Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Related Manuals for Bosch ETT 008.31
Summary of Contents for Bosch ETT 008.31
- Page 1 Repair instructions Exhaust gas analyzer ETT 008.31 - ETT 008.38...
-
Page 2: Table Of Contents
Contents: Page Contents: Page Important information Checking the start-up process Compulsory calibration Checking the ”Analysis” function Checking fault monitoring Servicing the analyzer Performing the leak test Half-yearly service Yearly service Checking and fine-tuning measuring accuracy Test equipment for customer service Taking account of barometric altitude Test gases for customer service Checking the indicating accuracy... - Page 3 Contents: Page 10.5 Service limit values 10.5.1 Adjusting the channel amplifier 10.6 Installing the O measuring sensor (up to software version A10) 10.6.1 Installing and calibrating the measuring sensor 10.7 Replacing the battery 10.8 Replacing the motherboard 10.9 Replacing the sensor board 10.10 Replacing the pump seal kit Safety test...
-
Page 4: Important Information
Important information Servicing the analyzer The service work described below must be carried out irrespec- Service and repair work on this piece of equipment may only be tive of the applicable laws in the country of operation. performed by competent, that is, adequately instructed and authorized persons. -
Page 5: Test Equipment For Customer Service
Test equipment for customer service Test gases for customer service (with manufacturer's certificate) 1 siphon, water gauge 100 cm, inside diameter max. 8 mm 1 flow meter (variable-area type), measuring range 1.0 l/min. In order to save on bottles of test-gas, mixed gases are sometimes to 10 l/min., measuring medium air, 20 °C, 1 bar absolute recommended. -
Page 6: Brief Description Of Appliance Function
Brief description of appliance function System adjustment The exhaust-gas analyzer is designed for the following measuring After the warm-up time and during various other processes, the ranges: exhaust-gas analyzer performs a system adjustment in con- junction with a self-test. Each time that the exhaust-gas analyzer Carbon monoxide (CO) 0...10.00 % vol. -
Page 7: Compensation Of Temperature Influence
(PU) for each two crankshaft 3.14 Filtration revolutions. The pulse count is adjusted using the button for ! Only Original Bosch filters part number 1 687 432 005 may selecting 2-stroke or 4-stroke measurement (Figure 1, Pos. 14). be used! Examples: 4-cylinder four-stroke engine;... -
Page 8: Extended Operating Functions
Extended operating functions The functin switch S 60 on the side of the analyzer has three 1 - 0 - 2 settings which allocate various modes to the ”Select” , ”Enter o ” and ”Test u buttons. SELECT Switch position 0: Input mode (auxiliary function) and test mode S 60 ENTER... -
Page 9: Input Mode
Input mode (switch S 60 at position 0, auxiliary functions) Input mode permits you to carry out various checks and setting work on the device. An" for "Display"("Anzeige") appears in - Select the individual functions using the "Select" button. A code for each function and "An the oil-temperature display field. -
Page 10: Leak Test
4.1.1 Leak test Press "SELECT" Display Meaning/function The pump starts up. The analysis system is purged for 20 sec. with zero gas L E.Ei 6A5" flashes to prompt the flow of test gas. The display "6A5 - Either suck up car exhaust gas*) via the exhaust sample probe (the test gas pump can be switched on with the "Enter o o o o o "... -
Page 11: Lambda Measurement On / Off
4.1.2 Lambda measurement ON / OFF Press "SELECT" Display Meaning/function Press "Enter o" to switch lambda calculation on L A.Ei lambda calculation off. L A.Ei 4.1.3 O measurement ON/ OFF Press "SELECT" Display Meaning/function Press "Enter o" to switch O - measurement on 02.Ei measurement off. -
Page 12: Co Correction Co
4.1.4 CO correction CO ON / OFF vrai Press "SELECT" Display Meaning/function Press "Enter o" to switch CO correction on C0.Ei CO correction off. If CO correction is switched on, the corresponding value is printed out on the printer log. C0.Ei 4.1.5 Summer time ON / OFF Press... -
Page 13: Air-Pressure Gauge On / Off
4.1.6 Air-pressure gauge ON / OFF Press "SELECT" Display Meaning/function If an air-pressure gauge is built in, press the "Enter o" button to activate the correction of pressure influence in accordance with the values measured by the pressure gauge. Pr.Ei no no no"... -
Page 14: Fine-Tuning The Zero Of O
4.1.8 Fine-tuning the zero of O (from software version A 13) Press "SELECT" Display Meaning/function An automatic process is executed. 10.02 0F.Ei 28.05 The current date is shown in the display window for HC and CO. 2525 In the O display window, the voltage value from the O measuring sensor is displayed. -
Page 15: Selecting A Printer
4.1.11 Selecting a printer Press "SELECT" Display Meaning/function 11 x The following settings are possible: 1 1 1 1 1 = external printer 20 characters (Switzerland) 2 2 2 2 2 = internal printer (PDR 078) 3 3 3 3 3 = external printer (PDR 200) L P.Ei 4.1.12 Selecting the operator terminal Press... -
Page 16: Error Messages Regarding Temperature
4.1.13.1 Error messages regarding temperature compensation no no no". - Temperature-compensation selection is set to "no - Temperature compensation was started during the warm-up phase. Err1 - Device had not cooled sufficiently prior to temperature compensation. - Ambient temperature fluctuated greatly during temperature compensation. -
Page 17: Test Mode ( Switch S 60 At Position 0)
Test mode ( switch S 60 at position 0) In this menu, internal measured values and device settings can be displayed for the purpose of assessing error messages when repairing the device. To display this information, press the "Test u" button once or several times. The indicated mea- sured value or analyzer parameter remains on display for the duration that the "Test u"... - Page 18 Press "Test u u u u u " Display Meaning/function Measured supply voltage (auxiliary power) in % of the nomi- nal mains value. 3.494 The output voltage of the air-pressure gauge is shown in the HC display field. Err" appears in The current air pressure or an error message "Err the display field for engine speed (see Section 8.9).
- Page 19 Fine-tuning mode (switch S 60 at position 1, mean values, air-pressure gauge and chopper-motor recognition) Procedure Display Press button Press simultaneously Current measured Current setting value Function symbol in value in display in engine-speed temperature display window d.An d.An d.An d.An d.An Select 1 x...
-
Page 20: Fine-Tuning Mode
Fine-tuning mode (switch S 60 at position 2, upper-range values, activation of temperature compensation and setting appropriate version for country of use) Procedure Display Press button Press simultaneously Current measured Current setting value Function symbol in value in display in engine-speed temperature dislpay window window window... -
Page 21: Function Test
Function test Visual inspection (device is switched off and disconnected from mains) - Check safety seal on rear wall of housing: If used in countries with compulsory calibration, the device must be calibrated again if the seal is damaged. - Check that power cord is in perfect condition, replace if damaged. - Check that mains jack and female connectors for the clamp-on speed sensor and oil-temperature sensor are secure. -
Page 22: Checking The Start-Up Process
Checking the start-up process Switch on the device, monitor the sequence by viewing the display: Sequence Time Display Press mains button, appliance indicates version: U13U A.15 A,x = Release x 5 sec. Segment test. All display elements light up, 8888 8888 including the LED above the buttons. -
Page 23: Checking The "Analysis" Function
Checking the "Analysis" function In analysis mode, the device automatically performs a system adjustment every 15 minutes. However, if analysis is taking place at that moment, the next system adjustment is only initiated once analysis has ended, i.e. as soon as the probe is withdrawn from the exhaust pipe and the measured values have dropped to zero. -
Page 24: Checking Fault Monitoring
- Fluctuations (noise) may be caused by dirt in the analyzer part, a defective receiving chamber, a faulty (noisy) channel amplifier or an unstable reference voltage 5 V Dirt in the gas-conveyance system primarily affects the HC measuring channel. Whenever errors caused by dirt arise, cross sensitivity to condensation also increases. -
Page 25: Checking And Fine-Tuning Measuring Accuracy
Checking and fine-tuning measuring accuracy ! Before commencing testing or fine-tuning work as described in Sections 6.2 or 6.3, the analyzer must be warmed up for a period of 10 minutes. The cover of the device must be closed during this time. It is essential to note the instructions in Section 6.1 before checking and fine-tuning measuring accuracy. -
Page 26: Fine-Tuning The Indicating Accuracy
Fine-tuning the indicating accuracy In devices for which calibration is compulsory by law, the calibration seal on the rear wall of the device must be removed for fine-tuning. To do so, loosen the screw beneath the seal and swivel the safety panel to the side (function switch S 60 is now accessible). The gas outlet must lead to the open air and have a sufficiently wide cross section. -
Page 27: Checking Cross Sensitivity
b) Fine-tuning the mean value Set function switch S 60 to position 1 (mean values). Select the HC channel using the "Select" button, and simultaneously press ”Enter o” to switch on the fine-tuning function. d.Ei d.Ei d.Ei d.Ei d.Ei (set mena value) °C display window: HC display window: Current measured value... -
Page 28: Fine-Tuning The Air-Pressure Gauge
Fine-tuning the air-pressure gauge The analyzer requires two reference points in the range of 700 to 1100 mbar. These points should be spaced by approx. 100 mbar. In both cases, a reference pressure is set in the device as default, and the device ascertains the exact value of this reference pressure as part of the fine-tuning function. - Page 29 Fine-tuning Set function switch S 60 to position "1". Call the air-pressure gauge function with the "Select" button, "bo An bo An bo An bo An bo An" is displayed. Press "Select" and Taste "Enter o" at the same bo.Ei bo.Ei bo.Ei bo.Ei"...
-
Page 30: Recognition Of Chopper Motor
Press "Select" Display Meaning/function Ab5o Ab5o" fine- Ab5o Ab5o The analyzer then automatically switches to the "Ab5o tuning function. The display "700" appears in the CO display field. Adjustment range: 700 hPa to 1100 hPa Ab5o bo.Ei Perfrom fine-tuning with the "Enter o" or "Test u" buttons. After this, do not press any buttons;... -
Page 31: Error Messages / Malfunctions
Error messages / malfunctions The exhaust-gas analyzer is equipped with extensive self-test functions. Malfunctions which can be detected automatically are indicated by means of the error messages described below (Sections 7.1 to 7.3). Error messages are displayed in two forms: a) One group (Sections 7.1 and 7.2) takes the form of binary numbers (1, 2, 4, 8, etc.). -
Page 32: Error Messages In The Co 2 Display Field
Error messages in the CO display field Error messages Possible cause Trouble-shooting Flow disturbed during zero adjustment See Section 8.2 "Flow faults" Flow of test gas disturbed See Section 8.2 "Flow faults" Fault in measuring-channel identification See Section 8.5 "Faulty channel identification"... -
Page 33: Symbolic Error Messages
Symbolic error messages Error messages Possible cause Trouble-shooting Oil-temperature probe not connected or Connect oil-temperature probe and perform incorrect processing of measured values trouble-shooting to Section 8.11 "Faulty oil- temperature measuring channel" Engine-speed clamp-on sensor not connected Connect engine-speed clamp-on sensor or incorrect processing of measured values and perform trouble-shooting to Section 8.10 "Faulty engine-speed measuring... -
Page 34: Other Malfunctions
Other malfunctions Malfunction Trouble-shooting to Section: Control-panel keys defective, 8.3 "Indicating faults" or replace display module. appropriate LED does not light Pump does not start up. 8.14 "Faulty pump actuation" Function switch S 60 8.15 "Checking the sensor-board" appears defective. Main switch appears defective. -
Page 35: Checking For An Obstruction
8.2.1 Checking for an obstruction In the zero-gas system: - Open the device. - Remove coarse filter GF 4 from hose 8. - Press the "Pump" button. Error message remains: Remove hose 9 from test-gas pump, press "Pump" button. Error message remains: Perform check to Sections 8.2.2 to 8.2.4, or Error message no longer shown: Solenoid valve is not switching over. -
Page 36: Checking Air-Tightness
8.2.2 Checking the pressure switches - Switch off the device. - Connect the calibration-gas inlet and the outlet for gas and condensation and connect to a siphon as illustrated. Keep hoses short. - Connect a multimeter (continuity test) to pressure switch pins 3 and 1 (pin 2 is not internally connected!) - Carefully introduce pressure P (blow into the hose). -
Page 37: Checking The Pump Delivery Rate
8.2.4 Checking the pump delivery rate - Connect the flow meter to the test-gas inlet. - Press the "Pump" button. Check: That a delivery rate of > 4 l/min is achieved during zero adjustment. That an overall delivery rate of > 8 l/min is achieved after zero adjustment. -
Page 38: Indicating Faults
Indicating faults In the case of a fault on the display, we must distinguish between the following: - If the error message Err 32 Err 32 Err 32 Err 32 Err 32 appears (fault in the display control), simply replace the display module without performing further tests. - Likewise, if a single segment or an LED has failed, replace the display module. -
Page 39: Ram Check Error
RAM check error System parameters are stored in the RAM module. During the RAM check, these system parameters are monitored to ensure that they remain within sensible limits pre-defined by the manufacturer. If the RAM contents are outside these limits, an error message results. A faulty RAM content may have various causes: - A faulty powwer supply (battery) - Replaced motherboard... -
Page 40: Faulty Channel Identification
Faulty channel identification The "channel amplifier" modules feature a coding plug S 1. The connection assigned here enables the microprocessor unit (MPU) to identify the measuring channel in question. Take care to ensure the correct coding when replacing a receiving chamber! Check that the jumper plug is correctly situated. -
Page 41: Faulty Channel Amplifier
Faulty channel amplifier Amplifier output signal outside permitted range during zero adjustment. The MPU detects a voltage < 1.0V (lower limit) or > 3.5V (upper limit) in the measuring channel on the motherboard (X 107, X 207 or X 307) designated by the fault number. Diagram, circuit diagram of channel amplification, simplified representation If sum-total error 7 (Err 1 + 2 + 4) occurs, a fault in the chopper motor or lamp is probable. - Page 42 Amplifier signal lies outside one of the limit values: - With the digital multimeter (DMM), check the signal of the channel amplifier concerned at X 7 (reference point X 9) to see whether it matches the measured value on the motherboard (at X 107, X 207 and X 307). For performing measurements on the channel amplifiers, unscrew the analyzer part (3 screws on the back of the chopper) and temporarily fasten it with a screw in a bore-hole in the upper edge of the device's rear wall.
-
Page 43: Faulty Sensor Board Identification
Faulty sensor-board identification The self-test routine detects faulty equipment on the sensor board. For "Sensor board" location diagram of components, see section 8.15, "Checking the sensor board". Check: - Has the wrong sensor board been installed (check ordering data!)? - Is there a fault in the hardware? Using the DMM, measure on the sensor board: X 83 MA = reference point... -
Page 44: Faulty Engine-Speed Measuring Channel
8.10 Faulty engine-speed measuring channel In the case of an error message concerning engine-speed measurement: - Check that the selector button for 2-stroke / 4-stroke is correctly set. - Check whether the fault can be remedied by installing a new clamp-on speed sensor. - Check the pulse input. -
Page 45: Faulty Oil-Temperature Measuring Channel
8.11 Faulty oil-temperature measuring channel - Check the sensor resistance: Pin1 to pin 2 = 1005 + 5 Ω @ 25 °C 1530 +12 Ω @ 90 °C or check whether the fault can be remedied with a new sensor. - Sensor OK: switch off and open the exhaust-gas analyzer. -
Page 46: Supply-Voltage Alarm
8.13 Supply-voltage alarm The exhaust-gas analyzer internally monitors the voltage at the filter capacitor C1 (nominal value 10V, see circuit diagram, Sections 12.1 and 12.2). An error message is displayed when the voltage drops below a lower limit of approx. 7.6V or exceeds an upper limit of approx. 12.5 V. This ensures that the exhaust-gas analyzer is unable to perform incorrect analysis when subject to under-voltage or overvoltage. -
Page 47: Checking Function Of Switch S60
8.15.3 Checking function of switch S 60 - Connect the DMM to X81 (reference point, MD). - Measure at X60 and X61 V + 5.2V. - Press switch S60, check: At setting 1, LED H61 lights up, X61 = 0V At setting 2, LED H60 lights up, X60 = 0V. -
Page 48: Sensor Board, Component Location Diagram
8.15.5 Sensor board, component location diagram... -
Page 49: Power Supply To Power Electronics
8.16 Power supply to power electronics The covered parts of the printed circuit board carry live voltage. Do not remove the cover! An auxiliary supply of AC 110 V is supplied by the transformer via connector X 1. This voltage is switched through electronically to the pump via connector X 2. -
Page 50: Power Supply To Motherboard
8.17 Power supply to motherboard Also refer to circuit diagram in Sections 12.1 and 12.2. This diagram illustrates the voltages at the transformer and filter capacitor C 1 and their distribution in the exhaust-gas analyzer. Diagram, power supply to motherboard (simplified representation) Here, check that the voltages on the motherboard are in conformity with the table below. -
Page 51: Motherboard, Component Location Diagram
8.17.1 Motherboard, component location diagram... -
Page 52: Functions Of The Serial Interface
Functions of the serial interface Technical data of serial interface V24 Pin assignment: Signal Printer log Shield 1200 baud 1 Start bit 8 Data bits 0 V/V24 no parity bit 2 stop bits Number of characters per line for printout = 20 characters ! Ensure the correct setting for the printer! See Section 4.1.11. -
Page 53: Selecting "Language
9.2.2 Selecting "Language" Sequence Keypad entry Exhaust gas analyzer Feedback Receives and sends feedback Receives and starts input procedure for language "Language", sends "Language" Receives "German", Feedback Receives "French", sends back Receives "Italian", sends back An incorrect entry (only "D", "F" and "I" are permitted) in this field is interrupted by the analyzer which prompts you once more to enter the language with "*Language:". -
Page 54: Entering The Date/Time
9.2.4 Entering the date/time Sequence Keypad entry Exhaust-gas analyzer Feedback Receives and sends back Receives and starts input procedure Day: by transmitting "TAG" 1(2) digits, CR Receives and stores both digits as MONTH: DAY in the clock element. Transmits "MONTH" 1(2) digits, CR Receives and stroes both digits as YEAR:... -
Page 55: Repair Work
10. Repair work 10.1 Replacing the lamp - Remove the 3 fastening screws (1) of the complete unit on the rear wall of the device. - Lift up and remove the analyzer part. - Remove the screw (2) and the retaining bracket (3). -
Page 56: Cleaning The Analyzer Part
i Here, likewise, use Extran MA 10.4 Cleaning the analyzer part cleaning fluid (see Section 10.1 on cleaning the lamp). Procedure: - Remove the analyzer part. - Unscrew the analyzer part components and clean the seals (1) and windows (2) with a damp, lint-free cloth. -
Page 57: Adjusting The Channel Amplifier
i The amplification of the channel amplifier in question must only be adjusted if, 10.5.1 Adjusting the channel amplifier following replacement of a receiving chamber, the new receiving chamber does not comply with the ADC limit values of + 1.5 V to + 3 V. In new analyzers, the amplification is fine-tuned together with the actual integrated components - lamp, analyzing chamber and chopper. -
Page 58: (Up To Software Version A10)
10.6 Installing the O measuring sensor 10.6.1 Installing and calibrating the O2 measuring sensor (up to software version A10) (from software version A13) - Disconnect the exhaust-gas analyzer from the mains. - Disconnect the exhaust-gas analyzer from the mains. - Unpack the O measuring sensor and unscrew the closure cap. -
Page 59: Replacing The Motherboard
10.8 Replacing the motherboard The motherboard contains a battery-backed RAM module. The system settings are stored in this module. These settings must be re- entered when the motherboard has been replaced. - Replace the motherboard. - Insert a battery (Section 10.7). - Switch on the exhaust-gas analyzer and wait until system adjustment is complete. -
Page 60: Safety Test
Safety test The mains plug is removed, the mains switch of the specimen device is switched on. (to DIN 57411 / VDE 411) Following assembly work on the exhaust-gas analyzer, check that all protective conduc- tors are correctly connected and mechanically secure. For protective-conductor con- nections, refer to the circuit diagram in Sections 12.1 and 12.2. -
Page 61: Diagrams, Circuit Diagrams And Gas-Route Diagram
Diagrams, circuit diagrams and gas-route diagram 12.1 Circuit diagram 1... - Page 62 12.2 Circuit diagram 2...
-
Page 63: Gas-Route Diagram
12.3 Gas-route diagram... -
Page 64: Diagrams
12.4 Diagrams Figure 1 Figure 2 SELECT ENTER TEST Coarse filter GF 1 Mains socket for non-heating appliances Input filter GF 2 Condensation outlet Condensation tank Serial interface Paper filter cover Serial interface (optional) "TEST u u u u u " button Fine filter "ENTER o o o o o "... - Page 66 ETT 8.31 0 684 100 831 ETT 8.38 0 684 100 838 Robert Bosch GmbH Geschäftsbereich KH Produktbereich Prüftechnik Postfach 1129 D 73201 Plochingen...