Product Manual - Infrared Industries
Contents
1. 28 Exha ust Dilution I Rn RS IERIE ESS ERIS IERIE es Oi 30 CHAPTERS tanium mtn 33 EXHAUST GASJEMISSION EE E 33 Combustion Fundamentals 888888888888 33 GOS Eundarment lse i Rs tie Beek 33 Oxides of Nitrogen optional e ide eee anne a ea sb eb bus 34 Hydrocarbons enescu oo e A A A A A a 36 Carbon Monoxide it A AAA 36 CONDON DTE IAC a EUREN 38 LO THEE 40 Stoichiometric Fuel Mixtures to ette te the ete RID den 40 Catalytic COnVelters aet e oae dn PERS ERAN a 42 CHAPTER A EEA E A AEE EA NUR SRI ORITUR e RR AREE 45 TESTING 0 45 Using Analyzer Readings for Diagnosis eese eese eee nennen RON RON O RR nO ene 45 General Tailpipe Testing Tips io nte nere sa E ENERO RE ette eire id taa 47 Vel cle Inspecti n e re e EI 49 Engine Sa AA ia 50 Connecting Probe Hose to System ie pO a e MO PET PO sachs E D NEP NE mds 50 PITT A SHEILA 51 CHAPTER S IE Did ln OI e E Re PS 22 MAINTENANCE eire DR D rte stitit t eU E Ute oni diste e ie 52 Sample Hose oc aeo e e p GR RH DRE t ap P e iM 52 Filter Assembly c niter he eI ERR ER pec e I P e De Re tee de eic Re ne aa as oT 52 FONE PONG and2. 50 80 85 90 95 10 105 1 1 1 15 12 1 25 LAMBDA evaporative emissions CARBON MONOXIDE As Figure 6 shows the lowest HC emissions occur at an air fuel ratio of about 16 2 1 Since no engine combustion is perfect some vaporized HC in the combustion chamber is left unburned and exits the engine with the exhaust gases The amount of HC emissions from the engine depends to a great extent on combustion chamber design Also if the fuel mixture is too lean or rich to support complete combustion or if ignition does not occur in the combustion chamber at all HC emissions increase dramatically Gasoline evaporating from the carburetor and fuel tank are also sources of HC emissions known as evaporative emissions Vehicles built since 1970 minimize the escape of Carbon monoxide CO is an exhaust byproduct formed when combustion takes place in an engine with less than an ideal volume of oxygen rich fuel mixture combining a carbon atom with only one oxygen atom The carbon in the combustion chamber comes from the HC fuel and the oxygen from the inducted air Figure 7 CO Vs Lambda Carbon Monoxide CO RICH LEAN to 85 9 95 10 105 11 1 45 12 LAMBDA The richer the fuel mixture in the combustion chamber more HC less air the higher the concentration of CO in the exhaust Therefore anything that causes a rich air fuel ratio results in a high CO content
3. infrared Industrii CALIFORNIA USA 800 344 0321 2999 oe Figure 2 Rear Panel 1 Paper Filter Element 2 12 Volt DC Power Connector 3 Secondary Filter Drain 4 Water Separator Screen 5 Aspirator Water Purge Port 6 Sample Hose Connector 7 Zero Port 8 NOx Cell 5 gas only 9 Sample Gas Exhaust Port 10 Calibration Port 11 TACH Connector 12 Serial Communication Port 13 02 Cell CHAPTER 1 CONFIGURING THE ANALYZER The FGA4500XDS has various configuration choices that should be set by the operator before the first use This section outlines the configuration screens Jl INFRARED WINDUSTRIES Configuration Menu Leak Test Check 02 Cell Factorv Cal Reset Calibration RPM Setting Serial Port MORE PRESS MODE TO SAVE Configuration Menu MORE System Information Exhaust Dilution Record Interval Playback Erase Data Set Date amp Time PRESS MODE TO SAVE After powering on the analyzer you will see this screen called the Home Screen From this screen you can access the Configuration Menu by pressingthe MODE button This is the Configuration Menu screen To select an item use the A and V buttons to move between menu items The current item will appear in blue outlined with a blue box Press the MODE button to select the menu item Press MODE EXIT to return to the Home Screen at any time Not all menu items fit
4. increase because of incomplete combustion 1 CO levels are lowest when the air fuel ratio is nearly ideal because there is less oxygen and carbon left over due to the more complete combustion occurring at 8 85 3 95 10 105 11 1 15 12 1 25 LAMBDA ideal ratios Richer than ideal mixtures cause CO to increase leaner has little affect 2 COzlevels are highest when air fuel ratios areclose to ideal and decrease when the mixture becomes richer or leaner 3 CO levels are near zero when the air fuel ratio is near ideal because most of itis consumed in combustion It remains low with richer mixtures and increases when the mixture leans out STOICHIOMETRIC FUEL MIXTURES As can be seen from Figure the ideal stoichiometric 14 66 1 air fuel ratio Lambda 1 0 is near the point where the emission levels drastically change The stoichiometric air fuel ratio where the HC and CO levels are lowest is as close to perfect combustion as can be attained 40 Electronically Controlled Carburator Oxygen Catalytic Air and Fuel Mixture Control Solenoid Electronic Control Module Figure 11 Carbureted Fuel Feedback System Combustion temperatures and the air fuel ratio requirements can change in engines under dynamic load The only way to ensure that the air fuel ration remains stoichiometric under most operating conditions is to use a feedback system So modern e
5. Digital Altitude MEASURED Non Dispersive Infrared NDIR Chemical Cell Range 0 to 10 00 Range 0 to 10 000ppm Range 0 to 20 Range 0 to 25 Range 0 to 4 000ppm 2 C to 40 C 35 6 F to 104 F 40 C to 75 C 40 F to 167 F 120 240 VAC 10 50 60 Hz 12 5 Lb 18 5 cm high 29 5 cm wide 43 5 cm length 7 3 in high 11 5 in wide 17 in length 18mm high digits 4 digit LED s TI RS 232C 300m to 1000m 980 ft to 3300 ft 67 APPENDIX D WARRANTY NOTICE TO BUYER AND OR USER OF THE ANALYZER Exclusion of warranties and limitation of damages and remedies This analyzer is warranted against defects in materials and workmanship under normal use and service for one year from the date of delivery to the original purchaser The sole obligation of the seller and or manufacturer under this warranty is limited to repairing or replacing as the seller or manufacturer may elect free of charge at the place of business of the seller or manufacturer any parts that prove in the seller or manufacturers judgment to be defective in materials or workmanship within one year after delivery to the original purchaser This warranty shall not apply and is void if in the opinion of the seller and or manufacturer the portable analyzer or any component thereof has been damaged by accident other causes not arising out of defects in materials or workmanship WARRANTY EXCLUSIONS THIS WARRANTY AND THE SELLER AND
6. Filter service frequency is dependent on the operating conditions Continuous use testing vehicles that have not been warmed up to normal operating temperature or testing engines that have excessive emissions will require more frequent filter service analyzer an hose and probe disposable filter and bowl tubing to pump input Figure 3 Filter Assemblies The primary filter element is an unwoven disposable material inside a disposable bowl If debris builds up on the filter material becomes discolored and the sample flow is reduced the filter and bowl should be replaced Turn off power to the analyzer Remove the water drain tubing from the bottom of the filter bowl Remove the filter bowl by turning it counterclockwise Replace the old filter and bowl with a new one Use only Summit part number 12 01 05028 as a replacement Bow c FRONT PANEL AND EXTERIOR To maintain the appearance of the analyzer periodically clean the exterior with a soft damp cloth Use a mild detergent to remove grease CAUTION DO NOT USE CLEANERS SUCH AS ACETONE BENZENE CARBON TETRACHLORIDE GASOLINE OR TOLUENE AS THEY CAN DAMAGE PLASTIC COMPONENTS AND AFFECT ANALYZER ACCURACY IF THEY CONTAMINATE THE SAMPLING SYSTEM Gasoline brake fluid and penetrating oil spills should be immediately cleaned from the analyzer surface to protect its finish OXYGEN SENSOR 54 The oxygen sensor used in the analyzer requires replaceme
7. Start the test by pressing the MEASURE button The display will now prompt you to enter the starting odometer reading and the engine displacement GPM Mode odoM 000 0 Disp 0000 Use the arrow keys A and gt to enter the values 1 Accelerate the VUT at a rate of approximately 3 3 mph per second for about 10 seconds or until the VUT reaches 30 mph 2 Press the MEASURE key on the FGA4500XDS 3 Cruise at 30 mph for approximately 10 seconds 4 Decelerate to 0 mph 5 Press the MEASURE key to end the test You will now be prompted for the ending odometer reading Use the arrow keys A and gt to enter the values Press the MEASURE key and the final results will be displayed At this point you may print out the results by pressing the PRINT key When finished with the results press MEASURE to go back to stand by mode EXHAUST DILUTION The EXHAUST DILUTION function provides the operator with a warning in the MEASURE mode that the probe may not be positioned properly or that there may be a leak in the exhaust system of the vehicle It is 30 common to have the hose probe come out of the exhaust because the hose was kicked or for some other reason The EXHAUST DILUTION function is meant to warn the operator that this has happened The warning is based on the measurement of CO2 Typically vehicle exhaust has anywhere form 16 to 25 CO If the CO is ever below 12 whe
8. Check Engine Service Engine Soon or Power Loss lamp is functioning Ensure that personnel have not removed the bulb BASIC ENGINE OTHER SERVICE FUNCTIONS Check that engine timing idle speed fuel feedback system vacuum wave form cylinder time balance bar graph cranking amps bar graph etc are normal for the vehicle being tested ELECTRICAL SYSTEM Verify alternator operation and battery condition AC voltage from the alternator can cause improper computer operation and cause miscalculation of fuel delivery and timing 49 ENGINE CONDITIONING Before testing tailpipe emission levels engines should be at operating temperature 1 2 3 Maintain engine speed at 2000 RPM for 30 seconds Drop engine speed to idle for 30 seconds Test the engine Some vehicles require special conditioning other than the procedure given here prior to testing idle emission levels Failure to follow conditioning procedures will usually cause vehicles to fail state tailpipe emission tests even though all systems are operating as designed For further assistance contact the state emission inspection program administrator CONNECTING PROBE HOSE TO SYSTEM 1 8 9 Connect the FGA 4000 Analyzer power cord into a standard 120 VAC 50 60 Hz electrical receptacle or 240 VAC 50 60 Hz for analyzer set up for that voltage Set the POWER switch on the front of the analyzer to ON The analyzer enters the Warm up mode immediately
9. future tests 5 Do not place the probe in an exhaust pipe until the vehicle is at normal operating temperature This allows the exhaust system time to burn off any residual moisture 6 Test engines only when they are at normal operating temperature Testing with a cold engine does not provide useful test results due to fuel mixture enrichment and will contaminate the sampling filter quickly requiring more frequent analyzer service intervals 7 Never drive a vehicle over the probe sample hose or power cord 8 Perform the Leak Test periodically especially after probe changes and filter service to ensure accurate analysis 9 Prolonged use of the analyzer in conjunction with a dynamometer and a hot running vehicle under load could damage the exhaust probe hose and affect readings 10 To comply with anti tampering laws always follow the manufacturer s specifications when working on emission control devices 11 Always comply with the governing emission control standards and regulations in your locality when testing exhaust emission levels 12 Check the manufacturer s specifications and procedures before testing a vehicle 13 Before testing Tailpipe emission levels maintain engine speed at about 2000 RPM for 30 seconds followed by a 30 second normalization period at idle speed before reading gas values 14 Leaks in the exhaust system will adversely affect readings and should be repaired prior to testing 15 On vehicles w
10. Allow the analyzer to perform a complete Warm up and Zero cycle This may take up to fifteen minutes The remaining steps may be completed during analyzer warm up Connect the exhaust sample hose to the back of the analyzer at the filter assembly Wait until the analyzer indicates that it is in the STANDBY mode 30 minutes after the analyzer is in the STANDBY mode insert the probe into the vehicle tailpipe ensuring that the probe is fully inserted Press the START key Read the exhaust gas values on the displays 10 Compare the values shown to 11 All emissions standards 12 The engine manufacturer s specifications 50 analyzer disposable filter and bowl tubing to pump input Figure 14 Connecting Probe Hose to System NOTE On vehicles with diffuser screens in the tailpipe use the optional Anti Dilution Probe INTERPRETATION A fuel injected engine that meets all of the above requirements may still have problems masked by the feedback fuel control system Consult the vehicle maintenance schedule and perform the recommended service that may be required including service on emission control devices If values exceed specifications and allowances further diagnostic testing of the engine and exhaust system may be required 51 CHAPTER 5 MAINTENANCE The analyzer requires very little maintenance The following chart itemizes the schedule for those items that do require periodic maintenance wow Cal
11. EX eriOr TE ee ede ecce 54 Oxygen Sensor ainin e Danke ER eier ap pn bie Aes 54 NOx Sensor Oxide of Nitrogen ede dee tede ede dee tede e et od dee ee 55 Routine Cleaning s P ER E RU e RU REED PUR des 56 Returning the Analyzer for Service Repairs 57 CHAPTER 65 nn en ehe eiie een ie iet e e ertt NN 58 TROUBLESHOOTING PEORES ERE SE ERROR PO DRE een 58 Analyzer Troubleshooting e tet p baee ee Re ee Haee t de 58 APPENDIX TRE NN 61 LAMBDA CALCULATIONS due ette Redes 61 Brettschneider Fquation x e ke erre o dir e e his th ree A vn ete i Pepe o ss ih 61 APPENDIX Ds nn E ep damen eene eeiam 64 DAC OUTPUTS e OUI E CO ir tte diee 64 67 SBECIEICATIONS ie d PREND ORE 67 e eee eet bn 67 Output Data Interface ia easier Oa e EO e RP aei e be epe 67 APPENDIX ren ni IR E 68 WARRANTY 68 Notice to Buyer and or user of the analyzer 68 APPENDIX DA 70 GLOSSARYOR TERMS bran eU osea LM ead MI ims 70 INTRODUCTI
12. High hydrocarbon HC readings usually indicate excessive unburned fuel caused by lack of ignition or by incomplete combustion Common causes include a faulty ignition system vacuum leaks and fuel mixture problems 3 High oxygen 02 readings indicate too lean an air fuel ratio 4 Low Oz indicates a rich fuel mixture 5 High carbon dioxide 2 readings indicate a nearly ideal air fuel ratio and efficient combustion 6 Low CO readings indicate a fuel mixture either too rich or too lean exhaust system leaks or analyzer sample dilution 7 The byproducts of combustion are dependent on the air fuel ratio 8 O2 combines with HC to form CO and H20 9 O2 combines with CO to form 10 CO is an indicator of richness 11 HC is an indicator of leanness and misfires 12 02 is a better indicator of leanness and misfires than HC 13 CO and O2 are equal at the stoichiometric air fuel ratio 45 14 2 and CO are indicators of exhaust system integrity sample hose and probe integrity or both 15 is an indicator of combustion efficiency that peaks at or near the stoichiometric air fuel ratios and decreases with lean or rich air fuel ratio 16 Air injection systems dilute the exhaust sample with 02 17 O2 is essential for proper operation of the catalytic converter Its concentrations are essentially unchanged by the catalytic converter providing a window through the catalytic converter to the engine O
13. OR MANUFACTURER S OBLIGATION HEREUNDER 19 IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING WITHOUT LIMITATION THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND ALL OTHER REPRESENTATIONS CONCERNING THE SALE USE AND OR PERFORMANCE OF THE ANALYZER No person is authorized to give any other warranties or to assume any other liability on behalf of the seller or manufacturer This warranty shall not be extended altered or varied except by written agreement signed by the seller and the buyer LIMITATION OF DAMAGES IN NO EVENT SHALL THE MANUFACTURER OR SELLER OF THE PORTABLE ANALYZER BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF OR IN CONNECTION WITH ANY OBLIGATION IMPOSED UPON THE SELLER OR MANUFACTURER IN CONNECTION WITH THIS WARRANTY SUCH INCIDENTAL AND CONSEQUENTIAL DAMAGES SHALL INCLUDE WITHOUT LIMITATION LOSS OF USE LOSS OF INCOME LOSS OF PROFIT INCLUDING LOSSES TO BUSINESS INTERRUPTION LOSSES SUSTAINED AS THE RESULT OF INJURY INCLUDING DEATH TO ANY PERSON 68 AND LOSS OF OR DAMAGE TO PROPERTY THE LIABILITY OF THE SELLER AND OR MANUFACTURER ON THIS WARRANTY IS LIMITED TO ACCEPTING RETURN OF THE PORTABLE ANALYZER REFUNDING ANY AMOUNT PAID THEREON AND CANCELING ANY BALANCE STILL OWING ON THE EQUIPMENT THIS REMEDY IS EXCLUSIVE REPAIR OR REPLACEMENT PROCEDURE 69 APPENDIX GLOSSARY OF TERMS This glossary defines terms used throughout t
14. SENSOR 55 1 Turn offthe power to the analyzer 2 Remove the NOx sensor connector from the top of the sensor 3 Remove the NOx sensor form the bottom of the O2 NOx Transducer Manifold at the back of the analyzer Turn the NOx sensor counterclockwise viewed from below and remove it from the manifold 4 Install the new sensor in the mounting block 5 Turn the sensor clockwise viewed from the top into the mounting block until the O ring is seated 6 Install the sensor connector into the top of the sensor ensuring it is connected correctly NOTE connector is keyed so that it only plugs in correctly one way Do not force the connector into the Sensor ROUTINE CLEANING The analyzer should be cleaned routinely to prevent the build up of dirt which can contaminate samples and mar the appearance of the instrument Clean the case exterior and other accessible parts of the analyzer with a cloth dampened with warm water and mild soap 56 RETURNING THE ANALYZER FOR SERVICE REPAIRS If the analyzer needs service contact your dealer for complete instructions If you need to ship the analyzer pack it in its original container We recommend that you insure the shipment To help in getting effective service follow these guidelines 1 Follow all instructions in this manual to be sure that the problem is with the analyzer and not with other equipment sample purity or cable connections 2 Ifyou determine that repair i
15. in the exhaust shows the relationship between CO output and air fuel ratio Figure 7 shows that the CO level decreases as the air fuel ratio approaches about 15 1 Lambda 1 05 and maintains this low level even while the mixture is further leaned out Because of 36 this CO is a good indicator of fuel mixture richness but a poor indicator of leanness This fact makes the HC and CO content in the exhaust good gauges of engine performance in addition to their importance for Clean Air Law compliance When HC and CO readings are compared with oxygen and carbon dioxide readings the results can be used to indicate catalytic converter efficiency 37 CARBON DIOXIDE Carbon dioxide CO2 is a combustion byproduct formed when one carbon atom bonds with two oxygen atoms an oxygen molecule and by the oxidation of CO in the catalytic converter Unlike CO CO2 is comparatively harmless animals give off CO2 as a byproduct of respiration Figure 8 CO2 Vs Lambda CARBON DIOXIDE C02 cos CERA CO is a good indicator of combustion efficiency because its volume in the exhaust peaks at stoichiometric air fuel ratios Figure 8 shows the relationship of CO to the air fuel ratio CO peaks as the combustion chamber fuel mixture approaches about 15 1 Lambda 1 05 and decreases when the mixture becomes leaner or richer This fact makes CO in the exhaust a good indicator of efficient combustion levels can als
16. necessary Service filter elements Low sample flow Restriction in Zero port Check for obstructions in zero port on during zeroing the back of the analyzer Zero port is under the CAL port All function keys Microprocessor latch up Turn analyzer power switch OFF and inoperative then back ON 59 60 APPENDIXA LAMBDA CALCULATIONS BRETTSCHNEIDER EQUATION In order to calculate the value of Lambda from measurements of combustion by products in the exhaust ofa gasoline engine a mathematical model is necessary This model must include consideration for the chemical make up of the fuel being burned and many other factors The model is complicated and the derivation of the equation beyond the scope of this manual We will merely site the equation used by the system and the assumptions that were used in implementing it The equation used in the system is the one derived from a model created by Prof Brettschneider It is commonly referred to in the industry as Brettschneider s Equation It is shown below A B C where A es GE 21 50ux CO CO2 K CO CO2 In the equation for A the term x the mass ratio of water in air even at a relative humidity of 100 this term is very small As x becomes small A approaches 1 A is assumed to be 1 in the system s calculations CO2 CO 2 NOx 2 02 Hcv 4 K K C0 C02 Ocv 2 C0 C02 1 Hcv 4 Ocv 2 CO CO2 HC In the equation for B Hcv is
17. reason to believe that the factory calibration is no longer producing accurate analysis results The gas analyzer does not require gas calibration very often Therefore the gas calibration tanks are normally closed It will be assumed in the calibration process described below that the calibration gas is turned off at the tank CAUTION WHEN CALIBRATING OXYGEN WITH CAL GAS other than ambient air THE INTERVALS BETWEEN CALIBRATIONS FOR THE OXYGEN SENSOR WILL BE CONSIDERABLY FURTHER APART DAYS WEEKS OR MONTHS DEPENDING ON HOW OFTEN THE UNIT IS GAS CALIBRATED AS COMPARED TO THE AUTO ZERO CYCLE PERIODS MINUTES BECAUSE THE ANALYZER IS INHERENTLY SPAN STABLE IT IS BEST IF THE OXYGEN SENSOR IS ALLOWED TO SELF CALIBRATE AUTOMATICALLY ON AMBIENT AIR DURING THE AUTO ZERO CYCLE RATHER THAN TO USE CAL GAS NOTE The oxygen sensor and circuitry do not need calibration they ate checked automatically during zeroing If the sensor deteriorates to the point of needing replacement a Zero Failure may occur after zeroing To calibrate the analyzer see Chapter 1 DUAL EXHAUST DUAL EXHAUST is a sub mode of the MEASURE mode In this mode the right and left exhaust measurements will be averaged The sequence for a Dual Exhaust Measurement is 25 Dual Exhaust Measurement Insert Probe In First Exhaust Press MEASURE to Continue Dual Exhaust Measurement 3 co 1 25 02 18 67 AFR 0 00 Press MEASURE to Continue Dual Exh
18. this feature PRINTER OPTION Full systems can be ordered with the internal printer option The printout will represent the display values that the system measures and calculates at the instant the PRINT button is depressed RECORDING DATA 23 When RECORD is selected the analyzer will store the readings in memory If previous data has been recorded in the analyzer the current recordings will be appended to the end ofthe previous data Recording will continue until STOP RECORD is selected from the Measurement Mode display or the time has exceeded the Record Interval set in the Configuration Menu A record interval of zero will indicate to only stop recording when STOP RECORD is selected or there is no more space in memory for data to be stored Approximately 16 minutes of data can be stored by the analyzer After you are done with the MEASURE mode and the analyzer is in standby you can replay the data by selecting Playback in the Configuration Menu The data can also be uploaded to the PC CALIBRATION The analyzer as shipped has been calibrated at the factory and is designed to maintain calibration accuracy for extended periods of operation Due to the sophisticated circuitry used in the analyzer frequent calibration is not required However we recommend a gas calibration about every six months to ensure the integrity ofthe analyzer Some states have regulations governing the time intervals between calibrations It is important to comply wi
19. 1 Levels of Combustion Components and Tune up Problems CONDITION RESULTS Too Lean Poor engine power Misfiring at cruising speeds Burned valves Burned pistons Scored cylinders Spark knock or ping Slightly Lean High gas mileage Low exhaust emissions Reduced engine power Slight tendency to knock or ping Stoichiometric Best all around performance Slightly Rich Maximum engine power Higher emissions Higher fuel consumption Lower tendency to knock or ping Too rich Poor fuel mileage Misfiring Increased air pollution Oil contamination Black exhaust Along with the use of other tools and equipment the analyzer can be used as a diagnostic tool to help identify that a problem exists This logical approach along with other information and knowledge will lead in a direction that will help to identify the most likely cause of the problem GENERAL TAILPIPE TESTING TIPS 1 Read and follow the maintenance and calibration procedures outlined in this manual 47 2 Do nottest exhaust emissions on vehicles that are smoking excessively or are in obvious need of engine repair Testing exhaust gas under such conditions may contaminate the sampling system and cause inaccurate readings 3 Keep the probe tip openings clean and free of debris 4 Do not place the probe tip in liquids or allow liquids to be drawn into the analyzer s sampling system If the sampling system is contaminated by any liquids it will affect the accuracy of any
20. INFRARED INDUSTRIES Measurement Mode 0 co 0 00 0 00 Nox PPM 20 87 RPM AFR FGA4500XDS User s Manual Infrared Industries 25590 Seaboard Lane Hayward CA 94545 Phone 800 344 0321 Fax 510 782 8101 www infraredindustries com TABLE OF CONTENTS CONTENTS iie d n dedo 8 ANALYZER SETUP eA oed ume ep ee e e die e de eet eet 10 TOWER UU NM 10 Printer Paper Install ti n 2 2 3 dee a asi 11 SYSTEM FEATURES eid eiecti de e eed eee ede ef e ed eode eei decies 13 ront Ranes 13 nn dd cited dada eine 14 CHAPTER lis 15 CONFIGURING THE ANALYZER eti d eee deep 15 Data Capture Options iir HERE retur PPS HERE des Error Bookmark not defined GEM Meas re Mode sie tee T reete debe tte Ue eet ee de eere ves Error Bookmark not defined CHAPTER uenenum S 22 USING THE ANALYZER sn garnieren hin cedet tee need pec E EE 22 rrr oS 22 Measuring Gas n 23 Recording s Saee ideis no ht SG d tie ne dest 23 A ERREICHEN 24 DUG Exhaust xe RIRs i n ute er siste NU CO 25 VL KON arrose e UR EQ P ERE EN RIEN UR ER GR RR ET MR EN GE RR 27 Grams per Mile Kilometer is at RR SR ER AREE RR QE ET I BREST
21. ON The analyzer allows the measurement of four or five gases in automotive exhaust It is capable of determining volume concentrations of HC as N hexane CO carbon monoxide CO2 carbon dioxide O2 oxygen and optionally NOx nitric oxide Based on gas concentrations the analyzer will calculate the Air to Fuel Ration AFR Lambda A and Grams per Mile GPM or Grams per Kilometer It will also provide a read out for the optional Tachometer that handles up to 30 000 RPM With this much information in one place you can diagnose and tune any fuel related issues while having all of the relevant information displayed in six super bright oversized displays All of the above is available as analog outputs in either 0 5VDC or 0 10VDC for interfacing to a data acquisition system In addition to the above you features the analyzer can measure exhaust gases from two tail pipes and average the readings or set up an exhaust dilution value to warn you if there are air leaks in the exhaust system The analyzer is fully portable Weighing only 9 pounds the unit is intended for use in a variety of indoor or outdoor environments The analyzer can be plugged into standard power outlet voltages ranging from 90 VAC or 260 VAC 50 60 Hz You can connect the FGA4500XDS to the car battery or cigarette lighter and take it along for a drive test to see how the vehicle behaves in real driving situations Using the internal record feature you can store the d
22. TROUBLESHOOTING ANALYZER TROUBLESHOOTING There are three failure modes that the analyzer might encounter General Failure Zero Failure and Failure to Calibrate For a General Failure and Zero Failure perform the following procedure 1 Verify that all the back panel ports are unobstructed including e Cal gas e Zero e Sample hose e Drain hose e Cal gas e Zero e Sample hose e Drain hose 2 Verify that the O2 sensor wire harness is properly connected to the top of the sensor 3 Replace the O2 sensor if it has been installed for more than six months or if its age is unknown 4 Check the filters 5 Ifa failure is still indicated service is required by an authorized Summit Analyzer service center For a Failure to Calibrate perform the following procedure 1 Repeat calibration 58 2 Ifthe analyzer still fails to be calibrated the analyzer can still be used but it will be at reduced accuracy It should be sent in for service when convenient When the default cal values are in use the analyzer can still be used but the displayed values will be less accurate It is recommended that the gas calibration procedure be performed to ensure accuracy SYMPTOM PROBABLE CAUSE SOLUTION Low sample flow 1 Restrictions in sample hose or Check for kinked plugged or probe pinched hose or probe Clean 2 Restrictions in sample filter probe tip with a small pointed tool Disconnect hose from sample inlet and blow out if
23. ata during the drive test and playback or download the information to a POC when you return ANALYZER SET UP This section provides a description of the set up of the analyzer When you are setting up the analyzer for the first time check for any damage that may have occurred during shipment POWER UP The analyzer can be operated from either AC or DC power sources For AC connections the analyzer will accept 90 260 VDC For DC the analyzer will run off 10 16VDC The AC power input connection is a standard 3 wire recessed computer type connector Various types of power cords may be used to connect to wall power Each will have a different connector to be compatible with the various supply voltages and wall sockets Attach the power cord to the rear of the analyzer and plug the end of the cord into the appropriate power source The 12VDC cable can be plugged into a cigarette lighter or battery for the power source Make sure that the sample probe has been placed in an area where there is only air to be drawn into the sample line Press the Power button to turn on the unit In the first 5 seconds all display segments and indicators will light in order to make sure they are functional The front panel will then display PLEASE STAND BY while the analyzer is warming up The warm up times may vary depending on analyzer s internal temperature The Zero and Pump indicators will be on during approximately 30 seconds after warm up period Do not attem
24. aust Measurement Second Pipe Insert Probe In Second Exhaust Press MEASURE to Continue Dual Exhaust Measurement 3 co 1 25 2 55 02 18 67 0 AFR 0 00 Press MEASURE to Continue Dual Exhaust Measurement Average 3 co 1 25 02 18 67 AFR 0 00 Press MEASURE to Continue To start the Dual Exhaust measurement insert the probe in the first exhaust and press MEASURE After the reading stabilizes press the MEASURE key This will store the first reading in memory Now insert the probe in the second exhaust and press MEASURE After the reading stabilizes press the MEASURE key This will take the second measurement and average the two exhaust pipe readings Press MEASURE The averaged results are displayed Press MEASURE to go back to the Measurement Mode display 26 ZEROING AUTOMATIC AUTO ZERO After power up and the WARM UP LOCKOUT phase has been completed the unit will begin operating The system will use a graduated AUTO ZERO timing cycle in order to automatically initiate AUTO ZERO cycles As we have seen above various operating modes may initiate an auto zero cycle The system does not include these as being a part of the AUTO ZERO automatic cycle The system does an AUTO ZERO every time the system enters STANDBY i e leaves a mode After this AUTO ZERO cycle the automatic cycle timing continues until the system leaves STANDBY The time period is normally fixed at about 10 minut
25. button will start the MEASURE sequence The first push ofthe MEASURE push button takes the analyzer out of the STANDBY mode and puts it in the MEASURE mode The Measurement Mode Display look like Measurement Mode 3 co 1 25 2 55 02 18 67 0 AFR 0 00 Press MODE to Select GPM GPKM TEST DUAL EXHAUST RECORD MEASURING In the MEASURE mode the analyzer turns on the pump drawing in the sample gas from the probe into the analyzer The analyzer then measures the sample gas and reports these reading to the display During the same process the analyzer will calculate the AFR and LAMBDA values are then reported to the display While in the MEASURE mode the analyzer will lockout the PUMP and ZERO keys on the display From the Measurement mode the analyzer can perform a Grams Per Mile GPM test calculate a Dual Exhaust measurement and record data These activities are listed at the bottom of the display and can be performed by using the and buttons to select the activity followed by pressing MODE to start the activity The currently selected activity is highlighted in blue letters and a rectangle surrounding the choice FREEZE DISPLAYS If it is desired to freeze the readings in the MEASURE mode press the HOLD push button while in the MEASURE mode This will freeze the display and the concentration values will not be updated while the displays are frozen Pushing the HOLD push button while the display is frozen will deactivate
26. dding Oz to the molecular structure of HC and CO This turns the HC into H20 water and CO2 carbon dioxide The CO is converted to Figure 13 shows the equations for this process 42 Oxidation of any compound requires an abundance of O2 In most cases engines are equipped with an auxiliary air inlet device typically called an A I R Air Injection Reaction pump or a pulse air system to inject additional air into the exhaust manifold or catalytic converter providing the oxygen needed for the reaction oxidation to take place Converters of this type are called oxidation or two way converters since they only treat two gases 43 As converter technology has progressed catalysts have been developed to treat NOx In this reaction oxygen is removed from the NOx compounds reducing them to nitrogen and oxygen This is called a reduction reaction Converters that combine the oxidation of HC and CO with the reduction of NOx are known as three way converters Three way converters are even more sensitive to air fuel ratio because their reduction of NO is only efficient at stoichiometric air fuel ratios HC 02 oxidation A H20 CO2 CO O2 CO EP M CM EXHAUST Pt Pd Rh EXHAUST IN un MEM GE OUT Figure 13 HC and CO Oxidation in a Catalytic Converter Catalytic converters both two and three way types only lower HC CO and NOx by a certain amount When the engine is operating properly these emissions a
27. e analyzer the date and time is printed on the printouts To set the date and time use the A and buttons to change highlighted values and use the buttons to select between fields The date format is dd mm yy and the time format is hh mm ss Press MODE to save the changes 21 CHAPTER 2 USING THE ANALYZER WARM UP PRE WARM UP LOCKOUT PHASE The system enters the PRE WARM UP LOCKOUT phase when power is first applied by pressing the POWER ON OFF switch main front panel The system goes into this state for five minutes During PRE WARM UP LOCKOUT the system turns on all the display segments and indicators All the digital displays show 8888 the decimal points and all the indicators are lit This is referred to as LAMP TEST The operator should use this phase to ensure that all lights and display segments are functional Inoperative display segments can easily lead to inaccurate visual readings The pump runs during this phase to purge any residual gases from the sample hose During this phase the operator should have the probe exposed to ambient air and should not be near any exhaust No other modes of operation can be initiated during this phase After the PRE WARM UP LOCKOUT phase five minute time period expires the unit goes into the WARM UP OPERATE phase The first function in this phase is an Auto Zero After the auto zero the system tests itself If the system is stable it will leave the WARM UP OPERATE phase and move
28. es but the ambient temperature affects the technical requirement for an AUTO ZERO cycle Therefore the system varies the time in between AUTO ZERO cycles based on the ambient temperature and the changes in ambient temperature MANUAL AUTO ZERO The operator may initiate an auto zero cycle any time the system is in STANDBY If the operator pushes the ZERO push button when the system is in CAL mode the CAL indicator is ON the AUTO ZERO indicator will flash to indicate that this may well be a bad time to zero the system because in MEASURE mode the cell is likely to have gas other than air in it AUTO ZERO SEQUENCE In the AUTO ZERO mode The sample pump is turned on e The SAMPLE ZERO solenoid is switched to the ZERO GAS and the sample cell is purged completely The system acquires and stores new zero data During this process the ZERO indicator light is on continuously The AUTO ZERO cycles last about 25 seconds 27 GRAMS PER MILE KILOMETER GPM is a sub mode of the MEASURE mode and implements an approximation to the IM240 tests In this mode you will be prompted to enter the beginning odometer reading and engine displacements in liters Once this information is entered the test begins and the IM240 driving pattern is driven or simulated on a dynamometer After the test is complete the ending odometer reading is entered and the test results are displayed in grams per mile or kilometer See Appendix C for details on this optio
29. he manual Air Fuel Ratio AFR The ratio by volume of air to vaporized fuel in the combustion chamber of an engine It is usually expressed as the amount of air to one part of fuel For example the ideal mixture for most fuels is 14 7 parts of air to one part of fuel This would be written as the ratio 14 7 to 1 or an AFR of 14 7 1 The smaller the quantity of air the richer the fuel mixture the larger the quantity of air the leaner the mixture Display The light emitting diode LED digital display where gas concentrations and calculated results are displayed Indicator Small LEDs that are on the front panel These devices are lit when the system is in the state the device represents Function A distinct operation of the analyzer Function Key A push button that initiates functions in the various analyzer modes of operation Lean Mixture An air fuel mixture containing less than the ideal amount of fuel LED Light Emitting Diodes used in the displays Lambda 4 A parameter that expresses air fuel ratio Lambda is the ratio of the measured air fuel ration to the ideal or most efficient air fuel ratio as shown below L AFR measured 14 67 When AFR is displayed as Lambda a value of 1 0 represents the ideal air fuel mixture of 14 67 1 Values of Lambda greater than 1 0 such as 1 3 represent a lean mixture Values of Lambda smaller than one such as 0 85 represent a rich mixture Mode An operational state for the sys
30. ibration Check Every Three Months Oxygen Sensor Replace Every Six Months Nitric Oxide Sensor Opt Replace Every Six Months Service filters more frequently if analyzer is operating continuously Checking and Cleaning the Probe Periodically check the holes at the end of the probe for dirt and debris Disconnect the hose from the analyzer at the sample inlet Using a small pointed tool clean the probe and blow away any debris using compressed air CAUTION DO NOT APPLY COMPRESSED AIR TO THE PROBE TIP WITHOUT DISCONNECTING THE SAMPLE HOSE FROM THE FILTER ASSEMBLY BACK PRESSURE COULD DAMAGE THE SAMPLING SYSTEM REPLACING THE PROBE 1 Remove the sample probe from the handle 2 Install the new probe on the handle and tighten Use only Teflon tape on fittings SAMPLE HOSE The sample hose must be free of cuts and abrasions that may cause leaks FILTER ASSEMBLY 52 The filter assembly uses a single filter and disposable bowl to keep the pump and internal sample system clean The exhaust gas sample enters the filter from the sample hose The filter element removes all the contaminants from the exhaust sample Exhaust gas flows through this filter element from the inside out so contaminants collect on the inside of the filter element Also water vapor contained in the sample gas condenses in the filter bowl where it is evacuated through the elbow fitting at the bottom of the filter bowl by the system pump 53 SERVICING THE FILTER
31. iscussion of combustion Under perfect conditions the combustion of a stoichiometric air gasoline mixture would result in carbon dioxide COz water vapor H20 and nitrogen which are all harmless combustion byproducts 33 Therefore if we measured the exhaust of a gasoline engine and found only H20 and we could assume that the engine was operating at an optimal level This also implies that if you measure the products of complete combustion H20 and and the products of incomplete combustion CO and O2 that the Air Fuel Ratio or Lambda could be calculated from these measurements This in fact is the case and the FGA 4000 series product offers an option to calculate Lambda from the gas concentrations measured The equation used by the system to calculate Lambda is discussed in detail in Appendix C NOTE Air fuel ratios are expressed by weight not volume An air fuel ratio of 12 1 Lambda 8 is 12 pounds of air mixed with one pound of fuel When a fuel mixture is lean there is too much air and too little fuel in the air fuel ratio If a mixture is rich it has too much fuel and too little air Because internal combustion engines are not 10096 efficient even with ideal fuel mixtures other substances are formed in the combustion chamber during combustion and are exhausted from the engine The major by products of real world combustion include e Carbon Dioxide COz e Carbon Monoxide CO e Oxides
32. ith air injection systems these systems should be disabled before some diagnostic tests Denying the system this air results in undiluted gas samples and inhibits catalytic converter operation for more accurate diagnosis 16 Insert the test probe fully into the tailpipe when testing exhaust emissions to prevent diluted readings 48 17 On exhaust systems with twin tailpipes that exit acommon resonator or muffler the exhaust sample can be diluted from outside air entering the tailpipe outlets To prevent this block off the pipe not used for the sample probe 18 On engines with fuel injection tailpipe emission readings are only valid atidle speed Testing at higher engine speeds is only valid when using a dynamometer However fuel injected engines should still be conditioned with the engine speed near 2000 RPM as recommended in TESTING TIP 14 19 On V type engines with only one oxygen sensor a misfiring cylinder in one location may have more impact on the Oz sensor than a cylinder in another location NOTE Remember to remove the blocking device when testing is complete VEHICLE INSPECTION EXHAUST SYSTEM INTEGRITY 1 Air management system Ensure that check valves are not leaking 2 Diverter valve air switching valve Ensure that valve is not sticking or leaking into closed off port 3 Exhaust system pipes and connections Check that connections are tight and there are no obvious leaks ENGINE LAMPS Verify that the
33. levels are higher on vehicles with properly operating air injection systems 18 If CO goes up O2 goes down 19 If O2 goes up CO goes down 20 With the air injection system disabled and the CO above 1 the catalytic converter is oxygen starved Without Oz it does not fire allowing exhaust concentrations to be more like readings taken ahead of the converter If readings are within the manufacturer s or local state federal allowable limits it can generally be assumed that the fuel ignition and emission control systems are functioning properly If they exceed the limits repairs or adjustments are probably needed The chart below lists some of the kinds of problems that could result in abnormal gas readings Oz Possible Problem s Rich mixture with ignition misfire Legend Faulty thermostat or coolant sensor Exhaust leak after the converter I Injector misfire catalytic converter operating H H H H Injector misfire catalytic converter not working combination of rich mixture and vacuum leak L L H H Ignition misfire lean conditions vacuum or air leak between airflow sensor and throttle body false air L H L Good combustion efficiency and catalytic converter action 46 L H L All systems operating within tolerance normal reading The following table lists some of the results possible when the air fuel ratio is sustained at conditions ranging from too lean to too rich Table
34. n About 30 states presently require smog checks of vehicles and of these only about 7 require in IM240 tests The IM240 test uses a dynamometer in a varying driving pattern and gives the results in grams per mile kilometer The IM240 driving pattern lasts for 240 seconds and involves the speed changes s shown in the graph below 60 50 Speed mileh 0 50 100 150 200 250 Time s The first 94 seconds of this pattern re sometimes referred to as a Fast Pass test If all of the limits for gm mile for the gases being tested are met during this phase then the vehicle passes the test and the more extensive 240 second drive test is not conducted This driving test can be approximated without a dynamometer by conducting a road test instead and taking data using the Infrared Industries model FGA4500XDS engine gas analyzer To perform this test follow the steps below THE 94 SECOND FAST PASS TEST APPROXIMATION 1 Position the vehicle under test VUT on a flat road with an uninterrupted length approximately 1 mile or place it on a dynometer The VUT and catalytic converter must be up to temperature 2 Connectthe tachometer and exhaust gas inputs to the FGA4500XDS 28 3 Putthe FGA4500XDS in the GPM measure mode from the stand by mode press the MODE button until you see on the display 29 Use V or A to select gpm grams mile measure modes When selected press MODE EXIT
35. n it should be measuring vehicle emissions it is most likely because the probe has fallen out Therefore the system checks to make sure that there is at least 12 CO in the gas in the sample cell when in MEASURE mode If not it flashes the EXHAUST DILUTION indicator The feature can be enabled or disabled by the operator The default is that EXHAUST DILUTION is enabled and that the threshold is 12 The function is enabled and the operator has an opportunity to modify the EXHAUST DILUTION threshold by pushing the EXHAUST DILUTION push button momentarily The threshold for the EXHAUST DILUTION function will be displayed in the top right CO display all other displays will be blank The operator can press the fl and U push buttons and the EXHAUST DILUTION threshold will increases or decreases its value When the operator has the value he wants to use we recommend 12 pressing ENTER will save the EXHAUST DILUTION threshold value and the EXHAUST DILUTION indicator will come on The system now has EXHAUST DILUTION active To disable the function when the feature is on i e the EXHAUST DILUTION indicator is lit press and hold the EXHAUST DILUTION push button for more than five 5 seconds When the feature is disabled the EXHAUST DILUTION indicator will be turned ou 31 32 CHAPTER 3 EXHAUST GAS EMISSION COMBUSTION FUNDAMENTALS To understand and interpret the information provided by the analyzer it is helpful to have an
36. nce This menu screen allows the operator to select between a 2 cycle and 4 cycle engine Use the lt and gt button to toggle between 2 cycle and 4 cycle engine This option is required because most 4 cycle ignition engines fire only on the compression stroke or every other crankshaft revolution 2 cycle engines fire with each revolution of the crankshaft so if your analyzer was set on 4 stroke cycle while measuring a 2 cycle engine your analyzer would display Y your actual engine RPM The same problem would occur if you had your analyzer set to 2 stroke while measuring a 4 cycle engine only in this case the analyzer would display 2X or twice the actual engine RPM Engine equipped with DIS Distributor less Ignition System along with some 4 cycle ignitions due fire on the exhaust stroke In these 18 SERIAL PORT Serial Port Configuration Printer PRESS MODE TO SELECT SYSTEM INFORMATION System Information PEF 0 512 Serial No 3890 Version 7 61 PRESS MODE TO CONTINUE cases an accurate RPM reading can be achieved by simply setting the analyzer to 2 stroke This selection defines the communications on the serial port Select PC if remote control and display is desired Note contact IRI for information on the software required for PC control Printer is selected if you are going to connect an external printer to the serial interface This screen shows information regarding
37. ngine computers monitor the O2 content of the exhaust gas The computer calculates the air fuel ratio and commands the fuel delivery device either fuel injector or carburetor to deliver the amount of fuel required to maintain the correct fuel air ratio A typical system is shown in 11 41 CATALYTIC CONVERTERS Ceramic monoliths type Figure 12 Typical Catalytic Converters The first attempt at reducing emission levels in automobiles was to get the air fuel ratios as close as possible to stoichiometric However even engines designed for low emissions and which are operating properly may not have HC and CO emission levels low enough to meet Clean Air Standards Catalytic converters are installed to further reduce emission levels A catalyst is a substance that increases the rate of a chemical reaction without being used up itself The catalytic converters used in automobiles contain a combination of the noble metals platinum palladium and rhodium These metals are applied to small beads or to ceramic baffle materials These materials called substrates provide tremendous surface area for exhaust gases to come in contact with the noble metal catalysts 12 shows the construction of two typical catalytic converters In operation exhaust gases pass into the catalytic converter from the engine where the gases flow past the catalytic metals Contact with these metals causes reactions known as catalytic oxidation in the exhaust gases a
38. nt every 12 months Several faults can be caused by an oxygen sensor defect including e Zero Failure in the after a zero procedure manual or automatic General Failure This may occur if the wire harness to the O sensor is not connected NOTE Once the shipping container can is opened the sensor begins to deteriorate Sensor life in open air is six months regardless of how often the analyzer is used SERVICING THE OXYGEN SENSOR 1 Turn off the power to the analyzer 2 Remove the oxygen sensor connector from the top of the sensor 3 Remove the O2 sensor form the top of the 02 NOx Transducer Manifold at the back of the analyzer Turn the O2 sensor counterclockwise viewed from above and remove it from the mounting block 4 Install the new sensor in the mounting block Turn the sensor clockwise viewed from the top into the mounting block until the O ring is seated 5 Install the sensor connector into the top of the sensor ensuring it is connected correctly NOTE The connector is keyed so that it only plugs in correctly one way Do not force the connector into the sensor NOX SENSOR OXIDE OF NITROGEN The NOx sensor used in the analyzer requires replacement every 12 months Several faults can be caused by a NOx sensors defect including e Zero Failure or after a zero procedure manual or automatic e General Failure This may occur if the wire harness to the NOx sensor is not connected SERVICING THE NOX
39. o be used as an indicator of exhaust system integrity 80 85 90 95 1 0 105 11 1 15 12 126 LAMBDA OXYGEN The level of oxygen 02 in exhaust gas is an indicator of air fuel ratio leanness The O originates in the air the engine inducts and mixes with the HC for combustion Since the atmosphere is about 21 the percentage or O2 in the exhaust gas after combustion is an indication of air fuel ratio leanness Figure 9 O2 Vs Lambda OXYGEN 02 02 LEAN RICH 18 In Figure 9 the O2 concentration is shown to be at a steady 14 low level when the fuel mixture is richer than about 12 15 1 Lambda 1 05 because all available oxygen is consumed 10 in the combustion process As the mixture gets leaner the O2 steadily increases because less of it is used in combustion Higher concentrations of O2 in the exhaust are therefore directly proportional to leaner air fuel ratios 8 85 9 95 10 105 11 115 12 125 LAMBDA 38 39 CONCLUSION Figure 10 Combustion Products Vs Lambda HC ppm PRODUCTS OF COMBUSTION RICH gt LEAN Figure 10 shows the relationship between the air fuel ratio and the four exhaust gases monitored by the analyzer It shows HC levels are lowest when the air fuel ratio is ideal because most of the fuel is consumed in combustion Richer or leaner mixtures or ignition problems cause the HC to
40. o purge the gas lines The bar at the bottom of the screen shows the progress of the process as it moves from left to right Once the purge is complete you will see this screen Enter each gas tag value by using the and Y buttons to change the value of the highlighted white digit and the and gt buttons to select a different digit To advance to the next Tag value press the MODE button When entering the tag values you should enter them just as they are on the calibration bottle Any gas you do not want to calibrate should be left with a value of zero Oxygen 02 does not get calibrated Fields containing a decimal point require tag values to be entered as percentages Fields without a decimal point should be entered as ppm Once you have entered the data for each gas begin calibration by pressing MODE 17 TURN CAL GAS 0 2 55 02 PRESS MODE TO CONTINUE CALIBRATING co 2 55 02 Turn Calibration Gas Off PRESS MODE TO CONTINUE RPM SETTING RPM Setting 2 Stroke 4 Stroke PRESS MODE TO SELECT At this point turn on your calibration gas When the gas is on and the gas readings have stabilized press MODE otherwise you can exit the calibration by pressing MODE EXIT This window will now display the current concentration values for the gases Calibration complete Turn off the calibration gas and press MODE to complete the calibration seque
41. of Nitrogen NOx e Hydrocarbons HC e Oxygen 02 Because the carbon monoxide oxides of nitrogen and hydrocarbon exhaust products are related to health and environmental concerns these emissions from automobiles are regulated by federal and state agencies OXIDES OF NITROGEN OPTIONAL Nitrogen makes up about 7896 of the air in Earth s atmosphere and oxygen about 2196 Therefore about 7896 of the air in the combustion chamber is nitrogen Nitrogen is inert and does not contribute to or detract from combustion Nitrogen and oxygen only combine with each other to form harmful oxides including nitric oxide NO and nitrogen dioxide NO when both gaseous elements are heated above 1371 C 2500 F NOTE Oxides of nitrogen NOX include all the nitrogen compounds formed in an engine s combustion chamber including nitric oxide NO and nitrogen dioxide NO2 The x subscript in place of numbers indicates that all nitrogen oxygen compounds are included Under some engine conditions the combustion chamber temperatures easily exceed 1371 C 2500 F combining oxygen and nitrogen to form NOx 34 Figure 5 NOx Vs Lambda NOx ppm 3500 3000 2500 2000 1500 1000 500 RICH OXIDES OF NITROGEN NOx LEAN 8 85 9 95 10 105 11 115 12 1 25 LAMBDA Error Reference source not found 5 shows the concentration of NOx in relation to the air fuel ra
42. on one screen To go between the two screens select the MORE menu item Press MODE EXIT to return to the Home Screen at any time 15 LEAK TEST Leak Test Please Standby Test in Process Leak Test LEAK TEST PASSED PRESS MODE TO CONTINUE CHECK O2 CELL 02 Chemical Cell Check PRESS MODE TO CONTINUE This option will run a leak check of the system To run the test place the red cap on the end of the probe before selecting this menu item During the test this screen will be displayed When the test is complete the results will be displayed Possible results are PASSED BAD PUMP OR FAILED Press MODE to exit the test This test assumes that air is in the sample stream and reads the O2 cell to see if it needs replacement The bar graph shows how much life is left in the cell The color of the bar graph will turn red when the O2 cells needs to be replaced 16 FACTORY CAL RESET Reset to Factory Calibration PRESS MODE TO SELECT CALIBRATION Please Standby Zeroing nalyzer ENTER TAG VALUES co 2 55 02 PRESS MODE TO GO TO NEXT VALUE This option allows you to resetthe analyzer to the calibration values set by the manufacturer when the analyzer was shipped out Use the 4 and gt button to toggle between YES and NO Press MODE to confirm your selection By pressing the Calibration button from the main settings screen the analyzer goes into standby and begins t
43. pt to flow any gases into the analyzer through the CAL port This will severely affect the accuracy of the analyzer After the warm up cycle is completed and the probe is in the tailpipe press the MEASURE key to begin measurements Note Check the flow indicator to make sure you have sufficient flow the indicator should be all green Once the analyzer is warmed up you can begin measuring gas concentrations by connecting the sampling hose probe assembly to the inlet port located on the filter in the back of the analyzer Insert sampling probe to a gas source or an exhaust stream Press the Measure button 6 to begin sampling of the gases Allow a few seconds for the gases to reach the analyzer While in measure mode you can hold or freeze the display values by pressing the Hold button 8 as displayed in chapter 3 10 PRINTER PAPER INSTALLATION If the analyzer was ordered with the optional embedded printer then it will be necessary at times to replenish the paper To install paper follow the following steps Turn the unit onto its right side Remove the access panel on the bottom ofthe machine One Phillips screw secures the panel Push printer cam lock bar forward Insert paper roll with paper feeding from the top and down into the feed rollers Push paper out slot on front panel Pull cam lock to closed position PE 205 20 AA Replace access panel Bottom ofthe analyzer Front Cam bar Feed roller Fron
44. re low enough for the converter to decrease them to levels less than specified by state and federal regulations CATALYTIC CONVERTERS AND GAS ANALYSIS Since catalytic converters lower HC and CO producing CO and H20 monitoring HC and CO alone in catalytic converter equipped vehicles does not give an accurate picture of engine catalytic converter performance and operating efficiency The analyzer monitors O2 and CO as well as HC and CO so that all four exhaust products can be compared This provides a more accurate representation of the operation of the engine and the catalytic converter 44 CHAPTER 4 TESTING USING ANALYZER READINGS FOR DIAGNOSIS This exhaust analyzer is a highly versatile test instrument In addition to testing carbon monoxide CO carbon dioxide C02 oxygen O2 hydrocarbon HC and optionally oxides of nitrogen NOx for emission control certification requirements or after a tune up it can be used to assist in detecting and locating ignition fuel exhaust emission control and engine service problems There are a few general facts to keep in mind when using the analyzer 1 High carbon monoxide CO readings usually indicate a fuel mixture richer than ideal The amount of CO in a vehicle s exhaust is directly related to its air fuel ratio High CO levels result from inadequate O2 supply needed for more complete combustion This is caused by a mixture that is too rich too much fuel or not enough air 2
45. s required contact the factory to receive a Return Materials Authorization RMA number This is required prior to sending the unit in for repair Also be sure to include the following items when returning the analyzer for service 3 Adescription of the precise sample and operating circumstances 4 A brief description of the symptoms 5 The serial number 6 Your name address and telephone number Before purchasing and using this analyzer the user should determine the suitability of the product for his or her intended use and the user assumes all risks and liabilities whatsoever in connection therewith Ifa product malfunction should occur you may contact the seller or the manufacturer at Infrared Industries Inc 25590 Seaboard Lane Hayward Ca 94545 Voice 510 782 8100 or 800 344 0321 E mail service infraredindustries com If it is necessary to return the analyzer notify the seller in your area or contact Infrared Industries at the address phone number above You must obtain a RMA number before sending the unit in Note the RMA number on the outside of the box Package the instrument carefully and securely Do not ship the instrument with any accessories or power cords in the box Please include a written description of any observation of the malfunction along with the return ship to address and your contact phone fax number Then proceed to ship the instrument with freight prepaid to the address above 57 CHAPTER 6
46. t Feed paper through rollers Paper feeds from behind roll Paper roll 11 12 SYSTEM FEATURES FRONT PANEL Before attempting to operate the analyzer review the system features described below as well as all warning labels Identification and understanding of the physical features of the instrument will make operation easier ZERO PUMP A A Figure 1 Front Panel 1 LCD Screen 2 Measure Button Press to begin measure mode Pump is turned on automatically in measure mode 3 Hold Button Freezes all six display parameters in Measure mode only Blinks when in Hold 5 Pump Button Allows manual on off operation of the pump Can be used to purge gas from the analyzer 1 2 3 4 Zero Button Zeros the analyzer for approx 1 minute Pump is automatically controlled during zero 5 6 Power Button Push momentarily to turn on the analyzer Push and hold to turn off the analyzer 7 7 Print Mode Exit button In Measure or standby mode the button will start the optional built in or external printer When in mode selection process initiated by Mode button 18 Print Mode exit button will terminate the mode selection and go back to standby mode 8 Arrow buttons x4 Used to navigate when in Mode selection operation 9 Mode Button Enters the mode selection operation where different aspects of the analyzer can be set up or changed Refer to the Mode Selection section for more detail 13 REAR PANEL
47. tem such as warm up or standby Rich Mixture An air fuel mixture containing more than the ideal amount of fuel Stoichiometric Describes the ideal air fuel ratio Tail Pipe The vehicle s exhaust port 70
48. th the governing regulations for your locality NOTE When using calibration gas the bottle should be Rept at about 21 C 70 F for 8 hours prior to use Sudden temperature changes can condense some of the components in the bottle changing their concentration CALIBRATION GAS AND REGULATOR A bottle of calibration gas is required to check analyzer calibration and to perform calibration For the high pressure cylinders of gas a regulator is needed to monitor the pressure of the calibration gas bottle and to regulate it to the pressure required for testing and calibration Calibration gas has a known concentration of HC CO and CO2 The gas is available in a range of concentrations We recommend using calibration gas of the following concentrations when checking or calibrating the FGA4500XDS Gas Analyzer For a 4 Gas Analyzer use BAR90 Mid or For a 5 Gas Analyzer use BAR97 High or HC propane 1500ppm HC propane 3000ppm e 0 12 e 02 12 e CO 8 e CO4 NOX 3000ppm e Balance N2 24 NOTE We list balance N2 here because we recommend that O2 be calibrated using air during AUTO ZERO If you choose to use cal gas with different concentrations it must be within the following ranges propane 140 ppm to 3400 ppm e CO 5 to 15 e CO 0 9 to 8 5 FIELD CALIBRATION WITH CERTIFIED CAL GAS The analyzer does not need regular field calibration However field calibration can be performed when there is
49. the analyzer The PEF value serial number and the version of the firmware are displayed 19 EXHAUST DILUTION Exhaust Dilution Enable Disable PRESS MODE TO SELECT RECORD TIME Record Time Enter Record Time in Seconds PRESS MODE TO SAVE PLAYBACKS Playback Mode 3 co 2 55 02 AFR The EXHAUST DILUTION function provides the operator with a warning in the MEASURE mode that the probe may not be positioned properly or that there may be a leak in the exhaust system of the vehicle To enable this function select Enable using the lt and buttons then press MODE The record time indicates the amount of time to record data once record data is selected in MEASURE mode Use the A and buttons to change the value of the selected digit in white and use the buttons to select a different digit Press MODE to save the value The Playback is selected any data stored in the analyzer is played back on the display To cancel the playback press MODE EXIT 20 ERASE DATA Are You Sure You Want To Erase The Stored Data PRESS MODE TO CONTINUE SET DATE amp TIME Set Date and Time 28 03 11 22 04 10 PRESS MODE TO SAVE When the analyzer records data it saves the data until you select to erase the data To erase the data use the and buttons to select Yes or No the press MODE to perform the function When a printer is connected to th
50. the Hydrogen Fraction of the fuel The default value for Hcv is 1 8 Ocv is the Oxygen Fraction of the fuel The default value for Ocv is 0 assume no oxygenated fuels K 3 5 the water gas constant of combustion 61 Wev 2 1 CO CO2 K CO CO2 CO CO2 HC 1 Hcv 4 Ocv 2 CO CO2 HC In the equation for C Wcv is the Water Fraction of the fuel Because 1 the equation for Lambda becomes B C Note Hcv and Ocv affect how the gasoline composition changes the calculation of Lambda Normal gasoline is only hydrogen and carbon and therefore the default values that the factory puts in for Hcv is 1 8 and for Ocv is 0 However when oxygenates are added to the fuel as required by law in some locations these parameters should be changed The operator can do th s in STANDBY mode 62 63 APPENDIX DAC OUTPUTS This gas analyzer supports eight DAC output channels Each Channel is defined as follows Pin Description Range 0 10 Volts 1 HC 0 9999 PPM 2 0 10 3 2 0 20 4 02 0 25 5 NOx if applicable 0 5000 PPM 6 Lambda 0 5 7 0 9999 RPM 8 Air Fuel Ratio AFR 0 50 9 Ground 64 66 APPENDIX C SPECIFICATIONS The following specifications are subject to change without notice PRINCIPAL GASES RANGES and NOx CO carbon monoxide HG as n hexane OUTPUT DATA INTERFACE
51. tio When based only on air fuel ratio combustion chamber temperatures peak at air fuel ratios of about 18 1 Lambda 1 25 allowing the formation of NOx Since modern engines do not normally run at 18 1 Lambda 1 25 theoretically NOx emissions should not be a problem However lean air fuel ratios are not the only cause of NO emissions Moderate to heavy engine loads also cause combustion chamber temperatures to increase at ratios much richer than 18 1 Lambda 1 25 NOx is not often monitored because 1 NOx is normally only formed when the engine is under load Thus it would be ideal to measure NOx while the vehicle is under load 2 NOx does not indicate engine performance or efficiency as does oxygen hydrocarbons carbon monoxide and carbon dioxide The formation of NOx does not affect engine performance but some devices used to prevent it from forming can affect performance and contribute to higher levels of HC and CO if they are not functioning properly 35 HYDROCARBONS Hydrocarbons HC are organic compounds made up of hydrogen and carbon atoms The HC present in gasoline engine exhaust is unburned gasoline vapor and is measured in parts per million PPM HC levels in engine exhaust vary with the air fuel ratio Figure 6 shows the relationship of HC concentration in exhaust to air fuel mixture Figure 6 HC Vs Lambda HYDROCARBONS HC LEAN PPMHC 300 250 200 150 100
52. to STANDBY mode If the stability test indicates that the system requires more warm up time the system will enter the WARM UP OPERATE phase In the STAND BY OPERATE mode of the WARM UP phase the system will allow the operator to initiate a measurement A measurement is initiated in the normal fashion The system will make the measurement in this mode and may be at full accuracy In the STAND BY mode the operator will also be able to turn the pump on and off by the use of the PUMP switch The pump can be used normally in this mode to purge the gas from the probe or any other purpose In the STAND BY mode the operator will be able to enter AUTOZERO mode If the operator does not initiate any of the functions allowed in the WARM UP OPERATE phase the system will wait for five minutes auto zero itself and test again for stability If the system is stable at the end of that time the system will move into STANDBY mode If the system is still not stable the system will remain in the WARM UP OPERATE phase and begin to wait for another five minutes If during the WARM UP OPERATE phase the operator initiates an allowable operation the five minute time period will be restarted when the allowable operation is complete The WARM UP OPERATE phase allows measurements to be made quickly after power up and only slightly outside the specified accuracy limits of a fully warmed up unit 22 MEASURING GAS MEASURE INITIATION Pressing the MEASURE push
53. understanding of what the analyzed combustion byproducts are how and where they are formed in a gasoline engine and the relationship between them at different air fuel ratios Figure 4 The Combustion Process In a gasoline powered internal combustion engine normal combustion is the spark ignition of a compressed mixture of hydrocarbon fuels and air taking place in the combustion chamber This action produces the pressure that forces the piston FUEL downward Figure 4 shows the compressed air OTT fuel mixture being ignited by the spark plug EXHAUST OUT The fuel induction system of a gasoline engine forms air fuel mixtures by vaporizing gasoline a hydrocarbon and mixing it with air in a given proportion always more air than gasoline vapor COMBUSTION There is 14 times as much air as fuel by weight needed to vaporize the fuel into a state for ignition and to supply enough oxygen to the fuel so it can burn in the combustion reaction GAS FUNDAMENTALS LAMBDA The ideal air fuel ratio for perfect combustion in a gasoline engine is 14 66 1 or 14 66 pounds of air to each pound of vaporized gasoline This is known as a stoichiometric ratio or stoichiometric fuel mixture NOTE Lambda A is Air Fuel Ratio 14 66 This parameter is easier to use because it is 1 0 when the combustion is optimal Lambda is less than one for rich combustion and greater than one for lean combustion We will use Lambda in our d
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