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Systems Overview
435 hp
460 ft-lb
9-14 MPG
Lowest emissions
Ease of service
Less service
505 hp
More Power
470 ft-lb
More Torque
16-26 MPG
1969
GLOBAL MANPOWER DEVELOPMENT
When were
the good old days?
Today
EPA 88
0.5
PM
0.4
0.3
EPA 91
0.2
0.1
EPA
07/10
EPA
04
EPA
94
EPA
98
0
0
NOx (g/bhp.hr)
GLOBAL MANPOWER DEVELOPMENT
10
11
Predominantly external
components
Flow
Sensor
Throttle
CGI
Cooler
Intake Valve
Actuation
CCV
Filter
ATAAC
CGI
Valve
High
Pressure
Injection
System
Diesel
Particulate
Filter
ACERT 2007
Diesel Particulate Filter
Dual DPF
Single DPF
Vertical or Horizontal
Mounting
Dual DPF
600 Hp & Up
What is a DPF
Cells Fill Up
Soot Collects
Along the Inlet
Walls
Particulate Matter
or Soot
Clean
Exhaust Out
HC
Catalyst (Platinum)
CO
NOx
PM (soot+SOF+sulfates)
O2
Washcoat
CO2
H2O
NOx
O2
Ash Distribution
Low density ash plug near outlet of filter
High density ash layer on wall thickness
increasing from inlet to outlet
Core Materials
Cordierite
Inexpensive raw material
(cordierite is basically sand)
Low thermal expansion coefficient
Good mechanical strength
Cordierite
GLOBAL MANPOWER DEVELOPMENT
CGI Connection
DPF Outlet
DPF Inlet
Skin
Temperature
Protection
V-Band ClampsTorque 100 inch/pounds
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DPF Sensors
Particulate Trap # 1 Intake
Temperature Sensor
Particulate Trap #1
Differential Pressure
Sensor Tap
Particulate Trap # 1
Differential Pressure
Sensor Tap
Inlet Section
Inlet Section
Distributor
Tube
Formed Marmon
Flange
Condensate
Ring
Insulation
Lifting
Eye
Formed Flange
Connections to
Center Section
Inlet - Description
Inlet Diffuser
Tube
Outer Shell
Condensation Ring
Outer End
Cap
Inner End
Cap
Insulation
Lifting Eye
Inner Shell
Center Section
Sensor Box
Temperature
Probe
Pressure
Boss
Sensor Box
Strap
Center Section
1- time use gasket
Center Section
Retaining ring is
welded in place
Irreversibility
Cone feature is longer on reverse side of filter and will
cause interference with tab if trying to install backwards
75 in/lbs
Sensor Box
Insulation
Outlet Section
Outlet Description
Outer Shell
Irreversibility
Tabs
Outer End
Cap
Condensation
Ring
Inner End
Cap
Insulation
Inner Shell
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Lifting Eye
Rain Protection
System on
Verticals
Air Flow
CGI Line
Purge Pump
Power Connector
Failed DPF
Good Filter
Weld marks
Good Filter
Staining is Acceptable,
Black soot is not
LC Lab DPF
LC Lab DPF
Nuked Trap
Rules of Engagement
Engines Purchased from Leasing Company
Single Lease Customer Operation
All 6 Units Operated on the same Route
South East to West Coast
Products History
Cat C15
Line Haul
ACERT
1. 355,515 Miles
2. 480,973 Miles
Cummins
Line Haul
Cooled-EGR
360,901 Miles
455,319 Miles
DDC S60
Line Haul
Cooled-EGR
381,100 Miles
480,717 Miles
Soot
Build Up
Detroit Intake
Phase 2
Phase 1
Soot Build Up
GLOBAL MANPOWER DEVELOPMENT
Cummins Intake
Soot Build Up
Cat Intake
Phase 1
Phase 2
Airflow Restricitons
Acid Attacking
Valve Faces
GLOBAL MANPOWER DEVELOPMENT
Soot Build-Up
Valves Free
of Deposits
Phase 1
Phase 2
Soot Build Up
Phase 2
530,000
Cat
GLOBAL MANPOWER DEVELOPMENT
Cummins
490,000
DDC
Cooled EGR
ACERT Technology
ACERT 2007
Special DPF Maintenance
Size
75(l) x 40(w) x 83(h)
1.9m(l) x 1.01m(w) x 2.1m(h)
Weight
1100 lbs
500 kg
HEPA
Filter
Control
Panel
Filters
Disposable
Bucket
(Behind Door)
Expansion
Tank
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Accumulator Tank
Seal
Bed
Hand Pump Raise
the bed
Seals Unit in Tool
Hydraulic Cylinders
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Ash
Collection
Area
Hook-up Cat ET
Reset Ash Model
Interim Process - Call DSN
Customer Cost
$400 to $600 USD
Consumables
Five Items
HEPA Filter
Cartridge Filters (2)
Disposal Bucket
Air Dryer Desiccant
Coalescing Filter
Consumables
HEPA Filter
319-2193
Life
500 - 1000 DPF
Cleanings
Cost
$840.76 USD D/N
Consumables
Cartridge filter
319-2194
14 dia, 30 long
2 filters/pack
Life
15 to 100 DPF Cleanings
Cost
$ 349.45 USD D/N
Consumables
Cartridge filter
319-2194
Soot in DPF dramatically
14 dia, 30 long
shortens Cartridge Filter
2 filters/pack life!
Life
before
Regen
Cleaning
DPF
Cost
$ 349.45 USD D/N
Consumables
Filter Bucket
319-1833
Life
3 or 4 per clean out
Clean out every 15 100 DPF Cleanings
Cost
$113.97 USD D/N
Consumables
Air Dryer Desiccant
320-2679
Life
25 DPF Cleanings
Can be oven dried and re-used
Cost
$XX.XX USD D/N
Consumables
Coalescing Filter
320-2680
Life
500+ DPF Cleanings
Cost
$XX.XX USD D/N
Additional Adapters
Mass Transit Bus
Cleaner Costs*
Dealer Net
319-2189 Cleaner Gp
$16,169.47
Individual Pricing
319-2187 Cleaner DPF
319-2190 Adaptor group
319-1834 Cone 11 inch - $245.12
319-1835 Cone 13 inch - $249.66
319-1836 Cone 15 inch - $256.90
319-1838 Adaptor-lower large - $747.64
319-1839 Adaptor-lower small - $750.54
*Dealer Net prices as of 14 Sep 07
GLOBAL MANPOWER DEVELOPMENT
$14,787.77
$2,024.87
Shop Tips
This image is the result of
NOT using Anti-Seize on
the DPF Inlet
thermocouple sensor spin
nut or DPF mounting
boss during initial
installation in Tech Center
Building L (DPF Upgrade).
CGI Line
CGI Line
CGI Line
GLOBAL MANPOWER DEVELOPMENT
CGI Actuator
Aftertreatment Regeneration
Device
Soot Cleaning
Soot is a byproduct of
incomplete combustion
Definition of Ash
Ash Cleaning
Ash is Noncombustible
residue of a lubricating
oil or fuel
Elevated exhaust
temperatures convert the
soot to vapor
Regeneration Types
Active Regeneration
No
Regeneration
0C
32F
200C
392F
Passive Regeneration
400C
752F
600C
1112F
700C
1292F
Passive Regeneration
Occurs when the engine is under high
load
Exhaust temperatures alone are
enough to regenerate small amounts
of soot
Passive Regeneration
0C
32F
200C
392F
400C
752F
600C
1112F
700C
1292F
Active Regeneration
Mobile Active (No Interaction) (Moving)
Enhanced Passive (No Interaction)
(Stationary)
Manual (Requires Interaction)
Active Regeneration
(Stationary)
0C
32F
200C
392F
400C
752F
600C
1112F
700C
1292F
0C
32F
200C
392F
400C
752F
600C
1112F
700C
1292F
200C
392F
400C
752F
600C
1112F
700C
1292F
Manual Regeneration
Occurs at 0 MPH
DPF lamp must be illuminated
Must initiate with force switch
ET commanded manual regen does not
require DPF lamp to be illuminated
Active Regeneration
0C
32F
200C
392F
400C
752F
600C
1112F
700C
1292F
Manual Regen
Hold manual regen switch for 4 seconds
ECM tests the air valve and fuel valve
DPF lamp will go out and engine speed
will ramp to 1400 rpm
Engine fan turns on (for parasitic
loading)
HEST lamp will come on when exhaust
temp exceeds 450 C
Emissions Strategies
Mid-Range Warm-Up
Emissions compliance sooner
Runs if dpf out is less than 250 C and
vehicle speed is 0 MPH
Engine RPM remains at low idle due to VNT
usage
Runs until dpf inlet is greater than 450 C (1
second) or dpf outlet is greater than 325 C
for 2 minutes
Emissions Strategies
HC Clean-up (on MR and HD)
Eliminate HC slip (raw fuel in the DPF)
Engine RPM will elevate to 700 RPM
Runs every one hour based on a timer
Timer will be 0 if:
Vehicle speed is above 0 mph
Soot is greater than 115% (enhanced passive starts at 120%)
Dpf inlet is greater than 400 C or outlet is greater than 150 C
Runs until dpf inlet is above 400 C or outlet is greater than 325
for 2 minutes
Time
HD - 12 hours (6 hours with sensor fault)
MR - 5 hours
perrylb:
perrylb:
illustrator
illustrator
Trigger Graph
Soot
Pressure
12 Hrs (5 MR)
Time (hours)
Pressure
Soot %
Time
Coolant Temperature
Ambient Air Temperature
Altitude
Fuel Flow
DPF Inlet & Outlet Temperature
Shot Mode
Engine Speed
Exhaust Gas Temperature #1 (Turbo Out)
Exhaust Gas Temperature #3 (Flame Length)
CGI Flow
Timing
Total Exhaust Flow
HEST Lamp
0
INCREASING SOOT LOAD
100
ARD Head
Spark Plug
Ignition Coil/cable
Combustion Air
Line and sensor
Fuel
Lines/valves/sens
ors
ARD Housing
GLOBAL MANPOWER DEVELOPMENT
Combustion Zones
Secondary
Zone
Max length 12
Primary
Zone
ARD Housings
ARD Head
Nozzle
Swirler Plate
ARD Combustion
Combustion Air Holes
ARD Head
Combustion Containment
Canister
ARD Housing
ARD Head
Combustion Containment
Canister
ARD Housing
Main Fuel
Line
Pilot
Fuel
Line
Pilot
Solenoid
Main
Solenoid
Main Fuel
Pressure Sensor
Coolant In Main
Pilot
Main
Coolant Out
Flame Length
DPF
Outlet
DPF
Inlet
Turbo Out
sensors
To Disable Regeneration
Set the disable regeneration switch
on the dash (If Installed)
OR
Go to ET configuration screen and
use the ARD Data Link Disable
parameter to manually disable the
regen.
Both actions will manually disable the CRS (air,fuel,and
spark).
GLOBAL MANPOWER DEVELOPMENT
AVNT
DAVNT