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Repair instructions

Exhaust gas analyzer
ETT 008.31 - ETT 008.38

Содержание ETT 008.31

Страница 1: ...1 Repair instructions Exhaust gas analyzer ETT 008 31 ETT 008 38 ...

Страница 2: ...arth 21 Contents Page 5 4 Checking the start up process 22 5 5 Checking the Analysis function 23 5 6 Checking fault monitoring 24 5 7 Performing the leak test 24 6 Checking and fine tuning measuring accuracy 25 6 1 Taking account of barometric altitude 25 6 2 Checking the indicating accuracy 25 6 3 Fine tuning the indicating accuracy 26 6 4 Checking cross sensitivity 27 6 5 Fine tuning the air pre...

Страница 3: ...easuring sensor 58 10 7 Replacing the battery 58 10 8 Replacing the motherboard 59 10 9 Replacing the sensor board 59 10 10 Replacing the pump seal kit 59 11 Safety test 60 to DIN 57411 VDE 411 60 11 1 Checking the protective earth 60 11 2 Voltage test 60 12 Diagrams circuit diagrams and gas route diagram 61 12 1 Circuit diagram 1 61 12 2 Circuit diagram 2 62 12 3 Gas route diagram 63 12 4 Diagram...

Страница 4: ...service work reports must be drawn up containing the following information Time of service Type of service work Name of person or company carrying out service These reports must be preserved for a duration of five years The operating instructions must be kept with the exhaust gas analyzer in such a way that they are available at all times The user of the exhaust gas analyzer is re sponsibleforobse...

Страница 5: ...s mixed gases are sometimes recommended No 1 14 CO2 Accuracy of analysis 1 No 2 16 000 ppm C3 H8 propane Accuracy of analysis 1 No 3 9 CO Accuracy of analysis 1 No 4 5 CO 7 5 CO2 2 000 ppm C3 H8 propane Accuracy of analysis 1 No 5 2 CO 3 800 ppm C3 H8 propane Accuracy of analysis 1 No 6 8 000 ppm C3 H8 propane 1 CO Accuracy of analysis 1 In some countries A and B are used for the calibration of te...

Страница 6: ...xhaust gas analyzer performs a system adjustment in con junction with a self test Each time that the exhaust gas analyzer carries out system adjustment a solenoid valve switches the zero gas inlet with carbon canister into the test gas duct for the duration of the adjustment During this process the actual system sensitivity of the HC CO and CO2 measuring channels is deter mined using zero gas air ...

Страница 7: ...ss air factor if the measured CO2 content exceeds 2 vol that is when vehicle exhaust gases are flowing through the analyzer To obtain this option the functions Lambda measurement and Oxygen measurement must be acti vated see Sections 4 1 2 and 4 1 3 3 11 Lambda measurement The exhaust gas analyzer calculates the excess air factor from the measured concentrations of CO HC CO2 and O2 The lambda valu...

Страница 8: ...ng applies to all three operating modes A particular function can be selected and indicated on the display by pressing the Select button once or several times This function is activated by simultaneously pressing the Enter u button Once this function has been activated settings or parameters can be modified by means of the Enter o or Test u buttons Pressing the Select button again terminates the f...

Страница 9: ...ial measurements adjustment LA An Pre select lambda calculation On Off C0 An Pre select COvrai calculation On Off 5o An Switch between Summer Winter Pr An Pre selectair pressuremeasurementOn Off CA An Pre select calibration weekly or each time button is pressed Ho An Set altitude 0F An Set oxygen zero An An Analysis mode LP An Select printer tE An Select operator terminal tc An Start temperature c...

Страница 10: ...early test see Section 6 After a flow time of 20 seconds the display switches to Abd Abd Abd Abd Abd seal abdichten The analyzer automatically terminates flow through the exhaust sample probe via the pump by switching off the pump Manual flow through the calibration inlet must be termina ted manually In either of the above cases the test gas inlet must be sealed off e g by bending the intake hose ...

Страница 11: ...ing function 2 x Press Enter o to switch lambda calculation on or lambda calculation off 4 1 3 O2 measurement ON OFF Press SELECT Display Meaning function 3 x Press Enter o to switch O2 measurement on or O2 measurement off YE5 L A Ei no L A Ei YE5 02 Ei no 02 Ei ...

Страница 12: ...switch CO correction on or CO correction off If CO correction is switched on the corresponding value is printed out on the printer log 4 1 5 Summer time ON OFF Press SELECT Display Meaning function 5 x Press Enter o to switch summer time on or summer time off YE5 C0 Ei no C0 Ei YE5 50 Ei no 50 Ei ...

Страница 13: ... appears in the engine speed display field Enter the altitude in steps of 100 metres using the Enter o or Test u buttons 4 1 8 Fine tuning the zero of O2 up to software version A 10 Press SELECT Display Meaning function 8 x Introduce a calibration gas consisting of at least 10 CO2 and no oxygen into the calibration gas inlet Set the admission pressure on the bottle pressure reducer to 0 7 bar The ...

Страница 14: ...e with Section 8 2 2 4 1 10 Analysis mode Press SELECT Display Meaning function 10 x In analysis mode calibration gas of any concentration entering via the calibration gas inlet can be displayed without the pump having to be switched on The admission pressure must be set to 0 7 bar on the bottle pressure reducer This mode enables measuring accuracy to be checked using a minimal amount of calibrati...

Страница 15: ...no no no no no appears in the display window for engine speed the temperature compensation sequence has not been enabled To enable temperature compensation this function must be selected as described in Section 4 4 Before temperature compensation please observe the follo wing points Let device cool for 2 hours with cover closed Set up switched off device in a calm spot free from draughts Switch on...

Страница 16: ...nsation was terminated incorrectly all further measurement is disabled 4 1 14 External display ON OFF Press SELECT Display Meaning function 14 x Press the Enter o button to switch the external display on or external display off When the external display is switched on the printer selec tion is automatically set to the internal printer 4 1 15 Selecting analog interface optional Press SELECT Display...

Страница 17: ...non linearized values 2 x Temperature in the analyzer part in C averaged temperature of all receiving chambers 3 x Measured values from the analog to digital converter ADC in the HC CO and CO2 measuring channels in volts 4 x Temperature compensated measured values from the analog to digital converter ADC in the HC CO and CO2 measuring channels in volts 5 x Current date 6 x Current time 7 x Identif...

Страница 18: ... is shown in the HC display field The current air pressure or an error message Err Err Err Err Err appears in the display field for engine speed see Section 8 9 10 x The number of exhaust gas measurements performed is shown in the engine speed display field 11 x The check sum of the software version is shown in the engine speed display field 94 U 3 494 980 Pr 28 coun 94 U ...

Страница 19: ... An d An Entero CO xxxx d Ei d Ei d Ei d Ei d Ei With the Enter o and Test u buttons the current setting value can now be changed until the current measured value matches the test gas concentration Select 3 x C02 xxxx d An d An d An d An d An Entero CO2 xxxx d Ei d Ei d Ei d Ei d Ei With the Enter o and Test u buttons the current setting value can now be changed until the current measured value ma...

Страница 20: ...x x E Ei E Ei E Ei E Ei E Ei With the Enter o and Test u buttons the current setting value can now be changed until the current measured value matches the test gas concentration Select 3 x C02 xxxx E An E An E An E An E An Entero CO2 xxxx E Ei E Ei E Ei E Ei E Ei With the Enter o and Test u buttons the current setting value can now be changed until the current measured value matches the test gas c...

Страница 21: ...e hose with compressed air Replace coarse filter GF 1 if clearly clogged and re assemble intake hose coarse filter and probe Condensation tank Remove carefully Check edge of condensation tank for cracks replace if damaged Replace coarse filter GF 2 in the condensation tank if seriously clogged Push the coarse filter into the connecting hose as far as the connecting piece which adjoins the head Con...

Страница 22: ... oil temperature 15 sec Standby mode or if appropriate error messages If error messages are displayed perform trouble shooting to Sections 7 and 8 Err Err Err Err Err C temperature sensor is not yet connected or is defective Trouble shooting to Section 8 11 Device does not start up Check fuses F1 and F2 in the mains connector rear wall of device replace if they have blown If this is unsuccessful c...

Страница 23: ...s than 2 Display of oil temperature Or Err Err Err Err Err if oil temperature sensor is not yet connected Terminate analysis by pressing the pump button The pump runs on for approx 15sec in order to purge the gas ducts with ambient air via the zero gas inlet Analysis may be re started while the pump is still running Checking the stability of the display Monitor the stability of the displayed value...

Страница 24: ... displayed value still deviates excessively after the intake hose has been removed clean the analyzer part to Section 10 4 During this process clean all parts which convey test gas and replace the hoses if necessary 5 6 Checking fault monitoring Block off the zero gas inlet on the rear of the device with your finger Press the pump button During system adjustment the error message Err 1 Err 1 Err 1...

Страница 25: ...he altitude in the analyzer must be set to the value which most accurately corresponds to the current air pressure After you have finished checking or fine tuning the device set the altitude at which the device is to be used by the operator Altitude for mean air pressure Altitude in m Mean air pressure above sea level in torr in Hpa mbar 700 825 1099 600 815 1087 500 806 1074 400 797 1062 300 787 ...

Страница 26: ...easuring channel Upper range value Nr 1 14 CO2 Mean value Nr 4 7 5 CO2 4 HC measuring channel Upper range value Nr 2 16 000 ppm C3 H8 large measuring range Mean value Nr 6 8 000 ppm C3 H8 5 CO measuring channel Upper range value Nr 3 9 CO large measuring range Mean value Nr 4 5 CO Within a measuring range proceed as follows using the example of No 1 HC channel small measuring range engine speed LE...

Страница 27: ...n The calibration factor of the mean value is now accepted and the next possible function displayed Continue fine tuning with the CO measuring channel small measuring range 6 4 Checking cross sensitivity Here the device s cross sensitivity to condensation is checked Remove the test gas hose from the test gas inlet of the device Prepare the gas wash bead bottle filled with an effective water column...

Страница 28: ... Ab5o Ab5o Ab5o Ab5o Ab5o function display The permitted adjustment ranges are in the function display LuFt LuFt LuFt LuFt LuFt 700 to 1100hPa mbar absolute pressure dELt dELt dELt dELt dELt 50 to 200 cm water gauge relative pressure 50 to 200 cm water gauge relative pressure i The absolute pressure set in LuFt LuFt LuFt LuFt LuFt and the relative pressure to be set in dELt dELt dELt dELt dELt may...

Страница 29: ...ection required Press Enter o or Test u but wait at least 1 second for the device to react Correction required Acknowledge your entry by simultaneously pressing Enter o und Test u The first reference point is now fine tuned The analyzer switches over to fine tuning of the second reference point The analyzer prompts you to fine tune the second reference point Fine tuning appears on the display dELt...

Страница 30: ...lyzer so that the air pressure gauge can set itself to ambient pressure Only then press the Select button the analyzer now quits fine tuning 6 6 Recognition of chopper motor i Set function switch S 60 to setting 1 Press Select Display Meaning function 5 x An automatic sequence takes place The counter in the engine speed display window counts backwards from 15 to 0 During this time the exhaust gas ...

Страница 31: ...hem in Section 7 4 7 1 Error messages in the CO display field Error messages Possible cause Trouble shooting Amplifier output signal of HC measuring See Section 8 7 Faulty channel amplifier outside tolerance Amplifier output signal of CO measuring See Section 8 7 Faulty channel amplifier channel outside tolerance Amplifier output signal of CO2 measuring See Section 8 7 Faulty channel amplifier cha...

Страница 32: ...ication See Section 8 5 Faulty channel identification Fault in sensor board equipment See Section 8 8 Faulty sensor board identification Faulty display control Replace display module Also see Section 8 3 Altitude entered incorrectly See Section 8 9 incorrect measurement by air pressure gauge Faulty pressure influence correction Chopper motor not recognized See Section 6 6 Recognition of chopper mo...

Страница 33: ...tion 8 12 Faulty O2 measuring channel Undesirable constituents in air sucked in Repeat zero adjustment taking care to during system adjustment ensure that clean air is sucked in O2 measuring sensor connector not plugged in Plug in O2 measuring sensor connector O2 measuring sensor defective Replace O2 measuring sensor and perform trouble shooting to Section 8 12 Faulty O2 measuring channel Faulty O...

Страница 34: ... test hose 6 then hose 9 or if the test still produces incorrect results seal hose 16 as well the pump could also be leaky and suck up outside air Replace faulty components 8 2 Flow faults with zero gas and test gas flow The error message Flow fault during zero adjustment or Flow fault in test gas line occurs when one of the pressure switches DS 1 or DS 2 is defective or detects inadequate pressur...

Страница 35: ...e purpose of purging the device approx 15 seconds Control voltage OK Replace solenoid valve Control voltage faulty Check power supply to power electronics to Section 8 16 Replace faulty components as appropriate In the test gas system Remove hose from the test gas inlet Press the Pump button Error message remains Remove condensation tank press Pump button Error message remains Remove condensation ...

Страница 36: ...is maximum 20 mm water gauge per minute In the event of a negative result isolate different components from the test one after the other by sealing off the hoses leading to them until you have found the leaky component First of all seal off the hose leading to the inlet for calibration gas EKG This seal remains in place throughout the remainder of the test As regards the additional hoses listed be...

Страница 37: ...are failed increase the pump capacity step by step in input mode as described in Section 4 1 9 Adjusting the pump capacity until the overall delivery rate exceeds 8 l min Do not increase the pump capacity unnecessarily If the overall delivery rate does not reach 8 l min replace the pump seal kit to Section 10 10 Check the flow values after replacing the seal kit In input mode set the maximum pump ...

Страница 38: ...pply PANZ has failed First check the continuity of fuse F6 on the transformer or measure 7 V between grey and red Examine the display module to ensure that connector X3 to the transformer is in order and that the auxiliary supply PANZ is rectified PANZ 7 V The measuring points are on the rear of the display module see adjacent diagram If the results of these checks are negative replace the display...

Страница 39: ...s In this way several faulty parameters can be displayed in a single number e g 1105 1 16 64 1024 HC display Faulty parameters For correction see Section 1 HC measuring channel mean value small measuring range 2 HC measuring channel mean value large measuring range 4 HC measuring channel upper range value small measuring range 8 HC measuring channel upper range value large measuring range 16 CO me...

Страница 40: ...t test point X 101 reference point X 16 on the motherboard A temperature of 0 C corresponds to a voltage of 2 15 V 75 C corresponds to a voltage of 2 80 V If the measured value is plausible yet the display still shows an error replace the motherboard incorrect processing of measuring values If the measured value at X 101 lies outside the premitted range of 2 15 V bis 2 80 V There is a temperature ...

Страница 41: ...s running can be seen from the motor shaft If it has failed replace the chopper If this is unsuccessful replace the power electronics module Check the lamp resistance remove connectors from X 6 and X 3 on the motherboard Cold resistance 3o Ω 3 If not replace lamp Check UREF on the motherboard at X 13 to X 16 UREF 5 V 10 mV If necessary adjust UREF with R 12 to 5 V 2 mV If individual errors appear ...

Страница 42: ...ers of the 3 screws With the digital multimeter check URef of the channel amplifier in question at X 12 to X 9 URef 5 V 10 mV With the digital multimeter measure the bridge diagonal voltage of the channel amplifier in question at X 8 to X 10 UDC 0 V 100 mV Measure the bridge operating point at X 8 and X 10 to X 9 UDC 1 0 V bis 1 4 V In the event of a fault in the channel amplifier or in the stripl...

Страница 43: ...ed altitude check according to Section 4 1 7 Faulty air pressure gauge or line fault Faulty processing of measured values Further information about the source of the fault can be called up in test mode as described in Section 4 2 Here you can read the output voltage of the air pressure gauge in the HC display field and the displayed value derived from this mbar in the engine speed display field du...

Страница 44: ...aust gas 5 Hz 1200 rpm 600 rpm analyzer must be opened to to to 39 5 Hz 9480 rpm 4740 rpm 40 Hz 4800 rpm to to 79 Hz 9480 rpm 80 Hz On the sensor board module check that the supply voltages are being fed correctly Check power supply to sensor board according to Section 8 15 If faulty additionally check power supply to motherboard to Section 7 17 Replace defective components as appropriate If the v...

Страница 45: ...reached at the O2 amplifier output Faulty O2 measuring sensor or faulty O2 amplifier u u u u u O2 amplifier signal is negative 10 mV probe connector has reversed polarity or amplifier is faulty If the error message 0FF5 0FF5 0FF5 0FF5 0FF5 zero fault or EnPF EnPF EnPF EnPF EnPF sensitivity fault appear a new O2 measuring sensor should always be installed before performing any further tests After t...

Страница 46: ...ump actuation The auxiliary power supply for the pump is obtained direct from the mains voltage The voltage is dangerous contact voltage It is non floating Check with a multimeter at the pump terminals Pump switched on UAC 85 to 90V Pump switched off UAC 0 3V If these values are not met check the power electronics module to ensure that the auxiliary supply is being correctly generated Proceed as d...

Страница 47: ... 2V Press switch S60 check At setting 1 LED H61 lights up X61 0V At setting 2 LED H60 lights up X60 0V If there is no voltage first replace the connecting line X80 from the sensor board to X20 on the motherboard if the switch function is faulty replace the sensor board module 8 15 4 Circuit diagram of sensor board ...

Страница 48: ...48 8 15 5 Sensor board component location diagram ...

Страница 49: ...via connector X 2 The supply voltage P5VD is generated on the motherboard see Section 8 17 the alternating voltage AC 22 V is supplied by the transformer see circuit diagram in Sections 12 1 and 12 2 Perform the test in accordance with the table below Test point Measured value Diagram power supply to power electronics simplified representation X 14 MD X 13 1 0 VAC X 12 5 2 V 100 mV X 11 15 V 1 0 V...

Страница 50: ...ltages on the motherboard are in conformity with the table below If not also check the source voltages at the transformer in accordance with Sections 12 1 and 12 2 Test point Designation Voltage Adjustable at X 16 MA Reference point ANA X 17 P 12 VA 12 0 V 1 0 V X 18 N 12 VA 12 0 V 1 0 V X 13 P 5 V URef 5 0 V 10 mV R 12 X 10 MD Reference point DIG X 14 N 5 VD 5 0 V 0 5 V X 15 P 5 VD 5 2 V 0 1 V R ...

Страница 51: ...51 8 17 1 Motherboard component location diagram ...

Страница 52: ...r connector of the exhaust gas analyzer The exhaust gas analyzer sends received characters back to the keypad using the so called echo principle 9 2 1 Basic command structure 1st character CR starts data communication CODE prompts you to enter a command code 2nd character Command code Only D N and S are permitted S CR initiates input procedure for Language See Section 9 2 2 N CR initiates input pr...

Страница 53: ...ed by the analyzer which prompts you once more to enter the language with Language 4 CR Ends input 9 2 3 Entries in the Name field Sequence Keypad entry Exhaust gas analyzer Feedback 1 N Receives and sends back N 2 CR Receives and starts input procedure by transmitting NAME 3 max 120 ASCII Receives and sends back character Entered character characters LF Inserts line feed and sends back No visible...

Страница 54: ...CR Receives and stores both digits as Hour YEAR in the clock element Transmits HOUR 6 1 2 digits CR Receives and stores both digits as MINUTE HOUR in the clock element Transmits MINUTE 7 1 2 digits CR Receives and stores both digits as MINUTE in the clock element End of input of DATUM UHRZEIT i The device monitors the plausibility of the entry It interrupts an obviously incorrect entry e g Date 33...

Страница 55: ...ace might be damaged Rinse the lamp thoroughly with distilled or demineralized water Dip the lamp in alcohol and dry with a hot air dryer This process should ensure that all water is removed and that the water leaves no stains Take care not to get alcohol in the viton hoses of the exhaust gas analyzer Aftercleaningandinstallingthelamp performachecktoensurethattheexhaust gasanalyzer is still within...

Страница 56: ...ssary Section 10 6 You must use a torque screwdriver with a tightening torque of 1 6 Nm for assembling the analyzer part After installing the analyzer part you must Check the service limit values Section 10 5 and Re tune the exhaust gas analyzer Section 6 3 1 2 3 3 In Section 8 7 Faulty channel amplifier a lower limit value of 1 V and an upper limit value of 3 5 V is specified When values fall bel...

Страница 57: ...stalled During amplifier adjustment take care to ensure that the analyzing chamber is perfectly clean Section 10 4 and that zero gas is in perfect condition Procedure for amplifier adjustment Unsolder the resistor R 7 on the channel amplifier in question Connect a decade resistor in place of R 7 In the Test mode menu change the display to the A D voltage values Section 4 2 Introduce a flow of zero...

Страница 58: ...play field disappears Zero has been found when the millivolt display remains constant Store the zero by pressing the Select key 10 6 1 InstallingandcalibratingtheO2measuringsensor from software version A13 Disconnect the exhaust gas analyzer from the mains Unpack the O2 measuring sensor and unscrew the closure cap Leave the O ring on the screw in gland of the O2 measuring sensor Remember the adjus...

Страница 59: ...sor as shown in the circuit diagram in Section 8 15 4 Following replacement Check the start up process Section 5 4 Fine tune zero of oxygen measurement Section 4 1 8 10 10 Replacing the pump seal kit Remove the 4 fastening screws of the pump from the floor of the device M5x16 The pump can now be moved sufficiently to allow replacement of the seal kit The connecting line does not have to be removed...

Страница 60: ...nd contacts L and N to the protective conductor R 10 MΩ Ω Ω Ω Ω The exhaust gas analyzer is fully assembled the mains plug is withdrawn and the mains switch of the specimen device is switched on Group the terminals as follows Group Designation Terminals I Auxiliary power L and N on mains plug I I Protective conductor Contact on mains plug Engine speed input All Oil temperature input All Serial int...

Страница 61: ...61 12 Diagrams circuit diagrams and gas route diagram 12 1 Circuit diagram 1 ...

Страница 62: ...62 12 2 Circuit diagram 2 ...

Страница 63: ...63 12 3 Gas route diagram ...

Страница 64: ...r optional 16 Mains button 17 Exhaust sampleprobe 18 Jack for leak test 5 6 4 2 3 8 7 9 10 11 12 13 1 14 459512 6Ha 15 17 18 16 Figure 2 19 Mains socket for non heating appliances 20 Condensationoutlet 21 Serial interface 22 Serial interface optional 23 TEST u u u u u button 24 ENTER o o o o o button 25 SELECT button 26 Cap 27 Female connector for oil temperature 28 Female connector for engine spe...

Страница 65: ...65 ...

Страница 66: ... E DIS 975 115 KH PR WIF 944 1 En 06 08 99 Printed in the Federal Republic of Germany Imprimé en République Fédérale d Allemagne par Robert Bosch GmbH Robert Bosch GmbH Geschäftsbereich KH ProduktbereichPrüftechnik Postfach 1129 D 73201 Plochingen ...

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