2 2 10-20101222 Huss Mk-System (User Manual) v1 en
2 2 10-20101222 Huss Mk-System (User Manual) v1 en
2 2 10-20101222 Huss Mk-System (User Manual) v1 en
PREFACE
Dear customer,
Yours,
HUSS Umwelttechnik GmbH
2
CONTENTS
GENERAL INFORMATION 4
PRODUCT INFORMATION 6
FUNCTIONAL DESCRIPTION 7
EXPLODED VIEW 8
TECHNICAL DATA 9
CUT-AWAY DIAGRAM 9
HUSS CONTROL V2 AND V3 10
INTERFACE DESCRIPTION 18
TERMINAL CONNECTION DIAGRAM V2/V3 20
FAQ 21
MAINTENANCE 23
GUARANTEE 24
EC-DECLARATION OF INCORPORATION 27
3
GENERAL INFORMATION
4
Danger!
Danger! Extremely hot!
5
PRODUCT INFORMATION
The modular diesel particulate filter with The main application for the diesel exhaust
stainless steel housing cleans the diesel exhaust particulate filter is the diesel driven vehicle
gases of nearly all particulate matter. Other which is used in halls, tunnels etc..
limited harmful substances are not reduced. Moreover, the diesel exhaust particulate filter
Thus, the use of a diesel exhaust particle filter can of course also be used in other diesel driven
ensures low-pollution, clean breathable air and machines.
keeps clean products, workshops and job sites.
At the same time highest requirements for the HUSS diesel particulate filters meet the
protection of the environment are fulfilled. requirements of TRGS 554,
TA Luft and VERT/Switzerland.
DESIGNATED PURPOSE – NORMAL USE
Application range of TRGS 554, DIN 51628
HUSS diesel particulate filters are intended only (Technical rules for hazardous substances)
for exhaust filtering of equipment with diesel
engines. The manufacturer will not take over any These technical rules apply to job sites where
liability for abnormal use. Basically, the general emissions of diesel engines
rules for the prevention of accidents such as may occur in the air.
other generally approved rules for technical
safety and for industrial medicine have to be
kept.
6
FUNCTIONAL DESCRIPTION/ REGENERATION
Functional description:
description :
7
EXPLODED VIEW
1 module A
1.1 shock protection module A 7 fuel pump
2 module B 8 burner
2.1 shock protection module B 8.1 sealing
3 module C 8.2 back- pressure valve
3.1 shock protection module C 8.3 temperature sensor
4 module connection bracket 8.4 glow plug
4.1 flange seal 9 blower
5 base plate 10 back- pressure collector
5.1 bracket for filter support 11 exhaust gas outlet
6.0.1 exhaust gas inlet - bent 12 HUSS control
6.0.2 exhaust gas inlet- straight 13 condensate separator
6.2 sealing exhaust gas entry
8
TECHNICAL DATA
Cut-
ut -away diagram:
9
HUSS CONTROL V2 AND V3
fig.
fig. HUSS Control V3
10
Operation of HUSS Control V2:
The device is fixed in the visibility field
of the operator ( e.g. at the instrument board).
Display
The upper line shows the functioning steps, in
the lower line, a bar shows the status of the
filter (backpressure and time of regeneration).
Normal operation
•Switch the ignition key to “ON.” The buzzer will GREEN AND RED LED ARE
self-test on
be activated for at least 1 second, both LED will
light at the same time.
11
Messages during normal operation,
operation , which
show the condition of the diesel particulate
filter:
• With this information --- normal operation status of filter GREEN LED IS
possible. HHHHHHHH BLINKING
Regeneration
Note:
Note The display counts down from 5 seconds
until the start of regeneration. Releasing the
“M” key prior to the completion of the 5 second
countdown will cause the operation to abort and
a system self-test will follow.
12
Further displays after expiration of 5 seconds
during regeneration
Glow plug / precooling ------
• The blower starts to cool down the system.
13
Disorders displayed by the HUSS-
HUSS-Control V2
14
HUSS Control V3:
V3:
15
OPERATING CONDITIONS
FUNCTION LED
Turn ignition to “ON“
GREEN, YELLOW AND The buzzer is activated for at least 1 sec.,
RED LED At the same time all the three LEDs are lighting for a short moment.
ARE SHORTLY If no message is recorded, the engine
BLINKING can be started
GREEN LED IS
Start engine
BLINKING
GREEN LED IS
LIGHTING AND
50% of run time until pre-alarm
YELLOW LED IS
BLINKING
Start regeneration
regeneration:
egeneration:
• Park the vehicle on a plain surface
• Switch off the engine.
• Ignition: “ON“:
The HUSS-Control is supplied with voltage.
RED LED IS LIGHTING • Push the white key and keep it for 5 sec. Regeneration starts after these 5 sec. have
expired.
Note:
The display shows the time of 5 sec. until the start of regeneration in reverse. Release
of the white key prior to the expiry of
the 5 sec. leads to abortion - a self-test follows
GREEN LED IS
Regeneration sucessfully finished ( buzzer is active for 2 seconds)
BLINKING
16
Disorders:
Disorders :
In case a disorder occurs during the
regeneration, it is automatically interrupted
and the red LED will be lighting. The error
codes can be read by using a laptop with
HUSS software, but can also be identified
using the LEDs on the display. Thereto the
ignition has to be switched on and the
white button has to be pushed 3 times.
17
Error codes:
codes :
LED
BIT Error
DES
DESCRIPTION BLINK
Code
ORDER
1
0 1= Alert pressure exceeded 1x yellow
2
1 1= Loading time exceeded 2x yellow
4
2 1= Regeneration aborted 3x yellow
3x yellow 12
3 1= Voltage less than < 8V
1x green
3x yellow 20
4 1= Glow plug error
2x green
3x yellow 36
5 1= Blower error
3x green
3x yellow 68
6 1= Fuel pump error
4x green
3x yellow 132
7 1= Delta-temperature error
5x green
256
8 1= Datalogger memory error 4x yellow
1= Minimum temperature 3x yellow 516
9
error 6x green
1024
10 1=Reset error while start
2048
11 1= Service interval expired 5x yellow
4096
12 1= White ash 6x yellow
1= Internal error - re-enter red and 8192
13
settings yellow
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CONNECTION DESCRIPTION
CONNECTION PIN DESCRIPTION
Function: The control voltage delivers the supply voltage of the
HUSS Control.
It supplies all components except for the power element and is
12/24V control voltage 27 measured by clamp 15.
Voltage: 12V – 24V (-30%, +20%)
If it should be possible to switch off the ignition after the start of
the regeneration, this cable has to be attached to clamp 30.
Function: The ignition signal serves as start signal for the
control. As the HUSS Control is only voltage-supplied by pin 27
12/24V ignition signal 32 upon active ignition, this signal can also be taken up by pin 27
(and/or clamp 15).
Voltage: 12V – 24V (-30%, + 20%)
Function: This signal serves the information that the engine is
Oil pressure switch or electric 17
running. As soon as this signal is active, the standby mode is
generator clamp No.61
switched to drive operation.
Function: The starter block will be active upon running
Starter block 6,7 regeneration or if the max. allowed backpressure is exceeded.
Both connections will thus be opened.
Voltage: potential-free Current: max. 1A
Function: The ignition and/or diesel block will be activated 2
Ignition block minutes after the max. allowed backpressure has been exceeded
and/or diesel 9,10 or after start-up of the HUSS Control without prior exceeding of
block the charge pressure. Both connections will thus be opened.
Voltage: potential-free Current: max. 1A
Battery or Is connected with the negative terminal of the battery or the
chassis 29
negative vehicle chassis.
12V/24V supply 28,42 Is connected with the positive terminal of the battery via a 40A-
of power element fuse.
19
CONNECTOR PIN DESCRIPTION
From this connection comes the supply voltage, when the
External buzzer 12 internal buzzer of the HUSS Control is activated. Otherwise it
would have no voltage
16,30
Temperature sensor Is connected with the temperature sensor PT100
31
Glow plug 13,14 Is connected with the glow plug
Metering pump 3 Is connected with the metering pump
Blower 1 Is connected with the blower
Magnetic valve 5 Is connected with the magnetic valve
Connection for external start of the regeneration by a certain
External start option 19
signal instead of key pressure of the HUSS Control
12/24V ignition signal (V3) 40 Display is switched on by signal “ignition on“
Ground (V3) 39 Bonding display
Data for display (V3) 24 Data exchange between display and control unit
Data for display (V3) 25 Data exchange between display and control unit
20
TERMINAL CONNECTION DIAGRAM V2/V3
21
FAQ
DISPLAY SHOWS POSSIBLE SOURCES OF ERRORS AND THEIR ELIMINATION
No switch over from
“engine ready” Check oil pressure switch, HUSS cable and electric generator
to “filter status”
Interruption of regeneration Most frequently a problem of the burner:
after half of combustion time clean fine filter in and in front of fuel pump
Dismantle glow plug, check flow with mouth or
hose, check electric cables; mount new glow plug
Fault glow plug
in case of regular service, control main fuse 40 Amp.
and its contact pins.
Check electric cables and functioning with external
Error magnetic valve cables; should the error come up again in spite of
correct function, check / replace HUSS-Control
Check electric cables and functioning with external
cables; control mass connection;
Error fuel pump installation position:
pumps item no. 89 373 A 12V or 24 V: vertical
pumps item no. 25 5008 45 12 V: horizontal
Check electric cables and functioning with external
cables, check bonding, finger test in suction nozzle:
dust = okay, soot = faulty magnetic valve or magnetic valve opening
Error blower
through high backpressure = fi lter overloaded; blower can be damaged
inside by hot exhaust gases. Take care of retail pieces sucked in (e.g.
paper, water).
Error G-M-D-G“ Check main fuse and fuse support, use only 40A. main fuses.
Reverse blowing of filter with dismantled burner until
no more grey ash clouds can be seen anymore.
Point out to the operator of the vehicle the engine oil consumption
and filter characteristics.
White ash
Reset in the menu all maintenance displays [fault indications,
service hours, regeneration, interruptions
of regeneration, advanced regenerations and maintenance
counter (reset: M)]
Only one block (HUSS-Control V202, 203, 204):
display “pressure sensor interrupted“ with parallel
alert signal (HUSS-Control V205): pressure cable
Filter status
in the exhaust gas inlet may be jammed: Clean
it. Exhaust gas pipe from the engine to the filter leaky? Check and clean
backpressure hose and condensate collector.
22
Electro-magnetic incompatibility of the HUSS Control
Cofusing signs with other electric components in the cabin;
use of silent rubbers or position change of the HUSS Control
Recommendation
Recommendation
• Use engine lubricants with low formation of
white ash.
• The quality of engine lubricants is of essential
importance for the service life and the
permanent application in the field
• Ask therefore your dealer, the manufacturer or
the service department for engine lubricants
free of white ash or with only little white ash.
23
MAINTENANCE
Maintenance works on Diesel Exhaust (higher soot number) and thus lead to a reduced
Particulate Filters operation time of the filter.
For carrying out the maintenance works, one has
to request for the HUSS service or instructed •After 1.500 operation hours, but at least once
technical staff. per year, the emissions of the diesel engine have
If you fail to perform all scheduled maintenance, to be checked according to TRGS 554.
HUSS will deny warranty coverage and the
durability of the filter is shortened. The data
logger (optionally) is here also logging the data, IMPORTANT
whereby the detectability is adduced.
The use of additive fuels may influence the
Maintenance works, which can be operated
exhaust gas and thus the service life of the
without the HUSS service staff.
diesel exhaust particulate filter, depending on
the additive supplement.
EQUIPMENT
In order to guarantee an impeccable functioning Thus, HUSS has to be contacted prior to the use
of the filter, it has to be ensured that the diesel of additives.
engine is properly functioning and is operated
and maintained in accordance with the service
instruction of the engine manufacturer.
Already minimal divergences from the
determined operation of the engine can involve
an increase of the soot particles emission
WARRANTY STATEMENT
Advices for preservation of the guarantee (1) General:
claims The HUSS Umwelttechnik GmbH grants a
(status: warranty period of 12 month starting with the
(status : 05.2009):
delivery date to the customer. Place of warranty
is the place of the company or its subsidiary.
The aim of this warranty statement is to explain
in detail and in addition to the “general terms
and conditions” under which conditions the (2) Usage of original HUSS
warranty of the HUSS Umwelttechnik is valid. parts/components:
The main focus is, to avoid problems in the For installation, maintenance work or reparation
communication before they arise. All it is only allowed to use parts or components
documents, mentioned in the text below, are being included in the original scope of delivery
available at the application engineering or being included in the original spare part list.
department of our company.
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(3) Modification
Modification of HUSS parts/components: the product. After the training the customer/
Modification of HUSS parts or components needs end user needs to confirm, by signing the
to be released by the HUSS Umwelttechnik disposal log, that he has been trained and that
GmbH in a written form. This is also valid for the product had a proper function. This form
modification regarding the exhaust piping e.g. sheet has to be filled in completely and send
the exhaust inlet or outlet. back to the HUSS Umwelttechnik GmbH.
(4) Installation in accordance to the (9) Period of maintenance and service: The
technical instruction manual: periods of maintenance and service need to be
The installation has to be done absolutely complied during the period of warranty. The
according to the technical instruction manual. services during the period of warranty have to be
In case of a doubt the technical staff of the HUSS done by the HUSS Umwelttechnik or by an
Umwelttechnik GmbH has to be consulted. authorized service partner. The form sheet about
the services has to be filled in completely and
5) Settings of the control unit*:
unit*: send to the HUSS Umwelttechnik. The
The settings of the control unit* have to be compliance with the periods of service and
done according to the data sheet of the maintenance does not only refer to the filter but
particular filter type. The settings have to be also for the machine itself.
equalized with the corresponding
data of the engine supplier. In case of a (10) Product identification
identification card/Delivery
doubt the technical staff of the HUSS report:
Umwelttechnik GmbH has to be consulted. In In case that filter systems will be completed out
case of disrespect the guarantee claim expires. of components, or components will be changed,
*at MK-systems HUSS Control the serial numbers of all components need to be
*at MD-systems ECU registered in the product identification card.
* at MA-systems ACS (additive control system) This card needs to be send back to the
* at ME-systems ZA3 HUSS Umwelttechnik GmbH.
(6) Dimensioning
Dimensionin g of the filter:
For the dimensioning of the filter the engine
power in kW is only an approximated value. In (11) General issues in case of reclamation:
case of a doubt the technical staff of the HUSS If in case of reclamation parts or components
Umwelttechnik GmbH has to be consulted. will be changed, they become the property of
the HUSS Umwelttechnik GmbH. It is up to HUSS
(7) Installation log/Checklist: Umwelttechnik GmbH to decide, whether new
From each installation project an installation log parts or overhauled parts will be used. The
according to the checklist has to be made. This period of warranty for changed parts or
form sheet has to be filled in completely and components ends with the end of the period of
send back to the HUSS Umwelttechnik GmbH. warranty of the entire system. No warranty will
be given in case of an accident, damages done
by purpose, services by unauthorized personnel,
(8) Briefing of the customer/Disposal log: or damages caused by inappropriate usage.
After the installation is done, the customer/end There is no entitlement of system upgrade in
user has to be trained with the correct usage of
25
case of changes in design or further on (17) Usage of fuel according to DIN EN 590:
developments of the products. The fuel of the engine has to be according to the
DIN EN 590 and DIN 51628 regulations..
(12) Consumable parts and waste parts:
par ts: For
consumable parts and parts subject to wear e.g. (18) Maximum soot emission:
wires, wire-connections, glow-plugs or gaskets, In order to assure the function of the filter the
no warranty claim can be accepted. engine is allowed to emit exhaust gases with a
maximum soot number of 2.0 according to
(13) Reclamation report/ return Bosch.
consignments of parts/components:
If parts/components were reconsigned to the
HUSS Umwelttechnik GmbH a complete
reclamation report has to be transmitted, too. A
reclamation case has to be announced towards
the HUSS Umwelttechnik GmbH in a 30 working
days period.
26
EC- DECLARATION OF INCORPORATION
EC-
EC- declaration of incorporation
(according to the EC machinery directive DESCRIPTION AND diesel exhaust particulate
2006/42/EG schedule II part 1, chapter B) FUNCTION OF THE MACHINE filter
FS 40MK, FS 50MK,
FS 80MK, FS 100MK,
TYPE OF MACHINE/
MK 35, MK 75,
Hereby we, MODEL AND TRADE NAME
MK 150, MK 200,
HUSS Umwelttechnik GmbH declare, MK 300
DIN EN ISO 12100-1, DIN
that the following described incomplete APPLIED BASIC STANDARDS EN ISO 12100-2, DIN EN
machine concerning its plan and construction as 60204-1
well as the construction introduced by us is in APPLIED HARMONIZED ISO 3691-1
STANDARDS
accordance with the basic security- and health
VERT (CH),
protection requirements of the EC machinery APPLIED NATIONAL TRGS 554 (GER),
directive 2006/42/EG. The following basic STANDARDS AND TECHNICAL
requirements were applied in detail: schedule I EST (UK),
SPECIFICATIONS
and schedule IV Teknologisk Inst. (DK)
27
NOTES
NOT ES:
ES :
28
NOTES
NOT ES:
ES :
29
NOTES
NOT ES:
ES :
30
NOTES
NOT ES:
ES :
31
Printed in Germany
All rights reserved
HUSS Umwelttechnik GmbH, Stand 05/2010
32