SCR Retrofit Aftertreatment General Information Caterpillar


General Information
`
SCR Retrofit Aftertreatment [UENR4332]
ENGINE ARRANGEMENT
SCR Retrofit Aftertreatment General Information
1.1. Systems Operation
2.2. SCR Systems Diagram
3.2. Reactor Housing Operation
4.3. Diesel Oxidation Catalyst Operation
5.3. Diesel Particulate Filter Operation
6.2. Selective Catalytic Reduction Substrate Block
7.2. Air and DEF Flow Schematic
8.2. Dosing Cabinet Exploded View
9.3. Dosing Pump Operation
10.3. Touch Monitor Operation
11.3. Storage and Literature
12.2. LED Operation
13.2. Modes of Operation for the 450-6116 Software (Retrofit Selective Catalytic Reduction Land Software)
14.2. Webpage Interface for the 450-6116 Software (Retrofit Selective Catalytic Reduction Land Software)
15.3. Operation Page
16.3. Status Page
17.3. About Page
18.3. Setup Page
19.3. Closed Loop Tuning Page
20.3. Open Loop Tuning Page
21.3. Configuration Page
22.2. Modes of Operation for the 450-6117 Software (Retrofit Selective Catalytic Reduction Marine Software)
23.2. Webpage Interface for the 450-6117 Software (Retrofit Selective Catalytic Reduction Marine Software)
24.3. Operation Page
25.3. Status Page
26.3. About Page
27.3. Setup Page
28.3. Heater Configuration Page
29.3. Closed Loop Tuning Page
30.3. Open Loop Tuning Page
31.3. Configuration Page
32.2. Modes of Operation for the 450-6118 Software (Retrofit Selective Catalytic Reduction Open Loop Software)
33.2. Webpage Interface for the 450-6118 Software (Retrofit Selective Catalytic Reduction Open Loop Software)
34.3. Operation Page
35.3. Status Page
36.3. About Page
37.3. Setup Page
38.3. Open Loop Tuning Page
39.3. Configuration Page
40.2. Modes of Operation for the 450-7654 Software (Retrofit Selective Catalytic Reduction Software)
41.2. Webpage Interface for the 450-7654 Software
42.3. Operation Page
43.3. System Setup Page
44.3. Dosing Map Setup Page
45.3. Closed Loop Setup Page
46.3. Heater Setup Page
47.3. Network System Setup Page
48.2. MODBUS Addresses

The Retrofit Selective Catalytic Reduction (SCR) System includes the following components: Diesel Oxidation Catalyst (DOC) or a Diesel Particulate Filter (DPF), Selective Catalytic Reduction (SCR) catalyst, Pre/Post Nitrogen Oxide (NOx ) sensors, mixing section and a Dosing Cabinet.

Engine exhaust flows into the Retrofit SCR System reactor housing through the exhaust inlet. Exhaust flows through the DOC or DPF. Diesel Exhaust Fluid (DEF) is injected into exhaust by the Lance as the DEF atomizes through the nozzle due to high-pressure air. The atomized DEF is injected into the exhaust flow prior to a series of mixing fans. This creates a uniform mixture and consistent disbursement across the SCR Catalyst sections.

Precise DEF injection is controlled through the SCR Controller, by monitoring inputs from the sensors installed in the engine and SCR System. The inputs include: a pre-pressure sensor located in the inlet manifold, a thermocouple located in the reactor housing, a Pre NOx sensor installed in the inlet to the reactor and a post NOx sensor in the exhaust out. Each sensor provides an input to the SCR Controller to control DEF injection for NOx reduction.

Three main components of the Retrofit SCR system:

1. The Retrofit SCR system reactor is constructed of stainless steel. The SCR reactor is a double walled unit that houses the appropriate components to meet sites-specific requirements.

2. The dosing cabinet contains a controller, DEF dosing system, and an air regulation system. A heated Tube Wire Bundle (TWB) transports DEF and air from the dosing cabinet to the reactor. The following three sensor kits are associated with the system:

  • Injector kit

  • NOx sensor and mounting kit

  • Sensor kit installation

3. The SCR controller uses one of the following software:

  • 450-6116 Software (Retrofit Selective Catalytic Reduction Land Software)

  • 450-6117 Software (Retrofit Selective Catalytic Reduction Marine Software)

  • 450-6118 Software (Retrofit Selective Catalytic Reduction Open Loop Software)

  • 450-7654 Software (Retrofit Selective Catalytic Reduction Software)

Note: The 450-7654 Software (Retrofit Selective Catalytic Reduction Software) replaces all previous versions of software.




Illustration 1g03670391

Typical internal view of a horizontal system

Systems Operation

SCR Systems Diagram




Illustration 2g03432594

SCR temperature sensor (3) can be installed into the port next to injector assembly (7) .

(1) Exhaust back pressure sensor

(2) Inlet NOx sensor

(3) SCR temperature sensor

(4) Outlet NOx sensor

(5) Boost temperature sensor

(6) Boost pressure sensor

(7) Injector assembly

(8) Customer supplied back pressure valve

(9) TWB

(10) Circulating pump

(11) DEF supply ball valve

(12) Compressed air supply ball valve

(13) Air compressor

The standard system configuration begins DEF dosing and NOx reduction at an exhaust temperature of 300° C (572° F) within the reactor housing. Optimal NOx reduction occurs above 350° C (662° F). Maximum allowable exhaust temperature is 550° C (1022° F). Special configurations for different exhaust temperatures or operating conditions may be available.

Reactor Housing Operation

The reactor housing contains a NOx sensor located on the inlet and outlet piping. These sensors communicate via CAN bus to the SCR Controller for DEF management. The values can be viewed by use of a computer interfaced with SCR Controller. Refer to Illustration 2 for the correct location of the sensors.

Control of the Open Loop (OL) SCR system requires four inputs that are external to the dosing cabinet:

  • Boost pressure sensor

  • Boost temperature sensor

  • Exhaust back pressure sensor

  • Exhaust temperature sensor

Control of the Closed Loop (CL) SCR system requires six inputs that are external to the dosing cabinet:

  • Boost pressure sensor

  • Boost temperature sensor

  • Exhaust back pressure sensor

  • Exhaust temperature sensor

  • Pre NOx Sensor

  • Post NOx Sensor

Diesel Oxidation Catalyst Operation




Illustration 3g03398644

Exhaust flow through a Diesel Oxidation Catalyst.

The DOC oxidizes hydrocarbons contained in the exhaust gas. The DOC is a flow-through device. A chemical reaction takes place that reduces the amount of hydrocarbons and carbon monoxide when the exhaust gas flows through the cells that are coated with precious metals located within the DOC.

The temperature of the exhaust is an important factor to activate the catalyst. Below 200° C (392° F) little to no catalyst activity is occurring. This means that emissions from the engine are not being reduced. As the exhaust temperature rises above 200° C (392° F), the catalyst activity increases rapidly. The catalyst begins to operate efficiently at exhaust temperatures between 280° C (536° F) and 360° C (680° F). Temperatures greater than 360° C (680° F) promote optimum efficiency. The greater temperatures will promote optimum CO + O2 = CO2 and HC+02 = H2O + CO2 conversion. PM reductions can occur due to the oxidizing of the Soluble Organic Fraction (SOF), the adsorbed liquid hydrocarbon layer, on the surface of the soot particles. The SOF may account for the nearly 20 percent PM by weight. Operation of the DOC at temperatures greater than 700° C (1292° F) is not recommended and may result in reduction of the catalyst efficiency.

Diesel Particulate Filter Operation




Illustration 4g03398873

Exhaust flow through a Diesel Particulate Filter.

The DPF is used to reduce greater than 85 percent of the emissions of particulate matter (soot). These emissions are reduced by filtration as the exhaust passes through the DPF wall. Carbon monoxide (CO), and Hydrocarbons (HC) are also reduced as the engine exhaust passes through the catalytic oxidation and filtration units. The DPF filter substrate uses a series of alternately blocked channels which forces exhaust gasses to flow through the channel walls. Particulates are physically captured and chemical reactions take place (see Illustration 4). Carbon monoxide and hydrocarbons are converted into carbon dioxide and water vapor. These filters are self-regenerating. Self-regenerating filters are not disposable, but, instead, will "burn off" the accumulated soot continuously if the proper exhaust temperature profile is met.

Proper DPF regeneration REQUIRES the following conditions:

  • Ultra Low Sulfur Diesel Fuel Must Be Used. Ultra Low Sulfur Diesel Fuel must have an average sulfur content of 15 parts per million (ppm).

  • Ultra Low Sulfur Diesel (ULSD) fuel (≤ 15 ppm (mg/kg) sulfur) is required by regulation for diesel engine use in California. The United States (U.S.) Environmental Protection Agency (EPA) defines Ultra Low Sulfur Diesel (ULSD - S15) as a U.S. diesel fuel with a sulfur content not to exceed 15 parts per million (ppm (mg/kg)). Also, the sulfur content in the diesel fuel is not to exceed 0.0015 percent by weight. ULSD fuel must meet the S-15 fuels designation in the latest edition of ASTM D975 and/or conform to AVSpare Fuel Specification.

  • Biodiesel fuel may be used up to the B20 blend level (20 percent biodiesel and 80 percent appropriate ULSD fuel). If the final B20 blend conforms to ASTM D7467 and API gravity 30-45. The neat biodiesel blend stock should conform to ASTM 6751.

  • The engine exhaust temperature at the DPF inlet must be 240° C (464° F) or greater for at least 40 percent of the time.

  • The ratio of nitrogen oxides (NOx) to particulate matter (PM) must be a minimum of 25:1. This ratio is the NOx level, in grams/brake horsepower hour, divided by the PM level). This technology is currently applicable to 1996 or newer Tier I or Tier 2 engines. Current AVSpare retrofit passive DPF product is not applicable to Tier 3 engines.

  • Consult with State and Federal agencies for verification requirements.

  • The engine should be maintained and must not consume oil at a rate greater than the rate specified by the engine manufacturer.

  • AVSpare DEO-ULS (Ultra Low Sulfur) 319-2260 Oil exceeds the performance requirements of API category CJ-4 oil and is recommended due to a low ash specification. Engine oil that meets or exceeds the specifications in the AVSpare ECF-3 or API CJ4 Categories may be used in these applications. Oil burned during the combustion process accounts for almost all of the DPF ash accumulation (because of oil additives). The use of the recommended low ash oil results in lower ash accumulation in the filter. Failure to use the recommended grade of oil may result in more frequent ash removal service intervals.

Selective Catalytic Reduction Substrate Block

The SCR catalyst which promotes the chemical reaction between the NOx and ammonia. The process converts the NOx into nitrogen and water. The catalyst material is coated onto ceramic honeycombed bricks which are bound together by (or canned with) stainless steel sheet metal. The canned sections are set in two or three layers (or stages).

The reactor may contain one of two types of SCR catalyst. One is designed for a lower temperature range of 315 to 405 °C (600 to 761 °F). The other is designed for a higher temperature range of 355 to 580 °C (671 to 1076 °F).


NOTICE

Operating an SCR catalyst above the design maximum temperature limit will reduce the catalyst life and damage to the catalyst.


Operating the engine without dosing DEF may result in a visible exhaust plume. The plume is temporary, and will clear up when dosing begins.

Air and DEF Flow Schematic




Illustration 5g03398975

Air pressure is 0.28 cubic meter (10 cubic feet) per minute at 586 ± 103 kPa (85 ± 15 psi).

DEF is supplied by a circulation loop at 14 ± 7 kPa (2 ± 1 psi).

Dosing Cabinet Exploded View




Illustration 6g03398976

The Dosing Cabinet contains components of the dosing system.

  • Touch monitor, located on the inside of the dosing cabinet door, displays operational values.

  • SCR Controller analyzes input data and controls various solenoids and pumps to achieve desired reductions.

  • Circuit breakers and fuses are located inside the dosing cabinet.

  • Dosing pump regulates dosage to the injector assembly.

  • Air and purge solenoids are controlled by a 24V signal from the SCR Controller to control the flow of air to the injector assembly.

  • Pump display shows the current flow rate.

  • Y-sediment strainer contains a 60 micron screen that removes debris from the DEF before the pump.

  • 24V power supply powers the SCR Controller, fan, and touch monitor.

  • Air pressure regulator allows adjustment of the air used for dosing.

  • Dosing pump is equipped with a purge valve.

  • DEF back pressure valve maintains a minimum DEF system pressure to reduce the risk of flooding the reactor during engine off condition.

  • Air delivery pressure gauge indicates the air pressure delivered to the TWB.

  • DEF delivery pressure gauge indicates the DEF delivered to the TWB and displays the pressure fluctuations during dosing.

  • Air supply switch tells the SCR Controller when air pressure drops below 310 kPa (45 psi).

  • Check valve allows air and DEF flow in only one direction.

  • Ethernet switch connects the touch monitor, the SCR Controller, and has an open port for network connections.

  • Manual purge switch, toggle switch mounted on the DIN rail. Center position is OFF. Move the switch in the up or down position to initiate purge then return to the center position. Manual purge cannot be interrupted unless the system is rebooted.

  • DIN-Block routes wiring to designated devices.

  • 24V fan in the cabinet moves air inside the cabinet. The fan does not cool or move fresh air, but moves the same air continuously in cabinet.

Dosing Pump Operation




Illustration 7g03399069

Typical dosing pump

The Dosing pump regulates the DEF dosage into the system. The pump display will show current flow rate. The pump is powered by AC current through a circuit breaker in the cabinet. The pump operates on a 4 mA to 20 mA signal from the SCR Controller that is tuned during commissioning.

Touch Monitor Operation




Illustration 8g03446159

(1) Touch monitor




Illustration 9g03445978

(2) USB port

(3) Ethernet port

(4) Switch for power display

The dosing cabinet is equipped with a touch monitor.

The power switch is located on the lower right-hand side of the display and is pushed upwards until the power light illuminates. When the touch monitor is turned on, click the "Start New Session" button to view the operations page.

Storage and Literature




Illustration 10g03399077

(1) Storage compartment

The Storage compartment is located on the inside of the dosing cabinet door.

LED Operation

A system status box on the "Operation" page displayed on the touch monitor also communicates the state of the system and the system components. Refer to "Status Page" for more information.

On the outside of the cabinet are three lights signifying system status:

1. The Power Lamp signifies there is power to the dosing cabinet and the SCR Controller is booted.

2. The DEF Lamp is used to signify whether the SCR is in Run Mode (constantly illuminated) or in Purge Mode (flashing).

3. The Fault Lamp is used to signify any faults that may be occurring in the system (flashing), or if the system is in Manual Purge Mode.

Table 1
Power, DEF, and Fault Lights    
Green (1)     Blue (2)     Red (3)     Status     Action    
OFF     OFF     OFF     Controller not operating     Check power supply to the Dosing Cabinet    
ON     OFF     OFF     Power on: Controller in Standby     Check the status to see if one of the operating conditions is not met    
ON     ON     OFF     Run mode     Normal operating condition    
ON     BLINKING     OFF     Purge mode     Check if low boost
Check if low air pressure
Check if low exhaust temp    
ON     OFF     BLINKING     Fault     Check "Operation" screen status display for a reported fault
Ensure that the air supply is
586 ± 103 kPa (85 ± 15 psi)
Ensure that Manual purge switch is off
Reboot system if necessary    
ON     BLINKING     BLINKING     Manual purge     Turn switch off after the purge cycle has completed    
ON     ON     BLINKING     Open loop mode     Check NOx sensors
Replace if necessary    
( 1 ) Green light – Power Supply/Cabinet is powered on and controller is booted
( 2 ) Blue light – DEF Dosing is present
( 3 ) Red light – System has been placed into manual purge or a fault is present

Modes of Operation for the 450-6116 Software (Retrofit Selective Catalytic Reduction Land Software)

Note: The previous software was revision CL 6.0.9.

1. Standby: In this mode the green LED is the only light on. No air or DEF is flowing and the system has purged itself. Standby is the default mode and the mode the system will return to anytime an operational condition is not met (see STATUS section).

2. Startup: Start-up mode is used any time the system switches from standby to normal operation. This mode will fill the DEF line so NOx reduction can begin immediately. The blue LED will turn on once DEF starts to flow.

3. Run: The system enters this mode once the startup mode is completed. The Run mode is indicated by a solid blue LED (to indicate DEF flow). When in Run mode the DEF is being dosed to the injector assembly according to the amount of NOx in the exhaust, and the pump flow rate will vary accordingly.

4. Purge: Any time the system switches out of normal operation the system will enter a purge mode to dry out the DEF lines. Purge mode is indicated by a flashing blue LED and a pump speed of zero. Pressurized air is flowing through both the air line and the DEF line at this time. The purge cycle lasts for 6 minutes.

5. Fault: If the system is experiencing a sensor fault or a low air line pressure for more than 8 hours continuous, the system goes into a fault to alert the operator. The green LED is on and the red LED is flashing.

Webpage Interface for the 450-6116 Software (Retrofit Selective Catalytic Reduction Land Software)

This section details use of the web page Interface, whether you choose to connect with a laptop or locally using the touch monitor. If using the touch monitor and you desire to input numeric values, enlarge the numeric keypad on the top of the touch monitor.

Alternately, you can connect a USB keyboard to a USB port on the touch monitor. If connected with a laptop, simply use the computers keypad to enter the values.

The interface is divided into three tabbed pages: Operation, Status and About. The program automatically opens to the Operation Page of the web page Interface.

Launch and save the following addresses to the Toolbar for easy access:

  • http://169.254.0.2/epod/web/setup.htm

  • http://169.254.0.2/epod/web/operation.htm

Operation Page




Illustration 11g03413240

The "Operation" page web address is http://169.254.0.2/epod/web/operation.htm

In the "Operation" page, as shown above, the user can monitor all operating parameters as well as change the desired amount of NOx reduction. The following parameters are viewed:

  • Desired NOx reduction, percent

  • Actual NOx reduction, percent

  • Pump output of DEF, liters per hour

  • Pre-SCR catalyst NOx value, ppm (or Engine out NOx )

  • Post-SCR catalyst NOx value, ppm (or Stack out NOx )

  • Boost pressure, psi

  • Boost or intake manifold temperature, °C

  • Exhaust backpressure, inches of water

  • Exhaust temperature, °C

  • Mode of operation

  • Cumulative DEF

  • Last cumulative DEF reset

  • Engine hours (length of time since commissioning that the system has sensed a boost pressure)

  • E-POD hours (length of time pump is operating)

  • System status

There is one input variable (Desired Reduction) for operator control. To change the value of a variable, strike the white box with your stylus or mouse. Enter the desired value in the appropriate white box by striking numbers with the stylus or with your keyboards numeric keypad. To accept the value, click anywhere outside of the box. Hitting "enter" on a laptop or USB keyboard will not cause the value to be accepted. Always verify that the value in the gray box has changed as this value is the value the SCR Controller uses. Click the "Save" button if you want the desired reduction that you entered to be permanent in the program.

Status Page




Illustration 12g03413239

The "Status" page displays the status log file. Any changes to the status of the system will be recorded on this page. The systems status is also shown in "Operation" page in the status box. Possible text displays, with an explanation of each, follows:

  • No problems found - System is operating.

  • Air line pressure too low - The air solenoid is open, but the line pressure is not high enough to open the pressure switch. A warning is displayed and the system enters "Purge" mode.

  • Exhaust temperature too low - The exhaust temperature is lower than the software imposed limit.

  • Boost pressure too low - The boost pressure is lower than the software imposed limit. A warning is displayed.

  • Hardware Purge - The DIN-Block mounted purge switch is in the "ON" position.

  • Exhaust Pressure Sensor Fault: Check Connections – The SCR Controller is not receiving a signal from the exhaust pressure transducer. Check the wiring and transducer for problems.

  • Boost Pressure Sensor Fault: Check Connections – The SCR Controller is not receiving a signal from the boost pressure transducer. Check the wiring and transducer for problems.

If the NOx sensors are inoperable, the system defaults to an Open loop condition where flow is based upon turbo boost pressure. Actual reductions will read a constant 85 percent reduction. These codes continue until the NOx sensor error is corrected. Refer to Troubleshooting, UENR4333, "Diagnostic Codes" for more information.

Note: During OL Mode, the system will display an 85 percent reductions in the Actual Reductions, this reduction is a default value the Actual Reductions is unknown.

About Page




Illustration 13g03670562

The "About" page displays basic information such as serial numbers and software version, for the SCR system in operation.

Setup Page




Illustration 14g03432482

The "Setup" page web address is http://169.254.0.2/epod/web/setup.htm.

  • Boost Multiplier: 25.00 Factory setting do not change.

  • Boost Offset: -0.5 Starting point for sensor calibration: Add to decrease sensor reading. Lower to increase reading.

  • Dp Multiplier: 9.0025 Factory setting do not change.

  • Dp Offset: -0.5 Starting point for sensor calibration: Add to decrease sensor reading. Lower to increase reading.

  • Pump Multiplier: 500 (Starting point) (DDA-17 = 1600) - Set Pump Output to high end of range. Example, DME 60 Calibrate high side using 55Lhr, low side 5Lhr

  • Pump Offset: 500 is the starting point, fine-tune

  • Pump Output: Only works in "Setup" mode. Enter desired value to manually control dosing. Mainly for OL Map setup and calibration of the pump.

  • Radio Buttons will manually operate the LEDs and solenoids while in "Setup" mode.

Note: Operator must save all variables and manually select the "Exit Setup" button or unit will remain in "Setup" mode.

Closed Loop Tuning Page




Illustration 15g03659477

The Catalyst Temp Low Limit is the SCR Systems starting temperature, measured in degrees C, to allow Startup mode.

The Boost Pressure Low Limit is the threshold which activates the Purge cycle. To set the Boost Pressure Low Limit, a pressure reading should be taken at a 0 percent load situation.

Note: Usually increase 7 to 14 kPa (1 to 2 psi) for Diesel and Natural Gas engines. Natural Gas engines will require an adjustment of the load point settings to bring up to positive boost reading.

To set the Exhaust Pressure Low Limit, record exhaust pressure in a 0 percent load situation. Using the recorded pressure, add 1 inch H2O and enter the value in the Exhaust Pressure Low Limit input field.

Maximum System Efficiency is the maximum amount of efficiency the system is required to achieve. This number is not adjusted and its purpose is to prevent Ammonia Slip.

Slip Time is the time the controller takes to update the flow rate of the dosing pump to prevent Ammonia Slip. Base Loop Time is the time the controller takes to update the flow rate of the dosing pump to prevent low NOXconversion. The Slip Time and Base Loop Time are tuned per site and should have the same value.

Note: Larger systems and colder weather applications will require more time.

All other settings on the CL Tuning page are default and should not be changed. The default values are set for the system to operate efficiently in Closed Loop (CL) mode.

NH3 Flow Adjust Min: A minimum percent adjustment of DEF flow for Cat SCR ECM to achieve Desired Reductions.

NH3 Flow Adjust Max: A maximum percent adjustment to DEF flow for the Cat SCR ECM to achieve Desired Reductions.

Open Loop Tuning Page




Illustration 16g03670669

The "OL Tuning" page web address is http://169.254.0.2/epod/web/oltuning.htm.

  • OL Map: Record Boost readings at each Load Point

  • OL Map: Record Pump Flow rate at each Load Point for site specific NOx reduction

  • Flow rate needed to achieve 85 percent reduction (or 5 percent below Desired Reduction)

  • Startup pump Output: The amount of DEF that will be dosed during the startup procedure to fill the Tube Wire Bundle (TWB). 100 percent load flow rate or greater if required

  • Startup Output time: Record the amount of time 100 percent flow rate is needed to fill TWB and prime DEF to Nozzle. Delivery gauge will increase to 5 to 8 psi once DEF reaches the nozzle.

Configuration Page




Illustration 17g03432492

The "Configuration" page web address is http://169.254.0.2/epod/web/IPConfig.htm.

All SCR Controllers are shipped from the factory with the IP address and subnet mask listed below:

  • IP Address: 169.254.0.2

  • Subnet Mask: 255.255.0.0

  • Port: 502

  • Socket: 1 (if needed)

Changing the IP address of the SCR Controllers can be done using the "Configuration" page. If the IP address and subnet mask of the SCR Controller are changed, then the new IP address and subnet mask values when configuring the MODBUS TCP/IP server to communicate with the SCR Controller. The touch monitor will also need to be reconfigured. Refer to Testing and Adjusting, "Touch Monitor - Setup" Because the IP address and subnet mask of the SCR Controller is configurable, it is possible to place multiple SCR Controllers on a network. The port and socket values are not configurable on the SCR Controllers.

Modbus Key activation: Used for earlier versions of software. Enter one of the following Modbus Keys into the appropriate SCR Controller "New Modbus Key":

  • Red SCR Controllers, MODBUS Key = 6E01C724

  • Blue SCR Controllers, MODBUS Key = FFFFD14C

  • Green SCR Controllers, MODBUS Key = 5849EAB4

If this process does not work, take a snapshot of all web pages for reference, upgrade to the current software, and manually enter all settings. The current 450-7654 Software (Retrofit Selective Catalytic Reduction Software) will not need the New MODBUS Key.

Modes of Operation for the 450-6117 Software (Retrofit Selective Catalytic Reduction Marine Software)

Note: The previous software was revision CL 5.1.9.

1. Standby: In this mode the green LED is the only light on. No air or DEF is flowing and the system has purged itself. Standby is the default mode and the mode the system will return to anytime an operational condition is not met (see STATUS section).

2. Startup: Start-up mode is used any time the system switches from standby to normal operation. This mode will fill the DEF line so NOx reduction can begin immediately. The blue LED will turn on once DEF starts to flow.

3. Run: The system enters this mode once the startup mode is completed. The Run mode is indicated by a solid blue LED (to indicate DEF flow). When in Run mode the DEF is being dosed to the injector assembly according to the amount of NOx in the exhaust, and the pump flow rate will vary accordingly.

4. Purge: Any time the system switches out of normal operation the system will enter a purge mode to dry out the DEF lines. Purge mode is indicated by a flashing blue LED and a pump speed of zero. Pressurized air is flowing through both the air line and the DEF line at this time. The purge cycle lasts for 6 minutes.

5. Fault: If the system is experiencing a sensor fault or a low air line pressure for more than 8 hours continuous, the system goes into a fault to alert the operator. The green LED is on and the red LED is flashing.

Webpage Interface for the 450-6117 Software (Retrofit Selective Catalytic Reduction Marine Software)

This section details use of the web page Interface, whether you choose to connect with a laptop or locally using the touch monitor. If using the touch monitor and you desire to input numeric values, enlarge the numeric keypad on the top of the touch monitor.

Alternately, you can connect a USB keyboard to a USB port on the touch monitor. If connected with a laptop, simply use the computers keypad to enter the values.

The interface is divided into three tabbed pages: Operation, Status and About. The program automatically opens to the Operation Page of the web page Interface.

Launch and save the following addresses to the Toolbar for easy access:

  • http://169.254.0.2/epod/web/setup.htm

  • http://169.254.0.2/epod/web/operation.htm

Operation Page




Illustration 18g03670460

The "Operation" page web address is http://169.254.0.2/epod/web/operation.htm

In the "Operation" page, as shown above, the user can monitor all operating parameters as well as change the desired amount of NOx reduction. The following parameters are viewed:

  • Desired reduction percent is the only programmable value

  • Actual reduction percent

  • Pump output of DEF, liters per hour

  • Pre-SCR catalyst NOx value, ppm (or Engine out NOx )

  • Post-SCR catalyst NOx value, ppm (or Stack out NOx )

  • Boost pressure, psi

  • Boost or intake manifold temperature, °C

  • Exhaust backpressure, inches of water

  • Exhaust temperature, °C

  • Pre-filter temperature: Exhaust temperature before the DPFs

  • Heater temperature: Temperature at mounting flange of the heater assembly

  • Heater status

  • Heater output

  • Current mode: Percent of power output by the heater

  • Cumulative DEF

  • Last cumulative DEF reset

  • Engine hours (length of time since commissioning that the system has sensed a boost pressure)

  • E-POD hours (length of time pump is operating)

  • System status

There is one input variable (Desired Reduction) for operator control. To change the value of a variable, strike the white box with your stylus or mouse. Enter the desired value in the appropriate white box by striking numbers with the stylus or with your keyboards numeric keypad. To accept the value, click anywhere outside of the box. Hitting "enter" on a laptop or USB keyboard will not cause the value to be accepted. Always verify that the value in the gray box has changed as this value is the value the SCR Controller uses. Click the "Save" button if you want the desired reduction that you entered to be permanent in the program.

Status Page




Illustration 19g03413239

The "Status" page displays the status log file. Any changes to the status of the system will be recorded on this page. The systems status is also shown in "Operation" page in the status box. Possible text displays, with an explanation of each, follows:

  • No problems found - System is operating.

  • Air line pressure too low - The air solenoid is open, but the line pressure is not high enough to open the pressure switch. A warning is displayed and the system enters "Purge" mode.

  • Exhaust temperature too low - The exhaust temperature is lower than the software imposed limit.

  • Boost pressure too low - The boost pressure is lower than the software imposed limit. A warning is displayed.

  • Hardware Purge - The DIN-Block mounted purge switch is in the "ON" position.

  • Exhaust Pressure Sensor Fault: Check Connections – The SCR Controller is not receiving a signal from the exhaust pressure transducer. Check the wiring and transducer for problems.

  • Boost Pressure Sensor Fault: Check Connections – The SCR Controller is not receiving a signal from the boost pressure transducer. Check the wiring and transducer for problems.

If the NOx sensors are inoperable, the system defaults to an Open loop condition where flow is based upon turbo boost pressure. Actual reductions will read a constant 85 percent reduction. These codes continue until the NOx sensor error is corrected. Refer to Troubleshooting, UENR4333, "Diagnostic Codes" for more information.

Note: During OL Mode, the system will display an 85 percent reductions in the Actual Reductions, this reduction is a default value the Actual Reductions is unknown.

About Page




Illustration 20g03670562

The "About" page displays basic information such as serial numbers and software version, for the SCR system in operation.

Setup Page




Illustration 21g03670462

The "Setup" page web address is http://169.254.0.2/epod/web/setup.htm.

  • Boost Multiplier: 25.00 Factory setting do not change.

  • Boost Offset: -0.5 Starting point for sensor calibration: Add to decrease sensor reading. Lower to increase reading.

  • Dp Multiplier: 9.0025 Factory setting do not change.

  • Dp Offset: -0.5 Starting point for sensor calibration: Add to decrease sensor reading. Lower to increase reading.

  • Pump Multiplier: 500 (Starting point) (DDA-17 = 1600) - Set Pump Output to high end of range. Example, DME 60 Calibrate high side using 55Lhr, low side 5Lhr

  • Pump Offset: 500 is the starting point, fine-tune

  • Pump Output: Only works in "Setup" mode. Enter desired value to manually control dosing. Mainly for OL Map setup and calibration of the pump.

  • Radio Buttons will manually operate the LEDs and solenoids while in "Setup" mode.

  • Heater Configuration Button will bring up the Heater Configuration Page.

Note: Operator must save all variables and manually select the "Exit Setup" button or unit will remain in "Setup" mode.

Heater Configuration Page




Illustration 22g03670480

All settings are default.

Closed Loop Tuning Page




Illustration 23g03659477

The Catalyst Temp Low Limit is the SCR Systems starting temperature, measured in degrees C, to allow Startup mode.

The Boost Pressure Low Limit is the threshold which activates the Purge cycle. To set the Boost Pressure Low Limit, a pressure reading should be taken at a 0 percent load situation.

Note: Usually increase 7 to 14 kPa (1 to 2 psi) for Diesel and Natural Gas engines. Natural Gas engines will require an adjustment of the load point settings to bring up to positive boost reading.

To set the Exhaust Pressure Low Limit, record exhaust pressure in a 0 percent load situation. Using the recorded pressure, add 1 inch H2O and enter the value in the Exhaust Pressure Low Limit input field.

Maximum System Efficiency is the maximum amount of efficiency the system is required to achieve. This number is not adjusted and its purpose is to prevent Ammonia Slip.

Slip Time is the time the controller takes to update the flow rate of the dosing pump to prevent Ammonia Slip. Base Loop Time is the time the controller takes to update the flow rate of the dosing pump to prevent low NOXconversion. The Slip Time and Base Loop Time are tuned per site and should have the same value.

Note: Larger systems and colder weather applications will require more time.

All other settings on the CL Tuning page are default and should not be changed. The default values are set for the system to operate efficiently in Closed Loop (CL) mode.

NH3 Flow Adjust Min: A minimum percent adjustment of DEF flow for Cat SCR ECM to achieve Desired Reductions.

NH3 Flow Adjust Max: A maximum percent adjustment to DEF flow for the Cat SCR ECM to achieve Desired Reductions.

Open Loop Tuning Page




Illustration 24g03670669

The "OL Tuning" page web address is http://169.254.0.2/epod/web/oltuning.htm.

  • OL Map: Record Boost readings at each Load Point

  • OL Map: Record Pump Flow rate at each Load Point for site specific NOx reduction

  • Flow rate needed to achieve 85 percent reduction (or 5 percent below Desired Reduction)

  • Startup pump Output: The amount of DEF that will be dosed during the startup procedure to fill the Tube Wire Bundle (TWB). 100 percent load flow rate or greater if required

  • Startup Output time: Record the amount of time 100 percent flow rate is needed to fill TWB and prime DEF to Nozzle. Delivery gauge will increase to 5 to 8 psi once DEF reaches the nozzle.

Configuration Page




Illustration 25g03432492

The "Configuration" page web address is http://169.254.0.2/epod/web/IPConfig.htm.

All SCR Controllers are shipped from the factory with the IP address and subnet mask listed below:

  • IP Address: 169.254.0.2

  • Subnet Mask: 255.255.0.0

  • Port: 502

  • Socket: 1 (if needed)

Changing the IP address of the SCR Controllers can be done using the "Configuration" page. If the IP address and subnet mask of the SCR Controller are changed, then the new IP address and subnet mask values when configuring the MODBUS TCP/IP server to communicate with the SCR Controller. The touch monitor will also need to be reconfigured. Refer to Testing and Adjusting, "Touch Monitor - Setup" Because the IP address and subnet mask of the SCR Controller is configurable, it is possible to place multiple SCR Controllers on a network. The port and socket values are not configurable on the SCR Controllers.

Modbus Key activation: Used for earlier versions of software. Enter one of the following Modbus Keys into the appropriate SCR Controller "New Modbus Key":

  • Red SCR Controllers, MODBUS Key = 6E01C724

  • Blue SCR Controllers, MODBUS Key = FFFFD14C

  • Green SCR Controllers, MODBUS Key = 5849EAB4

If this process does not work, take a snapshot of all web pages for reference, upgrade to the current software, and manually enter all settings. The current 450-7654 Software (Retrofit Selective Catalytic Reduction Software) will not need the New MODBUS Key.

Modes of Operation for the 450-6118 Software (Retrofit Selective Catalytic Reduction Open Loop Software)

Note: The previous software was revision OL 7.0.2.

1. Standby: In this mode the green LED is the only light on. No air or DEF is flowing and the system has purged itself. Standby is the default mode and the mode the system will return to anytime an operational condition is not met (see STATUS section).

2. Startup: Start-up mode is used any time the system switches from standby to normal operation. This mode will fill the DEF line so NOx reduction can begin immediately. The blue LED will turn on once DEF starts to flow.

3. Run: The system enters this mode once the startup mode is completed. The Run mode is indicated by a solid blue LED (to indicate DEF flow). When in Run mode the DEF is being dosed to the injector assembly according to the amount of boost pressure, and the pump flow rate will vary accordingly.

4. Purge: Any time the system switches out of normal operation the system will enter a purge mode to dry out the DEF lines. Purge mode is indicated by a flashing blue LED and a pump speed of zero. Pressurized air is flowing through both the air line and the DEF line at this time. The purge cycle lasts for 6 minutes.

5. Fault: If the system is experiencing a sensor fault or a low air line pressure for more than 8 hours continuous, the system goes into a fault to alert the operator. The green LED is on and the red LED is flashing.

Webpage Interface for the 450-6118 Software (Retrofit Selective Catalytic Reduction Open Loop Software)

This section details use of the web page Interface, whether you choose to connect with a laptop or locally using the touch monitor. If using the touch monitor and you desire to input numeric values, enlarge the numeric keypad on the top of the touch monitor.

Alternately, you can connect a USB keyboard to a USB port on the touch monitor. If connected with a laptop, simply use the computers keypad to enter the values.

The interface is divided into three tabbed pages: Operation, Status and About. The program automatically opens to the Operation Page of the web page Interface.

Launch and save the following addresses to the Toolbar for easy access:

  • http://169.254.0.2/epod/web/setup.htm

  • http://169.254.0.2/epod/web/operation.htm

Operation Page




Illustration 26g03670513

The "Operation" page web address is http://169.254.0.2/epod/web/operation.htm

In the "Operation" page, as shown above, the user can monitor all operating parameters as well as change the desired amount of NOx reduction. The following parameters are viewed:

  • Pump output of DEF, liters per hour

  • Boost pressure, psi

  • Boost or intake manifold temperature, °C

  • Exhaust backpressure, inches of water

  • Exhaust temperature, °C

  • Mode of operation

  • Cumulative DEF

  • Last cumulative DEF reset

  • Engine hours (length of time since commissioning that the system has sensed a boost pressure)

  • E-POD hours (length of time pump is operating)

  • System status

There is one input variable (Desired Reduction) for operator control. To change the value of a variable, strike the white box with your stylus or mouse. Enter the desired value in the appropriate white box by striking numbers with the stylus or with your keyboards numeric keypad. To accept the value, click anywhere outside of the box. Hitting "enter" on a laptop or USB keyboard will not cause the value to be accepted. Always verify that the value in the gray box has changed as this value is the value the SCR Controller uses. Click the "Save" button if you want the desired reduction that you entered to be permanent in the program.

Status Page




Illustration 27g03413239

The "Status" page displays the status log file. Any changes to the status of the system will be recorded on this page. The systems status is also shown in "Operation" page in the status box. Possible text displays, with an explanation of each, follows:

  • No problems found - System is operating.

  • Air line pressure too low - The air solenoid is open, but the line pressure is not high enough to open the pressure switch. A warning is displayed and the system enters "Purge" mode.

  • Exhaust temperature too low - The exhaust temperature is lower than the software imposed limit.

  • Boost pressure too low - The boost pressure is lower than the software imposed limit. A warning is displayed.

  • Hardware Purge - The DIN-Block mounted purge switch is in the "ON" position.

  • Exhaust Pressure Sensor Fault: Check Connections – The SCR Controller is not receiving a signal from the exhaust pressure transducer. Check the wiring and transducer for problems.

  • Boost Pressure Sensor Fault: Check Connections – The SCR Controller is not receiving a signal from the boost pressure transducer. Check the wiring and transducer for problems.

If the NOx sensors are inoperable, the system defaults to an Open loop condition where flow is based upon turbo boost pressure. Actual reductions will read a constant 85 percent reduction. These codes continue until the NOx sensor error is corrected. Refer to Troubleshooting, UENR4333, "Diagnostic Codes" for more information.

Note: During OL Mode, the system will display an 85 percent reductions in the Actual Reductions, this reduction is a default value the Actual Reductions is unknown.

About Page




Illustration 28g03670562

The "About" page displays basic information such as serial numbers and software version, for the SCR system in operation.

Setup Page




Illustration 29g03670515

The "Setup" page web address is http://169.254.0.2/epod/web/setup.htm.

  • Boost Multiplier: 25.00 Factory setting do not change.

  • Boost Offset: -0.5 Starting point for sensor calibration: Add to decrease sensor reading. Lower to increase reading.

  • Dp Multiplier: 9.0025 Factory setting do not change.

  • Dp Offset: -0.5 Starting point for sensor calibration: Add to decrease sensor reading. Lower to increase reading.

  • Pump Multiplier: 500 (Starting point) (DDA-17 = 1600) - Set Pump Output to high end of range. Example, DME 60 Calibrate high side using 55Lhr, low side 5Lhr

  • Pump Offset: 500 is the starting point, fine-tune

  • Pump Output: Only works in "Setup" mode. Enter desired value to manually control dosing. Mainly for OL Map setup and calibration of the pump.

  • Radio Buttons will manually operate the LEDs and solenoids while in "Setup" mode.

Note: Operator must save all variables and manually select the "Exit Setup" button or unit will remain in "Setup" mode.

Open Loop Tuning Page




Illustration 30g03670517

The "OL Tuning" page web address is http://169.254.0.2/epod/web/oltuning.htm.

  • OL Map: Record Boost readings at each Load Point

  • OL Map: Record Pump Flow rate at each Load Point for site specific NOx reduction

  • Flow rate needed to achieve 85 percent reduction (or 5 percent below Desired Reduction)

  • Startup pump Output: The amount of DEF that will be dosed during the startup procedure to fill the Tube Wire Bundle (TWB). 100 percent load flow rate or greater if required

  • Startup Output time: Record the amount of time 100 percent flow rate is needed to fill TWB and prime DEF to Nozzle. Delivery gauge will increase to 5 to 8 psi once DEF reaches the nozzle.

Configuration Page




Illustration 31g03670520

The "Configuration" page web address is http://169.254.0.2/epod/web/IPConfig.htm.

All controllers are shipped from the factory with the IP address and subnet mask listed below:

  • IP Address: 169.254.0.2

  • Subnet Mask: 255.255.0.0

  • Port: 502

  • Socket: 1 (if needed)

Changing the IP address of the controllers can be done using the software deployment tool.

Modbus Key activation: Used for earlier versions of software. Enter one of the following Modbus Keys into the appropriate SCR ECM "New Modbus Key": Green controllers, MODBUS Key = 5849EAB4

If this process does not work, take a snapshot of all webpages for reference, upgrade to the current software, and manually enter all settings. The current 450-7654 Software (Retrofit Selective Catalytic Reduction Software) will not need the New MODBUS Key.

Modes of Operation for the 450-7654 Software (Retrofit Selective Catalytic Reduction Software)

Note: The previous software was revision 10.1.10.

1. Standby: In this mode the green LED is the only light on. No air or DEF is flowing and the system has purged itself. Standby is the default mode and the mode the system will return to anytime an operational condition is not met (see STATUS section).

2. Sensor Check: The SCR Controller checks air pressure status and initiates NOx sensor warm up, this takes 3 minutes.

3. Tube Fill: "Tube Fill" is used any time the system switches from standby to normal operation. This mode will fill the DEF line using the "Dosing" map, so NOx reduction can begin immediately. The blue LED will flash once DEF starts to flow.

4. Run: The system enters this mode once the "Tube Fill" is completed. The Run mode is indicated by a solid blue LED (to indicate DEF flow). When in Run mode, the DEF is being dosed to the injector assembly according to the amount of NOx in the exhaust, boost pressure, and the pump flow rate will vary accordingly.

5. Dry Out: Checks the percent of "Actual Reduction" is below 15 percent, if in "CL" mode and the percent of "Actual Reduction" above is 15 percent this mode will run until the "Actual Reduction" is below 15 percent.

6. Purge: The system will enter a "Purge" mode to dry out the DEF lines. "Purge" mode is indicated by a flashing blue LED and a pump speed of zero. Pressurized air is flowing through both the air line and the DEF line at this time. The purge cycle lasts for 6 minutes.

7. Fault: If the system is experiencing a sensor fault or a low air line pressure, the system goes into a fault to alert the operator. The green LED is on and the red LED is flashing.

8. Reduced Reduction Mode (RRM): If the system cannot achieve desired reductions for a set period of time

9. Setup: The system has been put in setup and is in manual control for the duration of the "Timer".

Webpage Interface for the 450-7654 Software

This section details use of the web page Interface, whether you choose to connect with a laptop or locally using the touch monitor. If using the touch monitor and you desire to input numeric values, enlarge the numeric keypad on the top of the touch monitor.

Alternately, you can connect a USB keyboard to a USB port on the touch monitor. If connected with a laptop, simply use the computers keypad to enter the values.

The interface is divided into three tabbed pages: Operation, Status and About. The program automatically opens to the Operation Page of the web page Interface.

Launch and save the following addresses to the Toolbar for easy access:

  • http://169.254.0.2/caterpillar/web/setup.htm

  • http://169.254.0.2/caterpillar/web/operation.htm

Note: All other pages can be accessed from the "System Setup" page.

Operation Page




Illustration 32g03645688

The "Operation" page web address is http://169.254.0.2/caterpillar/web/operation.htm

In the "Operation" page, as shown above, the user can monitor all operating parameters as well as change the desired amount of NOx reduction. The following parameters are viewed:

  • System Name (location and site specific)

  • Cabinet Serial Number

  • SCR System Serial Number

  • Engine Serial Number

  • Status - current state of SCR system

  • Current mode

  • Dosing hours

  • Controller Temperature, °C

  • Boost pressure, psi

  • Boost Temperature

  • Exhaust backpressure, inches of water

  • Exhaust alarm limit

  • Exhaust Temperature, °C

  • Heater Temperature, °C

  • Inlet Temperature, °C

  • Outlet Temperature, °C

  • Pump output of DEF, liters per hour

  • Cumulative DEF

  • Heater Output

  • Software Version

  • Status window

The "Status" window displays the system status. Text displays, with an explanation of each, follows:

  • No problems found - System is operating.

  • Air line pressure too low - The air solenoid is open, but the line pressure is not high enough to open the pressure switch. A warning is displayed and the system enters "Purge" mode.

  • Exhaust temperature too low - The exhaust temperature is lower than the software imposed limit.

  • Boost pressure too low - The boost pressure is lower than the software imposed limit. A warning is displayed.

  • Hardware Purge - The DIN-Block mounted purge switch is in the "ON" position.

  • Exhaust Pressure Sensor Fault: Check Connections – The SCR Controller is not receiving a signal from the exhaust pressure transducer. Check the wiring and transducer for problems.

  • Boost Pressure Sensor Fault: Check Connections – The SCR Controller is not receiving a signal from the boost pressure transducer. Check the wiring and transducer for problems.

If the NOx sensors are sensed to be inoperable, the system defaults to an OL condition where flow is based upon turbo boost pressure. Actual reductions will read a constant 85 percent reduction. These codes continue until the NOx sensor error is corrected. Refer to Troubleshooting, UENR3367, "Diagnostic Codes" for more information.

Note: During "OL" mode, the system will display an 85 percent reductions in the Actual Reductions, this reduction is a default value the Actual Reductions is unknown.

System Setup Page

Note: All settings must match the commissioning report, refer to Special Instruction, REHS9221, "Cat Retrofit Selective Catalyst Reduction System Commissioning Report".




Illustration 33g03645795

The "System Setup" page web address is http://169.254.0.2/caterpillar/web/setup.htm.

  • Hardware Information - System Name (location and site specific)

  • Hardware Information - Cabinet Serial Number

  • Hardware Information - SCR System Serial Number

  • Hardware Information - Engine Serial Number

  • Startup - Catalyst Low Limit: 300° C

  • Startup - Boost Low Limit: 2.5 psi varies depending on load characteristics

  • Purge Delay

  • Boost Pressure Sensor - Multiplier: 25.00 - Factory setting Do Not Change

  • Boost Pressure Sensor - Offset: -0.5 Starting point for sensor calibration: Add to decrease sensor reading. Lower to increase reading.

  • Exhaust Pressure Sensor - Multiplier: 9.0025 - Factory setting Do Not Change

  • Exhaust Pressure Sensor - Offset: -0.5 Starting point for sensor calibration: Add to decrease sensor reading. Lower to increase reading.

  • Pump - Multiplier: 500 (Starting point)(DDA-17=1600) - Set "Pump Output" to the high end of the range. Example, DME 60 Calibrate high side using 55 l/hr, low side 5 l/hr.

  • Pump - Offset: 500 Starting point, fine-tune

  • Setup Mode -Timeout: The amount of time before system returns to standby.

  • Pump - Output: Only works in "Setup" mode. Enter desired value to manually control dosing. Mainly for the "Dosing Map" setup and calibration of the pump. air supply to cabinet is required.

  • LED - Green

  • LED - Blue

  • LED - Red

  • Solenoid - Air

  • Solenoid - Purge

  • Data log - Log interval: Typically 20 seconds (1 second to 5 seconds for troubleshooting)

  • Clock - Date: Follow the format provided on the screen on the right-hand side of the Date.

  • Clock - Time: Follow the format provided on the screen on the right-hand side of the Time.

  • Controller - Maximum temperature

  • Controller - Open Loop/Close Loop

  • Controller - Heater present

Note: Operator must save all variables.

Dosing Map Setup Page




Illustration 34g03646242

The following "Dosing Map Setup" parameters are viewed:

  • Boost Pressure: Recorded Boost values at the given load.

  • DEF Flow Rate: The recorded amount of DEF Flow to obtain "OL" map setting. Typically 10 percent less than "Desired Target".

  • Pre-NOx: The amount of NOx recorded at the given load from the Pre-NOx sensor.

  • Backpressure Alarm: The initial settings should be recorded ONLY when DPF are new or just installed after a cleaning. Record the amount of inches of water column measured at each load point and multiply by 2. To disable alarm for DOC use or otherwise: Input 102 cm of H2O (40 inch of H2O) in all Backpressure alarms. No setting shall exceed the Engine Technical Marketing Information (TMI) Specifications for the engine: unless disabling the alarm.

  • NOx Compensation: This feature is to be enabled when a unit has correct DEF Flow rate and Pre-NOx values ONLY. NOx compensation feature is adaptive to weather and Pre-NOx variations.

Closed Loop Setup Page




Illustration 35g03646333

The following "Closed Loop Setup" parameters are viewed:

  • Desired Target: Set to sites permitted NOx reduction plus 0.25 percent.

  • RRM Applied: The SCR Controller reduces the "Desired Target" to achieve stable operation.

  • Actual Target: "Desired Target" minus "RRM"

  • Actual Reduction: Current NOx reduction achieved.

  • Pre-catalyst: The current NOx value at the "Pre-Catalyst" or engine out location.

  • Post-catalyst: The current NOx value at the "Post-Catalyst" or stack out location.

  • Open Loop: Operating at the dosing map values.

  • NOx Compensation:

  • PID:

  • PID NOx Compensation: Changes to the dosing map to achieve "Desire Target".

  • Pump Output: The current "Pump Output" after all the compensations are applied.

Heater Setup Page




Illustration 36g03646334

The following "Heater Setup" parameters are viewed:

  • On Temperature: When the engine running and the exhaust temperature reaches this value, the heater is turned on.

  • Hysteresis: Increments of temperature the software attempts to reach and determines heater output.

  • Off Temperature: When the engine running and the exhaust temperature reaches this value, the heater is turned off.

  • Over Temperature: This value is to warn of a potential over temperature or hazard in the system.

  • Setup: Manually control the heater with this mode.

  • Desired Output: The operator can update settings and manually control the heater.

  • Actual Output: Displays the percentage of heater output.

  • Multiplier: 1000

  • Offset: 0

  • Boost Pressure Signal: Use a 1 to select which component will allow heater operation.

  • Engine Run Signal: Use a 1 to select which component will allow heater operation.

Note: Either the "Boost Pressure Signal" or the "Engine Run Signal" is selected for heater to be functional. Both signals cannot be selected simultaneously.

Network System Setup Page




Illustration 37g03646190

The "Network System Setup" page web address is http://169.254.0.2/caterpillar/web/network.htm.

All SCR Controllers are shipped from the factory with the IP address and subnet mask listed below:

  • Communications Parameters: IP Address: 169.254.0.2

  • Communications Parameters: Netmask: 255.255.0.0

Changing the IP address of the SCR Controllers can be done using the "Network System Setup" page. If the IP address and subnet mask of the SCR Controller are changed, then the new IP address and subnet mask values when configuring the MODBUS TCP/IP server to communicate with the SCR Controller. The touch monitor will also need to be reconfigured. Refer to Testing and Adjusting, "Touch Monitor - System Setup" Because the IP address and subnet mask of the SCR Controller is configurable, it is possible to place multiple SCR Controllers on a network. The port and socket values are not configurable on the SCR Controllers.

MODBUS Addresses

Each MODBUS address is shown in Table 2 and is for customer supplied remote monitoring equipment.

Table 2
Tag Name     MODBUS Address     Data Type    
Air solenoid     100001     Boolean    
DEF Solenoid     100002     Boolean    
Low Air Pressure     100003     Boolean    
Blue LED     100004     Boolean    
Red LED     100005     Boolean    
Green LED     100006     Boolean    
Air Line Fault     100007     Boolean    
Hardware Purge     100008     Boolean    
Reductions Actual     300001     Float    
Reductions Desired     300003     Float    
Pre NOx     300005     Float    
Post NOx     300007     Float    
NH3FlowAdjust     300009     Float    
Boost Pressure     300011     Float    
Boost Temperature     300013     Float    
Pump Output     300015     Float    
Exhaust Pressure     300017     Float    
Exhaust Temperature     300019     Float    
System Hours     300021     Float    
Engine Hours     300023     Float    
Cumulative DEF Usage     300025     Float    
Data Log Interval     300027     DWord    
SCR Controller Serial Number     300029     DWord    
Cabinet Serial Number     300031     DWord    
SCR System Serial Number     300033     DWord    

Information System:

2013/11/04 A New Water Pump Seal is Used on Certain C18 Marine Engines Equipped with the Bronze Impeller Auxiliary Pump {1361}
2013/10/29 The Clamp Assembly for Muffler Has Been Improved On Certain C Series and D Series Excavators {1062}
XQC1600 Power Module Setup
C280-08 Marine Engine Exhaust Outlet Nitrogen Oxide Sensor - Replace
XQC1600 Power Module Fuel Related Components in Cold Weather
XQC1600 Power Module Generator Operation
2014/05/20 An Improved Water Pump Seal Assembly Is Used on Certain Commercial Engines {1361, 7555}
C280-08 Marine Engine Symbols
374F Excavator Machine System Cab
374F Excavator Machine System Air Cleaner
2013/10/31 Top End and Major Engine Overhaul Foundational Kits Are Available for 3512 Petroleum Engines {1000}
2013/10/31 Major Engine Overhaul Foundational Kits Are Available for 3406 Marine Engines {1000}
Jacket Water Heater Group Parts List For Certain 3500 Engines{1383}
770G and 772G Off-Highway Truck Systems Pump and Motor (Parking Brake Release, Secondary Steering)
Selective Catalytic Reduction Retrofit Aftertreatment General Information
C4.4 Industrial Engine Coolant Level - Check
C4.4 Industrial Engine Engine Air Cleaner Element (Dual Element/Canister Type) - Clean/Replace - If Equipped
C280-12 Marine Engine Product Storage
C280-08 Marine Engine Alarms and Shutoffs
C280-08 Marine Engine Before Starting Engine
C280-08 Marine Engine Burn Prevention
C280-08 Marine Engine General Hazard Information
14L Motor Grader Air Cleaner - Remove and Install
2013/10/28 Engine ECM Clearing Process for Dealers Is Now Available on Certain Applications {1901, 1920}