Zavoli Alisei N

Technical Manual
Calibration Software for the Alisei Injection

System
(Installer Version ZAV009)
MT_IS_SWI-003.04-E del 06/10/09

MT_IS_SWI-003.04-E
Technical Manual del 04/10/09
Calibration Software for the Alisei
Injection System
Document Technical ID:

MT_IS_SWI-003-I
Rev. Date Review n. Issued by Reviewed/Approval
by
0 19/12/2006 First ROS DDT
Issue
1 26/03/2007 Second ROS DDT
Issue
2 11/10/2007 Third ROS DDT
Issue
3 16/02/2009 Fourth ROS DDT
Issue
4 06/10/2009 Fifth ROS DDT
Issue
PREFACE
This manual is not a comprehensive guide on the calibration and management of the Alisei
system. These operations require the support of specific equipment and specialized personnel.
Therefore, the goal of this manual is to provide general guidelines for the management and
calibration of the Alisei injection system.
ZAVOLI S.r.l. disclaims any responsibility for system malfunctions due to alterations performed
by non-authorized personnel. Illegal tampering with the system will cause its warranty to become
null and void.
ZAVOLI S.r.l. reserves the right to revise its software in accordance with new applications and
techniques available in the future. ZAVOLI S.r.l. disclaims any responsibility for system
malfunctions caused by failure to update this manual.
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ZAVOLI s.r.l. Via Pitagora n° 400 47023 CESENA Fr. Case Castagnoli (FC) Italy
Tel. 0547/ 646409 – Telefax 0547 / 646411 Assistenza Tecnica Tel. 0547 / 300426
Web site: www.zavoli.com E-mail: [email protected]
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General Index
Introduction ……………………………………………………. ……4
1. ……………….. System Requirements ….…………………………..………….. ……4
1.1 ………… Installation of the Software …………………………………… ……4
2. ……………….. Main Menu.……………………...……………………………… ……5
3. ………………. Vehicle Configuration … ………….…………………………. ……8
3.1 ………… F1 Change ……..…………………….…………………………. ……10
3.2 ………… F2 Lambda………….……………….….………………………. ……14
3.3 ………… F3 Sensors………….……………………………………………. ……17
3.4 …………. F4 Map …….………………………..…………………………. ……19
3.5 …………. F5 Gas/Petrol…………………………………….……………… ……21
3.6 …………. F6 Madify Carb ………………..…….………….……………… ……24
4. ………………... Display……………………………..………………………….…. ……27
5. ……………….. Diagnosis………….....…………………………………………… ……30
6. ……………….. Autocalibration.…………………………………………………. ……32
7. ……………….. Save Configuration …...………………………………………… ……33
8. ……………….. Load Configuration ..…………………………………………… ……34
9. ……………….. ECU Reprogramming…..……………………………………… ……35
10. ……………….. Alisei Program - Error Codes ………………………….……… ……37
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Introduction
Our calibration software can be opened even if the control unit is not connected. However, in order
to connect to the control unit your PC must be properly connected to the latter by means of an
interface cable (code 200001) and a USB-serial adapter (for PCs without a serial port). The adapter
can be purchased from an authorized seller.
The control unit must also be connected to the +12 volt battery (Red/Black cable) as well as to the
ground (Black) cable.
1. System Requirements
Operative System: - Windows 98 2nd Edition (or higher)

Memory (Ram): - No less than 16 Megabytes
Hard Disk: - No less than 20 free Megabytes before installation
Resolution: - 800 x 600, or higher
The system should also support an Internet Explorer browser, 5.5 version or higher.
1.1 Installation of the Software
To install our calibration software, insert the CD-ROM into the CD-ROM drive and wait for the
Setup installation window to appear. If the installation program does not automatically start the
setup process, select “Start” in the task bar, then click on “Run” and type: "D:\setup.exe" (D
indicates the CD-ROM drive).
During the installation, you will be asked to select in which directory the program should be
installed. We suggest that the default directory be used.
When the installation process is completed, the AliseiN software icon will automatically appear on
your desktop.
NOTE: to use the “Installer Version” of this software, please connect the hardware plug for
USB or Parallel port to your PC.
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2. Main Menu
The main menu (Fig. 2-1) allows you to access all the options of the calibration software. Options
are listed and described in the following pages.
Fig 2-1
The bottom of the page displays the following information (Fig. 2-2):
1. It indicates whether the control unit is connected to the calibration software or not. Please
remember that all settings programmed while the control unit is disconnected will not be
saved when the connection is restored – unless they are specifically saved in a configuration
file. When you open the program, it will automatically try to connect to the control unit. If a
connection cannot be established, an ‘Error’ window will appear on your display.
In this case, please check for the following:
- that the serial interface is properly connected,

- that the control unit is connected both to the battery and the ground cable,
- whether the under-the-key control has been disconnected for over an hour. To connect it,
simply turn the dashboard controls on for a few seconds, or start the vehicle.
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To establish a new connection, click on the “Connection” menu and then on “Connect”, or press
“Ctrl+C".
2. It indicates the Standard Configuration setting of a vehicle. In order to upload an existing

configuration in the control unit, the latter must be connected to the configuration software.
3. It indicates the firmware version of the control unit. To update it, please click on the
“RESET CONTROL UNIT” menu and select a firmware.
NOTE: This operation is possible only if your computer features INTERNET EXPLORER,
version 5.5 or higher.
4. It indicates whether the configuration currently loaded in the control unit is using LPG or
Methane parameters. To select the type of fuel you want to use, click on the “VEHICLE
CONFIGURATION” menu.
Firmware Version 5.6

Fig 2-2
Fig. 2-3 shows the main menu toolbar. It includes the following menus:
File: when you select “File”, a scroll-down menu appears. Exit the program by clicking on
“Exit”.
Connection: when you select “Connection”, a scroll-down menu appears. It features the
following menu options:
- Connect: select it to transfer data from the control unit to the computer and vice-versa.
- Disconnect: click on it to disconnect the control unit from your computer.
Settings: when you click on “Settings”, a scroll-down menu will appear. The menu contains the
following options;
- Language: it allows you to set the language of the program.
- S/N: “Serial Number”. It displays the serial number of the most recent hardware and
software configurations of the system.
Help: It provides information about the version of the software in use.
Internet Updates: If your computer is connected to the Internet, this option will allow you to
download updates for the software.
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Always make sure to use an updated version of the software. For more information,
please contact our Technical Assistance Center.
Fig. 2-3
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3. VEHICLE CONFIGURATION
This menu is composed of 6 pages, which will allow you to set up parameters for the gas control
unit (Fig. 3-1).
Fig 3-1
As shown in Fig. 3-2, the bottom of each page gives you an overview of the current general
operating signals of the system.
A B C Fig 3-2
D E
A. This section indicates whether the vehicle is using gas or petrol. When the system is in a cut-
off mode, the words CUT-OFF will appear on the display.
B. This section displays the following information:

ROUNDS: engine revolutions are read in real time by the gas control unit.
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GAS T.: it indicates the gas temperature, as gauged by the temperature sensor located on the
GAS tube near the gas injectors.
REGULATOR T.: it indicates the temperature of the gas regulator, as gauged by the
temperature sensor located on the GAS regulator.
C. This section displays both Gas Injection Times (Gas Tinj.) and Petrol Injection Times (Petr.
Tinj).
D. This section provides information about:

GAS PRESS.: the difference in pressure between the gas inside the gas injectors and the
intake manifold, as determined by the pressure gauge supplied with the kit.
MAP: If an AEB025 pressure sensor has been installed in the system, this parameter
indicates the pressure of the intake manifold.
SENSOR AEB025: it indicates the type of pressure gauge connected to the system.
E. This section displays the following information:

- The current of the lambda sensor, as gauged by the purple wire connection. If the latter is
not connected, no parameter will be displayed (=n. a.).
- The figure read by the GAS injection control unit by means of the fuel level sensor
connected to it.
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3.1
By pressing F1 on your keyboard, or by clicking on F1 with your mouse, you can access the
“Change” menu, shown in Fig. 3.1-1.
All parameters highlighted in YELLOW should be changed when both the

dashboard controls and the switch are off.
Fig 3.1-1
TYPE OF FUEL
This will allow you to initialize the control unit using default parameters for a proper operation of
the system with the fuel of your choice.
Select:
LPG: for vehicles fuelled by LPG.
METHANE: for vehicles fuelled by METHANE.
When you select either LPG or METHANE, the save directory of your configuration files will be
changed, too (see Load Configuration).
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INJ.
This function allows you to select the type of activation strategy needed for GAS injectors
depending on the system in use:
SEQUENTIAL: Select “Sequential” for vehicles with a sequential or semi-sequential engine. The
GAS injector will be activated with each PETROL injection.
FULL GROUP: Select “Full Group” for vehicles with a full-group engine. The GAS injector will
be activated with every other PETROL injection.
INJECTORS
This menu allows you to select the type of GAS injectors supplied with the installation kit.
Select PAN if you are using modular PAN injectors; select MATRIX if you are using Matrix
injectors.
If you are loading a configuration which has been previously saved on your computer, the menu
will indicate the type of gas injectors selected in the configuration.
If the GAS injectors do not correspond to the ones indicated in this menu, you will have to load a
configuration file based on your current injectors, or change the gas injectors altogether. In case the
injectors installed in the vehicle do not correspond to the ones you have selected, injectors will be
controlled by incorrect parameters. This may lead to malfunctions in your gas system.
REGULATOR
This function allows you to select the type of regulator in use:
STANDARD: Select standard when you are using a ZETA N regulator, for engines up to 160kw.
SUPER: Select standard when you are using a ZETA S regulator, for engines 160kw and over.
ROUNDS SIGNAL TYPE

It programs the control unit to gauge RPMs by means of the BROWN wire (Brown wire of the
control unit cables):
STANDARD: Select this option when the brown wire is connected to either one of the following
signals:
- reading tachometer with square wave signal (0 ÷ 12 V);
- coil negative.
WEAK SIGNAL: Select this option when the brown wire is connected to either one of the
following signals:
- gauging tachometer with square wave signal (0 ÷ 5 V);
- static ignition control with square wave signal (0 ÷ 5 V).
These signals can only be read by means of an oscilloscope.
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CYLINDER NUMBER
This parameter supplies the control unit with information about the number of cylinders in the
vehicle, and the number of gas injectors that need to be activated:
Enter 3 CYLINDERS or 4 CYLINDERS, depending on the number of cylinders in your vehicle.
If your control unit is designed for a 5-6-8-cylinder vehicle, your menu will display the following
options: select 5 CYLINDERS, 6 CYLINDERS or 8 CYLINDERS, depending on the number of
cylinders in the vehicle.
IGNITION TYPE
This parameter is used by the control unit to gauge the engine regime, which varies according to the
type of ignition to which the BROWN wire is connected.
Enter:
SINGLE-COIL: for vehicles featuring one coil per cylinder, and when the BROWN wire is
connected to the negative pole of one of the coils;
TWO-COIL: for vehicles featuring one coil per spark-plug couple, and when the BROWN wire is
connected to the negative pole of one of the coils;
TACHOMETER: for vehicles with one coil and a mechanic distributor, and if the BROWN wire is
connected to the negative pole of this coil. Enter this option also in case BROWN wire is connected
to the tachometer signal wire.
TACHOMETER 2: select this option when in a 6- or 8-cylinder vehicle (with the BROWN wire
connected to the tachometer), RPMs are not being gauged correctly.
SWITCH TYPE
It allows you to select the type of switch, from PETROL mode to GAS mode.
ACCELERATION: Switching from PETROL to GAS occurs when the vehicle is accelerating, as
soon as the RPM number surpasses the “RPM THRESHOLD FOR FUEL SWITCH”.
DECELERATION: In this case, the switch from PETROL to GAS occurs as a consequence of
either one of the following conditions:
- When the RPM number surpasses the “RPM THRESHOLD FOR FUEL SWITCH” and then
drops below it.
- When a Cut-Off condition occurs and the RPM number is higher than the “RPM THRESHOLD
FOR FUEL SWITCH”.
RPM THRESHOLD FOR FUEL SWITCH

It indicates the RPM level which prompts the switch from PETROL to GAS.
REGULATOR TEMPERATURE FOR FUEL SWITCH

It indicates the temperature that the regulator must reach before the switch to gas is performed. The
control unit WILL NOT SWITCH TO GAS unless a certain temperature level has been reached.
If, when using gas, the temperature drops below the desired threshold, the control unit will still
continue to use GAS. We suggest that the temperature threshold be set between 20°C and 45°C
because:
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- If the threshold is set at a lower temperature, the switch from PETROL to GAS will occur when
the regulator has not reached its best operating temperature for GAS to be dispensed properly;
- If the threshold is set at a higher temperature, it will take too long before the switch from PETROL
to GAS is performed.
PETROL-TO-GAS SWITCH DELAY

It indicates the shortest amount of time before the system is allowed switch from PETROL to GAS
after the engine has been turned on.
We suggest that this time threshold be set at 20 seconds (or longer) in order for the system to work
correctly.
OVERLAP TIME
It indicates the period of time during which an overlap of PETROL and GAS occurs. This prevents
potential failures to occur in the system while it switches from one type of fuel to the other.
We recommend that the default setting (ZERO) be used. Please contact our
Technical Support Centre if you have any questions.
RESET CONTROL UNIT AND REVERT TO DEFAULT PARAMETERS

By clicking on this bar, you will reset all the configuration parameters of the control unit. The
system will revert to its original default parameters. We suggest clicking on this bar when you are
not sure if all the new control unit parameters have been set up correctly, and want to revert to the
original C.U. setup (see Fig. 3.1-2).
Fig. 3.1-2
WARNING! Make sure to change the highlighted parameters only when the controls located
under the key ignition slot are off.
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3.2
By pressing the F2 key, or by clicking on F2 with your mouse, you will access the “Lambda” menu,
described in the following paragraphs (Fig. 3.2-1).
Fig. 3.2-1
NUMBER OF BENCHES
It allows you to select the number of benches included in your engine.
ADJUST SECOND BENCH

If the engine has two benches and two front Lambda sensors, this menu item will help you increase
(or decrease) the GAS carburetion level of the second bench if the latter is not calibrated with the
first. In particular, with 4-cylinder vehicles, this parameter sets the carburetion of the B-C GAS
injectors slightly off balance with the A-D GAS injectors. With 6-8-cylinder vehicles, on the other
hand, the carburetion of the GAS injectors connected to RED BAND joints is set off balance with
the other GAS injectors.
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TYPE OF FRONT LAMBDA SENSOR

This parameter helps the control unit to check that the Lambda sensor is working correctly. Before
selecting the type of Lambda sensor in use, please make sure that the sensor is working correctly.
Use a digital multimeter.
If you are using sensors with a current of 0-1 Volts; 0-5 Volts; 5-0 Volts or 0.8-1.6 Volts and would
like to check their current, please follow these directions:
- Connect the PURPLE wire to the Lambda sensor, without breaking the original connection (the
GREY wire should not be connected).
- If you are using UEGO Lambda sensors, you will not be able to check the current of the
sensor.
0 ÷ 1 V – Select this option if the current on the signal wire ranges between the following levels:
- about 0 ÷ 0.2 V with a poor fuel mixture;
- about 0.8 ÷ 1 V with a rich fuel mixture.
0 ÷ 5 V - Select this option if the current on the signal wire ranges between the following levels:
- about 0 ÷ 0.2 V with a poor fuel mixture;
- about 4.8 ÷ 5 V with a rich fuel mixture.
5 ÷ 0 V - Select this option if the current on the signal wire ranges between the following levels:
- about 4.8 ÷ 5 V with a poor fuel mixture;
- about 0 ÷ 0.2 V with a rich fuel mixture.
0.8 ÷ 1.6 V - Select this option if the current on the signal wire ranges between the following levels:
- about 0.7 ÷ 0.8 V with a poor fuel mixture;
- about 1.4 ÷ 1.6 V with a rich fuel mixture.
UEGO – If you are using UEGO sensors, do not select any parameter and do not connect any wire.
LAMBDA1 SENSOR (PURPLE WIRE)

It allows users to read the parameters of a Lambda sensor and emulate it. In case of diagnostic
errors (ex: “Catalyst Failure”), the sensor will read the front Lambda sensors and emulate the rear
ones.
NOT CONNECTED: The Lambda sensor parameters are not displayed (n. a.) and no emulation
occurs.
FRONT: When the vehicle is using GAS, the parameter of the front Lambda sensor is displayed.
REAR: When the vehicle is using GAS, the parameter of the rear Lambda sensor is displayed. The
emulation process is activated after a period of time which can easily be set up by the user in the
“Emulation Delay” bar. We suggest performing this operation whenever the catalyst is not working
properly and the PETROL control unit led is on.
LAMBDA2 SENSOR (PURPLE/BLACK WIRE)

It allows users to read the parameters of a Lambda sensor and emulate it. In case of diagnostic
errors (ex: “Catalyst Failure”), the sensor will read the front Lambda sensors and emulate the rear
ones.
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NOT CONNECTED: The Lambda sensor parameters are not displayed (n. a.) and no emulation
occurs.
FRONT: When the vehicle is using GAS, the parameter of the front Lambda sensor is displayed.
REAR: When the vehicle is using GAS, the parameter of the rear Lambda sensor is displayed. The
emulation process is activated after a period of time which can easily be set up by the user in the
“Emulation Delay” bar. We suggest performing this operation whenever the catalyst is not working
properly and the PETROL control unit led is on.
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3.3
By pressing the F3 key, or by clicking on F3 with your mouse, you will access the “Sensors” menu,
described as follows (Fig. 3.3-1).
Fig. 3.3-1
MAP SENSOR TYPE
It informs the GAS control unit about the type of MAP sensor in use (AEB 025 or AEB 013).
GAS LEVEL SENSOR TYPE

It informs the GAS control unit about the type of level sensor in use:
AEB - enter AEB if the GAS control unit is connected to an AEB standard output signal sensor (ex:
AEB1050). To connect the sensor, please refer to the GAS control unit installation chart.
0 - 90 ohm - enter 0 - 90 ohm if the control unit is connected to an output signal sensor with a range
of 0 – 90 ohm (ex. AEB1090). To connect the sensor, please refer to the GAS control unit
installation chart.
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NON-STANDARD
Enter this option if you are using an LPG or METHANE resistive sensor with a variable
STRAIGHT signal (lower ohm on “empty”, and higher ohm on “full”).
INVERTED NON-STANDARD
Enter this option if you are using an LPG or METHANE resistive sensor with a variable
INVERTED signal (higher ohm on “empty”, and lower ohm on “full”).
NON-STANDARD LEVEL REFERENCE

This option will only be available if you enter “NON-STANDARD or INVERTED NON-
STANDARD” in the “GAS LEVEL SENSOR TYPE” field. Enter the reference levels for the level
sensor setup according to the following directions:
- with your finger, move the sensor indicator starting on a “full” tank and take notes of the
parameters indicated at each reference point (RESERVE, ¼, 2/4, ¾).
- write down the parameters in the corresponding blank fields.
- press the “ACCEPT” button
The switch will display the following adjustments:

RESERVE = LEVEL range when the reserve red LED turns on and the ¼ LED turns off.
¼ REFERENCE = LEVEL range when the 2/4 LED turns off.
2/4 REFERENCE = LEVEL range when the ¾ LED turns off.
¾ REFERENCE = LEVEL range when the 4/4 LED turns off.
THE REAR SOLENOID VALVE WITH DEDICATED WIRE

It enables the diagnosis for the gas solenoid valve of the tank.
In the case that on the GAS ecu the BLU-WHITE and the BLACK wirings are not present we
recommend you not to enable this function in order to avoid the storage of faulty codes by GAS
ecu. (Those wires are expressly dedicated to the feeding of rear multivalve)
HIGHER LEVEL OF GAS IN THE TUBES

In general, the GAS control unit activates the GAS solenoid valves for about 1 second before
switching from PETROL to GAS. This allows enough time for the gas tubes to fill up. If the default
time of 1 second is not enough and the vehicle turns off when switching from one type of fuel to the
other, you can activate this option. The GAS valves will be opened at least 5 seconds before the
system switches to GAS, thus allowing for higher levels of fuel in the GAS tubes. If the option is
not activated, a warning will be displayed on the screen to remind the user not to stop the PETROL
pump.
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3.4
By pressing the F4 key, or by clicking on F4 with your mouse, you will access the “Chart” menu,
described as follows (Fig. 3.4-1).
Fig. 3.4-1
This menu will allow you to display the “K” multiplication coefficients used by the control unit to
determine GAS injection times. The Y (vertical) ax displays petrol injection times, while the X
(horizontal) ax displays RPMs. The red dot indicates the reference parameters for the RPM and
petrol injection time that the engine is currently using. By increasing the “K” coefficient, GAS
injection times will be increased too, while on the other hand, by decreasing the “K” coefficient, the
opposite operation will be performed.
For a correct control of the carburetion, you can read the lambda correctors in the program,
connecting the wires to the EOBD diagnosis connector of the car. This function is available only
with the LPG ecus;
 3-4 cylinders E.C.U. “AEB2001NC”

 5-6-8 cylinders E.C.U. “AEB2568D”
In order to change “K” coefficients, select one or more fields in the chart and click on ‘Enter’. A
window listing the following adjustment options will appear (see Fig. 3.4-2):
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ABSOLUTE: The number entered in the blank field will appear on the chart.
LINEAR: The number entered in the blank field will be either added to or subtracted from (in case
of a negative number) the figure in the selected square(s).
PERCENTUAL: The % value of the number entered in the blank field will be added to (or
subtracted from) the figure in the selected square(s).
Fig. 3.4-2
PC-CONTROLLED SWITCH
When you activate this function, the “SWITCH” bar will appear on your right. By clicking on it,
you can prompt the system to switch from PETROL to GAS directly from your PC. When this
function is activated, the switch located inside the vehicle is temporarily disabled.
MAP-RESET
Pushing the "Map Rest " button the LPG ecu takes the map back to the basic parameters
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3.5
By pressing the F5 key, or by clicking on F5 with your mouse, you will access the “Gas/Petrol”
menu, described as follows (Fig. 3.5-1).
Fig. 3.5-1
SEQUENTIAL FUEL CHANGE-OVER

Enabling this function, the change-over to GAS is gradual, cylinder by cylinder (by default setting
recommended). When using that function, generally the change-over is smoother. In the case that
the function is not enabled, petrol injectors are excluded all simultaneously and the change-over is
therefore immediate. This function is automatically disabled when starting the car in emergency
mode through the change-over switch.
ANTICIPATE INJECTION SEQUENCE

It is a guided procedure which allows you to automatically perform an injection sequence and
anticipate the injection of fuel. The new timing of the injection sequence is determined in part by
the “Number of Benches” control (section F2 Lambda). This operation may improve the vehicle’s
performance, especially if the gas injectors are not too close to the intake manifold. Please use this
function only when necessary, as it prompts the vehicle to ABRUPTLY switch from PETROL to
GAS.
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ADAPTIVITY
Enabling this function, after the carburetion control and the connection of the wires to the EOBD
connector of the car, the LPG ecu will correct the carburetion according to the values of the lambda
correctors.
ENGINE AT IDLE
GAS – by activating this function the vehicle will always use GAS when at idle (default and
recommended setting).
PETROL TEMPORARY SWITCH BACK – when going back to idle mode, the vehicle will
switch back to petrol for a few seconds, then switch back to gas again. This will prevent the vehicle
from stalling. We recommend users to activate this function only when necessary. The “Idle
identification RPM” parameter determines the RPM threshold to be used to activate this function.
PETROL – When running below the default RPM threshold, the vehicle will always use petrol.
The system will automatically switch to gas as soon as the engine RPM goes over the “Idle
identification RPM”. This function can only be used when the vehicle cannot use gas at idle, or if it
tends to stall. Although the Petrol/Gas switch will not show that the system is running on petrol (it
will still consider gas as the current fuel source), the computer will. In particular, you will notice
that Gas Injection Time has dropped down to zero. As a matter of fact, in this phase the switch will
still consider gas as the main fuel source, and gas solenoid valves will still be active. If the
“Anticipate Injection Sequence” function is still active at this time, please make sure that this does
not interfere with the system.
RUNNING AT A HIGH RPM

GAS – when this function is activated, the vehicle runs on gas even at high RPM and at high engine
load (default and recommended option).
PETROL ADDITION – enabling this function some additional petrol will be supplied to the
standard GAS injection. Set the following parameters:
- The Rpm over which petrol addition will be supplied
- The Injection time for PETROL addition, that is the reference petrol time injection read, over
which the PETROL addition will be supplied.
ATTENTION: The function PETROL addition will be enabled only if both conditions are
respected.
- The value of petrol addition, that is the opening time of PETROL INJECTION, supplied as
addition.
The graphic indicator, laying on the right ginger of the box “Operation at high
RPM”, will turn yellow to signal the temporary operating with petrol addition .
PETROL – by activating this function, the vehicle will temporarily use PETROL under high RPM
and heavy engine load conditions. The function will be active until the accelerator pedal is released.
Users can customize both the number of RPMs and the injection time threshold for the GAS control
unit to switch to PETROL.
The switch from one kind of fuel to the other will only occur if both conditions are met.
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This function can be particularly useful with vehicles using delicate catalysts that tend to overheat
when using GAS. This function is also particularly functional for vehicles with very powerful
engines (most commonly turbo). As a matter of fact, these vehicles tend to use large GAS injectors
to properly fuel a heavy-load engine – a condition which causes the engine to be unstable when
under lighter loads.
Although the Petrol/Gas switch will not show that the system is using petrol (it will still consider
gas as the current fuel source), the computer will. In particular, you will notice that Gas Injection
Time has dropped down to zero. As a matter of fact, in this phase the switch will still consider gas
as the main fuel source, and gas solenoid valves will still be active. If the “Anticipate Injection
Sequence” function is still active at this time, please make sure that this does not interfere with the
system.
The graphic indicator, laying at the right winger of the box "Operation at high
RPM", will turn to RED to signal the temporary operating on PETROL of the
vehicle..
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3.6
By pressing the F6 key, or by clicking on F6 with your mouse, you will access the “Modify Carb.”
menu, described as follows (Fig. 3.6-1).
Fig. 3.6-1
This menu allows you to manually switch gas carburetion and refine the self-calibration procedure
of the GAS system. When the self-calibration procedure is completed, please check the
carburetion system and adjust it as indicated. This operation can be performed by means of a
diagnostic tester displaying the correctors/integrators of the petrol control unit (ex: for OBDII
vehicles you can use an OBDII diagnostic tester). Please make sure to test them through the various
stages of engine load.
The CARBURETION SWITCH section includes 2 columns:
IDLE: For engines running at 1,000 RPM;

BEYOND IDLE: For engines running at over 1,000 RPM.
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Both columns are divided into 4 cells indicating various engine loads. When a cell is highlighted in
red, the current engine load is displayed. The arrows located in the columns can be used to increase
or decrease figures in any cell by 5 points.
TESTING CARBURETION - PROCEDURE:

Before making any adjustments, please make sure that the vehicle is in good working
conditions when using petrol. The Gas fueling system is based on the vehicle’s original Petrol
fueling system.
- Start the vehicle on petrol and wait for the engine to reach its regular operating temperature of
about 90°C;
- Select the cell indicating the carburetion level you would like to test. Make sure to keep the
accelerator pedal in the same steady position;
- Check the integrators/connectors by means of an OBDII palm tester;
- Switch to gas and try to go back to the same RPM (and the same cell);
- Check the integrators/connectors again;
- If while the vehicle is using gas, the correctors/integrators are 3-4 units higher/lower than when
running on petrol (ex: they increase from 8% to 11-12%), adjust the carburetion. Please remember
that:
- If the correctors/integrators rise toward positive numbers, the petrol control unit is
detecting poor carburetion. In this case, enter a number similar to the variation of the
correctors/integrators in your cell.
- If the correctors/integrators slide toward negative numbers, the petrol control unit is
detecting excessive carburetion. In this case, enter a negative number in your cell.
- After each adjustment, make sure to check that the correctors/integrators are at the
same level for both Gas and Petrol.
- Repeat this procedure for every cell in your columns, and remember that in order to
complete some cells, a regular driving test is required.
If correctors/integrators are at the same level while using either Gas or Petrol, it is not necessary to
adjust the carburetion.
EXTRA-INJECTION SENSITIVITY LEVEL

EXTRA-INJECTIONS are short, additional injections of fuel which occur when the vehicle is using
petrol – and generally, when accelerating. They are designed to improve carburetion and, at the
same time, engine performance.
Extra-injections can be detected by checking either the RED dot in the chart, or the petrol injection
time. The latter will drop from a regular injection time (ex: 8m) to a very short injection time (ex:
0.8m), and then eventually go back to its regular value.
When using gas, if extra-injections were to become the norm, carburetion would become excessive,
and RPM parameters would increase considerably. Usually, when this happens the engine tends to
skip (which is quite common with methane-based systems, and less of an issue for LPG systems).
By checking the “EXTRA-INJECTION SENSITIVITY LEVEL” box, the parameters regulating
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GAS extra-injections can be adjusted. In particular, the opening times of the GAS injectors during
the extra-injection will be either increased or decreased by moving the slider bar toward the “+” or
the “- “sign. If the box is not checked, the extra-injection will not be identified as such by the
system, and the GAS control unit will treat it as a regular fuel injection.
EXCESSIVE CARBURETION DURING ACCELERATION

When accelerations are abrupt, some vehicles respond by increasing the PETROL injection time
from a MEDIUM-LOW level to a high level (ex: 15-16m). When using GAS, this may cause
malfunctions in the system, due to excessive carburetion. To solve the problem, use the “Excessive
carburetion during acceleration” sliding bar and follow these directions:
- Move the bar toward the “+” sign if you want the control unit to emulate any variation in
PETROL injection times.
- Move the bar toward the “-“sign if you want these variations to be filtered and controlled.
INJECTION TIME CUTBACK IN MAZDA VEHICLES

When using PETROL and accelerating, some MAZDA vehicles will switch from a SEQUENTIAL
injection strategy to a HALF-GROUP strategy (where PETROL injectors are opened in pairs). This
condition is easily detectable: just accelerate and check the progress of the RED dot on your chart,
or the PETROL injection times. When switching from an injection strategy to another, injection
times will drop down to approximately half their standard value (ex: from 8m to 4m), and the RED
dot will keep switching from the higher to the lowest value. However, in some vehicles, the dot will
change only after a fixed RPM threshold has been reached, and will then go back to the original
PETROL injection time. When using GAS, the switch from SEQUENTIAL to HALF-GROUP
(short injection time) can be the cause of a number of malfunctions, since the carburetion of GAS
can become excessive and the engine tends to skip. To solve this problem, enter the value required
to counteract this issue in the “Injection time cutback in MAZDA vehicles” box.
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4. Display
This page displays all the signals supervised by the control unit (fig. 4-1).
5
6
1 3 7
8
2
4
10
Fig.4-1
1) It displays the temperature of the GAS regulator (in °C);
2) It displays the GAS temperature (in °C);
3) It displays the current RPM;
4) It indicates whether the vehicle is using GAS or PETROL;
5) It displays the current Gas injection time (min.);
6) It displays the current PETROL injection time (min.);
7) It indicates the difference in pressure (bar) between GAS in the injectors and GAS in the
manifold intakes, as gauged by the pressure gauge supplied with the kit;
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8) It displays the pressure of the manifold intakes (bar);

9) It indicates the current of the Lambda sensor. If the wires of the Lambda sensor are not
connected, no result will be displayed on your screen;
10) It supplies useful information for the exact adjustment of the nozzles installed on the GAS
injectors.
Shifting from the left to the right of the graphic, keeping the right button of the mouse pressed you
can enlarge the selected area.; similarly, shifting from the right to the left of the graphic you can
cancel that operation bringing back the display to the original set.
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1) Inside "Graph” menu it is possible to select following entries:
 Trace Manager: it allows to choose all

the parameters (traces) to be displayed
on the graph.
 Print it allows to print the displayed
graph.
 Cancel zoom: it allows to bring the
graph back to the original displaying
(100%).
 Exit : it allows to escape from the
“Graph” menu.
2) Legend of the graph: it shows the colours corresponding to the different displayed signals. Only
the traces selected in “Trace manager” are displayed on the “Graph” menu (see point 1).
N.B. The traces "T inj.gas 2" and "T inj.benz.2" refer respectively to the “Gas
Injection Time” and "Petrol Injection Time" of the second bank.
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5. DIAGNOSIS
This page displays all the parameters that the control unit monitors through its diagnosis system
(Fig. 5-1).
Gas Injectors ERROR

Connection of the Petrol Injectors ERROR
Tank Solenoid Valve ERROR
Regulator Solenoid Valve ERROR
Gas Pressure Sensor ERROR
Map Sensor ERROR
Gas Temperature Sensor ERROR
Fig. 5-1
As soon as the GAS control unit detects a diagnosis error in a parameter, it proceeds to perform a
specific action.
Diagnosis Action
Gas Injectors Switch to Petrol
Connection of the Petrol Injectors Switch to Petrol
Tank Solenoid Valve Switch to Petrol
Regulator Solenoid Valve Switch to Petrol
Gas Pressure Sensor Switch to Petrol
Map Sensor Switch to Petrol
Gas Temperature Sensor Switch to Petrol
Water Temperature Sensor Switch to Petrol
Switch No Action
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Inside the box "Petrol injector signal diagnosis", the petrol injection times reading is graphically
represented.
The entry "OK" indicates that the reading of the signal is correct, whereas the entry “X” indicates
the presence of a fault in the reading in correspondence of injector A,B,C or D.
N.B. On 5/6/8 cylinders vehicles , PETROL injectors and correspondent GAS

injectors of the second bank are written in red colour.
In the box "Gas Injector Cut Out ", selecting "Off", it is possible to electrically exclude one or more
GAS injectors. In that way the corresponding PETROL injector will be enabled. That operation is
particularly useful for the diagnosis of the malfunctioning of one or more GAS injectors.
Any diagnosis errors detected by the control unit can be erased from its memory by pressing the
lower right-hand key “Erase Diagnosis Errors”. Whenever errors are detected, the yellow led turns
on and the green led flashes slowly to notify the driver of the malfunction. The buzzer located
inside the switch goes off, too, for an easier identification of the error. To turn off the buzzer, just
press the switch button. This will prompt the system to switch from Gas to Petrol.
Some errors will trigger an automatic switch to Petrol. In this case, the control unit
will proceed to switch to Petrol as soon as the error is detected. To switch back to
Gas, turn off the vehicle and start it up again.
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6. AUTOCALIBRATION
This section will show you how to perform a autocalibration of the Gas control unit. This operation
helps the vehicle achieve the best possible carburetion as well as optimal performance levels when
using GAS (Fig. 6-1).
Before starting the self-calibration procedure, please make sure that the vehicle is
in good working conditions when using petrol. The Gas fueling system is based on
the vehicle’s original Petrol fueling system.
Fig. 6-1
To start the self-calibration procedure, follow these simple directions:

1) Start the vehicle on petrol and wait for the engine to reach its regular operating temperature of
about 90°C;
2) Start the self-calibration procedure by pressing ENTER and then follow the directions displayed
on your monitor.
Once the desired RPM has been reached, the control unit will switch from petrol to gas for a few
times. At this point, even if the RPM keeps changing, it is important to keep the accelerator in a
steady position. Do not try to bring your RPM back to the level it reached when the vehicle was
using PETROL.
After performing the self-calibration, try switching the vehicle back to gas. Check that all
parameters are correct, and adjust carburetion if needed (use the chart described in paragraph 3.4).
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7. SAVE CONFIGURATION
This sub-menu will help you save all the calibration parameters set up in the “vehicle
configuration” menu in a separate file. This file can later be used to set up control units installed in
similar vehicles, using the same type of fuel – METHANE or LPG (Fig. 7-1).
Fig. 7-1
To save your parameters, enter the name of the file you want to save in the corresponding blank
field and click on OK. When you select a configuration in the list of saved files, the system will
automatically attach the file to your e-mail.
The guided selection of cylinder number (lower left-hand of the screen) will only be
available if the control unit is not connected to your computer. If it is, information
about the cylinders will automatically be saved in your file.
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8. LOAD CONFIGURATION
This sub-menu will allow you to upload an existing configuration into your control unit (Fig. 8-1).
Fig. 8-1
Configuration files are located in two separate directories: one for LPG configurations and one for
METHANE. Before uploading a configuration, go to “VEHICLE CONFIGURATION” and in the
“Type of Fuel” field select methane or LPG according to the configuration you wish to upload.
The guided selection of cylinder number (lower left-hand of the screen) will only be available if the
control unit is not connected to your computer. If it is, only the available configurations for your
type of control unit will be listed. Select the file you wish to upload and then click on OK.
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9. ECU REPROGRAMMING
This sub-menu allows you to update the gas control unit FIRMWARE (a system management
program installed in the unit itself) whenever updates are available (Fig. 9-1).
Fig. 9-1
The CD-ROM for the installation of the calibration software includes the latest firmware version
available at the time when the CD was issued. More recent versions of the software can be sent
through e-mails or saved on a disk.
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To avoid losing previously saved configurations, make sure that the control unit is connected to
your computer before you update your FIRMWARE.
On the lower left-hand corner of the main menu, you will be able to check whether the control unit
is connected to your PC or not (Fig. 9-2).
Fig. 9-2
In order to reset the control unit, Internet Explorer 5.5 (or higher version) must be
installed on your computer.
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10 ALISEI PROGRAM - ERROR CODES
SETUP ERRORS CAUSE

PLANNING
Preparation Errors:
P01 It is impossible to connect to the control unit through COM or USB
ports. The system cannot find a connection to the control unit. The
control unit is not communicating with the system; the communication
pathway may have been interrupted.
P02 The connected control unit is not compatible (either because of its
hardware or its firmware).
P03 An error has occurred while opening the setup file.
P04 An error has occurred while decrypting the setup file. (The setup
procedure requires an Internet Explorer version higher than 5.5, with
128-bit cryptography).
Setup Errors:
P05 Wrong setup current.
P06 An error has occurred while erasing flash memory.
P07 An error has occurred while initializing the system
(BAD_PREPARATION).
P08 An error has occurred while initializing the system (BAD_ERASE).
P09 An error has occurred while starting the setup process.
P10 Input data are void.
P11 Wrong cryptographic mode.
P12 Generic setup error.
P1000 and up An error has occurred while setting up the record (ERR.CODE-1000).
Writing of the firmware has failed. Try again.
Hardware key
H01 An error has occurred while reading/writing the hardware key.
H02 No hardware key compatible with the program has been found.
H03 The number of accesses/the data of the key have expired.
H04 Data not compatible with the data stored in the key.
Connection
C01 It is impossible to connect to the control unit through COM or USB
ports. The system cannot find a connection to the control unit. The
control unit is not communicating with the system; the communication
path may have been interrupted.
C02 An error has occurred while loading the control unit identification
data.
C03 The firmware of the connected control unit is not compatible with the
calibration tool.
C04 The calibration tool is not compatible with the firmware of the
connected control unit.
Pag. 37 di 37

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Technical Manual

Calibration Software for the Alisei Injection

MT_IS_SWI-003.04-E del 06/10/09

Document Technical ID:

1. ……………….. System Requirements ….…………………………..………….. ……4

1.1 ………… Installation of the Software …………………………………… ……4

2. ……………….. Main Menu.……………………...……………………………… ……5

3. ………………. Vehicle Configuration … ………….…………………………. ……8

3.1 ………… F1 Change ……..…………………….…………………………. ……10

3.2 ………… F2 Lambda………….……………….….………………………. ……14

3.3 ………… F3 Sensors………….……………………………………………. ……17

3.4 …………. F4 Map …….………………………..…………………………. ……19

3.5 …………. F5 Gas/Petrol…………………………………….……………… ……21

3.6 …………. F6 Madify Carb ………………..…….………….……………… ……24

4. ………………... Display……………………………..………………………….…. ……27

5. ……………….. Diagnosis………….....…………………………………………… ……30

6. ……………….. Autocalibration.…………………………………………………. ……32

7. ……………….. Save Configuration …...………………………………………… ……33

8. ……………….. Load Configuration ..…………………………………………… ……34

9. ……………….. ECU Reprogramming…..……………………………………… ……35

10. ……………….. Alisei Program - Error Codes ………………………….……… ……37

Operative System: - Windows 98 2nd Edition (or higher)

1.1 Installation of the Software

- that the serial interface is properly connected,

2. It indicates the Standard Configuration setting of a vehicle. In order to upload an existing

Firmware Version 5.6

B. This section displays the following information:

D. This section provides information about:

E. This section displays the following information:

All parameters highlighted in YELLOW should be changed when both the

ROUNDS SIGNAL TYPE

These signals can only be read by means of an oscilloscope.

RPM THRESHOLD FOR FUEL SWITCH

REGULATOR TEMPERATURE FOR FUEL SWITCH

PETROL-TO-GAS SWITCH DELAY

RESET CONTROL UNIT AND REVERT TO DEFAULT PARAMETERS

ADJUST SECOND BENCH

TYPE OF FRONT LAMBDA SENSOR

LAMBDA1 SENSOR (PURPLE WIRE)

LAMBDA2 SENSOR (PURPLE/BLACK WIRE)

GAS LEVEL SENSOR TYPE

NON-STANDARD LEVEL REFERENCE

The switch will display the following adjustments:

THE REAR SOLENOID VALVE WITH DEDICATED WIRE

HIGHER LEVEL OF GAS IN THE TUBES

 3-4 cylinders E.C.U. “AEB2001NC”

SEQUENTIAL FUEL CHANGE-OVER

ANTICIPATE INJECTION SEQUENCE

RUNNING AT A HIGH RPM

IDLE: For engines running at 1,000 RPM;

TESTING CARBURETION - PROCEDURE:

EXTRA-INJECTION SENSITIVITY LEVEL

EXCESSIVE CARBURETION DURING ACCELERATION

INJECTION TIME CUTBACK IN MAZDA VEHICLES