VOGELS VGI User manual

HARDWARE MANUAL
LPG Engine kit
VGI
Vogels Autogas Systems
Ekkersrijt 3016, 5692 CA Son, The Netherlands
Email: [e-mail]
Online: www.vogelsautogas.com

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INHOUDSOPGAVE:
INHOUDSOPGAVE:.....................................................................................................................................................2
1 SYSTEM DESCRIPTION AND INSTALLATION:..................................................................................................4
1.1 I NTRODUCTION .................................................................................................................................................4
1.2 I NLET AND OUTLET SIGNALS :..............................................................................................................................5
1.2.1 Inlet signals .............................................................................................................................................5
1.2.2 Outlet signals ..........................................................................................................................................6
1.3 C OMPONENTS SURVEY ......................................................................................................................................6
1.4 G ENERAL CONDITIONALS BEFORE THE INSTALLATION ..........................................................................................7
1.5 G AS HOSES SURVEY :........................................................................................................................................8
1.6 P RESSURE REGULATORS ..................................................................................................................................9
1.6.1 Pressure Regulator Landi LI02...............................................................................................................9
1.6.2 Pressure regulator Landi IG1................................................................................................................10
1.6.3 Pressure Regulator Emer Palladio:.......................................................................................................11
1.6.4 Pressure regulator installation instructions:..........................................................................................12
1.7 G AS FILTER - UNIT ............................................................................................................................................13
1.8 G AS I NJECTOR R AILS ......................................................................................................................................14
1.8.1 Injectorrail Landi GI...............................................................................................................................14
1.8.2 Injector rail AEBINJ...............................................................................................................................15
1.8.3 Injector rail Valtek Type 34 ...................................................................................................................16
1.8.4 Injectorrail installation instructions........................................................................................................17
1.9 N OZZLES ........................................................................................................................................................18
1.9.1 Nozzle installation instructions:.............................................................................................................18
1.10 W ATER TEMPERATURE SENSOR .......................................................................................................................18
1.11 P RESSURE - MAP- SENSOR AEB025................................................................................................................19
1.11.1 MAP-sensor installation instructions:....................................................................................................19
1.12 G AS -ECU......................................................................................................................................................20
1.12.1 ECU Landi LRE184 / LRE188...............................................................................................................21
1.12.1.1 Electrical Connection Survey Landi Omegas 4 Cyl. ECU .............................................................22
1.12.1.2 Cable and Pin-out information for Landi ECU 4 cyl.......................................................................23
1.12.1.3 Cable and Pin-out information for Landi ECU 8 cyl.......................................................................24
1.12.2 ECU VGI 4 Cyl. AEB2001NC OBD.......................................................................................................25
1.12.2.1 PIN-OUT ECU VGI 4 Cyl. AEB2001NC ........................................................................................26
1.12.2.2 Electrical Connections ECU VGI 4 cyl. AEB2001NC ....................................................................27
1.12.3 ECU VGI 4 Cyl. MP 48 OBD.................................................................................................................25
1.12.3.1 PIN-OUT ECU VGI 4 Cyl. MP 48 OBD..........................................................................................26
1.12.3.2 Electrical Connections ECU VGI 4 cyl. MP 48 OBD......................................................................30
1.12.4 ECU VGI 8 Cyl. AEB2568D OBD .........................................................................................................31
1.12.4.1 PIN-OUT ECU VGI 8 Cyl. AEB2568D...........................................................................................32
1.12.4.2 Electrical Connections ECU VGI 8 cyl. AEB2568D.......................................................................33
1.13 GAS ECU I NSTALLATION I NSTRUCTIONS .........................................................................................................34
1.14 E LECTRICAL I NSTALLATION I NSTRUCTIONS :......................................................................................................35
1.14.1 Fuse Installation Instructions ................................................................................................................35
1.14.2 Injection Signal Cutting Installation Instructions: ..................................................................................36
1.14.3 OBD Connections .................................................................................................................................40
1.15 U SERINTERFACE / G AS S WITCH .......................................................................................................................41
Emergency start procedure on gas .....................................................................................................................41

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2 MAINTENANCE AND SERVICE.........................................................................................................................42
2.1 I
NTRODUCTION ...............................................................................................................................................42
2.2 M AINTENANCE ................................................................................................................................................42
Error codes and diagnostic check .......................................................................................................................42
External check.....................................................................................................................................................42
Filter unit maintenance........................................................................................................................................42
System pressure check and adjustment .............................................................................................................43
2.3 R ECOMMENDATIONS .......................................................................................................................................43
2.4 I N C ASE O F A CCIDENT ....................................................................................................................................43
2.5 ARRANGEMENT OF THE LPG RETROFIT SYSTEM TYPE APPROVAL MARK.......................................43
This document is called: VGI Components and Installation Manual#02.pdf

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1 System description and installation:
1.1 Introduction
The VGI gas system is one of the most modern auto gas systems momentarily available in the market. It concerns
as the name already indicates a sequential slave injection system, which means that for each cylinder the right
amount of gas is being injected.
The system uses the petrol-injector signals as main inlet signal to determine the right amount of gas to be injected
for each cylinder of the engine on that particular moment.
The system normally starts on petrol and when the engine is warm enough, the fuel switch in gas mode, the gas
ECU (Electronic Control Unit) will pick the right moment to switch over to gas.
As first the solenoids on the tank and pressure regulator will open, so LPG can enter the pressure regulator. The
pressure will be regulated at approximately 1 bar overpressure for the rest of the gas injection system. The gas
flows from the pressure regulator through a dry gas filter the injector rail to feed each single gas injector. The gas
filter will block particulars and avoid them polluting the gas injectors. From the switch-over moment (petrol to gas)
the petrol injector signals will be interrupted by the gas-ECU and routed to its micro processor to calculate the gas
injection signals.
Using the petrol injection signal to determine the gas injection signal is called the slave system principle. Moreover
the VGI system works according the “same cylinder” principle, which means that the gas injection signal is based
upon the petrol injection signal of the very same cylinder and rotation of the engine. So no delay which can cause
any control frequency degreasing will occur. So is the gas injection signal for cylindernr. 1 based upon the petrol
injection signal of petrol injectornr. 1 of that very same moment. Each gas injector will inject the same amount of
gas in fuel quantity as it would do on petrol.
Petrol and LPG are two very different fuels and have totally different properties which need to be taken in
consideration for the “translation” of the petrol to gas injection signal. In transient conditions and during the
warming up phase, compensation strategies need to be activated to correct the differences between the two fuels.
To be able to effectuate these compensation strategies, the system uses other inlet signals such as gas
temperature, gas pressure and water temperature. Besides the driving of the gas injectors the gas ECU has also
other functions, such as measuring and indicating the fuel level, driving the solenoids on the tank and pressure
regulator and switch over from one fuel to another. When the car has run out of LPG the system automatically
switches back to petrol and warns the driver with an acoustic sound.
During the installation and maintenance of the system it is possible to check its functioning and check its
diagnostics with the interface loom and interface software installed on a laptop or other PC.
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1.2 Inlet and outlet signals:
1.2.1 Inlet signals
Gas ECU
Cyl.1
Cyl.4
Cyl.3
Cyl.2
Petrol injectors
R.P.M
Engine temp.
MAP
G. Inj.1
G. Inj.4
G. Inj.3
G. Inj.2
Gas temp . & pressure
Pressure
regulator
LPG-tank
Fuel level
Tank solenoid
Gas solenoid
Gas filter
Inlet signal Function
Petrol-injection signals The system uses as main inlet signal the petrol injection signals of each separate
petrol injector to determine the gas injector signal. The VGI system is a “slave system”
and follows the petrol injector signals to translate this signal to a gas injection signal.
The power supply of the petrol injectors is used as an ignition signal for the gas-ECU.
RPM signal The RPM signal (engine speed) is used as a reference parameter to be able to
translate the petrol injection signal to the gas injection signal. Moreover the signal is
used to determine whether the engine is still running.
Water temperature signal The water temperature is used as a condition for switch over from petrol to gas.
Moreover it’s being used for the correction of the fuel differences in cold engine
conditions. The temperature signal can be taken from a temperature sensor that is to
be placed in a water hose or from the original engine temperature sensor.
Gas pressure signal By an increasing absolute gas pressure the density of the gas will increase as well and
so will the energy value per volume unit. To compensate this variation, a gas pressure
correction strategy is introduced to shorten in this case the injection duration. A very
low gas pressure will make the system switch back to petrol.
Gas temperature signal An increasing gas temperature will lead to a lower gas density. To compensate this
variation, a gas temperature correction strategy is introduced to increase in this case
the injection duration.
Fuel level signal The fuel level sensor gives the gas ECU an indication of the remaining fuel in the tank.
The gas ECU displays the fuel level on the fuel switch.
MAP signal The manifold absolute pressure signal can be used as an option to determine the
pressure difference between the inlet and outlet of the gas injectors.
Lambda signal As an option the lambda signal can be connected to the gas ECU to display its value in
the interface software. This can be beneficial during the calibration of the vehicle.

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1.2.2 Outlet signals
1.3 Components survey
1 Fuel switch / User interface
2 Gas ECU (Electronic Control Unit)
3 Dry gas filter
4 Pressure regulator
5 Gas injector rail with pressure and temperature sensor
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Outlet signal Function
Gas-injectionsignal The main outlet signals are gas injector signals which determine the amount of
injected fuel into the engine. Each cylinder has its own injector and signal. Petrol
injection signal of cylinder A corresponds with gas injector A.
Tank solenoid signal This signal opens or closes the solenoid valve on the outlet of the LPG tank, so LPG
can or cannot run to the pressure regulator.
Gas solenoid valve This signal opens or closes the solenoid valve on the inlet of pressure regulator, so
LPG can or cannot run into the pressure regulator and the rest of the system.
Serial communication
with the fuel switch. The fuel switch and Gas ECU are connected with each other through a serial communication link. They inform each other on fule selection, fuel level and possible
diagnostics errors.
Serial communication
with a PC. Using an interface cable and an interface program on the PC or laptop it is possible to check the system and modify settings. The gas ECU and PC communicate trough a
serial connection.

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1.4 General conditionals before the installation
Before the conversion
Check before you start with any conversion of there are any malfunctions or diagnostics in the vehicle on petrol.
This can avoid many problems after the conversion.
Moreover check the vehicle on the following points:
•The state of the engine air inlet filter.
•The state of the ignition system such as spark plugs, spark plug cablesabels, coils.
•Inlet and outlet valves for leakkage and check the valves clearance.
•Functioning of the lambda probe and the catalyst.
When neccessary first make the proper adjustments on petrol and replace broken parts before converting the
vehicle to gas.
The following types of vehicles can NOT be converted with the VGI system
- With engine with a carburettor
- Bosch K-jetronic injection
- Engines with Peak and Hold petrol injectors (Resistance of injector is less than 6 Ohm)
- Direct injection engines (Use a special version of VGI)
Remarks regarding all gas containing components
•Fix all components in the engine compartment according the specific installation manual of that particular
vehicle. Fix the components using the brackets coming with the kit on to solids parts of the vehicle or directly
on to these solid parts.
•Never fix a gas component in or close to space of the ventilation system of the passenger compartment.
•Never fix any component closer than 200 mm away from a heat source such as the exhaust system for
example. In any case this unavoidable, place a heat sheeld of minimum 1 mm thick in between.
•Avoid hoses and tubes to make sharp bends or to fold.
Remarks regarding all components
Add a protective anti corrosion layer to all metal components such as the regulator and brackets and all fixing
points after the complete installation and check-up of the system. Do this to avoid rust and corrosion and a good
conservation of the system and vehicle.
Fix all components according European and or national regulations.

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1.5 Gas hoses survey:
The pictures below give a schematic view of how the (gas) hoses are connected to the various gas components
and therefor how these components are connected to one another.
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Legenda:
1. LPG-inlet
2. 14 mm hose between pressure regulator and gasfilter.
3. 14 mm hose between gasfilter and injectorrail.
4. 6 mm hose between injectorrail and nozzle in inlet manifold.
5. MAP-connection
6. Overpressure connection. The hose has to finish outside of the enige compartment (R-67-01)
Gas hose installation instructions:
•Avoid gas hoses to run closely to heat sources.
•Avoid gas hoses to run past sharp objects and possibly be damaged in time.
•Connect the gas hoses correctly to the components and avoid and check for leakages.

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1.6 Pressure regulators
The VGI gas system is available with different types of pressure regulators. The choice depends on the power of
the engine and the budget of the installation.
LI02
IG1
Palladio
The available pressure regulators are decribed below:
1.6.1 Pressure Regulator Landi LI02
The pressure regulator (Fig. 4) is a single-stage, compensated, diaphragm type, with water-gas heat exchanger, It
is calibrated for a supply pressure of: - 0.95 bar (95 kPa), higher than the pressure present in the inlet manifold for
normally-aspirated vehicles.
Technical specifications:
Weight 840 g.
Working pressure:…………. 0.95 bar (95 kPa) rel.
Nominal operating flow rate:…………..… 30 Kg/h
Working temperature:……………… -20 to 120 °C
Safety valve calibration pressure:. 3.5 bar (350 kPa)
Type approval R67:………….. E13 67R-010056
Shut-off valve specifications:
Type:…………………….…MED Type 71
Coil tension:………………….…..12V DC
Power of coil:……………………..….11W
Normally:……………………….…..Closed
Homologation LPG No.:.E4 67R-0193001
Legend:
1) LPG-input and connection with shut-
off valve.
2) LPG-outlet
3) Pressure adjustment
4) Engine vacuum (MAP)
5) Overpressure valve
6) Water in- and outlet
7) Fixing point
A: Pressure Regulator
B: Filter-unit
C: Injector rail
D: Nozzles
E: MAP-connection
F: Inlet manifold
G: Gas inlet
H: Gas Tube 14mm
I: Gas Tube 14mm
L: Gas Tube 6mm
M: MAP Tube
N: Water heating tubes

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1.6.2 Pressure regulator Landi IG1
The IG1 pressure regulator is a two-stage type. It is heated with engine heat by the engine coolant. The integrated
valve (1 to 3) also filters incoming gas. The pressure regulator adjusts the output pressure to just 1.0 bar (100 kPa)
above the pressure at the compensation port (6) (MAP). The first stage has an operating pressure of 1.6 bar above
atmposperic pressure. The second stage ensures further pressure reduction and is adjustable.
Specifications:
First stage operating pressure:1.6 bar (160 kPa) relative
Second stage operating pressure:.1.0 bar (100 kPa) rel.
Nominal flow volume:.......................................40 Nm3/h
Working temperature:……………………… -20 to 120 °C
Pressure relief flow valve:....................4.5 bar (450 kPa)
Homologation LPG No.:....................... E13 67R-010025
Shut-off valve specifications:
Type:…………………….…MED Type 71
Coil tension:………………….…..12V DC
Power of coil:……………………..….11W
Normally:……………………….…..Closed
Homologation LPG No.:.E4 67R-0193001
The IG1 pressure reducer is available in 3 versions:
IG1 Normal: until engine power of 160 kW.
IG1 Maggiorato: until engine power of 200 kW
IG1 Super Maggiorato: until engine power of 280 kW
Legend:
1) LPG inlet port
2) Filter
3) LPG flow valve
4) LPG outlet port
5) Second stage pressure adjustment
6) MAP connection
7) Water inlet and outlet port
8) Fixing points
A: Pressure Regulator
B: Filter-unit
C: Injector rail
D: Nozzles
E: MAP-connection
F: Inlet manifold
G: Gas inlet
H: Gas Tube 14mm
I: Gas Tube 14mm
L: Gas Tube 6mm
M: MAP Tube
N: Water heating tubes