5 Quality QUALITY OMVL is a Company certified with a Quality System ISO 9001:2000. This certificate, released by TUV Italy - which belongs to the German Group TUV Suddeutschland - is related to the entire process of designing, manufacturing and marketing of gas components and complete fuel supplying systems for gas-propelled vehicles. OMVL Company processes are defined, monitored and subjected to programs of constant improvements in order to reach high goals in efficency and effectiveness which guarantee a continuous and increasing consumer satisfaction of our products branded REG. REG products are subjected to a process control for the entire manufacturing course which starts from in-coming material control to final tests under pressure performed on the production as a whole in accordance with the international and internal Regulations in order to guarantee and maintain continually a high standard of quality and safety. The LPG and CNG converting components are approved in line with the European Regulations R67 01 and R110.
Moreover, the CNG converting components are approved in accordance with ISO Regulation. REG converting systems for small, medium and high power engines are approved in line with the European standards for emissions of pollution Euro4. 5 6 6 spa 7 Introduction MINIMUM COMPUTER REQUIREMENTS FOR SOFTWARE INSTALLATION Operating system. Windows 98 SE or later Memory (ram): Mbytes at least Hard disk: Mbytes of free space at least Screen resolution: x 600 or better Internet Explorer version 5.5 or later should also be installed INSTALLING THE SOFTWARE When you are ready to install the software, insert the cd-rom in the computer and wait for the installation wizard to pop-up.
Should the wizard fail to start, click the Start button in the Applications Bar and select Run. Enter: D: setup.exe (where D is your Cd-rom drive). You will be asked to choose a directory where the software will be installed; we recommend to choose the default one. Once the installation has been completed, the icon of the program will be automatically put on your desktop.
INTRODUCTION It s not necessary to connect the ECU to start the software. However, if you want to program the ECU, you need to connect the it to the PC with an interface cable, part number OMVL (not supplied in the kit, should be ordered separately). Furthermore, the control unit must be powered by the +12 V battery voltage (via the red-black wire) and properly grounded (black wire). 8 Main Menu This menu is used to access all the submenus contained in the software, all of which are listed and described below: The following information is provided at the bottom of the page: (1) (2) (3) (4) 1) This indicates if the control unit is connected or not connected to the PC. It is important to remember that any settings made when the control unit is not connected will be lost at the time of connection, unless they have been already saved in a configuration file. The program will automatically attempt to connect to the control unit when you open it.
If the program can t connect to the ECU, a window will pop-up reporting an error. You should check: - the connection of the serial interface, - the connection of the control unit to the battery and to ground, - if the key has been switched off for more than an hour, you should switch it on for a few seconds or crank-up the car, if the switch doesn t light up with the instruments. To attempt a connection again, open the Connection menu at the top of the window and select Connect. 2) This is the name that can be given or has been given to the configuration of the vehicle; for a new control unit, the standard configuration is standard LPG. The control unit must be connected to the configuration software in order to download an existing configuration into the control unit.
3) This is the version of the control unit s software; select the ECU REPROGRAMMING sub-menu to update it. Note: this is only possible if INTERNET EXPLORER version 5.5 or later is installed on your PC. 4) This indicates if the current configuration downloaded into the control unit uses the operating parameters for CNG or LPG; go to the VEHICLE CONFIGURATION sub-menu to select the type of fuel. 9 Vehicle configuration This sub-menu is made up of 7 pages (when the REG009 dongle-key is plugged into the PC) where you can change the parameters that define the behaviour of the gas control unit. These parameters must be set according to the signals that are present on the vehicle.
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At the bottom of any page you have a resuming sight of the gas ECU parameters. (1) (2) (3) (4) (5) 1) This box displays whether the vehicle is powered by petrol or gas.
The description CUT-OFF may also appear when the system is in cut-off. 2) This box displays the: Engine Revs currently read by the control unit. T.gas is the temperature of the gas inside the injection rail. T.reducer is the temperature of the water inside the pressure reducer. 3) This box displays the gas (Tinj.gas) and petrol (Tinj.petrol) injection times.
4) In this box you can see: Press.gas the difference in pressure between the injection rail and the manifold air pressure of the intake, read by the pressure sensor supplied in the kit MAP Manifold Air Pressure reading (only if you are using an AEB025 sensor) and type of sensor used. 5) This box displays the voltage of the lambda probe and the gas level in the tank (in a 0 to 255 range). Info: if you do not connect the purple wire to the lambda probe, you can t read the lambda voltage on the screen. 10 F1 Change - over (1) Note: all the parameters painted in YELLOW can be changed only when the key is off and the change-over switch is off. FUEL TYPE This box is used to reset the control unit to the default parameters for the selected fuel type.
Select: - GPL for vehicles powered by LPG; - METHANE for vehicles powered by CNG. The selecion of LPG or METHANE changes also the directory where the configuration files are saved (see Load configuration paragraph).
ISelect the type of petrol injection of the original ECU: Sequential: the petrol injection is sequential Full-group: the petrol injection is halfgroup or full-group. 12 PAGE F2 LAMBDA TYPE OF LAMDA PROBE the control unit car clearly read the lambda probe voltage only if you set this parameter correctly. Please check that the lambda probe is working with a digital multimeter, before you select the type of Lambda Probe. WARNING: Connect only the PURPLE wire to the lambda probe: the GREY wire MUST REMAIN DISCONNECTED! If you do not connect the PURPLE wire, it is not necessary to set the TYPE OF LAMBDA PROBE The GREY wire should be connected only for the emulation.
0 1 V Select this option if the voltage output of the lambda probe is: approximately V for lean mixture; approximately V for rich mixture. 0 5 V Select this option if the voltage output of the lambda probe is: approximately V for lean mixture; approximately V for rich mixture. 5 0 V Select this option if the voltage output of the lambda probe is: approximately V for lean mixture; approximately V for rich mixture. NUMBER OF FRONTAL LAMBDA PROBES Set the number of pre-cat lambda probes installed in the vehicle: 1 or 2 FUEL TRIM BANK 2 If you set 2 frontal lambda probes, you can increase or decrease this correction value (form 20 to +20) for the second bank, in case of 6-8 cylinders engine. This correction is applied to the K ratio defined in the map of the first bank.
If the correction is set to 0, both banks use the same K ratio. 0,8 1,6 V Select this option if the voltage output of the lambda probe is: approximately V for lean mixture; approximately V for rich mixture. UEGO Select this option only for wide-band resistive probes with 5 wires.
13 PAGE F3 EMISSIONS The parameters on this page are used only for emission tests. They become effective only if you cut the wire of the lambda probe (black wire, in a 4 wires probe), connect the piece coming from the probe to the PURPLE wire of the gas ECU and the piece going to the original ECU to the GREY wire of the gas harness.
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Please take a look to the connection scheme, if your probe is a 5 wires UEGO probe. HIGH EMULATION LEVEL. While idling the car in petrol, read the maximum lambda probe s voltage and set this parameter accordingly. Connection scheme for UEGO, 5-wires lambda probes Type BOSH LOW EMULATION LEVEL. While idling the car in petrol, read the minimum lambda probe s voltage and set this parameter accordingly.: the default values are set accordingly to the type of lambda probe you choosed in the F2 Lambda page. INITIAL EMULATION DELAY When you start the engine, the gas ECU will activate the emulation after the amount of time you set. Set it to 0 to disable the emulation.
14 PAGE F4 SENSOR TYPE OF MAP SENSOR Lets you choose the type of MAP sensor installed: AEB025 or AEB013. TYPE OF GA LEVEL SENSOR This sets the type of level sensor that you use: AEB -set this if you are using a sensor with standard AEB output signal (like the AEB1050); for connection instructions, look to the installation diagram for the gas control unit ohm -set 0-90 ohm if the sensor gives an output from 0 to 90 ohm (like the AEB1090); refer to the installation diagram for the gas control unit.
Non standard select this option for all non AEB sensors that give an output directly proportional to the gas level in the tank (0, 255). With this option selected you can define the thresholds for the level gauge in steps of 1 4 of the tank.
The maximum value is for the full level, the minimum for the empty level. Non standard inverted select this option for all non AEB sensors that give an output inversely proportional to the gas level in the tank (255, 0). With this option selected you can define the thresholds for the level gauge in steps of 1 4 of the tank. The maximum value is for the empty level, the minimum for the full level. 15 PAGE F5 MAP It is possible to modify the gas mixture in this page, adjusting the map created by the automatic calibration procedure. Changing the map is not mandatory: we recommend to check the mixture and modify the map only if necessary. You can check if the engine is correctly carbureated while on gas using a diagnostic tool capable of reading the petrol ECU fuel trims (for example you can use an OBD-II scan tool on OBD-II equipped cars): simply check the fuel trims at different revs.
You can check the carbureation also without a scan-tool, checking the strobing of the lambda signal while switching form petrol to gas and viceversa. You can still make some test, even if the lambda probe is not connected to the gas ECU: just compare the petrol injection timings while on petrol and while on gas, switching from petrol to gas and vice-versa. Petrol injection timings K ratio for given petrol injection time and engine s rev Engine s revs You should check that the K figures in the map change smoothly from one cell to the other; eventually modify the map to achieve a smoother map. If you need to modify a figure of the map, select its cell and double-click the left mouse button on it, or press ENTER on the keyboard.
You can select also a whole area of the map and press ENTER to change all the figures in the selected cells at the same time. There are three way of modifying the figures: Absolute: changes the selected figures into the new value you enter. Linear: sum/subtract the value you enter to the selected figures. Percentage: increase or decrease the figures in the cell/cells by the percentage you enter.
16 PAGE F5 MAP SWITCH FROM PC With this button you can switch to petrol or to gas without using the switch inside the car (when you select the Switch from PC button, the switch inside the car is momentary disabled). MODIFY MAP REFS The value of the first time line should be checked at idle (with all loads off, like A/C, head lamps, etc.), while on petrol. Take a value lower or equal to the petrol injection time you read in the parameters panel, on the bottom of the window. Fill the 12th time line with the same procedure (take the max petrol injection timing while driving the car at the highest revs). The values in the time lines should increase smoothly in the first 5-6 rows, while the other values should increase proportionally till the 12th line. PAGE F6 ADJUSTMENTS REDUCER TEMPERATURE CORRECTIONS You can change the temperatures and the correction percentages.
You should modify the temperatures only if the reducer tempetrature for change-over is lower than the figures in the correction table. You should change the correction percentages only if you think that the mixture is too rich at a specific temperature. GAS TEMPERATURE CORRECTIONS This table lets you compensate the variation of the gas density over temperature. 17 PAGE F7 MODIFY CARB. In this page you can modify the gas carbureation to fine-tune the map created by the autocalibration. This operation is not mandatory and we strongly suggest to check the carbureation before making any modification. There are 2 columns in the MODIFY CARB section: Idle: when the engine s speed is below 1100 RPM; Out of idle: when the speed is above 1100 RPM.
Both columns are divided up into 4 boxes showing the engine load. The boxes are painted in red to show the actual working point of the engine.
SENSITIVITY The DREAM XXI N ECU converts the extrainjection pulses generated by the petrol ECU into gas injections. However, the petrol extrainjection timings are very short and under some conditions the gas injectors could not fully open, giving thus an inaccurate flow of gas. To avoid this problem you can change the Extrainjection sensitivity: when you set the extrainjection fader to the minimum value, the gas ECU converts the petrol injection timings into gas injection timings without extra-injection (thus the extra-offset time is 0). When the fader is set to the maximum, the DREAM XXI N ECU converts the petrol injection timings into gas injection timings with the maximum extra-injection time (extra-offset time is 3.6 ms). The suggested settings for the fader are 0 for CNG systems and middle position for LPG systems. WEAKENING ON MAZDA We found out that some Mazda engines under certain conditions switch their injection strategies from sequential to full-group. When this happens, the petrol injection timings decrease by a 50% and the dot on the map moves to a higher row, pointing at wrong figures.
The engine then starts to shake and the car doesn t run smoothly. The Weakening on MAZDA lets you set a value that will be subtracted from the figures in the map, taking them back to the right value. ENRICHMENT IN ACCELERATION This feature is active only when the bar under the fader is painted in blue: this happens while you are accelerating or decelerating.
In these conditions, you can enrich or lean the mixture to enhance the drivability. (You can use this only if you installed an AEB025 pressure sensor). LEANING ENRICHING 17 18 PROCEDURE FOR VERIFYING CARBUREATION PROCEDURE FOR VERIFYING CARBUREATION Before proceeding with any modifications, first verify that the vehicle runs fine while on petrol, because the Gas injection is based on the Petrol one. 19 DISPLAY This page displays all the signals that are acquired by the control unit: ) Displays the temperature of the gas reducer; 2) Displays the gas temperature; 3) Displays the current number of engine s revs; 4) Indicates if the vehicle is running on Gas or Petrol; 5) This box displays the current Gas injection time; the current petrol injection time; the difference in pressure between the gas in the injection rail and the intake manifold, read by the pressure sensor supplied in the kit; 6) This is the voltage of the lambda probe of the car. Nothing will be displayed if the lambda wires (purple and grey) are not connected; 7) Detects the size of the nozzles checking the map generated with the auto-calibration.
7 Nozzle Dimension Table: CNG SYSTEM Nozzle code Nozzle diam. Nozzle section Power for cylinder Cylinder volume Nozzle diam. On mainfold mm mm 2 kw cc mm,75 2,5 4,5 Nozzle Dimension Table: LPG SYSTEM Nozzle code Nozzle diam. Nozzle section Power for cylinder Cylinder volume Nozzle diam.
On mainfold mm mm 2 kw cc mm,5 4,5 19. 20 AUTOCALIBRATION The calibration of the control unit can be done in this section so that correct carburetion of the vehicle can be achieved when running on GAS. Before starting the automatic calibration procedure, verify that the vehicle runs smoothly on petrol, because the injection is based on the Petrol one. Follow these instructions to proceed to the automatic calibration: 1) Start the vehicle on petrol and wait for the engine to reach its normal operating temperature (approximately 90 ); 2) Start the automatic calibration procedure by pressing the ENTER key and follow the instructions shown on screen. When the engine revs have reached the value specified on screen, the control unit will perform several switch from petrol to gas. The engine s revs will probably drift during the first stages. It is important to keep the accelerator pedal steady even if the revs drift, without trying to correct the revs.
If the engine stalls during the automatic calibration procedure, enter VEHICLE CONFIGURATION in the F1 Change-over section and select Reset ecu and go to base parameters. After resetting, restore the settings for the parameters in VEHICLE CONFIGURATION, if necessary. Check the nozzles size!
Return to AUTOCALIBRATION and start the automatic calibration procedure again, as described above. Try the auto-calibration while driving on the road, if it seems that it s difficult to complete it while on idle. After completing the AUTOCALIBRATION, try the vehicle on gas and verify that it runs smoothly.
Note: Starting from software version 4.1.0, the default starting injection time has been changed from 4.2ms to 3.5ms. This should ease out the autocalibration process, most of all with Range Rovers, that had some troubles during this process in the past.
21 SAVE CONFIGURATION All the parameters set in vehicle configuration can be saved using this menu, in a file that can be used later for the programming of other control units installed on the same model of vehicle that use the same type of fuel: Methane or LPG. To save it, specify the Name of file to be saved and click OK. Note: selection of the number of cylinders (in the bottom section of the window) only appears if the control unit is not connected to the computer. If the control unit is connected to the computer, this information will be saved when you select NO.
OF CYLINDERS in the vehicle configuration page. LOAD CONFIGURATION An existing configuration can be loaded into a control unit using this menu. The configuration files are contained in two separate directories: one for LPG configurations and the other for METHANE configurations. Before loading a configuration, you must enter VEHICLE CONFIGURATION and select METHANE or LPG in Fuel type according to the configuration that you want to load. Selection of the number of cylinders (in the bottom section of the window) only appears if the control unit is not connected to the computer. If the control unit is connected to the computer, this information will be saved when you select NO. OF CYLINDERS in the vehicle configuration page.
Select the file that you want to load and click OK. Note: To avoid problems during the control unit programming stage, do not rename configurations and avoid moving them to directories other than the original ones.
22 ECU REPROGRAMMING It is possible to update the FIRMWARE (the management program inside the control unit) for the gas control unit using this menu. The installation CD-Rom for the calibration software always includes the latest version of the firmware available at the time the CD-Rom is produced, whereas any later firmware versions may be sent by or by disk and must be requested to your dealer. To update the FIRMWARE, select ECU REPROGRAMMING and the Select programming file window will appear. Select the update file and click open. Should there be more than one file, select the one with the highest number (the latest version).
Note: in order to avoid the loss of the configuration in the control unit, check that the control unit is connected to the computer before updating the FIRMWARE. IMPORTANT Reprogramming is only possible if INTERNET EXPLORER version 5.5 or above is installed on your PC 22 spa 23 24 spa Components OMVL spa Via Rivella, 20 - Pernumia (PD) Tel Fax Ufficio Commerciale/Commercial Departement: Assistenza Tecnica/Technical Assistance.
Win 8 MB DREAM XXI N is the latest gas injection system designed and developed by OMVL. It can be installed on all fuel injected vehicles. Powered by LPG or CNG, the system is fully compliant to the latest safety standards for gas fuel systems (67R01 and R110) and keeps emissions well within the limits established by the strictest standards (EURO4). DREAM XXI N is extremely reliable in all vehicle operating conditions, and guarantees excellent performance. OMVL integrated the mechanical and electronic subsystems, to allow an easy and quick installation, and to guarantee efficient and reliable operation.