# Software documentation for the AGIS gas injection controller

(AppStudio Gas Injection System)

Project and realization:

App Studio s.c.

00-707 Warszawa

ul. A. Ponikowskiego 1

tel. (0 22) 651-00-80

Authors:

Micha³ Anuszewski

mailto:michala@appstudio.pl

Janusz Zambrzycki

mailto:jzambrz@appstudio.pl

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# Introduction

We are pleased to present our new product – AGIS i8 sequential gas injection controller.

It has been generally designed for application in cars with modern OBD2 systems for fuel delivery diagnosis; however it may be also installed in older car models.

Due to modern construction and efficient processor it gives the possibility to meet strict standards concerning fumes emission while maintaining the drive dynamics similar to that when gasoline is used.

# Installation tips.

Before soldering the ends of the beam, it is required to disconnect the beam pins from the controller socket.

Start connecting the beam from the mass.

The controller casing should be installed in possibly cold places far from electric interference sources (such as: high voltage wiring etc.)

Controller setting should be done after each injectors’ calibration or pressure regulation.

Requirements:

- Connecting lambda probe,

- Installing all cut-outs specified in the beam diagram.

# Possible problems during installing the system.

· Installed controller does not switch to gas.

a) Standard “switch to gasoline” pressure set in the controller is: 60 kPa and therefore, if the reducing valve maintains lower pressure the controller will not switch to gas.

It is recommended to screw in the regulating screw on the reducing valve, switch into gas and regulate the pressure to 100 kPa.

b) Original temperature limit in the controller casing is 85 ºC. Accidental modification of this value to for example: 15 degrees may disable switching the controller into gas.

· After switching into gas the diagnostics show long injection times ( 40 - 120 ms)

Possibly the emulator has been connected the wrong way on one or more cylinders or the controlling impulses polarisation on injectors is set inversely.

First of all the beam connection should be checked or set the option: Gasoline injectors switched with 12V signal” in the “advanced settings”.

· Engine wobbles on slow revolutions when working on gas

Cause: Too high or uneven output of gas injections applied. It is recommended to use the closest smaller size or reduce the output in the installed ones.
Software downloading

The CD supplied with the LPG controllers contains the‘Agis_i8.exe’ software.

It enables tracking the motor work parameters as well as the controller calibration.

After starting, the software shows in the real time the motor work parameters registered by the LPG in figures as well as in the form of bar graphs

These are the following parameters:

- Motor revolutions,

- Injection times for all injectors (gasoline – red, gas – green),

- Temperature of the heater,

- Temperature of the gas stream,

- temperature inside the controller casing,

- pressure,

- Lambda sonda signal,

- Feed voltage (only during work with the LPG).

In the left top corner there are keys for switching the controller into gasoline, gas and setting for AUTO mode, meaning automatic switching into gas upon fulfilling relevant conditions (temperature and revolutions).

At the bottom, the application shows the state of connection with the LPG controller (connected/disconnected), and errors indicated by the controller.

# Controller calibration – step by step.

The first action upon the controller installation is the configuration of the basic parameters which are shown on the tab ‘Configuration’ and further tab ‘Base settings’.

This is the place to set the parameters for automatic switching into gas, the source of ignition signal (single coil, double coil, rev-counter etc.)

At this step, also the minimum pressure for the controller to recognize empty LPG tank is to be chosen. The pressure should not be lower than 70% of the reference pressure (the pressure maintained by the reducing valve during work with gas on low revolutions).

Additionally the type of LPG injectors’ type should be chosen from the list.

The next activity involves the LPG controller calibration.

After setting the auto calibration the software will sequentially switch the controller from gasoline into gas, and generate the corrections to finally input final values into the controller after a few such cycles.

Upon successful process of calibration the controller may be switched into ‘AUTO’ mode and perform the test run.

In special cases when the corrections are generated in the auto calibration process and differ from correct values, the application informs the user. There are two situations possible:

· The size of LPG injectors chosen is too large, and therefore during the auto calibration the following message is displayed:

· When the LPG injectors are too small, the following message may be displayed:

These messages do not stop the process of auto calibration and only indicate the necessity of installing new LPG injectors.
Advanced settings.

The tab ‘Advanced settings’ provides access to special settings and options of the AGIS i8 controller.

Some of these crucial settings are described below:

## Main correction.

It is a correction partially permanent and temporary and states the LPG injection duration increase in milliseconds against fuel durations.

On the basis of correct chosen LPG injectors, the main correction should incorporate between 1 ms and 3 ms.

The correction is generated automatically in “Autocalibration”, but it is also possible to be amended manually. In the case of manual amendments, two different main corrections may be specified for the chosen LPG injectors (various engine cylinders).

The described situation is presented below: even cylinders have a different correction from the odd ones. Marking the 'check-box' with the injector number defines that for this very injector the injection duration is to be specified using the second main correction.

The example above shows 6 'check-boxes' which states the amount of injectors worked by one controller.

Note: The procedure ‘Autocallibration’ generates only one main correction.

For manual modifications of the Main correction it is handy to change it using the indicator light from the tab ‘Autocallibration’:

It may be edited and input using the key or changed smoothly in steps of 0.025ms using the indicator light:

## Corrections for the variation pressure.

Reference – the gas pressure injector’s slats during work with gas on low revolutions. Default set to 100kPa and that is the way for the reducer to be regulated.

Inclination – describes the mixture enrichment while the pressure on the slat decreases.

Examples:

a) reference – 100kPa, inclination – 1 -> at the pressure decrease to 90kPa, the gas injection duration will be extended by 10%

b) reference – 100kPa, inclination – 0.2 -> at the pressure decrease to 90kPa, the gas injection duration will be extended by 2%

c) reference – 100kPa, inclination – 1 -> at the pressure decrease to 90kPa, the gas injection duration will be extended by 5%

d) reference – 100kPa, inclination – 0.2 -> at the pressure decrease to 90kPa, the gas injection duration will be extended by 1%

In a situation when the LPG injectors are chosen correctly, the inclination is equal to 1.

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## Type of gasoline injection.

The LPG controller may work, depending on the fuel injection type in the following modes:

If the LPG controller is installed in a car with semi sequential or non sequential fuel injection, it is required to supply the controller with this information. In this situation the LPG controller behaves as follows (according to description given in the application):

Corrections for injections duration.

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The corrections table placed below the graph helps to set the LPG controller correctly depleting or enriching the mixture with tolerance +/- 25% for sequences of fuel injections duration.

The green square on the injection duration scale indicates actual fuel injection duration.

Corrections are to be input into fields upon marking the group of cells and opening the menu.

With the right mouse click.

Edition of single cells is possible by double click on the cell, which is shown in the drawing below:

Note:

To activate the corrections it is required to input it into the device.

Map of corrections.

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The AGIS i8 controller enables a very precise adjustment of the mixture in every engine work area. It is shown in the map of corrections in the tab ‘Map’.

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The above graph shows a sample map of corrections, which enrich the LPG mixture for high and low revolutions up to 12%.

Using the map enables corrections of the LPG mixture within a range between –50% and +50%.

The edition of map cells is identical as for tab ‘Corrections’.

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Note:

The map should be input into the device to start working.

The green square on the map indicates present engine work conditions, meaning the fuel injection duration and revolutions.

# Automatic calibration durring drive (Create Map).

Automatic LPG tunning is enable when additional MAP sensor is plug-in and manifold intake pressure is meassured. Picture below describes how to connect this sensor to AGIS controler wires:

After correct MAP sensor connection we can activate PC application property page called “Map create”, which shows actual manifold intake pressure in range from 0 to 100kPa and meassured points.

Manifold intake pressure below 40kPa indicates low engine load and intake pressure greater than 90kPa indicates highest engine load.

Durring vehicle calibration simple injection maps are calculated, one while driving on gasoline, second – on LPG. Software then calculates corrections based on this two maps.

After this software displays corrections as suggested settings on property page “Corrections”.

Attention: It’s strongly recommended to run automatic calibration durring drive after autocalibration on idle.

Autocalibation procedure algorithm:

1. Turn AGIS controller to “gasoline mode” and press button “Start”.

2. Make model drive on gasoline and try to hold intake pressure in the range from 30kPa to 100kPa.

Attention:

Durring drive Lamda sensor must ‘work’. Long acceleration is not permitted. Optimum driving time – 10 min.

3. Then do the same on “LPG mode”.

4. After this stop calculation (button “Stop”). We should get map with points in range 30 to 100kPa both on gasoline and LPG:

5. Press button “Calculate correction”. Software will show page “Corrections” with suggested settings:

Manual corrections modification is enabled. Then settings can be written to device.

Attention: suggested corerctions are not automatically written. User must write it by pressing “Write to device” button.

# Calibration of the gas level sensor.

The tab ‘LPG level sensor” shows a board which helps to choose the correct sensor or its calibration, if non standard sensor is installed.

As shown in the chart, the controller is configured in the following manner:

- complete if: indication <= 241

- three quarters if: 241 < indication < 249

- half if: 249 < indication < 253

- one quarter if: 253 < indication < 255

- reserve if: indication >= 255

Setting for typical sensors will be suggested automatically upon choosing relevant type from the list. The controller operates the following types of sensors:

· AEB 1050 and similar,

· Reserve sensor,

· Sensor 90 ohm.

Switching into gasoline after the pressure reduction caused by an empty LPG tank is indicated by the control panel by flashing of each LED sequentially: one goes on when the previous one goes off (an effect of floating diodes).

## Description of the LPG control panel.

1) Automat (before switching to LPG, LEDs are flashing simultaneously)

2) Gasoline (Leds off)

3) LPG finished (after switching into gasoline, the leds switch on alternately)

4) After switching into LPG, the control panel shows its amount in the tank:

LPG – full tank

LPG - 3/4 of the tank

LPG - 1/2 of the tank

LPG - 1/4 of the tank

LPG - Reserve (red LED flashes)

# Review and deleting the error codes.

The tab ‘Error codes’ shows a board with all codes of errors saved in the controller.

The error may be deleted after identifying and correcting the source of the error by pressing the key ‘Clear errors’.

# Information about the LPG controller.

The abilities and the version of the LPG controller are presented in the controller tab.

It contains also statistics about the controller work with gasoline and the LPG.

The version of the software is given in the menu ‘Information-> About the program’.

# Saving the car setting into the file.

After choosing the menu ‘File -> save settings in file...’ a window displays and the data about the car as well as information about the installation should be input.

Enables creating a car data base with saved settings.

For using the base, one can input setting choosing the required car. It is done with a key “Read ... from file...” on tabs: ‘Base settings’, ‘Advanced settings’, ‘Corrections’, ‘Map’. After pressing it, a dialogue is displayed giving a possibility of searching and choosing setting for the required car:

After pressing the key “Select” an appropriate form will be filled with the same settings as the chosen car. All that should be done is to input the settings into the controller.

Note:

During the input of settings from the data base of cars, those settings are input, which concern the active tab, for example if we work on a tab ‘Map’ only the map of corrections is input etc. If we need to input all settings, then it is required to use the key ‘Read... from file ...’ on the following tabs: ‘Base settings’, ‘Advanced settings’, ‘Corrections’, ‘Map’.

The AGIS application saves files with car settings in a catalogue:

%System Drive%\Program Files\Agis\Settings...