SCR Coolant Circuit Flow Test

CES Application Engineering

Andy Koch
November 2015
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 Objectives

 After completing this course you will be able to:

 Understand why coolant flow is required for SCR system

 When coolant flow test is required

 Understand test procedure, setup and pass/fail criteria

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 Bosch Dosing System Coolant Flow
 Why is Engine coolant required for SCR System?
 Engine Coolant is used to cool the dosing module during operation
 Coolant flow to DEF tank to thaw the DEF tank in freeze conditions
 It is important that coolant flow from the engine is controlled to maintain
correct flow balance
 T4F Aftertreatment Architectures currently using Bosch Dosing
System
– QSF 3.8
– QSB 4.5, 6.7 (<174 HP), 6.7 (>174 HP)
– QSL 9
– QSX 15

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 Coolant Circuit to Bosch Dosing System

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 UL2 Dosing System Coolant Flow
 Utilizes Engine Coolant for thawing purposes in
freeze conditions
 Used for Supply Unit and DEF tank only
 Dosing module is cooled circulating DEF
 Coolant not used for cooling dosing module/injector

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 Coolant Circuit to UL2 Dosing System

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 Bosch Dosing System
 Engine models
– QSF 3.8 T4F
– QSB 4.5, 6.7 (<174 HP) T4F, 6.7 (>174 HP) T4F
– QSL 9 T4F
– QSX 15 T4F
– All EPA 2010
– All EPA 2013
 Reference AEB’s
– 24.75
– 24.76
– 24.76 Attachment A
– 21.112
– 21.79

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 UL2 Dosing System
 Engine models
– QSG 12 T4F
– ISB 6.7 2017
– ISL 9 2017
– ISX 15 2017
 Reference AEB’s
– 21.167
– 24.74
– 21.178

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 Key Requirements
 From Engine:
– Maximum Coolant from Engine to SCR System
 Dosing System (NA for UL2 Dosing System):
– Minimum coolant flow to dosing module
– Maximum coolant flow limit to dosing module
 DEF tank (NA for UL2 Dosing System):
– Minimum coolant flow to DEF tank
 The above requirements will change from engine to
engine and the engine speed tested.
 AEB 24.76 / 24.74 has the limits for each engine

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 Max Flow Limit to Dosing Module
Bosch 2.2 Dosing Module

Too much flow through the dosing

module can erode the internal
coolant passages over time

Bosch 2.5 Dosing Module

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 When is Coolant Flow Test required?
 Pre-Engineered Solution
– Bosch – Follow coolant Circuit Configurations in AEB 24.76 /
21.112 / 21.79
– UL2 – Follow coolant Circuit Configuration in AEB 24.74
– For T4F, AEB 24.76 Attachment A can be used to determine
if installation meets the Pre-Engineered Solution in the AEB
or not.
 Test will be required if OEM deviates from the Pre-
Engineered Solution given in the AEB

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 Sample of Equivalent Lengths calculator
(AEB 24.76 Attachment A)

Coolant Flow test required Coolant Flow test not required

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 DEF System – Coolant Flow Testing
Test Objective
 Determine maximum coolant draw from the engine to support SCR system
 Determine that the min and max coolant flow to Dosing Module (for Bosch
only)
 Determine that coolant flow to the DEF heater is equal to or greater than the
coolant flow provided by the Cummins “maximum restriction” coolant circuit
design (for Bosch only)

Note: The test is only required when the OEM coolant circuit design does
not meet the length or layout requirements in AEB

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 DEF System – Coolant Flow Testing
Test Equipment
 Coolant Flow meter or Pressure transducer
 Calterm to actuate coolant flow valve, monitor ECM
parameters- coolant temperature, Engine speed
 Data logger to monitor/collect temperature and
flow/pressure data
 Notes:
– Coolant Flow meter – A coolant flow meter that is appropriately sized for the
coolant line internal diameter is required. A magnetic flow meter, turbine type flow
meter, or ultrasonic type flow meter are acceptable for measuring the coolant flow
rate.
– Pressure Transducers – At least two pressure transducers will be required to
measure pressure drop across the DEF dosing module. A differential pressure
transducer or manometer is also acceptable to measure pressure drop across the
DEF dosing module. (Range 0 – 15 psi)
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 Test Setup – Coolant Flow Testing (Bosch)

 Flow meters to be installed in 2 of 3 locations shown above.

Preferably A and B.
 If OEM opts to use pressure transducers, they may choose to
use one across DM and DEF tank
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Test Setup – Coolant Flow Testing (UL2)

 Flow meter can be installed anywhere ion the above circuit.

 If OEM opts to use pressure transducers, they may choose to
use one across DEF Supply Module or DEF tank

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 Test Conditions (Bosch Dosing System)
 Engine Conditions:
– Rated Speed
– If your machine will incorporate a TK by-pass, ensure that you are testing
with the this component enabled.
– All OEM accessories using engine coolant should be flowing coolant
when performing this test.

 Thermostat Position
Component Flow Rate Requirement Thermostat DEF Heater
Position Position
Engine Supply < Maximum From Engine (with or without Closed Open
accessory flow
Dosing Module > minimum flow required for dosing module Open Open

DEF Tank Supply > the minimum flow required to Tank supply Open Open

 Thermostat condition may be obtained using blocked open

thermostat or by at temperature high enough to maintain open
thermostat

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 Test Conditions (UL2 Dosing System)
 Engine Conditions:
– Rated Speed
– If your machine will incorporate a TK by-pass, ensure that you are testing
with the this component enabled.
– All OEM accessories using engine coolant should be flowing coolant
when performing this test.

 Thermostat Position
– Open
– Closed
 Thermostat condition may be obtained using blocked open
thermostat or by at temperature high enough to maintain open
thermostat

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Test Procedure – Coolant Flow Testing
Test Procedure:
 Ensure Test setup is complete
 Operating conditions that support fully open and fully closed thermostat

Note: If a TK bypass option can be used with the installation, then this option must also be tested to determine
that it meets flow requirements
1. Override DEF Heater coolant control valve to the open position. Use Calterm overrides or provide battery power
supply directly to valve. Disconnecting valve from main harness will produce a fault code on the engine system. Calterm
override: O_UTC_TankHeater1_Enbl = 1, Reset to 0 after test

O_UTC_TankHeater1_Val = 100 %, Reset to 0 after test

2. Start the engine and make sure data logger is reading flow meter, pressure transducers, and engine speed properly.
3. Take the engine speed to the value specified for Engine Family.
4. Allow the engine speed and flow to stabilize (allow 1 minute).
5. Once stable, begin recording using the data logger. Monitor coolant temperature throughout the recording period to
ensure the thermostat remains in the fully closed or fully open position for the test various section of the test. Data
should be recorded for a period of at least one minute.
6. Average the coolant flow and pressure readings for the stable period and compare them to coolant flow limit (see
appropriate Figure in appropriate AEB depending upon engine application).
7. If flow is outside of the permitted limits then system modification will be required.

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Data Evaluation (Bosch Dosing System)

Maximum Coolant flow

from Engine

Minimum Coolant flow

to dosing module
and DEF Tank

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Data Evaluation (UL2 Dosing System)

Maximum Coolant flow

from Engine

Minimum Coolant flow

to dosing module
and DEF Tank

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 Pass/Fail Criteria – Bosch Dosing System
 AEB 24.76 has curves showing pass/fail criteria for all T4F engines using
Bosch dosing system
 Below shown is an example curve for QSL 9
Note: Refer to latest AEB on GCE for pass/fail limits

Minimum Coolant flow to dosing module

Maximum Coolant flow from engine without accessory flow

Maximum Coolant flow from engine with accessory flow

Minimum Coolant flow to DEF tank heater

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Pass/Fail Criteria – Bosch Dosing System
 If Pressure transducers were used instead flow meters use the
pressure drop to coolant flow co-relation curves to find the flow rate
corresponding to the pressure drop.
 Dosing Module pressure drop curve can be found in AEB 24.76
 DEF tank supplier provided the pressure drop curve for the heater
Note: Refer to latest AEB on GCE for pass/fail limits

QSB6.7>174hp and QSL9 Dosing Module Pressure Drop

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 Pass/Fail Criteria – UL2 Dosing System
QSG 12 and EPA 2017 Engine models
Note: Refer to latest AEB on GCE for pass/fail limits

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