DPF Thermal Regenerator - Donaldson Company

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OWNER'S MANUALInstallation, Operation, and Maintenance InformationDPF Thermal RegeneratorCleaning System Part No. X007955This manual is property of the owner. Leave with the unit when installation and start-up are complete.Donaldson Company reserves the right to change design and specifications without prior notice.Do not make any system modifications or adjustments that would alter the original retrofit installation.Modifications may not meet California ARB Executive Order requirements, be considered illegal devices andmay result in denial of warranty coverage.Consult your Donaldson certified emissions dealer if you have questions regarding the installation, operation,maintenance or warranty.Illustrations are for reference only as actual product may vary.This is the safety alert symbol. It is used to alert you topotential personal injury hazards. Obey all safety messagesthat follow this symbol to avoid possible injury or death.

Donaldson Retrofit Emissions System2 Exhaust Gas Temperature Data Logger Owner's Manual - P480348 Rev 2

Donaldson Retrofit Emissions SystemContentsIntroduction. 3Pre-Installation. 3Cabinet Schematic. 4Installation. 5Explanation of Operation. 5Filter Tracking. 5How to Regenerate A Dirty Diesel Particulate Filter. 6Total Filter Cleaning Time.6Remove The Filter from Vehicle and Pulse Clean.6Cleaning Cycle.7Reset the Backpressure Monitor (if applicable).7Record Filter Service.7Service & Maintenance Procedures. 8Emptying The Ash Collection Drum.8Spare Parts List.8Electrical Schematics. 9Power Circuit .9Control Circuit .9Troubleshooting Guide .12Warranty. 15Donaldson DPF Thermal Regenerator Manual - P4808023

Donaldson Retrofit Emissions SystemIntroductionThank you for purchasing the Donaldson DPF ThermalRegenerator!Donaldson markets two separate cleaning cabinets for routinecleaning and regeneration of diesel particulate filters (DPFs).The first stage is the DPF Pulse Cleaner.The DPF Thermal Regenerator cabinet is the second stage ofour DPF Cleaning System – designed to remove hydrocarbonsand unburned particulate matter within the filter channels.This unit is designed for Donaldson DPFs, but accommodatesmultiple sizes of DPFs (up to 14" in diameter and up to 20" inheight, 14" w/Thermal wrap).68.5"The DPF Thermal Regenerator provides vehicle maintenancefacilities an enclosed, automated cabinet that burns dieselparticulate matter (PM) on a highly loaded (or plugged) dieselparticulate filter.The thermal regeneration process for a diesel particulate filteris required for one of two situations; (1) routine service asrequired in the owners manual or (2) as indicated by your onboard service monitor. The length of time required to clean onediesel particulate filter with the DPF Thermal Regenerator isseven (7) hours.28"Cabinet Dimensional Foot print: 28"W x 43"D x 68.5" HClearance Requirement: 12" open space on all sides (52"W x 67"Dx 80.5" H) Works with DPF Sized: up to 15" in diameter and up to20" in height.After a diesel particulate filter has completed the thermalregeneration process in the cabinet, the DPF must be pulsecleaned a final time (using a DPF Pulse Cleaner) to remove ashremaining on the filter.Pre-InstallationDPF Thermal Regenerator Location Unit weight: 500 lbs. Rests on foot levelers Install indoors only and on a hard flat surface Allow a minimum 12" clearance on all sides C onsider placing near a DPF Pulse Cleaner and on levelground Do not place on second floor of building4 Donaldson DPF Thermal Regenerator Manual - P48080243"The following must be available PRIOR to installing theDPF Thermal Regenerator P ower Supply: single phase 30 amp 208 or 240VAC and 15amp 120VAC power Clean, dry compressed air source:90 PSI @ 4 SCFM E xterior vent connection (to roof or outside wall) - usestandard 6" metal ventilation duct (refer to state & localcode) S pace Requirement: Foot print (see above):28"W x 43"D x 68.5"H (add 12" clearance to all sides) C ontact your local disposal company for proper ashdisposal regulations and procedures

Donaldson Retrofit Emissions SystemCabinet SchematicDiesel Particulate Filter*PhotoelectricSensor**Exhaust Vent*Ventilation Fans*Control Panel*Door Lock Solenoid**Rear ElectricalEnclosure*240 VAC ConnectField Install*120 VAC Plug*Cabinet OverTemperature Switch**Compressed AirPressure Switch**Interlock Door Switch**Thermal Wrap*Adapter Table*Compressed AirSupply Connection*Heater Assembly*Leg Levelers*Drum Clamp*Ash Collection Drum*Heater TemperatureControl Thermocouple*Compressed AirSolenoid** Features** SafetyCabinet Control Panel FeaturesStart ButtonInitiates the cleaning cycle. Note: This button does not illuminate.E-StopEmergencyStop buttonTamper-proof Temperature DisplayThe information on this display works with builtin safety sensors. Do not tamper or remove thedisplay's protective shield. Damage to the displaymay void your warranty or disable the cleaningsystem.Heating/Cool Down Cycle & Complete IndicatorsThe entire process will take 7 hours. The lights will illuminatecontinuously during their respective cycle or until the cleaned filter isremoved from the unit.Exhaust Gas Temperature Data Logger Owner's Manual - P4803485

Donaldson Retrofit Emissions SystemInstallationfollowed by a cool down cycle to slowly lower the temperatureof the filter and reduce the potential of filter damage fromthermal shock.1. Install the cabinet on a solid, level surface. Make sure toleave a minimum 12" clearance on all sides. Using the leglevelers, adjust until cabinet is level.After the cool down cycle is completed, the diesel particulatefilter can be removed from the Thermal Regenerator cabinet andreinstalled in the Pulse Cleaner for a final cleaning of the ashresidue.2. Connect the cabinet vent ducting. The vent ductingmust be metal, 6” diameter and as short as possible.All horizontal runs should pitch upward at least 1/4”per linear foot. Check local and state codes for properventilation.The DPF Thermal Regenerator has six safety devices. They aredenoted by a double asterisks (**) on page 4 and include:1. An open door alert switch that prevents the cleaningprocess from starting if the door is not properly closed.3. Connect the cabinet air valve assembly to a clean, drycompressed air supply (90 PSI @ 4 SCFM) with a 1/4”I.D. minimum line size. Install a compressed air shut offvalve and bleed type air filter upstream of the connection.Follow all local codes.2. An electric door lock that prevents the door from openingduring the cleaning process.3. A filter placement sensor checks if the dirty filter and heatblanket is properly positioned and placed on the heaterassembly. The cleaning operation will not start if the filterheat blanket is not installed correctly.4. H ard-wire a single phase 208 or 240 VAC/30A branchcircuit and service disconnect to the cabinet rear enclosureas indicated in the Control Circuit electrical schematic inthis manual. Follow all local electrical codes.4. A n air pressure safety switch - detects improper airpressure.5. S oft-wire a single phase 120 VAC/15A electrical cord witha grounded female connector to the cabinet rear enclosure120 VAC plug. Follow local electrical codes. Refer to thePower Circuit electrical schematic in this manual.5.Explanation of Operation A high-heat cabinet sensor shutdown. If the filter does nothave the proper thermal wrap protection excessive heat inthe cabinet is generated and this sensor shuts down thecleaning cycle.PR button.6. LabelAnemergency stop (E-Stop)size 3”x5” .0125” Corner RadiiRev 0ELIA diesel particulate filter must be pulseP000000cleaned before3 color - Orange (PMS152), Red (PMS 185) and BlackMIDPF Thermal Regenerator Exterior Cabinet Labelcleaning in the thermal regenerator. Afterpulse cleaning the.0125 Corner RadiiNAJoan Furst x3200RYfilter, wrap the filter with the supplied thermal wrap , placethe filter (dirty side [inlet] down) inside thecabinetcentered1st draft- Oct 14 2010(minus coolant)Tracking3rd draft -02 Dec 20102nd draft -17 FilterNov 2010on the heater assembly. Verify theCaution!Donaldson recommendsWarning!that a tagging system be used to trackCaution!"shiny" part of the thermal wrap isthefilterduringtheentirecleaning system.facing towards the back/rear of theDO NOT Insert Filtermachine and lock the cabinet doorsSoaked with Oil or FuelRe-install the Filter in the Same Vehiclebefore starting the DPF ThermalDO NOTNOTEfrom Which It Came.InsertRegenerator.DO NOTFilterDO NOT operate until you read and understandthe instructions and warnings in the InstallationOperation and Maintenance Manual.DO NOT operate until you read and understandthe instructions and warnings in the InstallationOperation and Maintenance Manual.OilOilThe cleaning cycle duration isseven (7) hours. During the cleaningprocess the filter goes through apre-heating stage, a controlledcombustion air pulse heating cycle,ORFuelFilters that are soaked from a turbochargeroil seal failure or have any evidence of liquidmust not be thermally regenerated. This mayresult in fire leading to personal injury orproperty damage.OilFuelORDiesel particulateInsertfilters come in different sizes (e.g. 10.5" vs 11.25"Filtervs. 12" dia.) and thefiltering capabilities may also be different; (e.g.Soakedwith Oil100a turbochargercpsi vs.Filters that are soaked fromoil 200). In most cases a retrofit system has been carefullyorFuelseal failure or have any evidence of liquid mustto the vehicle's engine and duty cycle. If the same DPFnot be thermallymatchedregenerated.NOT operatevehicle,until you read andis thisnotunitputemissions system and engineInserting a filter intomay in to theDOsameunderstand the instructions and warningsresult in fire leading to personal injuryin thecomprisedInstallation Operation andandperformance may bevoid the diesel particulateMaintenance Manual.or property damage.filter muffler warranty.Soakedwith Oilor FuelInserting a filter into this unit mayresult in fire leading to personal injuryor property damage.Label No. P000000CAUTION!Do Not Regenerate Fuel/Oil Soaked Cores.Regenerating fuel/oil soaked cores will damage the DPF section.Contact Donaldson Technical Services for further information.6 Donaldson DPF Thermal Regenerator Manual - P480802FuelLabel No. P000000Label No. P000000

Donaldson Retrofit Emissions SystemWrap the Thermal Shield Around the Filter andCenter the Filter on the Heating UnitHow to Regenerate A "Dirty" DieselParticulate FilterA diesel particulate filter removes particulate matter andinorganic ash from diesel exhaust. Under normal operatingconditions the filter collects and burns particulate matter.However, inorganic ash from the oil does not burn so it slowlyaccumulates in the filter. This makes it necessary to remove theash from the filter on a periodic basis.NOTEInstallation Note on theThermal ShieldThe thermal shield retains the heat within the filter duringthermal regeneration process. If the filter does not havethe thermal shield, a high-heat sensor will shut downthe cleaning cycle.3. Position filter on the heating assembly (inlet, dirty side down).Center the filter over the tapered hole in the table.Diesel particulate filters capture all particulate matter andother volatile compounds generated from a diesel engine.Proper protection gear is recommended for the individualhandling the filter during the service procedure.CAUTION!PPE for regular handling of filter duringcleanering process.The ash collection drum may contain particulate matter and inorganicash generated from a diesel engine. Wear proper eye, face (breathing)and hand protection gear when servicing the ash collection drum toprevent exposure or inhalation.Total Filter Regeneration TimeThe entire regeneration cycle is seven (7) hours. During thisprocess, the filter goes through a controlled combustion airpulse heating cycle followed by a cool-down cycle that slowlylowers the temperature of the filter to reduce filter damage.Remove the Filter from Vehicle and Pulse Clean1. Remove the diesel particulate filter from the vehicle inaccordance with the instructions provided in the owners manual.If there is oil, coolant or fuel found in the exhaust stream whileremoving the DPF section, DO NOT CLEAN. Please contactDonaldson Engineering for further instruction.CAUTION!Do Not Regenerate Fuel/Oil Soaked Cores.Regenerating fuel/oil soaked cores will damage the DPF section.Contact Donaldson Technical Services for further information.2. Pulse clean the filter prior to cleaning the filter in the DPFThermal Regenerator. Soot can be packed so tightly in overloaded filters that it willblock the combustion air from entering the channels. Pulsecleaning the filter will remove some soot/particulate mattermaximizing the effectiveness of the thermal regenerator filtercleaning cycle.4. Using the adjustable thermal wrap supplied, wrap the thermalshield around the filter and secure using the spring-loaded hooks.The thermal wrap is required to keep the temperature down toa safe level inside the cabinet and minimize thermal gradientsacross the filter. It can be used for filters diameters 9.5" to 14".The outer reflective surface of the thermal wrap should be clean.Over time, the surface may lose the clean, reflective finish orbecome dirty. Loss of the reflective surface will prevent operationbecause the safety photo sensor will not recognize that thethermal wrap is in place. Replacement wraps are available fromDonaldson.5. With filter secured and thermal wrap attached, close and latch thecabinet door and push the cycle start button.After pushing the start button, the ventilation fans will engage, the"HEATING" light will illuminate and the heating cycle begins.NOTETemperature DisplayDo not tamper or remove the display's protective shield.Damage to the display may void your warranty or disablethe cleaning system.NOTEHeating Light Does NotIlluminateThere are numerous safety mechanisms that preventthe HEATING CYCLE from starting. If the HEATING lightis not illuminated, refer to the trouble shooting guide inthis document.Donaldson DPF Thermal Regenerator Manual - P4808027

Donaldson Retrofit Emissions SystemControl PLC Indicator Light Display7. Open the cabinet door.On Start-Up: PLC Light8. U se protective gloves when you remove the filter from the heatingunit.INPUTS OUTPUTS 0PWR 1RUN 2 34 5 678 ERRSTAT0123456After Pressing "Start"INPUTSOUTPUTS 0 1 PWRRUN 2ERR 34 STAT0 5 678 123459. Release the spring-loaded hooks from the thermal wrap, rotate andpull the wrap out of the cabinet.10. Remove the filter from the thermal regenerator.11. Pulse clean the regenerated filter with a DPF pulse cleaner.NOTEPulse Clean theRegenerated FilterThe regeneration cycle may leave ash on the filter. Theash needs to be removed before use. Run the dieselparticulate filter through a DPF pulse cleaner beforeinstalling in the vehicle.6Reset the Backpressure Monitor (if applicable)Control PanelIf the vehicle is equipped with an on-board backpressure (or filterservice) monitor, reset it using the instructions supplied with the EDMor BPM IOM.Start ButtonInitiates the cleaning cycle.Heat Cycle ModeIncludes pre-heatingand heat/pulse cyclesE-StopEmergencyStopbuttonHeating/CoolDown Cycle &Complete LightsIndicate thecleaning cyclestatusCool Down Cycle ModeHeat shuts offCool down air pulse cycleTemperature DisplayThe information onthis display workswith built in safetysensors.Cleaning CycleRecord Filter ServiceThe control panel on the cabinet front (shown above) has three cyclemodes: heating, cooling and complete. When the COMPLETE light isflashing, the regeneration (cleaning) cycle is over and the filter can beremoved from the cabinet.Regulatory agencies require the following service records bemaintained. Consider adding the following information in your vehiclemaintenance logs. DPF section Part number DPF serial number6. After seven (7) hours the COMPLETE cycle mode light will flash.Press the E-stop and release button to reset the system for thenext cleaning.CAUTION! The Filter will beHot When the COMPLETE CycleLight IlluminatesAt the end of the cleaning cycle (when the "complete"light flashes), the filter is still hot enough to burn youif touched ( 180ºF). Wear thick, heat resistance gloveswhen handling the filter to prevent burns.8 Donaldson DPF Thermal Regenerator Manual - P480802 Date of filter cleaning Mileage at filter cleaning Test pressure before and after cleaning EDM log file/screen shot of faults Frequency (#of time cleaned)

Donaldson Retrofit Emissions SystemDonaldson Retrofit Emissions SystemSpare Parts ListFilter Cleaning Record KeepingDonaldson requires record keeping/tracking for all cleaningoccurances. Donaldson Engineering recommends the following databe tracked:DescriptionPart NumberAsh Collection Drum and ClampP228053Heater AssemblyP230184 Serial NumberDoor SwitchP228028 DateDoor Lock SolenoidP228073Cabinet Temperature SwitchP228067Photoelectric SensorP228068 VIN or Vehicle ID # Frequency (if possible)Ventilation Fan *P228065 EDM Download from VehicleThermal WrapP230194 Person completeing cleaningCompressed Air Pressure SwitchP228062Compressed Air Solenoid ValveP228071Fuse KitP225336Donaldson Engineering may request these records in a warrantysituation.* Unit has two fans the part number list is for one.Service & MaintenanceProceduresThe DPF Thermal Regenerator requires minimal service. On a routinebasis, the ash collection drum will need to be emptied.Emptying The Ash Collection Drum1. Before proceeding - determine local laws and regulations for thedisposal of ash.2. Move the container for collected ash material close to the ashcollection drum for ease of transfer.CAUTION!Use Extra Care in Handling TheAsh Collection DrumDuring Service!Take care to support the drum during service. Droppingthe drum during service will cause soot/ash to disperse.See CAUTION above for personal protection gear.3. Release collection drum from unit by releasing the latch clampand carefully lower it to the floor.4. Empty drum contents and dispose of according to local laws andregulations.5. Replace ash collection drum and reconnect the latch clamp. Thedrum is designed for resuse, but if you elect to dispose of thedrum, for ease of maintenance, replacement parts are availablethrough your Donaldson dealer.9 Donaldson DPF Thermal Regenerator Manual - P480802Donaldson DPF Thermal Regenerator Manual - P480802 Rev 1 - PRELIMINARY9

Donaldson Retrofit Emissions SystemDonaldson Retrofit Emissions SystemElectricalSchematicsControl Circuit10 Donaldson DPF Thermal Regenerator Manual - P480802 Rev 1 - PRELIMINARYDonaldson DPF Thermal Regenerator Manual - P48080210

Donaldson Retrofit Emissions SystemDonaldson Retrofit Emissions SystemElectricalSchematicsControl Circuit11 Donaldson DPF Thermal Regenerator Manual - P480802Donaldson DPF Thermal Regenerator Manual - P480802 Rev 1 - PRELIMINARY11

Donaldson Retrofit Emissions SystemControl Circuit- continued12 Donaldson DPF Thermal Regenerator Manual - P480802

Donaldson Retrofit Emissions SystemThermal Regenerator Troubleshooting GuideTrouble1. Unit doesnot start, noilluminatedlights,temperaturecontroller isilluminatedPossible CauseTemporarily short circuit door switch.Check door switch.Doors switch has impropercontactTemporarily short circuit door switch.Check door switch electrical connections.Look in rear of machine for the red LEDon the photoelectric eye located directlybelow the electrical box. If there is noilluminated LED, follow the "remedy".Look in rear of machine for the red LEDon the photoelectric eye located directlybelow the electrical box. If there is noilluminated LED, follow the "remedy".Use thermometer to verify internal lowercabinet temperature.Temporarily short circuit temperatureswitch.Rotate thermal wrap such that the reflective portionis towards the photoelectric eye.The thermal wrap must maintain high luster. Buffshield to a shine near the sensor, if necessary.Ventilation fans not workingN/ACheck fan operation.Short circuited emergency stopbuttonDo not attempt to disconnect.Replace emergency stop button.Thermal wrap not properlyinstalled on substrateCabinet temperature over 140 FTemperature switch failedFuse 201 failedFuse 301 failed3. Temperaturecontroller outputis "ER.il", "Attn"4. Unit does notstart, blinkingYELLOW light5. Unit does notstart, blinkingRED light6. Temperature doesnot increase ondisplay whenstart button isdepressed, solidRED lightRemedy/ActionsDoor not closed properlyPhotoelectric eye failed2. Temperaturecontroller is notilluminatedTestElectrical connection gap to atemperature controller.Check LED lights on the back of the PLC. Ifno lights are illuminated, replace fuse.Check LED lights on the back of the PLC. Ifno lights are illuminated, replace fuse.Replace photoelectric eye.Allow cabinet temperature to adequately cool.Replace temperature switch.Check and replace fuse 201.Check and replace fuse 301, door solenoid.N/ACheck connections and repair.No Power (120v)N/AN/AN/ACheck and replace fuse 109Repair or replace temperature controller.Check power supply.Thermocouple is disconnectedN/ACheck thermocouple connectionThermocouple is miswiredN/ACheck wire orientationAir supply disconnectedSee installation and operation manual forair supply requirements.Connect air supply to specification requirements.Insufficient air pressureSee installation and operation manual forair supply requirements.Check air supply is at least 60PSI and no more than120PSIPressure switch misadjustedUse multimeter to check continuity inpressure switch. Use set screw to adjust.Adjust pressure switch to 60PSICheck issue 9.N/ACheck issue 9.No power. (208-240VAC)N/ACheck breaker and power supply. Verify the heatercircuit is at least 208VAC single phase.Thermocouple defective.induce thermocouple to high or lowtemperature, monitor display.Repair or replace temperature thermocouple.Temperature controller failed.N/ARepair or replace temperature controller.Heater defective or inoperative.N/ARepair or replace temperature heater.Fuse 109 failed.Temperature controller failed.Donaldson DPF Thermal Regenerator Manual - P48080213

Donaldson Retrofit Emissions System7. Unit shuts downduring operation,NO illuminatedlights8. Unit shuts downduring operation,blinking YELLOWlight9. Unit shuts downduring operation,blinking RED light10. Soot combustionfumes exitingtop ventCheck issue 1 above.N/ACheck issue 1 above.Elevate cabinet temperatureabove 1400 F.N/ACheck environment ambient temperature.Fuse 303 failed.N/AN/AN/ACheck exhaust ducting restriction.Check fan operation.Check and replace fuse 303.Check issue 4 above.N/ACheck issue 4 above.Exhaust ducting restriction.Fan operation.N/ACheck circuit breaker.Heater temperature failed toreach 500 F in 3 minutes. 1400 For exceeded.N/ARepair or replace heater or thermocouple.Exhaust ducting restriction.N/ACheck exhaust ducting restrictionFan inoperation.N/AN/ACheck fan operation.Check and replace fuse 303.Note: Cycle power on the machine during each troubleshooting exercise by pushing the EMERGENCY STOP button and then twisting it to reset it. This will reset theControl Panel and give an accurate indication if the troubleshooting test or repair fixed the issue.14 Donaldson DPF Thermal Regenerator Manual - P480802

Donaldson Retrofit Emissions SystemWarrantyDonaldson warrants to the original purchaser that the majorstructural components of the goods will be free from defects inmaterials and workmanship for two (2) years from the date ofshipment, if properly installed, maintained and operated under normalconditions. Donaldson warrants all other Donaldson built componentsand accessories for twelve (12) months from date of shipment.Donaldson does not warrant against damage due to corrosion,abrasion, normal wear and tear, product modification, or productmisapplication.Donaldson also makes no warranty whatsoever as to any goodsmanufactured or supplied by others including electric motors, fans,heater coils, solenoid valves, switches and control components.After Donaldson has been given adequate opportunity to remedyany defects in material or workmanship, Donaldson retains thesole option to accept the return of the goods, with freight paidby the purchaser, and to refund the purchase price for the goodsafter confirming the goods are returned undamaged and in usablecondition. Such a refund will be in the full extent of Donaldson’sliability. Donaldson shall not be liable for any other costs, expenses ordamages whether direct, indirect, special, incidental, consequentialor otherwise. The terms of this warranty may be modified onlyby a special warranty document signed by a Director, GeneralManager or Vice President of Donaldson. THERE EXIST NO OTHERREPRESENTATIONS, WARRANTIES OR GUARANTEES EXCEPTAS STATED IN THIS PARAGRAPH AND ALL OTHER WARRANTIESINCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULARPURPOSE, WHETHER EXPRESS OR IMPLIED ARE HEREBY EXPRESSLYEXCLUDED AND DISCLAIMED.Donaldson DPF Thermal Regenerator Manual - P48080215

Donaldson Retrofit Emissions SystemDonaldson Company, Inc.Minneapolis, MN 55440-1299www.donaldsonexhaust.com 2012 Donaldson Company, Inc.All rights reserved. Printed in USATechnical Support 866-817-8733emissions@donaldson.comIOM P480802December, 2012

Heater Temperature Control Thermocouple* . 240 VAC Connect Field Install* Heater Assembly* Thermal Wrap* Diesel Particulate Filter* * Features ** Safety. 6 Donaldson DPF Thermal Regenerator Manual - P480802 Donaldson Retrofit Emissions System Installation. . valve and bleed type air filter upstream of the connection.

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