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

Rev. 09/2020 11
4.1 Technical Data
4.1.1 Certifications
The NOXsensor is certified as follows:
CE
EMC Directive
–EN 61326-2-3 – Electrical equipment for measurement, control and laboratory use - EMC
requirements - Part 2-3: Particular requirements - Test configurations, operational condi-
tions and performance criteria for transducers with integrated or remote signal conditioning
–EN 55011 – Industrial, scientific and medical equipment - Radio-frequency disturbance
characteristics - Limits and methods of measurement
–Group 1, Class A and B
RoHS Directive
4 Product Description

4 Product Description
12 Rev. 09/2020
4.1.2 Mechanical Data
The NOXsensor has the following mechanical characteristics:
Feature Value
Dimensions Length o
f
probe: 25.4 mm (1")
Length of sensing element: 96.9 mm (3.82")
Evaluation unit (length x width x height):
148 mm x 65 mm x 35.4 mm (5.83" x 2.56" x 1.4")
Length of connection cable: 900 mm (35.4")
Shape of device See section Overview Drawings on page 16
IP protection rating IP 6K9K with mating plug connected to evaluation unit
and sensing element mounted in suitable welding boss
from MOTORTECH
Climatic environmental conditions Operating temperature evaluation unit:
–40 °C to +115 °C (–40 °F to +239 °F)
Operating temperature hexagon nut:
–40 °C to +620 °C (–40 °F to +1,148 °F)
Operating temperature sensor grommet and connec-
tion cable:
–40 °C to +200 °C (–40 °F to +392 °F)
Storage temperature in original packaging with protec-
tive cap never removed:
–40 °C to +65 °C (–40 °F to +149 °F) for max. 2 years
Exhaust gas temperature range:
–40 °C to +800 °C (–40 °F to 1,472 °F)
Operating pressure range:
800 mbar abs to 1,600 mbar abs
Flammability class as per UL 94 Plastic housing parts of the evaluation unit: HB
Mounting cycles Max. 2
Mating cycles evaluation unit Max. 20
Service life 6,000 h with average temperature of evaluation unit at
+90 °C (+194 °F)

4 Product Description
Rev. 09/2020 13
4.1.3 Product Identification – Labeling on the Device
The part number (P/N) of the NOXsensor can be found on the upper label on the bottom side of
the evaluation unit.
The date of manufacture and the serial number of the NOXsensor can be read out via the two-
dimensional matrix code (Data Matrix) on the connector of the evaluation unit. For this purpose
you can use a QR scanner, for example, which can also read Data Matrix codes. You will find the
relevant information at the following positions in the read-out 49-character long string:
Position Meaning
22 + 23
Y
ear of manufacture (3rd and
4th digit)
24 + 25 Month of manufacture
26 + 27 Day of manufacture
28 – 31 Serial number

4 Product Description
14 Rev. 09/2020
4.1.4 Electrical Data
The NOXsensor has the following electrical characteristics:
Feature Value
Power supply 24 V DC (16 V DC to 36 V DC)
Maximum power consumption 20 W
Required current Max. 1.5 Aeff, 6.2 Apeak
Connector evaluation unit 5-pole, connector
The measuring probe of the NOXsensor has the following characteristics:
Feature Value
Measuring range nitrogen oxide
(NOX)
0 ppm to 1,500 ppm
Measuring accuracy nitric oxide
(NO)
See table 1 below
Response time nitrogen oxide
(NOX)
t10–90: max. 5,300 ms
Cross sensitivity NOXmeasure-
ment
Ammonia (NH3) typ. 100 %
Sensitivity NOXmeasurement Nitrogen dioxide (NO2) typ. 80 %
Measuring range oxygen (O2) 0 % to 20.9 %
Measuring accuracy oxygen (O2) See table 2 below
Exhaust gas velocity Min. 10 m/s
Pressure pulsation Max. 130 mbarpeak-to-peak above 10 Hz
NO2correction factor (KNO2) 0.8 (set ex works)
Measuring accuracy
The measuring accuracy of the NOXsensor can be affected negatively by
pressure pulsations above 130 mbarpeak-to-peak in the frequency range above
10 Hz. Therefore, only use the NOXsensor outside this range.

4 Product Description
Rev. 09/2020 15
Table 1: Measuring accuracy nitric oxide (NO)
Measurement Measuring accuracy at evaluation unit operating temperature
–40 °C to +105 °C
(–40 °F to +221 °F)
+106 °C to +115 °C
(+222.8 °F to +239 °F)
NO ≤ 100 ppm ± 10 ppm ± 15 ppm
100 ppm < NO ≤ 500 ppm ± 10 % ± 10 % ± 5 ppmoffset
500 ppm < NO ≤ 1,500 ppm ± 15 % ± 15 % ± 5 ppmoffset
Table 2: Measuring accuracy oxygen (O2)
Measurement Measuring accuracy at evaluation unit operating temperature
–40 °C to +115 °C (–40 °F to +239 °F)
O2≤ 5 % ± 2,500 ppm abs
5 % < O2≤ 20.9 % ± 5 % rel
4.1.5 Interfaces
CAN Bus Interface
–Network protocol: SAE J1939
–Transmission rate: 250 kbit/s

4 Product Description
16 Rev. 09/2020
4.1.6 Overview Drawings
Dimensions

Rev. 09/2020 17
Replacement of NOXsensor in EasyNOXsystem
If you want to replace an identical NOXsensor from MOTORTECH in the
exhaust pipe, read the section Replacement of NOXSensor in the EasyNOX
operating manual.
5.1 Preparation
Make sure that your application meets the following requirements.
5.1.1 External Power Supply
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.
5 Mounting Instruction

5 Mounting Instruction
18 Rev. 09/2020
5.1.2 Mounting Position of Sensing Element
The mounting position of the sensing element must be defined in such a way that no condensa-
tion water is able to collect in the protective tube of the sensing element. The possible tilt angles
depend on the course of the exhaust pipe. Mounting in a vertical exhaust pipe is not recom-
mended by MOTORTECH.
Horizontal exhaust pipe tilt angles
Exhaust gas flow
Vertical exhaust pipe tilt angles
Exhaust gas flow
To ensure proper functioning of the connection cable, the minimum bending radius of the con-
nection cable of 20 mm (0.79") must be observed at the mounting position and the angle of the
cable outlet at the sensor grommet must be less than 15°.
The sensing element becomes hot during operation. Therefore, the sensing element must be
installed on the exhaust pipe in a suitable location at which people at the plant cannot be
burned by it, or an appropriate protection must be installed around the sensing element that
prevents contact with it.
5.1.3 Mounting Position of Evaluation Unit
To prevent the formation of discharge sparks or electric shock when touching the housing, the
evaluation unit of the NOXsensor must be mounted on a grounded be mounted plate.

5 Mounting Instruction
Rev. 09/2020 19
5.2 Unpacking
Before unpacking, please observe the instructions in section Proper Transport on page 9.
To prevent condensation from forming in the sensing element of the NOXsensor, you should
avoid any temperature shocks when opening the packaging. Before opening, allow the shipping
unit to adjust to the mounting temperature by storing it at mounting temperature for at least one
day.
After having opened the packaging, avoid temperature changes of more than ± 5 °C (9 °F). The
NOXsensor must not be taken out of its packaging in polluted air and under bad weather condi-
tions (e.g. oil, water, snow, dust, sand, smoke).
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).
5.3 Material Needed
For mounting the NOXsensor, you need the following material:
–Suitable welding boss from MOTORTECH
–Locking screw for welding boss from MOTORTECH
–Suitable harness from MOTORTECH for connecting the NOXsensor to the master control
If you have any questions about the needed material, contact your MOTORTECH contact person
(see Customer Service Information on page 25).

5 Mounting Instruction
20 Rev. 09/2020
5.4 Mounting
Operational safety!
To safely mount the NOXsensor, be sure to observe the following:
–To protect the NOXsensor and yourself, wear ESD-compliant work
gloves. To protect the NOXsensor against electrostatic discharge, also
comply with IEC 61340-5-1 and IEC TR 61340-5-2 in their respective valid
versions.
–Under no circumstances touch the probe of the sensing element while
mounting.
–If mechanical shock to the sensing element occurs (e.g. drop on the
floor), the NOXsensor must not be used under any circumstances and
must be disposed of. In cases of doubt, contact your MOTORTECH con-
tact person (see Customer Service Information on page 25).
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.
Replacement of NOXsensor in EasyNOXsystem
If you want to replace an identical NOXsensor from MOTORTECH in the
exhaust pipe, read the section Replacement of NOXSensor in the EasyNOX
operating manual.
Before mounting, it is essential to observe the instructions in the section Preparation on
page 17.
Make sure that the engine is switched off when mounting. Also make sure that the exhaust pipe
has cooled down sufficiently and that there are no exhaust gases in the exhaust pipe.
The sensing element of the NOXsensor is screwed into the exhaust pipe via a suitable welding
boss made of stainless steel (material number 1.4301) from MOTORTECH and connected to the
master control via a suitable harness from MOTORTECH. For welding in the welding boss, the
locking screw of the welding boss can be used as welding aid.