Ossenberg INFRAGAS-109 User manual

GAS ANALYZER
INFRAGAS-109 - INFRAGAS-205 • INFRAGAS-209
INFRAGAS-305 • INFRAGAS-309
OPERATION AND
MAINTENANCE MANUAL
GB
Edition RAEE: June 2010
-
Vers. 1.20
ASSEMBLAD – Automotive Division - Tec nical dept.
…. \ M109-205-209-305-309_GB12_01-2010.doc

ASSEMBLAD Infragas-109-205-209-305-309_GB12 – Operation and maintenance manual
ASSEMBLAD S.r.l. - Costruzioni Elettronic e - 50013 Campi Bisenzio - Firenze - Italy
E-mail: [email protected] - Web: www.assemblad.it
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Note:

ASSEMBLAD Infragas-109-205-209-305-309_GB12 – Operation and maintenance manual
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INDEX
1 GENERAL INFORMATION.............................................................................. 5
2 TECHNICAL DATA .......................................................................................... 6
3 DESCRIPTION................................................................................................. 8
3.1 GENERAL SPECIFICATIONS....................................................................... 8
3.2 FRONT PANEL INFRAGAS-205/305............................................................ 9
3.3 KEYBOARD................................................................................................. 10
3.4 REAR PANEL INFRAGAS 205/305............................................................. 11
3.5 CONNECTOR PANEL INFRAGAS 109....................................................... 12
3.6 CONNECTOR PANEL INFRAGAS 209/309................................................ 12
3.7 GAS PANEL INFRAGAS 109...................................................................... 13
3.8 GAS PANEL INFRAGAS 209/309............................................................... 13
3.9 DISPLAY AND MENU ................................................................................. 14
3.10 ACCESSORIES......................................................................................... 20
3.11 MOTORCYCLE PROBE............................................................................ 20
4 INSTALLATION.............................................................................................. 22
4.1 TRANSPORT AND INSTALLATION ............................................................ 22
4.2 CONNECTION TO POWER SUPPLY.......................................................... 22
5 OPERATION .................................................................................................. 23
5.1 OPERATIONS TO BE AVOID..................................................................... 23
5.2 NOTES AND CAUTIONS............................................................................ 23
5.3 INSTRUMENT POWER ON........................................................................ 24
5.4 STANDARD MEASURE FOR CAR............................................................. 24
5.5 STANDARD MEASURE FOR MOTORCYCLE............................................ 24
5.6 SMOKE METER.......................................................................................... 25
5.7 RPM COUNTER.......................................................................................... 25
5.8 SPEEDOMETER......................................................................................... 25
5.9 EOBD .......................................................................................................... 25
5.10 PRINTER................................................................................................... 25
5.11 MCTC-NET................................................................................................ 25
5.12 LAW AND DEFINITION REFERENCES ................................................... 26
5.13 HC RESIDUAL TEST ................................................................................ 27
5.14 LEAK TEST ............................................................................................... 27
6 “INFPLUSWIN” SOFTWARE ........................................................................ 28
6.1 GAS ANALYZER......................................................................................... 29
6.2 FUNCTION KEY.......................................................................................... 30
6.3 DISPLAYED FIELDS................................................................................... 30
6.4 INPUT LIMITS AND VEHICLE DATA.......................................................... 31
6.5 TEST EXECUTION...................................................................................... 32
6.6 REPORT PRINTOUT .................................................................................. 33

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7 STANDARD MAINTENANCE......................................................................... 34
7.1 INSTRUMENT CLEANING.......................................................................... 34
7.2 FUSE REPLACEMENT ............................................................................... 34
7.3 CARBON FILTER REPLACEMENT............................................................ 34
7.4 OXYGEN SENSOR REPLACEMENT ......................................................... 34
7.5 NOX SENSOR REPLACEMENT................................................................. 34
8 TROUBLESHOOTING ................................................................................... 35
8.1 PONYDOCTOR........................................................................................... 37
9 METROLOGICAL LOGBOOK ....................................................................... 38
10 USER INFORMATION - RAEE DIRECTIVE
(#)
........................................... 38
11 WARRANTY................................................................................................. 39

ASSEMBLAD Infragas-109-205-209-305-309_GB12 – Operation and maintenance manual
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1 GENERAL INFORMATION
Please read carefully this manual before use and strictly attain to the following instructions
to carry out measures and maintenance operations.
INFRAGAS-109 / 209 / 309 / 205 / 305 are infrared gas analyzers to measure car and
motorcycle exhaust gas.
Some operation, measure, device or function have an asterisk between brackets (*); this
means that such operation, measure, device or function is available only on certain
models while on others can be an optional.
The technical characteristics and homologations may be referred only on certain models.
Open the equipment only during operation for which it is clearly indicated and after having
switched off the power supply; close the equipment and put it in the original configuration
before switching on again, in particular close and lock the cover.
Take care of the correct tubing and pipe connection, avoid to breath fumes and make sure
they can be dispersed in an open ambient.
The manufacturer decline every responsibility in case of an incorrect use or an use not
expressly specified in this manual; the responsibility is anyhow limited to the equipment’s
repair operation with the exclusion of any other direct or indirect damage.
For more information please read the chapter “Warranty condition”.
For technical support or spare parts requests please read the chapter “Technical Support”
Due to the continuous technical development of Assemblad equipments, the gas analyzer
could have new functions, or modified functions, than that specified on this manual.
The gas analyzers performs measures in compliance with Italian “D. M. n. 628 of
23/10/1996”, and subsequent modifications as for “Circ. n. 88/95 of 6/09/1999”.
The gas analyzer performs measures in compliance with Italian “D. M. of 16/01/2000” ,
and subsequent modifications as per “C. d. of M.d.T. of 4/01/2002” and “Circ. 64/404 of
19/01/2005”
The gas analyzers is approved in accordance with the MCTCNET technical and functional
specifications as per “Circolare n. 6247/698 del 16/11/1999” and subsequent modifications
and integrations.
The gas analysers are homologated for OIML R99, edition 2008, class 00.

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2 TECHNICAL DATA
RANGE AND RESOLUTION
RANGE RESOLUTION
CO 0 ÷ 9.99 vol. % 0.001 %
CO2 0 ÷ 19.99 vol. % 0.01 %
HC 0 ÷ 15000 ppm 1 ppm
O2 0 ÷ 25,0 vol. % 0,01%
RPM 0 ÷ 9999 rpm/1' 1 rpm/1'
Oil Temp. 0 ÷ 150 °C 0.1 °C
Int. Temp. 0 ÷ 50°C 0.1 °C
Amb. Press. 800 ÷ 1050 mbar 1 mbar
NOx (*) 0 ÷ 5000 ppm 1 ppm
CO corr. 0 ÷ 9.9 vol. % 0.1 %
Lambda 0.500 ÷ 2.000 0.001
OPERATIONAL CHARACTERISTIC
Response Time - 20 sec. max
Warming Time - 2 min. typical
Temperature range - 0 °C ÷+ 40 °C
Supply - 9 ÷16 Vcc
Power - 30 W max
Barometric pressure - 850 ÷1060 mbar
Gas flow - 3 l/min
Compressed air (*) - from 2 to 4 bar
Periodic calibration - 12 months max.
Dimensions - 263x155x84 mm (Infragas-109)
- 290x198x168 mm (Infragas-209/309)
- 344x160x270 mm (infragas-205/305)
Weight without pipe - 2,0 Kg about (Infragas-109)
- 5,8 Kg about (Infragas-209/309)
- 3,0 Kg about (Infragas-205/305)

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DISPLAY – KEYBOARD
N. 1 Display LCD with backlight 240*128 pixel.
N. 16 alphanumerical keys.
PRINTER
Thermal printer 32 column customizable with workshop data.
SERIAL INTERFACE
1 or 5 (*) serial interface RS-232 9 pin, 9600 baud, 8 bit, no parity, 1 stop bit.
OTHER FUNCTIONS
Compatible with communication protocol MCTCNET
Low flow warning
Automatic and continuous condense drainage
Automatic calibration
Error indication
Clock – calendar (*)

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3 DESCRIPTION
INFRAGAS-205 PONY is an multifunctional exhaust gas analyzer for vehicles based on
microprocessor electronic.
3.1 GENERAL SPECIFICATIONS
- CO, CO2 and HC measure with non dispersive infrared absorption method.
- O2 (oxygen) measure with electrochemical transducer contained into the equipment.
- RPM measure using an external universal RPM counter.
- Oil temperature measure with a dedicated probe.
- Lambda and CO correction calculation in accordance with the international norms.
- Ambient pressure measure with barometric pressure transducer.
- Internal temperature measure for measures compensation.
- Clock/Calendar with a dedicated battery in order to maintain data also with power off.
Date and time can be easily set with the keyboard (see specific chapter) or using a
PC connection.
- Automatic drainage of condense. In case a fault occurs an indication will appear on
the display and the gas suction will stop.
- Motorcycle version performs an automatic cleaning of the probe during every
calibration.
- Visualization of each value on the hi-intensity backlight LCD for the best visibility in
every working area.
- Thermal printer, customizable with workshop data. Each measured value, also the
ones not displayed, will be printed.
- Membrane protected keyboard to avoid moisture and liquid ingress.
- Gas filter device (condense separator and corpuscular filter) fitted on rear panel for a
quick and easy maintenance.
- Display indication of faults as: missing flow, pneumatic line fault , condense drainage
fault, etc.
- Measure with automatic calibration, test procedures indication and vehicle gas
suction indication.
- Standard serial interface RS-232 for connections with personal computer and other
equipments.
- Bluetooth interface for connections with personal computer and other equipments (*).

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3.2 FRONT PANEL INFRAGAS-205/305
Main items on the front panel of Infragas-205/305:
1) Display LCD
2) Keyboard
3) Thermal printer.
1
2
3

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3.3 KEYBOARD
Keyboard Infragas 205/305
Key MEAS: Start measure.
Key OK/PRINT: Confirm entered data.
Print results when test is finished.
Key F3: Force test to continue or end also in case of non positive data.
Key ESC. Stop test execution and go back to main menu.
Go back of one level when into a menu.
Key 0 ÷9 Alphanumerical data input (mobile phone style).
Key Arrows Choice of set-up data.
Alphanumerical data cancellation.
LCD contrast setting.
Choice of data to be displayed.

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3.4 REAR PANEL INFRAGAS 205/305
Main items on the rear panel of Infragas-205/305:
1) Power on switch.
2) Fuse.
3) Power supply plug.
4) External RPM Counter connection.
5) Oil temperature probe connection.
6) Drainage.
7) Exhaust Gas input.
8) Condense separator and filter cartridge (5 micron).
9) Condense separator and filter cartridge coalescence (motorcycle*).
10) Condense sensor.
11) Compressed air input (motorcycle*).
12) Exhaust Gas output.
13) PC Serial connection.
14) Smokemeter Serial connection.
15) Speedometer Serial connection.
16) Universal RPM counter Serial connection.
17) EOBD Serial connection (*).
18) Active carbon filter.
19) Oxygen Sensor
20) NOx Sensor (*)
17 16 15 14 13 11 9 8
12 20 19 18 6 10
7
5
4
3
1
2
0 - I

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3.5 CONNECTOR PANEL INFRAGAS 109
3.6 CONNECTOR PANEL INFRAGAS 209/309
Main items on the connector panel of Infragas-109/209/309:
01 – Power on switch.
02 – Led
03 – External RPM Counter connection.
04 – Compressed air input
05 – Drainage.
06 – Fuse gas analyser
07 – RS-232 connector
08 – Power supply plug.
09 – Oil temperature probe connection.
10 – Exhaust Gas output.
11 – Connector battery charger.
12 – Fuse battery
01
02
03
05
06
04
07
09
12
11
10
01
02
03
05
06
07
08
09
10

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3.7 GAS PANEL INFRAGAS 109
3.8 GAS PANEL INFRAGAS 209/309
Main items on the gas panel of Infragas-109/209/309:
01 – Condense separator
02 – Exhaust Gas input.
03 – Filter cartridge (5 um)
04 – Cup of condense separator
05 – Condense pipe
06 – Filter cartridge 25 um (Coalescent 0,01 um for Infragas-309)
07 – Input condense sensor case
08 – Condense sensor case
09 – Condense discharge
10 – Valve for manual discharge
01
02
03
04
05
07
08
09
01
02
03
04
06
05
07
08
09
10

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26/06/06 INFRAGAS-205 .
1 – VEHICLE DATA
2 – AMBIENT DATA
3 – LIMITS SETTING
4 – INSTRUMENTS
-------------------
5 – MAINTENANCE
6 - LANGUAGE
AMBIENT DATA .
1 – Temperature : 20°C
2 – Amb. pressure : 1000hP
3 – Rel. humidity : 35%
4 – Wind speed : 0m/s
3.9 DISPLAY AND MENU
The gas analyser INFRAGAS-205 has a display to show the menu and the measurement.
Some part may be not enabled, some other reserved for technical service.
MAIN MENU
This menu is displayed when we turn on the instrument and when we come-back from
other menu.
In the high-left corner is showed the data, in the upper centre is reported the selected
instrument, to operate the choice push the key-number.
After a short time the backlight is switched-off, push the ESC key to restore.
Use the arrow keys to set the contrast of the LCD, this function work only in this menu.
AMBIENT DATA
Use this menu to enter ambient data.
These data must be read from a dedicated instrument and they will be printed onto the
test result report.
Press ESC to go back to the main menu.

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VEHICLE DATA .
1 – Plate :
2 – Reg. date : dd/mm/yyyy
3 – Fuel type : Gas. CAT
4 – N. cylinder : 4
5 – Engine :
6 – Chassis :
7 – oth choices :
VEHICLE DATA .
1 – Vehicle type: Car
2 – Displacement:
3 – n. exhaust : 1
4 – Transmission: Gear
5 – conf. 97/24 : No
6 – Trade name :
7 – oth choices :
VEHICLE DATA .
1 – type :
2 – Company :
3 – Mileage :
4 – Km of condit:
5 – V.max Km/h :
VEHICLE DATA
Press the corresponding key number to select the value you want to set, use the
alphanumerical keys to enter a value, then press OK to confirm.
The ⇐key delete previous character, the ⇒key insert a space.
Before entering the registration date delete “dd/mm/yyyy”, then enter the correct date. The
slash symbol will be automatically entered.
The following selections must be choice using the arrow keys:
Fuel type, N. cylinder, Vehicle type, Transmission, conf.97/24.
This selections, with Reg.date, will have an impact on the acceptable limits of the test.
Press ESC to go back to the main menu.

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LIMITS SETTING .
1 – Max RPM at minimum rate: 1000 rpm
2 – Min RPM at accel. rate: 2000 rpm
3 – Max RPM at accel. rate: 3000 rpm
4 – Max COcorr at min. rate: 0.50 %vol
5 – Max COcorr at acc. rate: 0.30 %vol
6 – Max Lambda : 0.97
7 – Min Lambda : 1.03
INSTRUMENTS .
1 – ANALYSER
2 – SMOKEMETER
3 – RPM
4 – SPEED TESTER
5 - REMOTE
LIMITS SETTING
Acceptable limits of the test are set in accordance with the vehicle data entered.
It is possible, however, to edit such limits pressing the corresponding key, delete the
present limit, enter a new value and press OK to confirm.
In case of no catalytic vehicle some limits will not be present because they are not
requested for the test execution.
Press ESC to go back to the main menu.
INSTRUMENTS
Press the corresponding numeric key to select the instrument you want to use then press
OK to confirm.
If you need to connect and/or control the equipment with a PC you must select ‘REMOTE’.
With this selection the PC will be able to communicate with the internal gas analyser and
with the connected smoke meter and RPM.

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MAINTENANCE .
1 – Date/time setup
2 – Garage data
3 – RPM-meter data
4 – Services
5 – Set-Up
6 – Instrument data
7 – Leak test
DATE-TIME SETUP .
1 – Year : 6
2 – Month : 6
3 – Day : 26
4 – Hour : 15
5 – Minutes: 56
GARAGE DATA – OPERATOR .
1 – row1 : ..........................
2 – row2 : ..........................
3 – row3 : ..........................
4 – row4 : ..........................
5 – row5 : ..........................
6 – Surname: .............
7 – Name : .............
MAINTENANCE
From this menu it is possible to enter on assistance and service functions.
Assistance and Set-Up are restricted to authorized technical personnel only and the
access require a password.
SET DATE/TIME
Press the corresponding numeric key to modify a value, delete present value using ⇐key,
enter a new value and press OK to confirm.
Press ESC to go back to the previous menu.
WORKSHOP DATA
Press the corresponding numeric key to modify a value, delete present value using ⇐key,
enter a new value and press OK to confirm, max 24 character per line.
Press ESC to go back to the previous menu.

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RPM METER DATA .
1 – Manuf. : ASSEMBLAD
2 – Model : RPM-405
3 – Approv. : OM00000F/NET
4 – S.N. : ZA100000
5 – Exp. data: 01/01/2010
6 – RPM enab.: YES
7 – RPM ext. : YES
INSTRUMENT DATA .
1 – Manuf. : ASSEMBLAD
2 – Model : INFRAGAS 205
3 – Approv. : OM00000C/NET
4 – S.N. : BC100000
5 – Exp data : 01/01/2010
6 – SW.Ver. : 1.200
7 – PEF : 0.500
RPM DATA
In this menu the external RPM counter data will be entered.
Press the corresponding numeric key to modify a value, delete present value using ⇐key,
enter a new value and press OK to confirm.
Attention: if it is enabled the externat RPM conter but not connected or activated, the
instrument report “COM: ERROR”
Press ESC to go back to the previous menu.
INSTRUMENT DATA
In this menu it is possible to read the information of the instrument connected.
Data cannot be modified (read only), they are acquired from the instrument.
Press ESC to go back to the previous menu.

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LEAK TEST
This function is able to perform the leak test on the pneumatic circuit of the gas analyzer.
Refer to the specific paragraph for detailed instructions.
MEASUREMENT SCREEN
With the key F1 MEAS a measure is activated, the instrument perform an autozeroing, in
this phase is possible to select the type DIAGNOSIS or CERTIFICATION with the key F3.
During the test phase the following data will be displayed:
- Test type, certification or diagnosis.
- Test duration in seconds.
- 6 windows with measured value displayed. To select different parameters press the
corresponding numeric key, use arrows keys to select the required parameters,
press OK to confirm.
Some help or error messages could be displayed depending on specific events that can
occur during the test phase.
INFRAGAS-205 .
Measurement 02
1-CO
0.000
4-Lmd
OR
2-CO2
00.00
3-HC
00000
5-COc
0.0
6-RPM
0000
INFRAGAS-205 .
Measurement 23
1-CO
0.011
4-Lmd
1.004
2-CO2
15.21
3-HC
00027
5-COc
0.0
6-RPM
0914

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3.10 ACCESSORIES
STANDARD ACCESSORIES
1) Gas probe (for car). It is made by a teflon pipe protected by an external spring with a
corpuscular filter that stops the non gaseous and bigger particles. The probe end is
made with a steel tube connected to a flexible and interchangeable stainless steel
terminal.
2) Power supply 220Vac12 Vcc, the model with battery inside have instead a battery
charger
3) Oil temperature probe.
4) PC connection cable.
5) Operation and maintenance manual.
OPTIONAL ACCESSORIES
1) Trolley.
2) NOx sensor
3) Personal computer.
4) Software DRAGONGAS.
5) BlueTooth interface
6) Metrological logbook.
3.11 MOTORCYCLE PROBE
The gas probe supplied for
motorcycle equipment is different
from the one supplied for car
analyzer
The motorcycle probe is made by
a Teflon tube with a condense
separator, manually drained, with
a 25 um filter.
The tube is protected by a spring
and it is connected to the gas
analyzer and to the condense
separator through quick
connections.
The condense separator is
mounted on a metal support, be
sure that the drain valve
positioned on the lower side is
closed, verify that the flow direction goes from the terminal to the analyzer.