Ultratune Gas Analyser User Manual
Contents
1. OF gt Leakage Test FAILED Check sampling hose and ALL External Filters and Hoses If the problem persists please call a Service Technician aq Leak Test Control Panel Miel Ei Leakage Test Passed Finish Issue 1 0 ULTRA TUNE Page 5 of 11 Gas Analyser User Manual Doc Ref 100 098 034 3 4 Filter Replacement Immediately before use the four filters located on the front panel should be inspected for excessive contamination If excessive contamination is present they should be replaced with an approved replacement The Master Filter With water trap contaminates from the inside and contamination is therefore not immediately obvious Please contact your supplier for details on spare filters Note A Leakage Test must be performed after replacing any of the filters to check the seal on the flexible piping connectors 3 5 Starting Emission Measurements Once the warm up and the leakage test have been completed sampling of a vehicle exhaust pipe emission may begin Click on the Start button now and the Gas Analyser will begin sampling Insert the probe of the Gas Analyser fully into the Exhaust Outlet The vehicle engine temperature must be at normal operating temperature Note Please observe the manufacturers specifications Auto Data books will normally provide the optimum running temperature as well 3 6 Interpretation of Measured Results Immediately after the exhaust emission gases reach the G2. Congratulations on your purchase of the 4 Gas ULTRA TUNE Exhaust Gas Analyser The information in this document 15 subject to change without notice and does not represent a commitment on the part of ULTRA TUNE No part of this manual may be reproduced or transmitted in any form or means electronic or mechanical including photocopying and recording for any purpose without the written permission of ULTRA TUNE The software described in this document is furnished under a license agreement and may be used only within the constraints of the license agreement These constraints are as follows a A single license of the Gas Analyser Software is implicitly supplied upon your purchase of the Gas Analyser Unit Use of more than one Gas Analyser Unit off the same license 15 prohibited b Disassembly or reverse engineering of the software in any form or means 1s prohibited c The licensee may make a copy of the software for backup purposes only d The licence issued is specific to each Gas Analyser The licensee may therefore install the software on as many computers as desired 2 0 Getting Started 2 1 Brief System Overview Two versions of the ULTRA TUNE Gas Analyser are available a Gas Analyser and PC contained within single cavity housing b Gas Analyser only contained within single cavity housing Includes external PC interconnection cable Depending on your choice of the above it may be required for you to interconnect the communication ca
3. very small error but this should not exceed a few ppm units in either direction Once the Gas Analyser has reached steady state operating temperatures the error usually reduced to almost zero 4 6 Leakage Test Failure A failed leakage test window appears as per the example in paragraph 3 3 Leakage test failure can be caused by internal or external leaks in the Gas Analyser piping system Typical trouble spots include linkages in the piping system The user should attempt clamping any external piping connections to identify leakage points Failing this the unit should be referred to a service technician to trace internal leakage faults or faulty pressure transducers 4 7 Low Flow Detected If a low sampling flow rate is detected the software will alert the user with warning window The Gas Analyser employs internal pumps to facilitate the flow of gas from the sampling probe through the system to the exhaust gas ports If the flow is blocked or the pressure is insufficient the built in self diagnostics will prevent further measurement Please follow the instructions in the warning window to correct the condition Probable causes include a The Master Filter has been obstructed b There is a leak in the filter connecting pipes Issue 1 0 ULTRA TUNE Page 9 of 11 Gas Analyser User Manual Doc Ref 100 098 034 4 8 Insufficient Bar Graph Resolution The MAXIMUM values of the bar graphs may be set using the GRAPH LIMITS control win
4. Gas Analyser User Manual Doc Ref 100 098 034 Table of Contents LU BEFORE STARTING PF CHAP CUP ETUR 2 ZU GEITING S TAICEED ce ko deer v Eo dea dee esc os cose Eau N a 2 2 4 DDR ROY Se 2 2 2 ELECTRICAL INTERCONNECTION WITH EXTERNAL PERSONAL COMPUTER csccsccsscssccscceccsccsscscescescens 3 2 9 OAS INTERCONNECTION LM 3 24 IRONTTANBL OVERVIEW S 5 4 3 5 domu spo tte amma ceto ute ulta 3 3 07 OPERA TIONAL DESCRIPTION 5 eos cee srckseecccehensisselsessnessecdvssacesnelsedesewsoesesvaesouccuesbeasesedsacseseseteoneaes 4 2 1 MAIN SOFTWARE CONTROL PANEL OVERVIEW sensro ete Uce eu oad sven ued aden tee dedi eed seen de ews 4 32 eesti gio bale Patel te mU 4 SPME Sd cL E eee E RI SE ne AN 5 3S4 PIEPBR BP Ee Ma NW soupe MEM su MU G 6 5 5 OD LARTING 2 MISSION IVIBASUPEMBNIS cet ctin totos teen n Sac DD LU LM DD D LET 6 30 INTBRPREEATIONSOP MEASURED TS tpe sii eu ate aba xem edid MO EE LEE 6 3o JI RUIN TING Loa eater oett E end I A ee 6 3 8 TERMINATING EMISSION MEASUREMENT cccccsscccscccsscccscccsscesscusccescceesscusccussceusseusccecceusceusceesceeussenscss 7 9 9 S DM I UE LOL D
5. The CO HC readings are measured using an infrared spectrometer located within the analyser while the O readings are measured using a chemical sensor module The result is a reliable and repeatable measurement of the principle gas concentrations required to perform a Lambda calculation Issue 1 0 ULTRA TUNE Page 2 of 11 Gas Analyser User Manual Doc Ref 100 098 034 2 2 Electrical Interconnection with External Personal Computer The Ultra Tune Gas Analyser communicates with an external Personal Computer via a single standard RS232 communications port only Most modern PC s are supplied with at least 2 RS232 communications ports located on the rear panel assembly It is recommended that the user connects a mouse or alternative pointer control device to the 9 pin COM port connector leaving the 25 pin COM port available for connection to the Gas Analyser In the event that the connectors are of the incorrect pin count 25 way to 9 way and vice versa conversion adapters should be readily available from any reputable computer vendor Alternatively please contact your Gas Analyser supplier who will supply a conversion adapter 2 3 Gas Interconnection Four gas connector ports are available on the front panel assembly of the Gas Analyser These perform functions as follows a Calibration Port Only used when performing calibration procedures with reference gas b Sampling Port The emission sample is sucked into this port from the sampl
6. Units In W Show CO Temperature Units In Celsius Ei ns ow Hydrocarbon Range 0 20000 ppmHex Show 02 PN Show NOx Oxygen Resolution High Show RPM Number of RPM Cycles 4 Cycle Show RH Show Pressure Show Oil Temp Show Ambient Temp Show External Temp Ignition Normal Pressure Resolution High Hydrocarbon Reading ppm ENEN ENEN EN Oil Temperature As Peleus As 1 min m Temperature Resolution High Cancel 7 Help Gas Analyser Only On Startup Ho 5 Windows Selected Printer Apple Laser riter on LPT1 Printed Report Type E A Graphics 4 12 Lambda Reading Missing The Lambda reading calculation requires the presence of realistic CO CO and O values If the software Main Panel Screen Lambda measurement indicates while valid exhaust emissions are being sampled please contact your dealer 4 13 Further Technical Support If you have any questions or technical queries please do not hesitate to contact your supplier or call for technical support on 082 652 4707 ULTRA TUNE Technical Consultant direct Issue 1 0 ULTRA TUNE Page 1 lof 11
7. as Analyser sensors the Main Panel Bar graphs and Lambda gauge will begin to display the mixture composition The IDEAL mixture for most cars running under idling conditions is a LAMBDA value of 1 00 Interpretation of the Lambda value measurement in conjunction with the oxygen measurement will give the user valuable insight into the vehicles performance Some interpretation examples are given below Should the measured value EXCEED 1 00 eg 1 40 the mixture is TOO LEAN Should the value be LESS THAN 1 00 eg 0 80 the mixture is TOO RICH If Oxygen content too high Fuel Air Ratio may require adjustment Exhaust may have a leak Probe may not be properly seated in the exhaust outlet Probe may have a leak An internal User adjustable time delay may stop sampling automatically after the time has elapsed If this time is insufficient the user may adjust the auto stop time under the Constants Setup window 3 Printing Results Sheets The Gas Analyser software supports the printing of measurement results using any Windows supported printer Once the button is clicked and the unit switches to RUNNING mode a button appears under the Lambda reading Clicking this button will result in one of two output formats being printed on the Windows system printer Graphic printouts are recommended for Laser or Bubblejet printers while Text printouts are recommended for Dot Matrix printers The selection between printout options is made under th
8. ble between the PC and the Gas Analyser Please see paragraph 2 2 for more details The analyser is shipped as standard with the ability to measure the concentration of 4 basic emission gases as follows a Carbon Monoxide In percent of total sample volume b Carbon Dioxide In percent of total sample volume c Oxygen In percent of total sample volume d Hydro Carbons In parts per million Hexane Propane ppm Additional measurements that may be included at a increased cost by customer request are as follows a NOx gas concentration b Engine RPM c External Temperature These measured values are used to calculate the Lambda Reading in real time using the internationally accepted Brettschneider Formulae and display it on the PC screen A correctly tuned motor should result in a Lambda reading of 1 00 although this is considered an optimum value Please see paragraph 3 5 for further details The Gas Analyser uses an extensive array of built in test facilities to ensure sustainable accuracy and long term reliability Automatic Zero Calibration is periodically performed to reduce short term inaccuracies even further The user may monitor the zero calibration sequence by observing the cycle on the PC screen A maintenance scheduled reference gas calibration 15 required approximately every year depending on the frequency of operation of the unit during that period Please refer to your dealer for further details
9. dow as follows Graph Limits The user may adjust these values to obtain a more visible bar graph measurement For example the CO limit may be changed from 10 to 2 since CO emissions are usually quite low when catalytic converters are fitted 4 9 Cannot Obtain Printout of Results The Gas Analyser software is capable of printing the results of a measurement on any Windows supported printer Please ensure that the Printer options under Windows are correctly setup The exact setup procedure is dependant on your particular operating system but is usually found under the Settings or Control Panel folders Please ensure that the Selected Printer under PREFERENCES is also correct Note There are two printout formats full graphic and text only as selected under the PREFERENCES menu The analyser must be sampling in order for a printout to be made 4 10 Selecting the Test Option under Main Does Nothing The Test option listed under the Main pulldown menu is reserved for diagnostic and service purposes and is not accessible under normal operating conditions Issue 1 0 ULTRA TUNE Page lO of 11 Gas Analyser User Manual Doc Ref 100 098 034 4 11 Items Missing From Main Control Panel The user may select which items appear on the Main Control Panel from the PREFERENCES window The factory preset checkboxes are as follows Preferences Unit Selection Display Options Pressure
10. e PREFERENCES window selected from the Main pulldown menu Issue 1 0 ULTRA TUNE Page 6 of 11 Gas Analyser User Manual Doc Ref 100 098 034 3 8 Terminating Emission Measurement process The sampling pump will turn off and the button will reappear The PERIODIC ZERO CALIBRATION window will pop up automatically and the unit will complete a mandatory zero calibration cycle before returning to IDLE state Note The unit will force a PERIODIC ZERO CALIBRATION when required from time to time without having completed a sampling phase This is normal operation and ensures that the unit will be promptly ready for measurement when it is required It is for this reason that the user is urged not to leave the sampling probe in the exhaust outlet for extended periods of time while the unit is not in use To begin using sampling exhaust emissions once again simply click the button again Once the user has completed the measurement ie the button will terminate the sampling Penodic ero Calibration Ea Current Phase Get State All Pumps Off Change to Filter Pump On stabilise ero HC CO CO Calibrate 02 3 9 System Shutdown Ensure that the unit is in its IDLE condition as indicated by the CURRENT STATUS window on the bottom left of the screen IDLE condition may be forced by clicking the button if required Clickig the button on the top right of the screen will close the Gas Analyser application Dep
11. ending on how your Gas Analyser software was installed this will either shut down Windows completely or return the user to the Windows operating system If the Gas Analyser is contained in a separate enclosure to the Computer the computer should be switched off BEFORE the Gas Analyser This sequence is important It is advisable to remove the power connection to the Gas Analyser and Computer to avoid damage from power line spikes and lightning induced surges Issue 1 0 ULTRA TUNE Page 7 of 11 Gas Analyser User Manual Doc Ref 100 098 034 4 0 Trouble shooting 4 1 Condensation Warning The internal spectrometer may be rendered inoperable by excessive moisture content in the sampled gases To prevent this from happening the Gas Analyser has interlock hardware built in to warn the user when excessive condensation is present The following window will pop up superimposed on the Main Control Panel Current Phase Get State Elapsed Time 5 All Pumps Off Change to Filter Drain Pump On Clear Condensate Hestore State The unit attempts to clear the condensation by switching to its Drain filter path and averting gas from the spectrometer sub system If the fault persists after the sequence of execution described in the window completes itself please follow these instructions a Shut down the computer Use the keystrokes CONTROL ALT DELETE simultaneously if required b Disconnect the sampling hose from the Gas Analyser and blow
12. ensue 7 EIRMOD LIB OS ds LO LOU NL CR sere EE A E EO EA E EARO 8 dI CONDENSATION AV ARNIN iu mani SERM toned Lon ra cu Ead 8 4 2 CONDENSATION WARNING WINDOW FROZEN 0 cccscccscccscccscccssccusccesccessseusccesceeesseusccuscceesseusscuscsesesens 8 45 CANNOT DETECT GAS ANALYSER sons 8 4 4 GAS ANALYSER SWITCHES TO IDLE MODE ON ITS 9 4 5 NEGATIVE HYDRO CARBON MEASUREMENT scccsscccssccscccscccssccesccusccecceusceusccescceusceusceuseceesseusceueeenesens 9 q 0 LEAKAGE FEST ATE URE padecer 9 4 7 LOWFLOW DETECTED wide ETT Seite 9 4 8 INSUFFICIENT BAR GRAPH RESOLUTION ccecccseccscccsccccccusccesccecccesccesccecscesceuscceseeesseusccesceeaeceusess 10 49 CANNOT OBTAIN PRINTOUT OF RESULTS iie etre e bes aos Hewes cc ume dne o resa e m s a 10 4 10 SELECTING THE TEST OPTION UNDER MAIN DOES 10 ITEMS MISSING FROM MAN CONTROL PANEL 11 MM PAME A T 11 a 15 PORTHBR TECHNICAL SUPPOR TD stasis cnt eae aerias eden ah 11 Issue 1 0 ULTRA TUNE Page of 11 Gas Analyser User Manual Doc Ref 100 098 034 ULTRA TUNE Gas Analyser User Manual 1 0 Before Starting
13. ing probe using negative pressure c Exhaust Port 1 Exit port for Sampled emission gas under positive pressure d Exhaust Port 2 Exit port for Drain cycle under positive pressure 2 4 Front Panel Overview Power LED Calibration Port Sampling Filter Sampling Port Calibration Carbon Filter Master Filter with Water Trap The filters are required to prevent contamination of the gas concentration sensors within the unit and will require periodic replacement The frequency of this replacement depends on how regularly the unit is sampling incoming exhaust gases It is for this reason that the user is recommended NOT to leave the gas analyser sampling for extended periods of time when the measured values are not being used Issue 1 0 ULTRA TUNE Page 3 of 11 User Information Gas Analyser User Manual Doc Ref 100 098 034 3 0 Operational Description Bar Graph Indicators 3 1 Main Software Control Panel Overview gy Ultra Tune Exhaust Gas Analyser Version 1 12a CO b EN l CO2 HC ppm CT O2 Start Leak Test Current Status TEST STATUS Idle Pressure 1027 9 mbar Ambient 3161 Celsius 3 2 Initial Switch ON If your Gas Analyser is contained in a separate enclosure to the Computer please ensure that the Gas Analyser Power is turned ON approximately 10 seconds BEFORE the Computer power is turned ON This allows the Computer software to locate and identify the Gas Analyser im
14. mediately upon power up This sequence is an important step to ensuring reliable communication between the Gas Analyser and the Computer Immediately after the Gas Analyser is powered up it will begin its warm up sequence This can take anything between 8 and 15 minutes This warm up sequence is timed within the Gas Analyser system from system start up This means that even though the Analyser may have been running for some time powering off and back on again will require that the warm up sequence is repeated It is for this reason that ULTRA TUNE recommends that the user does not cycle the power to the unit on a regular basis The user may observe the CURRENT STATUS window of the main control panel to determine whether warm up is in process Once the warm up has completed the CURRENT STATUS will display TEST STATUS Idle The Gas Analyser software will enable the button located to the left under the Lambda gauge Sampling of the exhaust gas via the sampling probe is started by clicking this button The user should however refer to paragraph 3 2 before clicking the Start button Issue 1 0 ULTRA TUNE Page 4 of 11 Lambda Gauge Lambda Digital Leak Test Start Start Testing System Pressure System Temperature Gas Analyser User Manual Doc Ref 100 098 034 3 3 Leakage Testing The Gas Analyser measures the pressure within its sampling system continuously This pressure measure
15. ment in mbar may be observed on the main control panel In order to extract certain relative gas densities the unit needs to be confident that there are no leaks in its sampling system Including the exhaust sampling probe A Leakage Test 15 facilitated for this purpose This test should be performed at least once a day by clicking the button located to the right under the Lambda gauge A Leak Test Control Panel pops up with instructions to ensure that the sampling probe is attached and that its end is pressure sealed against any samples being sucked in The user should ensure that a good seal is maintained throughout the Leakage test period Approximately 30seconds since the majority of Leakage test failures are as a result of inadequate sealing of the sampling probe Do Test button should then be clicked An internal pump will start up and the result will be displayed the Leak Test Control Panel once the test period has expired Ifa failure is reported please refer to the Trouble Shooting paragraph no 4 6 of this document gj Leak Test Control Panel OF XI Please ensure that the sampling probe has been connected to the gas analyser and that the probe has been Capped The probe must remain capped throughout the leak test which will take approximately 30 seconds To continue with the leak test Press Test To Abort the Leak Test Press Cancel Do Test Leak Test Control Panel
16. ndow d Another application running under the Windows operating system has control of the Serial Communications port to which the Gas Analyser is connected Typical culprits include FAX software and PC to PC data transfer packages Issue 1 0 ULTRA TUNE Page 8 of 11 Gas Analyser User Manual Doc Ref 100 098 034 4 4 Gas Analyser Switches To Idle Mode On Its Own Please ensure that the Maximum Run Time setting found under the CONSTANTS SETUP window 15 sufficient to allow completion of an emission measurement The Brettschneider Constants are displayed for user reference only and cannot be edited under normal conditions These constants are set by Government Emission Control authorities Constants Setup Brettschneider Constants Maximum Hun Time Communications E Seral Port 0 Temperature Protect CY 0 01 7500000000012 Abort run if Ambient H cy 1 27599999999984 Exceeds External by 7 map RUE Unit Has Full Keyboard Attached 4 4 5 Negative Hydro Carbon Measurement The HC ppm measurement may read slightly negative when no exhaust emission is present at the sampling probe input The PERIODIC ZERO CALIBRATION may automatically remove this condition however while the Gas Analyser is still reaching stable operating internal temperatures this condition may persist The reason for this 1s the incredibly high resolution of the HC measurement process Measurement of Parts Per Million gas molecules can result in a
17. out the HOSE with compressed air to remove any moisture content Do not blow into the Gas Analyser under any circumstances c Inspect the filters for condensation build up and renew filters if required d Power up the Analyser and leave it to run under sampling conditions with the probe disconnected for at least 2 hours Auto Stop time out may force the unit to terminate sampling prematurely depending on the time out setting found on the CONSTANTS SETUP window Adjust this value if required or alternatively restart the sampling process manually each time 4 2 Condensation Warning Window Frozen If the condensation warning window appears superimposed over the normal Main Control Panel window and the user cannot exit from this window by any means it is possible that the Computer and Gas Analyser serial communication link has failed and the application has locked up Pressing CONTROL ALT DELETE simultaneously is the only way to escape the condition Shut down the computer and the gas analyser for a period of approximately 10 minutes before powering up the system again as described under section 3 0 4 3 Cannot Detect Gas Analyser If the CURRENT STATUS window reports Communication Failure probable causes include a Gas Analyser was powered up after the Computer b Communications cable has been damaged or is not properly connected c Communications Serial Port number is incorrectly set under the CONSTANTS SETUP wi
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