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ECM NOx/NH3 5240 Instruction Manual
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ECM NOx/NH3 5240 Instruction Manual

Nox, nh3, and o2 analyzer
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NOx/NH3 5240
NO
, NH
, and O
Analyzer
x
3
2
Instruction Manual
10/18/13

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Summary of Contents for ECM NOx/NH3 5240

  • Page 1 NOx/NH3 5240 , NH , and O Analyzer Instruction Manual 10/18/13...
  • Page 2  COPYRIGHT 2013 by ECM: ENGINE CONTROL AND MONITORING. All 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 change without notice.

  • Page 3: Table Of Contents

    Introduction The NOx/NH3 5240 NOx/NH3 5240 Kit Contents Safety Warnings How to Use Hooking up the NOx/NH3 5240 Mounting the Sampling System Front Panel and the “SYS” Key MOd (Module) Setup Option RATE Setup Option FUEL Setup Option (H:C, O:C, N:C, H2)

  • Page 5: Introduction

    Introduction The NOx 5240 The NOx/NH3 5240 is a ceramic sensor-based NOx, NH , and O analyzer for the development of engines and their aftertreatment systems. Its features include:  Wide range of operation: NOx : 0 to 5000 ppm : 0 to 1000 ppm ...

  • Page 6: Nox/Nh3 5240 Kit Contents

    NOx/NH3 5240 Kit Contents The following items are included with a NOx/NH3 5240 kit: Item No. Description Part Number NOx/NH3 5240 Display Head 01-07 NOx/NH3 Sensor (2 included) 06-06 (called Sensors A and B but they are interchangeable) Eurofast 12 mm Cable, 10 m, (2 included) 09-03/10 Flexi-Eurofast 12mm Cable, 0.3m, (2 included)
  • Page 7 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 Compensation Kit for External Mounting Block P/N /P 7. NOx/NH3 5240 Calibration Kit (hoses and flowmeter) P/N 14-11...

  • Page 8: Safety Warnings

    Never work on a running engine. When installing the NOx/NH3 5240 on a stopped engine, it is best to think-out your moves before you make them. Route and cable-tie all cables away from hot, moving, sharp, or high voltage (spark) objects.

  • Page 9: How To Use

    How to Use Hooking up the NOx/NH3 5240 Figure 1 shows the NOx/NH3 5240 Analyzer kit. The kit consists of 3 parts: 1. The display head and cabling 2. The sampling system; composed of: i. The external mounting block (with Sensor A mounted on it) ii.
  • Page 10 Figure 1: NOx/NH3 5240 Analyzer...
  • Page 11 P/N 09-04, 0.3 m CAN Bus P/N 13-01, Manuals and Flexi-Eurofast Connector Configuration Tool Cable P/N 01-07 Connector NOx/NH3 5240 P/N 12-01 19” Rackmount Panel Display Head (optional) Figure 2: Front and Back of Display Head Figure 2: Close-up of Sampling System...
  • Page 12 Figure 3: Sampling System...
  • Page 13 Figure 4: Inside the remoteSAMPLER 1000 (early model without drain solenoid shown)
  • Page 14 Figure 5: External Mounting Block (Sensor and Mounting Boss Also Shown)

  • Page 15: Mounting The Sampling System

    Mounting the Sampling System The NOx/NH3 5240’s sampling system (see Figure 3) is closed (i.e. sample returned to the exhaust). This reduces the system’s sensitivity to exhaust pressure. The sample intake and exhaust locations must be located at least 0.3m from each-other. Otherwise, air added to the sample exhaust will dilute the sample intake.
  • Page 16 For vehicle installations, ECM has used a Viair 450C-IG air compressor (Viair P/N 45050), 2 gallon air tank (Viair P/N 91022), 110/150 psi pressure relay switch (Viair P/N 90111), and a tank port fitting kit (Viair P/N 90005).

  • Page 17: Front Panel And The "Sys" Key

    Front Panel and the “SYS” Key The display head has two modes of operation: RUN (when measurements or error codes are displayed) and SYS (where the instrument is set-up). The SYS key toggles between the modes. When in RUN mode, the parameter being displayed is indicated by leds to the right of the display.
  • Page 18 MOd, RATE, AOUT, dISP, and CAL (just CAL(P) for lower display) appear on the upper and lower displays. FUEL appears on upper display only. CONF appears on lower display only. All entries must be followed by pressing the ENT key. Default values shown in square parentheses. Table 1: Menu Tree for NOx/NH3 5240...

  • Page 19: Mod (Module) Setup Option

    MOd (Module) Setup Option In MOd setup, the serial number of the NOX/NH3 module assigned to the upper or lower display is entered. The serial number is written on a label on the module (see Figure 4). The module connected to Sensor A (in external mounting block) must be assigned to the upper display.

  • Page 20: Disp (Display) Setup Option (P1 To P6)

    6. When 0V is displayed, press ENT. Using the , , and ENT keys, set the parameter value that you want to result in an analog output voltage of 0V on analog output 2. The first time you do this, it may be a little tricky. You are setting one digit at a time and for some numbers, the display will shift to the left so you can set the right-most digits.
  • Page 21 Pressure sensor measured pressure (abs.) in kPa (Sensor B) I1XB Ip1 non Pcomp, Sensor B Non-pressure compensated NOx sensor B Ip1 pumping current Non-pressure compensated NOx sensor B IP2 pumping I2XB Ip2 non Pcomp, Sensor B current Table 2: Parameter List for the NOx/NH3 5240...

  • Page 22: Cal (Calibrate) Setup Option (O2, Nox, Samp)

    The sensors are factory calibrated and can be sent back to ECM for recalibration. The frequency of recalibration is application-dependent and can only be determined by experience.
  • Page 23 Figure 6: System Re-Plumbed for Calibration...
  • Page 24  O2 , , AFR, Φ, and FAR The O2 SPAN function is for the recalibration of the analyzer’s %O measurements. This recalibration is stored in the sensors’ memory chips and is used instead of the factory calibration. The FACT function (under “O2”) cancels the user calibration resulting in the factory calibration being used.
  • Page 25 lower display. The age factor goes down with use. When the age factor is 0.75 or below, it is recommended that the sensor be replaced. The age factors are reset to “1.00” after the FACT option (see above) has been executed. ...
  • Page 26 Td = 274 x (L + 2.715) ASAM ASAM is the filter coefficient for the flowrate of the gases from Sensor A (in the external mounting block) to Sensor B in the remoteSAMPLER. Contact ECM for assistance before changing ASAM from the default value. CNH3 CNH3 allows the user to check the calibration of the NH3 measurement using a NH3 + NO (0~5000 ppm) + N2 (balance) dry model gas mixture.
  • Page 27 gases though water because the water will absorb NH3. Feed dry gases directly from the tank to the external mounting block. 5. Turn the pump on by attaching the compressed air. Readjust the tank pressure until 5 lpm is obtained. 6.

  • Page 28: Cal (Calibrate) Setup Option (P, Avg, Skew)

    = the parameter value at time “t + 5ms” t+5ms ParameterAverage = the parameter average at time “t” The default averaging filter values are given within square parentheses in Table 1. These values should not be modified without first consulting ECM.
  • Page 29  SKEW d, NOxw, NOxd, P, AFR, Φ, FAR, , %O SKEW allows the parameters NH w, NH w, and d each to be modified by a programmable transform of the form: ParameterSkewed = M x Parameter + B [Equation 3] where: d, NOxw, NOxd, P, AFR, Φ, FAR, , %O ParameterSkewed = NH...

  • Page 30: Conf (Configure) Setup Option (Leds, 1V4V, Can, Neg, Lock, Fact)

    CONF (Configure) Setup Option (LEdS, 1V4V, CAN, MOdE, FACT) CONF setup appears at the end of the setup list on the lower display. To enter CONF, press the SYS key until “MOd” appears on the upper display, press the  key until “CONF” appears on the bottom display, and then press the ENT key.
  • Page 31 5240 is connected directly to a PC via a CAN adapter, pressing the ENT key will result in data for the .dbc file for the current NOx/NH3 5240 setup being sent to the PC. This .dbc file can be used with programs accepting the VectorCAN .dbc format. How to get this .dbc file is explained in more detail below: 1.
  • Page 32 ENT key. Within a second, the .dbc file for that particular NOx/NH3 5240 analyzer setup will be sent to the PC. It is a good idea to LOCK the display head after this (see “LOCK” below) since changing a new displayed parameter or new analog out parameter will change the data transmitted via CAN to that of the new parameter.

  • Page 33: Specifications And Limits

    Specifications and Limits Measurements and Accuracies Parameter Range Response Time Accuracy 0 to 1000 ppm < 1 s ±5 ppm (0 to 1000 ppm) ±1% of reading (elsewhere) 0 to 5000 ppm < 1 s ±5 ppm (0 to 1000 ppm) ±1% of reading (elsewhere) ±0.8% (at =1) Lambda ()

  • Page 34: Sensor Limits And Specifications

    Sensor Limits and Specifications  NOx/NH3 Sensors Exhaust Gas Temperature Range: 0 - 850 °C, 32 - 1562 °F Maximum Exhaust Temperature: 950 °C, 1742 °F Maximum Rate of Temperature Change: 50 °C/s, 122 °F/s Fuel Composition: H:C ratio range: 1.00 - 10.00, or Hydrogen (H O:C ratio range: 0.00 - 10.00 N:C ratio range: 0.00 - 1.00 gasoline: 1.70 <...
  • Page 35  Sample Line Kit (P/N 12-45 (USA), P/N 12-46 (Metric)) Notes: 1. Two kits included. 2. Stainless steel end of tubing towards exhaust. PFA end towards remote remoteSAMPLER. 3. Program parameter Td = 274 x (L + 2.715) where L is length (in meters) of external mounting block-to-remoteSAMPLER sample line length and Td is in msec.
  • Page 36 P/N 12-08A (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 sensor.

  • Page 37: Output Specifications

    Output Specifications  Analog Outputs Output Range (linearized in displayed units): 0 to 5V, 0 to 1V, 20 mA max. Output Impedance: 2.66 kΩ Bits Resolution: 12 bits Update Rate: 100 ms Isolation: Electrically isolated from power supply ground. All analog output grounds common. ...

  • Page 38: General Specifications

    Current Draw: 0.5 A (display), 2.4 A steady-state (NOx/NH3 sensors and modules), on start-up, NOx/NH3 sensors and modules may draw as much as 8 A for 30 s. Case Ground: The NOx/NH3 5240 display head case is connected to power ground via a 2.15 kΩ resistor.  Key-on Signal “ON”...

  • Page 39: Appendices

    Appendix A: 5200 Series Instruments Parts List 01 Display Heads (Just display head. Must add cables, etc.) 01-01 NOx 5210 (just head, no module, no cable, no sensor) 01-02 Lambda 5220 (just head, no module, no cable, no sensor) 01-03 EGR 5230 (just head, no module, no cable, no sensor) 01-04 dashCAN (includes cable and T) 01-05 dashCAN+ 01-06 dashCANc...
  • Page 40 06-02 NOx Type "G" (use with NOxCANg) 06-03 Calibrate NOx Sensor 06-04 Cal Sheet with NOx Sensor 06-05 NOx Type "T" (use with NOxCANt) 06-06 NOx/NH3 Sensor (use with NOx/NH3 5240) 07 Sensors 07-01 Pressure, 0-75 psia, 1/4", (USA) 07-02 Pressure, 0-517 kPa, 6mm, (Metric) 07-03 Pressure, Type P, 0-75 psia, 1/4", (USA)
  • Page 41 09-09 Termination Resistor for Hub Block 10 Sensor Cables 10-01 Module Y Cable (Superseded by -21) 10-02 1m L/N/C/bCAN Cable, (12 term.) 10-02/25' L/N/C/bCAN Cable, (12 term., teflon) 10-03 2m L/N/C/bCAN Cable, (12 term.) 10-04 1m Pressure Cable (LCAN, NCAN, not Lp,C,bCAN), (4 term.) 10-05 2m Pressure Cable (LCAN, NCAN, not Lp,C,bCAN), (4 term.) append suffix SD to cable for Teflon (Severe Duty) Version 10-09 Adapter to use P/N 05-01 with AFM1000, M1200, etc...
  • Page 42 11 Cables 11-01 DC Power Cable, DB9F, Spades 11-02 DC Power Cable, DB9F, Banana Plugs 11-03 DB9M to CSM Lemo F Adapter (CSM Upstream) 11-04 DB9M to ETAS Lemo Adapter 11-05 Female Eurofast to DB9F 11-06 Male Eurofast to CSM Lemo F Adapter (CSM Downstream) 11-07 In-Line Power Entry Cable 11-08 2m Key-on Cable 11-09 2m Heater Cable...
  • Page 43 12-10 18mm Cu Gasket 12-11 Pressure Line Assembly, 6mm dia, 483mm, (Metric) 12-11A Pressure Line Assembly, 6mm dia, 711mm (Metric) 12-12 1/4" ISO tapered MS Boss and Brass Plug, (Metric) 12-13 1/4" ISO tapered SS Boss and Brass Plug, (Metric) 12-14 1/4"...
  • Page 44 14-02 18mm 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 Sulfate (3 gm) 14-11 NOx/NH3 5240 Calibration Kit...

  • Page 45: Error Codes And Troubleshooting

    Appendix B: Error Codes and Troubleshooting If one of the NOx/NH3 5240’s displays flashes “ERR” followed by “####” (the Error Code), an error has been detected in that display’s module (or attached sensors). The below table lists the errors. The errors are also flashed on the module’s LED.

  • Page 46: Calculating The %O

    Appendix C: Calculating the %O in Air The Configuration Tool Software has a routine to calculate the %O in air. If the software is not available, the below may be used. The oxygen concentration in dry air (zero humidity) is 20.945 and decreases with increasing humidity.
  • Page 47 1. Press SYS until “LOCK” is displayed. Then press ENT. 2. “50” will be displayed. Press  until “60” is displayed. Then press ENT. Display is now unLOCKed. If an unauthorized person learns that 60 is the key number, contact ECM.

  • Page 48: Using The Configuration Tool Software

    The ECM Configuration Tool with be used with analyzers (i.e. NOx 5210, Lambda 5220, EGR 5230, NOx/NH3 5240). One or more analyzers can be connected to the same CAN bus using the CAN connector on the back of the analyzers. Make sure that the CAN bus is properly terminated.
  • Page 49 for the data going to analog outputs 1 and 2. CID2 is for analog outputs 3 and 4. CID3 is for analog outputs 5 and 6. CID4 is for the upper and lower displays. ERCd is for the error codes and auxiliary codes. After entering the CAN id for ERCd, “.dBC” will appear on the display.

  • Page 50: Installation On Ford F-250 Pickup Truck

    Appendix F: Installation on Ford F-250 Pick-up Truck This installation example is for a 2012 Ford F-250 Extended Cab pickup truck with the 6.7L Power Stroke® Engine. The remoteSAMPLER is mounted on a ¼” 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.
  • Page 51 Here are the plate dimensions. Only six holes 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 ½” dia. x 1” long drilled dowels, and through existing holes in the frame.
  • Page 52 Plate is mounted on two existing holes in the frame. Here’s the plate mounted.
  • Page 53 Mount the remoteSAMPLER on the 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/N 4403K39 (USA), P/N 4403K84 (Metric)).
  • Page 54 The 2 gallon air tank (Viair P/N 91022) was mounted on the frame just forward of the remoteSAMPLER using custom-made brackets. Again, existing holes on the frame were used. Ahead of the tank you can see the compressor (Viair 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).
  • Page 55 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 The truck has a short section of exhaust pipe after the SCR that can be removed so that the ¼” NPT female fittings can be welded on. This picture shows many bosses welded to the pipe but only two will be used. A piece of tape labeled “1” is on the fitting that the external mounting block will be mounted on.
  • Page 57 Here is the external mounting block mounted on the forward boss that was welded to the exhaust. Sensor A is installed in the block. Note that the sample line coming from the block uses a 90 degree hard right Swagelok fitting (not supplied) instead of the straight-on tube fitting supplied with the analyzer.
  • Page 58 The line from the external mounting block goes to the “Sample Inlet” port on the remoteSAMPLER. Use a length 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 With the system off (i.e. pump off), fill the scrubber with a cupric sulfate/water solution (3 gm cupric sulfate/150 cc water) until 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 remoteSAMPLER if necessary.
  • Page 60 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 The display head fits nicely in the dash tray. There is a removable panel on the dash through which the EIB cable and the “Key” wire can be routed. Turn the display on and enter the value for Td (msec) 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.

  • Page 62: Warranty And Disclaimers

    Warranty and Disclaimers WARRANTY The products described in this manual, with the exception of the NOx/NH3 sensors and pressure sensors, are warranted to be free from defects in material and workmanship for a period of 365 days from the date of shipment to the buyer. Within the 365 day warranty period, we shall at our option repair such items or reimburse the customer the original price of such items which are returned to us with shipping charges prepaid and which are determined by us to be defective.
  • Page 63 SIM300, 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 (Class A & Annex A) EN61010-1: 2001 (Electrical Safety)
  • Page 66 Los Altos, CA 94023-0040  USA  (408) 734-3433  Fax: (408) 734-3432  www.ecm-co.com...

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Noxnh3-5240

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