ECM NOx 5210 Series Instruction Manual
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ECM NOx 5210 Series Instruction Manual

Single/dual nox analyzer
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NOx 5210*
Single/Dual NOx Analyzer
Instruction Manual
* Note:
ECM's NOx analyzer can be either single or dual channeled. Each channel can use one of
three NOx sensors: the Type T sensor, the Type G sensor, or the "Original" NOx sensor.
6/10/22

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  • Page 1 Single/Dual NOx Analyzer Instruction Manual * Note: ECM’s NOx analyzer can be either single or dual channeled. Each channel can use one of three NOx sensors: the Type T sensor, the Type G sensor, or the “Original” NOx sensor. 6/10/22...
  • Page 2  COPYRIGHT 2012 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

    Table of Contents Introduction The NOx 5210 NOx 5210 Kit Contents Safety Warnings How to Use Hooking up the NOx 5210 Mounting the NOx Sensor and Pressure Sensor Front Panel and the “SYS” Key MOd (Module) Setup Option RATE Setup Option FUEL Setup Option (H:C, O:C, N:C, H2) AOUT (Analog Output) Setup Option (A1 to A6) dISP (Display) Setup Option (P1 to P6)

  • Page 5: Introduction

    Introduction The NOx 5210 The NOx 5210 is a compact, ceramic sensor-based NOx and O analyzer for the development of engines and their aftertreatment systems. Its features include:  Single or dual channel NOx sensor operation  Works with Type T, Type G, and the “Original” NOx sensors ...

  • Page 6: Nox 5210 Kit Contents

    NOx 5210 Kit Contents The following items are included with a single-channel, NOx 5210 kit: Item No. Description Part Number NOx 5210 Display Head 01-01 NOxCANt Module (for Type T sensor), or 02-07 NOxCANg Module (for Type G sensor), or 02-03 NOxCAN Module (for “Original”...
  • Page 7 For pressure-compensation, these additional items are included (per NOx channel): Item No. Description Part Number Pressure Sensor with ¼” tube fitting (USA), or 07-01 Pressure Sensor with 6 mm tube fitting (Metric) 07-02 Module Y Cable 10-21 Pressure Sensor Cable, 1 m 10-04 Pressure Line Assembly, 28”, (USA), or 12-08A...

  • Page 8: Safety Warnings

    Safety Warnings In installation and use of this product, comply with the National Electrical Code and any other applicable Federal, State, or local safety codes. The NOx sensor is heated, gets hot, and can burn you. Always wear eye protection when working near engines, vehicles, or machinery. During installation, turn off the power and take all other necessary precautions to prevent injury, property loss, and equipment damage.

  • Page 9: How To Use

    The cable between the display head and module(s) is called the EIB (ECM Instrument Bus) and carries signal and power. There must be a termination resistor at each end of the EIB.
  • Page 10 EIB with Power Entry at Module End Connect Connect Power Entry Module EIB Connector Display Head Pressure NOx Sensor Sensor Figure 1: NOx 5210 with Power Entry at Module End...
  • Page 11 EIB with Power Entry at Display Head End Connect Module Power Entry EIB Connector Display Head NOx Sensor Pressure Sensor Figure 2: NOx 5210 with Power Entry at Display Head End...
  • Page 12 P/N 09-02, 2 m P/N 09-06 P/N 09-01, 4 m P/N 09-05 Eurofast 12 mm Eurofast Termination Eurofast 12 mm Eurofast “T” Cable Resistor Cable P/N 09-04. 0.3 m Flexi-Eurofast Cable P/N 02-02 P/N 01-01 P/N 04-01 P/N 11-16 NOxCAN Module, or NOx 5210 AC/DC Power Supply, DC Power Cable,...
  • Page 13 P/N 11-05 Female Eurofast to DB9F P/N 09-05 Eurofast “T” P/N 09-04 P/N 11-08, 2 m Eurofast Key-on Cable Termination (2.7-32 V) Resistor 500 kHz Broadcast P/N 09-04, 0.3 m CAN Bus P/N 13-01, Manuals and Flexi-Eurofast Connector Configuration Tool Cable P/N 01-01 Connector...
  • Page 14 P/N 02-02 NOxCAN Module, or P/N 02-03 NOxCANg Module, or P/N 02-07 NOxCANt Module P/N 06-01, Original NOx Sensor, or P/N 06-02, Type G NOx Sensor, or P/N 06-05, Type T NOx Sensor P/N 10-21, 0.2 m, Module Y Cable P/N 10-02, 1 m Lambda/NOx Cable, or P/N 10-03, 2 m, or...

  • Page 15: Mounting The Nox Sensor And Pressure Sensor

    Mounting the NOx Sensor and Pressure Sensor NOx Sensor   Thread is 18mm x 1.5mm (Original and Type T Sensor) or 20mm x 1.5mm (Type G Sensor)  Mount between 300 mm from exhaust valve and ten exhaust diameters upstream of exhaust end.

  • Page 16: Front Panel And The "Sys" Key

    Front Panel and the “SYS” Key The NOx 5210 display head can be thought of as two single-channel display heads in one package. One NOx module can be assigned to the upper display, upper four leds, and analog outputs 1, 2, 3 (i.e. the upper channel) and a second NOx module can be assigned to the lower display, lower four leds, and analog outputs 4, 5, 6 (i.e.
  • Page 17 Setup Option Level 1 Level 2 Level 3 Function Select module s/n [NONE] RATE Set display update rate [FAST] FUEL Program fuel H:C,O:C,N:C and if H [1.85,0,0,NO] AOUT A1 (upper channel) Program analog output 1 [NOx,0,2000] A2 (upper channel) Program analog output 2 [O2,-25.00,25.00] A3 (upper channel) Program analog output 3 [LAM,0.400,25.00] A4 (lower channel)

  • Page 18: Mod (Module) Setup Option

    MOd (Module) Setup Option In MOd setup, the serial number of the NOx module assigned to the upper or lower channel is entered. The serial number is written on a label on the module (see Figure B1). The module assigned to the upper channel will send information to the upper display and the analog outputs 1, 2, and 3.
  • Page 19 4. Press the  and  keys until the parameter (see Table 2) that will drive A2 is displayed. Then press the ENT key. Keep in mind that if CONF MOdE is set to STNd, only a subset of Table 2 will be available. 5.
  • Page 20 NOx sensor Ip2 pumping current (unsigned integer format) ERFL Error bit flags (bits) Module error flags (unsigned long format) ERCd ECM CANOpen Error Code ECM CANOpen Error Code PR10 Praw10 (bits) 10 bit Pressure sensor output voltage (unsigned integer format)

  • Page 21: Disp (Display) Setup Option (P1 To P6)

    With use, NOx sensors can age requiring recalibration to maintain measurement accuracy. Recalibration can be performed by the user or by sending the sensor back to ECM. There are two parts of the NOx sensor: the O (Lambda, AFR, FAR, PHI) measuring part and the NOx measuring part.
  • Page 22  , , AFR, Φ, and The O2 SPAN function is for the recalibration of the NOx sensor’s %O FAR measurements. This recalibration is stored in the sensor’s memory chip and is used instead of the factory calibration. The FACT function cancels the user calibration resulting in the factory calibration being used.
  • Page 23 AGEF (NOx sensor age factor) After the NOx sensor has had its O measurement spanned, data from this span is compared to data from the sensor when it was new. From this, a parameter (AGEF) is calculated that indicates the relative sensitivity of the sensor compared to when it was new. If AGEF is 1.00, the sensor’s sensitivity has not changed.
  • Page 24 10. Press SYS to return to RUN mode. 11. The user calibration is written into the memory chip in the NOx sensor’s connector and will be used to calculate NOx. If the NOx sensor is removed and installed on another module, this user calibration will go with the sensor and be used with the new module.
  • Page 25 (entered under “GAMMA”, “ENGW”) and two different “GAMM” coefficients (GAMMA, BETA) used when the sensor is in model gases (entered under “GAMMA”, “MODL”). ECM factory sets these numbers for each NOx sensor and they should only be modified after consultation with ECM.

  • Page 26: Cal (Calibrate) Setup Option For Original Nox Sensor

    With use, NOx sensors can age requiring recalibration to maintain measurement accuracy. Recalibration can be performed by the user or by sending the sensor back to ECM. There are two parts of the NOx sensor: the O (Lambda, AFR, FAR, PHI) measuring part and the NOx measuring part.
  • Page 27 humidity air, use the Configuration Tool Software or refer to Appendix D. 20.7 is a common number. 4. Press the SYS key until “MOd” appears. 5. Press the  key until “CAL” is on the display of the channel to be calibrated. Then press the ENT key.
  • Page 28 simulate these temperatures in a model gas apparatus. In addition, it is recommended that a BTU200 (ceramic sensor heater) be used. ZERO (for NOx measurement) To perform a NOx zero: 1. A zero should be performed after the NOx sensor has been on for at least eight hours (hanging in air).

  • Page 29: Cal (Calibrate) Setup Option (P, Avg, Skew)

    another module, this user calibration will go with the sensor and be used with the new module. FACT (return to factory NOx calibration) To return to the factory calibration for the NOx sensor: 1. Make sure the NOx sensor is attached to the module. 2.

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

    = the parameter average at time “t” The default averaging filter values are given within square parentheses in Table 1. These values and the length of the pressure line assembly should not be modified without first consulting ECM. SKEW ...
  • Page 31 LEdS  The display intensity is programmable. Press the ENT key when “LEdS” appears on the lower display, press the  or  keys until the display intensity is suitable, press ENT, and press SYS to return to RUN mode. 1V4V ...
  • Page 32 Each of the eight parameters in CANid1 to CANid4 is a single-precision 32 bit floating point number that conforms to the IEEE-754 standard. All eight of these parameters are transmitted on the CAN bus least significant byte first (Intel format). Parameters 1 through 8 (everything except error codes) sent on the CAN bus are averaged (“AVG”d, see CAL Setup Option).
  • Page 33 The rate at which CAN data is sent can also be programmed via the “RATE” parameter under “CAN”. To program how often the CAN data is to be sent: enter SYS mode,  down to “CONF”, press the ENT key,  down to “CAN”, press the ENT key,  down to “RATE”, press the ENT key, then enter the rate in ms.
  • Page 34 MOdE  “ENHd” and “STNd” refer to whether the full list in Table 2 (for ENHd) or a subset (for STNd) will be available to assign to an analog output (A1 to A6) or a displayed parameter (P1 to P6). “LOCK”...

  • Page 35: Specifications And Limits

    Specifications and Limits Measurements and Accuracies Parameter Range Response Time Accuracy NOx (Type T) 0 to 5000 ppm < 1 s ±20 ppm (0 to 1000 ppm) ±2.0% of reading (elsewhere) NOx (Type G) 0 to 5000 ppm < 1 s ±15 ppm (0 to 1000 ppm) ±1.5% of reading (elsewhere) NOx (Original)

  • Page 36: Sensor Limits And Specifications

    Sensor Limits and Specifications NOx Sensor  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 37 Pressure Sensor  Note: Must attach to engine via ECM-supplied pressure sensor tubing only! Do not directly attach to the exhaust or pressure sensor damage will result. Diaphragm Material: Stainless steel Maximum Pressure: 200 Psia, 1379 kPa (absolute) Operating Temperature Range: -40 to 105 °C Thread on Pressure Sensor: ¼”...

  • Page 38: 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: 5 ms Isolation: Electrically isolated from power supply ground. All analog output grounds common. ...

  • Page 39: General Specifications

    General Specifications  Power DC: 11 to 28 VDC Current Draw: 0.5 A (display), 1.2 A steady-state (NOx sensor and module), On start-up, NOx sensor and module may draw as much as 4 A for 30 s. Case Ground: The NOx 5210 display head case is connected to power ground via a 2.15 kΩ...

  • Page 40: 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 41 05-06 Delphi OSL 05-07 NTK 4mA Cofired (ZFAS-U2) 05-08 Bosch LSU4.9, Type P 05-09 Bosch ADV 05-10 NTK, 6mA, Type P 05-11 Bosch LSU4.2, Type PI (Intake) 05-12 CO, CO2 06 NOx and NH3 Sensors 06-01 NOx Original (use with NOxCAN) 06-02 NOx Type "G"...
  • Page 42 10 Sensor Cables 10-01 Module Y Cable (Superceded 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 10-12 Adapter to Pressure Sensor Wires...
  • Page 43 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 44 12-10 18mm Cu Gasket 12-11 Pressure Line Assembly, 6mm, 483mm, (Metric) 12-11A Pressure Line Assembly, 6mm, 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" ISO tapered Al Boss and Brass Plug, (Metric) 12-15 15A Fuse 12-16 Bifurcated Intake Sample Probe, 8mm 12-17 Replacement Bifurcated Tube, 8mm...
  • Page 45 14-06 Metal Brush 14-07 Lambda Sensor Calibration System 14-08 20mm x 1.5mm Bottoming Tap...

  • Page 46: Module Eib Mode And Stand-Alone Mode

    Appendix B: Module EIB Mode and Stand-alone Mode The NOxCAN module can be used in conjunction with a display head (EIB mode) or on its own (Stand-alone mode). When delivered to be used with a display head, the module is setup in EIB mode.
  • Page 47 2. Install and start the Configuration Tool (software). Click on the “Module” tab. Select the CAN adapter being used. Then start the communication. 3. Click on the “Set to EIB Mode”. Wait for “Done” Message. Stop communication and exit program.
  • Page 48 4. Take the nut off the end of the module. Use an 18mm socket without the wrench. 5. Release the two tangs at each side of the module. 6. Slide the PCB out. Remove the jumper from JP4. You can hang it on one pin of JP4 when “off”.
  • Page 49 7. Make sure both O-rings are on the threaded connector. 8. Slide the PCB into the enclosure until the two tangs “click”. 9. Put the nut on and tighten ONLY ½ turn from where it is seated. If this nut is tightened too much, the connector will crack and the enclosure will not be sealed.

  • Page 50: Error Codes And Troubleshooting

    Sensor warm-up period (not really an error) 0002 Green/Both/Red 2s Power on reset / Init hardware 0011 Pulse Red 1x/2s 16 bit ADC failed to init. Internal module error. Contact ECM. 0012 Pulse Red 1x/2s +Vsw shorted. Internal module error. Contact ECM. 0013 Red ON...

  • Page 51: Calculating The %O

    Appendix D: 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 52 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 53: Using The Configuration Tool Software

    Appendix F: Using the Configuration Tool Software The ECM Configuration Tool with be used with analyzers (i.e. NOx 5210, Lambda 5220, EGR 5230). 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 54 display. Press ENT and the format of the messages for that analyzer will be sent to the Configuration Tool. Each analyzer’s serial number will appear in the “Device:” window list (open window to see all present) after its message format has been received by the Configuration Tool. When an analyzer’s serial number is in the “Device:”...

  • Page 55: The Nox Type F Sensor

    Appendix G: The NOx Type F Sensor The NOx Type F sensor (P/N 06-09) is a modified NOx Type T sensor where the exhaust gases have to pass through an NH3-adsorbing filter before reaching the sense elements inside the sensor. Therefore, instead of measuring NOx + NH3 (as any NOx sensor does), the NOx Type F sensor measures NOx only.
  • Page 56 How to use the NOx Type F sensor  1. Put antiseize on sensor thread 2. Put filter on sensor. Filter contains acid so use gloves.
  • Page 57 3. Screw cap over sensor 4. Put antiseize on cap threads...
  • Page 58 5. Use P/N: 12-56 Mounting Boss (3/4” NPT) 6. Lightly tighten using hex on sensor...
  • Page 59 7. During removal, sometimes cap will remain in boss. Use flats to remove. 8. Typical application; mounted in tube attached to tailpipe...

  • Page 60: Warranty And Disclaimers

    Warranty and Disclaimers WARRANTY The products described in this manual, with the exception of the NOx sensor and pressure sensor, 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 61 586 Weddell Drive, Suite 2 Sunnyvale, CA 94089-2134 AND MONITORING Phone: (408) 734-3433 FAX: (408) 734-3432 Email: sales@ecm-co.com Web: www.ecm-co.com EC DECLARATION OF CONFORMITY We declare under our sole responsibility that the products: AFM1540 Lambda Module AFM1600 Lambda and O Analyzer DIS1000 Display Head...
  • Page 64 Los Altos, CA 94023-0040  USA  (408) 734-3433  Fax: (408) 734-3432  www.ecm-co.com...

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