ACERT™ 2007 Systems Overview
Good Old Days
1969
Today
Regulated Diesel Emissions • Particulate Matter (PM) • Soot from incomplete combustion • Soluble organic fractions from the fuel & lubricating oil (SOF) • Sulfates formed from the sulfur in the fuel • Oxides of Nitrogen (NO X) • Composed of nitric oxide (NO) and nitrogen dioxide (NO2) • Hydrocarbons (HC) • Regulated either as total hydrocarbon emissions (THC) or as non-methane hydrocarbons (NMHC) • Carbon Monoxide (CO) • Smoke/Opacity
On-Highway Emissions 1988 to 2010 0.6
EPA ‘88
0.5 0.4 M P
0.3 EPA ‘91
0.2 0.1
EPA 07/10
EPA ‘04
EPA ‘94
EPA ‘98
0 0
1
2
3
4
5
6
7
NOx (g/bhp.hr)
8
9
10
11
New Engine Content • Core engines remain essentially the same • Percent new content • C7 / C9 = approx. 35% • C13 = approx. 32% • C15 = approx. 32%
• Predominantly external components
2007 System Overview Series Turbochargers
Flow Sensor Throttle CGI Cooler
CGI Valve
C A A T A
Intake Valve Actuation
CCV Filter
C
C
T
T
High Pressure Injection System
Diesel Particulate Filter
ACERT™ 2007 Diesel Particulate Filter
Diesel Particulate Filter (DPF)
Dual DPF
Diesel Particulate Filter (DPF) 1. What is a DPF? 2. How does a DPF work? 3. What does a DPF look like? 4. Is special DPF maintenance required?
Diesel Particulate Filter
•Single DPF •Vertical or Horizontal Mounting
•Dual DPF •600 Hp & Up
What is a DPF Soot Collects Along the Inlet Walls
Particulate Matter or Soot
Cells Fill Up
Clean Exhaust Out
How does a DPF work Substrate
HC Catalyst (Platinum) CO NOx PM (soot+SOF+sulfates) O2
Washcoat
CO2 H2O NOx O2
Ash Distribution • Low density ash plug near outlet of filter
density ty ash ash layer layer on on wall wall – thickn thickness ess • High densi increasing from inlet to outlet
Core Materials Cordierite • Inexpensive raw material (cordierite is basically sand) • Low thermal expansion coefficient • Good mechanical strength
Cordierite
What does a DPF look like? Sensors on Center Section
CGI Connection DPF Outlet
DPF Inlet
Skin Temperature Protection V-Band Clamps—Torque 100 inch/pound inch/pounds s
DPF Sensors Particulate Trap # 1 Intake Temperature Sensor
Particulate Trap #1 Outlet Temperature Sensor
Particulate Trap #1 Differential Pressure Sensor Tap
Particulate Trap # 1 Differential Pressure Sensor Tap
Inlet Section
Inlet Section Distributor Tube
Formed Marmon Flange Condensate Ring
Insulation
Lifting Eye
Formed Flange Connections to Center Section
Inlet - Description Inlet Diffuser Tube
Outer Shell
Condensation Ring Outer End Cap
Inner End Cap
Insulation
Lifting Eye
Inner Shell
Center Section Sensor Box
Temperature Probe Pressure Boss
Sensor Box Strap
Filter does not slide out of center section
Center Section 1- ti time me us use e gas gaske kett
Ceramic mat material – review safety material in Service Manuals
Center Section Retaining ring is welded in place
Irreversibility Cone feature is longer on reverse side of filter and will cause interference with tab if trying to install backwards
Cent Ce nter er Se Sect ctio ion n – Se Sens nsor or Bo Box x Rock Guards
75 in/lbs
Sensor Box
Insulation
Outlet Section
Outlet Description Outer Shell Irreversibility Tabs Outer End Cap
Condensation Ring
Inner End Cap Insulation
Inner Shell
Lifting Eye
Outl Ou tlet et Se Sect ctio ion n - Ve Vert rtiica call
Drain in this area
Rain Protection System on Verticals
Typical DPF Installation CGI Line
Air Flow CGI Line
OEM DPF Harness Connection
Purge Pump Power Connector
DPF 1 & 2 Connectors
Center Section Analysis
“Goo “G ood” d” DP DPF F – no si sign gns s of of soot on outlet
Soot collected on outlet side of DPF -failed
Center Section Analysis
Soot collected on outlet side of DPF -failed
Failed DPF
Soot collected on outlet side of DPF
What do you think?
Good Filter Weld marks
This is a new filter from the t he factory
What do you think?
Good Filter
Staining is Acceptable, Black soot is not
This is a used filter from service
LC Lab DPF
LC Lab DPF
Nuked Trap
What’s Happening to the Iron?
Rules of Engagement • Engines Purchased from Leasing Company • Single Lease Customer Operation • All 6 Units Operated on the same Route • South East to West Coast
• 2 Phase Program (Phase 1=360K, Phase 2=475K) • Outside Engine Industry Expert Conducts • Teardown, Inspections & Written Reports
Products History
Cat C15 Line Haul ACERT™ 1. 355, 355,515 515 M iles 2. 480, 480,973 973 M iles
Cummins
DDC S60
Line Haul Cooled-EGR 360,901 360, 901 M iles 455,319 455, 319 M iles
Line Haul Cooled-EGR 381,100 381, 100 M iles 480,717 480, 717 M iles
Sam e Oil Oi l Change In tervals
Competitive Tear Down I nlet M anif anifolds olds
Soot Build Up
Detroit Intake Phase 2
Phase 1
Soot Build Up
Cummins Intake
Soot Build Up
Cat Intake
Competitive Tear Down P erforman ce Deterioration Cooled-EGR contaminates the air system with soot, blocking ports and acids attack valve seats
Phase 1
Detroit Valves and Ports Soot Build-Up
Phase 2
Airflow Restricitons
Cummins Valves & Ports
Acid Attacking Valve Faces
Soot Build-Up
Reduced Air Flow
Cat Valves & Intake Port Phase 2 Airflow Unrestricted
Valves Free of Deposits
Cummins EGR Cooler Inlet Plugging
Phase 1
Outlet 60% plugged
Phase 2
Detroit EGR Cooler
Soot Build Up
Phase 2
Engine Inspection Report DETROIT Deep p wear wear grooves grooves – top ring ring revers reversal al area area • Dee • Lack of honing marks throughout ring swept area • # 6 intake valves show unusually high levels of deposits • Oil rings show severe wear in expanders • High soot levels, normal result from using EGR
Engine Inspection Report CUMMINS • Significant Wear Overall • Significant Higher Top Ring Side Wear • Cyl. Liners Worn Through Hone Pattern • 60 MM Wide Below Top Ring Reversal Point • High Soot Levels, Normal Result from Using EGR
Engine Inspection Report CATERPILLAR • Excellent Top Ring Wear for 480K Miles • Very Light Liner Step @ End of Ring Travel • Lower Soot Levels = Lower Wear Levels
Anticipated Life In Miles 1,000,000
530,000
Cat
Cum m ins
490,000
DDC
Cooled EGR • More Soot Into the Air Intake • More Soot Build-Up in the Engine Oil • More Wear of Critical Parts • More Repair Costs over Time? • Higher Overall Operating Costs? • Overhaul before Trade Cycle? • Resale ?
ACERT™ Technology • More Cool Clean Air • Cleaner Air = Cleaner Oil • Better Durability/Reliability • Lower Overall Operating Cost than EGR • B50 = Million Miles to Overhaul • Higher Resale Value
ACERT™ 2007 Special DPF Maintenance
DPF Ash Service
DPF Ash Cleaning Tool • Requirements • Shop Air (100 psi) • 120 VAC
• Size • 75”(l) x 40”(w) x 83”(h) • 1.9m(l) x 1.01m(w) x 2.1m(h)
• Weight • 1100 lbs • 500 kg
DPF Ash Cleaning Tool Computer Controlled Valve
HEPA Filter Control Panel
Filters Disposable Bucket (Behind Door)
Expansion Tank
Accum ulat or Tank Tank
Ash Cleaning Tool Features • Extensive testing • Patented “pulse” cleaning process • Extended Cartridge filter life • Self cleaning feature
• Pre-check burst to determine if DPF is cleanable
Ash Cleaning Tool Features • Computer controlled • Fully Automated
• Cleans all Caterpillar DPF sizes • Full containment of Ash for easy disposal • HEPA filter system
Ash Cleaning Process
Ash Cleaning Process Rege gen n DP DPF F on on the the Tr Truc uck k • Re • Cat ET attached • Ash Service Test
• Let Cool and Remove Filter • Place Filter in Tool
Ash Cleaning Process Adapter Seal DP F •Variou s
adapto rs for the different DP F’s •1
adaptor can be used for m ultiple sizes
Seal
Ash Cleaning Process
B ed Hand Pum p Raise Rais e the bed Seals Unit in Tool T ool Hydraulic Cylinders
Ash Cleaning Process • Start Process • Air Flow • 30 Puffs • 45 Minutes • Totally Automated
Ash Cleaning Process
Ash Collection Area
Ash Cleaning Process • Remove Filter from Tool • Re-install on Truck • Replace Seals
• Hook-up Cat ET • Reset Ash Model • In Inte terim rim Proc Proces ess s - Ca Call ll DSN DSN
• Send the truck on its way!
Ash Cleaning Process • Cost • Total time 3 hours labor • Consumable Costs • Tool Cost
• Customer Cost • $400 to $600 USD
Part Numbers & Costs
Tool Part Numbers • 319-2189 Cleaner Gp • Includes: 3199-21 2187 87 Cle Clean aner er – DP DPF F • 31 • 319-2190 Adaptor group • • • • •
319-18 3191834 34 Cone Cone – 11 inc inch h 31931 9-18 1835 35 Cone Cone – 13 inc inch h 31931 9-18 1836 36 Cone Cone – 15 inc inch h 319-18 319 -1838 38 Adaptor Adaptor-lo -lower wer – lar large ge 319-18 319 -1839 39 Adaptor Adaptor-lo -lower wer – sma small ll
Consumables • Five Items • HEPA Filter • Cartridge Filters (2) • Disposal Bucket • Air Dryer Desiccant • Coalescing Filter
Consumables • HEPA Filter • 319-2193 • Life DPF • 500 - 1000 DP Cleanings
• Cost • $840.76 USD D/N
Consumables • Cartridge filter • 319-2194 • 14 dia, 30 long • 2 filters/pack • Life • 15 to 100 DPF Cleanings
• Cost • $ 349.45 USD D/N
Consumables • Cartridge filter • 319-2194 Soot in DP F dram atica atically lly • 14 dia, 30 long shortens Cartridge Filter • 2 filters/pack life! • Life
• 15 to 100 DPF Cleanings
before Cle Regen Cleaning aning DP F • Cost • $ 349.45 USD D/N
Consumables • Filter Bucket • 319-1833 • Life • 3 or 4 per clean out • Clean out every 15 100 DPF Cleanings
• Cost • $113.97 USD D/N
Consumables • Air Dryer Desiccant • 320-2679 • Life • 25 DPF Cleanings • Can be oven dried and re-used
• Cost • $XX.XX USD D/N
Consumables • Coalescing Filter • 320-2680 • Life • 500+ DPF Cleanings
• Cost • $XX.XX USD D/N
Additional Adapters Mass Transit Bus
• Use 319-2192 Adaptor-MTB* • Use with 319-1835 cone • Cost • $739.74 USD D/N
*T his is NOT part of the standard 319 -219 0 Adapt or *This Group , it is ordered separat ely!
Cleaner Costs* Dealer Net
319-2189 Cleaner Gp
$16,169.47
Individual Pricing 319-2187 Cleaner – DPF 319-2190 Adaptor group 31931 9-18 1834 34 Con Cone e – 11 inc inch h - $2 $245 45.1 .12 2 31931 9-18 1835 35 Con Cone e – 13 inc inch h - $2 $249 49.6 .66 6 31931 9-18 1836 36 Con Cone e – 15 inc inch h - $2 $256 56.9 .90 0 319-1 319 -183 838 8 Adapt Adaptor or-l -low ower er – la larg rge e - $7 $747 47.6 .64 4 319-1 319 -183 839 9 Adapt Adaptor or-l -low ower er – sm smal alll - $7 $750 50.5 .54 4 *Dealer Net prices as of 14 Sep 07
$14,787.77 $ 2 ,0 2 4 .8 7
Shop Tips This image is the result of NOT using Anti-Seize on the DPF Inlet thermocouple sensor spin nut or DPF mounting boss during initial installation in Tech Center Building L (DPF Upgrade).
CGI Line
CGI Line
CGI Line
CGI Venturi & Cooler
CGI Line to the Mixing Valve
CGI Actuator
Mixing Valve Door
Aftert Afte rtre reat atme ment nt Re Rege gene nera rati tion on Device
Cat Regeneration System Consists of: • ARD (Af (Aftert tertrea reatme tment nt Reg Regene enerati ration on Device) • DPF (Diesel Particulate Filter) • Electronic Controls
CRS CR S – Ca Catt Reg Regen ener erat atio ion n Sys Syste tem m Goal: To increase exhaust gas temperature to accelerate regeneration of the Diesel Particulate Filter (DPF)
C (s) + O2 + Energy (heat) = CO2 (g) + H2O Trapped in the DPF
From Engine or ARD In engine exhaust
Out tail pipe
Soot and Ash Definition of Soot
Soot Cleaning
Soot is a byproduct of incomplete combustion
• DP DPF F Col Colle lect cts s the the soot soot
Definition of Ash
Ash Cleaning
Ash is Noncombustible residue of a lubricating oil or fuel
• DP DPF F Col Colle lect cts s the the as ash h
• El Elev evat ated ed exh exhau aust st temperatures convert the soot to vapor
• As Ash h is re remo move ved d usin using ga special service tool
Regeneration Types Active Regeneration No Regeneration
0°C 32°F
200°C 392°F
Passive Regeneration
400°C 752°F
600°C 1112°F
700°C 1292°F
Passive Regeneration • Occurs when the engine is under high load • Exhaust temperatures alone are enough to regenerate small amounts of soot Passive Regeneration
0°C 32°F
200°C 392°F
400°C 752°F
600°C 1112°F
700°C 1292°F
Active Regeneration • Mobile Active (No Interaction) (Moving) • Enhanced Passive (No Interaction) (Stationary) • Manual (Requires Interaction) Active Regeneration (Stationary)
0°C 32°F
200°C 392°F
400°C 752°F
600°C 1112°F
700°C 1292°F
Mobile Active Regeneration • Occurs when a regeneration is needed and vehicle is over 20 MPH • No operator notification Active Regeneration
0°C 32°F
200°C 392°F
400°C 752°F
600°C 1112°F
700°C 1292°F
Enhanced Passive Regeneration • Occurs at 0 MPH • Maintain soot during extensive idle periods • Lower exhaust temp • 700 RPM, Fan On Enhanced Passive • 400°C for 20 minutes every 2 hours 0°C 32°F
200°C 392°F
400°C 752°F
600°C 1112°F
700°C 1292°F
Manual Regeneration • Occurs at 0 MPH • DPF lamp must be illuminated • Must initiate with force switch • ET comm command anded ed manua manuall regen regen doe does s not not require DPF lamp to be illuminated Active Regeneration
0°C 32°F
200°C 392°F
400°C 752°F
600°C 1112°F
700°C 1292°F
Manu Ma nual al Re Rege gen n Re Requ quir irem emen ents ts • Level 1 regeneration warning reached • DPF Light “On”
• Coolant Coolant Temp gre greate aterr than than 20° 20°C C (68°F) • ARD out Temp gre greate aterr than than 30° 30°C C (86°F) • Aftertreatment Disable Switch Off or Not Programmed • Clutch Pedal Position Switch Off (open)
Manu Ma nual al Re Rege gen n Re Requ quir irem emen ents ts • Transmission neutral switch engaged • Service brake switch #2 engaged • In park (if automatic transmission) • PTO On/Off Switch in the “Off” position (if programmed) • Regeneration in PTO set to enabled (if programmed) • Vehicle must be stationary
Manual Regen • Hold Hold manua manuall regen regen swi switch tch for 4 sec second onds s • ECM tests the air valve and fuel valve • DPF lamp will go out and engine speed will ramp to 1400 rpm • Engine fan turns on (for parasitic loading) • HEST lamp will come on when exhaust temp exceeds exceeds 450° 450°C C
ARD Lights for 5 Reasons • Auto Automa matic tic – DP DPF F regen regener erat atio ion n • Enh Enhanc anced ed pass passive ive – mai mainte ntenan nance ce of of the DPF • Ma Manu nual al – DP DPF F rege regene nera ratio tion n • Mid Mid-Ra -Range nge war warm-u m-up p – emi emissi ssions ons strategies and white smoke elimination • HC cle cleanu anup p (MR/ (MR/HD) HD) – emi emissi ssions ons strategies and white smoke elimination
Emissions Strategies Mid-Range Warm-Up • Emissions compliance sooner Runs if dp dpff ou outt is is les less s tha than n 250 250° ° C an and d • Runs vehicle speed is 0 MPH • Engine RPM remains at low idle due to VNT usage Runs s until until dpf dpf inl inlet et is grea greater ter than than 450° 450°C C (1 • Run second sec ond)) or dpf dpf out outlet let is great greater er than than 325° 325°C C for 2 minutes
Emissions Strategies HC Clean-up (on MR and HD) • Eliminate HC slip (raw fuel in the DPF) • En Engin gine e RPM RPM wi willll ele eleva vate te to 70 700 0 RPM RPM • Ru Runs ns ev ever ery y one one ho hour ur bas based ed on a tim timer er • Timer will be 0 if: • Veh Vehicl icle e speed speed is abov above e 0 mph • Soot is greater greater than 115% (enhanc (enhanced ed passive passive starts starts at 120%) • Dpf inl inlet et is is great greater er than than 400°C 400°C or outlet outlet is grea greater ter than than 150°C 150°C
•Runs until •Runs until dpf dpf inl inlet et is abov above e 400°C or outlet is greater than 325° C for 2 minutes
What Triggers a Regen? • ECM soot calculation • ECM calculates the amount of soot the engine is putting out under all operating conditions
• Time hours (6 (6 hours hours with with senso sensorr fault) fault) • HD - 12 hours • MR - 5 hours
• DPF differential pressure • Used as a fail safe since there is no direct correlation between soot loading and differential pressure
perrylb: perrylb: illustrator illustrator
Trigger Graph Soot
% t o o S
Time
Pressure
Time (hours)
12 Hrs (5 MR)
P r e s s u r e
Partial Soot Loading Model Inputs • • • • • • • • • • • •
Coolant Temperature Ambient Air Temperature Altitude Fuel Flow DPF Inlet & Outlet Temperature Shot Mode Engine Speed Exhaust Gas Temperature #1 (Turbo Out) Exhaust Gas Temperature #3 (Flame Length) CGI Flow Timing Total Exhaust Flow
CRS Indicators and Switches Force For ce Reg Regen en Sw Switc itch h DPF Lamp
HEST Lamp
Manual Disable Switch
Operator Interface Review Stop Engine Lamp Engine derate Check Chec k engine lamp D P F L am a m p - b li l i nk nk D P F L am a m p - s ol o l id id
0
INCR INCREA EASI SING NG SOOT SOOT LOAD LOAD
t u o k c o L m e t s y S t n e n a m r e P
100
ARD Combustion System • ARD Head • Spark Plug • Ignition Coil/cable • Combustion Air Line and sensor • Fuel Lines/valves/sens ors • ARD Housing
Combustion Zones Secondary Zone
Max length 12”
Primary Zone
ARD Housings
ARD Head
Nozzle
Swir Swirle lerr Plat Plate e
ARD Combustion Combustion Air Holes
Pilot & Main Exit here
ARD Combustion System
Combustion Air Vents The spark for ignition jumps directl dire ctly y to the swirle swirlerr pla plate te
ARD Housing Assembly
ARD Head
Combustion Containment Canister
ARD Housing
ARD Housing Assembly
ARD Head
Combustion Containment Canister
ARD Housing
ARD Fuel Supply • Fuel Filter base • Fuel Enable Valve • Pilot and Main Fuel PWM valves • Pilot and Main Fuel Pressure Sensors
ARD Fuel Supply Fuel Enable Valve
ARD Fuel Supply
Main Fuel Line
Pilot Fuel Line
Pilot Solenoid
Main Solenoid
Pilot Fuel Pressure Sensor
Main Fuel Pressure Sensor
ARD Fuel Supply Pilot
Pilot Main
Coolant In Main
Coolant Out
New Fuel Manifold Location
ARD Air Supply Venturi
Differential Pressure Sensor
CRS Combustion Air Valve
CRS Temp Sensors Flame Detect
Flame Length
DPF Outlet
DPF Inlet Turbo Out
Temp Control & Monitoring • Exhaust gas
temperature #1 • Exhaust gas
temperature #2 • Exhaust gas
temperature #3 • Particulate trap inlet
and outlet temperature
Temp Control & Monitoring
Exhaust Gas Temperature #2 Sensor Exhaust Gas Temperature #3 Sensor
Temp Control & Monitoring Particulate trap # 1 outlet and inlet i nlet temperature sensors
To Disable Regeneration • Set the disable regeneration switch on the dash (If Installed) OR • Go to ET configuration screen and use the ARD Data Link Disable parameter to manually disable the regen. Both actions will manually disable the CRS (air,fuel,and spark).
Cat Common Rail Fuel System
Variable Nozzle Turbocharger
AVNT
DAVNT
