vi GEE CU Ee ee a lay Bur ars cla) Exhaust-gas cleaning system Self-Tuition Programme n° 1 rorefacion ASISTENCIALExhaust-gas regulating systems The current widespread concer for the environment has forced almost all countries to establish standards to regulate exhaust emissions. SEAT, a company which is always at the leading edge of technology, sets out in this self-tuition folder details on all anti-contamination systems which are fitted to its vehicles; as well as com- plying with the most stringent international standards, these systems reduce fuel consumption by highpressure maintenance methods.9 ° a © a an Exhaust-gas composition Exhaust-gas testing Lambda sensor Catalytic-converter mechanism Regulated three-way catalyst Microcatalytic converter Oxidising catalytic converter Activated-charcoal system Inertia activated stopExhaust-gas composition Three toxic substances are produced in the motorised fuel-combustion process; these subs- tances together represent between 1% and 2% of all emissions under partial load. The optimisation of the fuel consumption of engines over the last few years has made possible this low proportion of toxic substances. However, one must not lose sight of the large numbers of vehicles, which under particular cli- matic conditions - may cause environmental problerns. 1. Carbon monoxide CO Carbon monoxide is a colourless, odourless gas. In the human body, CO can cause oxygen deficiency, as it combines with haemoglobin in the blood (Haemoglobin = red corpuscles}. CO is produced by incomplete combustion (insufficiency of air). 2. Nitrogen oxides NOx During combustion in the engine in the presence of free oxygen, a part of the nitrogen absorbed from the air combines with oxygen, producing nitrogen oxides, NOx. This is one of the substances responsible for the death of forests. 3, Hydrocarbons HC During the combustion phase, the unbumt fuel (HC) is released via the exhaust. Hydrocarbons will only be completely eliminated from the engine by the use of technology which is still under development.The fuel-air mixture only ignites and bums in specific proportions. In the case of petrol, the proportion for total fuel combustion is 14:1. i.e. for kilogramme of fuel, 14 kilogrammes of air are needed. This is called the stoichiometric ratio, and is represented by = 1, when the air - fuel proportion is 14: ‘Stoichiometric relation A ich Lean > 0 Oo8 10 12 14 2 Charisteric curves of harmful substances in Otto engine. NOx concentration —= The free oxygen reacts with nitrogen, especially under conditions of high pressure and temperature, to form nitrogen oxides, NOx, ang 09 1,0 1,1 1,2 1,3 1.4% Nitrogen oxides reach their highest concentration when the stoichiometric maratio (\ = 1) is approximately reached, and this concentration increases rapidly in proportion to the load on the engine.Exhaust-gas testing Testing procedures and analysis Using a power-test bench, a preset running programme is simulated (such a programme is con- sidered to be representative of running behaviour in specific areas), and the mass of toxic subs- tances released is determined. The test bench can be adjusted in such a way that the braking forse corresponds to the resis- tance encountered under road conditions according to the state of the roadway; using an inertia mass, the weight of the vehicle can be simulated. Europa Test (ECE/CE) Length: 1.013 km (repeated 4 times) Spe 100 km/h 50 0 100 195s Time Running eure Filter Heat exchanger Exhaust gases Roller tst banch The short European running-in cycle is valid in the EC; in this cycle, the number of grammes per test is measured In the USA, the number of grammes per mile is measured; hence, the two test methods cannot be compared. In Switzerland and Sweden, only the first part of the US cycle is tested, The two most well-knows methods are “Europatest” (ECE type 1), and the “US Federal Test” (CVS).Limiting values of exhaust gases Country co cH NOx ‘Sweden 24 g/km 2,1 g/km 1,9 g/km Switzerland 24 g/km 2.1 g/km 1,9 g/km Switzerland 9,3 g/km 0,9 g/km .1,2 g/km since 1987 The limiting values for the Otto engine are used for the Diesel engine. Furthermore, the emission of soot particles is mea- sured, Collection pockets (3 units} Serer r- (| + AY i or separator I = = =e qe Constant Tmaintenance Flow of volumete flow take CVS equipment Analyte equipment computer US-Test-75 Length: 17.8 km Speed 100 10 - minute km/h ! break rt 50 1 | ' ° utd 100 505 900 1375 0 100 505s TimeBy means of the lambda sensor, it is possible to detect the lightest changes which occur in the oxygen content of exhaust emissions. The lambda sensor sends signals to the electronic control unit, which corrects the opening time of the fuel injector nozzles. Structure of the lambda Sensor Connection cable for the sensor signal ‘Atmospheric ar entry Ceramic body of sensor PTC hasthing element ‘A ceramic body is installed in a steel casing. The inner and outer surfaces are coated with platinum. At approximately 300° C, the coating becomes a conductor of oxygen ions. The PTC heating element is used to heat the sensor rapidly. The PTC element is characterised by a high initial electricity consumption, so that the working temperature may be reached quickly. Electricity consumption falls as temperature rises.Method of operation The proportion of oxygen in exhaust gases and in the air is different; as a result, a potential difference forms between the two platinum surfaces. The voltage changes in line with changes in the oxygen content of exhaust gases, thus being transmitted as a signal to the control device. The following advantages result from this: © Uniform composition of the mixture © Changes to the richness of the mixture with changes in altitude © Correction of changes due to hot or cold air. Control unit Control rley Injoctor valves Lambde sensor Catalytic converter Siting the sensor at the entrance to the catalytic converter has shown that the sensor traps the 0, with some delay, due to the fact that hydrogen Ho diffuses faster than Oz. Hence, the sensor is sited at an intermediate position, along the catalytic converter (between two sections of the converter cartridge), in such a way that the Hz will have been oxidised in the first section.The word “catalyst” comes from the Greek word “katalysis", meaning “solution”. Ina scientific context, this word is used to indicate a substance which promotes chemical reac- tions. In the technology used on motorised vehicles, the catalyst is used to modify the toxic components of gases, thus reducing the emission of carbon monoxide (CO), hydrocarbons (HC), and nitrogen oxides (NOx). The catalytic-converter body can basically be ceramic (A) or metallic (B); in both cases, it is made of microcells impregnated with noble metals, as shown in figures C and D. Ceramic base Metal bese Figures a, tase ~— }—“intermediate layer ~ Noble metals Catalytic converters can only be used in combination with lead-free petrol, given that anti-pinking agents (tetraethyl lead, etc.) quickly deposit residues on the surface of the catalyst and the lambda sensor, neutralising the action of these two devices. 10SEAT currently incorporates three different types of catalytic converter, according to the model in which each catalytic converter is to be used. Regulated three-way catalytic converter Injector valve LU-2 command module Lambda sensor (CO measuring tube Throo-way eatlytic converter Microcatalytic converter ing catalytic converter (CO measurement tube Oxidising catalyst The catalytic converters are positioned on a section of the exhaust pipe so as to guarantee optimum operating temperatures (between 300° C and 900° C}. "The three-way bed catalytic converter is so called because it is able to reduce the three main harmful exhaust gases in Otto engines inside a casing. ‘© Carbon monoxide (CO) © Hydrocarbon (HC) © Nitrogen oxides (NOx) The catalytic converter is able to reduce up to 90% of harmful substances if the fuel-air mixture is close to the stoichiometric ratio= lambda 1.0. The catalytic converter becomes effective at an exhaust gas temperature of approximately 300° C. Lambda probe Catalytic converter mount ‘and catalytic elements Structure The oval-shaped housing consists of two steel nickel semi casings welded together. Inside is a ceramic element (single piece) made of a corderite material which is extremely resistant to high temperatures and has a low expansion coefficient. ‘An intermediate coating of aluminium oxide is applied to the ceramic body. This coating is then vaporised with a small quantity of platinum and rhodium at ratio of : Rh = 5: 1. Between the housing and catalytic converter mount is a flexible bracket (metal strands). 12Operation EoaeRARGRS Carbon monoxide (CO) and hydrocarbons (HC) are oxygen deficient. On the other hand, the contaminating substances NOx contain unwanted oxygen. The catalytic converter ie. the noble metals platinum and thodium, remobes the oxygen molecule from the nitrogen oxide (NOx) and binds it to the carbon monoxide (CO). Nitrogen (N,) and carbon dioxide (CO;) are thus released. The hydrocarbons react with the oxygen, removing water (H,0) and carbon dioxide (C02) . The exhaust gases after treatment in the catalytic converter ‘As shown in the diagram, the toxic substances in the exhaust gases have almost completely disappeared following treatment in the catalytic converter. These small quantities of contaminating elements are found only in the narrow margin around lambda = 1. This margin is called the “lambda window’ To the left and ring of this window the values rise immediately. The lambda probe serves to ensure that the operating area remains within the lambda window. Lambda window 13The nor-regulated three-way micto catalytic converter also reduces the three toxic substances. CARBON MONOXIDE (CO) HYDROCARBONS (HC) NITROGEN OXIDE (NOx) The smaller dimensions of the catalytic converter and the fact that itis fitted to lower powered engines which do not have an electronically controlled mixture, explains the lesser degree of effectiveness. Front exhaust pipe section Catalytic converter mount and catalytic elements a CO measuring pipe Micro-catalvic converter Structure The micro-catalytic converter consists of a stee! cylindrical body in which there are two sheets of rust-resistant steel (smooth/corrugated). An intermediate coating of aluminium oxide is applied to this round base and a final vaporised coating of platinum and rhodium. 14A single-piece metal body is placed on the oval-shaped steel housing. The former is treated with a coating of aluminium oxide vaporised with platinum and paladium. Front exhaust pipe section Catalytic converter mount ‘nd eatsytc elements The toxic elements the exhaust gases are thus eliminated The noble metals (Platinum and Paladium) operate at high temperatures causing an oxidizing reaction which converts the hydrocarbons (HC) into water (HO) and the carbon monoxide (CO) into harmless carbon dioxide (CO2) . 15In the case of conventional air-conditioning and ventilation systems owing to variable tempera: ture conditions, vapours which are expelled appear in the fuel tanks. To prevent these vaporised fuel emissions and in order to comply with different legal require- ments, the activated carbon system is used. Method of operation Engine off. Gases deriving from the fuel tank reach the activated carbon store and are absorbed like a sponge. Idling When idling, the cut-off valve is closed, No gases can pass through from the activated carbon store to the air intake distributer. Load Under load, the cut-off valve is depressed and opens. The gases go from the activated carbon tank through the cut-off valve (avoiding the butterfly valve) and directly to the intake manifold. PRESSURE LIMITING VALVE This prevents excessive pressure caused by expansion in the fuel tank allowing the excess to pass into the breather. ANTI-DUMP VALVE This protects the system in the event of an accident. 16HC = Tothe en Cutoff vale Amtidump valve = Hom fiter ake mai ee Vacuum connsction A | Activated carbon store Breather Pressure limiting valve Fuel tank 7When driving, there are situations when the vehicle travels without engine power i.e. under its ‘own inertia. During this phase in conventional systems, the engine continues to be powered. By incorpora- ‘ting an inertia disengagement system, the fuel supply is only cut off in this situation when a certain 1.p.m. is reached. When acceleration occurs, the fuel supply is restored, Inertia disengagement saves up to 10% on fuel consumption especially in town driving and on downward inclines. In addition, contamination is reduced when the system does not produce combustion. 18LU-2 Jetronic system The fuel is cut off through the injection control unit when the vehicle runs inertially and is above 1800 rpm. Control relay Injection contol unit Ignition contol unit Operation: The injection control unit analyses the information: = gas butterfly closed (this information is supplied by the gas butterfly switch) = the engine rotates at more than 1800 rpm. (this comes from the ignition control unit, completely eliminating the injection impulses) If the number of revolutions drops or if the gas butterly contact opens, the fuel supply is restored.Pierburg carburettor 36-1-B-3 Partial load: At partial loads, the r.p.m. signal is above 1,800 r.p.m and the pressure sensor is Distroutor closed because of the @ |__ Delay existing vacuum. Under these conditions, the control unit energizes the solenoid valve and the atmospheric pressure is applied to the minimum cut-off, which — opens so the fuel can flow. fies” Fuel cut-off when coasting: When the vehicle is coasting, the throttle valve is closed and the r.p.m. signal is above 1,800 r.p.m. ‘The pressure sensor is open because of the atmospheric pressure. These signals make the control unit to de-energize the solenoid valve and therefore vacuum presse “9? is applied to the minimum $250" cut-off, which closes. © preventing the flow of fuel. B Idle speed: valve > Air filter |— trroite damper assembly r © a — Throttle ‘damper assembly | a, — Ianition col Eloctrovalve — Ignition call When the r.p.m. value is close to the idle speed, the control unit energizes again the solenoid valve, and the fuel supply is re-established. 20— Pressure switch for engine load signal. = Solenoid valve for fuel cut-off, = Fuel cut-off electronic module, = Automatic starting heating resistor, — Grounding point in the windscreen ‘wiper motor support. 2 23 24 25 (26 27 2Weber DSTA/150 carburetor The fuel is cut off electrically by the throttle damper assembly when the vehicle is running ine tially and is above 2000 rpm. This function is gaverned by the control unit. Butterfly witch Theattle damper ascombly Contr unit Operation: The electronic control unit analyses the information: = gas butterfly closed This information comes from connector 1 of the ignition coil. = the engine rotates at more than 2000 rpm This information come from connection 1 of the ignition coil. With this information the control unit interrupts the current to the throttle damper assembly causing it to close. The gas butterfly switch can be altered by means of the adjustment screw. 2F21 — Fuel cut-off in the carburettor. F30 — Throttle valve switch. 18 — Fuel cutoff electronic module. 3 — Grounding point next to the right front headlamp. 50 ee eee ee a ae E is fia] Fo 35 NoM 7 o5 F30 233.851,90,0780 (02.90) Be sesso