Prins VALVECARE-DI Guía del usuario

VALVECARE-DI SYSTEM MANUAL

SYSTEM VERSION

ValveCare-DI

DATE

23-11-2020

Revision version

v 1.2

PAGE 1

General manual ValveCare-DI

2020

TABLE OF CONTENTS1

TABLE OF CONTENTS.............................................................................................................. 11

MANUAL UPDATES / REVISION .............................................................................................. 22

ABOUT THIS MANUAL............................................................................................................ 23

SAFETY INSTRUCTIONS........................................................................................................... 24

GENERAL INSTRUCTIONS........................................................................................................ 35

TOOL REQUIREMENTS............................................................................................................ 46

ABBREVIATIONS AND TERMS................................................................................................. 47Abbreviations ........................................................................................................................... 47.1 Terms........................................................................................................................................ 47.2

INTRODUCTION...................................................................................................................... 58Highlights.................................................................................................................................. 58.1

SYSTEM OVERVIEW................................................................................................................ 59

GENERAL OPERATION ............................................................................................................ 610

HARDWARE............................................................................................................................ 711 Dosing module ......................................................................................................................... 711.1 Wiring loom.............................................................................................................................. 711.2 Resistor..................................................................................................................................... 811.3 Additional white wiring module (DLM Gen3)........................................................................... 811.4 Additive reservoir..................................................................................................................... 811.5 Mirror leaflet............................................................................................................................ 811.6 ValveCare-DI Additive Fluid...................................................................................................... 811.7 Nipples and hose connections ................................................................................................. 911.8 3 & 4 Cylinder sets.................................................................................................................. 1111.9 5 & 6 Cylinder sets.................................................................................................................. 1111.10

PRINS LPG SYSTEM INTEGRATION........................................................................................ 1212 Installation flow...................................................................................................................... 1212.1 Supported software ............................................................................................................... 1212.2 Advanced Calibration parameters.......................................................................................... 1312.3 Add 1K8 resistor (MPI engines).............................................................................................. 1312.4 VSI-2.0 MPI –AFC Compact.................................................................................................... 1412.5 VSI-2.0 MPI –AFC V2.x ........................................................................................................... 1512.6 VSI-2.0 DI –AFC V2.x.............................................................................................................. 1612.7 VSI-3 DI –AFC 3.0 DI............................................................................................................... 1712.8 Direct LiquiMax Gen3............................................................................................................. 1812.9 Direct LiquiMax Gen3 [Without additional wire]................................................................... 1912.10

VALVECARE-DI SOFTWARE AND SETTINGS........................................................................... 2013 ValveCare-DI Software download .......................................................................................... 2013.1 Connection to laptop ............................................................................................................. 2113.2 Check ValveCare-DI software version .................................................................................... 2113.3 Set ValveCare-DI parameters [Configuration]........................................................................ 2213.4 Ventilate lines......................................................................................................................... 2313.5 ValveCare-DI system check [Live]........................................................................................... 2413.6 Tools....................................................................................................................................... 2413.7 Flash Module ValveCare-DI module....................................................................................... 2413.8

SERVICE AND MAINTENANCE............................................................................................... 2514 Check...................................................................................................................................... 2514.1 Refill the reservoir.................................................................................................................. 2514.2

TROUBLE SHOOTING............................................................................................................ 2615 ValveCare-DI module ............................................................................................................. 2615.1 Prins AFC Software V2............................................................................................................ 2615.2

PAGE 2

General manual ValveCare-DI

2020

Manual updates / revision2

Rev. nr

Rev. Date

Subject update

1.0

02-06-2020

First official release

1.1

10-09-2020

More detailed information; added DLM

1.2

06-10-2020

Added ValveCare-DI settings for 2 tank strategy [separate]

About this manual3

This manual describes:

Operation of the ValveCare-DI system

System and components description

General installation instructions

Prins system integration

Calibration setting (for Firmware 1055 ->)

Service and maintenance

General diagnostics

Safety instructions4

Always avoid direct contact between additive and skin, eyes or mouth. Always wear

protective clothing and safety goggles during work or maintenance on the ValveCare-DI

dosing system.

If the additive comes in contact with the eyes, this may cause irritation. In this case rinse

the eyes 10 to 15 minutes with water and seek medical attention.

If the additive comes in contact with the skin, this may cause irritation. In this case wash

the skin thoroughly with soap and rinse with plenty of water. Seek medical attention if the

irritation persists.

If the additive is swallowed, do not provoke vomiting. Rinse the mouth with water and

drink 2 to 4 glasses of water. Then immediately seek medical attention.

Observe the statutory national regulations when installing the device.

Only competent and qualified persons are allowed to install, maintain and repair the

dosing unit and peripheral equipment.

When connecting or disconnecting electrical wiring, always switch off the power supply by

disconnecting the vehicle's battery.

Assembly of ValveCare-DI device with non-original parts, which have not been checked and

recommended by Prins, is not allowed and may cause material damages for which Prins

cannot be held liable.

This manual was developed by Prins Autogassystemen B.V.

reproduced or published without the permission of Prins

Autogassystemen BV

For more information:

Prins Autogassystemen B.V.

Jan Hilgersweg 22

5657 ES Eindhoven, the Netherlands

Tel: (+31) 040-2547700

www.prinsautogas.com

PAGE 3

General manual ValveCare-DI

2020

General instructions5

The installation of the system shall be done in accordance with the installation manual provided by

Prins Autogassystemen.

This manual is based on Dutch regulations; always install the system in accordance with

local regulations.

Fitting and maintenance is only allowed by LPG engineers.

Failure to follow the instructions in this manual can result in a poor or non-working LPG-

installation or a dangerous situation.

For maintenance instructions and filter registration also see the Driver’s Guide.

Prins Autogassystemen is not responsible for any damages to people or objects as a result

of changes to Prins products.

Power and fuses:

Make sure the ignition key is outside the car / windows open.

Be aware of central door locking, radio / telephone memory code and

alarm system.

Always disconnect the battery when installing the ValveCare-DI system.

Do not place the fuse before having completed the installation of the

system.

ValveCare-DI dosing module

ValveCare-DI dosing module has to be configured with the Valve-Protector software.

Never disconnect the connectors, unless you have removed the main fuse.

Prins AFC Software v2

Set the advanced calibration parameters like described in this document

For a MPI system run the import file from the Members Area.

Harness and wiring:

The text on the wire explains the function of the wire.

The wire harnesses are mainly not model specific. Therefore it may be necessary to

adjust the wire length.

Ensure maximum care is taken when connecting the wiring.

Ensure that it does not run near any of the ignition components.

Make sure there is no stretch on the wire harness.

Solder and insulate all electrical connections.

Make professional joints using solder and shrink sleeve.

Hardware installation:

Always use this manual for installation instructions.

Thread all drilled holes with an anti-corrosion agent, after removing the chips.

Check components for gas leakage with a gas leak detection device after the

installation. Also check for air and fluid leakage.

Contact your local distributer for:

Homologation information.

Technical information

Sales information

Warranty:

Register the components for warranty period after installation.

Work safe:

WEAR SAFETY GOGGLES

PAGE 4

General manual ValveCare-DI

2020

Tool requirements 6

Cable diagnostic ValveCare-DI

099/040003

ValveCare-DI software

Prins Diagnostic program V2.0

Tool kit PDT Diagnose

191/020001

Hose cutter

099/520024/A

Compressed air & air gun

Soldering iron & soldering tin

Insulating tape & adhesive

shrink sleeve

Basic workshop

equipment/tools

Abbreviations and terms7

Abbreviations7.1

Abbreviations

Out written

Explanation

Analog digital

Sensor input

AFC

Alternative Fuel Controller

LPG computer

Direct injection

Fuel injection in cilinder chamber

DIG IN

Digital Input

Input of on / off signal (high / low)

MPI

Multi Point Injection

Fuel injection in inlet manifold

VSI

Vapour Sequential Injection

Gas conversion systems for engines

DLM

Direct LiquiMax

Terms7.2

Terms

Explanation

Prins AFC Software V2

Name of the calibration, service and diagnostic program

PAGE 5

General manual ValveCare-DI

2020

Introduction8

Despite the name ValveCare-di suggests that the system can only be installed with VSI-DI, it can

certainly also be combined with VSI-2.0 MPI and Direct LiquiMax Gen3.

The ValveCare-DI system is a full electronic sequential regulated additive dosing system suitable for

direct injected and port gas injected engines. It can be applied to VSI-2.0 (MPI), VSI-2.0 DI, VSI-3 DI

and Direct LiquiMax. In combination with the highly effective Prins additive, the system will

contribute to a cleaner combustion chamber and improved durability of valves and valve-seats

against excessive wear.

The Prins ValveCare-DI dosing module contains special software to communicate with the Prins

AFC.

Highlights8.1

Ideal distribution by electronic regulated sequential feed into the combustion chamber

Suitable for both turbo and non-turbo engines

Easily refillable additive-reservoir

Self-diagnosis on inbuilt components

Only additive consumption during running on LPG

System overview9

1) Dosing unit

2) Additive-reservoir

3) Low level indicator

4) Additive feed lines

5) Super Seal connectors for easy fitting and integrating into the Prins system

6) Additive feed line connection

PAGE 6

General manual ValveCare-DI

2020

General operation10

The ValveCare-DI system only injects additive during running on LPG. The electronically operated

dosing unit sequentially divides the additive in equal quantities, depending on the LPG

consumption (higher LPG consumption -> more additives). The additive is injected per cilinder. It is

transported via a PTFE hose, connected to the LPG injector hose, or directly into the inlet manifold

with separate nozzles.

The additive reservoir can be fitted separately from the dosing unit for an easier and more user

friendly installation.

The additive is highly effective and protects valves, valve seats, injectors and the

combustion chambers against excessively pollution and wear.

The consumption of the additive has a ratio of 1 litre additive on 1000 litre LPG.

After 100l gas the injected additive should be 100ml.

In case the additive reservoir is empty, the Prins switch will indicate a blue exclamation mark

(blinking), and the engine can run another 4 hours on LPG.

After 4 hours the engine only runs on petrol and the exclamation mark and will be active. Filling up

the additive-reservoir will make driving on LPG possible again.

Blue exclamation mark blinks

ValveCare-DI additive level is low -> 4 hours LPG mode

left.

Fill-up the additive-reservoir with ValveCare-DI additive

Blue exclamation mark constantly on

Prins logo blinking

Beep sound audible

Engine only runs on petrol

Fill-up the additive-reservoir with ValveCare-DI

additive

Caution!

Do not use or mix other additive with the original Blue Prins ValveCare-DI

additive. Use of other additive can harm the system and warranty will

expire directly

Before assembling or working on the ValveCare dosing system, all safety

regulations must be observed.

PAGE 7

General manual ValveCare-DI

2020

Hardware11

Dosing module11.1

Fit the dosing unit in a proper location, taking in mind that on both sides of

the dosing unit, additive feed lines come out. These feed lines have to be

connected to the gas supply lines between injector rail and manifold.

Part numbers

099/040010 4 cylinder divider

099/040011 6 cylinder divider

Wiring loom11.2

The wiring loom has 3 super seal connectors for connecting the dosing unit and

additive reservoir. The other ends should be connected (soldered) to the Prins

wiring loom/car wiring, according to the electrical diagram.

Add the extra 1K8 resistor for the VSI-2.0 MPI systems, like described in the wiring

diagram.

Part number

Wiring loom 191/130032

Connector

ValveCare-DI

Wiring

Connection

Remark

2 pole

Grey

Red

12Volt ignition wire (+15)

Add a 15 amp fuse

Brown

Battery ground

4pole

Grey

Additive level sensor

Orange

+12V Tank off valve

Gas system active

Purple

Gas injector pulse or RPM

Engine load / RPM

Yellow

Pink

Diagnostic input for AFC

Interface to AFC

2 pole

Grey

Additive reservoir Level sensor

Brown

Attention

Always disconnect the battery ground, before working on the electrical system.

Insulate all soldered connections with adhesive shrink sleeves or vulcanisation

tape.

PAGE 8

General manual ValveCare-DI

2020

Resistor11.3

Add the extra 1K8 resistor for the VSI-2.0 MPI systems, like described in the wiring diagram.

Part number

091/000035

Additional white wiring module (DLM Gen3)11.4

Some DLM Gen3 wiring looms do not have wire 60. Check if the wire is available in

the main connector. Order the wiring module and install it like described in the

wiring diagram.

Part number

Tyco 191/140049

Bosch 191/140036

Additive reservoir11.5

Fit the reservoir in an easy to access location in the engine compartment. The car

owner should easily find and have access and refill the reservoir.

Part number

099/040009

Mirror leaflet11.6

To inform the driver

Part number

099/200040

ValveCare-DI Additive Fluid11.7

The additive is highly effective and protects valves, valve seats, injectors and the

combustion chambers against excessively pollution and wear.

The consumption of the additive has a ratio of 1 litre additive on 1000 litre LPG.

After 100l gas the injected additive should be 100ml.

Only use Prins ValveCare-DI fluid. Warranty will be void if any other

liquid is used.

Part number

099/040001 1 litre bottle

099/200040 12x1 litre bottles

Remark!

No bottles of ValveCare-DI are standard supplied in the kit. Order the fluid

separately.

PAGE 9

General manual ValveCare-DI

2020

Nipples and hose connections11.8

Variants11.8.1

Choose the correct type of mounting kit, depending on the used gas feed line between the gas

injectors and the manifold.

5mm and 6mm rubber gas and PTFE feed hose

Cut the 5mm LPG hose at a suitable position.

Insert the additive T-piece and secure it using

suitable clip collars.

Connect the additive hose into the push-fit

connector of the correct output on the module.

6mm nylon gas feed hose

Cut the nylon hose.

Insert the additive T-piece and secure it using

suitable clip collars.

Connect the additive hose into the push-fit

connector of the correct output on the module.

Direct manifold m5

Direct LiquiMax Gen3

Direct LiquiMax applications

Drill a 4.2 mm hole into the manifold. Tap an

M5 thread into this hole. Screw in the additive

jet, using thread sealant paste. The length of

the thread can be sawn down if required. The

end of the jet should not touch the wall inside

the manifold.

Remark!

Cut the PTFE (white) and Nylon (black) hose whit a sharp knife of hose

cutter in a perfect 90 degree angle. This is Necessary for a proper fitting in

the coupling and prevents any damages to the internal coupling seals.

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