1. Introduction
The Tomasetto AT09 Nordic LPG/CNG Gas Pressure Reducer is a single-stage reducer specifically designed for sequential injection systems in vehicles converted to operate on Liquefied Petroleum Gas (LPG) or Compressed Natural Gas (CNG). This device is homologated under ECE 67R-01 standards, ensuring compliance with European regulations for automotive LPG/CNG components. Its primary function is to regulate the high-pressure gas from the vehicle's fuel tank to a stable, lower pressure suitable for the engine's injection system.
This manual provides essential information regarding the product's features, specifications, installation requirements, operation, and maintenance to ensure safe and efficient use.
2. Safety Information
WARNING: Improper installation or handling of gas conversion systems can lead to serious injury, property damage, or death. Always adhere to safety guidelines.
- Professional Installation Required: Installation and commissioning of the AT09 Nordic reducer must be performed exclusively by a professional automotive parts facility or a qualified technician specializing in LPG/CNG systems. Self-installation is strongly discouraged due to the complexity of the system and the need for specialized tools and software calibration.
- Qualified Service Only: In the event of any malfunction or issue, contact qualified service technicians immediately. Unauthorized handling or attempts at self-repair can pose significant safety hazards and may void any warranties.
- Regulatory Compliance: Before converting your vehicle, ensure it complies with all applicable local, national, and international regulations for LPG/CNG vehicle conversions. Operating a non-compliant vehicle can result in legal penalties and safety risks.
- Gas System Integrity: Regularly inspect the gas system for leaks or damage. Any signs of gas odor, unusual noises, or performance issues should be addressed by a professional without delay.
3. Product Overview and Features
The Tomasetto AT09 Nordic reducer is an advanced component designed to optimize the performance and efficiency of LPG/CNG sequential injection systems. Key features include:
- Single-Stage Regulation: Efficiently reduces high-pressure gas to a stable, usable pressure for the engine.
- Integrated Filter Unit: Helps protect the system from impurities in the gas, ensuring cleaner fuel delivery and extending component lifespan.
- Inlet Solenoid Valve: Controls the flow of gas into the reducer, providing precise and safe operation.
- Additional Post-Heating: Features an enhanced post-heating mechanism for the LPG at the outlet. This allows for higher gas flow and maintains a higher gas temperature at the exit, which is crucial for optimal engine performance, especially in colder conditions or when the engine demands maximum power.
- Adjustable Outlet Pressure: The outlet pressure can be adjusted within a range of 0.9 to 1.8 bar (90 to 180 kPa) when not connected to the engine, allowing for fine-tuning during professional calibration.
- Cost Savings: Enables vehicles to run on more economical fuels like LPG or CNG, significantly reducing operational costs compared to gasoline.
- Environmental Benefits: Promotes more complete combustion, leading to reduced exhaust emissions and a lower environmental impact.
- High Performance and Stability: Engineered for reliable and stable operation, contributing to consistent engine performance and driving safety.
4. Specifications
| Parameter | Value |
|---|---|
| Material | Aluminium die cast body |
| Weight | 1.5 kg |
| Dimensions (L x W x H) | 120 x 125 x 105 mm |
| Max. Inlet Pressure | 3 MPa |
| Outlet Pressure (variable, not connected to engine) | 90 to 180 kPa (0.9 to 1.8 bar) |
| Solenoid Voltage | 12 V DC |
| Solenoid Absorption | 17 W |
| Inlet Connection | M10x1 pipe Ø6 mm |
| Outlet Connection | Fixed fitting Ø12 mm |
| Homologation | ECE 67R-01 |
5. Installation
The installation of the Tomasetto AT09 Nordic Gas Pressure Reducer is a complex procedure that requires specialized knowledge, tools, and software for proper calibration. It involves working with high-pressure gas systems and vehicle electronics, which can be dangerous if not handled correctly.
- Professional Service is Mandatory: This product is intended for installation by certified LPG/CNG conversion specialists only. Do not attempt to install this unit yourself.
- System Integration: The reducer must be correctly integrated into the vehicle's existing fuel system, cooling system, and electrical system. This includes proper connection of gas lines, water hoses for heating, and electrical wiring for the solenoid valve.
- Software Calibration: After physical installation, the system requires precise software calibration to ensure optimal fuel delivery, engine performance, and compliance with emission standards. This calibration is specific to the vehicle model and engine type.
- Leak Testing: Thorough leak testing of all gas connections is critical after installation to prevent gas leaks, which are extremely hazardous.
Refer to the official user manual PDF for detailed diagrams and instructions, which can be found at: Tomasetto AT09 Nordic User Manual (PDF).
6. Operation
Once professionally installed and calibrated, the Tomasetto AT09 Nordic Gas Pressure Reducer operates automatically as part of your vehicle's LPG/CNG sequential injection system. The system is designed to seamlessly switch between gasoline and gas (LPG/CNG) modes, typically controlled by an in-cabin switch or automatically based on engine parameters.
- Automatic Fuel Switching: The system will generally start on gasoline and automatically switch to gas once the engine reaches a specific temperature and RPM, as configured during calibration.
- Manual Override: Most systems include a manual switch to select between gasoline and gas modes, or to force a switch if needed. Consult your vehicle's specific LPG/CNG system manual for details on its operation.
- Pressure Regulation: The reducer continuously maintains the optimal gas pressure for the injectors, ensuring consistent engine performance.
No direct user interaction with the reducer itself is required during normal operation.
7. Maintenance
Regular maintenance is crucial for the longevity and safe operation of your LPG/CNG system, including the AT09 Nordic reducer. All maintenance should be performed by a qualified technician.
- Filter Replacement: The integrated filter unit within the reducer requires periodic replacement. The frequency depends on the quality of the gas used and driving conditions. Consult your installer or the system's maintenance schedule for recommended intervals.
- System Inspection: Regular checks of all gas lines, connections, and electrical components for wear, damage, or leaks are essential.
- Calibration Check: Periodically, the system's calibration may need to be checked and adjusted to maintain optimal performance and efficiency.
- Component Lifespan: While designed for durability, components like the reducer have a finite lifespan. Adhere to manufacturer recommendations for component replacement.
8. Troubleshooting
If you experience any issues with your LPG/CNG system, such as reduced performance, unusual noises, gas odors, or difficulty switching fuels, it is imperative to seek professional assistance.
- Do Not Attempt Self-Repair: Due to the high-pressure gas and complex electronic components, attempting to diagnose or repair issues yourself can be extremely dangerous.
- Contact a Qualified Technician: Immediately contact a certified LPG/CNG specialist for diagnosis and repair. Provide them with a detailed description of the problem.
- Safety Precaution: If you detect a gas odor, immediately turn off the engine, ensure all windows are open for ventilation, and evacuate the vehicle. Do not start the engine or operate any electrical components.
9. User Tips
- Choose a Reputable Installer: The quality of installation directly impacts the safety and performance of your LPG/CNG system. Select an installer with proven experience and certifications.
- Regular Servicing: Adhere to the recommended service schedule for your gas system. This includes filter changes and system checks, which can prevent minor issues from becoming major problems.
- Monitor Fuel Levels: Always be aware of both your gas and gasoline fuel levels. Running out of gas can cause the system to automatically switch to gasoline, which is normal, but it's good practice to avoid running tanks completely dry.
10. Warranty and Support
For warranty information, technical support, or service inquiries regarding your Tomasetto AT09 Nordic Gas Pressure Reducer, please contact your authorized dealer or the original point of purchase. Ensure you have your purchase details and product serial number available when contacting support.