Natraul Gas Injector

Technical Customer Information (TCI)
Y 280 K00 511_702

Page 1 of 14
Date 14.06.2006

Alle Rechte bei Robert Bosch GmbH, auch fr den Fall von Schutzrechtsanmeldungen. Jede Verfgungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
Robert Bosch GmbH reserves all rights even in the event of industrial Property rights. We reserve all rights of disposal such as copying and passing on to third parties.
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4

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

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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

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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

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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 (N
2
)
Operating pressure 700 kPa (absolute)
Test Temperature 23C 2C
Injector number 0 280 158 807
Test Nr. Nominal value Tolerance Assessment
Nominal flow 3.1

Q
stat

10,4 kg/h
6 %
3S
q
dyn

7 % 3S
with impulse width t
i
= 3,5 ms
(Set point t
i.E
)

2,7 kg/h

Deviation of linearity: 3.2
t
i.1
= 3 ms

0 % 5 %
t
i.2
= 5 ms

0 % 5 %
Values
in Toler-
ance
Minimum opening voltage U
Bmin
:

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
l mbar

Values in
Tolerance
Insulation resistance: 3.5 -- 1 M
Values in
Tolerance
Injector resistance R
EV
at 20 C -- 12 5 % 3S

Correlation factor for dynamic (qdyn) and static mass flow (Qstat) between Nitrogen (N
2
) and
Natural Gas (quality H) : 0,72

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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/s
2
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.

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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 (N
2
) 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.

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3.2 Linearity
3.2.1 Definition nominal characteristics
The nominal dynamic flow quantity is defined by a characteristic (q
dyn
(t
i
)) which goes
through the nominal dynamic set point (q
dyn
/t
i.E
) with a slope corresponding to the
nominal static flow (Q
stat
).

Calculated by:

dyn E i i Stat i dyn
q t t Q t q + = ) ( ) (
.

[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 t
i
=
3/4/5/6/7 ms (according to SAE-method).

[ ]
10
5

=
x x ix
q q t
m

m
q
t
x
s

=
2 , 0
5
(values for Q
stat
and q
dyn
at a fix Period
refer to section 1, characteristic data;
t
i.E
= impulse width at q
dyn
)

m = slope of the ideal straight line

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

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3.2.3 Calculation method of linearity deviation
The deviation percentage for a given t
i
from the individual ideal flow rate can be cal-
culated as:

[ ]
( )
100 1
) (
% ) (
=
s i
i dyn
i dyn
t t m
t q
t q

with:
q
dyn
(t
i
) [%] = linearity deviation in % at t
i

q
dyn
(t
i
) = dynamic flow rate at t
i

t
i
= impulse width at which the deviation of linearity is to be calculated
t
s
= delay time (intercept of regression line with t-axis)

3.3 Measurement of minimum opening voltage
3.3.1 Definition
The minimum opening voltage (U
Bmin
) 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 U
Bmin
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 t
i
: 10 ms
Definition "Injector just opens": Opening time (t
on
) maximum 9 ms.
Test circuit:
U
bmin
U
batt
ECU
(Driver
Stage)
R
cable
= 400 m
Fuel Injector
T = 20 ms / t
i
= 10 ms

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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 2
nd
and 9
th
pulse 1,0 ms

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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:
Q
stat
= 6%
q
dyn
= 9 % at t
i
= 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/s
2

Shock duration: 5 ... 8 ms
Test procedure: 6 shocks in the direction of the injector axis and
6 shocks perpendicular to the injector axis.
Q
stat
= 5 %
q
dyn
= 7 % at t
i
= 3,5 ms
4.3 Hot - Soak Test
Temperature profile:

Zyklus
t1
t2
-40C
20C
70C
140C
cycle
operation

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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

Q
stat
= +7 / - 3%
q
dyn
= 9 % at t
i
= 3,5 ms
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.

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4.6 Endurance
4.6.1 Standard endurance test
Laboratory Endurance at room temperature about 1,90 x 10
8
pulses.
This equals: 264 h at a frequency of 200 Hz (T = 5 ms)
Pulse width: t
i
= 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
Q
stat
= 4 / + 7 %
q
dyn
= 5 / + 12 % at t
i
= 3,5 ms

4.6.2 Short endurance test
A short endurance, lasting 1,44 x 10
8
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: t
i
= 2,5 ms

Test conditions and permissible deviation : see 4.6.1.

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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 Q
stat
, q
dyn
and leakage.
Q
stat
= 10 %
q
dyn
= 15 % at t
i
= 3,5 ms
Total leakage rate: <1 * 10
-3
mbar*l/s
The operation of the injector corresponding to the operating conditions specified in
section 2, especially only the use of the specified natural gas, is the premise for the
acceptance as field returns
7. Type approval according to ECE R110
The release of an natural gas injector for the use in natural gas vehicles occur addi-
tional to the tests described in this TCI through the Type approval agency (German
Federal Motor Vehicle Registration Agency). The Type approval is done with the
current ECE R110 at the certification date.

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Legal binding signature

Robert Bosch GmbH

............................................ , ............... ............................................ , ...............
(City) (Date) (City) (Date)

.............................................................. ..............................................................
__________________________________________________________________________

Customer

............................................ , ............... ............................................ , ...............
(City) (Date) (City) (Date)

.............................................................. ..............................................................

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Technical Customer Information (TCI)

Y 280 K00 511_702

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