KANEAUTO 4-4 & KANE AUTO 5-4

KANEAUTO 4-4 & KANE AUTO 5-4 Hand Held Gas Analyser Kane International Ltd Kane House Swallowfield Welwyn Garden City Hertfordshire AL7 1JG Tel: +44 (0) 1707 375550 Fax: +44 (0) 1707 393277 E-mail: info@kane.co.uk www.kane.co.uk Stock No: 17991-2 February 2006

User Guide The KANE AUTO 4-4 analyser tests vehicle exhaust emissions for O 2, CO 2, HC, CO and optionally NOx in the KANE AUTO 5-4 All analysers have a protective rubber sleeve with a magnet for hands free operation. The large display shows 2 readings at a time and all data can be printed via an optional infrared printer. The printed data can be 'live' data or 'frozen data'. The analysers are controlled using 4 buttons and a rotary dial. The four buttons (from left to right) switch the analyser on and off, print actual or saved data, switch the backlight on and off, switch the pump on and off and save data. The buttons with UP, DOWN and ENTER arrows also change settings such as date, time, and the display s top line. The rotary dial changes the display s 2 nd line and selects access to the menu to make changes to the date, time, fuel, etc. The analyser can store up to 255 sets of readings. The analysers have a small internal battery which will power the analyzer in standby mode, this means that tests can normally be 'instant' as soon as external 12V power is applied. The internal battery will power the analyser in standby for 40 minutes, or so, from full charge. We recommend that when the instrument is running but not in use that it be connected to its battery charger or to a 12V supply for trickle charging. If the analyzer is switched off, overnight trickle charging should be enough time to recharge the internal battery. (Charging for extended periods when the unit is switched off may reduce battery life). In standby mode the pump, and backlight are off. For extended vehicle testing we recommend that the analyser's in-vehicle adaptor be used. Page 2 KANE AUTO 4-4 / KANE AUTO 5-4

1. BEFORE USING THE ANALYSER FOR THE FIRST TIME: Fully charge the analyser's battery with an overnight charge. Do not leave the analyzer on charge for much longer than 1 day or the internal battery life will be reduced. Set the analyser s correct time, date, fuel source, etc, after it is switched on and calibrated See USING THE ROTARY DIAL below. These are stored when the analyser is switched off. 2. BEFORE USING THE ANALYSER EVERY TIME: Check the water trap is empty and the particle filter is not dirty: - To empty water trap, unplug its rubber stopper and re-plug once it is empty. - To change the filter, remove protective rubber sleeve, pull out the water trap unit from the analyser, remove the water trap s particle filter from its spigot and replace. Reconnect the water trap and rubber protective sleeve. Check the exhaust probe and hose for damage. A leaky hose or probe will give erroneous readings, in particular the oxygen readings will be higher than expected. After switch on, check fuel type, date and time are correct and battery power is sufficient. SAFETY WARNING This analyser extracts combustion gases that may be toxic in relatively low concentrations. These gases are exhausted from the back of the instrument. This analyser must only be used in wellventilated locations by trained and competent persons after due consideration of all the potential hazards. Page 3 KANE AUTO 4-4 / KANE AUTO 5-4

3. USING THE ANALYSER AND ITS FOUR BUTTONS: Switching ON the Analyser Press button to switch the unit ON in fresh air. This lets the analyser auto calibrate its sensors properly. Take care because in most workshop environments there can be high levels of HC up to 1 metre (3 feet) above floor level. When ZERO CAL is shown on screen the pump will stop, press enter to start Zero. On switch on, the analyser beeps four times and displays on its top line the default fuel, the date and time and optionally the model number. Its bottom line counts down from typically 99 until the sensors are ready to use. If the analyser will not auto calibrate, one or more of its sensors need to be replaced or recalibrated by an authorized repair center. When countdown is finished the display s top line shows the last selected function and the bottom line displays whatever the rotary dial is turned to. Switching OFF the Analyser Press button to switch the analyser OFF. The display counts down from 30 with the pump on to clean the sensors with fresh air If the probe is still connected, make sure analyser and probe are in fresh air. Press HOLD / ENTER if you want to stop the countdown and return to making measurements. Using UP / DOWN / ENTER Buttons Press the DOWN button for more than 1 second to change the display s top line. The Rotary Dial changes the display s bottom line. For example, the analyser will display CO 2 on its top line and Lambda on its bottom line if you turn the rotary dial to Lambda and push the DOWN button until CO 2 is displayed on the top line. Use the UP / DOWN / ENTER keys to change settings (such as time, date and fuel) when the rotary dial is turned to MENU. In normal operation (not MENU) the ENTER key is used to either HOLD the readings for printing (a short button press) or to save readings if memory locations are available (a long button press). The display will flash STORExxx to give the store location of the saved data or will continue to flash if held until reset by a short button press. Page 4 KANE AUTO 4-4 / KANE AUTO 5-4

Switching on and off the backlight. Press and release PRINT / BACKLIGHT quickly to switch backlight on or off. Printing Data Press for more than 1 second before releasing to start the analyser printing. The analyser displays "PRINTING" until this is completed. Make sure the printer is switched on, ready to accept data and its infrared receiver is in line with the analyser s emitter (on top of the analyser). Switching PUMP on / off The analyser normally operates with the pump on. Press PUMP quickly to switch the pump off and on. If the internal battery is low the pump will switch off. When the pump is switched off, the analyser displays "PUMP OFF" approx every 30 seconds. See notes later on BATTERY SAVING MODE Freezing the display Press HOLD / ENTER to freeze all readings. The display flashes and can be printed by pressing PRINT key. Press HOLD / ENTER again for live measurements. Page 5 KANE AUTO 4-4 / KANE AUTO 5-4

4. USING THE ROTARY DIAL (starting from Menu): Rotating the dial selects the display s 2 nd line, unless MENU is selected. rotor positions are: Menu Time Date NOx 5 gas version only O2 CO2 CO HC Fuel time to zero Lambda/AFR COK air free Page 6 KANE AUTO 4-4 / KANE AUTO 5-4

MENU SELECTION MENU Rotate the dial to MENU and use the UP or DOWN buttons to select the following function for change: 1. Time Uses Military time as standard: 7am = 07:00, 7pm = 19:00 2. Date with date format selection 3. FUEL 4. LAMBDA/AFR will blank if the O2 reading is high 5. The display s contrast 6. Language 7. ZERO - if O2 reading is low unit will wait and display PROBE? To remind you to remove the probe from the exhaust.press enter to start. Zero will run about 45 seconds after O2 reading goes high. 8. Battery Save if selected automatically swiches off pump after brief operation. 9. Service Password protected. Level 1 for user re-calibration. Level 2 for authorized service personnel only. 10 Memory functions When you have selected the function to change, press ENTER to select. Repeat this to scroll through the menu and select (using the ENTER key) and change (using the UP / DOWN keys) the function. The final, logical ENTER returns you to the main menu display. To exit the Menu function at any time, rotate the dial to another position - Unless the final logical ENTER is pressed, no changes are made. Note: in ZERO mode, once the mode is entered it will continue until finished. Page 7 KANE AUTO 4-4 / KANE AUTO 5-4

MEMORY Functions With the rotor pointing to MENU use the UP/DOWN keys to select MEMORY and press ENTER The UP/DOWN keys can then be use to select : VIEW AUTOSTORE CLEAR Press ENTER to choose. VIEW The top line displays VIEW The bottom line displays the last viewed number or 1 Use UP/DOWN to select next view number ( within the range of data stored ) Press ENTER to select The top line displays for example : V 01 The bottom line displays the stored info as selected on the rotary dial Use UP/DOWN to scroll to later or earlier data. Hold down the print button to print one set of stored data Press ENTER to exit back to start. AUTOSTORE Zero may operate during auto store, If you need a sequence of up to 30 minutes of continuous readings it is recommended that you select ZERO via the menu before starting a series of Auto stored readings. ON /OFF and INTERVAL The top line displays AUTO STO Use the UP/DOWN keys to select from OFF or ON If you select on then use the UP and DOWN keys to set the logging interval TIME 2-60 secs Press ENTER to select The display top line will then revert to MENU Select any required position on the rotary dial. Every time readings are stored the top line will flash LOG from 0 if the memory is reset or from the last store number until the memory is full or until the pump is switched off. There will also be a beep for every store. Page 8 KANE AUTO 4-4 / KANE AUTO 5-4

CLEAR The top line will display CLEAR? The bottom line will display NO Use the UP/DOWN keys to toggle between NO and YES Press ENTER to select and exit. Page 9 KANE AUTO 4-4 / KANE AUTO 5-4

ROTARY DIAL POSITIONS - FUNCTIONS MENU Enters MENU mode TIME Displays Time DATE Displays Date in user selected format NOx (5 gas version only) Displays NOx values in ppm for 5 gas version Displays "- - - - " for 4 gas version O 2 Displays Oxygen values in %. CO 2 Displays calculated Carbon Dioxide values once O 2 values are below 18%. CO Displays carbon monoxide reading in %. HC Fuel Displays hydrocarbon reading in ppm hexane for petrol/gasoline propane for LPG methane for CNG Displays fuel selected T to zero Displays time left before next zeroing is required LAMBDA/AFR Displays Lambda or AFR according to user selection COK Displays the calculated air free CO reading Page 10 KANE AUTO 4-4 / KANE AUTO 5-4

5. MEASURING EXHAUST GASES After the countdown is finished and the analyser is correctly set up, put its probe into the vehicles exhaust. Make sure you do not exceed the analyser s operating specifications. In particular: Do not exceed the probe s maximum temperature (any plastic parts must not contact exhaust). Do not exceed the analyser s internal temperature operating range Do not put the analyser on a hot surface Do not exceed the water trap s levels Do not let the analyser s particle filter become dirty and blocked View data and rotate the dial to see changes as you make adjustments. Press HOLD first to freeze the readings before printing. Press PRINT to print the results. Every 30 minutes the analyser will automatically demand to be re-zeroed. This needs to be done with the probe or gas inlet in fresh air. Alternatively before starting a test sequence you can cause the sensors to re-zero using the ZERO function in MENU. Page 11 KANE AUTO 4-4 / KANE AUTO 5-4

EXAMPLE PRINTOUT IN AMBIENT AIR The standard printouts are: AUTO -- Date: 26 / 12 /02 Time: 14:27:08.. Fuel LPG O2 % 20.9 CO2 % 0.0 HC ppm 0 CO % 0.0 COK 0 Lambda ------ AUTO -- Date: 12 / 26 /02 Time: 14:27:08.. Fuel :PETROL/ GASOLENE O2 % 20.9 CO2 % 0.0 HC ppm 0 CO % ----- COK % ----- LAMBDA ----- NOx ppm 0 Page 12 KANE AUTO 4-4 / KANE AUTO 5-4

Battery saving features To assist in prolonging battery life the analyser's pump and back light will switch off if the internal battery is low. The pump may be switched back on briefly a number of times to allow readings to be taken for about 1 minute. In all cases when the internal battery level reaches a critical point where measurement accuracy may be compromised, the analyser will go into sleep mode to conserve power so that normal operation can be resumed when external power is applied. To protect the internal battery from deep discharge the analyser will be switched off completely if the battery level falls too low. See battery save function in MENU SELECTION. NOTE: Allow a few seconds for readings to stabilize when re-connecting to external power. Page 13 KANE AUTO 4-4 / KANE AUTO 5-4

6. WHEN YOU FINISH USING THE ANALYSER Leave the analyser connected to an external supply. Remove its probe from the exhaust - THE PROBE WILL BE HOT - let it cool. Do not put the probe in water which will be sucked into the analyser, damaging its pump and sensors. When the analyser s readings return to ambient levels, switch it off. The analyser counts down from 30 before switch off with the pump running to self clean its sensors. 7. ANALYSER PROBLEM SOLVING If any problems are not solved with these solutions, contact us or an authorized repair center. Fault symptom Oxygen too high CO 2 too low Oxygen reading (- - - -) Causes / Solutions Air leaking into probe, tubing, water trap, connectors or internal to analyser. Oxygen cell needs replacing. Analyser was stored in a cold environment and is not at normal working temperature. Oxygen cell is exhausted Pump is switched off Batteries not holding charge Analyser not running on mains adapter. Analyser does not respond to exhaust gas Batteries exhausted. AC charger not giving correct output. Fuse blown in charger plug. Particle filter blocked. Probe or tubing blocked. Pump not working or damaged with contaminants. 8. ANALYSER ANNUAL RECALIBRATION AND SERVICE Although sensor life is typically more than two years, the analyser should be re-calibrated and serviced annually to stop any long-term sensor or electronics drift or accidental damage. Local regulations may require more frequent re-calibration. Page 14 KANE AUTO 4-4 / KANE AUTO 5-4

9. ANALYSER SPECIFICATION (NOTE MAY BE SUBJECT TO CHANGE) Parameter Resolution Accuracy*1 vol % Specified Range OVER RANGE Gas Measurement Oxygen 0.02% + / - 0.25% + / - 5% 0-21% 25% Carbon Monoxide 0.01% + / - 0.15% + / - 10% 5% 20% Carbon Dioxide *2 HC 0.1% 1 ppm + / - 0.5% + / - 20ppm + / - 10% + / - 10% 0-15% 2000 ppm n/a 30,000ppm NOx (5 gas version only) 1 ppm + / - 20ppm + / - 10% 1500ppm *3 5000ppm *3 Pre-programmed Fuels Dimensions Weight Handset Probe Ambient Operating Range Battery Life Petrol/gasoline, LPG, CNG 1kg / 2.2lb 200mm / 7.9 x 45mm / 1.8 x 90mm / 3.5 4m neoprene hose & 20 cm (insertion length) stainless steel flexible probe +0 C to +40 C / 32-104 F 10% to 90% RH non- condensing 20 mins from full charge AC adapter Input: 110Vac/220 Vac nominal Output: 12 V dc *1 *2 *3 Using dry gases at STP with the instrument not subjected to sudden changes of temperature, pressure, position or severe vibration - CO calibration applies to exhaust gas only. Calculated 5000ppm is absolute maximum, avoid prolonged reading above 1500ppm NOx as sensor life may be reduced. NOx Zero may need to be reset by switching the unit on and off in fresh air. Note: With the fuel set for CNG the HC reading is more sensitive to fluctuations then when the fuel is set for Petrol Page 15 KANE AUTO 4-4 / KANE AUTO 5-4

10. ELECTROMAGNETIC COMPATIBILITY European Council Directive 89/336/EEC requires electronic equipment not to generate electromagnetic disturbances exceeding defined levels and have adequate immunity levels for normal operation. Specific standards applicable to this analyser are stated below. As there are electrical products in use pre-dating this Directive, they may emit excess electromagnetic radiation levels and, occasionally, it may be appropriate to check the analyser before use by: Use the normal start up sequence in the location where the analyser will be used. Switch on all localized electrical equipment capable of causing interference. Check all readings are as expected. A level of disturbance is acceptable. If not acceptable, adjust the analyser s position to minimize interference or switch off, if possible, the offending equipment during your test. At the time of writing this manual (Dec 2002) Kane International Ltd are not aware of any field based situation where such interference has occurred and this advice is only given to satisfy the requirements of the Directive. This product has been tested for compliance with the following generic standards: EN 50081-1 EN 50082-1 and is certified to be compliant Specification EC/EMC/KI/A5-4 details the specific test configuration, performance and conditions of use. Page 16 KANE AUTO 4-4 / KANE AUTO 5-4

SERVICE MODE This mode can be selected from MENU and gives password protected access to certain functions WARNING: entering inappropriate codes may corrupt the calibration of this instrument. The User Level pass code to read PEF is 3333. The User level pass code to view software issue is 1111 CAL: RESET CAL: This allows the analyser's calibration to be updated to match local calibration gases. (depending on model) (depending on model) This allows the analyser's calibration to be reset to its original factory calibration Page 17 KANE AUTO 4-4 / KANE AUTO 5-4

Appendix 1 - Main Parameters: Here are the legends used and what they mean: O 2 : Oxygen reading in percentage (%) CO: Carbon Monoxide reading displayed in % COK Carbon Monoxide calculation as if there were 0% Oxygen present. CO 2 : Carbon Dioxide calculation in %. HCh: HCp: NO: BAT DATE : TIME : LAMBDA: AFR: Hydrocarbon reading referenced to hexane Hydrocarbon reading referenced to propane Oxides of nitrogen reading in ppm Displays the nominal internal Battery Voltage or internal Supply Date shown as day, month and year. The order can be changed using the menu function. Date is recorded when each combustion test is printed. The time is shown in hours and minutes, expressed in Military time or the 24hr clock. Time is recorded when each combustion test is printed. Gives an indication of the burning efficiency of the engine. An alternative to Lambda. For petrol/gasoline fuel AFR = Lambda x 14.7. For LPG fuel AFR = lambda x 15.6 (typically). Page 18 KANE AUTO 4-4 / KANE AUTO 5-4