Kane AUTO600 User manual

AUTO600
SMOKEMETER
Stock No: 19266-2 February 2013
© Kane International Ltd

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IMPORTANT SAFETY INSTRUCTIONS
•Read all instructions.
•Please take care when handling the probe as it may be hot
•Ensure equipment or any electrical cables are free from damage
•Please beware of cables coming in contact with rotating engine
parts or other moving components
•Allow the AUTO600 to cool before storage
•The AUTO600 extracts exhaust gases that may be toxic in
relatively low concentrations. These gases are exhausted from the
top and the base of the AUTO600 base unit.
•Use in an adequately ventilated area
•Ensure the test vehicle is at normal operating temperature before
carrying out an opacity test
•Due to the nature of the opacity test ensure the vehicle being
tested has been properly maintained. Kane take no responsibility
for any damage caused to a vehicle as a result of the testing
process.
•Clean the exterior of the product with a damp cloth only. Do not
use solvents of any kind.
SAVE THESE INSTRUCTIONS

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1. INTRODUCTION
The AUTO600 is a portable and re chargeable ‘partial flow’ diesel
engine Smokemeter designed for “Continuous” and “Peak” testing of
exhaust gases in diesel vehicles.
It is designed to meet recognised standards for accuracy and
repeatability for Category A (Cars & Light Commercial) and Category B
(Commercial) vehicles.
Measurement Units are %H (Hartridge units) and k (/m).
Comprising of a rugged smoke measuring base unit linked via Bluetooth
or optionally cable to the handset control module the AUTO600 offers
ease and flexibility of use.

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2. PRINCIPLE OF OPERATION
The AUTO600 takes a sample of exhaust gas through a flexible probe
inserted into the vehicle’s exhaust. The gases are passed through a tube
that is illuminated by a near monochromatic visible light source. The
obscuration of this light gives an accurate measurement of the density of
the smoke emitted by the vehicle.
A fan is used to deliver clean fresh air to the smoke tube prior to the test
sequence. This is to ensure the AUTO600 has an accurate zero.
Vectored air curtains are directed at the lenses at each end of the smoke
tube to prevent “sooting” of the lenses, which would change the zero
calibration.
The measurement tube and smoke delivery system are heated to
prevent condensation and loss of smoke particles. This is to ensure
accurate and repeatable measurements are obtained.
3. BEFORE USING FOR THE FIRST TIME
The AUTO600 base unit has an integrated nickel-metal hydride (NiMh)
battery pack that can be recharged by using a mains powered charger.
The first charge should be for twelve hours continuously. When an
external charger is connected and power is detected the green LED
above the charger socket flashes.
NiMh batteries are suitable for top up charging at any time, even for short
periods. The charger can be left connected to the AUTO600
continuously.
TIP: For maximum battery operational life it is strongly
recommended that the AUTO600 is connected to the mains
charger or the vehicle DC adapter during the warm up
period. This ensures that the high power needed during this
phase does not drain the internal battery. This will
substantially increase operational battery life.
The expected operational battery life is four hours on a full charge.

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1
2
3
4
5
6
3.1 BASE UNIT:
1. Probe Connection
2. Handset Cable Socket
3. LED Indicators (internal heaters)
4. Smoke Sample Exhaust
5. Charger Socket, Charging Indicator and Fuse
6. Base Unit On/Off switch
CAUTION!
The fuse fitted to the AUTO600 is a 20*5mm, 5A quick blow fuse. Do not
fit any other part.
3.2 HANDSET:
The Handset requires two alkaline AA cells and is supplied with these. If
required these can be replaced with rechargeable NiMh AA cells which
must be recharged outside the handset.

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1. Handset cable connection
2. Units key selects measurement units in k (/m) or Hartridge (%H)
3. Backlight and contrast key. Press repeatedly for four levels of
contrast with the backlight on and four levels with backlight off
9
8
6
4
7
3
2
15

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4. Enter key used to confirm a selection throughout the AUTO600’s
operation.
5. Infra-red printer port.
6. On/Off key.
7. Scroll up key.
8. Scroll down and print key.
9. MODE key selects operating modes.
a. Zero Check
b. Peak
c. Menu
I Trigger
ii Cat A/B
iii Time
iv Date
v Cal Filter
vi Serial Number
vii Language
d. Zero Smoke
The Mode key is also used as an ‘escape’ key to avoid certain actions in
setting up the AUTO600.
The handset will operate for at least fifty hours on a fresh set of batteries
with Bluetooth communications, longer when using the serial cable. The
handset will keep the time and date as set even when turned off. When
new batteries are needed the handset will interrupt the normal screen
display with a message. It will also report the condition of the base unit’s
batteries.
When the handset batteries require replacement, ensure it is turned off
first before replacing the cells. This will avoid resetting the time and date
again. The handset will keep accurate time and date for a short period
with the batteries removed but only when the display is off.

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4. PREPARING FOR USE
The Main Switch:
There is a master ON/OFF switch located at the front of the base unit
This must be switched on before use and when charging.
The OFF position is provided for
when longer term storage is
anticipated to ensure that the
batteries are not discharged.
Attaching the probe:
The probe attaches to the AUTO600’s body using a metal screw thread
attachment. This only needs to be hand tight. Take care not to over
tighten or cross thread it.
Do not insert the probe into the
vehicle exhaust until:
a) The vehicle’s engine is up to
the required temperature
b) The AUTO600 has
completed its warm up
sequence and has auto-
calibrated itself.
c) Instructed to do so by the
handset in PEAK mode
operation.
Bluetooth or cable connectivity:
It is possible to use either Bluetooth to link the handset and base unit, or
the included cable if preferred. It is not possible to switch from one to the
other while in use. In order to change the connection method the
AUTO600 must be powered down and then restarted.
Bluetooth communication between the handset and the base unit is
achieved using Class1 devices. These have a nominal range of one
hundred metres.

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5. USING THE AUTO600
It is recommended that the AUTO600 is used with Bluetooth
communications as this avoids use of cables and potential trip hazards. It
is also a very convenient method of operation as it gives the user greater
flexibility in taking smoke measurements.
Connect the AUTO600’s base unit
to the mains or DC adapter and
press the ON/OFF button. Use a
long key press on the handset to
turn the instrument on. This will
initiate the AUTO600’s start up
sequence.
The handset screen will display the
system status and the warm-up
sequence begins.
The screen will display the warm
up time and the LEDs on the base
unit will start to flash in sequence
for up to twenty five minutes
depending on the ambient
temperature.
The three LEDs on the base unit represent each of the three internal
heaters and will flash slowly between dim and bright until operating
temperature has been reached when the flash rate will change.
Once the AUTO600 has reached operating temperature and performed a
zero calibration, the handset display will change and indicate vehicle
category, measurement units and Bluetooth connectivity as below.

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The AUTO600 is now ready for use
Bluetooth
connection
symbol
Vehicle Category
Cat A Cars & light commercial
Cat B Commercial
Measurement
Units

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5.1 ”CONTINUOUS” SMOKE TESTING
Following the warm-up sequence, the AUTO600 can be used for
continuous smoke testing and will monitor the exhaust smoke opacity
continuously in “real time”. In fresh air the reading will be zero.
Setting up test parameters
To change the measurement units press the “UNITS” button to select
either %H (Hartridge) or k (/m).
To change vehicle category press “MODE” until “MENU” option is
displayed. Press “ENTER” and scroll to “Cat A/B” using the “UP” or
“DOWN” key. Press “ENTER”. Select “CatA” or “CatB” and press
“ENTER” to confirm the option required.
It is important that the end cap is fitted for Cat B vehicles and not fitted
for Cat A vehicles. The smoke test results obtained will not be within the
stated accuracy unless the cap is fitted as described.
Press “MODE” to exit back to the main test screen.
CAUTION: Ensure the vehicle is at normal operating temperature
particularly its oil temperature!

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Position the base unit close to the exhaust pipe and insert the probe,
start the vehicle and depress the vehicle’s accelerator pedal to obtain the
required increase in engine speed. The smoke emission can be
monitored on the handset.
THESE LIVE READINGS CANNOT BE PRINTED OR SAVED
5.2 ”PEAK” SMOKE TESTING
The AUTO600 smokemeter also operates in a peak mode. This is the
standard method of testing diesel smoke emissions.
The AUTO600 monitors the smoke emission on accelerating the diesel
vehicle’s engine to its maximum speed. The vehicle’s engine speed
should be increased rapidly to its maximum and held at this level for a
total period of three seconds. The AUTO600 provides instructions on its
handset when to “ACCELERATE” and “STOP” the test. The AUTO600
automatically detects the engine acceleration by an increase in smoke
emission as extra fuel is supplied to the engine during this time. The
default trigger sensitivity is generally suitable for a wide range of smoke
emission but it can be adjusted in the “MENU”. The default setting is “3”.
In fresh air the smoke reading displayed will be zero but inside an
exhaust the background level of smoke will be detected and displayed. A
reading less than 0.1k is typical.
The AUTO600 can be set to take an average of the last three or five
“PEAK” smoke tests. If the number of tests performed is less than this
then the average of the readings obtained is displayed. The average
smoke emission is presented to the user between tests and is
automatically calculated as the number of tests increases.

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Set up test parameters:
Press the “MODE” button until the “PEAK” option is displayed and press
“ENTER”. Follow the screen prompts.
If the AUTO600 has performed a peak
smoke test since it was switched on the
handset will start a zeroing sequence.
Follow the on screen prompts until the
handset displays the current vehicle
category. This may be changed by
using the “UP”, “DOWN” and “ENTER”
keys.
Select the measurement units required
using the “UNITS” key and press
“ENTER” to confirm.
Select the number of smoke tests to average using the “UP” “DOWN”
and “ENTER” keys. The choice is three or five peaks.
At this stage the AUTO600 summarises the test parameters on the
screen.
The screen then displays the key actions needed to stop and start the
smoke test sequence. It is very important that the probe is fitted into the
running vehicle’s exhaust before the “ENTER” key is pressed to start
testing. The AUTO600 monitors the vehicle’s idle smoke emission and
uses this to detect when the engine is accelerated. If this sequence is not
followed false smoke triggers and unreliable readings will result.
Starting the test sequence:
CAUTION: Ensure the vehicle is at normal operating temperature,
particularly its oil temperature, and the engine is running!
Insert the probe into the exhaust.
Press the “ENTER” key to start the test and press the “UP” and “DOWN”
keys at the same time to end the test. A test can only be terminated at
the end of the “5 4 3 2 1” countdown. It is only at this point that the full
smoke information is available.

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Follow the screen prompts precisely. Wait for the countdown and when
instructed the vehicle’s accelerator pedal must be fully depressed in a
smooth motion in under one second and held at full acceleration for a
period of three seconds until the screen shows “STOP”.
Repeat the sequence for a minimum of three or five times in order to get
the average reading required. The AUTO600 will average fewer readings
however.
The results of the individual tests and the average can be printed using
the Kane infrared printer. Ensure the emitter on the top of the handset
and the printer are lined up and in range, before pressing the print
button. Follow the screen prompts if further copies of the test results are
needed. If necessary the results can be printed from the normal screen,
but if the AUTO600 is switched off all information is lost.
NOTE:-
THESE READINGS CANNOT BE SAVED
A REPEAT TEST WILL REQUIRE A RE-ZERO
What should the readings be?
•2.50k for vehicles with non-turbocharged engines, used before 1
July 2008
•3.00k for vehicles with turbocharged engines, used before 1 July
2008
•1.50k for vehicles used on or after 1 July 2008

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Drift
The Auto600 monitors its change in zero as peak testing progresses and
produces an average drift figure. This is the average change in zero for
every peak test. If the drift figure exceeds 0.05k the test should be
repeated. This may occur on vehicles with high emissions.
What are the causes of excessive smoke?
Smoke is the product of combustion. Vehicles may produce three kinds
of smoke, two of which indicate engine problems. The three types are:
•Blue smoke (mainly oil and unburnt fuel), which indicates a poorly
serviced and/or tuned engine.
•Black smoke (soot, oil and unburnt fuel) which indicates a
mechanical fault with the engine or air intake restriction.
•White smoke (water droplets and unburnt fuel) which is produced
when the engine is started from cold and disappears when the
engine warms up.
With older engines, the white smoke produced has a sharp smell, which
may cause irritation to your upper respiratory system.
What factors effect the composition of diesel smoke emission
The quantity and composition of diesel smoke may vary depending on:
•The quality of diesel fuel used
•The type of engine, e.g. standard, turbo or injector
•The state of engine tuning
•The fuel pump setting
•The workload demand on the engine
•The engine temperature
•Whether the engine has been regularly maintained

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6: MODE FUNCTION
Pressing the handset “MODE” key repeatedly allows access to
the following functions.
ZeroCheK: This turns the fan on for forty five seconds to clear the
measurement tube of any smoke.
NOTE: the probe must be in fresh air at this time.
Follow the Screen prompts “REMOVE PROBE FROM
EXHAUST…PRESS ENTER TO CONTINUE”
“Zero Chk Underway”
Peak: Press “ENTER” For Peak testing sequence.
Follow the screen prompts to set up test parameters and begin the
test procedure. The AUTO600 detects the change in smoke level
and holds the highest reading that it sees. Once this change is
detected and stored, screen prompts invite further peak tests. This
will continue until the “UP” and ”DOWN” keys are pressed together.
Individual test results, the current smoke average, and the drift figure
are displayed as they are made available. These results can be
printed at the end of the testing sequence. See section 5.1for full
details.
Menu: Press “ENTER” to access Menu and scroll to function
required
Trigger: Press “ENTER” to adjust peak test sensitivity
trigger point. The default setting for the trigger level is 3. In
low smoke situations if the “PEAK” fails to trigger increase
the sensitivity. The range is 0 to 5.
“0” should only be used in high smoke situations when
absolutely necessary. High smoke situations risk dirtying the
optics.
Follow the screen prompts and use “UP “DOWN” and
“ENTER” to adjust
Cat A/B:
Depending on the test vehicle category and use “UP
“DOWN” and “ENTER” to select “Cat A” for Cars and light
commercial and “Cat B” for Commercial

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Time: Press the “ENTER” key to access and “UP” or
“DOWN” to adjust. “ENTER” key confirms setting.
Date: Press the “ENTER” key to access and “UP” or “DOWN”
to adjust. “ENTER” key confirms setting.
CalFiltr: To be only used if calibration verification is required
Follow procedure on page 27.
SerialNo: Each handset and base measuring unit has a
unique serial number to access press “ENTER” please use
this when registering your product www.kane.co.uk. The
serial number is also on the labels fitted to the base and
handset.
Language: Follow the on screen instructions to select the
language needed. Note that if the handset batteries are
allowed to run down the language selection will revert to the
default, English.
ZeroSmke: Press ‘ENTER’ key to select this function which zeros
the smokemeter. Follow the on screen instructions to set the
process running, ensuring the smoke probe has been removed from
the exhaust of the vehicle and is in fresh air.
7: Maintenance
7:1 General Maintenance
Check calibration of your instrument annually to ensure it meets
original performance specifications.
Keep your instrument dry. If it gets wet, wipe dry immediately.
Liquids can degrade electronic circuits.
Whenever practical, keep the instrument away from dust and dirt
that can cause premature wear.
Although your instrument is built to withstand the rigours of daily
use, it can be damaged by severe impacts. Use reasonable caution
when using and storing the meter.

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7.2 Periodic Service
CAUTION!
Repair and service of this instrument is to be performed by qualified
personnel only. Improper repair or service could result in physical
degradation of the instrument. This could alter the protection from
personal injury this meter provides to the operator. Perform only those
maintenance tasks that you are qualified to do.
7.3 Cleaning
CAUTION!
Periodically clean your instrument case using a damp cloth. DO NOT use
abrasive, flammable liquids, cleaning solvents, or strong detergents as
they may damage the finish, impair safety, or affect the reliability of the
structural components.
7:4 Regular Maintenance
If the readings are erratic or if the AUTO600 will not zero it may be
necessary to clean the lenses and also the measurement tube. Follow
the procedure below observing the cautions.
The AUTO600 may be returned to the Kane Service Centre if preferred.
CAUTION!
•Some internal parts of the AUTO600 are heated to temperatures in
excess of 70
o
C.
•Switch the AUTO600 off for 30 minutes or so to allow it to cool
before touching any internal parts.
•Beware of fine soot particles in the measurement tube and avoid
inhaling while cleaning. These particles may cause irritation if
breathed in.

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7.4.1: How to remove the end caps:
The end caps are each held in place by two captive Philips headed
screws. Once these have been completely undone the end caps are
removed by sliding them horizontally away from the main case assembly.

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7.4.2: How to remove the light source
CAUTION!
ALWAYS ALLOW THE AUTO600 TO COOL BEFORE PERFORMING
THIS OPERATION. HOT SURFACES MAY BE PRESENT.
The light source is marked with an identification label (1). A matching
label is attached to the correct end of the main case assembly.
Disconnect the light source’s connector by gentling pulling on the cable
where it enters the body of the main case assembly. The connector is
locking so exercise care when extracting the connector. Note the
orientation of the connector. The key way lugs face outwards.
Hold the body of the light source assembly and rotate it anticlockwise
until the marker point is at the 12 o clock position. (a rotation of approx.
15 degrees) The light source can now be removed by withdrawing it
horizontally along the main access of the case assembly.