TA 1400-0301

Technical Instruction

Emissions monitoring

© INNIO Jenbacher GmbH & Co OG

Achenseestr. 1-3
A-6200 Jenbach, Austria
www.innio.com
 TA 1400-0301
Emissions monitoring

1 Scope ..................................................................................................................................... 1
2 Purpose.................................................................................................................................. 1
3 Safety information................................................................................................................. 2
4 Additional information.......................................................................................................... 2
5 Functional description.......................................................................................................... 2
6 System overview ................................................................................................................... 2
6.1 NOx sensor ............................................................................................................................. 3
6.2 Temperature and pressure sensors for catalytic converter monitoring ................................... 4
6.3 Temperature and flap position of the CL.Air thermal reactor .................................................. 5
7 Handling instructions for the NOx sensor.......................................................................... 5
8 Explanation and notes on emission trend data (DIA.NE XT4) .......................................... 6
9 Emission report..................................................................................................................... 8
10 Emission-related warnings and recommendations for action.......................................... 9
11 Emission-relevant parameters........................................................................................... 12
12 Revision code...................................................................................................................... 14

The target recipients of this document are:

Customers, distribution partners, service partners, commissioning partners, subsidiaries/branches,
Jenbach location
INNIO proprietary information: CONFIDENTIAL
The information contained in this document is the proprietary information of INNIO Jenbacher GmbH &
Co OG and its subsidiaries and is disclosed in confidence. It is the property of INNIO and shall not be
used, disclosed to others or reproduced without express written consent. This includes but is not limited
to use for the creation, manufacture, development or derivation of any repairs, modifications, spare parts,
designs or configuration changes, or for obtaining government or regulatory approval to do so. If consent
is given for reproduction in whole or in part, this notice and the notice set forth on each page of this
document shall appear in any such reproduction in whole or in part.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY

1 Scope
This technical instruction (TA) applies to the following Jenbacher Gas Engines:
• Type 2 engines
• Type 3 engines
• Type 4 engines
• Type 6 engines
• Type 9 engines

2 Purpose
This Technical Instruction (TA) describes the emission monitoring according to VDMA Specification 6299
for verifying the continuous effective operation of the emission control device(s) of the combustion engine
plant. In addition, the display of the visualisation unit on the DIA.NE XT4 is explained, as well as
measures to be taken in case of warning messages.

Author(s): Kecht S. Responsible: Böwing R. Release date: 08/07/2020

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3 Safety information

WARNING
Personal injury
Failure to use personal protective equipment and comply with safety instructions or
employee protection information may lead to personal injury.
Ø Wear the relevant personal protective equipment (PPE).
Ø Observe the safety instructions as per TA 2300-0005.
Ø Observe the employee protection information as per TA 2300-0001.

4 Additional information

Relevant documents:
IW 8057 M0 – NOx
TA 1100-0110 – Boundary conditions for Jenbacher gas engines
TA 1531-0015 – Installation Instructions for Catalysts
TA 1531-0016 – Installation instructions and operating instructions for SCR and OXI silencer
TA 2300-0001 – Employee protection
TA 2300-0005 – Safety instructions

5 Functional description
The emission control system is used for the qualitative monitoring of engine emissions and for monitoring
any exhaust aftertreatment unit that the INNIO Jenbacher GmbH & Co OG features/installs. This is
carried out for nitrogen oxides (NOx) with one or more NOx sensor(s). Temperature sensors and
pressure sensors are used to monitor a catalytic system. In the case of a thermal reactor (CL.Air), the flap
position and the reaction chamber temperature are monitored. In addition, limit values are monitored in
the engine control system and warnings are generated if they are exceeded or not met. Depending on the
warning, the installation operator must take immediate action, within 24 hours, in accordance with the
legal requirements, e.g. 44th German Federal Immission Control Act, (Bundes-Immissionsschutzgesetz -
BImSchV) in Germany, see also chapter ⇨ Emission-related warnings and recommendations for action or
inform the responsible emission authority (refer to the 44th BImSchV, Section 20).
Depending on the access authorization, emission-relevant parameters can be changed. They are also
recorded by the engine control unit and stored with a time stamp and user ID. All measured emission
values, including daily average values for NOx, emission-relevant warnings and parameter changes can
be exported and submitted to the authorities along with the verification measurement. The following figure
shows a schematic system overview. Sensor positions and exhaust aftertreatment systems are listed
where possible.

6 System overview
Possible NOx sensor positions and sensors on exhaust aftertreatment units:

Author(s): Kecht S. Responsible: Böwing R. Release date: 08/07/2020

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Emissions monitoring

System overview of emission monitoring

① Engine ⑥ Exhaust gas heat exchanger
② Turbocharger ⑦ Chimney
③ SCR catalytic converter ⑧ NOx sensor
④ Oxi catalytic converter T Temperature Measurement
⑤ Thermal reactor CL.Air P pressure measurement

6.1 NOx sensor

An NOx sensor can be used to quantify the NOx emissions of the engine. The sensor measures the NOx
and O2 concentration in the exhaust gas. The sensor consists of the following sub-components:
• Control and signal evaluation unit (Sensor Control Unit - SCU) ①
• Sensor cable ② (must not be disconnected from the SCU)
• Sensor element ③

Author(s): Kecht S. Responsible: Böwing R. Release date: 08/07/2020

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Emissions monitoring

Example image of a NOX sensor (not installed)

The measurement positions for measuring exhaust emissions vary depending on the system
configuration:
• downstream of the turbocharger outlet of the engine, if necessary also 2 sensors for each engine for
measurement on cylinder bank A/cylinder bank B
• downstream of the outlet of an SCR aftertreatment system
In new systems, emission measurement positions are marked by ESP1 and ESP2 in the technical
diagram (see TA 1100-0110 under chapter Exhaust gas measurement positions). In addition, the NOx
sensors should be arranged in accordance with the system overview, see chapter ⇨ System overview, in
order to carry out comparative measurements. Depending on the system design, additional measurement
connections may be necessary.

TA 1100-0110 – Boundary conditions for Jenbacher gas engines

6.2 Temperature and pressure sensors for catalytic converter monitoring

The sensor package is used to monitor the exhaust gas temperature and pressure at the inlet and outlet
of the SCR/oxidation catalytic converter. Temperature sensors are used to monitor whether the catalytic
converter is operating within the permissible temperature range. Pressure sensors can be used to detect
ageing (blocking). In addition, a fast pressure sensor is installed, which serves to detect deflagration in
the exhaust tract.

Author(s): Kecht S. Responsible: Böwing R. Release date: 08/07/2020

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Emissions monitoring

Example setup of the sensor system for OXI monitoring (2x temperature (pos. 19), 2x pressure for differential
pressure measurement (pos. 18) and fast pressure sensor for deflagration detection (pos. 20)) for catalytic converter
monitoring

6.3 Temperature and flap position of the CL.Air thermal reactor

The flap position of the thermal reactor is monitored and the reactor temperature is measured and
recorded in terms of quality by the sensors already contained in the system.
A warning is output if the device is not operating properly.

7 Handling instructions for the NOx sensor

The NOx sensor is a sensitive measuring instrument. As a result, the sensor must be handled with care to
avoid damaging it.
Permissible storage temperature: -40 °C ... +65 °C
The maximum storage time recommended by the manufacturer is 2 years after production.
The sensor element must never be subjected to any severe mechanical jolts, such as falling down onto a
hard surface. If a sensor has been subjected to a high mechanical load, the manufacturer recommends
disposing of it immediately.
The sensor element is generally supplied with a protective cap, which must be removed before
connecting the sensor plug to the control cabinet. The sensor must never go into heating mode with the
plastic protective cap fitted, as the high temperatures will scorch the cap, thereby damaging the sensor.

Author(s): Kecht S. Responsible: Böwing R. Release date: 08/07/2020

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Emissions monitoring

The connecting cable between the sensor element and SCU must not be subjected to any tensile forces;
the SCU and sensor element must not be carried holding the intermediate cable. It must also not be
disconnected.
Do not paint the SCU and sensor element.
The SCU housing does not contain any parts that need to be maintained and must not be opened as
doing so will void the warranty.
If possible, avoid cleaning the sensor element by mechanical means or using a cleaning fluid as this
could permanently damage the unit.

Note: In measuring mode, the sensor is heated up to a temperature of approx. 800 °C and the exhaust
line is still hot even after the engine has stopped. When handling hot sensors, suitable PPE (especially
protective gloves) must therefore be used.

Replacing the sensor:

The NOx sensor is a wear part and must be replaced to maintain the measuring accuracy according to IW
8057 M0.

IW 8057 M0 – NOx
When replacing a sensor, make sure that the new sensor has been stored at room temperature for
approx. 1 hour. If there is any moisture on the sensor element, the sensor would be immediately
destroyed during the heating phase.
If the sensor element is exchanged, it must be exchanged with the SCU as a complete unit. The sensor
element cannot be replaced by itself, since the sensor and SCU are matched to each other at the factory.
The sensor may only be replaced when the engine is at a standstill (without flow). Otherwise, it may be
permanently damaged. If an offset is stored in the parameter menu, it must be reset. A comparison with
the emission measurement kit must be carried out. Afterwards, the LEANOX parameters must be set.

Note: If a warning is displayed on the control after the sensor has been replaced that it is not connected
(W2610, W9203, W9206, W9209), the sensor must be briefly disconnected from the power supply (fuse
in the control cabinet). Afterwards the warning must be acknowledged.

8 Explanation and notes on emission trend data (DIA.NE XT4)

The current values and the status of the emissions are displayed on the VIS EXH/emissions screen, see
figure below. A NOx short-term average (floating, 30 min) is displayed, as well as a NOx daily average,
which is generated once at the end of the day. It remains constant until the next day. This means that the
displayed daily average value corresponds to the daily average value of the previous day. This trend can
be downloaded as a PDF export using the DIA.NE XT4 HMI client, see ① on the EXH/Emissions
diagnostic screen.
The visualisation of the emission monitoring can also be called up in the diagnosis menu under EXH/
Emissions. The EXH/Emissions diagnostic screen shows an overview of the various limit values and
average emission values (short-term averages and daily averages), as well as a violation counter that
calculates the total of emission level violations (hours). The tolerance shown is only used as a triggering
threshold for the warning.
The standard activation time of the trend is 1 year, but the user can use the zoom function to view any
time period. If catalytic converter monitoring is available, the temperatures and pressures of the catalytic
converter monitoring are also shown in this trend.

Author(s): Kecht S. Responsible: Böwing R. Release date: 08/07/2020

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Emissions monitoring

EXH/Emissions VIS screen

Author(s): Kecht S. Responsible: Böwing R. Release date: 08/07/2020

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Emissions monitoring

EXH/Emissions diagnostic screen

9 Emission report
In addition to the graphical representation of the emission values, there is also a function to generate an
emission report (RPT) over the selected time period. To do this, go to RPT ① Display ② under report
"Emissionsmonitoring_DEU" select ③ and choose the desired period ④ and ⑤. This lists all emission-
relevant warnings and parameter changes, which can then be exported as a PDF or printed out ⑥, see
figure below.
In addition, a report is automatically generated for each day by default. This daily report is also used for
internal evaluation purposes and may not be changed. For more details on the warnings and
recommendations for action, see the following chapters.

Author(s): Kecht S. Responsible: Böwing R. Release date: 08/07/2020

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 TA 1400-0301
Emissions monitoring

Emission report

10 Emission-related warnings and recommendations for action

Note: All listed warnings may influence the emission behaviour of the engine. This is why quick
action or clarification is necessary to ensure that the system operates properly.
Warning Text Comment/Recommendation for action
number
9252 NOx emissions - daily average Take immediate action (within 24 hours), check
(previous day), high other warnings, contact responsible service
3485 NOx emissions - short-term average, This is generally only active during SCR after-
high treatment, check other warnings and take
immediate action (within 24 hours), contact the
responsible service
3381 NOx emissions - short-term average, See W3485, the engine however is also shut down
high in a controlled manner
3484 CO emissions - short-term average, This is generally only active for certain SCR
high aftertreatment processes, check other warnings,
contact the service immediately
9202 Measuring signal fault NOx – NOx Failure of NOx sensor (at the respective position) or
sensor engine outlet signal plausibility error, if this occurs repeatedly or
9205 Measuring signal fault NOx – NOx permanently, contact the responsible service
sensor engine outlet - cylinder bank A immediately or, if authorized, replace NOx sensor
and adjust LEANOX
9208 Measuring signal fault NOx – NOx
sensor engine outlet - cylinder bank B
9211 Measuring signal fault NOx – NOx
sensor CAT outlet

Author(s): Kecht S. Responsible: Böwing R. Release date: 08/07/2020

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Emissions monitoring

Warning Text Comment/Recommendation for action

number
9201 Measuring signal fault O2 – NOx Failure of NOx sensor O2 value (at the respective
sensor engine outlet position) or signal plausibility error, if this occurs
9204 Measuring signal fault O2 – NOx repeatedly or permanently, contact the responsible
sensor engine outlet - cylinder bank A service immediately or, if authorized, replace NOx
sensor and adjust LEANOX
9207 Measuring signal fault O2 – NOx
sensor engine outlet - cylinder bank B
9210 Measuring signal fault O2 – NOx
sensor CAT outlet
9250 O2 deviation cylinder bank A/B, Warning indicates a significant deviation between
maximum - NOx sensor engine outlet cylinder banks if two NOx sensors are installed on
9251 NOx deviation cylinder bank A/B, the engine. Contact the responsible Service
maximum - NOx sensor engine outlet department.
2607 CAN fault – NOx sensor CAN interface Incorrect software configuration of the NOx
1 sensor(s). Contact the Service department
2609 CAN fault – NOx sensor CAN interface immediately.
2
2610 No connection to sensor - NOx sensor Interruption of the connection to the NOx sensor (at
engine outlet the respective position), e.g. cable break. Check the
9203 No connection to sensor - NOx sensor cabling and plug connection. Contact the
engine outlet - cylinder bank A responsible Service department immediately.
9206 No connection to sensor - NOx sensor
engine outlet - cylinder bank B
9209 No connection to sensor - NOx sensor
CAT outlet
9233 Service life reached - NOx sensor Permissible service life of the NOx sensor (at the
engine outlet respective position) reached. If authorized, replace
9234 Service life reached - NOx sensor NOx sensor according to TA specifications. Carry
engine outlet A out comparison measurement with exhaust-gas test
kit and contact the responsible Service department
9235 Service life reached - NOx sensor immediately.
engine outlet B
9236 Service life reached - NOx sensor
CAT outlet
2084 LEANOX straight line calculation error
Parametrization error, contact responsible service
2487 Maintenance instruction, NOx We recommend checking emissions and LEANOX
measurement/LEANOX measurement according to the maintenance schedule. Contact the
recommended responsible Service department as soon as
possible.
2488 Maintenance instruction, NOx The emissions and LEANOX must be checked in
measurement/LEANOX measurement accordance with schedule. Contact the responsible
mandatory Service department as soon as possible.
9253 LEANOXplus limit reached / LEANOX The emission must be checked and LEANOX
calibration recommended adjusted. Contact the responsible Service
department as soon as possible.
9041 Emission-relevant parameter changed Operating message for old controls, which indicates
a change of an emission-relevant parameter - No
action necessary.

Author(s): Kecht S. Responsible: Böwing R. Release date: 08/07/2020

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Warning Text Comment/Recommendation for action

number
2319 Oxidation catalytic converter outlet Excessive temperature at catalytic converter outlet.
temperature, maximum We recommend an emission comparison
measurement for functional testing. Contact the
Service department immediately.
2500 Oxidation catalytic converter inlet Excessive temperature at the catalytic converter
temperature high inlet. We recommend emission comparison
measurement for functional testing. Contact the
Service department immediately.
9310 Oxidation catalytic converter outlet Check the faulty measuring point, cabling and
temperature, measuring signal fault sensors. Contact the responsible service
2499 Oxidation catalytic converter inlet immediately.
temperature measuring signal fault
2494 Oxidation catalytic converter inlet
pressure, measuring signal fault
2495 Oxidation catalytic converter outlet
pressure, measuring signal fault
2496 Oxidation catalytic converter, minimum Large bypass or faulty pressure measurement.
differential pressure Contact responsible service.
9277 SCR urea dosing stopped - error Warning total for urea dosing system, observe other
warnings, promptly eliminate faults. Contact the
responsible Service department immediately.
3487 SCR Exhaust gas temperature Excessive temperature at the catalytic converter
upstream of CAT, maximum inlet. We recommend emission comparison
measurement for functional testing. Contact the
Service department immediately.
3488 SCR Exhaust gas temperature Excessive temperature at catalytic converter outlet.
downstream of CAT, maximum We recommend an emission comparison
measurement for functional testing. Contact the
Service department immediately.
3466 SCR measuring signal failure, exhaust Check the faulty measuring point, cabling and
gas temperature upstream of CAT sensors. Contact the responsible service.
3467 SCR measuring signal failure, exhaust
gas temperature downstream of CAT
2464 SCR measuring signal failure, exhaust
gas pressure upstream of CAT
3465 SCR measuring signal failure, exhaust
gas pressure downstream of CAT
3469 SCR exhaust gas differential pressure Differential pressure too high due to deposits or
CAT, maximum sensor errors. Contact responsible service.
3505 Thermal reactor: Reaction chamber Necessary reaction chamber temperature cannot be
temperature, minimum reached. Contact the responsible service
immediately.
3501 Thermal reactor: Preheating time The reaction chamber temperature is not reached
exceeded during the permissible preheating time. Contact the
responsible Service department.
9309 Thermal reactor: Not in operation/ Warning total for thermal reactor, observe other
failed warnings for eliminating faults. Contact the
responsible Service department.

Author(s): Kecht S. Responsible: Böwing R. Release date: 08/07/2020

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Emissions monitoring

Warning Text Comment/Recommendation for action

number
9319 Communication error NOx package Check the network connection between the XT4
(XT panel XT4 server) server and the controller. Check the cabling.
Contact the Service department immediately, since
emissions cannot be recorded.

11 Emission-relevant parameters
All emission-related parameters are listed below. Only the parameter number is transmitted, especially
with old control systems. You can use this list to assign the function.
Parameter Brief description/function
11072 Related parameters for LEANOX setting
11073 Power point 1 - gas type 1
11074
11071
11088 Related parameters for LEANOX setting
11089 Power point 2 - gas type 1
11090
11087
11119 Ignition timing - gas type 1
11076 Related parameters for LEANOX setting
11077 Power point 1 - gas type 2
11078
11075
11092 Related parameters for LEANOX setting
11093 Power point 2 - gas type 2
11094
11091
11120 Ignition timing - gas type 2
11080 Related parameters for LEANOX setting
11081 Power point 1 - gas type 3
11082
11079
11096 Related parameters for LEANOX setting
11097 Power point 2 - gas type 3
11098
11095
11121 Ignition timing - gas type 3
11084 Related parameters for LEANOX setting
11085 Power point 1 - gas type 4
11086
11083
11100 Related parameters for LEANOX setting
11101 Power point 2 - gas type 4

Author(s): Kecht S. Responsible: Böwing R. Release date: 08/07/2020

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Parameter Brief description/function

11102
11099
11122 Ignition timing - gas type 4
13974 Parameters for boost pressure compensation by LEANOX for engine ageing
13976
13973
13976
13972 Activation of boost pressure compensation (engine ageing) for LEANOX
14305 Activation of LEANOXPLUS (NOx control)
14338 Setpoint for NOx emission control at engine outlet
14067 NOx sensor configuration (number/position of sensors)
14156 NOx sensor engine outlet - NOx offset
14155 NOx sensor engine outlet - O2 offset
14158 NOx sensor engine outlet (cylinder bank a) - NOx offset
14157 NOx sensor engine outlet (cylinder bank A) - O2 offset
14160 NOx sensor engine outlet (cylinder bank B) - NOx offset
14159 NOx sensor engine outlet (cylinder bank B) - O2 offset
14162 NOx sensor CAT outlet - NOx offset
14161 NOx sensor CAT outlet - O2 offset
14280 NOx sensor at engine outlet, maximum
14281 NOx emissions at engine outlet, maximum tolerance
14282 NOx emissions at CAT outlet, maximum
14283 NOx emissions at CAT outlet, maximum tolerance
14154 Reference oxygen
14279 Monitoring options for emission monitoring (short-term, daily average, engine shutdown)
14113 Activation of oxidation catalytic converter monitoring
14117 Activation of oxidation catalytic converter inlet temperature
14121 Activation of oxidation catalytic converter outlet temperature
14120 Oxidation catalytic converter inlet temperature, maximum
14124 Oxidation catalytic converter outlet temperature, maximum
13961 Activation of SCR catalytic converter (function and monitoring)
13899 Activation of exhaust gas temperature upstream of CAT (SCR/OXI)
13902 Activation of exhaust gas temperature downstream of CAT (SCR/OXI)
13868 Minimum motor load for release of urea dosing
13869 Minimum average catalytic converter temperature for release of urea dosing
13900 Exhaust gas temperature upstream of SCR/OXI, maximum
13901 Exhaust gas temperature downstream of SCR/OXI, maximum
13907 Exhaust gas differential pressure of SCR/OXI, maximum
12223 Activation of thermal reactor
12236 Reaction chamber temperature setpoint without gas injection

Author(s): Kecht S. Responsible: Böwing R. Release date: 08/07/2020

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12 Revision code
Revision history
Index Date Description/Revision summary Expert
Auditor
1 08.07.2020 Erstausgabe / First issue Url M.
SprungMarke!!!68406156555
Böwing R.

Author(s): Kecht S. Responsible: Böwing R. Release date: 08/07/2020

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