Purifilter Plus Hybrid Diesel Particulate Filter Operation and Maintenance Manual M (EGR)

Transcription

1 Purifilter Plus Hybrid Diesel Particulate Filter Operation and Maintenance Manual M (EGR) New York Edition **IMPORTANT WARRANTY INFORMATION & ENGINE LABEL INSIDE** Revised: November 2010

2 NOTE! Before beginning installation, check the packing list enclosed and report any shortages or damages within fourteen (14) days of receipt. Return the warranty card upon installing the Purifilter Plus Hybrid Diesel Particulate Filter. The copy to return can be found as the attached YELLOW form. 2

3 Table of Contents Purifilter Plus Diagram..Page 4 Introduction and Application Page 5 Component Description..Page 6 Preparing Before Installation.Page 7 Installation Instructions Page 8 Regeneration Control Panel Installation..Page 9 Health and Safety Practices. Page 10 Knowing When to Regenerate.. Page 11 Control Panel Schematic.. Page 12 Regeneration Instructions.....Page 13 Missed a Regeneration? What to Do?...Page 14 Maintenance...Page 15 Ash Removal......Page 16 Troubleshooting......Page 17 Regeneration Control Panel Trouble Shooting.....Page 19 Sample Log....Page 20 Records....Page 21 Warranty..Page 22 VDECS Label to Affix to Engine......Page 24 Glossary of Terms..Page 25 Contact Information....Page 26 Page 3 3

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5 INTRODUCTION The ECS Purifilter Plus hybrid diesel particulate filter incorporates electric elements with a passively regenerating Purifilter DPF. While the engine is in operation, the passive catalyst coated onto the Purifilter DPF allows for the oxidation of accumulated soot. Periodically, when parked, the unit can also be plugged into a common off-board electrical panel which will actively regenerate the DPF insuring that all soot is combusted. The result is a DPF with an extended application range for highway and non-road diesel engines with an enhanced ability to operate under variable or colder duty cycles. The Purifilter Plus hybrid diesel particulate filter consists of a vehicle mounted DPF assembly and off-board regeneration panel. This vehicle mounted assembly includes the DPF, wiring harness and Backpressure Monitor & Logger. The filter assembly is manufactured using stainless steel and designed to be mounted within the exhaust system replacing the vehicle s original muffler. The wall mounted assembly is comprised of a control panel and a quick disconnect air line and electrical connector. Active regeneration is performed by connecting an air hose and electrical plug from the panel to the vehicle when the vehicle is out of service. The Purifilter Plus can be purchased in either 240V AC single phase or 480V AC three-phase supply voltages. PURIFILTER PLUS APPLICATIONS The Purifilter Plus hybrid diesel particulate filter system can be applied to most 1994 to 2006 highway vehicles that have the ability to be periodically connected to an off-board mounted regeneration panel. Purifilter Plus is ideal for use with school, shuttle and urban buses as well as other municipal, state, utility and refuse fleets where vehicle duty cycles may be variable or cooler than that required by traditional passive Level 3 DPF s. A full list of applicable Engine Family Names can be accessed on the ARB or ECS websites. 5

6 COMPONENT DESCRIPTION Vehicle Mounted Assembly The vehicle mounted filter assembly consists of an inlet section containing the electrical heating elements, a catalyzed DPF centerbody and an outlet section. 1. Inlet Section / Heater Base The inlet section contains the heater elements, (figure 9) that when powered combust the soot in the filter center body during a process referred to as active regeneration. Varieties of inlet configurations are available to facilitate vehicle fit. Figure 8 Vehicle Mounted Assembly 2. Catalyzed DPF Center Body Purifilter Plus utilizes a catalyzed silicon carbide wallflow diesel particulate filter. This is the same DPF centerbody employed in the Purifilter H. The filter center body is sized to afford reasonable exhaust restriction and sufficient surface area for the catalyst to oxidize the collected particulate. 3. Outlet Section A wide variety of outlet section configurations are available to provide a suitable fit for most vehicles. The outlet must be protected from water entry by the use of a rain cap. 4. Backpressure Monitor & Logger A Backpressure Monitor & Logger tracks the operation of the Purifilter Plus Hybrid unit and transmit signals to a small dash mounted readout (figure 11). This Backpressure Monitor stores relevant operational data and provides a visual indication as to when the Purifilter Plus Hybrid unit requires active regeneration. The dash display unit is provided with a wiring harness, required fittings and CD software disk. Please refer to the Backpressure Monitor & Logger manual for more details. 4. Regeneration Control Panel Wall Mounted Assembly The regeneration control panel (figure 12) houses the power and air supply to the heater elements. When connected to the regeneration control panel, active regeneration can be performed.. Figure 11 Backpuressure Monitor & Logger 6

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8 Installation Instructions: Filter Assembly on Vehicle The Purifilter Plus is designed to replace the existing vehicle silencer. Installation position of the filter should be as close to the exhaust manifold as possible, normally where existing silencer is located. The following generic instructions are provided as basic information to purchasers of the Purifilter Plus. Purifilter Plus installations should only be performed by Engine Control Systems approved and trained technicians who will provide a separate installation warranty. 1. Avoid unnecessary and sharp pipe bends, diameter reductions, etc., that may increase exhaust backpressure. The diameter of the outlet pipe must be at least that of the outlet flange. The outlet must be protected from water entry. The Purifilter Plus vehicle assembly is heavier than standard silencers therefore the mounting support brackets should be able to withstand the increased weight. 2. Mount the Purifilter Plus on the chassis with supplied brackets or other suitable brackets and vibration dampers where indicated. 3. A minimum 24 length of flexible piping or bellows pipe should be installed between the turbocharger outlet and the inlet of the Purifilter Plus. This flex or bellows pipe shall yield about a 20% stretch from fully compressed to fully stretched. 4. Purifilter Plus vehicle assemblies should be mounted away from flammables. Please keep all flammables such as fuels, grease, oil, plastics, wiring harness, and rubbers away from the Purifilter Plus. Leaks in the area of the vehicle assembly should be repaired immediately. 4. Secure the wiring and air hose are away from moving parts and heat sources. The inlet base gets extremely hot when regenerating; a shield or additional insulation may be required on some installs to protect adjacent vehicle components which are susceptible to damage from heat (i.e. hydraulic lines, wiring, plastic, etc.). 5. Mount the electrical plug of the junction box and air hose of the heater base securely where accessible for frequent plug - in to avoid movement and interfering with other components. Ideally, these components will be installed behind an access door protecting these components from direct collision, water and road spray. 6. Before connecting the exhaust inlet pipe to the base heater, make sure the Back Pressure fittings are installed and welded on the inlet pipe for the Back Pressure monitor & Logger. Please see the Back Pressure Monitor and Logger Manual for installation instructions. The BP fittings are included in the Back Pressure Monitor Logger Kit. 7. Install the BP Monitor and Logger following the instructions contained within the separate manual. It is critically important that the remote readout display be mounted in a location visible to the driver so that LED indicator lights can be observed and reported. There are two indicator lights that specifically indicate the need to schedule or perform regeneration immediately. NOTE! Vehicle Installs should be performed by ECS AP- PROVED & TRAINED TECHNICIANS NOTE! Opacity test should be done before installation and recorded! NOTE! CJ4 Engine Oil is a low ash oil and is highly recommended as it will reduce your maintenance needs and cost NOTE! Do not weld anything to the to the filter center body. This will void the warranty. NOTE! Do not weld on the vehicle without disconnecting BP Monitor Logger power and vehicle battery. 8

9 REGENERATION CONTROL PANEL INSTALLATION NOTE! A certified electrician and ECS qualified technician MUST install product Only a licensed electrician should install the control panel on the wall or other suitable surface where the required power is available and where vehicle can be parked and plugged in. The panel should be away from combustible material. There are 4 holes on the back of the control panel for mounting purposes. The panel should be installed in a dry, covered area and not directly exposed to sun or precipitation. This can be done by installing the panel inside of a building and running the connection cables outside, or by installing the panel outside contained in a weather tight cabinet, or installed outside but under a dry covered area. Alternatively, the panel can also be connected to a cart to allow it to be wheeled up to the side of the vehicle. This option works well on sites where space is limited and access to a stationary fixed panel may not be possible. Only a licensed electrician only should connect to the available power supply using the electrical schematic provided with each panel to make the required connections. Scheduling and Tracking Vehicle Plug-in It is strongly recommended that a proactive vehicle plug-in schedule be implemented for every fleet vehicle equipped with a Purifilter Plus. This can be as simple as using a calendar with vehicle identification numbers scheduled on appropriate dates. Reactive plug-in should occur when the Backpressure Monitor Remote Readout LED s indicate Yellow (schedule regeneration within 48 hrs) or Red (plug-in vehicle that same day) alarms occur. It is also strongly recommended that plug-in logs be maintained at the regeneration control panel to confirm that scheduled vehicle plug-ins occur when scheduled. A regeneration log is the quickest way to track whether vehicle plug-in is occurring. A sample log sheet is included on page 18 of this manual. The Backpressure Monitor & Logger system on-board a vehicle can also be readily downloaded to confirm that regular plug-in are occurring. 9

10 HEALTH AND SAFETY PRACTICES Installing and maintaining the Purifilter Plus Hybrid safely It is the responsibility of the operator to ensure that persons involved in the installation and maintenance of the Purifilter Plus hybrid diesel particulate filter systems are aware of heavy lifting hazards and best practice lifting techniques. The Purifilter Plus can range in weight from 20lbs to over 80lbs. ECS manufacturers the CombiClean (DPF cleaning station). This equipment is available to efficiently perform the safe removal and collection of ash and unburned soot in a controlled environment. Attempting to service a Purifilter Plus centerbody with compressed shop air without the use of a Regeneration Control Panel or Combi- Clean station is strongly discouraged and is not an acceptable way to remove ash from the centerbody. See the troubleshooting section of this manual for more information on dealing with plugged filter centerbodies. Appropriate safety precautions such as a facemask and protective clothing, should be adhered to when dealing with the debris produced by the Purifilter Plus. The dust removed should be treated as similar to vehicle brake dust and considered hazardous if inhaled. Waste materials collected from servicing a Purifilter Plus should be disposed of in accordance with local regulations. 10

11 KNOWING WHEN TO REGENERATE The Purifilter Plus hybrid diesel particulate filter system can be proactively or reactively regenerated. It is strongly recommended that as a starting point, fleets follow the proactive regeneration recommendation determined by datalogging prior to system installation. After an initial period of operation, the BP Monitor Logger can be downloaded and the data used to revise the initial proactive regeneration period. Employing a proactive regeneration strategy minimizes disruptions to normal vehicle operation. It is recommended that proactive regeneration be performed immediately after vehicle shut down when the exhaust system is still hot. If regeneration is being performed in a response to a Yellow or Red alarm condition, the regeneration should be performed immediately upon engine shut down with the exhaust in a hot condition to promote a thorough regeneration. The Purifilter Plus is also continuously monitored by the BP Monitor & Logger and this information is routed to the remote readout unit which is positioned in a visible location to the vehicle operator. Figure. The BP Monitor & Logger Unit Your BP Monitor & Logger The Purifilter Plus Hybrid is designed to alert the operator when regeneration is required. Every system is equipped with a BP monitor which, has logging capabilities and the following warning lights; POWER: This Green LED is used to indicate that the BP Monitor & Logger unit is powered properly. If this light is not illuminated, service of the BP monitor & logger is required. SCHEDULE DPF SERVICE: When flashing continuously for more than 45 seconds during vehicle operation, this Yellow LED indicates that the DPF regeneration needs to be scheduled and should be performed within the next two days. Figure. Remote Driver Display (should be mounted in a location readily visible to the vehicle or equipment operator) SERVICE DPF NOW: When flashing for more than 45 seconds continuously, this Red LED indicates that DPF regeneration is needed as soon as possible and at longest by the end of that day. At this point, it is critical to perform regeneration as if this warning is ignored too much soot build up and as a result require additional servicing of the Purifilter Plus system or BP Monitor & Logger System. SYSTEM ERROR: When illuminated, this LED indicates that an internal wiring or connection fault exists within the BP Monitor & Logger System and maintenance is required. Please refer to the Regeneration Control Panel Schematic and the active regeneration instructions on the following pages for step by step instructions as to how to regenerate the Purifilter Plus System. 11

12 Control Panel Schematic A wiring diagram is included with every Control Panel. It is essential to retain this schematic as it will allow any licensed electrician to install the panel and assist with troubleshooting should problems arise. 1. Ammeter 1 depicting power usage by the first bank of heating elements 2. Ammeter 2 depicting the power usage by the second bank of heating elements 3. Ammeter 3 Depicting power usage by the third bank of heating elements (480 V models only) 4. Timer counts down time remaining until the regeneration process is complete 5. Green Light Illuminated when regeneration is complete 6. Orange Light Illuminated when regeneration is in progress 7. Red Light Illuminated if there is low air pressure detected. When this light is on, the power to the heater base is disconnected. Regeneration will not occur. 8. Temperature Controller Depicting current internal temperature of filter center body 9. Main ON/OFF Switch Initiates the regeneration process 10. Control Panel Lock Out When the Main switch is turned ON, the panel door cannot be opened 11. Control Panel Color the control panel is OSHA safety blue to warn of possible danger 12. Mounting Hole There are 4 holes for mounting purposes Control Panel 75 lbs. 12

13 REGENERATION INSTRUCTIONS NOTE! The Purifilter Plus must not be covered with any combustibles such as grease oil or any flammable material NOTE! Regeneration is best performed immediately upon engine shut down. The filter regeneration process must be completed without interruption! 1. Park the vehicle beside the regeneration panel closely enough that the power and air connections can be made. 2. Make sure the vehicle engine is turned off. 3. Identify the air line coupling and electric coupling located on the vehicle and connect the air and electric lines from the control panel. When the connections are made, the starter disable switch will prevent the vehicle from being started. 4. Some regeneration panels may require that a separate transformer be turned on first to supply the correct voltage to the control panel. Follow the steps required to turn on this transformer if one exists. 5. Check to see if a panel disconnect switch is present and if so, that it is ON. 6. On the Purifilter Plus Hybrid Control Panel, turn Main switch (9) to ON (see page 14 for control panel schematic). This will activate the air blowers and heater elements. 7. The regeneration in progress light (6) will be illuminated. 8. Check that the ammeters (1), (2) and (3) show an equal current draw. (If troubleshooting a problem, the actual current values can be found on the electrical drawing provided with panel) V Systems: SCP10 thru SCP23- The heating process will take 150 minutes. The digital counter (4) will count down 150 minutes. SCP28 The heating process will take 240 minutes 240 V Systems: The heating process will take 240 minutes. The digital counter (4) will count down 240 minutes. Figure. Identifying the air line (left) and electrical (right) connections. 10. When regeneration is complete. The ammeters (1), (2) and (3) will show 0, and the digital timer (4) will show 0, and the regeneration complete green light (5) will be illuminated. The LOW AIR PRES- SURE red light will also be illuminated. 11.Turn the Main switch (9) to OFF. 12. Disconnect the air and electric couplings. Wrap them upon their holding hook. The vehicle can now be started and is ready for use. ACTIVE REGENERATION RECORD KEEPING Figure. Vehicle Plugged in for regeneration ECS recommends that records be kept of vehicle plug-in for active regeneration. A sample log sheet is provided on page 19 which can be photocopied or used as a template. Keeping a log at the location of the regeneration panel will assist fleets to quickly check that vehicles are being proactively plugged-in at prescribed times. 13

14 MISSED A REGENERATION? WHAT TO DO? When a scheduled regeneration is missed, the BP Monitor Remote Readout should be checked for active alarms. This can be done by driving the vehicle and observing if any alarms are present or by downloading the data from the BP Monitor & Logger. If you drive the vehicle. If when the vehicle is driven no Yellow or Red alarms occur simply schedule the vehicle for plug-in at the next convenient time. If when the vehicle is driven the Yellow Alarm LED flashes continuously for more the 45 seconds (A YELLOW ALARM EVENT), plug-in the vehicle to the regeneration control panel and perform an active regeneration within the next 24 hours. If when the vehicle is driven a Red Alarm LED flashes continuously for more the 45 seconds (A RED ALARM EVENT), plug-in the vehicle to the regeneration control panel immediately and perform an active regeneration immediately. If after regeneration, either any Yellow or Red alarms persist, the BP Monitor & Logger should be downloaded. Read the next section for instructions what to do with the datalogger download. If you download the BP Monitor & Datalogger.. If the BP Monitor Logger has been downloaded, examine the histograms to determine if any Yellow or Red alarms are present. See the BP Monitor & Logger Manual for instructions how to perform this. If no Yellow or Red alarms are present, schedule the vehicle for plug-in at the next convenient time. If Yellow alarms are present, schedule the vehicle for plug-in within the next 24 hours. If Red alarms are present for no more than two days, plug-in the vehicle and perform regeneration immediately. This should return the filter to a clean condition. If Red alarms were present for more than two days, plug the vehicle in immediately and perform two back to back regenerations. If Red alarms are present in the downloaded histograms for more than two days, perform two back to back regenerations. If the vehicle when driven still presents Red alarms, the filter should be removed and cleaned on a Combiclean cleaning machine and returned to a clean condition. In this event, the BP Monitor & Logger water trap and BP sensor line should also be cleaned as an extended Red alarm event can cause this line to become fouled. If you still have trouble, move to the Troubleshooting Section. 14

15 MAINTENANCE Purifilter Plus maintenance records should be maintained to monitor and insure performance. Records should always be updated at each service interval and with every test. Regular preventative maintenance as described below will insure performance and vehicle up-time. Record keeping will also help predict issues before problems arise and protect your warranty. The following maintenance items should be preformed: At every oil change; 1. Check the BP Monitor & Logger and insure its proper operation. See BP Monitor & Logger Manual for specific instructions. 2. Inspect and clean if necessary, the water trap and its filter and line in the BP Monitor & Logger system. See BP Monitor & Logger Manual for specific instructions. 3. General inspection of installation hardware, electrical and air lines. 4. If the Purifilter Plus Hybrid filter assembly is installed in the vicinity of vehicle components which may develop oil, fuel, brake, transmission or power steering or hydraulic fluid leaks, inspect for the presence of any leaks and repair leaks immediately if any are found. At every filter de-ashing; De-ashing should be performed at the intervals listed in the Table on page 16. Maintenance records should be kept listing vehicle identification, vehicle mileage, and dates. These records should also list the following performed service items: 1. Service items performed at every oil change listed above. 2. Perform data download from BP Monitor & Logger. Review data for any change in vehicle duty cycle, or any existing fault within system. Confirmation of pro-active plug-in period. 3. Backpressure Measurement before and after filter de-ashing. Measurements to be performed at idle and rated speed/no load. 4. Engine Out Smoke opacity measurement at idle and rated speed / no load if opacity is excessive, other engine maintenance needs to be performed to reduce opacity to previously recorded value. 5. Filter observations from inspection. 6. Inspection of installation components and repair of any defects found. 7. Install new sealing gaskets. 15

16 ASH REMOVAL Although the regeneration process burns the collected soot, it leaves traces of residual ash. Ash is derived from lube oil and other wear metals that do not combust. Ash accumulates within the filter and needs to be removed periodically. The use of a low ash lubricant meeting a CJ-4 standard is highly recommended and will extend the interval between ash cleaning and reduce your maintenance cost. If engine performance is not maintained, the filter may be required to be removed and cleaned more frequently resulting in more downtime which can be costly. Perform Ash removal at intervals prescribed in the table below. Most vehicles will only require de-ashing once a year. Vehicle Type Engine Hours Miles Yearly Urban Buses & Solid Waste Fleets ,000 to 30, / yr School Buses 1 / yr Municipal & Short Haul Delivery Fleets ,000 1 / yr Long Haul ,000 1 / yr Table. Filter De-ashing intervals. Prior to ash removal, perform the following: 1. Regenerate the filter body on the vehicle. 2. Let the filter body cool down 3. Use the ECS CombiClean filter cleaning station to remove ash from the filter. 4. Prior to re-installing the filter to the vehicle, perform opacity tests and perform any indicated engine maintenance. 5. RECORD ENGINE HOURS, VEHICLE MILEAGE, FILTER AND installation inspection and record comments on the record sheets provided or into your vehicle maintenance logs. 6. Perform scheduled maintenance of Purifilter Plus system and BP Monitor & Logger. Alternatively, contact your local ECS Distributor who will perform this process for you for a fee. Waste Disposal Ash removed during the cleaning process should be disposed of in accordance with all applicable Federal, State and local laws governing waste disposal. 16

17 CONTAMINATED FILTERS If a Purifilter is contaminated with oil, coolant or diesel fuel, remove IMMEDIATELY and do not use. Contact ECS or an authorized ECS dealer for further information. DO NOT attempt to clean an oil, coolant or diesel-laden filter on any cleaning machine. Contact ECS for further instruction. DO NOT WASH A PURIFILTER WITH: - GASOLINE OR OTHER SOLVENTS - DIESEL FUEL - STEAM - HIGH PRESSURE WATER - WATER OPERATE IN THE CORRECT FLOW DIRECTION AS INDICATED ON THE FILTER CENTER BODY DO NOT USE COMPRESSED AIR ON A HOT FILTER Use caution when working near a hot filter, especially after vehicle use. Please follow proper lifting techniques when handling a filter. Use approved techniques and equipment when cleaning a filter. 20

18 General Troubleshooting 1. Frequent Yellow or Red Alarms prior to scheduled proactive plug-in Perform the following; Download the BP Monitor & Logger to determine whether scheduled regenerations have been missed. If so, perform a back to back regeneration to see if problems is resolved. During regeneration insure there are no faults shown by the regeneration control panel. If the regeneration is not occuring properly, troubleshoot the vehicle installation or control panel depending upon the fault being revealed during regeneration. Download the datalogger and evaluate whether a change in exhaust temperature or a trend in backpressure is apparent. If the duty cycle has changed, discuss with your ECS distributor what adjustment may be necessary. If your fleet operates in an area where seasonal changes are dramatic you may need to employ different plug-in schedules to offset seasonal changes. Example: Many fleets may require more frequent plug-ins during the winter months. If the datalogger download appears normal, remove the filter centerbody and perform an engine-out opacity test to confirm the condition of the engine. If opacity has increased from the value reported at the time of installation, inspect the engine air filter, intake air system for leaks, turbocharger problems injectors & pump, or if oil consumption is excessive - do a compression test. Opacity issues must be corrected prior to re-installation of the Purifilter Plus centerbody. 2. Loss of engine power with no alarms Perform the following; Download the BP monitor and logger and examine whether backpressure is being recorded. If there is no BP data (all zeros), service the backpressure sensor line insuring lines are clean, water trap is clean. If problem is still present, the fault is internal to the BP monitor and logger call you ECS Distributor for service. DO NOT OPEN THE BP MONITOR LOGGER BOX OR WARRANTY WILL MAY BE VOIDED. Using a manometer, measure the backpressure restriction across the filter centerbody. If excessive, remove the filter centerbody for inspection. If the filter is plugged, clean the filter centerbody on a Combiclean cleaning station. Perform an engine out opacity test. Is the result consistent with initial opacity recorded at time of installation. If it is higher than at the time of installation, inspect the engine air filter, intake air system for leaks, turbocharger problems injectors & pump, or if oil consumption is excessive - do a compression test. Opacity issues must be corrected prior to re-installation of the Purifilter Plus centerbody. 17

19 General Troubleshooting cont d 3. Loss of Engine Power with Red Alarm Perform the following; Remove vehicle from service immediately Download the BP Monitor & datalogger and determine the peak observed backpressure. If peak backpressure exceeds 350 mbar, remove the filter for cleaning using a Combiclean cleaning machine. If using a manometer, manually measure the backpressure between the engine and the Purifilter Plus Hybrid assembly. If peak backpressure exceeds 350 mbar, remove the filter for cleaning using a Combiclean cleaning machine. If visible signs of oil or diesel fuel are present, do not clean the filter. Contact your ECS distributor for support. If peak backpressure is >350 mbar, remove the Purifilter Plus centerbody, and measure engine out opacity. Inspect engine air filter, intake air system for leaks, turbocharger problems, injectors & pump, or if oil consumption is excessive - do a compression test. Opacity issues must be corrected prior to re-installation of the Purifilter Plus centerbody. If peak backpressure is <350 mbar, remove the Purifilter Plus centerbody, and measure engine out opacity. Inspect engine air filter, intake air system for leaks, turbocharger problems, injectors & pump, or if oil consumption is excessive - do a compression test. Opacity issues must be corrected prior to re-installation of the Purifilter Plus centerbody. If there are any visible signs of fuel or oil in the filter centerbody, do not clean the filter. Contact your ECS distributor for support. If there are no visible signs of fuel or oil in the filter centerbody, re-install the filter centerbody and perform back to back active regenerations prior to returning vehicle to service. 4. Visible signs of black smoke Perform the following; Remove the DPF centerbody for inspection. Contact ECS distributor for support. 5. Visible signs of white smoke White smoke is typically water vapor which will typically clear after a few minutes. If white smoke persists, inspect your engine for signs of coolant consumption. If there is a coolant leak, remove the filter and allow it to dry. Inspect the filter for signs of damage prior to re-installation. Call you ECS distributor for support. 6. Visible signs of blue smoke Blue smoke is typically indicates the presence of unburned fuel or engine oil. Blue smoke may be visible for the first few minutes after vehicle start. If blue smoke persists, remove the filter for inspection and correct underlying engine fault. 18

20 Regeneration Control Panel Trouble Shooting If the control panel is not operating correctly, have a licensed electrician check the following: 1. Electrical Heaters The ammeters on the regeneration control panel should display consistent ampere draws within the provided ranges below. All 240V Single Phase Systems: 14 to 17 amps 480V 3-Phase Systems: Filter Model / Type Amp. (at 480V) SCP10 thru SCP23 all 9 to 11 amps SCP28 17 to 21 amps If the ammeters do not indicate the above values, check the following: If all three ammeters report values below the ranges above or zero, check the power supply to the panel or power from contactor within the panel. If one of the ammeters reports a low or zero value, this typically indicates an element has failed within the heat base in the DPF inlet section on the vehicle. If no signs of power in the panel are present, check power supply from disconnect switch and fuses related to that switch. Is the regeneration in process light illuminated?. If illuminated, problem is within the panel, call licensed electrician or ECS distributor. The fuses are OK Check if the low air pressure light is On. If so, there is a problem with the air pump or pressure switch. The regeneration unit is connected according to the circuit diagram. Correct circuit diagram number is shown in the installation instructions included with the panel. If After checking the above conditions, if the ampere draw is still insufficient, check functionality of inlet heater base on vehicle. 2. Temperature Control ((8) on Panel Schematic page 13) The thermostat is set at C for all systems. This temperature should be reached after 10 minutes or the start of the regeneration cycle. Upon reaching the set temperature, the thermostat will maintain the temperature by regularly cycling the heaters. Make sure the ammeters indicate that this is the case by visually checking the movement of the pointer. If this temperature is not being reached, contact your local ECS distributor. 4. Air Supply ((7) on Panel Schematic page 13) The amount of air supplied to the filter center body is critical to regeneration. If this light illumates, check air pressure switch or pump. Make sure the connection between the vehicle and panel is secure and without leaks. Insure that the original parts have not been replaced with other types (different diameters, flow restriction, etc.). Contact ECS local distributor for support. 19

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22 RECORDS Items Please Fill Out Date and Engine Hours Vehicle Odometer miles/km Vehicle Registration Purifilter Serial Number Idle Backpressure Purifilter Cleaning Notes (ie. Visual condition ) Items Please Fill Out Date and Engine Hours Vehicle Odometer miles/km Vehicle Registration Purifilter Serial Number Idle Backpressure Purifilter Cleaning Notes (ie. Visual condition ) Signed Items Please Fill Out Date and Engine Hours Vehicle Odometer miles/km Vehicle Registration Purifilter Serial Number Idle Backpressure Purifilter Cleaning Notes (ie. Visual condition ) Signed Sample forms 21

23 WARRANTY RIGHTS AND OBLIGATIONS For Purifilter Plus Units sold for On-road applications Sold by Engine Control Systems Limited/Ltd. Engine Control Systems Limited and Engine Control Systems Ltd. (hereafter referred to as ECS ) must warrant the diesel emission control system in the application for which it is sold or leased to be free from defects in design, materials, workmanship, or operation of the diesel emission control system which cause the diesel emission control system to fail to conform to the emission control performance level it was verified to, or to the requirements in the California Code of Regulations, Title 13, Sections 2700 to 2706, and 2710, for the periods of time listed below, provided there has been no abuse, neglect, or improper maintenance of your diesel emission control system, vehicle or equipment, as specified in the owner s manuals. Where a warrantable condition exists, this warranty also covers the engine from damage caused by the diesel emission control system, subject to the same exclusions for abuse, neglect or improper maintenance of your vehicle or equipment. Please review your owner s manual for other warranty information. Your diesel emission control system may include a core part (e.g., particulate filter) as well as hoses, connectors, a back pressure monitor, and other emission related assemblies. Where a warrantable condition exists, ECS will repair or replace your diesel emission control system at no cost to you including diagnosis, parts, and labor. WARRANTY COVERAGE For on-road applications; For vehicles with GVWR of at least 33,000 lbs. the warranty shall be 2 year, unlimited miles if the truck; - is typically driven over 100,000 miles per year, and - has less than 300,000 miles on the odometer at the time of installation For vehicles with GVWR of at least 19,500 lbs. and engines rated above 250 hp-5 years or 150,000 miles whichever comes first For vehicles with GVWR of at least 19,500 lbs. and engines rated 250hp and lower 5 years or 100,000 miles whichever comes first For vehicles with GVWR or less than 19,500 lbs. 5 years or 60,000 miles, whichever comes first If any emission-related part of your diesel emission control system is defective in design, materials, workmanship, or operation of the diesel emission control system thus causing the diesel emission control system to fail to conform to the emission control performance level it was verified to, or to the requirements in the California Code of Regulations, Title 13, Sections 2700 to 2706, and 2710, within the warranty period, as defined above, ECS will repair or replace the diesel emission control system, including parts and labor. In addition, ECS will replace or repair the engine components to the condition they were in prior to the failure, including parts and labor, for damage to the engine proximately caused by the verified diesel emission control strategy. This also includes those relevant diagnostic expenses in the case in which a warranty claim is valid. ECS may, at its option, instead pay the fair market value of the engine prior to the time the failure occurs. OWNER S WARRANTY RESPONSIBILITY As the vehicle owner, you are responsible for performing the required maintenance described in your owner s manual. ECS recommends that you retain all maintenance records and receipts for maintenance expenses for your vehicle, engine, or equipment, and diesel emission control system. If you do not keep your receipts or fail to perform all scheduled maintenance, ECS may have grounds to deny warranty coverage. You are responsible for presenting your vehicle, equipment, or engine, and diesel emission control system to an ECS dealer as soon as a problem is detected. The warranty repair or replacement should be completed in a reasonable amount of time, not to exceed 30 days. If a replacement is needed, this may be extended to 90 days should a replacement not be available, but must be performed as soon as a replacement becomes available. If you have questions regarding your warranty rights and responsibilities, you should contact ECS at or the California Air Resources Board at 9528 Telstar Avenue, El Monte, California 91731, or (800) , or electronic mail: helpline@arb.ca.gov. 22

24 Installation Warranty Statement The installation of your Purifilter Plus hybrid diesel particulate filter system is covered by a separate warranty as mandated by ARB regulations. The installer of your Purifilter Plus in most cases will be an authorized ECS distributor or under contract to an authorized ECS distributor. As per ARB regulations, the installer of a verified emissions control device must furnish the owner with a copy of the following statement. YOUR WARRANTY RIGHTS AND OBLIGATIONS (Installer s name) must warrant that the installation of a diesel emission control system is free from defects in workmanship or materials which cause the diesel emission control system to fail to conform to the emission control performance level it was verified to, or to the requirements in the California Code of Regulations, Title 13, Sections 2700 to The warranty period and the extent of the warranty coverage provided by (installer s name) must be the same as the warranty provided by the product manufacturer, and the same exclusions apply. OWNER S WARRANTY RESPONSIBILITY As the vehicle, engine or equipment owner, you are responsible for presenting your vehicle, engine, or equipment and diesel emission control system to (installer s name) as soon as a problem with the installation is detected. If you have questions regarding your warranty rights and responsibilities, you should contact (installer s contact information) at XXX-XXXX or the Calilfornia Air Resources Board at 9528 Telstar Avenue, El Monte, California, 91731, or , or electronic mail: helpline@arb.ca.gov. 23

25 Glossary of Terms Active Regeneration when soot is oxidized and reduced to ash within the filter and the oxidation process is initiated by an outside source (such as electricity) Ash the residue that is left after soot and other elements have been oxidized or combusted AZ Catalyst improves reductions of HC, CO and PM. Can be housed in the outlet section Backpressure the pressure is an exhaust system caused by pipe bends, silencers or other restrictions to exhaust flow Backpressure Monitor a signal lamp to ware the driver of increased backpressure in the filter assembly detected by pressure switch mounted before the filter center body Balance Point The point at which the amount of soot being collected is equal to the amount of soot being oxidized Catalyst an entire device consisting of a filter, a precious metal coating and a surrounding shell. It is by definition, a compound, element or other substance that encourages a reaction to take place between two or more elements of compounds, without changing or becoming part of the reaction itself. In exhaust technology, a catalyst is generally a formulation of precious metals and/or base metals. Their function is normally to promote an oxidation process. Data Logger a small computer which is able to store signals from sensors against time Diesel Particulate Filter a filter which physically removes fine particulates from an exhaust stream can be referred to as a trap, filter, particulate trap, soot trap, soot filter, catalyzed trap or regenerative trap. Duty Cycle the normal type of duty that a vehicle performs at regular intervals. For example, a park and ride bus would have a very predictable route and short cycle frequency compared to a long distance haulage truck. Filter Assembly houses the inlet section, outlet section and filter center body Filter Center Body made up of Silicon Carbide, the filter center body traps the particulate matter from the exhaust and stores it as soot until regeneration Inlet Section takes in exhaust from the vehicle Outlet Section passes clean exhaust, which can either house the AZ catalyst or not Particulate this is any form of fine dust, however particulate has become the term for diesel engine derived soot or dust less than 10 microns in diameter. Passive Regeneration when soot is oxidized and reduced to ash within the filter, the filter is undergoing an automatic process that bring its condition close to optimum. Regeneration when soot is oxidized and reduced to ash within the filter, the filter is undergoing an automatic process that brings its condition close to optimum Thermocouple is a device that converts temperature to an electrical output. This output can be interpreted and stored by a small computer 24

26 Contact Information Engine Control Systems Limited World Headquarters 83 Commerce Valley Drive East Thornhill, Ontario, L3T 7T3 Phone: Toll Free: Fax: Engine Control Systems Ltd. North America Western 4910 Longley Lane, Suite 103 Reno, Nevada, Phone: Fax: Engine Control Systems Europe AB European Headquarters Box 9015, Agnesfridsvagen, 184 SE Malmo, Sweden Phone: 46 (40) Fax: 46 (40) Website:

27 Labels for New York State: M (Affix to a visible location such as a door jamb or firewall) The attached label is to be affixed to a visible location such as a door jamb or firewall) upon installation of an ECS Purifilter Plus and Purifilter to comply with Part 248 of 6 NYCRR, entitled Use of Ultra Low Sulfur Diesel Fuel and Best Available Retrofit Technology for Heavy Duty Vehicles (BART). The label should be affixed in an easily visible location which is clean and free from grease, oil or loose paint. This label should not cover any part of other engine labels which are present for engine manufacturer regulatory requirements. Additionally, it is the installer s responsibility to legibly transfer the information needed to the spaces provided on the label using a permanent pen and remove the backing to seal the label. Failure to perform these steps may result in enforcement penalty. When installed, there is an image of the label beneath for confirmation and future reference. Engine Control Systems assumes no liability. Protective Coat Engine Label