Motortech NOX User manual

NOXSensor
Installation Instruction
P/N 01.50.027-EN | Rev. 09/2020

Original installation instruction
© Copyright 2020 MOTORTECH GmbH. All rights reserved.
MOTORTECH products and the MOTORTECH logo 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 used for reference purposes only.
Information contained in this publication may be changed without prior notice.

Rev. 09/2020 3
1 General Information .....................................................................................................5
1.1 What Is the Purpose of this Installation Instruction? ..................................................5
1.2 Who Is this Installation Instruction Targeted to?........................................................5
1.3 What Symbols Are Used in the Installation Instruction? .............................................5
1.4 Which Abbreviations/Acronyms Are Used in the Installation Instruction?....................6
2 Safety Instructions ......................................................................................................7
2.1 General Safety Instructions ..................................................................................... 7
2.2 Electrostatic Discharge Hazards ..............................................................................8
2.3 Special Safety Instructions for the Device ................................................................8
2.4 Proper Transport ....................................................................................................9
2.5 Proper Disposal......................................................................................................9
3 Intended Use ............................................................................................................. 10
3.1 Functional Description .......................................................................................... 10
3.2 Applications......................................................................................................... 10
4 Product Description ................................................................................................... 11
4.1 Technical Data .......................................................................................................11
4.1.1 Certifications ......................................................................................................11
4.1.2 Mechanical Data ................................................................................................ 12
4.1.3 Product Identification – Labeling on the Device.................................................... 13
4.1.4 Electrical Data.................................................................................................... 14
4.1.5 Interfaces .......................................................................................................... 15
4.1.6 Overview Drawings ............................................................................................ 16
5 Mounting Instruction ................................................................................................. 17
5.1 Preparation .......................................................................................................... 17
5.1.1 External Power Supply ........................................................................................ 17
5.1.2 Mounting Position of Sensing Element ................................................................ 18
5.1.3 Mounting Position of Evaluation Unit................................................................... 18
5.2 Unpacking ........................................................................................................... 19
5.3 Material Needed ................................................................................................... 19
5.4 Mounting .............................................................................................................20
5.5 Setting CAN Identifier ...........................................................................................22
5.6 Setting up Master Control .....................................................................................22
5.7 Dismounting......................................................................................................... 23
6 Errors ........................................................................................................................25
6.1 Customer Service Information................................................................................ 25
Table of Contents

Table of Contents
4 Rev. 09/2020
6.2 Returning Equipment for Repair / Inspection.......................................................... 25
6.3 Instructions for Packaging the Equipment .............................................................. 25
7 Maintenance............................................................................................................. 26
7.1 Cleaning the NOXSensor .......................................................................................26
7.2 Spare Parts and Accessories ................................................................................. 26

Rev. 09/2020 5
Prior to use, read this installation instruction carefully and familiarize yourself with the product.
Installation and start-up should not be carried out before reading and understanding this docu-
ment. Keep this installation instruction readily available so that you can reference it as needed.
1.1 What Is the Purpose of this Installation Instruction?
This installation instruction serves as an aid for the installation of the product and supports the
technical staff with all maintenance tasks to be performed. Furthermore, this instruction is
aimed at preventing dangers to life and health of the user and third parties.
1.2 Who Is this Installation Instruction Targeted to?
This installation instruction provides a code of conduct for personnel tasked with the setup,
operation, maintenance, and repair of gas engines. A certain level of technical knowledge with
respect to the operation of gas engines and basic knowledge of the electronic components used
are necessary. Persons who are only authorized to operate the gas engine shall be trained by
the operating company and shall be expressly instructed concerning potential hazards.
1.3 What Symbols Are Used in the Installation Instruction?
The following symbols are used in this instruction and must be observed:
Example
This symbol indicates examples, which point out necessary handling steps
and techniques. In addition, you receive additional information from the
examples, which will increase your knowledge.
Notice
This symbol indicates important notices for the user. Follow these. In addi-
tion, this symbol is used for overviews that give you a summary of the
necessary work steps.
Warning
This symbol indicates warnings for possible risks of property damage or
risks to health. Read these warning notices carefully and take the men-
tioned precautionary measures.
1 General Information

1 General Information
6 Rev. 09/2020
Danger
This symbol indicates warnings for danger to life, especially due to high
voltage. Read these warning notices carefully and take the mentioned
precautionary measures.
1.4 Which Abbreviations/Acronyms Are Used in the Installation Instruction?
The following abbreviations/acronyms are used in the installation instruction.
Abb. Term Description Explanation
CAN bus Controller Area
Network bus
Bus for control de-
vices / networks
Asynchronous serial connec-
tion system for linking control
units
DC Direct Current
EMC Electromagnetic
Compatibility
Compatibility of electrical or
electronic equipment items
with their surroundings
HB Horizontal Burning Flammability class as per UL 94
QR Quick Response
RoHS Restriction of
Hazardous
Substances

Rev. 09/2020 7
2.1 General Safety Instructions
MOTORTECH equipment is manufactured as state of the art and therefore safe and reliable to
operate. Nevertheless the equipment can cause risks or damage can occur, if the following
instructions are not complied with:
–The gas engine must only be operated by trained and authorized personnel.
–Observe all safety instructions of the system and all safety instructions of the system opera-
tor.
–Operate the equipment only within the parameters specified in the technical data.
–Use the equipment correctly and for its intended use only.
–Never apply force.
–For all work such as installation, conversion, adaptation, maintenance, and repair, all equip-
ment must be disconnected from the mains and secured against unintentional reactivation.
–Perform only such maintenance and repair work as is described in this installation instruc-
tion, and follow the instructions given while working.
–Further work must only be performed by personnel authorized by MOTORTECH. Non-compli-
ance with the instructions will void any warranties for the proper function of the equipment
as well as the responsibility for the validity of the certifications.
–Safety devices must not be dismounted or disabled.
–Avoid all activities that can impair the function of the equipment.
–Operate the equipment only while it is in proper condition.
–Investigate all changes detected while operating the gas engine.
–Ensure compliance with all laws, directives, and regulations applicable to the operation of
your system, including such not expressly stated herein.
–If the system is not entirely tight and sealed, gas may escape and result in explosion hazard.
The inhalation of gas can also lead to death or severe health damages. Therefore, upon
completion of all assembly works, always check the system's tightness.
–Always ensure adequate ventilation of the engine compartment.
–Ensure a safe position at the gas engine.
–There is a risk of burning on hot surfaces. Allow the gas engine to cool down before starting
any work.
–Personal protective equipment (PPE), e.g. safety shoes and gloves, must be worn during all
work on the gas engine.
–Noise from the system can cause permanent or temporary damage to your hearing. Wear
suitable hearing protection at the system.
–Your behavior can reduce possible residual risks to a minimum. Observe responsible han-
dling of the gas engine and the gas-carrying system.
2 Safety Instructions

2 Safety Instructions
8 Rev. 09/2020
2.2 Electrostatic Discharge Hazards
Electronic equipment is sensitive to static electricity. To protect these components from damage
caused by static electricity, special precautions must be taken to minimize or prevent electro-
static discharge.
Observe these safety precautions while you work with the equipment or in its vicinity.
–Before performing maintenance or repair work, ensure that the static electricity inherent to
your body is discharged.
–Do not wear clothing made from synthetic materials to prevent static electricity from build-
ing up. Your clothing should therefore be made of cotton or cotton mix materials.
–Keep plastics such as vinyl and Styrofoam materials as far away from the equipment as
possible.
–Do not remove the circuit boards from the housing of the device.
2.3 Special Safety Instructions for the Device
Operational safety!
To prevent arcing or sparking and short circuits that can cause electric
shock and serious damage to the connected equipment, always switch off
the power supply to the NOXsensor before disconnecting its electrical
connections.
Explosion hazard!
Only use the NOXsensor for measurement in non-explosive 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.
Risk of burning!
There is a risk of burns when touching the sensing element of the NOX
sensor because the sensing element becomes hot during operation. There-
fore, note the following points:
–Therefore, install the sensing element on the exhaust pipe at a suitable
location at which people at the plant cannot be burned by it, or install
an appropriate protection around the sensing element that prevents
contact with it.
–The sensing element must have cooled down sufficiently at the end of
operation before you can touch the sensing element again.

2 Safety Instructions
Rev. 09/2020 9
Risk of injury!
The NOXsensor is designed for operation in circuits with protected extra-
low voltage (PELV). The voltages in these circuits must not exceed 50 V AC
or 75 V DC. To protect the circuit against overload and short circuits, the
supply voltage cable must be secured with a suitable fuse.
Operational safety!
The chemical elements magnesium (Mg), silicon (Si), phosphorus (P), and
sulfur (S) can change the measuring characteristics of the NOXsensor. Make
sure that these chemical elements are not present in your application. Do
not use sprays containing these chemical elements. Only use material in
the exhaust pipe free of these chemical elements.
Operational safety!
To ensure proper functioning of the NOXsensor, the probe must not come
into contact with condensation water and other liquid components. The
sensor and its electronics must not be painted either. Do not open the cover
of the evaluation unit’s connector.
Operational safety!
The sensing element may be mounted and dismounted a maximum of two
times. The electrical connection to the NOXsensor’s evaluation unit may be
established and disconnected a maximum of 20 times. After that, proper
functioning of the sensor can no longer be guaranteed.
2.4 Proper Transport
Let the NOXsensor remain in its original packaging until it reaches its place of use. To prevent
damage to the sensor, carry the NOXsensor separately by hand. Make sure that you do not twist
the connection cable (max. 180°). Under no circumstances should you wrap the connection cable
around the evaluation unit, but wrap the connection cable separately from the evaluation unit
and maintain the minimum bending radius of 20 mm (0.79"). Do not remove the protective cap
from the sensing element until you are instructed to do so within this installation instruction
(see section Mounting on page 20).
2.5 Proper Disposal
After the expiration of its service life, MOTORTECH equipment can be disposed of with other
commercial waste, or it may be returned to MOTORTECH. We will ensure its environmentally
friendly disposal.

10 Rev. 09/2020
3.1 Functional Description
The NOXsensor measures the nitrogen oxide and oxygen concentration in the exhaust gas of
stationary gas engines in industrial environments and transmits the measured values via the
CAN bus to a master control.
3.2 Applications
The NOXsensor is designed for use on stationary gas engines in industrial environments in a
non-hazardous area.
The NOXsensor is suitable for exhaust gases and exhaust pipes that are free of ammonia, mag-
nesium, silicon, phosphorus, and sulfur and may only be used for measurements in non-explo-
sive gas mixtures.
Any use other than the one described in the installation instruction shall be considered
improper use and will result in the voiding of all warranties.
3 Intended Use