Installation and Operating Manual. ECV5 and ECVI IOM 6-18

Transcription

1 Istallatio ad Operatig Maual ECV5 ad ECVI IOM 6-18

2 Table of Cotets PREFACE...5 REGULATORY COMPLIANCE...6 SAFETY...6 ELECTROSTATIC DISCHARGE AWARENESS...7 GLOSSARY OF TERMS INTRODUCTION...8 RICH-BURN COMBUSTION...9 Rich-Bur Oxyge Sesor...9 Beefits of Rich-Bur...9 LEAN-BURN COMBUSTION...10 Lea-Bur Oxyge Sesor...10 Beefits of Lea-Bur...10 ACHIEVING EMISSION COMPLIANCE ECV5 FOR RICH OR LEAN-BURN CONFIGURATIONS...12 PRODUCTION OF EMISSIONS...12 EXHAUST GAS TREATMENT ECV5 GENERAL INFORMATION...14 SPECIFICATIONS...14 ENVIRONMENT...15 EMC...15 Fuel Type...15 Ilet Fuel Gas Pressure...15 FGP Adjustmet...15 Fuel ad Service Gas FEATURES...16 RANGE...16 CLOSED LOOP PRESSURE CONTROL...17 FULLY AUTOMATIC CONTROL...17 VARIABLE DYNAMIC GAIN...17 COMMUNICATIONS THEORY OF OPERATION...18 THE SYSTEM...18 FULL FUEL-AUTHORITY...19 PRESSURE SENSOR...19 MECHANICAL VALVE DESIGN...19 Balaced Poppet...19 Positio Sesor...19 High speed Actuator...19 CATALYST (CAT) MONITOR...19 WIDE-RANGE OXYGEN SENSOR...20 Wide-Rage Sesor Heater Power Cotrol...20 ALTRONIC, LLC

3 ECVI...20 NOX SENSOR...21 THERMOCOUPLES MA INPUT FOR A DELTA-P TRANSDUCER ECV5 INSTALLATION INSTRUCTIONS ECVI MONITOR SCREENS...23 INITIAL DISPLAY SCREEN...23 MAIN SCREEN...23 PRESSURE/POSITION MEASUREMENT SCREEN...24 CATALYST MONITOR SCREEN...24 FLOW METER...25 DIAGNOSTICS SCREEN...26 SETTINGS SCREEN ECVI SETTINGS SCREENS...27 INITIAL DISPLAY SCREEN...27 MAIN SCREEN...28 SETTINGS SCREEN...28 CANBUS SETUP SCREEN...29 FREE AIR CAL SCREEN...29 FUEL PRESSURE SETUP SCREEN...30 O2 SENSOR SETUP SCREEN...31 O2 DITHERING SETUP SCREEN...32 DYNAMIC O2 SCHEDULE SETUP SCREEN...32 OPTIONAL START PRESSURE SETTINGS SCREEN...33 CAT MONITOR SETUP SCREEN...34 MODBUS ADDRESS SETUP SCREEN...35 PROCEDURE FOR ENTERING PARAMETERS ON SETUP SCREENS ECVI/ECV5 SETUP PROCEDURES...38 SETUP OF THE ECV5 WITH CAT MONITOR USING THE ECVI WITH IDEC DISPLAY...38 Cofigurig the Uit...38 Settig Device ID S o THE IDEC Display...39 Settig Up CANbus...41 Iitial Startup Settigs...41 Coductig a Free Air Calibratio...41 Startig the Egie...41 Chagig Settigs for Normal Operatio...42 SETUP NOX SENSOR TRIM AND DITHERING USING THE IDEC DISPLAY...43 Checkig Stability of the NOx Sesor Pv (Feedback)...43 Settig Up ad Eablig O2 Sesor Ditherig...44 Settig Up ad Eablig the NOx Sesor Trim...45 ALTRONIC, LLC

4 10. OPTIONAL EQUIPMENT...46 CABLES...46 NOX SENSOR...46 CATALYST DELTA-P TRANSDUCER...46 FM-50 FUEL FLOW METER...46 MIXING VENTURI S TROUBLESHOOTING...46 VALVE STROKE LIMITED...46 PRESSURE CONTROL LOOP...46 GOVERNOR CONTROL...46 O2 SENSOR PRODUCT WARRANTY TECHNICAL ASSISTANCE APPENDICIES...48 A1. ECV5_B Modbus Registers...48 A2. CANbus Commuicatios...52 A3. Cat Moitor Modbus Registers...55 A4. Evelope, ECV5, 2.0 i. ANSI Flage...63 A5. Evelope, ECVI...64 A6. ECV5 Cable...65 A7. Catalyst Moitor, Page A8. Catalyst Moitor, Page A9. ECVI PWB Wirig Diagram, Dual Bak...68 A10. ECVI PWB Wirig Diagram, Sigle Bak...69 A11. O2 Sesor Cable Wirig Diagram...70 ALTRONIC, LLC

5 Preface It is highly recommeded that the user read this maual i its etirety before commecig operatios. It is either our itetio or our obligatio, to istruct others o how to desig or implemet egie cotrol systems. We will ot assume resposibility for egie cotrols ot desiged or istalled by our authorized represetatives. This maual is desiged to describe the istallatio ad operatio of the ECV5 Emissio Cotrol Valve for either rich or lea bur applicatios o atural gas egies. The ECV5 ad optioal ECVI Display represet the curret state of the art i Air/Fuel Ratio Cotrollers. The combiatio of a sophisticated mechaical desig of the balaced poppet valve, the advaced electroic desig, ad oboard microprocessor combies to provide the best available cotrol techology for cotrollig gas egies. This maual is iteded to help the ed user istall ad operate the ECV5 Emissio Cotrol Valve ad the ECVI Display to miimize risk of ijury to persoel or damage to egie or equipmet. Do ot attempt to operate, maitai, or repair the fuel cotrol valve util the cotets of this documet have bee read ad are thoroughly uderstood. Every attempt has bee made to provide sufficiet iformatio i this maual for the proper operatio of the ECV5 Emissio Cotrol Valve ad the ECVI Display. All iformatio cotaied withi shall be cosidered proprietary iformatio ad its release to uauthorized persoel is strictly prohibited. ALTRONIC, LLC

6 Regulatory Compliace These listigs are limited oly to those uits bearig the CSA idetificatio: CSA: CSA Certified for Class I, Divisio 2, Groups A, B, C, ad D, T3 at 85 C ambiet for use i Caada ad the Uited States Certificate Type 3R Raiproof Eclosure This product is certified as a compoet for use i other equipmet. The fial combiatio is subject to acceptace by the authority havig jurisdictio or local ispectio. Wirig must be i accordace with North America Class I, Divisio 2 wirig methods, as applicable, ad i accordace with the authority havig jurisdictio. Special Coditios for Safe Use: Field wirig must be suitable for at least 85 C. WARNING! Do ot remove covers or coect/discoect electrical coectors uless power has bee switched off or the area is kow to be o-hazardous. Substitutio of compoets my impair suitability for Class I, Divisio 2, or Zoe 2. Do ot clea equipmet uless the area is kow to be o-hazardous. NOTE: Do ot coect ay cable grouds or istrumet groud, cotrol groud, or ay oearth groud system. Safety It is ecessary to always use extreme cautio whe workig with ay fuel system. Altroic Fuel Cotrol Valves are ormally used with atural gas. Natural gas, whe combied with air, becomes very combustible. Cotaied withi a eclosure such as a gas turbie egie or its exhaust system, the mixture ca explode i a violet maer whe igited. Cotrols for gas egies should always be desiged to provide redudat fuel shut dows. The ECV5 plays a importat part i the safety of the whole system. The ECV5 is ot a shutoff valve. The ECV5 is ot the primary cotrol to shut dow the egie. Shutoff valves should be used i additio to the Emissio Cotrol Valve. The fuel system should be desiged i such a way that: No sigle failure of a compoet will cause the fuel system to admit fuel to the egie whe the egie has bee shut dow. No sigle failure ca result i grossly over-fuelig the egie whe attemptig to start. No fuel is trapped dowstream of the ECV5 or potetially leaked ito the egie fuel maifold. It is strogly recommeded that the egie should be purged of ay potetial gas i the fuel maifold prior to turig o the igitio system. Additioally, the Igitio Permissive should be used to isure that the igitio system is o ad operatig prior to the ECV5 allowig gas to the egie. Failure to follow the above rules may lead to possibly serious damage to equipmet ad/or ijury to persoel. ALTRONIC, LLC

7 Electrostatic Discharge Awareess Electroic cotrols cotai static-sesitive parts. Observe the followig precautios to prevet damage to these parts: Discharge body static before hadlig the cotrol uit. Avoid all plastic, viyl, ad styrofoam aroud prited circuit boards. Do ot touch the compoets or coductors o a prited circuit board with your bare hads or with coductive devices. Follow these precautios whe workig with or ear the cotrol uit: Avoid the build-up of static electricity o your body by ot wearig clothig made of sythetic materials. Wear cotto or cotto-bled materials whe possible. These fabrics do ot store static electric charges as much as sythetics do. Do ot remove the prited circuit board (PCB) from the cotrol cabiet uless absolutely ecessary. If you must remove the PCB for the cotrol cabiet, follow these precautios: Do ot touch ay part of the PCB except by the edges. Do ot touch the electrical coductors, the coectors, or the compoets with coductive devices or with your bare hads. Whe replacig a PCB, keep the ew PCB i the plastic atistatic protective bag it comes i util you are ready to istall it. Immediately after removig the old PCB from the cotrol cabiet, place it i the atistatic protective bag. Glossary of Terms Term Air/Fuel Ratio (AFR) CO CO2 EGR EGT Excess Oxyge Lambda Lea Combustio LVDT NOx NSCR Rich Combustio SCR Sesor: O2 Lamda Sesor: O2 Wide bad Stoichiometric Supply Pressure THCs Three-Way Catalyst UHCs VOC Defiitio The ratio of mass air rate to mass fuel rate Carbo Mooxide Carbo Dioxide Egie Gas Regulator or Electroic Gas Regulator Egie Gas Temperature > 10% O2 Stoichiometric air/fuel ratio Lambda = 1.0 lea (fuel limited) beig > 1.0 rich (O2 limited) beig < 1.0 > 4% O2 Liear Variable Differetial Trasformer Oxides of Nitroge (NO ad NO2) No-Selective Catalytic Reductio (see Three-Way Catalyst) < 1% O2 Selective Catalytic Reductio A exhaust sesig device. Outputs a low sigal whe lea of lambda ad a high sigal whe rich of lambda. A exhaust sesig device. Outputs a high sigal whe lea of lambda ad a low sigal whe rich of lambda. Theoretical air/fuel ratio where all fuel ad oxyge are completely cosumed leavig o O2 i the exhaust. Equals Lambda 1.0. The fuel gas supply pressure immediately upstream of the ECV5 Total Hydrocarbos A device cotaiig both reductio ad oxidatio materials to covert NOx, CO, ad THC emissios to C, N, CO2, O2, ad H2O Ubured Hydrocarbos Volatile Orgaic Compoud ALTRONIC, LLC

8 1. Itroductio Before exhaust emissios were a cocer, atural gas egies used maily by the atural gas idustry were desiged to ru with excess air. Air/Fuel ratio cotrollers were mechaical devices that were ot very accurate ad sometimes ot eve used. These egies ra very well with 5% to 20% excess air. The air/fuel ratio would ofte vary with load ad as log as the egies would carry the load ad did t detoate or misfire, the operators were happy. Whe exhaust emissios became importat, it was discovered that these egies were ruig with very high NOx levels, sometimes at the peak of the NOx curve. Two strategies evolved to reduce the NOx while cotaiig the CO ad ubured hydrocarbos: Stoichiometric or Rich-Bur combustio ad Lea-Bur Combustio. The graph below is represetative of the Cylider Pressure o the vertical (Y-axis) ad the actual air/fuel ratio divided by the stoichiometric air/fuel ratio o the horizotal (X-axis). The graph is ot to scale ad does ot represet ay particular egie. Typical Emissio Curve without Exhaust Treatmet The Excess Air Ratio o the X-axis is referred to as Lambda. Stoichiometric air/fuel ratio is 1.0 i the figure above. Rich-bur operatio is to the left of the stoichiometric poit ad lea-bur operatio is ay ratio to the right of the stoichiometric poit. As see i the graph above, the Excess Air Ratio, Lambda, eeds to be much higher tha 1.0, to reduce the NOx sigificatly. Operatio i the detoatio or kock regio ad the icomplete combustio regio must be avoided. Accordig to the graph, the egie ca be operated at a higher load or BMEP without detoatig whe operatig with a large amout of excess air. The higher BMEP meas more horsepower is available ad the egie will be a little more efficiet because of the higher cylider pressure. ALTRONIC, LLC

9 Rich-Bur Combustio The first, ad easiest to implemet method is to operate the egies at a stoichiometric fuel mixture. This is also referred to as rich-bur operatio. A stoichiometric mixture is the chemically correct fuel mixture for combustio, with ear zero oxyge left over i the exhaust. This method of operatio is suitable for a three-way catalytic coverter. The mixture must be precisely cotrolled i order for the reactio i a catalytic coverter to oxidize the CO to CO2 ad reduce the NO ad NO2 to N2 ad O2 ad ot have udesirable products left over. Block Diagram of EVC5 ad Cat Moitor i Rich Bur Combustio Cofiguratio Rich-Bur Oxyge Sesor To achieve the mixture cotrol precisio required for the catalyst, a oxyge (O2) sesor is placed i the exhaust ahead of the catalytic coverter. The output of the O2 sesor is fed back to the cotrol device to close the loop o the amout of oxyge i the exhaust. The mixture is cotrolled to maitai very small oxyge cotet, less tha 0.02% i the exhaust, as idicated by the voltage produced by the O2 sesor. This idicates that the combustio process is cosumig early all of the oxyge. If a higher oxyge cotet is idicated, the egie is ruig too lea ad a lower oxyge cotet idicates the mixture is too rich. Beefits of Rich-Bur Oe of the beefits of a catalytic coverter o egies ruig i a Rich-Bur mode is that they operate with very small quatities of NOx ad CO i the exhaust. At the discharge of the catalytic coverter, NOx i the rage of a few parts per millio is achievable. ALTRONIC, LLC

10 Lea-Bur Combustio The secod strategy for reducig emissios is to ru the egie with as much excess air as possible. Ay air/fuel reactio requires a eergy source to iitiate combustio. I atural gas egies, the spark plug performs this fuctio. I the lea-bur egies, the combustio process is ehaced by pre-mixig the air ad fuel upstream of the turbocharger before itroductio ito the cylider. This creates a more cocetrated mixture i the combustio chamber ad reduces the occurrece of kockig or detoatio. To prevet either kockig or misfirig, the combustio process must be cotrolled withi a arrow operatig widow. Iput air temperatures ad volume, together with air to fuel ratio ad compressio ratio, are costatly moitored. The microprocessor-based egie cotroller regulates the fuel flow, air/ gas mixture ad igitio timig. Lea-Bur egies are desiged to operate at a lea air/gas ratio of Lambda = 1.7 (traditioal stoichiometric atural gas egies have a air/gas ratio of Lambda = 1.0). I the precedig graph that plots Break Mea Effective Pressure (BMEP) agaist Air Excess (Lambda), the operatig widow is a very arrow bad where efficiecy peaks ad NOx is ear its miimum. A richer mixture (stoichiometric) ca potetially produce kockig ad higher NOx emissios. A leaer mixture tha Lambda 1.7 may ot combust reliably ad could cause misfirig, which raises hydrocarbo (HC) emissios. Full-authority electroic egies, sesors, ad microprocessors i ewer lea-bur egies are critical for maitaiig combustio withi these boudaries. The desig of the lea-bur egie icorporates a simple ope combustio chamber housed i the pisto crow. The shape of the pisto crow itroduces turbulece i the icomig air/fuel mixture that promotes more complete combustio by thoroughly exposig it to the advacig flame frot. The flame plate of the cylider head is regular (flat) ad the spark plug is cetrally located. The air ad gas are mixed usig a goveror cotrolled gas ozzle operatig i a Veturi. If a power cylider has more air compressed ito it, the specific heat of the air charge i the cylider is higher, which meas it ca absorb the same quatity of heat with less temperature rise. The reductio i temperature causes a reductio i the oxidatio of the itroge. Egies ruig with large amouts of excess air ca achieve levels of NOx below 2 grams/bhp-hr without a catalytic coverter. A selective catalytic coverter ca be used to reduce the NOx level further but has the disadvatage of requirig the ijectio of urea or ammoia. Air/fuel ratio i lea bur egies ca be as high as 22:1. Whe full power is eeded, such as durig acceleratio or hill climbig, a lea bur egie reverts to a stoichiometric (14.7:1) ratio or richer. Lea-Bur Oxyge Sesor The Wide Rage Oxyge Sesor Iterface used for Lea Bur ad Rich Bur egies idicates a very wide rage of oxyge i the exhaust ad is ofte referred to as a Lambda sesor. Lambda is the air-fuel ratio that the egie is ruig, divided by the stoichiometric air/fuel ratio, as show i the graph o page 8. Beefits of Lea-Bur Egies ruig i the Lea-Bur mode offer several importat advatages: lowered combustio temperatures reduced emissios fuel flexibility Oe of the results of this techology is sigificatly reduced emissio i the exhaust. Lea-bur gas egie geerators ca have NOx emissios as low as.85 grams/bhp-hr ad produce low amouts of hydrocarbos (HC), carbo mooxide (CO) ad particulate matter (PM), allowig geerator sets to meet the most striget air quality regulatios without after treatmet devices i the exhaust stream. For eve lower emissios, lea-bur gas egie geerator sets are also available with factory-itegrated after treatmet optios such as Selective Catalytic Reductio (SCR) ad Oxidatio Catalysts, resultig i NOx levels at or below 0.85 grams/bhp-hr. With these after treatmet optios, gas egie geerators have bee show to meet the most striget prime power emissios regulatios aywhere i the world. Aother advatage of the lea-bur techology with full-authority electroic egie cotrols is the ability to operate o gas with a wide rage of quality. The Methae Number (MN) measuremet is used to determie fuel gas suitability as a egie fuel. Most atural gas has a MN from 70 to 97. Pipelie quality gas typically has a MN of about 75. Resource recovery gas from ladfills or sewage treatmet facilities is typically of lower quality, but is ofte suitable for use i leabur egies. Some lea-bur gas egie geerators will operate o gas with a MN of 50 or greater, providig excellet fuel flexibility. However, gas with a MN below 70 may require de-ratig of the geerator output. Lea-bur gas egie geerator sets are settig a ew stadard for fuel efficiecy, high power output for their size, ad low emissios. I regios with supplies of atural gas, these geerator sets are providig highly reliable electric power for utility peakig, distributed geeratio, prime power, ad combied heat ad power systems. ALTRONIC, LLC

11 Achievig Emissio Compliace Emissio performace ecessitates that a umber of systems ad compoets operate together cosistetly ad flawlessly over a log period of time. This requiremet traslates ito the followig: Superior air/fuel ratio cotroller set to optimize catalyst performace ad capable of maitaiig the air/fuel ratio withi a favorable lambda rage regardless of chages i fuel compositio, ambiet coditios, or egie operatig load Wide-bad oxyge sesors arrow-bad sesors do ot have this capability NOx sesor coected i a feedback cotrol loop to trim the AFR cotroller as it seeks lowest NOx emissios Advaced fuel cotrol valves with very fast, very precise, cotrol capabilities Well maitaied egie igitio timig that does ot deviate too advaced or retarded, both of which effect egie emissios High quality NSCR catalyst with high surface area, high catalytic activity, ad log service life Catalyst desiged with low gas hourly space velocity, i.e., high catalyst volume Catalyst housig with superior seals to elimiate exhaust gas bypass aroud the catalyst Uder these coditios ad i a clea exhaust eviromet, a good quality, properly sized, NSCR catalyst should achieve high performace over a exteded period of time. However, eve with tight lambda cotrol, low-load operatig coditios are likely to reduce the egie exhaust gas temperature ad possibly reduce the performace efficiecy of the NSCR catalyst. A striget performace specificatio miimizes performace loss over thousads of hours of operatio. Eve the most exceptioally desiged catalyst loses performace because exteral factors over time. These factors iclude: Cotamiats like ash ad sulfur mask ad plug the surface ad the pores of the catalyst Chemical cotamiats react with, ad poiso the precious metal active igrediets, or egie malfuctio causes excessive temperatures i the catalyst as fuel combusts across the catalyst resultig i catalyst siterig Therefore, log-term, high catalyst performace also imposes the followig system requiremets: Very low-ash egie lube oil to completely elimiate the depositio of ash o the catalyst surface Absece of ay chemicals that poiso the catalyst comig from the fuel, the combustio air, the lube oil, the atifreeze, poor i-cylider combustio, ad ay or all other sources. Absece of igitio system problems that result i ubured fuel reachig the catalyst ad causig a over-temperature coditio From a system stadpoit log-term emissio performace requires moitorig ad maiteace of: The egie, its igitio system, its lube oil system, its coolat system, etc. Fuel pressure cotrol, fuel flow cotrol, fuel flow measuremet The air-fuel ratio cotroller, the wide bad oxyge sesors, the NOx sesor, the temperature sesors Measuremet ad documetatio of emissio performace for the ew system to establish bechmark performace From a catalyst stadpoit: Chemical washig may be required periodically to remove cotamiats to maitai performace durig the warraty period. A well-desiged catalyst should respod well to chemical washig but caot reverse the effects of thermal siterig or certai cotamiats that irreversibly poiso the precious metals. It may be prudet to have a spare set of catalyst osite to miimize dowtime whe chemical cleaig is required. I summary, emissio performace requires a system approach that icludes equipmet, operatig coditios ad routie maiteace that exted far beyod the scope of the catalyst. ALTRONIC, LLC

12 2. ECV5 for Rich or Lea-Bur Cofiguratios The ECV5 is the heart of the AFR system. The logic ad electroic circuitry for closed loop cotrol of a egie AFR is withi the ECV5. The Cat Moitor is the iterface betwee the O2 sesors ad NOx sesors to the ECV5. The ECVI (I for iterface) provides a juctio poit for all itercoectios betwee the differet devices ad a graphical user iterface. No cotrol logic or settigs are saved i the display. The AFR ca be used for rich bur or lea bur egies simply by pickig a differet O2 sesor iput. The O2 sesor iputs from the Cat Moitor are 0 to 5Vdc with the higher the voltage, the more oxyge i the exhaust. This is opposite of arrow bad sesors commoly used. Stoichiometric or (Lambda 1.0) will be ear 1.0Vdc percet O2 is 5.0Vdc. So a lea setpoit will be from 2.25Vdc to 3.0Vdc. By usig this sigal, the ECV5 ca sese if the egie is ruig too rich or too lea. If the O2 sesor voltage is higher tha the O2 setpoit, the egie is ruig too lea. The ECV5 will respod by icreasig the iteral pressure setpoit. Likewise, if the voltage is lower, the egie is too rich, ad the pressure setpoit will be decreased. The pressure setpoit always starts at the default pressure. The default pressure is the pressure the valve maitais for startig the egie, or if the O2 sesor fails. There are programmable high ad low limits. For safety, these limits should be set to the ormal operatig rage of that particular egie. The NOx sesor ca be used either o a rich bur egie or lea bur. The NOx sesor o a rich bur egie is istalled i the exhaust after the catalyst. I a lea bur egie, there is o catalyst therefore, the NOx sesor would be istalled directly i the exhaust. The NOx sesor is coected to the Cat Moitor via the CANbus. The Cat Moitor will trim the O2 sesor setpoit leaer or richer to reach the desired NOx level, or tue the AFR to the optimal settig for best performace from the catalyst. Productio of Emissios Operatio of ay fuel-fired power geeratig equipmet results i emissios of exhaust gases. Pricipal amog these are carbo dioxide (CO2), water vapor (H2O), oxides of itroge (NO ad NO2, geerally referred to as NOx), oxides of sulfur (SOx), carbo mooxide (CO), ubured hydrocarbos (UHC), ad particulates. The evirometal permittig requiremets for osite geeratio impose restrictios o emissios of NOx, SOx, CO, ad particulates because of their cotributios to smog ad acid rai. Regios of the U.S. with sigificat air quality problems are classified as No-Attaimet Zoes ad severe limits are placed o aual emissios of these pollutats i those areas. As a cosequece, requiremets for pollutio abatemet equipmet are more striget i these areas. The rates of emissios deped o the quatities of fuel cosumed, the type of fuel used, ad the temperature of combustio. Thermal NOx emissios are a cosequece of the high combustio temperatures; the higher the temperature level the greater the formatio rate for NOx. This is true o matter what fuel is used. Fuel based NOx emissios are egligible i systems usig atural gas, but they ca be a sigificat source of pollutio whe fuel oil is used. SOx formatio is a cosequece of sulfur cotaied i the fuel ad is isigificat for atural gas but must be cosidered whe fuel oil or other fuels are used. Geerally, techologies for reducig NOx ad SOx emissios icrease emissios of CO ad UHCs. As a fuel is bured i a egie, various exhaust emissios are produced: Hydrocarbos (HC s) from ubured fuel are formed from a rich fuel mixture (or a lea fuel mixture where there is excess air, leadig to a lea misfire. Carbo Mooxide (CO) from a rich fuel mixture, ad ever from a lea fuel mixture. Carbo Dioxide (CO2) formed durig ay combustio process whe oxyge ad carbo are preset i the primary combustio igrediets. Oxyge (O2) from a lea fuel mixture. Oxides of Nitroge (Nitroge Oxide) NOx. Nitroge is preset i the air we breathe, ad the egies air it cosumes. Nitroge displaces the air by approximately 75%. Nitroge does t bur, but it ca oxidize at temperatures over 2,500 F. NOx is a health hazard ad oe of the EPA s primary emissio problems. Oe method of cotrollig NOx is to reduce combustio temperatures. A EGR valve is the easiest device to use. It bleeds a small amout of iert exhaust gas ito the icomig air stream, dilutig the oxyge, ad reducig combustio temperatures. Aother method of NOx reductio is to ru a richer fuel mixture. By addig more fuel, the amout of air is displaced, reducig NOx. The exhaust catalyst, covertig the CO ad HC ito CO2, hadles the left over fuel. With a liquid fuel egie, the additio of more fuel also lowers the combustio temperature by the codesig effect. Here the fuel is evaporatig ad absorbig combustio heat. With a vapor fuel, the reverse is true. If the egie is ruig lea (over λ=1.2), the exhaust actually begis to cool dow, thus reducig exhaust ad combustio temperatures. ALTRONIC, LLC

13 Exhaust Gas Treatmet Geerally, there are trade-offs betwee low NOx emissios ad high efficiecy for ay egie. There are also trade-offs betwee low NOx emissios ad emissios of the products of icomplete combustio (CO ad ubured hydrocarbos). There are three mai approaches to these trade-offs that come ito play depedig o regulatios ad ecoomics. Oe approach is to cotrol for lowest NOx, acceptig a fuel efficiecy pealty ad possibly higher CO ad hydrocarbo emissios. A secod optio is fidig a optimal balace betwee emissios ad efficiecy. A third optio is to desig for highest efficiecy ad use post-combustio exhaust treatmet. There are several types of catalytic exhaust gas treatmet processes that are applicable to various types of reciprocatig egies three-way catalyst, selective catalytic reductio, oxidatio catalysts, ad lea NOx catalysts. The catalytic three-way coversio process (TWC) is the basic automotive catalytic coverter process that reduces cocetratios of all three major criteria pollutats NOx, CO ad VOCs. The TWC is also called o-selective catalytic reductio (NSCR). NOx ad CO reductios are geerally greater tha 90%, ad VOCs are reduced approximately 80% i a properly cotrolled TWC system. Because the coversios of NOx to N2 ad CO ad hydrocarbos to CO2 ad H2O will ot take place i a atmosphere with excess oxyge (exhaust gas must cotai less tha 0.5% O2), TWCs are oly effective with stoichiometric or rich-burig egies. Typical egie out NOx emissio rates for a rich bur egie are 10 to 15 gm/bhp-hr. NOx emissios with TWC cotrol are as low as 0.15 gm/bhp-hr. The ECV5 used i cojuctio with a NOx sesor guaratees the best possible emissios. It is ot ucommo to be able to cotrol below 1ppm of NOx over a period of moths usig a NOx sesor with a pateted emissio miimizatio algorithm. Stoichiometric ad rich bur egies geerally have lower efficiecies tha lea bur egies. The TWC system also icreases maiteace costs by as much as 25%. TWCs are based o oble metal catalysts that are vulerable to poisoig ad maskig, limitig their use to egies operated with clea fuels, e.g., atural gas ad uleaded gasolie. Also, the egies must use lubricats that geerate catalyst-poisoig compouds ad have low cocetratios of heavy ad base metal additives. Ubured fuel, ubured lube oil, ad particulate matter ca also foul the catalyst. TWC techology is ot applicable to lea bur gas egies or diesels. Lea bur egies equipped with selective catalytic reductio (SCR) techology selectively reduces NOx to N2 i the presece of a reducig aget. NOx reductios of 80% to 90% are achievable with SCR. Higher reductios are possible with the use of more catalyst, more reducig aget, or both. The two agets used commercially are ammoia (NH3 i ahydrous liquid form or aqueous solutio) ad aqueous urea. Urea decomposes i the hot exhaust gas ad SCR reactor releasig ammoia. Approximately 0.9 to 1.0 moles of ammoia is required per mole of NOx at the SCR reactor ilet i order to achieve a 80% to 90% NOx reductio. SCR systems add a sigificat cost to the istallatio ad maiteace of a egie system ad ca severely impact the ecoomic feasibility of smaller egie projects. SCR requires o-site storage of ammoia, a hazardous chemical. I additio, ammoia ca slip through the process ureacted ad cotribute to evirometal health cocers. Oxidatio catalysts geerally are precious metal compouds that promote oxidatio of CO ad hydrocarbos to CO2 ad H2O i the presece of excess O2. CO ad NMHC coversio levels of 98% to 99% are achievable. Methae coversio may approach 60% to 70%. Oxidatio catalysts are ow widely used with all types of egies, icludig diesel egies. They are beig used icreasigly with lea bur gas egies to reduce their relatively high CO ad hydrocarbo emissios. Lea-NOx catalysts utilize a hydrocarbo reductat (usually the egie fuel) ijected upstream of the catalyst to reduce NOx. While still uder developmet, it appears that NOx reductio of 80% ad both CO ad NMHC emissios reductios of 60% may be possible. Log-term testig, however, has raised issues about sustaied performace of the catalysts. Curret lea-nox catalysts are proe to poisoig by both lube oil ad fuel sulfur. Both precious metal ad base metal catalysts are highly itolerat of sulfur. Fuel use ca be sigificat with this techology i that the high NOx output of diesel egies would require approximately 3% of the egie fuel cosumptio for the catalyst system. ALTRONIC, LLC

14 Emissios with Catalyst i Rich Bur Combustio Cofiguratio 3. ECV5 Geeral Iformatio Specificatios Electrical Iput Characteristics Iput Voltage Rage Maximum Steady State Iput Curret Maximum Trasiet Iput Curret VDC Rage; 24Vdc Nomial 3A Nomial 5A Max Mechaical Characteristics Valve Maximum Effective Area.560 i2 Valve Miimum Effective Area 0 Weight 17.3 lbs. Moutig ANSI Class Pipe Flage (See evelope drawig) Temperature Steady State Ambiet Temp Storage Temp Fuel Gas Ilet Temp -40 to +185 F -40 to +185 F -40 to +185 F Fuel Coectios Filter Requiremets Less tha 50 µm Dyamics Step Respose Slew Time Overshoot < 100ms for a 10 90% ad 90 10% step < 2% of step ALTRONIC, LLC

15 Eviromet EMC EN (2005) Immuity for Idustrial Eviromets EN (2001) Emissios for Idustrial Eviromets Fuel Type The ECV5 operates o gases ragig from pipelie quality atural gas to specialty gas (such as ladfill, digester, or other biogases). The ECV5 also operates o gases ragig from pipelie quality atural gas to propae. Proper applicatio of the valve for fuel flow, FGP, eergy cotet, etc., is the resposibility of the OEM/packager/customer. The fuel gas flowig through the valve ca cosist of the followig compouds with limits if they apply: Compoet Specificatio Gaseous hydrocarbos (methae, ethae, propae, etc.) No limit CO No limit CO2 No limit Hydroge < 10% Oxyge No limit Nitroge No limit Sulfur compouds icludig Hydroge sulfide < 500mg/10kWh (< 2000mg/10kWh) Chlorie ad fluorie compouds (typically chlorofluorocarbos) < 100mg/10kWh (< 400mg/10kWh) Silico < 5mg/10kWh (<20mg/10kWh) Ammoia < 50mg/10kWh Oil or hydrocarbos i liquid (mist form) < 5mg/10kWh Fie particulates, icludig silico (less tha 1.0μm) < 3mg/10kWh Overall, the gas Specific Gravity should be betwee 0.4 ad 2.0 for the ECV5. The eergy cotet should be betwee 1 ad 9.5kWh/m3. The values i parethesis ( ) are allowed, but may result i reduced valve life. The above fuel limits ca be coverted to ppm by multiplyig the give umber by the LHV of the fuel i questio, the dividig by 36. The LHV must be i uits of MJ/kg. Ilet Fuel Gas Pressure The maximum ilet fuel gas pressure (FGP) for the ECV5 is 50psig. Most applicatios will have a much lower FGP. If the FGP is too high, the required ECV5 stroke will be reduced ad istability may result. FGP Adjustmet With the egie ruig at max load ad the target air fuel ratio, adjust the ilet FGP so that the ECV5 stroke is approximately 75%. ALTRONIC, LLC

16 Fuel ad Service Gas NOTE: Operators are urged to cosult local legislative authority for sulfur limitatios o fuels. Atipollutio legislatio may require a lower sulfur cotet tha specified i the fuel table. The selectio of a satisfactory fuel depeds o the physical ad chemical compositio of the fuel. Natural gas fuel requiremets are give i the followig table. Natural Gas Fuel Physical ad Chemical Requiremets Gas Temperature -40 F to +185 F (-40 C to +85 C) Lower Heatig Value 700 to 2,500Btu/scf. Lower heatig values outside this rage are acceptable with approval of Altroic Egieerig. Compositio Gas compositio shall be such that dew poit at egie supply pressure of 150 psig (10.5kg/cm2) must be at least 10 F (6 C) below gas fuel supply temperature. Dew poit ca be calculated from the compositio or determied experimetally with a istrumet such as the Alor Dew Poiter, maufactured by Alor Istrumet Compay, Chicago, Illiois. Cotamiats: Fuel Gas Total cotamiats shall ot exceed: 30ppm x (lower heatig value by weight Btu/ lb)/(19000btu/lb) or 30ppm x (kg-cal/kg)/(10534kg-cal/kg) Particles larger tha 10 micros shall ot exceed: 0.3ppm x (lower heatig value by weight Btu/lb)/(19000Btu/kg) or 0.3ppm x (kg-cal/kg)/(10534kg-cal/kg) No etraied water is allowed; i.e., o water i excess of saturatio of at 150psig (10.5kg/cm2) pressure or maximum operatig pressure. Percet-by-weight total sulfur, icludig hydroge sulfide, shall ot exceed: 1% x (lower heatig value by weight Btu/lb)/(19000Btu/lb) Service Gas (If separate supply for peumatic started ad auxiliary pump gas motors) No more tha 0.7 grams of solid cotamiats per 1000cu ft. (28.3cu m) of gas are allowed; 99 percet of these solids shall be smaller tha 10 micros. No etraied water is allowed; i.e., o water i excess saturatio at maximum operatig pressure. No more tha 0.5 poud (0.23kg) sulfur per 1000cu ft. (28.3cu m) of gas (icludig hydroge sulfide) is allowed. 4. Features Rage The ECV5 is a true full-authority fuel valve, the rage of the ECV5 is much greater tha a system relyig o a pressure regulator with a bypass valve or a restrictor stepper motor. The rage of the ECV5 will help tremedously whe workig with applicatios where ay of the followig may occur: Load Chages BTU Value of the fuel gas chages Ambiet Air Temperature Chages Bypass type systems are ormally set up o the lea limit ad they add fuel to cotrol i the desired rage. I the evet that a large load is removed, the system caot cotrol beyod this lea limit. I the evet that the BTU value of the gas declies, the uit sometimes caot add eough fuel to keep up with the chage. This cotrol rage o a bypass type system is ormally a maximum of 10% to 15% chage. ALTRONIC, LLC

17 A restrictor valve type of system is ormally set up to ru rich ad the restrictor valve piches off fuel to cotrol i the acceptable rage. This system also lacks the rage to keep up with large load chages or BTU swigs. Closed Loop Pressure Cotrol This cotrol techique is really what separates the ECV5 from other cotrollers whe it comes to reducig emissios. The ECV5 operates as a variable pressure cotroller where the O2 sesor costatly readjusts the cotrol pressure setpoit as required to meet emissios. This techique helps to stabilize the egie cotrol by cotrollig the movig setpoit ad reducig droop i the regulator. This itegrated pressure cotrol cocept is pateted ad is ulike ay other cotroller. By reducig or icreasig the pressure gai settigs i the ECV5, the valve will react as quickly or ca be dampeed as much as is required by the applicatio. Fully Automatic Cotrol The ECV5 is fully automatic. This meas that o matter what the operatioal chages are i the egie, the ECV5 will keep up with the chages. There is o eed to call a operator to reset a setpoit or adjust the cotroller. These chages are automatic. Variable Dyamic Gai The ECV5 automatically adjusts the amout of gai applied based o the stroke of the valve. This meas that if the valve is barely beig stroked, the gais are barely applied, ad as the stroke icreases, so do the gais. At maximum stroke, the gais are still appropriate for this amout of stroke. This uique cotrol techique allows the ECV5 to cotrol effectively at startup, light loads, or fully loaded. Commuicatios The circuit board iside the ECVI serves as a juctio poit for all coectios betwee the ECVI, the Cat Moitor, ECV5, ad optioally, the FM50 Flow Meter. Commuicatio from each device is of two differet protocols: CANbus J1939 ad Modbus RTU. (See available registers i appedix) Modbus gives the HMI (ECVI display) the ability to iterface with each device, while CANbus is used for commuicatio betwee the devices. All devices use the followig RS232 commuicatio settigs: RS232 Settig Value Baud rate 9600 Data bits 8 Stop bit 1 Parity Noe Flow Cotrol Noe Default Modbus ID 1 The ECV5, Cat Moitor, ad flow meters each have a RS232 serial port built ito each device. The ECVI circuit board has multiple RS232 to RS485 coverters that lik all serial commuicatios to a sigle RS485 bus for commuicatio to the display. Each device o the RS485 Modbus etwork must have a uique Modbus address which should be set as follows: Device Modbus Address (ID) ECV5 Left bak 1 ECV5 Right Bak (dual bak cofiguratio oly) 2 Catalyst Moitor 3 Flow Meter 25 There are two termials o the circuit board that are coected to this RS485 Modbus. These termials are for a optioal user iterface such as a SCADA system or PLC. However oly oe device may be the Modbus master. If aother device is actig as the Modbus master, the HMI (ECVI display) may ot be coected. Modbus TCP/IP is available through the Cat Moitor. ALTRONIC, LLC

18 5. Theory of Operatio The ECVI is the user iterface for the ECV5 ad the Catalyst Moitor. It serves as the cetral hub where all of the separate compoets of the system are coected. The idividual compoets commuicate with each other via CANbus while the user iterface commuicates to each device with a Modbus serial port. The ECV5 is essetially a electroic pressure regulator. Whe the system receives a igitio cofirm sigal, the ECV5 will ope ad cotrol the fuel pressure to the default pressure settig for startup. Whe ruig i default mode or startup, the ECV5 regulates fuel pressure to the veturi mixer just like a pressure regulator. If the O2 sesor fails, the system will ru i default mode util shut dow. The ECV5 will stay i default mode util the Warmup Timer expires ad the ECV5 is receivig a valid O2 sesor sigal from the Catalyst Moitor. Oce the warm up period is over ad a valid O2 readig is received, the ECV5 will go i to AFR mode. At this poit, the ECV5 will vary the fuel pressure i order to maitai a desired air-to-fuel ratio. If a NOx sesor is istalled o the system, the Cat Moitor will adjust the O2 sesor set-poit to compesate for chages (i.e., ambiet air temperature, load, or eve degradatio of the catalyst) throughout the day. If the igitio cofirm sigal drops, the ECV5 valve will close, the heater for the O2 sesors ad NOx sesor will tur off, ad the system will wait for the egie to re-start. The System The system cosists of the followig compoets: ECVI box ad display. The ECVI box cotais termial strips to coect wire from various other compoets. ECV5 AFR cotrol valve. The ECV5 cotais a microprocessor that reads a voltage from a oxyge sesor ad modulates the outlet pressure of the valve to cotrol the air to fuel ratio of the egie. The system cofiguratio may cotai oe or two ECV5s depedig o if the applicatio is a sigle or dual bak egie. Catalyst (Cat) Moitor. The Cat Moitor iterfaces the wide bad O2 sesors ad NOx sesors with the ECV5. The Cat Moitor ca make mior adjustmets to the O2 sesor setpoit withi the ECV5 by lookig at the NOx sesor. The Catalyst Moitor should be mouted ear the exhaust ad o more tha 30 feet from the O2 sesors. The NOx sesor is coected to the Cat Moitor via CANbus. The NOx sesor cable legth should be o more tha 50 ft. distace from the Cat Moitor to the ECVI. Oxyge (O2) sesors. The Catalyst Moitor ca coect up to two wide bad O2 sesors. Oe O2 sesor for the left bak ad oe for the right bak. The Cat Moitor uses a Bosch LSU4.2 O2 sesor. NOx sesors. The NOx sesor is located i the exhaust. O rich-bur egies, the NOx sesor is located after the catalyst. The NOx sesor is coected to the Cat Moitor via CANbus. Veturi. The veturi serves as a fuel mixer assurig eve distributio of the fuel through the airflow. The veturi is located dowstream of the ECV5 ad somewhere o the air ilet of the egie. The veturi may be stadaloe or a drop-i style that replaces the diaphragm assembly iside the carburetor. Fuctioal Diagram of ECV5 ad System ALTRONIC, LLC

19 Full Fuel-Authority The ECV5 meters all fuel eterig the egie from o flow to full flow. This prevets the valve from ruig out of rage i difficult applicatios such as those with large swigs i the heatig value of the gas. This feature also eables the valve to chage the fuel flow very quickly i respose to load trasiets. The full fuel authority of the ECV5 is key to keepig the emissios withi required limits uder all coditios. Pressure Sesor The ECV5 fuctios as a high-speed, precisio pressure regulator with a setpoit that is electrically drive by a oxyge sesor. A itegrated pressure trasducer costatly moitors the outlet pressure of the valve. This pressure is commuicated to the valve s o-board electroics where it is compared to either the default pressure setpoit or the dyamic setpoit derived from the oxyge sesor iput. Ay differece betwee the pressure measuremet ad the setpoit is corrected by adjustig the poppet positio. This process is repeated every 1 millisecod ad the pressure is adjustable from -8 to 24 i. H2O. The ed result is a electroic pressure regulator that does ot suffer from the commo problems associated with mechaical regulators such as droop ad limited rage. Mechaical Valve Desig Ulike may of the valves used i competig emissios cotrol systems, the ECV5 was specifically desiged for reciprocatig egies usig gaseous fuels. It is ot a modified pressure regulator, a biasig restrictor, or a valve borrowed from a differet market sector or maufacturer. Followig are some of the key mechaical desig features that cotribute to the superior performace of the ECV5. Balaced Poppet The ECV5 utilizes a balaced meterig poppet. This is a prove desig that has bee used for decades i umerous idustries usig flow cotrol valves. Low frictio rollig diaphragms couterbalace the forces exerted o the valve poppet by upstream ad dowstream pressures. This elimiates the eed for additioal sprig ad actuator forces to be wasted o overcomig these pressure forces. The result is a efficiet valve that uses less power over a wide rage of pressures. Positio Sesor The performace of the ECV5 is further improved usig closed loop positio cotrol. A LVDT positio sesor cotiually commuicates the poppet positio to the valve s computer. This sigal is the compared to the positio setpoit geerated by the pressure cotrol loop. Ay error i positio is quickly corrected. This feature improves trasiet performace ad helps elimiate istability caused by flow forces o the poppet. The positio sesor is also a useful diagostic tool. High Speed Actuator At the heart of the ECV5 is a high-speed, electromechaical, liear actuator that is used to drive the meterig poppet. The actuator is comprised of a powerful rare-earth maget ad a precisio woud coil attached to the poppet shaft. Whe the coil is eergized it creates a magetic field i the opposite directio of that created by the maget. These opposig forces drive the poppet i the ope directio. The closig force is geerated by a stailess steel compressio sprig, makig the valve fail-safe i the closed directio. The actuator is capable of geeratig forces i excess of 20 pouds ad goig from the fully closed to the fully ope positio i less tha 50 millisecods. This gives the valve uprecedeted respose to the ever-chagig demads of the egie. Catalyst (Cat) Moitor The Cat Moitor is available i three differet cofiguratios: CM1 Thermocouple, 4-20mA iput, relay output, CANbus iterface, Modbus RTU RS232 iterface. Modbus TCP/IP Etheret iterface ad a optioal 2.4GHz radio iterface. CM2 All the fuctios of a CM1 plus oe wide rage O2 sesor. This is what is typically used for a sigle bak egie. CM3 All the fuctios of a CM2 with a additioal wide rage O2 sesor for a dual bak egie with two exhausts. ALTRONIC, LLC

20 The Cat Moitor serves several fuctios: The Cat Moitor cotrols the heater of the O2 sesor ad pump curret coverts the readig to a liear voltage to percet O2 sigal. Oe volt is ear stoichiometric or lambda oe ad five volts is atmospheric or 20.9 percet oxyge. This sigal is used as a process variable iput to the ECV5. O a dual bak system there are idividual sigals for each bak. Reads the exhaust temperature pre- ad post-catalyst. A relay output is provided for a high temperature output. A 4-20mA iput is provided for a Delta-P trasducer. The Delta-P trasducer is istalled with oe side measurig the upstream pressure of the catalyst ad the other side to the dowstream side of the catalyst. The purpose is to measure the pressure drop across the device to detect foulig of the elemet. The Cat Moitor is the iterface to the NOx sesor. The Cat Moitor will adjust the O2 sesor setpoit of each of the ECV5 valves though the CANbus accordig to the NOx miimizatio logic. Most of the data read by the Cat Moitor is logged to the thumb drive istalled iside the Cat Moitor. This is a CSV spread sheet file. The ed user ca periodically remove the thumb drive for diagostic purposes or for loggig data required uder RICE/NESHAP. The light blikig o the Cat Moitor s cover idicates that it is writig to the thumb drive. Do ot remove the thumb drive while it s i the process of writig. The frequecy of the loggig is programmable ad the data amout that ca be stored is depedet o the istalled drive s storage capability. With the default settigs ad 4 GB drive that are istalled at the factory, the Cat Moitor ca store up to 4 years of data. A Etheret iterface is provided for use with a SCADA system or plat PLC. Wide-Rage Oxyge Sesor Whe cotrollig air/fuel mix o a egie ruig i Rich or Lea Bur mode, it is ecessary to use a wide-rage oxyge sesor, which has a much greater rage tha a traditioal 2 wire Lambda sesor. The Wide-Rage Oxyge sesor, used i cojuctio with the ECV5, is a plaar dual-cell limit-curret sesor. The sesor elemet of the wide-rage sesor is the combiatio of a Nerst cocetratio cell with a oxyge pump cell. Whe used with its cotrol electroics, the sesor is capable of precise measuremet throughout a wide Lambda rage (0.7< λ < air). The Nerst cocetratio cell is held to the stoichiometric voltage (450mv) by oxyge pumped from the oxyge pump cell where the curret to the oxyge pump cell is proportioal to the oxyge cocetratio. There are several versios of the Bosch sesor. Oly Bosch LSU4.2 should be used. Wide-Rage Sesor Heater Power Cotrol The heater cotrol circuitry of the uit does the followig: Provides power to the heater whe a Igitio Cofirm sigal is received from the ECVI. Limits the curret to the heater at iitial tur-o. Ramps up heater curret after a delay util the operatig poit is reached. Cotrols power to the heater so that the iteral temperature of the sesor maitais at about 800ºC (1472ºF). The cotrol regio is determied by measurig the iteral ac resistace of the Nerst cell. The Nerst cell resistace is about 80 ohms whe the iteral temperature is about 800ºC. As the iteral resistace drops toward 80 ohms the heater cotroller takes over ad icreases/decreases curret to the heater to maitai 80 ohms. The curret to the heater must be closely cotrolled because the accuracy of the measuremet is a fuctio of the temperature of the sesor. The coector of the oxyge sesor cotais a calibratio resistor to ormalize curret to the oxyge pump cell. The cable from the cotrol electroics to the sesor requires six leads: circuit commo, Nerst cell output, two leads for curret to the oxyge pump cell ad two leads to the heater. ECVI The ECVI provides a iterface for chagig ad viewig parameters i a ECV5 AFR system durig iitial setup ad operatio. The display commuicates with the ECV5 (two ECV5s i a dual bak istallatio) ad the Catalyst Moitor over a Modbus etwork, ad provides access to settigs such as default pressure or oxyge sesor setpoit. Parameters displayed iclude catalyst temperatures ad differetial pressure from the Catalyst Moitor, ad valve positio, fuel pressure, ad curret oxyge sesor readig from the ECV5. The ECVI provides a cetral locatio for system wirig as well as parameter touch screes. CANbus commuicatio betwee devices, aalog sigals betwee devices, ad power distributio to each device are wired o the board located iside the ECVI. ALTRONIC, LLC

21 NOx Sesor The ECV5 system icorporates a pateted method for usig a NOx sesor i rich bur applicatios. The NOx sesor is istalled after the catalyst i the exhaust ad coected to the Cat Moitor via the CANbus. The Cat Moitor cotiually reads the NOx sesor ad adjusts the O2 sesor setpoit to the optimal setpoit reducig NOx without raisig the level of CO sigificatly. Usig the NOx sesor, the Cat Moitor ca detect whether the egie is ruig too rich or too lea. It s commo for the O2 sesor setpoit to vary throughout the day depedig o a umber of factors: load, ambiet temperature, egie speed, or catalyst temperature. It is ot ucommo for the O2 sesor iput to adjust more tha.005 lambda i the course of a day. Furthermore, the system ca make correctios for chages i the coditio of the catalyst or oxyge sesor due to age ad degradatio. NOx readigs below 1ppm are typical whe implemetig NOx sesor cotrol depedig upo the coditio of the catalyst elemets. Ditherig is a importat cotrol feature whe implemetig. Usig the NOx sesor without ditherig may cause large spikes i CO to occur. WARNING! The NOx sesor cable has 24Vdc o oe of its cotacts. If the NOx sesor is ot coected, care must be take ot to let the wires short across each other or to groud. DO NOT TAPE THEM TOGETHER. Thermocouples The supplied thermocouple is a type K i a stailess steel probe for a ¼ ich thermo well. The wire is straded type K with Teflo isulatio for heat resistace ad stadard size thermocouple coector with 2 male cotacts. The cable supplied with the thermocouple assembly is straded, twisted pair, shielded, type K with a matig coector ad has the same isulatio. Although the shieldig may ot be required i all istallatios it is recommeded that it be used. 4-20ma Iput for a Delta-P Trasducer The Cat moitor has the provisio to coect a 4-20mA loop-powered pressure trasducer to measure the delta-pressure across the catalyst. These coectios are made via a two-wire Belde-type cable that is coected to the mai cable haress (see cable drawig). The Cat moitor ca be programmed to geerate a fault or shutdow based o the level of delta pressure. This data is also logged o the thumb drive. WARNING! The Delta-P trasducer has 24Vdc o oe of its cotacts. If the Delta-P sesor is ot coected, care must be take ot to let the wires short across each other or to groud. DO NOT TAPE THEM TOGETHER. ALTRONIC, LLC

22 6. ECV5 Istallatio Istructios The ECV5 gas-meterig valve should be ispected immediately after upackig. Check for ay damage that may have occurred durig shippig. If there are ay questios regardig the physical itegrity of the valve, call Altroic immediately. NOTE: If possible, keep the origial shippig cotaier. If future trasportatio or storage of the valve is ecessary, this cotaier will provide the optimum protectio. Thigs to keep i mid: Always provide a adequate supply pressure for the applicatio. Ideally, the valve should stroke about 70% at full steady state load. Supply the valve with 24Vdc, 5 amps at the valve. Dual bak uits eed 5 amps per valve. Usig small gauge wire may cause a large voltage drop resultig i a iadequate power source at the valve. Avoid groud loops whe coectig the ECV5. Never istall valve wires withi the same coduit or i close proximity to high voltage power sources. Never pait the valve. Do ot istall the valve i such a maer where codesate may build up iside the electroics housig. Do ot weld. The ECV5 is desiged to be istalled o atural gas fired reciprocatig egies. Locate the ECV5 so that there is a miimum of flow restrictios betwee it ad the carburetor or mixig veturi. There should be o valves other tha a potetial bleed valve dowstream of the ECV5. The ECV5 should be istalled dowstream of the shut off valve. The ECV5 is geerally able to overcome problems with pressure cotrol at various distaces from the carburetor or mixig bowl. The optimum distace from the ECV5 to the carburetor or mixig bowl is approximately i. Maitai the least amout of pressure drop as possible (i.e., o 90 degree elbows, reducers, ad close ipples) sweep 90 s are ideal. Vibratio o rigid pipig supply lies may cause metal fatigue. Use flexible hose somewhere i the fuel supply to the valve rather tha istallig completely rigid pipig, allowig egie vibratio to be absorbed rather tha trasferred to the carburetor or mixig veturi. O dual bak uits, it is ideal to mirror the istallatio o both sides of the egie as closely as possible, so that the pressure drop to each carburetor or mixig veturi is essetially the same. A balace lie should be coected from the air box side of the carburetor or mixig veturi to the referece port o the side of the ECV5 cotrol housig o turbocharged uits. The referece port is a Alle head plug with a hole i the ceter. This port is a #4 SAE straight thread, O-rig port. The thread size is 7/ NOTE: DO NOT USE NPT FITTINGS! ALTRONIC, LLC

23 7. ECVI Moitor Screes This sectio describes the ECVI moitor screes for sigle or dual bak egies. The ECVI moitor screes display the ECV5 ad Catalyst Moitor fuctios such as flow rate, pressure, actuator positio, pressure setpoits, pre- ad post-cat temperatures, etc., via a graphical iterface i real time. Screes for sigle bak egie cofiguratio are pictured o the left side of the pages; screes for dual bak egie cofiguratio are pictured o the right. Where there is oly oe scree show, it applies to both cofiguratios. Iitial Display Scree The Iitial Display Scree appears upo power up of the ECVI. Either a sigle bak egie cofiguratio or a dual bak egie cofiguratio may be selected. The Mai scree for the selected cofiguratio will be displayed ad accessible. Mai Scree The Mai Scree displays a overview of the ECV5/Cat Moitor system. It is accessed by pressig either the Sigle Bak Egie or the Dual Bak Egie butto. The Mai Scree lets the operator see at a glace how the system is operatig such as pre- ad post-catalyst temperatures, differetial pressure, O2 setpoit, ad pressure setpoit. Press ay of the buttos at the bottom of the scree to access other screes ad fuctios. ALTRONIC, LLC

24 Pressure/Positio Measuremet Scree The Pressure/Positio scree lets the operator view the dowstream pressure measured i iches of water colum. It also lets you see the positio of the valve actuator ad the percetage the valve is ope. The Pressure/Positio Measuremet Scree displays the followig parameters: Fuel pressure setpoit (Sp) Fuel pressure process variable (Pv) Pre-catalyst temperature Post-catalyst temperature Differetial pressure ECV5 cotrol mode: Egie Stopped Default Cotrol AFR Cotrol Press ay of the buttos at the bottom of the scree to access other screes ad fuctios. Catalyst Moitor Scree The Catalyst Moitor Scree lets the operator view the O2 level setpoit ad trim values, NOx sesor output, whether the egie is ruig lea or rich, ad the trimmig directio. It also shows the commuicatio status betwee the Cat Moitor ad the ECVI. ALTRONIC, LLC

25 The Catalyst Moitor Scree displays the followig parameters: NOx sesor setpoit (Sp) oly used o lea-bur applicatios NOX sesor process variable (Pv) O2 sesor setpoit dyamic (expressed i Lambda) O2 trim (expressed i Lambda) O2 trim directio: Leaer Richer Commuicatio Status: Active Timeout Press ay of the buttos at the bottom of the scree to access other screes ad fuctios. Flow Meter The Flow Meter Scree lets the operator view the fuel flow rate. It also keeps track of flow for various time periods. The Flow Meter displays the followig parameters: Curret flow Accumulated flow Curret hour accumulated flow Curret day accumulated flow Curret moth accumulated flow Curret year accumulated flow Previous hour accumulated flow Yesterday accumulated flow Last moth accumulated flow Last year accumulated flow Commuicatio Status: Active Timeout Pressig the Clear Accumulated butto will zero the Accumulated flow parameter. Press the Back butto to retur to the Mai Scree. ALTRONIC, LLC

26 Diagostics Scree The Diagostics Scree is used for diagosig problems dealig with Etheret coectios, NOx Sesor, O2 trim, ad CANbus setup. The Left Bak CAN Active idicator should be gree o both sigle ad dual bak cofiguratios. If ot, check Left bak CAN address = 1. The Right Bak CAN idicator should be gree for dual bak cofiguratios. If ot, check Right bak CAN address = 2. The NOx CAN active idicator should be gree if the NOx Sesor is preset. If ot, check the NOx Sesor status or NOx Sesor wirig. Power must be cycled for a CAN address chage to take effect. The Diagostics Scree displays the followig parameters: Etheret coectio status: Cable Discoected IP Address Not Set Waitig for IP Address MAC Address ot Set Not Coected Coected Trimmig status: Ready/Active CANbus is OFF Not i AFR Mode NOx Sigal ot ready NOx Heater Error NOx Error Trim Limits ot set NOx Sesor status: Warmup Valid Not used OFF IP Address: Dyamic IP Static IP CANbus status: Active Gree butto Iactive Red butto Press the Back butto to retur to the Mai Scree. ALTRONIC, LLC

27 Settigs Scree The Settigs Scree is used to eter the parameters ad fuctios that the other screes moitor. Pressig a particular scree butto displays that setup scree for eterig parameters (i.e., pressig the Modbus butto displays the Modbus Setup Scree). After parameters have bee etered, press Save Settigs to store the ew parameters. Press the Iit Display butto to retur to the Iitial Display Scree. Press the Back butto to retur to the Mai Scree. 8. ECVI Settigs Screes This sectio describes the ECVI Settigs screes for sigle or dual bak egie cofiguratios. The ECVI settigs screes are used to eter various parameters ad fuctios for the ECV5 ad Catalyst Moitor via a graphical iterface such as flow rate, pressure ad actuator positio, pressure setpoits, pre ad post Cat temperatures, etc. Screes for sigle bak egie cofiguratio are pictured o the left side (left bak) of the pages; screes for dual bak egie cofiguratio are pictured o the right (right bak). Where there is oly oe scree show, it applies to both cofiguratios. Iitial Display Scree The Iitial Display Scree appears upo power up of the ECVI. From there either a sigle bak egie cofiguratio or a dual bak egie cofiguratio may be selected. The Mai scree for the selected cofiguratio will be displayed ad accessible. ALTRONIC, LLC

28 Mai Scree The Mai Scree displays a overview of the ECV5/Cat Moitor system. It is accessed by pressig either the Sigle Bak Egie or the Dual Bak Egie butto. The Mai Scree lets the operator see at a glace how the system is operatig. Press the Setup butto at the bottom of the scree to access the Setup Scree. Settigs Scree The Settigs Scree is the iterface used to select the various screes to eter parameters ad fuctios for moitorig. Pressig a particular scree butto displays that setup scree for eterig parameters (i.e., pressig the Modbus butto displays the Modbus Setup Scree). After parameters have bee etered, press the Save Settigs butto to store the ew parameters. To eter parameters o the various screes, see Procedure for Eterig Parameters o Setup Screes i this sectio. Press the Iit Display butto to retur to the Iitial Display Scree. Press the Back butto at the bottom of the scree to retur to the Mai Scree. ALTRONIC, LLC

29 CANbus Setup Scree The CANbus assigmet screes are iteded to display ad allow correctig of CANbus addressig. The umber show i the box should match the default listed. If ot, it ca be chaged maually. Press the Back butto to retur to the Settigs Scree. Free Air Cal Scree The Free Air Cal scree is a required calibratio for O2 Sesor fuctioality. O scree directios must be followed. Oce setup is complete, pressig the Free Air Cal butto begis the process. The status above the butto will display the status of the calibratio. NOTE: Do ot chage screes durig the Cal process. Press the Back butto to retur to the Settigs Scree. To perform the Free Air Cal procedure, see Setup of the ECV5 with Cat Moitor with IDEC Display i Chapter 9. ALTRONIC, LLC

30 Fuel Pressure Setup Scree The Fuel Pressure Setup scree allows the operator to set ECV5 fuel pressure parameters. The graph scree provides a lie chart to show device status over time. The cotrols o this page allow for umeric iput: Parameter Overview: Default Pressure Discharge pressure setpoit the ECV5 will aim to reach/maitai i Default cotrol mode. KP Gai The startig value for the proportioal gai (KP), used to calculate proportioal output which is set i proportio to the curret error. The proportioal gai accelerates the movemet of the process variable towards setpoit while i closed pressure cotrol loop. The proportioal compoet depeds oly o the error, which is the differece betwee the setpoit ad the process variable. KI (mi) The startig value for the Miimum Itegral Gai (KI) used to dyamically calculate the actual itegral gai based o the valve s curret positio. KI (max) The startig value for the Maximum Itegral Gai (KI) used to dyamically calculate the actual itegral gai dyamically based o the valve s curret positio. The itegral gai accelerates the movemet of the process variable towards setpoit, itegratig the error over time, ad elimiatig the residual steady-state error that occurs with a pure proportioal cotroller. Miimum Pressure Absolute miimum limit for the operatioal fuel pressure. Maximum Pressure Absolute maximum limit for the operatioal fuel pressure. Press the Back butto to retur to the Settigs Scree. ALTRONIC, LLC

31 O2 Sesor Setup Scree The O2 Sesor Setup scree allows the operator to set the O2 Sesor values. The graph scree provides a lie graph to show device status over time (cotrols all for umeric iput of the O2 setpoit ad O2 gai). This is where the duratio is set for Default Mode. Parameter Overview: O2 Sesor Setpoit The startig value for the target O2 setpoit used i closed O2 cotrol loop. l The ECV5 will aim to reach/maitai this setpoit while i Air Fuel Ratio cotrol mode. l The O2 setpoit could be further adjusted by dyamically calculated O2 trim (computed withi Catalyst Moitor, ad set to ECV5 via CANbus) O2 Gai Itegral gai used i O2 closed cotrol loop. l The itegral term accelerates the movemet of the process variable towards setpoit, itegratig the error over time. Warmup Timer The wait period (i secods) to allow the oxyge sesor to reach the operatig temperature. The Warmup Timer starts coutig dow whe the ECV5 cotrol mode is chaged from Stopped to Default (Igitio Cofirm sigal is active). Whe the Warmup Timer expires ad the O2 sesor feedback is withi operatioal rage, the valve will switch to Air Fuel Ratio cotrol mode. Press the Back butto to retur to the Settigs Scree. ALTRONIC, LLC

32 O2 Ditherig Setup Scree The O2 Ditherig Setup scree allows the operator to set the O2 ditherig values. Parameter Overview: O2 Ditherig Eable/Disable toggle switch Ditherig Rate The startig value for the dither frequecy. Ditherig Amplitude The dither adjustmet over a sigle period. Press the Back butto to retur to the Settigs Scree. To perform the Ditherig procedure, see Setup Ditherig ad NOx Sesor Trim Usig the IDEC Display i Chapter 9. Dyamic O2 Schedule Setup Scree The Dyamic O2 Schedule allows for automatic adjustmet of the O2 setpoit based o maifold pressure iput (4-20mA). Parameter Overview: ON/OFF Eable/Disable toggle switch Dyamic schedule will be automatically disabled if oe of the poits are set. Schedule Poits 1-10 At miimum 2 schedule poits should be cofigured if dyamic schedule is to be used. Press the Back butto to retur to the Settigs Scree. ALTRONIC, LLC

33 Optioal Start Pressure Settigs Scree The Optioal Start Pressure Setup scree allows for optioal egie startup with default pressure set below the miimum pressure limit. The graph scree provides a lie graph to show device status over time. Parameter Overview: Delay Timer The wait period (i secods) prior to pressure demad adjustmet. Ramp Rate The frequecy (i milisecods) at which fuel pressure demad will be icreased i steps of i. W. C. Press the Back butto to retur to the Settigs Scree. ALTRONIC, LLC

34 Cat Moitor Setup Scree The Cat Moitor Setup scree allows the operator to eter parameters for the Cat Moitor. Parameter Overview: O2 Set poit Trim Filter rate Represets the frequecy rate at which NOx sesor feedback is sampled. Trim Step O2 trim adjustmet step for the O2 setpoit. Miimum Trim The absolute miimum limit for the O2 trim adjustmet. Maximum Trim The absolute maximum limit for the O2 trim adjustmet. Catalyst Temperature Pre-Cat/Post Cat Overtemp The maximum pre-catalyst ad post-catalyst temperature limits for triggerig egie shutdow. NOx Sesor For lea bur oly: l Setpoit The startig value for the target NOx setpoit used i miimizatio cotrol algorithm. l Gai The startig value for the itegral gai i NOx miimizatio cotrol loop. l Offset The startig value for the offset adjustmet i NOx miimizatio cotrol loop. DP Max Differetial pressure maximum settig used to scale 4-20mA DP iput For use with Etheret l Use Static IP Eable/Disable toggle switch. If disabled, the IP address will be assiged dyamically. l IP Address Iteret Protocol address assiged to Catalyst Moitor IP address is a 32-bit umber cosistig of 4 octets i accordace with Iteret Protocol Versio 4 (IPv4) Press the Back butto to retur to the Settigs Scree. ALTRONIC, LLC

35 Modbus Address Setup Scree Oly oe device ca be coected to the ECV5 while settig the Modbus addresses. Remove wires for all devices except the device you are cofigurig. Failure to do so may corrupt values stored i the valves or Cat Moitor which my yield upredictable results. Do ot discoect the valve at the cao plug. The ucoected cable will act as a atea for electroic oise, ad prevet commuicatio to the other devices. The Modbus Setup scree cotrols how the HMI commuicates with the devices: Catalyst Moitor = 3 Right Bak = 2 Left Bak = 1 WARNING! Left ad right assigmets ca be easily reversed programmatically or by beig wired i reverse. Follow istallatio istructios carefully ad precisely. Press the Back butto to retur to the Settigs Scree. ALTRONIC, LLC

36 Procedure for Eterig Parameters o Setup Screes To eter parameters o a setup scree, do the followig: O the Mai scree, select the butto accordig to egie cofiguratio. The Iterface Scree appears. Press Setup. Settigs scree appears. Press the butto for the scree you wish to chage/modify parameters (i this example, the O2 Sesor butto has bee pressed.) ALTRONIC, LLC

37 The O2 Sesor Settigs scree is displayed. Press the pad for the parameter you wish to chage/modify. Keypad appears. Eter the parameters o the keypad ad press ENT. Keypad disappears. Repeat as ecessary for eterig other parameters. Press BACK whe fiished. The Settigs Scree appears. Press Save Settigs Repeat as desired to chage/modify parameters o a differet scree. Whe fiished, press Back. The Iterface scree appears. ALTRONIC, LLC

38 9. ECVI/ECV5 Setup Procedures Setup of the ECV5 with Cat Moitor Usig the ECVI with IDEC Display Cofigurig the Uit 1. Upo receipt of equipmet, ispect all equipmet for damage or missig parts. 2. Esure cable legths meet requiremets for istallatio. NOTE: ECV5 cables are 25- or 50-foot legths, Catalyst Moitor cables are 30-foot legths, ad O2 sesor cables are 30-foot legths. NOx sesor extesio cables are 10- ad 30-foot legths. 3. Istall required equipmet where desired, payig attetio to the cable legths. 4. After istallig the veturi iserts, locate ad close the load screw, payig attetio to the umber of turs eeded to screw it all the way i. The tur the load screw out to approximately 4 turs ad mark it. 5. Ru all cables through coduit desired by customer (flex or rigid). Whe pullig wirig for the O2 Sesor ad NOx Sesor through coduit, esure the coector is removed from the wires. For the O2 Sesor wires a special tool is required. For the NOx Sesor wire, a paper clip will suffice. Record the wire color to umber o each of the coectors. 6. If ot usig the Differetial Pressure (DP) Gauge with the Catalyst Moitor, the cable ed eeds to be trimmed ad taped to prevet a short. This cable will have 24Vdc positive supplied to it whe 24Vdc power is supplied to the Catalyst Moitor. 7. If usig the Differetial Pressure Gauge with the Catalyst Moitor, do the followig: Remove cover o top of DP Gauge. Coect black wire to termial 1 o DP Gauge 4-20mA Retur. Coect red wire to termial 3 o DP Gauge 4-20mA Loop Power. Coect the shield to the DP Gauge Groud termial. Leave termial 2 empty. Replace cover to top of DP Gauge. Trim all ope-eded excess wires ad coect to the ECVI. ALTRONIC, LLC

39 NOTE: The customer must provide a 24Vdc positive ad egative lead (esurig the correct amperage 5 amps per ECV5 ad 5 amps for the Catalyst Moitor) to the ECVI for power to the equipmet ad a 24Vdc positive for the igitio cofirm. The igitio cofirm sigal from the customer should be from a source that will remove power if a fault occurs, which will allow both ECV5 s to shut, thus shuttig off the fuel to the egie. Some sources of 24Vdc positive ca be from the PLC, the electricallyoperated fuel soleoid, a oil pressure switch, etc. DO NOT CONNECT THE CUSTOMER S 24Vdc POWER WIRES AT THIS TIME. 8. Discoect the ECV5 Cables from the ECV5 s. 9. Discoect the O2 Sesor cables from the Cat Moitor. 10. Discoect the Cat Moitor Cable from the Cat Moitor. 11. With power shut off, coect the customer s 24Vdc power wires. 12. Tur the customer s power o. 13. Usig a voltage tester, measure all red wires as power or hot ad all black wires as retur or egative, esurig correct polarity ad DC Voltage. Oce correct set up is complete, shut off the customer power ad recoect all equipmet ONE AT A TIME (Cat Moitor, ECV5 Left Bak, ECV5 Right Bak ad O2 Sesor cables. Tur o power from the customer after coectig the Cat Moitor. Esure the Cat Moitor powers up. Shut off power from the customer ad recoect the ECV5 Left Bak. Tur o power from the customer after coectig the ECV5 Left Bak. Esure the ECV5 Left Bak powers up. Shut off power from the customer ad recoect the ECV5 Right Bak. Tur o power from the customer after coectig the ECV5 Right Bak. Esure the ECV5 Right Bak powers up. The Cat Moitor, ECV5 Left Bak ad ECV5 Right Bak are ow powered. Settig Device ID s o the IDEC Display NOTE: The default factory settig for the Catalyst Moitor Modbus/Device ID is set to 3 ad the ECV5 has the Modbus/Device ID set to 1. Previously the catalyst moitor ad both ECV5 Modbus/Device ID were set to 1. If the Catalyst Moitor to be used will be with the Visio 120 Display, the Modbus/ Device ID will have to be chaged to Modbus/Device ID 1 usig the Catalyst Moitor Valve Viewer program. ALTRONIC, LLC

40 Equipmet Modbus ID Tx Color Rx Color Left Bak ECV5 1 Gree White/Gree Right Bak ECV5 2 Gree White/Gree Cat Moitor 3 Gree Brow 1. Assig Cat Moitor (this step is ot be required o a ew system) Shut off customer power to equipmet. O the ECVI PWB, remove the Tx ad Rx coectios to the Right ad Left Bak ECV5 s. (ONLY the Cat Moitor commuicatio wires should be coected) Tur o customer power to equipmet. From the mai scree of the IDEC Display press the SETUP butto. Press the MODBUS ID butto. To the right of CONFIGURE Cat Moitor, press ASSIGN Cat Moitor. The umber 3 will appear i the field. Press the BACK butto, the press the SAVE SETTINGS butto. 2. Assig Right Bak ECV5 Shut off customer power to equipmet. O the ECVI PWB, remove the Tx ad Rx coectios to the Cat Moitor. (the Left Bak ECV5 is already discoected) O the ECVI PWB coect the Tx ad Rx coectios to the Right Bak ECV5. (ONLY the Right Bak commuicatio wires should be coected) Tur o customer power to equipmet. From the mai scree of the IDEC Display press the SETUP butto. Press the MODBUS ID butto. To the right of CONFIGURE RIGHT BANK ECV5, press the ASSIGN RIGHT BANK butto. The umber 2 will appear i the field. Press the BACK butto, the press the SAVE SETTINGS butto. 3. Assig Left Bak ECV5 (this step is ot be required o a ew system) Shut off customer power to equipmet. O the ECVI PWB, remove the Tx ad Rx coectios to the Right Bak ECV5. (the Cat Moitor is already discoected) O the ECVI PWB coect the Tx ad Rx coectios to the Left Bak ECV5. (ONLY the Left Bak commuicatio wires should be coected) Tur o customer power to equipmet. From the mai scree of the IDEC Display press the SETUP butto. Press the MODBUS ID butto. To the right of CONFIGURE LEFT BANK ECV5, press the ASSIGN LEFT BANK butto. The umber 1 will appear i the field. Press the BACK butto, the press the SAVE SETTINGS butto. Shut off customer power to equipmet. Coect the Cat Moitor ad Right Bak Tx ad Rx (All commuicatio wires should ow be coected). Tur o customer power to equipmet ad check; O the Mai Scree you should see (if doe correctly) Egie Stopped o both the Right ad Left Bak ECV5 s. Press the CATALYST MONITOR butto ad look at the top of the ew scree ad you should see (if doe correctly) ACTIVE uder Commuicatio Status. ALTRONIC, LLC

41 Settig Up CANbus Esure that the Left Bak CANbus address is set to 1 ad the Right Bak CANbus address is set to 2. From the Mai scree press the SETUP butto. Press the CANbus butto. After settig the Ca Bus Id s, press the BACK butto the press the SAVE SETTINGS butto. Cycle power for chages to take effect. Iitial Startup Settigs The followig are settigs that must be chaged for iitial startup. Press the SETUP butto the press the FUEL PRESSURE LEFT BANK butto. Chage the Default Pressure from 4.5 to Press the BACK butto ad the press SAVE SETTINGS. Press the FUEL PRESSURE RIGHT BANK butto ad chage the Default Pressure from 4.5 to Press the BACK butto ad the press SAVE SETTINGS. Press the O2 SENSOR LEFT BANK butto Chage the O2 Setpoit from to the followig; for a Rich Bur, esure the O2 setpoit is ad for a Lea Bur Now chage the Warmup Timer to 300 secods. Press the BACK butto ad the press SAVE SETTINGS. Press the O2 SENSOR RIGHT BANK butto. Chage the O2 Setpoit from to the followig; for a Rich Bur, esure the O2 setpoit is ad for a Lea Bur Now chage the Warmup Timer to 300 secods. Press the BACK butto ad the press SAVE SETTINGS. All other settigs should be at the correct value for egie startig operatio. Coductig a Free Air Calibratio The followig are the steps for coductig a Free Air Calibratio of the O2 Sesors. Esure the O2 Sesors are removed from the exhaust ad are still plugged i to the coector. From the Mai Scree press the SETUP butto. Press the FREE AIR CALIBRATION butto. Read the istructios ad the press the FREE AIR CAL butto. After approximately 3 miutes, the test will tell you if the Free Air Calibratio was successful or if it failed. If the Free Air Calibratio failed, carefully touch each O2 sesor ad feel which oe is hot. If the O2 Sesors are hot but ot too hot to hold, that is a good O2 sesor. If the O2 sesor is cold or too hot to hold, that is a bad O2 sesor. Replace the bad O2 sesor ad coduct aother Free Air Calibratio. *CAUTION: Careful hadlig is a must! They will bur you! Oce the Free Air Calibratio is successful, press the BACK butto ad the press the SAVE SETTINGS butto. Re-istall the O2 sesors ito the exhaust system. Startig the Egie Start the egie ad ru at low idle with o load. The Default Pressure may eed adjustmet for egie startig because the Default Pressure is sometimes egie specific. The settig of is the correct settig for most egies usig the exteral veturi or the veturi iserts. Watch the IDEC Display ad liste to the egie, moitorig egie stability ad esurig the Pressure Feedback or Pressure PV (Processed Voltage) is meetig the Pressure Setpoit. If the egie is ustable, adjust the pressure gais as required. Whe the egie is stable ad all coditios appear to be ormal, watch for the egie go ito Air Fuel Ratio. Just prior to the egie goig ito Air Fuel Ratio, a O2 Sesor Feedback Voltage is displayed. If the voltage is to the right of the O2 Sesor Setpoit, the egie is Lea. If the voltage is to the left of the O2 Sesor Setpoit, the egie is Rich. You will see (via the display) whe the egie goes ito Air Fuel Ratio. Check the Mai Scree of the display to esure that both baks go ito Air Fuel Ratio. The moitor the Pressure Setpoit esurig that the pressures ALTRONIC, LLC

42 are ot excessive (above iches) or too low (ito a egative). If either coditio exists, adjust the carburetor load screw (for veturi iserts, for veturi stadaloe use veturi adjustmet) to maitai approximately ich. Use the left, the right load screws ad brig pressures up or dow to ich slowly ad with miimal separatio betwee baks. NOTE: Turig the load screw i (tighteig) will icrease the pressure setpoit ad turig the load screw out (looseig) will reduce the pressure setpoit. This ca oly be doe whe both ECV5 s are i the Air Fuel Ratio mode. Adjustmets are ot immediate. Let the pressure setpoit settle out, the adjust agai if eeded. Oce all pressures are correct ad the O2 Sesor Process Voltage is meetig the setpoit, take the egie to rated speed. Moitor all pressures ad voltages. Oce satisfied, start brigig o load. Start with a light load, moitorig all pressures ad voltages ad adjust as ecessary. NOTE: Oce the pressure loop is adjusted i default mode, there is o reaso to readjust. Oce the egie is ruig i Air Fuel Ratio mode, the oly gai that might eed to be adjusted is the O2 sesor gai, ad this is usually whe there is a light load or o load coditio. Whe the egie is at full load ad operatig ormally, adjust supply pressure to brig the ECV5 valve positio to approximately 60% to 75%. For a lea bur egie, the positio is lower because you have to esure that the Pre Combustio Gas Pressure is correct for the egie. Oce all coditios are ormal, brig the egie ito compliace USING THE LEFT AND RIGHT O2 SENSOR SETPOINT ONLY. No adjustmet of the Load/Power Screw is required to brig the egie ito compliace. Whe the egie is ruig at full load ad i compliace, adjust the load screw to brig each ECV5 Pressure Setpoit from betwee to Whe adjustig the load screw oly tur 1 flat of the Hex Bolt at a time. Let the bak that is beig adjusted settle out, the adjust the other side as ecessary to balace each bak. Chagig Settigs for Normal Operatio Whe the egie is ruig at full load ad is i compliace, the followig settigs must be chaged for ormal operatio: From the Mai Scree of the Display, press the SETUP butto. Press the O2 SENSOR LEFT BANK butto. Chage the O2 Sesor Warmup Timer from 300 secods (where it was first set for iitial start-up) to whatever is desired by the customer. From the factory it is set to 60 secods. It has bee oticed that at times the customer will operate the egie at a light or o load coditio util the Oil temp reaches a certai poit. If this is the case the the O2 Sesor Warmup Timer should be set to allow for egie warmup time before goig ito Air Fuel Ratio Mode. Usually 120 secods is sufficiet. Oce the O2 Sesor Warmup Timer is chaged to the customer s specificatio, press the BACK butto ad the Press the SAVE SETTINGS butto. Press the O2 SENSOR RIGHT BANK butto. Repeat the O2 SENSOR LEFT BANK process as described above for O2 SENSOR RIGHT BANK. Oce the O2 Sesor Warmup Timer is chaged to the customer s specificatio, press the BACK butto ad the Press the SAVE SETTINGS butto. Press the FUEL PRESSURE LEFT BANK butto. ALTRONIC, LLC

43 Chage the Miimum ad Maximum pressure to a poit that will allow the ECV5 s to fully operate betwee these poits. Previously, the load screw was adjusted to brig each ECV5 Pressure Setpoit to approximately to whe operatig at a full load. NOTE: The miimum ad maximum pressure setpoits are software rails that protect the catalyst ad egie. If a O2 sesor fails, it will fail i the rich positio (dow to 0 o the O2 setpoit). Oce the ECV5 sees 100 o the O2 setpoit, it automattically trafers from Air/Fuel Ratio mode to Default mode. Without these software rails, the affected bak could over-fuel ad damage the catalyst or egie. Settig Miimum Pressure rail to ad the Maximum rail to is sufficiet for ormal egie operatio; however, whe a egie has ot bee operated for a couple of days ad the atmosphere is cold, the pressure Setpoit ca be higher tha ormal (i Air/Fuel Ratio mode) util the egie warms up. The spread betwee the Miimum ad Maximum Pressures must be set so as to ot impede the operatio of the egie ad allow the egie to meet its emissios requiremets. Oce chaged to the desired limits, press the BACK butto ad the press the SAVE SETTINGS butto. Press the FUEL PRESSURE RIGHT BANK butto. Chage the Miimum ad Maximum Pressure to the same as the previous bak. Press the BACK butto the press the SAVE SETTINGS butto. Setup NOx Sesor Trim ad Ditherig Usig the IDEC Display Checkig Stability of the NOx Sesor Pv (Feedback) After the egie has bee set up ad ruig ormally through all loads ad meetig Emissio compliace, follow these steps to eable NOx Sesor Trim ad O2 Ditherig. Press the CATALYST MONITOR butto located at the bottom left of the Mai scree. Observe the NOx Sesor PV bar ad the NOX Sesor Feedback dial. The ideal readig for these two readigs will be flat ad stable. If ot, the some gai adjustmet will be ecessary. If there are umerous BUMPS i the NOx Sesor PV Bar ad the NOx Sesor Feedback Dial, it meas that the egie is ot as fiely tued as is desired. ALTRONIC, LLC

44 NOTE: DO NOT MAKE LARGE ADJUSTMENTS. Make small adjustmets ad observe the NOx sesor feedback. Cotiue to make small adjustmets util the NOx sesor feedback is stable. Do ot adjust pressure gais or O2 sesor gais too high or too low. If uusually high or low gais are eeded to flat-lie the bumps, stop, put the gais back to default, ad cotact Altroic for further guidace. It is ot uusual (usig the ECV5 pressure ad O2 sesor gais) to get completely flat NOx sesor feedback. This ca occur if the catalyst or catalyst elemets are iefficiet or eed to be replaced. Cotact Altroic. Settig Up ad Eablig O2 Sesor Ditherig Oce the NOx Sesor, Pv Bar ad the NOx Sesor Feedback Dial are stable (by adjustig Pressure ad O2 Sesor Gais). Set up ad Eable the O2 Ditherig as follows: Factory default values for the Left ad Right Bak: Left Bak Right Bak Eable/Disable OFF Eable/Disable OFF Rate 500 Rate 500 Amplitude 10 Amplitude 10 O2 Dither Slave OFF O2 Dither Slave OFF Press the SETUP tab at the bottom of the Mai Scree. Locate the DITHERING LEFT BANK ad DITHERING RIGHT BANK buttos o the third row ad chage the Default values to the values below. Left Bak Right Bak Eable/Disable OFF Eable/Disable OFF Rate 500 Rate 500 Amplitude 150 Amplitude 150 O2 Dither Slave OFF O2 Dither Slave OFF Eable the O2 Sesor Ditherig by pressig the ON/OFF butto located directly to the right of the label O2 DITHERING. Press the BACK butto located at the bottom of the curret scree. If ruig a Dual Bak, press the DITHERING RIGHT BANK butto ad tur o the O2 SENSOR DITHERING ad the O2 DITHERING SLAVE. The values after completio are listed i the ext table: Left Bak Right Bak Eable/Disable ON Eable/Disable ON Rate 500 Rate 500 Amplitude 150 Amplitude 150 O2 Dither Slave OFF O2 Dither Slave ON Press the BACK butto located at the bottom of the curret scree. Press the SAVE SETTINGS butto located at the bottom of the curret scree. Press the BACK butto located at the bottom of the curret scree. You will ow be back at the Mai Scree. ALTRONIC, LLC

45 NOTE: Pay attetio whe turig the Ditherig Slave o for the Right Bak oly. Left is off ad right is o. If ruig dual baks (two ECV5 s), the Left Bak O2 Ditherig Slave should be off, ad the Right Bak O2 Ditherig Slave should be o. If ruig a sigle bak (oe ECV5), the Left Bak O2 ditherig slave should be off. Observe the NOx Sesor PV bar ad the NOx Sesor Feedback dial. After the settigs have bee chaged, as listed above, the NOX SENSOR Bar ad Dial should have smoothed out. Do ot be cocered with the occasioal BUMP. Settig Up ad Eablig the NOx Sesor Trim With the ECV5 s O2 Setpoit Ditherig eabled ad operatig ormally, follow the below steps to Set Up ad Eable the NOX Sesor Trim: From the Mai Scree press the SETUP butto located o the bottom of the scree. Press the CATALYST MONITOR butto located i the upper left. Uder the left colum, the O2 SET-POINT TRIM the Default values are as follows: Filter Rate 6000 Trim Step 1 Miimum Trim 0 Maximum Trim 0 Chage the Default values to as follows: Filter Rate 6000 Trim Step 1 Miimum Trim -100 Maximum Trim +100 NOTE: Whe the miimum trim ad the maximum trim values are zero (0) the NOx sesor trim is disabled. Whe a value is placed i both miimum ad maximum trim, the NOx sesor trim is eabled. Press the BACK butto located at the bottom of the curret scree. Press the SAVE SETTINGS butto located i the fourth row of tabs. Press the BACK butto located at the bottom of the curret scree. You should ow be back at the Mai scree. Press the CATALYST MONITOR butto located o the bottom left of the curret scree ad observe the Left ad Right Bak SP Trim. This trim will maitai.0000 for approximately 5 miutes, the it will chage either Richer or Leaer, whatever is required by the NOx Sesor. Oce you have oticed a visual chage i the trim, the egie will be ruig i a stable coditio, ad the emissios will be maitaiig compliace. THE ENGINE HAS NOW BEEN FINE TUNED AND THE O2 SETPOINT DITHERING AND NOx SENSOR TRIM ARE EN- ABLED. QUESTIONS CONCERNING THESE ADJUSTMENTS SHOULD BE DIRECTED TO ALTRONIC. ALTRONIC, LLC

46 10. Optioal Equipmet Cables The ECV5 iterface cable is a custom cable, which icludes all ecessary wires betwee the ECV5 ad ECVI iterface. The wire is sized appropriately for its use ad the wires are color-coded. This cable comes i 25 foot legths, but ca be ordered i 50 foot legths. The FM-50 (Flow Meter) comes with a 30 foot cable, but a 60 foot cable ca be ordered. NOx Sesor Our method for usig a NOx Sesor i both rich bur ad lea bur applicatios is pateted. The NOx Sesor is istalled after the catalyst, i the exhaust stream ad commuicates to the CAT Moitor via CaBus. The CAT Moitor cotiually reads the NOx Sesor ad adjusts the O2 Sesor Set Poit to the optimal set poit reducig NOx without raisig the level of CO sigificatly. Catalyst Delta-P Trasducer The Cat Moitor ca coect a 4-20mA loop-powered pressure trasducer to measure the Delta-Pressure across the catalyst. These coectios are made via a two-wire Beldo type cable that is maufactured ito the CAT Moitor cable. The CAT Moitor ca be programmed to geerate a fault or shutdow, based o the level of Delta-Pressure. This data is also logged o a thumb drive mouted iside of the Catalyst Moitor. The actual Delta-Pressure ca be read o the ECVI display or o the gauge itself. FM-50 Fuel Flow Meter The FM-50 provides a true Mass Flow Calculatio which corrects for temperature ad pressure fluctuatios. Various agecies ow require fuel measuremet o idividual gas egies. The FM-50 offers a very simple-to-istall optio that ca provide istataeous flow or totalized flow over a period of hours, days or moths. The FM-50 data ca be read o the ECVI display or the FM-50 itself. Mixig Veturi s The Mixig Veturi is desiged to precisely mix the fuel ad air to be admitted the egie. It is used with the ECV5 Emissios Cotrol Valve to replace the carburetor ad pressure regulator o both Rich Bur ad Lea Bur egies. 11. Troubleshootig Valve Stroke Limited Check the stroke of the valve at full load. If the stroke is less tha 70% o positio (40% 50% is ideal), lower the supply pressure to the fuel valve. Pressure Cotrol Loop Check the pressure cotrol loop. What pressure is required for o load? What pressure is required for full load? Compare the pressure measured by the valve to a exteral measuremet o each bak. Usig the scope, check the pressure cotrol respose to load chages with O2 sesor active. Goveror Cotrol Measure the maifold pressure o each bak. Observe if the butterfly/butterflies match. O2 Sesor Observe the output of the O2 sesor(s). Vary the ijectio pressure to chage the mixture. See if the O2 Sesor Voltage chages ad how much pressure chage is required to do so. Sesitivity to mixture varies (default mode oly). Are there differeces i the carburetors performace? Do they track? Check the ilet pressure to the carburetors. Check the adjustmets o the carburetors. ALTRONIC, LLC

47 12. Product Warraty Altroic, LLC warrats that all goods are free from defects i workmaship ad material as of the time ad place of delivery. As a matter of geeral warraty policy, Altroic, LLC hoors a origial buyer s warraty claim i the evet of failure withi 12 moths of shipmet to the ed-user, whe the equipmet has bee istalled ad operated uder ormal coditios ad i accordace with istallatio istructios cotaied i the operatig maual ad geerally accepted operatig practices. All warraty work must be performed at the Altroic maufacturig facility i Girard, Ohio. The customer is resposible for shipmet or delivery of the product to the facility. Altroic will pay retur groud freight. The customer will pay ay expedited freight fees. 13. Techical Assistace If you eed techical assistace, please gather the followig iformatio ad have it hady before cotactig us. Geeral Your ame Your Address Phoe umber Site Locatio Egie Iformatio Maufacturer Egie Model Number Number of Baks Fuel type Power Output Ratig ECV5 Iformatio Serial Number ECVI Iformatio Serial Number 712 Trumbull Aveue Girard, Ohio Phoe: ; Fax: altroic-girard@hoerbiger.com ALTRONIC, LLC

48 14. Appedicies A1. ECV5_B Modbus Registers 40x Iput Registers Register Descriptio Scalig Factor O2 Sesor Process Variable 1.0E Igore Igore Igore Igore Positio process variable 1.0E Positio demad 1.0E Maifold pressure 1.0E Pressure demad 1.0E Actuator output Actual Igitio cofirm Actual Actuator power Actual Sesor igore Actual Sp adjusted 1.0E Aalog iput 4-20mA 1.0E Igore Igore Igore Positio proportioal cotributio Actual Positio itegral cotributio Actual Pressure proportioal cotributio Actual Pressure itegral cotributio Actual O2 itegral cotributio Actual Igore Igore Igore Igore Warmup timer Actual Igore Igore Default mode Actual Sequece Actual Igore O2 Sesor Sp selected 1.0E O2 Sesor Sp selected i lambda 1.0E Start timer Actual CAN Tx Error Actual CAN Rx Error Actual ALTRONIC, LLC

49 Register Descriptio Scalig Factor CAN pressure demad 1.0E O2 dither value 1.0E CAN O2 dither 1.0E Pressure dither value 1.0E CAN pressure dither 1.0E CM O2 Sp trim i lambda 1.0E O2 Pv i percet O2 1.0E O2 Sp i percet O2 1.0E O2 Pv i lambda 1.0E O2 Sp i lambda 1.0E Igore Curret pressure itegral gai Actual 401x Holdig Registers Register Descriptio Scalig Factor Stroke gai Actual Stroke offset Actual O2 Set-poit 1.0E Demad gai Actual Demad offset Actual ma gai Actual ma offset Actual O2 gai Actual O2 offset Actual Maifold pressure gai Actual Maifold pressure offset Actual Default Pressure 1.0E Positio proportioal gai Actual Positio itegral gai Actual Pressure proportioal gai Actual Pressure itegral gai Actual Load gai prop. Actual Load gai it Actual O2 itegral Actual Actuator offset Actual Maximum pressure 1.0E Miimum pressure 1.0E Serial Number Actual Modbus address Actual DAC1 gai Actual Dac1 offset Actual Calibrated Actual ALTRONIC, LLC

50 Register Descriptio Scalig Factor Diag Actual Valve type Actual Force igitio cofirm Actual Force actuator power Actual Force sesor igore Actual Save data Actual Warmup timer start Actual O2 Fail timer start Actual Actuator limit Actual ma miimum 1.0E ma maximum 1.0E Set-poit miimum 1.0E Set-poit maximum 1.0E Sp eable Actual Zeroig Actual KI miimum Actual KI maximum Actual Start_timer_start Actual Ramp Rate Actual Lvdt Limit Actual MaPressure Poit 0 1.0E MaPressure Poit 1 1.0E MaPressure Poit 2 1.0E MaPressure Poit 3 1.0E MaPressure Poit 4 1.0E MaPressure Poit 5 1.0E MaPressure Poit 6 1.0E MaPressure Poit 7 1.0E MaPressure Poit 8 1.0E MaPressure Poit 9 1.0E O2 Set-poit Poit 0 1.0E O2 Set-poit Poit 1 1.0E O2 Set-poit Poit 2 1.0E O2 Set-poit Poit 3 1.0E O2 Set-poit Poit 4 1.0E O2 Set-poit Poit 5 1.0E O2 Set-poit Poit 6 1.0E O2 Set-poit Poit 7 1.0E O2 Set-poit Poit 8 1.0E O2 Set-poit Poit 9 1.0E O2 stadard free air Actual O2 stadard zero Actual ALTRONIC, LLC

51 Register Descriptio Scalig Factor O2 calibratio value Actual O2 calibratio slope Actual O2 calibratio offset Actual Iit calibratio Actual O2 calibratio complete Actual O2 correctio factor Actual Dither Slave eabled Actual Pressure Slave eabled Actual CAN eabled Actual O2 Dither eabled Actual O2 Dither period Actual O2 Dither amplitude Actual Pressure Dither eabled Actual Pressure Dither period Actual Pressure Dither amplitude Actual Miimum O2 Sp Trim Actual Maximum O2 Sp Trim Actual O2 Pv Miimum 1.0E CAN Address Actual O2 Percet Miimum 1.0E O2 Percet Maximum 1.0E-03 Scalig: 1. To covert data from the valve represeted i fixed-poit type to egieerig uits,multiply the value by the scalig factor. Example: You read 3200 from register (Default Pressure). 3200*0.001 = 3.2 Default pressure = 3.2 i W.C. 2. To sed data to the valve, covert it to fixed-poit format by multiplyig the actual settig by reverse scalig factor, the write data to Modbus register. You eed to set Default Pressure to 4 i. W.C. 4 * 1000 = 4000 Write 4000 to Modbus register Register 40144: Value 0x1234(Hex) writte to this register, directs the valve s processor to save holdig registers (401x) ito static memory for the ext power cycle. ALTRONIC, LLC

52 A2. CANbus Commuicatios ECV5 ad Catalyst Moitor devices support CAN commuicatios. All messages use the CAN.2.0 B 29-bit Exteded Data Form format, bus speed 250 Kbit/s. ECV5 Packet Descriptio O2 Ifo CAN ID 0x Byte 0 O2 Set poit high byte Byte 1 O2 Set poit low byte Byte 2 O2 Feedback high byte Byte 3 O2 Feedback low byte Byte 4 0 Byte 5 0 Byte 6 0 Byte 7 0 Packet Descriptio Pressure Ifo CAN ID 0x1A Byte 0 Pressure Setpoit High Byte Byte 1 Fuel Pressure Setpoit Low Byte Byte 2 Fuel Pressure Feedback High Byte Byte 3 Fuel Pressure Feedback Low Byte Byte 4 Maifold Pressure High Byte Byte 5 Maifold Pressure Low Byte Byte 6 0 Byte 7 0 Packet Descriptio Misc Ifo CAN ID 0x1B Byte 0 Actuator Output High Byte Byte 1 Actuator Output Low Byte Byte 2 Speed High Byte Byte 3 Speed Low Byte Byte 4 Sequece High Byte Byte 5 Sequece Low Byte Byte 6 0 Byte 7 0 ALTRONIC, LLC

53 Cat Moitor Packet Descriptio CM Ifo CAN ID 0x Byte 0 Pre-Cat Temp High Byte Byte 1 Pre-Cat Temp Low Byte Byte 2 Post-Cat Temp High Byte Byte 3 Post-Cat Temp Low Byte Byte 4 Differetial Pressure High Byte Byte 5 Differetial Pressure Low Byte Byte 6 0 Byte 7 0 Packet Descriptio NOx Sesor Refresh CAN ID 0x18FEDF00 Byte 0 0 Byte 1 0 Byte 2 0 Byte 3 0 Byte 4 0 Byte 5 0 Byte 6 0 Byte 7 5 = Heater ON; 0 = Heater OFF Packet Descriptio O2 Setpoit Trim CAN ID 0x Byte 0 O2 Trim High Byte Byte 1 O2 Trim Low Byte Byte 2 0 Byte 3 0 Byte 4 0 Byte 5 0 Byte 6 0 Byte 7 0 ALTRONIC, LLC

54 NOx Sesor Packet Descriptio CAN ID Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 NOx Data 0x18F00F52 NOx Low Byte NOx High Byte O2 Low Byte O2 High Byte Status Heater Status ad Error NOx Error O2 Error Descriptio Scale Rage Uit O2 ifo (EGC2/ECV5) O2 Set poit Lambda O2 ifo (EGC2/ECV5) O2 Feedback Lambda Pressure ifo (EGC2/ECV5) Fuel Pressure Setpoit Mi - Max Pressure Setpoit i.w.c. Pressure ifo (EGC2/ECV5) Fuel Pressure Feedback Mi - Max Pressure Setpoit i.w.c. Pressure ifo (EGC2/ECV5) Maifold Pressure i.hg Misc ifo (EGC2/ECV5) Actuator Couts Misc ifo (EGC2/ECV5) Speed RPM Misc ifo (EGC2/ECV5) Sequece Couts *To covert NOx readig to ppm: (NOx readig * 0.05) **To covert O2 readig to %: (O2 readig * ) - 12 ALTRONIC, LLC

55 A3. Cat Moitor Modbus Registers Iput Registers Register Descriptio Defiitio pre_cat_ox Igore post_cat_ox NOx readig from post-cat NOx sesor pre_cat_o2 Igore post_cat_o2 O2 readig from post-cat NOx sesor pre_cat_temp Pre-catalyst temperature post_cat_temp Post-catalyst temperature pre_status_supply Igore pre_status_sesor_heater Igore pre_status_ox_sigal Igore pre_status_o2_sigal Igore post_status_supply NOx sesor supply status post_status_sesor_heater Nox sesor heater status post_status_ox_sigal NOx sesor NOx sigal status post_status_o2_sigal NOx sesor O2 sigal status pre_status_ox_error Igore pre_status_o2_error Igore post_status_ox_error Error Code post_status_o2_error Error Code rtc_sec Real time clock: secod rtc_mi Real time clock: miute rtc_hour Real time clock: hour rtc_wday Real time clock: week day rtc_mdate Real time clock: date rtc_moth Real time clock: moth rtc_year Real time clock: year ecu_lb_ca_off Left bak valve CANbus ot detected/tured off ecu_rb_ca_off Right bak valve CANbus ot detected/tured off pre_ox_ca_off Igore post_ox_ca_off NOx sesor CANbus ot detected/tured off battery_voltage Catalyst Moitor supply voltage milliamp_iput ma readig from DP catalyst_dp Differetial pressure across catalyst ox_heater NOx heater ON/OFF flag ox_warmup_timer Nox/O2 heater warmup timer left_bak_o2_setpoit Left bak valve - O2 sesor setpoit left_bak_o2_feedback Left bak valve - O2 sesor feedback left_bak_press_setpoit Left bak valve - pressure setpoit left_bak_press_feedback Left bak valve - pressure feedback left_bak_maifold_press Left bak valve - maifold pressure left_bak_actuator_output Left bak valve - actuator output ALTRONIC, LLC

56 Register Descriptio Defiitio left_bak_speed Left bak valve - speed (if applicable) left_bak_sequece Left bak valve - sequece right_bak_o2_setpoit Right bak valve - O2 sesor setpoit right_bak_o2_feedback Right bak valve - O2 sesor feedback right_bak_press_setpoit Right bak valve - pressure setpoit right_bak_press_feedback Right bak valve - pressure feedback right_bak_maifold_press Right bak valve - maifold pressure right_bak_actuator_output Right bak valve - actuator output right_bak_speed Right bak valve - speed (if applicable) right_bak_sequece Right bak valve - sequece o2_sp_trim O2 sesor setpoit trim post_cat_ox_avg Average post-cat Nox sigal ig_cofirm Igitio cofirm flag alarm_reset Alarm reset flag pre_temp_avg Average pre-catalyst temperature post_temp_avg Average post-catalyst temperature dp_avg Average catalyst differetial pressure o2_1_avg Average left bak O2 readig o2_2_avg Average right bak O2 readig pre_temp_log Log average/log pre-catalyst temperature post_temp_log Log average/log post-catalyst temperature dp_log Log average/log catalyst differetial pressure o2_1_log Log average/log left bak O2 readig o2_2_log Log average/log right bak O2 readig alarm_status_high Over rage alarm status alarm_status_low Uder rage alarm status shutdow_status_high Over rage shutdows status shutdow_status_low Uder rage shutdow status filesize Curret log file size freespace USB disk free space dac1_output Left bak O2 DAC output dac2_output Right Bak O2 DAC output o2_heater O2 heater ON/OFF flag percet_o2_1 Left bak O2 percet o2_1_heater_pv Left bak O2 heater feedback o2_1_heater_avg Left bak O2 heater average feedback o2_1_heater_out Left bak O2 heater output percet_o2_2 Right bak O2 percet o2_2_heater_pv Right bak O2 heater feedback o2_2_heater_avg Right bak O2 heater average feedback o2_2_heater_out Right bak O2 heater output o2_1_status Left bak O2 status ALTRONIC, LLC

57 Register Descriptio Defiitio o2_2_status Right bak O2 status o2_warmup_timer O2 warmup timer o2_trim_directio O2 trim directio adc1 ADC readig chael adc2 ADC readig chael adc3 ADC readig chael adc4 ADC readig chael adc5 ADC readig chael adc6 ADC readig chael adc7 ADC readig chael adc8 ADC readig chael pre_status_o2_error Not used o2_1_workig O2 sesor at operatig temperature o2_2_workig O2 sesor at operatig temperature eth_status Diagostics eth_txabrt Diagostics eth_reset Diagostics eth_tx Diagostics eth_rx Diagostics eth_packets_avail Diagostics eth_state Diagostics eth_rtc_sec Diagostics eth_rtc_mi Diagostics eth_rtc_hour Diagostics eth_rtc_wday Diagostics eth_rtc_mdate Diagostics eth_rtc_moth Diagostics eth_rtc_year Diagostics eth_ip_1 Diagostics eth_ip_2 Diagostics eth_ip_3 Diagostics eth_ip_4 Diagostics eth_use_static_ip Diagostics trimmig_active Diagostics x_regs Number of iput(3x) registers ALTRONIC, LLC

58 Holdig Registers Register Descriptio Defiitio rtc_update Update real time clock flag mi_adjust_o2_trim Miimum O2 trim adjustmet max_adjust_o2_trim Maximum O2 trim adjustmet versio Software versio milliamp_gai ma iput gai milliamp_offset ma iput offset serial_umber Serial umber modbus_address Modbus address calibrated Origial calibratio flag f_ig_cofirm Force igitio cofirm flag f_alarm_reset Force Alarm reset flag save_data_commad Save holdig registers to flash warmup_timer_start Warmup timer duratio ma_mi Miimum ma iput ma_max Maximum ma Iput dp_mi Miimum catalyst differetial pressure dp_max Maximum catalyst differetial pressure ox_trasmit_rate CAN trasmit rate - NOx cm_ifo_trasmit_rate CAN trasmit rate - Catalyst Moitor ifo o2_trim_trasmit_rate CAN trasmit rate - O2 setpoit trim f_heater Force Nox/O2 heater flag o2_trim_step O2 setpoit trim icremet ox_filter_rate NOx averagig filter rate mi_meter Miute meter - Read Oly hour_meter Hour meter - Read Oly data_log_eable USB data logger eable flag log_rate USB data logger rate sample_rate O2 averagig rate overall_rate Not used log_time_after_shutdow Time i secods to cotiue loggig data after shutdow pre_temp_shutdow Pre-catalyst temperature Shutdow/Alarm eable flag pre_temp_avg_shutdow Average pre-catalyst temperature Shutdow/Alarm eable flag pre_temp_log_shutdow Log average/log pre-catalyst temperature Shutdow/Alarm eable flag pre_temp_avg_rate Pre-catalyst temperature averagig rate pre_temp_alarm_mi Pre-catalyst temperature alarm miimum pre_temp_alarm_max Pre-catalyst temperature alarm maximum pre_temp_alarm_delay Pre-catalyst temperature alarm delay pre_temp_avg_alarm_mi Average pre-catalyst temperature alarm miimum pre_temp_avg_alarm_max Average pre-catalyst temperature alarm maximum pre_temp_avg_alarm_delay Average pre-catalyst temperature alarm delay pre_temp_log_alarm_mi Log average/log pre-catalyst temperature alarm miimum ALTRONIC, LLC

59 Register Descriptio Defiitio pre_temp_log_alarm_max Log average/log pre-catalyst temperature alarm maximum pre_temp_log_alarm_delay Log average/log pre-catalyst temperature alarm delay pre_temp_shutdow_mi Pre-catalyst temperature shutdow miimum pre_temp_shutdow_max Pre-catalyst temperature shutdow maximum pre_temp_shutdow_delay Pre-catalyst temperature shutdow delay pre_temp_avg_shutdow_mi Average pre-catalyst temperature shutdow miimum pre_temp_avg_shutdow_max Average pre-catalyst temperature shutdow maximum pre_temp_avg_shutdow_delay Average pre-catalyst temperature shutdow delay pre_temp_log_shutdow_mi Log average/log pre-catalyst temperature shutdow miimum pre_temp_log_shutdow_max Log average/log pre-catalyst temperature shutdow maximum pre_temp_log_shutdow_delay Log average/log pre-catalyst temperature shutdow delay post_temp_shutdow Post-catalyst temperature Shutdow/Alarm eable flag post_temp_avg_shutdow Average post-catalyst temperature Shutdow/Alarm eable flag post_temp_log_shutdow Log average/log post-catalyst temperature Shutdow/Alarm eable flag post_temp_avg_rate Post-catalyst temperature averagig rate post_temp_alarm_mi Post-catalyst temperature alarm miimum post_temp_alarm_max Post-catalyst temperature alarm maximum post_temp_alarm_delay Post-catalyst temperature alarm delay post_temp_avg_alarm_mi Average post-catalyst temperature alarm miimum post_temp_avg_alarm_max Average post-catalyst temperature alarm maximum post_temp_avg_alarm_delay Average post-catalyst temperature alarm delay post_temp_log_alarm_mi Log average/log post-catalyst temperature alarm miimum post_temp_log_alarm_max Log average/log post-catalyst temperature alarm maximum post_temp_log_alarm_delay Log average/log post-catalyst temperature alarm delay post_temp_shutdow_mi Post-catalyst temperature shutdow miimum post_temp_shutdow_max Post-catalyst temperature shutdow maximum post_temp_shutdow_delay Post-catalyst temperature shutdow delay post_temp_avg_shutdow_mi Average post-catalyst temperature shutdow miimum post_temp_avg_shutdow_max Average post-catalyst temperature shutdow maximum post_temp_avg_shutdow_delay Average post-catalyst temperature shutdow delay post_temp_log_shutdow_mi Log average/log post-catalyst temperature shutdow miimum post_temp_log_shutdow_max Log average/log post-catalyst temperature shutdow maximum post_temp_log_shutdow_delay Log average/log post-catalyst temperature shutdow delay catalyst_dp_shutdow Catalyst differetial pressure Shutdow/Alarm eable flag catalyst_dp_avg_shutdow Average catalyst differetial pressure Shutdow/Alarm eable flag catalyst_dp_log_shutdow Log average/log catalyst differetial pressure Shutdow/Alarm eable flag catalyst_dp_avg_rate Catalyst differetial pressure averagig rate catalyst_dp_alarm_mi Catalyst differetial pressure alarm miimum catalyst_dp_alarm_max Catalyst differetial pressure alarm maximum catalyst_dp_alarm_delay Catalyst differetial pressure alarm delay catalyst_dp_avg_alarm_mi Average catalyst differetial pressure alarm miimum ALTRONIC, LLC

60 Register Descriptio Defiitio catalyst_dp_avg_alarm_max Average catalyst differetial pressure alarm maximum catalyst_dp_avg_alarm_delay Average catalyst differetial pressure alarm delay catalyst_dp_log_alarm_mi Log average/log catalyst differetial pressure alarm miimum catalyst_dp_log_alarm_max Log average/log catalyst differetial pressure alarm maximum catalyst_dp_log_alarm_delay Log average/log catalyst differetial pressure alarm delay catalyst_dp_shutdow_mi Catalyst differetial pressure shutdow miimum catalyst_dp_shutdow_max Catalyst differetial pressure shutdow maximum catalyst_dp_shutdow_delay Catalyst differetial pressure shutdow delay catalyst_dp_avg_shutdow_mi Average catalyst differetial pressure shutdow miimum catalyst_dp_avg_shutdow_max Average catalyst differetial pressure shutdow maximum catalyst_dp_avg_shutdow_delay Average catalyst differetial pressure shutdow delay catalyst_dp_log_shutdow_mi Log average/log catalyst differetial pressure shutdow miimum catalyst_dp_log_shutdow_max Log average/log catalyst differetial pressure shutdow maximum catalyst_dp_log_shutdow_delay Log average/log catalyst differetial pressure shutdow delay delta_temp_shutdow Catalyst differetial temperature Shutdow/Alarm eable flag delta_temp_avg_shutdow Average catalyst differetial temperature Shutdow/Alarm eable flag delta_temp_log_shutdow Log average/log catalyst differetial temperature Shutdow/Alarm eable flag delta_temp_avg_rate Catalyst differetial temperature averagig rate delta_temp_alarm_mi Catalyst differetial temperature alarm miimum delta_temp_alarm_max Catalyst differetial temperature alarm maximum delta_temp_alarm_delay Catalyst differetial temperature alarm delay delta_temp_avg_alarm_mi Average catalyst differetial temperature alarm miimum delta_temp_avg_alarm_max Average catalyst differetial temperature alarm maximum delta_temp_avg_alarm_delay Average catalyst differetial temperature alarm delay delta_temp_log_alarm_mi Log average/log catalyst differetial temperature alarm miimum delta_temp_log_alarm_max Log average/log catalyst differetial temperature alarm maximum delta_temp_log_alarm_delay Log average/log catalyst differetial temperature alarm delay delta_temp_shutdow_mi Catalyst differetial temperature shutdow miimum delta_temp_shutdow_max Catalyst differetial temperature shutdow maximum delta_temp_shutdow_delay Catalyst differetial temperature shutdow delay delta_temp_avg_shutdow_mi Average catalyst differetial temperature shutdow miimum delta_temp_avg_shutdow_max Average catalyst differetial temperature shutdow maximum delta_temp_avg_shutdow_delay Average catalyst differetial temperature shutdow delay delta_temp_log_shutdow_mi Log average/log catalyst differetial temperature shutdow miimum delta_temp_log_shutdow_max Log average/log catalyst differetial temperature shutdow maximum delta_temp_log_shutdow_delay Log average/log catalyst differetial temperature shutdow delay dac1_offset Left bak O2 voltage output offset dac1_gai Left bak O2 voltage output gai dac2_offset Right bak O2 voltage output offset dac2_gai Right bak O2 voltage output gai o2_1_offset Left bak O2 offset ALTRONIC, LLC

61 Register Descriptio Defiitio o2_1_gai Left bak O2 gai o2_2_offset Right bak O2 offset o2_2_gai Right bak O2 gai o2_heater_i O2 heater itegral gai o2_heater_p O2 heater proportioal gai o2_heater_sp O2 heater setpoit o2_heater_ramp_rate O2 heater warmup ramp rate o2_cal_timer_start O2 calibratio warmup timer duratio o2_percet_max O2 percet maximum o2_percet_mi O2 percet miimum o2_1_eable Left bak O2 sesor eable o2_2_eable Right bak O2 sesor eable alarm_relay_active_closed Alarm relay polarity shutdow_relay_active_closed Shutdow relay polarity cofig Catalyst Moitor cofiguratio do_cal Iitiate O2 sesor free air calibratio o2_cal_complete O2 calibratio complete ox_setpoit NOx sesor setpoit ox_itegral_gai NOx itegral gai ox_offset NOx offset f_dac Force DAC flag mac_1 MAC address octet mac_2 MAC address octet mac_3 MAC address octet mac_4 MAC address octet mac_5 MAC address octet mac_6 MAC address octet ip_1 IP address octe ip_2 IP address octe ip_3 IP address octe ip_4 IP address octe use_static_ip Static address flag set_sec Set real time clock: secod set_mi Set real time clock: miute set_hour Set real time clock: hour set_wday Set real time clock: week day set_mdate Set real time clock: date set_moth Set real time clock: moth set_year Set real time clock: year modbus_address_2 Modbus address arrowbad_output_e Narrow bad O2 output eable flag ew_ox_alg_e NOx algorithm eable flag ALTRONIC, LLC

62 Register Descriptio Defiitio lea_multiplier Lea multiplier (algorithm) rich_multiplier Rich multiplier (algorithm) adaptive_ic_table_0 Table settig0 (algorithm) adaptive_ic_table_1 Table settig0 (algorithm) adaptive_ic_table_2 Table settig0 (algorithm) adaptive_ic_table_3 Table settig0 (algorithm) adaptive_ic_table_4 Table settig0 (algorithm) adaptive_ic_table_5 Table settig0 (algorithm) adaptive_ic_table_6 Table settig0 (algorithm) spare0 Not used spare1 Not used spare2 Not used spare3 Not used regs Not used regs Number of holdig(4x) registers ALTRONIC, LLC

63 A4. Evelope, ECV5, 2.0 i. ANSI Flage EXTERNAL PRESSURE REFERENCE -4 SAE STRAIGHT THREAD O'RING BOSS PORT 22 PIN CONNECTOR (OPTIONAL 1/2-14 NPT CONDUIT ENTRY) ANSI CLASS 150 2" PIPE FLANGE /8-11 UNC, 4PL EQ. SPACED ON 4.75 ALTRONIC, LLC

64 A5. Evelope, ECVI ALTRONIC, LLC

65 A6. ECV5 Cable ALTRONIC, LLC

66 A7. Catalyst Moitor, Page 1 ALTRONIC, LLC

67 A8. Catalyst Moitor, Page 2 ALTRONIC, LLC

68 A9. ECVI PWB Wirig Diagram, Dual Bak ALTRONIC, LLC

69 A10. ECVI PWB Wirig Diagram, Sigle Bak ALTRONIC, LLC

70 A11. O2 Sesor Cable Wirig Diagram ALTRONIC, LLC