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VariSCR –

Emission Controller

Operating Manual

P/N 01.50.025 – EN | Rev. 06/2020

Summary of Contents for VariSCR

Page 1: ...VariSCR NOX Emission Controller Operating Manual P N 01 50 025 EN Rev 06 2020...

Page 2: ...ogo are registered and or common law trademarks of the MOTORTECH GmbH All further trademarks and logos displayed or used in this publication are the property of the respective entitled person and are...

Page 3: ...1 Functional Description 15 3 2 Applications 15 4 Product Description 17 4 1 Technical Data 17 4 1 1 Certifications 17 4 1 2 Mechanical Data 17 4 1 3 Warning Notices on the Device 17 4 1 4 Product Ide...

Page 4: ...anual Pump Adjustment 54 8 8 Online Update Settings 56 8 9 Access Control for the VariSCR Emission Controller 57 8 9 1 Enable Disable Access Control 57 8 9 2 Login Logout 57 8 9 3 Changing the PIN 58...

Page 5: ...time Adjustments 93 8 13 1 Runtime Adjustments Pump 93 8 13 2 Runtime Adjustments Dosing Valve 94 8 13 3 Runtime Adjustments Gas Mixer 95 8 14 Log 95 9 Operation 97 9 1 Start up 97 9 1 1 Determine Val...

Page 6: ...level of technical knowledge with respect to the operation of gas engines and basic knowledge of electronic ignition systems are necessary Persons who are only authorized to operate the gas engine sh...

Page 7: ...serial connection system for linking control units CE Conformit Europ enne Conformity with EU directives Mark based on EU legislation for certain products in conjunction with product safety CPU Centra...

Page 8: ...06 2020 Abb Term Description Explanation SCR Selective Catalytic Reduction Technology for the reduction of nitrogen oxides in exhaust gases USB Universal Serial Bus Serial connection system to link a...

Page 9: ...med by personnel authorized by MOTORTECH Non compliance with the instructions will void any warranties for the proper function of the equipment as well as the responsibility for the validity of the ce...

Page 10: ...to your body is discharged Do not wear clothing made from synthetic materials to prevent static electricity from building up Your clothing should therefore be made of cotton or cotton mix materials Ke...

Page 11: ...he possibility to connect the earth potential and the negative pole of the power supply separated from each other How ground loops are created A ground loop is a ground connection of an electric wirin...

Page 12: ...sive gas mixtures as explosive gas mixtures can ignite on the hot sensing element Especially in the case of engine malfunction make sure that no unburned gas mixture enters the exhaust pipe Operationa...

Page 13: ...ions must be taken into account Risk of burning The surfaces of the system may heat up to high temperatures Ensure good heat transfer through ventilation when installing in the control cabinet Risk of...

Page 14: ...in residential areas and cannot ensure adequate protection of radio reception in such environments 2 5 Proper Disposal After the expiration of its service life MOTORTECH equipment can be disposed of...

Page 15: ...of pressure and speed of the AdBlue pump Monitoring of the exhaust temperature before and after the catalytic converter Monitoring of the NOX sensors and temperature sensors function The emission cont...

Page 16: ...incl pressure and temperature sensor dosing valve and heating Master Generator CHP Control System Pump module AdBlue tank NOX and temperature sensor before the SCR catalytic converter Exhaust tract SC...

Page 17: ...orage device enclosed with the device 4 1 2 Mechanical Data The VariSCR emission controller has the following mechanical characteristics Feature Value Dimensions 160 mm x 126 mm x 61 mm 6 30 x 4 96 x...

Page 18: ...umber of the emission controller S N Arrangement number of the emission controller A N Revision number of the emission controller indicating its precise construction status R N Exemplary representatio...

Page 19: ...t is high impedance Active output is low impedance Switching voltage max 32 V Current max 100 mA Max voltage drop at 100 mA 2 5 V galvanically isolated rated insulation voltage max 70 V DC Analog volt...

Page 20: ...AdBlue pressure Permissible voltage 0 V DC to 4 5 V DC Measuring range 0 bar to 19 5 bar abs 0 psi to 282 8 psi abs Measuring tolerance 2 of measured value Analog voltage input for AdBlue temperature...

Page 21: ...nsor 15 V DC to 25 V DC max 30 A load Input for the MAT sensor Sensor type PT100 Power supply 2 mA Three wire technology Measuring range 50 C to 150 C 58 F to 302 F Measuring tolerance 1 5 C in the ra...

Page 22: ...4 Product Description 22 Rev 06 2020 Field bus protocols No emission specific values are currently available in the field bus protocols 4 1 7 Overview Drawings Ports Connections and LEDs...

Page 23: ...Catalyst Sensors Connection of the NOX sensors and the temperature sensors before and after the catalytic converter via CAN bus Pump Module Connection of the pump module Dosing Unit Connection of the...

Page 24: ...ge 28 This LED lights up if the supply voltage is available Status signaling The status of the VariSCR emission controller is signaled via the LED Status Flashing green Error free operation Flashing o...

Page 25: ...e to electronic components Risk of destruction Make sure that the device is not covered and ensure sufficient circulation of air Scope of Supply The scope of supply of the VariSCR emission controller...

Page 26: ...ted to each other The GND connections must not be used for the supply 24 V DC The GND connections may only be connected to the respective components sensors etc Risk of damage to the device Incorrectl...

Page 27: ...sing unit Sensor signals Press Temp 4 wire shielded cable min conductor cross section 0 2 mm max cable length 15 m 49 MAT sensor 3 wire cable min conductor cross section 0 2 mm max cable length 15 m 4...

Page 28: ...standards and regulations must be taken into account Risk of injury When the power supply to the VariSCR emission controller is established the connected pump builds up the pressure If the AdBlue pip...

Page 29: ...6 Wiring Rev 06 2020 29 L 18 V DC to 32 V DC nominal voltage 24 V DC Variations 1 Battery Generator Control unit 2 Power supply 3 Battery Charger...

Page 30: ...ors on an earthed metal plate Module Sensors 1 NOX sensor before the catalytic converter 2 NOX sensor after the catalytic converter 3 Temperature sensors before and after the catalytic converter The m...

Page 31: ...onverter via CAN observe the following notes Each bus end must be fitted with a terminating resistor of 120 see drawing The maximum wire length is 250 m 820 depending on the bit rate The stub lines to...

Page 32: ...dule is wired using the 5 pole connector in the device cover Pin Designation Function 7 Pump Module Power Power supply of the pump module 8 Control Control signal for the pump 9 RPM Feedback signal pu...

Page 33: ...e cover Pin Designation Function 1 Dosing Unit Power Power supply of the dosing unit 2 Press Pressure signal 3 Temp Temperature signal 4 GND Ground of the dosing unit 5 Valve Control signal for the do...

Page 34: ...er The GND connections must not be used for the supply 24 V DC The GND connections may only be connected to the respective components sensors etc 6 5 Wiring MAT and MAP Sensor The MAT and MAP sensors...

Page 35: ...ature sensor 5 MAP Power Power supply for the pressure sensor 6 I in Current input for the pressure sensor signal 7 I in 8 U in Voltage input not currently used 9 GND Ground of the pressure sensor 10...

Page 36: ...el is applied the emission controller switches to the active operation mode At engine standstill the stop level low level must be applied in order to switch off the emission controller respectively to...

Page 37: ...Wiring Rev 06 2020 37 6 7 Wiring Binary Outputs The binary outputs are wired using the 12 pole connector The outputs can switch both the operating voltage and the ground L 5 V DC to 32 V DC max 100 m...

Page 38: ...The output is low impedance if a too high exhaust gas temperature has been measured before or after the catalytic converter 14 Catalyst Overtemp 15 GPO1 16 GPO1 17 GPO2 18 GPO2 19 Power The output is...

Page 39: ...ing the 8 pole plug Pin Designation Function 23 Analog Inputs 0 10 V U in currently without function 24 0 10 V GND 25 0 20 mA I in currently without function 26 0 20 mA I in 27 Shield Shield 28 Analog...

Page 40: ...minals for the analog inputs and outputs not selected in the MICT must remain unoccupied 6 9 Wiring CAN Bus The wiring of the CAN bus interface for communication with other devices is done via the 4 p...

Page 41: ...h of a stub Maximum length of all stubs 1 Mbit s 25 m 82 1 5 m 5 7 5 m 25 800 kbit s 50 m 164 2 5 m 8 12 5 m 41 500 kbit s 100 m 328 5 5 m 18 27 5 m 90 250 kbit s 250 m 820 11 m 36 55 m 180 125 kbit s...

Page 42: ...x or full duplex and twisted cables must be used With both variants the load resistance RT is the characteristic impedance of the cable Wiring Half Duplex First device Last device Second device Second...

Page 43: ...ng Rev 06 2020 43 Connection to VariSCR emission controller The Modbus is wired using the 6 pole connector Field bus protocols No emission specific values are currently available in the field bus prot...

Page 44: ...trol SCR Dosing Valve on page 69 7 2 Pump Self Test The pump self test checks whether the pump speed and pump pressure are within the minimum and maximum values specified in the configuration Two type...

Page 45: ...the power supply even if the device has been switched off via the start stop input The temperature values at which the heating of the dosing valve is switched on and off can be configured in the MICT...

Page 46: ...If the access control for the emission controller is activated it is independent from the access levels that control authorizations within the MICT Access Control A user is logged in to the Advanced S...

Page 47: ...an change the operation mode and can confirm errors Level 2 Service The service can also perform runtime adjustments and run the pump self test manually Level 3 Master At this level the master can als...

Page 48: ...the VariSCR emission controller To install the MICT proceed as follows 1 Start the installation Via the menu Start the file Start exe on the storage device Start the installation routine of the MICT...

Page 49: ...n this level the user can open a configuration and transfer it to the device However he cannot make changes to the configuration The user has read only access to all other settings Customer This level...

Page 50: ...ew The configuration pages are divided into the following sections Pos Area Menu bar Toolbar Navigation bar Configuration section Status bar The functions in the menu navigation bar and the toolbar as...

Page 51: ...as been activated and the user has logged on with a PIN Indication of the MICT program version 8 5 Menu Bar and Toolbar The following functions are available to you via the symbols on the toolbar and...

Page 52: ...mode Device Upload from device Uploads configuration data from the device to the computer Device Runtime data Opens the window Runtime Data Refer to the section Runtime Data on page 76 Device Log Ope...

Page 53: ...ad the section Access Control for the VariSCR Emission Controller on page 57 Settings Language Opens the window Select Language in which you can change the interface language of the MICT Settings Onli...

Page 54: ...ou have the following possibilities to adjust the opening of the dosing valve keys Use the keys to adjust the current dosing valve opening by 0 1 1 or 10 Entry field You can directly enter the desired...

Page 55: ...on to start the test Set Click the button to transfer the changed parameters to the emission controller Stop Click the button to stop a running test The status displays have the following meaning Runn...

Page 56: ...t start up of the MICT Use a proxy to access the web Use the checkbox to activate settings for internet access via a proxy server which you can then set up by entering http Proxy and Port Show Log Wit...

Page 57: ...tivated and the PINs were changed these PINs will continue to be used To activate the access control again you will need the PIN for level 3 Master It is therefore recommended to reset all PINs before...

Page 58: ...yet logged into the Master level 3 level you will be prompted to log in with the relevant PIN 3 Confirm the input with OK 4 To reset all PINs you will be prompted again to enter the PIN for the level...

Page 59: ...desired control signals it requires information on the device connected and the master control connected This information is stored in a configuration file on the emission controller You need the MICT...

Page 60: ...ve Click on the symbol to create a new configuration and select the entry Emission Controllers VariSCR Standard Click on the symbol to open a saved configuration Click on the symbol to save the config...

Page 61: ...this type of configuration in the MICT the following situations may occur No values are present in the configuration for certain MICT functions The MICT assumes the standard values for these function...

Page 62: ...try from the navigation bar The corresponding configuration data are then displayed in the configuration section and can be processed The following sections will describe the settings and adjustments...

Page 63: ...he function of the VariSCR emission controller only the value Exhaust control SCR can be set Output Currently no output can be selected External manual automatic selection enabled Disable the check bo...

Page 64: ...tart the device from the master control External engine running enabled Activate the checkbox to enable the binary input Engine Running on the emission controller 8 11 2 Exhaust Control Parameter Set...

Page 65: ...Lower limit of the operating temperature at which the injection of AdBlue into the catalytic converter is started Reference Temperature Internal value for the calculation of temperature dependent cor...

Page 66: ...sary change the basic setting for the PID control of the pump This can be adjusted during operation via the runtime adjustments see Runtime Adjustments Pump on page 93 When you make the settings you c...

Page 67: ...vice is switched off the pump ensures cooling for the time specified in the corresponding field 8 11 4 Exhaust Control SCR Pump Self Test You can activate and adjust two types of pump self test for pr...

Page 68: ...emission controller goes into the error mode Pressure Activate the checkbox to monitor the pump pressure Timeout If the pressure is not within the specified minimum and maximum values within the spec...

Page 69: ...ing operation via the runtime adjustments see Runtime Adjustments Dosing Valve on page 94 When you make the settings you can be supported by the trend views in the runtime data see Runtime Data Trends...

Page 70: ...the NOX value at the intake from which the injection is to take place Heater Activate the heater via the corresponding checkbox You define the respective limit values via the Switch On Level and Swit...

Page 71: ...ng rate can also be set for each point of the characteristic curve This setting must be determined once for each SCR system This is supported by an Excel file that you can find on the storage device i...

Page 72: ...let before starting injection If this value is exceeded the emission controller enters the error mode if the corresponding checkbox has been activated If the checkbox is not activated an information i...

Page 73: ...SCR Catalyst Sensors field and select the J1939option Enter 0 for the Source Address and select the 250 kbit s Bitrate CAN Via the field CAN deactivate or activate the CAN interface of the device ALL...

Page 74: ...s RS485 Via the field RS485 deactivate or activate the RS485 interface of the device RS485 Settings Bitrate Select the desired data transfer rate from the list The Modbus bit rate can be defined betwe...

Page 75: ...e currently available in the field bus protocols 8 11 9 Miscellaneous Service Contact This configuration page can be viewed by all users but changes can only be made with authorization for the Advance...

Page 76: ...this purpose the following functions are at your disposal in the toolbar in the window Symbol Function Prints the runtime data Prints the runtime data to a PDF file Opens the print preview Starts the...

Page 77: ...al The diagram shows the current pressure as a bar and value The green triangle indicates the target value The tooltip displays the target value numerically A red triangle at the beginning or end indi...

Page 78: ...r Warning The yellow status display indicates that a warning is pending Refer to the section Runtime Data Message Log on page 87 Error The red status display indicates that an error has occurred Refer...

Page 79: ...occurred Automatic The following status displays are possible Green The emission controller is in automatic mode Refer to the section Manual and Automatic Operation on page 45 Red An error occurred Pu...

Page 80: ...Yellow Only feed forward control is taken into account Red An error occurred Heater The green status display indicates that the heater of the dosing unit is working Dosing Valve Opening The current pe...

Page 81: ...2 Runtime Data Sensors The window displays detailed information about the sensors used in the SCR system Basically the colors of the status displays have the following meaning Green No error Yellow O...

Page 82: ...e green status display indicates that the supply voltage is within the permissible range In addition the status of the supply voltage is displayed Heater The green status display indicates that the he...

Page 83: ...lays detailed information on the dosing unit Dosing Unit Pressure Current AdBlue pressure at the dosing valve Temperature Current temperature at the dosing valve Pump Target Target value of the speed...

Page 84: ...e measured values of the MAP and MAT sensors Dosing Unit Controller Feed Forward Control Opening angle resulting from the feed forward control PID controller Opening angle resulting from PID control M...

Page 85: ...dow is closed again The trend view is not available in the runtime data trace You can choose between two views Pump Trend of the pump pressure and the pump speed target and actual values as well as th...

Page 86: ...lor of the fields behind the checkbox corresponds to the color of the respective curve in the diagrams The small symbol within the color fields indicates in which diagram the corresponding value is di...

Page 87: ...listed The following information is provided Operating Hours Operating hours counter reading at the time of message Time Time and date cannot be shown for VariSCR emission controllers Category Messag...

Page 88: ...e or more messages are lost due to exhausted memory pool or message queue overrun Shutdown timestamps cleared Dosing valve info Output catalyst overtemperature is set For each information the status o...

Page 89: ...e full Error triggered by command Coprocessor handler message queue full General error Input handler message queue full Low Power Output handler message queue full Over current Over temperature Power...

Page 90: ...which operation mode Manual or Automatic is currently active and how the operation mode was adjusted Here there are the following two options Control Displays whether the operation mode was adjusted...

Page 91: ...currently not available Measurements Supply voltage Current supply voltage of the emission controller Current Temp Current temperature of the board Max Temp Maximum board temperature reached since th...

Page 92: ...iew you can find an overview of the device and version data You can also print the current runtime data or in case of problems send them to the MOTORTECH Service Department via fax or as a PDF file vi...

Page 93: ...nd are retained even in the case of a VariSCR emission controller restart Changes that have been saved in the device configuration are only displayed after re uploading the device configuration in the...

Page 94: ...f the dosing valve can be corrected during operation of the device Use the arrow keys above and below the decimal digit you want to increase or decrease Alternatively you can place the mouse pointer o...

Page 95: ...5 8 13 3 Runtime Adjustments Gas Mixer This function is currently not available 8 14 Log Click on the symbol to open the window Log This window is only available to users with authorizations starting...

Page 96: ...merely shown on the display Select file With this button you can select a file to which you want to save the logged data If you are prompted to create a log file in the case of a service request proce...

Page 97: ...use the preset values 4 Start the engine 5 Adjust the mixture control so that the NOX sensor before the catalytic converter measures a NOX value that corresponds to the engine manufacturer s specific...

Page 98: ...in calculating the required values The determined values are entered in the MICT in the configuration page Exhaust Control SCR Feed Forward Control Proceed as follows 1 Start the MICT on your compute...

Page 99: ...the temperature value in the column MAT in the Excel file Example 6 In the Runtime Data Sensors window check the NOX value before the catalytic converter It should correspond to the value set via the...

Page 100: ...ia the menu item Device Manual Valve Adjustment until the NOX value at the catalytic converter outlet corresponds to the desired final value e g 30 ppm in the window Runtime Data Sensors Refer to the...

Page 101: ...e optimized values for the feed forward control 11 Enter the values of the colored columns into the configuration page Exhaust Control SCR Feed Forward Control in the MICT Example 12 Download the chan...

Page 102: ...tware MOTORTECH Flash Tool Install MOTORTECH Flash Tool Directly from the storage device Start the installation routine of the MOTORTECH Flash Tool directly It is on the storage device in the subdirec...

Page 103: ...loads the file information of the selected firmware file Device Search devices Restarts the search for connected devices Device Flash device Starts the update process or downgrade process Settings Lan...

Page 104: ...your computer via the USB interface you can usually still carry out a firmware update To do so observe the instructions in the information windows of the MOTORTECH Flash Tool for the following steps...

Page 105: ...outs for the connection helps The time out settings are displayed in the main view by the following entry in the menu bar View Extended connection settings Enter the following settings Update Request...

Page 106: ...can be acknowledged by simultaneous pressing of buttons Open and Close in manual mode or by the external reset signal Warnings can for example be caused by Overload of the device Overtemperature or ov...

Page 107: ...t input By pressing the Open and Close button simultaneously Via Error acknowledge in the MICT Critical errors can only be acknowledged by switching the device off and on Error confirmation in automat...

Page 108: ...sentative MOTORTECH GmbH Hogrevestr 21 23 29223 Celle Germany Phone 49 5141 93 99 0 Fax 49 5141 93 99 98 www motortech de motortech motortech de MOTORTECH Americas LLC 1400 Dealers Avenue Suite A New...

Page 109: ...2020 109 11 1 Spare Parts and Accessories For spare parts and accessories please refer to our current Product Guide which is available for you to download on the internet at www motortech de 11 Maint...

Page 110: ...knowledge 51 107 Logging 95 Feed forward control Setting 98 Field bus Configure 73 Select 63 Technical data 21 Wiring 40 42 I Input Configure 63 Technical data 18 Wiring 36 37 39 O Operating data Over...

Page 111: ...Rev 06 2020 111...

Page 112: ......

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