Engine Control Systems M18-0017 Operation And Maintenance Manual

OPERATION AND MAINTENANCE MANUAL
Backpressure Monitor & Logger
Revision: 7.0 June 2011 Part Number: M18-0017
Table of Contents
Symbols used in this Manual ..................................................................................................... 3
Introduction ................................................................................................................................ 4
Parts List .................................................................................................................................... 5
Understanding the BPM Connections ........................................................................................ 6
Understanding the Remote Driver Display ................................................................................ 7
Installation Procedure ................................................................................................................ 8
Using the DPF Utilities Software .............................................................................................. 14
Maintenance............................................................................................................................. 17
BPM Troubleshooting Guide .................................................................................................... 18
2
Symbols Used in this Manual
This symbol emphasizes non-compliance with instructions or procedures can re-
WARNING
CAUTION
sult in serious injuries or death to personnel.
This symbol emphasizes non-compliance with instructions or procedures may cause damage to equipment.
ATTENTION
TECH TIP
This symbol highlights and draws specific attention to important information
This symbol indicates that in this situation, the technician would suggest this course of action to be done.
3
Introduction
A diesel particulate filter (DPF) is used to reduce the exhaust particulate matter emitted by an engine. By definition, the DPF accumulates the particulate matter (soot) and oxidizes it with a passive, active, or combined strategy.
Diesel engines are sensitive to backpressure created by any restriction in the exhaust flow. When a DPF is used, the backpressure varies depending on the soot loading in the filter. The filter will fill up with soot and ash over time and periodically require cleaning. As a result, a backpressure monitor is used to inform the vehicle op­erator that the filter needs cleaning.
Monitoring exhaust backpressure is also a useful way to identify the condition of the engine. Increased soot levels from the engine will cause the filter to load faster. Identifying this trend allows the service technician to correct engine problems before they become severe. Backpressure monitoring can also indicate DPF over­loading and/or slow soot combustion.
Engine Control Systems is pleased to offer a DPF Backpressure Monitor & Logger with features to pro­tect both your engine and your DPF. The Backpressure Monitor & Logger will be referred to as the BPM through­out this manual.
4
Please completely read this manual.
ATTENTION
Parts List
The following parts are included in the BPM kit. Please take time to read all installation instructions and setup proce­dure carefully to ensure proper installation and use of the provided software. Spare parts for older BPM models are listed at the bottom of this page.
Backpressure Monitor & Logger Part List
(Complete kit - A56-0067)
PART # DESCRIPTION QTY
A56-0066 Backpressure Monitor - Watlow thermocouple & Deutsch connector 1
J35-0269 Remote Driver Display 1
C25-0232 Condensation Trap 1
J16-0021 Fitting – ¼ NPT male - ¼ hose barb 1 J16-0126 Clear plastic tube — 10 ft 1 J16-0313 ¼“ swage to ¼“ swage brass 1 J16-0314 ¼” swage to ¼” NPT brass 2 J16-0316 Synflex tube - 1/4” OD, 6 ft 1 J16-0322 Brass tube insert 2 J19-0161 Stainless steel backpressure tube—1/4” OD 1 J35-0333 Watlow K-Type Thermocouple 1 J35-0334 K-Type thermocouple extension wire 1 J16-0340 Coupling—M14 x 1.5 1 J35-0270 Power cable — 20 ft 1 J35-0271 Remote Driver display cable—20 ft 1 J35-0272 Data cable—3 ft 1 J35-0277 2 amp fuse 1 J35-0278 Fuse holder 1 J16-0005 Coupling-NPT-SS 1/4 - 3/4” OD 1
M18-0017 Backpressure Monitor & Logger Installation & Setup Manual 1
M16-0019 Utility CD 1 M18-0026 BPM Driver’s Display Visor Card 1
Optional Accessories
J35-0273 Remote Driver Display Extension cable—20 ft. 1 J35-0336 Remote Driver Display Extension cable—40 ft. 1
Spare Parts for Old Style BPM with Omega thermocouple
A56-0063 Backpressure Monitor - Omega thermocouple & yellow connector 1
J35-0275 Omega Thermoco uple — 6” K-type 1 J35-0226 Thermocouple wire—15 ft 1 J35-0276 Thermocouple wire strain relief - #PCLM-SMP 1 J16-0285 Thermocouple plug — male 1 J16-0315 1/8” swage to ¼” NPT brass 1
If you are missing any components, contact your ECS representative before continuing the installation.
ATTENTION
5
Understanding the BPM Connections
Figure 1 - Backpressure Monitor & logger (BPM)
POWER
Connects to continuous vehicle battery power. The BPM will operate with a 12V or 24V power source.
DATA
Connects to the PC for setup and data downloading.
REGEN
Connects to the junction box on Purifilter Plus systems only. The BPM can monitor the regeneration status when connected.
REMOTE
Connects to the Remote Driver Display.
TC
Connects to the K-Type thermocouple that measures the exhaust temperature.
PRESSURE
Connects to the pressure line that samples the exhaust stream backpressure
Use caution when plugging in the cables. Make sure the pins are aligned properly before pushing in the connector.
CAUTION
6
Understanding the Remote Driver Display
Figure 2 - Remote Driver Display
Pink light - SYSTEM ERROR
This pink light flashes when there is a BPM system error. It has two modes of operation: flashing and off.
FLASHING soon as possible. If the error light stays on in combination with the red alarm light, the BPM and DPF should be inspected as soon as possible. Refer to the troubleshooting guide for error light causes and m ore information.
OFF:
: A flashing error light indicates that there is a system error and the BPM should be inspected as
The unit is working properly.
Red light - SERVICE DPF NOW
This red light indicates that very high exhaust backpressure exists and the DPF is in need of immediate atten­tion. There are two modes of operation: ON (solidly illuminated) and off.
ON
: When the light is illuminated for longer than 45 seconds, the operator should service the DPF within 24hrs. If the red light is on in combination with the system error light, the vehicle should be parked in a safe location immediately. If when parked, the red light and pink light remain on with the vehicle at idle and/or with engine turned off, do not continue to operate the vehicle. Engine damage may result. Product warranty may be void. Refer to the troubleshooting guide for more information.
OFF:
The unit is working properly.
Yellow light - SCHEDULE DPF SERVICE
This yellow light indicates that higher than normal exhaust backpressure exists and that there is a need to schedule the DPF for service. The light has two modes of operation: ON (solidly illuminated) and off.
ON
: It is normal that this light may briefly illuminate when pulling heavy loads up grades. When the light illumi­nates for periods longer than 45 seconds should schedule the DPF for service. Delays in servicing may raise the alarm level to “SERVICE DPF NOW”. Refer to the troubleshooting guide for more information.
OFF:
The DPF is not in need of service
Green light - POWER
This green light indicates that the system is powered and is operational. There are two modes of operation for this light: ON and OFF.
ON:
When the light is illuminated the system is powered properly. This light remains illuminated even when the
engine is shut off.
OFF
: The system is either not powered or there is a problem with the system. Refer to the troubleshooting guide
for more information..
while the vehicle is in normal use on a level roadway, the operator
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Installation Procedure
Tools and Accessories Required
 Power drill with 3/8” drill bit.  Self tapping 3/16” screws  Welding Tools for couplings  Zip ties for fastening cabling to the vehicle  Electrical Connectors  Laptop
Step 1 - Installing the thermocouple and stainless steel backpressure sampling tube
a. Drill two 3/8” holes in the exhaust pipe for the couplings. The couplings should be installed on a
straight section of pipe and not on bends or flex pipe. They should also be located upstream of the DPF and as close as possible to the DPF inlet.
b. Find the 1/4” NPT coupling and the M14 coupling and weld to the exhaust pipe so that they align with
the drilled holes. The M14 coupling is the larger coupling. The NPT coupling should be upstream of the M14 coupling.
c. Locate the thermocouple, apply anti-sieve to the threads, and tighten into the M14 coupling as shown
in Figure 3. Keep thermocouple wire away from hot surfaces.
d. Locate the 1/4” swage to 1/4” NPT brass fitting, apply anti-seize to the NPT threads, and tighten into
the NPT coupling.
e. Insert the stainless steel sampling tube into the 1/4” swage hole until it stops. Tighten the compression
nut finger tight and then turn one full turn further with a wrench. The backpressure sampling tube is shown in Figure 4.
Figure 3 - Installation of the thermocouple sen­sor at the DPF inlet (pressure tube not installed yet). Keep thermocouple wire away from hot surfaces.
If the exhaust inlet diameter is less than 3 inches, an NPT coupling and a ther-
mocouple adaptor will be required to center the thermocouple tip within the
ATTENTION
8
pipe. Please call technical services.
Figure 4 - Installation of the backpressure sampling tube
Installation Procedure (cont’d)
Step 2 - Mounting the BPM
Mount the BPM in a location that is protected from direct water spray, excess heat, and moving parts. Some rec­ommended locations include a battery box or engine compartment. Figure 5 shows recommended locations. If
the BPM cannot be installed in the recommended locations, cover the BPM with a shield or a box to protect it.
Ensure that the BPM is exposed to atmospheric pressure. The following page illustrates acce ptable orientations.
a
Figure 5 - Examples of properly mounted BPMs; a) in an electrical panel; b) in the engine compartment; c) in a battery box. BPM shown may differ from the one supplied.
Do not install the BPM in direct ex­posure to water spray or rain. Do not
CAUTION
pressure wash the BPM.
Do not install the BPM inside the driver’s compartment. A leak could expose the driver to exhaust gas.
CAUTION
If the BPM cannot be installed in the recommended locations, cover the BPM
b
c
with a shield or a box to protect it. Ensure that the BPM is exposed to atmos-
ATTENTION
pheric pressure.
The BPM will operate properly up to a maximum temperature of 70°C. Make
sure the BPM is installed in a location that does not exceed this temperature.
ATTENTION
9
Installation Procedure (cont’d)
ACCEPTABLE BPM orientations:
a. Vertical surface with tube to the right b. Vertical surface with tube to the left c. Vertical surface with tube downward d. Hanging from a horizontal surface with face downward (not
shown)
a
b
c
UNACCEPTABLE BPM orientations:
a. Vertical surface with tube upward b. Sitting on a horizontal surface with the face upward
b
a
UNCCEPTABLE mounting locations or orientations will VOID the warranty!
ATTENTION
10
Installation Procedure (cont’d)
Step 3 - Assemble the Condensation Trap
Locate the condensation trap, 1/4” NPT to 1/4” barbed fitting, and 1/4” swage to 1/4” NPT brass fitting.
a. Apply anti-seize compound to the NPT threads of each fitting b. Remove the condensation trap from the box. Be careful not to lose the two small crews in the box that
fasten the bracket to the trap. c. Thread the barbed fitting into the outlet d. Thread the swage fitting into the inlet
Step 4 - Mount the Condensation Trap
Mount the condensation trap at a location higher than the exhaust system so that excess condensation drains to the exhaust. The condensation trap should be installed below the BPM to prevent any moisture from entering the BPM. Make sure it is away from all moving parts and excessive heat. The flow direction will be marked by an arrow or small triangle pointing in the direction of flow. The exhaust sample should flow from the exhaust stream towards the BPM.
a. Remove the condensation trap bracket from the box and use it to mark the holes b. Drill two mounting holes on the vehicle for the bracket c. Fasten the bracket to the condensation trap using the two screws provided. Make sure the outlet is
facing the correct direction. d. Mount the condensation trap to the vehicle using the drilled holes. e. Measure and cut the appropriate length of clear plastic tube f. Push the clear plastic tube onto the barbed fittings at the condensation trap and BPM
marked with a square and tighten.
marked with a triangle and tighten.
Figure 6 - Two examples of condensation trap mounting.
The flow direction is marked on the condensation trap by an arrow or small triangle pointing in the direction of flow. The exhaust sample should flow from the exhaust stream towards the BPM.
ATTENTION
11
Installation Procedure (cont’d)
Step 5 - Assemble and route the Synflex backpressure sampling tube
a. Measure and cut the appropriate length of Synflex tube to go from the end of the stainless steel tube to
the condensation trap. Cut the ends square and clean to ensure proper sealing when assembled. b. Locate the brass tube inserts and press into each end of the synflex tube c. Locate the 1/4” swage to 1/4” swage fitting d. Connect one end of the fitting to the stainless steel tube. Tighten compression nut finger tight and then
tighten one full turn with a wrench e. Slide one end of the synflex tube into the fitting. Tighten compression nut finger tight and then tighten
one full turn with a wrench. f. Route the synflex tube to the condensation trap and slide the tube into the inlet fitting. Tighten com-
pression nut finger tight and then tighten one full turn with a wrench.
Be careful not to lose the small brass tube inserts.
CAUTION
Step 6 - Route the thermocouple wire
a. Plug the thermocouple extension wire into the thermocouple and route to the BPM. Do not cut the ther-
mocouple extension wire. Plug the thermocouple extension into the BPM.
Do not cut or shorten the thermocouple extension wire.
ATTENTION
ATTENTION
Route wires with existing wire harnesses and keep away from hot surfaces. Wire loom is recommended but not provided.
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Installation Procedure (cont’d)
Step 7 - Mount the Remote Driver Display
Mount the Remote Driver Display in clear view of the driver as shown in Figure 7. Do not interfere with any driv­ing mechanisms, instruments, or gages. Plug the six pin Remote Driver Display cable into the Remote Driver Display and route to the BPM. Plug the other end into the “Remote” plug on the BPM.
ARB Verification requires that the Remote Driver Display is visible when sitting in the
ATTENTION
driver’s seat.
Use caution when plugging in the ca­bles. Make sure the pins are aligned properly before pushing in the con-
CAUTION
nector.
Figure 7 - Remote Driver Display mounted to instru­ment panel
Step 8 - Install the Power Cable
The BPM must be connected to a continuous and unswitched power supply of 12V or 24V. It is strongly recom­mended to wire directly to ONE
a. Locate the power cable, measure, and cut to the desired length. b. Strip the outer gray wire to expose 6” of the black and white wire. c. Connect the provided the fuse holder to the WHITE (positive) wire. Do not insert the fuse yet. d. Connect the red wire to the positive terminal of the battery e. Connect the black wire to the negative terminal of the battery. Connect wires to a single battery. f. Route the power cable to the BPM and plug it into the “Power” connector. g. Insert the 2 amp fuse into the fuse holder.
battery.
ATTENTION
ATTENTION
In the event of jump starting the vehicle, remove the BPM fuse. Failure to do so could result in BPM damage.
In the event of welding on the vehicle, remove the BPM fuse. Failure to do so could result in BPM damage.
Figure 8 - Installing the power cable
TECH TIP
Connect the BPM directly to only ONE
battery
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Using the DPF Utilities Software
STEP 1 - Install the DPF Utilities Software
The software required to view and retrieve data from the BPM is provided with your kit.
Computer Requirements
The software requires the minimum system requirements:
 Windows XP/2000 System  Pentium 3 Class System or newer  At least 64 MB of RAM  RS-232 Serial port  Serial port to USB adaptor if no serial port is available
Software Installation
Insert the CD containing the ECS Backpressure Monitor & Logger Software into your computer’s CD-ROM drive. Click install and follow the procedures on screen.
STEP 2: Making the Connection
a. Connect your computer to the BPM using the data cable provided. b. Double click on the ECS_DPF_Utilites shortcut located on the desktop. This will launch the DPF Alarm
Logger Utilities window shown in Figure 9. c. Enter the Comm port number and select “OK.”
Figure 9 - Select the Comm port that the data cable is plugged in to.
TECH TIP
14
Comm port 1 will work for most users. However, if you are using a USB to serial port adaptor, you may have to change this number
Using the DPF Utilities Software (cont’d)
STEP 3: Viewing Real-time data from the BPM
After clicking “OK,” the Parameter View tab will open as shown in Figure 10. From this tab, you can see real-time data from the BPM. The flashing blue light next to the word “Update” indicates that the computer is connected to the BPM. Check to make sure that the thermocouple reading is reasonable. For example, if the thermocouple is exposed to room temperature, it will read around 20
o
C.
Figure 10 - “Parameter View” tab showing real-time data from the BPM.
TECH TIP
Ensure that you have a good connection by checking the tem­perature readings. For a cold engine, the thermocouple tem­perature should read ambient temperature. It is possible to have a flashing blue light, but and bad connection. If you have a thermocouple reading of 0.0, you are not connected prop­erly. Try a different Comm port setting.
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Using the DPF Utilities Software (cont’d)
STEP 4: Accessing the data stored in the BPM
Selecting the “Log View” tab will bring up the data transfer area of the utilities program. This is shown in Figure
11. This is where all communications and information can be controlled by the user. On the right hand side are buttons used for downloading and saving the data stored in the BPM. The “Parameter
Logs” contains the temperature, pressure, regeneration status, and alarm status taken every 12 seconds over the past 24 hours. The “Histogram Logs” contain frequency data in the form of a histogram from the last 365 days.
Select the desired radio button and click on “Get data.” The data will show up in the white viewing pane on the left.
When you have selected to read one type of data (Histogram or Parameters) you must clear the screen before displaying the next time to ensure accurate data display. This can be done with the “Clear Log Display” button in the upper right hand section of this tab.
Figure 11 - The Log View tab is where the data transfer takes place.
STEP 5: Saving the BPM data
Once the desired data is shown in the viewing pane, it can be saved to your computer. Clicking on the “Save for Excel” button will save the data in the viewing pane to a CSV file that can be opened by
most viewing programs. It is recommended to save all data log files, both Parameter logs and both Histogram logs, at every de-ashing for
future reference. Each log must be brought into the viewing pane individually and saved individually.
TECH TIP
16
Include the date and vehicle information in the filename when saving the data.
Maintenance
Proper maintenance of the BPM system is important for reliable operation. Lack of BPM maintenance may void DPF warranty. The following service items should be performed:
At every oil change
 Empty any water that has collected in the condensation trap. To do this, twist off the metal bowl protec-
tor and remove the bowl. Empty water out of the bowl and reinstall.
 Inspect the clear tube that goes from the condensation trap to the BPM. There should be no visible
soot. If there is soot, see troubleshooting guide for further instruction.
 Inspect the pressure line going from the DPF to the condensation trap. Make sure that this line is clear.
To clean the line, remove line at the condensation trap and use compressed air to blow out the line.
 Serve items as defined by the appropriate Purifilter or Purifilter Plus product manual.
At every Filter de-ashing
 All the service items outlined to be performed at every oil change above
 Service items as defined by appropriate Purifilter or Purifilter Plus manual
 Engine-Out Opacity should be measured. If opacity indicates engine maintenance is required, this
maintenance should be performed prior to re-installation of the filter.
:
:
 Download histogram data and parameter data from the BPM and save it. Refer to page 16 for
downloading and saving instructions.
17
BPM Troubleshooting Guide
Note: Refer to Purifilter or Purifilter Plus Product Manuals for Additional Troubleshooting information
Event Probable Cause(s) Action
1 Yellow light illuminates continu-
ously for periods longer than 45 seconds in duration
2 Red light illuminates continu-
ously for periods longer than 45 seconds in duration OR red light stays illuminated at all times.
Engine exhaust backpressure is increasing and the DPF should be scheduled for service within the next 72 hours.
Engine exhaust backpressure is at a level where the DPF should be cleaned within the next 24 hours.
Purifilter systems - download BPM histogram and parameter files and confirm reported Yellow Alarm
 Confirm duty cycle is acceptable for pas-
sive regeneration.
 Remove DPF and clean  Perform all service items defined in the
Maintenance section under this service
Purifilter Plus systems - perform on-board regeneration.
Purifilter systems - download BPM histogram and parameter files and confirm reported Red Alarm
 Confirm duty cycle is acceptable for pas-
sive regeneration
 Remove DPF and clean
3 Pink system error light flashes
continuously
Backpressure Sensor problem * The logged parameter data and user interface will show “-3276.8” in the pressure column when there is an abnormal pressure condition.
Thermocouple connection problem * The logged parameter data will
show “SAT” in the temperature column and user interface when the thermocouple is disconnected
High backpressure Error. Back­pressure greater than 500 mbar. This will latch the system error light.
 Perform all service items defined in the
Maintenance section under this service
 If red light remains illuminated, contact
your ECS distributor to reset the red light
Purifilter Plus systems - perform on-board regeneration.
Refer to Purifilter Plus manual if problem is apparent.
Check the backpressure sensor line for any breaks or leaks . Check the tubing between the water trap and exhaust pipe for any blockage and clear with compressed air blowing toward the exhaust pipe. Service the condensation trap and condensation trap filter.
Check thermocouple connections. Check thermocouple sensor. Make sure the thermo­couple polarity is correct. Refer to installation instructions.
Follow the actions required in item 2 above. Contact your ECS distributor to reset the system error light.
4 All lights on the remote driver
display are on continuously
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Internal problem with the BPM Contact your ECS distributor. Power supply voltage has been
out of the normal operating range. The BPM will operate with a sup­ply voltage between 9V and 30V.
Disconnect power to the BPM for 20 seconds and then reconnect power. This can be done by removing the fuse or the power connec­tor, whichever is more convenient.
BPM Troubleshooting Guide (cont’d)
Event Probable Cause(s) Action
5
DPF requires more frequent cleanings than usual
6 System Error Light flashes in
combination with Red and/or Yellow alarm illumination when vehicle is driven or at idle.
7
System Error Light flashes shortly after engine shut down
8 When the engine is warming
up, the thermocouple tempera­ture decreases.
Filter is not completely clean Clean filter again with reference to the ap-
plicable ECS product manual.
Engine requires servicing Measure the opacity of the engine out ex-
haust. If it is out of the manufacturers specification, service engine immediately.
Severe system backpressure due to engine malfunction or failure to service filter.
Remove, inspect and clean the DPF on appropriate cleaning machine. Perform engine inspection and correct faults found. Confirm engine opacity prior to re­installation of cleaned filter. Service BPM Logger condensation trap and clean sen­sor line. Contact your ECS distributor to rest lights.
Engine shut down while exces­sively hot
The yellow and red wires are crossed in the thermocouple connector. This only applies to the old (yellow) Omega thermo-
Start engine and operate. After two minutes the System Error light should turn off. If this error persists, contact your ECS distributor.
Check the connector and ensure that the YELLOW is connected to the positive ter­minal and the RED is connected to the negative terminal.
couple style.
9 Soot in the clear tube between
the condensation trap and the BPM
10
Remote driver display shows no lights
High backpressure occurred at some point.
Download data from the BPM and check for signs of high backpressure. Service condensation trap. Clean DPF or regener­ate as required.
No power getting to the remote driver display
Check that power is getting to the Remote Driver Display. Locate the “Remote” con­nection at the BPM. Pull out the connector and check that 5 volts is available at the center pin. If there is power, the Remote Driver Display is faulty. If there is no power, the remote driver display is not get­ting power from the BPM. See next item for troubleshooting.
No power getting to the BPM. Inspect BPM fuse and connectors first. If
no troubles found, disconnect the power connector at the BPM and check for power from the battery. If there is vehicle battery voltage, then the BPM could be faulty.
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Engine Control Systems Limited World Headquarters
83 Commerce Valley Drive East Thornhill, ON, L3T 7T3 Phone: 905-707-7746 Toll Free: 1-800-661-9963 Fax: 905-707-7686
Engine Control Systems Ltd. North America—Western
4910 Longley Lane, Suite 103 Reno, Nevada, 89502 Phone: 1-775-827-3400 Fax: 1-775-827-1670
Engine Control Systems Europe AB European Headquarters
Box 9015, Agnesfridsvagen, 184 SE-200 39 Malmo, Sweden Phone: 46 (40) 670 1550 Fax: 46 (40) 210 335
Website: www.enginecontrolsystems.com Email: ecs@enginecontrolsystems.com
Contact Information
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