AdBlue emulators and SCR systems – everything you need to know

AdBlue emulators are devices intended to take over control of the SCR (Selective Catalytic Reduction) system. SCR system is responsible for control of exhaust system on the modern truck, bus or other vehicles. A lot of the vehicles made and used in Europe equipped with diesel engines. Older diesel engines had a simple catalytic converter called DOC (Diesel Oxidation Catalyst). This type of catalytic converter is common for all compression-ignition engines. Diesel oxidation catalytic converters made from ceramic core coated with palladium, platinum and aluminum oxide. These coatings serve as catalysts to oxidize the remains of the hydrocarbons and carbon monoxide in the exhaust gasses with oxygen to form carbon dioxide and water. But at certain conditions diesel engines may produce significant amounts of NOx (Mono-Nitrogen Oxides) emissions. Mono-nitrogen oxides NO and NO2 (nitric oxide and nitrogen dioxide) considered as pollutants and led to the introduction of SCR (Selective Catalytic Reduction) systems.

Selective Catalytic Reduction system

Selective Catalytic Reduction (SCR) system is a device that has one purpose, to reduce the quantity of Mono-Nitrogen Oxides (NOx) in engine exhaust gasses. While diesel oxidation catalytic converter (DOC) is capable of reducing emissions of hydrocarbons and carbon monoxide, SCR is capable of reducing NOx emissions. SCR catalytic converter core usually made from ceramic (titanium oxide) and coated with oxides of such metals as tungsten, vanadium, molybdenum and other precious or rare metals.

Anyway, this type of catalytic converter needs an additional component to perform necessary reduction reaction. The required reduction reaction is only possible by adding a solution of anhydrous ammonia, aqueous ammonia or urea. This additive called DEF (Diesel Exhaust Fluid). The most popular DEF solution on the market is AdBlue. AdBlue is a registered trademark of German Association of the Automotive Industry (VDA). That’s why emulators of SCR systems often called AdBlue Emulators.

Selective Catalytic Reduction (SCR) catalytic converter works by injecting Diesel Exhaust Fluid (DEF) for example AdBlue to the exhaust system. DEF injected before catalytic converter chamber where its vapor mixes with exhaust gasses. Selective Catalytic Reduction System is capable of reducing NOx quantity in exhaust gasses only when the specified temperature reached in catalytic converter chamber. It is important that the temperature will reach 360-450°C otherwise SCR effectiveness is relatively small. It means that it needs some time after the cold engine starts to arrive at the required temperature to start the NOx reduction process effectively. SCR system has an exhaust temperature sensor which sends temperature data to the SCR electronic control unit (ECU).

Diesel Particulate Filter

Diesel Particulate Filter or simply DPF is a device that is common to all modern diesel engines. It is designed to remove any possible diesel particulate matter (solid particles) or soot from the exhaust gasses before they are exhausted to the atmosphere. Particulate matter is a result of incomplete or just improper diesel combustion cycle. There are several reasons which could cause the production of particles:

• Cold engine starts, especially in the ultra low-temperature environment.
• Lack of intake air pressure or flow due to damaged turbo charger or clogged intake channels.
• Reduced compression in cylinders due to damaged engine components.
• High engine load or sudden power demand on rapid acceleration.
• Clogged exhaust gas recirculation (EGR) system.
• Poor fuel quality, engine oil in the combustion chamber of cylinders and other factors.

Diesel particulate matter particles considered as one of the most harmful pollutants. All EURO 6 type exhaust systems must have DPF (Diesel Particulate Filter) systems. Some DPF filters are single use, and some of them are capable of regenerating at certain conditions (DPF regeneration). Recovery is possible by burning more fuel and rising exhaust system temperature which makes possible to burn out any contamination from the filter. DPF regeneration controlled by a vehicle engine control unit (ECU) and executed when necessary conditions are reached (exhaust temperature, fuel quantity in the tank, vehicle speed, and engine speed).

SCR and DPF systems failures

The most common troubles on the road for truck drivers caused by SCR or DPF system failures. In both cases, the vehicle will be difficult to drive due to limp mode activated by central ECU of the engine. Limp mode noticeably reduces engine power to protect the environment from possible highly polluted exhaust gasses even when the engine is capable of working properly.

As the ride with a truck is virtually impossible when it has faulty SCR or DPF system, it can cause significant headaches for a driver. Repair cost for any of these systems has a high price tag especially if you need this fix asap.

In some northern regions of Europe and Russia, environment temperatures can be low as -40°C. These ultra-low temperatures are way beyond the freezing point (will freeze if its temperature falls below -11°C) of diesel exhaust fluid (DEF). Injecting frozen diesel exhaust fluid to the SCR chamber is impossible. Also, it will damage the DEF pump, and whole SCR system will be faulty.

Moreover, we need to mention that there are a lot of countries outside the EU which do not require EURO 6, EURO 5 or even EURO 4 standard compliance and those complex and sensitive SCR or DPF systems.

So what to do if you need a quick fix of your faulty SCR system, or you want to disable SCR system permanently and save a lot of money? Well, there are three ways:

• You can leave your truck in the workshop for the complete system repair (we recommend it if your truck mostly used in the European Union). It will cost you a lot, but your vehicle will meet the required EURO standard.
• You can disable the SCR system by reprogramming an ECU. We do not suggest this method. Yes, it is quite simple for an experienced professional, but it will cost you to bring back the SCR system back if you change your mind. Reprogramming will disappear after every firmware update if you upgrade the software of your vehicle. Also, it could make some trouble if you decide to sell the truck with its altered software.
• Finally, you can choose the easiest, cheap and popular way – install the AdBlue Emulator. It is safe to use, easy to install even if you don’t have specialized knowledge in vehicle electronics or special tools, and you can turn it off or uninstall completely anytime you want in a matter of several minutes. You can resell it if you don’t need it anymore (try this with ECU reprogramming).

AdBlue Emulators (SCR emulators) – how it works

So-called AdBlue Emulator is a device that is designed to override controls of the original on board Selective Catalytic Reduction (SCR) system. AdBlue emulators are of different types, adapted to the particular truck or engine models. Such device installed on the compatible vehicle takes control over whole SCR system and its components. It imitates proper work of the Selective Catalytic Reduction system on the CAN/OBD level. When installed it keeps SCR system inactive, and at the same time, it sends necessary data to the central ECU to avoid limp mode. There are no errors on OBD system because AdBlue emulator emulates all parameters and data. No loss of engine power, no increased smoke from the exhaust system, no DTC errors on OBD system and zero consumption of DEF, and if your truck engine works fine there is no more pollution than usual. Latest AdBlue emulator models are capable of overriding exhaust temperature and NOx sensors for full functionality.

AdBlue emulator could help you to drive on the regular engine mode even if the SCR system is faulty. But the main reason why so many trucks equipped with AdBlue emulators is the saving of money on a diesel exhaust fluid.

AdBlue Emulator types

AdBlue emulators appeared right after the introduction of EURO 4 type trucks. EURO 4 vehicles already had SCR systems and these systems suffered from various faults. The first generation of AdBlue emulators was designed just to remove errors from OBD system if SCR was faulty. Second generation AdBlue emulators appeared with the intention to override SCR system controls and to delete OBD errors caused by faulty or disconnected SCR systems. Modern AdBlue emulators share a lot of features and are available for the full range of vehicles and engines with abilities to override NOx and temperature sensors of the exhaust system. Now you can purchase AdBlue Emulator module for EURO 4, EURO 5 and EURO 6 type truck.

What AdBlue Emulator products we can offer

At this moment we can offer AdBlue emulators for almost any truck that might need one. All our emulators since the first generation designed and manufactured in Europe thus ensures the highest quality on the market. Regularly conducted research and development work allows us to offer best SCR emulation devices on the global market. We can provide AdBlue emulators for trucks and engines made by DAF, MAN, Iveco, Scania, Volvo, Mercedes-Benz, FORD, Renault and other. We were first to introduce EURO 6 AdBlue Emulator for Volvo trucks, and now we are supplying our customers around the world with the EURO 6 AdBlue emulators that are compatible with DAF, MAN, Iveco, Volvo, Scania, Mercedes-Benz, Renault and Scania EURO 6 trucks. If this is not enough, we want to remind you that we have AdBlue emulators compatible with DAF LF (Grundfos), Scania R730, Mercedes-Benz MP4 (EURO 5) and Volvo FH4 (EURO 5) trucks.

Legal regulations

Finally, we want to point out that such devices as AdBlue emulators in some countries may be illegal, and you have to decide to use it or not on your own. Please analyze your local law for environmental standards and don’t forget to check out the standards of countries that you want to visit or cross with your truck. The lack of knowledge of the law does not relieve you from the responsibility. We recommend you to stick to the rules and keep your vehicle in compliance with required environmental standards.

AdBlue emulators and related products