Installation Guide Diesel Particulate Filters with DiNLOG Monitoring System

Transcription

1 DiPEX & DiSiC Installation Guide Diesel Particulate Filters with DiNLOG Monitoring System PEX SYSTEM SiC SYSTEM SiC CATALYSED Contents 1. What is a DiPEX filter? 2. Is a DiPEX filter suitable for my vehicle? 3. Vehicle requirements 4. Layout of components 5. Installation of system 6. Maintenance 7. Lubricating oil 8. Diesel porous walls. In passing through these walls, diesel particles and other debris will be removed from the gasses by filtration with an efficiency of more than 95%. Catalytic Oxidising Process The organic part of the accumulated soot will thereafter be converted into CO2 and water by a catalytic oxidising process. DiPEX & DiSiC Product info DiPEX and DiSiC - Catalysed Diesel Particulate Filter (CDPF) Bus and Truck Applications Applications of the DiPEX and DiSiC system are typically buses and trucks with operating temperatures above 240 C on average. The DiPEX system can also be built into van applications with temperature profiles matching the required average. Ceramic Honeycomb Structure The DiPEX system is, like the DiSiC technology, designed as a honeycomb structure. The ceramic honeycomb structure with every second channel blocked is designed to allow exhaust gasses to pass through the micro For Low Operating Temperatures and Profiles Use DiSiC System If operating temperatures and profile are lower than required, or temperature peaks happen very rarely, it is recommended not to use the catalysed DiPEX system, but instead the DiSiC system - in combination with a fuel borne catalyst (FBC). Sensitive to the Sulphur Level in the Fuel The filter technologies are sensitive to the sulphur level in the fuel. Sulphur levels higher than ULSD (50 ppm) will require even higher operating temperatures and shorter maintenance intervals.

2 Compliance with EURO I, II and III The standard filters can be fitted on EURO II and III compliant engines. EURO I compliant engines will require a DPX2 technology, which is the same filter substrate as the standard, but combined with a base metal oxide base pre-filter in front - either as a separate module or as an integrated part inside the inlet module. Older engines are to be evaluated on an individual basis, but under the provision that no K-values* exceed 3.0. *K-value=Raw emission Vehicle Compatibility The Dinex DiPEX and DiSiC filters will under normal circumstances work at below temperature intervals. Minimum Temperature Requirements for EURO I or Equivalent and Older Engines: Peak: Average: Time above 250 C: 40% Time above 300 C: 20% Time above 350 C: 10% 400 C or above 240 C or above Opacity Requirements for Diesel Particulate Filter Installations Prior to installation of diesel particulate filters, the opacity of the vehicles must be checked, and if the vehicle does not fulfil the requirements, the vehicle must be repaired, which usually involve changing injection nozzles and/or adjusting the injection pump. Longer intervals with lower temperature (low load driving or idling) will provoke the DiNLOG to give an alarm and motorway driving is required for min. of 10 minutes (obs-pay attention to speed and traffic regulations). If this does not cure the problem, please consult your Dinex workshop for mechanical cleaning. Opacity requirements for DiPEX filters EURO I or older: maximum K-value = 3,0 m-1 EURO II or newer: maximum K-value = 2,0 m-1 After installation of a particulate filter the K-value must not exceed K=0, 20 m-1 Minimum Temperature Requirements for EURO II or equivalent and newer engines: Peak: 400 C or above Average: 220 C or above Time above 250 C: 30% Time above 300 C: 15% Time above 350 C: 5%

3 Layout of Basic Components Flex pipe - in most cases connected from manifold to inlet can (Please note directional arrows on flex pipe) This pipe may be insulated to increase temperature. Flex pipe Inlet can Lambdalarsen clamp Particulate filter Outlet can (in which tail pipe is usually inserted) Body mounting strap Installation of System Some systems are designed to use original mounting brackets; however, due to the weight of the system, modified mounting brackets and rubbers may be required and will be supplied in such circumstances. Please check when ordering. It is recommended that the installation is carried out by two persons using vehicle lifts as a pit can prove restrictive. Recommended Equipment/Tools Other Tools May Also be Required Cradle Jack/Tall Hydraulic Jack 10mm, 13mm, 15mm & 17mm deep, sockets and ratchet 5mm, 7mm & 8mm, Hexagon sockets, appropriate lighting, Safety Equipment compliant with site regulations 1. Check kit contains all parts needed. 2. Remove existing system ensuring parts to be reused are not discarded. 3. If new mounting brackets and rubbers are supplied, install these first as these are needed to hold the system in place using the mounting straps. 4. Connect front pipe to manifold. Do not secure tightly at this point as rotation may be required later in the installation. 5. Connect inlet can to front pipe. This may be supported using a mounting strap. 6. Slide Lambdalarsen clamp over end of inlet can.

4 7. Depending on where mounting straps are located, it may be preferable to build up the inlet can, filter and outlet can in one unit prior to fitting. Do not tighten clamps fully as further adjustments may be necessary. 16. It is recommended that after 1000 km/500 miles the above procedure is repeated. Dinex Filter Service & Maintenance Instruction 8. Align filter assembly with front pipe and mounting brackets. 9. Secure system using mounting straps. 10. Once the system is seated correctly, rotate filter so that the inspection plate is visible from the underside of the vehicle. 11. Ensure Lambdalarsen clamps are seated correctly around filter and cans, tighten to 12Nm. 12. Tighten all remaining components, working back from the manifold to the tail pipe. 13. Proceed to data logger installation*. *available at Once the system is installed, run engine and check system for any excessive vibrations or rattles, which may require adjustment. Run until system reaches running temperature, turn off engine, allow to cool, recheck tightness of all clamps as they may expand with heat. 1. Check the condition of the filter by conducting a smoke (opacity) measurement at the tailpipe. The values should be measured by conducting snap idle/free acceleration tests whilst running from idle to maximum revs. Conduct this according to the smoke meter machine instructions. The K-value should not exceed 0.20 for a turbo-charged engine and 0.30 for a normally aspirated engine. If the respective value is exceeded, the filter may be damaged and an investigation is necessary. 2. Measure the back pressure in the exhaust system prior to filter cleaning by connecting the pressure monitoring device to one of the available bosses on the inlet baffle (the pre-filter expansion chamber). The measurement should be recorded in mbar. 3. Conduct the filter cleaning sequence as described in "DiPEX and DiSiC Cleaning & Maintenance Guide". Note that new sealing clamps must be fitted at each filter service. 15. Complete SVR (Site Visit Report) form, detailing filter id plate serial numbers, and return signed by installation company and customer to Dinex.

5 4. Check the condition of the raw engine emissions by conducting a smoke (opacity) measurement at the turbo. With the filter removed, remove the front pipe or flex to measure the opacity. The K-value should not exceed 2.0 for a turbocharged engine, or 3.0 if the engine is pre-euro 2 and uses a pre-filter. be regenerated, and will need to be removed by cleaning the filter. Hence to extend the service intervals of the filter, it is recommendable to use a lubricating oil with a minimum of in-organic components. Various oil manufacturers have developed specific oil types for the DPF technology. 5. Inspect and re-install all the exhaust system components. Take special care to check that heat shields, clamps, flex pipes and mounting brackets are all in good order, not just the filter assembly and pipes. 6. Measure the back pressure in the exhaust system after cleaning the filter using the same procedure as for (2) above. The measurement should be recorded in mbar. 7. Check the engine oil level and make a note of it on a scale of 1-11, 10 being full and 11 above maximum. 8. Complete a Site Visit Report (SVR) recording all the data collected above. It is essential that the filter serial number is recorded together with the vehicle registration and chassis numbers. Content Lubricating Oil All in-organic constituents of the fuel or oil will be trapped in the wall-flow filters (primarily calcium, phosphor, sulphates and ash). These components cannot Diesel Ultra Low Sulphur Diesel is recommended (less than 50 ppm). The filter technology does operate with higher sulphur contents, up to 350 ppm, though it demands higher temperatures, and lower efficiency of the filter must be expected. The filter will not be damaged by temporarily use of higher sulphur contents and will retain its optimal efficiency again when ultra low sulphur fuel is used. The problem with sulphur is in general that it reduces the catalytic activity in the precious metal coating. Further, sulphur in the fuel is being emitted from the engine as SO2. When SO2 passes the catalytic active surface in the filter, SO3 is generated. SO3 can thereafter condense to secondary particles and/or react with other inorganic constituents, forming sulphates (e.g. CaSO4). Condensation that takes place downstream of the filter unit will contribute to the total emission of Particulate Matter (TPM) but not contribute significantly when opacity-measuring methods are used.