Installation Manual - Medic-car
Contents
1. Installation Manual QUALITY MANAGEMENT SYSTEM CERTIFIED BY DNV OST 9 4 d a2 IK evision U J anuar yz U 1 U INDEX 1 0 GENERAL 5 44 page 2 0 CONNECTION OF THE INJECTORS CUT OFF WIRING page 3 0 EASY FAST SMART 3 4 CYLINDER LPG PNEUMATIC DIAGRAM page 4 0 EASY FAST SMART 3 4 CYLINDER CNG PNEUMATIC DIAGRAM page 5 0 EASY FAST SMART 3 4 CYLINDER LPG WIRING page 6 0 EASY FAST SMART 3 4 CYLINDER CNG WIRING DIAGRAM page 7 0 OPERATION me incest page 8 0 EASY FAST INTERFACE SOFTWARE na enhn nhan aa page 8 1 MINIMUM REQUIREMENTS TO INSTALL THE SOFTWARE page 8 2 SORTWARE INSTALLATION cert aet ctos genta eate de MDC e page 8 3 INTRODUC HON cc PUE page 8 4 E page 8 5 mue sg page SD nU ION page S528 SIE NS 5 mese S oos oem AGNOS 8 62. a I E 5 2 000 090 0070 70 0 0004 S Z rI5 r 0575555555555 d 1 ine xciv HH PL ERE T a 0 t 1 KI f CF Al NL LIN 6 For cars with air mass metering device ART WAT TARY ANT TNT YH AAA 3 RQ AO SQ STF AIR FLOW METER a SS O ES re n n mn ee Te eee Ep See Water OUT Water 2 6 1 8x1 copper pipe 15x23 rubber water hose LS 6x13 rubber hose Fill in plug 2 Multivalve 3 Riducer with lock off valve 4 Filter 6 Pressure and temperature sensors Injector assembly 4 0 EASY FAST SMART 4 CYLINDER CNG PNEUMATIC DIAGRAM Cg E g E q 2 lt ee i Eei 1 alt Pf AR HB No _ esie OU ar eat P HA aa LLL EE s Jo 2 Water IN ASQ Os MA Dds S NNNM LQ Filling valve N Pressure reducer with CUT OFF Manometer with level sensor Injector assembly 5 6 Pressure and temperature sensor NS NS WS For cars without air mass metering device mamme 6 1 seol pipe 12x19 gas rubber hose
3. ACQUISI 8 7 7620002220670 8 8 265 EIE 8 9 LOAD CAISIBISSRHION T page NO FIRMWARE UMS o e page 8 11 LANGUAGE S MEE page 5 12 DIAGRAMS T TU page TROUBLESHOOTING 2 1 0 INDEX GENERAL RECOMMENDATIONS Before installing the gas system disconnect the battery earth cable unless specified to the con trary by the car maker Attention this may delete the car radio and telephone memories and jam the centralised door locking and anti theft systems In this case you may connect the battery temporarily Always smooth holes after drilling and apply anti rust to the edges Apply silicon to each cable through hole to prevent water from entering the interior Install the control unit as far away as possible from areas where water could infiltrate far away from heat sources e g exhaust manifolds far away from high voltage cables and wherever possible with the connector pointing downwards If the fuse blows do not replace it with one of a higher current rating Do not attempt to open the control unit as this could cause irreparable damage LOVATO decli nes all liability for injury to people or damage to property should its equipment be tampered with In this event the warranty shall also be invalid
4. 6 24 INDEX INDEX During methane autocalibration you must store the maximum gasoline injection time on idle So we need to press the accelerator pedal 4 5 times Between an acceleration and the subsequent wait that the rom are stabilized around at the minimum value REVS 822 mm _ GAS time 0 00 ms G PRES 2 36 GAS 21 PETROL time 3 6 ms MAP n d bar EXTRA INJ T RED EM C CUT OFF DIAGNOSTICS REVS 818 rpm 500 1000 1500 2000 2500 3000 3500 REVS 30 mpm GAS time 4 50 ms G PRES 1 31 GAS 58 PETROL time 2 7 ms MAP n d bar EXTRA INJ T RED EAM CUT OFF DIAGNOSTICS REVS 730 500 1000 1500 2000 2500 3000 Calibration progress y REVS 64 mpm GAS time 0 00 ms G PRES 1 34 bar Gis 59 o PETROL time 3 11 ms MAP n d bar EXTRA IN T RED EE C CUT OFF DIAGNOSTICS Calibration terminated correctly The system is now switched to petrol as per normal ignition REVS 1885 GAS time 0 00 ms G PRES 2 91 bar PETROL ti 0 d ba T GAS 21 ET me 0 00 ms n d r EXTRA INJ 8 RED DIAGNOSTICS REVS 1885 rpm 1000 1500 2000 2500 3000 3500 Repeat this operation 4 5 times and press ENTER to continue Value acquired 18 26 CNG REVS 09 mpm GAS 0 00 ms G PRES 1 34 bar GAS 59 PETROL time 3 39 ms MAP n d bar E
5. GAS TEMPERATURE ADJUSTMENTS By clicking the cursor to LESS the temperature correction is reduced By clicking the cursor to PLUS the temperature corrector is increased On corrector vectors you can see such as percentage changing in the correction coefficients applied then on the map DELAY FOR FIRST SWITCHING TO GAS In this vector is expressed in seconds the waiting time for the first switching to gas related to the gas temperature read at the time of starting the car The dealy time can be modified if necessary In any case comparing the vector value with the switching delay with warm engine par 8 5 2 the system will take the higher value ADJUSTMENT RE ENTRY FROM CUT OFF After you return from a CUT OFF is possible strengthening or weakening the fuel mixture for a number of injected Editing the parameter Adjustment re entry from CUT OFF you can increase or decrease in the percentage the coefficients of the map This change remains for the number of injected set in the parameter Number of injected phases 8 5 6 DIAGNOSTICS This page shows all parameters that the control unit controls through the diagnosis When the gas control unit detects a diagnosis error on the read parameter it performs the action cor responding to the detected error Code Diagnostics ERROR MESSAGES CODE DIAGNOSIS ACTION S101 Connection of petrol injectors None 18 INDEX INDEX 5104 Gas pressure sensor Switching to Petrol
6. INDEX 5 0 EASY FAST SMART 4 CYLINDER LPG WIRING DIAGRAM 2 2 N 2 EX IL el Os t o M Ls 12 a PURPLE PURPLE PURPLE a PURPLE N 4 S ELL S EEESEESSSEEEEEESESS LILLIE LL LLL LL OLLI Lie LLL LLL LLL LLL 7 A saa 6 Pressure and temperature sensor 8 EASY FAST SMART control unit 9 o ooo o 11 65 RPM signal 6 0 EASY FAST SMART 4 CYLINDER CNG WIRING DIAGRAM 22777777777777777777 4 gt f 19 lo ale a _ 5 lt gt lt gt lt gt LIII 9 a SSE gt RPM signal gt RSS AAAS S NO 3 Injector harness gt lt 2222222222272222222222222222222222222222222272222222 LEVEL INDICATOR LEVEL INDICATOR LEVEL INDICATOR STANDARD LOVATO STANDARD LOV1050 STANDARD 0 900HM PURPLE BROWN CONNECTED RED BLACK BLUE WHITE GREEN mum INDEX SS 222222222227 9 N NNSSSSSSNSNSNNNNNSNNANNNSNNANNNNNNANANANSNNANANSANNSNNANNNNNSANSINNNNSDO BLUE WHITE SSS LESSEE TEE a SN QM MM S SSSSSSSSSSSSSSSSSSSSSSSSSS A RED BL
7. EXTRA INJ T RED c TE 9 TARGET bank 1 00 ms This menu allows performing a numerical display of the multiplication coefficients called K used by the control unit in the calculation of the gas injection time The table shows on the vertical axis the petrol injection times while on the horizontal axis there is the number of engine revolutions The red point shown on the map identifies the revolutions references and the petrol injection times with which the engine is working with gas feeding the point is green By increasing the value of K at same PETROL injection time the gas injection time is strengthened while reducing the value of K the contrary operation is performed obtaining a weaker mixture in the system To modify the values of K select one or more boxes of the map and press the key enter A window appears with the following modification modes ABSOLUTE it allows bringing the map exactly back to the value corresponding to the one entered LINEAR It adds or deduces in case a number with negative sign is entered the entered value to from the one already present in the selected box s PERCENTAGE It adds or deduces in percentage the entered value to from the one already present in the selected box s 16 INDEX INDEX EXTRA INJECTIONS SENSITIVITY The EXTRA INJECTIONS are very short injections performed additionally to the normal injection and are carried out during the petrol feeding usually
8. Select this option when the BLACK wire is connected to one of these signals revolution counter wire with square wave signal 0 12 V coil negative WEAK SIGNAL Select this option when the BLACK wire is connected to one of these signals revolution counter wire with square wave signal 0 5 V Static switching on signal with square wave signal 0 5 V These signals can be identified only using an oscilloscope 12 INDEX INDEX TYPE OF IGNITION This parameter is used by the control unit to calculate correctly the engine standard operation which varies according to the type of ignition on which the BLACK wire is connected Set SINGLE COIL for cars with a coil every cylinder if the BLACK wire is connected to the negative pole of one of the coils DOUBLE COIL for cars with a coil every 2 spark plugs if the BLACK wire is connec ted to the negative pole of one of the coils REVOLUTION COUNTER for cars with a coil and mechanical distributor if the BLACK wire is connected to the negative pole of this coil or on all the cars where the BLACK wire is connected to the wire signal revolution counter REVOLUTION COUNTER 2 not used NUMBER OF CYLINDERS This parameter is used to indicate to the control unit how many cylinders has the car and therefo re how many gas injectors shall it control set 3 CYLINDERS or 4 CYLINDERS in function of the number of cylinders of the car RESET By clicking on the push button of program
9. 2nd edition or following versions Memory RAM At least 16 MB Hard disk At least free 20 MB upon installation ocreen resolution 800 x 600 or higher Moreover it is necessary to have installed Internet Explorer 5 5 or later versions 8 2 SOFTWARE INSTALLATION To install the calibration software insert the CD Rom in the reader of the computer and wait until the guided installation window appears Should the installation program not start select Start from the Application Bar Select Execute and enter DAsetup exe where D indicates the CD Rom reader During the installation you will be asked to select the folder in which the program shall be installed We suggest not changing the pre set folder After the installation the program icon is created automatically on the desktop 8 3 INTRODUCTION The calibration software works by hardware key code 7155002 and can be opened without being ne cessarily connected to the control unit To connect to the control unit it is instead necessary that the PC and the control unit are correctly connected by a serial cable Code 0570001 Installation kit and a serial USB adapter if the PC is not equipped with a Serial port Code 4685001 Serial USB adapter Alternatively you can use the SERIAL KIT WIRELESS cod 1685001 Moreover the control unit has to be connected to the 12 volt battery RED BLACK wire to the ground BROWN wire and to 12V under key dashboard ON engine OFF
10. 5106 Gas temperature sensor Switching to Petrol 5108 Switch presence None 5111 Gas temperature too low Switching to petrol with system ready to switch on gas The detected diagnostic errors can be deleted from the memory of the control unit simply by pres sing the key on the bottom right Errors resetting The detected error will be signaled to the driver by the switching on with fixed light of the YELLOW LED and the slow blinking of the green LED on the switch Moreover to ease the identification of the alarm status it is enabled the buzzer present within the switch itself To disable the acoustic alarm press the push button of the switch switching the car feeding from gas to petrol To return to GAS operation it is necessary to shut off and re start the vehicle In the case of diagnosis Gas temperature too cold S111 the display is different the switchover indicates the switch to gasoline but the system is ready to re switch to gas as soon as the condi tions for switching to gas are restored INJECTORS TEST F1 ESC INI e Petrol injectors signal diagnosis injector signal properly read injector signal not read Correspondence verification of gas petrol injectors gt gt gt gas iniector driven gas iniector excluded Petrol injectors signal diagnosis You can check if the wiring of petrol injectors have some problems verifacation of the emulat
11. 8 4 MAIN MENU 1umi 1 OD ees a Configuration Citroen C3_ LPG From this menu it is possible to access all sub menus of the calibration software that are given and individually described here below On the lower part of the page there is the following information lt version 1 5 21 n Configuration Citroen LPG 1 This indicates if the control unit is connected or not to the calibration software It is important to remember that all settings and regulations being performed with the disconnected control unit will be lost upon connection unless they are previously stored in a configuration file When the program is opened it automatically tries to connect to the control unit INDEX If the program does not connect an error window appears At this point verify the connection of the serial interface that the control unit is connected to the battery and to the ground ifthe under key has been disabled for more than an hour to connect it is necessary to enable the panel for some seconds of to star the car By clicking on the icon 1 it is possible to enable Ctrl C or disable Ctrl D the communication 2 This indicates the software version 3 This indicates the firmware version To update it access the sub menu NEW FIRMWARE and select the wished firmware among the suggested ones NB This operation is possible only if INTERNET EXPLORER 5 5 or later version
12. ACK PURPLE S 2 A ee INDEX INDEX 7 0 OPERATION OF THE SWITCH The switch supplied with the kit is equipped with a push button 7 luminous LEDs and an internal buz Ta E B DESCRIPTION Changeover switch ORANGE LED Car running on petrol GREEN LED Car running on gas and diagnosis indicator RED LED Reserve GREEN LEDs Quantity of gas in the tank PUSH BUTTON It is used to select the type of feeding petrol or gas By pressing it it is possible to switch from one type of fuel to the other FUNCTIONS OF THE STATUS LED YELLOW LED GREEN LED BUZZER DESCRIPTION ON fixed Petrol operation ON fixed OFF Gas operation TT Petrol operation Petrol operation ON fixed OFF Blinking The control unit has performed the automatic switching to petrol because gas is finished Petrol operation OF OFF O The vehicle is working with petrol and doesn t switch to gas because it doesn t detect the revolutions signal SWITCHING TO PETROL DUE TO GAS LOW PRESSURE When the switch reaches the reserve and the gas pressure falls under a pre set value the control unit switches automatically to the petrol feeding This occurs to avoid that the engine can operate with a too weak mixture damaging in this way the catalytic converter Before switching again to the gas feeding perform a fuel filling The switching to petrol due to GAS LOW PRESSURE is signaled by
13. D C CUT OFF T RED BEEN C CUT OFF DIAGNOSTICS DIAGNOSTICS Disable any TAP Turn off the engine loads conditioner headlights fan etc Press return to start autocalibration gt Press return to start autocalibration 2 To perform the self calibration follow these instructions 1 Start the car with petrol feeding 2 Start the self calibration procedure by pressing the key ENTER and follow the instructions given on screen The system checks the operating time from the time of starting the engine If the engine has been star ted recently the software will display the following windows REVS 64 rpm GAStime 0 00 ms G PRES 1 33 bar PETROL time 3 06 ms MAP n d bar REVS 41 mpm 4 39 ms G PRES 1 30 bar ee o e 304 ms MAP nd bar S EXTRA INJ T RED BEEN C CUT OFF _ DIAGNOSTICS GAS 60 gt EXTRA INJ T RED C CUT OFF DIAGNOSTICS REVS 764 rpm REVS 741 rem 500 1000 1500 2000 2500 3000 500 1000 1500 2000 2500 3000 3500 Waiting for warming 27 sec 3 Wait checking parameters x E B a SS a CS REVS 839 rpm GAS time 0 00 ms G PRES 2 37 bar GAS 20 PETROL time 3 9 ms MAP bar EXTRA INJ 1 T RED BEEN C CUT OFF DIAGNOSTICS REVS 839 rpm 500 1000 1500 2000 2500 3000 3500 Leave the vehicle idling switched to petrol
14. MEDY 3 Reserved for other S100 System Error type of ECU Diagnosis red lamp is light on n S101 System Error e n er Usual status displayed Error Code and Descrip Connectivity Petrol Injector Check the connectivity petrol injector tion are showed in the 982 injector is disable with gas ECU Diagnostic Table Reserved for other Reserved for other Orange petrol status led Diagnosis red lamp is is light on light on Pressure and temperature sensor Replace the temperature S104 System Error aa PISE Green gas status led Error Code and Descrip Petrol status forced CHIE te Senor Check the Ene Pee OFTON and pressure sensor or Sensor short circuit open circuit or with gas ECU power supply of sensors blinking tion are showed in the ower supply failure the ECU if necessary Long buzzer beep Diagnostic Table PP Reserved for other Orange petrol status led Diagnosis red lamp is Gas is light on light on Pressure and temperature sensor Check the connectivity 5106 System Error Temperature Green gas status led Error Code Descrip Petrol status forced Gas Temperature Sensor a RM A with gas ECU and pressure sensor Sensor blinking tion are showed in the short circuit or open circuit Long buzzer beep Diagnostic Table Reserved for other S107 System Error type of ECU Diagnosis red lamp is light on Change Over Switch N Check the 5V p
15. XTRA INJ T RED C CUT OFF DIAGNOSTICS REVS 09 rpm 500 1000 1500 2000 2500 3000 3500 Calibration complete data transfer in progress x After having concluded the SELF CALIBRATION test the car with gas feeding verifying that it works correctly and correct if necessary the carburetion acting on the map as previously described During the self calibration the car is brought to gas feeding automatically and the slider gives an indi cation of the self calibration progress status The slider moves forward rapidly during the first calibration and then slowly during the final calibration 23 INDEX INDEX 8 8 SAVE CONFIGURATION In this submenu it is possible to save in a file all calibration parameters set in the menu car configura tion This file can then be used to configure other control units installed on cars of the same model and with the same type of fuel METHANE or LPG Remark the selection of the number of cylinders on the bottom of the window appears only if the control unit is not connected to the computer If the control unit is connected to the computer this information is automatically stored Car s brand Name of file to save Citroen C3 Available files Date Je Citroen C3 02 02 2010 10 51 p Configurazione test 15 01 2010 11 26 Control unit type To save select the brand of the car from the drop menu if you wish to file the configuration on the sp
16. ated Always make electrical connections using the relative joints or soft solder them to prevent the formation of false contacts Always observe the current laws and or regulations in the State where the LPG system is moun ted Remember that as per the relative standards all the assembly instructions refer to the driving position Before mounting the electronic control unit make sure the relative fuses are disconnected Do not wash the engine after installation WARNING FAILURE TO OBSERVE THE INSTRUCTIONS CONTAINED IN THIS MANUAL MAY CAUSE THE SYSTEM TO WORK INCORRECTLY OR NOT WORK AT ALL THIS MAY CAUSE DAMAGE TO LOVATO COMPONENTS AND INVALIDATE THE WARRANT Y INDEX INDEX 2 0 CONNECTION OF THE INJECTORS CUT OFF WIRING Verify the polarity of the injectors acting as follows 1 Disconnect all connectors of the original injectors 2 Prepare a multimeter to measure the direct voltage with full range equal to 20V and connect the negative lead to the ground 3 Place the positive lead on one of the contacts of the connector injector 4 Insert the panel and check on the multimeter the measured voltage value If the reading is about 12V that is the positive cable WARNING FEEDING OF THE INJECTORS IS TIMED THEREFORE AFTER SOME SECONDS FROM SWITCHING ON OF THE PANEL IT IS DISABLED IT IS SUGGESTED TO VERIFY THE POLARITY OF ALL INJECTORS SINCE SOME CARS HAVE AN INVERTED INJECTOR WITH REFERENCE TO THE OTHERS After
17. cquisition Documenti recenti 2 Desktop wi Documenti Risorse del computer Risorse di rete Nome file C3 acquisition Salva come Real time acquisitions Annulla By clicking RUN the signals showed into the SCOPE window while clicking STOP the acquisition is stopped You can store the acquisition by using the SAVE button With the LOAD button you are able to view a chart previously saved Acquisition Settings RUN SAVE LOAD mo wes VOY sr Its possible in the settings window to set the time resolution and the amplitude while into the legend you can enable or disable the display of individual tracks The program also offers the possibility to zoom a part of the graph and print it 21 INDEX INDEX 8 7 SELF CALIBRATION In this section it is possible to perform the automatic calibration of the gas control unit in order to obtain a averagely correct carburetion of the car during the gas operation Before starting the self calibration procedure it is necessary to verify that the car is in good petrol fee ding conditions since the gas feeding system bases on the petrol one By pressing the push button Self calibration the following window will open REVS 25 GAS time 4 36 ms G PRES 121 REVS 818 GAS time 2 94 ms G PRES 2 25 GAS 58 PETROL time 3 05 ms MAP n d bar GAS 19 PETROL time 3 0 ms MAP bar EXTRA INJ EXTRA INJ T RE
18. during acceleration to enrich slightly the carburetion increasing the engine yield The extra injections can be recognized by observing the signaling LED or the movement of the point During the gas operation if we manage the extra injections as a normal injection we could enrich too much the carburetion risking to increase the engine revolutions jagging this occurs above all in the methane plant in the LPG ones this problem is usually less relevant By enabling the tick next to EXTRA INJECTIONS SENSITIVITY it is possible to modify the pa rameters concerning the gas extra injections increasing or decreasing the opening time of the gas injectors during the extra injection By shifting the slider towards the negative sign the extra injected gas time decreases and the mixture becomes weaker By shifting the slider towards the positive sing the gas extra injections time increases and the mixture becomes richer By not enabling the tick the extra injection is not considered as such and the gas control unit manages the impulse as a normal fuel injection LEANING ON MAZDA On some MAZDA models during the petrol feeding during acceleration a switching occurs from a SEQUENTIAL type injection mode to a half group injection mode with opening by pairs of the petrol injectors This condition can be easily recognized observing during the acceleration the movement of the RED point on the map or the PETROL injection time During the swi
19. e cific folder of the brand specify the Name of the file to be saved and click on SAVE By selecting a configuration from the list of the available ones it is possible to send by e mail the file that will be automatically attached to the message 8 9 LOAD CONFIGURATION From this submenu it is possible to load onto the control unit an already existing configuration The configuration files are contained in two separate folders one for LPG configurations and the other for the methane configurations Cars brand Available files Date Citroen C3 02 02 2010 10 51 Configurazione_test 15 01 2010 11 26 Control unit type Before loading a configuration it is necessary to access VEHICLE CONFIGURATION and select un der Fuel type methane or LPG according to the configuration that one wishes to load The selection of the number of cylinders on the bottom of the window appears only if the control unit is not connected to the computer If the control unit is connected to the computer the lists suggests only the configurations available for the model of control unit automatically recognized Select the file that you wish to load and click on LOAD e INDEX INDEX 8 10 NEW FIRMWARE It allows you to update the ECU firmware Select programming file Cerca Firmware ck Eee 9 Lovato 3 03000 Ip4 1 LovatoPlus_ 01021 Ip4 Documenti E L
20. eferen ce set under REVOLUTION THRESHOLD FOR THE SWITCHING REV THRESHOLD FOR SWITCHING This identifies the engine revolutions at which one wishes to perform the petrol gas switching SWITCHING DELAY WITH WARM ENGINE This indicates the minimum time from the start of the engine for the switching from PETROL to GAS We suggest setting a time not shorter than 25 seconds to assure the correct operation of the sy stem 13 INDEX INDEX SWITCHING TO PETROL FOR LOW GAS TEMPERATURE If the temperature of GAS falls below the threshold set the ECU switches to the petrol mode and the corresponding diagnosis is activated code 5110 The ECU automatically back to gas mode when the gas temperature allows it ANTICIPATE INJECTION SEQUENCE This is a guided procedure allowing the automatic acquisition of the injection sequence as well as the enabling of an advance phase shift of the gas injection the entity of the phase shift depends also on the command Number of main bearings of the page F3 Sensors This advance can increase the car operation above all in case of gas injectors far from the suction manifold This function is to be used only if really necessary since it disables the characteristic of GRA DUAL PETROL GAS switching performing such switching instantaneously IDLE OPERATION GAS By enabling this function the car at minimum always works by GAS feeding default and suggested option CHANGE BACK TO PETROL Dur
21. f the power supply and try None again to program ECU ECU Microprocessor Replace the ECU Programming Error during Error initialization Pop UP window with er ECU Programming ror code and description doesn t run Turn off the power supply and try None again to program ECU ECU Microprocessor Replace the ECU Programming Error during start Error programming Pop UP window with er ECU Programming ror code and description doesn t run Turn off the power supply and try None again to program ECU ECU Microprocessor Replace the ECU Programming Empty size of Error input data Pop UP window with er ECU Programming ror code and description doesn t run Input Data File corrupted None Replace the file Input Data File Programming Wrong mode of Error encryption Pop UP window with er ECU Programming ror code and description doesn t run Input Data File corrupted None Replace the file Input Data File Generic programming error Programming Error Pop UP window with er ECU Programming ror code and description doesn t run Turn off the power supply and try None again to program ECU ECU Microprocessor Replace the ECU Programming Error during Re Error cord programming Pop UP window with er ECU Programming ror code and description doesn t run Turn off the power supply and try None again to program ECU ECU Microprocessor Replace the ECU Check the connectiv
22. having verified the polarity of the injectors it is possible to connect the injector emulation har ness Cut the petrol injector negative wire The wires of a single color have to be connected to the injectors while the corresponding ones with a black stripe have to be connected to the gasoline injection control unit Respect the matching between the sheath of the injector emulator wiring and the gas injector On the injector control where the gas injector A has been connected pneumatically it is necessary to connect the wires of the sheath of the injector emulator wiring BLUE BLUE BLACK wires as shown on the following drawing The same is valid for the other injectors In case of connection on a 3 cylinder car the YELLOW AND YELLOW BLACK wires have to be left disconnected 2 2 BLUE BLACK A BLUE gt lt WHITE RED RED BLACK B RED 9c GREEN BLACK C GREEN lt YELLOW BLACK D YELLOW gt lt Wiring connection description Injector Type of car i BICID Cylinder X X X 4 Oylinder X X XX PETROL INJECTORS INDEX INDEX 3 0 EASY FAST SMART 4 CYLINDER LPG PNEUMATIC DIAGRAM IL I PILI E 6 Gj
23. ing the return to minimum the car switches for some seconds to petrol and then returns to gas feeding avoiding in some cases the shut off during this phase It is suggested to use this function only if necessary The va Revolutions for identifications of the minimum Giri per identificazione del mi nimo determines the number of revolutions under which this procedure is enabled PETROL The operation at minimum under the set value of revolutions is always by petrol fe eding The restoration of gas operation occurs when the revolutions exceed the set value This function has to be used only when the operation at minimum by gas feeding is impossible insta ble and results in frequent shut offs The indication that the system is working by petrol feeding does not occur by means of indication on the switch that remains on gas feeding but by the reading on the computer of the gas injection time that becomes null In fact in this phase the switch keeps signaling the gas operation and the gas solenoid valves remain enabled In case of presence of the advance converter which remains fed in this phase it is necessary to pay attention that introduced advance does not disturb the operation of the system OPERATION AT HIGH REVOLUTIONS GAS The car works on gas If the gas time limit is reached gas exceeds the time of cyvle a small correspondent quantity of petrol is added at the same time The signalling on the switch remain on gas o
24. is installed 4 This is the name of the car configuration If a previously saved configuration is loaded on the control unit the name of such configuration will appear If the control unit is new appears the message StandardSmartLovato 1 followed by LPG 5 Click on this icon to exit the program 8 5 CAR CONFIGURATION This menu consists of 4 screen pages in which it is possible to set the parameters managing the be havior of the gas control unit On the upper part of all pages there is a summarizing display of the current values of the general ope ration signals of the system G PRES 1 30 MAP n d EXTRA INJ CUT OFF DIAGNOSTICS rpm GAS time 433 ms PETROL time 3 03 ms 1 This box shows whether the car is PETROL or gas fed as well as the gas level indicator moreo ver there is the push button allowing the switching via software 2 This box shows REVS These are the engine revolutions measured in real time by the gas control unit T GAS This is the gas temperature detected by the temperature sensor positioned on the filter 3 This box shows the gas gas time and petrol Petrol time injection times For each variable it is possible to have one or two values according to the number of main bearings set in the drop menu Number of main bearings of the window Sensors 4 This box shows GAS PRES This is the pressure difference between the gas present in the gas injector
25. istic parameters previously set for the correct operation with the type of fuel used Select LPG for cars with LPG feeding METHANE for cars with METHANE feeding By selecting LPG or METHANE moreover it changes also the folder where the configuration files are saved see Load configuration INJECTION TYPE This function allows selecting the enabling strategy of the gas injectors with reference to the type of system SEQUENTIAL SUGGESTED OPTION The GAS injector is enabled at each PETROL injection FULL GROUP The GAS injector is enabled every 2 PETROL injections INJECTORS TYPE This window allows selecting the type of GAS injectors supplied with the Installation kit Should a previously saved configuration be loaded this window shows the type of gas injectors foreseen in the configuration file If the type of gas injectors previously saved in control unit does not correspond to the ones shown in this window a warning message is displayed To solve the problem it is necessary to load a configuration file which foresees the installed injectors or to change the type of gas injectors set in the control unit Should the injectors installed on the car not match the selected ones the injectors are piloted by wrong parameters causing gas malfunctions or the damaging of the same injectors TYPE OF REVOLUTION SIGNAL It pre arranges the control unit for the detection of the revolution signal by means of the BLACK wire STANDARD
26. ith er Update firmware Input Data File Input Data File corrupted Reinstall the Calibration Error Input Data File ror code and description not possible Replace the file Software Tool Eor ndeoin Check the version of Internet Explorer Communication r ecrypung Pop UP window with er Update firmware It s requires the presence of Internet of file of None ee Operation System on the PC i l Error ror code and description not possible Explorer version 5 5 or next with en programming cryption at least 128 bit Programming Wrong voltage of Error programming USB COM port problem with PC Port Connectivity of Serial Interface or ECU Functionality of Serial Interface or ECU Replace the ECU or the PC or the Serial Interface Device as the case Communication Communication Pop UP window with er ECU doesn t 01 missing ror code and description communicate Pop UP window with er ECU Programming ror code and description doesn t run Check the power ECU supply and try Internal ECU Power Supply again to program ECU Replace the ECU Programming Error cancelling Error flash Pop UP window with er ECU Programming ror code and description doesn t run Turn off the power supply and try None again to program ECU ECU Microprocessor Replace the ECU Programming Error during Error initialization Pop UP window with er ECU Programming ror code and description doesn t run Turn of
27. ity of ECU fuse amp Check that the USB COM USB COM port problem with PC Port power supply port of PC is running and Connectivity of Serial Interface or ECU Replace the ECU or the Connection Communication PC or the Serial Interface Pop UP window with er ECU doesn t None Error missing ror code and description communicate Functionality of Serial Interface or ECU Check the connectivity and functionali virtual device is number ty of serial interface device from 1 to 9 Check the connectivity of ECU fuse amp Error loading the i Replace the Serial Interfa c02 Connection idanpesd n dala None Pop UP window with er ECU doesn t Connectivity of Serial Interface or ECU power supply ce Devic or the EGU th Error ror code and description communicate Functionality of Serial Interface or ECU Check the connectivity and functionali ty of serial interface device C03 inate os None Pop UP IDCM un et E doesn Firmware of ECU Use the correct Input Data File Error not compatible ror code and description communicate Sonne cuon olv None PC Software calibration tool Upgrade the software version el not INDEX of the ECU CaSe INDEX ERROR ERROR CODE INDICATOR LAMP DIAGNOSTIC WINDOW DIAGNOSTIC SYSTEM CODE CATEGORY DESCRIPTION ON SWITCH ON SOFTWARE BEHAVIOUR TROUBLE AREA ERROR REMEDY 1 ERROR REMEDY 2 ERROR RE
28. ning linearly the GAS carburetion concerning the second main bearings when the two main bearings work slightly un balanced In detail by acting on this parameter in case 4 cylinder cars the carburetion of the gas injectors B and C is unbalanced with reference to that of the gas injectors A and D GAS LEVEL INDICATOR This indicates to the gas control unit what type of level sensor has been used LOVATO1050 set LOVATO AEB 1050 if to the gas control unit it is connected a sensor with standard output signal LOVATO1050 For the connection refer to the assembling diagram of the gas control unit LOVATO 526025 set LOVATO if to the gas control unit it is connected a sensor with standard output signal LOVATO1050 For the connection refer to the assembling diagram of the gas control unit 0 90 ohm set 0 90 ohm if to the gas control unit it is connected a sensor with output signal ranging from 0 to 90 ohm For the connection refer to the assembling diagram of the gas control unit Not standard Set this option if it is connected LPG or METHANE resistive sensor with a variable STRAIGHT signal lower value Ohm with empty level and higher value Ohm with full level Not standard inverted Set this option if it is connected LPG or METHANE resistive sensor with a variable INVERTED signal higher value Ohm with empty level and lower value Ohm with full level References for the not standard indicator This option appear
29. or cable wiring Verification of gas petrol injectors correspondance When the car is gas powered you can exclude a gas injector and activate the correspondent petrol injector if the connection aren t correct a cylinder isn t powered and another is double powered gas and petrol with obvious ano malous operation of car s engine When you exit from thi window the gas injectors are activated If the advance of injection sequence is activated it isn t possible to execute this test TIMERS Fi F2 Error Injectors test GAS TIMERS PETROL TIMERS ABSOLUTE 21257 ABSOLUTE 8 25 MAINTENANCE gt 360 hours 31 57 gt NOTE timers display format is hh mm NOTE timers display format is hh mm STARTING IN GAS MODE CRANK NUMBER 0 RESET NOTE function is disabled after 10 start on gas 19 8 6 INDEX Operating gas time The absolute and partial hours of gas mode operating are visualized The counter of partial hours can be erased by the user after a maintenance Operating petrol time The absolute hours of petrol mode operating are visualized Forsed gas star The number of forced gas start is visualized If you use ten time forced gas Start if you use five time forced gas start this function is unable to be used in order to safeguard the 5 carburation Only with a PC you can reset the counter for enable again
30. ovatoPlus 3t01090 Ip4 d LovatoSmart_ 00100 Ip4 LovatoValvetronik 03001 1 4 Risorse del computer Risorse di rete Nome file Tipo file 34 cylinder programming files l Annulla Choose the right firmware to be inserted and follow the instructions 8 11 LANGUAGE It is possible to choose the language of the software by clicking on language buttom and select the one you want on the menu Italiano w English Deutsch Francais Portugu s Hrvatski P nne T rk e Polski Slovensky esky Espa ol Shqip 2 8 12 DIAGRAMS It is possible to see wiring and pneumatic diagrams by clicking on diagrams buttom and choose the desired pattern CNG electric diagrams LPG electric diagrams CNG pneumatic diagrams LPG pneumatic diagrams 25 INDEX INDEX 9 0 TROUBLESHOOTING ERROR ERROR CODE INDICATOR LAMPS DIAGNOSTIC WINDOW DIAGNOSTIC CODE CATEGORY DESCRIPTION ON SWITCH ON SOFTWARE SYSTEM BEHAVIOUR TROUBLE AREA ERROR REMEDY 1 ERROR REMEDY 2 ERROR REMEDY 3 Check the connectivity of ECU fuse amp Check that the USB COM power supply port of PC are running or Check the connectivity and functionali virtual N device is number ty of serial interface device from 1 to 9 Communication ECU is Pop UP window with er ECU doesn t None Use a correct model of ECU Error incompatible ror code and description communicate Communication Can t opening None Pop UP window w
31. ower S108 System Error iiis ot RONE Error Code and Descrip HUU BONG U iae problem with connectivity Check the supply of the Change Over Rope Hi wien Switch All LEDs are off mode with gas ECU or the ECU as the case tion are showed in the or power supply failure Switch Diagnostic Table 5109 System Error Reserved for application Reserved for Diagnosis red lamp is Orange petrol status led light on Car power exceeds the power redu Gas temperature is light on Petrol status forced S111 System Error Error Code and Descrip Gas is too cold cer use a post heating or a major Check water heater circuit too cold Green gas status led Ready to switch gas m tion are showed in the reducer blinking Diagnostic Table 27 INDEX
32. peration Removing the cue from the check box you disable this function and if the gas time limit is reached the car automatically changes back to petrol with consequent signalling on the switch PETROL The car temporarily runs on petrol mode at high rom and high engine loads You can set the number of rom and the injection time over which car will run in petrol both condi tions must be met to run on petrol mode In this case the switch is on gas mode PETROL CONTRIBUTION You can make a small contribution of petrol during gas mode You can set the injection time beyond which you can get the petrol contribution and set the millisecon ds of contribution This contribution is then subtracted from the petrol injection time before calculating the correspon ding gas injection time 14 INDEX INDEX 8 5 3 SENSORS In this window it is to the level sensor REVS 781 rmm GAStime 4 36 ms G PRES 1 20 A mem PETROLtme 305 ms MAP 2 EXTRA INJ _ RED EE DIAGNOSTICS Number of banks EN SAS eve indicator Increase GAS pipe filling time NUMBER OF BANKS This selection is necessary to set the number of the main bearings in which the engine is subdi vided SECOND BANKS CORRECTOR By setting the number of the main bearings on two this item appears On cars equipped with two front lambda probes this allows modifying strengthening or weake
33. reset cancel all settings of the control unit and loads the default configuration 8 5 2 SWITCHING This window allows selecting the switching mode from petrol to gas and vice versa F1 F3 F4 F5 F6 ESG m Diagnosys A REVS 722 rpm GAS time 4 48 ms G PRES 1 31 bar fo lec PETROLte 31 ms MAP 3 2 2 EXTRA INI RED C DEA DIAGNOSTICS Anticipates injection sequence L deceleration Petrol ae in gas Switching in deceleration Idle operation Rev threshold for switching 1600 rpm E GAS Change back to petrol E Petrol Switching delay with engine 25 5 Switching to petrol for low gas 0 perature Operation at high revs GAS Petrol addiction once time gas limit is reached Petrol addiction Modify this setting only with the engine aff Petrol SWITCHING During acceleration The switching from PETROL to GAS occurs during acceleration when the car exceeds the num ber of revolutions set under REV THRESHOLD FOR SWITCHING During deceleration The switching from PETROL to GAS in this case can occur following any of these two conditions When the number of engine revolutions exceeds the reference set under REV THRESHOLD FOR SWITCHING and then falls under such reference When a Cut Off condition occurs with the number of engine revolutions higher than the r
34. s and that present in the suction manifolds detected by the pressure sensor inserted in the filter 5 Within this box there are three warning lamps which light when the car is in the conditions of EXTRA INJECTION CUT OFF and DIAGNOSTICS EXTRA INJECTIONS If the program detects any extra injection the corresponding warning lamp lights with YELLOW color and becomes GREEN for 2 300 ms so that it is visible for the operator when the extra injection occurs CUT OFF The warning lamp lights in RED color when the car is in CUT OFF status DIAGNOSTICS The warning lamp lights in RED color when an error is detected by the diagnosis system of the plant By clicking on Diagnosis the diagnosis window is opened to monitor the type of error 11 INDEX INDEX 8 5 1 CONFIGURATION In this window it is possible to set the parameters that characterize the car F2 F4 F5 F6 5 EB NI Map UON M MZ 22 REVS 746 rpm GAS time ms G PRES 1 30 GAS c BENED 3 03 ms MAP nd bar 2 EXTRA IN __ CUT OFF T RED ad C DIAGNOSTICS Fuel type LPG Rev signal type TTE Injection type Ignition type double coil Injector type ovato be Number of cylinders 4cylindes REMARKS RESET WARNING ALL PARAMETERS HIGHLIGHTED IN BLUE HAVE TO BE MODIFIED WITH DISABLED PANEL AND OFF SWITCH TYPE OF FUEL This selection is used to initialize the control unit with the character
35. s only if in the box TYPE OF GAS LEVEL SENSOR it is set NOT STANDARD or NOT STANDARD INVERTED Set the reference values necessary for the setting of the level sensor as follows manually shift the indicator of the sensor star ting from the full value and write down the indi cated value for each reference RESERVE 1 4 2 4 3 4 enter the noted values in the corresponding bo INDEX INDEX xes press the push button ACCEPT On the switch it is therefore possible to see the following changes Reserve LEVEL value when the LED of 1 4 switches off and the reserve one switches on Reference 1 4 LEVEL value when the LED of 2 4 switches off Reference 2 4 LEVEL value when the LED of 3 4 switches off Reference 3 4 LEVEL value when the LED of 4 4 switches off GAS PIPE FILLING TIME Usually the gas control unit to prevent the possible shut off of the car during the switching from one type of fuel to the other enables the gas solenoid valves 5 seconds before performing the switching this allows a greater filling of the piping It is possible to disable this function In this case the gas solenoid valves are enabled only for about 1 second WARNING IT IS SUGGESTED NEVER TO DISCONNECT THE PETROL PUMP 8 5 4 MAP EL F2 F3 F5 F6 ESC Sensors mom Diagnosys 22 REVS 791 rpm_ GAS time 4 72 ms G PRES 1 30 s PETROLtme 35 ms MAP bar 2
36. tching from one injection mode to the other it is possible to observe that the injec tion time usually displayed acquires a value equal to about the half of the one previously carried out for example from about 8 ms it shifts to about 4 ms and a continuous variation of the RED point is displayed between these two values or in some cars such point remains fixed on a given number of revolutions to return consequently to the initial PETROL injection time During the gas operation this work condition can cause malfunctions since when the injection switches from a sequenTIAL mode to a half group mode low injection time the GAS carburetion tends to enrich very much causing rips Therefore to avoid this problem just enter under Weakening on MAZDA a proper value to con trast this trend TARGET By pressing the push button REC it is possible to store on screen the petrol time PETROL time with petrol feeding on a given area of the map to ease the comparison with the petrol time PE TROL Time with gas feeding in the same condition 17 INDEX INDEX 8 5 5 ADJUSTMENTS M el REVS 0 GAS time 0 00 ms G PRES n d bar PETROL time 0 00 ms MAP n d EXTRA INJ T GAS nd nd EE CUT OFF DIAGNOSTICS Switching delay with gas temperature 0 5 10 15 120 90 Adjustment re entry from cutoff Number of injected phases
37. the switch with the switching on of the YELLOW LED petrol operation the alternated switching on of the RED LED indicator and of the 4 GREEN LEDs and by the acoustic warning given by the internal buzzer To restore the switch to the normal operation it is necessary to press the PUSH BUTTON once the YELLOW LED remains switched on to indicate that the car is petrol fed and the buzzer stops buzzing 8 ion m Petrol operation ON fixed Blinking Control unit prepared to switch automatically to gas OFF FF INDEX INDEX EMERGENCY Should the car not be able to start with petrol feeding e g due to problems on the petrol pump etc it is possible to start it directly with GAS feeding To do this just start the car keeping the switch push button pressed WARNING DIRECT GAS STARTING IS TO BE CONSIDERED AN EMERGENCY OPERATION ITS REPEA TED USE CAN LEAD TO DAMAGES TO THE CATALYTIC CONVERTER OR THE SWITCHING ON OF THE CHECK ENGINE WARNING LAMP DIAGNOSIS Should a diagnosis error be detected and the feeding be consequently switched to petrol the ORAN GE LED is fixed ON petrol feeding the GREEN LED blinks and the buzzer buzzes intermittently the LEDs of the level indicator are OFF To interrupt the acoustic signaling it is necessary to press the push button of the switch INDEX INDEX 8 0 EASY FAST INTERFACE SOFTWARE 8 1 MINIMUM REQUIREMENTS OF THE COMPUTER TO INSTALL THE SOFTWARE Operating system Windows 98
38. this function DISPLAY This page shows all signals managed by the control unit 1 2 3 4 5 6 7 8 9 10 11 12 This shows the number of engine revolutions in real time rpm This shows the gas temperature expressed in C This shows the gas pressure present in the filter bar This shows the gas injection time in real time ms This shows the petrol injection time in real time ms This shows the level of gas present in the tank This allows the switching from petrol to gas by computer This indicates whether the car is working in gas or petrol mode This supplies useful hints on the correct dimensioning of the nozzles installed on the gas injec tors This supplies a visual indication on some operation statuses of the car and of the plant with gas CUT OFF extra injections diagnostics or to enable the acquisition function This allows returning to the main menu This shows the presence or not of the key on signal A red cross will apear over the key if the Signal is not present INDEX INDEX 8 6 1 ACQUISITION ALOVATO By clicking on acquire the window displays opens the following window By clicking on REC the program starts to record the tracks of the various set variables When the push button STOP is pressed the program ends the recording and opens the window to save the recording Save acquired data with name Salva in Acquisition egt ED C3_a
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