CPCB IV+ Training

Oct 2024
CPCB IV+: Overview
• CPCB II Vs CPCB IV+

• CRDI System

• ATS System

• CPCB IV+ Sensors and Actuator, CAN Communication

• OBD Tools usage (Bosch/Motorpal/Multronics/Mega Series)

• Mega Series
CPCB IV+: Overview
• Indian Central pollution control board (CPCB) is considering to implement next level of emission legislation
norms for Genset under <800 kW, the proposed emission norms is CPCB IV+.

• Reduction of 90% NOx and 93% PM emission for the engine in the range of 56 to 560 kW is targeted.

• Change scope : Major changes are considered for Engine combustion, FIE system , After treatment and
Thermal management for ATS.

• Market : Domestic/SARC (existing market size considered for CPCB IV+)

CPCB IV+: Overview
CPCB II TO CPCB IV+ TRANSITION
CPCB II Scope CPCB IV+ Scope
Genset Engine Exhaust
Sr. No. Rating Model Sr No Engine Model FIE System
Rating Make system
1 5 kVA LDA 510
2 7.5 kVA G600 1 5 kVA LDA 510
Mech GCL Conventional
3 10 kVA G12 -II 2 7.5 kVA G600
3 10 kVA G12 -II
4 15 kVA G15 -II Mech Conventional
4 15 kVA G15 -II
5 20 kVA G20 -II Escorts
5 20 kVA G20 -II
6 30 kVA G30 –II Mech DOC
6 30 kVA G30 -II
7 40 kVA 3G11TA 7 40 kVA 3G11TAG33
8 45 kVA 3G11TA 8 45 kVA 3G11TAG32
Mech DOC + PFF
9 62.5 kVA 3G11TA 9 50 kVA 3G11TAG31
10 57 kVA 3G11TAG31
10 75 kVA 3G11TA
11 82.5 kVA 3G11TAG41
11 82.5 kVA 3G11TA CRDI
12 125 kVA 4G11TAG41
12 100 kVA 4G11TA 13 100 kVA 4G11TAG32
13 125 kVA 4G11TA 14 125 kVA 4G11TAG31 GCL
14 160 kVA 6G11TA 15 160 kVA 6G11TAG33 Mech
16 180 kVA 6G11TAG32 DOC + SCR +
15 200 kVA 6G11TA
ASC
16 250 kVA D3V6 17 200 kVA 6G11TAG31
18 250 kVA 6G11TAG41 CRDI
17 320 kVA D3V8
19 320 kVA D3V6TAG41 CRDI
18 400 kVA NEWD
20 400 kVA 12V14ATG31
19 500 kVA NEWD Mech
21 500 kVA 12V14ATG31
CPCB IV+: Overview
CPCB IV+ Genset Features :
• India’s first CPCB IV+ Emission Compliant engine with Mech FIE
CPCB IV+ • Lower Foot- Print
• Low Fuel Consumption
• Lower Service Cost
• Low oil Consumption
• Easy for Servicing
• Easy - Repairable Mechanical FIE
• High Block loading capability
• No EGR Strategy
• Most compact 250 & 320 kVA engine
SMS Notification to Push Notification on • Advance CRDi Technology -3G, 4G, 6G, V6
Predefined Numbers Mobile App*
• India’s first Intelligent and technologically advanced Smart gensets
CPCB II to CPCB IV+ Changes
3G11TAG -57 kVA
• FIP
• Injector
• Turbo charger
• Exhaust Manifold- EGR & Heat
shield
• mounting change
• EGR Cooler – Added
• Exhaust Bend – suitable to after
treatment
• Turbo charger
• DOC + PFF
CPCB II to CPCB IV+ Changes
6G11TAG- 250 KVA -CRDI
• Crankcase- In proposal crankcase casting with ladder
frame arrangement, MB cap change
• Cylinder Head – Yes, Valve coating change
• Connecting Rod –Notch Added
• Crankshaft- No Change
• Camshaft- No Change
• Piston – Piston & Piston cooling nozzle change_ Gallery
Cooled Piston
• Main bearing & con rod bearing- material change
• Sump- Capacity change from 17 Ltr to 25 Ltr
• Strainer change, Oil pump capacity change
• FIE Parts –Injector, FIP change, HPP, injector clamp &
Bolt
• Sensors- CAM, Crankshaft, Boost Pr. sensors
• Flywheel Housing & Flywheel part change – For Timing
Locking arrangement
• Exhaust Manifold- Heat shield mounting change
• Intake Manifold – Sensor mounting provision
• Exhaust Bend – suitable to after treatment
Fuel Injection
Mechanical FIP

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Fuel Injection
Common Rail FIP
Fuel Injection
Common Rail FIP

NJECTOR HIGH PRESSURE PIPE

INJECTOR CLAMP

FUEL PIPE
FIP

PIPE CLIPS COMMON RAIL

BRACKET
BRACKET RAIL MOUNTING
WATERSEPARATOR

SUPPORT BRACKET
FUEL PIPE

WATER BRACKET FOR FUEL

FILTER
SEPARATOR
FUEL FILTER ELEMENT
After Treatment System
Components
After Treatment System
Components
After Treatment System
DOC (Diesel Oxidation Catalyst)
Typically, use of DOC depends on engine design and
operating conditions results into :
• 30 –80% conversion of the gaseous HC
• 40 to 90 % reduction of CO
• Dry soot does not get oxidized. But oxidation of 50 to
80% of soluble organic fraction and some PAH occurs
that gives 30 to 60 % reduction in total PM emissions
• Conversion of fuel Sulphur to SO3 and emission of
sulphuric acid aerosol
After Treatment System
PFF (Partial flow filter)
PFF is a ceramics substrate made from Cordierite with
only one side is sealed to secure PM filtration
performance:
• 25 –65% PM filtration efficiency can be achieved
using PFF
• Regeneration – Passive Regeneration
After Treatment System
SCR (Selective catalytic reduction)
• Selective Catalytic Reduction (SCR) technology
combined with the AdBlue®-DEF significantly reduces
soot and nitrogen oxide (NOx) emissions to meet
Euro 4, 5 & 6 emission standards.
• Principle Of Operation:- Ammonia in Diesel Exhaust
Fluid reacts on the SCR catalyst with the NOx and
converts it to nitrogen.
• Diesel Exhaust Fluid is made up of high-purity urea
and de-ionised water.

Typical Reactions in SCR:-

4NH3 + 4NO + O2 ® 4N2 + 6H2O -- Standard
2NH3 + NO + NO2 ® 2N2 + 3H2O--Fast
8NH3 + 6NO2 ® 7N2 + 12H2O-- slow
After Treatment System
SCR (Selective catalytic reduction)
After Treatment System
SCR (Selective catalytic reduction)
• SCR catalysts are the only class of automotive catalysts that don’t contain precious metals.

• They are manufactured from various base metal oxides, such as titanium oxide which is used as a carrier
and oxides of tungsten and vanadium as the active catalytic component.

• Iron- and copper-exchanged zeolite systems are another class of SCR catalysts which currently offer the
highest conversion rates.

• Most SCR catalysts are using ceramic substrates but there are also extruded products available mostly for
vanadia based formulations.
After Treatment System
Materials used in Diesel ATS
Quick Review
Components
GENSET CRDI Engine Mech Engine

• NOx Sensor • Cam Sensor • Boost Pressure

• Ambient Sensor • Crank Sensor Sensor
• Exhaust temp Sensor • Water Temp • FIE
• Urea Tank • Boost Pressure • Injector
- Urea Tank Sensor • Piston
- LQT Sensor • FIE • Turbo
- Filter • Injector • HPP
• Urea Pump • Piston
- Filter • Turbo
• Urea Injector • HPP
• Urea Pipes
• Wiring Harness
• Controller -6120
• ATS – DOC+ SCR + ASC
NCD Demonstration
NCD Family- N1

Document No - MDSG20230131
Index

1. NCD Demonstration Requirement

2. Lack of DEF (reagent)
1. - Warning
2. - Low level Inducement
3. - Severe level Inducement
3. Ambient Sensor Disconnection/NOx Sensor Disconnection/Poor DEF quality
1. - Warning
2. - Time required for Low level Inducement Counter
3. - Low level Inducement ( Audio waring Visual Alarm)
4. - Time required for Low level Inducement Counter - ( Audio waring Visual Alarm)
5. - Severe level Inducement
6. - Engine Shut off

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NCD System – Operator Inducement : Levels
• Warning level inducement:- (10 /36)hrs
When operator warning has become active for low-level inducement, activate visual warning with no alarms.
• LOW LEVEL INDUCEMENT:- (Total 72 Hrs = Warning – Remaining Hrs)
Low level inducement will be audio/visual warning with no torque or power derate/ reduction for both variable speed
and constant speed engines. The audio/visual warning can be activated as per the the inducement warning system.
At commencement of low-level inducement, the audio warning system shall beep once in 5seconds with 2-second-long
beep. Such audio warning shall remain active as long as low level inducement state is active.
• SEVERE LEVEL INDUCEMENT :- 0 Hrs _(When severe inducement start, Engine should shut down immediately)
Strategy A
An audio/visual warning and a grace period of 72 hours after which the severe inducement will effectively disable
Genset operation to cause the operator to remedy any problems related to inducement. No torque derate is applicable
with this severe inducement strategy
Strategy B:
An audio/visual warning with a torque derate of minimum 50% and a grace period of 120 hours after which the severe
inducement will effectively disable Genset operation to cause the operator to remedy any problems related to
inducement.
Genset engines, torque between the peak torque speed and the governor breakpoint shall be gradually reduced from
rated torque by a minimum of 1 percent per minute to 50 percent of maximum torque or lower
At commencement of severe-level inducement, the audio warning system shall beep once in 2 seconds with 2-second-
long beep. Such audio warning shall remain active when Engine Ignition is ON or Engine shutdown, but ignition is ON.

Total -72 Hrs

Warning -10/36 Hrs Low Level Increment Severe
2. Lack of DEF ( reagent)

2.1 Warning – When the DEF (reagent) level goes below 25% of the tank level, the GCU will
display the “Warning" message on the Genset display.

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2. Lack of DEF ( reagent)

2.2 Low Level Inducement : – When the DEF (reagent) level goes below 15% of the tank
level, the GCU will display the "Low level (Moderate)" message on the Genset display.

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2. Lack of DEF ( reagent)

2.3 Severe Level Inducement : When the DEF (reagent) level goes below 5% of the
tank level, the GCU will display the “Severe level ( High Moderate)" message on the
GCU display.

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3. Ambient Sensor Disconnection / NOx Sensor
Disconnection / Poor DEF quality

3.1 Warning :– When any connected NCD sensor disconnected/ tampered or a bad
quality DEF (reagent) used, then GCU will display a "DTC" code (linked to the sensor)
on the GCU display and immediately Engine /Genset enters in the “Warning
Inducement” and the GCU will display "Warning" massage on the Genset display.

“DTC Code” “Warning Inducement ”

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3. Ambient Sensor Disconnection / NOx Sensor
Disconnection / Poor DEF quality

3.2 Time remaining for low level Inducement – When Genset enters in the "Warning Inducement" im
the Inducement counter will starts and the GCU displays the massage of "Time for Low Level Inducem
reducing counter on the GCU display.
“Counter – Time for low level Inducement ”

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3. Ambient Sensor Disconnection / NOx Sensor
Disconnection / Poor DEF quality

3.3 Low Level inducement – After completion of “Warning Inducement” (10 Hrs),
immediately Engine/ Genset will enters in the “ Low level inducement” and the GCU
displays the massage of “Low level inducement (Low – Most severe)” on the Genset
display.

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3. Ambient Sensor Disconnection / NOx Sensor
Disconnection / Poor DEF quality

3.4 Time remaining for Severe level Inducement – When Genset enters in “Low
level Inducement” immediately inducement counter will start and GCU will display
the massage “ Time for Severe level Inducement” with reducing counter.

“Counter – Time for Sever level Inducement ”

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3. Ambient Sensor Disconnection / NOx Sensor
Disconnection / Poor DEF quality

3.5 Server Level inducement – After completion of the “Low Level Inducement” (62
Hrs) immediately Engine/Genset enters in the “ Severe level inducement” and the
GCU displays the massage of “Severe level inducement( High- Most severe)” on the
Genset display and engine/ Genset will shutdown.

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