Sun Microsystems DGA 5000 User manual

EMISSIONS DIAGNOSTIC
PLATFORM
•Operator’s Manual
HIGH TECH SECURES YOURFUTURE

Operator’s Manual
EMISSIONS DIAGNOSTIC
PLATFORM
Software Version V5.X.X.X
Models: DGA5000, Geogas5000
Diagnostic Gas Analyser
Copyright 2002 - 2016 Snap-on UK HoldingsLtd.
All rights reserved
Part number : ZEEEAGB132A 30-J-164 UK Rev.:G
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DISCLAIMER OF WARRANTIES AND LIMITATIONSOF
LIABILITIES
Whilst the authors have taken due care in the preparation of this manual,
nothing contained herein:
• modifies or alters in any way the standard terms and conditions ofthe
purchase, lease or rental agreement under the terms of which the
equipment to which this manual relates wasacquired,
• increases in any way the liability to the customer or to thirdparties.
TO THE READER
Whilst every effort has been made to ensure that the information
contained in this manual is correct, complete and up-to date, the rightto
change any part of this document at any time without prior notice is
reserved.
Beforeinstalling,maintaining or operatingthisunit, pleaseread
thismanualcarefully,payingextraattentiontothesafetywarnings
and precautions.
Copyright 2016 Snap-on UK Holdings Ltd - All RightsReserved
Contact Information
Snap-on Diagnostics UK Ltd
Denney Road
Hardwick Industrial Estate
Kings Lynn
Norfolk
PE30 4Hg
United Kingdom
Tel: [phone]
Fax: [phone]
Web-site:
http://diagnostics.snapon.co.uk
Trademark Information
Snap-onand SUNare registered trademarks of Snap-onIncorporated
in the United States and / or other countries.
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Table of Contents ............................................................iii
1 Safety.................................................................................1
1.1 Safety Signal Words...........................................................................2
1.2 Safety Notice......................................................................................2
1.2.1 Read all Instructions.............................................................3
1.3 Conventions.......................................................................................3
2 Product Specification ......................................................5
2.1 General..............................................................................................5
2.2 Gas Bench.........................................................................................5
2.2.1 SGM II..................................................................................5
3 Introduction ...................................................................... 7
3.1 The DGA 5000...................................................................................8
3.2 Maintenance ......................................................................................8
3.3 Options ..............................................................................................8
4 Functional Description.....................................................9
4.1 Platform Layout..................................................................................9
4.2 Gas Module Layout............................................................................9
4.2.1 Gas Module Layout - SGMII.................................................9
4.3 Common Program Elements............................................................11
4.4 Gas Analyser Icons..........................................................................11
5 System and Gas Analyser General Screens................16
5.1 Gas Analyser Menu..........................................................................17
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Table of Contents

5.2 The Gas Analyser Maintenance Menu............................................. 19
5.3 Gas Analyser Maintenance Menu Options....................................... 20
5.4 Gas Analyser System Settings ........................................................ 21
5.5 Gas Analyser System Information ................................................... 22
5.6 Print................................................................................................. 24
6 Preparatory Steps…………………………………………26
6.1 Connections.................................................................................... 26
6.1.1 Power Connections............................................................ 26
6.1.2 Data Connections.............................................................. 26
6.1.3 Gas Module Pneumatic Connections................................. 27
6.2 Start-Up........................................................................................... 27
6.2.1 Power Up........................................................................... 27
6.2.2 Gas Analyser Start-up........................................................ 28
6.2.3 Warm up............................................................................ 28
6.2.4 Zero-calibration.................................................................. 29
6.3 Daily Leak Check ............................................................................ 30
6.4 HC Residue Check.......................................................................... 31
6.5 Settings........................................................................................... 32
6.5.1 Fuel Type Selection ........................................................... 32
6.5.2 Speed Factor Setting ......................................................... 32
6.5.3 Lambda/AFR Selection...................................................... 32
6.6 Vehicle Connections........................................................................ 33
6.6.1 RPM Pick-Up..................................................................... 33
6.6.2 Oil Temperature Probe....................................................... 33
7 Operation - General........................................................34
7.1 Testing Tips.............................................................................................34
7.2 Measurement Procedure................................................................. 35
7.3 Shut Down Procedure ..................................................................... 36
8 Operation - The Free Measurement Procedure ...........38
8.1 The Free Measurement Screen....................................................... 39
8.1.1 Engine Speed Measurement Setup.................................... 41
8.2 Free Measurement Vehicle Setup ................................................... 42
8.3 Saving and Loading Vehicle Setups................................................ 44
8.4 Editing Limit Sets............................................................................. 46
8.5 Free Measurement Test Procedure ................................................. 47
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8.6 Storing Data in the Data Buffers.......................................................48
8.7 The Print Preview Window...............................................................50
8.8 Printing Test Results ........................................................................51
9 Maintenance..................................................................52
9.1 System Checks................................................................................52
9.2 Leak Check (Vacuum)........................................................................ 52
9.3 Leak Check (Gas)............................................................................55
9.4 Gas Calibration Check.....................................................................58
9.5 Check and/or Install the O2 Cell.......................................................59
9.6 Routine Maintenance Procedures....................................................63
9.6.1 Periodic Checks .................................................................63
9.6.2 Filters.................................................................................63
9.6.3 Sample Probe and Hose ....................................................64
9.6.4 Test Leads..........................................................................65
9.6.5 O2 Cell...............................................................................65
9.6.6 General ..............................................................................66
9.7 Error, Warning and System Status Messages...................................66
9.7.1 Automatic Pop-up Windows................................................66
9.8 The Error/Warning Button ................................................................68
9.9 Maintenance Parts...........................................................................71
Index................................................................................72
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All Safety Precautions relevant to the unit are described in the Safety
Precautions book, part number: EAZ0007E04A
Figure 1-1 part number: EAZ0007E04A
The Safety Precautions book should be fully understood by every
operator. We suggest that (a copy of) of the Safety Precautions bookbe
stored near the unit, in sight of theoperator.
The Operator‟s Manual will contain specific warnings and cautions when
possible dangerous situations may be encountered during thedescribed
procedures.
1
1
Safety

1.1 Safety Signal Words
All safety messages contain asafety signal word that indicates thelevel of
the hazard. An icon, when present, gives a graphical description of the
hazard. Safety Signal wordsare:
Indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury to the operator or to
bystanders.
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury to the operator or to
bystanders.
Indicates a potentially hazardous situation which, if not avoided,
may result in moderate or minor injury to the operator or to
bystanders.
1.2 Safety Notice
Read this manual thoroughly before operating theunit.
The unit is intended for use by properly trained, skilled professional
automotive technicians. The safety messages presented in theSafety
Precautions book and throughout this manual are reminders to the
operator to exercise extreme care when using thisunit.
There are many variations in procedures, techniques, tools, and parts for
servicing vehicles, as well as in the skill of the individual doing the work.
Because of the vast number of test applications and variations in the
products that can be tested with this instrument, we cannot possibly
anticipate or provide advice or safety messages to cover every situation.
It is the automotive technician‟s responsibility to be knowledgeable of the
system being tested. It is essential to use proper service methods and
test procedures and to perform tests in an appropriate and acceptable
manner that does not endanger your safety, the safety of others in the
work area, or vehicle or equipment being tested.
It is assumed the operator has a thorough understanding of vehicle
systems before using the unit. Understanding of these system principles
and operating theories is necessary for competent, safe and accurate
use of this unit.
2
C H A P T E R 1

Before using the unit, always refer to and follow safety messages and
applicable test procedures provided by the manufacturer of the vehicle
or equipment being tested.
Use equipment only as described in the manual.
1.2.1 Read all Instructions
Read, understand and follow all safety messages and instructions inthe
Safety Precautions book, this manual and on theunit.
1.3 Conventions
This manual contains text styles that ask you to pay extraattention:
Note:
Suggestion or explanation.
Stresses that the following action may cause damage to the unitor
objects attached to it.
Stresses that the following action could cause (severe) injury to the
operator or others.
The operator must have full knowledge of all information stated in
the Operator’s Manual.
3
CONVENTIONS

4
C H A P T E R 1

2.1 General
This section provides details of the power supply and dimensions ofthe
Diagnostic Platform and the minimum PCspecifications.
2.2 Gas Bench
2.2.1 SGM II
Table 2-1 Operation &Storage
Table 2-2 Measurements
Parameter
Range/
Resolution
Accuracy: Relative/Absolute
%vol CO:
0.000 –15.00
0.01 %vol
%vol CO2:
0.00 –20.00
0.1 %vol
ppmvol HC:
0 –9999
1 ppm vol
%vol O2:
0 –25.00
0.01 % vol O2<4% / 0.1%vol
rpm
0 –9999
±1.0%
°C:
0 –120
°F:
14 –302
Note:
*accuracyaccordingtoOIMLClass0
2.2.1.1 Propane Equivalence Factor
The P.E.F.value is variable.
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Operating Conditions
Max. ambient temp.
+40 °C
Min. ambient temp.
+5 °C
Rel. humidity:
up to 90%, non-condensing
Max atmospheric
pressure variation
750 –1150 mbar
Storage Conditions
Temperature:
-20 to +55 °C
Rel. humidity:
Up to 90%, non-condensing
2
Product Specification

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C H A P T E R 2

3.1 The DGA 5000\Geogas 5000
The SUN® DGA 5000\GEOGAS5000 is a versatile, high-performance
PC-based test instrument for the analysis of motor vehicle exhaust
gases. The unit is designed to meet the performance requirements of
OIML Class 0 and ISO 3930.
The basic configuration of the unit comprises:
- A gas analysis module containing a NDIR gasbench.
- An rpm/oil temperature module (ROTI) for the measurement
of engine speed and oil temperature.
- An exhaust probe and hose assembly, used for the collectionof
the gas sample from the vehicletailpipe.
The DGA 5000\Geogas 5000 forms part of the Emissions Diagnostic
Platform System.
Specific software versions will be available for performing theemissions
tests specified by separate national or internationaljurisdictions.
Although this jurisdiction specific software may alter the DGA 5000
standard software described herein, this manual is also applicableto
these specific programs when used in conjunction with the specific
documentation relating to such programs.
With the standard software the unit is capable of measuring the
concentrations of up to five gases in vehicle exhaustemissions:
- Carbon Monoxide, Carbon Dioxide and Hydrocarbons (CO, CO2
and HC) by infra-red absorption.
- Oxygen (O2) by an operator changeable electrochemicalcell.
In addition to the gas measurements the unit alsodisplays:
- Lambda () according toBrettschneider.
- Engine speed (rpm) via the ROTImodule.
- Oil temperature via the ROTI module by means of an oil
temperature probe substituted for the oildipstick.
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3
Introduction

Note:
In cases where a EOBD Device is connected to the analyser,rpm
and oil temperature data will be obtained via theOBDdevice.
- CO corrigé (COc) may be displayed using a formula corrected for
fuel type.
3.2 Maintenance
Details of the maintenance operations that should be carried out bythe
operator are included in this manual together with a list of operator
service messages and a list of maintenanceparts.
All maintenance operations, other than those specifically described in
this manual, must be carried out by trained service personnelauthorised
by themanufacturer.
In particular, full gas calibrations must only be performed by aqualified
representative of themanufacturer.
3.3 Options
Can differ depending on market, please refer to your Sales group fora
list of options if applicable to your market.
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C H A P T E R 3

4.1 Platform Layout
This section provides details of the Diagnostic Platform generallayout.
4.2 Gas Module Layout
4.2.1 Gas Module Layout - SGMII
Figure 4-2 The Gas Module - Side & Bottom Panels
1. USB connection for PC interface
2. Power LED indicator
3. 12vDC power input jack
4. O2 Sensor (p/n7096E4060-31)
5. Clean air inlet (with charcoal filter (p/n 7096E9061-54) tofilter
incoming air)
6. Water Bowl (p/n 1-41780A)
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9
10
11
12
1
3
2
5
4
6
7
4
Functional Description

C H A P T E R 4
FUNCTIONAL DESCRIPTION
7. Gas Sample inlet (connection point for exhaust probe/ samplehose
assembly).
8. Gas sample outlet (outlet for gas sample from gasbench)
9. Water outlet (connect a tube to this outlet to drain water fromthe
water removal system)
10. Gas sample outlet (outlet for gas sample from gasbench)
11. Fan Assembly
12. Optional Bluetooth Antenna for Wireless connectivity (futureoption)
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C H A P T E R 4
FUNCTIONAL DESCRIPTION
4.3 Common Program Elements
For details of program elements that are common across the
EmissionsDiagnostic Platform system, refer to the following sections
of the Emissions Diagnostic Platform Operator‟s Manual:
• For details of screen elements, refer to the Manual 4.2:
„Screen Elements‟.
• For details of buttons together with an illustrated guide to iconsused
in common by all system modules, refer to the Manual 4.3:
„Buttons‟.
• For details of the use of drop-down menus, refer to theManual
4.4: „Drop-down Menus‟.
• For details of Diagnostic Platform System Screens, refer to the
Manual 5: „Diagnostic Platform System Screens‟.
• For details of controls and navigation, refer to the Manual 6.1:
„Navigation‟.
4.4 Gas Analyser Icons
The toolbar and menu icons shown in the tables are specific to theGas
Analyser.
Table 4-1 Gas Analyser Toolbar Icons
Icon
Name
Description
Home
Use this button to return to the Home Page
Main Menu.
Vehicle Setup
Use this button to access the vehicle setup
screens (see „Free Measurement Vehicle
Setup‟)
Print Preview
Use this button to preview the data to beprinted.
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