1. Down Pipe Temperature Drop
CES Application Engineering - AE Training
Vishaul Ravi

2. Information Security
Protect Information - Competitors desire to know what we are doing Discuss only with other team members who have a “Valid Right and Need to Know” Information shared should be clearly stated as Cummins Confidential and the vehicle OEM should use same “Need to Know” criteria for distribution within their company
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3. Scope This presentation provides
The installation and test procedure for ensuring the downpipe temperature loss for the following MR and HD applications
MR Applications
QSB 6.7 (>174 hp)
QSL 9 (all ratings)
HD Applications
QSG 12
QSX 15 (all ratings)
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4. Objectives After completing this course you will be able to:
Understand the reasons for performing Aftertreatment temperature drop testing and why it is important
Recognize the Aftertreatment locations for temperature drop measurement
Realize the available test methods and tools, and acceptable requirement limits for completion of the testing
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5. What is ‘Downpipe temperature Drop’?
Down Pipe Temp Drop: The temperature loss within the OEM Down Pipe, which is the tubing from Turbo outlet to the aftertreatment Inlet
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6. Why Interested in Temperature Drop?
Hot exhaust gas is required to reach the Aftertreatment system for particulate and NOx emissions to be efficiently reduced
For DOC and DPF systems, higher temps are required to:
Meet Regeneration and SCR conditioning temperatures
Increase catalyst performance
Minimizes active regeneration requirements.
For SCR systems
Minimized DEF Deposits
Increases SCR Efficiency
Meeting temp drop ensures performance at low ambient temperatures
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7. What is Exhaust System Cleaning (Regeneration)?
Thermal regeneration of filters involves the oxidation of solid particulates to gaseous products, preferably to CO2. Depending on the after treatment design and the engine operating conditions (exhaust gas temperatures), the oxidation of the carbon in diesel soot can be made possible in a few different ways as described in the next few slides
Are references to an external website allowed?
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8. Types of Exhaust System Cleaning (Regeneration)
Passive regeneration
No change in engine operation.
Occurs when temps are high enough to naturally regenerate
Active regeneration (In Mission)
Active regeneration happens during the normal operation of the machine.
Based on the inputs to the DPF, the Aftertreatment control system will initiate regeneration.
No observable engine changes but addition fuel is added to raise exhaust temperatures.
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9. Types of Exhaust System Cleaning (Regeneration) Contd...
Active Regeneration (Out of mission)
Non-Mission regeneration is initiated by the operator when system is unable to go into In-Mission Regeneration.
Operator flips switch to initiate regeneration.
Engine must be in Idle state
Engine will stop regeneration and act normally if operator begins using equipment.
DPF Lamp
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10. SCR Exhaust System Cleaning
What is it?
A proactive (exhaust heat management) approach to ensure that the DEF/urea introduction into the SCR system is proactively managed to provide the optimum product performance, efficiency, and reliability.
Uses the same heat management process via in-cylinder diesel dosing with VGT assist to periodically elevate the exhaust temperature.

11. Temperature Drop Considerations
Temperature Drop is affected by:
Tubing length
Tubing diameter
Tubing elbows
Tubing insulation
Equipment configuration
Proximity to cooling devices such as fan air flow
Temperature Drop can be reduced by:
Use of insulated or double-wall tubing
Insulation thickness and quality
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12. Temperature Measurement Locations
A = Turbo Out Temp (Thermocouple)
(Non-ECM parameter)
B = OEM installed thermocouple
installed in the downpipe before the DOC (Non- ECM parameter)
Down Pipe
DOC
Down Pipe Temp Drop = A - B
OEM ancillary tube
Decomposition Reactor Tube
OEM ancillary tube
SCR
Tailpipe
Measurement Locations:
A – Turbo Outlet Temp
B – DOC Inlet Temp
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13. Temperature Measurement Locations
A – Turbo Outlet Temp
B – DOC/DPF Inlet Temp
Can you identify these locations on the two configurations shown? A B
DOC Only System
DOC + DPF System A B A B
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14. Test Procedure (Mid-Range example)
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15. Test Conditions
Test must be carried out between 10 to 40oC (50 to 104 oF) ambient conditions
The test must be run for a minimum of 40 mins for both MR and HD systems
Test may be conducted in a chassis dynamometer or outside.
Cooling fan should be locked On.
Air-condition should be switched off.
Test during a non-mission regeneration:
HC dosing OFF ( correction per AEB Attach. B and AEB27.10 Attach. E) for Heavy Duty.
Non-mission SCR conditioning with HC dosing OFF for Mid-Range.
The regen must be run for a minimum of 40 mins (MR and HD)
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16. Test Preparation
Instrumentation: Two external thermocouples for Turbo Out and Ambient Air Temperatures capable of logging at a sample rate of 1 Hz
Calterm logging parameters at sample rate of 1 Hz:
Turbine Outlet Temperature – Non-ECM Parameter (A)
DOC/DPF inlet temperature – Non-ECM Parameter (B)
Exhaust flow rate
Engine RPM
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17. Take Note
Use Caution: During Regeneration (Exhaust System Cleaning) and SCR Exhaust System Cleaning, the exhaust gas temperatures could reach 975C (1787F), and surface temperatures could exceed 700C (1292F)
To prepare for a non-mission regeneration:
Select appropriate vehicle location (surface and surrounding acceptable for high temperatures)
Park equipment securely
Set up a safe exhaust area
Ensure exhaust surfaces are clear
Expect engine speed changes (engine speed may reach rpm, depending upon equipment)
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18. Starting a Non-Mission SCR Conditioning with HC Dosing Off
Example Only: QSB 6.7. Refer to AEB for up to date list of Calterm Parameters
1. Verify no active fault codes exist in Calterm
6. Verify EXM_NonMission_Regen_Active = 1
2. Verify Permit_Switch = 1
a. If EXM_NonMission_Regen_Active ≠ 1, THEN Verify EXM_NonMissionRegen_En =1,
if Permit_Switch≠ 1,
Set O_AIM_PermitSwEnbl = 1
b.if EXM_NonMissionRegen_En ≠1,
O_AIM_PermitSwVal =1
3. Verify C_SFR_DeSOxTimedRegen_Enbl = 1
THEN SET
H_EXM_AcceleratorPedalEnCond =1
4. Turn off HC Dosing
H_EXM_VehicleSpeedEnCond =1
Override O_OCR_fg_HC_Inj_Enbl = 1
H_EXM_EPD_EndCond = 1
Override O_OCR_fg_HC_Inj_Val = 0
H_EXM_ClutchEnCond = 1
H_EXM_ServiceBrakeEnCond = 1
5. Initiate Non-mission SCR conditioning
H_EXM_OOGearEnCond =1
Set C_SFR_tmh_SinceDeSOxRegenThd = 0
H_EXM_CtrlPTO_EnCond = 1
Set C_SFR_tmh_SinceAnyRegenThd = 0
H_EXM_EngineWarmEnCond = 1
Set C_SFR_tmh_DeSOxRegenThd = 0
H_EXM_AirHandlingSysEnCond = 1
Set C_SFR_tmh_DeSOxNMTrig_Max = 0
H_EXM_DL_RTD_IngibitRegen = 0
Override O_AIM_NMRegen_SW_Enbl = 1
V_ATP_Permit_Switch = 1
Override O_AIM_NMRegen_Sw_Val = 1
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19. Data Logs and Test Conclusion
Verify that SCR Conditioning has initiated
Combustion_Control_Path_Owner = 66
Wait for all the temperatures to stabilize. Experience shows a minimum of 40 mins run time is required.
Log data for a minimum of 5 minutes after the temperatures have stabilized. Save this data file for analysis.
Test can be concluded after the data has been saved by:
Changing all Calterm parameters in back to their original values by going to Edit<Revert All in Calterm Window.
Wait for PTM_Final_Oper_Mode = 1 and Combustion_Control_Path_Owner = to ensure that SCR conditioning is complete
Once SCR conditioning is complete, idle for 5 minutes to allow system to cool before key-off

20. Data Analysis
Compute Average Engine Speed, Exhaust Flow Rate, and Values for Temperatures A, B.
Compute Downpipe Temperature Drop and compare to IQA Pass Criteria (shown in the next slide).
Calculator Input Information for Data Analysis
Average Engine Speed = _____________[rpm]
Average Exhaust Flow Rate [g/s] = ___________[g/s]
Average Ambient Air Temperature [Deg C], AAT= _____________[Deg C]
Average Turbo Out Temperature [Deg C], A= _____________[Deg C]
Average Non ECM DOC In Temperature [Deg C], B = ___________ [Deg C]
Input the above values in the Down-pipe temperature worksheet and calculator provided as an attachement to determine if the configuration has passed the downpipe temperature drop requirement
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21. IQA Pass Criteria Engine/Rating Tier 4 Final
Max Down Pipe Temp Drop for Std Conditions (AB)
Test Ambient Temperature
QSB6.7 >174Hp
≤ 20 oC
10 to 40 oC
QSL9 – All Ratings
QSG12 – All Ratings
≤ 28.2 oC
QSX15 – All Ratings

22. Test Method and Tools To Use
AEB Attachment E (Heavy Duty), F (Mid-Range) – provides Test Method to measure Down Pipe Temp Drop
AEB Attachment B (Heavy Duty)– provides Down Pipe Temp Drop worksheet and calculator
Example
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23. Example: Temperature drop testB
Ambient Air Temp
Mass flow
Down Pipe Temp Drop
Delta A-B
285.2
262.4
22.8
92.0
23.0
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24. Example: Equipment Temperature drop test
Determine the result of the test from the Downpipe temperature drop worksheet and calculator mentioned on slide 24 A B A B
Ambient Air Temp
Mass flow
Down Pipe Temp Drop
Delta A-B
285.2
262.4
22.8
92.0
23.0
Temp drop is higher than permissible
The Downpipe temperature loss from the Turbine outlet (A) to the DOC inlet (B) must be 20deg Celsius or less
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25. Summary – Aftertreatment Temp Drop
When performing Aftertreatment Temperature Drop Testing:
Review system layout and identify any issues
Locate thermocouples correctly on the assembly
Use Calterm to monitor key measurements
Check that corrected temperature drop values meet requirements
You are now familiar with Application Engineering’s role in Aftertreatment Down Pipe Temperature Drop
9/22/2018
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26. Change Control Date Author Description Pages Nov 27, 2012
Vivek Jaryal, Orvin Kendall
Original document published
All
Feb 6, 2013
Vinay Ha
Add example exercise
21, 22
5/7/2013
Nathan Solomon, Rebeka Sultana
Updated Training Material for T4F
5/10/2013
Nathan Solomon
Added Test Results and Changed Presentation based on Review
2/5/2014
Vishaul Ravi
Updated the presentation with the new temp drop requirements. No combined system temperature drop moving forward
Multiple
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