit fresh learning. NOTE 2: If during the learning phase, the YELLOW light stays on all the time and the system does not learn the carburation, the engine speed must be raised so as to have a higher frequency of movement of the GREEN and RED light. NOTE 3: If the power supply to the control unit is cut (+12V Battery), carry out the setting operation again following the instructions above. CLS Series 6

7 Warranty Mansi Engineering guarantees its parts to be free from defects in workmanship and materials when operated under normal conditions and in accordance with nameplate characteristic limits. In case of electronic unit, this warranty shall be in effect for a period of 18 months from date of manufacture. However wiring cables or harnesses are not covered by any type of warranty. THIS WARRANTY SHALL BE IN LIEU OF ANY OTHER WARRANTY, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Mansi Engineering will repair or replace, at its option, any device which has been found to be defective and is within the warranty period, provided that the device is shipped, with previous factory authorization, freight prepaid, to the nearest authorized service center. Mansi Engineering is not responsible for removal, installation, or any other incidental expenses incurred in shipping the device to or from Mansi Engineering. Mansi Engineering's liability under this warranty shall be solely limited to repair or replacement of the device within the warranty period, and Mansi Engineering will not be liable under any circumstances, for consequential or incidental damages, including, but not limited to, personnel injury or labor costs. Under no circumstances will Mansi Engineering be responsible for any expense in connection with any repairs made by anyone other than the factory or an authorized service center, unless such repairs have been specifically authorized in writing. Notes CLS Series 7

8 Please Read Carefully: Information in this document is provided solely in connection with Mansi Engineering products. Mansi Engineering reserves the right to make changes, corrections, modifications or improvements, to this document, and the products and services described herein at any time, without notice. All MANSI products are sold pursuant to Mansi Engineering s terms and conditions of sale. Purchasers are solely responsible for the choice, selection and use of the MANSI products and services described herein, and Mansi Engineering assumes no liability whatsoever relating to the choice, selection or use of its products and services described herein. No license, express or implied, to any intellectual property rights is granted under this document. If any part of this document refers to any third party products or services it shall not be deemed a license grant by Mansi Engineering for the use of such third party products or services, or any intellectual property contained therein or considered as a warranty covering the use in any manner whatsoever of such third party products or services or any intellectual property contained therein. UNLESS OTHERWISE SET FORTH IN MANSI ENGINEERING S TERMS AND CONDITIONS OF SALE MANSI ENGINEERING DISCLAIMS ANY EXPRESS OR IMPLIED WARRANTY WITH RESPECT TO THE USE AND/OR SALE OF MANSI PRODUCTS INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE (AND THEIR EQUIVALENTS UNDER THE LAWS OF ANY JURISDICTION), OR INFRINGEMENT OF ANY PATENT, COPYRIGHT OR OTHER INTELLECTUAL PROPERTY RIGHT. UNLESS EXPRESSLY APPROVED IN WRITING BY AN AUTHORIZED MANSI ENGINEERING REPRESENTATIVE, MANSI PRODUCTS ARE NOT RECOMMENDED, AUTHORIZED OR WARRANTED FOR USE IN MILITARY, AIR CRAFT, SPACE, LIFE SAVING, OR LIFE SUSTAINING APPLICATIONS, NOR IN PRODUCTS OR SYSTEMS WHERE FAILURE OR MALFUNCTION MAY RESULT IN PERSONAL INJURY, DEATH, OR SEVERE PROPERTY OR ENVIRONMENTAL DAMAGE. MANSI PRODUCTS WHICH ARE NOT SPECIFIED AS "PREMIUM GRADE" MAY ONLY BE USED IN AUTOMOTIVE APPLICATIONS AT USER S OWN RISK. Resale of MANSI products with provisions different from the statements and/or technical features set forth in this document shall immediately void any warranty granted by Mansi Engineering for the product or service described herein and shall not create or extend in any manner whatsoever, any liability of Mansi Engineering. MANSI, Mansi Engineering, MANSI logo and Mansi Engineering logo are trademarks or registered trademarks of Mansi Engineering. All other names are the property of their respective owners. Information in this document supersedes and replaces all information previously supplied Mansi Engineering - All rights reserved Contact Information Mansi Engineering B1 Sharad Complex, Opp Tubewell Stn, Gulbai Tekra, Ahmedabad Gujarat. INDIA. Phones Fax s Sales: sales@mansi.ws Support: support@mansi.ws Billing: billing@mansi.ws General Information: info@mansi.ws CLS Series 8