NOx 5210*

Single/Dual NOx Analyzer

Instruction Manual

* Note:

ECM’s NOx analyzer can be either single or dual channeled. Each channel can use one of
three NOx sensors: the Type T sensor, the Type G sensor, or the “Original” NOx sensor.

7/30/12
 COPYRIGHT 2012 by ECM: ENGINE CONTROL AND MONITORING.
All Rights Reserved.

No part of this manual may be photocopied or reproduced in any form without prior written
consent from ECM: ENGINE CONTROL AND MONITORING.

Information and specifications subject to change without notice.

Printed in the United States of America.

 Table of Contents

Introduction 1
The NOx 5210 1
NOx 5210 Kit Contents 2

Safety Warnings 4

How to Use 5
Hooking up the NOx 5210 5
Mounting the NOx Sensor and Pressure Sensor 11
Front Panel and the “SYS” Key 12
MOd (Module) Setup Option 14
RATE Setup Option 14
FUEL Setup Option (H:C, O:C, N:C, H2) 14
AOUT (Analog Output) Setup Option (A1 to A6) 14
dISP (Display) Setup Option (P1 to P6) 17
CAL (Calibrate) Setup Option for Type T and Type G NOx Sensor 17
CAL (Calibrate) Setup Option for Original NOx Sensor 22
CAL (Calibrate) Setup Option (P, AVG, SKEW) 25
CONF (Configure) Setup Option (LEdS, 1V4V, CAN, MOdE, FACT) 26

Specifications and Limits 31

Measurements and Accuracies 31
Sensor Limits and Specifications 32
Output Specifications 34
General Specifications 35

Appendices 36
A. 5200 Series Instruments Parts List 36
B. Module EIB Mode and Stand-alone Mode 42
C. Error Codes and Troubleshooting 46
D. Calculating the %O2 in Air 47
E. LOCKing and unLOCKing Display Head 48
F. Using the Configuration Tool Software 49

Warranty and Disclaimers 45

i
 Introduction
The NOx 5210

The NOx 5210 is a compact, ceramic sensor-based NOx and O2 analyzer for the development
of engines and their aftertreatment systems. Its features include:

• Single or dual channel NOx sensor operation

• Works with Type T, Type G, and the “Original” NOx sensors1
• NOx 5210 systems can be linked together for multi-cylinder monitoring
• Wide range of operation: NOx : 0 to 5000 ppm
λ : 0.4 to 25.0
AFR : 6.0 to 364.0
Φ : 0.04 to 2.5
%O2 : 0.0 to 25.0
FAR2 : 27 to 1667
• Pressure compensation3 for NOx, λ, AFR, Φ, %O2, and FAR
• Can specify any fuel type by H:C, O:C, and N:C ratios, including H2
• Exhaust pressure measurement range3: 0 to 517 kPa (75 Psia)
• All sensor parameters available for display and output
• Calibration data for NOx sensor stored in sensor’s connector
• Six programmable 0 to 5V or 0 to 1V analog outputs
• Simulated EGO (exhaust gas oxygen) sensor outputs
• CAN output and .dbc generation software
• Up to 100 m between NOx sensor and display possible
• “Lockout” feature for front panel of display
• Power on/off can be controlled by external “key” signal
• 11-28 VDC and 95-250 VAC4 operation

The NOx 5210 analyzer can have one or two channels. Each channel uses one of three NOx
sensors (and its corresponding control module). Type T NOx sensors are recommended for
general-purpose NOx measurement for combustion processes that can be rich, lean, and
stoichiometric (i.e. spark ignition engines). Type G NOx sensors are recommended for NOx
measurement of combustion processes that are only lean of stoichiometric (i.e. diesel
engines). The “Original” NOx sensor was the old “general-purpose” NOx sensor and has
been replaced by the Type T. All NOx sensors have sensitivities to NH3 (ammonia).

1
When supplied with matching NOxCANt, NOxCANg, or NOxCAN modules.
2
FAR x 10000 is displayed. This is the most commonly used way to express FAR. For example, with an
H:C=1.85 fuel, Lambda=1 is FAR=686.8.
3
Optional.
4
With optional P/N 04-01 AC/DC Power Supply.

1
NOx 5210 Kit Contents

The following items are included with a single-channel, NOx 5210 kit:

Item No. Description Part Number

1. NOx 5210 Display Head 01-01

2. NOxCANt Module (for Type T sensor), or 02-07

NOxCANg Module (for Type G sensor), or 02-03
NOxCAN Module (for “Original” sensor) 02-02

3. NOx Sensor, Type T (18mm x 1.5mm thread), or 06-05

NOx Sensor, Type G (20mm x 1.5mm thread), or 06-02
NOx Sensor, Original (18mm x 1.5mm thread) 06-01

4. Inconel Shield (2 required), 12-09

Only installed on Original NOx sensor

5. Eurofast 12 mm Cable, 4 m 09-01

6. Eurofast 12 mm Cable, 2 m 09-02

7. Flexi-Eurofast 12mm Cable, 0.3 m, (3 required) 09-04

8. Eurofast “T”, (4 required) 09-05

9. Eurofast Termination Resistor, (3 required) 09-06

10. Lambda/NOx Sensor Cable, 1 m 10-02

11. DC Power Cable, Banana Plugs 11-16

12. Female Eurofast to DB9F 11-05

13. Key-on Cable, 2 m 11-08

14. 5200 Series Analyzer and Module Manuals 13-01

and Configuration Software, CD

15. Boss & Plug for Type G NOx sensor 12-28

(20mm x 1.5mm), only supplied with Type G sensor

2
For pressure-compensation, these additional items are included (per NOx channel):

Item No. Description Part Number

1. Pressure Sensor with ¼” tube fitting (USA), or 07-01

Pressure Sensor with 6 mm tube fitting (Metric) 07-02

2. Module Y Cable 10-21

3. Pressure Sensor Cable, 1 m 10-04

4. Pressure Line Assembly, 28”, (USA), or 12-08A

Pressure Line Assembly, 711 mm, (Metric) 12-11A

For a dual-channel kit, these additional items are included:

1. NOxCANt Module (for Type T sensor), or 02-07

NOxCANg Module (for Type G sensor), or 02-03
NOxCAN Module (for “Original” sensor) 02-02

2. NOx Sensor, Type T (18mm x 1.5mm thread), or 06-05

NOx Sensor, Type G (20mm x 1.5mm thread), or 06-02
NOx Sensor, Original (18mm x 1.5mm thread) 06-01

3. Inconel Shield (2 required), 12-09

Only installed on Original NOx sensor

4. Eurofast 12mm Cable, 2 m 09-02

6. Flexi-Eurofast 12mm Cable, 0.3 m 09-04

7. Eurofast “T” 09-05

8. Lambda/NOx Cable, 1m 10-02

9. Boss & Plug for Type G NOx sensor 12-28

(20mm x 1.5mm), only supplied with Type G sensor
Optional Items:

1. Lambda/NOx Sensor Cable, 2m or 3m 10-03 (2m) or 10-37 (3m)

2. Pressure Sensor Cable, 2m or 3m 10-05 (2m) or 10-40 (3m)
3. AC/DC Power Supply, Universal 24VDC @ 4.2A 04-01
4. Vboost Supply, 10-14VDC to 24VDC @ 14.5A 04-02
(helps to avoid battery drop-out issues during cold starts)
5. Ceramic Sensor Heater Kit (recommended for original NOx sensor) BTU200

3
 Safety Warnings
In installation and use of this product, comply with the National Electrical Code and any
other applicable Federal, State, or local safety codes.

The NOx sensor is heated, gets hot, and can burn you.

Always wear eye protection when working near engines, vehicles, or machinery.

During installation, turn off the power and take all other necessary precautions to prevent
injury, property loss, and equipment damage. Do not apply power until all wiring is
completed.

Never work on a running engine.

When installing the NOx 5210s cabling and sensor(s) on a stopped engine, it is best to think-
out your moves before you make them.

Route and cable-tie all cables away from hot, moving, sharp, or high voltage (spark) objects.

Take into consideration the movement of the engine, chassis, and wind buffeting when
instrumenting the engine.

Clear tools away from the engine before starting.

Operate the engine only in a well ventilated area and never when you or one of your co-
workers is tired.

When operating the NOx 5210 in a moving vehicle, the operator should keep his or her eyes
on the road.

One measure of professionalism is how much you and your co-workers can accomplish
without an injury. Always be at your professional best. Think and act with safety in mind.

4
 How to Use
Hooking up the NOx 5210

The NOx 5210 kit consists of 4 parts:

1. The display head

2. The module(s)1
3. The sensor(s)
4. Cabling

The NOx 5210 is unique in that it puts a control module close to the NOx sensor. There are
several advantages of doing this; the main ones are: improvements in signal-to-noise ratio,
multi-channel capability, simplified cabling, and an almost unlimited sensor-to-display head
distance.

The cable between the display head and module(s) is called the EIB (ECM Instrument Bus)
and carries signal and power. There must be a termination resistor at each end of the EIB.
The EIB can be powered at either the module end (Figure 1) or the display head end (Figure
2). To minimize the power voltage drop on the EIB, it is preferable to power the EIB from
the end closest to the module(s) because that is where most of the power is being consumed
(by the NOx sensor).

Branches/drops to display head(s) and module(s) are made from tees attached to the EIB. Up
to 32 display heads and modules (total) can exist on the same EIB. The EIB cable, tees, and
termination resistors are industry-standard Eurofast 12 mm. The EIB can be extended to a
length of 100 m.

The NOx 5210 can be turned on and off by the PWR button on the front of the display head
or by a voltage signal (2.7 - 32 V) applied to the KEY connector on the back of the display
head. The current requirements of this voltage signal are very low (100 µA).

After being turned on, the display head will test both displays and all leds and then show:
1. The display head’s serial number
2. The version of the display head’s software
3. The calibration date of the display head (MM.DD YYYY)
4. The serial number (see Figure B1) of the NOx module assigned to the upper channel
and the serial number of the NOx module assigned to the lower channel.
“….” means no NOx module has been assigned to the channel.
5. Parameter data from the NOx module assigned to that channel.
Figures 3 through 5 show details and part numbers of components in Figures 1 and 2.
Optional components are also shown.

1
Modules can be setup in EIB Mode or Stand-alone Mode. When the modules are used with a display head,
they must be in EIB mode. See Appendix B for more information.

5
 EIB with Power Entry at Module End

Connect
Connect Power Entry

Module
CAN

EIB Connector

Display Head

Pressure
NOx Sensor
Sensor

Figure 1: NOx 5210 with Power Entry at Module End

6
 EIB with Power Entry at Display Head End

Connect

Module

Power Entry

CAN

EIB Connector

Display Head

NOx Sensor Pressure

Sensor

Figure 2: NOx 5210 with Power Entry at Display Head End

7
 P/N 09-06 P/N 09-01, 4 m P/N 09-02, 2 m
Eurofast Termination Eurofast 12 mm P/N 09-05 Eurofast 12 mm
Resistor Cable Eurofast “T” Cable

P/N 09-04. 0.3 m

Flexi-Eurofast
Cable

P/N 01-01 P/N 02-02 P/N 04-01 P/N 11-16

NOx 5210 NOxCAN Module, or AC/DC Power Supply, DC Power Cable,
Display Head P/N 02-03 Universal, 24 V Banana Plugs (shown),
NOxCANg Module, or or P/N 11-15 (Spades)
P/N 02-07
NOxCANt Module
Figure 3a: Part Numbers of Components on EIB

Figure 3b: Add above in Location “2” for Second NOx Channel

8
 P/N 11-05
Female Eurofast
P/N 09-05 to DB9F
Eurofast
EIB “T” P/N 09-04
P/N 11-08, 2 m
Key-on Cable Eurofast
(2.7-32 V) Termination
Resistor

CAN
500 kHz
Broadcast

P/N 09-04, 0.3 m

Flexi-Eurofast CAN Bus P/N 13-01, Manuals and
Cable Connector Configuration Tool

EIB
P/N 01-01 Connector
NOx 5210
Display Head P/N 12-01
19” Rackmount Panel

Figure 4a: Part Numbers of Components near Display Head

Figure 4b: Front and Back of Display Head

9
 P/N 02-02
NOxCAN Module, or
P/N 02-03
NOxCANg Module, or
P/N 02-07
NOxCANt Module
P/N 06-01, Original NOx Sensor, or
P/N 06-02, Type G NOx Sensor, or
P/N 06-05, Type T NOx Sensor P/N 10-21, 0.2 m,
Module Y Cable

P/N 10-02, 1 m
Lambda/NOx Cable, or
P/N 10-03, 2 m, or
P/N 10-04, 1 m
P/N 10-37, 3 m
Pressure Cable, or
P/N 10-05, 2 m, or
P/N 10-40, 3m

P/N 12-08A, Pressure

Line Assembly, 19”,
(USA), or P/N 12-11A,
483 mm, (Metric)

Connect

P/N 07-01 Pressure Sensor,

18mm x 1.5mm (Original or 0-75 psia, ¼”, (USA), or
Type T), or P/N 07-02, 0-517 kPa, 6 mm, ¼” NPT (USA)
20mm x 1.5mm (Type G) (Metric) ¼” ISO (Metric)

Figure 5: Part Numbers of Components near Module

10
Mounting the NOx Sensor and Pressure Sensor

NOx Sensor

• Thread is 18mm x 1.5mm (Original and Type T Sensor) or 20mm x 1.5mm (Type G
Sensor)

• Mount between 300 mm from exhaust valve and ten exhaust diameters upstream of
exhaust end. Preferentially mount downstream of turbocharger and upstream of
exhaust catalyst.

• Do not exceed 850 °C exhaust gas temperature at location of sensor.

• Mount where condensed material will not collect on the sensor.

• Run tap into thread in exhaust before screwing in sensor.

• Put antiseize on threads and lightly tighten sensor.

• Occasionally run tap through mounting boss to clean threads.

• Occasionally clean threads on sensor with small metal brush.

• Do not operate engine with NOx sensor not being powered.

• Route NOx sensor cable away from hot, moving, sharp, or high voltage (spark) wires.

Pressure Sensor

• Do not mount pressure sensor directly to exhaust. Always use the supplied stainless
steel/teflon pressure line assembly between the engine’s exhaust system and the
pressure sensor. The stainless steel end goes towards the engine.

• Do not modify the length or diameter of the pressure line assembly.

• Thread on pressure line assembly is ¼” ISO (Metric) or ¼” NPT (USA).

• Measure pressure within 50 mm of NOx sensor.

• Locate pressure sensor where temperature is between -20 and 80 °C.

• Do not allow condensed material to collect in pressure line assembly.

• Run tap into threads in exhaust before screwing in pressure line assembly.

• Put antiseize on threads.

• Route pressure sensor cable away from hot, moving, sharp, or high voltage (spark)
wires.

11
Front Panel and the “SYS” Key

The NOx 5210 display head can be thought of as two single-channel display heads in one
package. One NOx module can be assigned to the upper display, upper four leds, and analog
outputs 1, 2, 3 (i.e. the upper channel) and a second NOx module can be assigned to the
lower display, lower four leds, and analog outputs 4, 5, 6 (i.e. the lower channel). Or one
NOx module can be assigned to both channels. If no module is assigned to a channel, “….”
appears on that channel’s display. More than two NOx modules can exist on the EIB but a
given display head can only show data from two of them. Adding another display head to the
EIB will allow data from another two NOx modules to be displayed.

The display head has two modes of operation: RUN (when measurements or error codes are
displayed) and SYS (where the instrument is set-up). The SYS key toggles between the
modes.

When in RUN mode, the parameter being displayed is indicated by leds to the right of the
display. There are four leds for each display and each led can be red or green. Five
parameters (NOx, %O2, λ, AFR, Φ) are fixed and three (P1, P2, P3 or P4, P5, P6) are
programmable from the list of parameters in Table 2. The ↑ and ↓ keys select which of the
eight parameters are displayed (unless the display is LOCKed, see below).

While in RUN mode, pressing the ENT key will toggle between the ↑ and ↓ keys changing
parameters on one channel’s display to changing parameters on the other channel’s display.

In RUN mode, four things other than data can be displayed:

1. “ERR” and “####” where “####” is an error code. See Appendix C.

2. “….” which means that a NOx module has not been assigned to that channel.
See MOd Setup Option.
3. “----“ which means that the display head has an internal problem.
4. “XXXX” which means that the display is not receiving any data.

When first entering SYS mode, either “MOd” will be on the upper display or “LOCK” will
be on the lower display. If “MOd” is displayed, the ↑ and ↓ keys will roll through the setup
options (see Table 1). First the options for the upper channel are shown on the upper display,
followed by identical options for the lower channel on the lower display, ending with the
global CONF (Configuration) setup. Pressing the ENT key will select the displayed setup
option and allow its programming.

If “LOCK” is displayed, the display head has been locked and neither the parameters
displayed nor the instrument setup can be changed until it is unlocked. Appendix E describes
how to LOCK and unLOCK the display head.

12
Setup Option Level 1 Level 2 Level 3 Function
MOd Select module s/n [NONE]
RATE Set display update rate [FAST]
FUEL Program fuel H:C,O:C,N:C and if H2 [1.85,0,0,NO]
AOUT A1 (upper channel) Program analog output 1 [NOx,0,2000]
A2 (upper channel) Program analog output 2 [O2,-25.00,25.00]
A3 (upper channel) Program analog output 3 [LAM,0.400,25.00]
A4 (lower channel) Program analog output 4 [NOx,0,2000]
A5 (lower channel) Program analog output 5 [O2,-25.00,25.00]
A6 (lower channel) Program analog output 6 [LAM,0.400,25.00]
dISP P1 (upper channel) Program upper display parameter P1 [FAR]
P2 (upper channel) Program upper display parameter P2 [P]
P3 (upper channel) Program upper display parameter P3 [O2]
P4 (lower channel) Program lower display parameter P4 [FAR]
P5 (lower channel) Program lower display parameter P5 [P]
P6 (lower channel) Program lower display parameter P6 [O2]
CAL O2 SPAN Calibrate NOx sensor (O2 measurement function)
FACT Reset NOx sensor to factory calibration for O2
AGEF Show age factor for NOx sensor
EXIT
NOX ZERO Calibrate NOx sensor zero (NOx measurement function)
SPAN Calibrate NOx sensor span (NOx measurement function)
FACT Reset NOx sensor (zero and span) to factory calibration for NOx
CURV (for Type G NOx sensor only) NOx reading to match engine
(wet) data or model gas data (ENGW or MODL), [ENGW]
GAMM ENGW (for Type G NOx sensor only) O2 compensation coefficients
for engine NOx numbers [GAMMA = 0, BETA = 0]
MODL (for Type G NOx sensor only) O2 compensation coefficients
for model gas NOx numbers [GAMMA = 1, BETA = 0.2]
EXIT
P UNIT Choose pressure units [KPA]
N, C Enter pressure sensor calibration numbers
AVG ILAM Program Ip1,%O2,λ,AFR,Φ,FAR averaging [0.375]
PLAM Program P (pressure) averaging [0.375]
I2NX Program Ip2, NOx averaging [0.375]
SKEW NOx Program gain and offset modifier [1,0]
P Program gain and offset modifier [1,0]
AFR Program gain and offset modifier [1,0]
PHI (Φ) Program gain and offset modifier [1,0]
FAR Program gain and offset modifier [1,0]
LAM (λ) Program gain and offset modifier [1,0]
O2 Program gain and offset modifier [1,0]
CONF LEdS Set display intensity [3333]
1V4V Check analog outputs at 1V and 4V
CAN IdS Program CAN addresses and produce .dbc file [1~5]
RATE Program CAN transmit rate [5 ms]
BAUd Program CAN baud rate [500k]
MOdE Select parameter list [ENHd] and lock display
FACT RST Reset all but FUEL, N, C, ILAM, PLAM, I2NX and …
EXIT NOx sensor user calibration to factory defaults

MOd ~ CAL appear on the upper or lower display for the upper or lower channel. CONF is for global setup.
All entries must be followed by pressing the ENT key. Default values shown in square parentheses.
Table 1: Menu Tree for NOx 5210

13
MOd (Module) Setup Option

In MOd setup, the serial number of the NOx module assigned to the upper or lower channel
is entered. The serial number is written on a label on the module (see Figure B1). The
module assigned to the upper channel will send information to the upper display and the
analog outputs 1, 2, and 3. The module assigned to the lower channel will send information
to the lower display and the analog outputs 4, 5, and 6. The same module can be assigned to
both channels.

After entering MOd (i.e. press ENT when “MOd” is displayed), the serial numbers of the
available modules on the EIB will displayed. Select using ↑ and ↓ followed by the ENT key.

RATE Setup Option

Different display update rates can be assigned to the upper and lower displays. The selected
display update rate does not affect the analog output update rate, the CAN transmission rate.

FUEL Setup Option (H:C, O:C, N:C, H2)

Fuel H:C, O:C, and N:C ratios and whether or not the fuel is H2 can be programmed. This
can be different for the module assigned to the upper channel and the module assigned to the
lower channel (unless the same module is assigned to both channels). The ENT, ↑, and ↓
keys are used for programming. If you get into trouble when programming, press the SYS
key twice to exit and re-enter setup to try again. Fuel H:C, O:C, and N:C ratios and whether
or not the fuel is H2 is information stored in the NOxCAN module.

AOUT (Analog Output) Setup Option (A1 to A6)

The display head has six programmable analog outputs. Each output can be programmed as 0
to 5V, 0 to 1V, or as an EGO (exhaust gas oxygen) sensor simulated output. The analog
outputs are updated every 5 ms based on information sent to it by a NOx module every 5 ms.
5 ms is the maximum rate and is not programmable. The module averages the data before it
is sent at this 5 ms rate. There is one programmable averaging filter for Ip1, λ, AFR, Φ,
%O2, FAR (ILAM), one for pressure (PLAM), and one for Ip2, NOx (I2NX). See CAL
Setup Option (AVG Suboption) for more information.

Parameter information from the module assigned to the upper channel can be sent to analog
outputs 1, 2, and 3. Parameter information from the module assigned to the lower channel
can be sent to analog outputs 4, 5, and 6.

The parameter selected to drive an analog output can be anything from Table 2 if the CONF
MOdE has been set to ENHd (see CONFIG Setup Option) or a subset of Table 2 if the
CONF MOdE has been set to STNd.

Here is an example of setting the analog output 2 (i.e. A2):

1. Press the SYS key until “MOd” is displayed.

2. Press the ↓ key until “AOUT” is on the top display. Then press the ENT key.
3. Press the ↓ key until “A2” (analog output 2) is on the display. Then press the ENT
key.

14
 4. Press the ↑ and ↓ keys until the parameter (see Table 2) that will drive A2 is
displayed. Then press the ENT key. Keep in mind that if CONF MOdE is set to
STNd, only a subset of Table 2 will be available.
5. Press the ↑ and ↓ keys to select 0V to 5V, 0V to 1V, or EGO sensor simulated output.
Then press the ENT key. EGO sensor simulation is only available on λ, AFR, Φ,
%O2, FAR parameters.
6. When 0V is displayed, press ENT. Using the ↑, ↓, and ENT keys, set the parameter
value that you want to result in an analog output voltage of 0V on analog output 2.
The first time you do this, it may be a little tricky. You are setting one digit at a time
and for some numbers, the display will shift to the left so you can set the right-most
digits. If you get into trouble when programming, press the SYS key twice to exit and
re-enter setup to try again.
7. When 5V (or 1V) is displayed, press ENT. Using the ↑, ↓, and ENT keys, set the
parameter value that you want to result in an analog output voltage of 5V (or 1V) on
analog output 2.
8. If you want the EGO sensor simulated output, when EGO is displayed, press ENT.
Using the ↑, ↓, and ENT keys, set the parameter value that you want the lean-to-rich
(0V-to-1V) transition to occur at. 0V will be output when lean of the programmed
value and 1V will be output when rich of the programmed value.
9. When “AOUT” is displayed, press SYS to return to RUN mode.

For analog outputs 4, 5, and 6, your entries will be shown on the bottom display.

15
Name Full Parameter Name Parameter Description
NOx NOx (ppm) NOx
O2R %O2real (%) %O2 before addition of Delta O2 curve
IP1 Ip1 (µA) Pressure-compensated Ip1 sensor pumping current
IP2 Ip2 (µA) Pressure-compensated Ip2 sensor pumping current
RPVS RPVS (ohms) NOx sensor internal VS cell resistance
VHCM VH Commanded (V) Desired heater voltage commanded by the module
VS VS (V) NOx sensor internal VS cell voltage
VP1P VP1P (V) NOx sensor Ip1 pumping voltage
VP2 VP2 (V) NOx sensor Ip2 pumping voltage
VSW Vsw (V), n/a for Type G Supply Voltage at the module. Not available for Type G.
VH VH Measured (V) Actual heater voltage at the module
TEMP Circuit Board Temp (°C) Temperature of the module circuit board
IP1R Ip1raw (bits) NOx sensor Ip1 pumping current (unsigned integer format)
IP2R Ip2raw (bits) NOx sensor Ip2 pumping current (unsigned integer format)
ERFL Error bit flags (bits) Module error flags (unsigned long format)
ERCd ECM CANOpen Error Code ECM CANOpen Error Code
PR10 Praw10 (bits) 10 bit Pressure sensor output voltage (unsigned integer format)
PCF Pressure Correction Factor NOx sensor Ip1 Pcomp correction factor (x 10000)
PCFE, O2E ECM diagnostic parameters
IP1E, PE ECM diagnostic parameters
P P (mmHg) Pressure sensor measured pressure (absolute) in mmHg
LAMR LAMBDAreal Lambda before addition of Delta Lambda Table
AFR Air-Fuel Ratio Air-Fuel ratio calculated using LAMBDA (see below)
PHI PHI PHI = 1/LAMBDA
FAR FAR*10000 FAR = (1/AFR) * 10000
LAM LAMBDA Lambda after addition of Delta Lambda Table
O2 O2 (%) %O2 after addition of Delta O2 Table
IPX Ip1 non Pcomp (mA) Non-pressure compensated NOx sensor Ip1 pumping current
PVLP P (V) Raw volts from pressure sensor
PKPA P (kPa) Pressure sensor measured pressure (absolute) in kPa
PBAR P (bar) Pressure sensor measured pressure (absolute) in bar
PPSI P (psi) Pressure sensor measured pressure (absolute) in psi
IP3 Ip3 (µA) (Type G only) NOx sensor Ip3 pumping current
Ip2 non Pcomp (µA)
IP2X Non-pressure compensated NOx sensor IP2 pumping current
(Type G and T only)
NOx Pressure Correction NOx sensor Ip2 pressure compensation correction factor x
NCF
(Type G and T only) 10000

Table 2: Parameter List for the NOx 5210

16
dISP (Display) Setup Option (P1 to P6)

Parameter information from the NOx module assigned to the upper channel can be displayed
as parameters P1, P2, and P3. Parameter information from the NOx module assigned to the
lower channel can be displayed as parameters P4, P5, and P6.

The parameter selected as P1, P2, etc can be anything from Table 2 if the CONF MOdE has
been set to ENHd (see CONFIG Setup Option) or a subset of Table 2 if the CONF MOdE
has been set to STNd.

Here is an example of setting displayed parameter P2:

1. Press the SYS key until “MOd” is displayed.

2. Press the ↓ key until “dISP” is on the top display. Then press the ENT key.
3. Press the ↓ key until “P2” is on the display. Then press the ENT key.
4. Press the ↑ or ↓ key until the parameter (see Table 2) that will be P2 is displayed.
Then press the ENT key. Keep in mind that if CONF MOdE is set to STNd, only a
subset of Table 2 will be available.
5. When “dISP” is displayed, press SYS to return to RUN mode.

If in the above example, displayed parameter P4 was being programmed, dISP, P4, and your
entries will be shown on the bottom display.

CAL (Calibrate) Setup Option for Type T and Type G NOx Sensors

This section is for Type T (uses NOxCANt module) and Type G (uses NOxCANg module)
NOx sensor applications only. For “Original” NOx sensor applications (uses NOxCAN
module), see the next section.

NOx sensors supplied with the NOx 5210 are factory calibrated. This calibration is stored in
a memory chip inside the sensor’s connector. With use, NOx sensors can age requiring
recalibration to maintain measurement accuracy. Recalibration can be performed by the user
or by sending the sensor back to ECM.

There are two parts of the NOx sensor: the O2 (Lambda, AFR, FAR, PHI) measuring part and
the NOx measuring part. Recalibration consists of one ZERO and two SPANs. They should
be performed in the following order:

1. SPAN the O2 measurement (see CAL, O2, SPAN Option)

2. ZERO the NOx measurement (see CAL, NOX, ZERO Option)
3. SPAN the NOx measurement (see CAL, NOX, SPAN Option)

It is important to realize that when in the exhaust of a running engine, the NOx sensor is
seeing H2O as just another gas. Therefore, it will report “wet” %O2 and NOx ppm numbers.
Classical gas analysis equipment (ex. NOx chemiluminescent analyzer (CLA)) typically (but
not always) has the water removed from the gases before they reach the analyzer. Thus
classical gas analyzers will report “dry” numbers which are always greater than “wet”
numbers. When comparing “wet” to “dry” numbers, make sure to correct for the removed
water.

17

O2

The O2 SPAN function is for the recalibration of the NOx sensor’s %O2, λ, AFR, Φ, and
FAR measurements. This recalibration is stored in the sensor’s memory chip and is used
instead of the factory calibration. The FACT function cancels the user calibration resulting in
the factory calibration being used.

SPAN (for %O2, λ, AFR, Φ, and FAR measurements)

To perform an O2 span:

1. A span should be performed after the NOx sensor has been on for at least 20 minutes.
2. Put the NOx sensor and pressure sensor (if so equipped) in ambient, stationary air.
Pressure during NOx sensor calibration is required if the calibration is to be pressure
compensated.
3. Calculate the %O2 in air. The %O2 of air with no humidity is 20.945. This
percentage decreases with increased humidity. To calculate the %O2 in non-zero
humidity air, use the Configuration Tool Software or refer to Appendix D. 20.7 is a
common number.
4. Press the SYS key until “MOd” appears.
5. Press the ↓ key until “CAL” is on the display of the channel to be calibrated. Then
press the ENT key.
6. With “O2” on the display, press the ENT key.
7. With “SPAN” on the display, press the ENT key.
8. Using the ↑ and ↓ keys, change the display to show the %O2 in air determined in 3
(above). Press the ENT key.
9. When “CAL” is displayed, press SYS to return to RUN model. See AGEF (below).
10. The user calibration is written into the memory chip in the NOx sensor’s connector
and will be used to calculate %O2, λ, AFR, Φ, and FAR. If the NOx sensor is
removed and installed on another module, this user calibration will be used with the
new module.

FACT (return to factory %O2, λ, AFR, Φ, and FAR calibration)

To return to the factory calibration of %O2, λ, AFR, Φ, and FAR for the NOx sensor:

1. Make sure the NOx sensor is attached to the module.

2. Press the SYS key until “MOd” appears.
3. Press the ↓ key until “CAL” is on the display of the channel to be calibrated. Then
press the ENT key.
4. With “O2” on the display, press the ENT key.
5. Press the ↓ key until “FACT” is on the display. Press the ENT key. The user O2
SPAN calibration of the NOx sensor is erased and the factory calibration will be used
to calculate %O2, λ, AFR, Φ, and FAR. The NOx sensor age factor (AGEF) will be
reset to “1.00”.

18
AGEF (NOx sensor age factor)

After the NOx sensor has had its O2 measurement spanned, data from this span is compared
to data from the sensor when it was new. From this, a parameter (AGEF) is calculated that
indicates the relative sensitivity of the sensor compared to when it was new. If AGEF is 1.00,
the sensor’s sensitivity has not changed. AGEF goes down with use. When the AGEF is
0.75 or below, it is recommended that the NOx sensor be replaced. AGEF is reset to “1.00”
after the FACT option (see above) has been executed.

NOx

The NOx ZERO and SPAN functions are for the recalibration of the NOx sensor’s NOx
measurements. This recalibration is stored in the sensor’s memory chip and is used instead
of the factory calibration. The FACT function cancels the user calibration resulting in the
factory calibration being used.

The calibration of the NOx measuring portion of the NOx sensor can be performed either in
the exhaust of an engine or using model gases. Model gases are mixtures of NOx, O2, and N2
that come from tanks, are mixed, and then bubbled through water before being passed by the
sensor. The ZERO should be performed before the SPAN.

ZERO (for NOx measurement)

To perform a NOx zero:

1. A zero should be performed after the NOx sensor has been on for at least 20 minutes.
2. (For Type G Only) If the NOx sensor is being zeroed in air, make sure the “CURV”
function is set to “MODL” (for matching a model gas mixture). If the NOx sensor is
being zeroed in an engine, make sure the “CURV” function is set to “ENGW” (for
matching wet NOx numbers from an engine). To set the “CURV” function, see the
“CURV” section (in a few pages).
3. Put the NOx sensor and pressure sensor (if so equipped) in ambient, stationary air or
in the exhaust of a running engine (at low NOx levels as determined by a CLA).
Pressure during NOx sensor calibration is required if the calibration is to be pressure
compensated. IMPORTANT NOTE: Do not zero in pure N2 or pure N2 bubbled
through water! This will damage the sensor.
4. Press the SYS key until “MOd” appears.
5. Press the ↓ key until “CAL” is on the display of the channel to be calibrated. Then
press the ENT key.
6. Press the ↓ key until “NOx” appears. Then pressure the ENT key.
7. With “ZERO” on the display, press the ENT key.
8. Using the ↑ and ↓ keys, change the display to read 0 ppm. Note: In the case of
zeroing in a running engine, the actual NOx may not be 0 ppm (ex. 10 ppm). In that
case, use the arrows to get the display to read the actual ppm NOx (ex. 10 ppm)
measured by a NOx CLA. The zero function supports “off zero” zeroing. Press the
ENT key when the display reads the correct NOx value. When performing a zero
using exhaust gases, wet NOx numbers should be used.
9. (For Type G Only) Program the “CURV” function as “ENGW” before measuring
NOx in an engine.

19
 10. Press SYS to return to RUN mode.
11. The user calibration is written into the memory chip in the NOx sensor’s connector
and will be used to calculate NOx. If the NOx sensor is removed and installed on
another module, this user calibration will go with the sensor and be used with the new
module.

SPAN (for NOx measurement)

To perform a NOx span:

1. A span should be performed after the NOx sensor has been on for at least 20 minutes.
2. (for Type G only) If the NOx sensor is being spanned using model gases, make sure
the “CURV” function is set to “MODL” (for matching a model gas mixture). If the
NOx sensor is being spanned in an engine, make sure the “CURV” function is set to
“ENGW” (for matching wet NOx numbers from an engine). To set the “CURV”
function, see the “CURV” section (in a few pages).
3. To span in the exhaust, put the NOx sensor and pressure sensor (if so equipped) in the
exhaust of a running engine. Using a NOx CLA, determine the wet NOx in the
exhaust. Go to step 6 (below).
4. To span using model gas, put the NOx sensor and pressure sensor (if so equipped) in
an enclosed vessel fed by a NO + O2 (approximately 20%) + N2 mixture that is first
bubbled through water. For a vessel of 50mm diameter, the flowrate should be about
5 lpm. Pressure during NOx sensor calibration is required if the calibration is to be
pressure compensated; however, during the span try to keep the pressure within 7 kPa
(1 psi) of atmospheric. IMPORTANT NOTE: Do not span in a mixture that
contains less than 1% O2! Use approximately 20% O2 for best calibration.
5. Calculate NOx ppm that the NOx sensor is exposed to (NOxactual). Since the NO + O2
+ N2 mixture is being bubbled through water, this value is reduced from the
concentration in the tank of gas.

NOxactual = NOxtank x ((P – Pws)/P) [Equation 1]

where:
NOxactual = actual NOx ppm the NOx sensor is exposed to

NOxtank = NOx ppm in the tank NOx + O2 + N2 mixture

P = the absolute pressure in the vessel

Pws = the saturated water vapor pressure. See Appendix D.

Use the temperature of the water to enter the table.

IMPORTANT NOTE: We have found that the best calibration is performed based
on using measured NOx data from a NOx CLA sampling from the vessel holding the
NOx sensor (i.e. not using the above formula). We believe that this is because of
reactions that occur in the lines from the tanks to the sensor.

6. Press the SYS key until “MOd” appears.

7. Press the ↓ key until “CAL” is on the display of the channel to be calibrated. Then
press the ENT key.

20
 8. Press the ↓ key until “NOx” appears. Then press the ENT key.
9. Press the ↓ key until “SPAN” appears. Then press the ENT key.
10. Using the ↑ and ↓ keys, change the display to read NOxactual calculated above (or
from a NOx CLA if available). Press the ENT key when the display reads the correct
NOx value. When performing a span using exhaust gases, wet NOx numbers should
be used.
11. (for Type G Only) Program the “CURV” function as “ENGW” before measuring
NOx in an engine.
12. Press SYS to return to RUN mode.
13. The user calibration is written into the memory chip in the NOx sensor’s connector
and will be used to calculate NOx. If the NOx sensor is removed and installed on
another module, this user calibration will go with the sensor and be used with the new
module.

FACT (return to factory NOx calibration)

To return to the factory calibration for the NOx sensor:

1. Make sure the NOx sensor is attached to the module.

2. Press the SYS key until “MOd” appears.
3. Press the ↓ key until “CAL” is on the display of the channel to be calibrated.
Then press the ENT key.
4. Press the ↓ key until “NOx” appears. Then press the ENT key.
5. Press the ↓ key until “FACT” is on the display. Press the ENT key. The user
NOx ZERO and SPAN calibration of the NOx sensor is erased and the factory
calibration will be used to calculate NOx.

CURV (for Type G only)

The “CURV” function must be programmed as “ENGW” when the NOx sensor is measuring
NOx in the exhaust of an engine, or programmed as “MODL” when the NOx sensor is
measuring NOx in a model gas. To program “CURV”:

1. Press the SYS key until “MOd” appears.

2. Press the ↓ key until “CAL” is on the display of the channel to be calibrated.
Then press the ENT key.
3. Press the ↓ key until “NOx” appears. Then press the ENT key.
4. Press the ↓ key until “CURV” is on the display. Press the ENT key.
5. Press the ↓ and ↑ keys until “ENGW” or “MODL” is displayed. Press the ENT
key.
6. Press SYS to return to RUN mode.

GAMM (for Type G only)

The NOx-measuring portion of the Type G NOx sensor has a sensitivity to oxygen. To
compensate (i.e. correct) for this sensitivity, the “GAMM” function was added. The oxygen
compensation is different if the NOx sensor is in the exhaust of a running engine or if it is in
model gases. Thus, there are two “GAMM” coefficients (GAMMA, BETA) used when the
sensor is in an engine (entered under “GAMMA”, “ENGW”) and two different “GAMM”
coefficients (GAMMA, BETA) used when the sensor is in model gases (entered under

21
“GAMMA”, “MODL”). ECM factory sets these numbers for each NOx sensor and they
should only be modified after consultation with ECM.

CAL (Calibrate) Setup Option for Original NOx Sensor

This section is for “Original” NOx sensor applications only. This sensor uses a NOxCAN
module. For Type T (uses NOxCANt module) and Type G (NOxCANg module) NOx sensor
applications, see the previous section.

NOx sensors supplied with the NOx 5210 are factory calibrated. This calibration is stored in
a memory chip inside the sensor’s connector. With use, NOx sensors can age requiring
recalibration to maintain measurement accuracy. Recalibration can be performed by the user
or by sending the sensor back to ECM.

There are two parts of the NOx sensor: the O2 (Lambda, AFR, FAR, PHI) measuring part and
the NOx measuring part. The recalibration consists of one ZERO and two SPANs. They
should be performed in the following order:

1. SPAN the O2 measurement (see CAL, O2, SPAN Option)

2. ZERO the NOx measurement (see CAL, NOX, ZERO Option)
3. SPAN the NOx measurement (see CAL, NOX, SPAN Option)

It is important to realize that when in the exhaust of a running engine, the NOx sensor is
seeing H2O as just another gas. Therefore, it will report “wet” %O2 and ppm NOx numbers.
Classical gas analysis equipment (ex. NOx CLA) typically (but not always) has the water
removed from the gases before they reach the analyzer. Thus classical gas analyzers will
report “dry” numbers which are always greater than “wet” numbers. When comparing “wet”
to “dry” numbers, make sure to compensate for the removed water.

O2

The O2 SPAN function is for the recalibration of the NOx sensor’s %O2, λ, AFR, Φ, and
FAR measurements. This recalibration is stored in the sensor’s memory chip and is used
instead of the factory calibration. The FACT function cancels the user calibration resulting in
the factory calibration being used.

SPAN (for %O2, λ, AFR, Φ, and FAR measurements)

To perform an O2 span:

1. A span should be performed after the NOx sensor has been on for at least eight hours
(hanging in air). This is to remove any adsorbed water which can be an issue with the
Originals NOx sensor.
2. Put the NOx sensor and pressure sensor (if so equipped) in ambient, stationary air.
Pressure during NOx sensor calibration is required if the calibration is to be pressure
compensated.

22
 3. Calculate the %O2 in air. The %O2 of air with no humidity is 20.945. This
percentage decreases with increased humidity. To calculate the %O2 in non-zero
humidity air, use the Configuration Tool Software or refer to Appendix D. 20.7 is a
common number.
4. Press the SYS key until “MOd” appears.
5. Press the ↓ key until “CAL” is on the display of the channel to be calibrated. Then
press the ENT key.
6. With “O2” on the display, press the ENT key.
7. With “SPAN” on the display, press the ENT key.
8. Using the ↑ and ↓ keys, change the display to show the %O2 in air determined in 3
(above). Press the ENT key.
9. When “CAL” is displayed, press SYS to return to RUN model. See AGEF (below).
10. The user calibration is written into the memory chip in the NOx sensor’s connector
and will be used to calculate %O2, λ, AFR, Φ, and FAR. If the NOx sensor is
removed and installed on another module, this user calibration will be used with the
new module.

FACT (return to factory %O2, λ, AFR, Φ, and FAR calibration)

To return to the factory calibration of %O2, λ, AFR, Φ, and FAR for the NOx sensor:

1. Make sure the NOx sensor is attached to the module.

2. Press the SYS key until “MOd” appears.
3. Press the ↓ key until “CAL” is on the display of the channel to be calibrated.
Then press the ENT key.
4. With “O2” on the display, press the ENT key.
5. Press the ↓ key until “FACT” is on the display. Press the ENT key. The user O2
SPAN calibration of the NOx sensor is erased and the factory calibration will be
used to calculate %O2, λ, AFR, Φ, and FAR. The NOx sensor age factor (AGEF)
will be reset to “1.00”.

AGEF (NOx sensor age factor)

After the NOx sensor has had its O2 measurement spanned, data from this span is compared
to data from the sensor when it was new. From this, a parameter (AGEF) is calculated that
indicates the relative sensitivity of the sensor compared to when it was new. If AGEF is 1.00,
the sensor’s sensitivity has not changed. AGEF goes down with use. When the AGEF is
0.75 or below, it is recommended that the NOx sensor be replaced. AGEF is reset to “1.00”
after the FACT option (see above) has been executed.

NOx

The NOx ZERO and SPAN functions are for the recalibration of the NOx sensor’s NOx
measurements. This recalibration is stored in the sensor’s memory chip and is used instead
of the factory calibration. The FACT function cancels the user calibration resulting in the
factory calibration being used. The ZERO should be performed before the SPAN.

IMPORTANT NOTE: The calibration of the NOx measuring portion of the Original NOx
sensor should only be performed in the exhaust of a running engine and in comparison to a
NOx CLA (chemiluminescent analyzer). This is because the Original NOx sensor’s

23
calibration is very sensitive to mounting (i.e. exhaust pipe) temperatures and it is difficult to
simulate these temperatures in a model gas apparatus. In addition, it is recommended that a
BTU200 (ceramic sensor heater) be used.

ZERO (for NOx measurement)

To perform a NOx zero:

1. A zero should be performed after the NOx sensor has been on for at least eight hours
(hanging in air). This is to remove adsorbed water which can be an issue with the
Original NOx sensor.
2. Put the NOx sensor and pressure sensor (if so equipped) in the exhaust of a running
engine. Pressure during NOx sensor calibration is required if the calibration is to be
pressure compensated. IMPORTANT NOTE: Do not zero in pure N2 or N2 bubbled
through water! This will damage the sensor.
3. Press the SYS key until “MOd” appears.
4. Press the ↓ key until “CAL” is on the display of the channel to be calibrated. Then
press the ENT key.
5. Press the ↓ key until “NOx” appears. Then pressure the ENT key.
6. With “ZERO” on the display, press the ENT key.
7. Using the ↑ and ↓ keys, change the display to read 0 ppm. Note: In the case of
zeroing in a running engine, the actual NOx may not be 0 ppm (ex. 10 ppm). In that
case, use the arrows to get the display to read the actual ppm NOx (ex. 10 ppm)
measured by a NOx CLA. The zero function supports “off zero” zeroing. Press the
ENT key when the display reads the correct NOx value. When performing a zero
using exhaust gases, wet NOx numbers should be used.
8. Press SYS to return to RUN model.
9. The user calibration is written into the memory chip in the NOx sensor’s connector
and will be used to calculate NOx. If the NOx sensor is removed and installed on
another module, this user calibration will go with the sensor and be used with the new
module.

SPAN (for NOx measurement)

To perform a NOx span:

1. A span should be performed after the NOx sensor has been on for at least eight hours
(hanging in air) or immediately following a zero.
2. To span, put the NOx sensor and pressure sensor (if so equipped) in the exhaust of a
running engine. Using a NOx CLA, determine the wet NOx in the exhaust.
3. Press the SYS key until “MOd” appears.
4. Press the ↓ key until “CAL” is on the display of the channel to be calibrated. Then
press the ENT key.
5. Press the ↓ key until “NOx” appears. Then press the ENT key.
6. Press the ↓ key until “SPAN” appears. Then press the ENT key.
7. Using the ↑ and ↓ keys, change the display to read the wet NOx. Press the ENT key
when the display reads the correct NOx value.
8. Press SYS to return to RUN mode.
9. The user calibration is written into the memory chip in the NOx sensor’s connector
and will be used to calculate NOx. If the NOx sensor is removed and installed on

24
 another module, this user calibration will go with the sensor and be used with the new
module.

FACT (return to factory NOx calibration)

To return to the factory calibration for the NOx sensor:

1. Make sure the NOx sensor is attached to the module.

2. Press the SYS key until “MOd” appears.
3. Press the ↓ key until “CAL” is on the display of the channel to be calibrated.
Then press the ENT key.
4. Press the ↓ key until “NOx” appears. Then press the ENT key.
5. Press the ↓ key until “FACT” is on the display. Press the ENT key. The user
NOx ZERO and NOx SPAN calibration of the NOx sensor is erased and the
factory calibration will be used to calculate NOx.

CAL (Calibrate) Setup Option (P, AVG, SKEW)

P

Pressure sensor calibration numbers (N and C) and displayed pressure units can be
programmed. The “N” and “C” values must match those written on a label on the pressure
sensor. The pressure sensor cannot be user calibrated.

The programmable pressure units are PSIA, KPAA, MMHG (mmHg), BAR, and KGCM
(kg/cm2). All pressures shown are absolute (i.e. not gauge).

AVG

Raw data is sampled from the NOx sensor and pressure sensor every 5 ms. This data is
averaged by the NOx module every 5 ms before being sent to the display head every 5 ms.
For the parameters Ip1, %O2, λ, AFR, Φ, and FAR, the averaging filter (also called recursive
averaging filter or digital low-pass filter) is ILAM. For Ip2 and NOx, the averaging filter is
I2NX. For pressure, the averaging filter is PLAM. How the averaging filters are used is
shown by Equation 2. The averaging filters are user-programmable and can be assigned
values from 0.001 (heavy averaging) to 1.000 (no averaging).

ParameterAveraget+5ms = α x Parametert+5ms + (1 – α) x ParameterAveraget [Equation 2]

25
where:

ParameterAveraget+5ms = the parameter average at time “t+5ms”

α = ILAM (for Ip1, %O2, λ, AFR, Φ, FAR) or

I2NX (for Ip2, NOx) or
PLAM for pressure.

These user-programmable filters range from 0.001 (heavy averaging) to 1.000

(no averaging).

Parametert+5ms = the parameter value at time “t + 5ms”

ParameterAveraget = the parameter average at time “t”

The default averaging filter values are given within square parentheses in Table 1. These
values and the length of the pressure line assembly should not be modified without first
consulting ECM.

SKEW

SKEW allows the parameters NOx, P, AFR, Φ, FAR, λ, and %O2 each to be modified by a
programmable transform of the form:

ParameterSkewed = M x Parameter + B [Equation 3]

where:

ParameterSkewed = NOx, P, AFR, Φ, FAR, λ, or %O2 value after being skewed.

Parameter = NOx, P, AFR, Φ, FAR, λ, or %O2 measurement before being skewed.

M = Skewing gain. The default values for M are 1.000.

B = Skewing offset. The default values for B are 0.000.

The skewed parameters are displayed and output (i.e. analog outputs, CAN).

CONF (Configure) Setup Option (LEdS, 1V4V, CAN, MOdE, FACT)

CONF setup appears at the end of the setup list for the lower channel. To enter CONF, press
the SYS key until “MOd” appears on the upper display, press the ↓ key until “CONF”
appears on the bottom display, and then press the ENT key. CONF relates to display head (as
opposed to NOx module or sensor setup).

26

LEdS

The display intensity is programmable. Press the ENT key when “LEdS” appears on the
lower display, press the ↑ or ↓ keys until the display intensity is suitable, press ENT, and
press SYS to return to RUN mode.

1V4V

This feature commands a 1 V (when “1V” is on lower display) or 4 V (when “4V” is on

lower display) output on all six analog outputs. This feature is useful when troubleshooting
the interface with an external data acquisition device.

CAN

Figure 4a shows cabling connected to the back of the display head for CAN communication.
Depending on where the display head appears in your CAN bus, the termination resistor may
have to be present or removed.

The CAN data communicated is:

1. What is being sent to analog output 1

2. What is being sent to analog output 2
3. What is being sent to analog output 3
4. What is being sent to analog output 4
5. What is being sent to analog output 5
6. What is being sent to analog output 6
7. What is being sent to the upper display (but not averaged by display)
8. What is being sent to the lower display (but not averaged by display)
9. An error code for the upper channel. See Appendix C.
10. An error code for the lower channel. See Appendix C.
11. An auxiliary code for the upper channel.
12. An auxiliary code for the lower channel.

It is important to note that if a parameter that is being displayed is changed (by pressing the ↑
or ↓ key), the CAN data will also be changed to that newly displayed parameter for 7 or 8
(above). Similarly for an analog output. LOCKing the display head can be used to avoid this
problem.

The CAN data is broadcast at 500 kHz in the following format:

CANid byte 0 byte 1 byte 2 byte 3 byte 4 byte 5 byte 6 byte 7

CANid1 What is being sent to analog output 1 What is being sent to analog output 2
CANid2 What is being sent to analog output 3 What is being sent to analog output 4
CANid3 What is being sent to analog output 5 What is being sent to analog output 6
CANid4 What is being sent to upper display What is being sent to the lower display
ERCd Error code for upper display/channel Error code for lower display/channel
Error Error Aux. N/A Error Error Aux. N/A
Code Code Code Code Code Code
Low High Low High

27
Each of the eight parameters in CANid1 to CANid4 is a single-precision 32 bit floating point
number that conforms to the IEEE-754 standard. All eight of these parameters are
transmitted on the CAN bus least significant byte first (Intel format). Parameters 1 through 8
(everything except error codes) sent on the CAN bus are averaged (“AVG”d, see CAL Setup
Option).

Error codes are transmitted with address ERCd. The error codes are 16 bit integers that refer
to those listed in Appendix C. The error codes are transmitted on the CAN bus least
significant byte first (Intel format). The auxiliary code is the countdown number appearing
on the channel’s display. If there is no error or active countdown, an error message is not
broadcast.

Addresses CANid1 through CANid4 and ERCd are user programmable. To program them:
enter SYS mode, ↓ down to “CONF”, press the ENT key, ↓ down to “CAN”, press the ENT
key once (while displaying “CAN”), press the ENT key again (while displaying “IdS”), and
enter them (CId1, CId2, CId3, CId4) one by one (enter number then press the ENT key).
After entering ERCd, “.dBC” will appear on the display. If the CAN port of the NOx 5210 is
connected directly to a PC via a CAN adapter, pressing the ENT key will result in data for the
.dbc file for the current NOx 5210 setup being sent to the PC. This .dbc file can be used with
programs accepting the VectorCAN .dbc format. How to get this .dbc file is explained in
more detail below:

1. Configure the analog outputs and displays as desired. The parameters assigned to the
analog outputs and displays are what will be broadcast on the CAN bus.
2. Connect the NOx 5210 display head directly to the CAN adapter connected to the PC.
There should be nothing else on the CAN bus. Just the display head and the PC.
3. Start the Configuration Program and click on the “Display Head” tab. Select the
CAN adapter being used. Then start the communication.

28
The rate at which CAN data is sent can also be programmed via the “RATE” parameter under
“CAN”. To program how often the CAN data is to be sent: enter SYS mode, ↓ down to
“CONF”, press the ENT key, ↓ down to “CAN”, press the ENT key, ↓ down to “RATE”,
press the ENT key, then enter the rate in ms. The allowable range is 5ms to 9999ms with
5ms being the default.

The CAN baud rate is programmed via the “BAUd” parameter under “CAN”.

4. Click on the “Generate .dbc” button on the PC’s screen. Enter the filename and
directory for the .dbc file.

5. Get to the CAN setup in the display head and enter the desired CAN addresses for
CANid1 to CANid4 (CId1, CId2, CId3, CId4), and ERCd. Then when “.dBC” is
shown on the display, press the ENT key. Within a second, the .dbc file for that
particular NOx 5210 analyzer setup will be sent to the PC. It is a good idea to LOCK
the display head after this (see “MODE” below) since changing a new displayed
parameter or new analog out parameter will change the data transmitted via CAN to
that of the new parameter.

6. The analog parameters are called A#_sn where “#” is the analog output number and
“sn” is the serial number of the display head (ex. A1_45405300). The serial number
is the first thing that is displayed on startup on the display head. The display
parameters are called TopDisp_sn, and BtmDisp_sn. The error codes are called
TopErr_sn, TopAux_sn, BtmErr_sn, and BtmAux_sn. During NOx sensor warm-up
when the display is counting down, TopAux_sn or BtmAux_sn will contain the
countdown number.
7. See Appendix F for additional information.

29

MOdE

“ENHd” and “STNd” refer to whether the full list in Table 2 (for ENHd) or a subset (for
STNd) will be available to assign to an analog output (A1 to A6) or a displayed parameter
(P1 to P6).

“LOCK” locks the selection of displayed parameters and instrument setup. When locked, the
display head can just be turned on and off. It cannot be modified unless unlocked. Refer to
Appendix E for more information.

FACT

“FACT” (in the CONF Setup Option) resets the display head to the default setup. The
default setup is shown [in square parentheses] in Table 1. “FACT” (in the CONF Setup
Option) does not reset FUEL, pressure sensor calibration numbers N and C, averaging filters
ILAM and PLAM, nor does it cancel a user calibration of a NOx sensor. To cancel a user
calibration of a NOx sensor use “FACT” (Twice: once for O2 and once for NOx) in the CAL
Setup Option.

30
 Specifications and Limits
Measurements and Accuracies

Parameter Range Response Time Accuracy

NOx (Type T) 0 to 5000 ppm1 < 1 s6 ±20 ppm (0 to 1000 ppm)
±2.0% of reading (elsewhere)

NOx (Type G) 0 to 5000 ppm2 < 1 s6 ±15 ppm (0 to 1000 ppm)

±1.5% of reading (elsewhere)

NOx (Original) 0 to 5000 ppm1 < 700 ms6 ±30 ppm (0 to 1000 ppm)
±3% of reading (elsewhere)
Lambda (λ) 0.4 to 25 < 150 ms7 ±0.8% (at λ=1)
±1.8% (elsewhere)
AFR 6 to 3643 < 150 ms7 ±0.8% (at 14.56 AFR)
±1.8% (elsewhere)
Equivalence Ratio (Φ) 0.04 to 2.5 < 150 ms7 ±0.8% (at Φ=1)
±1.8% (elsewhere)
FAR 27 to 16673,4 < 150 ms7 ±0.8% (at 687 FAR)
±1.8% (555<FAR<833)
%O2 -25 to 25%5 < 150 ms7 ±0.2 (absolute)
Pressure 0 to 517 kPa, 75 Psia < 50ms8 ±5.2 kPa
±0.75 Psia
1
NOx measurement at all stoichiometries (i.e. λ < 1, λ = 1, λ >1).
2
NOx measurement for only lean stoichiometries (i.e. λ >1).
3
AFR and FAR range given above for a fuel with an H:C ratio of 1.85, however all fuel
types supported by analyzer and programmable by H:C, O:C, and N:C ratios.
4
FAR x 10000 is displayed. This is the most commonly used way to express FAR.
For example, with an H:C=1.85 fuel, Lambda=1 is FAR=686.8.
5
For stoichiometries richer than Lambda=1 (i.e. λ < 1), negative %O2s are displayed.
This novel convention is used by some researchers for lean-burn engines.
6
The response time is affected by averaging filter I2NX (for Ip2, NOx)
See CAL Setup for more information.
7
The response times are affected by averaging filter ILAM (for Ip1, %O2, λ, AFR, Φ, FAR).
See CAL Setup for more information.
8
The response times are affected by averaging filter PLAM (for P).
See CAL Setup for more information.

31
Sensor Limits and Specifications

NOx Sensor

Exhaust Gas Temperature Range: 0 - 850 °C, 32 - 1562 °F

Maximum Exhaust Temperature: 950 °C, 1742 °F
Maximum Rate of Temperature Change: 50 °C/s, 122 °F/s

Fuel Composition:

H:C ratio range: 1.00 - 10.00, or Hydrogen (H2)

O:C ratio range: 0.00 - 10.00
N:C ratio range: 0.00 - 1.00

gasoline: 1.70 < H:C < 2.10, O:C=0.0, N:C=0.0, (1.75 or 1.85 are commonly used)
methanol: H:C=4.0, O:C=1.0, N:C=0.0
ethanol: H:C=3.0, O:C=0.5, N:C=0.0
propane: H:C=2.67, O:C=0.0, N:C=0.0
methane: H:C=4.0, O:C=0.0, N:C=0.0

Maximum allowable levels of fuel "Impurities":

Lead: 0.012 gm/gal., 0.003 gm/ltr.

Phosphorous: 0.0008 gm/gal., 0.00027 gm/ltr.
Sulfur: 0.035% by weight

Do not use the NOx sensor in a heavily-sooting or crankcase-oil-burning engine

because these conditions will shorten the life of the sensor.

Thread Size: 18mm x 1.5mm (Type T and Original NTK). 20mm x 1.5mm (Type G),
Lightly coat with non-lead containing antiseize compound.

The Type T and Original NOx sensor's thread size is identical to that of the
exhaust gas oxygen sensors used in production automobiles with 3-way
exhaust catalysts.

Hex Size: 22 mm

Tightening Torque: 40 ±4 Nm, 30 ±3 ft-lbf

32

Pressure Sensor

Note: Must attach to engine via ECM-supplied pressure sensor tubing only!
Do not directly attach to the exhaust or pressure sensor damage will result.

Diaphragm Material: Stainless steel

Maximum Pressure: 200 Psia, 1379 kPa (absolute)

Operating Temperature Range: -40 to 105 °C

Thread on Pressure Sensor: ¼” NPT

Fitting on Pressure Sensor: Swagelok SS-400-7-4 to mate with ¼” tube (USA) or

Swagelok SS-6MO-7-4 to mate with 6 mm tube (Metric)

Pressure Sensor Tubing

Note: Stainless steel end of tubing towards engine. Teflon end towards pressure sensor.

Mating Thread with Engine: ¼” NPT (USA) or ¼” ISO tapered (Metric)

Tubing Assembled Length: 19” (USA) or 483 mm (Metric)

Tubing Diameter: ¼” (USA) or 6mm (Metric)

Nut, Front Ferrule, Back Ferrule at Pressure Sensor end of Tubing:

Swagelok SS-402-1, SS-403-1, SS-404-1 (USA) or
Swagelok SS-6M3-1, SS-6M4-1, SS-6M2-1 (Metric)

Union between Stainless Steel and Teflon Tubing: Swagelok SS-400-6 (USA) or
Swagelok SS-6MO-6 (Metric)

Fitting on Engine End of Tubing: Swagelok SS-400-1-4, ¼” tube to ¼” NPT (USA) or

Swagelok SS-6MO-1-4RT, 6 mm tube to ¼” ISO tapered (Metric)

33
Output Specifications

Analog Outputs

Output Range (linearized in displayed units): 0 to 5V, 0 to 1V, 20 mA max.

Output Impedance: 2.66 kΩ

Bits Resolution: 12 bits

Update Rate: 5 ms

Isolation: Electrically isolated from power supply ground.

All analog output grounds common.

CAN

Protocol: Broadcast.

Broadcast Rate: Programmable 5 to 9999ms. 5ms default.

Speed: Programmable, 500 kHz default.

Isolation: Electrically isolated from power supply ground.

34
General Specifications

Power

DC: 11 to 28 VDC

Current Draw: 0.5 A (display), 1.2 A steady-state (NOx sensor and module),
On start-up, NOx sensor and module may draw as much as 4 A for 30 s.

Case Ground: The NOx 5210 display head case is connected to power ground via a
2.15 kΩ resistor.

Key-on Signal

“ON” Voltage Level: 2.7 to 32 VDC

Current Draw: 100 µA

Environment

Display Head: -40 to 85 °C, 100% humidity non-condensing, display head is not sealed

Module: -55 to 125 °C, 100% humidity, module is sealed, IP67

Dimensions and Weight

Display Head: 108 mm x 64 mm x 178 mm, 4 ¼” x 2 ½” x 7", (W x H x D)

676 gm, 24 oz

Module: 120 mm x 37 mm x 143 mm, 4 ¾” x 1 ½” x 5 ¾”, (W x H x D)

244 gm, 8.7 oz

35
 Appendix A: 5200 Series Instruments Parts List
01 Display Heads (Just display head. Must add cables, etc.)

01-01 NOx 5210 (just head, no module, no cable, no sensor)

01-02 Lambda 5220 (just head, no module, no cable, no sensor)
01-03 EGR 5230 (just head, no module, no cable, no sensor)
01-04 dashCAN (includes cable and T)
01-05 dashCAN+
01-06 dashCANc

02 CAN Modules (just module)

02-01 LambdaCAN (just module, no sensor, no cables)

02-02 NOxCAN (for original sensor, just module, no sensor, no cables)
02-03 NOxCAN-G (for "G" sensor just module, no sensor, no cables)
02-04 LambdaCANc (just module, no sensor, no cables)
02-05 appsCAN (just module, no cables)
02-06 baroCAN (just module, no sensors, no cables)
02-07 NOxCAN-T (for "T" sensor, just module, no sensor, no cables)
02-08 LambdaCANp (just module, no sensor, no cables)
02-09 LambdaCANd (just module, no sensor, no cables)
02-10 gpCAN (just module, no cables)
02-11 COCO2CAN (just module, no sensor, no cables)

03 Simulators, Heater

03-01 LambdaCAN Sensor Simulator (just module, no cable)

03-02 NOx Sensor Simulator (just module, no cable)
03-03 Ceramic Sensor Heater (just module, no cable)
03-04 NOxg Sensor Simulator (just module, no cable)
03-05 NOxt Sensor Simulator (just module, no cable)
03-06 LambdaCANp Sensor Simulator (just module, no cable)

04 Power Supplies

04-01 AC/DC Power Supply, Universal, 24V

04-02 Vboost Supply, 10~14VDC to 24VDC @ 14.5A
04-03 30A AC/DC Power Supply, 15V, 120VAC
04-04 15A AC/DC Power Supply, 15V, 120VAC
04-05 60A AC/DC Power Supply, PWR 60, 15V, 120VAC

05 Linear O2 (Lambda) and CO/CO2 Sensors

05-01 NTK 6 mA
05-02 Bosch LSU4.2
05-03 Bosch LSU4.9
05-04 NTK 4 mA

36
05-05 Bosch LSU4.2, Type P
05-06 Delphi OSL
05-07 NTK 4mA Cofired (ZFAS-U2)
05-08 Bosch LSU4.9, Type P
05-09 Bosch ADV
05-10 NTK, 6mA, Type P
05-11 Bosch LSU4.2, Type PI (Intake)
05-12 CO, CO2

06 NOx and NH3 Sensors

06-01 NOx Original (use with NOxCAN)

06-02 NOx Type "G" (use with NOxCANg)
06-03 Calibrate NOx Sensor
06-04 Cal Sheet with NOx Sensor
06-05 NOx Type "T" (use with NOxCANt)

07 Sensors

07-01 Pressure, 0-75 psia, 1/4", (USA)

07-02 Pressure, 0-517 kPa, 6mm, (Metric)
07-03 Pressure, Type P, 0-75 psia, 1/4", (USA)
07-04 Pressure, Type P, 0-517 kPa, 6mm, (Metric)
07-05 Pressure, Type KP, 0-100 psia, 1/4", (USA)
07-06 Pressure, Type KP, 0-689 kPa, 6mm, (Metric)
07-07 RH (Humidity) Sensor, ¼” NPT
07-08 Pressure (Lp,C,bCAN only), 0-75 psia, 1/4", (USA)
07-09 Pressure (Lp,C,bCAN only), 0-517 kPa, 6mm, (Metric)
07-10 Pressure (Lp,C,bCAN only), Type KP, 0-75 psia, 1/4", (USA)
07-11 Pressure (Lp,C,bCAN only), Type KP, 0-517 kPa, 6mm, (Metric)

08 Actuators

08-01 Ceramic Sensor Heater Mount for 05-01, 05-04, 05-07, 05-10, 06-01, 06-05, 06-07 Sensors

09 Eurofast Cables, Ts, Term. Resistors, Connectors

09-01 4m Eurofast 12mm Cable

09-02 2m Eurofast 12mm Cable
09-03/n "n"m, Eurofast 12mm Cable
09-03/10 10m, Eurofast 12mm Cable
09-03/20 20m, Eurofast 12mm Cable
09-04 Flexi-Eurofast Cable, 0.3m
09-05 Eurofast "T"
09-06 Eurofast Termination Resistor
09-07 Eurofast Male Connector
09-08 8 Channel Eurofast Hub Block

37
09-09 Termination Resistor for Hub Block

10 Sensor Cables

10-01 Module Y Cable (Superceded by -21)

10-02 1m L/N/C/bCAN Cable, (12 term.)
10-02/25' L/N/C/bCAN Cable, (12 term., teflon)
10-03 2m L/N/C/bCAN Cable, (12 term.)
10-04 1m Pressure Cable (LCAN, NCAN, not Lp,C,bCAN), (4 term.)
10-05 2m Pressure Cable (LCAN, NCAN, not Lp,C,bCAN), (4 term.)
append suffix SD to cable for Teflon (Severe Duty) Version

10-09 Adapter to use P/N 05-01 with AFM1000, M1200, etc

10-12 Adapter to Pressure Sensor Wires

10-14 Adapter to use P/N 2400E-1 sensor (CPC) with LCAN

10-16 Adapter to use P/N 2400E-1S sensor (Fischer) with LCAN

10-17 Adapter to use P/N 1001A-2 (Deutsch) with LCAN
10-21 Module Y Cable (for all except Lp, C, and bCAN)

10-26 1m Humidity Cable (bCAN), (6 term.)

10-27 2m Humidity Cable (bCAN), (6 term.)

10-30 Module Y Cable (for bCAN only)

10-31 1m Extension Cable for 12 terminal Deutsch
10-32 2m Extension Cable for 12 terminal Deutsch

10-34 Module Y Cable (for Lp and CCAN only)

10-35 1m Pressure Cable (Lp,C,bCAN only), (8 term.)
10-36 2m Pressure Cable (Lp,C,bCAN only), (8 term.)
10-37 3m L/N/C/bCAN Cable, (12 term.)
10-38 3m Pressure Cable (Lp,C,bCAN only), (8 term.)
10-39 1-to-4 Pressure Sensor Adapter (for /P kits only. Not for /PB kits)
10-40 3m Pressure Cable (LCAN, NCAN, not Lp,C,bCAN), (4 term.)

38
11 Cables

11-01 DC Power Cable, DB9F, Spades

11-02 DC Power Cable, DB9F, Banana Plugs
11-03 DB9M to CSM Lemo F Adapter (CSM Upstream)
11-04 DB9M to ETAS Lemo Adapter
11-05 Female Eurofast to DB9F
11-06 Male Eurofast to CSM Lemo F Adapter (CSM Downstream)
11-07 In-Line Power Entry Cable
11-08 2m Key-on Cable
11-09 2m Heater Cable
11-10 2m Hub Power/Eurofast Harness
11-11 Simulator (SIM300, 400, 500, 600, 700, 800) Cable

11-14 BNC to Banana Cable

11-15 DC Power Cable, Spades
11-16 DC Power Cable, Banana Plugs
11-17 Deutsch DTM3M to DB9F
11-18 3m DB9 Cable, M-F
11-19 EIB Power Tap to Ceramic Sensor Heater Controller
11-20 25' DB9 M-F Cable
11-21 SIM-200 Calibration Kit
11-22 Left (gray) appsCAN Connector with 300mm Pigtail Wires
11-23 Right (blk) appsCAN Connector with 300mm Pigtail Wires
11-24 Connector Kit: 2 connectors, 24 terminals, 12 plugs
11-25 Male Eurofast to Braided Shield Ground
11-26 Boom Box Cable for CAN Products (80' CAN, 30' Power)
11-27 Boom Box to Hub Springy Cable (1m relaxed, 2m stretched)
10-28 Male Eurofast to DB9F
11-29 Simulator Power Cable
11-30 Simulator LSU4.9 Adapter Cable
11-31 Lemo to Eurofast Adapter Cable for LCANc
11-32 M-F Eurofast Panelmount Connector
11-33 1m CSM F Lemo to DB9F
11-34 1m CSM Power Lemo to Male Eurofast
11-35 Termination Resistor for in F Lemo Package

12 Mounting Panels, Bosses, Probes, and Hardware

12-01 19" Rackmount Panel. Holds up to 4 Displays

12-02 18mm x 1.5mm MS Boss and SS Plug
12-03 18mm x 1.5mm SS Boss and SS Plug
12-04 18mm x 1.5mm Tall Al Boss, Cu Gasket, Al Plug
12-05 1/4" NPT MS Boss and Brass Plug, (USA)
12-06 1/4" NPT SS Boss and Brass Plug, (USA)
12-07 1/4" NPT Al Boss and Brass Plug, (USA)
12-08 Pressure Line Assembly, 1/4" dia, 19", (USA)
12-08A Pressure Line Assembly, 1/4" dia, 28" (USA)
12-09 Inconel Shield

39
12-10 18mm Cu Gasket
12-11 Pressure Line Assembly, 6mm, 483mm, (Metric)
12-11A Pressure Line Assembly, 6mm, 711mm (Metric)
12-12 1/4" ISO tapered MS Boss and Brass Plug, (Metric)
12-13 1/4" ISO tapered SS Boss and Brass Plug, (Metric)
12-14 1/4" ISO tapered Al Boss and Brass Plug, (Metric)
12-15 15A Fuse
12-16 Bifurcated Intake Sample Probe, 8mm
12-17 Replacement Bifurcated Tube, 8mm
12-18 Aluminum Sensor Mounting Block, 18mm
12-19 Individual Cylinder Exhaust Probe, 18mm Sensor (USA)
12-20 Individual Cylinder Exhaust Probe, 18mm Sensor (Metric)
12-21PS Rolling Cart to Support 8 LCAN or NCANs (Pwr & Suc)
12-22 Sampling-Type Exhaust Probe (USA)
12-23 Sampling-Type Exhaust Probe (Metric)
12-24 Small Heated Aluminum Sensor Heater Block, 18mm
12-25 1/4" UNC Module Stacking Standoff
12-26 Small Aluminum Sensor Mounting Block, 18mm
12-27 Cu Gasket for 20mm x 1.5mm Boss and Plug
12-28 20mm x 1.5mm SS Boss and SS Plug for NGK NOx
12-29 18mm x 1.5mm (male) to 1/4" NPT (female)
12-30 Carrying Case, Medium
12-31 Aluminum Sensor Mounting Block, 20mm & 18mm
12-32 Small Aluminum Sensor Mounting Block, 20mm & 18mm
12-33 Pressure Line Assembly (for baroCAN), 1/4", (USA)
12-34 Presure Line Assembly (for baroCAN), 6mm, (Metric)
12-35 Carrying Case for SIM300
12-36 Carrying Case for SIM400
12-37 Carrying Case for SIM500
12-38 Carrying Case for SIM600
12-39 Carrying Case for SIM700
12-40 Individual Cylinder Exhaust Probe, 20mm Sensor (USA)
12-41 Individual Cylinder Exhaust Probe, 20mm Sensor (Metric)
12-42 Aluminum Mounting Plate for 8-ch Block and Modules
12-43 Carrying Case for SIM800
12-44 Multi-channel Cart

13 Software, CAN Adapters, and Manuals

13-01 5200 Series Manuals and Config Software (CD)

13-02 Kvaser Leaf Light CAN Adapter
13-Product Name (Manual)

14 Tools

14-01 18mm x 1.5mm Tap

14-02 18mm x 1.5mm Die
14-03 1/4" NPT Tap
14-04 1/4" ISO Tapered Tap
14-05 Antiseize

40
14-06 Metal Brush
14-07 Lambda Sensor Calibration System
14-08 20mm x 1.5mm Bottoming Tap

41
 Appendix B: Module EIB Mode and Stand-alone Mode
The NOxCAN module can be used in conjunction with a display head (EIB mode) or on its
own (Stand-alone mode). When delivered to be used with a display head, the module is setup
in EIB mode. When delivered to be used alone, the module is setup in Stand-alone mode.

In EIB mode, the module communicates to the display head via a special high-speed
communication protocol. The module must be EIB mode when on the EIB with a display
head. When in Stand-alone Mode, the module communicates via the common 500 kHz CAN
broadcast protocol.

The module must be properly configured in EIB mode or Stand-alone mode depending on
how it will be used.

To convert from one mode to the other requires software reprogramming of the NOx module
(using the Configuration Tool) followed by the removal (set to EIB) or installation (set to
Stand-alone) of a jumper inside the module.

To convert a module from Stand-alone to EIB Mode

(Note: Lambda module shown in pictures but procedure for NOx module is identical)

1. Connect the NOx module to a power supply and a PC (via a CAN communication
adapter) using the cabling shown below. A sensor does not have to be connected to
the module. Note that only one module is connected and the display head is not
involved.

Module Serial P/N 11-02, DC Power Cable,

To power
Number DB9F, Banana Plugs (shown), or
P/N 11-01, DC Power Cable,
DB9F, Spades

“T”
Resistor
To CAN adapter
on PC

Figure B1: NOxCAN Module prepared for Reprogramming

42
2. Install and start the Configuration Tool (software). Click on the “Module” tab.
Select the CAN adapter being used. Then start the communication.

3. Click on the “Set to EIB Mode”. Wait for “Done” Message.

Stop communication and exit program.

43
 4. Take the nut off the end of the module. Use an 18mm socket without the wrench.

5. Release the two tangs at each side of the module.

6. Slide the PCB out. Remove the jumper from JP4. You can hang it on one pin of JP4
when “off”.

Jumper

JP4

44
 7. Make sure both O-rings are on the threaded connector.

8. Slide the PCB into the enclosure until the two tangs “click”.
9. Put the nut on and tighten ONLY ½ turn from where it is seated. If this nut is
tightened too much, the connector will crack and the enclosure will not be sealed.
10. The NOx module is now in EIB mode and can be on the EIB with a display.

To convert a module from EIB to Stand-alone Mode

The process is similar to the previously-described procedure. Note that in EIB mode, the
module will not show up in the device list of the configuration program.

1. Use the Configuration Tool (software) to “Set to Stand-alone Mode”.

2. Install the jumper on JP4 in the NOx module.
3. In Stand-alone Mode, the module will continuously broadcast data via 500 kHz CAN.
For more information, refer to the NOxCAN Module Instruction Manual.

45
 Appendix C: Error Codes and Troubleshooting
If one of the NOx 5210’s displays flashes “ERR” followed by “####” (the Error Code), an
error has been detected in that channel’s module (or attached sensors). The below table lists
the errors. The errors are also flashed on the module’s LED.

Error
Code Module LED Action Description of Error
NONE Green ON All OK (green light constantly on)
0001 Flash Green, 10 hz Sensor warm-up period (not really an error)
0002 Green/Both/Red 2s Power on reset / Init hardware
0011 Pulse Red 1x/2s 16 bit ADC failed to init. Internal module error. Contact ECM.
0012 Pulse Red 1x/2s +Vsw shorted. Internal module error. Contact ECM.
0013 Red ON Sensor turned off (red led constantly on)
0014 Pulse Red 1x/2s NOx sensor heater open / NOx sensor not connected.
0015 Pulse Red 1x/2s NOx sensor heater shorted. Bad NOx cable or sensor.
0021 Pulse Red 2x/2s Memory chip in NOx sensor’s bus shorted. Bad cable or sensor.
0022 Pulse Red 2x/2s No memory chip in NOx sensor detected. Bad cable or sensor.
0023 Pulse Red 2x/2s CRC16 error. Bad cable or sensor.
0024 Pulse Red 2x/2s Invalid NOx sensor memory chip parameter. Wrong sensor.
0025 Pulse Red 2x/2s Non-compatible NOx sensor memory chip format (old Rev.)
0031 Pulse Red 3x/2s Vsw < 6 for > 7 sec. Supply voltage too low.
0032 Pulse Red 3x/2s Vsw > 30 V. Supply voltage too high.
0041 Pulse Red 4x/2s VS too high. Bad NOx sensor or cable.
0051 Pulse Red 5x/2s RPVS too high. Sensor too cold, bad, or battery voltage too low.
0052 Pulse Red 5x/2s (VH Commanded – VH Measured) > 0.5 V for > 10 sec. Battery
voltage too low.
0061 Pulse Red 6x/2s VP+ > 6 V. Bad NOx cable or cracked sensor (common).
0062 Pulse Red 6x/2s VP+ < 2 V. Bad NOx cable or cracked sensor (common).
0063 Pulse Red 6x/2s VP2 out of range
0064 Pulse Red 6x/2s 0.25 V > VS+ > 0.75 V for 7.5s. Bad NOx sensor.
0065 Pulse Red 6x/2s User data (span) in NOx sensor memory chip corrupted.
User must reperform NOx sensor span.

The two most common problems are a damaged NOx sensor and a low supply voltage (less
than 11 V). When the NOx sensor is damaged, it must be replaced. It cannot be repaired.
The NOx sensor should be considered an expendable component and a spare kept.

Three other displays of interest are:

1. “….” which means that a NOx module has not been assigned to that channel.
See MOd Setup Option.
2. “----“ which means that the display head has an internal problem.
3. “XXXX” which means that the display is not receiving any data. The NOx module is
disconnected, dead, or the EIB cable is broken.

46
 Appendix D: Calculating the %O2 in Air
The Configuration Tool Software has a routine to calculate the %O2 in air. If the software is
not available, the below may be used.

The oxygen concentration in dry air (zero humidity) is 20.945 and decreases with increasing
humidity. The %O2 in air can be calculated from the barometric pressure (Pb, in mmHg), the
relative humidity (Rh), and the saturated water vapor pressure (Pws, in mmHg) by using the
following formula:

%O2 = 20.945% x (Pb - Pws x (Rh/100)) / Pb

The saturated water vapor pressure (Pws) is a function of the ambient temperature (Ta) and is
given in the table below. For example, at 21 °C, Pws = 18.65 mmHg.

Ta 0 1 2 3 4 5 6 7 8 9
(°C)
Pws (mm Hg)
0 4.579 4.926 5.294 5.685 6.101 6.543 7.013 7.513 8.045 8.609
10 9.209 9.844 10.518 11.231 11.987 12.788 13.634 14.530 15.477 16.477
20 17.535 18.650 19.827 21.068 22.377 23.756 25.209 26.739 28.349 30.043
30 31.824 33.695 35.663 37.729 39.898 42.175 44.563 47.067 49.692 52.442
40 55.324 58.34 61.50 64.8 68.26 71.88 75.65 79.60 83.71 88.02
50 92.51 97.2 102.09 107.2 112.51 118.04 123.80 129.82 136.08 142.60
60 149.38 156.43 163.77 171.38 179.31 187.54 196.09 204.96 214.17 223.73
70 233.7 243.9 254.6 265.7 277.2 289.1 301.4 314.1 327.3 341.0
80 355.1 369.7 384.9 400.6 416.8 433.6 450.9 468.7 487.1 506.1
90 525.76 546.05 566.99 588.60 610.90 633.9 657.62 682.07 707.27 733.24

1 mmHg = 0.01934 lbf/in2 = 1 torr

1 atm = 14.696 lbf/in2 = 760 torr = 101325 N/m2

47
 Appendix E: LOCKing and unLOCKing Display Head
When the display head is locked, the parameters displayed and instrument setup cannot be
modified. The display head can just be turned on and off.

To LOCK the display head

1. Press SYS until “MOd” is displayed.

2. Press ↓ until “CONF” is displayed. Then press ENT.
3. Press ↓ until “MOdE” is displayed. Then press ENT.
4. Press ↓ until “LOCK” is displayed. Then press ENT.
5. “50” will be displayed. Press ↑ until “60” is displayed. Then press ENT.
Display is now LOCKed.

To unLOCK the display head

1. Press SYS until “LOCK” is displayed. Then press ENT.

2. “50” will be displayed. Press ↑ until “60” is displayed. Then press ENT.
Display is now unLOCKed.

If an unauthorized person learns that 60 is the key number, contact ECM.

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 Appendix F: Using the Configuration Tool Software
The ECM Configuration Tool with be used with analyzers (i.e. NOx 5210, Lambda 5220,
EGR 5230). One or more analyzers can be connected to the same CAN bus using the CAN
connector on the back of the analyzers. Make sure that the CAN bus is properly terminated.

The Configuration Tool can be used for the following:

To produce a .dbc file for one or more analyzers on the same CAN bus.
Real-time display of data from analyzers. Only one analyzer’s data is shown at a time.
Log data from one or more analyzers.

Once the analyzers are connected to the CAN bus and turned on, start the Configuration
Tool, select the “Analyzers” tab, select the CAN Adapter, and then press the start button.
“Status:” should change to “Port Opened”.

Producing a .dbc File

Devices receiving CAN messages from one or more analyzers must understand the format of
the messages. A .dbc file is used to describe the format. Using the Configuration Tool, a
.dbc file describing the format of messages from one or more analyzers on the same CAN bus
can be created.

Each analyzer communicates eight pieces of data, two error codes, and two auxiliary codes.
The eight pieces of data are: what is being sent to the six analog outputs and what is sent to
the upper and lower displays. Before producing a .dbc file for the analyzer(s), each analyzer
on the CAN bus should have its displays and analog outputs programmed for the desired
data.

Once the analyzer(s) have been programmed, send (one analyzer at a time) each analyzer’s
message format to the Configuration Tool.

To do this:

In the software, press “Add Device”

On an analyzer, press SYS, arrow down to CONF, press ENT, arrow down to CAN, press
ENT, and with “IdS” on the display, press ENT.
Five CAN ids need to be entered: one each for CID1, CID2, CID3, CID4, and ERCd. These
are entered in decimals. The allowable range is 1 to 2047. If analyzers and modules are on
the same CAN bus (not EIB bus), be careful to avoid using the CAN ids used by the modules.
The CAN ids used by the modules are: 0x00, 0x80 + Module NID, 0x180 + NID, 0x280 +
NID, 0x380 + NID, 0x480 + NID, 0x580 + NID, 0x600 + NID, 0x700 + NID, 0x7E4, and
0x7E5. Note that these module CAN ids are given in hex. CID1 is the CAN id for the data
going to analog outputs 1 and 2. CID2 is for analog outputs 3 and 4. CID3 is for analog
outputs 5 and 6. CID4 is for the upper and lower displays. ERCd is for the error codes and
auxiliary codes. After entering the CAN id for ERCd, “.dBC” will appear on the display.

49
Press ENT and the format of the messages for that analyzer will be sent to the Configuration
Tool.

Each analyzer’s serial number will appear in the “Device:” window list (open window to see
all present) after its message format has been received by the Configuration Tool. When an
analyzer’s serial number is in the “Device:” window, its data will appear at the bottom of the
Configuration Tool’s screen.

After the last analyzer on the CAN bus has sent its message format to the Configuration Tool,
that list of analyzers can be saved using “Save List” and later recalled using “Load List”.
This saves having to resend message formats to the Configuration Tool next time the tool is
used.

A .dbc file for all analyzers in the “Device:” window list is produced by pressing “Generate
.dbc”.

Real-Time Display

When an analyzer’s serial number is in the “Device:” window, its data will appear at the
bottom of the Configuration Tool’s screen.

Logging Data

Analyzers whose serial numbers are in the “Device:” window list can be data logged. Press
the “Log Data” button and follow the instructions. Data is saved in .csv format.

50
 Warranty and Disclaimers
WARRANTY

The products described in this manual, with the exception of the NOx sensor and pressure
sensor, are warranted to be free from defects in material and workmanship for a period of 365
days from the date of shipment to the buyer. Within the 365 day warranty period, we shall at
our option repair such items or reimburse the customer the original price of such items which
are returned to us with shipping charges prepaid and which are determined by us to be
defective. This warranty does not apply to any item which has been subjected to misuse,
negligence or accident; or misapplied; or modified; or improperly installed.

The NOx sensor and pressure sensor are considered an expendable part and as such cannot be
covered by a warranty.

This warranty comprises the sole and entire warranty pertaining to the items provided
hereunder. Seller makes no other warranty, guarantee, or representation of any kind
whatsoever. All other warranties, including but not limited to merchantability and fitness for
purpose, whether express, implied, or arising by operation of law, trade usage, or course of
dealing are hereby disclaimed.

The warranty is void if the display head is opened.

LIMITATION OF REMEDY

Seller's liability arising from or in any way connected with the items sold and/or services
provided shall be limited exclusively to repair or replacement of the items sold or refund of
the purchase price paid by buyer, at seller's sole option. In no event shall seller be liable for
any incidental, consequential or special damages of any kind or nature whatsoever, including
but not limited to lost profits arising from or in any way connected with items sold and/or
services provided to buyer, whether alleged to arise from breach of contract, express or
implied warranty, or in tort, including without limitation, negligence, failure to warn or strict
liability. In no event shall the company's liability to buyer arising out of or relating to the sale
of any product or service exceed the purchase price paid by buyer to the company for such
product or service.

PRODUCT CHANGES

We reserve the right to discontinue a particular product or to make technical design changes
at any time without notice.

51
 ENGINE CONTROL 586 Weddell Drive, Suite 2

ECM AND MONITORING

Sunnyvale, CA 94089-2134
USA
Phone: (408) 734-3433
FAX: (408) 734-3432
Email: [email protected]
Web: www.ecm-co.com

EC DECLARATION OF CONFORMITY

We declare under our sole responsibility that the products:

AFM1540 Lambda Module

AFM1600 Lambda and O2 Analyzer
DIS1000 Display Head
EGR 4830 Analyzer
Lambda 5220 Lambda Analyzer
NOx 5210 NOx Analyzer
EGR 5230 EGR Analyzer
LambdaCAN, LambdaCANc, LambdaCANd, LambdaCANp Lambda Modules
NOxCAN, NOxCANg, NOxCANt NOx Modules
NOx1000 NOx Module
baroCAN Module
dashCAN, dashCANc, dashCAN+
appsCAN
SIM300, SIM400, SIM500, SIM600, SIM700, SIM800
BTU200

To which this declaration relates are in conformity with the essential requirements of the following standards:
EN61326: 1997/A2: 2001 (Class A & Annex A)
EN61010-1: 2001 (Electrical Safety)

And therefore conform to the requirements of the following directives:

89/336/EEC Electromagnetic Compatibility (EMC)
72/23/EEC Low Voltage Directive (LVD)

Ronald S. Patrick
Vice President Sales
July 26, 2012

52
Los Altos, CA 94023-0040 • USA • (408) 734-3433 • Fax: (408) 734-3432 • www.ecm-co.com