Infrared industries FGA User manual

FGA4000XDS

Four and Five

Gas Analyzer

Operator’s Manual

Revision10-17-2018

Infrared Industries

25590 Seaboard Lane

Hayward, CA 94545

Phone 800.344.0321 • 510.782.8100

www.infraredindustries.com

Table of Contents

INTRODUCTION..................................................................................................................................................................................6

ANALYZER SET-UP ............................................................................................................................................................................8

Power UP ......................................................................................................................................................................................8

Printer Paper Installation..............................................................................................................................................................9

SYSTEM FEATURES .........................................................................................................................................................................10

Front Panel..................................................................................................................................................................................10

REAR PANEL..............................................................................................................................................................................11

CHAPTER 1–...................................................................................................................................................................................12

CONFIGURING THE ANALYZER........................................................................................................................................................12

Data Capture Option:..................................................................................................................................................................12

Lower Left Window: ....................................................................................................................................................................12

Lower Right Window:..................................................................................................................................................................12

Speed Option: ..............................................................................................................................................................................12

Measure Mode Option:................................................................................................................................................................13

Exhaust Dilution:.........................................................................................................................................................................13

Tachometer:.................................................................................................................................................................................13

Serial Port Communication:........................................................................................................................................................13

Time and Date:............................................................................................................................................................................13

Leak Check:.................................................................................................................................................................................14

Field Calibration:........................................................................................................................................................................14

FACTORY CALIBRATION RESET: ............................................................................................................................................15

GPM Measure Mode: ..................................................................................................................................................................15

System Information:.....................................................................................................................................................................16

CHAPTER 2–...................................................................................................................................................................................18

USING THE ANALYZER.....................................................................................................................................................................18

Warm-up......................................................................................................................................................................................18

Measuring Gas ............................................................................................................................................................................19

Recording Data............................................................................................................................................................................19

Calibration...................................................................................................................................................................................20

Dual Exhaust ...............................................................................................................................................................................21

Tachometer..................................................................................................................................................................................22

Zeroing ........................................................................................................................................................................................22

Grams per Mile (Kilometer)........................................................................................................................................................23

Exhaust Dilution..........................................................................................................................................................................24

CHAPTER 3–...................................................................................................................................................................................26

EXHAUST GAS/EMISSION................................................................................................................................................................26

Combustion Fundamentals..........................................................................................................................................................26

Gas Fundamentals.......................................................................................................................................................................26

Oxides of Nitrogen (optional)......................................................................................................................................................27

Hydrocarbons..............................................................................................................................................................................28

Carbon Monoxide........................................................................................................................................................................28

Carbon Dioxide ...........................................................................................................................................................................29

Oxygen.........................................................................................................................................................................................29

Conclusion...................................................................................................................................................................................30

Stoichiometric Fuel Mixtures.......................................................................................................................................................30

Catalytic Converters....................................................................................................................................................................31

CHAPTER 4–...................................................................................................................................................................................34

TESTING..........................................................................................................................................................................................34

Using Analyzer Readings for Diagnosis......................................................................................................................................34

General Tailpipe Testing Tips .....................................................................................................................................................36

Vehicle Inspection........................................................................................................................................................................37

Engine Conditioning....................................................................................................................................................................38

Connecting Probe Hose to System...............................................................................................................................................38

Interpretation...............................................................................................................................................................................38

CHAPTER 5–...................................................................................................................................................................................40

MAINTENANCE................................................................................................................................................................................40

Sample Hose ................................................................................................................................................................................40

Filter Assembly............................................................................................................................................................................40

Front Panel and Exterior.............................................................................................................................................................41

Oxygen Sensor.............................................................................................................................................................................41

NOx Sensor - Oxide of Nitrogen..................................................................................................................................................42

Routine Cleaning.........................................................................................................................................................................42

Returning the Analyzer for Service/Repairs ................................................................................................................................43

CHAPTER 6–...................................................................................................................................................................................44

TROUBLESHOOTING ........................................................................................................................................................................44

Analyzer Troubleshooting............................................................................................................................................................44

APPENDIX A–.................................................................................................................................................................................46

LAMBDA CALCULATIONS.................................................................................................................................................................46

Brettschneider Equation..............................................................................................................................................................46

APPENDIX B–.................................................................................................................................................................................48

DAC OUTPUTS ................................................................................................................................................................................48

APPENDIX C–.................................................................................................................................................................................50

OBDII OPTION ...............................................................................................................................................................................50

APPENDIX D-..................................................................................................................................................................................52

SPECIFICATIONS .............................................................................................................................................................................52

Principal Gases/Ranges measured..............................................................................................................................................52

Output Data Interface: ................................................................................................................................................................52

APPENDIX E–.................................................................................................................................................................................54

WARRANTY......................................................................................................................................................................................54

Notice to Buyer and/or user of the analyzer:...............................................................................................................................54

APPENDIX F–.................................................................................................................................................................................56

GLOSSARY OF TERMS......................................................................................................................................................................56

Introduction

The analyzer allows the measurement of four or five gases in automotive exhaust. It is capable of determining volume

concentrations of HC (as N-hexane), CO (carbon monoxide), CO2(carbon dioxide), O2(oxygen), and optionally NOx

(nitric oxide).

Based on gas concentrations the analyzer will calculate the Air to Fuel Ration (AFR), Lambda () and Grams per Mile

(GPM) or Grams per Kilometer. It will also provide a read-out for the optional Tachometer that handles up to 30,000

RPM. With this much information in one place, you can diagnose and tune any fuel-related issues while having all of

the relevant information displayed in six super-bright, oversized displays.

All of the above is available as analog outputs in either 0 - 5VDC or 0 - 10VDC for interfacing to a data acquisition

system.

In addition to the above you features; the analyzer can measure exhaust gases from two tail pipes and average the

readings, or set up an exhaust dilution value to warn you if there are air-leaks in the exhaust system.

The analyzer is fully portable. Weighing only

9 pounds the unit is intended for use in a variety of indoor or outdoor

environments. The analyzer can be plugged into standard power outlet voltages ranging from 90 VAC or 260 VAC,

50/60 Hz. You can connect the FGA4000XDS to the car battery or cigarette lighter and take it along for a drive test

to see how the vehicle behaves in real driving situations. Using the internal record feature you can store the data during

the drive test and playback or download the information to a POC when you return.

Analyzer Set-up

This section provides a description of the set-up of the analyzer. When setting up the analyzer for the first time check

for any damage that may have occurred during shipment.

P O W E R U P

The analyzer can be operated from either AC or DC power sources. For AC connections the analyzer will accept 90 –

260 VDC. For DC the analyzer will run off 10-16VDC.

The AC power-input connection is a standard 3-wire recessed; computer-type connector. Various types of power

cords may be used to connect to wall power. Each will have a different connector to be compatible with the various

supply voltages and wall sockets.

Attach the power cord to the rear of the analyzer and plug the end of the cord into the appropriate power source. The

12VDC cable can be plugged into a cigarette lighter or battery for the power source. Make sure that the sample probe

has been placed in an area where there is only air to be drawn into the sample line. Press the Power button to turn on

the unit

In the first 5 seconds, all display segments and indicators will light in order to make sure they are functional. The front

panel will then display PLEASE STAND BY while the analyzer is warming up. The warm-up times may vary

depending on analyzer’s internal temperature. The Zero and Pump indicators will be on during approximately 30

seconds after warm-up period. Do not attempt to flow any gases into the analyzer through the CAL port. This will

severely affect the accuracy of the analyzer.

After the warm-up cycle is completed and the probe is in the tailpipe, press the MEASURE key to begin

measurements.

Note: Check the flow indicator to make sure you have sufficient flow; the indicator should be all green.

Once the analyzer is warmed up, you can begin measuring gas concentrations by connecting the sampling hose/probe

assembly to the inlet port located on the filter in the back of the analyzer. Insert sampling probe to a gas source or an

exhaust stream. Press the Measure button [6] to begin sampling of the gases. Allow a few seconds for the gases to

reach the analyzer. While in measure mode, you can hold or freeze the display values by pressing the Hold button [8]

as displayed in chapter 3.

P R I N T E R P A P E R I N S T A L L A T I O N

If the analyzer was ordered with the optional embedded printer then it will be necessary at times to replenish the paper.

To install paper follow the following steps:

1. Turn the unit onto its right side.

2. Remove the access panel on the bottom of the machine. One Phillips screw secures the panel.

3. Push printer cam lock bar forward.

4. Insert paper roll with paper feeding from the top and down into the feed rollers.

5. Push paper out slot on front panel.

6. Pull cam lock to closed position.

7. Replace access panel.

10.

11.

Front

Feed paper through rollers

Paper feeds from behind roll

Paper roll

Bottom of the analyzer

Front

Cam bar

Feed roller

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