Operation & Maintenance Manual · 2019. 6. 27. · CRT® System Operation & Maintenance Manual 4 Section 2 - CRT® System Operation CRT® System Operating Characteristics. The essential

CRT® System

Operation & Maintenance Manual

E x h a u s t E n g i n e e r i n g E x c e l l e n c e

LITM002©E

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Contents

Section Title PageNos.

Introduction 2 1. TechnicalDescription&IdentificationofParts 3 2. CRT®SystemOperation 4 3. RegularMaintenanceCheck 6 4. CRT®SystemServiceIntervals 6 5. ElectronicServiceIndicator 8

6. CRT®SystemServiceRecords 9 7. DismantlingyourCRT®System 10 8. Re-assemblingyourCRT®System 11 9. ServicingtheCRT®SystemFilter 13 10. CatalystMaintenance 14 11. SummaryofWarnings 15 GlossaryofTerms 16

1

CRT®SystemOperation&MaintenanceManual

HighlyActiveCatalystModule

Wall-FlowFilterModule

InletModule

OutletModule©2004EminoxLtd

Porttofacilitatesmokeorbackpressuretesting


2

Introduction

Your CRT® system is a Continuously Regenerating Trap using novel patentedtechnologywhich largelyeliminatesharmfulpollutants fromyourdieselengineexhaust,inadditiontoprovidingthenormalfunctionsofasilencersystemsuchasnoisereduction.Typicalreductionsforsomeofthemajorpollutantsare:

Particulatematter(PM)75to95% Hydrocarbons(HC)75to95% CarbonMonoxide(CO)75to95% NitrogenOxides(NOx)upto10%

Your CRT® system contains a specially formulated, highly active Catalyst anda wall-flow ceramic filter housed in modular units. The patented chemicaltechnologypromotesselfcleaningofthesootorparticulatemattertrappedwithintheceramicwallflowfilter.Theefficiencyofthisprocessdeterminestheservicefrequency.

Your CRT® system is housed in high grade stainless steel which protects thesystemfromcorrosiongivingmanyyearsofusefulservice.

Section1-TechnicalDescription&IdentificationofParts

YourCRT®systemismadeupoffourmajorpartsillustratedinthediagrambelow: 1.InletModule 2.CatalystModule 3.FilterModule 4.OutletModule

Note:1. Incertaincircumstancesmodulesmaybecombined.2. TheCatalystmustalwaysbepositionedupstreamoftheFilter.

3

1.InletModule

2.CatalystModule

3.FilterModule

4.OutletModule

ToTailpipeExhaustgasfromengine

ServicePortiffitted

3.FilterModule

PluggedCells

(“Chequerboard”structureie:Alternatecellsareplugged)

2.CatalystModule

BothmadefromCeramic

SubstrateCatalyst Filter

OpenCells(“Honeycomb”structure)


4

Section2-CRT®SystemOperation

CRT®SystemOperatingCharacteristics.

TheessentialcharacteristicoftheCRT®systemistocaptureandoxidisethesootorparticulatemattercontainedindieselexhaust,commonlyobservedassmoke.Theparticulatematteriscaughtwithinthewallflowfilterandthencontinuouslyoxidised, at typical exhaust gas temperatures, into harmless gas by the novelpatentedchemicaltechnology.

Under normal operating conditions, with a properly maintained engine undertypical loading, the soot component of diesel exhaust is oxidised harmlesslyleaving only ash, mainly the incombustible residue of burnt engine oil. Thisaccumulates very gradually in the Filter and should be removed by regularservicing.

In conditions of prolonged low engine loading however, for example whenvehiclestravelatslowspeedsinurbanconurbationsorenginesareusedinastaticutilityrole,theexhaustgasmaynotachieveahighenoughtemperatureforthefulloxidationofthesoot.InthesecasestheServiceIntervaloftheCRT®systemmustthenbeshortenedinordertoremoveanyaccumulationofunburnedsootandash.

In theexceptionalcase,whenenginesootoutputexceeds thatspecifiedby themanufacturer, faster soot (and ash) accumulation within the Filter can causeexhaustgas flowrestrictionandacorresponding increase inBackPressure. Intheextremecondition,whentheFiltercarriesanundetectedhighconcentrationofsoot,arelativelyshortperiodofhighengineworkoutputcancausearapidriseofexhaustgastemperature.Thiscanleadtospontaneoussootignitionandveryhigh temperatures which can result in irreparable damage to the filter and theneedforreplacement.

ThefollowingconditionsareessentialforsatisfactoryCRT®systemoperation:

• Useonlydieselfuelwithsulphurcontentlessthan50ppmandconformingtoEN590

• Donotusefueladditivesotherthanthosealreadyincorporatedingeneralcommercialdieselfuelsupplies

• Additionally the following biodiesel and water-diesel emulsion fuels areapprovedforusewithCRT®technology

• Biodiesel 30%Diester GreenenergyGlobalDiesel,5%biodiesel,95%ULSD GlobalCommoditiesUKLtd,driveEco RixBiodieselLtd,Bioblend5 PetroplusMarketingLtd,Bio-plus

• Water-fuelemulsions BPAspira@10%demineralisedwater LubrizolPuriNOx™@10%demineralisedwater

5

• The engine is properly maintained so that the level of smoke producedby the engine does not exceed the maximum limits set by the enginemanufacturer.IfthisisnotavailablethenEminoxrecommend:-

• Eminox approve the use of E4 and E6 oil. Eminox recommend the useofE6ratedengineoilsaheadofE4,becauseof theirpotential toextendcatalystlifeandtheadvantagesofextendedfilterserviceintervals.Whicheveroilisused,itisimportanttoensurethatitisalowashengineoilwithasulphurcontentoflessthan7,000ppm.

• Eminox recommend that oil consumption is monitored closely. Itis important that oil consumption rates should not exceed enginemanufacturer’slimits,typicallylessthan1litreper1,000km

• Thevehiclemustbeservicedaccordingtomanufacturer’srecommendationsin order to maintain the optimal engine performance, which the CRT®systemisdesignedtobecompatiblewith

• Repeatedlongperiodsofengineidlingshouldbeavoided.Thiscanlowertheenginetemperaturebelowthatrequiredforfilterregeneration,causingsoottoaccumulateandblockthefilter

Warning.The factorsdescribed in thisSectionhaveaneffecton the lifeof theCatalyst.UndernormaloperatingconditionswheretheengineiswellmaintainedandthecorrectoilisusedyourCatalysthasbeendesignedtolastfortheoperatinglifeofavehicle.IftheseconditionshavenotbeenmetitispossiblethattheCatalystwillrequireearlierreplacement.

The activity level of the catalyst, contained in many diesel particulate filtersystems, can also affect the frequency of filter servicing. We recommend thatcatalystsarecheckedafter5-6yearstoensureoptimumsystemperformance.Weofferacatalysttestingservicetochecktheactivitylevelofthecatalystandadviseonwhetherthiscouldbeaffectingyoursystemperformanceandservicingcosts.

AimoftheManual.TheaimofthefollowingSectionsofthisManualistosetoutCRT®servicerequirementswhichshouldavoidtheextremeconditionthatleadstofilterdamage

Note:AHealthandSafetyriskassessmentshouldbedonebeforeattemptingtocarryoutworkdescribed in thefollowingSectionsof thisManual.TohelpwithyourRiskAssessment,materialsafetydatasheets(MSDS)forbothashandsootareavailablefromtheEminoxLtdwebsitewww.eminox.com.

E1+E0 E2 E3

Pass Fail Pass Fail Pass Fail

K <1.25 >=1.25 <1.0 >=1.0 <0.8 >=0.8


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Section3–RegularMaintenanceCheckCaution:BeforecheckingyourCRT®systemyoushouldobservetherequirementsofyourHealth&SafetyRiskAssessment.

Back Pressure. Exhaust Back Pressure (BP) rises as a CRT® system Filteraccumulatesashandsoot.BPchecksatregularintervalscanindicatetheextentofthisaccumulation,andthepointatwhichtheFilterneedstobeserviced,seeSection4.

BPshouldbemeasuredwhenthe:

• vehicleisstationary

• engineisasclosetooperatingtemperatureaspossible

• engineisrunatmaxstaticrpm(theconditionreachedwhentheacceleratorpedalisfullydepressedwiththetransmissioninneutral).CaremustbetakenifaLimiterisfittedtomakeallowanceforanrpmthatislowerthanthestandardsetbythemanufacturerseeSection4.

RecordBPusing:

• anElectronicServiceIndicator(ESI)ifthisisfitted,seeSection5

• EminoxhandheldDigitalPressureGauge(PartNumberQM1466)connectedby a tube to the BP tapping point fitted to your system. This could beto a Schrader valve output locatedwithin the engine bay or at someother easily accessible position, ortotheCRT®systemServicePort (byremovingtheAllenscrew).

Section4-CRT®SystemServiceIntervals

Engine Duty Cycle. The efficiency of soot oxidation within the CRT® systemincreaseswithexhaustgastemperature. Itfollowsthat,ifanenginehasalowworkoutputoridlesforlongperiods,thismayreduceeffectiveregenerationandleadtosootaccumulationandanearlierservicerequirement.EminoxthereforestronglyrecommendsthataregularcheckofBPismaintainedinordertoguardagainstexcessashandsootaccumulationduetooperationinadverseconditionsand/or deterioration in engine performance leading to high engine out smoke.Alternatively it ispossible to identify categoriesofenginedutycyclewhicharelistedbelowandcanbeusedaguide.

AGuidetoServiceIntervalPrediction.

*oras indicatedby theElectronicService Indicator (ESI),whicheveroccursfirst

Warning.

• Longperiodsof idleshouldbeavoided. Inaworkshopenvironmentthisshouldbelimitedto15minutesperday.

The Interpretation of Back Pressure. BP varies with the maximum static rpm(which may have an rpm limiter fitted or reset as a matter of Fleet operatingpolicy),andwithenginetemperature(whereitisnotpossibletoreachanormaloperating level during a service). The BP Limit is the conservative figure thatEminox Ltd will provide for your engine configuration which can help to takeaccountoftheseuncertainties.BestpracticeistorecordBPreadingsundersimilarmeasurementconditions (seeSection2)at intervalsofnotmore than4weeks.InterpretationmaybeassistedbyplottingagraphofBPagainsttime.WhentheBPLimit isreachedtheFiltermustbeservicedbutagraphmayassistwiththedetectionofarapidriseinBPwhichisastrongerindicationthatdamageislikelytooccur.

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DutyCycle TypicalExample TypicalServiceInterval

Highandsustainedworkload

Longhaultruck

Intercitytrainorcoach

Upto1year*

Variableengineworkrate

Allpurposedeliverytruck

Busoperatinginamixofcityandruralareas

Upto1year*

Lowengineworkrate

Busoperatinginheavytrafficandcongestedcitycentres

Wasterefusevehicles

Upto6months*Monitorbackpressureatleastonceevery6weeks

Warning.

• If the BP limit is reached within the CRT® system Service Interval it islikelythatenginesmokehasincreased.(Aconditionthatwillbemaskedby the CRT® system). You must then check engine smoke output. Ifcorrective action is not taken you will risk catastrophic failure of theFilter,andinvalidationofanywarrantycover.Youmayalsoexperienceadeteriorationinengineperformance.

• Themeasurementofengineoutsmokeisagaugeofengineperformance,notanindicationofthestateofaCRT®system.Ideally,smokereadingsshould be taken with the CRT® system disconnected, with appropriatesafeguardsagainstfumesandnoise.

• If you do not know what the manufacturer’s smoke limits are for yourenginethenyoushouldconsultyourenginesupplier.AlternativelyEminoxLtdRecommends:-

• IfblacksmokeemergesfromthetailpipeoftheCRTthisisaclearindicationthatthesystemisnotworkingandshouldbethoroughlyinvestigated.

Section5–ElectronicServiceIndicator(whenfitted).

Operation. The Eminox Ltd Electronic ServiceIndicator (ESI) is a robust Back Pressure (BP)recordingdevicenormallyfittedwithinanenginebay,oradjacenttoit.Ithastwokeyelements;apressuresensorconnectedbyheatresistanttubetotheCRT®systeminlet(orupstreamoftheCRT®system),andacentralprocessorunit(CPU)whichcontinuouslymeasuresdynamicBP.

ESI Warning System. The ESI warning systemconsists of 3 coloured lights. Limits are setwithin the micro-processor by Eminox Ltd for aparticularengineconfigurationanddutycycle.TheESI triggers theappropriatelightilluminationwhenapresetBPhasbeenexceeded:

Green. Systemon,BPatacceptablelevelsAmber. BP above acceptable levels. Filter will require servicing shortly.

CheckbyrecordingBPatmaxstaticrpm.Red. Filterrequiresanimmediateservice. Thedisplayalsoshowsthe

BPintheformatCxxxandMxxxwhereC=currentvalueofBP,M=themaximumBPsincetheunitwaslastre-setandxxx=numericalvalue of BP in mbar. The display alternates between these twoformatsautomaticallywhilsttheunitisturnedon.


8

E1+E0 E2 E3

Pass Fail Pass Fail Pass Fail

K <1.25 >=1.25 <1.0 >=1.0 <0.8 >=0.8

9


BPMeasurementatMaxStaticrpm.TheESIdigitaldisplaymayalsobeusedtoreadamaximumBPwhenthevehicleisstationary(whenthehighestBPreadingremainsondisplay).Itispossiblethereforeforonemantoruntheenginetomaxstaticrpm,allowthevehicletoreturntoidle(orstoptheengine),thenwalkbacktoreadmaxBP. Thisshouldbeused as an independent checkontheAmberandRedlightsontheWarningSystem.

The CPU retains the BP tracehistory of the vehicle. Thiscanbedownloadedforanalysis.Resettingtheunittocarryoutamaxstaticrpmpressurereadingdoesnoterasethismemory.

Section6-CRT®SystemServiceRecords.

Thefollowinginformationshouldberecordedonyourvehiclechecksheetateachservice:

• BackPressurebeforeandafterservice(notethattheenginemustbewarmatthetimeofmeasurement)

• Vehiclemileage

• FilterandCatalystSerialNumbers

• Filtercleaning,methodanddate

Note:EminoxLtdwillrequireservicerecordsinordertoinvestigateanywarrantyclaim. Failure to provide service records will invalidate your warranty cover. AtypicalCRT®systemServiceRecordSheetcanbeobtainedfromtheEminoxLtdwebsitewww.eminox.com

Section7-DismantlingyourCRT®System

Caution: Before dismantling your CRT® system you should observe therequirementsofyourHealth&SafetyRiskAssessment.

Note: Unless the Filter is already marked with the exhaust gas flow directionthrough the Filter, this should be marked on the outside of the casing beforeremoval,unlessitistobereturnedtobereconditionedasanEminoxLtdServiceExchangeFilter.

YourCRT®systemmayberemovedasacompleteunitbyslackeningInletModuleandOutletModulepiperetainingBandClampsanddismantling thesupportingbracketsasnecessary.SomeinstallationsliketwinsystemsmayrequirethatoneormoreModulesbe released first, inwhichcasedisconnect theV-ClampsandremovetheCRT®systemunitsindividually.

When the Filter Module is to be removed for servicing or exchange it may bepossible torelease itasasingleunitbydisconnecting itsV-ClampsandeasingawaytheadjacentModulesandpipework.

WhentheCRT®systemisdismantledalwaysinspectallpartsforobviousexternaldamage, particularly the flared end of all units which form together with thegasketsthegastightjointbeneaththeV-Clamps.AsignificantdentinaCatalystorFilterModulemaywellhavedamagedtheceramicsubstrate.Checkforobvioussignsofdamageonthesurfacesoftheceramicsubstrate.AnydamagedModulemustbereplaced.


10

11

Jointring

V-Clamp

Gasket

Section8-Re-assemblingyourCRT®System

Caution: Before re-assembling your CRT® system you should observe therequirementsofyourHealth&SafetyRiskAssessment.

Re-assembleyourCRT®systeminthereversesequenceusingnewgasketsand,if needed, new V-clamps. The Catalyst Module may be re-assembled in eitherdirectionandmustbefittedupstreamoftheFilter.TheFiltershouldbereplacedsoastomaintainthemarkedpreviousexhaustgasflowdirection.

Note: ItisrecommendedthattheFilterModuleisrefittedwiththeCRT®systemSerialNoandIDNoeasilyvisibletotheVehicleandOperationsServicesAgency(VOSA)forthepurposesoftheirReducedPollutionCertificate(RPC)inspections.

SerialNo.

PartNo.

IDNo.


12

Thefollowingtorquesettingsshouldbeapplied.Notethatitisessentialnottoover-tightentheclampsthatprovidethestructuralrigidityoftheCRT®systemasthiscanleadtoinservicefailurewhichcouldhaveseriousresults.

• CRT®systemBandClamps(pipework) 14Nm

• CRT®systemV-Clamps 14Nm

• Hi-TorqueClamps(heatshields) 11Nm

• ServicePortPlug(iffitted) 68Nm

• AllenScrews 20Nm

FollowingthereplacementoftheCRT®systemandallexhaustpipes:

• Connectthegarageexhaustextractorandstarttheengine.

• Allowtheenginetoreachnormaloperatingtemperature.

• Run at idle for five minutes, then gradually increase to full rpm. Thenleaveontickover for5minutesbeforeshuttingoff theengine.RemovetheexhaustextractorunitandcheckthesecurityofCRT®systemandpipeworkfixingsmakingsuretherearenoleaksinthesystem.

• Checkthatanyinsulationfittedtothepipe-workisreplacedandproperlysecuredwithatightfittingtothepipe.

PleasequotetheCRT®systemSerialNumberswhenorderingspareparts.

Section9-ServicingtheCRT®SystemFilter

Caution:BeforeservicingyourFilteryoushouldobservetherequirementsofyourHealth&SafetyRiskAssessment.

TheuniquedesignoftheEminoxCRT®andSCRT®systemsmeanthatthefiltersarecontinuouslyregenerating,however,incombustibleresiduescanstillbuildupon the filter.SimilarlyFBCandFBCActivesystemsaredesigned to regenerateduringuse.Foroptimalperformance,thefilterneedsperiodiccleaningtoremoveincombustibleashandanyexcesssoot.Failuretocleanthefiltercanresultinfilterblockage,causingbuildupofsootandultimatelyanexothermicreactionwhichwilldamagethefilter.

Eminoxhasdevelopedaspecialistcleaningprocesswhichrejuvenatesthefilterfor the best possible performance. Filters are professionally reconditioned andtheirperformancetested.Thisisbackedbya12monthwarrantyforreconditionedfilters.Thecleaningprocesshelpsmaintaintheserviceintervalandimprovesthelongevityofthefilter.

A range of filter servicing packages are available, for details please visitwww.eminox.comorcontactuson+44(0)1427810088

The environmental benefits of fitting an Eminox Systems are well establishedCRT® Systems significantly reduce exhaust emissions, including CarbonMonoxide, Hydrocarbons and Particulate Matter, FBC systems also reduceparticulate matter, the SCRT® system additionally reduces Nitrogen OxidesThe environmental benefits have encouraged many operators to run greenvehicles. A clean filter will ensure that the CRT® and SCRT® systems willcontinue to offer trouble free performance and carry on reducing harmfulemissions.

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NormalAppearance LocalInternalDamage Extensiveinternaldamage


14

Section10-CatalystMaintenance

Caution:BeforemaintainingyourCatalystyoushouldobservetherequirementsofyourHealth&SafetyRiskAssessment.

WhenoperatingunderNormalConditionstheCatalystshouldnotbecomecloggedbysoot.However,duringaFilterserviceitisadvisabletochecktheconditionoftheCatalystandtodislodgeanyaccumulatedsootbyusingasoftbrush.InspectthosevisiblesurfacesoftheCatalystthatareaccessible(notalwayspossibleontheupstreamside)toensurethatthereisnosurfacecrackingorpittingandthatthe ceramic substrate is secure within the high grade stainless steel housing.Shouldanydefectbefound,replacetheCatalystModule.

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Section11–Warnings

TheperformanceofyourCRT®systemandenginearelinked.Iftheconditionofeitherisallowedtodeteriorateitwillhaveaharmfuleffectupontheother.ThiscanbeavoidediftheinstructionsinthisManualarefollowed.Inparticular,thefollowingmeasureswillminimisethechancesofpoorperformance:

Never:• Usejointingcompound,gasketcementorsuchlikeonupstreamexhaust

connections. These may contain silicon (a catalyst poison) which candestroyyourCRT®system

• ExceedtheCRT®systemServiceInterval,• Run the vehicle when the engine is generating excessively high smoke

levels,• Allowtheengineoilconsumptiontoexceedenginemanufacturerslimits,• Overfilltheenginewithoil,• Allowtheenginetoidleforlongperiods,andinaWorkshopnotmorethan

15minutescontinuously• Allowanyinsulationmaterialtobecomedislodged.

Always:• ServicethefilterwhenaBackPressurelimitisreachedorwhenaBPgraph

indicatesarapidrise• Re-assemble a filter correctly with the marked or previous gas flow

direction• Usefuelwithasulphurcontentlessthan50ppm,• Usefuels, fueladditivesoralternativefuelswhichconformtoEN590,or

whicharespecificallyapprovedbyEminoxLtd• UseE4orE6oil.EminoxrecommendtheuseofE6ratedengineoilsahead

ofE4,becauseoftheirpotentialtoextendcatalystlifeandtheadvantagesofextendedfilterserviceintervals.Whicheveroilisused,itisimportanttoensurethatitisalowashengineoilwithasulphurcontentoflessthan7,000ppm.


16

GlossaryofTerms

Term Meaning

Ash The incombustible particulate matter in the exhaust gas, mainlyresiduesofcomponentsofthelubricatingoil. BackPressure The pressure above atmospheric within an exhaust systemcausedbyflowresistance. BandClamps Flat metal clamps which are used to connect your CRT®Systemtotheexhaustpipes. Catalyst A ceramic substrate coated with precious metals to oxidise pollutantsintheexhaustgas. CatalystModule ThemetalhousingcontainingtheCatalyst. CeramicSubstrate A ceramic extrusion usually in the form of a cylinder with channels running its full length, used as the basis of both the Catalyst and Filter. The channels in the Catalyst are open at both ends. In the filter every other channel is blocked forming a chequer board effect. This forces the gas to flow through tiny pores in the walls of the channels preventingthepassageofsoot. CRT®System Continuously Regenerating Trap. A unique patented process which uses a Catalyst to convert some NOx into NO2. This oxidises or burns any soot which is collected on the walls of the filter at temperatures in excess of 250°C so cleaningthefilter. Filter AextrudedceramicsubstrateusedtotrapSootandAsh. FilterModule ThemetalhousingcontainingtheFilter. InletModule The metal housing into which the exhaust down pipe from theengineenterstheCRT®System. MaximumStaticrpm The rpm reached by the engine when the accelerator pedal is fully depressed with the vehicle stationary and the transmissioninneutral(sometimescalled‘max.static’). OutletModule The metal housing from which the exhaust exits your CRT®System.ParticulateMatter(PM) PM is the solid content of Soot and Ash in the exhaust gas normallyobservedasdarkorblacksmoke. ppm ‘Partspermillion’.Ameasurementusedtoquantifyverysmall amountsofatraceelementwithinalargeroverallsubstance. SerialNumber Auniquenumberetchedontoaplateweldedontotheoutside of the Catalyst Module and the Filter Module used to record wheneithermodulewasmanufacturedandfitted. ServicePort An access port may be built into the Inlet Module of your CRT®Systemwhichcontainsasmallerthreadedorificetoallow theconnectionofatubetoaBackPressuregauge. SmokeReading The visible and measurable opacity (blockage of light) of the exhaustgas.Thisisrelatedtotheamountofparticulatematter emittedbytheengine. Soot The combustible particulate matter in the exhaust gas created as part of the normal engine combustion process typically observedassmoke. V-Clamps The metal clamps with a V shaped cross section which are used tohold the fourmodulesofyourCRT®System together. They are also often used to connect the turbo charger to the engineandexhaustpipes.

Website www.eminox.com Email [email protected] Telephone +44 (0) 1427 810088

Eminox LtdNorth Warren Road, Gainsborough, Lincolnshire, DN21 2TU.

Tel: +44 (0) 1427 810088Fax: +44 (0) 1427 810061www.eminox.com

©E

min

ox

Ltd

201

1: C

RT

® S

yste

m is

a R

egis

tere

d T

rad

emar

k o

f Jo

hn

son

Mat

they

plc

Documents

Operation & Maintenance Manual · 2019. 6. 27. · CRT® System Operation & Maintenance Manual 4 Section 2 - CRT® System Operation CRT® System Operating Characteristics. The essential