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42

S E R V I C I N G T H E O X Y G E N S E N S O R

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 O2/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.

N O X S E N S O R - O X I D E O F N I T R O G E N

The NOx sensor used in the analyzer requires replacement every 12 months. Several faults can be caused by a NOx
sensors defect, including:



Zero Failure in or after a zero procedure (manual or automatic).



General Failure. This may occur if the wire harness to the NOx sensor is not connected.

S E R V I C I N G T H E N O X S E N S O R

1.

Turn off the 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:

The connector is keyed so that it only plugs in correctly one way.

Do not

force the connector

into the sensor.

R O U T I N E C L E A N I N G

The analyzer should be cleaned routinely to prevent the buildup 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.

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Summary of Contents for FGA

Page 1: ...FGA4000XDS Four and Five Gas Analyzer ...

Page 2: ...1 ...

Page 3: ...2 Operator s Manual Revision10 17 2018 Infrared Industries 25590 Seaboard Lane Hayward CA 94545 Phone 800 344 0321 510 782 8100 www infraredindustries com ...

Page 4: ...3 ...

Page 5: ...ation 16 CHAPTER 2 18 USING THE ANALYZER 18 Warm up 18 Measuring Gas 19 Recording Data 19 Calibration 20 Dual Exhaust 21 Tachometer 22 Zeroing 22 Grams per Mile Kilometer 23 Exhaust Dilution 24 CHAPTER 3 26 EXHAUST GAS EMISSION 26 Combustion Fundamentals 26 Gas Fundamentals 26 Oxides of Nitrogen optional 27 Hydrocarbons 28 Carbon Monoxide 28 Carbon Dioxide 29 Oxygen 29 Conclusion 30 Stoichiometric...

Page 6: ...HAPTER 6 44 TROUBLESHOOTING 44 Analyzer Troubleshooting 44 APPENDIX A 46 LAMBDA CALCULATIONS 46 Brettschneider Equation 46 APPENDIX B 48 DAC OUTPUTS 48 APPENDIX C 50 OBDII OPTION 50 APPENDIX D 52 SPECIFICATIONS 52 Principal Gases Ranges measured 52 Output Data Interface 52 APPENDIX E 54 WARRANTY 54 Notice to Buyer and or user of the analyzer 54 APPENDIX F 56 GLOSSARY OF TERMS 56 ...

Page 7: ...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 ...

Page 8: ...7 ...

Page 9: ...n 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 attempt to flow any gases into the...

Page 10: ... 2 Remove the access panel on the bottom of the machine One Phillips screw secures the panel 3 Push printer cam lock bar forward 4 Insert paper roll with paper feeding from the top and down into the feed rollers 5 Push paper out slot on front panel 6 Pull cam lock to closed position 7 Replace access panel 1 2 3 4 5 6 7 8 9 10 11 Front Feed paper through rollers Paper feeds from behind roll Paper r...

Page 11: ...ling probe should be in 10 Zero Button Zeros the analyzer for approx 1 minute Pump is automatically controlled during zero 11 Flow Indicator During pump s operation all bars will be on In case of a flow restriction in the gas sampling system the bars will turn off starting from right side indicating flow restriction In case of total restriction the first segment will blink indicating no flow 12 Pu...

Page 12: ...ses the green segments extinguish one at a time until the last one remains At that point a red segment lights indicating flow below specifications This will be active only when the pump is running R E A R P A N E L 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 Por...

Page 13: ... captured into memory When Measure Mode is exited the recording will stop Each time Measure Mode is entered the data will be appended to the end of the stored data Each time the analyzer is powered up the default setting for this option is no L O W E R L E F T W I N D O W Use the and buttons to move between the choices As a choice is selected the symbol will flash next to the window You can select...

Page 14: ... will prompt the operator for the year of the vehicle being measured E X H A U S T D I L U T I O N 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 YES using the and buttons T A C H O M E T E R This menu screen allows th...

Page 15: ...nt to reset the analyzer to the factory default setting press MODE EXIT See Factory Calibration Reset below The tag values should be entered just as they are on the calibration bottle You are not required to calculate HC using the PEF value Instead enter the propane value and the analyzer will internally convert it to HC When tag values for CO and CO2 are entered they are entered as percentages Fo...

Page 16: ...ll leave the calibration values as they were before the calibration was started G P M M E A S U R E M O D E In the Measure Mode Options when GPM is selected the analyzer will compute grams per mile or kilometer when the analyzer is put in Measure Mode by pressing the MEASURE button Once in measure mode the analyzer will display The Measure light will start flashing In the middle right window the s...

Page 17: ... M A T I O N In Standby Mode you can retrieve information about the analyzer by pressing the button and holding for 5 seconds The screen will display The first line is the PEF value The second line is the current pressure in the sample cell The third line is the current ambient temperature Celsius By pressing MODE a second screen of information will appear The first line is the current version of ...

Page 18: ...17 ...

Page 19: ... 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 t...

Page 20: ...ode 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 this feature P R I N T E R O P T I O N 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 but...

Page 21: ...e 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 An output pressure to the analyzer of 2 4 psi is all that is needed to perform a calibration The key to a good calibration is to wait for the reading of the calibration gas on the analyzer to stabilize before progressin...

Page 22: ...s to move to individual digits Press the MODE button 18 to advance to the next window Enter all zeros if do not wish to calibrate a particular gas We recommend always entering all zeros in the O2 window By pressing the MODE button after entering the last tag value you will see the message TURN CAL GAS ON GO Make sure the Cal Gas is connected to the CAL port in the back of the unit The CAL port is ...

Page 23: ...e 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 minutes but the ambient temperatu...

Page 24: ... the graph below 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 ...

Page 25: ...I O N 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 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 ...

Page 26: ...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 EX...

Page 27: ...ect 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 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...

Page 28: ...e 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 Figure 5 NOx vs Lambda Figure 5 shows the concentration of...

Page 29: ...ize the escape of evaporative emissions C A R B O N M O N O X I D E 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 The richer th...

Page 30: ... in the exhaust a good indicator of efficient combustion CO2 levels can also be used as an indicator of exhaust system integrity O X Y G E N The level of oxygen O2 in exhaust gas is an indicator of air fuel ratio leanness The O2 originates in the air the engine inducts and mixes with the HC for combustion Since the atmosphere is about 21 O2 the percentage Of O2 in the exhaust gas after combustion ...

Page 31: ... because most of it is consumed in combustion It remains low with richer mixtures and increases when the mixture leans out S T O I C H I O M E T R I C F U E L M I X T U R E S As can be seen from Figure 11 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 i...

Page 32: ...ace area for exhaust gases to come in contact with the noble metal catalysts Figure 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 adding O2 to the molecular structure ...

Page 33: ...er HC CO and NOX by a certain amount When the engine is operating properly these emissions are low enough for the converter to decrease them to levels less than specified by state and federal regulations C A T A L Y T I C C O N V E R T E R S A N D G A S A N A L Y S I S Since catalytic converters lower HC and CO producing CO2 and H2O monitoring HC and CO alone in catalytic converter equipped vehicl...

Page 34: ...33 ...

Page 35: ...r 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 CO2 and H2O 9 O2 combines with CO to form CO2 10 CO is an indicator of richness 11 HC is an indicator of leanness and misfires 12 O2 is a better indicator of leanness and misfires than HC 13 CO and O2 are equal at the stoichiometric air fuel r...

Page 36: ...fuel ratio is sustained at conditions ranging from too lean to too rich Table 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 ...

Page 37: ...cturer 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 seco...

Page 38: ...S Verify that the Check Engine Service Engine Soon or Power Loss lamp is functioning Ensure that personnel have not removed the bulb B A S I C E N G I N E O T H E R S E R V I C E F U N C T I O N S 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 E L E C T R I C A L S Y S T E...

Page 39: ...mplete Warm up and Zero cycle This may take up to fifteen minutes The remaining steps may be completed during analyzer warm up 5 Connect the exhaust sample hose to the back of the analyzer at the filter assembly 6 Wait until the analyzer indicates that it is in the STANDBY mode 7 30 minutes after the analyzer is in the STANDBY mode insert the probe into the vehicle tailpipe ensuring that the probe...

Page 40: ...39 ...

Page 41: ...mpressed 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 R E P L A C I N G T H E P R O B E 1 Remove the sample probe from the handle 2 Install the new probe on the handle and tighten Use only Teflon tape on fittings S A M P L E H O S E The sample hose must be free of cuts and abra...

Page 42: ...lacement F R O N T P A N E L A N D E X T E R I O R 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 brak...

Page 43: ...ter a zero procedure manual or automatic General Failure This may occur if the wire harness to the NOx sensor is not connected S E R V I C I N G T H E N O X S E N S O R 1 Turn off the 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 countercloc...

Page 44: ...er 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 If a product malfunction should occur you may contact the seller or the manufacturer at Infrared Industries Inc 25590 Seaboard Lane Hayward Ca 9454...

Page 45: ...lowing procedure 1 Repeat calibration 2 If the 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 accurac...

Page 46: ...45 ...

Page 47: ...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 B CO2 CO 2 NOx 2 O2 Hcv 4 K K CO CO2 Ocv 2 CO CO2 1 Hcv 4 Ocv 2 CO CO2 HC In the equation for B Hcv is the Hydrogen to Carbon Ratio of the fuel The default value for Hcv is 1 8 Ocv is the Oxygen to Carbon Ratio of the fuel The default value for...

Page 48: ...47 ...

Page 49: ... 3 CO2 0 20 4 O2 0 25 5 NOx if applicable 0 5000 PPM 6 Lambda 0 5 7 TACH 0 9999 RPM 8 Air Fuel Ratio AFR 0 50 9 Ground During a GPM Test the DAC Outputs are expressed as follows Pin Description Range 0 1 5 10V 1 HC 0 10 Grams Per Second 2 CO 0 50 GPS 3 CO2 0 50 GPS 4 O2 0 25 GPS 5 NOx if applicable 0 5 GPS 6 Lambda 0 5 7 TACH 0 9999 RPM 8 Air Fuel Ratio AFR 0 50 9 Ground ...

Page 50: ...49 ...

Page 51: ...st be set to obd2 See Chapter 1 on how to configure the serial port To use this feature The Serial Port configuration must be set to obd2 See Chapter 1 on how to configure the serial port Connect the serial adapter to the back of the analyzer Plug the OBDII scanner into the vehicle When the vehicle is turned on the RPM values will be displayed on the analyzer Make sure the display is configured to...

Page 52: ...51 ...

Page 53: ... to 10 000ppm CO2 carbon dioxide Range 0 to 20 O2 oxygen Range 0 to 25 NOX Nitric Oxide Option Range 0 to 4 000ppm Operating Temperature 2 C to 40 C 35 6 F to 104 F Storage Temperature 40 C to 75 C 40 F to 167 F Power 120 240 VAC 10 50 60 Hz Weight 12 5 Lb Size 18 5 cm high 29 5 cm wide 43 5 cm length 7 3 in high 11 5 in wide 17 in length Displays 18mm high digits 4 digit LED s O U T P U T D A T A...

Page 54: ...53 ...

Page 55: ...RRANTIES 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 e...

Page 56: ...55 ...

Page 57: ... 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 L A parameter that expresses air fuel ratio Lambda is the ratio of the measured air fuel ration to the idea...

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