Motortech EasyNOx User manual

EasyNOX– NOXMonitoring
Operating Manual
P/N 01.50.026-EN | Rev. 06/2021

Original instructions
© Copyright 2021 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. 06/2021 3
1 General Information .....................................................................................................7
1.1 What Is the Purpose of this Operating Manual? ......................................................... 7
1.2 Who Is this Operating Manual Targeted to?............................................................... 7
1.3 Which Symbols Are Used in the Operating Manual?................................................... 7
1.4 Which Abbreviations/Acronyms Are Used in the Operating Manual?...........................8
2 Safety Instructions .................................................................................................... 10
2.1 General Safety Instructions ................................................................................... 10
2.2 Electrostatic Discharge Hazards .............................................................................11
2.3 Information on Electric Isolation............................................................................ 12
2.4 Special Safety Instructions.................................................................................... 14
2.4.1 EasyNOₓSystem................................................................................................. 14
2.4.2 NOₓSensor P/N 56.03.003 ................................................................................. 17
2.5 Proper Storage ..................................................................................................... 18
2.6 Proper Transport .................................................................................................. 18
2.7 Proper Disposal.................................................................................................... 18
3 Intended Use ............................................................................................................. 19
3.1 Functional Description .......................................................................................... 19
3.2 Applications.........................................................................................................20
4 Product Description ...................................................................................................22
4.1 Technical Data ......................................................................................................22
4.1.1 Certifications .....................................................................................................22
4.1.2 Mechanical Data ................................................................................................23
4.1.3 Product Identification – Labeling on the Device....................................................26
4.1.4 Electrical Data....................................................................................................28
4.1.5 Display.............................................................................................................. 31
4.1.6 Interfaces.......................................................................................................... 32
4.1.7 Overview Drawings............................................................................................. 33
4.1.7.1 Dimensions ..................................................................................................... 33
4.1.7.2 Components ................................................................................................... 37
4.1.8 Ports/Connections and LEDs...............................................................................39
5 Functions...................................................................................................................42
5.1 NOₓMonitoring .....................................................................................................42
5.1.1 Measured Value Display and Measured Value Output ...........................................42
5.1.2 Conversion of Nitrogen Oxide Readings ...............................................................42
5.1.3 Limit Monitoring ................................................................................................43
5.1.4 Failure Hour Counter ..........................................................................................44
Table of Contents

Table of Contents
4 Rev. 06/2021
5.1.5 Exhaust Gas Temperature Monitoring ..................................................................44
5.1.6 Dew Point Detection...........................................................................................44
5.1.7 Normal Operation Detection................................................................................ 45
5.1.8 Daily Log ........................................................................................................... 45
5.1.9 Annual Log ........................................................................................................ 45
5.1.10 Logbook .......................................................................................................... 45
5.1.11 NOₓMonitoring Report ......................................................................................46
5.2 I/O Communication Module .................................................................................. 47
5.3 Generic Device ..................................................................................................... 47
6 Installation Instruction ............................................................................................. 48
6.1 Unpacking............................................................................................................48
6.2 Mounting of EasyNOₓ............................................................................................49
6.3 Mounting of CAN Bus/NOₓSensor Module..............................................................49
6.4 Mounting the Sensing Element of NOₓSensor P/N 56.03.003 .................................. 50
6.4.1 Mounting Position of Sensing Element .................................................................51
6.4.2 Laying the Connection Cable .............................................................................. 53
6.4.3 Mounting the Sensing Element........................................................................... 53
6.5 Determining the NO2/NOₓRatio ............................................................................. 55
6.6 Installation Locations of Thermocouples................................................................ 55
6.7 Installation Location of Manifold Pressure Sensor .................................................. 56
6.8 Determining Charging Pressure for Normal Operation Detection.............................. 57
6.9 Mounting of I/O Communication Module ............................................................... 57
7 Wiring and Configuration ...........................................................................................58
7.1 EasyNOₓ............................................................................................................... 58
7.1.1 Opening and Closing of Housing.......................................................................... 58
7.1.2 Wiring ............................................................................................................... 59
7.1.3 Replacement of Memory Card .............................................................................62
7.2 CAN Bus/NOₓSensor Module ................................................................................62
7.2.1 Opening and Closing of Module ..........................................................................62
7.2.2 Grounding......................................................................................................... 63
7.2.3 Wiring of Thermocouples.................................................................................... 63
7.2.4 Wiring of Manifold Pressure Sensor, MAP Signal, Load Signal ..............................64
7.2.5 Wiring of Power Supply and CAN Bus................................................................... 65
7.2.6 Closing of Cable Glands .....................................................................................66
7.2.7 CAN Bus Termination .........................................................................................66
7.2.8 Node ID NOₓSensor ...........................................................................................66
7.2.9 Node ID CAN Bus Module ................................................................................... 67

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Rev. 06/2021 5
7.2.10 Bit Rate CAN Bus Module .................................................................................. 67
7.2.11 Device Setup EasyNOₓ.......................................................................................67
7.3 CAN Bus Wiring CAN1 ............................................................................................ 67
7.4 I/O Communication Module...................................................................................69
7.4.1 Assignment .......................................................................................................70
7.4.2 Wiring of Power Supply ...................................................................................... 72
7.4.3 CAN Bus Wiring, CAN Bus Termination................................................................. 72
7.4.4 Wiring of Inputs and Outputs .............................................................................. 72
7.4.5 Device Setup EasyNOₓ........................................................................................ 73
8 General Operation .....................................................................................................74
8.1 Switching on and off the Device.............................................................................74
8.2 Navigation ........................................................................................................... 74
8.3 Menu Bar.............................................................................................................76
8.4 Start Menu...........................................................................................................78
8.4.1 Devices .............................................................................................................80
8.4.1.1 Device Activation.............................................................................................82
8.4.1.2 Adding a Device ..............................................................................................83
8.4.1.3 Editing a Device ..............................................................................................86
8.4.1.4 Deleting a Device ............................................................................................86
8.4.2 Display .............................................................................................................86
8.4.3 Connection .......................................................................................................90
8.5 Access Control ..................................................................................................... 91
8.5.1 Enabling/Disabling Access Control .....................................................................92
8.5.2 Logging in and Logging out ................................................................................94
8.5.3 Changing the PIN...............................................................................................95
8.5.4 Resetting the PINs .............................................................................................95
8.6 Event Log............................................................................................................. 97
8.7 Help ....................................................................................................................98
9 Devices..................................................................................................................... 99
9.1 NOₓMonitor..........................................................................................................99
9.1.1 Main Menu....................................................................................................... 100
9.1.2 Overview ..........................................................................................................101
9.1.3 History ............................................................................................................ 106
9.1.4 Logbook .......................................................................................................... 108
9.1.5 Export ..............................................................................................................110
9.1.6 Preferences ......................................................................................................112
9.1.7 Operator...........................................................................................................116

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6 Rev. 06/2021
9.1.8 Sensor ............................................................................................................. 117
9.2 I/O Communication Module ................................................................................ 120
9.2.1 Main Menu ...................................................................................................... 120
9.2.2 Preferences..................................................................................................... 122
9.2.2.1 Binary Inputs.................................................................................................123
9.2.2.2 Binary Outputs ............................................................................................. 124
9.2.2.3 Analog Inputs................................................................................................125
9.2.2.4 Analog Outputs ............................................................................................ 126
9.3 Generic Device ....................................................................................................127
10 Operation...............................................................................................................128
10.1 Start-up............................................................................................................ 128
10.2 Shutdown ........................................................................................................ 128
10.3 Software Update ............................................................................................... 129
11 Errors ......................................................................................................................131
11.1 Possible Faults ................................................................................................... 131
11.2 Customer Service Information .............................................................................132
11.3 Returning Equipment for Repair / Inspection ........................................................133
11.4 Instructions for Packaging the Equipment ............................................................133
12 Maintenance .......................................................................................................... 134
12.1 Cleaning the Touchscreen.................................................................................. 134
12.2 Maintenance of Housing.................................................................................... 134
12.3 Battery Change..................................................................................................135
12.4 Replacing the NOₓSensor...................................................................................135
12.5 Spare Parts and Accessories.............................................................................. 138
13 Index...................................................................................................................... 139

Rev. 06/2021 7
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 docu-
ment. 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, opera-
tion, 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 neces-
sary. Persons who are only authorized to operate the gas engine shall be trained by the operat-
ing 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 addi-
tion, this symbol is used for overviews that give you a summary of the nec-
essary 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
8 Rev. 06/2021
Danger
This symbol indicates warnings for danger to life, especially due to high
voltage. Read these warning notices carefully and take the mentioned pre-
cautionary 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 de-
vices / networks
Asynchronous serial connec-
tion system for linking control
units
CE Conformité
Européenne
Conformity with EU
directives
Mark based on EU legislation
for certain products in conjunc-
tion with product safety
CSV Comma-separated
Values
Data separated by
comma
Text file for storage or ex-
change of structured data
DC Direct Current
DIP Dual In-Line Package Housing form for electronic
components with two rows of
connections for push-fit assem-
bly
DIS Draft International
Standard
Draft ISO standard
ECU Electronic Control Unit Electronic module for control
and regulation
EMC Electromagnetic
Compatibility
Compatibility of electrical or
electronic equipment items
with their surroundings
ESD Electrostatic
Discharge
HMI Human-Machine
Interface
Interface between a human and
a machine or a computer
I/O Input/Output Communication of an informa-
tion system with the outside
world

1 General Information
Rev. 06/2021 9
Abb. Term Description Explanation
ISO International
Organization for
Standardization
LED Light Emitting Diode Light emitting electronic semi-
conductor
MAP Manifold Absolute
Pressure
MMC Multimedia Card Digital storage medium
PRAK PIN Reset
Authorization Key
Key for resetting all
PINs
Key that resets all PINs of the
EasyNOₓ.
PRRK PIN Reset Request Key Key for applying for a
PIN reset key
Key with which the key for re-
setting all EasyNOₓPINs can be
requested.
RoHS Restriction of
Hazardous
Substances
SD card Secure Digital card Secure digital data
storage card
Digital storage medium
SDHC
card
Secure Digital
High-Capacity card
Secure, high-capacity
digital memory card
Digital storage medium
USB Universal Serial Bus Serial connection system to
link a computer to external de-
vices
UTC Coordinated Universal
Time

10 Rev. 06/2021
2.1 General Safety Instructions
The following safety instructions must be followed in the area in which the device is operated:
High voltage! Danger to life!
While the engine is running, there is danger to life through high voltage par-
ticularly in the area of the ignition system. The following parts should there-
fore not be touched or removed unless explicitly stated otherwise:
–Ignition coils and caps
–Wires of the high voltage circuit
–In- and output wiring of the ignition controller
–Pickups and their wiring
Danger to persons with pacemakers!
Electromagnetic impulses in the wiring of the ignition system may exceed
the permissible limits of pacemakers. Persons with pacemakers must there-
fore not be present in the vicinity of the ignition system being operated.
Mark the operating location of the ignition system with the corresponding
standardized warning symbol.
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 in-
structions 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 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-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.
2 Safety Instructions