TEN INNOVA 3000 User manual

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User Manual
INNOVA 3000
The contents of this manual and INNOVA 3000 software are the property of Test Equipment Nederland BV (Herein thereafter referred to as
TEN). Copying the manual or parts of the manual and software is strictly prohibited. For additional copies of the manual or software please
contact TEN.
The information contained in this manual is believed to be correct but does not purport to be all inclusive and should only be used as a guide.
TEN shall not be liable for errors contained herein or for any incidental or consequential damage, loss or injury arising from use of this guide or
their equipment.
The INNOVA 3000 is manufactured by TEN and conforms to requirements of, and in accordance with the EMC directive 89/336/EC.

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Table of contents
1 Introduction .................................................................................................................................................................3
2 Front Screen and Connection Panel...........................................................................................................................4
3 Specifications of the INNOVA 3000............................................................................................................................6
4 Principle and operation...............................................................................................................................................7
5 User information..........................................................................................................................................................8
6 Using the INNOVA 3000.......................................................................................................................................... 10
7 Periodic Checks....................................................................................................................................................... 11
8 Messages................................................................................................................................................................. 12
9 Program of the INNOVA 3000 ................................................................................................................................. 17
11 Official (MOT) test.................................................................................................................................................. 21
12 Standard test (MID)................................................................................................................................................ 22
13 System purge......................................................................................................................................................... 25
14 System diagnosis................................................................................................................................................... 26
15 User menu ............................................................................................................................................................. 30
16 Maintenance .......................................................................................................................................................... 33
17 Troubleshooting..................................................................................................................................................... 34

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1 Introduction
Thank you for choosing to purchase the INNOVA 3000 Exhaust Emissions Analyser manufactured by TEN
Automotive. Please take a few minutes to read this User Manual carefully!
The INNOVA 3000 is designed to comply with the highest technical and accuracy requirements of modern day,
mandatory vehicle testing, worldwide. The flexibility and smart design of the INNOVA 3000 facilitates a wide range
of options for testing and measuring exhaust emissions of vehicles with Petrol, Diesel, LPG and CNG engines.
The INNOVA 3000 boasts the achievement of gaining MID Type Approval, meeting the demands and technical
specification required for Government vehicle testing throughout Europe. The non dispersive, fully digital infrared
gas bench incorporates the component quality and technology required for high accuracy emissions testing, with
the minimum of maintenance. The gas processing system is protected from moisture and contamination by the
combined automatic drain and filtration system.
The heart of the INNOVA 3000 comprises of a powerful personal computer controlling the software processes and
program routines resulting in a clear, high resolution visual display presentation on the full colour flat panel monitor.
With data entry and software program control via the QWERTY keyboard and mouse, the INNOVA 3000 performs
easy, step by step test routines, with the minimum of effort. Test results can be stored on PC as well as printed on
the A4 colour printer.
For quick and comprehensive diagnosis the INNOVA 3000 is fitted with RPM and OIL/Engine Temperature
measurement capability with a range of accessories and adaptors to keep up with advances in motor vehicle
technology. These range from inductive RPM Clamps, Pulse Sensors and Oil Temperature Transducers to
“Bluetooth connectivity” Data interface devices such as OUBT, CobraScan and EDA2 “Compact” portable
smokemeter. Please contact your supplier for further information and available options.
Contact information:
TEN Automotive Equipment Ltd
Lubeck Road
North Lynn Industrial Estate
King’s Lynn
Norfolk
PE30 2JE
Tel: [phone]
Fax: [phone]
E-mail: [e-mail]

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2 Front Screen and Connection Panel
Figure 1: Front Screen of the INNOVA 3000
1: LED indication power on/off.

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Figure 2. Connection Panel of the INNOVA 3000
15. Mains voltage input with main switch and fuses (2x2AT).
16. Fan.
17. Oxygen Sensor.
18. Drain separator with integrated pre-filter, fine filter and connection for sample probe
19. Inline filter (water drain system).
20. Carbon filter.
21. Gas outlet with leak check adapter.
22. Water outlet, (water drain system).
23. Calibration gas inlet.
24. COM 1, RS 232 communication port INNOVA 3000 to smoke meter
25. COM 2, RS 232 communication port INNOVA 3000 to PC.
26. Not used.
27. Not used.
28. Not used.
29. Connection for the inductive RPM clamp.
30. Connection for the Piëzo or optional RPM Pulse adapter.
31. Connection for the Oil temperature probe.
32. Connection for the Multi meter cable

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3 Specifications of the INNOVA 3000
POWER SUPPLY
Voltage 220/240 Volt AC
Frequency 50 Hz
Power 60 Watt max.
RANGES
Carbon monoxide CO 0-10 % vol
Carbon dioxide CO20-20 % vol
Hydrocarbons HC 0-10000 ppm vol
Oxygen O20-25 % vol
Lambda 0.000-9.999
RPM 400- 10000 1/min
Oil temperature 0-150 C
Multi meter 0-2, 0-10, 0-100 volt dc
RESOLUTIONS
Carbon monoxide CO 0.01 % vol
Carbon dioxide CO2 0.1 % vol
Hydrocarbons HC 1 ppm vol
Oxygen O20.01% vol (O2< 4 % vol)
0.1 % vol (O24 % vol)
Lambda 0.001
RPM 10 1/min
Oil temperature 1 C
Multi meter 0.1, 0.1, 1 volt dc
REMAINING PARAMETERS
Warm-up time 10 minutes
Response time 12 seconds
Nominal sample flow 300 litres per hour
Ambient temperature 5 - 40 C
Storage temperature 5 - 60 C

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4 Principle and operation
The fundamental principle of the Gasbench, where the exhaust gas is guided through for measurement, is based on
non dispersive infrared absorption, also known as NDIR. While the Gasbench emits infrared light through the
measuring chamber, certain gasses are absorbing the light. This level of absorption gives a direct lead of the gas
concentration in the measuring chamber. Every gas absorbs the infrared light at a different frequency area. The
Gasbench is fully digital and with its own microcontroller it calculates, compensates and linearizes every gas value.
The following gas components are found in the exhaust emissions of motor vehicles equipped with an electrical
ignition. The INNOVA 3000 provides simultaneous measurements of:
- CO carbon monoxide
- CO2carbon dioxide
- HC hydro carbons
- O2oxygen
In addition to the infrared gasbench the INNOVA 3000 is also equipped with an electro-chemical sensor which
measures the oxygen concentration in the sampled exhaust gas. With the data from both the oxygen and infrared
Gasbench readings, a lambda calculation is made. This so called lambda value gives an indication about the
efficiency of the combustion, i.e. if the engine is running too rich or too lean.
The RPM meter of the INNOVA 3000 is interrupt triggered and, as a result, is very accurate. After intricate filtering
of disturbances and interference the pulse or signal is directed to the microcontroller which calculates the pulse into
a numeric value. This technique offers a smart solution to easily select the RPM sensor used and appropriate
division factor.
The Oil temperature probe is equipped with a heat sensing semiconducting resistor. As the temperature of the
sensor changes, also the resistor value of the sensor changes so every change in Oil temperature can be
determined.

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5 User information
Using the sample probe
For sampling the exhaust gas the INNOVA 3000 is equipped with a 7 metre long hose fitted with a stainless steel
'flexible tip' exhaust sample probe. Insert the sample probe at least 30 centimetres into the exhaust tailpipe of the
vehicle. Clasp the spring of the probe around the tailpipe if possible.
Although the probe is flexible, never bend the probe excessively as this may cause leakage. Ensure that the
exhaust extraction system does not influence the sample system of the analyser.
IMPORTANT!: Take care when removing the sample probe after measurement as the probe can reach
temperatures in excess of 100 ºC due to hot exhaust gasses. Always grip the handle of the probe and if necessary
use gloves.
Using the inductive clamp
The inductive clamp is used to record the engine speed of vehicles with a petrol engine. Position the inductive
clamp around one of the spark plug leads. Take care that this lead isn’t bundled with other leads as this can create
noise signals on the clamp and therefore results in an incorrect RPM measurement. Take care that the direction of
the arrow on the clamp points towards the spark plug.
Please note it is possible to adjust the division ratio of the RPM signal for a correct RPM measurement (for
example; on DIS systems or coil output lead).

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Using the Oil temperature probe
The Oil temperature probe monitors the actual temperature of the engine. Please ensure the engine is turned off.
Remove the vehicle's dipstick and adjust the length of the temperature probe to the length of the dipstick. Place the
Oil temperature probe into the dipstick-hole, to the predetermined length, and start the engine.
IMPORTANT!:Be sure the length of the probe is adjusted correctly otherwise serious damage may occur, to the
engine or the probe itself. Caution is advised when working on or near to a vehicle’s engine. Be aware of moving
belts and pulleys and there is a burn hazard as some parts of the engine and exhaust system can have extreme
high temperatures.
After completing the test, switch the engine off. Remove the Oil temperature sensor and replace the vehicle's
dipstick.
Conditions of operation
The Innova must be connected to a proper mains power outlet with the correct output power rating and a protective
earth contact. Use of an extension reel or lead is not recommended.
Avoid working with hydrocarbons (and oil based products) in the direct area of the analyser. The residual vapour
may affect the test results and cause 'HC hang-up'. Always use the gas analyser in a well ventilated area.
Operation temperature of the Innova must be between +5 and +40 [°C] and relative humidity must not exceed 90
[%]. If these limits are exceeded the measurement accuracy can no longer be guaranteed. At this point any legal
measurement is not allowed.
IMPORTANT! Do not allow the operational or storage temperature of the Innova to fall below +5°C as freezing may
occur in the water drain system and cause subsequent damage. Damage may also occur to the PC if subject to
freezing conditions.
IMPORTANT! Always use good extraction facilities in the workshop. Vehicle exhaust emissions contain gaseous
toxic components like carbon monoxide that can be fatal, or seriously harm your health.

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6 Using the INNOVA 3000
The INNOVA 3000 is delivered complete, assembled, installed with software and is ready to use. Please note the
INNOVA 3000 contains a PC computer which is located in the cabinet. Ensure the PC is switched on when
operating.
The INNOVA 3000 program runs on a 'Windows' operating system. Please take care you shut down the program
and computer properly, otherwise system errors may occur. Switch the INNOVA 3000 on with the main switch on
the connection panel at the rear. The front screen 'power' indicator will illuminate.
Ensure the printer contains enough paper and the printer power is switched on. Fill the paper tray/feed if required.
After performing the power-up sequence the Innova 3000 test program will automatically start. Please note there is
an approximate 10 minute warm-up period before exhaust gas measurement can be performed.
Operating the INNOVA 3000
Operation and presentation of the Innova program is done by the PC computer. The computer is supplied with a
colour flat panel monitor, keyboard and a mouse.
The monitor
At the front of the flat panel monitor there are some control buttons and a power switch to switch the monitor on/off.
We advise that this is left switched on all the time as the monitor will automatically go into 'standby mode' as soon
as the computer is shut down and will power up when the computer is switched on again. Please refer to the
manual, supplied with the monitor, if necessary.
Keyboard and Mouse
During operation of the INNOVA 3000 program, the keyboard is used to make function selections and data entry.
After power-up of the computer the 'num lock' led should illuminate on the keyboard indicating it is ready for use. In
addition to the keyboard, the Innova is also equipped with a mouse. You can move the pointer and use the select to
activate program functions. Data or text input is not possible with the mouse.
Operating the INNOVA 3000 program
The INNOVA 3000 software program is menu driven. After power-up the Innova program performs an automatic
system self check before the 'Main menu' is initialised. At this point a message will be displayed if an error is
detected. From the 'Main menu' a number of sub-menus can be selected, for example 'Petrol menu' or 'Diesel
menu'. This form of menu structuring allows the Innova to be operated very easily. In most menus the function keys
(F1, F2 etc.) are active and its function is represented in the “F” key list at the bottom of the Innova screen. The
“Tab”key or “Shift + Tab”key allows you to toggle between different groups or columns, for example menu items or
keys in the “F”key list. Within a group or column individual items can be highlighted with the arrow keys and
selected with the Enter key.
The mouse can also be used to select an item. Move the pointer to the item and click the left mouse button to
confirm the choice.
Basic keyboard and mouse functions for the INNOVA 3000 program are typical for any 'Windows based' program. It
is advisable to use the function keys on the keyboard when operating the Innova program. Mouse control is not
normally required.

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7 Periodic Checks
As mentioned previously, the INNOVA 3000 executes some internal self checks during start up. In addition, the
INNOVA 3000 performs periodic control checks to ensure the integrity of the sampling and measurement system.
These checks include the Leak check test, the HC residue check and Gas calibration.
The Leak check test
This test is performed weekly (or daily). The INNOVA checks for leaks within the exhaust gas sampling system.
Follow the software prompts carefully ensuring a good “airtight” connection seal between the sample probe and the
Leak check adapter. Press the Enter key, the program will perform a leak check automatically.
If the test fails, the Official and Standard test will be blocked. You can repeat the leak check by selecting the
following sequence: Main menu -> Petrol menu -> System diagnosis -> Leak check
The HC residue check
The HC residue check is automatically performed before a measurement. During this test it is determined how
many hydrocarbons are present in the current ambient air or if there is any HC residue left from a previous
measurement. EU Regulations state that this amount must not exceed 20 ppm. If the concentration is higher than
20 the Official and Standard test will be blocked. If this occurs the HC residue check should be started over again
by selecting the following sequence: Main menu -> Petrol menu -> System diagnosis -> HC-residue check.
Please note that during this test, the sample probe must not be positioned in or near the exhaust tailpipe. Fuel
vapour, brake cleaner, oil or other hydrocarbons may also influence the test.
Gas calibration
The INNOVA 3000 requires calibration every twelve months to ensure accuracy of measurement. Only qualified
service personnel should perform this task as a special composite calibration gas is required and applied during a
“controlled” calibration procedure.
During power-up the INNOVA 3000 monitors the date of the last successful calibration and displays a 'calibration
due' message if the Innova is within 14 days of the calibration due date. Failure to calibrate before the calibration
due date will result in exhaust gas measurement being blocked.

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8 Messages
While using the INNOVA 3000 certain graphical screens or messages may appear to notify, or prompt the User of
an event or a fault. Some of these messages will be displayed with additional text.
Warm up
This message is displayed if the INNOVA 3000 gas bench is in the warm-up phase and may take up to a maximum
of 10 minutes to complete. The INNOVA 3000 will not allow exhaust gas measurement during this warm-up phase.
Zero calibration
Zero calibration is required frequently, at a number of stages in the program, to ensure that changes in ambient
temperature do not affect the accuracy of measurement. During this process, measurements are prevented and a
symbol is displayed.
During Standard test measurement, a Zero calibration is necessary every 30 minutes or, it can be activated or
‘forced’using the special Zero function key. This will allow ambient air to flow through the carbon filter and gas
bench, to ensure the zero reference settings are correct.
Please note at this point the exhaust sample probe does not need to be removed from the tailpipe of the vehicle.

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Low-flow detection
The INNOVA 3000 will continuously monitor the flow of exhaust gas through the sample system. If the flow is
restricted and below an acceptable limit, exhaust gas measurements are prevented and a warning symbol is
displayed. Gas flow problems usually occur when the exhaust sample hose, sample probe or filters are blocked or
contaminated. If this message occurs, we advise to check the filters for contamination and if necessary, replace the
filters. If there is a blockage, remove the blockage or clean the specific parts to continue testing. The low flow
message will disappear automatically if the sample flow is within limits. If problems persist then contact your service
agent.
Drain check / Water detected
During combustion, large amounts of water can be produced and collect in the vehicle’s exhaust system. The
INNOVA 3000 is designed and equipped with an auto drain system that removes the excessive water while
sampling the vehicle exhaust.
Under normal conditions the filtration system will drain the water coming out of the exhaust of the vehicle and
discharge through the INNOVA 3000 'water out' pipe.
If the amount of water is excessive or the gas sampling system is blocked, the INNOVA 3000 automatically
prevents measurements, displays a warning symbol and drains for at least 1 minute before measurements
commence again. This sequence is repeated until the water or blockage is cleared or removed.
The INNOVA 3000 will automatically return to the measuring program if the gas sampling system is operating
correctly and within limits. If the above warning occurs frequently then please check the exhaust probe, sample
hose and filters. Clean filters, replace or clear blockage if necessary.

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Oxygen sensor voltage
The oxygen sensor output voltage is monitored frequently for contamination and ageing. This process is automatic
and happens during every zero calibration. If the sensor output is getting close to its lower operating limit, the
INNOVA 3000 will warn the User that the sensor may soon require replacing. If the sensor is outside the specified
limits, the oxygen and lambda readings will be disabled and sensor icon will illuminate on the screen. If this occurs,
please contact your service provider for a replacement.
Please note; If this message occurs, the graphical icon of the oxygen sensor ‘lights up’ and the values of the oxygen
channel and lambda are blocked and the readings show (--.—and -.---). If a zero calibration is executed and the
oxygen sensor is within limits the message will disappear.

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Communication error
The INNOVA 3000 consists of an exhaust gas sampling/measuring unit and a PC for the program operation and
presentation. Both these units are connected via a serial communication cable in order that the computer can
control the exhaust gas sampling/measuring unit and obtain data for processing and presentation. If the
communication fails, the INNOVA 3000 will display an error message on the screen and provide instructions for
troubleshooting.
If this occurs check the serial communication cable between the PC and the COM2 port of the sampling/measure
unit. In addition, it is a good idea to power down the INNOVA 3000 and power up again (Make sure Windows is shut
down first). If this message persists then please contact your service provider.
Other messages
The PC is equipped with a Windows operating system. For a number of reasons error messages may be generated
from the operating system. If this is the case, check the message and follow the instructions at the screen. If
necessary refer to the manual of the PC manufacturer or contact your supplier.

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9 Program of the INNOVA 3000
After a power-up and initialisation, the INNOVA 3000 automatically performs internal self tests and the Gasbench
will start its warm-up sequence. After booting the PC the splash screen of the INNOVA 3000 appears.
The screen will display the software version and country to which the software program is applicable.
Press F4 to continue.
The system status screen displays the information and status of the sampling/measuring. Both indicators should be
green when the system is functioning correctly. If indicators are red then a retry can be made by pressing the F8
key.
Please note; there may be a message shown when the INNOVA 3000 have to be calibrated within 14 days. The
User may contact their service supplier to arrange calibration.
IMPORTANT! Failure to calibrate before the calibration due date will result in exhaust gas measurement being
blocked.

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If the Calibration date has expired the following screen appears.
The F4 button will allow the program to proceed but no exhaust emissions measurements can be made. The Main
menu screen of the INNOVA 3000 appears which all options and sub-menus can be selected.
If the PC software of the INNOVA 3000 is not correctly configured or the PC does not comply to the required
standard a fault screen appears. The Innova program has to be shut down. No measurements can be made until
software has been configured correctly.

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The software of the INNOVA 3000 consists of multiple modules. One essential software module is SSM32.dll. If the
SSM32.dll module cannot be loaded, or is not functioning correctly, the following screen will be displayed. This
module function is important and necessary for the correct operation of the INNOVA 3000.
If the software of the INNOVA 3000 is configured correctly the Main menu screen is displayed. From this menu all
options and sub-menus may be selected. The main menu contains the following items:
Petrol menu: Program for engine analysis on Petrol and LPG/CNG fuelled vehicles. This part contains the
Official test, Standard test, and various system tests.
Diesel menu: Program for engine analysis on Diesel fuelled vehicles. This part contains MOT test, Standard
test and some diagnostic tests. For more information please refer to the EDA 3000 User manual
OBD menu: Program area where various EOBD data and parameters can be checked or monitored, such as
RPM, temperature, Trouble codes, Readiness code and Lambda sensor signal.
Multimeter: Program area for Multimeter functions with numerical and graphic presentation.
User menu: Program area where various data or parameters can be checked, or entered, such as Garage
details, Testers names, time and date. Installed software version can also be checked.
Service menu: Program area for authorised service personnel, this may not be accessed by the User. The
Service menu is accessed by password and should only be used by authorised technicians.

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