Motortech VariSCR User manual

VariSCR –
NOXEmission Controller
Operating Manual
P/N 01.50.025 – EN | Rev. 06/2020

Original instructions
© 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. 06/2020 3
1 General Information .................................................................................................... 6
1.1 What Is the Purpose of this Operating Manual? .........................................................6
1.2 Who Is this Operating Manual Targeted to?...............................................................6
1.3 Which Symbols Are Used in the Operating Manual?...................................................6
1.4 Which Abbreviations/Acronyms Are Used in the Operating Manual?...........................7
2 Safety Instructions ..................................................................................................... 9
2.1 General Safety Instructions .....................................................................................9
2.2 Electrostatic Discharge Hazards ............................................................................ 10
2.3 Information on Electric Isolation............................................................................ 10
2.4 Special Safety Instructions for the Device .............................................................. 12
2.5 Proper Disposal.................................................................................................... 14
3 Intended Use ............................................................................................................. 15
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 Identification – Labeling on the Device.................................................... 18
4.1.5 Electrical Data.................................................................................................... 18
4.1.6 Interfaces.......................................................................................................... 21
4.1.7 Overview Drawings.............................................................................................22
5 Installation Instructions.............................................................................................25
5.1 Installation Instructions ........................................................................................ 25
6 Wiring ...................................................................................................................... 26
6.1 Wiring – Power Supply ..........................................................................................28
6.2 Wiring – Sensors on the SCR Catalytic Converter ....................................................30
6.3 Wiring – Pump Module.......................................................................................... 32
6.4 Wiring – Dosing Unit.............................................................................................33
6.5 Wiring – MAT and MAP Sensor...............................................................................34
6.6 Wiring – Binary Inputs ..........................................................................................36
6.7 Wiring – Binary Outputs........................................................................................ 37
6.8 Wiring – Analog Inputs and Outputs ......................................................................39
6.9 Wiring – CAN Bus .................................................................................................40
Table of Contents

Table of Contents
4 Rev. 06/2020
6.10 Wiring – Modbus (RS485)....................................................................................42
7 Functions...................................................................................................................44
7.1 NOx Emission Control............................................................................................ 44
7.2 Pump Self Test .....................................................................................................44
7.3 Control of the Pressure of the Pump.......................................................................44
7.4 Cooling of the Dosing Valve................................................................................... 45
7.5 Protection against Freezing of the Dosing Valve...................................................... 45
7.6 Manual and Automatic Operation .......................................................................... 45
7.7 Access Control......................................................................................................46
8 Settings via the MICT................................................................................................ 48
8.1 MICT System Requirements...................................................................................48
8.2 MICT Installation..................................................................................................48
8.3 Access Levels in the MICT ..................................................................................... 49
8.4 Configuration Pages (Overview) ............................................................................ 50
8.5 Menu Bar and Toolbar............................................................................................51
8.6 Manual Valve Adjustment ..................................................................................... 54
8.7 Manual 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
8.9.4 Reset all PINs.................................................................................................... 58
8.10 Working with Configurations ............................................................................... 59
8.10.1 Create, Open, Save...........................................................................................60
8.10.2 Upload, Download ........................................................................................... 61
8.10.3 Compatibility Information................................................................................. 61
8.11 Configuration...................................................................................................... 62
8.11.1 Inputs/Outputs – Control Setup......................................................................... 63
8.11.2 Exhaust Control – Parameter.............................................................................64
8.11.3 Exhaust Control – SCR – Pump Setup.................................................................66
8.11.4 Exhaust Control – SCR – Pump Self Test............................................................. 67
8.11.5 Exhaust Control – SCR – Dosing Valve ...............................................................69
8.11.6 Exhaust Control – SCR – Feed Forward Control ................................................... 70
8.11.7 Exhaust Control – Check ....................................................................................71
8.11.8 Miscellaneous – Communication....................................................................... 73
8.11.9 Miscellaneous – Service Contact....................................................................... 75

Table of Contents
Rev. 06/2020 5
8.12 Runtime Data...................................................................................................... 76
8.12.1 Runtime Data – Overview ..................................................................................78
8.12.2 Runtime Data – Sensors ................................................................................... 81
8.12.3 Runtime Data – Dosing Unit ..............................................................................83
8.12.4 Runtime Data – Trends .....................................................................................85
8.12.5 Runtime Data – Message Log ............................................................................87
8.12.5.1 Information ...................................................................................................88
8.12.5.2 Warnings......................................................................................................88
8.12.5.3 Errors ...........................................................................................................89
8.12.6 Runtime Data – Diagnostics..............................................................................90
8.12.7 Runtime Data – Information ..............................................................................92
8.13 Runtime 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 Values for Feed Forward Control ..........................................................98
9.2 Firmware Update ................................................................................................ 102
10 Errors ..................................................................................................................... 106
10.1 Troubleshooting................................................................................................ 106
10.2 Possible Faults ................................................................................................. 106
10.3 Acknowledging Faults ....................................................................................... 107
10.4 Customer Service Information............................................................................ 107
10.5 Returning Equipment for Repair/Inspection ........................................................ 108
10.6 Instructions for Packaging the Equipment .......................................................... 108
11 Maintenance........................................................................................................... 109
11.1 Spare Parts and Accessories............................................................................... 109
12 Index ..................................................................................................................... 110

6 Rev. 06/2020
Read through this operating manual carefully before use and become familiar with the product.
Installation and start-up should not be carried out before reading and understanding this
document. Keep this manual readily available so that you can reference it as needed.
1.1 What Is the Purpose of this Operating Manual?
This manual serves as an aid for the installation and operation of the product and supports the
technical staff with all operating and maintenance tasks to be performed. Furthermore, this
manual is aimed at preventing dangers to life and health of the user and third parties.
1.2 Who Is this Operating Manual Targeted to?
The operating manual 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 electronic ignition systems 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 Which Symbols Are Used in the Operating Manual?
The following symbols are used in this manual 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
addition, 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
mentioned precautionary measures.
1 General Information

1 General Information
Rev. 06/2020 7
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 Operating Manual?
In the operating manual or the user interface, the following abbreviations/acronyms are used.
Abb. Term Description Explanation
CAN bus Controller Area Network
bus
Bus for control
devices/ networks
Asynchronous serial
connection system for
linking control units
CE Conformité Européenne Conformity with EU
directives
Mark based on EU legislation
for certain products in
conjunction with product
safety
CPU Central Processing Unit
CSV Comma-separated
Values
Text file for storage or
exchange of structured data
DC Direct Current
EMC Electromagnetic
Compatibility
Compatibility of electrical or
electronic equipment items
with their surroundings
ESD Electrostatic Discharge
LED Light Emitting Diode Light emitting electronic
semiconductor
MAP Manifold Absolute
Pressure
MAT Manifold Air
Temperature
MICT MOTORTECH Integrated
Configuration Tool
Configuration software for
MOTORTECH control units

1 General Information
8 Rev. 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 computer to external
devices

Rev. 06/2020 9
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
operator.
–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
equipment must be disconnected from the mains and secured against unintentional
reactivation.
–Perform only such maintenance and repair work as is described in this operating manual,
and follow the instructions given while working.
–Only use spare parts supplied by MOTORTECH for the maintenance of the device.
–Further work must only be performed 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 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 that occur during operation of the gas engine or electronic engine
control.
–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 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 engine.
2 Safety Instructions

2 Safety Instructions
10 Rev. 06/2020
–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
handling of the gas engine and the gas-carrying system.
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
electrostatic 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
building 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 Information on Electric Isolation
If ground and earth potential are not properly isolated, the following problems as well as others
can occur:
–Electromagnetic interferences (e.g. ground loops)
–Signal corruption (e.g. of the analog voltage signal)
–Unwanted leakage currents
Therefore, earth potential and the negative pole of the power supply of all devices in the electric
assembly that provide the option, should be connected separately. If possible, the negative pole
of the power supply should only be connected to earth potential at one point in the entire
system.