Bosch BEA 150 Setup guide

1
Repair Instructions
Bosch Emissions Analysis
BEA 150
BEA 250
BEA 350
In conjunction with Service
software for PC

2
Contents: Page
1. Important information 4
1.1 Compulsory calibration 4
2. Testing equipment and settings for the
Service software 5
2.1 Testing equipment 5
2.2 Calibrating gases (with manufacturer's certicate) 5
2.3 Settings for the Service software 6
2.3.1 Setting the interface for the Service program 6
2.3.2 Service Software Language Selection 6
2.3.3 Language Selection for RTM 430
Smoke Opacity Module Service Software 7
3. Brief description of unit functions and
Servicing the unit 8
3.1 Exhaust-gas analyzer module 8
3.1.1 Analyzer part (HC, CO and CO2measurement) 8
3.1.2 System calibration 8
3.1.3 Self-test 8
3.1.4 Adjustment (HC, CO and CO2measuring channels) 8
3.1.5 O2measuring channel 8
3.1.6 Compensation of pressure inuence 8
3.1.7 Compensation of temperature inuence 8
3.1.8 Measurement of excess-air factor (lambda) 8
3.1.9 Corrected CO concentration (COvrai) 9
3.1.10 Parameterization 9
3.1.11 Filtration 9
3.1.12 Principle of ltration 9
3.2 Servicing the unit 9
3.2.1 Half-yearly service 9
3.2.2 Yearly service 9
4. Checking the AMM exhaust-gas analyzer
module 11
4.1 Read operating mode 12
4.2 Leakage test 12
4.3 Read measurement values 13
4.4 Read parameters 13
4.5 Write parameters 13
4.5.1 Country-specic settings 14
4.5.2 Lambda calculation On 15
4.5.3 Lambda calculation O 15
4.5.4 COvrai calculation On 15
4.5.5 COvrai calculation O 15
4.5.6 O2sensor available 16
4.5.7 O2sensor not available 16
4.5.8 Entering lambda coecients OCV and HCV 16
4.6 Identication 17
4.7 Test functions 17
4.7.1 Pump On 18
4.7.2 Pump O 18
4.7.3 Install new O2sensor 18
4.7.4 O2measurement 18
4.7.5 Readjustment with test gas 19
4.7.6 Analysis mode 21
4.7.7 Barometric sensor 21
4.7.8 Maintenance (service date) 22
4.8 Read adjustment data 22
4.9 Adjustment functions 23
4.10 Reset 23
4.11 Error inquiry 23
4.12 NO-Sensor 24
Contents: Page
4.12.1 Read NO-Sensor 24
4.12.2 Set NO-Sensor 24
4.12.3 NO-Measurement 25
4.12.4 Mounting a new NO-Sensor 25
4.12.5 Readjustment with test gas 28
4.12.6 Read calibration data 30
4.12.7 Calibration interval setting 30
4.12.8 Calibration sequence setting 30
4.13 Checking opacimeter RTM 430 31
5. Checking the PCB and periphery of the
BEA control module 32
5.1 Checking the interface for DTM 32
5.2 Checking the interface for RTM 33
5.3 Checking the interface for AMM 33
5.4 Checking the interface for OBD 34
5.5 Checking the interface for OBD extern
(without CAN-protocol) 34
5.5.1 Loop test 35
5.5.2 OBD error messages 36
5.6 Testing 26-pin interface for OBD external
(with CAN protocol) 37
5.7 Checking the interface for the data terminal
(not for BEA-Euro) 38
5.8 Checking the hard disk 38
5.9 Checking the Floppy disk drive 39
5.10 Checking the internal printer 39
5.11 Checking the external printer 39
5.12 Setting the date and time 40
5.13 Video RAM test 40
5.14 Display test 41
5.15 Display test geometry image 41
5.16 Display test full screen all white 41
5.17 Display test full screen all black 42
5.18 Checking the Foil keypad 42
5.19 Checking the PC keyboard 42
5.20 Checking the remote control 43
5.21 Checking the Test calibration switch for Customer
Service 43
5.22 Reading out the Error list 43
5.23 Download SystemSoft 43
6. Checking the engine-speed and
temperature measuring module (DTM) 45
6.1 Checking oil temperature and engine speed in
Diesel Diagnosis 45
6.1.1 Terminal diagram of connection cable for
clamp-on pickup 46
6.1.2 Terminal diagram of temperature sensor 46
6.2 Checking oil temperature and engine speed in
Petrol Diagnosis 47
6.2.1 Terminal diagram of inductive clip-on trigger sensor 48
6.3 Checking V-lambda 48
6.3.1 Terminal diagram of V-lambda cable 49
6.4 Checking the ignition point and dwell angle 49
6.5 Checking the dwell angle 50
6.5.1 Terminal diagram of timing light 51
6.5.2 Terminal diagram of TD/TN connection cable 51

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Contents: Page
7. Technical information (measuring ranges,
resolution and tolerances) 52
7.1 Exhaust-gas analysis in petrol-driven vehicles 52
7.2 Opacity measurement 52
7.3 Engine measurement system TDM+ 52
7.3.1 Temperature measurement 52
7.3.2 RPM measurement, petrol-driven vehicles 52
7.3.3 RPM measurement, diesel vehicles 52
7.3.4 Multiple measurements 53
7.3.5 Ignition point/timing 53
7.3.6 Dwell angle 53
7.3.7 Start of delivery/Injection timing 53
8. Trouble-shooting by message number 54
8.1 Explanations on reference numbers 54
8.2 General messages 54
8.3 Messages about boot test functions 55
8.4 Messages about software installation functions 56
8.5 Messages about printing functions 57
8.6 Messages about hardware test functions 57
8.7 Messages about opacimeter RTM 430 58
8.9 Messages about EAM exhaust-gas analyzer module 59
8.10 Reference numbers when downloading DTM rmware 60
8.11 Reference messages on OBD printed circuit board 61
8.11.1 Reference numbers for errors in "Fatal" group 61
8.11.2 Reference numbers for errors in "Status error" group 61
8.11.3 Reference numbers for errors in "Download" group 61
8.11.4 Reference numbers for errors in„Communication
error“ group 62
8.12 Reference numbers in combination with AWN.Modul 62
8.13 Malfunction messages for testing OBD printed
circuit board with KTS115PC program 63
8.13.1 Error messages for "SDTEST" 63
8.13.2 Error messages for "DLCTEST" 63
8.13.3 Error messages for "LBCTEST" 64
8.13.4 Error messages for "CANTEST" 64
9. Adjustment functions 65
9.1 Setting the Maintenance interval 65
9.2 Setting the calibration interval 66
9.3 Setting the calibration gas components 66
9.4 Setting the calibration sequenz 66
9.5 Setting the leakage test interval 67
9.6 Setting the HC test 67
9.7 Setting COvrai 67
9.8 National regulation settings 68
9.9 Download 68
10. Repairs 69
10.1 Adjusting mains voltage for toroidal mains transformer 69
10.2 AC / DC voltage supply to control module PCB 69
10.3 Block circuit diagram of voltage supply 71
10.4 View of equipment side of control module PCB 72
10.5 Visual inspection of measuring bank of exhaust-gas
analyzer module 73
10.6 Electrical test of measuring bank of exhaust-gas
analyzer module 73
10.7 Leak test of measuring bank 73
10.8 Cleaning the lamp reector 74
10.9 Cleaning the analysis chambers and windows 75
10.10 Replacing the measuring bank 76
10.11 Install new O2sensor 76
10.12 Checking cross sensitivity 78
Contents: Page
10.13 Checking the pump suction power 78
10.14 Replacing the pump 79
10.15 Checking the pressure sensor 79
10.16 Checking the response time of the pressure sensor 79
10.17 Replacing the pressure sensor 80
10.18 Replacing the water separator 80
10.19 Replacing the solenoid valve 81
10.20 Replacing the NO sensor 81
10.21 Replacing the internal printer 82
10.21.1 Replacing the printing mechanism 82
10.21.2 Replacing the controller PCB 82
10.22 Replacing the disk drive 83
10.23 Replacing the TFT display 83
10.24 Replacing the membrane keypad 84
10.25 Replacing the receiver diode for the remote control 84
10.26 Replacing the control module PCB 85
10.27 Replacing the temperature and RPM PCB 85
10.28 Replacing the control-power transformer 85
10.29 Replacing the OBD circuit board 86
10.30 Replacing AWN printed circuit board 87
10.31 Replacing the power switch 88
10.32 Replacing the battery 88
10.33 Replacing hard disc 88
11. BEA test software OS9 89
11.1 Hard disk 89
11.1.1 Identication 89
11.1.2 Testing 89
11.1.3 Formatting 90
11.2 Flash 90
11.3 Floppy disk 91
11.4 Language 91
12. Overview 92
12.1 Electrical wiring (Siemens analysis chamber) 92
12.2 Circuit diagram (Siemens analysis chamber) 93
12.3 Wiring diagram (Siemens analysis chamber) 94
12.4 Hosing (Siemens analysis chamber) 95
12.5 Gas circuit diagram (Siemens analysis chamber) 96
12.6 Electrical wiring (Andros analysis chamber) 97
12.7 Circuit diagram (Andros analysis chamber) 98
12.8 Wiring diagram (Andros analysis chamber) 99
12.9 Hosing (Andros analysis chamber) 100
12.10 Gas circuit diagram (Andros analysis chamber) 101
12.11 Overview of components 102

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1. Importantinformation
Installation and/or repair may only be performed by trained and
instructed service staff at Robert Bosch GmbH or by an organi-
zationnominatedbyRobertBoschGmbH.Allwarrantyclaimsare
rendered null and void in the event that any devices are opened
or modified by a non-authorized person.
Electricalsystemsandequipmentmayonlybeoperatedinproper
working condition (see also Test Equipment Information
0108_084). This requirement is met if it is ensured following a
modification or repair (initial test) that the applicable electrical
engineering standards have been complied with. To this end,
tests based on the type and scope of measures specified in the
electricalengineeringstandards(e.g.inGermanyBGVA2)areto
be carried out. The type and scope of tests to be carried out is
specified for Germany in VDE 0701/0702 Part 1. Compliance
with the corresponding national standards for countries outside
Germany must be ensured.
WhentheBEAisusedinsystemsforwhichcalibrationisrequired
bylaw, legalprovisions inthe countryof useregarding operation,
maintenance and calibration must be observed.
The BEA carries dangerous contact voltage. Unsatis-
factoryorinsufficientmaintenanceandrepairworkmay
lead to a risk of accident through electric shock.
TheBEAmustnotbeusedtomeasureexplosivegases.
The exhaust-gas analyzer must not be operated in
rooms where there is a risk of explosion.
During work with toxic gases, care must be taken to
ensure that a concentration which is hazardous to
health cannot arise in the workplace.
Improperly conducted maintenance and repair work
mayleadtoariskofintoxicationwhenworkingwithtoxic
gases.
Theprintedcircuitboardscontainelectrostaticsen-
sitivedevices.
ObserveESDregulations!
1.1Compulsorycalibration
The regulations governing the calibration of exhaust-gas analy-
zers in the specific country of use must be complied with.
Athalf-yearlyintervals
the BEA must be serviced by expert, instructed persons.
If an official test seal is broken during such work, proper and
expertrepairmust beperformed andconfirmedby theauthorized
Service Agent and a new calibration undertaken by the responsi-
ble calibration authorities.
Servicework
must be recorded in writing, including the following information:
zTime of service
zType of service work undertaken
zName of person or company performing the work
These records must be preserved for the duration of five years.
TheOperatingInstructionsmustbekeptwiththeBEAsothatthey
are available at all times.
TheowneroftheBEAisresponsibleforcompliance
withcalibrationlawsandforregularserviceand
maintenance.

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2.2 Calibratinggases(withmanufacturer'scertificate)
In order to save on calibrating-gas bottles, we recommend a
calibrating-gas bottle filled with mixed gases:
No. 4 5 % CO + 7.5 % CO2+ 2.000 ppm C3H8(propane)*,
accuracy of analysis ± 1%
In some countries (e.g. Germany), calibrating gases to OIML
Directive R99 A and B are used for calibration. In this case, gas
no. 4 can be dispensed with.
A 2000ppmvol.C3H8(propane)*,accuracyofanalysis±1%
3.5 % vol. CO, accuracy of analysis ± 1%
14 % vol. CO2, accuracy of analysis ± 1%
B 200 ppm vol. C3H8(propane)*, accuracy of analysis ± 2%
0.5 % vol. CO, accuracy of analysis ± 1%
6 % vol. CO2, accuracy of analysis ± 1%
* For practical reasons, the exhaust-gas analyzer module is
calibrated regularly with propane instead of hexane.
When the exhaust-gas analyzer module is calibrated in the
menu Readjustment with test gas in the Test functions
menu, the module is informed of the concentration of the
calibrating gas in ppm propane. The exhaust-gas analyzer
automatically takes account of the required "propane factor".
AdditionaltestequipmentandcalibratinggasforoptionalNO
measuringsensor
zNO calibrating-gas bottle: From 1000 to 5000 ppm NO + 2 %
zShutoff valve
zStopwatch
z0 - 12 V DC stabilizer
2. Testingequipmentandsettingsforthe
Servicesoftware
2.1 Testingequipment
z1 laptop or PC
zP100
zP140
zService software for BEA
zESA module system software to test Engine test functions
zKTS module system software to test OBD functions
iThesystemsoftwareversionsforEmissionsSystemAnalysis
and the KTS module must be installed on your laptop or PC,
otherwise the Service software will not be fully functional!
zBEA - PC or laptop, COM1 connecting lead.
As an alternative to the lead shown, the connecting lead for
the data terminal (DTL) 1 684 465 320, can be used.
zAdaptor cable AL350 to check OBD connecting line to
control device.
zTest connector KS350 to check OBD interface in BEA
z1 flow meter (rotameter), measuring range 1.5 to 2 l/min or
10 l/min, test medium air, 20 °C, 1 bar absolute
z1absolute-pressuregauge (barometer)or adjustingbarometer
set to absolute pressure. Measuring accuracy 5 hPa (5 mbar)
z1 gas wash bottle (pearl bottle)
z1 digital multimeter (DMM)
z1 DC calibrator, 0 to 15 mV
z1 stabilizer DC U = 0Volts - 30Volts
zViton hose for calibrating-gas connection (do not use hoses
of different material)
z1 U-tube, water gauge 100 cm, inside diameter max. 8 mm
zCompressedairforcleaningexhaust-sampleprobeandhose
zTorque screwdriver 0.2 - 4 Nm
Insert for inner TORX screws size T15
455901-7
1
5
6
9
1
5
6
9

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2.3 SettingsfortheService
software
2.3.1 Settingtheinterfaceforthe
Serviceprogram
2.3.2 ServiceSoftwareLanguage
Selection
iTheServicesoftwarecontainsthefunctionsforAMM(exhaust-gasanalyzermodule),
RTM (opacimeter) and the BEA (Bosch Emissions Analysis) control module.
Your laptop or PC must also have the system software for the emission system
analysis and KTS module installed.
Start the Service program BEAKD.
Open the File menu.
SelectSetandthenInterface.
Select the appropriate interface and con-
firm by double-clicking the left-hand
mouse button or by pressing E Enter .
Theinterfaceyouhaveselectedisdisplay-
ed below the results window.
Start theservice program BEAKD.
Open the File menu.
GotoSettingsandselecttheLanguage
menu.
Use the mouse or the oand ukeys to
selectthelaguagefortheserviceprogram.
Confirm by double clicking the mouse
button or pressing the Enter Ekey.
The following languages are available:
English
German
French

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2.3.3 LanguageSelectionforRTM430
SmokeOpacityModuleService
Software
Open the Exhaust Gas menuandselect
theRTMmenu.
OpentheSwapLanguagesmenu.
A DOS window is opened with a langua-
ge-selection capability.
Choose the language, by pressing
the appropriate number in front of the
language on your keyboard.
Afterenteringthecorrespondingnumber,
thelanguageis automatically changed to.

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3. Briefdescriptionofunitfunctionsand
Servicingtheunit
3.1 Exhaust-gasanalyzermodule
The exhaust-gas analyzer module is designed for the following
measuring ranges:
zCarbon monoxide (CO) 0...10.00 % vol.
zHydrocarbons (HC) 0...9999 ppm
zCarbon dioxide (CO2) 0...18 % vol.
zOxygen (O2) 0...22 % vol.
zExcess-air factor (lambda) 0.500...9.999
zNitrogen monoxide (NO) 0...5000 ppm vol. NO
3.1.1 Analyzerpart(HC,COandCO2measurement)
The measuring channels for HC, CO and CO2function using the
infrared pulsating-light method.
This technique makes use of the ability of different gases to
absorb infrared rays of a certain wavelength.
Aninfraredrayisproduced byalampandinterrupted incyclesby
achopperwheel,thenitpassesthroughanalysissystemsforCO,
HC and CO2in succession. The individual analysis systems are
sensitive to infrared light of different wavelengths and can there-
fore be mechanically arranged one behind the other.
Each of these systems consists of an analysis chamber through
whichtestgasflows,andareceivingchamberfilledwithasuitable
gas mixture.
The systems are constructed in such a way that when zero gas
(air) flows through the analysis chamber, a maximum electric
alternating-voltage signal – the measured-value signal – is gene-
rated in the receiving chambers.
The signal is amplified by the appropriate channel amplifier,
rectifiedandconveyedonthemotherboardtoananalog-to-digital
converter (ADC). The digitalized signal is read and stored by the
MPU.
When test gas containing the component to be measured flows
throughtheanalysischambers,component-specificwavelengths
of the infrared ray are attenuated accordingly. A smaller measu-
red-value signal is generated in the receiving chambers (see gas
circuit diagram, Section 12.5).
3.1.2 Systemcalibration
System calibration is always started automatically when the
systemswitchestoa measuringmodeandtheinfraredmeasured
values at this moment differ from zero.
Duringsystemcalibration,asolenoidvalveswitchesthezero-gas
inlet (with carbon canister) into the test-gas duct for the duration
of calibration. During this process, zero gas (air) is used to
determine the actual system sensitivity of the HC, CO and CO2
measuring channels. This value is then stored as the zero point.
If the exhaust-gas analyzer module is still in analysis mode after
15 minutes, system calibration is repeated. Here, the analyzer
module automatically checks whether analysis is currently taking
place and, if it is, delays system calibration until all measured
values have fallen to zero.
3.1.3 Self-test
The BEA performs a self-test during which it checks all its most
important functions. Any malfunctions detected result in an error
message (Section 8).
3.1.4 Adjustment(HC,COandCO2measuringchannels)
During1-pointadjustment(recalibration)withcalibratinggas,the
measurement effect (difference from zero) is measured. The
analyzer module is informed by means of a nominal value as to
which concentration of calibrating gas corresponds to this
measurement effect.
Youmaypreselectdifferentadjustmentoptionswhichvaryintype
and frequency, to suit your application.
3.1.5 O2measuringchannel
Thesensitivityofthismeasuringchannelisadjustedautomatically
during each system calibration. During this process, the measu-
red oxygen content is set against the compensating air = 20.9 %
and the condition of the O2measuring sensor is monitored. The
zero point of the O2measuring channel is recognised automati-
cally.
The oxygen measurement function can be deactivated
(Section4.5,Writeparametersmenu).
3.1.6 Compensationofpressureinfluence
Different levels of atmospheric pressure mean that different
concentrations are measured in the analysis system. In order for
the exhaust-gas analyzer module to achieve a correct measure-
ment, the atmospheric pressure to be taken into consideration is
determinedbymeansofanintegralpressuresensor.Theexhaust-
gas analyzer module can then calculate the correct displayed
value itself.
3.1.7 Compensationoftemperatureinfluence
Temperaturesensorsaresituatedonthereceivingchambersand
ontheinfraredlamp.Theoperatingtemperaturesmeasuredthere
are automatically taken into account during the adjustment of the
exhaust-gasanalyzermoduleandtheconversionofthemeasured
value to the displayed value.
3.1.8 Measurementofexcess-airfactor(lambda)
Theexhaust-gasanalyzermodulecalculates theexcess-airfactor
(lambda λ) from the measured concentrations of CO, HC, CO2
and O2. The lambda value is indicated on the display if the
measured CO2content exceeds 2 % and both the oxygen
measurement and excess-air measurement functions are activa-
ted. The oxygen measurement is extremely important for calcula-
ting the excess-air factor. An imprecise oxygen measurement
leads to the incorrect calculation of the excess-air factor. The
lambda measurement function can be deactivated (Section 4.5,
Writeparametersmenu).

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3.2 Servicingtheunit
The service work listed below must be performed irrespective of
legal requirements in the country of operation.
3.2.1Half-yearlyservice
iAt this interval, only work for testing and maintaining opera-
tional readiness must be performed.
1. Replace GF1 filter (Item 1)
2. Replace inlet filter GF2 (Item 2)
3. Check that both PVC hoses are connected to the gas outlet
(Items 3, 4)
4. Visual inspection of exhaust-sample probe (Item 6)
In the case of major contamination, blow out with com-
pressed air against the direction of suction
5. Perform leak test (Sec. 4.2)
6. Update service date (Sec. 4.7.8)
3.2.2 Yearly service
This service work must be performed by expert maintenance
personnel. It consists of the work included in the half-yearly
service plus the additional items:
!It is essential to read Sections 3.1.11 (Filtration) and 3.1.12
before replacing the filters!
1. Replace pump protection filters GF 3 and GF4.
iThepumpprotectionfilterGF4issituatedintheinteriorofthe
unit.
!When the GF4 filter is replaced annually, the internal piping
shouldalsoalwaysbereplaced. Usetheparts set1687010
125 for this purpose. Be very careful to consult the gas flow
plan in chapter 12.5.
459715/9Ha
GF3
GF4
AF1
459715/8Ha
1
6
342
3.1.9 CorrectedCOconcentration (COvrai)
Theexhaust-gasanalyzermodulecalculatesthetrueCOconcen-
tration (COvrai) from the concentrations of CO and CO2. This
process also takes , for example, factors such as leaks in the
exhaust system into consideration.
Thisfunctioncanbedeactivated(Section4.5,Writeparameters
menu).
3.1.10 Parameterization
The exhaust-gas analyzer module can be parameterized for its
specificintendedtasksintheSetparametersmenu(Section4.5).
Additional possibilities for parameterization are contained in the
Adjustmentfunctionsmenu(Section9).However,these-like
the adjustment functions themselves - can only be accessed if a
test seal has been broken.
3.1.11 Filtration
Particles and aerosols are removed from the test gas by a
cascade of filters.
Particles constitute solid bodies such as dust and soot, while
aerosolsaretiny droplets of fluid whichcondensein the gas duct
andanalysischambers.Theretheyformacoatingwhichmaygive
rise to error messages.
For this reason, it is imperative to ensure the correct manner of
filtration.
3.1.12 Principleoffiltration
Thefirstfilter,GF1,filtersthemajorityofparticlesandaerosolsout
of the gas flow. This filter clogs most rapidly and must therefore
bereplacedmost frequently:aboutoncea week.
The inlet filter, GF2, at second place in the cascade, filters out a
further part of particles and aerosols. The more clogged the filter
is,thesmallerthemeshsizeandthusthebetterthefilteringaction.
Thefilterbecomeswetveryquicklyfromwaterintheexhaustgas.
Thismoisturewashestheaerosolsoutoftheflowofgasandfilters
theparticlesbetter.Awetfilteristhereforedesirable!
This filter should be replaced from around once a month to once
a year.
Filters GF3 and GF4 have the task of protecting the internal
pumps. When the filtration system as a whole is being used
correctly, these filters must only be replaced once a year, at the
most.
FilterGF4,inparticular,alsohasabetterfilteringactionwhenwet
than dry.

10
Procedure:
Using a non-soluble felt pen, write the current date on the
adhesive label 1 689 980 296 and confirm with your signature
(see illustration).
Stick the completed adhesive labels onto the new GF3 and
GF4 coarse filters.
Install the new GF3 and GF4 coarse filters.
2. Replace the carbon canister AF1 in the zero gas pipe.
3. Check the measuring accuracy of the exhaust-gas analyzer
with calibrating gas.
iAlways ensure a flow rate of > 1 l/min when letting gas flow
through the calibrating-gas inlet. Allow a sufficient warm-up
time (min: 5 minutes).
Clickon Testfunctions(Sec. 4.7)and openthemenuitem
Analysismode(Sec.4.7.6).
Automatic zero calibration takes place.
Let test gas no. 4 (sensitivity test) or single gases of the
appropriate concentration in succession flow through the
exhaust-gasanalyzer viathe calibrating-gasinlet. Notedown
the displayed values.
Next,usetestgasesno.5andno.1(gasmixtureforsagtest)
to check linearity, and note down the displayed values.
Ifthe displaydeviates fromthe certifiedcalibrating-gasvalue
duringameasurement (sensitivityorlinearity) bymorethan5
%, replace the measuring bank (Section 10.10).
!If regular calibration is required due to special regulations,
executethemenuReadjustmentwithtestgas(4.7.5)inthe
Test functions menu (4.7). This will reset the monitoring
clock.
Datum/Date
Unterschrift/Sign
aktuelles Datum
Unterschrift
459558/23 Ha

11
Readoperatingmode Displaythecurrentstatus(mode)oftheexhaust-gas
analyzermodule.
Leakagetest Perform a manual leak test.
Readmeasurmentvalues Displaycurrent measuredvalues ofHC,CO, CO2,
O2, lambda COcor and air pressure.
Readparameters Read out set parameters.
Writeparameters Enter parameterswhich areimportant forthe opera-
tion of the exhaust-gas analyzer module (country-
specificstipulations).
Identification Read out software version and checksum.
Testfunctions Checkunitfunctions.
Readadjustmentdata Display setting data important for operation of the
exhaust-gas analyzer module (country-specific stipu-
lations).
Adjustmentfunctions Settings for the exhaust-gas analyzer module.
Reset Restart the exhaust-gas analyzer module. (When this
option is selected, the exhaust-gas analyzer module
is disabled for approx. 15 s).
Errorinquiry Read out the internal fault memory.
NO-Sensor Menu for operating the NO - Sensor.
4. CheckingtheAMM
exhaust-gasanalyzer
module
Open the Exhaust gas menu and select
AMM.
Then choose the Test program menu.
The Function selection menu (main
menu) opens.
TheFunctionselectionmenucontainsthe
followingitems:

12
4.1 Readoperatingmode
4.2 Leakagetest
The current status (mode) of the exhaust-
gas analyzer module is displayed.
Depending on when this menu is started,
the following modes may be displayed:
zLeakage test
zWarm-up phase
zStandby
zError message
Thismenuallowsyoutoperformaleakage
testmanuallytocheckthetightnessofthe
exhaust-gas analyzer module.
Seal off the exhaust-sample probe with
the plastic hose or the test bush and
confirm by pressing Eor clicking OK.
Follow the instructions on screen.
The pump is then switched on and off in
cyclesoveraperiodofapprox.3sec.until
acertainlevel ofvacuumisreached.After
this, the exhaust-gas analyzer module
measures the drop in pressure over a
period of 15 s. The time is counted back-
wards from 15 s to 0.
Removethesealfromtheexhaust-sample
probe and confirm by pressing Eor
clicking OK.
If the leakage test is failed, perform trou-
ble-shooting as described in Section 8.

13
4.3 Readmeasurementvalues
4.4 Readparameters
4.5Writeparameters
After zero calibration, an HC residue test
takes place.
Next,thecurrentmeasuredvaluesforHC,
CO, CO2, O2, lambda, COcor and air
pressure are displayed.
Theparameters set inthe Set parameters
mode (Section 4.5) are displayed. For
example:
Parameters specific to the country of use
or required by law are set in this menu.

14
4.5.1Country-specificsettings
Parameter settings
Parameter Germany Standard EU Denmark Switz. France Holland Italy
Lambda calculation ON ON ON ON ON ON ON
COcor calculation OFF OFF ON OFF ON OFF OFF
O2measurement ON ON ON ON ON ON ON
Adjustment data settings
Setting Germany Standard EU Denmark Switz. France Holland Italy
Recalibration interval 365 days 365 days 365 days 365 days 365 days 365 days 365 days
Gases for recalibration HC, CO, HC, CO, HC, CO, HC, CO, HC, CO, No setting HC, CO,
CO2CO2CO2CO2CO2CO2
Reaction when recalibration Disable No setting No setting Disable No setting Message No setting
due
Leak test configuration Days Days NO Days NO Days Days
Leak test interval 1 day 1 day NO 1 day NO 1 day 1 day
HC residue test YES YES YES YES YES YES YES
National regul. complied with YES NO YES YES NO YES YES
Change COcor setting Disabled Enabled Disabled Disabled Enabled Disabled Enabled
Service interval 183 days 183 days 183 days 183 days 183 days 183 days 183 days

15
4.5.2 LambdacalculationOn
4.5.3 LambdacalculationOff
4.5.4 COvraicalculationOn
4.5.5 COvraicalculationOff
OpentheLambdacalculationonmenu
usingtheo ukeysandconfirmwithEor
by double-clicking the mouse.
The OK box is displayed for approx. 1 s.
Lambda calculation is now activated.
Open the Lambda calculation off
menu using the o u keys and confirm
with Eor by double-clicking the mouse.
The OK box is displayed for approx. 1 s.
Lambda calculation is now deactivated.
Open the COvrai calculation on menu
usingthe oukeysandconfirmwithEor
by double-clicking the mouse.
The OK box is displayed for approx. 1 s.
COcor calculation is now activated.
Open the COvrai calculation Off menu
usingtheo ukeysandconfirmwithEor
by double-clicking the mouse.
The OK box is displayed for approx. 1 s.
COcor calculation is now deactivated.

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4.5.6 O2sensoravailable
4.5.7 O2sensornotavailable
4.5.8 Enteringlambdacoefficients
OCVandHCV
OpentheO2sensoravailablemenuusing
the oukeys and confirm with Eor by
double-clickingthemouse.
AfterconfirmationthattheO2sensorisnot
available, the measuring chamber's
measuring computer (SI BENCH) is re-
started. Afterthis itjumpsback tothe Set
parameterssubmenu.
iTheexhaust-gasanalyzeristhenonce
more in the warm-up phase. Further
measurement with the Service soft-
ware is disabled for 60 seconds. A
message appears on screen.
OpentheO2sensornotavailablemenu
usingthe ou keys and confirmwith Eor
by double-clicking the mouse.
AfterconfirmationthattheO2sensorisnot
available, the measuring chamber's
measuring computer (SI BENCH) is re-
started. Afterthis itjumpsback tothe Set
parameterssubmenu.
iTheexhaust-gasanalyzeristhenonce
more in the warm-up phase. Further
measurement with the Service soft-
ware is disabled for 60 seconds. A
message appears on screen.
iLambdacoefficientsmustalsobeset
inaccordancewithregulationsspeci-
fic to the country of use and must be
stipulated by the law of that country.
Lambda coefficients OCVand HCV
are fuel-specific values and are re-
quired to calculate the lambda value.
Enter the values for OCVon the keyboard
and confirm by clicking OK or by press-
ingE.
e.g.: 0.0175.
Enter the values for HCVon the keyboard
and confirm by clicking OK or by press-
ing E.
e.g.: 1.7261.

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4.5.8 Entering lambda coefficients
HCVand OCV
4.6 Identification
4.7 Testfunctions
Youarenowaskedifyourentryiscorrect.
Confirm your entry by clicking Yes or by
selectingYeswiththe vzbuttonsand
pressing E.
The OK box is displayed for approx. 1 s.
TheHCVandOCVvaluesarestoredinthe
exhaust-gas analyzer.
Ifyouhave entered the valuesincorrectly,
click No or cancel your entry with E.
Enterthelambdacoefficientvaluesagain.
Thesoftwareversionandchecksumofthe
exhaust-gas analyzer module are display-
ed. For example (see screenshot):
You can test various functions of the
exhaust-gas analyzer module in the Test
functions menu.

18
4.7.1 PumpOn
4.7.2 PumpOff
4.7.3 InstallnewO2sensor
4.7.4 O2measurement
Select this menu by double-clicking the
mouse or with the o u keys and confirm
with E.
The pump is switched on and the OK box
is displayed for 1 s.
Thisfunctioncanbeused,forexample, to
purge the exhaust-gas analyzer module if
it has been contaminated with HC.
Select this menu by double-clicking the
mouse or with the o u keys and confirm
with E.
The pump is switched off and the OK box
is displayed for 1 s.
SeeSection10.11.
Start the menu by double-clicking the
mouse or with E.
Thepumpisswitchedonandzerocalibra-
tion takes place. During this process, the
O2measuring channel is recalibrated to
20.9% O2(this same calibration is also
performed automatically during each
system calibration with zero gas/air).
After zero calibration, the pump is swit-
ched off.
Theexhaust-gasanalyzermoduledisplays
the concentration of oxygen with the cur-
rent ADC voltage value below it.
IfthecurrentADCvoltageliesatthelower
threshold of 7 mV, you must replace the
O2measuring sensor (Section 10.11).
Nominal voltage: 7 mV - 11 mV

19
4.7.5 Readjustmentwithtestgas iAdistinguishing featureof the exhau-
st-gas analyzer module is the excel-
lent long-time stability of its measu-
ring accuracy. Despite this, the ex-
haust-gas analyzer may be required
bylawor by the regulationsofappro-
val authorities to be recalibrated with
calibrating gas at given intervals.
To recalibrate the exhaust-gas analyzer,
you will need a calibrating-gas mixture
withthe followingconcentrations (depen-
ding on requirements):
HC: 400 to 2000 ppm vol C3H8,
entry in propane
CO: 1% to 10% vol CO
CO2: 5% to 18% vol CO2
Usingthekeyboard, enter the calibrating-
gas values for CO as stated on the certi-
ficate.
Confirm your entry of these values by
clicking OK or by pressing E.
Usingthekeyboard, enter the calibrating-
gasvaluesforCO2asstatedonthecertifi-
cate.
Confirm your entry of these values by
clicking OK or by pressing E.
Usingthekeyboard, enter the calibrating-
gas values for HC as stated on the certif-
icate.
Confirm your entry of these values by
clicking OK or by pressing E.

20
4.7.5 Readjustment with test gas Set the flow to > 1 l/min.
iOnly push the calibrating-gas hose
onto the calibrating-gas inlet follo-
wing successful zero calibration.
The calibrating-gas mixture must be fed
into the calibrating-gas inlet.
The exhaust-gas analyzer module per-
forms zero calibration.
Afterzerocalibration, pushthe calibrating-
gas hose onto the calibrating-gas inlet.
Start the flow at > 1 l/min.
The calibrating-gas values are displayed.
Overaperiodof30seconds,thesoftware
of the exhaust-gas analyzer module com-
pares the measured values with the
entered nominal values.
If readjustment with test gas has been
successful, quit the menu by clicking on
OK or with E.
The screen now returns to the Test
functions menu.
iIfrecalibrationwasunsuccessful,the
faultis statedin plaintext.Repeatthe
recalibration process.