Emission Reduction Systems, Inc.

FREQUENTLY ASKED QUESTIONS

FAQs for the Proventia FTF and Rypos RS 202-S Diesel Particulate Filters for Thermo King and Carrier Trailer and Bobtail mounted TRU Diesel Engines

Revised and Updated 4-11

Where do I find the ARB-TRU in use compliance schedule, so I can make sure when my TRU diesel engines need to be compliant?
Go back to the ERS Home Page and on the right side click on the tab that is labeled ARB-TRU Compliance Schedule, and the ARB compliance schedule will come up on your screen.  You can also print this schedule for your records and use as a reminder as to when you must be in compliance.

Understand you sell injector kits and nozzles….what’s included in these kits?
The injector kits include 4 complete injector assemblies for either Isuzu (same injector for di2.2 and se2.2) or Yanmar engine. Also included are copper gasket and o-ring for the Isuzu, or gasket and nozzle shield for the Yanmar. Injector return fuel lines are not included.  We also sell Injector nozzles which include a set of FOUR nozzles with gaskets and jumper lines.

Is an injector removal tool available?
YES-A puller tool is available for no charge with each FTF order, if requested. The tool fits either the Isuzu or Yanmar engines. It is designed to work within the tight clearances above the Yanmar and Isuzu engines installed in the TRU.

When is the DPF Filter for a Carrier TRU going to be available, and will it work just like the TK filter?
The Carrier TRU DPF filter was verified on March 9, 2009 and is available and in stock for purchase. It is a slightly different design from the TK filter. The TK filter is a ‘passive’ design that means it uses the engine heat to regenerate, or burn off, the particulate matter (soot). The Carrier filter is an ‘active’ design which uses electrical regeneration to burn the soot, and is verified as a Level 2 LETRU VDEC.  It also will have the ability and the option to be upgraded to a Level 3 ULETRU VDEC in late 2011.

Is a filter available for a bobtail TRU (i.e., straight truck)?
YES…On May 15, 2009 we (Proventia) received ARB verification for the FTF-Bobtail Diesel particulate Filter.  Based on the same principle as the trailer mounted passive FTF Thermo King filter, this newest addition to our product line replaces the current muffler on 1987-2002 Thermo King and Carrier Bobtail/Truck mounted TRUs.  Please see the brochures posted on our website for more details.

My shop does not do repairs. If I buy your filters, who can I get to install them?
We have dealers/installers in California, Oregon and Washington that are qualified to do the installation. The list of shops is growing so see your ERS representative for a location convenient to your facility. The installation requires about 2-3 hours for the FTF installation and 1-2 hours for the injector replacement.  We also have posted a list of these dealers/installers on the ERS website.  Just click on the “where to buy” button.

Do I have to use ULSD fuel after I install the FTF?
Yes, the Ultra Low Sulfur Diesel fuel (<15 ppm sulfur fuel) is required for proper operation of the FTF. The higher sulfur levels in regular off-road diesel fuel will clog the platinum catalyst inside the FTF, and eventually cause the FTF to become clogged with soot. You can apply for road tax credit for any ULSD fuel that is used for the TRU.

Can I use Bio-Diesel Fuel after install the FTF?
Yes, as long as you use ULSD (<15 ppm sulfur) B-20 Bio-Diesel fuel.  B-20 means that 80% of the fuel is still diesel fuel.

How often will I have to clean the FTF, and how do I clean it?
In field tests, the FTF has gone at least approximately 6000 hours without need for cleaning. It is possible to go even longer depending on the duty cycle of your TRU. High-speed operation helps to keep the FTF clean, so that means more door openings and daily loading/unloading of the trailer will generally keep the FTF in the cleanest condition. Long periods of time operating at low speed operation are the most difficult duty cycle in which to keep the FTF clean, however the FTF controller is designed to force the TRU into high speed operation if it has run too long at low speed.
Clean the FTF by removing the FTF from the TRU and blowing compressed air into the FTF outlet in the direction opposite of the exhaust flow. However, the ash that would be blown out of the inlet of the FTF must be collected into a chamber with a HEPA filter that collects all of the particulates for eventual disposal as a hazardous waste. Contact Rypos at 800-609-4021 or ERS for recommendations of companies that have capability to remove the ash from the FTF.

When cleaning the FTF, is the residue considered a hazardous waste and how do I dispose of it?
Yes, it is considered a hazardous waste. Follow ash disposal and handling guidelines as prescribed by CARB at: http://www.arb.ca.gov/diesel/tru/documents/ashguide.pdf

Do I have to do the oil consumption test before I install the FTF?
Yes, for the Thermo King units it is a requirement of the Executive Order issued by CARB for the Proventia  FTF that the oil consumption rate be checked according to the Proventia owners manual prior to installation of the FTF. If the oil consumption rate exceeds Proventia recommended guidelines, the engine should be serviced to fix the oil consumption problem before the FTF is installed. Excessive oil consumption can cause the FTF to become clogged with ash (from the burning of the oil) requiring the FTF to be cleaned frequently.  See ARB Executive Order DE-08-001-01.  Oil consumption cannot exceed 1 quart of oil usage in 50 hours of run time.  This is not a requirement for Carrier TRUs.

Do I have to change the injectors before I install the FTF?
Yes, for Thermo King units it is a requirement of the Executive Order issued by CARB for the Proventia FTF that the injectors be replaced prior to installation of the FTF. Worn injector nozzles can result in excessive soot in the exhaust, which will cause the FTF to become clogged with soot, and requiring the FTF to be cleaned frequently.  See ARB Executive Order DE-08-001-01.  This in not a requirement for Carrier TRUs.

How soon after the oil consumption test and injector replacement do I need to install the FTF on a TK TRU?
You can install the FTF immediately, or up to 4 weeks later would be okay.

Does the FTF increase fuel consumption and increase engine backpressure?
The FTF does cause a small engine backpressure increase, however the increased engine backpressure does not have an adverse effect on the engine components or engine wear. The FTF controller is designed to clean the filter when the engine backpressure reaches 2.5 psi during low speed operation. By comparison, an engine with a muffler (and without an FTF) will normally run with about 1-1.5 psi engine backpressure.
The effect on fuel consumption was not measurable and is less than a 1% penalty on the fuel consumption rate.

Does the FTF make the engine run hotter? Will it affect the TRU engine performance?
There is a slight increase in exhaust temperature of about 10-20F due to the increase in engine backpressure. The Proventia insulation that is installed on the exhaust tubing between the engine and the FTF is designed to keep the heat in the exhaust so that the FTF will burn itself clean, however this insulation does not cause the engine exhaust temperature within the engine to be hotter.

There is no loss in horsepower or any other effect on the TRU engine performance.

Can the FTF be retrofitted to a TK Super II or TK Sentry TRU?
Yes, kits are available for both of these models. The FTF, and kit contents, are unique for each of the TRU models: SB, Super II and Sentry.

Do all the FTF kits mount inside the current TRU cowling? Do any installations require cutting the TRU frames?
The SB and Sentry FTF mount horizontally inside the current TRU cowling.
The Super II FTF mounts vertically outside of the cowling, on the right side above the roadside service access door.
None of the FTF installations require any cutting of the TRU frames or access doors.

What is included in the FTF kits?
Each kit for an SB, Super II or Sentry is unique, but they all have these types of components:
-FTF with mounting brackets
-exhaust tube with backpressure fittings
-insulation pieces for exhaust tubing between the engine and the FTF
-exhaust manifold insulation, with bolts, washers, stainless steel band wraps
-FTF controller with wiring harness
-pressurizer for testing the FTF controller
-ULSD label for fuel tank
-CARB label with FTF serial number
-Owners manual with installation instructions

How does the FTF controller integrate with the TRU controller? Will the FTF controller set a code on the TRU controller? At what backpressure does the regeneration begin?
The FTF controller does not integrate with the TRU controller. The FTF controller will directly apply a 12V signal to the speed solenoid in order to force the TRU into high speed operation for 10 minutes, if the TRU has been running for too long at low speed operation (soot can accumulate within the FTF during extended low speed operation). The TRU controller does not generate any code from this.

The FTF controller contains a pressure switch that detects when the engine exhaust backpressure reaches 2.5 psi during low speed operation. At 2.5 psi, the FTF timer will energize the high speed solenoid for 10 minutes to force the TRU into high speed operation, which will burn off, and regenerate the accumulated soot within the FTF.

Do I have to remove the TRU from the trailer in order to install the new FTF?
No, the FTF installation is designed to be done with the TRU mounted on the trailer. The installation of the FTF, exhaust tubes, insulation and controller are easily accessible with the TRU mounted on the trailer. The installation of the exhaust manifold insulation would be easier with the TRU removed from the trailer, but is still accessible with the TRU on the trailer. See the installation manual for more details on the exhaust manifold insulation.

When I install the exhaust manifold insulation, some of the bolts might snap off. What will I do then?
The preferred installation method for the exhaust manifold insulation on the Isuzu se2.2 and Yanmar engines is to remove the existing exhaust manifold heat shield and install the new exhaust manifold insulation using new bolts/washers included in the FTF kit. If the old bolts snap off, the kit also includes three stainless steel band wraps that can be used to hold the new exhaust manifold insulation onto the exhaust manifold, as an alternative method.

On the Isuzu di2.2, there are no bolts to remove, and the exhaust manifold insulation is held onto the engine with the stainless steel band wraps.

Does the FTF cause engine seals to blow?
No. The engine crankshaft seals are primarily affected by the amount of exhaust blowby gas (the exhaust that leaks past the piston rings, due to worn rings), not by the exhaust backpressure.

What customers are currently running your FTFs and can we talk to them before we buy?
There are customers that are willing to share testimonials on their experience with the FTFs. Contact your Rypos or ERS representative for more information.

I have installed a remanufactured engine in my TRU. Do I still need to install your FTF in order to be compliant?
If the engine was remanufactured to a Tier 1 spec, then the effective model year will be the last year of the Tier 1 which is 2003. So this engine will need to be retrofit with a ULETRU VDECS in 2011.

If the engine was remanufactured to a pre-Tier 1 spec, then the effective model year will be 1998, and the engine will need to be retrofit with an FTF in 2008.
Isuzu se2.2 began in about 1995. Tier 1 began in 1999. So all Isuzu di2.2 are pre-Tier 1, and if Isuzu di2.2 are remanufactured, they need to be retrofit in 2008.

For more information see CARB advisory #08-05 at http://www.arb.ca.gov/diesel/tru/advisories.htm

Can I use 100% biodiesel fuel, instead of an FTF, in order to be compliant?
No biodiesel producer has begun the verification process for B100 biodiesel yet. If a biodiesel producer would begin an ARB verification right now, it would still be 2010 before the verification could be completed. For more information see CARB advisory #08-08 at http://www.arb.ca.gov/diesel/tru/advisories.htm

What repair parts should I keep in stock after I install your FTF?
A complete controller assembly, or the components within the controller that could fail such as: backpressure switch, timer, or an indicator gage.

Why is there a small hole in the FTF where exhaust is coming out? Why is there a hole in the bent tube?
These are both to eliminate the intrusion of rainwater into the engine. The hole in the FTF that is blowing exhaust is on the ‘clean’ side of the FTF.

Is the pressurizer that is pictured in the installation manual included in the FTF kit?
Yes, the intention of the kit is to provide all pieces of bolts, washers, clamps, pressurizer and miscellaneous parts necessary for a complete installation in order to minimize the installation time.

After I install the DPF, what are my next steps in regards to the ARB and other agencies?
After completing installation of the Proventia FTF exhaust filter system, the owner of the TRU can apply for a CARB IDN at the CARB TRU website: http://www.arb.ca.gov/diesel/tru.htm
See pages 9 to 11 at this website for complete details: http://www.arb.ca.gov/diesel/tru/documents/comply07-07.pdf

Can I apply for a CARB IDN if my TRU is from out-of-state or out-of-country?
Yes, but the CARB IDN is not mandatory for TRUs from out-of-state or out-of-country, however it will make the inspection process go smoother for you if your TRU is inspected within California for compliance.

Whom do I contact to purchase the Proventia FTF TK kits and the RYPOS Carrier kits?
Rypos, Inc is the exclusive distributor for the Proventia FTF TK kits and also for the Rypos Carrier kits.  Contact Doug Emig at ERS (a RYPOS/Proventia Affiliate)
At 925 362 8242 In Northern California, or if you are from out of State.   Or by email at dougemig@emissionreductioninc.com  or for more sales information go to the ERS website at http://www.emissionreductioninc.com

Can I lease the FTF filters?
Yes, there are financing and leasing options available. Contact your ERS representative for more details.

How much does the kit weigh? What is the shipping cost?
The Thermo King filter weighs approximately 26 pounds and costs $30 to ship by FedEx ground.  The Carrier filter weighs approximately 60 ponds and costs $60 to ship FedEx ground.

Can I source injectors through ERS?
Yes, you can purchase remanufactured injector kits (including gaskets) through ERS or directly from Rypos. There is an additional core charge until you return your old injectors.

How do I return the injector cores to gain credit for the core charge?
The injector kits include a mailing label that includes your return authorization for the injector cores. You can use the same packing materials to return the cores. Once the core is received, Rypos will issue a credit to you.

Can you provide test data?
In a separate attachment there is the test data for a 1500 hour field test. This shows that the FTF would slowly increase the engine exhaust backpressure, then the FTF would clean itself during normal operation which would reduce the backpressure again to a normal level. Ask to see the field test data from Rockview Dairy.

If my TRU averages between 2000 to 3000 hours per year, how long will the FTF last?
The FTF contains a metal filter media that is catalyzed with platinum. The platinum is not used up or depleted during normal TRU operation unless some materials are introduced into the FTF that can reduce the effectiveness of the platinum, such as fuel additives, sulfur, and engine oil. Fuel additives and high sulfur fuel can actually reduce the performance of the platinum within the FTF resulting in the need for frequent cleaning of the FTF. The burning of engine oil is normal in an engine, but will result in an accumulation of ash within the FTF. The FTF will need to periodically (approximately 5000 hours) have the ash cleaned out. If oil consumption rate increases as the engine ages, the FTF may need to be cleaned more frequently due to increased levels of burned engine oil and accumulated ash.

How long does FTF installation take?
Installation time is 3 hours for the Thermo King filter and 4.5 hours for the Carrier filter.  There is additional time needed to replace the injectors of 1-2 hours for the Thermo King filter

If I install a Diesel particulate Filter on my TRU engine by the end of 2011 how long will the DPF make me compliant?
Your TRU will meet the ARB ATCM regulations and be compliant for SEVEN years or until the end of year 2018.

I lease my refrigerated trailers.  Do I have to make the TRU engine compliant under the ARB TRU ATCM regulation and if so who is responsible for making these engines compliant?
Leasing companies are responsible for complying with the in-use performance standards for all TRUs they own that are operated in California.  Who is responsible for making them compliant will be determined by the terms of the lease contract.