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FPT - SCR System Installation Guideline to meet Emission

Standards Euro IV/V & Tier 4A with Bosch Denoxtronic 2


without Coolant Control Valve (CCV-less version)

Version 6.1
Arbon, 19-11-2009

Fritz Papst / Marco Pidria


Aftertreatment Systems

Arbon, November 2009 CONFIDENTIAL


Table of contents

page content
3 SCR system description, configurations, chemical reactions
6 AdBlue/DEF – urea/water solution as reducing agent, specifications
9 SCR system overview, layout
12 Urea Dosing System (UDS) - Bosch Denoxtronic 2 (DNOx2) overview
17 Supply module (SM) installation instructions
26 Dosing module (DM) installation instructions
32 Dosing / mixing unit and SCR muffler installation (Cursor engine)
40 Dosing / mixing unit and SCR muffler installation (Tector / NEF engine)
49 Instructions for modified exhaust pipe / SCR muffler layouts
54 AdBlue/DEF tank and WEMA combination unit
61 Material requirement for exhaust pipes and AdBlue/DEF tank
63 AdBlue/DEF pipes, hoses, connectors and filter
76 SCR control layout
77 Electrical layout and schemes
80 Exhaust temperature, NOx and humidity sensors
86 Parts list
87 Revisions
88 Contacts

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 2


SCR system description

 FPT has chosen SCR (selective catalyst reduction) for the medium engine (NEF/Tector)
and heavy engine (Cursor) ranges to meet present and future on-road and off-road
emission standards Euro V/VI and Tier 4A/B. Alternative emission reduction strategies by
means of EGR (exhaust gas recirculation) partly in combination with a particulate trap and
SCR are applied on the light duty applications (F1 engines range)

 Why Selective Catalyst Reduction ?


 Selective Catalytic Reduction (SCR) is a widely used technology for removing Nitrogen
Oxides (NOx) from lean exhaust gases
 To enable the catalytic reduction of NOx to N2, the presence of ammonia is needed
 As ammonia is a very toxic compound, usually an ammonia-releasing reagent is used
instead of pure ammonia
 AdBlue (trade name for Europe) or DEF (Diesel Exhaust Fluid, trade name for USA) is
a non-toxic aqueous urea solution. AdBlue/DEF is classified under the minimum risk
category of transportable fluids. AdBlue/DEF is guaranteed to meet the Standards of
ISO 22241 and the CEFIC regulations to safeguard the correct functioning of your
vehicle’s SCR system
 The AdBlue/DEF is injected into the exhaust system with a specific dosing module.
 In the exhaust system the liquid has to be atomized and distributed homogeneously in
the exhaust pipe or across the catalyst cross-section respectively

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 3


SCR configurations

SCR SCR cat only

configuration selected by FPT

SCR cat
SCR C
+ clean-up cat

SCR cat
O SCR C + pre-oxidation cat
+ clean-up cat

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 4


SCR chemical reactions

8 NH3 + 6 NO2 → 7 N2 + 12 H2O


Hydrolysis
4 NH3 + 4 NO + O2 → 4 N2 + 6 H2O
CO(NH2)2 + H2O → 2 NH3 + CO2

2 NH3 + NO + NO2 → 2 N2 + 3 H2O

EXHAUST GAS
SCR Catalyst

SCR

UREA injection

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 5


AdBlue/DEF physical properties

60
 The concentration of 32.5% was chosen
because at this mixing ratio the solution
50
has its lowest freezing point of -11°C

ea
(eutectic mixing ratio) 40

ur
γ-
 To maintain correct system operation 30
under cold conditions, AdBlue/DEF tank,

T [°C]
pipes, pump module and dosing module 20

a
need a de-freezing system

re
-u
10

β
 ... likewise, the complete AdBlue/DEF 0

rea
distribution network requires precautions H2O

-u
α
against freezing -10
-11.5°C

0 10 20 30 40 50 60 70
Urea concentration [°C]

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 6


AdBlue/DEF infrastructure

 The required network of AdBlue/DEF filling


stations in Europe is currently being growing up
by companies from the mineral oil business and
chemical industry

 Infrastructure has been set up in three steps:


1) Filling stations on the yard of large fleet
owners and any workshops of truck
companies (... open to all AdBlue/DEF users)
2) Public filling stations along expressways in
Europe
3) Public filling stations covering distribution
throughout Europe

 AdBlue/DEF filling stations can be found via


internet link: www.findadblue.com

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AdBlue/DEF specification ISO 22241 / AUS32 / DIN V 70070

Product properties for AdBlue®

Urea 32,5 % - solution in water


Min. Max.
Urea content 31.8 33.2 % by weight
Density at 20°C 1.087 1.093 g/cm³
Refracting index at 20°C 1.3814 1.3843
Alkalinity as NH3 0.2 %
Biuret 0.3 %
Aldehyde 5 mg/kg
Insolubles 20 mg/kg
Phosphate (PO4) 0.5 mg/kg
Calcium 0.5 mg/kg
Iron 0.5 mg/kg
Copper 0.2 mg/kg
Zinc 0.2 mg/kg
Chromium 0.2 mg/kg
Nickel 0.2 mg/kg
Aluminium 0.5 mg/kg
Magnesium 0.5 mg/kg
Sodium 0.5 mg/kg
Potassium 0.5 mg/kg

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SCR system overview main components

supply module

urea tank

SCR muffler
dosing module

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SCR system overview

 For the selective catalytic reduction of NOx, the presence of ammonia is needed. As
ammonia is a very toxic compound, usually an ammonia-releasing reagent is used instead
of pure ammonia. The reagent is introduced into the exhaust system upstream the SCR
catalyst. Achieving high NOx conversion and avoiding ammonia slip in the exhaust gas
requires very accurate dosing of a reducing agent
 Despite of several technical disadvantages (freezing point, dosing temperature threshold,
urea deposits, storage volume, etc.) European manufactures of HD trucks agreed to use
urea/water solution as reducing agent for SCR mainly for safety and handling reasons:
 Trade names for the urea/water solution (32.5%w): AdBlue/DEF
 Product composition, quality and properties of AdBlue/DEF have been
standardized by ISO 22241 / AUS32 / DIN V 70070
 FPT has chosen the Bosch urea dosing system (UDS) DNOx1 or DNOx2 for it’s SCR
current production systems. The UDS consist mainly of a supply module (SM) and a
dosing module (DM). The SM integrates a pump, valves, filters, sensors, pressure
controller and the dosing control unit (DCU) within an environmentally secure box. The DM
contains mainly the a PWM dosing valve and is located close to the exhaust pipe
upstream the SCR catalyst. Mid of 2005 the 1st air-assisted UDS DNOx1 was introduced
by IVECO for heavy trucks and busses. Wherever possible the DNOx1 system was then
replaced by the air-less DNOx2 system during 2006

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 10


System layout: air-less UDS (DNOx-2)

Intake air
humidity
& temp.
sensor
Air
filter
Dosing
Module

Supply
ECU Module
DEF mixer

DCU

NOx
Temperature sensor Temperature sensor
sensor
downstream upstream
DEF level &
SCR temperature
Sensor

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 11


DNOx 2 supply module (SM) 1/5

For prototype and final installation layouts please ask for detailed supplier customer information

Pressure sensor

Temperature sensor

Filter

4/2-way valve

Diaphragm pump

FPT no. 504374326, CNH no. 84246892, Bosch no. 0444022021

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 12


DNOx 2 system overview 2/5

External
External
pre-filter
pre-filter
100 micron
100 micron
(VOSS)
(VOSS)

previous CCV new CCV-less


version version

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 13


DNOx-2.0 CCV-less filters 3/5

Filter in DEF/AdBlue filer neck

SM main filter
10 µm
Filter in DEF/Adblue
supply line (Voss)
100 µm

Prefilter
100 µm

2 filters in Dosing Module


100 µm

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DNOx-2.0 CCV-less filters 4/5

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DNOx 2 dosing module (SM) 5/5

For prototype and final installation layouts please ask for detailed supplier customer information

6,5÷7,5 Nm

DM 6 kg/h for all NEF/Tector & Cursor 8/9/10/11/13 (Euro IV/V DM 9 kg/h for all Tier4A Cursor 13 engines:
only) engines: FPT no. 504381866, CNH no. 84248058,
FPT no. 504374327, CNH no. 84247021, Bosch no. 0444023058 Bosch no. 0444023062

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SM installation instructions 1/9

For prototype and final installation layouts please ask for detailed supplier customer information

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 17


SM installation instructions 2/9

For prototype and final installation layouts please ask for detailed supplier customer information

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SM installation instructions 3/9

DCU 15
35 pins
connector

filter

drain plug pressure


compensation

BACKFLOW OUTLET
to tank INLET
from tank

BACKFLOW INLET
from DM

OUTLET to DM pre-filter

For prototype and final installation layouts please ask for detailed supplier customer information

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 19


SM installation instructions 4/9

Usually the SM can be


installed without rubber
mounts. However, vibration
measurements have to be
carried out before FPT /
Bosch can give a
production release

For prototype and final installation layouts please ask for detailed supplier customer information

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 20


SM installation instructions 5/9

For prototype and final installation layouts please ask for detailed supplier customer information

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 21


SM installation instructions 6/9

For prototype and final installation layouts please ask for detailed supplier customer information

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 22


SM installation instructions 7/9

The specification of the pump limits the suction


height (negative pressure) of the inlet line (IL).
In this configuration maximum suction height is
reached when AdBlue/DEF level is at minimum level
(MAL) or reaches the begin of the inlet line (BIL).

For prototype and final installation layouts please ask for detailed supplier customer information

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 23


SM installation instructions 8/9

• After shut-off unwanted flow of AdBlue/DEF


from Supply Module to Dosing Module must
be avoided. In this configuration a routing of
AdBlue/DEF pressure line with a siphon
close to Dosing Module can avoid this
• The length of line between siphon and DM
shall be minimum to limit the volume of
AdBlue/DEF that may flow back to DM
• A test has to show that the remaining
AdBlue/DEF after after-run in the pressure
line matches siphon volume
• A flat siphon can avoid blocking of line by ice
if not complete cross section is frozen
For prototype and final installation layouts please ask for detailed supplier customer information

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SM installation instructions 9/9

• After shut-off unwanted flow of


AdBlue/DEF to Dosing Module
must be avoided
• A routing of AdBlue/DEF
pressure line higher than max.
level of AdBlue/DEF in tank can
avoid this

For prototype and final installation layouts please ask for detailed supplier customer information

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 25


DM installation instructions 1/6

Horizontal 5°

FPT recommends a
minimum inclination
of 5 degrees above
the horizon

For prototype and final installation layouts please ask for detailed supplier customer information

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DM installation instructions 2/6

0
°
Heat

In cases where the DM is


installed on an inclined

+4
exhaust pipe it is

5°-
15
suggested that the axis of

85
°-3

°
spray direction is pointing

75
+2
towards the ground. FPT
recommends a minimum
inclination of 5 degrees
above the horizon (p.24).
In order to keep the
temperatures of the DM
Deposits
connections as low as
possible the body should
be exposed toward the
driving wind or ventilation
cooling whenever
possible.

For prototype and final installation layouts please ask for detailed supplier customer information

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 27


DM installation instructions 3/6

Good Deposits Heat

For prototype and final installation layouts please ask for detailed supplier customer information

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 28


DM installation instructions 4/6

Air stream

Heat insulation
For prototype and final installation layouts please ask for detailed supplier customer information

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 29


DM installation instructions 5/6

Air stream

Air stream

Heat shield

For prototype and final installation layouts please ask for detailed supplier customer information

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 30


DM installation instructions 6/6

min.5°

-XX°
For prototype and final installation layouts please ask for detailed supplier customer information

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 31


Dosing and mixing unit installation (Cursor)

Version for Cursor engine (FPT patent), FPT drawing no. 4129 6199

Reference point (RP)

110
flow direction

105 111

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 32


Dosing and mixing unit installation (Cursor)

Exhaust pipe
with integrated
mixer unit for
Cursor engine
(Iveco Stralis)
FPT drawing
no. 4129 6197

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 33


Truck SCR muffler installations (Cursor)

urea injection positions

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 34


Truck SCR muffler installations (Cursor)

temperature sensor
SCR inlet

NOx sensor

temperature sensor
SCR outlet

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 35


Emcon horizontal Cursor SCR mufflers (LHD)

Note: latest production SCR mufflers


are equipped with NOx sensor boss

Cursor 8: 4129 8537 Cursor 10: 4129 8536


Cursor 13 < 368kW: 4127 2365 Cursor 13 412kW: 4127 2447

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 36


Emcon horizontal Cursor SCR mufflers (RHD)

Note: latest production SCR mufflers


are equipped with NOx sensor boss

Cursor 8: 4129 8541 Cursor 10: 4129 8540


Cursor 13 < 368kW: 4127 2366 Cursor 13 412kW: 4127 2448

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 37


Emcon vertical Cursor SCR mufflers

Note: latest production


SCR mufflers are
equipped with NOx
sensor boss

Cursor 8: 4127 2370 Cursor 13: 4127 2369

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 38


Cursor SCR muffler installation

StepSeal clamp for Cursor exhaust pipe/muffler connection, FPT drawing no. 4128 8279
tightening torque 50÷60 Nm

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 39


Dosing and mixing unit installation (Tector)

Version for Tector engine (FPT patent), FPT drawing no. 804 7376

Reference point (RP)

flow direction

110.5 102.5

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 40


Dosing and mixing unit installation (Tector)

Two exhaust pipe versions with integrated mixer unit are available for Tector engine
(iveco Eurocargo)

FPT no. 504148370 504148371

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 41


Truck SCR muffler installations (Tector)

urea injection positions

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 42


Cortubi Tector 4 SCR muffler with horizontal tailpipe

5041 35181

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 43


Cortubi Tector 4 SCR muffler with vertical tailpipe

Note: NOx sensor


has to be installed
in tailpipe close to
muffler outlet

5041 35189

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 44


Cortubi Tector 6 SCR muffler with horizontal tailpipe

5041 35186

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 45


Cortubi Tector 6 SCR muffler with vertical tailpipe

Note: NOx sensor


has to be installed
in tailpipe close to
muffler outlet

5041 35192

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 46


Cortubi Tector 4 / 6 SCR cylindrical muffler

5041 84309

Note: NOx sensor has to


be installed in tailpipe
close to muffler outlet

urea injection positions

Exhaust pipe samples for muffler in horizontal (left) and vertical (right) installation

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 47


Tector SCR muffler installation

V-clamp for Tector exhaust pipe/muffler connection, FPT drawing no. 504 105 924,
tightening torque 7 Nm

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 48


General instructions for modified exhaust pipe layouts 1/5

 Iveco standard SCR muffler in combination with Iveco standard exhaust Reference point mixer
pipes have been intensively tested and are released for best NOx (RP, see page 30/38)
conversion and the avoidance of urea deposits.
 For custom made exhaust pipes pay attention to the following
boundaries:
 The minimum pipe length between turbine outlet flange and dosing module

L_in
(DM) reference point (RP) is 230mm.
 The straight pipe distances from inlet bend to the dosing module (RP) and
DM (RP) to outlet bend should exceed the following values:
 30 deg. bend > 150 mm
 45 deg. bend > 200 mm
 90 deg. bend > 300 mm

L_out
For more details see next page 45
 For custom made exhaust pipes the following minimum distances between
DM (RP) and SCR muffler inlet have to be realised:
 320 mm for the Tector rectangular muffler (504135 181/189/186/192)
 1000 mm for the Tector cylindrical muffler (5041 84309)
 1200 mm for the Cursor horizontal & vertical muffler versions
 An insulated elbow/exhaust piping downstream of the mixer is
recommended if the above values cannot be accommodated.
 Depending on application and operation profile an exhaust pipe insulation
might be necessary (garbage collector).
 To prevent urea deposits, any disturbances like V-clamping, edges or
welding seams directly after the mixer outlet has to be avoided in the
exhaust pipes.
 Any installation has to be checked by FPT

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 49


General instructions for modified exhaust pipe layouts 2/5

Dosing
valve axis
α L_in β L_out α Reference
minimum minimum
point (RP) β
90° 300 mm 90° 300 mm

45° 200 mm 45° 200 mm


30° 150 mm 30° 150 mm Gas
flow
L_in minimum from turbine flange to RP = 230 mm

L_in L_out
End of Begin of
bend bend

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 50


Specific installation instruction for Cursor mixer 3/5

Dosing Mixer flange


valve axis
SCR inlet
α
Mixing unit
β
Mixer

Gas flow n
_mi
L

Begin of bend
End of bend L_in* L_out*

α L_in* β L_out* L_min


90° >189 mm 90° >195 mm > 1200 mm
45° >89 mm 45° <95 mm
30° >39 mm 30° >45 mm

No change of diameter on the whole tube / no edges


inside the tube (welding to be cleaned)

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 51


Specific installation instruction for Tector mixer 4/5

Dosing Mixer flange


valve axis
SCR inlet
α
Mixing unit
β
Mixer

Gas flow n
_mi
L

Begin of bend
End of bend L_in* L_out*

α L_in* β L_out*
90° >198 mm 90° >190 mm
45° >98 mm 45° >90 mm
30° >48 mm 30° >40 mm

No change of diameter on the whole tube / no edges


inside the tube (welding to be cleaned)

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 52


Instructions for modified pipe / muffler layouts 5/5

Layout recommendation for new SCR muffler designs


20
1)
18
mixing chamber volume [l/100kW]

mixing SCR
mixing pipe
chamber catalyst
16

14
range to be
used
12 2)
mixing SCR
chamber catalyst
10

mixing pipe
6 gas inlet, mixer &
dosing module

4
0.5 1.5 2.5 3.5 4.5 5.5 6.5 7.5
mixing pipe volume [l/100kW]
3)
Additional exhaust pipe limitations: SCR
mixing catalyst
1) mixing pipe not shorter than 650 mm*) for systems with axial gas inlet!
2) mixing pipe not shorter than 550 mm*) for systems with 90°gas redirection! chamber
3) mixing pipe not shorter than 450 mm*) for systems with 180°gas redirection!
*) includes L_out as shown on page 48

Ask FPT support (p.86) for detailed design layout instructions! mixing pipe

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 53


AdBlue/DEF tank 65 litres 4129 8226 1/7

FPT recommends to maintain AdBlue/DEF


temperature < 50°C in the AdBlue/DEF tank during
operating conditions. For storage and none operating
conditions the limits of the ISO DIS 22241-3
recommendation have to be met.
Based on experiences on different applications FPT &
Bosch recommend:
 not to install the AdBlue/DEF tank in the engine
compartment (if applicable)
 to avoid direct blowing of hot engine cooling air or
other hot stream towards the AdBlue/DEF tank
 to protect the AdBlue/DEF tank from direct sun light
 tank ventilation must be protected from dust / debris
entry into the circuit
 5 litres of AdBlue/DEF have to stay in the tank when
sensor level indicates zero, in all operating
conditions/inclinations & contained in a single
volume

65 litres AdBlue/DEF tank as installed on IVECO Stralis truck on right hand side,
available also with 45 litres (4129 8229) and 120 litres (4127 8669). Part numbers
shown refer to complete tank including filler cap with strainer and WEMA unit with coolant
heater coil. Iveco truck tanks are produced by Nova Simplast, 12046 Monta (CN), Italy

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 54


AdBlue/DEF tank 45 litres 4129 8229 2/7

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 55


AdBlue/DEF tank 65 litres 4129 8226 3/7

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 56


AdBlue/DEF tank 120 litres 4129 8669 4/7

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 57


AdBlue/DEF tank 27 litres 5/7

27 litres L-shape AdBlue/DEF tank as installed on IVECO


Eurocargo truck on right hand side

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 58


AdBlue/DEF tank 27 litres 6/7

Part numbers for complete 504 168 563 with tank heater
tank including filler cap 504 192 241 without tank heater
and WEMA tank unit: 504 168 558 tank drawing only

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 59


AdBlue/DEF tank with WEMA multi-function tank unit 7/7

coolant heater coil


connections

level & temperature


sensor connection

urea suction &


return connection

level sensor

 The WEMA multi-function unit contains urea tank level sensor, temperature
coolant sensor, suction and return pipe. Frozen AdBlue/DEF can be melted by
heater coil
means of a coolant heater coil. A solenoid which is actuated by the DCU
(Dosing Control Unit) of the DNOx supply module controls the engine coolant
flow through the heater
temperature  Depending on climatic & operating conditions, the tank unit is available also
sensor w/o heater coil. For new tank layouts a custom tailored tank unit is necessary
 For further information please contact: Mr Torsten Artz, Wema-System AS,
+47 55 60 37 52, torsten.artz@wema.no

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 60


Material requirements 1/2

Exhaust pipes
 all exhaust pipes downstream the urea injection point have to be manufactured in
stainless steel to prevent corrosion
 recommended material is 304 (AISI) / 1.4301 (DIN), but also 1.4571, 1.4541 can be
used
 all internal surfaces of exhaust pipes have to be cleaned from phosphor to
prevent SCR catalysts poisoning

Other machined metallic parts in contact with AdBlue/DEF


 can be made from the following stainless steels 1.4571, 1.4541, 1.4112, 1.4310,
1.4404

AdBlue/DEF tanks
 most plastic fluid tank materials can be selected for AdBlue/DEF
 recommended material is Polyethylene (PE)
 depending on production volume different processes are selected by the
suppliers (blow or rotation moulding)
 depending on the production volume it is recommended to use one of the Iveco
AdBlue tanks combined with the adapted WEMA multi-function unit to avoid
customized datasets
 any metallic tanks are not allowed!

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Material requirements 2/2

Plastic parts in contact with AdBlue/DEF


 the following table shows the suitability of the different materials
Material type Material AdBlue/DEF Ammonia resistant
resistant
Thermoplastics IXEF yes yes
PA66 yes yes
PTFE yes yes
PEEK yes yes
PPS-compounds yes yes
PVDF yes yes
Elastomeric BR yes yes
CR yes no
HNBR yes no
NR yes yes
FPM yes no
EPDM yes yes
NBR yes no

 VOSS tubes MLT 8.8x1.4, PA562 are recommended for AdBlue/DEF

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 62


AdBlue/DEF pipes, hoses and connectors 1/13

 Urea lines can be heated by means of engine coolant or electrically. Depending on


installation layout and production volumes both systems have pros and cons
 There are different suppliers on the market which offer these parts, however it’s important to
choose high quality products as the UDS is very sensitive with regard to leakages in
suction pipes
 FPT recommends VOSS as sub-system supplier for coolant & electrically heated urea pipes.
Contact: Mr M. Karlicsek, +49 22 67 63-5485, michael.karlicsek@voss.de
Mr. P. Quagliotti, +39 011 2673060, patrizio.quagliotti@it.voss.net
 Quality electrically heated hoses can be supplied also by Contitech.
Contact: Mr H. Koch, +49 5631 58-1510, harld.koch@fluid.contitech.de

Samples of a
electrically heated
AdBlue/DEF hose

Section of a coolant
heated AdBlue/DEF hose

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 63


AdBlue/DEF pipes, hoses and connectors 2/13

Coolant heated SCR systems are controlled by a WABCO water


shut-off valve controlled by the DNOx2 supply module
FPT no. 4124 1093

Coolant hose
connector
Normaquick 90°
0702 8008 012

Normaquick 0°
0702 8009 012

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 64


AdBlue/DEF pipe heating 3/13

Heat power vs. Heating up time vs. Temperature at Tamb = -25°C


Urea hose full & with total insulation & various ∅
110

100 09 - 14 W/m

90 11 - 17 W/m
12 - 17 W/m
14 - 22 W/m
80

70
Depending on heated hose insulation a
∅ 18mm w. tape
power of 10 to 15 W/m is needed to heat
time [min]

60
∅ 24mm w. tape
& 2 connectors
up a frozen hose within 30 minutes (FPT
50 target). For the final selection, it has to
∅ 24mm w. tape
be checked if compatible with the DCU
40 ∅ 34mm w. tape output stage

30

20

10

0
5 10 15 20 25 30
power [W/m]

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 65


AdBlue/DEF pipes, hoses and connectors 4/13

Sample of a coolant heated


AdBlue/DEF hose from tank to
supply module (Stralis AS/AT)
FPT no. 4124 1931

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 66


AdBlue/DEF pipes, hoses and connectors 5/13

FPT no. FPT no.


4124 1950 2nd pre-filter
4124 1949

Available coolant heated


AdBlue/DEF connection
sets for supply module

FPT no.
FPT no.
4124 1950
4124 1948

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 67


AdBlue/DEF pipes, hoses and connectors 6/13

Sample of a coolant heated


AdBlue/DEF hose from supply
module to dosing module
FPT no. 4124 1956

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 68


AdBlue/DEF connector (3/8”) 7/13

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 69


AdBlue/DEF connector (5/16”) 8/13

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 70


AdBlue/DEF pre-filter between tank and SM 9/13

Preferred filter position on


top of WEMA tank unit or
on SM near coolant hose
(for heat radiation during
defrosting!)

AdBlue pre-filter spare part:


Iveco No. 420555466
VOSS No. 5466160100

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 71


Connectors & tubes for tank module 10/13

VOSS connecter system SV 246


Urea tank outlet (NG8)
Voss no. 5 2 46 02 71 00 (black/white)

Urea tank return (NG8)


Voss no. 5 2 46 03 28 00 (black/black)

Coolant tank - engine (NG12)


Voss no. 5 2 46 03 30 00 (black/white)

Coolant SM – tank (NG12)


Voss no. 5 2 46 03 32 00 (black/blue)

VOSS tubes
Urea: MLT 8.8x1.4, PA562/PUR2621
Coolant: Grilamid 13x1.5 for pre-moulded
tubing (high production volumes!)
or standard coolant hoses for low
production volumes

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 72


Coolant pipes to AdBlue/DEF tank, SM & DM 11/13

SM
recommended coolant flow
~300 l/h @ rated engine speed
coolant flow from
crankcase / air
compressor

AdBlue tank pipe


harness WABCO shut-
off valve

return to water pump inlet

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 73


Coolant pipes to AdBlue/DEF tank, SM & DM 12/13

coolant from
crankcase / air
ECU DCU
compressor

WABCO shut-
off valve

DM SM 1 2

return to
water
pump inlet

AdBlue tank

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 74


AdBlue/DEF pipes, hoses and connectors 13/13

On FPT drawing no. 4128 3732


all necessary AdBlue/DEF and
coolant hoses with matching
connectors are listed for
custom made installations

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 75


SCR system – DNOx2 control layout

Urea tank level


& temp sensor Humidity and temp sensor
Integrated in the AdBlue tank (WEMA unit) (intake air filter)
Integrated in the DNOx supply module
To be installed by OEM

Urea Engine Data


tank Bus - J1939
DCU15 EDC7UC31

Urea press
sensor Urea temp
sensor via CAN
Urea
Supply Module

Cat temp
Urea
upstream
Dosing NOx sensor
Module

SCR
Exhaust Mixer Cat temp
downstream
gas flow

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 76


Electrical layout 1/3

Bosch, Y 462 U04 697, Terminal diagram,


DCU15D2-2.x, Denoxtronic 2 (C1-sample).pdf

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 77


Electrical layout 2/3

Bosch, Y 462 U02 463, Connector Set, DCU15D2-2.x,


Denoxtronic 2 (C-sample).pdf

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 78


Electrical layout 3/3
ROBERT BOSCH GMBH Terminal diagram DCU15D2 0 462 YU4 01T
STUTTGART Denoxtronic 2
Pos. Pin Abbrev. Name Wire-size
2
No. No. [mm ]
15 1 V_V_BAT+R Battery + via main relay (output) 2,5
16 2 V_V_BAT+R Battery + via main relay (output) 2,5
4 3 V_V_BAT+ Battery plus 2,5
6 4 V_V_BAT+ Battery plus 2,5
6 5 B_D_CANH1 Controller Area Network 1 (high) 0,75 1) 1) Proposal for CAN (and SAE) cable:
7 6 B_D_CANL1 Controller Area Network 1 (low) 0,75 1)
Twisted pair cable 2 x 0,75 mm2
9 7 B_D_CANH2 Controller Area Network 2 (high) 0,75 1)
twist length ≈ 40 mm (= 25/m).
10 8 B_D_CANL2 Controller Area Network 2 (low) 0,75 1)
9 dnc do not connect -
36 10 O_S_CLH Compensation line heating 1.5
40 11 O_S_RAMV Reduction agent metering valve 2,5
39 12 O_V_RAMV Reduction agent metering valve supply (BAT+ ) 2,5
13 dnc do not connect -
3 14 G_G_BAT- Battery minus 2.5
4 15 G_G_BAT- Battery minus 2.5
16 dnc do not connect -
29 17 G_R_CATTSPRE Catalyst temperature sensor ground (upstream) 0,75
20 18 I_A_RALS Reduction agent level sensor signal 0,75
21 19 G_R_RALS Reduction agent level sensor ground/Reduction agent tank temperature sensor ground 0,75
20 dnc do not connect -
19 21 O_S_SVS Service soon available 0.75
28 22 O_S_HH1 Hose heating 1 (Suction line heating) 1,5
24 23 O_S_RATH Reduction agent tank heating 1,5
3 24 I_S_T15 Terminal 15 (switched BAT+) 0,75
32 25 G_R_CATTSPOST Post-catalyst temperature sensor ground (downstream) 0,75
31 26 I_A_CATTSPOST Post-catalyst temperature sensor signal (downstream) 0,75
27 dnc do not connect -
28 28 I_A_CATTSPRE Catalyst temperature sensor signal (upstream) 0.75
22 29 I_A_TRATS Reduction agent tank temperature sensor signal 0,75
19 30 V_V_5VRALS Reduction agent level sensor supply 0.75
13 31 B_D_ISOK ISO-K interface 0.75
32 32 O_S_HH3 Hose heating 3 (Pressure line heating) 1,5
33 dnc do not connect -
34 34 O_S_HH4 Hose heating 4 (Back flow to supply module line heating) 1,5
30 35 O_S_HH2 Hose heating 2 (Back flow to tank line heating) 1,5

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 79


Exhaust temperature sensor for SCR muffler

 Two temp. sensors have to be installed on the SCR muffler.


Installation bosses exist on inlet / outlet housing, positioned
before and after the SCR catalyst, in a position well
representative of the exhaust flow
 Mounting positions from top between +/-90°from vertical axis.
Different colour coded connectors to avoid a mix-up of in & out
For prototype and final installation layouts please temperatures: FPT p/n 504102603 (SCR in, black, to be
ask for detailed supplier customer information connected to female connector p/n 1/01621/87), 504109529 (SCR
out, brown, to be connected to female connector 1/01621/88)

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 80


NOx sensor installed in SCR muffler end pipe 1/3

 NOx sensor ECU has to be installed on suitable place. Refer to detailed installation
instructions. Note: cable length can not be changed! FPT no. 41271167
 The sensor has to be positioned in provided boss on SCR muffler or on exhaust
end pipe where uniform gas mixture is guaranteed
 best NOx sensor measurements between 5 m/s and 60 m/s gas velocity; for 24V
NOx sensor (Cursor/NEF) it is possible a gas velocity of up to 80 m/s

For prototype and final installation layouts please ask for detailed supplier customer information

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 81


NOx sensor installed in SCR muffler end pipe 2/3

Sensor boss, recommended material Sensor ECU mounting positions


304 (AISI) / 1.4301 (DIN)

Sensor
installation
orientation

For prototype and final installation layouts please


ask for detailed supplier customer information

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 82


NOx sensor installed in SCR muffler end pipe 3/3

For prototype and final installation layouts please ask for detailed supplier customer information
Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 83
Humidity & temperature sensor 1/2
For prototype and final installation layouts please ask for detailed supplier customer information
2- %RH
3- Gnd

1- VCC
4- °T

FPT no.
504 101 690

Flow
direction

Humidity & temperature sensor to be


installed on suitable place with high air
velocity (no dead zones) after air filter, but
before blow-by / air compressor
connections.

Any installation has to be released by


Humirel. Contact address:
Romuald GALLORINI
Product Development Manager
phone: +33(0) 561 194 079
Romuald.Gallorini@meas-spec.com

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 84


Humidity & temperature sensor 2/2

Recommended installation examples on not horizontal air pipes:

 On the installation (image on the right) location (2) is recommended for


the sensor. The tip has to point down with a minimum angle of 40°and a
maximum of 89°according to the detailed the installation guideline. If
location (1) is necessary, the tip has to point down too (minimum 1°)

• With a bend a ‘dead flow zone’ should be avoid (B) on the drawing
below). In this case position (A) is preferred

• It is recommended orienting the sensor facing the air stream to help fluid
/ moisture / soot / particles being drained out

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 85


SCR system main components list

pos. part FPT no. Supplier no No. of


1 DNOx2 supply module (SM) without CCV 504 374 326 0 444 022 021 1
2 DNOx2 dosing module (DM) for CCV less SM, 6 kg/h 504 374 327 0444 023 058 1
9 kg/h 504 381 866 0444 023 062
3 AdBlue/DEF tank 45 litres including WEMA tank unit 4129 8229 1
AdBlue/DEF tank 65 litres including WEMA tank unit 4129 8226
AdBlue/DEF tank 120 litres including WEMA tank unit 4129 8669
4 90°exhaust temperature sensor, SCR inlet (black connector) 504 102 603 500 349 00 1
(504 109 525 family
drawing)
5 90°exhaust temperature sensor, SCR outlet (brown connector) 504 109 529 500 350 00 1
(504 109 525 family
drawing)
6 Humidity sensor 504 101 690 (plastic) HTM2500 B6C6 1
504 253 912 (metallic) HTM2500 B3C4
8 NOx sensor (24 V) 4127 1167 5WK9 6615C 1
9 Coolant shut-off valve 4124 1093 4460913010 (WABCO) 1
10 Electrical connector for Denoxtronic 2 supply module 804 5173 1
11 Electrical connector for Denoxtronic 2 dosing module 804 5171 1
12 Electrical connector for Exhaust temperature sensor, SCR inlet 804 5169 1
13 Electrical connector for Exhaust temperature sensor, SCR outlet 804 5170 1
14 Electrical connector for Humidity & temperature sensor 804 5175 1
15 Electrical connector for NOx sensor 804 5174 1
16 Electrical connector for coolant shut-off valve (WABCO) 804 5172 1
17 Electrical connector for WEMA tank unit 803 1989 1
18 External pre-filter 100 micron in urea suction line - 5466160100 (Voss) 1

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 86


Revision History

Version File name Author Date Changes, Remarks


DNOx2 installation instructions update (pages 15-), new cylindrical muffler for Tector
V4.4 SCRsystemInstallationGuideLineDnox2_V4-4.ppt F. Papst 20-11-2007
4&6 (page 40).

DM installation, page 26, Dosing / mixing unit and SCR muffler installations (Cursor /
Tector, pages 27-43), Instructions for modified exhaust pipe layouts (pages 44-46),
V4.5 SCRsystemInstallationGuideLineDnox2_V4-5.ppt F. Papst 16-12-2008
AdBlue/DEF pipes, hoses, connectors and filter (pages 56-68), Electrical layout (pages
70-72), Exhaust temperature, NOx and humidity sensors (pages 73-78).

Exhaust pipe samples for cylindrical Tector SDR muffler horizontal & vertical installation
V4.6 SCRsystemInstallationGuideLineDnox2_V4-6.ppt F. Papst 05-01-2009 (page 42), 27 litres AdBlue/DEF tank (page 52), urea pipes / 2nd pre-filter installation
(page 60), parts list (page 79).

Bosch drawings no. (pages 13, 14); added Bosch for production release (page 18);
F. Papst additional FPT spray axis recommendation (pages 25,26); additional limitation
V4.7 SCRsystemInstallationGuideLineDnox2_V4-7.ppt 02-02-2009
M. Pidria corrections (page 46); improved scheme (page 69); drawing references (page 70-71);
SCR components list (page 79).

F. Papst DM installation instructions (page 25-29); Instructions for modified exhaust pipe layouts
V5.0 SCRsystemInstallationGuideLineDnox2_V5.0.ppt 27-03-2009 Pages (47-50); AdBlue/DEF pipes, hoses and connectors (Page 61); AdBlue/DEF tank
M. Pidria 27 litres no. (page 57); Material requirements (page 59).

F. Papst SCR system description (p.3); pre-filter in scheme & parts list (p.12;84); additional DM
V5.1 SCRsystemInstallationGuideLineDnox2_V5.1.ppt 26-08-2009 9kg/h (p.14); exhaust pipe/mixer installations (p.47-51); AdBlue/DEF tank (p.52);
M. Pidria temperature sensor (p.78); NOx sensor (p.79-81); humidity sensor (p.82);

F. Papst Denoxtronic SM & DM with CCV less layout (p. 12-14); AdBlue/DEF filter (p.69); parts
V6.0 SCRsystemInstallationGuideLineDnox2_V6.0.ppt 04-10-2009
M. Pidria list (p. 84)

F. Papst DNOx filters (p.14); Removal of filter heater in SM (p. 19); AdBlue/DEF tank
V6.1 SCRsystemInstallationGuideLineDnox2_V6.1.ppt 19-11-2009 recommendations (p. 54); NOx sensor optimal gas velocity (p. 81)
M. Pidria

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 87


Contacts

For further general information and installation support please contact:

Mr. Fritz Papst Ing. Marco Federico Pidria


Aftertreatment Systems Product Engineering – EA&MS
FPT POWERTRAIN TECHNOLOGIES Aftertreatment Systems
Iveco Motorenforschung AG FIAT POWERTRAIN TECHNOLOGIES S.p.A.
Schlossgasse, Postfach 80 Corso Settembrini 40, 10135 Torino, Italia
CH-9320 Arbon, Switzerland Tel. +39 011 0036686, Fax +39 011 0035135
Telephone: +41 (0)71 44 77 230 Cell +39 335 7513831
Telefax: +41 (0)71 44 63 165 marcofederico.pidria@fptpowertrain.com
fritz.papst@fptpowertrain.com

For more detailed dosing system information please contact:

Mr. Sebastian Schwarz


Aftertreatment Systems
FPT POWERTRAIN TECHNOLOGIES
Iveco Motorenforschung AG
Schlossgasse, Postfach 80
CH-9320 Arbon, Switzerland
Telephone: +41 (0)71 44 77 252
Telefax: +41 (0)71 44 63 165
sebastian.schwarz@fptpowertrain.com

Arbon, November 2009 CONFIDENTIAL SCRsystemInstallationGuideLineDNOx2_V6.1.ppt 88