SCR Retrofit Aftertreatment Aftertreatment SCR System Verification - Test Caterpillar


Aftertreatment SCR System Verification - Test
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SCR Retrofit Aftertreatment [UENR4332]
AIR INLET AND EXHAUST SYSTEM
AFTERTREATMENT GP
SCR Retrofit Aftertreatment Aftertreatment SCR System Verification - Test
1.1. Touch Monitor - Setup
2.2. Introduction
3.3. Required Tools
4.3. Screen Calibration
5.3. Location Setting
6.3. Time Setting
7.3. Network Settings
8.2. Dosing Pump Calibration
9.3. Specifications
10.3. Introduction
11.3. Required Tools
12.3. Test Preparation - Dosing Pump Calibration
13.3. Test Procedure - Dosing Pump Calibration
14.3. Adjustment Procedure - Dosing Pump Calibration
15.2. Diesel Exhaust Fluid Priming
16.2. Air and Purge Solenoid
17.3. Introduction
18.3. Required Tools
19.3. Test Preparation - Solenoid
20.3. Test Procedure - Solenoid
21.2. Air Pressure Regulator
22.3. Specifications
23.3. Introduction
24.3. Required Tools
25.3. Service the Air Pressure Regulator
26.2. Pressure Gauges
27.2. Back Pressure Valve
28.3. Introduction
29.3. Service the Valve Body or Replace Viton Diaphragm
30.3. Adjustment Procedure - Back Pressure Valve
31.2. Air Pressure Switch
32.2. Setting Offset and Multiplier on 5V Pressure Sensors
33.3. Specifications
34.3. Introduction
35.3. Required Tools
36.3. Test Procedure - Offset and Multiplier on 5V Pressure Sensors
37.2. Y Sediment Strainer and Mesh Buttons
38.3. Y Sediment Strainer
39.3. Mesh Buttons
40.2. NO<SUB>x</SUB> Sensors
41.3. Installation
42.3. Removal
43.2. Commissioning Process
44.3. Required Tools
45.3. Site Setup
46.3. Dosing Cabinet Setup
47.3. Commissioning
48.3. Dosing Map Setup
49.3. 450-7654 Engine Software
50.2. Commissioning Supplement for Natural Gas Operation
51.3. Boost to Load calibration process
52.3. Example of the Boost to Load Calibration Process
53.2. Selective Catalytic Reduction Controller Replacement
54.2. Update the Software on the Selective Catalytic Reduction Controller
55.2. Back Up a System
56.2. Cleaning the Diesel Particulate Filter
57.3. Recommended Cleaning Procedure
58.3. Baking Procedure
59.3. Cleaning Procedure
60.1. Appendices
61.2. Appendix A
62.3. Recommended Spare Parts on Shelf
63.2. Appendix B
64.3. Record of DPF Cleaning
65.2. Appendix C
66.3. Filter Evaluation Form
67.2. Appendix D
68.3. Cleaned Filter Specification

Note: Repairs and services must be performed by an authorized Cat Dealer.

Touch Monitor - Setup

Introduction

The power supply receives power from the 24VDC power supply inside the dosing cabinet. The touch monitor communicates with the DCC values on a LAN through an Ethernet cable. The touch monitor displays the DCC values on different webpages. All the settings within the touch monitor can be changed for the location, network configuration, local time, and screen calibration.

Required Tools

Table 1
Required Tools    
Qty     Tools    
1     USB Keyboard    
1     USB Mouse    
1     Password (1q2w3e4r5t)    
1     Stylus provided in cabinet    

Screen Calibration

  1. Turn on the touch monitor.

    Note: If cursor is not at the point of contact, use a USB mouse or the provided stylus to navigate and open the calibration.

  1. Click the "Pen" icon at top of screen. A calibration window pops up.

  1. Select the "four points" button.

  1. Click the "Calibrate" button.

  1. Enter the supplied password.

  1. Touch all the red dots on the screen with the provided stylus.

  1. Check the point of contact of the cursor.

  1. Repeat Steps 2 through 7, as necessary.

Location Setting

  1. Tap the time in the upper right-hand corner with provided stylus.

  1. On the calendar, set the current date.

  1. Click on "Edit" next to locations.

  1. Click on "Current Location" or "Region". If the current location or region is not present, click on "Existing Location" and then click "edit".

  1. Remove or delete the existing location.

  1. With the portable USB keyboard and the drop-down menu with available cities select a local city with the stylus or the keyboard.

  1. With stylus tap the time zone drop-down box and select proper time zone for the units location.

  1. Click on "Ok".

  1. Verify the location on the "Preferences"window.

Time Setting

  1. Click on the "clock" in the upper right corner.

  1. Click on "current location".

  1. Click on "set".

  1. Enter the password 1Q2W3E4R5T on the "Authenticate" screen.

  1. Click on "time settings".

  1. Set time in a 24 hr format.

  1. Set the current date.

  1. Verify that the time is set, repeat if necessary.

Network Settings

Perform the following task if the IP address in the DCC is changed for the network configurations of the customer. This change is usually for data transmission or monitoring.

  1. Click on "Computer Screen Icon" at top of page.

  1. Select VPN Connections Select Configure VPN.

  1. Click the "Wired Tab".

  1. Click on "EDIT".

  1. Click on "EPOD Network"

  1. Click on "Edit".

  1. Select "IPV4"settings.

  1. Double click on "IP" under Addresses.

  1. Type in the new IP address with decimals, ensure to change the last digit of the IP address so that it differs from the actual DCC IP. The Screen IP address also cannot match any other devices on the network.

    Note: The Webpage on the Screen will need to be updated as well.

  1. Select "Edit".

  1. Select "Preferences" at the bottom of the "Edit" menu.

  1. Change the Home page address to match the IP of the DCC.

  1. Only change in the address will be to the IP

  1. Hit "ENTER" on Keyboard.

  1. Reboot the DCC and the Touch Monitor.

Dosing Pump Calibration

Specifications

Table 2
Pump Model     Value    
DDA17     0 - 17 l/hr    
DME19     0 - 19 l/hr    
DME60     0 - 60 l/hr    
DME150     0 -150 l/hr    

Introduction

Use this procedure to calibrate the DCC to the pump.

Calibration ensures accurate dosing amounts to achieve desired reductions, and prevents unwanted dosing during standby mode.

Calibration is required whenever a DCC or pump is changed.

Required Tools

Table 3
Required Tools    
Qty     Tool    
1     Laptop computer    
1     Ethernet cable (supplied inside dosing cabinet)    
1     Software Deployment Tool (optional to help determine IP address of DCC)    

Test Preparation - Dosing Pump Calibration

  1. Turn off the DEF ball valve to the cabinet.

  1. Turn off the power to the dosing cabinet and the pump.

  1. Disconnect 23 pin connector on top of the dosing cabinet.

  1. Turn on the power to the dosing cabinet and the pump.

  1. Press the "Pause" button on the pump display so that the pump will not pump any DEF during this process.



    Illustration 1g03399484

    The parameters modified are circled.

  1. On the "Setup" page, click the "Enter Setup" button to enable manual control of the pump.

Test Procedure - Dosing Pump Calibration

  1. Enter 0 in the white "Pump Output" box . The pump should read 0.00. Repeat with increasing values and verify that the pump reads within ± 0.2 l/hr of the pump output.

    Test the following values with the correct pump style:

    • DDA17 2 l/hr and 15 l/hr

    • DME19 2 l/hr and 17 l/hr

    • DME60 5 l/hr and 55 l/hr

    • DME150 13 l/hr and 130 l/hr

Adjustment Procedure - Dosing Pump Calibration

  1. Enter 0.5 in the white "Pump Output" box. The value will update and appear in the adjacent gray box.

  1. Read the display screen on the pump. The display screen should read 0.5 l/hr. If the pump reads a different number, the pump offset will need to be adjusted. Adjust the pump offset number up/down until the pump reads within ± 0.2 l/hr of the pump output.

  1. Change the pump output to 95 percent of the pump output (DME2 = 1.9, DDA17/DME19 = 15, DME60 = 57). The pump multiplier will need to be adjusted up/down until the pump reads within ± 0.2 l/hr of the pump output.

  1. Repeat Steps 1 through 3 until no adjustment of the multiplier or offset is needed.

  1. Click on "Save All Variables" at the bottom of the screen.

  1. Click on "Exit Setup" to exit the "Setup" mode and turn off the pump.

  1. Turn off the power to the dosing cabinet and the pump.

  1. Turn DEF ball valve back on and reconnect 23 pin connector.

  1. Turn on the power to the dosing cabinet and the pump.

Diesel Exhaust Fluid Priming

Prime all DEF supply lines to the dosing pump before attempting to operate.




Illustration 2g03399516

The purge valve location varies with different pump models.

(1) Dosing pump purge valve knob

  1. Open dosing cabinet ball valves for DEF.

  1. Turn on all the circuit breakers to power the dosing cabinet.

  1. Open the valve on the pump head to purge air from the DEF supply system and use the 100 percent button on the pump for full stroke. Pump until no air is in the pump head or Y-strainer.

    Note: Use a spill container ready to catch the DEF once dosing system primed and close valve.

  1. Turn the purge valve knob in the opposite direction until closed.

    Note: Do not use any tools to close this valve. Hand tighten only.

Air and Purge Solenoid

Introduction

The air and purge solenoids are operated by a 24 VDC signal coming from the DCC. The solenoids are normally closed. These signals are controlled automatically during normal operation or could be manually turned on while the DCC is in setup mode. The reason for this option is to be able to verify whether the solenoids are opening and closing. This option is only possible in the "Setup" mode.

Required Tools

Table 4
Required Tools    
Qty     Tool    
1     Ethernet cord    
1     Laptop computer    

Test Preparation - Solenoid




Illustration 3g03399120

(1) Air solenoid use for atomizing DEF during startup, run, and purge cycles

(2) Purge solenoid behind the Y-Sediment strainer




Illustration 4g03400112

Typical 24 VDC solenoid

(3) Solenoid coil

(4) Solenoid body

(5) Lock nut

(6) Washer

(7) Electrical connector

  1. Click the "Enter Setup" button on the "Setup" page.

  1. On the middle of the "Setup" page, locate the "Air Solenoid" and "Purge Solenoid" buttons.

Test Procedure - Solenoid

  1. Click the "Open" button for the air solenoid and watch for 290 ± 14 kPa (42 ± 2 psi) on the DEF delivery gauge.

  1. Click the "Close" button and verify pressure returns to 0 psi. Make sure that no air is no flowing.

  1. Click the "Open" button for the purge solenoid and watch for unregulated pressure on the DEF delivery gauge.

  1. Click the "Close" button and verify pressure returns to 0 psi. Make sure that no air is no flowing.

    If the solenoids are not opening or closing, refer to Troubleshooting, UENR4333, "Solenoids Are Not Functioning".

Air Pressure Regulator

Specifications

Table 5
Parameter     Value    
Regulated Air Pressure    
483 ± 14 kPa (70 ± 2 psi)    

Introduction

The air pressure regulator should maintain an air pressure setting of 483 ± 14 kPa (70 ± 2 psi). The air pressure setting is adjustable by the T-handle and lock nut on the face of the regulator.

Servicing of the air pressure regulator is required if air system is contaminated.

Required Tools

Table 6
Required Tools    
Qty     Tool    
1     9/16 wrench    
1     Screwdriver    

Service the Air Pressure Regulator




Illustration 5g03399071

(1) Outlet to the air solenoid

(2) Air pressure gauge

(3) Outlet purge line

(4) T-style adjustment handle

(5) Jam nut to maintain correct pressure

(6) Nose cone 8 screw securement

  1. Turn off the power to the dosing cabinet.

  1. Turn the air supply and DEF ball valves to the off position.

  1. Loosen the jam nut (5) for the T-style handle.

  1. Back T-style handle (4) all the way out to relieve pressure of the spring tensioner.

  1. Remove air pressure gauge (2) from the front face of the regulator.

  1. Remove the eight screws (not shown) from the regulator holding on nose cone (6) .

  1. Check the inside of the regulator for DEF deposits or contamination. Clean with warm water removing all contaminants and DEF deposits

  1. Inspect the diaphragm (not shown) and the nose cone (6) for contamination and clean with warm water.

  1. The diaphragm is part of the seal. Before reassembly, inspect the diaphragm for reuse.

  1. Reassemble the regulator.

  1. Adjust T-style handle (4) to achieve the desired air pressure.

  1. Tighten jam nut (4) against nose cone (6) .

Pressure Gauges

The stainless steel pressure gauges provide operating pressures of the system during operation, and assist in troubleshooting and maintenance. Both gauges are rear mounted with a ? inch NPT male threads. The DEF gauge has a maximum reading capacity of 1103 kPa (160 psi). The DEF gauge displays pressure pulsations during dosing pump operation. The Air Delivery Gauge has a maximum reading capacity of 689 kPa (100 psi). When the system is in standard run mode, the air delivery gauge should read approximately 69 kPa (10 psi) less than the set pressure on the pressure regulator. When the system is in startup or run mode, the air delivery gauge will fluctuate approximately 55 kPa (8 psi) due to the flow of DEF provide by the dosing pump. This fluctuation in pressure is created by the pumps back and forth stroke.




Illustration 6g03399756

(1) DEF pressure and purge gauge - 0 to 1103 kPa (0 to 160 psi)

(2) Air delivery gauge is used during operation and purge cycles - 689 kPa (100 psi)

During the startup operation and run cycle, the DEF gauge will show approximately 345 ± 28 kPa (50 ± 4 psi).

During the purge cycle, the DEF gauge will show unregulated air supply provided by the air compressor.

These gauges are non-serviceable. If the gauge is spun or needle indicator is bent, replacement is required. If the system is back flushed with DEF, replacement of the gauge is recommended.

Back Pressure Valve

Introduction

The diaphragm back pressure valve is designed to prevent DEF from flowing below 276 kPa (40 psi). When the preset pressure is exceeded, the diaphragm is forced up and the DEF flows through the valve to the injection point. The valve is preset for 276 kPa (40 psi). The valve is adjustable.

Service the Valve Body or Replace Viton Diaphragm




Illustration 7g03399825

(1) Allen screw

  1. Turn off the power to the dosing cabinet.

  1. Locate the back pressure valve.

  1. Loosen and remove the DEF lines.

  1. Put the valve body on a flat surface to remove screws.

  1. Pull off the rubber cover from the top and back the adjustment screw completely out.

  1. Turn the valve upside down until the spring is removed.

  1. Remove the top four allen screws with a M4 allen wrench.

  1. Remove off the nose cone.

  1. Wash all the parts in warm water until DEF has been dissolved.

  1. Allow all components to dry.

  1. Inspect the surfaces of the valve body and nose cone for: Cracking, Chips and Deformity.

  1. Replace Viton diaphragm.

  1. Reassemble in reverse order.

  1. Install the four allen screws using a crisscross pattern for tightening.

    Torque screws ... 5 N·m (43 lb in)

    The gap should maintain even spacing while being tightened

  1. Install the tensioner spring inside the nose cone. Refer to Adjustment Procedure - Back Pressure Valve.

  1. Install the rubber cover.

Adjustment Procedure - Back Pressure Valve

The back pressure valve has an adjustment screw under the rubber cover. Turning the adjustment screw to the right will apply more pressure to the diaphragm. Turning the adjustment screw to the left releases the tension from the spring and decreases the pressure creating more flow through the back pressure valve. It is best to maintain 310 kPa (45 psi) through the valve.

  1. Remove the rubber cover from the back pressure valve.

  1. Turn the adjustment screw counter-clockwise until the adjustment screw is flush with the top of the valve nose cone.

  1. When the screw is flush, turn the screw clockwise 6.5 turns. This action returns the Back pressure valve to 276 kPa (40 psi) opening pressure.

  1. Install the rubber cover onto the back pressure valve

Air Pressure Switch

The air pressure switch requires an air supply pressure of 310 kPa (45 psi) or greater for the system to operate. Air pressure falling bellow this setting will initiate a purge cycle. If the purge cycle cannot be completed using the remaining system air pressure, drying of DEF may contaminate the system.

Perform the following steps to verify whether the air pressure switch is working correctly:

  1. Turn the air pressure regulator tee handle counter-clockwise.

  1. Watch the gauge on the regulator for decreasing air pressure until 296 kPa (43 psi) shows on the gauge. At this time the systems air pressure switch should close.

  1. Set the regulator back to 310 kPa (45 psi).

Setting Offset and Multiplier on 5V Pressure Sensors

Specifications

Table 7
Parameter     Zero Point Value     Comment    
Boost Pressure    
0 ± 1 kPa (0 ± 0.2 psi)    
Verify with Cat ET or gauge group    
Exhaust Pressure    
0 ± 0.5 cm of H2O (0 ± 0.2 inch of H2O)    
Verify with Cat ET or gauge group    

Table 8
Parameter     Value     Comment    
Boost Multiplier     25.00     Factory setting, do not change.    
Boost Offset     -0.50     Used to set zero.    
dp Multiplier     9.00     Factory setting, do not change.    
dp Offset     -0.50     Used to set zero.    

Introduction

Setting the Offset and Multiplier on 5V pressure sensors calibrates the software to the sensors for an accurate data signal. This action should be performed when a system is commissioned, a sensor is changed, or a DCC is replaced.

Required Tools

Table 9
Required Tools    
Qty     Tool    
1     Laptop computer    
1     Ethernet cable (supplied inside dosing cabinet)    
1     Cat ET or gauge group    
1     Optional: Software Deployment Tool (to help determine IP address of DCC)    

Test Procedure - Offset and Multiplier on 5V Pressure Sensors

  1. Cabinet should be powered up, engine should not be operating.



    Illustration 8g03401320

  1. On the "Operation" page, observe the standby pressure readings with the engine not running. If the pressures are not within the zero point specifications, the zero offset will need to be adjusted.



    Illustration 9g03401359

    Note: The Boost and dp Offset variables are used to set the zero point of the boost and exhaust pressure sensors. If the standby pressure is too high, make the offset more negative. If the standby pressure is too low, make the offset more positive.

  1. Adjust the offset variable to zero with the sensors at ambient temperature.

  1. Adjust the offset variable for the sensor by entering the value in the white box and then clicking the mouse in the blue area of the screen.

  1. Check the standby pressure for the zero point value on the operations page. If the standby pressure is not at the zero point value, adjust offset values until pressures are in the zero point specification.

  1. When finished, scroll to the bottom of the "System Setup" page and select "Save Variables" to save the calibration settings. Save all settings to the downloaded copy of Special Instruction, REHS9221, "Cat Retrofit Selective Catalyst Reduction System Commissioning Report".

  1. Download a copy of Special Instruction, REHS9221, "Cat Retrofit Selective Catalyst Reduction System Commissioning Report" from SIS web.

  1. Record all the settings onto Special Instruction, REHS9221, "Cat Retrofit Selective Catalyst Reduction System Commissioning Report" that was downloaded.

Y Sediment Strainer and Mesh Buttons

Y Sediment Strainer

The Y Sediment Strainer removes impurities from the DEF before traveling through the dosing cabinet system. The strainer is equipped with a 60 micron screen and has two button strainers at the outlet of the Y sediment strainer. The bottom cap of the strainer screws off and on for maintenance of the metal screen.

Perform the following steps to clear the strainer of debris:

  1. Turn the dosing cabinets circuit breakers to the off position.

  1. Close the ball valve on the side of the dosing cabinet to the off position.

  1. Locate a shallow container to capture the DEF in the strainer.

  1. Unscrew the strainers bottom cap.

  1. Let the strainer bottom cap and used DEF fall into the container.

  1. Inspect strainer screen for imperfections

  1. Rinse strainer in lukewarm water.

  1. Replace strainer in reverse order.

    Regular maintenance of the 60 micron screen will detour maintenance needs for the button strainers.

Mesh Buttons




Illustration 10g03400342

(1) Y sediment strainer

(2) Button strainer

NOx Sensors

The NOx Sensors are sensitive to improper handling, to avoid damage handle the NOx sensors with extreme care. The NOx Sensors are nonserviceable.

Examples of misuse are as follows:

  • Mechanical shock

  • Painting

  • Cleaning of the NOx sensor

  • Power Supply

  • ESD

  • Carrying the NOx sensor by the cable

For additional information on sensor handling installation and specifications, refer to Special Instructions, REHS8151, "NOx Sensors Handling and Installation Procedures"

Installation

  1. System Power off.

  1. Attach the sensor to the mount provided on the SCR.

  1. Remove the protective cap from the sensing unit. Any deposit of dirt or dust on the threads should be avoided after removal of the protective cap. The anti-seizing paste on the threads should not be cleaned off.

  1. Install the sensor hand tight into the boss.

  1. Tighten the sensor collar avoiding twisting of the wiring during installation.

    Torque the sensor collar ... 50 ± 5 N·m (37 ± 4 lb ft)

    Note: Maximum allowable cable rotation after tightening is 180 degrees.

  1. Connect the mating plug to the electrical connector on the sensor Electronic Control Unit (ECU). Make sure that there are no particles inside the electrical connector.

Removal

  1. Turn off the power to the dosing cabinet.

    Note: Do not disconnect the plug when the NOx sensor is powered. This action may damage the DCC.

    Note: NOx sensors are at high temperatures during operation and require cool down before handling.

    Note: AVSpare recommends that protective gloves be worn.

  1. Unscrew the sensor from the boss port, holding on the sensors grommet until the unit is only finger tight with minimal thread engagement.

  1. Remove the four nuts and the four washers on the back of the mounting plate.

  1. Remove the remainder of the grommet and the sensor.

Commissioning Process

Commission the Retrofit SCR after all other systems are "Commissioned". Download the Special Instruction, REHS9221, "Cat Retrofit Selective Catalyst Reduction System Commissioning Report" from SIS Web.

Required Tools

Table 10
Required Tools    
Qty     Tool    
1     Laptop computer    
1     Ethernet cable (supplied inside dosing cabinet)    
1     Load bank    
1     Calibrated exhaust gas analyzer    
1     Calibrated gauge group    
1     Multimeter    
1     Software Deployment Tool (version 2.1.8 or newer)    
1     Software (version 10.1.10 or newer)    

Site Setup

  1. Fill out the Site Information before the system operation.

  1. Complete a preliminary inspection of the system using the checklist as a reference.

  1. Record the serial numbers, part numbers, and customer data.

  1. Fill out the "Site Preparation" checklist and record any applicable site comments.

Dosing Cabinet Setup

  1. In the Dosing Cabinet, close circuit breakers on DIN rail to apply power to all components.

  1. Press the "Touch Monitor" power button. Select "Start New Session" once the touch monitor is booted up.

  1. Make sure that the SCR system is communicating with the touch monitor.

  1. Perform "Touch Monitor-Setup". Enter the correct Location, Date, Time and Cursor/Screen calibration.

  1. Connect the laptop to SCR Controller. Ensure that all the WIFI connections and LAN connection are off.

    The laptop connects to the following Webpages:

    • System Setup

    • Operation

    • Dosing Map Setup

    • Network Setup

    • Closed Loop Setup

    • Heater Setup (Optional)

  1. Set the "Date" and "Time" on the "System Setup" page of the SCR Controller.

  1. Enter the site information into the "System Setup" page.

  1. Enter the default settings into "System Setup" Page.

    Note: The default settings should already be installed.

  1. Set the air pressure regulator inside the dosing cabinet to 483 kPa (70 psi). Verify that the air pressure is 483 kPa (70 psi) during dosing.

  1. Prime the dosing pump using the "100 percent" button on the dosing pump control panel and the priming valve on the pump head. Pump 1L to 2L of DEF out of the priming valve on the pump head. Clean the "Y" strainer out , if necessary.

  1. Enter the "Setup" mode on the "System Setup" page.

    Perform the following with the air pressure supplied to the dosing cabinet:

    • Open and close the DEF solenoid. The DEF delivery gauge should read the supplied air pressure when the solenoid is open.

    • The air solenoid opens at 276 ± 21 kPa (40 ± 3 psi) on the DEF delivery gauge.

    • The pump display responds to different flow rate settings. Calibrate the pump as needed.

  1. Calibrate the pressure sensors and dosing pump. The air supply to the dosing cabinet must be present to calibrate the dosing pump.

  1. Apply 100 percent load to the engine and allow the SCR system to reach operating temperature. Takes approximately 40 minutes to 60 minutes.

Commissioning

  1. Open all delivery lines to the dosing cabinet (DEF and pressurized air).

  1. Turn on the power to the dosing cabinet.

  1. Connect to the SCR Controller.

  1. Complete the "Touch Monitor-Setup" section of the Testing and Adjusting.

  1. Verify that the pump is calibrated. Refer to Testing and Adjusting, "Dosing Pump Calibration" for more information.

  1. Using the Software Deployment Tool (SDT) save the initial configuration.

  1. Enter "Setup" mode.

  1. Purge DEF lines to the DEF pump.

    • Obtain a DEF safe bottle to collect DEF and verify concentration.

    • Open the purge valve on the side of DEF pump.

    • Press and hold the 100 percent output button on the pump display until a steady stream of DEF is pulsing out of purge valve.

    • Verify the proper DEF concentration with a refractometer.

Dosing Map Setup




Illustration 11g03479997

  1. Run the engine at the following loads:100 percent, 25 percent, 75 percent and 50 percent.

  1. System Capability Test: Add 4 percent to the "Desired Target". Verify that the SCR system is able to achieve the "Desired Target" plus 4 percent during the initial Commissioning ONLY. Refer to Special Instruction, REHS9221, "Section 3: Dosing Map Setup-System Settings".

  1. Once all the loads have been ran and "Dosing Map Setup" is completed, using the "Open Loop Map" value in the "Desired Target " on the "Closed Loop Setup" page.

  1. Test the SCR system at all four loads. Record the "Closed Loop Setup" results, Post-NOx, and "Dosing Rate".

  1. Record the "Exhaust Back Pressure" at each load. Multiple the backpressure x 2 to get the alarm setting.

    Note: The alarm settings shall not exceed engine specifications for backpressure. To "DISABLE" this feature, set all points on Exhaust Pressure Map to 102 cm of H2o (40 inch of H2o).

450-7654 Engine Software




Illustration 12g03646242



Illustration 13g03646333

Note: This section is for previously commissioned SCR systems.

  1. Record all the settings from each web page on the SCR Controller onto the downloaded copy of Special Instruction, REHS9221, "Cat Retrofit Selective Catalyst Reduction System Commissioning Report".

  1. Use SDT 2.1.8 to upgrade the SCR Controller software to version 10.1.10 or newer

  1. Reboot the dosing cabinet and the touch monitor.

  1. Open the "System Setup" page. Input all the recorded and default settings into appropriate boxes on each page.

  1. Modify Dosing Flow rate as shown: Dosing Rate:_____l/hr x 0.95=_______l/hr (Enter each New Flow Rate).

  1. The Dosing map has two new parameters EO(Pre) NOx, and Back Pressure Alarm. Both Settings for each Load were included in Previous Commissioning Form

  1. Recorded Exhaust Back Pressure: ________x 2 = ________Alarm Map or Engine Max BP:________

    These settings are used to alarm the operator of systems operating with excessive backpressure. To "DISABLE" this feature, set all points on Exhaust Pressure Map to 40"H20.

  1. Once all the settings match up between the SCR Controller and the recorded values of Special Instruction, REHS9221, "Section 3: Dosing Map Setup-System Settings", save all the settings and use the SDT to "Copy Config FROM Controller". Retain a copy of the Configuration file and the Cat Retrofit Selective Catalytic Reduction System Commissioning Report.

Commissioning Supplement for Natural Gas Operation

Natural gas engines draw a vacuum on the intake manifold at low engine loads sometime less than 30 percent. The boost pressure sensor cannot operate receiving the negative values present in a vacuum, so populating the open loop map needs to be adjusted for the gas engine operation in a range of positive boost.

Populating the Open-Loop Map for a natural gas engine requires adjusting the load settings the engine is operating at due to the occurrence of a negative boost pressure at low loads. The software of the SCR system does not support a negative boost reading. The Engine loads used to set the map must be shifted upwards until the boost has a positive reading.

  • Retrieving the 100 percent load settings are the same. Running the engine at 100 percent load, the boost pressure, and flow rate of DEF are recorded. This would be the first load point to obtain.

  • Run the engine at a low load and gradually increase the load to produce a boost reading of approximately 14 to 21 kPa (2 to 3 psi). This will be used as the 25 percent load setting. The boost pressure and DEF flow rate should be recorded.

  • The 75 percent and 50 percent load settings are calculated in relation to the 100 percent load and 25 percent load.

  • The boost pressure low limit would be entered as 10 kPa (1.5 psi). If the boost pressure operates below 10 kPa (1.5 psi), the system would go into purge.

  • For the SCR system to be operating and reducing emissions, the engine load levels will have to remain on the positive boost range. When engine load drops below the minimum set point, the SCR system goes into purge.

Boost to Load calibration process

  1. Run the engine at full load (100 percent) and record the boost pressure reading. This reading will be the full load Boost Pressure (BP100)

  1. Run the engine at 25 percent load and record the boost pressure reading. The boost pressure should be around negative 21 kPa (3 psi).

  1. Increase Engine load until the boost reaches positive 14 to 21 kPa (2 to 3 psi). This engine load will be the lower load limit Boost Pressure (BP25).

  1. Subtract BP25 from BP100. The BPdelta is the pressure difference from maximum load to minimum load. BP100 – BP25 = BPdelta

  1. Divide BPdelta by 3.BPdelta /3 = BPstep o Your load settings are BPstep psi apart from each other

    • BP25 25 percent

    • BP25 + BPstep = BP50 50 percent

    • BP25 + 2xBPstep = BP75 75 percent

    • BP25 +3x BPstep = BP100 100 percent

    Try to achieve close to these boost pressures that you calculate as your load settings.

Example of the Boost to Load Calibration Process

  1. The engine is running at full load (100 percent) and shows 120 kPa (17.4 psi) of boost pressure. This boost pressure is your 100 percent boost pressure setting.

  1. Run the engine at 25 percent load and record the boost pressure reading. The boost pressure should be around negative 21 kPa (3 psi).

  1. Increase Engine load until the boost reaches positive 14 to 21 kPa (2 to 3 psi). This engine load will be the 25 percent load setting.

  1. Subtract 21 kPa (3 psi) from 120 kPa (17.4 psi) giving a difference of 99 kPa (14.4 psi).

    120 kPa (17.4 psi) - 21 kPa (3 psi) = 99 kPa (14.4 psi).

  1. Divide 99 kPa (14.4 psi) by 3. The load settings are 33 kPa (4.8 psi) apart from each other.

    • 21 kPa (3 psi) is 25 percent

    • 21 kPa (3 psi) + 33 kPa (4.8 psi) = 54 kPa (7.8 psi) is 50 percent

    • 21 kPa (3 psi) + 33 kPa (4.8 psi) + 33 kPa (4.8 psi) = 87 kPa (12.6 psi) is 75 percent

    • 21 kPa (3 psi) + 33 kPa (4.8 psi) + 33 kPa (4.8 psi) + 33 kPa (4.8 psi) = 120 kPa (17.4 psi) is 100 percent

    Try to achieve close to these boost pressures that you calculate as your load settings.

Selective Catalytic Reduction Controller Replacement




Illustration 14g03432388

Typical SCR Controller




Illustration 15g03401159

  1. Connect computer to dosing cabinet with Ethernet cable.

  1. Launch Software Deployment Tool, on launch, tool will search for DCCs. DCCs can be searched for at any time by clicking the "Refresh Controller List" button.

  1. Highlight the DCC on left to be copied and click the "Copy Configuration from Controller" button to save DCC configuration.

  1. Shut down the dosing cabinet, not necessary to disconnect the computer to replace DCC.

  1. Turn off the power within the dosing cabinet.

  1. Remove the two visible screw, washer, and locknut assemblies from the ECM and the electronics shelf.

  1. Loosen the two screw, locknut, washer assemblies behind the DCC on the electronics shelf.

  1. Unplug the Ethernet LAN cable from the DCC.

  1. Unfasten the allen head screw connecting the 40 pin connecter to the DCC.

  1. Reverse the steps for the installation of the DCC.

  1. Power the dosing cabinet backup.

  1. Click the "Refresh Controller List" to scan for DCCs.

  1. If the DCC needs the IP address set, select the DCC, then click the "Configure Controller Network Settings" button to set up DCC Name and IP address.

  1. Select the DCC on the left, and select software image on right and click the "Copy Image to Controller" button to deploy the software.

  1. Select configuration file on right to copy to the DCC and click the "Copy Config to Controller" button to put configuration setting back into DCC.

  1. Power cycle the DCC, so the DCC will read configuration file.

  1. Go into setup and configure the pump calibration and pressure sensors on the new DCC. The pump calibration and pressure sensors will change due to the new DCC. Refer to Steps in "Dosing Pump Calibration" and "Setting Offset and Multiplier on 5V Pressure Sensors" for more information.

  1. Go into setup and set the serial number of the DCC.

    If the software deployed to the DCC is an updated version, there may be new features that need variables to be updated and saved on the DCC "Setup" page.

    The updated version of software will be communicated in the release notes accompanying the software.

Update the Software on the Selective Catalytic Reduction Controller

  1. Connect computer to dosing cabinet with Ethernet cable.

  1. Launch Software Deployment Tool, on launch, tool will search for DCCs. DCCs can be searched for at any time by clicking the "Refresh Controller List" button.

  1. Highlight the DCC on the left and click the "Retrieve Config from Controller" button to save the DCC configuration.

  1. Highlight the DCC on left, and select software image on right and click the "Copy Image to Controller" button to deploy software to DCC.

  1. Click the "Copy Configuration To Controller" button to put original configuration setting onto new DCC.

  1. Power cycle the DCC so the DCC will read configuration file.

    If the software deployed to the DCC is an updated version, there may be new features that need variables to be updated and saved on the DCC setup pages.

    The updated version of software will be communicated in the release notes folder accompanying the software.

    Note: If release notes are available due to new features application, the new features will be communicated in the release notes folder under "support files".

Back Up a System

  1. Connect PC to dosing cabinet with Ethernet cable.

  1. Launch Software Deployment Tool, on launch, tool will search for DCCs. DCCs can be searched for at any time by clicking the "Refresh Controller List" button.

  1. Highlight the DCC on left and click the "Retrieve Configuration From Controller" button to save DCC configuration.

    Name the configuration with the site, engine number, software revision in the name.

Cleaning the Diesel Particulate Filter

Because the sections of the DPF are replaceable, a small stock of filter sections can be maintained. Filter sections from a small on hand stock can be used to replace filters in service at the next scheduled cleaning. The removed filters can be cleaned and returned for installation in the next vehicle. This process of maintaining a stock of filter sections can significantly reduce the amount of down time that will occur.

Note: Check State and Local air pollution regulations pertaining to record keeping of serviced filters. Some governmental entities may require filter tracking. Refer to "Appendix B" for recommended record keeping.

------ WARNING! ------

Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 half-face respirator when handling a used Diesel Particulate Filter or Catalytic Converter Muffler. Failure to do so could result in personal injury.

----------------------

Note: Perform a back pressure test prior to cleaning the DPF and record the results. After cleaning the DPF, run the engine at high idle for 5 to 15 minutes to bring the engine and exhaust system to operating temperature. Perform another back pressure test and record the results on the chart contained in "Appendix B".

Recommended Cleaning Procedure

  • Weigh and record the filter unit prior to baking

  • Controlled baking of the filter unit (see following "Baking Procedure" section)

  • Ash cleaning the filter unit using the 319-2189 Filter Cleaning Group

  • Weigh and record the filter unit after controlled baking and pulsed air cleaning

  • Reference "Appendix B" for proper record keeping

Note: Cleaning DPF units without baking shortens the life the HEPA filters within the Cleaner. The result is a shortened ash service interval because of incomplete soot removal.

Baking Procedure

This procedure will burn off the remaining soot on the DPF leaving a smaller quantity of ash by baking the filter under controlled circumstances. Failure to observe this procedure can result to damage or cracking to the DPF substrate. A commercial programmable oven is required for this procedure. Careful adherence to this procedure is imperative. Deviation from this procedure may lead to thermal shock and cracking of the DPF substrate or melting at high temperatures.

  1. Place filter into a programmable commercial oven designed for this purpose. Centered as much as possible on a rack with 2 inches of spacing below and above for best results.

  1. Program the oven as follows:

    1. Ramp oven temperature to 200° C (392° F) over 20 minutes.

    1. Hold oven temperature at 200° C (392° F) for 120 minutes (2 hours).

    1. Ramp oven temperature to 450° C (842° F) over 30 minutes (.5 hours).

    1. Hold oven temperature at 450° C (842° F) for 120 minutes (2 hours).

    1. Cool down to ambient temperature at natural rate within the oven with the doors closed. Do not use fans.

    1. Place filter in cleaning machine and clean as per machine instructions.

    1. Replace the filter in oven. Ramp temp to 650° C (1202° F) in 60 minutes (1 hour).

    1. Hold oven temperature at 650° C (1202° F) for 240 minutes (4 hours).

    1. Cool to ambient temperature at a natural rate. Do not use fans.

      Note: Allow the filter to cool in the oven with the door closed until the filter can be handled with bare hands.

Cleaning Procedure

Ash and soot should be removed from the DPF utilizing the AVSpare 319-2189 Diesel Particulate Filter Cleaner Gp . Using the Cleaner without following baking procedure, results in lower efficiency cleaning and will reduce the life of the HEPA filters in the machine. This tool uses pulsed air to flush the ash from the DPF and contains the filter ash through a HEPA filter and bag system. Other methods can release significant quantities of airborne ash and soot which may be considered a hazardous substance by some states. Adapters must be used to mount the DPF units in the machine. The 10.5 inch filter uses the 319-1839 Adapter and the 319-1835 Cone (Medium). The 12 inch DPF uses the 319-1838 Adapter with the 319-1836 Cone (Large).

Note: Other cleaning methods can release significant quantities of airborne ash and soot. Airborne ash and soot should not be inhaled and may be regulated as a hazardous substance by some states.

Appendices

Appendix A

Recommended Spare Parts on Shelf

Table 11
Recommended Spare Parts on Shelf    
Common Parts    
AVSpare Part Number     Description     Recommended on Shelf    
216-7994     Thermocouple     3    
216-7990     Installation As
(Swagelok fittings and copper tube)    
3    
302-1563     Exhaust Monitor Gp     1    
282-0031     Remote Display     1    
   
Individual Parts    
AVSpare Part Number     Description        
237-9335     Tee (1/4 inch)        
237-9337     Connector (1/4 inch)        
237-9340     Ferrule (1/4 inch)
(For 237-9337 Connector )    
   
237-9338     Reducer Bushing (1/8 inch)
(For Thermocouple)    
   
237-9342     Ferrule (1/8 inch)
(For 237-9338 Reducer Bushing )    
   
5P-1198     Tube (1/4 inch X 20 feet Copper)        

Appendix B

Record of DPF Cleaning

Note: This information must be maintained for warranty purposes.

Table 12
Record of DPF Cleaning    
Customer Name _______________ Initial Install Date _______________
Machine Model _______________ Machine S/N _______________
Machine Fleet Number_______________ EIN _______________
Filter S/N _______________ Filter Part Number _______________
Catalyst Module S/N _______________ Catalyst Part Number _______________
Initial Engine Hours ____________ Initial Back Pressure (Specify Units) ________ at FULL Throttle, NO-LOAD Condition.    
Cleaning Date:                                    
Engine Hours:                                    
Pre-Bake Weight (kg/lbs):
Specify Units    
                               
Post-Bake Weight (kg/lbs):
Specify Units    
                               
Weight After Pulsed Air (kg/lbs):                                    
Pre-Clean Back Pressure:
Specify Units    
                               
Post-Clean Back Pressure:
Specify Units    
                               
Cleaning Entity:                                    
Name/Initials of Technician:                                    

Appendix C

Filter Evaluation Form

Table 13
Filter Evaluation    
Date Received:         Customer:        
   
Filter Serial Number:         Filter Model Number:        
   
Pre-Clean Weight (kg):         Post-Clean Weight (kg):        
   
Net Ash Removed
(Pre-Clean/Post-Clean):    
    Photos Taken/Location:        
   
Notes:        
   
   
   
   
   
   



Illustration 16g02026337

Appendix D

Cleaned Filter Specification

Note: Scope: The following steps determine a properly cleaned AVSpare filter.

Note: This specification applies to filters that were cleaned of ash only. This specification is only valid subsequent to the "Recommended Cleaning Procedure". This specification should not be used to determine if soot filled filters are properly cleaned. All filters must be baked appropriately using the "Recommended Cleaning Procedure" prior to application of this specification.

HEALTH AND SAFETY

------ WARNING! ------

Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 half-face respirator when handling a used Diesel Particulate Filter or Catalytic Converter Muffler. Failure to do so could result in personal injury.

----------------------

Adhere to all local Health and Safety rules and regulations. Use all the personal protective equipment listed below:

  • Respirator

  • Safety shoes

  • Safety glasses

  • Latex gloves

  • Lab coat

RESOURCES

Necessary equipment:

  • 38 cm (15 inch) long by 0.9 mm (0.04 inch) thick stainless steel probe for "200 cpsi" (Cells/Square inch) filters

  • Tape measure

METHOD

Evaluation of a cleaned filter:

Note: A filter MUST meet all criteria in this section below to be considered clean.

  1. Inspect both inlet and outlet surfaces for oil/fuel contamination, gouges and/or cracks. No cracks may be visible. Gouges may not be exceed 4.0 mm (0.15 inch) deep.

  1. There must be no filter movement within the filters banding. This movement is defined as the substrate moving past the bent-over flange. The filter must be even or below the bent-over flange.

  1. There must not be any signs of the steel fiber ring coming loose or any mat material (cottony gauze) slipping past the filter. See Illustration 17 below.

  1. The flanges are not damaged beyond repair.

  1. There are no dents deeper than 6.4 mm (0.25 inch) in the outer can of the filter and the outer can is not cracked, torn or otherwise breached.

  1. No more than 20 cells are allowed to be damaged (showing soot) on the outlet face of the filter. Refer to Illustrations 18 and 19.

  1. Inspect the ash depth in the cells using the "Check Cell Depth" instructions below.



Illustration 17g02026392

Proper placement of the filter within the banding

(1) Outside Can

(2) Bent-over flange

(3) Steel fiber ring

(4) Mat material

(5) Filter

Note: Filter must be below the bent over-flange (2) .




Illustration 18g02026398

Acceptable filter with less than 20 damaged cells




Illustration 19g02026399

Unacceptable filter with too many damaged cells

Check Cell Depth

  1. Check cell depth by dropping the stainless steel probe into a cell location noted by a dot in Illustration 20 below.

  1. Lightly tap the probe with a finger until the probe does not travel into the cell any further. Mark the probe to record the depth.



    Illustration 20g02026405

  1. Measure the distance from the tip of the probe which entered the cell to the mark made on the probe. This distance is the cell depth. Repeat this step 17 times per Illustration 20.

  1. If the probe travels a minimum of 28.6 cm (11.25 inch) in all cells, the filter is considered clean.

  1. If the probe encounters heavy resistance in one or two cells, proceed to Step 6. Refer to Illustration 21.



    Illustration 21g02026406

    Evaluation of a Filter with Hardened Ash

    (1) Cell

    (2) 50.8 mm (2.0 inch) Square

    (3) Dot locations

  1. Identify the one or two cells (1) where heavy resistance was noted during the cell depth check. Refer to Illustration 21.

  1. Draw a 50.8 mm (2 inch) square (2) around cell (1) . Refer to Illustration 21.

  1. Check cell depth at the eight dot locations (3) . Refer to Illustration 21.

  1. If the probe encounters heavy resistance in three or more cells, THE FILTER IS NOT CONSIDERED CLEAN. THE FILTER MUST NOT RETURN TO SERVICE UNTIL THE FILTER IS PROPERLY CLEANED.