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Exhaust Gas Analyser 5 Gas Operation Manual
Exhaust Gas Analyser 5 Gas Operation Manual
Gas Analyser
2 or 4 stroke petrol engines
User manual
Ver. 2
AGS-688
Blank Page
CHAPTER 1 - INDEX
CHAPTER 1 - INDEX .............................................................. 3
CHAPTER 2 - GENERAL INFORMATION ................................... 5
2.1 GENERAL NOTES .............................................................5
2.2 MANUFACTURER IDENTIFICATION .....................................5
2.3 TECHNICAL SERVICE CENTERS .........................................5
2.4 MARKING ........................................................................5
CHAPTER 3 - SAFETY CONDITION .......................................... 6
3.1 IMPORTANT INFORMATION ON PERSONAL SAFETY ............6
3.1.1 Definitions................................................................6
3.1.2 Precautions For Operators Safety...............................7
3.2 IMPORTANT INFORMATION ON TOOL SAFETY ..................12
CHAPTER 4 - MANUAL STRUCTURE AND USE ...................... 13
4.1 MANUAL USE ................................................................13
4.2 SYMBOLS .....................................................................14
4.2.1 Safety ...................................................................14
4.2.2 Marking .................................................................14
CHAPTER 5 - GENERAL DESCRIPTION .................................. 15
5.1 AGS-688 KEY POINTS .......................................................15
5.2 FRONT VIEW ....................................................................16
5.3 REAR VIEW ......................................................................17
5.4 PNEUMATIC GROUP DETAILS .................................................18
5.5 CONTROL PANEL ...............................................................19
5.6 SUPPLIED ACCESSORIES ......................................................20
CHAPTER 6 - TECHNICAL FEATURES.................................... 21
6.1 LAMBDA FACTOR ............................................................21
CHAPTER 7 - INSTALLATION ................................................ 23
7.1 DEVICE INSTALLATION ...................................................23
7.1.1 Unpacking ..............................................................23
7.1.2 Preparation for use .................................................23
7.2 IMPORTANT INFORMATION ON ELECTRIC STORAGE
BATTERIES (BATTERIES, ETC.)......................................................23
7.3 DURING USE..................................................................24
7.4 WHEN THE TOOL IS NOT USED ........................................25
7.5 CLEANING – DISMANTLING AND DISPOSAL.......................25
7.6 HARDWARE INSTALLATION.............................................26
7.6.1 POSITIONING DEVICE..............................................26
7.6.2 CONNECTIONS WITH SUPPLIED ACCESSORIES.........26
7.6.3 CONNECTIONS WITH EXTERNAL ACCESSORIES .......27
7.6.3.1 POWER SUPPLY CONNECTIONS ............................. 28
7.6.3.2 PC CONNECTIONS ................................................. 28
7.6.3.3 BASIC CONFIGURATION ......................................... 28
7.6.3.4 CONFIGURATION WITH SERIAL MGT-300 ................. 28
7.6.3.5 RADIO CONFIGURATION WITH MGT-300/R ............... 28
7.6.3.6 CONFIGURATION WITH MGT-300 BLUE.................... 28
7.6.3.7 COMBI CONFIGURATION WITH SMOKEMETER AND
MGT-300 28
7.7 SOFTWARE INSTALLATION .............................................29
CHAPTER 8 - USE OF THE ANALYSER .................................. 30
8.1 GENERAL RULES TO USE THE MENU ...............................30
BRAIN BEE SPA and the resources involved in the making of this
manual disclaim all responsibility in relation to the use of the manual
itself, guaranteeing that all information contained therein has been
accurately verified.
2.4 MARKING
3.1.1 Definitions
DANGEROUS AREAS:
Any area within or close to the equipment implying risk for the safety
and health of exposed persons.
EXPOSED PERSON:
Any person completely or partially standing in a dangerous area.
OPERATOR:
The person/s in charge of operating the appliance for the set purpose.
OPERATORS CLASSIFICATION
The operator can be classified according to two main categories,
which, in some cases, refer to one single person:
• The operator charged with the equipment operation has the duty
to:
o Start and check the machine automatic operation;
o Carry out simple setting operations;
o Remove the causes of equipment stop not implying
breakings of members but simple operation anomalies.
• The operator charged with the machine maintenance is a
qualified technician who can intervene on the machine, with
guards open, and on mechanic and electrical members to carry
out setting, maintenance and repair operations.
USER
Body or person legally responsible for the equipment.
GENERAL PRECAUTIONS
• All the operators shall not be under the effect of tranquillizers,
drugs or alcohol when performing their job
• Before starting their job, operators shall be perfectly aware of
the position and operation of all the controls indicated on the
use manual.
• Always pay attention to any danger sign affixed on the
installation and within the company of the user.
• The employer is responsible for the spreading of this document
to the whole personnel that is going to work on the equipment.
• Besides the obligation to strictly comply with the instructions
contained in this manual, the operators shall inform their heads
on any deficiency or potentially dangerous situation that might
occur.
• In case of machine malfunctioning, check the procedures outlined
in the various chapters.
• Always refer to the safety standards adopted by the company
employing the equipment with a view to avoiding useless risks.
RISK OF ASPHYXIA
GASOLINE ENGINES
Exhaust gases of gasoline vehicles contain carbon monoxide, a
colourless and odourless gas which, if inhaled, can cause serious
physical problems.
Special attention is always required when working within pits, as
exhaust gases components are heavier than air and consequently
deposit on the bottom of the pit.
Attention shall be paid to natural gas vehicles as well.
DIESEL ENGINES
Diesel engine exhaust gas composition is not always the same. It can
change according to: type of engine, intake, conditions of use and fuel
composition.
Diesel exhaust is made up of gases (CO, CO2, NOX and HC) and
particulate (soot, sulphates, etc.); the small particles of carbon
making up soot remain suspended in the air and can thus be
breathed. Toxic components, albeit in small quantities, are present as
well.
SAFETY MEASURES:
- Always ensure good ventilation and air aspiration (especially in
the pits).
- In closed premises, always start the exhaust gas aspiration
system.
RISK OF SMASHING
SAFETY MEASURES:
- Make sure the vehicle has been secured by pulling the hand
brake and locking the wheels.
- Make sure the equipment has been positioned on a stable
support and, in case of trolley, that its wheels have been locked
before use.
RISK OF INJURY
SAFETY MEASURES:
- When the engine is turned on, do not put hands into the moving
parts area.
- When operating close to electrically started fans, let the engine
cool down beforehand and then remove the fan plug from the
engine.
- Keep the testing tools connection cables far from the engine
moving parts.
RISK OF BURN
When intervening on the engine, protect face, hands and feet with
suitable protective devices, avoid contact with hot surfaces, such as
sparking plugs, radiators, pipings of the cooling system and
electromechanic sensors. Catalytic mufflers reach extremely high
temperatures and can cause burns or fires.
Attentions shall thus be paid to avoid touching these objects without
suitable precautions.
SAFETY MEASURES:
- Wear protective gloves.
- Let cool down the engine and other independent accessories, if
any.
- Do not install testing tools connection cables over or close to
hot parts
- Do not keep the engine turned on once checks have been
completed.
When carrying out operations on the fuel system (injectors, fuel and
gasoline pump, etc.) there is risk of fire or explosion due to the fuels
employed and/or vapours formed by them.
SAFETY MEASURES:
- Disable start.
- Let the engine cool down.
- Do not use free flames or sparks sources.
- Do not smoke.
- Collect the outflowing fuel.
- Start the aspiration units in closed premises.
SAFETY MEASURES:
- The operator shall adopt personal protective equipment (safety
ear muffs).
- The operator shall also protect from noise the working stations
close to the areas where test on the vehicle.
SAFETY MEASURES:
- Connect the testing tools to an electric socket safety relay and
correctly grounded.
- For the testing tool connection, use exclusively the cables
provided with the tool itself, making sure insulation is not
damaged.
- Make sure the testing tool is grounded before turning it on.
- When carrying out interventions on the electrical system of a
vehicle (connection of testing tool, replacement of starting
system parts), supply voltage shall be unplugged (ex. battery).
- During checks and setting operations with the engine turned on,
attention shall be paid to avoid touching those vehicle live
components (for instance the starting system) without the
suitable precautions (for instance insulating gloves).
RISK OF INTOXICATION
The pipes that are used for exhaust gases sampling if subject to high
temperatures (exceeding 250 °C or due to fires) release a highly toxic
gas which, in case of inhalation, can be harmful for health.
SAFETY MEASURES:
- In case of inhalation, immediately contact a doctor.
- To remove combustion residues wear neoprene or PVC gloves.
- Fire residues can be neutralized with a calcium hydroxide
solution. This leads to the formation of calcium fluoride that can
be removed with water.
When using the tool, the following operations are not allowed as they
might cause, under certain circumstances, danger for persons and
cause permanent damage to the tool itself.
purchaser shall keep it with the utmost care; it shall
be placed closed to the equipment, within a specific
container and, above all, it shall be protected from
anything that might jeopardize its readability.
Operations requiring careful reading of the instructions
outlined in the use and maintenance manual are
highlighted by means of the symbol alongside.
4.2 SYMBOLS
4.2.1 Safety
ALTERNATING CURRENT
SAFETY GROUNDING
4.2.2 Marking
EC CONFORMITY MARKING
1
2
1 2 3 4 5 6
7 8 9 10
11 12
1 2 3 4 5 6
9 10 11 12 13
1 2 3 4 5 6 7 8
Where:
[] is the concentration in % vol, for HC only in ppm vol;
K1 is the conversion factor for HC if expressed in ppm vol n-hexane
(C6 H14) equivalent. Its value in this formula is 6x10–4;
HCV is the atomic ratio of hydrogen to carbon in the fuel. The
arbitrary value is 1,7261 for gasoline, 2,5 for LPG, 4 for methane ;
OCV is the atomic ratio of oxygen to carbon in the fuel. The arbitrary
value is 0,0176.
NOTE The simplified lambda calculation is only valid for measurements
on cars with negligible NOx concentrations in the exhaust gas.
CHAPTER 7 - INSTALLATION
7.1 DEVICE INSTALLATION
7.1.1 Unpacking
AGS-688 is supplied in a carton package. Carefully open the box and,
with the help of a cutter, cut the adhesive closing tape and remove
the device, protected by two polystyrene panels, and all supplied
accessories from the box.
Connections scheme
1 2 3 4 5 6
7.6.3.2 PC CONNECTIONS
It may be possible to establish a PC connection via a serial or a USB
cable with the analyser’s connectors.
In order to start the gas analyser, press the start button for a
second, and to turn it off, keep the button pressed for at least 3
seconds, and then release it.
1 2
Note: when started, the application goes straight to the GAS menu.
0804) RUN-IN
0805) STAND-BY TIMEOUT
0806) LEAK LIMIT
3001) KEYBOARD
3002) DISPLAY
3003) BUZZER
3004) PRINTER
3005) FAN
°C). Press and to change the time at the digit selected; press
contents of the line and to go to the next one; press to exit the
menu without saving the changes.
At the end, only when all of the 6 lines have been confirmed by
This menu serves to visualise the last access to the reserved area:
when started, the last access to the reserved area by the
arrows:
KEYBOARD
DISPLAY
From this menu, by pressing , all pixels of all the displays will turn
on: verify that there are no burned pixels. Press to exit the
menu.
BUZZER
From this menu, by pressing the buzzer will activate and start
PRINTER
FAN
From this menu, by pressing the procedure to test the fan shall
start: press and to vary the fan’s speed from 0 to 50% and
When starting it, the device will display the GAS menu.
Close the pneumatic circuit of the analyser by inserting the tip of the
gas sample probe into the proper hole present on the handle (as
indicated in the figure) and press . At the end of the test, if the
leak test has been successful, the programme shall proceed with the
Autozero; otherwise, an error message will be displayed:
see paragraph 8.4.3.4.
Remove the gas sample probe from the vehicle’s silencer and
From the free measurement menu press and select the type of
From the free measurement menu press and select the number
From the free measurement menu press and select the number
From the GAS menu select the “02” menu using the and
From the GAS menu select the “06” menu with the and
There are 4 available types, and they may be scrolled using the
and arrows:
RADIO: configure the external revolution counter with a radio
transmission of revolutions; in this case, revolutions
are detected by an MGT-300/R (optional)
Press again to exit the sub menu and to go back to the previous
menu.
Close the analyser’s pneumatic circuit by inserting the tip of the gas
sample probe into the proper hole on the handle (as shown in the
figure), and press . At the end of the test, if the leak test is
successful, the following message shall be visualised:
8.4.3.5 AUTOZERO
From this menu, the analyser makes clean air flow (through the active
carbons filter) into the internal measurement chamber and performs a
calibration of the concentration of CO CO2 HC gases to zero and to
the 20.80 % Vol. of the O2 value. The active carbons filter is used to
purify air from dust and from unburned hydrocarbons present in the
In this menu, all of the analyser’s possible errors together with their
state are visualised.
In the first line, there is the description of the error; O2 displays the
acronym that identifies the error (ERXX, where XX is a progressive
number); RPM/°C displays the state: active (ON) or deactivated (OFF).
Note: both the software version and the checksum are merely indicative and do not
correspond to the version installed in your gas analyser.
From this menu, it shall be possible to view the P.E.F. value of the
analyser’s measurement chamber, for every HC concentration
configured.
CHAPTER 9 - MAINTENANCE
Before carrying out any maintenance operation, make
sure the appliance is disconnected from the mains socket.
The filter (1) is used to purify the air used during the autozero from
filth and unburned hydrocarbons present in the ambient.
Under optimum conditions of use of the device, replacement of such a
filter should be performed once a year.
N.B.: replace the worn out sensor with only fully efficient sensors
When requested by the software, replace the O2 sensor in the
following way:
1. Remove the worn out O2 sensor by unscrewing it clockwise;
2. Remove the new O2 sensor’s protection cap;
3. Screw the new O2 sensor clockwise and connect the cable (2) of
the instrument.
Once calibration has expired, the software inhibits the printer and the
gas analyser may be used only for unofficial measurements: every
measurement beginning the following message will be showed:
.
For this reason, it is recommended to always to comply with the tests
set.