CLEARSKY OPERATION & USERS MANUAL FOR CLEARSKY COMFORTPRO DIESEL PARTICULATE FILTER (CARB-VERIFIED DPF) MODEL PG1050 MODEL PG1060 62-11477 REV.
CONTENTS A. SAFETY ......................................................................................... 1 Safety Considerations ...................................................................... 1 B. INSTALLATION .............................................................................. 1 1.0 SYSTEM OVERVIEW .................................................................... 2 1.1 What is it, why do you care? ...................................................... 2 1.2 APU Engine Oil......
A. SAFETY Read these instructions carefully before operating the system. Safety alerts labeled DANGER, WARNING and CAUTION alert you to special instructions or precautions concerning procedures that would be hazardous if performed incorrectly or carelessly. The safety alerts alone cannot eliminate all hazards. Strict compliance with these special instructions and common sense are major accident prevention measures. DANGER CAUTION Immediate hazards that will result in severe injury or death.
1.0 SYSTEM OVERVIEW 1.1 DPF: What is it, why do you care? The Diesel Particulare Filter (DPF) is a system that removes most of the black soot particles from the exhaust of your diesel engine. This results in cleaner air for everyone and much less black soot on your truck. The DPF also replaces the APU muffler and performs the noise reduction function. 1.2 APU Engine Oil The APU engine oil must be CJ-4 compliant low ash oil ONLY. 1.
3 6 4 5 7 8 10 9 13 3 5 1 12 2 11 Figure 1.
1.6 Theory of Operation The DPF is a system. It consists of a filter element, electrical heater, insulated exhaust piping, a controller and sensors for measuring exhaust temperature and back pressure. Briefly the system operates as follows: • APU runs normally, produces soot which is captured by filter. • As soot builds up the filter gradually becomes clogged and causes increasing exhaust back pressure.
1.6.4 System Information and Variables The system regulates the occurrence and duration of the regeneration event solely by exhaust back pressure. Additionally, exhaust temperature is used to control heater power and verify that the heater is working. These values may be monitored in the DPF Manager/Variables menu item on the Driver's Control Panel for the APU. The DCP2 will also display messages about the operation of the DPF system and any faults that occur. 1.6.
Whenever a regeneration has been completed the APU must complete a 2 minute cool down cycle before being turned off. If the ON/OFF button is pressed during this time the APU will shut down after the cool down period has been completed. If the ON/OFF button is pressed for 5 seconds the APU will shut down immediately. 1.6.8 Main Engine Interlock If your APU is equipped with the optional main engine interlock feature it will normally not operate when the truck engine is running.
1.7 DCP2 Menu Structure TIMER 1 • ON • OFF • SET START – [hours] – [minutes] – DAY - SUNDAY - MONDAY - TUESDAY - WEDNESDAY - THURSDAY - FRIDAY - SATURDAY - WEEKDAYS - WEEKENDS - ALL DAYS • SET DURATION – [xx.x hours] • SET TEMP – [xx°C/xx°F] TIMER 2 • ON • OFF • SET START – [hours] – [minutes] – DAY - SUNDAY - MONDAY - TUESDAY - WEDNESDAY - THURSDAY - FRIDAY - SATURDAY - WEEKDAYS - WEEKENDS - ALL DAYS • SET DURATION – [xx.x hours] • SET TEMP – [xx°C/xx°F] BATTERY MONITOR • ON • OFF • SET – [xx.
CALIBRATE VOLTAGE "Voltage" SYSTEM CONFIG • CHECK "Present Devices" (APU, CCU, DPF) • CONFIGURE – DPF – UNINSTALL DPF MANAGER • Start Regen (if APU running) or Start Emergency Regen (if APU not running) – YES – NO • STATUS "Operating OK" or "Regenerating Now" or "Regenerating Soon" • VARIABLES – EXHST P xx MBAR – EXHST T xx C VIEW FAULTS • Displays system faults with a time stamp according to the following format: "Date" "Time" "Device" "Description of fault" • "CLEARED" will be displayed if the fault wa
1.8 System Messages 1.8.1 DPF Detected Indicates that the DCP2 has received communication from a DPF controller recently connected to the CAN bus. The DCP2 will consider the DPF installed at this point and the message may be cleared by pressing the ESC/RESET key on the DCP2. 1.8.2 DPF Regen Start xxx s "IN x s" where x = 120 counting down to 0 This message will only be displayed during the warmup for an emergency regen and it represents the countdown timer for the warmup cycle. 1.8.
1.8.8 NOTICE It is not necessary to wait for the regen to complete before driving the truck. Also, for safety reasons, it is always possible to force the APU off by holding the ON/OFF button for 5 seconds. 1.8.9 APU Will Shutdown "REGENERATING" OR "COOLING DOWN" OR "MUST REGEN" "HOLD ON/OFF FOR 5 SEC TO SHUT DOWN" You attempted to shut down the APU either during a regen or when the exhaust pressure was over 100mB. In the second case the unit will start a regen immediately.
The following messages appear in small print at the bottom of the "home" screen (where time and date are shown): 1.8.15 DPF Regen Soon Indicates that the exhaust back pressure has reached 100mB. If the APU continues to run the back pressure will rise further; at 130mB a regeneration cycle will commence. If you shut down the APU (before reaching 130mB) the system will perform a regeneration cycle before shutting down. 1.8.
2.0 MAINTENANCE The DPF system requires very little maintenance: cleaning or replacing the filter element every 1000 hours of APU operation (or when notified by the system) is all that is needed. All other maintenance items are related to the APU: 2.0.1 Fuel Use low (or ultra low) sulfur diesel. ULSD is the default diesel formulation available for commercial sale in the United States and Canada. It is also permissible to use biodiesel up to B20 as long as it is low or ultra-low sulfur.
3.0 TROUBLESHOOTING Symptom Pressure Sensor Failure Action • Check that pressure sensor wiring harness is in good condition. • Check that connectors are mated properly. • With the APU running, check the exhaust pressure in the DPF Variables menu; the normal range is 15-130mBar. With the APU not running, or with the sensor removed from the pressure tube, the pressure should be less than 5mBar. It may take several seconds for the pressure to settle after starting or stopping the APU.
DPF Heater Failure • Check that temperature sensor and heater wiring harnesses are in good condition. • Check that connectors are mated properly. • Verify that the heater is good: With the heater COLD, disconnect the connector for the heater and check the resistance between pins on the heater side of the connector.
4.0 DPF WARRANTY STATEMENT Important Notice 4.0.1 The warranties described in this document cover failure of the Teleflex Ecotrans Technologies products listed herein that are the result of defects in Teleflex Ecotrans Technologies materials, workmanship and design, under normal use and service.
4.0.2 Installation Warranty Your Warranty Rights and Obligations Teleflex Ecotrans Technologies must warrant that the installation of a diesel emission control system is free from defects in workmanship or materials which cause the diesel emission control system to fail to conform to the emission control performance level it was verified to, or to the requirements in the California Code of Regulations, Title 13, Sections 2700 to 2706.
CLEARSKY COMFORTPRO DPF ( PG1050 & PG1060) OPERATION & USERS MANUAL 17
18 CLEARSKY COMFORTPRO DPF (PG1050 & PG1060) OPERATION & USERS MANUAL
POWER SYSTEMS Teleflex Ecotrans Technologies L.P. 3831 No.6 Road Richmond, B.C. Canada V6V 1P6 Tel: 604-270-6899 Fax: 604-270-0137 www.teleflexpower.com ISO 9001:2000 Teleflex and Proheat are registered trademarks of Teleflex Inc. and its subsidiary companies.
