Author Department Location Telephone Fax . Title. Revision File Name. Date

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1 Automation and Drives E-Box PC User Guide Author Department Location Telephone Fax Title Revision File Name Date Ludwig Kimmig A& D PI 2 CA Karlsruhe Ludwig.Kimmig@siemens.com E-Box PC User Guide 1.2e E-Box PC_1.2e_Manual.doc 12 December, 2001 Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 1 of 32

2 1 GENERAL HINTS FOR THE USER User Guide Use User Groups Calibration Obligation INSTRUCTIONS FOR YOUR SAFETY, FOR THE PROTECTION OF EQUIPMENT AND VEHICLE COMPONENTS Mains Voltages; High Voltage Danger of Burns to the Respiratory Organs Danger of Acid Burns Danger of Suffocation Danger of Injury, Danger of Crushing Danger of Burns Noise DISPLAYS AND OPERATING ELEMENTS SERIAL INTERFACE EXHAUST GAS MEASUREMENT ON GASOLINE ENGINES Functional Description Function Initial Startup Exhaust Gas Measurement TURBIDITY MEASUREMENT OF DIESEL EXHAUST GASES (OPTIONAL) Description of the Measuring Head Commissioning Measurement SPEED MEASUREMENT Clamp Sensor (option) Inductive Trigger Clamp Cable for Measuring the Battery Residual Ripple TD Pulse Terminal W Signal Conducting the Speed Measurement OIL TEMPERATURE MEASUREMENT MAINTENANCE Six Month Maintenance Annual Maintenance Tightness of the Sampling System Sampling Probe (28) Filter GF1 (30) Sampling Hose (31) Input Filter GF2 (18) Pump Protection Filter GF3 (19) and GF4 (20) Changing the Filters: Checking the Measuring Accuracy Checking the Flow Monitor Before Turning Off O2 Sensor Maintenance Work on the Diesel Measuring Head MAINTENANCE CERTIFICATION SCOPE OF DELIVERY SPARE PARTS, EXPENDABLE PARTS, SPECIAL ACCESSORIES TECHNICAL DATA...32 Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 2 of 32

3 1 General Hints for the User Dear customer, Please read the user guide before starting work! It contains important information and data which ensure perfect functioning of the equipment and save service costs when observed. This makes handling this measuring instrument much easier and leads to reliable measuring results. 1.1 User Guide The product described in this guide has left the factory in perfect and quality tested condition as far as its safety is concerned. In order to maintain this condition and to ensure perfect and safe operation of this product it may only be used in the manner described by the manufacturer. In addition, the perfect and safe operation of this product is conditional upon proper transport, proper storage and installation and careful operation and maintenance. This guide contains all the information necessary for proper use of the product it describes. It is aimed at technically qualified personnel who are specially trained or have good knowledge in the field of automotive test engineering. The knowledge and the technically perfect application of the safety information and warnings described in this guide are a prerequisite for the safe installation and commissioning as well as for safety during operation and maintenance of the described product. Only qualified personnel has the necessary professional knowledge to be able to interpret the safety information and warnings correctly in a generally valid way in individual cases and to put them into practice. For reasons of simplicity this manual does not contain all details on all versions of the described product nor can it cover every situation which could arise during installation, operation, maintenance and use in systems. If you require further information or if problems which are not dealt with in sufficient detail in this document arise, please request the desired information from your local or responsible Siemens branch. Use for the Intended Purpose in the sense of this user guide means that this product may only be used for the applications provided for in the technical description (see also chapter 3 of this guide) and only in conjunction with OEM equipment and components recommended or approved by Siemens. the product described in this guide has been designed, manufactured, tested and documented under consideration of the pertinent safety standards. Therefore there should be no danger of material damage or injury to persons providing that the handling rules and safety instructions described for planning, assembly, approved use and maintenance are observed. This device has been designed to ensure a safe isolation between the primary and secondary circuits. Low voltages which are connected must also be generated by safe isolation. Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 3 of 32

4 1.2 Use The E-Box PC exhaust gas measuring instrument in connection with a Personal Computer and suitable software, for example the E-Box_eval software serves for measuring automobile exhaust gases and exhaust gas turbidimetry for engine diagnostics and monitoring. The main products of combustion of fuel with air in the gasoline engine are carbon dioxide (CO 2 ) and water. Carbon monoxide (CO), nitrogen monoxide (NO x ) and hydrocarbons (HC) are produced as undesirable byproducts. The exhaust gas also contains remnants of unburned oxygen. CO (carbon monoxide) is absorbed into the bloodstream in place of oxygen and therefore has a toxic effect. NO (nitrogen monoxide) is also toxic and is also responsible for creating smog. This is caused by the reaction of nitrogen in the air with oxygen at high temperatures. NO reacts very quickly to NO 2 and other nitric oxides in air. We refer to NO x. Hydrocarbons are incompletely combusted fuel. CO 2 (carbon dioxide) is a product of complete combustion of fuel. It is asphyxiating in high concentrations. The aim of the exhaust gas measurement is to reduced the toxics and environmental pollutants to a minimum and to optimize combustion in the engine. This goes hand in hand with optimization of combustion and reduction of fuel consumption. A diesel engine produces soot as a result of incomplete combustion. This has a toxic effect and is also involved in the creation of smog. A measuring head can be connected to the E-Box PC with which the soot content of the diesel exhaust gas flow can be determined. The measuring principle is based on the optical turbidity measurement (absorption photometry). Defective parts of the vehicle can be determined by measuring the soot content in the exhaust gas of a diesel vehicle. Replacement of parts and repair of the vehicle lead to optimum combustion and to a reduction in the emitted particles as well as to a reduction in the fuel consumption. In addition, the E-Box PC allows the measurement of speed and oil temperature of the vehicle which enables the operating state of the automobile to be determined. 1.3 User Groups E-Box PC was constructed for trained specialists in the automotive industry. The operating instructions must be read carefully for your own safety and to avoid damage to the device due to improper handling. 1.4 Calibration Obligation The E-Box PC is subject to a calibration obligation for exhaust gas measuring instruments and must be calibrated according to national laws. The E-Box PC exhaust gas measuring instrument is suitable for conducting AU tests according to EU regulation 92/55 EEC of the European Commission of June 22 nd 1992 on vehicles with spark ignition engines. The measuring accuracy requirement complies with OIML R99 Class 0. The soot measurement on diesel vehicles can be made under stationary conditions both at constant speed and load and according to the free acceleration method. This instrument satisfies the measuring accuracy requirements compliant with ECE-R24. Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 4 of 32

5 2 Instructions for your Safety, for the Protection of Equipment and Vehicle Components 2.1 Mains Voltages; High Voltage Dangerous voltages occur in the lighting system and in the electrical installations of automotive vehicles. There is a danger of electric shock when touching live parts (e.g. ignition coil) due to sparkovers as a result of damaged insulation (e.g. ignition cables chewed by martens). This applies for the secondary and primary side of the ignition system, the cable harness with connections, lighting system and the connections of test instruments. Safety precautions: Only connect the E-Box PC to a properly earthed PE-socket. Only use the power cable provided. Only use extension cables with a PE-contact. Replace cables with damaged insulation. Connect the E-Box PC to the lighting system first before it is connected to the vehicle. Only manipulate the electrical installations of vehicles with the ignition switched off. Manipulations are for example the connection of devices, replacement of parts of the ignition system, removal of aggregates (e.g. generators), connection of aggregates to a test rig etc. Only perform tests and adjustment work with the ignition switched off and the engine at a standstill if possible. Do not touch live parts if you have to perform tests and adjustments with the ignition switched on or the engine running. This applies for all connecting leads of the E-Box PC and the connections of aggregates to test rigs. Only make test connections with suitable connecting elements (e.g. vehicle-specific adapter leads). Plug in test connections correctly and make sure the connection is firm. 2.2 Danger of Burns to the Respiratory Organs Exhaust gas sampling hoses are used in the exhaust gas measurement which may release a highly caustic gas (hydrogen fluoride) when heated up above 250 C or in the case of fire which can cause burns to the respiratory organs. Safety precautions: Consult a physician immediately after inhaling! Wear neoprene or PVC gloves to remove combustion residue. Neutralize combustion residue with a calcium hydroxide solution. Non-toxic calcium fluoride is produced which can be rinsed off. 2.3 Danger of Acid Burns Acids and lyes can cause serious burns to the unprotected skin, hydrogen fluoride in contact with moisture (water) produces hydrofluoric acid. Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 5 of 32

6 Condensation which forms in the hose is also acidic. When exchanging the O 2 measured value sensor please bear in mind that it contains lye. Safety precautions: Rinse burned areas of the skin immediately with water, then consult a physician! 2.4 Danger of Suffocation Automobile exhaust gases contain carbon monoxide (CO), a colorless, odorless gas. Inhalation of carbon monoxide leads to a lack of oxygen in the body. Special caution is necessary when working in pits because some exhaust gas constituents are heavier than air and collect at the bottom of the pit. Caution is also necessary with vehicles with autogas systems. Safety precautions: Always provide strong ventilation and suction (especially in pits) Switch on and connect up the suction system in closed rooms. 2.5 Danger of Injury, Danger of Crushing There is a danger of being crushed against a workbench if the vehicle is not secured against rolling. Running but also standing engines have rotating and moving parts (e.g. fan belt drives) which can cause injuries to hands and arms. There is a risk, especially with electrically powered fans, that the fan can start unexpectedly when the engine is at a standstill and the ignition is switched off. Safety precautions: Secure the vehicle against rolling during the test. Automatic transmission in park position, pull handbrake or block the wheels with wedges. Do not reach into the vicinity of rotating/moving parts when the engine is running. When working on and near to electrically powered fans, allow the engine to cool down first and pull out the plug from the fan motor. Do not lay the E-Box PC connecting cables near to rotating parts. 2.6 Danger of Burns When working on the hot engine, there is a danger of burns when you touch or get too close to components such as the exhaust manifold, turbocharger, lambda probe etc. These components can reach temperatures of a few hundred degrees Celsius. The measuring probe of the exhaust gas measuring instrument can also get very hot depending on the duration of the measurement. Safety precautions: Use safety gear, e.g. gloves. Allow the engine to cool down, also applies for stationary heaters. Do not lay the connecting leads of the test equipment on or near to hot parts. Do not run the engine for longer than is necessary for the test/adjustment. Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 6 of 32

7 2.7 Noise Noise levels above 70 db (A) may be produced during measurements on the vehicle particularly at high engine speeds. Noise levels of this magnitude can lead to damage to the hearing over long periods of exposure. Safety precautions: The user must protect workplaces near to the test site against noise if necessary. The operator should wear ear protectors if necessary. Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 7 of 32

8 3 Displays and Operating Elements Figure 1, rear 1. Mains switch 2. Fuse 3. Device plug 4. Serial interface PC 5. Connection for diesel measuring head 6. Speed measurement with TD pulse (engine electronics, optional), battery residual ripple, terminal W (dynamo, optional) 7. Trigger clamp 8. Clamp sensor (option) 9. Oil temperature 10. Device seal 11. Gas and condensation outlet 12. Gas outlet, calibration gas inlet 13. Sample gas inlet 14. Gas conditioning Probench Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 8 of 32

9 Figure 2, side view 15. Cover Probench 16. Probench 17. Locking spring Probench Pulling out the Probench drawer Press and pull off the cover of the Probench at the marked position. Press and pull out the Probench at the locking spring (figure 2, item 17). Pushing in the Probench drawer Push in the Probench until the locking spring snaps shut. Fit the cover and push in until the lock snaps shut Figure 3, left side view Probench 18. Inlet filter GF2 19. Safety filter GF3 20. Flow rate sensor 21. Oxygen sensor 22. Free sensor slot 23. Safety filter GF4 Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 9 of 32

10 Figure 4, right side view Probench 24. Solenoid valve 25. Active carbon filter 26. Sample gas inlet 27. Calibration gas inlet (gas outlet) 28. Gas and condensation outlet Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 10 of 32

11 Figure 5, Hose connection diagram 29. Sampling probe cm hose 31. Pre-filter GF1 32. Sampling hose 33. Gas outlet hoses Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 11 of 32

12 4 Serial Interface Interface parameters: Level: V24 (RS232) Baud rate: 9600 Data bit: 8 Stop bit: 1 Start bit: 1 Parity: none Pin assignment E-Box Pin number Pin assignment E-Box PC Pin number Function TxD 3 - TxD 3 - RxD RxD 5 - ground ground 9 10 output 0V Attention: Only use shielded cable for the connection between E-Box PC and pc. Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 12 of 32

13 5 Exhaust Gas Measurement on Gasoline Engines 5.1 Functional Description The E-Box PC is a modular measuring system for engine diagnosis and for legally prescribed supervision of gasoline- and diesel vehicles. The central unit contains the SIBENCH measuring module with which the components CO (carbon monoxide), HC (hydrocarbons), CO 2 (carbon dioxid) and optionally NO (nitrogen monoxide) are measured according to the so-called NDIR method (non-dispersive infrared method). The oxygen content of the automobile exhaust gas is determined with an electrochemical measuring cell. The lambda air factor is calculated based on the measured gas concentrations. The turbidity of the exhaust gas is measured with a connected diesel measuring head. It is determined in the partial flow method with the light of a green LED. Different sensors can be used to measure the speed: inductive trigger clamp, battery cable for the residual ripple of the battery voltage or clamp sensor. A temperature sensor inserted in the engine block in place of the oil dipstick is used to measure the oil temperature. The following measuring ranges are implemented: CO Carbon monoxide % vol HC Hydrocarbons (related to hexane) ppm vol CO 2 Carbon dioxide % vol NO Nitrogen monoxide ppm vol O 2 Oxygen % vol n Speed rpm T Temperature C l Lambda air factor (CO corr Corrected CO value %) 5.2 Function Warming up time The warming up time of the device is 1.5 minutes. No measurement is possible during this time. Drift correction The measuring instrument makes an automatic system check with ambient air at certain intervals after a measurement has been started. The system check is shifted to the end of the measurement when a measurement is currently in progress. Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 13 of 32

14 System check The measuring instrument switches a solenoid valve over to ambient air for the system check. Purging with zero gas takes place for 30 seconds. The sucked in ambient air is cleaned of hydrocarbons by an active carbon filter. The drift of the oxygen measurement and the drifts of zero points of the HC, CO, CO 2 and NO measurement are monitored and readjusted. Oxygen measurement The exhaust gas measuring instrument is equipped with an O 2 measured value sensor. The sensor is screwed to the Probench drawer. The oxygen measurement is adjusted automatically with every system check with the air oxygen of 20.9 % vol. The O 2 measured value sensor is a consumable part. Air factor measurement The measuring instrument calculates the lambda air factor from the measured concentrations of HC, CO, CO 2 and oxygen. An accurate oxygen measurement is important for the lambda calculation. 5.3 Initial Startup Attention! The measuring instrument must be installed at least 250 mm above the floor. The hoses of the gas outlets must be at least 300 mm long. They must be laid downwards from the instrument. Note: Only then the condensate draining is guaranteed, the measuring accuracy maintained and the measuring system adequately protected from soiling. Connect the exhaust gas sampling probe to the pre-filter with a 30 cm hose. Connect the sampling hose to the pre-filter Connect the sampling hose to the gas inlet of the measuring instrument. Attention! Connect two 70 cm long PVC hoses to the gas outlets. Feed the hoses into an open vessel for collection of the condensate. Observe the voltage specifications on the rating plate! Connect the exhaust gas measuring instrument to a properly earthed PE-socket with the enclosed power cable. Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 14 of 32

15 5.4 Exhaust Gas Measurement Attention! Always use the full 8 m length of the sampling hose for the exhaust gas measurement. Note: The automobile exhaust gas contains a large proportion of water. This condenses in the 8 m long hose. Condensation can form in the instrument when shorter hoses are used. Attention! The automobile exhaust gas and the exhaust system are hot. Danger of burns! Switch off the vehicle engine. Adapt the speed sensor Start the measurement A system check is made Then a HC residue test is made (the sampling probe may not be in the exhaust pipe) Insert the sampling probe in the exhaust pipe Start the engine Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 15 of 32

16 6 Turbidity Measurement of Diesel Exhaust Gases (optional) The diesel measuring head DIBENCH can be connected to the E-Box PC for testing the smoke density in the exhaust gas of diesel engines (measurement of soot emission). The measuring principle is based on the optical turbidity measurement (absorption photometry). The exhaust gas is fed through a light current in the measuring head and the turbidity of the light beam measured. Brief heating of the measuring vessel enable fast measurements. The exhaust gas turbidity test can be made under stationary conditions both at constant speed and load and according to the free acceleration method. This instrument satisfies the measuring accuracy requirements compliant with ECE-R24. The measured turbidity value is represented in the following units of measure: light absorption coefficient k [m -1 ] light weakening factor N [%] 6.1 Description of the Measuring Head The diesel exhaust gas is fed through the measuring chamber by the shortest route via the probe positioned in the exhaust.the particle flow renders the light current radiated by the transmission head turbid and emerges again at both ends of the measuring cell. The optical measuring instrument consists of a green power LED as a transmitter and a photodiode as a receiver. This converts the optical signal into an electrical signal. Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 16 of 32

17 Several constructional measures guarantee reproducible measuring results, e.g. a sensor monitors the pressure ratios in the measuring chamber; a heater prevents condensation of the water vapor contained in the exhaust gas in the measuring chamber; a fresh air stream directed frontally against the exhaust gas flow prevents soiling of the lenses by soot particles This measure builds up a curtain of air which intercepts the soot particles and deflects them aside into the air; a microcontroller monitors the fan currents. The instrument checks and regulates the temperature in the measuring chamber of the measuring head and takes into account the temperature influence in determination of the measured values. 6.2 Commissioning The device should be operated in a clean, dry place at constant temperatures if possible. Air is blown into the measuring chamber of the measuring head by the fans on the transmitter and receiver head. The air serves to keep the lenses clean. The suction vents of the fan may become soiled by dust and moisture. The device should therefore be switched off and covered over when cleaning in the workshop. The following connections must be made first Connect the data cables to the measuring head. Connect the 15-pole plug of the data cable to the E-Box PC ( figure 1, item 5). Connect the device plug of the power cable to the measuring head. Plug the PE-contact plug of the power cable into a socket (230 V, 50 Hz). Note: The data cable may only be connected to the measuring head by plugging and pulling the data cable plug! The plug should only be held by the sleeve. Make sure that the red marks on the socket and plug are in line. Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 17 of 32

18 Avoid turning the plug at all cost: Danger of short-circuit. Avoid frequent plugging and unplugging of the measuring head. This prolongs the life of the connection. 6.3 Measurement Note: The diesel measuring head must be installed so that it is not in the exhaust gas flow of the vehicle to be measured. Installation to the side of the vehicle blow out direction of the exhaust pipe has proven most effective. Fix the sampling probe in the exhaust pipe Connect the desired speed sensor Start the measurement Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 18 of 32

19 7 Speed Measurement Different sensors can be connected to the E-Box PC for measuring the speed on an gasoline- or diesel engine. The software detects largely automatically which sensors are connected and which is currently supplying a speed pulse. The standardization and calculation of the speed from the pulses takes place automatically. Under certain circumstances the number of pulses per 720 rotation (this is equivalent to 2 full revolutions) of the crankshaft must be entered. 7.1 Clamp Sensor (option) The piezoelectric clamp sensor is connected to the socket (figure 1; item 8). The clamp sensor serves for measuring the speed of many diesel engines. It is laid around an injection line and tightened with the knurled screw. The crocodile clip is clamped to the lead. The tiny expansion of the injection line at every injection process generates an electrical pulse which is used to determine the speed. Clamp the sensor to a straight stretch of the injection line of cylinder 1. Clean the pressing surfaces of the clamp sensor with a clean cloth. Clean the injection line at the clamping position. The position concerned should be rubbed down with a fine sandpaper if it shows signs of scratches, grooves, dents, clear varnish, rust or corrosion. Clean the sanded area. The clamp sensor must fit exactly onto the injection line. Clamp the sensor cable to the clamp sensor and the ground clip to the injection line next to the sensor. The screw of the clamp sensor may not be too loose but not too tight either. Attention! The clamp sensor is a highly sensitive component. No warranty is provided for mechanically damaged clamp sensors. 7.2 Inductive Trigger Clamp Connect the inductive trigger clamp to the socket (figure 1, item 7). The inductive trigger clamp is used to determine the engine speed on many vehicles with an gasoline engine. It is clamped to one of the ignition lines to a spark plug or to the ignition coil supply line. Every ignition spark generates an electrical pulse in the clamp with which the speed is determined. Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 19 of 32

20 7.3 Cable for Measuring the Battery Residual Ripple Connect the battery cable to the socket (figure 1, item 6). The battery cable is clamped between the plus and minus poles of the car battery. The load on the battery by the ignition and the charging by the charge current of the dynamo generate a residual ripple of the battery voltage. This is measured by the E-Box PC and converted into an engine speed. This measurement works on most gasoline and diesel vehicles. In most of the cases it is not necessary to switch on another load (light, air conditioner, fan etc.), but this may improve the reliability, especially if the battery is highly charged. 7.4 TD Pulse The TD pulse is a signal which the engine electronics provide at the diagnostic plug of many vehicles. The same cable is used for the measurement with which the battery residual ripple (chap. 6.3) is measured. The crocodile clip can be removed for better adaptation. The TD pulse is tapped on the vehicle at the appropriate output of the diagnostic socket. 7.5 Terminal W Signal The same cable is used as for measuring the battery residual ripple (chap. 6.3). The cable is connected to the dynamo between ground and the W terminal on the vehicle side. The W -signal terminal is often near to the dashboard as a connecting contact for the speed measurement. 7.6 Conducting the Speed Measurement Warning! Warning! All intervention in and work on the ignition system may only be made with the engine at a standstill and the ignition switched off. When connecting the trigger clamp, sparkovers on defective ignition systems can cause injury to persons and damage to material. Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 20 of 32

21 8 Oil Temperature Measurement Connect the oil temperature probe to the socket (figure 1, item 9). The oil dipstick is removed from the engine block to connect the oil temperature probe. The rubber stopper of the probe is set so that the probe is the same length as the dipstick. Then it is pushed into the engine block in place of the dipstick. Warning! All manipulations and work with the dipstick may only be carried out with the engine at a standstill. Switch off the warm engine. Replace the dipstick with the oil temperature probe to measure the oil temperature. Measure the oil temperature. Replace the dipstick in the engine block. Start the engine to make the exhaust gas measurement. Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 21 of 32

22 9 Maintenance Note: Routine maintenance keeps the instrument in good working order. The E-Box PC must be serviced every six months. Some additional annual maintenance work is necessary. Maintenance can be performed by service or by trained specialists of the instrument operator. The maintenance work must be logged and certified. 9.1 Six Month Maintenance Change the filter GF1 (30) in the sampling hose Change the inlet filter GF2 (18) Check whether the transparent hoses at the gas outlets are connected properly (31, 32). Check the sampling probe (28) visually Check for leakage Sign to verify maintenance work 9.2 Annual Maintenance Check the measuring accuracy of the instrument with a test gas Change the active carbon filter (25) in the zero gas channel Change the pump protection filter GF3 (19) and GF4 (23) The regulations of the appropriate authorities must be observed. 9.3 Tightness of the Sampling System A tight sampling system is absolutely essential for accurate exhaust gas measurements. This should be checked daily with a leakage test. The instrument offers a leakage test function for this. 9.4 Sampling Probe (28) Keep the opening at the tip of the probe clean. In the case of HC residue and condensation, remove the sampling probe from the hose and blow out with compressed air against the direction of suction. 9.5 Filter GF1 (30) This filter cleans most particles from the gas flow. It should therefore be changed most frequently. Interval for changing, depending on how often the exhaust gas measuring instrument is used, about once a week. In the case of heavy soiling (error message: inadequate flow ), change the filter. Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 22 of 32

23 Change the filter in the case of stubborn HC residue. 9.6 Sampling Hose (31) Check for damage. In the case of HC residue and condensation, remove the sampling hose from the measuring instrument and blow out with compressed air against the direction of suction. 9.7 Input Filter GF2 (18) Interval for changing, depending on how often the exhaust gas measuring instrument is used, about once a month. In the case of heavy soiling (error message: inadequate flow ), change the filter. Change the filter in the case of stubborn HC residue. 9.8 Pump Protection Filter GF3 (19) and GF4 (20) These filters serve mainly to protect the pump. Change the filter once a year at the most. Note: Note: Note: Frequent changing of these filters shortens the life expectancy of the E-Box PC and increases internal soiling. Wet filters have a better filtering effect than dry ones. Non-original filters may contain metal plates which can rust. The loose rust particles destroy the pump. Use original filters only. Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 23 of 32

24 9.9 Changing the Filters: Remove the filter (18) together with the angle brackets (34) from the top and bottom unions of the Probench. Remove both brackets from the filter by turning slightly and attach them to the new filter. Plug the new filter with the angled hose pieces to the unions. Observe the installation position printed on the Probench Checking the Measuring Accuracy The accuracy of the measurement must be checked at two points once a year. This is done by two test gas mixtures. Warning! The test gas is odorless, inflammable and toxic! If a test gas bottle with a bottle pressure greater than 0.7 bar is used, a pressure reducer (according to DIN 477 for test gas with a backpressure of 4 bar) must be attached to the test gas bottle to prevent damage in the exhaust gas measuring instrument. Attention! The test gas loses its accuracy after a certain time (see certificate of the test gas). The test gas can no longer be used for calibration when the expiration date has run out! Recommended test gas concentrations (mixing accuracy +/- 5%, certificate accuracy +/- 2 %): Test gas A Test gas B 0.5 % vol CO carbon monoxide 200 ppm vol C3H8 propane 6 % vol CO 2 carbon dioxide (500 ppm vol NO nitrogen monoxide) 3.5 % vol CO carbon monoxide 2000 ppm vol C3H8 propane 14 % vol CO 2 carbon dioxide (2500 ppm vol NO nitrogen monoxide) Other test gas concentrations can also be used. Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 24 of 32

25 The test gases can either be supplied without pressure with a running pump at the sample gas inlet, see setup, or with the pump switched off with a flow rate of about 1 l/min to the calibration gas inlet (27). Make zero adjustment Apply test gas A Wait for a stable display The measured values may not deviate by more than +/- 0,03 % vol CO, +/- 10 ppm HC, +/- 0,5 % vol CO 2 and 25 ppm vol NO from the certified values of the test gas bottles. Consider the PEF factor of for HC! Apply test gas B Wait for a stable display The measured values may not deviate by more than+/-0,175 % vol CO, +/-50 ppm HC, +/-0,7 % vol CO 2 and 125 ppm vol NO from the certified values of the test gas bottles. Consider the PEF factor of for HC! The following error limits apply when other test gas concentrations are used: CO: HC: CO2: NO: +/ % vol CO or +/- 5 % of the certified value +/- 10 ppm vol HC or +/- 5 % of the certified value +/ -0.5 % vol CO 2 or +/- 5 % of the certified value +/- 25 ppm vol NO or +/- 5 % of the certified value 9.11 Checking the Flow Monitor Seal the zero gas inlet (active carbon filter (25)) on the Probench with your finger. Start the measurement. The error message Inadequate flow should appear after system adjustment. Release the zero gas inlet, block the sample gas inlet (test hose on tip of sampling probe). Start the measurement The error message Inadequate flow should appear after system adjustment. If these errors cannot be displayed like this, there is an error in the flow monitor. Have troubleshooting done by after-sales service Before Turning Off Before turning off the instrument it should be purged with ambient air to reduce the degree of soiling and prevent premature aging. To do this: Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 25 of 32

26 Make sure that the sampling probe is in free air (not in the exhaust). Start the measurement and leave running for one minute. End purging. Press the mains switch O2 Sensor The O 2 sensor wears out in time. The zero point of the oxygen measurement is monitored constantly. An error message. appears when it deviates. The O 2 sensor must be changed. Note: Only use original O 2 sensors. Warning! The O 2 measured value sensor contains lye. Caution caustic! Attention! The O 2 measured value sensor is toxic waste. It must be disposed of in accordance with the valid regulations. Installation of the O 2 measured value sensor. Note: The O 2 measured value sensor may take up to 30 minutes to reach the necessary measuring accuracy after unpacking. Disconnect the exhaust gas measuring instrument from the mains Pull out the Probench (14). Remove the plug of the O 2 sensor (21) and unscrew the O 2 sensor. Screw in the new O 2 sensor by hand without tools and replug the plug. Push in the Probench (14), fit over the cover. Connect the exhaust gas measuring instrument to the mains Maintenance Work on the Diesel Measuring Head The diesel measuring head has low maintenance. Only the optics and the sampling probe need to be cleaned from time to time Soiled Optics The optical components of the diesel measuring head are purged continuously by fresh air. Nevertheless they may still become soiled after a time. The optics must then be cleaned. Attention! Only clean with the instrument switched off! Attention! The measuring head is heated. The temperature may be 70 C or more. Wait at least 30 minutes until the measuring head has cooled down. Unscrew the exhaust gas probe from the measuring head. Remove the center heat protection cover. This gives access to the knurled screw in the middle of the measuring vessel. Loosen the knurled screw and lift up. Fold up the middle part of the measuring head. This gives good access to the optics in the fixed side units. Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 26 of 32

27 Clean the optical lenses with a lint-free cloth and a little alcohol. Mount the measuring head and exhaust gas hose in reverse order. Switch the instrument back on, wait for the warming up time and make a fresh air adjustment Cleaning the Exhaust Gas Probe The exhaust gas probe must be cleaned of soot and other deposits once a week depending on how often it is used. The permeability should also be checked. Unscrew the sampling probe from the measuring head. Clean heavy soiling with soap and a brush. Blow out internal soiling with compressed air. Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 27 of 32

28 10 Maintenance Certification Maintenance work E-Box PC Serial no. Date Type of work Company Name Signature Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 28 of 32

29 Date Type of work Company Name Signature Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 29 of 32

30 11 Scope of Delivery The scope of delivery of the E-Box PC includes: E-Box PC standard instrument Sampling probe, 400 mm long Test hose for leakage test Gas sampling hose 8 m viton 5x1.5 2 PVC hoses 0.7 m Sample line filter Battery cable for speed measurement Power cable 2 pcs. 0.8 A slow-blow fuses 250 V (spare) O 2 measured value sensor (built-in) Operating instructions Trigger clamp Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 30 of 32

31 12 Spare Parts, Expendable Parts, Special Accessories Designation Sampling probe, 400 mm long Test hose for leakage test Gas sampling hose 8 m viton 5x1.5 PVC hose 0.7 m 5x1.5 Filter (e.g. GF1, 2, 3) Active carbon filter O 2 sensor CLASS R 17A SIE Oil temperature sensor Inductive trigger clamp Speed connecting lead Order number C74211 A102 B55 C79451 A3301 B345 C79451 A3407 C250 C79451 A3407 C252 C79127 Z400 A1 C79127 Z1473 A1 W79085 G4003 X C79451 Z38 U13 C79451 Z38 U15 7MB1156 7AA02 Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 31 of 32

32 13 Technical Data Measurement Measuring Range Resolution CO range % vol CO % vol HC range ppm vol HC 1 ppm vol CO 2 range % vol CO % vol NO range ppm vol NO 1 ppm vol O 2 range % vol O % vol Lambda display Speed rpm 1 rpm range (depending on speed sensor) Oil temperature C 1 C Turbidity N 0-99 % 0.1 % Turbidity k m % Air factor λ Mains supply 100 V to 240 V 50/60 Hz Power consumption 60 V A Electromagnetic compatibility Class A compliant with EN Permissible ambient temperature +2 C to +45 C Permissible relative humidity 5 % to 90 %, no condensation Air pressure 700 hpa to 1100 hpa ( 300 m to 2500 m above NN) Position of use horizontal +/- 5 inclination Operational altitude min. 250 mm (length of discharge hoses) min. 300 mm Warming up time exhaust gas measurement 1.5 min Warming up time diesel measurement approx. 15 minutes System adjustment 30 s, automatic, if necessary Sample gas flow 4 l/min (min. 2/l/min, max. 6 l/min) Display response time < 15 s for 95 % of the measuring accuracy Weight 10 kg Temperature limits Storage temperature: -20 C to +65 C Continuous load for viton hose and sampling probe 200 C max. Peak load for sampling probe 250 C max. for < 3 min Copyright Siemens AG All rights reserved! Subject to technical modifications! Page 32 of 32