Engine Control Systems M18-0017 Manual de usuario

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OPERATION AND MAINTENANCE MANUAL 

Backpressure Monitor & Logger

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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

WARNING

This symbol emphasizes non-compliance with instructions or procedures can re-

sult in serious injuries or death to personnel.

CAUTION

This symbol emphasizes non-compliance with instructions or procedures may

cause damage to equipment.

ATTENTION

This symbol highlights and draws specific attention to important information

Symbols Used in this Manual

TECH TIP

This symbol indicates that in this situation, the technician would suggest this

course of action to be done.

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 op-

erator 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 over-

loading and/or slow soot combustion.

Engine Control Systems is pleased to offer a DPF Backpressure Monitor & Logger with features to pro-

tect both your engine and your DPF. The Backpressure Monitor & Logger will be referred to as the BPM through-

out this manual.

ATTENTION

Please completely read this manual.

The following parts are included in the BPM kit. Please take time to read all installation instructions and setup proce-

dure 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 Thermocouple — 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

ATTENTION

If you are missing any components, contact your ECS representative before continuing

the installation.

Parts List

Understanding the BPM Connections

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.

Connects to the K-Type thermocouple that measures the exhaust temperature.

PRESSURE

Connects to the pressure line that samples the exhaust stream backpressure

CAUTION

Use caution when plugging in the cables. Make sure

the pins are aligned properly before pushing in the

connector.

Figure 1 - Backpressure Monitor & logger (BPM)

Understanding the 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: A flashing error light indicates that there is a system error and the BPM should be inspected as

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 more information.

OFF: 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 atten-

tion. 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 illumi-

nates for periods longer than 45 seconds while the vehicle is in normal use on a level roadway, the operator

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..

Figure 2 - Remote Driver Display

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

Installation Procedure

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 sen-

sor at the DPF inlet (pressure tube not installed

yet). Keep thermocouple wire away from hot

surfaces.

Figure 4 - Installation of the backpressure

sampling tube

ATTENTION

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

pipe. Please call technical services.

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 rec-

ommended 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 acceptable orientations.

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.

a b

CAUTION

Do not install the BPM in direct ex-

posure to water spray or rain. Do not

pressure wash the BPM.

CAUTION

Do not install the BPM inside the driver’s compartment. A leak could expose

the driver to exhaust gas.

ATTENTION

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 atmos-

pheric pressure.

ATTENTION

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.

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)

b c

UNACCEPTABLE BPM orientations:

a. Vertical surface with tube upward

b. Sitting on a horizontal surface with the face upward

ATTENTION

UNCCEPTABLE mounting locations or orientations will VOID the warranty!

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