14-nov-13 © 2013 prins autogassystemen b.v. · pdf filefiltering the cng flowing towards...

SilverLine-2.0 LPG System overview


Prins SilverLine Reducer

Very stable dynamic pressure behavior System pressure control with single stage valve System pressure is independent to inlet pressure (MAP). (This is due to linear flow character of injector) Adjustable pressure: 1,7-2,6 Bar Integrated temperature sensor ( NTC resistor R=2500 ohm at 20 °C) Pressure relief valve according to R67-01 regulations Flexible lock-off-valve both 6 and 8 mm


Prins reducer

16mm gas output

Water proof connetor

Lock off valve

Filter

Engine Coolant Temperature sensor Rotatable 16mm water pipes

System pressure adjusting screw


Reducer center disk

Coolant side: Gas side:

Gas out

Gas in

In out

ECT


Oparation


Coolant connections

Connected in Parallel or Serial to the heating system 16mm hose connection Plastic water hose can be rotated to the required position Check the coolant level, refill if required and de-aerate the circuit Check if the reducer and car heating heat up quickly Check pressure drop at full acceleration (cooling water flow)


+

2 3 4

afsluiter

verdamper

zuursof sensor

benzine injector cilinder 1

uitlaat

T-stuk

kachelradiateur met kachelkraan

LPG leiding Tank

overdruk slang

inlaatspruitstuk

vsi spruitstuk nippel

gasklephuis

koelvloeistof

in

uit

kachelkraan

injector rail

filter unit

VSI injector 1

Psys + Tlpg sensor

+

2 3 4

afsluiter

verdamper

overdruk slang

zuurstof sensor

kachelradiateur zonder kachelkraan

koelwater

LPG leiding Tank

benzine injector cilinder 1

inlaatspruitstuk

uitlaat

vsi spruitstuk nippel

uit

gasklephuis

injector rail

filter unit

VSI injector 1

Psys + Tlpg sensor

in

02000400060008000

10000120001400016000

-20 -10 0 10 20 30 40 50 60 70 80 90 100

Rnt

c [O

hm]

Temperature [°C]

NTC-curve

Engine Coolant Temperature sensor (ECT)

Discription: Integrated in the coolant section of the evaporator Temperature sensor (based on NTC-resistance) Reducer temperature Controls the switching over timing from petrol to LPG Monitoring flow Trouble codes: T_ECT> 171˚C voltage to low

T_ECT< -40 ˚C voltage to high


R NTC [Ohm] Temperature [C]9400 -10

2500 20

325 80

Mounting the reducer

The rear lid contains a cross for a closed connection One bolt M8 is sufficient for the fixation on the frame The reducer can be mounted in two ways: – With the 16 mm LPG output on top and the water connections

downwards (required) – With the cut-off-valve downwards


Pressure relief valve

Pressure relief valve according to R67-01 regulations Opens at 2,25 times operating pressure: 2.25x2,6=5.85 bar ±0,5 Over pressure is vented via 6mm hose to the inlet manifold Manifold nipples most be ordered separate!


Lock off valve (Reducer)

“Standard” Lock off valve (6mm) “Big Flow Capacity” lock off valve 8mm (engines >135kW) – Increased bore from 3.2 to 5.2mm – Coil is identical to standard lock off valve – Pilot operated Flexible position (180 degrees to rotate)


Replacing filter in lock off valve

•2x cover o-ring (renew)

•Filter bottom o-ring (recycle)

Attention:

relieve system pressure before changing the filter!


Map connection

Developed for turbo engines/engines with short ti_petrol on idle Gas Absolute Pressure= variable (dependent on Manifold Absolute Pressure [turbo pressure]) Delta Pressure= constant (differential pressure over the injector rail)


Use the MAP-sensor and regulator map connection with turbo applications and when injection times (Idle) are smaller than 3ms. use Prins extension turbo kit (180/70250). – There is a possibility to use cars own MAP-sensor

Connect the reducer and MAP-sensor like overview beside.


MAP-connections

Pressure adjustment

Adjustment tool Part number:099/9960 Standard pressure new reducer = 2,2 bar After mounting a new reducer always adjust the pressure! – Universal: see universal calibration manual


SilverLine-2.0 CNG System overview


Standard Prins SilverLine MAP CNG regulator Uncoated housing Provides highly stable outlet pressure and small pressure drop level at a wide range of tank pressure System pressure adjustable (1,6-2,5 [Bar]) Coolant heating to prevent ice formation Optional MAP referencing connection

Prins CNG regulator

© 2013 Prins Autogassystemen B.V.

Engine Coolant Temperature sensor (ECT)

Description: Integrated in the coolant section of the reducer Temperature sensor (based on NTC-resistance) Switch over to CNG based on ECT value Trouble codes: T_ECT> 171˚C voltage to low

T_ECT< -40 ˚C voltage to high


R ntc [KOhm] Temperature [°C] 42,7 -10

12,1 20

1,7 80

Coolant water connections

Connected in Parallel to the heating system 8 mm hose connection Check the coolant level, refill if required and de-aerate the circuit Check if the reducer and car heating heat up quickly Check pressure drop at full acceleration (cooling water flow)


Map connection

MAP connection for turbo engines/engines with short ti_petrol on idle Gas Absolute Pressure= variable (dependent on Manifold Absolute Pressure [turbo pressure]) Delta Pressure= constant (differential pressure over the injector rail) 14-Nov-13 © 2013 Prins Autogassystemen B.V.

♦ CNG fuel lines are made from steel (seamless not welded) ♦ Outside diameter 6mm ♦ CNG ISO 15500 110R approval ♦ Steel fuel lines are difficult to bend

Fuel Lines


We advice RVS Double-ferrule fittings!

Fuel lines coupling


Always use the correct connection material – use adapters from the same material as

the fuel lines We advise always double ferule (R110) – Gives the best sealing with the less

deformation of the fuel lines and for servicing

– Can be reassembled several times Fitting parts should be mixed by different brands Fitting instructions should be followed Installation by qualified persons

Fuel lines coupling


First assembly

1. Fully insert the tubing into the fitting and against the shoulder. 2. Rotate the nut finger tight. 3. Mark the nut at the 6 o’clock position. (See picture). 4. While holding the fitting body steady, tighten the nut one and one-quarter turns to the 9

o’clock position (see picture).


Second assembly

1. Insert tubing with ferrules into the fitting body until the front

ferrule Seats (fig 1). 2. Rotate the nut with a wrench to the previously pulled-up

position, at this point a significant increase in resistance will be encountered.

3. Tighten slightly with a wrench one quarter turn (15-20 Nm).


Function: Shutting off the CNG flow to the pressure regulator Filtering the CNG flowing towards the regulator (150µ). Providing housing for the manometer Cold engine T<450C 2 sec. Pre-opening Warm engine T >450C 1 sec. Pre-opening

Filter need only be replaced if excessive pollution is observed!

CNG Lock-off valve


♦ Indicates the fuel pressure in the tank ♦ The pressure is the indication of the amount of fuel in the tank ♦ Integrated built-in sensor for the tank indicator in the switch ♦ The manometer is mounted on the high pressure fuel line

between the shut-off valve and the reducer ♦ Linear hall sensor

Prins manometer


Filterunit


Combined Psys and T-LPG sensor

Filter

Support

Vaporous LPG out

(engines with 2 injector rails only)

Vaporous LPG input

Filter Unit

Lightweight nylon housing – high pressure resistance [ max.25bar] Special glass fiber filter material [3μm] Max. oil trap 4-5 gram Light weight (0,11 kg) 16mm gas inlet 11mm outlet Filter element replacement: – First time after 25.000km – Sub sequential every 75.000km

Attention!

For warranty the dealer who replaced the filter has to sign /stamp the service booklet!


For 3-4-5-cyl. engines

Combined P/T sensor

The system pressure will be measured: To produce corrections on the LPG injection times in case of pressure fluctuations, thereby the VSI-system is not dependent of pressure fluctuation.

The LPG temperature will be measured because: The density of LPG is dependent of the LPG temperature. The colder the LPG the higher the density of the LPG. From 20 to 60˚C the energy flow to the engine will varied up to 12 %. Placed after the filter so that filter pollution has no influence on LPG quantity Fault codes : T_lpg >171 ˚C or voltage to low

T_lpg <-40 ˚C or voltage to high Psys voltage to low Psys voltage to high


Sensor type Measuring range 191/000005/A 0.5 tot 5.5 bar

Prins SilverLine injectorrail

Standard Prins 4 cylinder injector rail 4 injector flow ranges – Engine capacities from 9 kW up to 47 kW each cylinder.


Adaptor nippels

1. Remove the inlet manifold. 2. Install the couplings as close as possible near the petrol injectors. 3. Drill x holes of 5 mm in the inlet manifold. 4. Cut M6x1 thread in these holes. 5. Place the inlet couplings with a lock compound in the inlet manifold.

Watch out that the lock compound doesn’t block the inlet coupling.

Attention! Always use hose clamp and check for gas leakage!


AFC Wiring loom

Main loom Injector loom

Bosch 81+40 Pin connectors IP 67. Wiring text printed on wire. One main fuse with waterproof fuse holder.



AFC-2.0 Fuel selection switch

New modern design Programmable RGB LED’s 3-wire connections instead of 7 LIN communication with AFC-2.0 ECU Automatic switch software update

“6” level indication LED’s Programmable LED colour Tank empty LED, default RED Programmable tank levels

Larger selection button Programmable logo colour System diagnostic LED Automatic daylight correction

Programmable Beeper volume

Automatic fuel switch software update – automatic update after communication with

diagnostic software (diagnostic LED’s flashes blue) Programmable tank sensor selection. – Pre-defined:

• Hall >> 5 indication levels • 0-95 Ohm >> 6 indication levels • CNG gauge >> 6 indication levels

– User defined: • >> 6 indication levels

Automatic daylight correction: – default linear correction. – programmable by look up table for optimization of LED illumination.


Fuel selection switch

Alternative Fuel Controller 2.0

Light weight aluminium housing [Bosch] Higher performance and extended possibilities [I/O] All power outputs are digitally protected against overload Integrated Injector Module

– Sequential switch over [blending possible] Switch intelligence integrated in AFC

– Communication through LIN Comprehensive interfaces

– UART, LIN Extended diagnostic functions through software

– Actuator tests through diagnostics – Freeze frame data Sleep current <1mA RPM signal through – ignition coil connection possible Ignition + connection through +injectors



Alternative Fuel Controler-2.0

Article label Breathing plug

Connector A (main 81 pin)

Connector B (injector 40 pin)

Power supply & ground(s) ECU side inj [1-6]

5 volt sensor supply (3x) Min Inj side [1-6]

+12 volt Lock off valves (2x) + GAS INJ [1-6]

Sensor input signals - GAS INJ [1-6]

Diagnostic connections [TXD&RXD] + petrol injectors

Plastic mounting support


Electrical wiring connections

Switched supply


[pin112]+ignition>> + petrol injectors Back up voltage for IM-circuit when fuse is broken!

RPM signal connection


[pin8] RPM sign.>>– ignition coil / hall signal

O2 sensor connections


[pin 19-20] Analog input (AD3+4) can be programmed for different sensors (Lambda1/2 / MAP / ValveCare)


[pin 13] +12V battery sense = potential difference measurement

[pin 32] ground battery sense = potential difference measurement

Map/turbo connection (optional)


[pin 17-18] Analog input (AD1+2) can be programmed for different sensors

( MAP / ValveCare)

Part 3


Signal processing

AFC Input-signals Battery voltage (Ubat, +30) Ignition switch (+15/+petrol inj.) Ground RPM signal (VSI-I) – max. 16 pulses per engine rotation – Min. 3,2V / peak max. 30V signal – + ignition (VSI-I RPM module) Petrol injection times (VSI-I>Injector-Module) Lambda signal (one or two) Depends on motor configuration Temperatures (Coolant & Gas) – By ECT-sensor in reducer – T-gas sensors in filter unit System pressure – pressure sensor in filter-unit Fuel choice via fuel switch Valve care (optional)


AFC output signals

Gas shut –off valves in the reducer and fuel reservoir Gas injector operation Interruption/simulation of petrol injectors integrated in AFC 5V sensor power supply for temperature, pressure, MAP sensor. Switch operation


VSI corrections

Colt start enrichment Engine warm-up enrichment Full load enrichment System Pressure Gas temperature Engine Coolant Temperature ECT Corrections:

- After Fuel Cut Off correction - Switch over corrections - NOx corrections (emission)

corrections Petrol ECU

corrections AFC


Basic mixture calculation

Petrol ECU calculates ti_petrol

AFC calculates ti_gas

ti_gas= (ti_p X RC + offset) x LPG_cor.

LPG_cor= P_sys/T_lpg/ECT/etc.


RPM signal

VSI-I computer can only process block wave/Hall sensor signals – Check with a oscilloscope if a useful RPM signal is available – Max. 16 pulses per engine rotation (min. 3,2V/Peak max.30V) AFC can process block wave/Hal & – ignition coil signals – Input programmable in AFC software


O2-sensor signal

Lambda signal will be used for mixture control and emission corrections (Nox cor.) AFC can only process narrow band/switching O2-sensor signal AFC can process max. 2 O2-sensor signals (2 banks) Always check after installation if O2-signal is stable Program correct O2 sensor


Prins AFC Software v2


Software/registration/update

Software registration through AFC software or Prins website. Auto-updates through internet. Warranty registration through warranty portal.


Part 4


Service /warranty procedure

Service Items

Filter change : both filter in lock of valve and filter unit. – First replacement after 25.000km – subsequently every 75.000km Check all hoses for: – damage – gas leaking – Engine coolant leakage – Petrol leakage Check fastening of components. Check electrical connections and wiring. Tighten torque of the allen screws of the reducer [8Nm]. Check for engine error codes and VSI system error codes. Check exhaust emissions. Necessary vehicle service with regard to ignition plugs, ignition cables engine valve clearance, etc.


Warranty procedures

WWW. prinsautogas.com


Warranty Portal

Warranty period SilverLine-2.0 is 2 years – Service and filter replacement has to be done Every Warranty Claim has to be made by use of the Warranty Portal. All parts which are returned have to be accompanied by a printed Warranty Request Form. Warranty parts have to be returned within 3 months after replacement.


World leader in alternative fuel systems

Thank you for your attention

14-nov-13 © 2013 prins autogassystemen b.v. · pdf filefiltering the cng flowing towards...

Documents