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ECM NOx/NH3 5240, Instruction Manual, Page: 1 / 66

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NOx/NH3 5240 

NO

x

, NH

3

, and O

2

 Analyzer 

 

 

 
 

Instruction Manual 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

10/18/13  

Summary of Contents for NOx/NH3 5240

Page 1: ...NOx NH3 5240 NOx NH3 and O2 Analyzer Instruction Manual 10 18 13...

Page 2: ...Rights Reserved No part of this manual may be photocopied or reproduced in any form without prior written consent from ECM ENGINE CONTROL AND MONITORING Information and specifications subject to chang...

Page 3: ...16 CAL Calibrate Setup Option O2 NOx SAMP 18 CAL Calibrate Setup Option P AVG SKEW 24 CONF Configure Setup Option LEdS 1V4V CAN NEG LOCK FACT 26 Specifications and Limits 29 Measurements and Accuracie...

Page 4: ......

Page 5: ...exhaust gas oxygen sensor output CAN output and dbc generation software Up to 100m between sensors and display possible Lockout feature for front panel of display Power on off can be controlled by ext...

Page 6: ...included 09 05 6 Eurofast Termination Resistor 2 included 09 06 7 Sensor Cable 1 m 10 02 8 DC Power Cable Banana Plugs 11 16 9 Female Eurofast to DB9F 11 05 10 Key on Cable 2 m 11 08 11 External Moun...

Page 7: ...4VDC 4 2A P N 04 01 4 Vboost Supply 10 14VDC to 24VDC 14 5A P N 04 02 helps to avoid battery drop out issues during cold starts 5 Pressure Compensation Kit for remoteSAMPLER P N 47 P 6 Pressure Compen...

Page 8: ...s away from hot moving sharp or high voltage spark objects Take into consideration the movement of the engine chassis and wind buffeting when instrumenting the engine Clear tools away from the engine...

Page 9: ...be turned on via the PWR button on the display head or a 2 7 to 32V signal to the Key connector on the back of the display head The current requirements of this signal are very low 100 A The length b...

Page 10: ...6 Figure 1 NOx NH3 5240 Analyzer...

Page 11: ...IB EIB Connector CAN Bus Connector P N 13 01 Manuals and Configuration Tool P N 09 04 0 3 m Flexi Eurofast Cable P N 09 05 Eurofast T P N 09 04 Eurofast Termination Resistor P N 12 01 19 Rackmount Pan...

Page 12: ...8 Figure 3 Sampling System...

Page 13: ...9 Figure 4 Inside the remoteSAMPLER 1000 early model without drain solenoid shown...

Page 14: ...10 Figure 5 External Mounting Block Sensor and Mounting Boss Also Shown...

Page 15: ...exhaust pipe Use the 0 3m of stainless steel line at the exhaust pipe end of the line Again you may trim the PFA to a suitable length An NH3 scrubber is inside the remoteSAMPLER see Figure 4 With the...

Page 16: ...e drawn from the exhaust This sample and the compressed air used to power the pump are returned to the exhaust For vehicle installations ECM has used a Viair 450C IG air compressor Viair P N 45050 2 g...

Page 17: ...play In RUN mode five things other than data can be displayed 1 ERR and where is an error code See Appendix B 2 which means that a module has not been assigned to that display See MOd Setup Option 3 w...

Page 18: ...AMPLER delay Td 274 x L 2 715 L length of line m from external mounting block to remoteSAMPLER Td is time in msec 800 ASAM remoteSAMPLER averaging 0 1 CNH3 Cal check NH3 using model gases EXIT P UNIT...

Page 19: ...uel H C O C and N C ratios and whether or not the fuel is H2 is information stored in the modules AOUT Analog Output Setup Option A1 to A6 The display head has six programmable analog outputs Analog o...

Page 20: ...tion to occur at 0V will be output when lean of the programmed value and 1V will be output when rich of the programmed value 9 When AOUT is displayed press SYS to return to RUN mode For analog outputs...

Page 21: ...ed pressure absolute in mmHg LAMR LAMBDAreal Lambda before addition of Delta Lambda Table AFR Air Fuel Ratio Air Fuel ratio calculated using LAMBDA see below PHI PHI PHI 1 LAMBDA FAR FAR 10000 FAR 1 A...

Page 22: ...ter to add water vapor There are two ways to do this the first is to add a bubbler at the Sample Inlet The second is to use the NH3 Scrubber as a bubbler by temporarily re plumbing the system Water or...

Page 23: ...19 Figure 6 System Re Plumbed for Calibration...

Page 24: ...played press SYS to return to RUN model See AGEF below 9 The user calibration is written into the memory chip in the sensors connectors and will be used to calculate O2 AFR FAR and the wet to dry conv...

Page 25: ...on is written into the memory in the sensors connectors and will be used to calculate NOx and NH3 If the sensors are removed and installed on another analyzer this user calibration will be carried ove...

Page 26: ...is erased and the factory calibration will be used to calculate NOx and NH3 SAMP SAMP contains features related to the remoteSAMPLER Td Td is the pure transport delay units msec of the gases from Sens...

Page 27: ...urn the pump on by reconnecting the compressed air 10 Adjust the pressure regulator inside the remoteSAMPLER to obtain 5 lpm into the external mounting block with the block drawing in ambient air Note...

Page 28: ...ot change their default values without contacting ECM How the averaging filters are used is shown by Equation 2 The averaging filters are user programmable and can be assigned values from 0 001 heavy...

Page 29: ...eter B Equation 3 where ParameterSkewed NH3w NH3d NOxw NOxd P AFR FAR O2w and O2d value after being skewed Parameter NH3w NH3d NOxw NOxd P AFR FAR O2w and O2d measurement before being skewed M Skewing...

Page 30: ...ppears in your CAN bus the termination resistor may have to be present or removed The rule is that they should be at the ends of the CAN bus The CAN data communicated is 1 What is being sent to analog...

Page 31: ...dcast Addresses CANid1 through CANid4 and ERCd are user programmable To program them enter SYS mode down to CONF press the ENT key down to CAN press the ENT key once while displaying CAN press the ENT...

Page 32: ...lay is counting down TopAux_sn or BtmAux_sn will contain the countdown number 7 See Appendix E for additional information NEG Parameters NH3w NH3d NOxw NOxd O2w and O2d are normally limited to a lower...

Page 33: ...absolute Pressure 0 to 517 kPa 75 Psia 150ms 5 2 kPa 0 75 Psia 1 The response time is for default settings of averaging filter ANH3 See CAL Setup for more information 2 The response time is for defau...

Page 34: ...ommonly used methanol H C 4 0 O C 1 0 N C 0 0 ethanol H C 3 0 O C 0 5 N C 0 0 propane H C 2 67 O C 0 0 N C 0 0 methane H C 4 0 O C 0 0 N C 0 0 Maximum allowable levels of fuel Impurities Lead 0 012 gm...

Page 35: ...g Thread with Engine NPT USA or ISO tapered Metric Tubing Lengths 0 3m stainless steel 1m PFA Perfluoroalkoxy Tubing Diameter USA or 6mm Metric Nut Front Ferrule Back Ferrule at remoteSAMPLER end of T...

Page 36: ...A USA 12 11A Metric Notes 1 Must be 28 711mm long Do not modify by more than 25 without contacting ECM 2 Stainless steel end of tubing towards external mounting block Teflon end towards pressure senso...

Page 37: ...Impedance 2 66 k Bits Resolution 12 bits Update Rate 100 ms Isolation Electrically isolated from power supply ground All analog output grounds common CAN Protocol Broadcast Broadcast Rate Programmable...

Page 38: ...al ON Voltage Level 2 7 to 32 VDC Current Draw 100 A Environment Display Head 40 to 85 C 100 humidity non condensing display head is not sealed remoteSAMPLER 55 to 125 C 100 humidity IP66 modules insi...

Page 39: ...NOxCAN T for T sensor just module no sensor no cables 02 08 LambdaCANp just module no sensor no cables 02 09 LambdaCANd just module no sensor no cables 02 10 gpCAN just module no cables 02 11 COCO2CA...

Page 40: ...05 Pressure Type KP 0 100 psia 1 4 USA 07 06 Pressure Type KP 0 689 kPa 6mm Metric 07 07 RH Humidity Sensor NPT 07 08 Pressure Lp C bCAN only 0 75 psia 1 4 USA 07 09 Pressure Lp C bCAN only 0 517 kPa...

Page 41: ...pter to use P N 2400E 1S sensor Fischer with LCAN 10 17 Adapter to use P N 1001A 2 Deutsch with LCAN 10 21 Module Y Cable for all except Lp C and bCAN 10 26 1m Humidity Cable bCAN 6 term 10 27 2m Humi...

Page 42: ...ires 11 24 Connector Kit 2 connectors 24 terminals 12 plugs 11 25 Male Eurofast to Braided Shield Ground 11 26 Boom Box Cable for CAN Products 80 CAN 30 Power 11 27 Boom Box to Hub Springy Cable 1m re...

Page 43: ...1 5mm SS Boss and SS Plug for NGK NOx 12 29 18mm x 1 5mm male to 1 4 NPT female 12 30 Carrying Case Medium 12 31 Aluminum Sensor Mounting Block 20mm 18mm 12 32 Small Aluminum Sensor Mounting Block 20...

Page 44: ...m x 1 5mm Die 14 03 1 4 NPT Tap 14 04 1 4 ISO Tapered Tap 14 05 Antiseize 14 06 Metal Brush 14 07 Lambda Sensor Calibration System 14 08 20mm x 1 5mm Bottoming Tap 14 09 Filler Bottle 14 10 Cupric Sul...

Page 45: ...025 Pulse Red 2x 2s Non compatible NOx NH3 sensor memory chip format old Rev 0031 Pulse Red 3x 2s Vsw 6 for 7 sec Supply voltage too low 0032 Pulse Red 3x 2s Vsw 30 V Supply voltage too high 0041 Puls...

Page 46: ...1 C Pws 18 65 mmHg Ta C 0 1 2 3 4 5 6 7 8 9 Pws mm Hg 0 4 579 4 926 5 294 5 685 6 101 6 543 7 013 7 513 8 045 8 609 10 9 209 9 844 10 518 11 231 11 987 12 788 13 634 14 530 15 477 16 477 20 17 535 18...

Page 47: ...until CONF is displayed Then press ENT 3 Press until MOdE is displayed Then press ENT 4 Press until LOCK is displayed Then press ENT 5 50 will be displayed Press until 60 is displayed Then press ENT...

Page 48: ...f messages from one or more analyzers on the same CAN bus can be created Each analyzer communicates eight pieces of data two error codes and two auxiliary codes The eight pieces of data are what is be...

Page 49: ...the Device window its data will appear at the bottom of the Configuration Tool s screen After the last analyzer on the CAN bus has sent its message format to the Configuration Tool that list of analy...

Page 50: ...a thick aluminum plate The aluminum plate is mounted on the outside of the frame on the right side of the truck using two existing holes in the frame The plate is held off of the frame using two 1 di...

Page 51: ...have to be drilled All units in inches Drill 5 16 2 Places Put two 5 16 x 2 bolts with washers through these holes through two 1 dia x 1 long drilled dowels and through existing holes in the frame In...

Page 52: ...48 Plate is mounted on two existing holes in the frame Here s the plate mounted...

Page 53: ...e plate and attach the Eurofast cable for the EIB to display head the Eurofast cable for power to battery and the line to the pressurized air source Note the orange silicone isolators McMaster Carr P...

Page 54: ...r 450C IG The compressor is attached to an aluminum plate which is attached to the cab body via rubber isolators McMaster Carr P N 5822K9 The rubber isolators significantly reduce the transfer of pump...

Page 55: ...51 Here are some pictures of the front of the tank showing the pressure relay switch Viair P N 90111 the feed from the pump the blow off valve and the tank mounts...

Page 56: ...labeled 2 is on the fitting that the sample will be returned to after going through the remoteSAMPLER The sample that is returned to the exhaust has air from the compressor added To avoid this air fro...

Page 57: ...the 90 degree hard right made it a little easier to plumb from the block to the remoteSAMPLER Once the block is screwed into the exhaust the Swagelok nut can be loosened to reorientate the block in a...

Page 58: ...h of PFA tubing near the remoteSAMPLER to give the sample line some give Measure the length of the sample line L This value will be used to calculate a Td value that must be entered into the analyzer...

Page 59: ...ntil it starts leaking out of the screw hole Reinstall the screw with gasket and tighten Turn the system on and check that the pressure is 15 psig Adjust the pressure using the regulator in the remote...

Page 60: ...56 Tap power from battery on LHS of engine compartment Use battery on RHS of engine compartment to power air pump Tap here for Key signal in fusebox near firewall on LHS of engine compartment...

Page 61: ...sec that is calculated via Td 274 x L 2 715 where L is the measured length in meters of the external mounting block to remoteSAMPLER sample line See Table 1 Check sample flowrate by removing external...

Page 62: ...tability and fitness for purpose whether express implied or arising by operation of law trade usage or course of dealing are hereby disclaimed The warranty is void if the display head is opened LIMITA...

Page 63: ...00 SIM400 SIM500 SIM600 SIM700 SIM800 BTU200 NOx NH3 5240 Analyzer To which this declaration relates are in conformity with the essential requirements of the following standards EN61326 1997 A2 2001 C...

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Page 66: ...Los Altos CA 94023 0040 USA 408 734 3433 Fax 408 734 3432 www ecm co com...

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