0280K00849 702 1

Technical Customer Information
0 280 K00 849-702

Page 1 of 16
Date 15.10.2007

Robert Bosch GmbH reserves all rights even in the event of industrial property. We reserve all rights of disposal such as copying and passing on to third parties.

Product:

NGI Natural Gas Injector
Type:

NGI2-DP (Durability Package)
Part Number:

0 280 158 813
Offer Drawing:

0 280 A01 321-702

Customer: Khodro
Valid from:

Production

Index Page Revision Date GS-FI/
ENI1-Mi
GS-FI/
ENI
GS/SCI-
P2
GS/SCI
1 - First edition 15.10.07

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Page 2 of 16
Date 15.10.2007


Contents

General 3
1. Characteristics 4
2. Operating conditions 5
2.1 Operating life 5
2.2 Temperature range 5
2.3 Permitted media 5
2.4 Vibration/Shake load 5
2.5 Key data for full functionality 5
2.6 Limitations of key data for normal functionality 6
2.7 Robustness with regard to external media 6
2.8 Functional values 6
2.9 Maximum switch-on time 6
2.10 Flow direction 7
2.11 Interfaces 7
2.12 Mechanical strength 7
2.13 Usage in Bifuel vehicles 7
3. Test data/Test methods 8
3.1 Flow measurement 8
3.2 Linearity 8
3.3 Measurement of minimum opening voltage 9
3.4 Leakage test 9
3.5 Measurement of insulation resistance 10
3.6 Measurement of opening behavior at low temperatures 11
4. Endurance and environmental tests 12
4.1 Dynamic tests 12
4.2 Climate tests 13
4.3 Endurance 13
5. Carrying out testing (production audit tests) 15
6. Field return evaluation 15
6.1 Zero-mileage return 15
6.2 Field return 15
7. Type approval according to ECE R110 15
Legally binding signature 16

Further documentation

Bosch Norm: N28 No. 578002500

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General
The NGI2 natural gas injector is only to be used in intake manifold injection
systems on Otto engines for civil automotive applications. Other applications for
the purpose of preparing or metering fluids or gases (e.g. liquid or gaseous LPG,
paints, medicaments, etc.) are not permitted and may cause severe damage.

Safety Information

Bosch CNG components are only suitable for use in OEM (Original Equipment Manu-
facturer, i.e. automakers) applications. Usage in other systems, e.g. in CNG
aftermarket vehicle conversion kits, could create risks such as component wear or
damage, overpressure, gas release or explosions.

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1. Characteristics
Driver Stage 1 289 918 801 (SEFI)
Test medium Nitrogen (N
2
)
Operating pressure 700 kPa (absolute pressure)
Test temperature
23C 2C
Test Chapter Nominal Tolerance Assessment
Nominal flow 3.1
Q
stat
3.1 10.40 kg/h 6 % cpk 1(
2

q
dyn
(t
i,E
= 3.5 ms) 3.1 2.95 kg/h 7 % cpk 1(
2

Deviation of linearity 3.2
t
i1
= 3 ms 3.2 0 %
5 %
t
i2
= 5 ms
3.2
0 %
5 %
cpk 1(
2

Minimum operation voltage U
Bmin
3.3 -- < 7.2 V cpk 1(
2

Leakage rate to the environ-
ment
3.4 --
< 0,003 mbar*l/s(
1

cpk 1(
2

Leakage rate seat

3.4

--
< 0,003 mbar*l/s(
1

cpk 1(
2

Insulation resistance 3.5 --
10 M
cpk 1(
2

Injector resistance R
EV
at
20 C
--
8.5 5 %
cpk 1(
2

(
1
Leakage rates are specified in helium at operating pressure according to chapter
3.4

(
2
values

of 100% measured injectors must be in tolerance

Proposed 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 fuel injector acoustics in the overall system were assessed and released by
the customer. Especially the acoustics caused by the expansion of gas has to be
avoided by the design of the manifold.

The use of the product is only permitted under the operating specified conditions
specified in this document. Any change in the product's operating environment
must be communicated to and released by Bosch. This applies especially for
applications subject to special reliability, robustness and safety requirements.

With regard to handling, storage and installation the following specifications
must be observed:
- Installation specification NGI2: No. see Offer Drawing
- Storage and handling recommendation: No. see Offer Drawing
2.1 Operating life
The component is designed for an operating life of 15 years and 380 million
switching cycles, corresponding to a distance of approximately 240,000 km.
The information concerning the design of the product for a certain operating life
does not represent a warranty for the properties of the product.
2.2 Temperature range
Temperature range Engine compartment 30C to +125C
Maximum temperature
Engine compartment short-term
(max. 45 minutes)
+135C
Temperature range Gas at injector inlet 30C to +125C
Maximum temperature
Gas short-term at injector
inlet (max. 5 minutes)
+135C
Minimum temperature
Gas short-term at injector
inlet(max. 5 minutes after
cold start)
-40C
2.3 Permitted media
Natural gas conforming to DVGW Regulation G260; Status 01.2000
- Water content: Dew point < -5C @ 10 bar absolute
- Filtered to particles < 10 m
- No liquid phase (e.g. oil or other media) in the framework of the condi-
tions of use
Deviations can lead to functional changes.
2.4 Vibration/Shake load
400 m/s on product (peak value)
Customer-specific check by measuring is required
2.5 Key data for full functionality

Operating
condition
Battery
voltage
Temperature Rail primary
pressure
(absolute)
Duration Frequency
of occur-
rence
Normal 7.516 V See above 550 700 kPa Any Any

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2.6 Limitations of key data for normal functionality
Operating
condition
Battery
voltage
Temperature Rail primary
pressure
(absolute)
Duration Frequency
of occur-
rence
Cold start,
gas direct

> 7.5 V > 15C gas
temp. at
injector inlet
& environment
< 700 kPa (2000 x)
Cold start,
switchover
from gasoline
operation
> 12 V > 5C gas
temp. injector
inlet &
environment
< 700 kPa (2000 x)
Hot start

> 8.5 V 135 C gas &
environment
< 700 kPa Temperature
< 125C
after 5
mins.

Full load
after cold
start

1216 V > -40C gas
temp. at
injector inlet
< 700 kPa 5 mins. 300 x

Description of limitations:

Operating condition Limitation
Booster start Not possible with driver stage CJ945
Overvoltage operation 1618 V @ Tamb > 20C with driver stage CJ945
Cold start, gas direct qdyn = f(pulse)
Cold start, switchover from
gasoline operation
qdyn = f(pulse)
Hot start qdyn = f(pressure, temperature)
Full load after cold start qdyn = f(temperature)
2.7 Robustness with regard to external media
The component is resistant to inlet manifold gases and external media:
Engine oil (e.g. 0W40); transmission oil (e.g. Titan Gear MP 80); brake fluid
(e.g. DOT4); engine cleaner (e.g. P3 solveclean HK), FAM test fuels (e.g. FAM-B).
2.8 Functional values
For gas valves, the metered fuel quantities depend on the following parameters:

- Gas quality Calorific value
- Gas temperature Density
- Primary pressure (Rail) Density
- Battery voltage Valve switch times
- Environment temperature Switch times, coil resistance

Compensation for these factors in the course of application of the system is
required.
2.9 Maximum switch-on time
0,5 h (at 13,4 V Batt, 110C TAmb, 40C TGas)

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2.10 Flow direction
Top-feed
2.11 Interfaces
- Valves fitted decoupled from vibrations through floating fit in o-rings
- Valve tip in inlet manifold positioned outside the stream of the gasoline
valve (for bifuel- or monofuel+ vehicles)
- Injector tip faces downwards when in vehicle to avoid collecting liquids such
as oil or fuel from manifold
- Injector must not dip into liquids that have collected in inlet manifold
Also see AZ 0 280 A01 321-702
2.12 Mechanical strength
Axial stress: 600 N
Bending stress: 6 Nm
Torsional stress: 4 Nm

The load values are permitted only during the assembly and dismantling proce-
dures. Application of force below the manifold side o-ring in the direction of
the outlet is not permitted.

2.13 Usage in Bifuel vehicles
The gas injector must be operated every 1000 km or once every month for a minimum
of 50 pulses.

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3. Test data/Test methods
3.1 Flow measurement
Test conditions

- Test setup: Approved and released Bosch test bench
- Test medium: Nitrogen (N
2
), Bosch Norm: N28 No. 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, Characteristics
- Driver stage: See section 1, Characteristics

This driver stage is designed only for setting and measuring of injectors. It
works in similar fashion to 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

Measurement procedure

The massflow [kg/h] must be measured at a stationary point.

Measurements are to be carried out in the following order:
1. Dynamic flow qdyn: Deviation of inlet pressure < 1% of nominal
value; deviation of massflow < 2 % of actual average value for a pe-
riod of t >5 sec.
2. Static flow Qstat: Deviation of inlet pressure < 1% of nominal
value; deviation of massflow < 1% of actual average value for a pe-
riod of t >5 sec.
The massflow per lift [mg/lift] can only be a calculated value.
3.2 Linearity
3.2.1 Definition of 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
calculating 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

3.2.2 Calculation method for linearity deviation
The deviation percentage for a given t
i
from the individual ideal flow rate can be
calculated as:

m = slope of the ideal straight line

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

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

with:
q
dyn
(t
i
) [%] = linearity deviation at ti
q
dyn
(t
i
) [kg/h] = dynamic flow at ti
t
i
[ms] = injection time
t
s
[ms] = 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
continuously increasing the supply voltage of the driver stage 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
temperature. The test value is the result of the temperature difference and the
control conditions.
- Test temperature: 23 C 3 C
- Cycle time T: 20 ms
- Pulse width t
i
: 10 ms
- Voltage gradient: 1V/s
- Start voltage: 4 V
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

3.4 Leakage test
Leakage rate is separated in seat leakage and leakage to environment. Leakage
rate to environment includes all possible leak paths generated through operating
pressure without seat leakage. Seat leakage emit exclusive to inlet manifold.

Definition Leakage rate:
Leakage is defined as emitted quantity of gas per time. The quantity of gases is
described with product of volume and pressure (cm * bar or equivalent mbar * l)

Leakage rate is influenced by
- pressure conditions

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- conditions of gas (particularly viscosity)
- geometrical dimensions of leak path
The leakage rate corresponds with the geometrical dimensions of leak path. Gas
and pressure conditions have to defined:

Leakage rates mentioned in chapter one are referenced to the following
conditions::
Gas: Helium
Viscosity : 1,9755 *10
-5
Pa s 0,015 *10
-5
Pa s
Temperature: 21C 2C
Pressure downstream p
a
: < 0,05 kPa absolut (vacuum)
Pressure upstream p
z
: operating pressure

The injector must be clean and dry. No liquid phase is allowed.

Test methods:
All methods, that have a measurement capablitiy for the in chapter one mentioned
value, are allowed. In dependance of the used test method a conversion is
necessary. Normaly test method differ from the above mentioned conditions by gas,
pressure or temperature.

Examples for conversion by different test conditions:
Different Pressure (proven correlation necessary):
=
h
bar cm
p p
p p
value metered leakage
a z
a z
*
*
3
2
1
2
1
2 2

Index 1 terms changed parameters

Different gas:
By usage of a different gas the viscosity is changed. The leakage depends recip-
rocally proportional to the viscosity:
=
h
bar cm
value metered leakage
*
*
3
1


Viscosities of other gases:
Methane: 1,112 *10
-5
Pa s
Air: 1,815 *10
-5
Pa s
Nitrogen: 1,772 *10
-5
Pa s

Different gas and pressure (proven correlation necessary):
=
h
bar cm
p p
p p
value meterd leakage
a z
a z
*
* *
3
1
2
1
2
1
2 2


3.5 Measurement of insulation resistance
The insulation resistance is measured between the (+/-) connector pins and
housing. The resistance must not be below the determined value in section 1.
- Test voltage: 750 V D.C.
- Test time: 2 secs.

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Measurement of opening behavior at low temperatures
3.5.1 Cold start, gas direct
Parameters:
- Duration T [ms]: 690 5
- Drive pulses n [no.]: 9
- Test pressure p1 [kPa]: Operating pressure from 1.
- Drive time ti [ms]: 8 0.5
- U batt [V]: 7.5V [ 0.1]
- Temperature [C]: +15

The opening time (t
on
) is to be measured for each injector and each pulse of a
lot.
t
on,av
= average(t
on
, pulse 59) of all injectors of a lot
Opening time deviation (t
on
, pulse 19) may only lie within the following range:
T
on,max
< t
on,av.
+ 0,6 ms
T
on,min
> t
on,av.
- 0,7 ms
For test of new injector lot size is 8 pcs.
For field return tests the lot consists of all injectors out of one engine.

3.5.2 Cold start, changeover from gasoline to cng mode
Parameters:
- Duration T [ms]: 690 5
Drive pulses n [no.]: 9
- Test pressure p1 [kPa]: Operating pressure from 1.
- Drive time ti [ms]: 6 0.5
U batt [V]: 12V [ 0.1]
- Temperature [C]: +5

The opening time (t
on
) is to be measured for each injector and each pulse of a
lot.
t
on,av
= average(t
on
, pulse 59) of all injectors of a lot
Opening time deviation (t
on
, pulse 19) may only lie within the following range:
T
on,max
< t
on,av.
+ 0,35 ms
T
on,min
> t
on,av.
- 0,35 ms
For test of new injector lot size is 8 pcs.
For field return tests the lot consists of all injectors out of one engine.

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4. Endurance and environmental tests
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
functional 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.
4.1 Dynamic tests
4.1.1 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

Test criteria and permissible deviation after the test:
- Q
stat
= 5 %
- q
dyn
= 7 % at t
i
= 3.5 ms
- Total leakage rates: See Section 1, characteristics

4.1.2 Sinusoidal acceleration Test
The injectors are mounted in a fixture. The test has sinusoidal and additional
random frequencies:

sinusoidal:
frequency
[Hz]
accelaration
[m/s]
50 10
200 160
250 160

random:
frequency
[Hz]
power
spectral
density
[(m/s)/Hz]
10 1,00
50 1,00
200 0,10
300 20,00
2000 20,00

duration: 24 h in every direction (injectors longitudinal axis and lateral axis)
frequency alteration: 1 octave/min

- Medium: N2 5,0
- Pressure: see section 1
- T =25 ms, ti = 3,5 ms

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Ambient temperature cycle: -30...+120...-30 C

Duration of the temperature cycle:
- storage 1h at 30C
- increasing within 1h from 30C to 120C
- storage 1h at 120C
- decreasing within 1h from 120C to 30C
Temperature tolerances: 5C

- Qstat = -10% / +10%
- qdyn = -15% / +15% at ti = 3.5 ms
- Total leakage rates: See Section 1, Characteristics

4.2 Climate tests
4.2.1 Salt spray test according to DIN 50 021
A 5% sodium chloride solution is sprayed continuously onto the injector.
From the o-ring onwards, the fuel inlet and outlet and the electrical connector
plug are tightly covered.
- Duration: 144 hrs
- Rating: No harmful rust must be observed.

4.2.2 Condensed moisture - climate change test according to DIN 50 017
1. Storage 8 hrs at 40 C in humid climate
2. Storage 16 hrs at room temperature
The fuel inlet and outlet are tightly covered from the o-ring on.
The plug is mounted onto the connector.
- Duration: 6 cycles (1 cycle = 24 hrs)
- Rating: No rust harmful to function must be found.

4.3 Endurance
4.3.1 Standard endurance test
- Gas and ambient temperature: 23 2C
- T = 5 ms, ti = 2.5 ms
- 380 million cycles (528 hrs), this approximately equals 240,000 km
- Medium: Natural gas quality H (DVGW Regulation see Section 2, Operating
conditions)
- Pressure: See Section 1, Characteristics

- Qstat = -4% / +7%
- qdyn = -5% / +12% at ti = 3.5 ms
- Total leakage rates: See Section 1, Characteristics

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4.3.2 Short endurance test (QZ test)
A short endurance test is carried out within specified periods (see section 5) to
monitor the manufacturing quality.

- Gas and ambient temperature: 23 2C
- T = 5 ms, ti = 2.5 ms
- 144 million cycles (200 hrs)
- Medium: Natural gas quality H (DVGW Regulation See Section 2, Operating
conditions)
- Pressure: See Section 1, Characteristics

- See Section 4.3.1

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5. Carrying out testing (production audit tests)
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 tests
needed from Section 4.
For design changes, the development department selects the tests needed and co-
ordinates the special design verification testing.
6. Field return evaluation
Functional values are determined according to the test conditions listed in
section 3 with the test equipment of the manufacturing plant.In case of com-
plaints, the product is declared free of fault if the following characteristic
data are attained:

6.1 Zero-mileage return
In the case of zero-mileage return, the tolerances of the new parts (see Section
1) must be used. For 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 oriented
towards a service life of 240,000 km, but in any case for a maximum of 15 years.
This statement regarding design of the product for a certain lifetime does not
represent a warranty for the characteristics of the product. The commercial
warranty and liability is regulated in the Conditions of Sale, irrespective of
the above figures.
In the case of an alleged defect of the injectors, the injectors are to be
considered free of defects if the injector functional parameters are within the
following stated tolerances for Q
stat
, q
dyn
and leakage.

- Q
stat
= 10 %
- q
dyn
= 15 % at t
i
= 3.5 ms
- Total leakage rate: See Section 1

The operation of the injector in accordance with the operating conditions speci-
fied in Section 2, especially the use of the specified natural gas only, is the
premise for acceptance of field returns.
7. Type approval according to ECE R110
Release of the NGI2 injector for use in natural gas vehicles according to ECE R
110 is carried out by a vehicle licensing authority. The release is documented by
the ECE mark on the injector. NGI2 injectors without an ECE mark are not li-
censed for use on public roads.

0 280 K00 849-702
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Date 15.10.2007


Legally binding signature

Robert Bosch GmbH

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

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

Customer

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

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

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