MANSI CDS Series Compact LPG/CNG Changeover Switch for MPFI and Carburetor Vehicles
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1 MANSI CDS Series Compact LPG/CNG Changeover Switch for MPFI and Carburetor Vehicles indicator LEDs, reserve level being indicated by the first LED blinking. An internal output overload protection protects the electronics from valve coil failures and accidental shorting of outputs to ground. Design provides for the vehicle RPM signal to be conveniently sensed in three ways: using a capacitive pickup clamp on one of the spark plug cable, or tying IMPULSE cable to ignition coil negative terminal or tying IMPULSE cable to ECU s RPM output terminal. These switches are conveniently configurable for use with MPFI or Carburetor vehicles by simply cutting a single harness cable at the time of fitment. During fitment these switches could be mounted underneath the dashboard or in a dashboard side slot. An adjustment preset enables setting of changeover RPM for MPFI vehicles and the fuel cutoff time delay for Carburetor vehicles. Features Compact Size: 82.0 x 33.6 x 21.1 mm (LxWxH). Functionality selection as per MPFI or Carburetor vehicle at the time of fitment. Intelligent Operation. Models available for use with various resistive or voltage level sensors. RPM sensing via capacitive pickup, ignition coil or ECU output. Output overload protection (CDS-xxS models only). Available with Relay or Solid State Switching Available with Rocker or Dome type switch. Mounting under dashboard or in side slot. ESD Safe, Microprocessor based design. RoHS compliant. Description MANSI CDS Series advanced dual fuel changeover switches boast a combination of compactness and state of the art technology and intelligent functionality eliminating redundant changeover operations and enabling efficient changeover. A progressive five staged fuel level display is provided using four Application MPFI based LPG/CNG Vehicles Carburetor based LPG/CNG Vehicles OEM fitment and after market conversion kits
2 Technical Overview Operating Voltage Range: 8V to 18V DC (Note: Customized design available for vehicles with 24V battery) Operating Temperature Range: -20 C to +85 C Maximum Operating Humidity: 95 %RH Vehicle Suitability: 3, 4, 5, 6, 7 and 8 Cylinders, 4 Stroke, MPFI and Carburetor based Vehicles Harness cable length: 1.85m Standards: Follows UNECE Regulations 67, 110 and 114 ESD Protection in CDS-xxS models: All terminals ESD Protection in CDS-xxM models: All terminals except Petrol and Gas. Petrol and Gas terminals are protected with negative surge protection snubber diode that can sustain 1kV peak reverse voltage. ESD Protection class: IEC level 4: 15 kv (air discharge) / 8 kv (contact discharge) Note: ESD Protection not available in Economy Grade models. CDS Series 2
3 Ordering Information Shown below is ordering code chart with example: CDS-MASDR90BCCWBANKGY. RoHS compliance certificate is available on request. HARNESS WIRE COLORS (OPTIONAL) MODEL FUNCTION ELECTRONIC COMPONENTS INTERNAL SWITCHING DEVICE CHANGEOVER SWITCH TYPE LEVEL SENSOR TYPE LEVEL SENSOR Ω / VOLTAGE LEVEL SIGNAL LIGHT COLOR CONNECTOR TYPE FRONT PANEL THEME PETROL GAS IGNITION KEY GND CAPACITIVE IMPULSE LEVEL SIGNAL MPFI / CARB SELECTOR CDS - M A S D R 90 B C C W B A N K G Y N = BROWN R = RED O = ORANGE Y = YELLOW G = GREEN B = BLUE P = PURPLE K = BLACK A = GRAY W = WHITE K = BLACK C = CHROME C = WIRE TO BOARD, CRIMPING TYPE S = WIRE TO BOARD, SCREW TERMINAL TYPE T = OTHER / CUSTOM G = GREEN B = BLUE O = ORANGE Y = YELLOW A = AMBER 90 = 90 Ω LEVEL SENSOR 100 = 30 KΩ-100 Ω LEVEL SENSOR 110 = 110 Ω LEVEL SENSOR VALUE IN OHMS IF LEVEL SENSOR IS RESISTIVE TYPE VALUE IN VOLTS IF LEVEL SENSOR IS VOLTAGE TYPE R = RESISTIVE TYPE V = VOLTAGE TYPE D = DOME MICROSWITCH. RED-GREEN DUAL LED AS GAS / PETROL INDICATOR. R = ROCKER SWITCH, 3 POSITION TYPE. GAS / PETROL INDICATOR LIGHTS SEPARATE. M = MECHANICAL RELAY S = SOLID STATE RELAY (NO MOVING PARTS) A = PREMIUM GRADE E = ECONOMY GRADE M = MILITARY GRADE GRADES BASED ON STATISTICAL LIFE. M = MPFI FACTORY SET, GROUND SELECTOR WIRE FOR CARBURETOR OPERATION C = CARBURETOR FACTORY SET, CUT SELECTOR WIRE FOR MPFI OPERATION Figure 1: CDS Series Ordering Codes CDS Series 3
4 Technical Specifications Available upon request. CDS Series 4
5 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. For any type of changeover switch it is important to ensure that gas valve turns off when engine stalls. CDS Series 5
6 Notice In case of Dome Microswitch models (CDS-xxxD models), the mode indicator light is not indicative of the state of gas and petrol valves. This light indicates only the mode selected by the user. For example, the user may choose to put the vehicle in gas mode, thereby glowing the mode light green, however at the same time gas valve may be in a cut off state due to stalling of engine. Step 1: Open package Package contains one device one wiring harness one user s manual one screw driver for setting the adjustment preset two self tapping screws one mounting clamp one 10A blade fuse one fuse holder Capacitive pickup clip with connecting lug, screw and nut. Economy grade models may have the capacitive pickup clip directly soldered on to the IMPULSE wire. Step 2: Perform wiring Take out the wires from the wiring harness from under the dashboard outwards to the engine compartment through an opening in the hull. Make sure to have the fuse intact in the fuse holder while performing the wiring. Make sure that all copper conductors are well twisted and connected using crimpable 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. Cut MPFI/CARB selector wire for MPFI Vehicles, whereas short it to ground for Carburetor vehicles. Level sensor ground should be electrically connected as close as possible to the device ground. Notice In case of 5, 6, 7 or 8 cylinder vehicles it is mandatory to tap the IMPULSE (RPM signal) from the capacitive pickup clamp by connecting it to a spark plug HT cable of choice, however the IMPULSE cable itself must not come in close proximity to any other HT cables. In case of 3 or 4 cylinder vehicles the IMPULSE can be connected either to the ECU RPM output (best practice) or the ignition coil negative terminal or to a spark plug HT cable of choice. Again, care must be taken to keep the IMPULSE cable away from other HT cables. CDS Series 6
7 PETROL VALVE (NOT REQUIRED FOR MPFI VEHICLE WITH INJECTOR EMULATOR) MAIN GAS VALVE IGNITION KEY FUSE 10A HT SPARK PLUG CABLE LV L SEL IGN GAS PET GND IM P Mansi CDS Series RPM/TIME CAPACITIVE PICKUP CLIP DISTRIBUTOR CUT VEHICLE TYPE SELECTOR WIRE FOR MPFI VEHICLES. SHORT TO GROUND FOR CARBURETOR VEHICLES. VAPORIZER (PRESSURE REDUCER) GAS VALVE MOUNTED ON TANK MULTIVALVE BATTERY NEGATIVE TERMINAL IGNITION COIL LEVEL SENSOR MOUNTED ON TANK MULTIVALVE Figure 2: CDS Wiring Schematic Step 3: Mount Device Connect harness plug to the device. Mount the device under dashboard using self tapping screws attached to the mounting clamp or mount it in one of the side slots. While mounting in side slot an adhesive may be used to hold the device in place (this should be done only after successfully testing the system). If the slot is smaller in size use a fine abrasive tool or sand paper to sand off the edges until the device fits tightly into the slot. Step 4: Test and Adjust Preset Turn on vehicle ignition and test device functions. Vary and test level lights by manually swinging the multivalve float. All four lights must turn on one by one as fuel level increases. In reserve fuel, the first light must blink. Turn on the engine and test device functions as well as set the adjustment preset. Once all tests pass use few drops of an adhesive such as super glue to hold the device in place if mounted in a dashboard slot. Function, CDS-xxxD models (Dome Microswitch type) Notice In case of Dome Microswitch models (CDS-xxxD models), the mode indicator light is not indicative of the state of gas and petrol valves. This light indicates only the mode selected by the user. For example, the user may choose to put the vehicle in gas mode, thereby glowing the mode light green, however at the same time gas valve may be in a cut off state due to stalling of engine. Carburetor Vehicles Upon turning on vehicle ignition, either red or green mode light comes up depending on the mode in which the vehicle was last turned off. The red light indicates petrol mode and the green light, gas mode. In petrol mode, petrol valve CDS Series 7
8 should turn on and stay on, while in gas mode gas valve turns on for a few seconds, as set by the adjustment preset, and then turns off. When gas valve turns off, the green light remains on, indicating that the vehicle is still in gas mode and will start on gas. Start the engine. In gas mode, gas valve must turn on at the time of cranking. Now, with engine on, tap the changeover key. If the vehicle is in gas mode, the model light will turn orange upon tapping of the key (petrol valve opens) and once enough petrol has entered the carburetor, tap the key once more to enter petrol mode (red light) and turning off the gas valve. This completes the changeover operation from gas mode to petrol mode. If the key is tapped while the vehicle is in petrol mode, the mode light will turn off (all valves close) and once the unused petrol in carburetor has been burnt up (as indicated by an engine hiccup), tap the changeover key once more to enter gas mode (green light) and turning on the gas valve. This completes the changeover operation from petrol mode to gas mode. MPFI Vehicles Upon turning on vehicle ignition, either red or green mode light comes up depending on the mode in which the vehicle was last turned off. The red light indicates petrol mode and the green light, gas mode. This informs the user in which mode the engine would start. In petrol mode, petrol valve is on. However in gas mode, gas valve is off whereas petrol valve is on (note again that the mode light is only indicative of the mode, not the state of gas and petrol valves). When the engine is turned on in petrol mode, it stays in petrol mode and the petrol valve remains on while the gas valve remains cut off. But, in gas mode the engine starts with petrol valve on and the mode light blinks informing the user that the system is ready to turn on gas valve and cut off petrol valve at the opportune engine RPM. At this moment, raising the engine RPM and decelerating completes the changeover. This changeover RPM point is set by the adjustment preset. Function, CDS-xxxR models (Rocker switch type) Carburetor Vehicles When ignition is turned on the device enters gas or petrol mode depending on where the rocker switch is pointing. In petrol mode the petrol valve and light turns on. In gas mode the gas valve and gas light turn on for few seconds that can be set by the adjustment preset. This supplies start up gas to the system. Then they turn off. Now, start the engine. In gas mode, gas valve and gas light must turn on at the time of cranking. To change over from gas to petrol, position the rocker switch in middle position so that both gas and petrol valves and lights turn on. Once enough petrol has been supplied to the carburetor position the rocker switch towards petrol position. This completes gas mode to petrol mode changeover. To change over from petrol to gas, position the rocker switch in middle position so that both gas and petrol valves and lights are cut off. In few seconds the engine will begin to have hiccups indicating that the excess petrol in carburetor has been burnt off. At this time position the rocker switch towards gas to turn on the gas valve and light. This completes the petrol mode to gas mode changeover process. MPFI Vehicles Upon turning on ignition, the petrol valve and light turn on irrespective of the position of the rocker switch. When engine starts the device stays in petrol mode if the rocker switch is positioned towards petrol. However, if the rocker switch is positioned towards gas mode, at the time of starting the engine the petrol valve is on and the petrol light blinks informing the user that the device is ready to changeover to gas mode. At this time the engine RPM must be CDS Series 8
9 raised and decelerated to an appropriate level to complete the changeover to gas mode, in which, the petrol valve and light cut off, whereas gas valve and light turn on. This changeover RPM point is set by the adjustment preset. Mechanical Dimensions CDS Series 9
10 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 CDS Series 10
11 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 CDS Series 11
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