MANSI FI Series Compact LPG/CNG Changeover Switch for MPFI Vehicles

Transcription

1 MANSI FI Series Compact LPG/CNG Changeover Switch for MPFI Vehicles 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. 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. Features Description MANSI FI Series advanced 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 indicator LEDs, reserve level being indicated by the first LED blinking. An internal output overload protection protects the Compact Size: 82.0 x 33.6 x 21.1 mm (LxWxH). 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 (FI-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. Application MPFI based LPG/CNG Vehicles OEM fitment and after market conversion kits 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 based Vehicles Harness cable length: 1.85m Standards: Follows UNECE Regulations 67, 110 and 114 ESD Protection in FI-xxS models: All terminals

2 ESD Protection in FI-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. FI Series 2

3 Ordering Information Shown below is ordering code chart with example: FI-MASRR90BCCWBANKGY. RoHS compliance certificate is available on request. FI Series 3

4 HARNESS WIRE COLORS (OPTIONAL) MODEL FUNCTION ELECTRONIC COMPONENTS INTERNAL SWITCHING DEVICE CHANGEOVER SWITCH TYPE LEVEL SENSOR TYPE LEVEL SENSOR LEVEL SIGNAL LIGHT COLOR CONNECTOR TYPE FRONT PANEL THEME PETROL GAS IGNITION KEY GND CAPACITIVE IMPULSE LEVEL SIGNAL FI - M A S R R 90 B C C W B A N K G 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 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 Figure 1: FI Series Ordering Codes Technical Specifications Available upon request. FI 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. FI Series 5

6 Notice In case of Dome Microswitch models (FI-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. 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. FI 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 IGN GAS PET GND IM P Mansi FI Series CAPACITIVE PICKUP CLIP DISTRIBUTOR VAPORIZER (PRESSURE REDUCER) GAS VALVE MOUNTED ON TANK MULTIVALVE BATTERY NEGATIVE TERMINAL IGNITION COIL LEVEL SENSOR MOUNTED ON TANK MULTIVALVE Figure 2: FI Series 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, FI-xxxR models (Rocker switch type) 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 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. FI Series 7

8 Mechanical Dimensionss FI Series 8

9 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 FI Series 9

10 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 FI Series 10