User s manual for CAP3201 USER MANUAL CAP3201 EMISSION STATION.

Transcription

1 PRO01353 Rev C USER MANUAL CAP3201 EMISSION STATION 1

2 T A B L E O F C O N T E N T S I. I. GENERAL DESCRIPTION OF THE STATION I.1. OVERALL DIAGRAM I.1.1. Main menu: I.1.2. Configurations : I.1.3. Protected access: I.2. OVERALL VIEW: I.2.1. The station I.2.2. List of components supplied I.2.3. Front side I.2.4. Rear Face I.2.5. External Gas Connectors I.2.6. Opacity measuring cell I.2.7. The temperature/tachometer module I.2.8. The keyboard (optional) I.3. INSTALLATION, START-UP I.3.1. Recommendations I.3.2. Starting I.4. MAINTENANCE, PRECAUTIONS DURING OPERATION I.4.1. General I.4.2. Cleaning cables and surfaces I.4.3. Removal and insertion of paper in the printer I Thermal printer: II. II.... GAS ANALYSIS: (PETROL VEHICLE) 27 II.1. PRINCIPLE OF OPERATION

3 II.1.1. Corrected CO II.1.2. Lambda Pneumatic circuit II.2. OPERATING CONDITIONS II.3. TECHNICAL CHARACTERISTICS II.4. EMISSION TEST II.4.1. Preliminary checks II.4.2. Cleaning and precautions during operation II Semi-annual maintenance II Annual maintenance II Probe maintenance II Maintenance of the separator II Replacing a filter II.5. GAS ANALYSIS II.5.1. Customer information : II.5.2. Description of the graphic interface: II.5.3. Preliminary checks II.5.4. RPM: II.5.5. Preparation for measurement II.5.6. Analysis and measurement II.5.7. Printing results II.6. OFFICIAL TESTING II.6.1. Vehicle registered before 1 October II.6.2. Vehicle registered before 1 January II.6.3. Catalyst vehicle registered before 01/07/ II.6.4. Catalyst vehicle registered before 01/07/2002: II.6.5. Printing results:

4 II.7. LIST OF FAULT REPORT MESSAGES AND FAULT TRACING II.7.1. Leak present II.7.2. Data invalid II.7.3. HC out of bounds II.7.4. CO out of bounds II.7.5. CO2 out of bounds II.7.6. O2 out of bounds II.7.7. NOx out of bounds II.7.8. Flow too low II.7.9. Out of paper II Lever open : II PB IMPR II HC residue in gas inlet II com. error II Adjustment necessary II Change O2 sensor II Condensation: wait II Heating problem II Other : III. III.... THE OPACIMETER: (DIESEL VEHICLES) 61 III.1. PRINCIPLE OF OPERATION III.2. OPERATING CONDITIONS III.3. TECHNICAL CHARACTERISTICS III.4. INSTALLATION AND PRECAUTIONS DURING OPERATION III.4.1. Installation, start-up : III.4.2. Cleaning and precautions during operation III.5. OPACITY TESTING PROCEDURE

5 III.5.1. Client information entry III.5.2. The engine : III.5.3. Description of the graphic interface: III.5.4. Displays the selected operating speed mode: III.5.5. Detecting the cell III.5.6. Auto-zero and error checking III.5.7. Insertion of the probe and sensors III The probe: III The oil temperature sensor: III Connecting the tachometer: III.5.8. Preliminary checks III.5.9. Conditioning the engine: III Free acceleration III Two non-measured accelerations in succession III Opacity measurement phase III Display of the results of each acceleration III Printing results III Measurement to standard III Measurement not to standard III.6. OPACITY VALUE DETERMINATION PROCEDURE III.7. OPACITY ANALYSIS III.8. OPACIMETER MESSAGES III.8.1. Error messages III «Zero in progress» III «Mains voltage out of bounds» III «Windows dirty» III «Fan is defective» III «EEPROM out of service»

6 III «Sensor problem» III «Preheating» III «Detector temp. out of bounds» III «Time exceeded» III «Probe connected?» III «Measurement invalid» III «Press ESC and start again» III.8.2. User guidance messages III «Acceleration No. X» III «Measurement in progress» III «Return to idle» IV. IV.... OBD SCANTOOL 90 IV.1. GENERAL IV.2. PRINCIPLE IV.3. MEASUREMENT AND TESTING IV.3.1. Connection IV.3.2. EOBD data IV Measurements IV Fault codes IV Tests not continuously performed IV The information IV The full report IV.3.3. Printing results IV.4. LIST OF DATA

7 IV.4.1. List of available measurements in the table «current measurements» and «freezed frame». 98 IV.4.2. EXEMPLE OF DTC (DATA TROUBLE CODE) : IV.4.3. List of available measurements in «Measurements and control of the lambda probes».115 IV.4.4. List of recoverable and possible information in the table «Information about the vehicle» IV.4.5. List of data composing the table «Computer information» IV.4.6. TABLE OF ABBREVIATIONS IV.4.7. TERMS AND DEFINITIONS V. V.... CONFIGURATIONS 121 V.1. GENERAL: V.2. TIME/DATE: V.3. GARAGE HEADER: V.4. OPERATOR: V.5. GAS ANALYSIS V.5.1. Standby V.5.2. Digit CO, Lambda V.5.3. O2 sensor condition V.5.4. Leak test V.5.5. Routine check V.5.6. Protected access V HC index: V Calibration: V AMB access: V.6. SMOKEMETER:

8 V.6.1. VL/PL: V.6.2. Engine speed and Oil temperature: V.6.3. Routine check: V.6.4. Protected access: V.7. CENTRAL CONTROL: V.7.1. GIEG-NET protocol: V GIEG-NET MONO : V GIEG-NET MULTI : V.7.2. PC protocol: V.7.3. MAHA protocol: V.8. PRINTING: V.9. SCREEN: V.10. OPTIONS : V.11. DEFAULT PARAMETERS: V.12. INFORMATION: VI. VI.... PETROL AND DIESEL TACHOMETER 138 VI.1. OPERATING PRINCIPLE VI.2. TECHNICAL CHARACTERISTICS VI.3. LIST OF KIT CONTENTS VI.4. CONNECTING THE TACHOMETER VI.5. MEASURING THE ENGINE SPEED VII. VII.... PREMIUM VERSION WIN VII.1. INSTALLATION AND SET-UP VII.2. GAS ANALYZER VII.2.1. Launching of the procedure VII.2.2. Limit values : VII.2.3. Print out preview

9 VII.3. SMOKEMETER : VII.3.1. Launching of the procedure : VII.3.2. Print out preview : VII.3.3. Opacity Analysis VII.4. EOBD VII.4.1. Launching of the procedure VII.4.2. Print out preview VII.5. LOOKING INTO THE TESTS :

10 FOREWORD We thank you for acquiring the CAP3201. Of recent design, it takes advantage of the most advanced technologies, both at the software and at the hardware level, harnessing them to serve your priorities: rapid testing, accuracy, reliability and long maintenance intervals. Especially designed for the garage setting, its friendly environment allows you to quickly and effectively master all the possibilities offered by this device. We are therefore convinced that it will give you complete satisfaction. This manual explains how to use the CAP3201 station, from installation through measurement procedures, as well as measures to be taken in case of malfunction. Please read this manual attentively before operating the device, in order to get the full benefit of it. Keep it in a safe place to consult it when necessary. Notice: notice. Information contained in this document is subject to change without prior CAPELEC will not be held responsible in any case for any damage, direct or indirect, of any kind whatever, nor for losses or expenses, resulting from improper use. 10

11 11

12 I. GENERAL DESCRIPTION OF THE STATION 12

13 I.1. OVERALL DIAGRAM The diagrams presented below allow the menu hierarchy to be understood; the user can thus easily follow the sequence of the various sub-parts. I.1.1. Main menu: GAS ANALYSIS Multigas analysis Official testing Vehicles before 30/09/86 Vehicles after 1/10/86 Catalyst vehicles EOBD vehicles SMOKEMETER Opacity testing procedure Opacity value determination procedure Opacity analysis E.O.B.D Scantool CONFIGURATIONS 13

14 I.1.2. Configurations : CONFIGURATIONS Time/Date YEAR MONTH DAY HOUR MINUTES Central control Printing Gieg-mono Gieg-multi PC Maha Garage header CAPELEC 126, rue Emile Baudot Le Millénaire MONTPELLIER Number of tickets Tél: Fax: printer INTERNAL EXTERNAL Operator 1: 2: 3: 4: 5: 6: 7: 8: 9: Screen Options NORMAL INVERSE Protected access Default parameters Initialization? CAPELEC Information Le Millénaire 126, rue Emile Baudot MONTPELLIER Gas analysis Standby Digit CO, lambda O2 sensor condition Leak test Routine check Protected access Opacimeter Engine speed Oil temp. Routine check Protected access 14

15 I.1.3. Protected access: CONFIGURATIONS GAS ANALYSIS SMOKEMETER OPTION Protected access Protected access Protected access CODE ***** CODE ***** CODE ***** Name: VL/PL Initiailization? K,N filters. Configuration Serial number HC index Calibration AMB access CO,HC, CO2 adjustment O2 initialization NOx initialization O2/air New O2 sensor 15

16 I.2. OVERALL VIEW: The CAP 3200 station is made up of a CAP3201, an opacity measurement cell and trolley. The CAP3201 has an LCD screen, a gas analysis module for petrol vehicles, a keyboard and a printer. The measurement cell is connected to the station by a power supply and data cable. It is packaged in the form of a small metal briefcase mounted on legs. I.2.1. The station CAP3201 Keyboard Trolley on rollers 16

17 I.2.2. List of components supplied 1 user manual, For gas analysis: Gas analyser, Sampling probe, Exhaust tube, Filters, Oil temperature measurement probe, A inductive pick-up. For calculating the opacity of a gas: Opacity cell, Sampling probe, A cell support, Cleaning brush, Cell power and data cable, A piezoelectric sensor cable. OPTIONS : Keyboard, Cart with rollers, External A4 format printer, OBD kit, A battery tachometer kit. 17

18 I.2.3. Front side LCD screen 5-key pad 18

19 I.2.4. Rear Face _1_ID plate _2_Separator (FD) _3_Test gas exhaust (GAS) _4_Condensate exhaust (COND) _5_Test gas inlet (GAS) _6_Ambient air port for zero setting _7_Fan with filter (FV) _8_Mains power socket 230V _9_Input connector for induction clip _10_TTL and piezoelectric input connector 19

20 _11_Input connector for oil temperature sensor _12_Contrast control for LCD screen _13_PS2 keyboard input connector _14_COM2 serial port connector _15_COM1 serial port connector _16_OBD connector _17_Gas pump protection filter (FG) _18_Condensate pump protection filter (FC) _19_Activated charcoal filter (FCC) _20_Input connector for battery motor drive operation 20

21 I.2.5. External Gas Connectors _1_Sampling probe _2_Exhaust collector attachment grip _3_Black tube (length 7,5m) _4 & 5_Transparent tube (length 1.5m), 21

22 I.2.6. Opacity measuring cell I.2.7. The temperature/tachometer module Temperature probe Piezoelectric sensor Sonde de température Induction clamp Cigar lighter connector for RPM BAT (OPTIONAL) Battery clamp for RPM BAT (OPTIONAL) 22

23 I.2.8. The keyboard (optional) It is a standart keyboard ( type : «AZERTY»). The mains touch are ENTER and ESC. Select with arrow (Up, Down, Left, Right). ENTER : Valid a choice Esc : Quit and return at the last window. French keyboard «azerty» I.3. INSTALLATION, START-UP I.3.1. Recommendations The machine can be left powered up 24 hours a day. It is recommended, however, that the electrical power supply be shut off during the night. Powering up the machine in the morning will involve several minutes wait before the gas analysis module is operational. Powering up the cell involves a waiting period of at most 5 minutes for the chamber to reach its operating temperature (preheating). I.3.2. Starting Connect the station to the 230 VAC 50 Hz mains. Signs of correct operation: The screen lights up and the cooling fan must start. The presentation page with the CAPELEC logo appears on the graphics screen. 23

24 M O N D A Y 1 5 N O V E M B E R E M I S S I O N T E S T S T A T I O N G A S A N A L Y S I S S M O K E M E T E R E O B D S C A N T O O L The main menu appears after a few seconds. M A I N M E N U Title G A S A N A L Y S I S S M O K E M E T E R E O B D S C A N T O O L C O N F I G U R A T I O N M ain menu: The machine is ready for use 24

25 I.4. MAINTENANCE, PRECAUTIONS DURING OPERATION I.4.1. General Each CAP3201 is inspected before delivery by a representative of the measuring instruments service, who affixes a stamp mark on the plate attached to the rear of the machine. I.4.2. Cleaning cables and surfaces The station, the screen, the keyboard (optionally) and the cables may be cleaned with alcohol on a clean rag. Any other solvent is strongly discouraged. I.4.3. I Removal and insertion of paper in the printer Thermal printer: Heater head Roller Lever closed To remove paper from the printer, the lever must always be opened. To load paper, there are two methods: First, the lever must be opened and the paper correctly cut (see below); then insert the paper up to the heater head. Finally, ensure that the paper is correctly aligned and close the lever. The printer is ready to run. 25

26 The lever must be closed; the paper must be cut as shown below. In this method, insertion is automatic. It is only necessary to insert the paper as far as the roller; the paper is automatically loaded, and the printer is ready to run. Finally, messages continually inform the user of the condition of the printer. For example: OUT OF PAPER or LEVER OPEN. These types of errors appear when the operator starts a print job; they are quickly resolved by adding paper or closing the lever. 26

27 II. GAS ANALYSIS: (PETROL VEHICLE) 27

28 II.1. PRINCIPLE OF OPERATION The gas analyser is a module destined for PTI and automotive workshops. It allows measurement of the carbon monoxide (CO), carbon dioxide (CO 2 ), hydrocarbons (HC) in hexane equivalent (C6H14), and oxygen (O 2 ) concentration of the gases from spark-ignition vehicles (petrol, high-octane petrol, LPG), with or without catalytic converter. As an option, it can be equipped with the NOx kit allowing nitrogen oxides to be measured. The CAP3201 also allows the following values to be obtained at any time: - Calculation of the corrected CO value - Calculation of Lambda value ) - The measurement of rotation speed (measured by induction clip, by battery input, - Measurement of oil temperature. The measurement of CO, CO 2 and HC is carried out using non-diffusing infrared radiation. The gas passes through a measuring chamber, at the ends of which are three infrared detectors and three emitters. Each emitter emits with a characteristic wavelength associated with one of the three gases. Each of the detectors issues an electrical signal corresponding to the intensity of the radiation received. Measurement of oxygen concentration is carried out by an active chemical sensor. ddp R=f(T C) ANODE ELECTROLYTE CATHODE MEMBRANE O 2 Principle of oxygen measurement: 28

29 The oxygen sensor is of the electrochemical type; it is based on the principle of electrolysis. In the presence of oxygen, an ionic current is created through the cathode, the electrolyte and the anode, giving rise to a potential difference at the terminals of a resistor, which varies as a function of temperature. As a result, the sensor is temperature-compensated N Descriptions 1 IR detector 2 Sample cell 3 IR emitter 4 O rings 5 Optical window P r inciple of NDIR measurement: The CAP3201 is based on non-diffusive infrared technology. Instead of using a refractory prism to achieve the very high spectral definition of infrared light (like those used in high performance equipment in laboratories), the machine uses NDIR. NDIR devices are generally used for measuring concentrations of a specific and limited set of gases in mixtures having a known and limited collection of base gases. It is possible for example to take the measure of the concentration of CO 2 of a base gas such as the exhaust gas of an automobile. One knows a priori that gases that might have an absorption spectrum masking that of CO 2 are absent. 29

30 A specific collection of gases (CO 2, C6H14, CO) is measured as follows: a unique range of wavelengths in the infrared spectrum is selected for each gas in order to measure the point where its absorption is high and where there are no other base gases which are equally absorbent. Optical filters transmitting only the given range of wavelengths are placed in front of the thermocouple detector. When the set is full of the gas to be analysed, the infrared detector measures the reduction in the infrared energy obtained for the range of wavelengths linked to each gas. The signal processing electronics then determine the ratio I/Io. I/Io = degree of absorption I = signal received (sample) for each gas to be measured. Io = reference signal 30

31 II.1.1. Corrected CO Corrected CO is calculated as follows: If (%CO + % CO 2 ) 15 then corrected CO = CO If (%CO + % CO 2 ) < 15 then corrected CO = CO x (15 (CO+ CO 2 )) II.1.2. Lambda It is derived from BRETTSCHNEIDER s formula. This coefficient is calculated from the value of CO, CO 2, HC and O 2. CO 1,7261 3,5 CO2 O2 0,0088 ( CO2 2 4 CO 3,5 CO2 1, ,0088 CO2 CO 6 HC CO) (CO, CO 2 and O 2 are given in %, HC in ppm) This calculation is constantly carried out by the analyser unless CO 2 is equal to 0%. If the vehicle is well tuned, its Lambda will lie between 0.97 and 1.03 CNG, LPG EFFECT (Only on special version) On special version, on the measure page you can select LPG, CNG or PETROL cars. The only effect is to change the HC calculation : LPG involves HC*0.5 CNG involves HC*0.3 PETROL involves HC*1. 31

32 Pneumatic circuit 32

33 II.2. OPERATING CONDITIONS The gas analyser is equipped with automatic monitoring of parameters that have an influence on measurements. If at least one of these parameters is out of bounds, hence threatening to metrologically alter the results, the gas analyser disables itself and prevents any measurement from being performed until operating conditions are re-established. Failure to observe operating conditions may result in degradation of the equipment or temporary disabling of the CAP3201: Atmospheric pressure 1000 mbar +10% -25% Mains voltage 230 VAC +10% -15% 50 Hz+-2% Ambient temperature: from -10 to 55 C Gas temperature: 200 C tolerated by the probe Storage temperature: -32 to +55 C Relative humidity: <98% non-condensing Ambient air clean and room well ventilated 33

34 II.3. TECHNICAL CHARACTERISTICS Preheating time: < 9 minutes at 0 C (1 minute minimum) Response time: 13 seconds for HC, CO, CO 2, 28 seconds for oxygen (transition from 20.9% to 0.1% for a gas with 0% O 2 ) Nominal pump delivery: 6 l/min. Minimum pump delivery: 3.5 l/min. Air pressure variation: automatic correction by integrated absolute pressure sensor Zero point and sensitivity: automatic compensation Automatic pump standby and automatic zeroing. Official range Capelec range Resolution CO 0 à 5 % vol 0 à 15 % vol 0,01 % vol ou 0,001 % vol CO 2 0 à 16 % vol 0 à 20 % vol 0,1 % vol HC (C 6 H 14 ) 0 à 2000 ppm vol 0 à ppm vol 1 ppm vol O 2 0 à 21 % vol 0 à 25 % vol 0,01% vol pour les titres volumiques 4 % vol 0,1% vol au delà λ 0,8 à 1,2 0,0 à 9,99 0,01 ou 0,001 Accuracy: HC = 10 ppm } Absolute or 5 % of the value read CO = 0,03 % } Absolute or 5 % of the value read CO 2 = 0,5 % } Absolute or 5 % of the value read O 2 = 0,1 % }Absolute or 5 % of the value read. Engine speed = RPM Oil temperature = +- 1 C Corrected CO = 0,03 % Air/fuel coefficient (Lambda)= 0,03 Resolution: HC = Normal resolution: 10 ppm vol. High resolution: 1 ppm vol. CO = Normal resolution: 0.01 % vol. High resolution: % vol. 34

35 CO 2 = Normal resolution: 0.1 % vol. O2 = If O2<4 % vol. high resolution: 0.01 % vol. Otherwise normal resolution: 0.1 % vol. Nox = 1 ppm vol. Engine speed = 1 tours/min Oil temperature = 1 C Corrected CO = 0,01 % Air/fuel coefficient (Lambda)= or 0.01, selectable II.4. EMISSION TEST II.4.1. Preliminary checks Place the machine in the designated location. The surface must be horizontal and must not be exposed to excessive vibrations, dust or cold. There must be no petrol vapour in the vicinity of its location. Connect the tube and the probe to the separator located on the rear side. Do not insert the probe into the exhaust pipe at this stage. Press the Stop/Start switch on the station. II.4.2. Cleaning and precautions during operation The CAP3201 is a machine needing little maintenance. Only the pneumatic circuit components that carry the gases, located on the outside of the analyser, need to be maintained by the user. Any maintenance operation other than those described below must be entrusted to a certified CAPELEC agent. On the other hand, failing to maintain the machine in conformity with these instructions cancels the warranty. Every three months, the condition of the pneumatic circuit including tubing, filters, pumps, electrovalves and connectors must be inspected. It is also necessary to check the accuracy of the machine in measuring CO, CO 2, HC, O 2 using a gas made up in part of these gases in known proportions. The latter operation must be carried out by a certified organization. II Semi-annual maintenance Change the separator filter FD, Change filters FC and FG, 35

36 Visually check that the filter connections are in conformity with the schematic diagram in paragraph I.2.4. Visual inspection of the sampling probe. Clean it if necessary in accordance with paragraph II Perform a leak test. Enter the new maintenance date. II Annual maintenance Annual maintenance operations include the semi-annual maintenance operations. In addition, it is necessary to carry out the following operations: Replace the pump protection filters (FG and FC), Replace the activated charcoal filter. (FCC), Check with a calibration gas that the error is less than the maximum allowable error. 1) Put into measuring mode. 2) Disconnect the sampling probe from the separator. 3) Connect the cylinder of calibration gas in its place. If the cylinder contains propane HC, select display of C6 HC, even though display is usually in C3 (hexane). Otherwise, use the PEF value to convert if the HC are around 2000 ppm vol. propane. 4) Note or print the stabilized measured values. If the error is too high compared with current regulatory requirements, adjustment is necessary. If regulations require regular adjustment using a calibration gas, this operation must be performed prior to error testing. II Probe maintenance The small orifices at the end of the probe must never be plugged. If condensation forms or if residue is deposited in excess, remove the probe from the tube and blow compressed air in the direction opposite to that of suction. Perform the same operation with the sampling tube. 36

37 II Maintenance of the separator The separator includes a filter. Replace the filter it has become grey. Filter replacement is carried out in the following manner: - Shut off the pumps - Unscrew the condensation residue collector located at the back of the machine. (FD). IMPORTANT: The absence of one of the components inside the separator or incorrect reassembly of the assembly will contaminate the measuring device and the measurements will be prematurely invalidated due to the resulting errors. This condition of the analyser will require an overhaul that cannot be provided in the context of the warranty. - A gas-tightness check must be carried out after any operation on the pneumatic circuit of the machine (paragraphe V.5.4.). II Replacing a filter If one of the filters appears to the eye to be soiled or if an error message is referred in the user manual to a filter replacement, the following points must be observed: - Turn off the machine. - Remove the filter to be replaced (behind the location designated for each filter, the reference is silkscreen printed on the case). Replace the old filter with the new one, maintaining the correct installation orientation (see sketch of the rear side paragraph I.2.4) - Turn on the machine. - Perform a leak test as described in paragraph V

38 II.5. GAS ANALYSIS G A S A N A L Y S I S M U L T I G A S A N A L Y S I S O F F I C I A L T E S T This menu allows you either to open a window allowing several gases to be analysed, or to choose a submenu relating to technical testing according to the year that the vehicle began operating. Select GAS ANALYSER and press OK II.5.1. Customer information : In addition, before any measurement or technical test procedure, the user may, if he desires, enter information about the client and his car (name of client, make of car, mileage and registration plate). These data will then appear on the test report. Entry of these data is optional. V.3). The method of data entry is the same as that describe for garage entry (see paragraph The entry window with keyboard option appears this way: C U S T O M E R : G A S A N A L Y S I S V E H I C L E : P L A T E : M I L E S : N O T E S : 38

39 II.5.2. Description of the graphic interface: G A S A N A L Y S I S R P M T I M E HC = Hydrocarbons expressed as hexane (display as propane is possible: see paragraph II.5.6.1) given in ppm (parts per million). CO = Carbon monoxide expressed in % by volume. COcorr. = Corrected CO (paragraph III.I.1). O 2 = Oxygen expressed in % by volume. CO 2 = Carbon dioxide given in % by volume. = Displays Lambda value. This value has no particular unit. We say that it is a coefficient or a ratio. tr/min = Engine speed in revolutions per minute. C = Oil temperature measurement expressed in degrees Celsius. The print key: it is displayed only when printing is possible. Pressing this key displays in the message window: F 1 : P R I N T F 2 : S E N D D A T A 39

40 This offers a choice: either press F1 to send the values displayed on screen to the internal or external (A4) printer or press F2 to send the current measurements to the multiplexer to later transfer them to the centre s computer. The storage key: Stores in memory the current values as of the moment the key was pressed. These values will be printed at print time on the same test report. The CAP3201 can store 6 current values, and at each store operation the corresponding number is displayed in the message box. The pump key: Activates or deactivates the pumps. Pressure on this key puts the machine either in STANDBY (rest) mode, or in measurement mode (activation of the pumps and launching of an auto-zero operation). The STANDBY invalidates all measures, which is manifested on the display by dashes in the measurement field, but the time is also displayed in the message frame. The operating speed key: Allows the engine speed to be selected.(ii.5.4.). The NOx / COcorr. key Press this key, and the COcorr. field on the gas analysis graphic interface will be replaced by NOx, and vice versa. The auto-zero key Allows an auto-zero operation to be executed at any time. Note that the device automatically launches an auto-zero operation when it is necessary, and periodically every minute. When an auto-zero operation occurs, the electrovalve switches so that the air aspirated by the gas analysis module is pure and thus is filtered by an activated charcoal filter. The freeze data key Freezes the measured values on the screen. By pressing this key again, the fields on the screen are again updated. 40

41 II.5.3. Preliminary checks Before undertaking any measurement, the operator must satisfy himself that the engine is operating correctly. The following points are to be observed: The vehicle exhaust line must be gas-tight. The gearbox must be in neutral, with the clutch engaged, for vehicles with manual or semi-automatic transmissions; the selector should be in neutral for vehicles with automatic transmissions or in accordance with the instructions of the vehicle manufacturer. Accessories and optional equipment that influence the engine speed at idle must not be activated, barring manufacturer s instructions or regulation to the contrary. The engine must be at normal operating temperature, that is with an oil temperature at least equal to 80 C. 41

42 II.5.4. RPM: Pressing this key displays the speed mode currently in use. On the other hand, if the user again presses the operating speed key, a new speed mode displays the new selection. By simply refraining from pressing the key again, the new speed mode is automatically loaded. Organization chart: MEASURE IN PROGRESS RPM touch YES YES Display the rpm mode in progress 3 s Induction 3 s Initialization Induction/2 3 s RPM touch Piezo 3 s E.O.B.D. 3 s TTL 3 s Battery 3 s Cylinder number? 42

43 «Induction» : Sensor operation: The induction clip allows detection of the moment that ignition occurs in a cylinder. Placed around the ignition lead of a cylinder, it generates a signal by inductive effect at the moment of ignition. At the rate of one spark per revolution for 2-stroke engines and 1 spark for two revolutions when a 4-stroke is involved, the induction clip allows the operating speed of a petrol engine to be measured. Connect the induction clip cable to the CAP3201 input connector for the induction clip (an icon indicates its location), then selection the induction mode using the operating speed key. The operating speed display appears automatically. «Induction/2» : The procedure is identical to the preceding one, only the value is divided by two. «Piezoelectric» : Sensor operation: The piezoelectric sensor allows detection of the moment of injection on a diesel engine. Placed around an injection tube, it detects the dilation caused by the variations of internal pressure caused by injection. The electric signal supplied by the sensor allows the operating speed of a diesel engine to be measured (one dilation of the tube for two engine revolutions). Connect the sensor cable to the CAP3201, then select the piezo mode using the operating speed key. The operating speed display appears automatically. «E.O.B.D» : This mode allows the engine speed to be read from the data sent to us by the computer on board a vehicle (voir partie IV). Connect the cable to the vehicle s computer; the plug provided for this purpose is usually located near the fusebox. Then connect the other end to the CAP3201. Select, using the operating speed key, the E.O.B.D. mode. The display appears automatically. «TTL» : This mode makes it possible to read an engine speed sensor with a TTL output. Connect the cable to the induction clip input of the analyser. Select, using the operating speed key, the TTL mode. The display appears automatically. «Battery» : The battery option is composed of an electronic card installed inside the CAP3201, a cable for data and for power supply from the cigar lighter to the case, and a cable for data and for power supply from the battery. This option is a battery-driven tachometer which allows operating speed to be measured on all vehicles - petrol, diesel and LPG. Connect the cable on the CAP3201 (RPM BAT); select the battery mode using the operating speed key. After three seconds, the operator must choose and confirm the number of cylinders. If the battery cable is correctly connected, the system carries out an initialization phase. After this phase the operating speed is displayed. ATTENTION: In the event of a problem, the headlights of the vehicle should be turned on, and everything else shut off. 43

44 See section VI. II.5.5. Preparation for measurement - Tachometer Install the sensor, then press the operating speed key to determine the appropriate mode. This mode is automatically saved. The value of the operating speed must immediately appear. (see paragraph II.5.4). - Oil temperature Remove the oil level dipstick and replace it in the tube with the oil temperature probe. Adjust the length so that the probe dips in the oil when the sealing cone acts as a stopper for the dipstick tube. The engine must be warm before any measurement takes place, which corresponds to an oil temperature greater than 80 C. - Gas measurement Insert the sampling probe as far as possible in the exhaust gas exit tube. The minimum depth, when the layout allows it, is 30 cm. If this condition cannot be fulfilled, it is necessary to use a collector tube that acts as an exhaust system extension. In exhaust systems with a single exhaust pot, but provided with two exit tubes, it is necessary to use a collector tube into which the probe is inserted. For analysis of the gases upstream of the catalytic converter, the entire length of the flexible sampling tube must be used. Start the measurement by pressing the PUMP key (if the pumps are not running). Start the engine (if the engine is running before the probe is inserted, it is preferable to activate the pumps and to wait for zeroing to finish before inserting the sampling probe as indicated above). II.5.6. Analysis and measurement Automatic calibration is then engaged for a period of 50 seconds. The pump starts running and the following message is displayed on the screen: ZERO IN PROGRESS. After this period, the LCD screen contains the message: Measurement in progress, the results of each measurement appear on the displays, the 44

45 system is ready to carry out a measurement (concentrations must be similar to those in air: 0% for CO, CO 2, 0 ppm vol. for HC, 20.9% for O 2.) The machine is ready to be used. It is recommended that a seal integrity test be performed in order to verify that the probe is correctly installed and that the equipment has not be damaged in transport (refer to paragraph V.5.4). 45

46 ON/OFF Automatic system check Warmup period < 5 min Time remaining is displayed Calibration, auto-zero check Auto-zero Pumps active G A S A N A L Y S I S R P M M E A S U R E I N P R O G R E S S No gas measurements for a certain time > standby time Key Key Elapsed time > 30 min. and no measurement in progress. Wait mode. Pumps resting, no measurements OR values drifting. 46 Operating diagram Activating the pump has the effect of triggering automatic calibration. This phase lasts xx seconds and is launched as soon as the pump is started. While this procedure is in progress, the message auto-zero in progress is displayed in the message box. When the message disappears, measurement operations become available on the screen. Automatic zeroing occurs every 30 minutes if the analyser is in

47 measurement mode. If a measurement is in progress, the analyser will await the end of the measurement operation before launching calibration. Before carrying out a zeroing operation, the analyser performs a check of the air intake. Note that if a field contains no value and remains in the ---- state, the associated measurement is not available. We note the following cases: The temperature probe is not connected to the analyser; oil temperature measurement is not available. The NOx option is not present; NOx measurement is not available. Concentrations of HC, CO, CO 2 and O 2 give values for LAMBDA which are out of bounds; LAMBDA is not available. One of the gas measurements is invalid. NOTICE: At any time during this phase, it is possible to stop the pumps by pressing the mode key and put the machine in the resting state. However, in order to avoid dirt accumulation, it is recommended that the machine be rinsed with clean air by letting the pumps run 1 minute with the probe removed from the exhaust pipe. It is possible to so configure the machine that after a certain time has elapsed without exhaust gas measurement, it automatically goes into standby (see paragraph V.5.1). II.5.7. Printing results Printing of values displayed on screen is accomplished by simply pressing the PRINT key. It is possible to print the results of measurements at two test points (for example, idle measurement and measurement under high-speed running). Pressure on the MEMORY key allows storage of a first series of results. During printing, both the values retained in memory and the current values will appear. Sending the report to a central storage set erases the values stored in memory. Printing is accomplished by simply pressing the PRINT key while the analyser is in measurement mode (pumps activated and auto-zero complete). ATTENTION: The operator has a choice of several print modes, the internal mode which allows the use of the thermal printer furnished with the machine, in this mode the user has nothing to do and the system is autonomous. On the other hand, if the external mode is activated, for the system to work correctly the printer must be turned on and ON LINE, that is, the green indicator light located on the SELECT ON 47

48 LINE button of the printer must be lit. If this is not the case, press this button; the indicator lights if paper is installed (see. paragraph I.4.2.2). Measure 1,2,3 are the memorize measure. Measure 4 is the currently measure. 48

49 II.6. OFFICIAL TESTING For technical tests, it is possible to obtain a printout of a test report giving a breakdown of the polluting status of the vehicle in relation to its registration date and current legislation. In the main menu, select the technical test menu. This action gives access to a menu for selecting one of the three categories. G A S A N A L Y S I S V E H I C L E 30/09/86 V E H I C L E 01/10/86 C A T A L Y S T V E H I C L E C A T A L Y S T V E H I C L E Using the up and down keys, scroll through the selection. Press OK or ENTER when the selection is made. It appears a client data entry window (see above), then the procedure starts. Vehicles are divided into 4 categories: 1) Vehicles placed in service before 01/10/86. Only testing of corrected CO at idle is required. The measurement must not exceed 4.50 %vol. 2) Vehicles placed in service between 02/10/86 and 31/12/92 and utility vehicles placed in service between 02/10/86 and 30/09/94. Only testing of corrected CO at idle is required. The measurement must not exceed 3.50 %vol. 3) Vehicles that began operating after 01/01/93 and utility vehicles that began operating after 01/10/94 until 01/07/2002. These vehicles are required to be equipped with catalytic converters. 49

50 Measurement of CO and LAMBDA must be carried out at fast idle (between 2500 and 3000 rpm). CO must not exceed 0.30% vol. and LAMBDA (l) must lie between 0.97 and CO must also be measured at idle. The measurement must not exceed 0.5 %vol. 4) Catalyst vehicles registered after 01/07/2002. II.6.1. Vehicle registered before 1 October 1986 Limit of corrected CO at idle: 4.5 %vol. Operator guide: NO. One single measurement carried out at idle. If CO 2 concentration is lower than 9.0 % vol., it is necessary to perform a leak test of the exhaust, and if necessary a leak test of the analyser. If a leak is detected in the exhaust line, the vehicle must be rejected and the measurement invalidated. Press the print key to validate the measurement and print it out. II.6.2. Vehicle registered before 1 January 1993 Limit of corrected CO at idle: 3.5 %vol. Operator guide: NO. One single measurement carried out at idle. If CO 2 concentration is lower than 9.0 % vol., it is necessary to perform a leak test of the exhaust, and if necessary a leak test of the analyser. If a leak is detected in the exhaust line, the vehicle must be rejected and the measurement invalidated. Press the print key to validate the measurement and print it out. II.6.3. Catalyst vehicle registered before 01/07/2002 Fast idle measurement: Fast idle CO limit: 0.3 %vol. 50

51 Lambda between 0.97 and 1.03 at fast idle. Measurement at idle: CO limit at idle: 0.5 %vol. No LAMBDA test at idle. Operator guide: YES. The guide allows the measurement to be carried out according to French standard NF R This standard describes the various steps necessary to measure CO and Lambda of a vehicle equipped with a catalytic converter. The user is guided by following instructions readable on the liquid crystal screen. When a phase is limited to time, the analyser indicates on the NOx display (lower right) the time remaining in seconds until the phase terminates. 51

52 Testing a Catalyst-Equipped Vehicle No Phase Messages Observations Duration Advancing to the following step 1 Zéro ZERO IN PROGRESS Takes place only if no zero has occurred in the last 3 minutes 10 S. Automatic 2 Preparation of the vehicle PRECONDITIONING VEHICLE Preparation for measurement Not Timed If oil > 80 C or if ENTER is pressed INSERT GAS MEASUREMENT PROBE 30 mm depth min. INSERT ENGINE OIL PROBE Optional if another thermometer is present CONNECT OPERATING SPEED SENSOR Optional if vehicle has onboard tachometer WAIT FOR OIL > 80 C OR PRESS ENTER If oil temperature measured by analyser, advancing to the next stage is automatic when temperature > 80 C 3 Temperature conditioning of the exhaust line MAINTAIN SPEED BETWEEN 2500 and 3000 Speed stable. Use the tachometer for assistance 60 S. Automatic 4 Fast idle measurement FAST IDLE MEASUREMENT Start of 1st measurement 2 Min. Max. After 2 minutes or as soon as measurement CO < 0.3 and 0.97< <1.03 during 5 second. MAINTAIN SPEED BETWEEN 2500 and 3000 Speed always between 2500 and 3000 rpm. If a value stored in memory is bad: 5 Return to stable idle condition RETURN TO IDLE AND WAIT Release the accelerator and wait for the expiration of the 20 sec. 20 S. 6 Idle measurement IDLE MEASUREMENT Start of 2nd measurement 15 S. Max. if CO<0.5 during 5 second. 7 Measurement results TEST RESULTS: Results are displayed Not Timed Test report, ex.: VEHICLE REJECTED LAMBDA > 1.03 Vehicle accepted or rejected. Displays bad value(s). If the result is bad with oil temperature not measured, repeat the test while measuring oil temperature. 52

53 II.6.4. Catalyst vehicle registered before 01/07/2002: This is the same procedure than in paragraph II.6.3 with the following limits: Fast idle measurement: Fast idle CO limit: 0.2 %vol. Lambda between 0.97 and 1.03 at fast idle. Measurement at idle: CO limit at idle: 0.3 %vol. No LAMBDA test at idle. Operator guide: YES. 53

54 II.6.5. Printing results: V e hicles placed in service before 01/10/86 V e hicles placed in service between 02/10/86 and 31/12/92 and utility v e hicles placed in service between 02/10/86 and 30/09/94 C atalyst vehicles 54

55 II.7. LIST OF FAULT REPORT MESSAGES AND FAULT TRACING Error number Message displayed Call Maintenance Do it yourself Explanation in section 1 Leak present YES II Data invalid YES II HC out of bounds YES II CO out of bounds YES II CO2 out of bounds YES II O2 out of bounds YES II NOx out of bounds - - II Lowflow detected YES II Out of paper YES II Lever open YES II Printer problem YES II HC residue in gas inlet YES II MB com. Error YES II Adjustment necessary YES II Change O2 sensor YES II Condensation: wait YES II Heating problem YES II

56 II.7.1. Leak present Repeat the test, disconnecting the probe from the device and plugging the gas entry port on the separator. If the problem disappears, the leak is in the probe tubing. Otherwise, it affects the machine. Check the filter connections. Check that the separator is correctly installed and adequately tightened. Test the various parts of the pneumatic circuit with leak tests, moving the plug progressively upstream, up to the pumps. circuit. Open the machine and perform a visual check of the pneumatic Replace the leaking portion of the pneumatic circuit. II.7.2. Data invalid Adjustment necessary. II.7.3. HC out of bounds Out of range. Check that the ambient air is not polluted and re-zero. Perform a further adjustment if the problem persists. II.7.4. CO out of bounds Out of range. Check that the ambient air is not polluted and re-zero. Perform a further adjustment if the problem persists. II.7.5. CO2 out of bounds Out of range. Check that the ambient air is not polluted and re-zero. 56

57 Perform a further adjustment if the problem persists. II.7.6. O2 out of bounds Out of range. Check that the ambient air is not polluted and re-zero. Check sensor connections. II.7.7. NOx out of bounds Out of range. Check NOx sensor connections (optional). Replace the NOx sensor if the message persists after several attempts to zero. II.7.8. Flow too low Check that the flexible tubes located at the rear of the machine are connected in accordance with the sketch in paragraph I.2.4. Check that they are not kinked, twisted or plugged. Disconnect the sampling probe to see whether the problem is connected with it, or persists. 1) If the probe is disconnected, the message is no longer active: Check that the sampling tube is not crushed by an external mass. Clean the probe and the flexible sampling tube with compressed air in accordance with paragraph I ) If the probe is disconnected, the message remains active: Check the flow with a flowmeter. If the flow is between the minimum flow and the nominal flow, it is necessary for Maintenance to open the machine to check the pressure switch and if necessary calibrate it using a pressure sensor at a trigger pressure of 160 mbar, or even to replace it. 57

58 If on the other hand the flow is outside the acceptable range indicated at the rear of the machine, it is necessary to open the machine to check what, in the pneumatic circuit, is reducing flow. If no flexible tube seems twisted, kinked or plugged, check the electrovalves and finally replace the pump diaphragms if necessary. II.7.9. Out of paper Put in a new ream of paper in accordance with paragraph I.4.2. II Lever open : The printer thermal lever is open. II PB IMPR Printer fault, save the error code and call maintenance. II HC residue in gas inlet When a measurement is carried out on ambient air, if the CO 2 concentration is below 2% by volume for more than twenty seconds while the HC measurement gives more than 20 ppm, it is assumed that hydrocarbon residues are present in the inlet tract. These residues may also be in the ambient air. One must therefore ensure that the work area is well ventilated. It may be necessary to clean the probe. If the problem appears again, clean the separator. If the HC measurement drops back to a level below 20 ppm for more than 20 seconds, this message disappears, a zero operation is carried out and the message measurement in progress appears. II com. error Check that the device is grounded. Extensions for the power supply cable are absolutely required to include a ground connector as well as the power supply plug. Communication between the main card and the test set is defective. First, check that the power supply and communication cables are correctly connected and that the happy LEDs are blinking. Connect the infrared set to 58

59 a computer and check that it is communicating correctly with the maintenance program. Next, check that at the Tx pin of the main card, a signal is regularly transmitted. Depending on the problem encountered, replace the defective component. II Adjustment necessary Call Maintenance; adjustment with the help of a calibration gas is necessary. This message indicates excessive drift in the machine. II Change O2 sensor During a zero operation, the system associates the oxygen concentration in air (20.9%) with the corresponding potential at the terminals of the oxygen sensor. This potential must lie between 2.15V and 1.95V. If the potential is not in this range, the message Change O2 sensor appears. This means that the oxygen sensor is defective or incorrectly connected. Replace it and follow the procedure indicated by the analyser. II Condensation: wait This message may appear during the start-up phase. In this case, one need only wait for the machine to be warmed up and ready to carry out measurements. If on the other hand this message appears in the course of a measurement and persists, it is necessary to carry out a check of the following points: Check that the separator is correctly connected. Check the flow at the condensate exhaust connector. Check the internal parameters in the maintenance menu. Perform a leak test. Depending on the results obtained, notify Maintenance, which will undertake the replacement of the defective part. 59

60 II Heating problem If the estimated start-up time of the machine (elapsed time between the time the machine is turned on and the time when measurements are possible) is greater than 15 minutes, this message appears. If the temperature is below 5 C, it is necessary to move the machine to a less cold space and restart it. II Other : a) RPM out of range This is manifested on screen by a ---- display. If this message appears, it means that the measurement of operating speed is greater than 9999 rpm. Check that in the Operating Speed menu, the correct sensor has been chosen and the information concerning the engine to be tested are correct and have been entered. b) TMP. Out of range This is manifested on screen by a ---- display. If the ambient temperature is less than 0 C or if a measurement is in progress on a vehicle, this means that the measured value is outside the range C. If neither of these is the case, check that the oil temperature probe is correctly connected to the connector assigned to it. If this is not the case, replace the sampling probe. 60

61 III. THE OPACIMETER: (DIESEL VEHICLES) 61

62 III.1. PRINCIPLE OF OPERATION In the composition of the exhaust gas emitted by diesel engines, the pollutant component is considered to be carbon in suspension. A polluting vehicle emits on acceleration a puff of gas that is darker (and thus more opaque) than a vehicle in good condition. The partial flow opacimeter is used to establish a measure of this phenomenon based on a given unit of measure, the K(m -1 ). The principle of opacity measurement is the following: a beam of light (emitter aimed at a receiver, with a constant distance between the two) is passed through a sample of gas. The fraction of incident light which reaches the receiver is inversely proportional to the concentration of particles in suspension in the gas. The measurement obtained is digitally corrected. The opacity of a vehicle is the maximum opacity value measured during acceleration. Several accelerations are needed to obtain a reliable measurement. The number of accelerations to be carried out for the opacity measurement of a given vehicle is defined by standard NF R Emitter 2- Receiver 3- Chamber temperature sensor 62

63 4- Heating elements 5- Gas temperature sensor 6- Gas inlet 7- Measurement chamber 8- Exhaust fan F unctional schematic of the measurement chamber. The opacimeter depends on the interactive operation of two sub-systems. The first is composed of the cell. This is what establishes the opacity measurement. The electronic system of this cell contains a microprocessor which makes it possible, on the basis of several temperature and pressure sensors, to regulate the system, to detect bad operating conditions and to correct the measurement. All this information is directly taken into account by the central unit which is responsible for detecting maximum opacity, displaying the results on an LCD screen, printing to a thermal printer or an external A4 format printer and guiding the operator throughout the procedure. According to current regulation, the periodic testing of opacimeters is not compulsory. These devices, may, however later become subject to this type of inspection. All the devices manufactured under reference number CAP3201 have been subjected after manufacture to a test that verifies the correct operation of the device and the validity of the measurement. 63

64 III.2. OPERATING CONDITIONS The opacimeter automatically checks the parameters that have an influence on the measurement. If at least one of these parameters is out of bounds, hence threatening to metrologically alter the results, the opacimeter disables itself and prevents any measurement from occurring until operating conditions have been reestablished. The following problems result in the system being disabled: Detector temperature out of bounds (limits extending from 41 C to 55 C) Chamber temperature out of bounds (limits extending from 70 C to 110 C) Supply voltage out of bounds Fan speed too low (limits extending from 2100 rpm to 2900 rpm) Computer to cell communication problem Windows need to be cleaned Problem with a temperature sensor 64

65 III.3. TECHNICAL CHARACTERISTICS Power supply: 1,5 A / 115 VAC 0,9 A / 230 VAC (+10%-15%) Hz (+-2%). Effective length of the measuring chamber: 215 mm cm. Preheating time: from 3 to 6 min depending on ambient temperature. Zero adjustment and calibration before use: automatic. Control of zero adjustment: automatic by electrical filter centred at 50%. Ambient temperature range for operation: +5 to +40 C. Humidity: 30% to 90%. Storage temperature: -32 C to +55 C. Measurement range of the measured value: Opacity: 0.00 to 9.99 m -1. Resolution 0.01 m -1. Maximum relative error: Under standard conditions (temperature +20 C, atmospheric pressure 1013 hpa, relative humidity 60% +/-15%), opacity error below 0.15 m -1. Measurement range of influencing factors (which allow correction of the opacity value): Temperature of the gas being measured: C (resolution 1 C) Physical response time 10% to 90%: less than 0.2 sec. for gas at 75L/min. Electrical response time: 0.9 sec. 65

66 III.4. INSTALLATION AND PRECAUTIONS DURING OPERATION III.4.1. Installation, start-up : Each CAP3201 is inspected before delivery by a representative of the measuring instruments service, who affixes a stamp mark on the plate attached to the rear of the machine. Check that the opacity cell is correctly connected to the station and connect it to the 230 VAC 50 Hz mains. Press the Stop/Start switch on the station. Press the Stop/Start switch of the cell. III.4.2. Cleaning and precautions during operation The opacity gauge is designed to function without maintenance. The only components requiring periodic maintenance are certain components of the cell. Occasionally, large carbon particles enter the chamber while the engine is being tested. The great inertia of these particles will cause them to be thrown against the windows located on either side of the chamber. A periodical monthly inspection is recommended to determine whether the two windows have an excessive coating. A carbon deposit may also be deposited in the measurement chamber. It is sufficient to sweep out the tube to eliminate the soot using the brush supplied with the opacimeter. Where the windows are concerned, a dry cotton rag is the proper tool for cleaning these two surfaces. DO NOT USE ANY CLEANING FLUID. It is not necessary to open the cell to carry out these maintenance operations. 66

67 III.5. OPACITY TESTING PROCEDURE This procedure allows a determination, for a given vehicle, of whether or not its opacity is lower than the current limit. S M O K E M E T E R O P A C I T Y C H E C K O F F I C I A L T E S T O P A C I T Y A N A L Y S I S Select in the main menu the opacimeter application, then the opacity testing procedure. A series of phases will then take place in sequence. It is important to follow the instructions just as they appear on the screen and to observe the directions in the user manual. III.5.1. Client information entry As soon as the test procedure is launched, the user may, if he wishes, enter information about the client and his car (name of client, make, mileage and registration number). These data will then appear on the test report. The client entry procedure is the same as for the garage header (voir paragraphe V.3). The entry window with keyboard option appears this way: C U S T O M E R : G A S A N A L Y S I S V E H I C L E : P L A T E : M I L E S : N O T E S : 67

68 III.5.2. The engine : The software then asks you about the type of engine to be tested. This lets it know the limit of opacity that may not be exceeded. O P A C I T Y C H E C K A T M O S P H. V E H I C L E T U R B O V E H I C L E First, it asks you whether the vehicle has a naturally aspirated engine (maximum authorized limit = 2.5 m -1 ) or a turbocharged engine (permissible limit = 3 m -1 ). Select the corresponding type using the UP arrow and the DOWN arrow and confirm the selection using the OK key. III.5.3. Description of the graphic interface: T U R B O V E H I C L E O P A C I T Y R P M Current opacity Tachometer Oil temperature GAS O I L Gas temperature Interval timer Message box This graphic interface is composed of several elements: The tachometer: 68

69 The tachometer reading may run from 0 to 9999 rpm. In addition, a graphic element allows the trend in engine operating speed to be quickly visualized. Only one of the sensors allowing the engine speed to be acquired is needed for reading the rotation speed (in revolutions per minute), see paragraph IV The oil temperature: The oil temperature gauge has been installed in the vehicle s oil dipstick well for the preliminary phase. The user can therefore monitor this temperature in the window provided for this purpose. Current opacity: This value constantly shows the current opacity; it is expressed with two opacity units. One is given per meter (m -1 ) and the other in percent. In addition, a graphic element allow rapid visualization of opacity between 0 and 99.9%. The message box: It directs the operator through the procedure. Messages displayed here are of two types: Error messages. Every detected error or timeout results either in cancellation of the procedure or invalidation of the free acceleration. In one case, the message window contains the type of error that caused the problem. Explanatory messages. During the procedure, several different phases follow one another in sequence. The message window indicates to the operator what he must do and what the opacimeter is doing. This allows easy understanding of the procedure and gives effective guidance to the operator. At any moment in the procedure, press DYS if you detect the slightest problem regarding the control of engine speed or a leak in the exhaust line. You can print a test report with the annotation unacceptable result. The «operating speed mode» key: Allows the operating speed mode to be selected depending on the sensor type used at the input (see paragraph III.5.2.). 69

70 The print key: This key allows the results to be printed or transferred to a central computer in a technical testing centre for example. III.5.4. Displays the selected operating speed mode: Each time the opacity program is launched, the operator knows the operating speed mode that is selected; he may therefore change this mode by pressing the key or leave it in the displayed mode. 70

71 Organization chart: MEASURE IN PROGRESS RPM touch YES YES Display the rpm mode in progress 3 s Induction Induction/2 3 s 3 s Initialization RPM touch Piezo 3 s E.O.B.D. 3 s TTL 3 s Battery 3 s Cylinder number? 71

72 Induction : Sensor operation: The induction clip allows detection of the moment that ignition occurs in a cylinder. Placed around the ignition lead of a cylinder, it generates a signal by inductive effect at the moment of ignition. At the rate of one spark per revolution for 2-stroke engines and 1 spark for two revolutions when a 4-stroke is involved, the induction clip allows the operating speed of a petrol engine to be measured. Connect the induction clip cable to the CAP3201 input connector for the induction clip (an icon indicates its location), then selection the induction mode using the operating speed key. The operating speed display appears automatically. Induction/2 : The procedure is identical to the preceding one, only the value is divided by two. Piezoelectric : Sensor operation: The piezoelectric sensor allows detection of the moment of injection on a diesel engine. Placed around an injection tube, it detects the dilation caused by the variations of internal pressure caused by injection. The electric signal supplied by the sensor allows the operating speed of a diesel engine to be measured (one dilation of the tube for two engine revolutions). Procedure: STEP ACTION COMMENT 1 Clean the injection tube locally with sandpaper. 2 Place the piezoelectric sensor on the cleaned part and tighten it firmly by hand. Connect the cable to the sensor. Ensure that the piezoelectric sensor is of the same diameter as the injection tube. All diameters are available as options. 3 Connect the ground clamp, preferably to the same tube. The tachometer is installed and it should be possible to read the operating speed of the engine on the screen. Note: We recommend that the tachometer, when it is used, be connected at the beginning of the test, that is before launching the testing or opacity value measurement procedure. 72

73 Connect the sensor cable to the CAP3201, then select the piezo mode using the operating speed key. The operating speed display appears automatically. E.O.B.D. : This mode allows the engine speed to be read from the data sent to us by the computer on board a vehicle (see part V). This option consists of an electronic card installed inside the CAP3201. All vehicles equipped with E.O.B.D. have operating speed readout. Connect the cable to the vehicle s computer; the plug provided for this purpose is usually located near the fusebox. Then connect the other end to the CAP3201. Select, using the operating speed key, the E.O.B.D. mode. The display appears automatically. TTL : This mode makes it possible to read an engine speed sensor with a TTL output. Connect the cable to the induction clip input of the analyser. Select, using the operating speed key, the TTL mode. The display appears automatically. Battery : The battery option is composed of an electronic card installed inside the CAP3201, a cable for data and for power supply from the cigarette lighter to the case, and a cable for data and for power supply from the battery. This option is a battery-driven tachometer which allows operating speed to be measured on all vehicles - petrol, diesel and LPG. Connect the cable on the CAP3201 (RPM BAT); select the battery mode using the operating speed key. After three seconds, the operator must choose and confirm the number of cylinders. If the battery cable is correctly connected, the system carries out an initialization phase. After this phase the operating speed is displayed. ATTENTION: In the event of a problem, the headlights of the vehicle should be turned on, and everything else shut off. See section VI. III.5.5. Detecting the cell At the beginning of the test, the presence of the cell is verified. After a few seconds, the cell is detected. If the contrary is true, the following message is displayed: C O M M U N I C A T I O N P R O B L E M P R E S S E S C T H E N R E S T A R T In this case, check whether the cell is plugged in and properly connected. 73

74 III.5.6. Auto-zero and error checking Following the phase which consists of preparing the vehicle for measurement and ensuring that it is operating correctly, the opacimeter needs to perform an autozero. This is an internal procedure in the measurement cell that allows it to calculate the sensitivity of the detect such that an invisible gas is assigned an opacity of 0.00 m - 1. This procedure is carried out automatically; it is vital, however, to check the following point: DURING THE AUTO-ZERO OPERATION, THE SAMPLING PROBE MUST NEVER BE INSERTED INTO THE EXHAUST LINE OF A RUNNING ENGINE. Before this procedure is launched, a general check of all the parameters of the cell is automatically carried out. Three cases could then occur: 1 ) The opacimeter was just started and the preheating phase is still active. In this case, it is necessary to wait for the measuring chamber to reach its operating temperature. A message to this effect is displayed on the screen: It provides information on the progress of the percentage of preheating of the cell. W A R M U P = 9 0 % 2 ) The opacimeter refuses to operate because it has detected an error or a breakdown. These errors are listed in III.8.1. For certain errors, it is possible to recover by carrying out the prescribed operations (cleaning the measurement cell windows, for example); for others, action by the Maintenance service is required. 3 ) The opacimeter is ready. The auto-zero operation will take place as soon as the opacimeter is assured of the normality of its current condition. During auto-zero, this message will be posted on the screen. Z E R O I N P R O G R E SS P L E A S E W A I T The auto-zero operation is a procedure which, taking ambient air as a reference, establishes the signal levels for zero opacity. It is therefore important not to put the measurement probe into the exhaust line before the software requests it. 74

75 III.5.7. Insertion of the probe and sensors Once the auto-zero operation is carried out, the following messages appear on the screen: I N S E R T T H E P R O B E I N T O T H E E X H A U S T I N S T A L L T H E O I L T E M P E R A T U R E S E N S O R C O N N E C T T H E T A C H O M E T E R Now is the time to put the sampling probe, the oil temperature sensor and the tachometer in place: III The probe: To do this, move the cell near the exhaust pipe outlet. The probe must be inserted to a depth at least equal to 5 cm. If the layout of the exhaust line allows it, it is preferable to insert it as deep as possible. Ensure that the probe is not kinked, which might alter the flow of gas arriving at the measuring chamber. pipe. The sliding clip on the probe allows the probe to be affixed to the exhaust Only the original probe, bearing the CAP10 reference label, allows valid results to be achieved. This probe may not be extended or modified. III The oil temperature sensor: It is necessary to insert the oil temperature sensor in the dipstick tube. Do not insert the probe too deeply. One solution consists of adjusting the rubber stopper on the probe so as to insert the probe to the same depth as the dipstick. III Connecting the tachometer: See paragraph (III.5.2.) 75

76 After inserting the probe and the sensors, with the engine still running, it is necessary to notify the opacimeter that all is ready. To do this, press the OK key to move on to the following phase. III.5.8. Preliminary checks Before undertaking any measurement, the operator must satisfy himself that the engine is operating correctly. Opacity measurement being a rather demanding procedure for the engines, it is imperative that this step be carefully followed to avoid engine damage and to obtain a valid opacity measurement. If an obvious malfunction is detected on the vehicle, press the MAL key. This will have the effect of rejecting the vehicle test and printing a test report specifying that the vehicle cannot be checked due to its poor condition. The following points are to be observed: The vehicle exhaust line must be gas-tight. This check can be carried out by partially blocking the exhaust while the engine is at idle. No leak must be observed. The gearbox must be in neutral, with the clutch engaged, for vehicles with manual or semi-automatic transmissions; the selector should be in neutral for vehicles with automatic transmissions or in accordance with the instructions of the vehicle manufacturer. Accessories and optional equipment that influence the engine speed at idle must not be activated, barring manufacturer s instructions or regulation to the contrary. The engine must be at normal operating temperature, that is with an oil temperature at least equal to 80 C. To satisfy this preliminary check, the following page is then displayed: W A I T F O R O I L > 8 0 C The opacimeter may be configured in what is called the P.L. mode (see Configuration - opacimeter). One can then move on to the following phase without having to 76

77 perform an oil temperature measurement or even connecting the probe. Simply press the OK key to escape this blocking phase. In this mode, the following message is activated: O R P R E S S O K In the so-called V.L. mode, required for technical inspections, oil temperature measurement is indispensable. No test can be carried out as long as the probe has not reached a temperature of 80 C, the oil temperature at which the engine is considered to be at its operating temperature and in no danger of deterioration during the test procedure. If, for certain vehicles, the manufacturer recommends a higher temperature, it is necessary to wait for this temperature to be reached before carrying out the first acceleration. On the page, the oil temperature is displayed. It must increase while the engine is running and reach 80 C after a certain time. If this is not the case, check that the probe is correctly inserted and in contact with the engine oil. This page also contains a tachometer window (located at the upper right). III.5.9. Conditioning the engine: Faced with this message, the operator has ten seconds or so to get into the vehicle, and is charged with carrying out the two preliminary phases of the procedure: vehicle. 1 ) Establish a preliminary check to verify the correct operation of the C H E C K G O V E R N O R O P E R A T I O N 2 ) Test governor operation for one minute. For a period of 60 seconds, the engine governor operation must be checked in the following manner: Check the normality of no-load governor operation by carrying out a series of accelerations, step by step, up to the governing level given by the vehicle manufacturer. If the duration of the check of the normality of no-load governor operation is less than 60 seconds, the balance of the time must be used to maintain the engine at a 77

78 stabilized operating speed around 40 to 60% of the maximum no-load speed, or approximately: rpm for a vehicle with an authorized gross weight less than 3.5 T; rpm for a vehicle with an authorized gross weight greater than 3.5 T; It is recommended to use the tachometer to reliably check engine governor operation. The operator must follow along with the following messages: A C C E L E R A T E S T E P B Y S T E P G O T O M A X S P E E D M A I N T A I N S P E E D A T 5 0 % O F M A X This vehicle preparation is indispensable; it may not be skipped. III Free acceleration Definition according to standard NF R : Acceleration achieved, with the engine initially at idle, by rapidly but not violently operating the accelerator control in such a way as to obtain maximum injection pump output. This position is maintained until the maximum operating speed of the engine is attained and the governor goes into action. The accelerator must therefore be pushed down all the way in order to advance from idle speed to maximum speed in the shortest possible time. This operation is an essential feature of the procedure, since the opacity that is recorded is the maximum opacity measured during free acceleration. In order to obtain a valid measurement, it is indispensable to undertake this operation so that the opacity is a maximum (maximum injection pump output). It is possible to detect that maximum speed has been reached, either by ear or using the tachometer. The pedal is then released to return to idle speed. As soon as free acceleration is to be carried out, messages indicate when to accelerate and when to release the accelerator pedal. The software analyses the opacity curve recorded during free acceleration to detect its maximum and establish the validity of the acceleration. 78

79 III Two non-measured accelerations in succession A series of two accelerations will now be requested. The following screen appears: C L E A N O U T N o 1 Faced with this screen, the user must push the accelerator down all the way. The following message should then appear: C L E A N O U T I N P R O G R E S S After a few seconds the following message appears: R E T U R N T O I D L E The operator must release the accelerator pedal so that the engine speed returns to idle speed. This operation is requested once again. These two accelerations are indispensable for cleaning out the exhaust system and thus avoiding excessive and meaningless opacity measurements. Two accelerations not counting toward the test are therefore carried out, and we move on to the test proper. III Opacity measurement phase After the engine preparation phase, the operator is now occupying the driver s seat of the vehicle. He now had nothing to do but concentrate on the message box, which dictates to him when to press the accelerator pedal and when to return to idle. Depending on the vehicle and the results, the operator will need to carry out two to five accelerations. The opacity of each acceleration is displayed on the left side of the page (the window assigned to the first acceleration being named K1, that assigned to the second called K2 and so forth). 79

80 III Display of the results of each acceleration The acceptance decision is made in the following manner: If the result of the two accelerations is below the current limit (2.50 m -1 for naturally aspirated engines and 3.00 m -1 for turbocharged engines), the procedure is terminated and the vehicle is accepted. Likewise, if the results are 1.5 times higher than the limit, the vehicle is rejected. Otherwise, 3 more accelerations are carried out and the results compared to the current limit. The result is considered acceptable if the mean value obtained is below the limit. Again, the operator has no calculation to perform and need only concern himself with responding to the orders given him by the software. If the result given by this procedure judges the opacity of the vehicle to be unacceptable, the vehicle will have to be subjected to the opacity value determination procedure (see paragraph IV.5). When the test is finished, the user may print or transfer the report by pressing the key corresponding to the icon. A new message appears: F 1 : P R I N T F 2 : T R A N S M I T It indicates whether the user wishes to print a report (F1) or transfer the same to a central data store (F2) or return to the previous message (ESC). 80

81 III Printing results III Measurement to standard M A L F U N C T I O N O F T H E V E H I C L E U N A C C E P T A B L E R E S U L T U nacceptable result case, due to o bvious malfunction A c c e ptable result case U nacceptable result case Indications on the printout ticket : - Garage header, - Customer informations, - Date/time, - type (PL or VL), - The procedure name, - If the measurement is in conformity with the standard (NFR ), - Serial number, 81

82 - Oil temperature information, - The engine (atmosphéric or turbo), - Opacity limit, - Speed engine min./max, - Oil temperture max., - Results, - the decision concerning acceptance of the vehicle. Finally, if the result of an acceleration is shown in the form -.--, it means that the acceleration was not detected. III Measurement not to standard When a free acceleration is carried out and the temperature of the gases entering the chamber is less than 40 C, the measurement is considered not to standard. The measurement is not rejected and the result is given for the sake of information. 82

83 R E S U L T FOR INFORMATION R E S U L T FOR INFORMATION The test report indicates that the measurement is not in conformity with the standard (NFR ) and that the result displayed is for information only. In the ticket examples, the absence of a cross in the third column of the measurement table indicates that the temperature is below 40 C... 83

84 III.6. OPACITY VALUE DETERMINATION PROCEDURE This test must be performed on vehicles whose results from the opacity check procedure have been judged unacceptable. It repeats the same steps as the opacity check procedure. This procedure, however, is longer but more accurate in that the number of free accelerations may go as high as 16 and measurements are taken into account only when the results of successive free accelerations are stabilized. This test is identical to the opacity check procedure, but conditions for termination are different and free acceleration results start to be processed beginning with acceleration number 4. The software continues to order free accelerations as long as the results of successive accelerations do not converge to a stable value. If after 16 accelerations the values are not stable enough, the procedure stops and indicates unstable opacity. O F FII CII A L T E S T O P A C I T Y R P M GAS O I L The UP and DOWN arrows allow scrolling of values when there are more than 5 of them. All the other buttons have the same characteristics as in the opacity check procedure. 84

85 U N S T A B L E O P A C I T Y T he machine gives the arithmetic m e an of the last four accelerations. T he values have not stabilized after 1 6 acceleration; the machine indicates unstable opacity. T he values have not stabilized after 1 6 acceleration; the machine indicates unstable opacity. What is m o r e, the accelerations have a gas temperature <40 C, hence the r e s ult is only for information. Indications on the printout ticket are identical to the opacity control procedure; only the termination criteria are different. 85

86 III.7. OPACITY ANALYSIS This page is dedicated to the repairman who wants to analyse the opacity curves of a vehicle without the constraints of the official procedure. O P A C I T Y A N A L Y S I S GAS O I L R P M Enable/Erase: Press K1 and/or K2 to enable. When an acceleration is detected, the curve is drawn on the screen. To erase curve 1 and/or 2 simply press ERA K1 or/and ERA K2. To draw a new curve, enable again. Print: Printing the opacity curves. Auto-zero: Recalibrates the instrument; the probe must not be in the exhaust when the function is requested. Operating speed mode: Allows the operating speed mode to be selected depending on the sensor type used at the input (Voir paragraphe III.5.2.). 86

87 III.8. OPACIMETER MESSAGES III.8.1. III Error messages «Zero in progress» This message should disappear after a few seconds at the end of the autozero operation. Maximum duration, 4 seconds. It is not an error; it means that the procedure for resetting opacity to zero is in progress. Wait. III «Mains voltage out of bounds» The cell input voltage should be between 195 and 253 VAC. Beyond that, the cell cannot operate correctly. Have the mains power checked. III «Windows dirty» You must shut off the machine and proceed with cleaning the cell lenses as described in the maintenance chapter of this manual. III «Fan is defective» The air flow system is unable to ensure a constant effective length. Call the Maintenance service. III «EEPROM out of service» This should not appear. Call Maintenance, which will come and reinitialize your cell. The measurements carried out are not valid. III «Sensor problem» A temperature sensor is defective; call the Maintenance service. 87

88 III «Preheating» Tube temperature must be 80 C. It is therefore necessary to carry out a warmup operation which varies from 3 to 6 minutes in length. III «Detector temp. out of bounds» The temperature of the optical detector must be between 25 ºC and 45 ºC. After a preheating period, this error resolves itself. Wait. III «Time exceeded» If no acceleration was detected within the prescribed interval, this message appears. III «Probe connected?» This message appears right after the preceding one, because in general nondetection of an acceleration is caused by an incorrectly inserted probe. III «Measurement invalid» The opacity curve contains several peaks, making it impossible to determine opacity. Use more vigorous foot pressure on the accelerator. III «Press ESC and start again» This message appears when an error threatens to impede the proper operation of the test. The test in progress is therefore interrupted, and it is necessary to quit the test by pressing ESC, then start over. III.8.2. User guidance messages III «Acceleration No. X» This message indicates the beginning of a new acceleration. 88

89 The user must therefore push the accelerator pedal all the way down as soon as this message is displayed. III «Measurement in progress» Acceleration has been detected; the accelerator pedal must be kept pushed to allow acquisition of opacity during the current acceleration. III «Return to idle» Starting with this message, the accelerator pedal must be released and the cell sends to the central unit information on the vehicle s opacity. 89

90 IV. OBD SCANTOOL On Board Diagnostic or Universal on-board diagnostic reader 90

91 IV.1. GENERAL The Scantool is a tool allowing access to the internal data of on-board systems. It connects to the OBDII autodiagnostic plug (SAE J1962 standard) of the vehicle and scans the information stored in memory or current data made available and accessible by one of the 5 standardized protocols. - ISO (SAE J1850) at 41.6 Kbps PWM (FORD). - ISO (SAE J1850) at 10.4 Kbps VPW (CHRYSLER- GM). - ISO at 10.4 Kbps (European vehicles). - ISO to 10.4 Kbps or Keyword 2000 (CAN equipped vehicles). - CAN (Controller Area Network; Keyword 2000 layer) (system which will be applied generally to European vehicles in the coming years). Since 1 January 2000, all petrol vehicles sold in Europe must compulsorily be equipped with an on-board computer controlling engine and drivetrain operation and capable of communicating its internal information to diagnostic devices according to at least one of the 4 protocols cited earlier. The European Directive aims to universalise access to information necessary for repair. This concept answers to the name of EOBD (European On Board Diagnostic). This technology is already implemented on American (Ford, GM, Chrysler) and Asian (Honda, Toyota, ) vehicles. European makes are the last to benefit from these functions. Since 1 January 2000, costly and manufacturer-specific equipment is obsolete. The same is true for the cartridge-based multi-brand systems. IV.2. PRINCIPLE The Scantool is not a measuring instrument. All information displayed on the screen is only information transmitted by the computer. Information available varies according to each model. Connected to the vehicle, the Scantool asks questions of the computer and displays the answers. Answers are information which can be classified by family: Fault codes stored in memory (injection, emission test, air conditioning, brakes, gearbox, body, chassis, network ), Codes for current faults, 91

92 Current measurements, Fixed arrays (snapshots of internal measurements at the time a fault occurs), Data on oxygen probes (measurements on lambda probes), Specific internal data (air conditioning, ABS, passenger cabin, engine and drive train control peripherals not provided for in the standard, ex. anti-slip control), Test procedures, Reinitialization procedure (erases faults stored in memory, turns off indicator lights on the dashboard and resets the oil change indicator to zero), Vehicle information (serial number, model,...) IV.3. MEASUREMENT AND TESTING IV.3.1. Connection The Scantool connects directly to the EOBD connector of the vehicle. This connector allows communication with, and power supply to the computer. Generally this connector is located under the dashboard on the driver s side, in the glove compartment or under the main ashtray. It is therefore easy to make measurement while staying, the Scantool in hand, inside the vehicle. This is especially appreciated in the context of measurements carried out on the road. Attention: Certain vehicles manufactured between 1996 and 2000 are equipped with this connector. Everything appears to show that they are equipped with OBD. That is not so. For a vehicle bought in France before 2000, only those of VOLVO brand as well as imported American vehicles satisfy this standard. 92

93 IV.3.2. IV EOBD data Measurements a) Service 01 Current measurements This service gives access to current measurements carried out by the computer on the engine/drive train assembly, the digital inputs and outputs and the system states. A number, called PID, is associated with each type of measurement. For each measurement that is available, the screen displays: - the PID, - the value, - the unit of measure (if required), - the measurement heading. model. The list of measurements displayed depends on the individual vehicle b) Service 05 Lambda probe measurements and testing This service gives access to all the oxygen probe parameters. For systems with several lines or with several sensors per line, it is necessary to select from the list the sensor that is to be checked. The values measured correspond to the following information relating to the oxygen probe signal. [Insert Lambda probe diagram...] IV Fault codes a) Service 03 Fault codes stored in memory This is the most complete service Destined for the long term to replace emission test checks in technical inspections, the OBD is an on-board computer that constantly 93

94 analyses the operation of the engine. At the slightest anomaly, the OBD system detects the source of the malfunction, establishes a diagnostic procedure and determines the most representative fault code. This fault code is stored in the computer s memory. Service 03 allows reading and display of fault codes stored in memory in the computer. When a fault code is in memory, an indicator (MI) lights up on the dashboard. Reading a fault code never erases it from memory. To erase a fault code after display, use service 04 (Erase / reinitalize computer). It is possible that the computer might have a code still in memory even thought the fault is no longer present (fault due to particular conditions, repair completed). The fault codes taken from the EOBD standard are limited to monitoring engine and drive train operation or any component capable of generating pollution in the event of a malfunction. In the long term, the European program seeks to replace current emission test checks by a simple readout of fault codes from memory, a vehicle without functional faults stored in memory being a vehicle that does not pollute. It is recommended that the description of a fault by the OBD system not be taken literally. In fact, a fault on a given sensor could be generated by several types of trouble. These faults are not always linked to the sensor itself: - Problem in the circuit connecting the sensor to the computer, - Electronic fault at the signal conditioning stage, system. - Out of bounds measurement due to a problem not upstream of the b) Service 02 Fixed arrays This service allows access to fixed arrays. A fixed array is a snapshot of current measurements or of a part of the current measurements at a given moment. Very generally, a fixed array may be stored in memory when a fault code is generated following a malfunction. Thus, this allows the conditions under which the problem appeared to be known. 94

95 Ex.: Readout of the fault codes displays the following message: P0302 Ignition misfire detected, Cylinder 2 After becoming aware of this problem, I will read the fixed array associated with it. I will for example be able to say that the ignition misfire took place at 195 km/h and that the engine was running at 4,200 rpm. This service is particularly valuable when an intermittent fault is involved. It thus allows knowledge of the conditions under which the fault occurred. Storage of a fixed array in memory does not occur systematically every time a fault code is stored in memory. c) Service 07 Current fault codes For certain malfunctions, the computer decides to generate a fault code in memory if this fault persists through several driving cycles. Service 03 gives access to persistent faults, while service 07 gives a list of malfunctions that are active at the moment the request is made. This service is particularly helpful for car mechanics. In fact, after repair and erasure of the fault codes, it is possible for him to verify that the malfunction is no longer present and that the problem is resolved. If the problem continues to persist, its fault code is displayed by this service. If, after two driving cycles, the fault code is still active, the MI indicator lights up and the fault code is stored in memory and thus becomes accessible to service 03. d) Service 04 - Erase / reinitialize computer When a fault is in memory, the repairman must attempt to determine the source of the fault and repair it. Once he thinks he has resolved the problem, it is imperative that he erase the fault in memory, because repairing a malfunction never erases the fault code in memory that is associated with it. Service 04 is responsible for carrying out this memory cleaning operation. 95

96 After launching this service, it is advisable to check that the faults have been erased from memory by returning to the preceding service. IV Tests not continuously performed a) Service 08 - Launching a specific test procedure Certain components are not continuously monitored. Verification of the correct functioning of such systems can only be carried out by launching a test using the diagnostic tool. This test will be launched by the user and will stop by itself. At present, only the emission vapour leak test is available. Early addition of a catalyst test is planned, but this function will be the subject of a future update. b) Service 06 - Systems not constantly monitored This service has the purpose of displaying the results of monitoring tests by the on-board diagnostics of specific components/systems which are not continuously monitored (these tests are activated by the service). The results of the tests are displayed without interpretation. In fact, the information is specific to each vehicle. It is therefore necessary to obtain information from a database or from the manufacturer to understand these results. IV The information a) Service 09 Information about the vehicle This screen gives access to all information relative to the vehicle (VIN, calibration identification, CVN ). b) Computer information This screen gives complete information on the type of computer providing the OBD function. It provides information on the type of OBD (American, European, Asian) and the type of protocol, as well as the functions that are provided because an OBD system cannot provide the full range of measurements described in this manual. 96

97 IV The full report This function gives a complete diagnostic on the vehicle in less than 1 minute. It is only necessary to be connected to a computer or a printer and to launch the test. The CAP4100 will extract the full set of information and send to the printer or computer all that is made available by the computer. IV.3.3. Printing results key. It is possible to print what is on the screen at any time by pressing the print 97

98 IV.4. LIST OF DATA IV.4.1. List of available measurements in the table «current measurements» and «freezed frame». Number of function Measurement unit Measurement name $01 Number of fault codes of the powerplant relative to the emissions $01 Active/Inactive Status of control systems $01 Active/Inactive Status of MI $02 Pxxxx Fault code which caused the storage of the required freezed frame $04 xxx.x % Calculated load value $05 xxx C Engine coolant temperature $06 xx.x % Short term fuel trim bank 1 $07 xx.x % Long term fuel trim bank 1 $08 xx.x % Short term fuel trim bank 2 $09 xx.x % Long term fuel trim bank 2 $0A xxx kpa Fuel pressure gauge $0B xxx kpa Intake manifold absolute pressure $0C xxxxx RPM Engine speed $0D xxx km/h Vehicle speed $0E xx.x Ignition timing advance $0F xxx C Intake air temperature $10 xxx.xx g/s Air flow rate from MAF sensor $11 xxx.x % Absolute throttle position $12 Commanded secondary air status $14-$1B x.xxx V Output voltage of the sensor 98

99 xxx.x % Long term fuel trim associated to sensor $1C OBD requirements to which vehicle is designed $1D Active/Inactive Location of oxygen sensors $1E Active/Inactive Status of the power take-off (PTO) $1F xx.xxx sec Time Since Engine Start $21 xxxxx Km Distance travelled while MI is activated $22 xxxx.xx KPa Fuel Rail Pressure relative to manifold vacuum $23 xxxxxx Kpa Fuel Rail Pressure $24-$2B xxx.xxx Equivalence Ratio (lambda) xxx.xxx V Oxygen Sensor Voltage $2C xxx.xxx % Commanded EGR $2D xxx.x % EGR Error $2E xxx.x % Commanded Evaporative Purge $2F xxx.x % Fuel Level Input $30 xxx Number of warm-ups since diagnostic trouble codes cleared $31 xxxxx Km Distance since diagnostic trouble codes cleared $4E xxxx hrs, xx min Time since diagnostic trouble codes cleared 99

100 IV.4.2. EXEMPLE OF DTC (DATA TROUBLE CODE) : The CAP4100 contains more than 3000 DTC. The following is a part of this DTC. Group of DTC #define P0xxx "- P0xxx Powertrain system groupings" #define P01xx "- Px1xx Fuel and air metering" #define P02xx "- Px2xx Fuel and air metering" #define P03xx "- Px3xx Ignition system or mifire" #define P04xx "- Px4xx Auxiliary emission controls" #define P05xx "- Px5xx vehicle speed, idle control, and auxiliary inputs" #define P06xx "- Px6xx Computer and auxiliary outputs" #define P07xx "- Px7xx Transmission" #define P08xx "- Px8xx Transmission" #define P09xx "- Px9xx Transmission" #define P0Axx "- P0Axx Hybrid propulsion" #define P10xx "- P10xx Manufacturer controlled fuel and metering and auxiliary emission controls" #define P11xx "- P11xx Manufacturer controlled fuel and air metering" #define P12xx "- P12xx Manufacturer controlled fuel and air metering" #define P13xx "- P13xx Manufacturer controlled ignition system or misfire" #define P14xx "- P14xx Manufacturer controlled auxiliary emission controls" #define P15xx "- P15xx Manufacturer controlled vehicle speed, idle control, and auxiliary inputs" #define P16xx "- P16xx Manufacturer controlled computer and auxiliary outputs" #define P17xx "- P17xx Manufacturer controlled transmission" #define P18xx "- P18xx Manufacturer controlled transmission" #define P19xx "- P19xx Manufacturer controlled transmission" #define P20xx "- P20xx Fuel and air metering and auxiliary emission controls" #define P21xx "- P21xx Fuel and air metering and auxiliary emission controls" #define P22xx "- P22xx Fuel and air metering and auxiliary emission controls" #define P23xx "- P23xx Ignition system or misfire" #define P24xx "- P24xx Auxililary Emission Controls" #define P25xx "- P25xx Auxiliary Inputs" 100

101 #define P26xx "- P26xx Computer & Auxiliary Output" #define P27xx "- P27xx Transmission" #define P29xx "- P29xx Fuel and air metering and auxiliary emission controls" #define P30xx "- P30xx Fuel and air metering and auxiliary emission controls" #define P31xx "- P31xx Fuel and air metering and auxiliary emission controls" #define P32xx "- P32xx Fuel and air metering and auxiliary emission controls" #define P33xx "- P33xx Ignition system or misfire" #define P34xx "- P34xx Cylinder Deactivation" #define U00xx "- U00xx Network Electrical" #define U01xx "- U01xx Network Comunication" #define U02xx "- U02xx Network Communication" #define U03xx "- U03xx Network Software" PRECISION : P0001 "Fuel Volume Regulator Control Circuit/Open" P0002 "Fuel Volume Regulator Control Circuit Range/Performance" P0003 "Fuel Volume Regulator Control Circuit Low" P0004 "Fuel Volume Regulator Control Circuit High" P0005 "Fuel Shutoff Valve Control Circuit/Open" P0006 "Fuel Shutoff Valve Control Circuit Low" P0007 "Fuel Shutoff Valve Control Circuit High" P0008 "Engine Position System Performance [Bank1]" P0009 "Engine Position System Performance [Bank2]" P0010 "'A' camshaft position actuator circuit [Bank1]" P0011 "'A' camshaft position - timing over - advanced or system performance - [Bank1]" P0012 "'A' camshaft position - timing over - retarded - [Bank1]" P0013 "'B' camshaft position actuator circuit - [Bank1]" P0014 "'B' camshaft position - timing over - advanced or system performance - [Bank1]" P0015 "'B' camshaft position - timing over - retarded - [Bank1]" P0016 "Crankshaft Position-Camshaft Position Correlation[Bank 1 Sensor A]" P0017 "Crankshaft Position-Camshaft Position Correlation[Bank 1 Sensor B]" 101

102 P0018 "Crankshaft Position-Camshaft Position Correlation[Bank 2 Sensor A]" P0019 "Crankshaft Position-Camshaft Position Correlation[Bank 2 Sensor B]" P0020 "'A' camshaft position actuator circuit - [Bank2]" P0021 "'A' camshaft position - timing over - advanced or system performance - [Bank2]" P0022 "'A' camshaft position - timing over - retarded - [Bank2]" P0023 "'B' camshaft position actuator circuit - [Bank2]" P0024 "'B' camshaft position - timing over - advanced or system performance - [Bank2]" P0025 "'B' camshaft position - timing over - retarded - [Bank2]" P0026 "Intake Valve Control Solenoid Circuit Range/Performance[Bank1]" P0027 "Exhaust Valve Control Solenoid Circuit Range/Performance[Bank1]" P0028 "Intake Valve Control Solenoid Circuit Range/Performance[Bank2]" P0029 "Exhaust Valve Control Solenoid Circuit Range/Performance[Bank2]" P0030 "HO2S heater control unit [Bank1 Sensor1]" P0031 "HO2S heater control unit low [Bank1] Sensor1]" P0032 "HO2S heater control unit high [Bank1 Sensor1]" P0033 "Turbo charger bypass valve control circuit" P0034 "Turbo charger bypass valve control circuit low" P0035 "Turbo charger bypass valve control circuit high" P0036 "HO2S heater control unit [Bank1 Sensor2]" P0037 "HO2S heater control unit low [Bank1 Sensor2]" P0038 "HO2S heater control unit high [Bank1 Sensor2]" P0039 "Turbo/Super Charger Bypass Valve Control Circuit Range/Performance" P0040 "O2 Sensor Signals Swapped Bank 1 Sensor 1/ Bank 2 Sensor 1" P0041 "O2 Sensor Signals Swapped Bank 1 Sensor 2/ Bank 2 Sensor 2" P0042 "HO2S heater control unit [Bank1 Sensor3]" P0043 "HO2S heater control unit low [Bank1 Sensor3]" P0044 "HO2S heater control unit high [Bank1 Sensor3]" P0045 "Turbo/Super Charger Boost Control Solenoid Circuit/Open" P0046 "Turbo/Super Charger Boost Control Solenoid Circuit Range/Performance" P0047 "Turbo/Super Charger Boost Control Solenoid Circuit Low" P0048 "Turbo/Super Charger Boost Control Solenoid Circuit High" P0049 "Turbo/Super Charger Turbine Ovespeed" 102

103 P0050 "HO2S heater control unit [Bank2 Sensor1]" P0051 "HO2S heater control unit low [Bank2 Sensor1]" P0052 "HO2S heater control unit high [Bank2 Sensor1]" P0053 "HO2S Heater Resistance [Bank 1 Sensor 1]" P0054 "HO2S Heater Resistance [Bank 1 Sensor 2]" P0055 "HO2S Heater Resistance [Bank 1 Sensor 3]" P0056 "HO2S heater control unit [Bank2 Sensor2]" P0057 "HO2S heater control unit low [Bank2 Sensor2]" P0058 "HO2S heater control unit high [Bank2 Sensor2]" P0059 "HO2S Heater Resistance [Bank 2 Sensor 1]" P0060 "HO2S Heater Resistance [Bank 2 Sensor 2]" P0061 "HO2S Heater Resistance [Bank 2 Sensor 3]" P0062 "HO2S heater control unit [Bank2 Sensor3]" P0063 "HO2S heater control unit low [Bank2 Sensor3]" P0064 "HO2S heater control unit high [Bank2 Sensor3]" P0065 "Air assisted injector control range / performance" P0066 "Air assisted injector control circuit low" P0067 "Air assisted injector control circuit high" P0068 "MAP/MAF - Throttle Position Correlation" P0069 "Manifold Absolute Pressure - Barometric Pressure Correlation" P0070 "Ambient air temperature sensor circuit" P0071 "Ambient air temperature sensor range / performance" P0072 "Ambient air temperature sensor circuit low" P0073 "Ambient air temperature sensor circuit high" P0074 "Ambient air temperature sensor circuit intermittent" P0075 "intake valve control solenoid circuit [Bank1]" P0076 "intake valve control solenoid circuit low [Bank1]" P0077 "intake valve control solenoid circuit high [Bank1]" P0078 "exhaust valve control solenoid circuit [Bank1]" P0079 "exhaust valve control solenoid circuit low [Bank1]" P0080 "exhaust valve control solenoid circuit high [Bank1]" P0081 "intake valve control solenoid circuit [Bank2]" P0082 "intake valve control solenoid circuit low [Bank2]" P0083 "intake valve control solenoid circuit high [Bank2]" 103

104 P0084 "exhaust valve control solenoid circuit [Bank2]" P0085 "exhaust valve control solenoid circuit low [Bank2]" P0086 "exhaust valve control solenoid circuit low [Bank2]" P0087 "Fuel Rail/System Pressure - Too Low" P0088 "Fuel Rail/System Pressure - Too High" P0089 "Fuel Pressure Regulator 1 Performance" P0090 "Fuel Pressure Regulator 1 Control Circuit" P0091 "Fuel Pressure Regulator 1 Control Circuit Low" P0092 "Fuel Pressure Regulator 1 Control Circuit High" P0093 "Fuel System Leak Detected - Large Leak" P0094 "Fuel System Leak Detected - Small Leak" P0095 "Intake Air Temperature Sensor 2 Circuit" P0096 "Intake Air Temperature Sensor 2 Circuit Range/Performance" P0097 "Intake Air Temperature Sensor 2 Circuit Low" P0098 "Intake Air Temperature Sensor 2 Circuit High" P0099 "Intake Air Temperature Sensor 2 Circuit Intermittent/Erratic" P0100 "Mass or volume air flow circuit malfunction" P0101 "Mass or volume air flow circuit range / performance problem" P0102 "Mass or volume air flow circuit low input" P0103 "Mass or volume air flow circuit high input" P0104 "Mass or volume air flow circuit intermittent" P0105 "Manifold absolute pressure / barometric pressure circuit malfunction" P0106 "Manifold absolute pressure / barometric pressure circuit range / performance problem" P0107 "Manifold absolute pressure / barometric pressure circuit low input" P0108 "Manifold absolute pressure / barometric pressure circuit high input" P0109 "Manifold absolute pressure / barometric pressure circuit intermittent" P0110 "Intake air temperature circuit malfunction" P0111 "Intake air temperature circuit range / performance problem" P0112 "Intake air temperature circuit low input" P0113 "Intake air temperature circuit high input" P0114 "Intake air temperature circuit intermittent" P0115 "Engine coolant temperature circuit malfunction" P0116 "Engine coolant temperature circuit range / performance problem" P0117 "Engine coolant temperature circuit low input" 104

105 P0118 "Engine coolant temperature circuit high input" P0119 "Engine coolant temperature circuit intermittent" P0120 "Throttle / pedal position sensor / switch 'A' circuit malfunction" P0121 "Throttle / pedal position sensor / switch 'A' circuit range / performance problem" P0122 "Throttle / pedal position sensor / switch 'A' circuit low input" P0123 "Throttle / pedal position sensor / switch 'A' circuit high input" P0124 "Throttle / pedal position sensor / switch 'A' circuit intermittent" P0125 "Insufficient coolant temperature for closed loop fuel control" P0126 "Insufficient coolant temperature for stable operation" P0127 "Intake air temperature too high" P0128 "coolant thermostat (coolant temperature below thermostat regulating temperature)" P0129 "Barometric Pressure Too Low" P0130 "O2 sensor circuit malfunction [Bank 1 Sensor 1]" P0131 "O2 sensor circuit low voltage [Bank 1 Sensor 1]" P0132 "O2 sensor circuit high voltage [Bank 1 Sensor 1]" P0133 "O2 sensor circuit slow response [Bank 1 Sensor 1]" P0134 "O2 sensor circuit no activity detected [Bank 1 Sensor 1]" P0135 "O2 sensor heater circuit malfunction [Bank 1 Sensor 1]" P0136 "O2 sensor circuit malfunction [Bank 1 Sensor 2]" P0137 "O2 sensor circuit low voltage [Bank 1 Sensor 2]" P0138 "O2 sensor circuit high voltage [Bank 1 Sensor 2]" P0139 "O2 sensor circuit slow response [Bank 1 Sensor 2]" P0140 "O2 sensor circuit no activity detected [Bank 1 Sensor 2]" P0141 "O2 sensor heater circuit malfunction [Bank 1 Sensor 2]" P0142 "O2 sensor circuit malfunction [Bank 1 Sensor 3]" P0143 "O2 sensor circuit low voltage [Bank 1 Sensor 3]" P0144 "O2 sensor circuit high voltage [Bank 1 Sensor 3]" P0145 "O2 sensor circuit slow response [Bank 1 Sensor 3]" P0146 "O2 sensor circuit no activity detected [Bank 1 Sensor 3]" P0147 "O2 sensor heater circuit malfunction [Bank 1 Sensor 3]" P0148 "Fuel delivery error" P0149 "Fuel timing error" P0150 "O2 sensor circuit malfunction [Bank 2 Sensor 1]" P0151 "O2 sensor circuit low voltage [Bank 2 Sensor 1]" 105

106 P0152 "O2 sensor circuit high voltage [Bank 2 Sensor 1]" P0153 "O2 sensor circuit slow response [Bank 2 Sensor 1]" P0154 "O2 sensor circuit no activity detected [Bank 2 Sensor 1]" P0155 "O2 sensor heater circuit malfunction [Bank 2 Sensor 1]" P0156 "O2 sensor circuit malfunction [Bank 2 Sensor 2]" P0157 "O2 sensor circuit low voltage [Bank 2 Sensor 2]" P0158 "O2 sensor circuit high voltage [Bank 2 Sensor 2]" P0159 "O2 sensor circuit slow response [Bank 2 Sensor 2]" P0160 "O2 sensor circuit no activity detected [Bank 2 Sensor 2]" P0161 "O2 sensor heater circuit malfunction [Bank 2 Sensor 2]" P0162 "O2 sensor circuit malfunction [Bank 2 Sensor 3]" P0163 "O2 sensor circuit low voltage [Bank 2 Sensor 3]" P0164 "O2 sensor circuit high voltage [Bank 2 Sensor 3]" P0165 "O2 sensor circuit slow response [Bank 2 Sensor 3]" P0166 "O2 sensor circuit no activity detected [Bank 2 Sensor 3]" P0167 "O2 sensor heater circuit malfunction [Bank 2 Sensor 3]" P0168 "Fuel temperature too high" P0169 "Incorrect fuel composition" P0170 "Fuel trim malfunction [Bank 1]" P0171 "System too lean [Bank 1]" P0172 "System too rich [Bank 1]" P0173 "Fuel trim malfunction [Bank 2]" P0174 "System too lean [Bank 2]" P0175 "System too rich [Bank 2]" P0176 "Fuel composition sensor circuit malfunction" P0177 "Fuel composition sensor circuit range / performance" P0178 "Fuel composition sensor circuit low input" P0179 "Fuel composition sensor circuit high input" P0180 "Fuel temperature sensor 'A' circuit malfunction" P0181 "Fuel temperature sensor 'A' circuit range / performance" P0182 "Fuel temperature sensor 'A' circuit low input" P0183 "Fuel temperature sensor 'A' circuit high input" P0184 "Fuel temperature sensor 'A' circuit intermittent" P0185 "Fuel temperature sensor 'B' circuit malfunction" P0186 "Fuel temperature sensor 'B' circuit range / performance" 106

107 P0187 "Fuel temperature sensor 'B' circuit low input" P0188 "Fuel temperature sensor 'B' circuit high input" P0189 "Fuel temperature sensor 'B' circuit intermittent" P0190 "Fuel rail pressure sensor circuit malfunction" P0191 "Fuel rail pressure sensor circuit range / performance" P0192 "Fuel rail pressure sensor circuit low input" P0193 "Fuel rail pressure sensor circuit high input" P0194 "Fuel rail pressure sensor circuit intermittent" P0195 "Engine oil temperature sensor malfunction" P0196 "Engine oil temperature sensor range / performance" P0197 "Engine oil temperature sensor low input" P0198 "Engine oil temperature sensor high input" P0199 "Engine oil temperature sensor intermittent" P0200 "Injector circuit malfunction" P0201 "Cylinder 1 - injector circuit malfunction" P0202 "Cylinder 2 - injector circuit malfunction" P0203 "Cylinder 3 - injector circuit malfunction" P0204 "Cylinder 4 - injector circuit malfunction" P0205 "Cylinder 5 - injector circuit malfunction" P0206 "Cylinder 6 - injector circuit malfunction" P0207 "Cylinder 7 - injector circuit malfunction" P0208 "Cylinder 8 - injector circuit malfunction" P0209 "Cylinder 9 - injector circuit malfunction" P0210 "Cylinder 10 - injector circuit malfunction" P0211 "Cylinder 11 - injector circuit malfunction" P0212 "Cylinder 12 - injector circuit malfunction" P0213 "Cold start injector 1 malfunction" P0214 "Cold start injector 1 malfunction" P0215 "Engine shut-off solenoid malfunction" P0216 "Injection timing control circuit malfunction" P0217 "Engine overtemperature condition" P0218 "Transmission overtemperature condition" P0219 "Engine overspeed condition" P0220 "Throttle / pedal position sensor / switch 'B' circuit malfunction" 107

108 P0221 "Throttle / pedal position sensor / switch 'B' circuit range / performance" P0222 "Throttle / pedal position sensor / switch 'B' circuit low input" P0223 "Throttle / pedal position sensor / switch 'B' circuit high input" P0224 "Throttle / pedal position sensor / switch 'B' circuit intermittent" P0225 "Throttle / pedal position sensor / switch 'C' circuit malfunction" P0226 "Throttle / pedal position sensor / switch 'C' circuit range / performance" P0227 "Throttle / pedal position sensor / switch 'C' circuit low input" P0228 "Throttle / pedal position sensor / switch 'C' circuit high input" P0229 "Throttle / pedal position sensor / switch 'C' circuit intermittent" P0230 "Fuel pump primary circuit malfunction" P0231 "Fuel pump secondary circuit low" P0232 "Fuel pump secondary circuit high" P0233 "Fuel pump secondary circuit intermittent" P0234 "Engine overboost condition" P0235 "Turbocharger boost sensor 'A' circuit malfunction" P0236 "Turbocharger boost sensor 'A' circuit range / performance" P0237 "Turbocharger boost sensor 'A' circuit low" P0238 "Turbocharger boost sensor 'A' circuit high" P0239 "Turbocharger boost sensor 'B' circuit malfunction" P0240 "Turbocharger boost sensor 'B' circuit range / performance" P0241 "Turbocharger boost sensor 'B' circuit low" P0242 "Turbocharger boost sensor 'B' circuit high" P0243 "Turbocharger wastegate solenoid 'A' malfunction" P0244 "Turbocharger wastegate solenoid 'A' range / performance" P0245 "Turbocharger wastegate solenoid 'A' low" P0246 "Turbocharger wastegate solenoid 'A' high" P0247 "Turbocharger wastegate solenoid 'B' malfunction" P0248 "Turbocharger wastegate solenoid 'B' range / performance" P0249 "Turbocharger wastegate solenoid 'B' low" P0250 "Turbocharger wastegate solenoid 'B' high" P0251 "Injection pump fuel metering control 'A' malfunction (cam / rotor / injector)" P0252 "Injection pump fuel metering control 'A' range / performance (cam / rotor / injector)" P0253 "Injection pump fuel metering control 'A' low (cam / rotor / injector)" P0254 "Injection pump fuel metering control 'A' high (cam / rotor / injector)" P0255 "Injection pump fuel metering control 'A' intermittent (cam / rotor / injector)" 108

109 P0256 "Injection pump fuel metering control 'B' malfunction (cam / rotor / injector)" P0257 "Injection pump fuel metering control 'B' range / performance (cam / rotor / injector)" P0258 "Injection pump fuel metering control 'B' low (cam / rotor / injector)" P0259 "Injection pump fuel metering control 'B' high (cam / rotor / injector)" P0260 "Injection pump fuel metering control 'B' intermittent (cam / rotor / injector)" P0261 "Cylinder 1 injector circuit low" P0262 "Cylinder 1 injector circuit high" P0263 "Cylinder 1 contribution / balance fault" P0264 "Cylinder 2 injector circuit low" P0265 "Cylinder 2 injector circuit high" P0266 "Cylinder 2 contribution / balance fault" P0267 "Cylinder 3 injector circuit low" P0268 "Cylinder 3 injector circuit high" P0269 "Cylinder 3 contribution / balance fault" P0270 "Cylinder 4 injector circuit low" P0271 "Cylinder 4 injector circuit high" P0272 "Cylinder 4 contribution / balance fault" P0273 "Cylinder 5 injector circuit low" P0274 "Cylinder 5 injector circuit high" P0275 "Cylinder 5 contribution / balance fault" P0276 "Cylinder 6 injector circuit low" P0277 "Cylinder 6 injector circuit high" P0278 "Cylinder 6 contribution / balance fault" P0279 "Cylinder 7 injector circuit low" P0280 "Cylinder 7 injector circuit high" P0281 "Cylinder 7 contribution / balance fault" P0282 "Cylinder 8 injector circuit low" P0283 "Cylinder 8 injector circuit high" P0284 "Cylinder 8 contribution / balance fault" P0285 "Cylinder 9 injector circuit low" P0286 "Cylinder 9 injector circuit high" 109

110 P0287 "Cylinder 9 contribution / balance fault" P0288 "Cylinder 10 injector circuit low" P0289 "Cylinder 10 injector circuit high" P0290 "Cylinder 10 contribution / balance fault" P0291 "Cylinder 11 injector circuit low" P0292 "Cylinder 11 injector circuit high" P0293 "Cylinder 11 contribution / balance fault" P0294 "Cylinder 12 injector circuit low" P0295 "Cylinder 12 injector circuit high" P0296 "Cylinder 12 contribution / balance fault" P0297 "Vehicule Overspeed Condition" P0298 "Engine Oil Over Temperature" P0299 "Turbo/Super Charger Underboost" P0300 "Random / multiple cylinder misfire detected" P0301 "Cylinder 1 misfire detected" P0302 "Cylinder 2 misfire detected" P0303 "Cylinder 3 misfire detected" P0304 "Cylinder 4 misfire detected" P0305 "Cylinder 5 misfire detected" P0306 "Cylinder 6 misfire detected" P0307 "Cylinder 7 misfire detected" P0308 "Cylinder 8 misfire detected" P0309 "Cylinder 9 misfire detected" P0310 "Cylinder 10 misfire detected" P0311 "Cylinder 11 misfire detected" P0312 "Cylinder 12 misfire detected" P0313 "Misfire Detected With Low Fuel" P0314 "Single cylinder misfire (cylinder not specified)" P0315 "Cranshaft Position System Variation Not Learned" P0316 "Engine Misfire Detected On Startup (First 1000 Revolutions)" P0317 "Rough Road Hardware Not Present" P0318 "Rough Road Sensor A Signal Circuit" P0319 "Rough road Sensor B" 110

111 P0320 "Ignition / distributor engine speed input circuit malfunction" P0321 "Ignition / distributor engine speed input circuit range / performance" P0322 "Ignition / distributor engine speed input circuit no signal" P0323 "Ignition / distributor engine speed input circuit intermittent" P0324 "Knock Control System Error" P0325 "Knock sensor 1 circuit malfunction [Bank 1 ou 1 Sensor]" P0326 "Knock sensor 1 circuit range / performance [Bank 1 ou 1 Sensor]" P0327 "Knock sensor 1 circuit low input [Bank 1 ou 1 Sensor]" P0328 "Knock sensor 1 circuit high input [Bank 1 ou 1 Sensor]" P0329 "Knock sensor 1 circuit intermittent [Bank 1 ou 1 Sensor]" P0330 "Knock sensor 2 circuit malfunction [Bank 2]" P0331 "Knock sensor 2 circuit range / performance [Bank 2]" P0332 "Knock sensor 2 circuit low input [Bank 2]" P0333 "Knock sensor 2 circuit high input [Bank 2]" P0334 "Knock sensor 2 circuit intermittent [Bank 2]" P0335 "Crankshaft position sensor 'A' circuit malfunction" P0336 "Crankshaft position sensor 'A' circuit range / performance" P0337 "Crankshaft position sensor 'A' circuit low input " P0338 "Crankshaft position sensor 'A' circuit high input " P0339 "Crankshaft position sensor 'A' circuit intermittent" P0340 "Camshaft position sensor 'A' circuit malfunction [Bank1]" P0341 "Camshaft position sensor 'A' circuit range / performance [Bank1]" P0342 "Camshaft position sensor 'A' circuit low input [Bank1]" P0343 "Camshaft position sensor 'A' circuit high input [Bank1]" P0344 "Camshaft position sensor 'A' circuit intermittent [Bank1]" P0345 "Camshaft position sensor 'A' circuit malfunction [Bank2]" P0346 "Camshaft position sensor 'A' circuit range / performance [Bank2]" P0347 "Camshaft position sensor 'A' circuit low input [Bank2]" P0348 "Camshaft position sensor 'A' circuit high input [Bank2]" P0349 "Camshaft position sensor 'A' circuit intermittent [Bank2]" P0350 "Ignition coil primary /secondary circuit malfunction" P0351 "Ignition coil 'A' primary /secondary circuit malfunction" P0352 "Ignition coil 'B' primary /secondary circuit malfunction" 111

112 P0353 "Ignition coil 'C' primary /secondary circuit malfunction" P0354 "Ignition coil 'D' primary /secondary circuit malfunction" P0355 "Ignition coil 'E' primary /secondary circuit malfunction" P0356 "Ignition coil 'F' primary /secondary circuit malfunction" P0357 "Ignition coil 'G' primary /secondary circuit malfunction" P0358 "Ignition coil 'H' primary /secondary circuit malfunction" P0359 "Ignition coil 'I' primary /secondary circuit malfunction" P0360 "Ignition coil 'J' primary /secondary circuit malfunction" P0361 "Ignition coil 'K' primary /secondary circuit malfunction" P0362 "Ignition coil 'L' primary /secondary circuit malfunction" P0363 "Misfire Detected - Fueling Disabled" P0365 "Camshaft position sensor 'B' circuit malfunction [Bank1]" P0366 "Camshaft position sensor 'B' circuit range / performance [Bank1]" P0367 "Camshaft position sensor 'B' circuit low input [Bank1]" P0368 "Camshaft position sensor 'B' circuit high input [Bank1]" P0369 "Camshaft position sensor 'B' circuit intermittent [Bank1]" P0370 "Timing reference high resolution signal 'A' malfunction" P0371 "Timing reference high resolution signal 'A' too many pulses" P0372 "Timing reference high resolution signal 'A' too few pulses" P0373 "Timing reference high resolution signal 'A' intermittent / erratic pulses" P0374 "Timing reference high resolution signal 'A' no pulses" P0375 "Timing reference high resolution signal 'B' malfunction" P0376 "Timing reference high resolution signal 'B' too many pulses" P0377 "Timing reference high resolution signal 'B' too few pulses" P0378 "Timing reference high resolution signal 'B' intermittent / erratic pulses" P0379 "Timing reference high resolution signal 'B' no pulses" P0380 "Glow plug / heater circuit 'A' malfunction" P0381 "Glow plug / heater indicator circuit malfunction" P0382 "Glow plug / heater circuit 'B' malfunction" P0385 "Crankshaft position sensor 'B' circuit malfunction" P0386 "Crankshaft position sensor 'B' circuit range / performance " P0387 "Crankshaft position sensor 'B' circuit low input" P0388 "Crankshaft position sensor 'B' circuit high input" P0389 "Crankshaft position sensor 'B' circuit intermittent" 112

113 P0390 "Camshaft position sensor 'B' circuit malfunction [Bank2]" P0391 "Camshaft position sensor 'B' circuit range / performance [Bank2]" P0392 "Camshaft position sensor 'B' circuit low input [Bank2]" P0393 "Camshaft position sensor 'B' circuit high input [Bank2]" P0394 "Camshaft position sensor 'B' circuit intermittent [Bank2]" P0400 "Exhaust gas recirculation flow malfunction" P0401 "Exhaust gas recirculation flow insufficient detected" P0402 "Exhaust gas recirculation flow excessive detected" P0403 "Exhaust gas recirculation circuit malfunction" P0404 "Exhaust gas recirculation circuit range / performance" P0405 "Exhaust gas recirculation sensor 'A' circuit low" P0406 "Exhaust gas recirculation sensor 'A' circuit high" P0407 "Exhaust gas recirculation sensor 'B' circuit low" P0408 "Exhaust gas recirculation sensor 'B' circuit high" P0409 "Exhaust gas recirculation sensor 'A' circuit" P0410 "Secondary air injection system malfunction" P0411 "Secondary air injection system incorrect flow detected" P0412 "Secondary air injection system switching valve 'A' circuit malfunction" P0413 "Secondary air injection system switching valve 'A' circuit open" P0414 "Secondary air injection system switching valve 'A' circuit shorted" P0415 "Secondary air injection system switching valve 'B' circuit malfunction" P0416 "Secondary air injection system switching valve 'B' circuit open" P0417 "Secondary air injection system switching valve 'B' circuit shorted" P0418 "Secondary air injection system relay 'A' circuit malfunction" P0419 "Secondary air injection system relay 'B' circuit malfunction" P0420 "Catalyst system efficiency below threshold [Bank1]" P0421 "Warmup catalyst efficiency below threshold [Bank1]" P0422 "Main catalyst efficiency below threshold [Bank1]" P0423 "Heated catalyst efficiency below threshold [Bank1]" P0424 "Heated catalyst temperature below threshold [Bank1]" P0425 "Catalyst temperature sensor [Bank1]" P0426 "Catalyst temperature sensor range / performance [Bank1]" P0427 "Catalyst temperature sensor low input [Bank1]" P0428 "Catalyst temperature sensor high input [Bank1]" P0429 "Catalyst heater control unit [Bank1]" 113

114 P0430 "Catalyst system efficiency below threshold [Bank2]" P0431 "Warmup catalyst efficiency below threshold [Bank2]" P0432 "Main catalyst efficiency below threshold [Bank2]" P0433 "Heated catalyst efficiency below threshold [Bank2]" P0434 "Heated catalyst temperature below threshold [Bank2]" P0435 "Catalyst temperature sensor [Bank2]" P0436 "Catalyst temperature sensor range / performance [Bank2]" P0437 "Catalyst temperature sensor low input [Bank2]" P0438 "Catalyst temperature sensor high input [Bank2]" P0439 "Catalyst heater control unit [Bank2]" P0440 "Evaporative emission control system malfunction" P0441 "Evaporative emission control system incorrect purge flow" P0442 "Evaporative emission control system small leak detected" P0443 "Evaporative emission control system purge control valve circuit malfunction" P0444 "Evaporative emission control system purge control valve circuit open" P0445 "Evaporative emission control system purge control valve circuit shorted" P0446 "Evaporative emission control system vent control circuit malfunction" P0447 "Evaporative emission control system vent control circuit open" P0448 "Evaporative emission control system vent control circuit shorted" P0449 "Evaporative emission control system vent valve / solenoid circuit malfunction" P0450 "Evaporative emission control system pressure sensor malfunction" P0451 "Evaporative emission control system pressure sensor range / performance" P0452 "Evaporative emission control system pressure sensor low input" P0453 "Evaporative emission control system pressure sensor high input" P0454 "Evaporative emission control system pressure sensor intermittent" P0455 "Evaporative emission control system important leak detected" P0456 "Evaporative emission control system small leak detected" P0457 "Evaporative emission control system leak detected - fuel cap lost or off" P0458 "Evaporative Emission System Purge Control Valve Circuit Low" P0459 "Evaporative Emission system Purge control Valve Circuit High" P0460 "Fuel level sensor circuit malfunction" P0461 "Fuel level sensor circuit range / performance" P0462 "Fuel level sensor circuit low input" 114

115 P0463 "Fuel level sensor circuit high input" P0464 "Fuel level sensor circuit intermittent" P0465 "Purge flow sensor circuit malfunction" P0466 "Purge flow sensor circuit range / performance" P0467 "Purge flow sensor circuit low input" P0468 "Purge flow sensor circuit high input" P0469 "Purge flow sensor circuit intermittent" P0470 "Exhaust pressure sensor malfunction" P0471 "Exhaust pressure sensor range / performance" P0472 "Exhaust pressure sensor low" IV.4.3. List of available measurements in «Measurements and control of the lambda probes». Number of function Measurement unit Measurement name $01 x.xxx V [ ] Rich to lean sensor threshold voltage $02 x.xxx V [ ] Lean to rich sensor threshold voltage $03 x.xxx V [ ] Low sensor voltage for switch time calculation $04 x.xxx V [ ] High sensor voltage for switch time calculation $05 x.xxx s [0-1.02] Rich to lean sensor switch time $06 x.xxx s [0-1.02] Lean to rich sensor switch time $07 x.xxx V [ ] Minimum sensor voltage for test cycle $08 x.xxx V [ ] Maximum sensor voltage for test cycle $09 x.xxx s [0-1.02] Time between sensor transitions 115

116 IV.4.4. List of recoverable and possible information in the table «Information about the vehicle». Number of function Measurement unit Measurement name $02 Chain of 17 characters $04 Chain of 16 characters VIN number (identification of the vehicle) Sampling identification $06 Chain of characters CVN number (checking of the sampling) $08 Chain of characters In-use Performance Tracking (IPT) 116

117 IV.4.5. List of data composing the table «Computer information». Name Type of communication supported by the computer Type of OBD regulation for which the vehicle is designed List of supervised systems Location of the oxygen sensors 117

118 IV.4.6. TABLE OF ABBREVIATIONS MI Malfunction Indicator PID Parameter Identification DTC Diagnostic Trouble Code PTO RAM Random Access Memory ROM Read Only Memory KAM Keep Alive Memory EGR Exhaust Gas Recirculation MAF A/C CYL. CVN VIN EOBD European On-Board Diagnostic OBD On Board Diagnostic 118

119 IV.4.7. TERMS AND DEFINITIONS Throttle absolute position sensor Value to represent the throttle opening. The throttle position at idle speed is mainly above 0 % and the full-opened position indicates generally less than 100 %. Bank The group of cylinders which powers the oxygen sensor. Bank 1 contains the cylinder number 1. Fuel prevision base The sampled prevision of programmed fuel in the command module of the transmission or in the programmable ROM when manufacturing or when updating via an external source, before every automatic correction. Calculated load value It is the exact air flow on peak air flow (at the level of the sea) multiplied by the atmospheric pressure ratio at the level of the sea on barometric pressure multiplied by one hundred. Continuous supervising Updated information at rhythm superior or equal to 2 measurements by second. Fuel adjustment Loop adjustment of the fuel prevision basis. The basic fuel adjustment refers to dynamic or instantaneous adjustments. Service An exchange of information initiated by the service technician so that to ask for a diagnosis information and so that to modify its behaviour for diagnostic requirements. It is also a testing mode in which are collected type of information and means to communicate with the computer. 119

120 120

121 V. CONFIGURATIONS 121

122 V.1. GENERAL: To launch this application, select the Configuration line in the main menu. The following screen appears: T I M E / D A T E G A R A G E H E A D E R O P E R A T O R G A S A N A L Y S I S O P A C I M E T E R C E N T R A L C O N T R O L This is a scrolling menu made of several options. Each option allows access to a parametersetting window. All such windows are described below. P R I N T I N G S C R E E N O P T I O N S D E F A U L T P A R A M E T E R S I N F O R M A T I O N V.2. TIME/DATE: Allows the CAP3201 s time and date to be updated. T I M E / D A T E Y E A R M O N T H D A Y D A Y T I M E M I N U T E M O N D A Y The field must be selected using the OK key; to change the value, press on the UP and DOWN arrows. Finally, to save the new values, you must press OK. 122

123 V.3. GARAGE HEADER: This application allows information related to the garage to be entered and personalized. This information appears at the beginning of the test report. The entry window has the form shown below. G A R A G E H E A D E R To type the data, one must use either: The five keys located below the screen; in case the keyboard option is not installed or non-existent. The UP and DOWN arrows allow rapid scrolling of numbers and figures. The >> button allows advancing to the next character, and conversely << allows a return to the preceding character. Finally, OK allows a change of entry zone, up to the NOTES zone. After this zone, the program leaves the client entry procedure. The alphanumeric keyboard is supplied as an option (see Configurations Keyboard). The UP, DOWN arrows allow a change of entry zone. To erase a character, use the key located at the upper right of the keyboard, or the LEFT arrow. To move to the following phase, you need only press the OK key (5-key pad) or type ENTER. The printer touch allow to print the garage header. This touch allow to change the range of character. 123

124 V.4. OPERATOR: This window allows entry of up to 9 operator names. The principle is identical to the entry of the garage header and client entry. O P E R A T O R In the main menu, the name of the current user is displayed; to change it, simply press, if the keyboard option is active, on the number 1 for the first operator, 2 for the second and so on; if the user does not have the keyboard option he can change using the Op+ icon. This name will be inscribed in the test report at the end of a test. V.5. GAS ANALYSIS This gives access to a submenu that allows selection of the standby interval of the gas analysis module, display of Lambda and CO to 3 or 2 decimal places; it also allows evaluation of the oxygen sensor s condition, execution of a leak test, display of routine control and access to the secure menu. 124

125 G A S A N A L Y SII S STA N D B Y D I G I T C O, L A M B D A O 2 S E N S O R C O N D I T I O N L E A K T E S T R O U T I N E C H E C K P R O T E C T E D A C C E S S V.5.1. Standby For standby, select the standby tab, then press OK. The time remaining until the gas analysis component is placed on standby is displayed in the dialog box. Using the UP and DOWN arrow, you can enter the time suited to your needs. V.5.2. Digit CO, Lambda The DIGIT CO and DIGIT LAMBDA submenus allow selection of the number of figures after the decimal that you want to have when CO and LAMBDA are displayed. IMPORTANT: If you choose CO at 3 DIGITS, the gas analyser is in high resolution for the CO and also for HC. So, the measurement range in high resolution is for the HC to 13 at 2000 ppm with 1 ppm of accuracy and in normal resolution the range resolution is to 13 at ppm with 10 ppm of accuracy. V.5.3. O2 sensor condition This window provides information on the condition of the oxygen sensor. The CAP3201 performs a diagnostic on the sensor and gives its opinion of the wear condition of the sensor. The state of wear is graduated from 0 to 100%, 100% corresponding to the most satisfactory state of wear. 125

126 V.5.4. Leak test The leak test is a procedure allowing the detecting of any seal problems that might occur in the pneumatic circuit. It is imperative to carry out this test at least once every three months. It is also preferable that it be carried out at least once per month by the user. The presence of a leak involves immediate maintenance work. This test is guided throughout. The operator must attentively follow the instructions given on the screen. Test upstream of the pump: The following message appears: Plug the inlet. Blocking of the inlet is automatically detected by the analyser. The pumps then shut off and the following message appears: Test in progress. It is necessary to keep the inlet hermetically shut. This phase lasts at most 11 seconds. At the end of this phase, a diagnosis of Leak present or Leak absent is given. Press the key to continue the test, otherwise. Test downstream of the pump: The following message appears: Plug the exhaust. Blocking of the exhaust is automatically detected by the analyser. The pumps then shut off and the following message appears: Test in progress. It is necessary to keep the inlet hermetically shut. This phase lasts at most 8 seconds. At the end of this phase, a diagnosis of Leak present or Leak absent is given. Stop test and exit: The presence of a leak disables measurement so long as a new test has not been carried out with a final result of Leak absent. V.5.5. Routine check This window is made up of 2 pages (PG1 and PG2). They provide information in real time on the condition of the gas analysis module, indicate the date and the name of the participants, and finally indicate the BENCH software version and its serial number. 126

127 R O U T I N E C H E C K G A S P R E S S U R E A M B I E N T T E M P. L A M P T E M P. D E T E C T O R L A M P R O U T I N E C H E C K b f 1 0 V.5.6. Protected access Type the 5-key secret code. Then. The machine asks for entry of the user name Carried out by: ; this name can contain between 3 to 15 characters. This information will be retained in memory and is not erasable. This part of the program is reserved for persons charged with periodic inspection of the machine. P R O T E C T E D A C C E S S H C I N D E X C A L I B R A T I O N A M B A C C E S S V HC index: This gives access to a submenu allowing display of HC in propane equivalent or hexane equivalent. 127

128 H C I N D EX PEF being variable, it is preferable, when calibrating with a cylinder containing propane, to go to propane mode and to read the measured value directly as propane. Note that the PEF displayed by the machine is the PEF for a value of HC propane near 2000 ppm vol. V Calibration: The second menu allows the machine to be calibrated; it is composed of several options: C A L I B R A T I O N C A L I B R A T E C O - HC- C O 2 O 2 I N T I A L I Z A T I O N N O X I N I T I A L I Z A T I O N a) CO, HC, CO2 adjustment procedure: Adjusting calibration gas concentrations: Note that for the oxygen concentration (air/oxygen ratio), it is imperative to leave the value set to 20.90%. This is the value used whenever the machine is re-zeroed. This value has no influence on the per-gas adjustment of the three infrared channels. IMPORTANT: HC must be entered in propane equivalent. Recall that the cylinder containing the gas required for analyser adjustment contains the following concentrations: CO: 3.50 % vol. CO 2 : 14.0 % vol. 128

129 HC: 2000 ppm propane by vol. Balance N 2 The operator must enter the values of the CO, CO2 and HC gas concentrations. To advance to the following step, OK or ENTER must be pressed. Launching the adjustment procedure: The operator is guided throughout the procedure by messages indicating to him the various steps that the CAP3201 carries out during an adjustment procedure. b) O2 initialization: This tab is used for installing a new O2 sensor. It is necessary to follow the procedure, which requires changing the O2 sensor first, then pressing OK. Once this step is completed, the CAP3201 initializes the sensor for 1 minute. This consists of recovering the reference voltage of the new sensor. c) NOx initialization: Same as O2 initialization. V AMB access: The final menu allows access to MICROBENCH, using a computer via an RS232 connection. The operator may carry out all the adjustment operations previously mentioned. A C C E S S A M B C O N N E C T T H E C O M P U T E R O N C O M 1 When this window is activated, the user can communicate with the gas analysis set. Quit to return to measurement mode: 129

130 V.6. SMOKEMETER: When the user selects Opacimeter the following window is activated: S M O K E M E T E R V L / P L E N G I N E S P E E D O I L T E M P. R O U T I N E C H E C K P R O T E C T E D A C C E S S V.6.1. VL/PL: The VL/PL selection list allows a choice of mode: either VL - in this mode, the operator is required to measure an oil temperature of at least 80 C. In the other mode, type PL, he can free himself of the need to measure temperature by validating manually. (see paragraph IV.4.6.). V.6.2. Engine speed and Oil temperature: The ENGINE SPEED and OIL TEMP selection list allow a choice whether information concerning the engine speed and the oil temperature will be printed on the test report. V.6.3. Routine check: The routine check program allows the user to check the opacimeter for correct operation. This page lists opacimeter faults. It is made of up 3 pages (PG1, PG2 and PG3). 130

131 Ambient temp. out of range Detector temp. out of range Tube temp. out of range Power supply out of range Fan stop Opacity out of range Cell in stand-by mode Zero running Sooting of the lenses Sampling armed R O U T I N E C H E C K This window show the cell current data. Example : the ambient temperature is correct if it s locate between 0 C and 50 C. R O U T I N E C H E C K Trigger armed Fault of the fans Gas temp. out of range Faulty EEPROM Fault on sensor OPACITY OPACITY OPACITYcorr. OPACITYcorr. This page gives the last current data. Moreover, it shows the cell currently opacity in % and /m. Measure = 1.39/m Variation = 0.01/m Filter used = 1.38 /m Smokemeter OK!!!! Finally, this page gives the result of optical attenuation test. GAS temp. TUBE temp. DET. temp. R O U T I N E C H E C K The page 3 gives a few temperatures, cell power supply, and fan speed. EXT. temp. Power supply Fan speed (rpm) CK and CN filters are the electrical filters used by the cell. Cell : Serial number Software version Finally, the page shows the software version and the serial number Two functions are also available: a) Auto-zero: This key launches the automatic auto-zero procedure. 131

132 As long as the value read in the opacity field is not in the neighbourhood of zero, relaunch the auto-zero function. b) Evaluation of the error in opacity measurement. «TEST» This is an automatic check by electrical filter centred at 50%, allowing the accuracy of measurements to be verified. The error is considered acceptable if its evaluation gives a result less than 5%. To carry out this evaluation, press the TEST key. The result is displayed on page 2; it shows the measurement obtained, the filter employed and the gap between the two values. A window appears giving an opinion of the credibility of the measurements carried out. If this opinion is negative opacimeter out of spec, clean the cell and restart the test. V.6.4. Protected access: This part of the program is reserved for CAPELEC personnel. It gives access to a submenu that allows the filter coefficients used in carrying out measurements to be selected. V.7. CENTRAL CONTROL: A central testing station must be able to connect a measuring device, the CAP3201 in this case, with a computer at the central technical testing station. There are different standard protocols allowing information exchange between devices of different makes. This window allows the operator to choose the type of communication protocol in order to be able to store all information on a central computer. 132

133 V.7.1. GIEG-NET protocol: At the GIEGNET protocol level, the CAP3201 follows rigorously the specifications of the GIEGNET PROTOCOL Version Thus the dialog is always initiated by the computer. It can be carried out directly with the measuring device (GIEG-NET MONO PROTOCOL diagram A) or via a multiplexer combining various measuring devices (GIEG-NET MULTI PROTOCOL diagram B). To transmit the desired results, it is necessary to first press the A new keyboard layout is loaded and the message box invites you to either: key. F1: PRINT F2: SEND DATA Diagram A: String Gas Computer Opa. Diagram B: Multiplexer String Gas Multiplexer Computer Opa. Pressing this key displays in the message window. 133

134 F 1 : P R I N T F 2 : S E N D D A T A Press F2 for send data. V GIEG-NET MONO : In this configuration, only the car s measurements can be saved, without having any registration information. If the centre s computer does not request the measurements before doing another car, the old measurements will be overwritten by the new ones. V GIEG-NET MULTI : In this configuration, the measurements must be accompanied by the registration of the vehicle. Thus the client entry portion is no longer the same and the following appears: G A S A N A L Y S I S 1111 www 34 is the registration number of a car sent by the centre s computer to the CAP3201 station. The hour indicates when the measurements are saved and if the field shows --:-- that means that the user has not yet carried out a test on that registration. The car is awaiting test. IMPORTANT: If the registration number already has values, it is possible to store new ones by selecting that plate and sending measurements. OTHER allows the user to carry out a test with a registration number other than that sent by the centre s computer. It will later be added to the list of registration number whose results have not been requested by the centre s computer. 134

135 It is possible to modify a registration number by pressing the MODI button while the registration number is displayed in reverse type. The data entry keyboard then appears and you will be able to carry out the desired modifications. To confirm the modifications, you must press the OK button. It the registration field is blank when this operation takes place, it is removed from the list, along with the accompanying measurements. V.7.2. PC protocol: Allows communication with the gas analysis or opacity software on the PC. When this protocol is selected, as soon as the computer is started and communicates with the CAP3201, the CAP3201 display will automatically position itself on the multi-gas analysis page, no matter where the user is in the menu. V.7.3. MAHA protocol: When this protocol is selected, while results are being printed, if the user presses F2 for transmission, the CAP3201 will send the data via its COM2 in MAHA format for processing by a MAHA set. V.8. PRINTING: This menu is made up of two submenus: Number of tickets : Allows 1, 2 or 3 reports to be automatically printed after each test sequence. Printer : The operator can select either an external A4 format printer or the internal thermal printer furnished with the machine. P R I N T I N G N U M B E R O F T I C K E T S N U M B E R O F T I C K E T S P R I N T E R ONE TWO T H R E E 135

136 V.9. SCREEN: The machine s screen can be configured; to do this, choose either NORMAL mode (normal operating mode of the screen), or the INVERSE mode (mode in which display is the exact inverse of the normal mode). Finally, it is sufficient to press OK to confirm one s choice. The screen sets itself automatically to the chosen mode. V.10. OPTIONS : This part of the program is reserved for persons charged with installing new functions. This page is protected by a 5-digit code. To install a new component, the Configuration tab must be selected. O P T I O N S C O N F I G U R A T I O N S E R I A L N U M B E R This window allows a quick survey of the functions and options already installed. Each component needs a code to be installed; press the INS key and type in the applicable code. If the code is correct, the new component is automatically active. To display the preceding code, press VIEW. V.11. DEFAULT PARAMETERS: ATTENTION: This window should be used with caution; it allows all the configuration values previously mentioned to be reinitialized. 136

137 V.12. INFORMATION: This window includes the coordinates of the manufacturer, the time and the date. For more information on our products, consult our Internet site: 137

138 VI. PETROL AND DIESEL TACHOMETER 138

139 VI.1. OPERATING PRINCIPLE The tachometer operates by analysing noise frequencies at the battery terminals. Certain peripheral devices in the vehicle, such as the alternator, have a direct effect on the voltage across the battery terminals. When the engine is running, this voltage does not remain perfectly steady. When studied more closely, one sees that the battery voltage oscillates slightly in proportion to the engine speed. By analysing these disturbances, the tachometer is able to calculate the engine speed and transmit it to your pollution checking equipment as an analog or digital signal. VI.2. TECHNICAL CHARACTERISTICS Measurement characteristics Automatic initialisation Measurement range: : rpm. Maximum error: <20 rpm at speeds below 2000 rpm o <2 % in other cases Response time: <1 second Measurement update rate: 10 times per second Initialisation time: <17 seconds VI.3. LIST OF KIT CONTENTS One battery connection cable. One cigar lighter connection cable. VI.4. CONNECTING THE TACHOMETER Connected to the cigar lighter 139

140 This is the simplest solution. It lets you measure the engine speed with no need to open the vehicle bonnet. On some vehicles, however, the engine speed measurement may be less accurate than with the unit connected directly to the battery. Connect the cable ( 1 ) to the INPUT socket RPM BAT. Remove the cigar lighter from its socket on the dashboard 140

141 Connected to the battery Connect the cable ( 2 ) to the INPUT socket (RPM BAT) on the du CAP3201 and use the clips to connect it to the battery terminals, taking care not to invert the polarity. NOTE: The tachometer is connected to the vehicle's DC power supply for two reasons to power the unit and to perform the engine speed measurements. It is therefore essential to connect the unit to the battery on the vehicle being tested, and not to a spare battery. Cigarette lighter Connector (1) Battery clamp ( 2 ) 141

142 VI.5. MEASURING THE ENGINE SPEED Pressing this key displays the speed mode currently in use. On the other hand, if the user again presses the operating speed key, a new speed mode displays the new selection. Select the rpm mode call battery. After three seconds, the message box request a cylinder number. This number corresponding to 4 stroke engine. If you want to measure a 2 stroke engine, see the figure: Cylinder number stroke 2 stroke Troubleshooting: On some vehicles, measurements may be inconsistent. There can be several causes for this. In the event of a problem (unstable or imprecise readings), minimise the risk of error as follows: - The battery should be slightly discharged. Better results will be obtained if the headlights are left on for a few minutes before starting the motor. - During the measurement procedure, switch on the headlights to boost power consumption. - If measurements were made from the cigar lighter, try measuring directly on the battery. If, after initialisation, the tickover speed is stable, but incorrect (e.g. double the actual speed), change the cylinder number setting until the correct value appears. 142

143 VII. PREMIUM VERSION WIN

144 VII.1. INSTALLATION AND SET-UP The software WIN3200 automaticaly starts when the PC starts to run. If you don t want to launch this software automaticaly under Windows 98/XP, go to the menu Start, Programs, Startup, click with the right button of the mouse on the icon WIN3200 and click with the left button of the mouse to delete it. Main menu: By the main menu you can launch six programs : Gas analyzer (keyboard short cut : touch F1) Smokemeter (keyboard short cut : touch F2) EOBD (keyboard short cut : touch F3) Setup (keyboard short cut : touch F4) Save Reports (keyboard short cut : touch F5) 144

145 Wingieg : centralization software (keyboard short cut : touch F6) When putting into the service the equipment, you have to go in the window " Setup " : Setup: You may not use the mouse and for that you have to press the key TAB. The setup window allows to setup your PC. You first have to select the serial COM port where you have connected the CAP3201. If you need to centralize your test reports, select the type of centralisation (Giegnet, maha ), and the COM port. Enter your header To validate the changes, press F1. 145

146 VII.2. GAS ANALYZER VII.2.1. Launching of the procedure The choice of the procedure is the same than for the CAP3201 alone, for further information please see chapter II.6. When you are ready, click on OK or type Enter. Be Careful : if the touch OK remains lighted, you have to check if the connection with the CAP3201. The gas analyzer CAP3201 must be set up on PC, for that you have to go into the menu CONFIGURATION CENTRALISATION then select PC. If the connection is correct between the PC and the gas analyzer, the WIN 3200 loads a second page (see below). 146

147 You can anytime come back on the garage header by pressing F11. The information F1, F2 meet with the keyboard short cuts. Icons are the same than on the gas analyzer, please see chapter II.5. VII.2.2. Limit values : The key F9 corresponds to a window of «limit values». 147

148 You can save the limit values with the key F1. Thus, during the gas analysis, if the bargraph located below the value in red, it means that the value measured is out of range. VII.2.3. Print out preview When the operator presses F1, the software gets back the gas analyser ticket : 148

149 The user can then : Print out the ticket with the short cut key F1. IMPORTANT : when the operator prints out a report, this one is automaticaly saved. It is not necessary to press F2 for that purpose. Save the report with the short cut key F2. Send the values to a centralisation bench with F3. ATTENTION if this key is greyed, that means that the operator has not chosen any centralisation (NO PORT) in the window Setup. Quit the window with ESC 149

150 VII.3. SMOKEMETER : VII.3.1. Launching of the procedure : The choice of the procedure is the same than for the stand-alone CAP3201, for further information please see chapter III.5. When you are ready, click on OK or type Enter. If the connection is correct between the PC and the gas analyzer, the WIN 3200 loads a second page (see below). 150

151 You can anytime come back on the garage header by pressing F11. The information F1, F2 meet with the keyboard short cuts. Icons are the same than on the gas analyzer, please see chapter II.5. VII.3.2. Print out preview : When the operator presses F1, the software gets back the gas analyser ticket : 151

152 The user can then : Print out the ticket with the short cut key F1. IMPORTANT : when the operator prints out a report, this one is automaticaly saved. It is not necessary to press F2 for that purpose. Save the report with the short cut key F2. Send the values to a centralisation bench with F3. ATTENTION if this key is greyed, that means that the operator has not chosen any centralisation (NO PORT) in the window Setup. Quit the window with ESC 152

153 VII.3.3. Opacity Analysis To launch the procedure, please press the F5 key. Once launched, the message box shows ACCELERATION No 1. From now, you can make the acquisition of a curve. This procedure enables to measure up to 5 curves. They are displayed in different colours. They can deleted independently the ones from the others thanks to the small buttons dedicated to each colour (located above the bargraph). Or with the F8 key, the curves will be all together deleted. 153

154 VII.4. EOBD VII.4.1. Launching of the procedure To go into the EOBD procedure EOBD, please click on the «EOBD SCANTOOL» icon or press F3 from the main menu. You can enter the customer s name. 154

155 VII.4.2. Print out preview When the operator presses F1, the software gets back the gas analyser ticket : The user can then : Print out the ticket with the short cut key F1. IMPORTANT : when the operator prints out a report, this one is automaticaly saved. It is not necessary to press F2 for that purpose. Save the report with the short cut key F2. Send the values to a centralisation bench with F3. ATTENTION if this key is greyed, that means that the operator has not chosen any centralisation (NO PORT) in the window Setup. 155

156 Quit the window with ESC VII.5. LOOKING INTO THE TESTS : You can get back the saved tests from the main menu. Please press the F4 key. When you open an exploration window, please double-click on the folder «GAS» to get back the gas analyzer measurements or double-click on the folder «SMOKE» to get back the smokemeter measurements.. 156

157 The measuremets are classified by month/year, double-click on the month of your choice : The measurements are classified by the number of the report followed by the registered plate number. Double-click on the report that you want to get back. Windows is going to open up Internet Explorer. You can print out this report by going to file/print out. 157

158 After sales Service Warranty card Equipment covered: Customer No.: Type: CAP3201 Serial No.: Date placed in service: Owner: Name: Address: Signature and stamp: Technician performing start-up procedure: Name: Date: Signature: 158

159 Start-up tag TO BE RETURNED TO THE FOLLOWING ADDRESS WITHIN 8 DAYS TO HAVE THE BENEFIT OF THE WARRANTY: CAPELEC S.A.R.L rue des Marels Parc Eurêka Equipment covered: Customer No.: Type: CAP3201 Serial No.: F Montpellier Phone: +(33) Fax: +(33) Date placed in service: Owner: Name: Address: Signature and stamp: Technician performing start-up procedure: Name: Date: Signature: 159

160 160

161 Anomaly Tag (Make a copy and fill out the sheet for each problem or suggested improvement to the software. Please return it to the address given below.) Date:... Name of garage:... Address:... Serial number:... TYPE OF REQUEST: (check the box that best fits your request) ANOMALY IN OPERATION: ANOMALY IN DESIGN: SUGGESTION FOR UPDATE: Description of the anomaly: Circumstances in which the anomaly occurred: Suggestions:

162 Send to: CAPELEC S.A.R.L rue des Marels Parc Eurêka F MONTPELLIER Phone: Fax: This symbol indicates that, in accordance with directive DEEE (2002/96/CE) and with the regulation of your country, this product should not be thrown with the household refuse. You must deposit it in a place of collecting envisaged to this end, for example, an official site of collection of the electric components and electronics (EEE) for their recycling or a terminal point of products authorized which is accessible when you acquire of a new product of the same type as the old one. Any deviation compared to these recommendations of elimination of this type of waste can have negative effects on the environment and the public health because these products EEE generally contain substances which can be dangerous. In parallel, your whole cooperation with the good reject of this product will support a better use of the natural resources. To obtain more information on the points of collection of the equipment to be recycled, contact your town hall, the service of collection of waste, approved plan DEEE or the service of garbage collection domestic. 162