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OPERATING MANUAL
Rev. 0 - 05/07
cod. 1160045
IMPORTANT !
We recommend you thoroughly read the instructions provided in this manual before
switching on the device.
This will enable you to obtain excellent performance and reliability over time.
Store this manual close to the device for quick reference by operators!
The Manufacturer shall not be liable for failures or other consequences deriving
from incorrect procedures on the part of the User.
No part of this manual may be reproduced in any form without prior written consent by the manufacturer.
CZ Srl reserves the right to make improvements or changes in its instruments at any time and without prior notice.
Other product names and companies mentioned in this document may be registered trademarks registered by the
respective owners.
Cod. 1160045
Document completed in may 2007
OPERATING MANUAL
Dear Customer,
Congratulations on purchasing our EGA 903 gas analyzer, a very modern instrument which will
help you for control and adjustment of vehicle emissions.
The technology applied and the quality achieved in years of experience in the sector, have made
EGA 903 an excellent instrument which will give you maximum satisfaction thanks to its efficiency
and reliability over time.
The device uses the latest technology for analysis emissions by an integrated display unit, build
on a powerful computer and a stable operating system (Linux), with a touch screen for easy
access to all the features directly on the colour high resolution LCD TFT.
This manual is to be considered an integral part of the instrument as it contains general
instructions for correct use of the device.
We therefore invite you to carefully read through the instructions before switching on the device,
to adequately train operators and to store the manual for future reference. These good practices
shall ensure that you obtain from the instrument top performance and reliability over time.
OPERATING MANUAL
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OPERATING MANUAL
INDEX
OPERATING MANUAL
INDEX
6 AUTODIAGNOSIS ...................................................................................................................... 31
6.1 Parameters .............................................................................................................................. 31
6.2 Errors ....................................................................................................................................... 34
6.3 Actuators ................................................................................................................................. 35
6.4 States....................................................................................................................................... 36
6.5 ISO........................................................................................................................................... 36
7 MULTIMETER............................................................................................................................. 37
7.1 Description .............................................................................................................................. 37
8
9 MAINTENANCE.......................................................................................................................... 42
9.1 Description of the operations .................................................................................................. 42
9.2 Leak Test ................................................................................................................................. 42
9.3 Maintenance of the filters ........................................................................................................ 44
9.4 Replacement of the Oxigen and /or NOx Sensor ................................................................... 45
9.5 Periodic Inspection.................................................................................................................. 45
9.6 Extraordinary maintenance ..................................................................................................... 45
9.7 Error messagges ..................................................................................................................... 46
9.8 Replacement of the paper roll and/or ink ribbon .................................................................... 48
10
INDEX
OPERATING MANUAL
CZ Srl
Declares under its sole responsibility that the product:
UNI EN ISO 12100-1 Safety of machinery Basic concepts, general principles for design
Basic terminology, methodology.
UNI EN ISO 12100-2 Safety of machinery Basic concepts, general principles for design
Technical principles.
Parma, 02/05/2007
Sign of Legal Representative
OPERATING MANUAL
DECLARATION OF CONFORMITY
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DECLARATION OF CONFORMITY
OPERATING MANUAL
SAFETY RULES
1.1
Carefully read the technical data plate to ensure that the frequency and voltage match mains
values.
Do not connect the unit to voltage or frequency other than those indicated on the plate.
Use the device only in dry places, sufficiently light and well aired.
If the gas analyzer is positioned on the special trolley during transport or handling, ensure
that there are no other objects on the instrument to prevent them from falling.
Do not wet the device and protect it from any direct contact with the rain.
Do not clean the device with products that may make damages on the plastic box or LCD.
Do not repair blown or defective fuses but replace them with fuses having equivalent
characteristics.
WARNING
If used correctly and in accordance with the instructions provided by Cz S.r.l. this
instrument present no hazard for operators.
The manufacturer shall not be liable for failures and other consequences deriving from
incorrect operations on the part of operators.
OPERATING MANUAL
SAFETY RULES
1.2
Use only the supply cables supplied and ensure that the insulation is in good condition.
Do not touch the high-tension cables present into the engine compartment when this is
operating.
Stop the vehicle using the parking brake, (if the vehicle is equipped with), insert running idle,
(or in case of automatic gear, parking position), and lock the wheels.
Inside the exhaust gas of the vehicles, both diesel and gasoline are present many poisonous
substances dangerous for the health. It is necessary to assure a good ventilation of the room
and anyway into closed rooms it is obligatory the use of a suction system.
Pay attention to the moving devices on the vehicle. Particularly the electric fans may start
even when the vehicle is switched off.
Use proper protections in case the noise emissions are more than the prescription of the law.
Do not smoke, and do not use free flames or sparks sources near to the vehicle.
Protect the face, arms and legs to avoid contact with hot surfaces of the vehicle.
Do not unscrew the radiator cap while the engine is running or still warm.
1.3
Disposal
Separate electrical, electronic, plastic and ferrous parts before demolishing the instrument.
SAFETY RULES
10
OPERATING MANUAL
MAIN FEATURES
2.1
Hardware
Power Supply:
1030 Vdc (Vehicle battery).
Universal mains adapter 90260 Vac 4760 Hz input.
Display:
Back lighhted colour TFT 6.4 LCD VGA resolution 640 X 480 pixel
Keyboard:
Emulated onscreen alphanumerical keyboard directly operated from the touch
screen.
Also compatible with external keyboard.
Hardware platform:
Low-power 300 MHz personal computer.
Operating System:
Proprietary Linux embedded distribution.
Memory card :
64 Mbyte.
Printer :
Dot matrix, 24 columns.
Connection ports:
Standard PS2 external keyboard;
Standard RS 232 (DB9);
Via Bluetooth (optional)
Standard LAN IEEE 802.3 10/100Mbps, network connection;
N. 2 USB ports for software upgrades, EOBD autodiagnosis, module and/or external
serial connections via USB/serial converter (not supplied), and possible external
printer (optional);
Aux CRT video output, 640 X 480 @ 65536 colours not interlaced;
Internal RPM input (RDI). In COMBI version the Diesel pickup cable is supplied on
request;
Engine oil temperature sensor input.
OPERATING MANUAL
11
MAIN FEATURES
2.2
Generals
Dimensions:
W = 400 mm, H = 200 mm, D = 340 mm
Weight:
~7 Kg
Operating temperature:
+ 5 C + 40C
Storage temperature:
25 C + 70C
Operating Air Pressure range:
815 1060 mbar.
Clock:
Date and time on print, built-in internal lithium battery.
2.3
Metrological characteristics
LAMBDA:
0.8 1.2
CO:
CO2:
0.001 %
0.01 %
HC:
O2:
1 ppm vol
0.01 % vol
LAMBDA:
0.001
Resolution:
MAIN FEATURES
12
OPERATING MANUAL
2.4
Conformity
General:
Directive 98/37/CEE.
Electromagnetic Compatibility (Directive 89/336 ECC)
OPERATING MANUAL
13
MAIN FEATURES
3.1
Package content
Picture 3.1
Picture 3.2
Inductive clamp
Picture 3.3
Picture 3.4
NOTE
We recommend you do not dispose of the packaging, because it will provide protection
if you need to transport the device.
ATTENTION
The instrument must be kept in a close, clean and dry place, avoid that
atmospheric agents and/or other corrosive substances could be in contact with
the instrument.
Ensure that all the parts listed are contained in the case, if any parts are missing
or damaged contained your local dealer.
PREPARING FOR USE
14
OPERATING MANUAL
3.2
Installation
Remove the instrument from the package and put it on the working
surface or on the specific trolley (optional).
Follow the instructions provided below and bear in mind that all the
unions and connectors are located in the rear part of the unit.
3.3
Picture 3.5
Connection
Insert the plug of the UNIVERSAL MAINS ADAPTER (Picture 3.1) to mains power.
Connect the plug of the UNIVERSAL MAINS ADAPTER to the POWER INPUT CONNECTOR
(Ref.10 Pict.3.6).
Connect the plug of the Power Supply Battery cable cod. 1060068 (optional) to the
POWER INPUT CONNECTOR (See Ref.10 Pict.3.6).
2)
Connect the power cable clamp to the car battery, making sure you maintain polarity:
the black clamp to the negative pole (-) and the red clamp to the positive pole (+).
Connect the drain pipe for condensate (optional) to the CONDENSATE OUTPUT joint
(Ref.15 Pict. 3.6).
Connect the EXHAUST SAMPLING PROBE* (Pict. 3.2) to the GAS INPUT (Ref.16 Pict. 3.6).
Connect the OIL TEMPERATURE PROBE (Picture 3.3) to the OIL TEMPERATURE PROBE INPUT
connector (See Ref.11 Pict. 3.6).
ATTENTION
Make sure gas outlets is not obstructed by foreign objects as this could prevent
correct operation.
Connect the INDUCTIVE CLAMP CABLE (Pict. 3.4) to the RPM INPUT (Ref.12 Pict. 3.6).
* Follow the specific indications given below for measuring vehicle or motorcycle exhaust
emissions.
OPERATING MANUAL
15
3.4
5
6
7
8
9
16
15
13
14
13
12
11
10
Picture 3.6
Legend
1.
2.
Main filter
3.
Power swicht
4.
Fuse
5.
6.
Keyboard connection
7.
8.
USB ports
9.
16
OPERATING MANUAL
3.5
Frontal view
Picture 3.7
Legend
1. Display TTF with Touch screen
2. Printer ( 24 columns)
3.6
The technical data plate is affixed on the lower side of the smoke meter.
Picture 3.8
OPERATING MANUAL
17
4.1
Description
The EGA 903 gas analyzer programme can handle all measurement operations either in
conformity with specific regulations or in a casual mode for a quick diagnosis.
Are the procedures are visualised by pages with
graphic symbols (buttons, sensible areas, etc..).
To select the desired function, touch on the screen with
a finger the defined area.
For regular use, the programme does not require the
use of a keyboard.
However it is possible to connect an external keyboard in order to enter in the data fields provided
the characteristics of the vehicle being tested.
The graphic interface opens with an initial page where the various options listed below can be
selected; this page is referred to as MAIN MENU.
allows to enter into pages dedicated to the description of the functions and the
18
OPERATING MANUAL
4.2
Settings
DATE AND TIME: to enter hour, minutes, seconds, day, etc. using the numerical keyboard
provided.
Touchscreen ADJUST: to adjust the position of the cursor with respect to the finger
contact position.
OPERATING MANUAL
19
4.2.1 Language
When you select the LANGUAGE function in the
SETTINGS page the page shown here will be displayed,
indicating the languages currently available.
The item which is not highlighted is the language
currently used.
20
OPERATING MANUAL
The calibration procedure is guided throughout by a set of messages that indicate all the steps to
be performed.
NOTA
The gas analyzer is already configured before delivery, however if there are inaccuracies
in the use of the touch screen, we suggest you carry out the calibration procedure.
OPERATING MANUAL
21
ATTENTION
Some settings are restricted and access to them is allowed only after entering a
password.
Select SETUP/CALIBRATION from the SYSTEM, to enter the following page.
The
system
then
displays
the
page
The menu GAS ANALYSER SETUP/CALIBR contains options in several pages; use the PgUP
and PgDown arrows to scroll through these pages.
Select MEASUREMENTS.
22
OPERATING MANUAL
It is also possible to adjust certain parameters such as the alarm value for low aspiration flow
conditions, depression threshold for activation of the leak test alarm and setting of autozero time.
NOTE
We recommend you maintain the values configured at the factory.
OPERATING MANUAL
23
Select PRINTER SETTINGS from the SYSTEM page, to enter the following page.
It is possible to set up the printer that you wish to use
to print out the test reports:
ATTENTION
Printing out of graphs (see MULTIMETER chapter) is possible only with an external
printer (via USB port).
24
OPERATING MANUAL
GAS ANALYSER
5.1
Test selection
- FREE TEST: used to carry out opacity tests without applying any particular regulation.
This test is ideal for an initial inspection of emissions, their consistency, their progress over time
and in relation to changes in engine conditions.
- GRAPHIC TEST: used to carry out opacity tests without applying any specific requirements in
the operating procedure.
The test results are displayed both in numerical form (digital) and in graphic form (single
parameters shown on coordinates against time).
At the end of the all test (GRAPHIC TEST excluded) you can print out all the values measured
during the tests.
With the REPORT function, present in the main menu GAS ANALISER, you can enter and save
the print report in the REPORT ARCHIVE (See chapter 8) and then print it out at a later time, or
print it out directly with the printer that you have previously set up (See paragraph 4.2.7).
OPERATING MANUAL
25
GAS ANALYSER
5.2
Free test
After performing the procedure required to connect the smoke meter to the test vehicle:
Select GAS EMISSIONS from the MAIN MENU.
Select FREE TEST from the GAS ANALYSER.
The first page relates to the characteristic data of the
vehicle being tested.
When you select one of the fields with white
background, relating to the items displayed (Make,
Model, etc.), an alphanumerical keyboard will appear
where you can enter/modify the text.
Press the
measurement
page
displays
the
following
Values calculated
(CO correct, Lambda factor );
At the end of the test, based on the setting of the REPORT function in the GAS ANALYSER menu
(see paragraph 5.1) you can press PRINT to print out or save a test report.
FREE TEST
26
OPERATING MANUAL
The field OIL displays, during the test, the temperature of the
Picture 5.1
ATTENTION
When inserting the temperature probe in its seat, make sure you do not wind the
cable inside the motor compartment.
5.2.2
Rpm measurement
2)
Picture 5.2
27
FREE TEST
5.3
Graphic test
Press the
Values calculated
(CO correct, Lambda factor );
The graphic representation over time is extremely useful to assess the behaviour of emissions
with the changing of engine conditions (for example with changes in rev number).
GRAPHIC TEST
28
OPERATING MANUAL
5.3.1
Rpm measurement
2)
Picture 5.3
Select the rpm field, a drop menu will appear to apply, if necessary,
a suitable division factor for the number of revolutions based on the
engines number of strokes.
OPERATING MANUAL
29
GRAPHIC TEST
The button
parameters.
Press button
A) The button
to restart recording.
B) The button
To see the patterns from the moment you have stopped recording.
After that, it is possible to begin a new recording or to stop when desired the pattern of the signal
under test, pressing
C) The button
.
To clean the display from any pattern.
to
and
; memorizing end
GRAPHIC TEST
to come back to the visualization live of the signal of the graphic to examine.
30
OPERATING MANUAL
AUTODIAGNOSIS
Parameters
Errors
Actuators
States
ISO
Picture 6.1
6.1
Parameters
31
AUTODIAGNOSIS
or
to make
or
The icon with the red arrows you see in the right up corner of the page
indicates that the communication is active. The absence of the arrows
indicates that the communication has not been activated or is lost.
The button
can be used to save in the REPORT ARCHIVE (See Chapter 8), the list of
page where it is possible to set the value of the time axle (sec/div) and min. and max values of
the examined parameters.
AUTODIAGNOSIS
32
OPERATING MANUAL
The button
Press button
A) The button
to restart recording.
B) The button
To see the patterns from the moment you have stopped recording. After that, it
is possible to begin a new recording or to stop when desired the pattern of the signal under test,
Pressing
To clean the display from any pattern. You have to press again
C) The button
to
OPERATING MANUAL
; memorizing end
; back
33
and
AUTODIAGNOSIS
can be used to save in the REPORT ARCHIVE (See Chapter 8), the
The button
6.2
Errors
The
warning
signal
indicates
the
of problem.
The user has to make the repair and then to continue
with the cancellation of the fault inside the memory of
the electronic board.
AUTODIAGNOSIS
34
OPERATING MANUAL
The button
can be used to save in the REPORT ARCHIVE(See Chapter 8), the list of the
6.3
Actuators
The operator can decide the duration test, in some systems, in other case the duration is fixed by
the program installed into the electronic module under test.
OPERATING MANUAL
35
AUTODIAGNOSIS
6.4
States
The button
key can be used to save in the REPORT ARCHIVE (See Chapter 8), the list of
6.5
ISO
ISO Code
Hardware Version
Software Version
The button
can be used to save in the REPORT ARCHIVE (See Chapter 8), the list of the
information visualized.
AUTODIAGNOSIS
36
OPERATING MANUAL
MULTIMETER
7.1
Description
The MULTIMETER function present in the diagnostic system has been designed for specific use
in the auto-diagnosis field.
The instrument makes it possible to measure electric values such as resistance and voltage.
These values can be displayed in numerical or graphic form.
Picture 7.1
Connect the Volt/Ohm cable (cod. 1090014) to LasterTool module and use the right pins (red
and black) to make measurements (See Pict.7.1).
In case of graphic display, it will be possible to record the variation of the width, according to the
time, in order to be able to check in quality and quantity the exact signal.
OPERATING MANUAL
37
MULTIMETER
The Multimeter allows recording the signal for making a post analysis of its waveform
To use such function a present standard symbolic buttons, working is the same way of the
graphic recording of the diagnostic device.
The button
In the proper field is displayed VOLTAGE or RESISTANCE according to the previous selection.
Pressing button
The button
the modification of the time scale (from 1 sec/div. to 60 sec/div.), indicated in the up left side of
the page.
The button
allows resetting the value of the signal under test in order to make a correct
measurement.
The button
allows recording the graphic movement concerning the electric signal under test.
A) The button
B) The button
to restart recording.
to see again the graphic display from the moment the recording has been
stopped. After that, it is possible to begin again a new recording or stop, at the desired moment,
the graphic of the signal under test pressing
C) The button
D) The button
MULTIMETER
38
OPERATING MANUAL
The button
to
Memorizing start
; back
and
Using such buttons, it is possible to examine on the screen moment by moment the patterns of
the captured signal.
Press button
examine.
The button
allows to store into the report archive (See Chapter 8), the previously saved
OPERATING MANUAL
39
MULTIMETER
The List Test Reports represents the archive which stores all the data saved after the gas test
reports (after pressing the PRINT key), and the graphs produced with the Multimeter
measurements.
40
OPERATING MANUAL
Pressing button SEQUENCE MODE you obtain a sequence of images, which correspond for
each image to a subdivision for a period of 30 sec. of the completely stored graphic.
of
images
making
the
graphic.
Press
to pass images.
Press
to print.
The report will be printed out by the printer that you have previous set up in gas analyzer EGA
903 (INTERNAL or USB).
Remember that graphs can only be printed out with an external printer.
NOTE
The printer connected to the EGA 903 has to be PCL protocol compatible.
OPERATING MANUAL
41
MAINTENANCE
9.1
The gas analyzer must be kept in perfect running order by means of regular maintenance
operations which the user must carry out personally.
To enable correct gas measurement, the following maintenance operation are of fundamental
importance:
Weekly: Leak Test of the pneumatic circuit and search for any blockages in the exhaust
sampling probe;
When indicated by the instrument: substitution of the Oxygen and/or NOx sensor;
9.2
Extraordinary maintenance.
Leak Test
The verification consists of checking the pneumatic circuit above the measuring chamber for
leaks.
The programme automatically carries out the leak test if this
has not already been carried out during the day.
Alternatively, the Leak Test verification can be carried out
from the measuring pages using the appropriate button.
Close the end of the sampling probe using the lid supplied
Pict. 9.1
42
OPERATING MANUAL
The programme will automatically start the exhaust pump, aspirating air from the circuit.
During the verification, the programme analyses the depression value in the measuring chamber.
A few seconds later the pump is stopped, thereby checking for the presence of any leaks in the
circuit.
Where no leaks are detected, the programme notifies the user to remove the lid from the probe,
otherwise an error message will give a negative test result.
Please bear in mind that, in the event the test should fail, the measurements are halted.
ATTENTION
Remember that good maintenance of the filtering system is vital for ensuring that the
instrument lasts well throughout the course of time.
OPERATING MANUAL
43
MAINTENANCE
9.3
Switch off the device and remove the power supply wire.
Pict. 9.2
Dry using compressed air blown from the inside towards the
outside of the filter.
Replace the cartridge in its support, and the whole set in its
original position.
Pict. 9.3
Check and/or substitute the paper filter installed on the tube on a weekly basis.
The filtering part installed in the exhaust sampling system should be checked, emptied and
washed (with water and soap, then dried with compressed air, including the beaker) on a
daily basis.
The paper filter mounted on the connecting tube between the motorcycle exhaust analyser
and exhaust sampling system should be checked and/or replaced on a daily basis.
MAINTENANCE
44
OPERATING MANUAL
9.4
In this case, the operation is prompted by the programme which automatically detects the
reduced remaining lifespan of the Oxygen and/or NOx sensor.
As a result, when the Oxygen and/or NOx sensor has been exhausted, the relevant error message
is displayed while the instrument is in usage, and measurements are halted.
To replace the sensor, proceed as follows:
Switch off the device and disconnect the power supply cable.
Install the new sensor by screwing it onto the rear block and connect the relevant connector.
NOTE
The spare parts are only available from CZ Srl and are exclusively distributed by
authorised dealers.
9.5
Periodic Inspection
NOTE
The PERIODIC INSPECTION operations are to be performed exclusively by authorized
CZ Srl Service Centres.
In case of doubts and/or malfunctions, please contact the closest authorised dealer.
9.6
Extraordinary maintenance
NOTE
The EXTRAORDINARY MAINTENANCE operations are to be performed exclusively by
authorized CZ Srl Service Centres.
In case of doubts and/or malfunctions, please contact the closest authorised dealer.
OPERATING MANUAL
45
MAINTENANCE
9.7
Error messagges
The following is a list of error messages that could appear on the screen of the gas analyzer.
ERROR
CODE
MESSAGE
DESCRIPTION
SOLUTION
F1/6
ABSOLUTE PRESSURE
SENSOR FAULTY
--
F1/5
DIFFERENTIAL PRESSURE
SENSOR FAULTY
--
F1/4
--
F1/3
F1/2
CHAMBER GAS
TEMPERATURE TOO HIGH
F1/1
CHAMBER GAS
TEMPERATURE TOO LOW
F2/6
REFERENCE VARIATION
TOO BIG
F2/5
OVERPRESSURE IN GAS
TUBE
F2/4
UNDERPRESSURE
ABSOLUTE
--
F2/3
OVERPRESSURE ABSOLUTE
F1/0
MAINTENANCE
46
OPERATING MANUAL
ERROR
CODE
MESSAGE
F2/2
LOW FLOW
F2/1
F2/0
F3/6
F3/5
OPERATING MANUAL
DESCRIPTION
SOLUTION
Check for the presence of any
obstructions in the exhaust sampling
probe.
Empty out any condensation present
in the separator.
Clean and substitute any filtering
elements.
Perform an autozero.
47
MAINTENANCE
9.8
48
OPERATING MANUAL
10
Code
1030002
Inductive clamp
1610004
2610003
Filter 27.40.7w
1240001
PFCARRELLO
1060068
NOTE
We recommend you use original spare parts and/or accessories.
To order the required part contact your closest CZ dealer.
OPERATING MANUAL
49
Cz S.r.l.
Via Campanini, 3/a - 43100 PARMA - ITALY
Telefono: 0521 798280 Fax 0521 707654
e-mail: info@cz-dynamic.it
Internet: http://www.czdynamic.com