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CNG MODULE

61 0009 2070

Instruction & Installation Manual

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IMPCO NATURAL GAS MODULE

“Simplify the use of Natural Gas in Forklifts”

The market for Natural Gas as a vehicle fuel has rapidly expanded over the last years. Especially in the field of Industrial Mobile Equipment Natural Gas is gaining more and more interest. IMPCO-BERU Technologies develops and manufactures products and systems that allow on-highway and off-highway engines to operate on clean burning, gaseous fuels such as LPG and natural gas. The IMPCO Natural Gas Module or CNG Module was initially developed to meet Forklift Truck customers’ demands to run engines with this alternative fuel against minimum impact to the existing machine. It allows for easy conversion from existing LPG powered equipment to Natural Gas whereas the IMPCO CNG Module will permanently replace the LPG tank. All high pressure components are mounted on the module and not in the engine compartment. Working principle The CNG Module is a CE approved and patented unit that can be filled with compressed natural gas to a maximum pressure of 20 MPa (200bar). The coolant heated high pressure regulator is an integral part of the Module and reduces the storage pressure to a pressure between 0,7 MPa and 1,2 MPa. Via the integrated fuel lock-off valve, the two stage low pressure regulator and the gas-air mixer the Natural Gas flows into the engine. Engine performance A non-optimized engine running on Natural Gas will show a power reduction of 12 to 16% (H-/L-Gas) compared to the LPG engine. However Natural Gas has a higher Octane rating than LPG and different combustion characteristics meaning that an LPG engine can actually perform better on Natural Gas provided compression ratio and ignition timing are optimized.

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Changes to the fuel system The volume of fuel fed to the engine is higher than with LPG meaning that the gas pressure from the two stage regulator to the Gas-Air Mixer needs to be increased or the fuel passage in the existing Air-Gas valve has to be changed, depending on the application. Apart from connecting the High Pressure Regulator to the liquid cooling system of the engine no further changes are needed to the existing LPG engine in the application. The CNG Module was developed specifically for conversion of engines equipped with IMPCO LPG systems. It is not recommended to use the CNG Module in combination with fuel systems other than IMPCO. Features

- Fulfils PED requirements - Capacity 75 liter - Dimensions Ø390mm / L=930mm

Benefits

- No external high pressure connections - Reduction of downtime during maintenance or

inspection - No dismantling during filling - Fits in the place of an LPG cylinder - Minimum changed to engine system from LPG to

Natural Gas

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Fuel comparison (*) at 200 bar Fuel type

Density [kg/l]

Heat value

[MJ/kg]

Heat value MJ/l

Heat value

MJ/mn³

volume Gasoline

[100] Petrol 0,73 43,5 31,8 100

Diesel 0,83 42,5 35,3 78

Propane 0,51 46,3 23,6 168

Butane 0,58 45,6 26,4 150

LPG (60/40)

0,54 46,1 24,9 159

CNG (H type)

7.2* 35,9 442

CNG (L type)

6.3* 31,7 501

FLT applications (data based on average machine use)

Lifting capacity [ton] 2 2,5 3 4 4,5

Energy use [MJ/hr] 70,6 88,2 105,8 141,1 158,7

LPG [l/hr] 3,3 4,1 4,9 6,5 7,3 Natural gas H type [mn³/hr] 2,3 2,5 2,9 3,9 4,4 Natural gas L type [mn³/hr] 2,6 3,2 3,8 5,1 5,8

Petrol [l/hr] 2,6 3,2 3,8 5,1 5,7

Diesel [l/hr] 2,0 2,5 3,0 4,0 4,5 Run Time CNG [hr] (200 bar, 75 ltr)

H-type natural gas 6,6 6,1 5,1 3,8 3,4

L-type natural gas 5,9 4,7 3,9 2,9 2,6

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Technical specifications:

For dimensions see drawing 1:

Empty weight module. 90 Kg

Cylinder capacity. 75 L

Natural gas capacity. 15 mn³

Maximum pressure 20 MPa @15°C.

Test pressure. 30 MPa @15°C.

Max allowed temperature 65 °C.

Min allowed temperature -40 °C.

PRD valve opening. 110°C +/-10 °C.

Burst disk. 33 MPa @20°C. Excess flow valve closing. 506

kPa (differential pressure)

Refuelling valve. NGV 1

System check. 1000 hours

System service. 10.000 Hours/ 5 years Allowed Fuels: Compressed natural gas meeting either of the following two conditions: Dry gas Water vapour would normally be limited to less than 32 mg/m³. Pressure dew point of -9°C at 20MPa. There are no constituent limits for dry gas, except for: Hydrogen sulphide and other soluble sulphides: max. 23 mg/m³. Oxygen: max. 1 % by Volume. Hydrogen shall be limited to 2 % by volume.

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Wet gas Gas that contains a water content higher than “Dry gas” normally meets the following constituent limits; - Hydrogen sulphide and other soluble sulphides: max. 23 g/m³. - Oxygen: max.1 % by Volume. - Hydrogen shall be limited to 0,1 % by volume.

Installation & Safety Guidelines Safety related aspects:

- The module is designed to be fitted permanently to the application. - Check the mechanical installation before use, the

module mechanical mounting should consist of a support frame fixed permanently to the application.

- The high pressure regulator MUST be heated by engine coolant, check the hose routing and hose protection against mechanical damage.

- The flexible hose between the module and application must have a DIN 4815-4 P30 or R110 class 1 approval and a minimum internal hose diameter of 8 mm (5/16").

- Alternatively a metal tube system may be used; minimal internal bore of the tubing must be 6 mm with a wall thickness of 1 mm minimum, copper tubing should NOT be used. Tubing must be stainless steel or corrosion protected steel.

- The module is approved for a maximum working pressure of 20 MPa (200 bar).

- The module may only be filled from Natural Gas high pressure filling points with Natural Gas meeting the specifications mentioned.

- The automatic tank valve may only be opened when the engine is rotating.

- The maximum use is 10 years. Production date details on the affixed label on the inside of the cage

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The module fulfils PED requirements, no manipulation or changes are allowed on the pressure containing parts of the module

- The user instructions should always be followed exactly - The owner is responsible to submit the system to

periodical inspections with the methods and time intervals according to the local standards and regulations

- It is recommended to submit the module once each 5 years to a visual internal and external inspection by a competent person

CNG Module mounting description (see drawings 2 -4)

- Module mounting should permanently and securely hold the cylinder in place and mounting must be in such a way that protection from external hits, heat sources, and chemical aggressors is guaranteed.

- The module should be mounted in a horizontal or vertical position.

- The mounting system should NOT be clamped, fitted or strapped on the protective cage.

- The mounting system shall allow the module to expand/contract causing no loosening or abrasion of the module. It must be capable to accept a diameter variation empty and full of 0,4% and a length variation of 0,2%.

- Metal to metal contact between the module and the support system should be avoided, protective non-metal linings or covers are recommended.

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Electrical system: The high pressure electrical lock-off valve must be connected to a 12V source which is only active when the engine is rotating. Pressure sensor (optional) connected to the vehicle electrical system or to a separate indicating device.

High pressure vessel: - The vessel must never be subjected to welding, drilling

or other machining that may jeopardize the structural integrity.

- An inspection shall be performed prior to filling or returning a module to service if:

o the module was involved in a fire; o the module was exposed to excessive heat; o the module was dropped or suspected to

have had mechanical impacts; o the module is believed to be damaged by any

other means. o there is unusual behaviour including, but not

limited to: The presence of odour added to

natural gas. Unexpected loss of gas pressure. Rattling or other indications of

looseness. Unusual snapping or hissing

sounds. The module is re-installed after

removal. The module installation is changed

significantly. The module is transferred to other

equipment. The module has been pressurised

over the limits of its design.

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Functional description See drawing 5 The module consists of a high pressure PED storage cylinder and a control section fitted to the same cylinder protected by a metal cage. Via the refuelling connector the module can be filled from a Natural Gas filling point. The cylinder pressure is indicated on a manometer and via an optional pressure sensor the cylinder pressure can be transferred to an external instrument. The cylinder pressure is reduced by the module to enable the engine system to run at reduced pressure. Fuel can only flow when the engine is rotating, the fuel flows from the cylinder via an automatic tank lock-off valve to the high pressure regulator, from the high pressure reducer into the engine.

Safety notification Transporting a CNG Module filled with Natural Gas is subject to safety regulations which can vary per country / region. Should the CNG Module be filled remote from its application please take the following into account. The outlet of the High Pressure Reducer is plugged off. Prior to removing the plug the pressure in the manifold has to be released via the test and evacuation connection. Filling:

- Stop the engine and secure the vehicle against rolling - Remove the protective cap from the refuelling

connector - Connect the high pressure filling connector to the filling

point and follow the instructions at the filling station - As soon as the filling process is ready disconnect the

filling connector and fit the protective cap to the refuelling connector

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Use: No further action has to be taken to operate the vehicle normally. The pressure reading on the manometer is an indication of the fuel quantity. 200 bar ==> Full tank 100 bar ==> 1/2 tank 0 bar ==> Empty tank. Note: Pressure reading only when the engine is running.

Safety devices: The high pressure electrical cylinder lock off valve is only OPEN when the engine is rotating. If for any reason the tank must be closed a manual valve is present to close the tank. In the event of a mechanical damage the outflow of the high pressure Natural Gas will be limited by an excess flow valve IN the cylinder lock off valve. In the event of a too high cylinder temperature a thermal activated valve is present to relieve the pressure, a burst disk is fitted to the tank to evacuate in the event of excessive cylinder pressure. All safety devices are located ON the cylinder lock off valve.

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Drawing 1: Dimensions in mm

Drawing 2: CNG Module Mounting (preferred)

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Drawing 3: CNG Module Mounting (preferred)

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Drawing 4: CNG Module Mounting (preferred)

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Drawing 5: Pneumatic Lay-Out

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Drawing 6: High Pressure Assembly

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