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FO R TH E R O MAN O I N JE CT I O N S YST E M
1) Definitions 2) Introduction 3) Components 4) Installation 5) Electrical Installation 6) Configuration 7) Tuning and Commissioning 8) Fault finding and diagnosis 9) Maintenance
1)
RIS
Definition
Romano vapour Injection System
MAP TPS ECU Lambda Probe Lean Rich RPM Fast fuel trim Manifold Absolute Pressure Throttle Position Sender Engine Control Unit Exhaust oxygen sensor A fuel air ratio deficient in fuel A fuel air ratio with excess fuel Revolutions per minute Instantaneous fuel trim according to lambda probes information Slow fuel trim Long term trend of fast trim
2)
Introduction
The RIS has been designed in order to adapt vehicles, designed to use petrol as there fuel, to use LPG. This is achieved by injecting LPG vapour into the inlet manifold in sequence with the engines inlet cycle. The use of sequentially operated electro-injectors and complex control measures gives an accurate control of fuel delivery thus giving excellent results in terms of performance, economy and exhaust emissions. As the fuel required is introduced into the manifold near the valves there is no risk of damaging backfires as there is with traditional venturi based systems.
More accurate control of fuel leading to improved fuel consumption and better emissions. Vast reduction of volume of fuel and air mixture in inlet manifold which eliminates damage due to backfires. Possibility of doing euro IV cars after 2004 Universal kit. One box of parts fits all cars. (Cylinder number and size needs to be considered) Disadvantages More expensive Designed for use with cars that are truly sequential on petrol
3)
Components
A. Reducer This is a single stage pressure reducer / vaporiser which uses the cars cooling system to heat the liquid gas to aid vaporisation. The reducer has an integral temperature sender which in order to monitor the temperature of the water jacket and ensure that adequate vaporisation is taking place. The vapour pressure is held at 0.95bar above manifold pressure a single adjuster is provided for initial setup of this pressure difference.
B. Vapour Filter This water heated filter is placed in the vapour supply line between the reducer and the injectors and prevents damaging particles being deposited in the injectors.
C. Injectors
These are Electro injectors activated by the Gas ECU to coincide with the engines inlet stroke. The injection duration is the primary control on the quantity of fuel being delivered for each cycle of the engine although this also relies on the size of the orifice within the injector itself. There are currently 5 sizes of injectors, the table below is an indication of there uses. Cylinder size in cc 200-300 300-400 400-500 500-650 650-850 Suitable injector size O A B C D
A brass nozzle is fitted to each branch of the manifold and connected to the Electro injector with a short length of rubber pipe.
D. GAS ECU The GAS ECU uses input signals in order to calculate the timing and duration of the injector operations. These are Petrol injector pulse, reducer temp, gas temp, gas pressure , MAP and RPM. The MAP and gas pressure sensors are supplied as a separate component. The output is sequential pulses to the vapour injectors.
E. Misc. A LPG liquid filter and various pipes and pipe fittings are also included in the kit.
4)
Mechanical Installation
Fig 1
Fig 2
Fig.4 5)
Electrical Installation The following additional electronic components may be needed when using the OLD KIT
1. Injection emulator 2. RPM multiplier: These components are use to make a true rev signal in multi-coil situations when a tachometer signal is not available. Three types are available. AEB386 is a 2-wire unit, AEB388 is a 6wire unit and AEB287is a 6-wire unit with built in amplifier suitable for cars in the VW group. Fig. 6 shows how they work in a dual coil setup. 3. OBDII Fix: Required on most post 2000 year cars and some American vehicles from 1996. Again three types: AEB424 for American models, AEB426 for European and Japanese and AEB425 for VW group and cars with a 5-wire lambda probe.
Fig 5
Wiring follows the same methods used with the traditional systems such as the Leonardo. A diagram is supplied with each kit the main thing to note is that the 6 and 8 cylinder kits have an extra driver and extra wires for the second bank lambda probes.
Wire colour
Black plug on ECU
Function
Negative or earth
Orange-black Brown
Connect to battery negative. It is good policy to run all earths to the same point. Permanent 12V Connect to battery positive via the fuse supplied. Switched 12V When using 144U connect to +12V of petrol injector Live when on LPG Connect to every thing that is powered when on gas. Solenoids, AEB387, emulators and fixes. Tank level sender Connect to white wire of tank level sender. Tank level sender If old type AEB sender connect to green wire otherwise don t use. Temperature signal Connect to temperature sender on reducer. The sender should be earthed via the body of the reducer. Temperature signal Connect to temperature sender on injector. The sender should be earthed . RPM signal Connect to true RPM signal. Might be able to find suitable signal in the petrol ECU, the coil pack . Petrol gas switch Pass through bulkhead and plug in changeover switch. Lambda probe signal Connect only for diagnostic purposes. Lambda emulation
Purple and black Lambda probe on bank 2. On V6 &V8 engines. Bank 1 is the Grey and black side with number 1 cylinder
Wire colour
Grey plug on gas ECU
Function
Petrol injector Petrol pulse width and Take care to use correct loom loom emulation 144,144INV,144U or 143
Connect in same order as petrol injector loom Any other wires are currently not used. Soldered joints are recommended.
6)
Configuration
Before the vehicle can run on gas a computer has to be linked up so that some basic configurations can be setup. This configuration is carried out using the RISN software and serial lead connection. (Note the dongle must be present on the computer for the software to operate..OLD KIT) From the main menu select the Vehicle Configuration option.
Key Function
F1 Gas Change over
Parameter
Type of revolution signal
Option
Standard Weak
Description
This is the default setting and is used for most vehicles Use this option if no or an intermittent signal is present when using the Standard option. Note where possible endeavour to acquire a signal that works with the standard option. Select the number of Cylinders (injectors) used . One coil per cylinder. Dual coil waste spark system Traditional single coil type signal for the changeover revs Minimum temperature for change over to gas. Max temp 40 usually set > 30
3,4,5,6 and 8 One coil Two coils RPM sensor Revs threshold for Numeric change over value Changeover temperature Numeric value
Key Function
F2 Lambda
Parameter
Type of lambda probe
Option
0 -1 Volt 0 5 Volt 5 0 Volt 0.8 1.6 Volt
Description
Select the correct type of lambda signal based on the original equipment fitted to the vehicle. Select the correct type of lambda signal based on the original equipment fitted to the vehicle. Select the correct type of lambda signal based on the original equipment fitted to the vehicle. Select the correct type of lambda signal based on the original equipment fitted to the vehicle.
Key Function
F3 Gas level
Parameter
Type level sendeer
Option
AEB 0 90ohm
Description
Standard AEB sensor 0-90 ohm sender
Key Function
F4 Modify carb
Parameter
Map the injector pulse conversion
Option
+ or-25%
Description
Adjust so that the petrol pulse width remains the same on gas as it is when on petrol
Filler: should be bayonet type and in recessed box Multivalve incorporates fill valve (8mm pipe), PRV, thermal fuse,
gauge and solenoid controlled feed (6mm pipe). Air Tight Box to vent gas.
Filter and solenoid terminates the pipe and filters the fuel Reducer/vaporizer/regulator/converter converts the fuel
from liquid to gas and regulates the pressure. Need to be orientated correctly and connected to the hot water system. Usually a main and idle adjustment.
Mixer feeds gas into inlet manifold. Change over switch: also monitors engine and switches gas off if
engine stalls.
Sender: Fits on multivalve and sends level signal to switch Relay: switches off petrol Emulator: switches off petrol and fools ECU into thinking everything is
OK.
Open loop system: no electronic control Closed loop control system electronically controls gas flow in
order to protect the catalyst.
Lambda probe monitors exhaust gas and inputs into control system.
obdII fix controls fuel trim errors on euro4 cars rev multiplier: used to find true rpm signal when fitting vapour
injection.
1
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