Astra cCRF User manual

Astra cCRF System
Operation & Maintenance Manual

Astra cCR System - Operation & Maintenance Manual
02 Installation, Commissioning and Maintenance Instructions
UK VCA approval number: e11*72/245*2006/28*4378*00
e11
03 4378

Installation, Commissioning and Maintenance Instructions 03
Contents
Section 1 Introductory notes
Section 2 System description & overview of parts
Section 3 System Operation
Section 4 Service Intervals
Section 5 OAC3cm Service & performance monitoring system
Section 6 Service records
Section 7 Maintenance
Issue 1
Issue Date: December 2010

04 Installation, Commissioning and Maintenance Instructions
Astra cCR System - Operation & Maintenance Manual
Section 1 -
Introductory notes
1. This manual relates solely to the Astra cCR diesel
particulate filter with OAC3cm monitoring system.
2. Check parts received against the parts list sent with the kit.
3. Please note that the system supplied, is wherever possible
designed to be installed on the vehicle with the use of
coventional hand tools only. However, due to variations in
individual vehicle specifications and accessories, specialist
tools may be required.
4. Installation and commissioning of the OAC3cm monitoring
module should only be conducted by a competent auto
electrician. Separate data sheets are provided relating to
OAC3cm control parameters.
5. If you are in any doubt about the specification of the
system supplied, please seek advice from Astra, or its
approved installation contractor.
6. Commissioning and/or adjustments to the OAC3cm
monitoring module ECU should only be completed by trained
personnel authorised by Astra Vehicle Technologies Ltd.
A proprietary service interface cable will be required,
together with a laptop computer capable of running a
Hyper terminal programme in Windows XP or earlier. Note :
Laptops running Windows Vista operating systems may
require an additional USB to serial port interface cable and
a free download – Hyper terminal program
Section 2 -
Astra cCRF system description & overview
of parts
The Astra cCRF is a catalysed continuously regenerating filter,
designed to virtually eliminate or remove the harmful pollutants
from a diesel engine exhaust.
The Astra cCRF system is a second generation continuously
regenerating diesel particulate filter (or trap) for heavy
commercial vehicles & buses.
Astra cCRF employs a "passive" regeneration method requiring
no additives, thus utilising using advanced gas exchange
techniques. During normal vehicle operation, frequent excursions
to high exhaust temperatures, allow the activity of a precious
metal coated catalyst to oxidise NO to NO2. NO2 subsequently
acts as the catalyst to ensure that soot particles combust as they
are collected in the filter.
Astra cCRF systems are truly "second generation" technology
as they employ a combination of the latest high activity, fast
reacting stainless steel oxidation catalysts, with the proven
durability of high efficiency Silicon Carbide particulate filters.
Astra cCRF filters are also zone coated with a proprietary
combination of base and precious metals to enhance filter
regeneration reliability and NOx performance.
Typical reductions achieved are:-
Carbon Monoxide (CO) > 90%
Hydrocarbons (HC) > 90%
Nitrogen Monoxide (NO) to
Nitrogen Dioxide (NO2) shift < 20%
Total NOx : Neutral or slight benefit
Particulate matter mass (PM) > 90%
Particulate count (PM) > 99%
In addition, the Astra cCR system is designed to replace the
sound attenuating function of the original silencer assembly.
Every Astra cCR system is manufactured from high grade 304
stainless steel, and is modular in construction allowing the filter
element to be removed for cleaning (* see notes).

The primary components of an Astra cCR system are:-
1. ast reacting stainless steel pre catalyst achieving gaseous reductions:-
2. 150 cpsi zone coated wall flow silicon carbide filter:-
3. Electronic back pressure and data recording monitor, provides servicing alerts
Installation, Commissioning and Maintenance Instructions 05
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06 Installation, Commissioning and Maintenance Instructions
Astra cCR System - Operation & Maintenance Manual
Section 3 –
Astra cCRF system operation
The following conditions are essential for satisfactory operation
of your Astra cCR system:
• The engine is properly maintained so as to avoid excessive
engine out smoke levels, and engine oil consumption is
less than 1 litre per 10000Km.
• A low ash (Low SAPS) engine lubricant is used, as
recommended by the engine manufacturer, or Astra
Vehicle Technologies Ltd.
• Diesel fuel conforming to EN590 and containing a
Sulphur content of less than 50ppm, and that no fuel
additives are used other than those already incorporated
in general commercial diesel fuel supplies and/or listed
within this manual.
In normal operation, the Silicon carbide filter section of the Astra
cCR system captures soot (sometimes also described as carbon
particulate or particulate matter), and commonly observed as
smoke. During normal vehicle operation, frequent excursions to
high exhaust temperatures, allow the activity of a precious metal
coated catalyst to oxidise NO to NO2. NO2 subsequently acts as
the catalyst to ensure that soot particles combust as they are
collected in the filter, leaving only ash remaining within the
filter.
Ash, which is mainly the incombustible residue of burnt engine
oil remains in the filter and gradually accumulates, between
service intervals. Accumulated ash should be removed by
specialist cleaning on a periodic basis. This manual discusses
typical service methods and intervals.
In conditions of prolonged low engine loading, for example when
vehicles travel at slow speeds in urban conurbations, exhaust gas
may not achieve frequent enough excursions to high temperature
to allow continuous regeneration of carbon. In these cases
service intervals may reduce.
Astra cCRF filters are recommended for applications working
within the following conditions:-
Temperature requirements for passive operation:-
eak temperature : 390°c or above
Ave cycle temperature : 215°c or above
Time above 350°c : 5% (recommended)
Time above 300°c : 20%
Time above 240°c : 30%
Note: if exhaust temperatures never peak above 280 – 300°c,
such a vehicle application may not be suitable for this type of
filter technology. In these circumstances, an Adastra BC DP ,
fuel borne catalyst regenerated filter technology may be more
suitable.
Typical applications suited to passive systems include:-
• Heavy load / speed conditions
• Long haul applications
• Mixed use cycles which include both regular high load
or speed with inner city operations

Section 4 –
Astra cCRF service intervals
During normal vehicle operation, the Astra cCR filter system
maintenance requirements depend upon the rate at which soot
and ash accumulate in the filter. The ash deposits are the
incombustible residues of burnt engine oil, soot and are mineral
in characteristic. As ash levels rise in the filter the capacity for
soot storage is reduced and the back pressure of the exhaust
system will rise more frequently. The dash lamp indicator of the
Astra cCR – OAC3cm monitoring system will indicate when the
filter system needs servicing. In addition, periodic filter cleaning
is recommended to maintain service intervals and system
performance. The table below summarises typical interval
periods for common duty cycles.
1. High load & sustained speeds
e.g a long haul rigid vehicle or tractor unit, inter city coach, etc.
In these circumstances or with duty cycles listed in section 3,
only ash will accumulate within the filter. Therefore the first
service should be anticipated after one year of service or as
indicated by your Astra OAC3cm performance monitor. If no
warnings experienced and after an initial service is completed,
thereafter it may be possible to implement a two year service
interval.
2. Variable engine work rate
A mixture of long and short haul, e.g an all purpose delivery
vehicle or bus operating in a mix of urban and rural
environments. Astra recommends a regular one year service
interval is completed as a minimum and/or as and when the
Astra OAC3cm performance monitor provides warning of service
requirement.
3. Low engine work rate
Such as a vehicle regularly operating in heavy traffic congestion,
with extended periods of idling*. In these circumstances there is
an increased possibility of soot accumulation within the filter
and it is essential that warnings of high back pressure from the
Astra OAC3cm performance monitor are observed and acted
upon. Increased frequency of service may be necessary, reducing
recommended service intervals to 6 months and/or as advised
by the monitoring system.
* Note: In all circumstances periods of idling longer than 15
minutes should be avoided.
Astra Filter - service exchange
ilter cleaning and the removal of accumulated ash can only
be achieved with specialist cleaning equipment. It is strongly
recommended therefore that an Astra service exchange filter is
used on a regular basis and at least once per 60,000Km or
annually (whichever sooner).
A service exchange filter unit can be arranged as a direct supply
to an operators workshop or servicing agent. Alternatively an
on-site fitting service can be provided by an approved Astra filter
service agent. All service exchange service units provided directly
by Astra carry a 6 month guarantee.
The Astra service exchange programme minimises vehicle down-
time, whilst providing a safe and environmentally responsible
means of managing waste disposal. A specially developed two
stage cleaning process is applied to all Astra service exchange
filters, initially baking the filter to remove unburned carbon, prior
to a vacuum and high pressure air cleaning of the filter channels.
High pressure washing of an Astra filter is also possible on
heavily soiled components.
Installation, Commissioning and Maintenance Instructions 07

08 Installation, Commissioning and Maintenance Instructions
Astra cCR System - Operation & Maintenance Manual
Visual inspection of exhaust pipe work
Astra filter system installations are manufactured utilising
stainless steel pipe work and filter housings and therefore
are generally long lasting and durable. Nevertheless, it is
recommended that whenever the exhaust system is being worked
upon during normal servicing, a visual inspection of the pipe
work integrity is completed. Many Astra filter installations
incorporate a length of stainless steel flexible pipe retained
between lap joint flex clamps. These sections are incorporated
to isolate the transfer of engine vibration to the filter system.
lexible pipe in the exhaust system is considered to be a normal
wearing item and will need to be replaced from time to time.
Check clamp joints in pipe work for tightness, a small amount
of leakage is normal and acceptable in metal to metal joints.
If however the flexible pipe is split or leaking, the component
will need to be replaced. This can be achieved by first removing
the lap joint clamps from either end of the flexible pipe section.
A replacement kit containing the flex pipe section and two
clamps, can be obtained directly from Astra, by quoting the kit
part number and serial number found on the nameplate. lex
pipes should be set to halfway between the compressed and
extended length, prior to installation. See fig 16.
ig 16 – typical flex pipe installation
Section 5 -
OAC3cm Service & performance monitoring
system
All Astra cCR systems include an electronic performance
monitor model OAC3cm), analysing parameters of back pressure,
temperature and running time. LED indications on the monitor
are repeated to a dash mounted indicator, alerting the operator
when the filter needs cleaning. Two outputs for control or alarm
relays, and an input for volt free reset contacts, are also
available.
Local LED’s on the monitor repeat system status, and a
proprietary service interface lead may be connected with a
computer (Astra authorised service engineer only), to access the
ECU’s diagnostic function for manual controls, and parameter
setting/configuration.
Logged data can also be downloaded from the ‘diagnostic’
function, for analysis of long term trends and proof of operating
conditions.
OAC3cm ECU Dash indication

Connecting to the Astra cCRF filter system
The OAC3cm electronic monitoring system connects to the inlet canister of the filter system, via a braided stainless steel hose
(high temperature end) and a white nylon tube (low temperature).
Your Astra ccR system will have been set up and commissioned upon installation by a qualified and accredited engineer. As all set
points and controls require a service interface cable connected between a laptop and the OAC3cm electronic monitor the following
technical data provided is in short form only. ull details of control parameters and settings are provided to authorised Astra
installation engineers or agents only.
Outline Block Diagram
Installation, Commissioning and Maintenance Instructions 09

10 Installation, Commissioning and Maintenance Instructions
Astra cCR System - Operation & Maintenance Manual
OAC3cmTechnical specification
Case:-
IP65 thermoplastic (Nylon 66), 134 mm x 118 mm x 36 mm
2 x 7.2 mm diameter mounting holes, 102 mm apart
the box should be mounted with the connector facing downwards
Supply (ignition):-
12/24 VDC
internal auto reset, 6A trip, 3A hold
external fuse to include total current supplied by ECU
Inputs:-
Pressure: 0 to 128 KPA, burst at 206 KPA (30PSI)
Push Button/Signal Reset
5 mA to chassis, preferably from volt free single pole contact
Temperature (optional)
‘K’ type thermocouple, mineral insulated ‘hot’ junction
Outputs:-
INDicator/Signal Relay drive at vehicle supply voltage
short circuit protected, nominal 1.8 Amp, trip at 5 Amp
Relay 1 drive at vehicle supply voltage
short circuit protected, nominal 1.8 Amp, trip at 5 Amp
Relay 2 drive at vehicle supply voltage
short circuit protected, nominal 1.8 Amp, trip at 5 Amp
Pressure inlet port:- SMC ‘M-5H-6’ hose nipple for 6/4mm plastic pipe
RS232 serial port:-
Connection:-
Service interface = 9 pin ‘D’ connector
Bits per second = 9600
Data bits = 8
Parity = none
Stop bits = 1
low control = Xon/off
Terminal Emulator Settings:-
unction keys =Terminal keys
Emulation =VT100/2
RTS/DTR signals = off
VCA approval: E11*72/245*2006/28*4378*00

Installation, Commissioning and Maintenance Instructions 11
Wiring Diagram
Section 6. Astra cCRF system –
service records
The following information should be recorded on your vehicle
maintenance check sheet at each service:-
• Back pressure before and after service (engine should be
at normal operating temperature at the time of
measurement
• Recorded smoke level
• Vehicle mileage
• Astra filter and catalyst serial numbers
• ilter cleaning history, with method used and date.
Note: Astra Vehicle Technologies Ltd will require service records
in order to investigate any warranty claim. ailure to provide
service records will invalidate your warranty cover.

Astra Vehicle Technologies Ltd
Innospec Manufacturing Park,
Oil Sites Rd, Ellesmere Port, Cheshire
CH65 4EY, UK
Phone: [phone]
ax: 0151 348 5778
e-mail: [email protected]
www.astra-vt.com