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Sensors

AMB II 9270-054 Hardware Interface Version 1.04

Doc # 9315-031 Rev E 24-May-2000

sensors europe sensors, inc.

1 COPYRIGHT MICROBENCH The information furnished in this manual is believed to be accurate and reliable. Information in this document is subjected to change without notice. Please contact our office in the US or Germany for application assistance. 1994-1999 Sensors, Inc., all rights reserved. Sensors, Inc. 6812 South State Road Saline, Michigan 48176 U.S.A

Sensors Europe GmbH Papiermühlenweg 74 D-40882 Ratingen Germany

Phone: +1 (734) 429-2100 Fax: +1 (734) 429-4080

Phone: +49-(0) 2102-85680-0 Fax: +49-(0) 2102-85680-56 e-mail: [email protected] Internet: www.sensors-inc.com

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2 CONTENT 1

COPYRIGHT MICROBENCH ......................................................................................................... 2

2

CONTENT ........................................................................................................................................ 3

3

IN GENERAL.................................................................................................................................... 4 3.1 3.2 3.3

4

INTRODUCTION ............................................................................................................................ 4 AREA OF USE .............................................................................................................................. 4 PRINCIPLE OF NDIR MEASUREMENT ............................................................................................ 4

MICROBENCH MODULE DESCRIPTION ...................................................................................... 5 4.1 MICROBENCH SYSTEM THEORY OF OPERATION ........................................................................ 5 4.2 SPECIFICATION ............................................................................................................................ 6 4.2.1 Storage Temperature ......................................................................................................... 6 4.2.2 Operational Temperature ................................................................................................... 6 4.2.3 Measured Gases................................................................................................................ 6 4.2.4 Ranges............................................................................................................................... 7 4.2.5 Accuracy/Performance....................................................................................................... 7 4.2.6 Resolution .......................................................................................................................... 7 4.2.7 Warm Up Time ................................................................................................................... 7 4.2.8 Response Time .................................................................................................................. 7 4.2.9 Flow Rate ........................................................................................................................... 7 4.2.10 Operating Pressure ............................................................................................................ 7 4.2.11 Proposed Calibration Gases for OIML Specification.......................................................... 8 4.2.12 Calibration Gases for BAR 90 Specification....................................................................... 8 4.2.13 O2 Specification.................................................................................................................. 8 4.2.14 NOx Specification ............................................................................................................... 8

5

MICROBENCH MODULE APPLICATION....................................................................................... 8 5.1 APPLICATION SPECIFICATION ....................................................................................................... 8 5.1.1 Power Requirements.......................................................................................................... 8 5.1.2 Mounting Requirements ..................................................................................................... 9 5.2 OPERATIONAL REQUIREMENTS .................................................................................................. 11 5.2.1 Sample System ................................................................................................................ 11 5.2.2 Summary.......................................................................................................................... 12 5.3 USER INTERFACE REQUIREMENTS SUMMARY ............................................................................. 12 5.3.1 Software & Communications............................................................................................ 12 5.3.2 Electrical & Electronic ...................................................................................................... 12 5.3.3 Mechanical & Pneumatic.................................................................................................. 12 5.4 MICROBENCH OPERATING INSTRUCTIONS .............................................................................. 13 5.5 RS-232 CONFIGURATION........................................................................................................... 13 5.6 CONNECTOR PIN-OUT ............................................................................................................... 14 5.6.1 Connector Location pc Board Assy 9211-032 ................................................................. 14 5.6.1.1 5.6.1.2 5.6.1.3 5.6.1.4 5.6.1.5 5.6.1.6 5.6.1.7 5.6.1.8 5.6.1.9

Connector – NOX Transducer (J1) ............................................................................................ 14 Connector – NOX (J3) ............................................................................................................... 15 Connector – O2 (J4) .................................................................................................................. 15 Connector – Analog RPM (JA4)................................................................................................. 16 Connector – Oil Temperature (J5) ............................................................................................. 16 Connector – Relative Humidity (JA5)......................................................................................... 17 Connector – RS232 Host (J7).................................................................................................... 17 Connector – Power (J8) ............................................................................................................. 18 Connector – I/O sample (J9, J10).............................................................................................. 18

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5.6.1.10 5.6.1.11

6

Connector – Digital RPM Input (J11) ..................................................................................... 19 Connector – External Temperature (J12) .............................................................................. 20

REVISION HISTORY ..................................................................................................................... 22

3 IN GENERAL 3.1 INTRODUCTION The Sensors 5 gas MICROBENCH is a small gas detection module designed for easy incorporation into automotive applications. Its innovative design meets OIML R 99 class 1, ISO 3930 and OIML R 99 class 1 specifications. System Cost Reduction Sensors MICROBENCH is designed to reduce the overall system costs of a gas analyzer. The low power consumption of 10 watts with a single 5 volts power supply allows the choice of a less expensive power supply. Due to the small size of the MICROBENCH the flow rate can be reduced to 0.3 l/min. Because of the small size of the MICROBENCH, the reduced size of the pump module and the simplification of the power supply, the complete analyzer could be built as a real handheld unit. Life Time Cost Reduction To offer overall lifetime cost reduction, Sensors removed all moving parts from the MICROBENCH and is now chopping the infrared sources power directly (patent pending). This new technology and the use of standard parts will increase the reliability of the MICROBENCH. 3.2 AREA OF USE The MICROBENCH Module will be used to determine different concentrations in the automobile exhaust gas. It measures carbon monoxide (CO), carbon dioxide (CO2) and hydrocarbons, i. e. as propane (C3H8) or hexane (C6H14). Using an electrochemical cell, oxygen (O2: Sensors' part number 7014-006) and Nitric Oxide (NOx: Sensor’s part number 7014-011) can also be determined. The measure of the above mentioned gases allows emission control for any mandatory inspection and maintenance program, as well as vehicle diagnosis based on exhaust gas measurement under static and dynamic conditions by sampling at the tailpipe or, on cars with a catalytic converter, before and after the catalytic converter. The MICROBENCH Module was especially developed to meet the OIML R 99 class I, OIML R 99 class 0 and ISO 3930 specification. 3.3 PRINCIPLE OF NDIR MEASUREMENT The MICROBENCH Module is based on a Non-Dispersive Infrared technology. Instead of using a refractive prism to achieve high spectral resolution of the infrared light stream (such as used in highend performance laboratory equipment), Sensors is applying NDIR in its MICROBENCH. NDIR devices are generally dedicated to the measurement of concentrations of a limited, specific set of gases in mixtures with a limited, known set of background gases. An example of such a limited framework might be the measurement of CO2 concentration within an automotive exhaust gas background. Gases that might have an absorption spectrum overlapping that of CO2 are known - a priori - to be absent.

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A specific set of gases (i. e. CO, C6H14, CO2 for the MICROBENCH) is measured as follows: a single waveband within the infrared spectrum is selected for each gas to measure (see Picture 3-1: Absorption Spectrum) where its absorption is known to be substantial and where no other background gas absorbs significantly. Optical band pass filters which transmit electromagnetic energies only within the waveband are placed before the thermocouple detector. When the sample cell is filled with sample gas, the IR detector measures the resultant reduction of transmitted IR energy within the waveband of each gas. Absorption Spectrum 100% 90% 80%

Transmission [%]

70% 60% CO CO2 Hexane

50% 40% 30% 20% 10% 0% 3

3.5

4

4.5

5

5.5

Wave length [:m]

Picture 3-1: Absorption Spectrum

4 MICROBENCH MODULE DESCRIPTION 4.1 MICROBENCH SYSTEM THEORY OF OPERATION The MICROBENCH Non-Dispersive Infrared gas analyzer is capable of measuring CO (carbon monoxide), CO2 (carbon dioxide), and HC (hydrocarbons). It also performs both zeroing and calibration routines that are completely microprocessor controlled. The gas readings and diagnostic data are then transmitted out to a host computer, over a standard 3- wire RS-232 line, by the on-board microprocessor.

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Vcc

Gas Out

CO x1 x2 x3 x4 x5 xn

u1

HC & REF

CO2

u1 x1

u5 un

Controler P

T

Gas In

16 bit L-micro controler 11.02.99 THS / Sensors Europe

Picture 4-1: Principle of the MICROBENCH

There are a number of technically significant improvements that the MICROBENCH offers over conventional gas analyzers: • Low Power Consumption • No Moving Parts • Single Power Operation • 5 Gas System • High Reliability • No Fan Required A comprehensive simple to use communication protocol allows the host PC to control the MICROBENCH activity. Things such as zero, calibration, as well as sample system control are easily accomplished with the powerful command set.

4.2 SPECIFICATION 4.2.1 STORAGE TEMPERATURE -50 °C to 70 °C 4.2.2 OPERATIONAL TEMPERATURE -12 °C to 48 °C 4.2.3 MEASURED GASES HC Hydrocarbons as C6H14 Hexane CO Carbon Monoxide CO2 Carbon Dioxide - 6 / 22 -

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HC Hydrocarbons as C3H8 Propane O2 Oxygen (optional through Electrochemical sensor) NOx Nitric Oxide (optional through Electrochemical sensor) 4.2.4 RANGES HC = 0 to 2000 ppm Hexane = 0 to 4000 ppm Propane = 0 to 3276.7 ppm Hexane = 0 to 3276.7 ppm Propane CO = 0 to 15% CO2 = 0 to 20% HC = 0 to 20000 ppm Hexane = 0 to 40000 ppm Propane O2 = 0 to 25% NOx = 0 to 5000 ppm (As Nitric Oxide)

(Standard resolution) (Standard resolution) (High resolution) (High resolution) (Standard resolution only) (Standard resolution only)

4.2.5 ACCURACY/PERFORMANCE The performance of the AMB is : 1. OIML R99 class 0 2. OIML R99 class 1 3. ISO 3930 4. BAR 90 4.2.6 RESOLUTION HC: 1 ppm vol. 0.1 ppm vol. CO: 0.01% vol. 0.001% vol. CO2: 0.1% vol. 0.01% vol. O 2: 0.01% vol. NOx: 1 ppm

(Standard resolution) (high resolution) (Standard resolution) (high resolution) (Standard resolution) (high resolution)

4.2.7 W ARM UP TIME The warm-up time is software controlled and depends on several internal parameter. For more details see Sensors Software manual. 4.2.8 RESPONSE TIME T90 = 3.5s 4.2.9 FLOW RATE 0.3 ... 6.0 l/min 4.2.10 OPERATING PRESSURE 750 mbar - 1100 mbar 1000 mbar nominal

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4.2.11 PROPOSED CALIBRATION GASES FOR OIML SPECIFICATION CO CO2 C3H8 N2

Cal Gas 1 0.50 % vol. 6.0 % vol. 200 ppm vol. rest

Cal Gas 2 3.50 % vol. 14.0 % vol. 2000 ppm vol. rest

Table 4-1:Calibration Gases for OIML R99

4.2.12 CALIBRATION GASES FOR BAR 90 SPECIFICATION CO CO2 C3H8 N2

Cal Gas 1 1.00 % vol. 6.0 % vol. 300 ppm vol. rest

Cal Gas 2 4.00 % vol. 12.0 % vol. 1200 ppm vol. rest

Table 4-2: Calibration Gases for BAR 90

4.2.13 O2 SPECIFICATION The MICROBENCH meets the German and English O2-requirements with its O2-Transducer (Sensors´ P/N: 7014-006). The MICROBENCH software determines whether the transducer is still accurate or inaccurate. Sensors’ O2-Transducer: New Transducer in ambient air: 7 - 13.5 mV Used Transducer in ambient air: 5 - 13.5 mV If the transducer is outside of the above specifications, a flag will indicate that there is a problem with the transducer. Limits are host programmable. 4.2.14 NOX SPECIFICATION For detailed information consult with Sensors’ application engineers. 5 MICROBENCH MODULE APPLICATION 5.1 APPLICATION SPECIFICATION 5.1.1 POWER REQUIREMENTS Nominal Supply Voltage: 5VDC ± 0.25V +/- 5 % (+/- 250mV) max. Supply Accuracy (1): Current: 2A typical 3A max. Maximum Ripple(2):

150 mV Pk - Pk max. (10 Hz to 1MHz)

Note (1): Supply Accuracy is the maximum allowable deviation of the DC supply, including ripple, from the nominal voltage.

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Note (2): Ripple > 1MHz may result in unpredictable Microbench performance. Non-periodic step changes in supply voltage may cause momentary short term disturbances in gas readings. Empirical testing is recommended. 5.1.2 MOUNTING REQUIREMENTS 1. Mount sample gas cell vertical to avoid water contamination. 2. Mounting near sources of RF1/EMI should be avoided. 3. Direct air flow to the Automotive Microbench has to be avoided. Convectional or indirect air flow are recommended processes to cool the bench. The ambient temperature around the bench should not exceed more than ambient temperature outside of the gas analyzer plus 5°C. 4. Consult with Sensors' Engineering Dept. for application assistance. Pressure Transducer Gas In

Sensors P/N: 2801-171 Non coductive mounting

Gas out

Picture 5-1: Mounting Orientation

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60.9 mm ( 2.40 in)

81.3 mm (3.20 in)

17.3 mm (0.682 in)

Drill and cp #6-32

3.81 mm (0.15 in)

J 12

144.8 mm (5.70 in) 4.44 mm (0.175 in)

Picture 5-2: Mounting Holes

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5.2 OPERATIONAL REQUIREMENTS 5.2.1 SAMPLE SYSTEM The design of the sample system has to assure that when the gas reaches the Automotive Microbench, the temperature is at ambient temperature. Hot gas can cause inaccurate readings or damage to the Automotive Microbench. Condensation in the bench has to be avoided, therefore the relative humidity must be below 98% non- condensing. In case the bench reports a condensation condition, it is recommended to shut the sample pump off until this condition is cleared. The sample gas purity should not contain particulate greater than 5Lm. The gas flow through the bench should be the same for all conditions (i.e. measuring mode, zeroing and calibration).

CAL 1.5 psi ZERO 0.5 psi

Sample IN

Charcoal Filter

SV1

VAC SW

Sample Pump

Drain Pump

AMB

O2

Sample out

Drain Out

SV1 / J6 Start-up Zero CAL Sample

0 1 1 0

Drain Pump /J5 Sample Pump / J5 0 0 1 1 0 0 1 1

Picture 5-3 : Priciple of an AMB II sample system

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5.2.2 SUMMARY • Relative humidity: • Gas temperature:

non condensing Tgas approx. Tambient (Ambient temperature reported by the AMB) < 5Lm Ambient temperature reported by the bench < 48°C

• Particulate size: • Ambient Temperature:

5.3 USER INTERFACE REQUIREMENTS SUMMARY

5.3.1 SOFTWARE & COMMUNICATIONS • 9600 Baud rate. • Communicates over RS-232. 5.3.2 ELECTRICAL & ELECTRONIC • + 5 VDC input • Typical 10 watts, max. 15 watts 5.3.3 MECHANICAL & PNEUMATIC • 0.3 .. 6.0 l/min sample flow • Weight: less than 450g • Package size:156 mm x 97 mm x 52 mm Note: Please consult with Sensors’ Engineering Department for application assistance.

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5.4 MICROBENCH OPERATING INSTRUCTIONS

1. Connect properly conditioned power as described in 5.1.1 on the Bench p. c. board, reference Schematic 9211-032 for details of power requirements. 2. Connect a PC 386 compatible on the Microprocessor p.c. Board through a standard RS-232 link to the serial port that you have configured on your PC compatible host computer. Reference Schematic 9211-032 for details. 3. Start the operating software for the MICROBENCH Module on a PC. Refer to the MICROBENCH Communication Specifications for detailed information. 4. Connect a sample handling system to the inlet tube (the 1/8“ ID tube). Connect the outlet tube (the 1/8“ ID tube) to a proper exhaust vent. 5. Power up the MICROBENCH module and wait for it to come out of warm-up. The warm-up is controlled by software and indicated by a status bit. 6. Zero the MICROBENCH. This is controlled by the computer and requires a supply of filtered ambient air. 7. Calibrate the MICROBENCH if necessary. This is also controlled by the computer and requires a supply of Tri-blend calibration gas. We recommend using the standard calibration gas blends, as described in Table 4-1:Calibration Gases. 8. Sample exhaust gases. Supply the MICROBENCH with a stream of properly conditioned exhaust gas sample at the pressure and flow rate as called out in 4.2.9 and 4.2.10. 5.5 RS-232 CONFIGURATION Baud Data Bits Stop Bits Parity

: 9600 : 8 : 1 : none

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5.6 CONNECTOR PIN-OUT 5.6.1 CONNECTOR LOCATION PC BOARD ASSY 9211-032

Connectors which are not described in this chapter are for Sensors internal use only and not intend to be used by anyone else. 5.6.1.1 CONNECTOR – NOX TRANSDUCER (J1) This input is designed to connect directly an electrochemical NO transducer (e.g.: CitTicel Type NX1) to the bench. J1 4-HDR

+10V

1

+NO in

2 10K

3 4

0.001 LF

100K 10

1 LF 0.001 LF 10K

-NO in

For Reference Only. See Schematic 9211-032

Drawing 5-1 : J1 - NOx Transducer

Housing: AMP# 102241-2 Pins: AMP# 1-87756-7

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Pin 1 2 3 4

Meaning +10V 1 LA sink (-NO in) AGND 1 LA sink (+NO in)

5.6.1.2 CONNECTOR – NOX (J3) This connector is used in conjunction with Sensors NO manifold (P/N:1408-114, -130) and NO transducer (P/N: 7014-010, -011). J3 4-HDR 1

+5V

2

-5V

A/D-NOX

3 4

499K

10K 0.1LF

Drawing 5-2 : J3 - NOX

Housing: AMP# 102241-2 Pins: AMP# 1-87756-7 Pin 1 2 3 4

Meaning Vcc (+5V), 1A source -5V, TBD mA source NO input (-2.5V .. +2.5V), 1 LA sink AGND

Pin Description 5-1: NOX

5.6.1.3 CONNECTOR – O2 (J4) This connector is used to connect an electrochemical O2 sensor to the bench.

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J4 3-HDR -O2 in 1 4.99K

2

10K 0.01 LF

3

+O2 in 10K 4.99K

Drawing 5-3 : J4 - O2

Housing: AMP# 102241-2 Pins: AMP# 1-87756-7 Pin 1 2 3

Meaning 1 LA sink (-O2 in) AGND 1 LA sink (+O2 in)

5.6.1.4 CONNECTOR – ANALOG RPM (JA4) Free A/D converter for customer specific applications. JA4 3MTA100 0.01LF 100K

RPM

1 2

+5V

3

Drawing 5-4 : JA4 - Analog RPM Input

Housing: AMP# 640441-3 Pins: 24AWG Wire Pin 1 2 3

Meaning 1LA sink (-2.5V ... +2.5V) Vcc source AGND

5.6.1.5 CONNECTOR – OIL TEMPERATURE (J5) This A/D input is used in conjunction with Sensors RPM/OIL-Temperature boards(9219-140, 147). If Sensors board is not used, this A/D input can be used for customer specific applications.

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2.5Vref

J5 3MTA100

10K T-OIL

1 2

5V 0.01LF

3

Drawing 5-5 : J5 - OIL TEMP

Housing: AMP# 640441-3 Pins: 24AWG Wire Pin 1 2 3

Meaning 1LA sink (-2.5V ... +2.5V) Vcc source AGND

5.6.1.6 CONNECTOR – RELATIVE HUMIDITY (JA5) Free A/D converter for customer specific applications. JA5 3MTA100 0.01LF

1M

HUMIDITY

1 2

+5V

3

Drawing 5-6 : Relative Humidity Input

Housing: AMP# 640441-3 Pins: 24AWG Wire Pin 1 2 3

Meaning 1LA sink (-2.5V ... +2.5V) Vcc source AGND

5.6.1.7 CONNECTOR – RS232 HOST (J7) This connector is used to communicate between the host computer and the AMB. Serial communication parameters are: - 9600 baud - 8 data bits - 1 stop bit - no parity

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J7 3MTA100 Rx 1 1K

Tx

2 1K 3 0.001 Lf

0.001 LF

Drawing 5-7 : J7 - RS 232

Housing: AMB# 640441-3 Pins: 24AWG Wire Pin 1 2 3

Meaning RxD (500 LA) TxD (500 LA) DGND

5.6.1.8 CONNECTOR – POWER (J8) J8 3MTA156

Vccin (+5V)

2

1N5819

1 10LF 10V

Drawing 5-8 : J8 - Power Input

Housing: MOLEX# 09-50-8023 Pins: MOLEX# 08-65-0114 Pin 1 2

Meaning Vcc(+5V) 3A Source DGND, AGND

5.6.1.9 CONNECTOR – I/O SAMPLE (J9, J10) These connectors read digital inputs or write digital outputs and can be used to control the pump system (P/N: 9213-014).

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J9 16HDR-2ROW

+5V

1 2 DOUT5

DRAIN

3

AIR

4

DOUT7 DOUT3 5 DOUT4 6

DRAIN

DOUT6 7 DOUT2 8

VAC-SW

DIN0 9 DIN1 10 DIN2 11 DIN3 12 DIN4 13 DIN5 14 DIN6 15 DIN7 16 +5V

J10 4MTA100 VAC-SW

1

AIR

2

DRAIN

3

PUMP

4

Drawing 5-9 : I/O Sample Sys

J9 Connector: ANY 16-Pin cable connector J10 Connector Housing: AMP# 640441-4 Pins: 24 AWG Wire 5.6.1.10 CONNECTOR – DIGITAL RPM INPUT (J11) This input is designed to read frequencies between 1Hz and 1 KHz. This input can be used to read RPM.

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Vcc

J11 3MTA100

10K

1 10K 2

Vcc 0.01LF

3

Drawing 5-10: J11-TTL RPM Input

Housing: AMB#640441-3 Pins: 24AWG Wire Pin 1 2 3

Meaning Digital Input Vcc DGND

Pin Description 5-2 : J11 - TTL RPM Input

5.6.1.11 CONNECTOR – EXTERNAL TEMPERATURE (J12) A/D input can be used for customer specific applications. +5V

0.1LF

J12 4MTA100 1

EXT-TEMP

2 3

0.01LF

499K

4 -5V 100R 0.1LF

Drawing 5-11 : J12 - External Temperature A/D Input

Housing: AMB#640441-3 Pins: 24AWG Wire Pin 1 2

Meaning Vcc Signal In (1LA sink)

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3 4

AGND -5V (TBD mA source)

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6 REVISION HISTORY Rev. A B C D

E

Date 6-1-99 7-14-99 8-30-99 12-1-99

5-24-00

Description Release V1.00 Added board drawing to 5.6.1 , Updated revision to V1.01, 9315-031 B Changed NO input circuit 5.6.1.1 Connector – NOX Transducer (J1) SCR AMB254 Add description for mounting holes on bc board (Picture 5-2: Mounting Holes) Correct Drawing 5-9 : I/O Sample Sys Changed NO input circuit 5.6.1.1 Connector – NOX Transducer (J1) Changed power supply specification

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