Gas Analyzers: INFRAGAS-196 INFRAGAS-196 PC-Module (1 to 6 Gas Available)

Gas Analyzers: INFRAGAS-196 INFRAGAS-196 PC-Module (1 to 6 Gas Available) OPERATING MANUAL Edition: Sept. 2005. Vers. 5.39 ASSEMBLAD - Technical office - Automotive Division Marte-C:\anno2005\196\M196gb539.doc G

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INDEX 1.0 DESCRIPTION...4 1.1 GENERAL SPECIFICATIONS...4 1.2 FRONT AND REAR PANEL...6 1.2.1 - Front Panel - ( Display and Keyboard )...6 1.2.2 - Display...7 1.2.3 - Keyboard...8 1.2.4 Rear Panel...10 1.3 STANDARD ACCESSORIES...11 1.4 OPTIONAL ACCESSORIES (REFER TO PART NUMBER)...11 2 DESCRIPTION OF OPERATIONS...12 2.1 INSTALLATION PROCEDURE...12 2.2 POWERING UP THE INSTRUMENTS...12 2.3 USE OF THE INSTRUMENT...12 2.4 CALIBRATION USING GAS BOTTLE...13 2.5 OXYGEN TRANSDUCER REPLACEMENT...13 2.6 NITRIC OXIDE TRANSDUCER REPLACEMENT...13 3 PERFORMING A TEST...14 3.1 STANDARD TEST...14 3.2 CARES AND NOTES...16 4.0 INFPLUS SOFTWARE...18 4.1. FEATURES OF THE PROGRAM...18 4.2. INSTALLATION UNDER DOS...18 4.3 RUNNING INFRAPLUS...19 4.4 GAS ANALYZER SECTION...20 4.4a. Analyzer's status...21 4.4b. Measurements...21 4.4c. Hot keys...21 4.4d. Subform of manufacturer's data...22 4.4e. Header...22 5.0 REAL-TIME CLOCK (*) SETUP (MANUAL ADJ)...23 6.0 OPERATIONS AVAILABLE FROM KEYBOARD...24 6.1 UPDATING THE CLOCK/CALENDAR...24 6.2 SELECT THE RIGHT FUEL...24 6.3 SELECT THE NUMBER OF ENGINE STROKES...24 7.0 RESIDUAL HC TEST...25 8.0 AIRTIGHT SEAL TEST (NOT IN ALL MODELS)...26 9.0 TECHNICAL DATA...27 10.0 - TROUBLESHOOTING AND MAINTENANCE...29 10.1 ERR1... ERR5 APPEARS ON CO, CO2 AND HC DISPLAYS...29 10.2 AUTOMATIC DRAINAGE OF CONDENSATE WATER...29 10.3 ADDITIONAL TROUBLESHOOTING...30 11.0 WARRANTY...34 (*) = meaning OPTIONAL (depending of the Part Number or Model ) 3

1.0 DESCRIPTION Infragas 196 is a self-calibrating, multifunctional infrared exhaust gas analyzer, with microprocessor based electronic circuitry. 1.1 GENERAL SPECIFICATIONS 1) CO, CO2 (*) and HC (*) measurements based upon a NDIR method. 2) O2 measurement (*) performed using an electrochemical transducer provided inside on the rear panel of the instrument. 3) NOx measurement (*) performed using an electrochemical transducer provided inside on the rear panel of the instrument. 4) RPM measurement (*) performed using the RPM Inductive Probe to be connected with one of the cylinders and has a 2/4 stroke selection. 5) Ambient Pressure measurement (PRESS mb) based upon a specific pressure transducer provided inside the instrument. 6) Ambient (AMB C) and Oil Temperature (OIL C) measurements performed using 2 separate temperature transducers provided one in the temperature probe (*) and the other inside the instrument. 7) Lambda computations (*) obtained from gas measurement to test car manufacturer spec's. 8) Real-Time Clock-Calendar (*) with battery backup allowing a data retention period of 5 days (minimum). A special function is provided to update the Real-Time Clock [Function not implemented on the model PC-Module ]. 9) Automatic Condensate Drainage or automatic stop of gas suction if the condensate drainage it s insufficient. 10) Red and Green high-efficiency LED display to improve brightness [ Function not implemented on the model PC-Module ]. 11) Functional 3-keys Membrane Keypad for a good protection against dust and oil. Two red LED lamps monitor power on (ON) [besides, power on led blinks in case of voltage 4

supply out of limits provided (220 Vac +/- 10 %)] and pump on (PUMP) [ Function not implemented on the model PC-Module ]. 12) 1 Green high-efficiency display showing (*) O2, Lambda, CO Correct, NO, NOx, RPM, Temp. Amb., Temp. Oil, 4S/2S selection and measurement selected on the 4 Green high-efficiency FUNCTION display [ O2%-FUNC ] [ Function not implemented on the model PC-Module ]. 13) Gas filtering devices (condensate filter and particle filter) provided externally on the rear panel for a quick maintenance. 14) Error and Special Operating condition messages on display to signal the occurrency of situations like flow missing (Err1...) and condensate drainage problems (Con) [Function not implemented on the model PC-Module ]. 15) Self-calibration feature (using MEAS key) with "Cal" message on display and automatic switch to gas suction at the end of this stage. Self-calibration does not require removal of the hose from car exhaust pipe [ Function not implemented on the model PC-Module ]. 16) Standard RS-232 Serial Interface (*) for future expansions for data processing equipments and for other external equipments or for Service. 5

1.2 FRONT and REAR PANEL 1.2.1 - Front Panel - ( Display and Keyboard ) [ Function not implemented on the model PC-Module ] The front panel of INFRAGAS-196 is shown in the picture below: 1 2 3 4 5 6 Front panel of Infragas-196 1) CO display. 2) Multifunction FUNC display. Usually O2 is displayed and the other functions (Lambda, RPM, Amb. Temp., Oil Temp., Amb. Press., NO, N0x,...) are selected from keyboard through the FUNC key and displayed. 3) display. It shows the correspondent simbol of the FUNCTION actived on FUNC display. 4) HC display. 5) CO2 display. 6) Keyboard. Note: Your Gas analyzer may be different from the one shown above. It depends on the model that you have purchased. This is the drawing for the full featured Standard Gas analyzer. 6

1.2.2. Display INFRAGAS-196 in its full configuration has on the front panel 5 displays; displays are splitted into 4 sets. In the normal operating mode, after the first automatical calibration,displays are showing: - CO =======> Carbon monoxide in Vol % from 0,00 to 9,99. - CO2 =======> Carbon dioxide in Vol % from 00,0 to 19,9. - HC =======> Hydrocarbons in ppm from 0000 to 5000. - FUNC =====> Oxygen in Vol % from 0,00 to 21,4. - =======> = Measure selected by keyboard using the FUNC key (see below) - during warm-up time the CO display shows the PEF value, HC shows the writing PEF, and the FUNC display shows the Warm-up time remaning in minutes. - during self-calibration stage CO and CO2 displays show "Cal" message on, the FUNC display shows ben, the display shows and the HC display shows 4-SP. - in case of an insufficient flow on gas path occurs, on CO CO2 and HC displays the messages Err1, Err2... Err5 appears. In this conditions gas measurement is inhibited (see Troubleshooting chapter) - in case of condensate excess, on CO, CO2 and HC displays the message "Con" appears indicating that instrument has stopped. During this stage any further action is inhibited. The display FUNC is able to show several values of other measurements. Values shows are: Oxygen, Lambda, RPM, Temperature, Barometric pressure, NO-Nitrogen oxide, NOx - Nitrogen dioxide, CO Correct. Measures are selected by the Keyboard using the FUNC key. The symbol that appears on the display means: 7

1.2.3 Keyboard MEAS FUNC P1 PUMP ON Infragas 196 - Keyboard built-in front panel Infragas 196 keyboard is composed of 3 keys each corresponding to a specific function, and 2 warning lights. 1) MEAS (MEASURE) key : causes the instrument to start a new measurement by initially performing a self-calibration stage. At the beginning the instrument switches its internal valve to suck in ambient air. This stage requires approx. 30 sec. during which the message "Cal" appears on CO and CO2 displays and data on gas displays (including HC and O2) have no meaning. During this stage a new push of MEAS key causes a termination of measurement sequence. At the end of self-calibration stage the message "Cal" disappears and instrument automatically switches to suck in gases from the hose, thus keeping the suction pump on until the MEAS key has been pressed or after about 10 minutes from this operation. 2) FUNC key: allows selection of measurement to be displayed on FUNCTION display [ FUNC + ]. Available measurements are: - Oxygen - Lambda value for many motor fuel ("L" on the rightmost digit) - CO Correct - Engine Oil Temperature - Ambient Temperature the value displayed show the inside temperature - Ambient Pressure in mbar - RPM - NO - NOx Each push of the FUNC key causes a switching of selection from top to bottom as indicated by the corresponding symbol on display. 8

Regardless of selection made on FUNCTION display, a printing will include every measurement performed by the instrument, even if not displaied. 3) P1 key: performs the print out of all measured and / or computed data (both displayed or not) together with date and time and Workshop data (*) if provided. Lambda value is relative to different propellant. A CO corr. parameter (corrected CO value) is also printed (see Chapter 3). If you need to have another report you must repeat the sequences: MEAS MEAS and after Cal time P1 when the display has a stable appearance. If the fuel setting is PEt, LPG, MEt, PEtC, LPGC, MEtC, the printing report action is generated by means of unique key P1 ; if the fuel setting is Unleaded Gasoline Cat the printing report in generated by two actions on key P1, the first in correspondence of the engine minimun rate then the second increasing the engine rate up to 2500-3000 RPM; the second action on the key P1 to end the print report. PEt = Petrol / Gasoline MEt = Methane LPG = Liquefied petroleum gas PEt C = Unleaded Petrol / Gasoline MEt C = Methane LPGC = Liquefied petroleum gas Catalityc cars Catalityc cars Catalityc cars You can select PEt, LPG, MEt, PEtC, LPGC, MEtC during the Cal time with FUNC key. During the Cal time you can select the RPM mode 4St or 2St with P1 key in order to set the right selection of RPM computation mode, referring to the engine type (4- stroke or 2-stroke). Pushing twice quickly this key when the analyzer is in standby will activate the modem, if present, or deactivate it if the analyzer is still online. 4) ON - warning light: When it is flashing you have a problem on power line. Check for line voltage (Main voltage = 230 Vac -10% +10% max). 5) PUMP - warning light: When this light is on the Pumps are working. 9

1.2.4 Rear Panel The rear panel of INFRAGAS-196 is shown in the picture below: 5 4 3 2 1 14 13 6 0 - I 12 11 7 8 9 10 Rear panel of Infragas-196 1) Condensate filter with gas inlet junction and a connection to the drainage valve. 2) Input water drainage. 3) Paper filter. 4) Gas outlet. 5) Temperature probe connector. 6) RPM probe connector. 7) Power supply socket and switch with fuse holder. 8) Water sensor. 9) Output water drainage 10) Drainage filter cup. 11) Standard RS-232 serial interface connector. 12) Empty / Not used 13) Particles filter. 14) Gas inlet. 10

1.3 STANDARD ACCESSORIES 1) 5,80 m. hose with gas takeup tip. 2) Line power cord. 3) This manual. 1.4 OPTIONAL ACCESSORIES (Refer to Part number) 1) O2, CO2, HC, NO, NOx (*) 2) RPM. and RPM probe (*) 3) RS-232 (*) 4) Clock / Calendar (*) 5) 24 columns internal printer (*) 6) Oil temperature probe. (*) 7) Trolley. 8) Personalized print out 11

2 DESCRIPTION OF OPERATIONS 2.1 INSTALLATION PROCEDURE Remove the instruments from its package, install it on a trolley and connect accessories as follows: - connect RPM inductive probe, if provided, to the RPM connector placed on rear panel; - connect gas hose to the gas takeup tip being sure that the arrow on the filter placed on the hose is in the direction of gas flow, then connect the other side of the hose to the condensate filter on rear panel; - connect temperature probe (*), if provided, to the rear panel connector; Leave accessories always connected to the instrument, even if not used, to speed up operations. Warning: once unpacked, the instrument may have internal NiCd battery discharged; this means that real-time clock (*) has no date / time or a date / time value incorrect. In this case the instrument must be connected to power and left powered on continuously for 24 hours to insure full charge to internal NiCd battery. Then follow instructions to setup real-time clock. 2.2 POWERING UP THE INSTRUMENTS Connect the line power cord to the instrument and switch it on; the instrument starts printing the preamble. Wait for 15 min. (15 min it is the max. time) of warm-up time before to start measurements on gases. The FUNC display show the warm-up time remaining. Warm-up procedure doesn t stop until the analyzer reach the requested temperature. After this procedure the analyzer automatically performs a self-calibration then it will pass to the exhaustion stage. 2.3 USE OF THE INSTRUMENT 1) After switching on, the instrument automatically sets to the following conditions: - 4-stroke engine type (RPM selection) - O2 display (FUNCTION selection) 12

2) Insert take-up tip into the motorcar exhaust pipe, connect RPM probe to one of the spark plugs cables and insert the temperature probe, if provided, into the oil measuring rod receptacle. 3) After warm-up, instrument is ready to work; user may select, using FUNC key, one of the auxiliary parameters available on FUNCTION display. 4) For gas measurement user presses MEAS key causing a self-calibration, after which analyzer passes to a gas exhaustion stage. During this period the instrument, if gas is present, periodically performs calibrating procedures (every 10 min.), while automatically turns the pump off in case of gas lack for at least 10 min. 5) Operator may decide every time to print out data using P1 key, provided that pump is on. 6) Once measurement has been completed, or whenever the operator wants, he may decide to terminate gas exhaustion pressing MEAS key. However, if no action is taken the instrument automatically turns the pump off after approx. 10 min. of continuous operation, to preserve the pump from an useless stress. 2.4 CALIBRATION USING GAS BOTTLE Manufacturer recommends a calibration with certified gas bottle (see Periodic Maintenance Utility chapter) every twelve months. In some countries legislation defines specific rules. Please contact our distributor for this periodical service activity. 2.5 OXYGEN TRANSDUCER REPLACEMENT The oxygen transducer (*) life-time is 12 months (minimum) from the date of delivery. Please contact our distributor for periodical replacement. If the oxygen measurement, as well as the Lambda factor, are not shown during the gas analysis it is the time to replace the oxygen sensor. 2.6 NITRIC OXIDE TRANSDUCER REPLACEMENT The Nitric Oxide transducer (*) life-time is 18 months. It starts from the date of delivery. Please contact our distributor for periodical replacement. 13

3 PERFORMING A TEST 3.1 STANDARD TEST Here the suggested procedure to test an engine is explained. It is also shown that INFRAGAS-196 is a complete instrument to test in an exhaustive way the combustion process and all the related devices of a car engine. A) Install and switch on the instrument as explained in the preceding chapters. B) Insert the gas takeup tip into the exhaust pipe. C) Start the car engine and connect the RPM probe to one of the spark plugs cables, being sure that the arrow on the body of the clamp is in the direction of cylinder. D) Insert the temperature probe into the oil rod receptacle. E) Using FUNC key select ambient temperature (AMB C) and verify that its value is in the range 0 45 C. F) Using FUNC key select ambient pressure (PRESS mb) and verify that its value is in the range 850 1050 mbar. G) Using FUNC key select oil temperature and wait until this parameter has reached 80 C to be sure that engine has been properly warmed up. In case of lower temperature keep the engine at about 2000 RPM until this temperature is reached. H) When the proper oil temperature has been reached verify that RPM value is in the range declared by the car manufacturer. In case of missing declaration RPM must not exceed 1000 RPM. I) If the 15 min. warm-up time is over, and Pump is OFF, press MEAS key and start sampling exhaust gases (after a preliminary automatic self-calibration) until gas readings are stable. J) Print data (*) as a report of measurements done. Note that printer gives an additional parameter: the corrected value of CO (CO corr). This paramenter is helpful in case of leaks in the car exhaust pipe. Expression for CO corr is the following: where (#) it is: [CO] corr % = (#) x [CO%] / ( [CO%]+[CO2%] ) = 15 for engines supplied with gasoline = 12 for engines supplied with CH4 = 14 for engines supplied with GPL 14

if CO+CO2 is lower than 15, otherwise CO corr = CO K) Compare following data with the corresponding ones declared by the car manufacturer, or with expected values: - CO - CO2 - HC - O2 - Lambda Lambda is a parameter computed as follows: Lambda = Num / Den where: Num: 21 x [ [CO2] + ([CO]/2) + [O2] + ((HCV/4) x 3,5 / (3,5 + [CO] / [CO2]) - 0.00877) x ([CO2] + [CO]) ] Den: [21+0.5628 x (([CO]/[CO2]) / (3,5+([CO] / [CO2]))]x[ 1+HCV/4-0,01754/2] x [CO2]+[CO]+[HC] x6 x10-4 ] where HCV = 1.85 for engine supplied with Gasoline = 2.57 for engine supplied with GPL = 4 for engine supplied with Methane With [CO], [CO2] e [O2] = % in vol. and HC = ppm in vol. If out of range data are measured, proceed with proper repairs and adjustments on the motorcar. L) After this work, print a report (*) of repairs and adjustments done. 15

3.2 CARES AND NOTES - During tests be sure that RPM probe cord is not passing close to the other cylinders or to the coil to avoid electronic noises. - Be sure that arrow on the clamp of RPM probe is in the right direction (to the cylinder). - Sometimes RPM probe cannot measure RPM. It depends on very special kind of plug cords strongly shielded. In such cases write manually RPM on printed report as read from the engine speed indicator. - Before every test, verify that condensate filter is not full of water to avoid an unpredictable stop of the test itself for a possible automatic condensate drainage. In this condition the analyzer must be switched OFF. The water must be removed from the filter before powering up the device again. - The internal porous septum of condensate filter must be cleaned periodically to avoid flow missing. To do this first be sure that pump is off, then remove the small silicone hose from the drainage valve pinchcock and unscrew carefully but firmly the plastic glass of filter; the internal septum can be removed by acting on the screw placed below it. The porous septum can be cleaned by bathing it with gasoline or trichloroethylene. After a while, blow in compressed air and put it back in its place. Finally screw the plastic glass, being sure that the o-ring is well positioned, and put the small silicone hose in the valve pinchcock. - Replace periodically the paper particle filter. - If the "Err1"... Err5 messages appears on FUNCTION display verify that: - the gas tip and the hose are not blocked up or full of condensate; - the condensate filter is not full; - the particle filter is not damaged or blocked up; - the gas exhaust of instrument is not blocked up. Note that in this case, after having removed the block, it takes about 5 min. to restore O2 measurement stability because of possible pneumatic stress of Oxygen sensor. - for more information see the Troubleshooting chapter on this manual. - It is advisable to remove, almost every day, water from gas hose by blowing in compressed air in the direction of particle filter arrow (from the tip to the instrument) obviously after having removed the hose from the instrument. 16

- When oil temperature is over maximum temperature the "or" message (out of range) is displayed on FUNCTION display, if oil temp. is selected. - The "or" message may also appear when Lambda are selected on FUNCTION display. It means that these parameters are out of range (see ranges in Chapter 6). - When temperature is below 0 C or above 45 C the "or" message is displayed on FUNCTION display if amb. temp. is selected. - When date / time values are not correct (out of range), date and time are not printed by the instrument. A date / time setup procedure must be performed. - The "ON" led on front panel blinks when power supply is out of its range or IR emitter its broken. 17

4.0 INFPLUS Software (Note: At the installation you can check on Assemblad Web Site www.assemblad.it, download section, if there is any up dated version) 4.1. Features of the program Infplus is a DOS program which is able to connect to ASSEMBLAD equipments through their serial ports in order to take control of them and displaying and archiving their data. Two database structures are also included in it, enabling the recording of the emission target parameters issued by the car manufacturers and also a customer database containing the data regarding both the customer and his vehicle. Infplus has also the capability of generate many statistical or analytical reports and redirecting them to the printer or to a text file, which is useful for importing from some commercial spreadsheet programs for further examinations. Inserting data in the databases, enabling their growth, is up to the user as ASSEMBLAD doesn t provide any prerecorded data regarding the vehicles. 4.2. Installation under DOS In order to install InfraPlus on your computer running DOS please insert the diskette into drive A: then type "A:install<enter>" The software will be copied on your hard disk in the directory named "INFPLUS". To run the program type "INFPLUS<enter>" from the DOS prompt of a DOS shell after rebooting the computer in DOS mode. A.pif file is also supplied in order to run the program from the Windows Desktop. 18

4.3 Running InfraPlus Before running InfraPlus please check the connection between the PC's RS232 COMx port and the analyzer. When running InfraPlus a main menu with 6 items and the ASSEMBLAD logo will appear. Don't worry if after few minutes the screen will change, it is just for saving the screen. InfraPlus is shipped as default with these communication settings: Port : COM1 Speed : 9600 Word : 8 bits Stop : 1 bit Parity : None If the default port (COM1) doesn't match with your PC's port, you have to switch the configured port to COM2 using the <F7> key. 19

WARNING!: Don't change at all the other parameters, please change only the COMx port if required. After that you can go to the gas analyzer section striking the <F1> key. If an error message will appear, or the system respond very slowly, please check again the wire connection as well as the communication parameters in use. 4.4 Gas Analyzer section This section shows - the analyzer's status - all measurements made by the Infragas analyzer. - a menu describing the hot keys availables. - a subform containing vehicle manufacturer's data - two header rows describing the vehicle under test 20

4.4a. Analyzer's status There are three small windows describing the current analyzer' status. 1. the Fuel window displaying the currently selected fuel. 2. the Stroke window displaying the n. of strokes for RPM evaluation 3. the Status window describing the internal analyzer's status as IDLE : Analyzer is waiting for commands MEASUR : Analyzer is measuring (printout is allowed) LOWFLO : Analyzer is in low flow condition CAL : Analyzer is calibrating itself LINE : Communication with Infragas 196 impossible 4.4b. Measurements Analyzer is showing here its measurements. A string 'over' means an overrange situation detected. A string '---' means no data available. When the analyzer is in 'MEASUR' status the measurements are compared with the current 'Test limits'. If they don't fall within these limits they will be shown in reverse mode. 4.4c. Hot keys <F1> VEHICLE TYPE Make selection of the vehicle's type. The selection is made from the registered vehicles. You can register new vehicles, as well as new manufacturers, using the <F3> key labeled DATA BANK on the first menu. A form requesting some data will appear. You can select first the manufacturer using the <space bar> or typing the first letter. Then you will be prompted for selecting the vehicle. You can select it by the <space bar>. Type the <ESC> key for leaving without confirming. <F2> VEHICLE DATA Get data concerning the vehicle under test. These data, if present, will be printed on the report. After the plate number insertion,a search in the internal plate number database is made. If the match is found, no more data are requested and the analysis screen is shown again. If no such plate number is found, some further data like the chassis number have to be entered. After that, a new database record regarding the vehicle is created and all the tests will be referred to that vehicle. Late, it is possible to reload that plate number for filling up the database record with the vehicle owner s data. <F3> 2S/4S Stroke selection for RPM evaluating. 21

<F4> FEEDING Fuel selection between Gasoline, LPG, Methane and Unleaded gasoline for Catalysed vehicles (only for Korean version: CO Ng and Alcohol). <F5> PUMP Activates and stops the pump. When the pump is activated the analyzer will go to a Calibration state first, then to a Measuring state. When the pump is stopped the analyzer will go back to the Idle status. <F6> LAMBDA sensor analysis (option) It displays a graphical screen that shows in real time the voltage across the lambda sensor for a period of 10 seconds of time. It is used for check the efficiency of the cathalyst system on cathalysed vehicles. In order to use this feature a special cable must be used for preleving the signal from the LAMBDA probe. <F7> PRINT Printing is enabled only when the analyzer is in its measuring state. A standard international form will be printed containing also, if inserted, other informations concerning the vehicle. If the printer is not connected, the report will be printed by the Infragas internal printer, if present. If a vehicle s plate has been previously entered, the measured values are recorded in the internal database after each print request, updating automatically the date and the result of the last test preformed. Only for Korean version: In order to obtain the Korean official form printout the key <F9> must be used instead. <F8> END Leaving the program. 4.4.d Subform of manufacturer's data This form is filled, if the information about the vehicle are inserted, with the vehicle manufacturer's data. They are useful for comparing them with those of the vehicle under test in order to make the best regulation for the vehicle. They are structured in two columns as minimum and maximum. 4.4.e Header If vehicle data are present, the vehicle's type and plate will be shown here. If not, a default string of the gas analyzer's manufacturer and the model will appear. 22

5.0 REAL-TIME CLOCK (*) SETUP (Manual adj) [ Function not implemented on the model PC-Module ] 1) Press FUNC key and P1 key simultaneously. The instrument will display the "GiO" message on HC display (day setting) and a 2 digit number on CO display, indicating currently stored day. Act on MEAS and P1 keys respectively to increase and decrease current day value and then press FUNC key. 2) The instrument now shows the "MES" message on HC display (month setting) and a 2 digit number on CO display, indicating currently stored month. Act on MEAS, P1 and FUNC keys as described above. 3) The instrument now shows the "Ann" message on HC display (year setting) and a 2 digit number on CO display, indicating currently stored year. Act on MEAS, P1 and FUNC keys as described above. 4) The instrument now shows the "ore" message on HC display (hour setting) and a 2 digit number on CO display, indicating currently stored hour. Act on MEAS, P1 and FUNC keys as described above. 5) The instrument now shows the "Min" message on HC display (minute setting) and a 2 digit number on CO display, indicating currently stored minute. Act on MEAS, P1 and FUNC keys as described above. After minutes setup, FUNC key pressure causes real-time clock setup termination and a return to normal run. 23

6.0 OPERATIONS AVAILABLE FROM KEYBOARD [ Function not implemented on the model PC-Module ] 6.1 UPDATING THE CLOCK/CALENDAR New Date & Time can be updated using an external PC running the A196 program connected via the serial line. If a PC can t be used press simultaneously the FUNC + P1 keys. The HC display will show in turn Gio, Mes, Ann, Ore, Min as Day, Month, Year, Hours, Minutes and the CO display the current setting for the value involved. The values shown in the CO display can be changed using the key MEAS to increase and the key P1 to decrease them. The key FUNC confirm the value shown then propose the next one in the shown CO2 list. 6.2 SELECT THE RIGHT FUEL For each vehicle test the right fuel must be selected in order to evaluate the values of LAMBDA and the CO corrected according to the existing laws. The selection is possible during the phase of electrical autozeroing preceding each vehicle test. In this situation the string CAL is written on both CO and CO2 display and the O2%-FUNC display show the actual selected fuel as: PEt = Petrol / Gasoline MEt = Methane LPG = Liquefied petroleum gas PEt C = Unleaded Petrol / Gasoline MEt C = Methane LPGC = Liquefied petroleum gas Catalityc cars Catalityc cars Catalityc cars Press in this phase the key FUNC until the right kind of fuel is shown. The selection made is active until a new one is issued. At the powering up the fuel selected is the default one as ben. 6.3 SELECT THE NUMBER OF ENGINE STROKES The selection is possible during the phase of electrical autozeroing preceding each vehicle test. In this situation the string CAL is written on both CO and CO2 display and the HC display show the actual selected mode: 4St. Press in this phase the key P1 until the right kind of mode is shown (4St or 2St). The selection made is active until a new one is issued. At the powering up the mode selected is: 4St. 24

7.0 RESIDUAL HC TEST Some version of the instrument does have an automatic procedure for the residual HC detection. On these instruments, the procedure is carried out immediately after the autozeroing phase. When the Cal disappears from displays the CO display will show a symbol like nnn indicating the residual HC test in progress. The procedure in the best case takes about 5 seconds of time after that the analyzer will resume its normal measuring state. If instead a value greater than 20ppm of HC is detected, the CO measurements are inhibited as long as the HC value still remain over 20ppm, enabling the incoming air flow to clean the internal path from residuals. Only when the HC value decreases below 20 ppm the normal measuring state is restored. For the instruments that don t have the above procedure configured, the same test should be performed manually by the operator as follows: Disconnect the gas probe from the vehicle being tested. Now have the analyzer carry out a calibration or auto-clear by pressing the MEAS key. After the CAL phase the CO, CO2 and HC displays should go down to zero relatively quickly. The CO and CO2 readings will certainly drop down rapidly, but the HC display could remain above 20 ppm especially if vehicles particularly rich in HC had been tested earlier. Eliminating Residual HC If residual HC exceeds ppm, leave the analyzer with the pump on and with the gas probe in air until the HC readings go below the required level. Persistent HC Residues: If, even after the above procedure and reasonable pumping time, HC readings remain high, some parts of the gas probe or condensate filter will have to be cleaned. Disconnect the tube from the probe. To clean the condensate filter switch off the analyzer. Remember to replace the corpuscular filter at the input to the gas probe periodically, as a large amount of oil and contaminant deposits form on it. And this could be the cause of very high HC residues. 25

8.0 AIRTIGHT SEAL TEST (Not in all models) To carry out the seal test, proceed as follows: After carrying out a calibration, and with the pump on, place the specific cap for this test (supplied with the analyzer) on the tip of the gas probe (or close off the holes on the end of the gas probe if you do not have the cap). as soon as the cap is on, the analyzer should realized that cannot draw in gas and the FUNCTION display will read Err1. If this appears, the seal test has been successfully passed. If the analyzer does not have the required seal, no Err1 reading will appear and you will have to investigate to find out what is wrong. Normally the problem is due to some breakage on the uptake probe or on the rubber tube leading to the analyzer. If you cannot remedy this fault, contact an authorized service center for advice and/or spare parts to eliminate the problem. 26

9.0 TECHNICAL DATA Ranges of measurements and display resolution: RANGE RESOLUTION CO 0 9.99 vol % 0.01 % CO2 (*) 0 19.9 vol % 0.1 % HC (*) 0 9999 ppm 1 ppm O2 (*) 0 9,99 vol % 0,01 % O2 (*) 10 21,4 vol % 0.1 % RPM (*) 400 9999 rpm 1 rpm Oil Temp. (*) 0 130 C 0.1 C Amb. Temp. (*)[#] 0 45 C 0.1 C Amb. Press. 850 1050 mbar 1 mbar NOx (*) 0 5000 ppm 1 ppm [#] Gas analyzer Internal Temperature Amb. Ranges and display resolutions of computed data: RANGE RESOLUTION CO corr. 0 9.99 vol % 0.01 % Lambda 0.50 1.50 0.01 Displays and leds: 5 high efficiency Red and Green led displays. Power on led indicator. Pump on led indicator. Keyboard: 3 functional keys keypad. Printer (*): On board 24 columns Serial interface (*): Standard RS-232 serial interface for connections with future expansions or data processing equipments or service. 27

Other functions: Flow missing warning message on display. Automatic condensate drainage. Automatic self-calibration. Voltage out of range indication. Future developments: The instrument has the possibility to add a further standard RS-232 serial interface. Moreover it is possible to update software to comply with future European or local laws. Response time: 20 sec. max Warm-up time: 15 min. max. Operating temperature: 5 45 C Power supply: 220 Vac, 50 Hz with 0.5 A max absorption (110, 230, 240 Vac and/or 50, 60 Hz on request) Dimensions: 395 x 195 x 440 mm Weight: 16 Kg approx. 28

10.0 - TROUBLESHOOTING and maintenance 10.1 Err1... Err5 appears on CO, CO2 and HC displays. Err1 = The input gas flow is insufficient. (Depress 80 mbar - Verify and cleaning thepaper filter and the condense filter). Err2 = The gas input circuit is closed. (Depress 150 mbar - Verify and cleaning the paper filter, the condense filter or inlet tube). Err3 = The gas output circuit is closed. Err4 = The N2 flow during Cal phase is insufficient or coal filter is dirty. (Check for coalfilter). Err5 = The N2 flow during Cal phase is stopped or coal filter is very dirty. (Check for coal filter or electrovalve). 10.2 Automatic drainage of condensate water The Err1 or Err2 messages appears when filter is dirty or an occlusion occurs in the gas path, both internal and external. Usually the problem is solved cleaning the filter (part E of the picture below). Remove the filter (E) and wash it using gasoline then dry it with compressed air. Infragas 196 have a permanent pump for flushing out condensate water by itself. If pump doesn t work properly (when it detects water into the gas tube) it stops itself immediately. The message Con is shown on displays. In this situation turn OFF the Gas Analyzer. Check the problem in filter, water pump, tube or water sensor (B) and remove the water from this through valve (F). Paper filter (D) (E) Input Gas (B) H 2 O sensor (C) valve H2O sensor (F) (Not in all Models) To the pump drenage input Infragas-196. Components on the rear panel 29

To clean the filter (E) remove the tube (C) and subsequently unscrew the filter cap and then the filter screw. To remove water from sensor (B) turn the knob (F) CCW (counter-clockwise). After this operation remember to close the valve (F), turning the knob CW (clockwise). 10.3 Additional troubleshooting Ref. Fault Possible Cause or Remedy 1 The analyzer does not go on. Remove the power supply cord. Open the door to the fuse box on the switch unit and replace the blown fuse. 2 All the displays read zero. Check voltage on the three analog chan- The printer is operating nels as described in the service manual. normally. The cause could be low infrared emissions. If this recurs, replace the infrared emitter and then carry out electric and gas calibrations. 3 Some of the displays show Check voltage on the three analog chanvalues close to the upper nels as described in the service manual. limit of the scale, such as The cause could be a lack of infrared CO=9.99 or CO2=19.9, etc. emissions. If this recurs, replace the infrared emitter and then carry out electric and gas calibrations. 4. One or more displays remain Check voltage on the three analog chanat zero or close to the maxi- nels as described in the service manual. mum value on the scale. The problem may be due to a broken infrared receiver. If this recurs, replace the infrared receiver or the entire preamp board and then carry out electric and gas calibrations. 5 Oxygen levels are always Check the expiry date on the sensor high, even in the presence (the mean life is about 15 months). of other gases. 6 When the analyzer is The analyzer has suffered an electric switched on the PEF shown shock. Reinitialize using the disk is not the same as stated. supplied with the device. Check the 30

service manual for the mode. 7 Some values on the display The analyzer has suffered an electric are absurd. shock. Reinitialize using the disk supplied with the device. Check the service manual for the mode. Carry out electric and gas calibrations. 8 The printer does not start Make sure the pump is on. Remember that when you press the P1 only one printout is possible for each key. measure cycle. 9 The printer only issues part If the analyzer is programmed for of the ticket, then it stops. catalyzed vehicles (unleaded fuel) the procedure is correct. Bring motor to the accelerated minimum, press P1 again, the printer will complete the message. 10 One or more displays read The analyzer shows a low flow of Err3 out gases. Make sure that the exhaust gas tube on the analyzer is free (sometimes microorganisms colonize this terminalpart and block gas outlet). 11 One or more displays read The measurement is out of range.. -or 12 One or more displays read The measurement is not available due to ---. lack of probe or it is not programmed. 13 One or more displays read The internal temperature range for proper Out. analyzer function has reached the allowed minimum or maximum. 14 The display readings quiver. Outside interference has generated an alarm in the display. Switch off the analyzer, then switch in back on to cancel this effect. (Make sure that the RPM probe wire does not cause interference). 15 The RPM displays gives Make sure that the RPM clamp is firmly discontinuous readings. closed and that there is no interference from nearby cables. Make sure there are no breaks on the spark plug cable and that it is not excessively shielded. Take appropriate measures if necessary. 31

(Some models of Infragas have a variable external damper to compensate for strong signals, use it if necessary). Make sure that there are no breaks or cracks in the ferrite core of the clamp. 16 There is no reading on the Oil temperature is only shown when the oil temperature display, or probe detects temperatures above 45 C. the reading is -or or ---. Never put the oil temperature probe in water, it could be irreparably damaged. 17 The ON (power) led on the The power supply voltage is beyond the keypad is flashing. range for proper operation. Some programs can print a message such as Mains voltage out of range once each time the device is switched on Take appropriate precautions which may include using a mains voltage stabilizer. 18 The oxygen display reading Check the gas inlet probe from the remains high while the other muffler, there may be breaks in it. gas readings are normal or Check airtight seals as described in the low. operator s or service manual. 19 The PUMP light on the keypad Make sure that the pump is actually is on, but the reading never aspirating gas. If there is no aspiration changes. the pump may be blocked or the membrane is broken. Replace the pump. 20 The analyzer cannot connect Make sure that the serial cable properly with the PC for connecting the PC and the analyzer is service via the serial port. properly inserted. If this does not happen, carefully recheck the serial cable, PC port and Baud rate settings. 21 The service PC cannot Find the disk for the analyzer you are find the analyzer file. checking. You can identify it by the analyzer serial number (in models only by the last 4 digits). If you are working with the PC using the C drive, copy File Axxxxxxx. 196 into the appropriate directory from the disk the one that comes with the analyzer. 22 The analyzer carries out There are probably voltage changes from unexpected electric calibra- standard power supply. tions. The printed message (on some versions 32

of the program) could show whether the problem is due to mains voltage or frequency. 24 During measurements the Operation should be considered normal. analyzer periodically carries The analyzer carries out periodic Cal out cal electric calibrations calibrations from the program when it even though they were not detects gas in the chamber, it can also requested. carry out other unexpected calibrations when it detects that some parameters do not fall within its correct measuring logic. 25 The printed report contains This is due to a fault in the print a white (unprinted) vertical mechanism which is irreparably strip. damaged. Contact the technical service department to have the printer replaced. 26 After a CAL phase Leave the pump on, with the gas probe in the HC display shows a value free air. The gas probe and filters above 20 ppm. could be contaminated by previous vehicles with high HC values. 27 The analyzer does not pass See Airtight Test chapter in the operator s the airtight test. manual. 33

11.0 WARRANTY This device was built with care and carefully inspected before it left the factory. It is guaranteed for one year from the date of purchase by the final user. To enjoy full rights under this warranty and avoid the risk of invalidation, you must mail a copy of the Warranty Certificate to the factory within 10 days of the purchase date. The warranty covers all defects in materials and workmanship. The warranty does not cover: wiring, probes, the remote control unit and the accessories. These items are subject to wear and their efficiency depends on how they are handled. The warranty does not cover damage caused by accidents, impact or dropping the instrument, or by negligence, improper use, non-compliance with the instructions and improper storage. If the device has such defects as to require technical service, you must return it to Assemblad or an authorized service center. Shipping charges shall be covered by the customer. ASSEMBLAD, even supplying support on demand for the first installation of the equipment, disclaims any liability for damages and injuries caused, even to third parties, by an improper installation, maintenance, defective or unsafe electrical connections. Further, ASSEMBLAD disclaims any claim for damages from anyone due to a miss utilization of the equipment for any reason. The warranty shall immediately become invalid if the device shows any signs of tampering. The sole court of jurisdiction for any disputes arising from the application and/or interpretation of this warranty is the Court of Florence (Italy). 34

COPYRIGHT by ASSEMBLAD S.r.l. Via Marzabotto, 4 50013 Campi Bisenzio (Florence) ITALY Tel. +39 / 055 / 890485 Fax +39 / 055 / 890496 http:// www.assemblad.it E-Mail: info@assemblad.it Reproduction and/or disclosure prohibited Edition: Sept. 2005 EMC CEE 89/336 73/23/CEE EN 50081-1 / EN 50082-1 EN 61010-1 and are Registered Trademark 35