Universal Enterprise AGA5000 Installation Manual

AUTO4-2

1-800-547-5740 • Fax: [phone]

www.ueitest.com • email: [e-mail]

Auto 2-2,AU T O 4-2 & AG A 5 0 0 0

®

INSTRUCTION MANUAL

DESCRIPTION

The UEI range of emission analyzers covering the models Auto 2-2, 4-2 and
AGA5000 has been designed to be used on petrol, LPG or CNG powered
engines*. All models measure carbon monoxide (CO), and unburnt
hydrocarbons (HC), with Oxygen (O2) and carbon dioxide (CO2) added to
four-gas models and nitric oxide (NO) included in five-gas variants. All four­gas analyzers have an upgrade facility for Nitric Oxide (NO).

Using the measured parameters CO, HC, O2 and CO2, additional parameters
such as Lambda, Air to Fuel ratio and corrected carbon monoxide (COK) can
also be calculated and displayed.

All measured and calculated parameters can be printed on the optional
infrared printer or saved to the analyzer’s memory.

Each analyzer is supplied with an RS232 output enabling communication
between the analyzer and a PC. Using the optional auto software kit, live
emission data can be displayed, saved directly to the PC or printed to
produce high quality test reports. Data stored in the analyzer can also be
uploaded, diagnosed graphically and/or converted into spreadsheets for
service records.

All models are battery powered to give true portability in the workshop
environment. The battery can be charged with the supplied mains adaptor
or 12V cable.

* For diesel applications, HC measured in the exhaust gas is indicated in ppm
(parts per million) n-hexane.

CONTENTS

1. ANALYZER LAYOUT AND FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Instrument features and keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Instrument layout (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.3 Standard Probe Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2. SAFETY WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3. FIRST TIME USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4. NORMAL START UP SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4.1 Every Time You Use The Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4.2 Automatic Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4.3 Main Display Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4.3.1 Line Scroll Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4.3.2 4 Page Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.3.3 8 Page Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.4 Sampling the Exhaust Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.5 Turning the Pump ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.6 Taking an oil temperature reading (certain analyzers only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

4.7 Reading the engine speed (RPM) (certain analyzers only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

4.8 Regular Checks During Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4.8.1 Low Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.9 Normal Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5. MOVING THROUGH THE MENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5.1 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5.2 Menu Options and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.2.1 Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.2.2 Select Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.2.3 Units Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5.2.4 Display Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.2.5 Set-Up Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6. PRINTING INFORMATION - OPTIONAL EXTRA ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

6.1 Printing a Live Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

6.2 Standard Printout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

7. STORING AND RETRIEVING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

7.1 Storing a Live Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

7.2 Viewing and Printing a Stored Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

7.3 Deleting Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

7.4 Auto Store . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

8. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

8.1 Emptying and Cleaning the in-line water trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

8.2 Changing the particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

9. PROBLEM SOLVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

10. ZERO CHECKS AND RE-CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

10.1 Zero Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

10.2 HC residue check (certain analyzers only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

10.3 Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

10.4 Gas Calibration Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

10.4.1 Calibration Gas Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

10.4.2 Calibration Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

10.4.3 User Re-calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

10.4.4 Printed Calibration Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

10.4.5 Reset Instrument Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

11. PRODUCT SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

APPENDICES

A. Main Display Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

B. LAMBDA Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

C. Procedure for changing Oxygen fuel cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

D. Electromagnetic Compatibility (CE) Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

1

1. ANALYZER LAYOUT AND FEATURES

1.1 Instrument Features and Keypad

Infra-red signal to printer

Battery

Charger

or 12 Volt

Adapter

Gas Connection to
Instrument

External Particle
Filter

In-line Water Trap
(Keep clear of
water at all times)

Water
Level Limit

ON/OFF

MENU

Allows access to all menu functions

PUMP

Turns pump on and off

ENTER

Accepts a command,
i.e. enters a menu option

UP

Scrolls up through options, i.e. Fuel

DOWN

Scrolls down through options

STORE

Enters data storage menu

PRINT

Prints current data
Turns on backlight

NO sensor

(standard on

AGA5000 only)

2

Instrument Layout (Rear)

1.2 Instrument Layout (Rear)

Serial
Number

NOTE! Cover
Does Not
Remove

Charger
Socket

Exhaust Port

*Note: DO NOT cover exhaust port as this will severely affect analyzer operation

IR Emitter

3

1.3 Standard Probe Configuration

4

2. SAFETY WARNING

This analyzer extracts combustion gases that may be toxic in relatively low concentrations. These gases are
exhausted from the top of the instrument. This instrument must only be used in well ventilated locations. It
must only be used by trained and competent persons after due consideration of all the potential hazards.

Protection Against Electric Shock (in accordance with EN 61010-1: 1993)

This instrument is designated as Class III equipment and should only be connected to SELV circuits. The
battery charger is designated as:

Class II equipment
Installation category II
Pollution degree 2
Indoor use only
Altitude to 2000m
Ambient temperature 0˚C-45˚C
Maximum relative humidity 80% for temperatures up to 31˚C decreasing linearly to 50%RH at 45˚C
Mains supply fluctuations not to exceed 10% of the nominal voltage.

3. FIRST TIME USE

Charge the battery for 12 hours, following this an overnight charge should be sufficient for an average 8
hour day (turning pump off to save power between tests). See Main Parameter displays for Battery Indicator.

The analyzer has a rechargeable lead acid battery, use only the mains charger or 12 volt adapter supplied or
damage may occur to the instrument and battery.

Check that you have all the items you have ordered.
Take time to read this manual fully.
When using the analyzer for the first time you will need to choose from:-

Language selection
Time
Printed header name and telephone number

The Menu Options and Settings (Section 5.2.5) gives details of how to change the above settings.

5

4. NORMAL START UP SEQUENCE

4.1 Every Time You Use The Analyzer

BEFORE SWITCH-ON CHECK THAT:

• The particle filter is dry and not dirty or damaged

• The water trap and probe line are empty of water

• All hose connections, etc. are properly made

• The probe is sampling CLEAN AMBIENT air

• The water trap is correctly fitted and the instrument upright

• The oil temperature probe is connected if required (Certain analyzers)
*DO NOT RUN ANALYZER WITHOUT WATER TRAP FITTED

Switch ON the instrument by pressing

4.2 Automatic Zero Calibration

During this sequence the analyzer pumps fresh air into the sensors to allow them to zero and the oxygen
sensor to be set to 20.9 %.

After switch-on the analyzer will briefly display header information:

And then show the initializing screen:

The time will count down in seconds to zero and is pre-set by the instrument. During countdown the
instrument will check flow rate and initialize the measuring system, do not block the end of the probe or
insert into or near the vehicle exhaust.

Once the initialization time has reached zero an audible beep will be heard and the option to perform a leak
test will be given. The following screen will be displayed:

Press to select YES and perform a leak test or use and enter NO to skip.

UEI

1-503-644-8723

INITIALIZING

TIME: 75

FRESH AIR PURGE

LEAK CHECK?

YES

PRESS ENTER

6

If YES is selected the following screen will be displayed :

Fit the probe seal as detailed in Section 10.3 and press

Once the test has PASSED remove the probe seal and press

If the test fails see Section 10.3.

Once the leak test is completed the instrument will zero the CO, HC and CO2 sensors and set oxygen to

20.9%. Keep the instrument and exhaust probe sampling fresh air.

The instrument will take approximately 75 seconds to set the zero.

If the readings are outside the allowable zero range as detailed in section 10 it is advisable to perform a
manual zero also detailed in section 5.2.2.

A HC residue check may also be requested. See Section 10.2.

The next screen is the MAIN DISPLAY of the analyzer:

Use to change the display.

All parameters are detailed in Appendix A - MAIN
DISPLAY PARAMETERS.

LEAK CHECK?

REMOVE EXHAUST PROBE

FIT PROBE SEAL

THEN PRESS ENTER

ZERO CAL

TIME: 75

FRESH AIR PURGE

CO % VOL 00.00
HC PPM VOL 0000
CO2 % VOL 00.0
O2 % VOL 20.90

CO % VOL 00.00
HC PPM VOL 0000
CO2 % VOL 00.0
LAMBDA 0.0000

7

4.3 Main Displays

The main display can be changed to show either 4 or 8 parameters at one time. Two options are available
when 4 parameters are selected.

• Line scroll mode allows you to customize the display to show the data you require.

• 4 Page Mode displays 4 lines of data in set format, each page is predefined

• 8 Page Mode displays 8 parameters on 4 lines in set format, the bottom two can be changed.

Changing between the different modes is detailed in Display Menu (Section 5.2.4.)

TIP! To turn the backlight ON in the main display press

Note: a short press turns the backlight on, a press and hold will print.

To increase battery life do not leave the backlight on.

4.3.1 Line Scroll Mode

Line scroll mode allows you to customize the bottom line of the display. This is the default mode following
analyzer turn on.

Use the key to change the bottom line of the display.

Change bottom line using

4.3.2 Page Mode

Use the key to change the information that is displayed on the screen. The following pages are
available, depending on model the sequence of displayed parameters may differ from those in the examples
which follow.

CO % VOL 00.00
HC PPM VOL 0000
CO2 % VOL 00.0
LAMBDA 0.0000

GASOLINE

DATE . . . . . . . . . . . . .07-08-01

TIME . . . . . . . . . . . . . . . .12:31:35

BATTERY % . . . . . . . . . . . . .54

CO % VOL . . .00.00

HC PPM VOL . . . .0000

CO2 % VOL . . . .00.0

O2 % VOL . . .20.90

8

LAMBDA . . . . . . . . . . . . . . .0.000

NO PPM . . . . . . . . .NOT FITTED

TIME TO ZERO . . . . . . . . . . . . . .10

OIL DEG C . . . . . . . . . . . . .50

RPM . . . . . . . . . . . . . . . . . . .0000

CO % VOL . . . . . . . . . . . . .00.00

HC PPM VOL . . . . . . . . . . .0000

O2 % VOL . . . . . . . . . . . . .20.90

4.3.3 8 Page Mode

Displays 8 parameters on the screen at one time. Symbols used in this mode are different to those used in 4
page and line scroll modes and are detailed in Appendix A - MAIN DISPLAY PARAMETERS.

The bottom line of the display can be changed to
display other parameters.

Use the keys to
change this line.

CO :00.00 O2 :20.90
HCH :0000 CO2 :00.0

λ

:0.000 NO :0000

02-23-01 13:45:22

CO :00.00 O2 :20.90
HCH :0000 CO2 :00.0

λ

:0.000 NO :0000

TZ :30 BAT :50

CO :00.00 O2 :20.90
HCh :0000 CO2 :00.0

λ

:0.000 NO :0000

Fuel: GASOLINE

4.4 Sampling the Exhaust Gas

Once the zero calibration and test procedures have been completed and the fuel has been selected (See
Section 5.2.2) the probe can be inserted into the desired vehicle exhaust.

Ensure the probe is inserted into the exhaust pipe so as to not allow air into the probe. The exhaust of a car
can pulse, especially at low RPM, drawing air in causing bad readings, ensure the flexible probe is fully
inserted and the clip attached to the exhaust pipe.

4.5 Turning the pump ON/OFF

The analyzer is fitted with a pump to draw gas from the vehicle exhaust. To conserve battery power, switch
off the pump when you are not taking a measurement. Gas values may drift slightly when the pump is
turned off but should return to zero when the pump is turned on again. Manually zero the analyzer if it does
not return to zero.

Use the key to turn ON and OFF the pump.

CERTAIN ANALYZERS ONLY
The analyzer will block readings while the pump is off and display ‘----‘ on all gas channels. It will also
display PUMP OFF every 30 seconds.

It is recommended that the analyzer samples fresh air for at least 60 seconds before the pump is turned off.

9

PUMP OFF
HC ppm vol . . .- - - -

CO2 % vol . . . .- - - -

O2 % vol . . . .- - - -