Bosch ETT 008.31 Setup guide

1
Repair instructions
Exhaust gas analyzer
ETT 008.31 - ETT 008.38

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Contents: Page
1. Important information 4
1.1 Compulsory calibration 4
2. Servicing the analyzer 4
2.1 Half-yearly service 4
2.2 Yearly service 4
2.3 Test equipment for customer service 5
2.4 Test gases for customer service 5
(with manufacturer's certificate) 5
3. Brief description of appliance function 6
3.1 Serial interface 6
3.2 Analyzer part (measurement of CO, HC and CO2)6
3.3 System adjustment 6
3.4 Self-test 6
3.5 Fine-tuning (HC, CO and CO2
measuring channels) 6
3.6 O2measuring channel (optional) 6
3.7 Correction of pressure influence 6
3.8 Compensation of temperature influence 7
3.9 Engine-speed measurement 7
3.10 Oil-temperature measurement (optional) 7
3.11 Lambda measurement 7
3.12 Corrected CO concentration (COvrai)7
3.13 Parameterization 7
3.14 Filtration 7
4. Extended operating functions 8
4.1 Input mode ( switch S 60 at position 0,
auxiliary functions) 9
4.1.1 Leak test 10
4.1.2 Lambda measurement ON / OFF 11
4.1.3 O2measurement ON / OFF 11
4.1.4 CO correction COvrai ON / OFF 12
4.1.5 Summer time ON / OFF 12
4.1.6 Air-pressure gauge ON / OFF 13
4.1.7 Entering the altitude 13
4.1.8 Fine-tuning the zero of O2
(up to software version A 10) 13
4.1.8 Fine-tuning the zero of O2
(from software version A 13) 14
4.1.9 Adjusting the pump capacity 14
4.1.10 Analysis mode 14
4.1.11 Selecting a printer 15
4.1.12 Selecting the operator terminal 15
4.1.13 Temperature compensation 15
4.1.13.1 Error messages regarding temperature
compensation 16
4.1.14 External display ON / OFF (optional, variant
for Sweden only) 16
4.1.15 Selecting analog interface (optional) 16
4.2 Test mode ( switch S 60 at position 0) 17
4.3 Fine-tuning mode (switch S 60 at position 1,
mean values, air-pressure gauge and
chopper motor recognition) 19
4.4 Fine-tuning mode (switch S 60 at position 2,
upper range values, activation of temperature
compensation and setting appropriate version
for country of use) 20
5 Function test 21
5.1 Visual inspection (device is switched off and
disconnected from mains) 21
5.2 Checking the external gas duct 21
5.3 Checking the protective earth 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-pressure gauge 28
6.6 Recognition of chopper motor 30
6.7 Procedure for setting appropriate version
for country of use 30
7 Error messages / malfunctions 31
7.1 Error messages in the CO display field 31
7.2 Error messages in the CO2display field 32
7.3 Symbolic error messages 33
7.4 Other malfunctions 34
8 Trouble-shooting 34
8.1 Leakage faults 34
8.2 Flow faults (with zero-gas and test-gas flow) 34
8.2.1 Checking for an obstruction 35
8.2.2 Checking the pressure switches 35
8.2.3 Checking air-tightness 36
8.2.4 Checking the pump delivery rate 37
8.3 Indicating faults 38
8.4 RAM check error 39
8.5 Faulty channel identification 40
8.6 Faulty temperature compensation 40
8.7 Faulty channel amplifier 41
8.8 Faulty sensor board identification 43
8.9 Faulty pressure-influence correction
(faulty altitude setting or air-pressure gauge) 43
8.10 Faulty engine-speed measuring channel 44
8.11 Faulty oil-temperature measuring channel 45
8.12 Faulty O2measuring channel 45
8.13 Supply-voltage alarm 46
8.14 Faulty pump actuation 46
8.15 Checking the sensor board 46
8.15.1 Checking the power supply 46
8.15.2 Checking the ”SELECT”,”ENTER o”
and ”TEST u” non-locking switches 46
8.15.3 Checking function of switch S60 47
8.15.4 Circuit diagram of sensor board 47
8.15.5 Sensor board, component location diagram 48
8.16 Power supply to power electronics 49
8.17 Power supply to motherboard 50
8.17.1 Motherboard, component location diagram 51
9 Functions of the serial interface 52
9.1 Technical data of serial interface V24 52
9.2 Operating the pocket keyboard 52
9.2.1 Basic command structure 52
9.2.2 Selecting ”Language” 53
9.2.3 Entries in the ”Name field” 53
9.2.4 Entering the date/time 54
10. Repair work 55
10.1 Replacing the lamp 55
10.2 Cleaning the lamp reflector 55
10.3 Replacing a receiver chamber 55
10.4 Cleaning the analyzer part 56

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Contents: Page
10.5 Service limit values 56
10.5.1 Adjusting the channel amplifier 57
10.6 Installing the O2measuring sensor 58
(up to software version A10) 58
10.6.1 Installing and calibrating the
O2measuring 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 Diagrams 64

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1. Importantinformation
Service and repair work on this piece of equipment may only be
performed by competent, that is, adequately instructed and
authorized persons.
A safety test as described in Section 11 must be performed
following all service and repair work with a possible influence on
safety functions.
When the device is to be used in countries where calibration is
compulsory by law, the legal regulations in force in the country of
use regarding operation, service and calibration must be obser-
ved.
The exhaust-gas analyzer carries dangerous con-
tact voltage. Poor service and repair work entails
a risk of accidents through electric shock.
Explosive gases may not be measured with this
exhaust-gas analyzer. The exhaust-gas analyzer
must not be used in potentially explosive at-
mospheres.
When working with toxic gases, care must be
taken to ensure that a concentration hazardous to
health cannot build up in the workplace. Unskilled
service and repair work entails a risk of intoxication
during operation with toxic gases.
The assembly contains electrostatic sensitive
devices.
Observe the regulations for ESD!
1.1 Compulsorycalibration
National laws governing the calibration of exhaust-gas analyzers
must be observed.
Every six months
the exhaust-gas analyzer must be serviced by competent per-
sons.
If, during such work, an official seal is damaged, proper and
expert repair work must be effected and confirmed by the autho-
rized Service Agent or a new calibration performed.
For 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-
sponsibleforobservingcalibration lawsand
for regular servicing.
2. Servicing the analyzer
The service work described below must be carried out irrespec-
tive of the applicable laws in the country of operation.
2.1 Half-yearly service
iThe only work to be performed at these intervals involves
checking and maintaining the device in working order.
!Before replacing filters, Sections 3.14 (Filtration) and 3.14.1
must be observed!
•Replace filter GF 1 (Figure 1, Pos. 1)
•Replace input filter GF 2 (Figure 1, Pos. 2)
•Replace paper filter (Figure 1, Pos. 4)
•Blow out fine filter (Figure 1, Pos. 5), replace if necessary
•Perform visual inspection of exhaust-sample probe. If seriously
clogged, blow out with compressed air against the intake
direction.
•Perform function test (Section 5)
•Check indicating accuracy (Section 6)
•Check zero point of oxygen measurement (Section 4.1.8)
•Perform leak test (Section 4.1.1)
2.2 Yearly service
This service work must be performed by a competent mainte-
nance agent. It comprises the tasks from the half-yearly service
plus the following points:
•Replace protective pump filter GF 3 (see gas-route diagram).
•Replace carbon canister in zero-gas duct (Figure 2, Pos. 31).
•Replace battery on motherboard/computer board
(Section 10.7).
•Replace O2measuring sensor (Section 10.6).
•Fine-tune air-pressure gauge (Section 6.5).

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2.3 Test equipment for customer service
1 siphon, water gauge 100 cm, inside diameter max. 8 mm
1 flow meter (variable-area type), measuring range 1.0 l/min.
to 10 l/min., measuring medium air, 20 °C, 1 bar absolute
1 absolute-pressure sensor (barometer) or adjusting barometer
set to absolute pressure. Measuring accuracy 5 Hpa (5 mbar)
1 gas-wash bottle (bead bottle)
1 digital multimeter (DMM)
1 oscilloscope, sensitivity 5mV/cm
1 thermometer with surface probe
1 P100 or P200 or P140 for engine-speed measurement
1 DC calibrator, 0 to 15 mV
1 data terminal (pocket keypad)
1 measured-value printer (integrated or connected externally via
serial interface)
Viton hose to test-gas connection (do not use any other type of
hose material)
Compressed air for cleaning test-gas probe and hose
2.4 Test gases for customer service
(with manufacturer's certificate)
In order to save on bottles of test-gas, mixed gases are sometimes
recommended.
No.1: 14 % CO2Accuracy of analysis ± 1 %
No.2: 16.000 ppm C3H8(propane)*)Accuracy of analysis ± 1 %
No.3: 9 % CO Accuracy of analysis ± 1 %
No.4: 5 % CO + 7.5 % CO2+
2.000 ppm C3H8(propane)*) Accuracy of analysis ± 1 %
No.5: 2 % CO +
3.800 ppm C3H8(propane)*) Accuracy of analysis ± 1 %
No.6: 8.000 ppm C3H8(propane)*) +
1 % CO Accuracy of analysis ± 1 %
In some countries, A and B are used for the calibration of test
gases in accordance with OIML Directive R99. These gases may
also be used for the purpose of fine-tuning. In this case, gases no.
1 and 4 need not be used.
A 2.000 ppm C3H8(propane)*) Accuracy of analysis ± 1 %
3.5 % vol. CO Accuracy of analysis ± 1 %
14 % CO2Accuracy of analysis ± 1 %
B 200 ppm C3H8(propane)*) Accuracy of analysis ± 1 %
0.5 % vol. CO Accuracy of analysis ± 1 %
6 % CO2Accuracy of analysis ± 1 %
*) The exhaust-gas analyzer is fine-tuned regularly with propane
(instead of hexane) for practical reasons. During fine-tuning,
the exhaust-gas analyzer is informed of the concentration of the
test gas in "ppm propane". The exhaust-gas analyzer auto-
matically takes account of the necessary "propane factor".

6
3. Brief description of appliance function
The exhaust-gas analyzer is designed for the following measuring
ranges:
Carbon monoxide (CO) 0...10.00 % vol.
Hydrocarbons (HC) 0...9999ppm
Carbon dioxide (CO2) 0...18 % vol.
Oxygen (O2) 0...21 % Vol. (optional)
Engine speed 0...9990rpm
Oil temperature 0...150 °C
Excess air factor
(λ, Lambda) 0.500...1.800(optional)
3.1 Serial interface
The exhaust-gas analyzer has a serial interface for connection to
the following items of equipment:
- Operator data terminal for entering the necessary identity data
during exhaust-gas tests, for entering the necessary measuring
parameters or for setting the internal battery-backed clock
(e.g. following a fault in the appliance).
- External printer (if the exhaust-gas analyzer does not feature an
integrated printer).
- Emission system analysis (3.110, 3.140, 3.250).
- Engine tester MOT 240 / 250 / 251 or FSA 560 / 600.
A special connecting line must be used for this purpose (see
operating instructions of different systems).
3.2 Analyzer part (measurement of CO, HC and CO2)
The channels for measuring CO, HC and CO2function accor-
ding to the infrared pulsating-light method. In this process, the
properties of the different gases are used to absorb infrared rays
of particular wavelengths. The infrared rays are produced by a
lamp, interrupted in cycles by a chopper wheel and fed one after
another through an analysis system for CO, HC and CO2. The
individual analysis systems are sensitive to infrared light of diffe-
rent wavelengths and can therefore be mechanically arranged
one behind the other.
Each of these systems consists of an analyzing chamber through
which test gas flows, and a receiving chamber filled with a
suitable gas mixture.
The systems are constructed in such a way that when zero gas
(air) flows through the analyzing chamber, a maximum electrical
alternating-voltage signal - the measured-value signal - is genera-
ted in the receiving chambers.
The signal is amplified by the appropriate channel amplifier,
rectified and conveyed on the motherboard to an analog-to-digital
converter (ADC). The digitalized signal is read and stored by the
MPU.
When test gas containing the component to be measured flows
through the analyzing chambers, component-specific wa-
velengths of the infrared ray are attenuated accordingly.
A smaller measured-value signal is generated in the receiving
chambers (see gas-route diagram, Section 12).
3.3 System adjustment
After the warm-up time and during various other processes, the
exhaust-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 CO2measuring channels is deter-
mined using zero gas (air) and stored as the zero point.
A system adjustment is always started automatically when the
system switches over to analyzing mode and the infrared measu-
red values at this moment differ from zero. If the exhaust-gas
analyzer is still in analyzing mode after 15 minutes, the system
adjustment is repeated. Here, the analyzer automatically checks
whether analysis is currently taking place and, if it is, delays
system adjustment until all measured values have dropped to
zero.
3.4 Self-test
In conjunction with the system adjustment, the exhaust-gas
analyzer performs a self-test during which it checks its most
important functions. Any malfunctions it detects result in an error
message (Section 7).
3.5 Fine-tuning (HC, CO and CO2measuring channels)
During fine-tuning with test gas (upper-range value gas), the
measurement effect (difference from zero) is measured. The
analyzer is informed by means of a "setpoint" which test-gas
concentration corresponds to this measurement effect.
Fine-tuning is also carried out with mean-value gas (concentrati-
on in the middle of the measuring range).
Following this process, the exhaust-gas analyzer can then deter-
mine the characteristic curve, and all measured values which
occur within the measuring range can be interpreted and correct-
ly indicated.
3.6 O2measuring channel (optional)
The sensitivity of this measuring channel is fine-tuned automati-
cally during each system adjustment. Here, the measured oxygen
content is set against the compensating air = 20.9 % and the
condition of the O2measuring sensor is monitored.
The zero of this O2measuring channel is fine-tuned manually
(see Section 4.1.8).
The oxygen measurement function can be deactivated
(Section 4.1.3).
3.7 Correction of pressure influence
Different levels of atmospheric pressure mean that different
concentrations are measured in the analysis system. In order for
the exhaust-gas analyzer to be able to display the correct value,
it is informed of the atmospheric pressure by means of a built-in
pressure sensor or by the entry of the mean altitude. The analyzer
can then calculate the correct display value itself.
In exhaust-gas analyzers without a built-in air-pressure gauge, the
new altitude must be entered if its location is changed
(Section 4.1.7).

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3.8 Compensation of temperature influence
Temperature sensors are situated on the receiving chambers.
The operating temperatures measured there are taken into consi-
deration during fine-tuning of the exhaust-gas analyzer and during
the conversion of the measured value into the displayed value.
The correction factors required for this purpose are ascertained
specifically for each measuring channel (HC, CO and CO2)
during an automatic temperature-compensation process (see
Sections 4.1.13 and 4.4).
3.9 Engine-speed measurement
On the rear side of the exhaust-gas analyzer, an inductive clamp-
on sensor can be connected to the designated jack and a
connecting line to terminal 1 or an optical pulse generator
connected (Figure 2, Pos. 7). In order to permit measurements to
be carried out on engines with differing numbers of cylinders and
at different signal sources, the exhaust-gas analyzer can be
informed of the number of pulses (PU) for each two crankshaft
revolutions. The pulse count is adjusted using the button for
selecting 2-stroke or 4-stroke measurement (Figure 1, Pos. 14).
Examples: 4-cylinder four-stroke engine; signal source
= cable to spark plug
Correct setting: PU = 1
4-cylinder four-stroke engine; signal source
= cable before distributor
Correct setting: PU = 4
The pulse count is adjusted for the exhaust-gas analyzer in the
range of 1 to 12 by pressing the "Select" button (Figure 2,
Pos. 25) several times.
3.10 Oil-temperaturemeasurement (optional)
The temperature sensor required for this measurement is con-
nected to the designated jack on the rear side of the exhaust-gas
analyzer (Figure 2, Pos. 27). In analysis mode, the oil-tempera-
ture display is automatically switched over to the lambda value
(excess-air factor) if the measured CO2content 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, CO2and O2. The
lambda value is indicated on the display if the measured CO2
content surpasses 2 % and both the oxygen measurement and
lambda measurement functions are activated. The oxygen mea-
surement is extremely important for calculating the excess-air
factor. An imprecise oxygen measurement leads to an incorrect
calculation of the excess-air factor. The lambda measurement
function can be deactivated (Section 4.1.2).
3.12 Corrected CO concentration (COvrai)
The exhaust-gas analyzer calculates the true CO concentration
(COvrai) from the concentrations of CO and CO2. For this pro-
cess, leaks in the exhaust system, for example, are taken into
consideration.
The true CO concentration is only printed out or is displayed on
the engine tester during operation with MOT 501. This function
can be deactivated (Section 4.1.4).
3.13 Parameterization
When the exhaust-gas analyzer has been switched to "Input
mode" (also see Section 4.1, input functions), it can be parame-
terized in accordance with the intended task. It is necessary to
break a test seal (in some countries) in order to get into input
mode.
3.14 Filtration
!Only Original Bosch filters part number 1 687 432 005 may
be used!
Particles and aerosols are removed from the test gas by means
of a cascade of filters.
Particles constitute solid bodies such as dust and soot, while
aerosols are tiny droplets of fluid which condense in the gas duct
and analyzing chambers. There, they form a coating which may
lead to error messages. Therefore, use of the correct filters is
extremely important.

8
4. Extended operating functions
The functin switch S 60 on the side of the analyzer has three
settings which allocate various modes to the ”Select” ,
”Enter o” and ”Test ubuttons.
Switch position 0: Input mode (auxiliary function) and test mode
Switch position 1: Fine-tuning mode (mean values)
Switch position 2: Fine-tuning mode (upper-range values)
The function switch S 60 is normally concealed by a protective cover. In calibrated devices, this cover is also secured by a calibration
seal. This seal must be removed if you have to work in fine-tuning mode. After this, the exhaust-gas analyzer must be re-calibrated.
The switch position 0is the standard setting.
In this setting, the functions described in Sections 4.1 (Input mode) and 4.2 (Test mode) may be used.
The following 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 function and accepts the modified settings or parameters. The next possible function
is displayed.
For further details on these operating functions, see Sections
- 4.1 Input mode (switch S 60 at position 0, auxiliary functions)
- 4.2 Test mode (switch S 60 at position 0)
- 4.3 Fine-tuning mode (switch S 60 at position 1, mean values)
- 4.4 Fine-tuning mode (switch S 60 at position 2, upper-range values)
If you suspect a malfunction in one of these control elements, perform trouble-shooting in accordance with Section 8.15, "Checking
the sensor board".
SELECT
ENTER
TEST
1 - 0 - 2
S 60

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Summary of select mode
iGoing into the "Select modes" varies with versions for
different countries!
The settings and various fine-tuning procedures described in
these instructions are based on the standard version.
Swiss Standard UK French
version version version version
U 13 H U 13 U U 13 E U 13 F
Press ETT 8.37, ETT 8.31, ETT 8.31 ETT 8.35
“SELECT” ETT 8.38 ETT 8.36 ETT 8.52
button
1 x LE.An LE.An LE.An LE.An
2 x 5C.An LA.An 5C.An LA.An
3 x 5C.An 02.An 5C.An 02.An
4 x 5C.An C0.An 5C.An C0.An
5 x Li.An 50.An AJ.An 50.An
6 x LA.An Pr.An LA.An Pr.An
7 x 02.An Ho.An 02.An 0F.An
8 x C0.An 0F.An C0.An Pl.An
9 x 5o.An PL.An 5o.An An.An
10 x Pr.An An.An Pr.An LP.An
11 x CA.An LP.An Ho.An tE.An
12 x Ho.An tE.An 0F.An tc.An
13 x 0F.An tc.An Pl.An EA.An
14 x An.An EA.An An.An 5t.An
15 x LP.An 5t.An LP.An
16 x tE.An tE.An
17 x tc.An tc.An
18 x EA.An EA.An
19 x dA.An 5t.An
20 x 5t.An
Select mode functions in plain text
Display in Function/seting mode
HC display field
LE.An Start leak test
5C.An Set setpoints, with automatic recognition
for test gases. Separate for HC, CO and
CO2
Li.An Limit value of oil temperature for official
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-select air-pressure measurement On / 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 compensation
EA.An External display switched on
dA.An Select single/dual printout
5t.An Pre-select analog output (only possible
with built-in analog interface)
PL.An Set pump capacity
AJ.An Start automatic calibration
02.An Oxygen measurement switched on
4.1 Input mode (switch S 60 at position 0, auxiliary functions)
Input mode permits you to carry out various checks and setting work on the device.
- Select the individual functions using the "Select" button. A code for each function and "AnAn
AnAn
An" for "Display"("Anzeige") appears in
the oil-temperature display field.
- Simultaneously press the "Enter o" button to activate the chosen function. A code for each function and "EiEi
EiEi
Ei " for "Input" ("Eingabe")
appears in the oil-temperature display field. After this, release both buttons.
You can now carry out modifications in the chosen function using the "Enter o" or "Test u" buttons.
- Press the "Select" button once more to return to standby mode.

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4.1.1 Leak test
Press
"SELECT" Display Meaning/function
1 x The pump starts up.
The analysis system is purged for 20 sec. with zero gas
The display "6A56A5
6A56A5
6A5" flashes to prompt the flow of test gas.
- Either suck up car exhaust gas*) via the exhaust sample
probe (the test gas pump can be switched on with the
"Enter oo
oo
o" button and switched off with the "Test uu
uu
u"
button.
- Or introduce test gas (with a proportion of 10-15% vol.
CO2) via the calibration-gas inlet (set admission pressure
on bottle-pressure reducer to 0.7 bar).
Once the analyzer recognizes the flow of CO2, the flashing
changes to a continuous display.
*) Use only test gas no. 1 for the half-yearly 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).
The analyzer must be informed that the inlet has been sealed
off. To do this, press "Enter o".
The analyzer checks air-tightness (approx. 40 seconds) with
the pump running.
"i.0i.0
i.0i.0
i.0 " (OK) is displayed if the exhaust-sample intake system
is sufficiently air-tight.
If error messages appear, perform trouble-shooting to
Section 8.
Err 1Err 1
Err 1Err 1
Err 1 = Large leak
Err 2Err 2
Err 2Err 2
Err 2 = Small leak
5P. L E.Ei
6A5 L E.Ei
Abd. L E.Ei
LEC L E.Ei
i.0. L E.Ei

11
4.1.2 Lambda measurement ON / OFF
Press
"SELECT" Display Meaning/function
2 x Press "Enter o" to switch lambda calculation on
or
lambda calculation off.
4.1.3 O2measurement ON/ OFF
Press
"SELECT" Display Meaning/function
3 x Press "Enter o" to switch O2- measurement on
or
O2measurement off.
YE5 L A.Ei
no L A.Ei
YE5 02.Ei
no 02.Ei

12
4.1.4 CO correction COvrai ON / OFF
Press
"SELECT" Display Meaning/function
4 x Press "Enter o" to 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

13
4.1.6 Air-pressure gauge ON / OFF
Press
"SELECT" Display Meaning/function
6 x If an air-pressure gauge is built in, press the "Enter o" button
to activate the correction of pressure influence in accordance
with the values measured by the pressure gauge.
In the "nono
nono
no" setting, the mean air pressure is corrected in line
with the entered altitude.
4.1.7 Entering the altitude
Press
"SELECT" Display Meaning/function
7 x The first time the analyzer is put into operation, the altitude,
rounded to the nearest hundred metres, must be entered. The
height 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% CO2and
no oxygen into the calibration-gas inlet.
Set the admission pressure on the bottle-pressure reducer to
0.7 bar
The millivolt display in the engine-speed display window
drops with the flow. Once the display has fallen below 80 mV,
the display "0FF50FF5
0FF50FF5
0FF5" in the oxygen display window disappears.
Zero has been found when the millivolt display in the engine-
speed display window remains constant.
YE5 Pr.Ei
no Pr.Ei
YE5 EA.Ei
0FF5
1732 0F.Ei
0.0
79 0F.Ei

14
4.1.8 Fine-tuning the zero of O2(from software version A 13)
Press
"SELECT" Display Meaning/function
8 x An automatic process is executed.
The current date is shown in the display window for HC
and CO.
In the O2display window, the voltage value from the O2measuring
sensor is displayed.
Limit values: 1.850V to 3.550V
4.1.9 Adjusting the pump capacity
Press
"SELECT" Display Meaning/function
9 x Here, after the system has switched from function "Pl.AnPl.An
Pl.AnPl.An
Pl.An"
to "Pl.EiPl.Ei
Pl.EiPl.Ei
Pl.Ei" first an error message "ErrErr
ErrErr
Err" appears in the display
window for engine speed.
Press the speed selector button: the LED lights up.
Set the pump capacity from 0 to 15 in the engine-speed dis-
play window using the "Enter o" and "Test u" buttons.
Check the setting in accordance with Section 8.2.2.
4.1.10 Analysismode
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 calibration gas. At 0.7 bar, the flow resi-
stance of the non-return valve is overcome and a suitable flow
is bound to be achieved (1 l/min to 4 l/min).
If a flow meter is connected to the gas outlet, the flow can be
set to a minimum of 0.5 l/min.
!Do not connect the flow meter to the calibration-gas inlet.
Calibration gas can also be introduced through the exhaust-
sample intake hose. To do so, switch in a flow meter between
the calibration-gas bottle and the sample intake hose. The
flow as a whole must not exceed 10 l/min.
10.02 98
870
5P 0F.Ei
1000 5.00
0.0 7.5
An.Ei
28.05 99
2525
0F.Ei
Err Pl.Ei

15
4.1.11 Selecting a printer
Press
"SELECT" Display Meaning/function
11 x The following settings are possible:
11
11
1= external printer 20 characters (Switzerland)
22
22
2= internal printer (PDR 078)
33
33
3= external printer (PDR 200)
4.1.12 Selecting the operator terminal
Press
"SELECT" Display Meaning/function
12 x The following settings are possible:
11
11
1= Pocket keypad PT 14 (V24 interface)
22
22
2= Data terminal DTL 224 (RS 232 interface)
4.1.13 Temperature compensation
Press
"SELECT" Display Meaning/function
13 x If "nono
nono
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 device with cover closed.
An automatic sequence takes place. The current ADC values
are shown in the display window for HC, CO and CO2. After
approx. 100 minutes, "i.0.i.0.
i.0.i.0.
i.0." appears in the engine-speed dis-
play window once compensation has been successfully com
pleted.
tE.Ei
no tc.An
7.345 7.446
7.407
i.0 tc.Ei
L P.Ei

16
4.1.13.1 Error messages regarding temperature compensation
- Temperature-compensation selection is set to "nono
nono
no".
- Temperature compensation was started during the warm-up
phase.
- Device had not cooled sufficiently prior to temperature
compensation.
- Ambient temperature fluctuated greatly during temperature
compensation.
- ADC values show excessive temperature sensitivity.
- Foreign gases are diffused into the system during tempera-
ture compensation.
- If temperature compensation 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 Meaning/function
15 x Press the "Enter o" or "Test u" buttons to alter the entry in
the engine-speed display window.
nono
nono
no Analog output not activated
00
00
0Measuring range 0 to 20 mA
44
44
4Measuring range 4 to 20 mA
YE5 EA.Ei
no EA.Ei
no 5t.Ei
Err2
Err3
Err1

17
4.2 Test mode ( switch S 60 at position 0)
In this menu, internal measured values and device settings can be displayed for the purpose of assessing error messages
when repairing the device. To display this information, press the "Test u" button once or several times. The indicated mea-
sured value or analyzer parameter remains on display for the duration that the "Test u" button is depressed.
Press
"Test uu
uu
u" Display Meaning/function
1 x Current measured values prior to linearization (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 CO2measuring 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 Identification number for error message "Err 128Err 128
Err 128Err 128
Err 128" CMOS-
RAM check. This identification number defines the para-
meter(s) recognized as faulty (see Section l7.1).
0.2 0.4
0.0
roh
36.87
tEP
2.820 2.794
2.435 2.729
Adu
7.738 7.546
7.875
Adut
19.05 99
dot
07.38 46
Uhr
CM05

18
Press
"Test uu
uu
u" Display Meaning/function
8 x Measured supply voltage (auxiliary power) in % of the nomi-
nal mains value.
9 x The output voltage of the air-pressure gauge is shown in the
HC display field.
The current air pressure or an error message "ErrErr
ErrErr
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

19
4.3 Fine-tuning mode (switch S 60 at position 1, mean values, air-pressure gauge and chopper-motor recognition)
Procedure Display
Press button Press simultaneously Current measured Current setting value Function symbol in
value in display in engine-speed temperature display
window
Select1x -- - - HC xxxx d.And.An
d.And.An
d.An
EnteroHC xxxx d.Eid.Ei
d.Eid.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.
Select2x - - - - CO xxxx d.And.An
d.And.An
d.An
EnteroCO xxxx d.Eid.Ei
d.Eid.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.
Select3x - - - - C02xxxx d.And.An
d.And.An
d.An
EnteroCO2xxxx d.Eid.Ei
d.Eid.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.
Select4x - - - - HC xxxx bo.Anbo.An
bo.Anbo.An
bo.An
EnteroHC xxxx bo.Eibo.Ei
bo.Eibo.Ei
bo.Ei
See Section 6.5 for fine-tuning procedure
Select 5 x - - - - Engine speed ErrErr
ErrErr
Err CH.AnCH.An
CH.AnCH.An
CH.An
Enter oEngine speed 1515
1515
15 CH.EiCH.Ei
CH.EiCH.Ei
CH.Ei
See Section 6.5 for fine-tuning procedure

20
4.4 Fine-tuning mode (switch S 60 at position 2, upper-range values, activation of temperature compensation and setting
appropriate version for country of use)
Procedure Display
Press button Press simultaneously Current measured Current setting value Function symbol in
value in display in engine-speed temperature dislpay window
window window
Select1x -- - - HC xxxx E.AnE.An
E.AnE.An
E.An
EnteroHC xxxx E.EiE.Ei
E.EiE.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.
Select2x - - - - CO xxxx E.AnE.An
E.AnE.An
E.An
Enter oCO x x x x E.EiE.Ei
E.EiE.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.
Select3x - - - - C02xxxx E.AnE.An
E.AnE.An
E.An
EnteroCO2xxxx E.EiE.Ei
E.EiE.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.
Select4x - - - - HC+CO+CO2xxxx tb.Antb.An
tb.Antb.An
tb.An
EnteroHC+CO+CO2xxxx tb.Eitb.Ei
tb.Eitb.Ei
tb.Ei
When the entry is set to "YE5 tb.EiYE5 tb.Ei
YE5 tb.EiYE5 tb.Ei
YE5 tb.Ei", temperature compensation is activated.
Select 5 x - - - - Engine speed U 13 UU 13 U
U 13 UU 13 U
U 13 U tY.AntY.An
tY.AntY.An
tY.An
Enter oEngine speed U 13 UU 13 U
U 13 UU 13 U
U 13 U tY.EitY.Ei
tY.EitY.Ei
tY.Ei
For setting see Section 6.7