Key Aftertreatment Component Temps - gce.cummins.com · Cummins has established Cooling System...

Key Aftertreatment Component Temps

CES Application Engineering - AE TrainingFeb 2013

Information Security

Protect Information - Competitors desire to know what d iwe are doing

Discuss only with other team members who have a “Valid Right and Need to Know”

Information shared should be clearly stated as C i C fid ti l d th hi l OEM h ldCummins Confidential and the vehicle OEM should use same “Need to Know” criteria for distribution within their companye co pa y

2/26/2013 Cummins Confidential2

Objectives

After completing this course you will be able to: Understand the importance of Key Component

Temperature Testing Be familiar with the Test Procedure and Acceptance Be familiar with the Test Procedure and Acceptance

Criteria Understand Methods for Reducing Key Component Temps Have awareness of proper use of Test Equipment


Reference AEB’sAEB DescriptionAEB 21.60 Euro 4 and Euro 5 Auto & Bus Installation Requirements

AEB 21.63 2007 Automotive Aftertreatment Installation Requirements

AEB 21.78 2010 Automotive Aftertreatment Diesel Particulate Filter (DPF) Installation Requirementshway

AEB 21.78 2010 Automotive Aftertreatment Diesel Particulate Filter (DPF) Installation Requirements

AEB 21.79 2010 Automotive and Bus Selective Catalytic Reduction (SCR) Installation Requirements

AEB 21.98 Automotive and Bus Exhaust Gas Diffuser Installation Requirements 2010 Requirements -Diesel Emissions

On-

Hig

AEB 21.103 Automotive and Bus Selective Catalytic Reduction Installation Requirements – Euro 4/China Stage 4

AEB 21.109 Installation Requirements for Assembly Close Coupled Catalytic Convertor on 2.8L ISF Euro 4 / China Stage 4 Engine

AEB 21.112 Automotive and Bus Aftertreatment(DPF and SCR) 2013 Installation Requirements

AEB 21.126 Euro IV Aftertreatment – Automotive SCR with Cummins EcoFit™ Urea Dosing System –Installation Requirement

AEB 21.139 ISX 15e5 Selective Catalytic Reduction Installation Requirements

y

AEB 24.40 Industrial Tier4 Interim Aftertreatment Installation Requirements

AEB 24.57 Industrial Tier 4 Interim / Euro Stage lllB Aftertreatment Installation Requirements for Cummins Compact Catalystgh

way

p y

AEB 24.61 Industrial MR (QSB6.7 and QSL9) Tier 4 Final / Euro Stage IV Aftertreatment Installation Requirement

AEB 24.62 Industrial Tier 4 Final Aftertreatment Installation Requirements – QSX15Off-

Hig

Importance of Key Component Temp Testing

Components, connectors, DEF lines, Coolant lines, t h d fi d t t li it f li bilitetc have defined temperature limits for reliability

The aftertreatment, though insulated, radiates and conducts a large amount of heat to surroundingsconducts a large amount of heat to surroundings The application together with design of exhaust

system will determine temperatures that keysystem will determine temperatures that key components will be exposed to CES experience shows large variability in keyCES experience shows large variability in key

component temps based on installation


Excessive Temperatures Can Cause Damage


Test Conditions

Temperature Validation Testing must be carried out using the highest engine rating that the OEM plans for thethe highest engine rating that the OEM plans for the application Engine should be at full load or worst case duty cycleEngine should be at full load or worst case duty cycle

condition If two aftertreatments are installed in close proximity to

each other, the aftertreatment component’s temperature test should be executed when both aftertreatments are in the In-Mission regeneration condition (system over-ridesthe In Mission regeneration condition (system over rides may be required to achieve this condition)


Automotive EPA2013 Test (AEB21.112)


Automotive EPA2013 Test (AEB21.112) AEB specifies detailed test procedures for each of the 5 Test MethodsAEB specifies detailed test procedures for each of the 5 Test Methods AEB excerpt below…Type 2 test


Automotive EPA2013 Test (AEB21.112) AEB Example…Type 2 test worksheetAEB Example…Type 2 test worksheet


Component Temp – Adjusted Value Component test data should be adjusted for a limiting ambient temperature

based upon geographic location (specified as cooling levels 1-4) When adjusted component temperatures do not exceed componentWhen adjusted component temperatures do not exceed component

temperature limits, then they are acceptable. Cummins has established Cooling System Standards (AEB 21.52)


Component Temp – Adjusted Value

Example of how to adjust data for Level 2 Region…LAT of 106 ºF (41C): Test Ambient where max component temperature occurred = 90 ºF (32C) If measured component temperature (e.g. NOx sensor ECU) = 180 ºF (82C) Adjusted component temperature = (LAT – Test Ambient) + Measured component temperature Adjusted component temperature = (106 - 90) + 180 ºF


Adjusted component temperature = 196 ºF ( Does not exceed maximum spec)


Measure at closest point to hot surface




#12


Measure at closest


point to hot surface

Industrial Tier 4 Interim Test (AEB24.40)


Tier 4 Final Requirements (MR, HD) As part of the IQA, OEMs must demonstrate that their installation design

meets the maximum temperature limits of the aftertreatment system components, as specified in the Table below. A test procedure for measuring key aftertreatment component temperatures is currently under development for Tier 4 Final/Euro Stage IV systems.


Automotive Acceptance Criteria

System Ref Doc Required Operation Information to Document*Always download latest AEB from GCE to determine latest procedure and acceptance criteria

yDescription

q p

MR/HD Automotive AEB 21 63 Not Given in AEB

Connector distance from A/T- or –Automotive

EPA2007AEB 21.63 Not Given in AEB Connector temp (if distance <8” from

A/T)

MR/HD A t ti AEB 21.78

Chassis Dyno- or -

St ti T t

1. Required component temps2. Ambient temperature

3 M th d h f t tAutomotive EPA2010 AEB 21.79 Stationary Test

-or -Road Test

3. Method chosen for test4. Other parameters as given in

AEB21.79 Appendix F

MR/HDChassis Dyno

or1. Required component temps

2 Ambient temperatureMR/HD Automotive EPA2013

AEB 21.112- or -

Stationary Test-or -

Road Test

2. Ambient temperature3. Method chosen for test

4. Other parameters as given in AEB21.112 Appendix F


Industrial Acceptance Criteria

System Ref Doc Required Operation Information to Document*Always download latest AEB from GCE to determine latest procedure and acceptance criteria

Description

MR/HD Tier 4 Interim / Euro AEB 24.40

Worst Case Duty Cycle / Full Load during In Mission

1. Required component temps2. Ambient temperature

Stage IIIb during In-Mission Regen

p3. Duty cycle used for test

MR/HD Tier 4 Final/ Euro Stage AEB 24.61

AEB 24 62 To be Determined

Not Yet Released, but Likely:1. Required component temps

2 Ambient temperatureIV AEB 24.62 2. Ambient temperature3. Method chosen for test


Methods for Reducing Key Component TempsPlacing aftertreatment in an enclosed area with no air flow is a recipe for high component temperatures Ensure that aftertreatment components get adequate air flow Ensure that aftertreatment components get adequate air flow

– Cooling fan can remove hot air from around aftertreatment– Airflow from vehicle movement may be sufficient in some applications

Louvers/vents above aftertreatment can let hot air escape and allow for– Louvers/vents above aftertreatment can let hot air escape and allow for natural convection

Ensure aftertreatment has plenty of clearance to adjacent panels or components on chassisor components on chassis

Avoid designs that “trap” heat Orient outlet into clear area - Do not allow exhaust outlet to be oriented

such that it would inhibit clear flow of gas if adjacent to an obstruction

Suggestion: Revise orientation of exhaust to 45deg to avoid blocked airflow from


adjacent obstructions

Test Equipment – Automotive EPA2010 & EPA2013 (AEB21 79 AEB21 112)

Safety equipment (PPE)D t l bl f 1 H li f

(AEB21.79, AEB21.112)

Data logger, capable of 1 Hz sampling frequency– EPA2010: 11 channel– EPA2013: 15 channel

Thermocouples Calterm Depending on test method chosen: Depending on test method chosen:

– Towing dyno, capable of fully loading engine at a controlled engine speed (test method 4)

– Fully functioning stationary vehicle capable of allowing vehicle to operateFully functioning stationary vehicle, capable of allowing vehicle to operate under highest anticipated duty cycle (test method 5)


Test Equipment – Industrial MR/HD Tier 4i (AEB24.40) Safety equipment (PPE) Calterm 4 channel data logger, capable of 1 Hz sampling frequency Thermocouples

- OR -- OR -

O t t l b l Omega temperature labels (Omega PN: TL-10-105-XX)

Ability to apply full load to engine


Checkpoint Exercise – Key AT Component Temps

1. In the picture shown, which parameter is identified?A. DEF Supply Module TempB. DEF Dosing Module connector tempC. DEF Engine Coolant Line from Dosing ModuleD. NH3 Sensor Cable Temp

2. True or False?Keeping temperatures below maximum allowable limits increases Aftertreatment

component reliability.

3. Which are methods for reducing Aftertreatment component temps?A. Avoid designs that “trap” heatB. Increase frequency of aftertreatment regenerationsC. Increase air flow to aftertreatment componentsD. Ensure leak-free joints for ancillary tubing


Summary – Key Aftertreatment Component Temp Testing

Items Discussed Regarding Key Component Temperature Testing:Temperature Testing: Understand the importance of Key

Component Temperature Testing B f ili ith th T t P d d Be familiar with the Test Procedure and

Acceptance Criteria Understand Methods for Reducing Key

Component Temps Have awareness of proper use of Test

Equipmentq p


Change Control

Date Author Description Pagesp gNov 27, 2012 Orvin Kendall Original document published All

Feb 20, 2013 Orvin Kendall Revision to add LAT adjustment information 9-14


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