natraul gas injector

Technical Customer Information (TCI) Y 280 K00 511_702 Page 1 of 14 Date 14.06.2006

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Product: Natural Gas Injector Type: NGI 2 Part Number: 0 280 158 807 Offer Drawing:

ECE-Number:

A 280 A00 586-702 110R-00120

Characteristic Data: Page 4 to 4 Test Method: Page 6 to 9 Durability Test: Page 10 to 13 Valid from: Production Comment:

Index Page Revision Date GS-FI/ PJ-NGI

GS/ SCI-P2

GS/SCI

1 --- First edition 22.08.06

Legally binding signatures see : Page 14 of 14



Table of contents page

1. Characteristic data 4

2. Operating conditions 5

3. Test methods 6

3.1 Flow measurement 6 3.1.1 Test conditions 6 3.1.2 Measurement procedure 6 3.1.2.1 Preparation 6 3.1.2.2 Measuring 6

3.2 Linearity 7 3.2.1 Definition nominal characteristics 7 3.2.2 Definition linearity of an injector (SAE-Method) 7 3.2.3 Calculation method of linearity deviation 8

3.3 Measurement of minimum opening voltage 8 3.3.1 Test procedure 8

3.4 Leakage test 9 3.4.1 Test procedure complete leakage test 9

3.5 Measurement of insulation resistance 9

3.6 Measurement start gas mode 9

4. Endurance and durability testing 10

4.1 Engine test 10

4.2 Shock Test 10

4.3 Hot Soak Test 10

4.4 Climate tests 11 4.4.1 Salt spray test according to DIN 50 021 11 4.4.2 Condensed moisture - climate change test according to DIN 50 017 12



4.5 Endurance 12 4.5.1 Standard endurance test 12 4.5.2 Short endurance test 12

5. Test frequency for production audit test and design changes 13

6. Zero-Mileage and field return evaluation 13

6.1 Zero-Mileage return 13

6.2 Field return 13

7. Type approval according to ECE R110 13

Legally binding signatures 14



Natural Gas Injector NGI2

1. Characteristic data

Note: Measurement conditions see section 3, Test methods. Numbers of the individual tests see table

Driver Stage 1 289 918 801 (SEFI) Test gas: Nitrogen (N2) Operating pressure 700 kPa (absolute) Test Temperature 23C 2C Injector number 0 280 158 807 Test Nr. Nominal value Tolerance AssessmentNominal flow 3.1

Qstat 10,4 kg/h 6 % 3S qdyn 7 % 3S

with impulse width ti = 3,5 ms (Set point ti.E)

2,7 kg/h

Deviation of linearity: 3.2 ti.1 = 3 ms 0 % 5 % ti.2 = 5 ms 0 % 5 %

Values in Toler-ance

Minimum opening voltage UBmin: Test value (+ 23 C)

3.3 --- < 7,5 V Values in Toler-ance

Permissible Helium leakage rate at test pressure:

3.4.1 -- < 1*10

-3 sec

lmbar Values in Tolerance

Insulation resistance: 3.5 -- 1 M Values in

ToleranceInjector resistance REV at 20 C -- 12 5 % 3S

Correlation factor for dynamic (qdyn) and static mass flow (Qstat) between Nitrogen (N2) and Natural Gas (quality H) : 0,72



2. Operating conditions

The natural gas injector should only be used for metering natural gas in naturally aspirated Otto engines for passenger cars. The fuel injector acoustics in the overall system was judged and released by the customer.

Regarding to handling, storage and installation the following specifications must be ob-served urgently: - Installation specification NGI2: No. see Offer Drawing - Storage, handling and installation specification: No. see Offer Drawing

Maximum Injector temperature in the vehicle (not operated): +140 C

Operating temperature: 1. Continuous permissible temperature: -30 C to +120 C

2. In short-term operation after hot start (about 3 min) permissible up to +130 C.

3. Permissible fuel temperature at injector inlet: continuous - 30 < +70 C short-term (about 2 min.) up to +130 C

Start in Gas mode (test procedure s. cap. 3.6 a): gas temperature +10 C on Injector inlet and battery voltage of 10 V (Medium: dry Nitrogen)

Permissible vibratory acceleration:

400 m/s2 on the product (peak level), subject to measurements with frequen-cies specific for the mounting location and to approval by Bosch.

Permissible gas: Natural gas free of water after DVGW- Regulation G260 (status 01.2000), fil-tered at particles < 10 m. Max. oil content of 5ppm under norm conditions solved in gas but not liquid can exists.

Supply voltage: 7,5 V to 16 V

Operation is only permissible with control unit and specified driver stage.

Medium resistance (from outside): The NGI2 withstands FAM-test fuels (e.g. FAM-B), engine oil (e.g. 0 W40), transmission fluid (e.g. TitanGear MP80), brake fluid (e.g. DOT 4), engine cleaner (e.g. P3 Solveclean KH)

Over pressure resistance: The injector must withstand 1650 kPa (overpressure) maximum internal pres-sure.

Maximum static opening pressure: The maximum static opening pressure is 10 bar (absolute pressure) at a volt-age of 14V.

Mechanical strength of the injector: Axial stress: 600 N Bending stress: 6 Nm Torsional stress: 4 Nm Remark: Force application points at all stresses only above the manifold sided

o-ring permissible. The load values are allowed only during the as-sembly and dismantling.



3. Test methods

The tests have to be carried out with suitable test equipment. Non-observance of this instruction can cause the destruction of the injector.

3.1 Flow measurement

3.1.1 Test conditions

Test setup: Approved and released test stand at Bosch

Test medium: Nitrogen (N2) purest, RB- Norm: N28 Nr. 578002500 density: 1,24 kg/m (at 0C and 1,013 bar)

Test temperature: 23 C 2 C

Test pressure: nominal value see section 1. characteristic data

Driver stage: see section 1. characteristic data

This driver stage is designed only for setting and remeasuring of injectors. It works like the driver in the vehicle, but is not necessarily identical.

Supply voltage for driver stage: 14 V 0,02 V

wire resistance: 400 m 20 m

cycle time: T = 10 ms

3.1.2 Measurement procedure

3.1.2.1 Measuring

The measurement of the dynamic and static flow must be carried out according to the test conditions specified in section 3.1.1.

The massflow [kg/h] is measured in a stationary point.

When measuring proceed in the following order:

1. dynamic flow rate: Deviation primary pressure < 1% of nominal value; deviation massflow < 2 % of actual average value for a period of t > 5 sec

2. static flow: Deviation primary pressure < 1% of nominal value; deviation mass-flow < 1% of actual average value for a period of t > 5 sec

The massflow per lift [mg/lift] can only be a calculated value.



3.2 Linearity

3.2.1 Definition nominal characteristics

The nominal dynamic flow quantity is defined by a characteristic (qdyn(ti)) which goes through the nominal dynamic set point (qdyn/ti.E) with a slope corresponding to the nominal static flow (Qstat).

Calculated by:

dynEiiStatidyn qttQtq += )()( .

[kg/h]

3.2.2 Definition linearity of an injector (SAE-method)

The deviation of linearity of an injector is defined as the difference between the real dynamic flow rate and the individual ideal flow rate characteristic.

The individual ideal flow rate characteristic of an injector is established by calculat-ing an ideal straight line by linear regression through 5 measurement points at ti = 3/4/5/6/7 ms (according to SAE-method).

[ ]10

5 =

xxix qqtm

mq

t xs

=

2,05

(values for Qstat and qdyn at a fix Period refer to section 1, characteristic data; ti.E = impulse width at qdyn)

m = slope of the ideal straight line ts = delay time (intercept of regression line

with t-axis)



3.2.3 Calculation method of linearity deviation

The deviation percentage for a given ti from the individual ideal flow rate can be cal-culated as:

[ ] ( ) 1001)(

%)(

=si

idynidyn ttm

tqtq

with:

qdyn(ti) [%] = linearity deviation in % at ti qdyn(ti) = dynamic flow rate at ti

ti = impulse width at which the deviation of linearity is to be calculated

ts = delay time (intercept of regression line with t-axis)

3.3 Measurement of minimum opening voltage

3.3.1 Definition

The minimum opening voltage (UBmin ) is the voltage required from the driver stage, to open the injector under dynamic cold start conditions. It is determined by con-tinuously increasing the supply voltage of the driver stage (voltage gradient 1 V/s) starting from 4 V until the injector just opens.

3.3.2 Test conditions

In the practical test UBmin is measured with a standard control unit at room tem-perature. The test value is the result of the temperature difference and the control conditions.

Conditions:

Test temperature: 23 C 2 C Cycle time T: 20 ms Pulse width ti: 10 ms

Definition "Injector just opens": Opening time (ton) maximum 9 ms.

Test circuit:

Ubmin

Ubatt

ECU(DriverStage)

Rcable = 400 m

Fuel Injector

T = 20 ms / ti = 10 ms



3.4 Leakage test 3.4.1 Test method for total leakage NGI 2 (Housing-, seat- and O-Ring leakage)

The leakage rate of the NGI2 is checked with helium leakage test.

Medium: Helium

Temperature: 23 2C

Test pressure: see section 1. characteristic data

Time: > 3 s

Test setup: Approved released test stand at Bosch.

Definition unit mbar*l/sec based on DIN EN 1330-8: Rate at which a volume of gas a specified pressure passes a given cross section (leak) of the system (Volume: 1l; pressure loss: 1 mbar per second). Test procedure: The leakage test is done in a vacuum cell. At first step the cell is evacuated. A test for rough leakage rates is done simultaneously through an pressure decrease test in the injector. After finishing this test, the inside of the injector is evacuated. After that the injector is charged with Helium. If the cell vacuum breaks down at that point a rough leakage exists. If the test pressure is achieved, the helium leakage rate is measured. At the end of the test the test pressure is taken off and the test cell is ventilated.

3.5 Measurement of insulation resistance The insulation resistance is measured between the (+/-) connector pins and housing. The resistance doesnt be under the determined value in section 1.

Test voltage: 750 V D.C. Test time: 2 sec.

3.6 Measurement start gas mode (= start and switch mode) Definition: Determination switching capability at different Gas- / ambient temperatures and bat-

tery voltages (Ubatt)

Test procedure:

T=100ms, ti=8ms

psys: system pressure

Ubatt: 12V (switching mode); 7,5 12V (Cold start)

Gas temperature / ambient temperature: area from -30C up to 10C. After every test @ specified temperature the injector is heated up to +23C and operated. Af-terward the injector is cooled down to the next temperature. Cooling and Storage time before operation approximately 40 min.

Criteria

a) Cold start capability: Opening Injector with first pulse (ton < 8ms)

b) Switching mode Opening Injector with first pulse (ton < 8ms) Deviation of opening time (ton) between 2nd and 9th pulse 1,0 ms



4. Endurance and durability testing The product functionality in the overall system must be confirmed by the customer through a corresponding vehicle test under realistic operating conditions.

The following design verification tests are meant to give information about the func-tional stability, the wear and corrosion resistance of the injector.

The tolerances indicated for the particular tests are related to the individual original value, measured according to section 3.1.

Acceptance criteria: Individual values in tolerance.

4.1 Engine test The reliability of the NGI2 is proofed through a customer specific engine test on a test bench, driven in the speed range of max. occurrence sinusoidal vibrations. Speed: 5600 - 6400 1/min (subject to vehicle measurement results) Range of speed: 100 1/min / min Time: 24 h Media: Natural Gas (quality H, see section Nr. 2 permissible gas) Pressure: see section 1. characteristic data Test criteria and permissible deviation after the test:

Qstat = 6% qdyn = 9 % at ti = 3,5 ms Total leakage rate: s. section1 characteristic data

4.2 Shock Test The injector is mounted in a fixture.

Acceleration: a = 500 m/s2 Shock duration: 5 ... 8 ms Test procedure: 6 shocks in the direction of the injector axis and 6 shocks perpendicular to the injector axis.

Test criteria and permissible deviation after the test:

Qstat = 5 % qdyn = 7 % at ti = 3,5 ms Total leakage rate: s. section1 characteristic data

4.3 Hot - Soak Test Temperature profile:

Zyklus

t1

t2-40C

20C

70C

140C

cycle

operation



Storage time:

t1: 30 min

t2: 5 min

Number of cycles: 10

Injector operation: + 20C to + 70C and + 70C to + 20 C

Pulse width (T): 40 ms

Injection time (ti): 18 ms

Test criteria and permissible deviation after the test: Qstat = +7 / - 3% qdyn = 9 % at ti = 3,5 ms Total leakage rate: s. section1 characteristic data

4.4 Climate tests

4.4.1 Salt spray test according to DIN 50 021

A 5%-sodium chloride solution is sprayed continuously on to the tested injector. From the O-ring onwards, the fuel inlet and outlet are capped and the electrical connector plug is capped.

Duration: 144 hrs

Rating: No harmful rust shall be found in the appearance.

4.4.2 Condensed moisture - climate change test according to DIN 50 017

Tested injector must be stored: 8 hrs at 40 C in humid climate 16 hrs at room temperature The fuel inlet and outlet are closed from the O-ring on. The plug is mounted onto connector.

Duration: 6 cycles (1 cycle = 24 hrs)

Rating: No harmful rust to function shall be found.



4.6 Endurance

4.6.1 Standard endurance test

Laboratory Endurance at room temperature about 1,90 x 108 pulses.

This equals: 264 h at a frequency of 200 Hz (T = 5 ms) Pulse width: ti = 2,5 ms

Endurance medium: Natural Gas quality H at DVGW Regulation (see 2. operating conditions).

Pressure: see section 1. characteristic data

Gas temperature: 23 2C

Test criteria and permissible deviation after the test:

Qstat = 4 / + 7 % qdyn = 5 / + 12 % at ti = 3,5 ms Total leakage rate: s. section1 characteristic data

4.6.2 Short endurance test

A short endurance, lasting 1,44 x 108 pulses, is carried out within specified periods (see section 5) to monitor manufacturing quality.

This equals: 200 h at a frequency of 200 Hz (T = 5ms) Pulse width: ti = 2,5 ms

Test conditions and permissible deviation : see 4.6.1.



5. Test frequency for production audit test and design changes At least once a year audit tests are performed per type family. For these tests parts of any injector type are taken out of production at random. For current production the quality assurance and development department select the needed tests out of section 4.

For design changes the development department selects the needed tests and co-ordinates the special design verification testing

6. Zero-Mileage and field return evaluation

Functional values are determined according to the test conditions listed in section 3. test methods, with the test equipment of the manufacturing plant.

Acceptance criteria: The Individual values are in tolerance.

6.1 Zero-Mileage return In the case of zero-km return, the tolerances of the new parts (see section 1) must be used. At the static and dynamic flow measurement the tolerance for repeatability of 2 % must be added.

6.2 Field return The technical development/application engineering of the product is aligned to a service life of 120,000 km, but in any case to a maximum of 15 years. This state-ment regarding design of the product for a certain lifetime does not represent a war-ranty for the characteristic of the product. The commercial warranty an liability is regulated in the terms of sales, independent of the above figures

In case of any alleged defect of the injectors, the injectors are to be considered free of defects, if the injectors functional parameters are within the following stated toler-ances for Qstat, qdyn and leakage.

Qstat = 10 % qdyn = 15 % at ti = 3,5 ms Total leakage rate:



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natraul gas injector

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