emission station - autoequip.rouser’s manual for ap3201 2 t a b l e o f c o n t e n t s i. i....

User’s manual for CAP3201

1

USER MANUAL

CAP3201 EMISSION STATION

PRO01353 Rev C

www.capelec.fr


2

T A B L E O F C O N T E N T S

I. I. GENERAL DESCRIPTION OF THE STATION .................................................................. 12

I.1. OVERALL DIAGRAM .......................................................................................................................... 13

I.2. OVERALL VIEW: ................................................................................................................................ 16

I.3. INSTALLATION, START-UP ................................................................................................................ 23

I.4. MAINTENANCE, PRECAUTIONS DURING OPERATION ..................................................................... 25

I.4.3.1. Thermal printer: .................................................................................................................... 25

II. II. .............................................................................................. GAS ANALYSIS: (PETROL VEHICLE) 27

II.1. PRINCIPLE OF OPERATION ............................................................................................................... 28

I.1.1. Main menu: ........................................................................................................................... 13

I.1.2. Configurations : ..................................................................................................................... 14

I.1.3. Protected access: .................................................................................................................. 15

I.2.1. The station ............................................................................................................................ 16

I.2.2. List of components supplied ................................................................................................. 17

I.2.3. Front side .............................................................................................................................. 18

I.2.4. Rear Face ............................................................................................................................... 19

I.2.5. External Gas Connectors ....................................................................................................... 21

I.2.6. Opacity measuring cell .......................................................................................................... 22

I.2.7. The temperature/tachometer module ................................................................................. 22

I.2.8. The keyboard (optional)........................................................................................................ 23

I.3.1. Recommendations ................................................................................................................ 23

I.3.2. Starting .................................................................................................................................. 23

I.4.1. General .................................................................................................................................. 25

I.4.2. Cleaning cables and surfaces ................................................................................................ 25

I.4.3. Removal and insertion of paper in the printer ..................................................................... 25


3

II.2. OPERATING CONDITIONS ................................................................................................................. 33

II.3. TECHNICAL CHARACTERISTICS ......................................................................................................... 34

II.4. EMISSION TEST ................................................................................................................................. 35

II.4.2.1. Semi-annual maintenance .................................................................................................... 35

II.4.2.2. Annual maintenance ............................................................................................................ 36

II.4.2.3. Probe maintenance .............................................................................................................. 36

II.4.2.4. Maintenance of the separator ............................................................................................. 37

II.4.2.5. Replacing a filter ................................................................................................................... 37

II.5. GAS ANALYSIS ................................................................................................................................... 38

II.6. OFFICIAL TESTING ............................................................................................................................. 49

II.1.1. Corrected CO ........................................................................................................................ 31

II.1.2. Lambda ................................................................................................................................. 31

Pneumatic circuit .............................................................................................................................. 32

II.4.1. Preliminary checks ............................................................................................................... 35

II.4.2. Cleaning and precautions during operation ........................................................................ 35

II.5.1. Customer information : ....................................................................................................... 38

II.5.2. Description of the graphic interface: ................................................................................... 39

II.5.3. Preliminary checks ............................................................................................................... 41

II.5.4. RPM: ..................................................................................................................................... 42

II.5.5. Preparation for measurement ............................................................................................. 44

II.5.6. Analysis and measurement .................................................................................................. 44

II.5.7. Printing results ..................................................................................................................... 47

II.6.1. Vehicle registered before 1 October 1986 .......................................................................... 50

II.6.2. Vehicle registered before 1 January 1993 ........................................................................... 50

II.6.3. Catalyst vehicle registered before 01/07/2002 ................................................................... 50

II.6.4. Catalyst vehicle registered before 01/07/2002: .................................................................. 53

II.6.5. Printing results: .................................................................................................................... 54


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II.7. LIST OF FAULT REPORT MESSAGES AND FAULT TRACING ............................................................... 55

III. III. ....................................................................................... THE OPACIMETER: (DIESEL VEHICLES) 61

III.1. PRINCIPLE OF OPERATION ............................................................................................................... 62

III.2. OPERATING CONDITIONS ................................................................................................................. 64

III.3. TECHNICAL CHARACTERISTICS ......................................................................................................... 65

III.4. INSTALLATION AND PRECAUTIONS DURING OPERATION ............................................................... 66

III.5. OPACITY TESTING PROCEDURE ........................................................................................................ 67

II.7.1. Leak present ......................................................................................................................... 56

II.7.2. Data invalid .......................................................................................................................... 56

II.7.3. HC out of bounds ................................................................................................................. 56

II.7.4. CO out of bounds ................................................................................................................. 56

II.7.5. CO2 out of bounds ............................................................................................................... 56

II.7.6. O2 out of bounds ................................................................................................................. 57

II.7.7. NOx out of bounds ............................................................................................................... 57

II.7.8. Flow too low......................................................................................................................... 57

II.7.9. Out of paper ......................................................................................................................... 58

II.7.10. Lever open : ....................................................................................................................... 58

II.7.11. PB IMPR .............................................................................................................................. 58

II.7.12. HC residue in gas inlet ........................................................................................................ 58

II.7.13. com. error .......................................................................................................................... 58

II.7.14. Adjustment necessary ........................................................................................................ 59

II.7.15. Change O2 sensor .............................................................................................................. 59

II.7.16. Condensation: wait ............................................................................................................ 59

II.7.17. Heating problem ................................................................................................................ 60

II.7.18. Other : ................................................................................................................................ 60

III.4.1. Installation, start-up : .......................................................................................................... 66

III.4.2. Cleaning and precautions during operation ....................................................................... 66


5

III.5.7.1. The probe: ........................................................................................................................... 75

III.5.7.2. The oil temperature sensor: ................................................................................................ 75

III.5.7.3. Connecting the tachometer: ............................................................................................... 75

III.5.14.1. Measurement to standard ................................................................................................ 81

III.5.14.2. Measurement not to standard .......................................................................................... 82

III.6. OPACITY VALUE DETERMINATION PROCEDURE .............................................................................. 84

III.7. OPACITY ANALYSIS ........................................................................................................................... 86

III.8. OPACIMETER MESSAGES ................................................................................................................. 87

III.8.1.1. «Zero in progress» ............................................................................................................... 87

III.8.1.2. « Mains voltage out of bounds » ......................................................................................... 87

III.8.1.3. « Windows dirty » ............................................................................................................... 87

III.8.1.4. « Fan is defective » .............................................................................................................. 87

III.8.1.5. « EEPROM out of service » .................................................................................................. 87

III.5.1. Client information entry ..................................................................................................... 67

III.5.2. The engine : ......................................................................................................................... 68

III.5.3. Description of the graphic interface: .................................................................................. 68

III.5.4. Displays the selected operating speed mode: .................................................................... 70

III.5.5. Detecting the cell ................................................................................................................ 73

III.5.6. Auto-zero and error checking ............................................................................................. 74

III.5.7. Insertion of the probe and sensors ..................................................................................... 75

III.5.8. Preliminary checks .............................................................................................................. 76

III.5.9. Conditioning the engine: ..................................................................................................... 77

III.5.10. Free acceleration .............................................................................................................. 78

III.5.11. Two non-measured accelerations in succession .............................................................. 79

III.5.12. Opacity measurement phase ............................................................................................ 79

III.5.13. Display of the results of each acceleration ....................................................................... 80

III.5.14. Printing results .................................................................................................................. 81

III.8.1. Error messages .................................................................................................................... 87


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III.8.1.6. « Sensor problem » ............................................................................................................. 87

III.8.1.7. « Preheating » ..................................................................................................................... 88

III.8.1.8. « Detector temp. out of bounds » ....................................................................................... 88

III.8.1.9. « Time exceeded »............................................................................................................... 88

III.8.1.10. « Probe connected?» ........................................................................................................ 88

III.8.1.11. « Measurement invalid »................................................................................................... 88

III.8.1.12. « Press ESC and start again » ............................................................................................. 88

III.8.2.1. « Acceleration No. X » ......................................................................................................... 88

III.8.2.2. « Measurement in progress » ............................................................................................. 89

III.8.2.3. « Return to idle » ................................................................................................................. 89

IV. IV. ............................................................................................................................. OBD SCANTOOL 90

IV.1. GENERAL........................................................................................................................................... 91

IV.2. PRINCIPLE ......................................................................................................................................... 91

IV.3. MEASUREMENT AND TESTING ......................................................................................................... 92

IV.3.2.1. Measurements .................................................................................................................... 93

IV.3.2.2. Fault codes .......................................................................................................................... 93

IV.3.2.3. Tests not continuously performed ...................................................................................... 96

IV.3.2.4. The information .................................................................................................................. 96

IV.3.2.5. The full report ..................................................................................................................... 97

IV.4. LIST OF DATA .................................................................................................................................... 98

III.8.2. User guidance messages ..................................................................................................... 88

IV.3.1. Connection .......................................................................................................................... 92

IV.3.2. EOBD data ........................................................................................................................... 93

IV.3.3. Printing results .................................................................................................................... 97


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V. V. ......................................................................................................................... CONFIGURATIONS 121

V.1. GENERAL: ....................................................................................................................................... 122

V.2. TIME/DATE: .................................................................................................................................... 122

V.3. GARAGE HEADER: ........................................................................................................................... 123

V.4. OPERATOR: ..................................................................................................................................... 124

V.5. GAS ANALYSIS ................................................................................................................................. 124

V.5.6.1. HC index: ............................................................................................................................ 127

V.5.6.2. Calibration: ......................................................................................................................... 128

V.5.6.3. AMB access: ....................................................................................................................... 129

V.6. SMOKEMETER: ............................................................................................................................... 130

IV.4.1. List of available measurements in the table « current measurements » and « freezed

frame ». 98

IV.4.2. EXEMPLE OF DTC (DATA TROUBLE CODE) : ......................................................................100

IV.4.3. List of available measurements in « Measurements and control of the lambda probes ».115

IV.4.4. List of recoverable and possible information in the table « Information about the

vehicle ». .........................................................................................................................................116

IV.4.5. List of data composing the table « Computer information ». .........................................117

IV.4.6. TABLE OF ABBREVIATIONS ................................................................................................118

IV.4.7. TERMS AND DEFINITIONS .................................................................................................119

V.5.1. Standby ..............................................................................................................................125

V.5.2. Digit CO, Lambda ...............................................................................................................125

V.5.3. O2 sensor condition ...........................................................................................................125

V.5.4. Leak test .............................................................................................................................126

V.5.5. Routine check ....................................................................................................................126

V.5.6. Protected access ................................................................................................................127


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V.7. CENTRAL CONTROL: ....................................................................................................................... 132

V.7.1.1. GIEG-NET MONO : .............................................................................................................. 134

V.7.1.2. GIEG-NET MULTI :............................................................................................................... 134

V.8. PRINTING: ....................................................................................................................................... 135

V.9. SCREEN: .......................................................................................................................................... 136

V.10. OPTIONS : ....................................................................................................................................... 136

V.11. DEFAULT PARAMETERS: ................................................................................................................. 136

V.12. INFORMATION: .............................................................................................................................. 137

VI. VI. ........................................................................................... PETROL AND DIESEL TACHOMETER 138

VI.1. OPERATING PRINCIPLE ................................................................................................................... 139

VI.2. TECHNICAL CHARACTERISTICS ....................................................................................................... 139

VI.3. LIST OF KIT CONTENTS ................................................................................................................... 139

VI.4. CONNECTING THE TACHOMETER .................................................................................................. 139

VI.5. MEASURING THE ENGINE SPEED ................................................................................................... 142

VII. VII. ................................................................................................... PREMIUM VERSION WIN3201 143

VII.1. INSTALLATION AND SET-UP ........................................................................................................... 144

VII.2. GAS ANALYZER ............................................................................................................................... 146

V.6.1. VL/PL: .................................................................................................................................130

V.6.2. Engine speed and Oil temperature: ...................................................................................130

V.6.3. Routine check: ...................................................................................................................130

V.6.4. Protected access: ...............................................................................................................132

V.7.1. GIEG-NET protocol: ............................................................................................................133

V.7.2. PC protocol: .......................................................................................................................135

V.7.3. MAHA protocol: .................................................................................................................135

VII.2.1. Launching of the procedure.............................................................................................146

VII.2.2. Limit values : ....................................................................................................................147

VII.2.3. Print out preview .............................................................................................................148


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VII.3. SMOKEMETER : .............................................................................................................................. 150

VII.4. EOBD .............................................................................................................................................. 154

VII.5. LOOKING INTO THE TESTS : ............................................................................................................ 156

VII.3.1. Launching of the procedure :...........................................................................................150

VII.3.2. Print out preview : ...........................................................................................................151

VII.3.3. Opacity Analysis ...............................................................................................................153

VII.4.1. Launching of the procedure.............................................................................................154

VII.4.2. Print out preview .............................................................................................................155


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FOREWORD

We thank you for acquiring the CAP3201. Of recent design, it takes advantage

of the most advanced technologies, both at the software and at the hardware level,

harnessing them to serve your priorities: rapid testing, accuracy, reliability and long

maintenance intervals. Especially designed for the garage setting, its friendly

environment allows you to quickly and effectively master all the possibilities offered

by this device. We are therefore convinced that it will give you complete satisfaction.

This manual explains how to use the CAP3201 station, from installation

through measurement procedures, as well as measures to be taken in case of

malfunction. Please read this manual attentively before operating the device, in order

to get the full benefit of it. Keep it in a safe place to consult it when necessary.

Notice:

Information contained in this document is subject to change without prior

notice.

CAPELEC will not be held responsible in any case for any damage, direct or

indirect, of any kind whatever, nor for losses or expenses, resulting from improper

use.


11


12

I. GENERAL DESCRIPTION OF THE

STATION


13

GAS ANALYSIS

Official testingMultigas

analysis

Vehicles

after

1/10/86

Vehicles

before

30/09/86

Catalyst

vehicles

E.O.B.D Scantool

CONFIGURATIONS

EOBD

vehicles

Opacity

testing

procedure

Opacity value

determination

procedure

Opacity

analysis

SMOKEMETER

I.1. OVERALL DIAGRAM

The diagrams presented below allow the menu hierarchy to be understood;

the user can thus easily follow the sequence of the various sub-parts.

I.1.1. Main menu:


14

I.1.2. Configurations :

Central controlTime/Date

Garage header

Printing

OperatorScreen

Default

parameters

Gieg-mono

Gieg-multi

PC

Maha

YEAR

MONTH

DAY

HOUR

MINUTES

CAPELEC

126, rue Emile Baudot

Le Millénaire

34000 MONTPELLIER

Tél: 04-67-156-156

Fax: 04-67-224-224

1:

2:

3:

4:

5:

6:

7:

8:

9:

NORMAL

INVERSE

Initialization ?

CONFIGURATIONS

Protected

access

Gas analysis

Standby

Digit

CO,

lambda

Opacimeter

Engine

speed

Oil

temp.

O2

sensor

condition

Leak testRoutine

check

Options

Information

CAPELEC

Le Millénaire

126, rue Emile Baudot

34000 MONTPELLIER

www.capelec.fr

printer

Number

of

tickets

INTERNAL

EXTERNAL

1

2

3

Routine

check

Protected

access

Protected

access


15

I.1.3. Protected access:

CONFIGURATIONS

SMOKEMETER

Protected access

GAS

ANALYSIS

Protected access

Name:

Initiailization? K,N filters.

CODE

*****

CODE

*****

O2 initialization

HC index Calibration AMB access

CO,HC, CO2

adjustment

New O2

sensorO2/air

NOx

initialization

OPTION

Protected access

ConfigurationSerial

number

CODE

*****

VL/PL


16

I.2. OVERALL VIEW:

The CAP 3200 station is made up of a CAP3201, an opacity measurement cell

and trolley.

The CAP3201 has an LCD screen, a gas analysis module for petrol vehicles, a

keyboard and a printer. The measurement cell is connected to the station by a power

supply and data cable. It is packaged in the form of a small metal briefcase mounted

on legs.

I.2.1. The station

CAP3201

Keyboard

Trolley on rollers

Opacity cell


17

I.2.2. List of components supplied

1 user manual,

For gas analysis:

Gas analyser,

Sampling probe,

Exhaust tube,

Filters,

Oil temperature measurement probe,

A inductive pick-up.

For calculating the opacity of a gas:

Opacity cell,

Sampling probe,

A cell support,

Cleaning brush,

Cell power and data cable,

A piezoelectric sensor cable.

OPTIONS :

Keyboard,

Cart with rollers,

External A4 format printer,

OBD kit,

A battery tachometer kit.


18

I.2.3. Front side

LCD screen

5-key pad

Thermal printer


19

I.2.4. Rear Face

_1_ID plate

_2_Separator (FD)

_3_Test gas exhaust (GAS)

_4_Condensate exhaust (COND)

_5_Test gas inlet (GAS)

_6_Ambient air port for zero setting

_7_Fan with filter (FV)

_8_Mains power socket 230V

_9_Input connector for induction clip

_10_TTL and piezoelectric input connector

3

2 1

4

9

5

7

8

10

11

12

13

14

19

18

17

16

15

20 6


20

_11_Input connector for oil temperature sensor

_12_Contrast control for LCD screen

_13_PS2 keyboard input connector

_14_COM2 serial port connector

_15_COM1 serial port connector

_16_OBD connector

_17_Gas pump protection filter (FG)

_18_Condensate pump protection filter (FC)

_19_Activated charcoal filter (FCC)

_20_Input connector for battery motor drive operation


21

I.2.5. External Gas Connectors

_1_Sampling probe

_2_Exhaust collector attachment grip

_3_Black tube (length 7,5m)

_4 & 5_Transparent tube (length 1.5m),

1

2

3

4

5


22

I.2.6. Opacity measuring cell

I.2.7. The temperature/tachometer module

Sonde de température

Temperature probe

Piezoelectric sensor

Induction clamp

Cigar lighter connector

for RPM BAT

(OPTIONAL)

Battery clamp for RPM

BAT (OPTIONAL)


23

I.2.8. The keyboard (optional)

It is a standart keyboard ( type : « AZERTY »).

The mains touch are ENTER and ESC.

Select with arrow (Up, Down, Left, Right) .

ENTER : Valid a choice

Esc : Quit and return at the last window.

French keyboard « azerty »

I.3. INSTALLATION, START-UP

I.3.1. Recommendations

The machine can be left powered up 24 hours a day. It is recommended,

however, that the electrical power supply be shut off during the night. Powering up

the machine in the morning will involve several minutes’ wait before the gas analysis

module is operational. Powering up the cell involves a waiting period of at most 5

minutes for the chamber to reach its operating temperature (preheating).

I.3.2. Starting

Connect the station to the 230 VAC 50 Hz mains.

Signs of correct operation:

The screen lights up and the cooling fan must start. The presentation page

with the CAPELEC logo appears on the graphics screen.


24

The main menu appears after a few seconds.

M ain m e nu: T he m ac h ine i s r e ady for us e

Title

Message box

5 dynamically

configurable keys

M A I N M E N U

G A S A N A L Y S I S

S M O K E M E T E R

E O B D S C A N T O O L

C O N F I G U R A T I O N

E M I S S I O N T E S T S T A T I O N


M O N D A Y 1 5 N O V E M B E R 2 0 0 2

S M O K E M E T E R

E O B D S C A N T O O L


25

I.4. MAINTENANCE, PRECAUTIONS DURING

OPERATION

I.4.1. General

Each CAP3201 is inspected before delivery by a representative of the

measuring instruments service, who affixes a stamp mark on the plate attached to the

rear of the machine.

I.4.2. Cleaning cables and surfaces

The station, the screen, the keyboard (optionally) and the cables may be

cleaned with alcohol on a clean rag. Any other solvent is strongly discouraged.

I.4.3. Removal and insertion of paper in the printer

I.4.3.1. Thermal printer:

To remove paper from the printer, the lever must always be opened.

To load paper, there are two methods:

First, the lever must be opened and the paper correctly cut (see below); then insert the

paper up to the heater head. Finally, ensure that the paper is correctly aligned and close

the lever. The printer is ready to run.

Heater head

Roller

Lever closed


26

The lever must be closed; the paper must be cut as shown below. In this method, insertion

is automatic. It is only necessary to insert the paper as far as the roller; the paper is

automatically loaded, and the printer is ready to run.

Finally, messages continually inform the user of the condition of the printer.

For example: OUT OF PAPER or LEVER OPEN. These types of errors appear when the

operator starts a print job; they are quickly resolved by adding paper or closing the

lever.

N

O Y

E

S

N

O

Y

E

S

N

O

N

O


27

II. GAS ANALYSIS: (PETROL VEHICLE)


28

II.1. PRINCIPLE OF OPERATION

The gas analyser is a module destined for PTI and automotive workshops. It allows

measurement of the carbon monoxide (CO), carbon dioxide (CO2), hydrocarbons (HC) in hexane

equivalent (C6H14), and oxygen (O2) concentration of the gases from spark-ignition vehicles

(petrol, high-octane petrol, LPG), with or without catalytic converter. As an option, it can be

equipped with the NOx kit allowing nitrogen oxides to be measured.

The CAP3201 also allows the following values to be obtained at any time:

- Calculation of the corrected CO value

- Calculation of Lambda value

- The measurement of rotation speed (measured by induction clip, by battery input,

…)

- Measurement of oil temperature.

The measurement of CO, CO2 and HC is carried out using non-diffusing infrared

radiation. The gas passes through a measuring chamber, at the ends of which are three

infrared detectors and three emitters. Each emitter emits with a characteristic wavelength

associated with one of the three gases.

Each of the detectors issues an electrical signal corresponding to the intensity of the

radiation received.

Measurement of oxygen concentration is carried out by an active chemical sensor.

ANODE

CATHODE

ELECTROLYTE

O2MEMBRANE

ddp

R=f(T°C)

Principle of oxygen measurement:


29

The oxygen sensor is of the electrochemical type; it is based on the principle of

electrolysis. In the presence of oxygen, an ionic current is created through the cathode, the

electrolyte and the anode, giving rise to a potential difference at the terminals of a resistor,

which varies as a function of temperature. As a result, the sensor is temperature-compensated.

N° Descriptions

1 IR detector

2 Sample cell

3 IR emitter

4 O rings

5 Optical window

P r inc ip le o f N D I R m e as ur e m e nt :

The CAP3201 is based on non-diffusive infrared technology.

Instead of using a refractory prism to achieve the very high spectral definition of

infrared light (like those used in high performance equipment in laboratories), the machine

uses NDIR. NDIR devices are generally used for measuring concentrations of a specific and

limited set of gases in mixtures having a known and limited collection of base gases.

It is possible for example to take the measure of the concentration of CO2 of a base

gas such as the exhaust gas of an automobile. One knows a priori that gases that might have an

absorption spectrum masking that of CO2 are absent.

3

1 2

5 4


30

A specific collection of gases (CO2, C6H14, CO) is measured as follows: a unique range

of wavelengths in the infrared spectrum is selected for each gas in order to measure the point

where its absorption is high and where there are no other base gases which are equally

absorbent.

Optical filters transmitting only the given range of wavelengths are placed in front of

the thermocouple detector. When the set is full of the gas to be analysed, the infrared

detector measures the reduction in the infrared energy obtained for the range of wavelengths

linked to each gas.

The signal processing electronics then determine the ratio I/Io.

I/Io = degree of absorption

I = signal received (sample) for each gas to be measured.

Io = reference signal


31

II.1.1. Corrected CO

Corrected CO is calculated as follows:

If (%CO + % CO2) 15 then corrected CO = CO

If (%CO + % CO2) < 15 then corrected CO = CO x (15 (CO+ CO2))

II.1.2. Lambda

It is derived from BRETTSCHNEIDER’s formula. This coefficient is

calculated from the value of CO, CO2, HC and O2.

4

2

2

2

22

1060088,04

7261,11

)(0088,0

5,3

5,3

4

7261,1

2

HCCOCO

COCO

CO

COO

COCO

(CO, CO2 and O2 are given in %, HC in ppm)

This calculation is constantly carried out by the analyser unless CO2 is

equal to 0%. If the vehicle is well tuned, its Lambda will lie between 0.97 and

1.03

CNG, LPG EFFECT (Only on special version)

On special version, on the measure page you can select LPG, CNG or

PETROL cars. The only effect is to change the HC calculation :

LPG involves HC*0.5

CNG involves HC*0.3

PETROL involves HC*1.


32

Pneumatic circuit


33

II.2. OPERATING CONDITIONS

The gas analyser is equipped with automatic monitoring of parameters that

have an influence on measurements. If at least one of these parameters is out of

bounds, hence threatening to metrologically alter the results, the gas analyser disables

itself and prevents any measurement from being performed until operating conditions

are re-established.

Failure to observe operating conditions may result in degradation of the

equipment or temporary disabling of the CAP3201:

Atmospheric pressure 1000 mbar +10% -25%

Mains voltage 230 VAC +10% -15% 50 Hz+-2%

Ambient temperature: from -10 to 55 °C

Gas temperature: 200 °C tolerated by the probe

Storage temperature: -32 to +55 °C

Relative humidity: <98% non-condensing

Ambient air clean and room well ventilated


34

II.3. TECHNICAL CHARACTERISTICS

Preheating time: < 9 minutes at 0°C (1 minute minimum)

Response time: 13 seconds for HC, CO, CO2, 28 seconds for oxygen

(transition from 20.9% to 0.1% for a gas with 0% O2)

Nominal pump delivery: 6 l/min.

Minimum pump delivery: 3.5 l/min.

Air pressure variation: automatic correction by integrated absolute

pressure sensor

Zero point and sensitivity: automatic compensation

Automatic pump standby and automatic zeroing.

Official range Capelec range Resolution

CO 0 à 5 % vol 0 à 15 % vol 0,01 % vol ou 0,001 % vol

CO2 0 à 16 % vol 0 à 20 % vol 0,1 % vol

HC (C6H14) 0 à 2000 ppm vol 0 à 10000 ppm vol 1 ppm vol

O2 0 à 21 % vol 0 à 25 % vol

0,01% vol pour les titres

volumiques ≤ 4 % vol

0,1% vol au delà

λ 0,8 à 1,2 0,0 à 9,99 0,01 ou 0,001

Accuracy:

HC = 10 ppm } Absolute or 5 % of the value read

CO = 0,03 % } Absolute or 5 % of the value read

CO2 = 0,5 % } Absolute or 5 % of the value read

O2 = 0,1 % }Absolute or 5 % of the value read.

Engine speed = +- 10 RPM

Oil temperature = +- 1 °C

Corrected CO = 0,03 %

Air/fuel coefficient (Lambda)= 0,03

Resolution:

HC = Normal resolution: 10 ppm vol.

High resolution: 1 ppm vol.

CO = Normal resolution: 0.01 % vol.

High resolution: 0.001 % vol.


35

CO2 = Normal resolution: 0.1 % vol.

O2 = If O2<4 % vol. high resolution: 0.01 % vol.

Otherwise normal resolution: 0.1 % vol.

Nox = 1 ppm vol.

Engine speed = 1 tours/min

Oil temperature = 1 °C

Corrected CO = 0,01 %

Air/fuel coefficient (Lambda)= 0.001 or 0.01, selectable

II.4. EMISSION TEST

II.4.1. Preliminary checks

Place the machine in the designated location. The surface must

be horizontal and must not be exposed to excessive vibrations,

dust or cold. There must be no petrol vapour in the vicinity of

its location.

Connect the tube and the probe to the separator located on

the rear side.

Do not insert the probe into the exhaust pipe at this stage.

Press the Stop/Start switch on the station.

II.4.2. Cleaning and precautions during operation

The CAP3201 is a machine needing little maintenance. Only the pneumatic

circuit components that carry the gases, located on the outside of the analyser, need

to be maintained by the user. Any maintenance operation other than those described

below must be entrusted to a certified CAPELEC agent. On the other hand, failing to

maintain the machine in conformity with these instructions cancels the warranty.

Every three months, the condition of the pneumatic circuit including tubing,

filters, pumps, electrovalves and connectors must be inspected. It is also necessary to

check the accuracy of the machine in measuring CO, CO2, HC, O2 using a gas made up

in part of these gases in known proportions. The latter operation must be carried out

by a certified organization.

II.4.2.1. Semi-annual maintenance

Change the separator filter FD,

Change filters FC and FG,


36

Visually check that the filter connections are in conformity with the

schematic diagram in paragraph I.2.4.

Visual inspection of the sampling probe. Clean it if necessary in accordance

with paragraph II.4.3.3.

Perform a leak test.

Enter the new maintenance date.

II.4.2.2. Annual maintenance

Annual maintenance operations include the semi-annual maintenance

operations. In addition, it is necessary to carry out the following operations:

Replace the pump protection filters (FG and FC),

Replace the activated charcoal filter. (FCC),

Check with a calibration gas that the error is less than the maximum

allowable error.

1) Put into measuring mode.

2) Disconnect the sampling probe from the separator.

3) Connect the cylinder of calibration gas in its place. If the cylinder

contains propane HC, select display of C6 HC, even though display is

usually in C3 (hexane). Otherwise, use the PEF value to convert if

the HC are around 2000 ppm vol. propane.

4) Note or print the stabilized measured values.

If the error is too high compared with current regulatory

requirements, adjustment is necessary.

If regulations require regular adjustment using a calibration gas, this

operation must be performed prior to error testing.

II.4.2.3. Probe maintenance

The small orifices at the end of the probe must never be plugged. If

condensation forms or if residue is deposited in excess, remove the probe

from the tube and blow compressed air in the direction opposite to that of

suction. Perform the same operation with the sampling tube.


37

II.4.2.4. Maintenance of the separator

The separator includes a filter.

Replace the filter it has become grey.

Filter replacement is carried out in the following manner:

- Shut off the pumps

- Unscrew the condensation residue collector located at the back of the

machine. (FD).

IMPORTANT: The absence of one of the components inside the separator or

incorrect reassembly of the assembly will contaminate the measuring device

and the measurements will be prematurely invalidated due to the resulting

errors. This condition of the analyser will require an overhaul that cannot be

provided in the context of the warranty.

- A gas-tightness check must be carried out after any operation on the

pneumatic circuit of the machine (paragraphe V.5.4.).

II.4.2.5. Replacing a filter

If one of the filters appears to the eye to be soiled or if an error

message is referred in the user manual to a filter replacement, the following

points must be observed:

- Turn off the machine.

- Remove the filter to be replaced (behind the location designated

for each filter, the reference is silkscreen printed on the case).

Replace the old filter with the new one, maintaining the correct

installation orientation (see sketch of the rear side paragraph I.2.4)

- Turn on the machine.

- Perform a leak test as described in paragraph V.5.4


38

II.5. GAS ANALYSIS

This menu allows you either to open a

window allowing several gases to be analysed,

or to choose a submenu relating to technical

testing according to the year that the vehicle

began operating.

Select GAS ANALYSER and press OK

II.5.1. Customer information :

In addition, before any measurement or technical test procedure, the user may, if he

desires, enter information about the client and his car (name of client, make of car, mileage

and registration plate). These data will then appear on the test report.

Entry of these data is optional.

The method of data entry is the same as that describe for garage entry (see paragraph

V.3).

The entry window with keyboard option appears this way:

M U L T I G A S A N A L Y S I S

O F F I C I A L T E S T


C U S T O M E R :


V E H I C L E :

P L A T E :

M I L E S :

N O T E S :


39

II.5.2. Description of the graphic interface:

HC = Hydrocarbons expressed as hexane (display as propane is possible: see paragraph

II.5.6.1) given in ppm (parts per million).

CO = Carbon monoxide expressed in % by volume.

COcorr. = Corrected CO (paragraph III.I.1).

O2 = Oxygen expressed in % by volume.

CO2 = Carbon dioxide given in % by volume.

= Displays Lambda value. This value has no particular unit. We say that it is a coefficient or a

ratio.

tr/min = Engine speed in revolutions per minute.

°C = Oil temperature measurement expressed in degrees Celsius.

The print key: it is displayed only when printing is possible.

Pressing this key displays in the message window:

F 1 : P R I N T

F 2 : S E N D D A T A

R P M

T I M E



40

This offers a choice: either press F1 to send the values displayed on screen to the

internal or external (A4) printer or press F2 to send the current measurements to the

multiplexer to later transfer them to the centre’s computer.

The storage key:

Stores in memory the current values as of the moment the key was pressed. These values

will be printed at print time on the same test report. The CAP3201 can store 6 current

values, and at each store operation the corresponding number is displayed in the message

box.

The pump key:

Activates or deactivates the pumps. Pressure on this key puts the machine either in

STANDBY (rest) mode, or in measurement mode (activation of the pumps and launching of

an auto-zero operation). The STANDBY invalidates all measures, which is manifested on the

display by dashes in the measurement field, but the time is also displayed in the message

frame.

The operating speed key:

Allows the engine speed to be selected.(II.5.4.).

The NOx / COcorr. key

Press this key, and the COcorr. field on the gas analysis graphic interface will be replaced by

NOx, and vice versa.

The auto-zero key

Allows an auto-zero operation to be executed at any time. Note that the device

automatically launches an auto-zero operation when it is necessary, and periodically every

minute.

When an auto-zero operation occurs, the electrovalve switches so that the air aspirated by

the gas analysis module is pure and thus is filtered by an activated charcoal filter.

The freeze data key

Freezes the measured values on the screen. By pressing this key again, the fields on the

screen are again updated.


41

II.5.3. Preliminary checks

Before undertaking any measurement, the operator must satisfy himself that

the engine is operating correctly.

The following points are to be observed:

The vehicle exhaust line must be gas-tight.

The gearbox must be in neutral, with the clutch engaged, for vehicles with

manual or semi-automatic transmissions; the selector should be in neutral for vehicles

with automatic transmissions or in accordance with the instructions of the vehicle

manufacturer.

Accessories and optional equipment that influence the engine speed at idle

must not be activated, barring manufacturer’s instructions or regulation to the

contrary.

The engine must be at normal operating temperature, that is with an oil

temperature at least equal to 80°C.


42

MEASURE IN

PROGRESS

RPM touch

Display the rpm

mode in progress

RPM touch

3 s

YES

Induction

Induction/2

Piezo

E.O.B.D.

TTL

3 s

3 s

3 s

3 s

3 s

YES

Battery3 s

Cylinder number?

Initialization

II.5.4. RPM:

Pressing this key displays the speed mode currently in use. On the other hand, if

the user again presses the operating speed key, a new speed mode displays the new

selection. By simply refraining from pressing the key again, the new speed mode is

automatically loaded.

Organization chart:


43

« Induction » : Sensor operation:

The induction clip allows detection of the moment that ignition occurs in a cylinder. Placed

around the ignition lead of a cylinder, it generates a signal by inductive effect at the moment of

ignition. At the rate of one spark per revolution for 2-stroke engines and 1 spark for two

revolutions when a 4-stroke is involved, the induction clip allows the operating speed of a

petrol engine to be measured.

Connect the induction clip cable to the CAP3201 input connector for the induction clip (an icon

indicates its location), then selection the “induction” mode using the operating speed key. The

operating speed display appears automatically.

« Induction/2 » : The procedure is identical to the preceding one, only the value is divided

by two.

« Piezoelectric» : Sensor operation:

The piezoelectric sensor allows detection of the moment of injection on a diesel

engine. Placed around an injection tube, it detects the dilation caused by the variations of

internal pressure caused by injection. The electric signal supplied by the sensor allows the

operating speed of a diesel engine to be measured (one dilation of the tube for two engine

revolutions).

Connect the sensor cable to the CAP3201, then select the “piezo” mode using the operating

speed key. The operating speed display appears automatically.

« E.O.B.D » : This mode allows the engine speed to be read from the data sent to us by the

computer on board a vehicle (voir partie IV).

Connect the cable to the vehicle’s computer; the plug provided for this purpose is usually

located near the fusebox. Then connect the other end to the CAP3201. Select, using the

operating speed key, the “E.O.B.D.” mode. The display appears automatically.

« TTL » : This mode makes it possible to read an engine speed sensor with a TTL output.

Connect the cable to the induction clip input of the analyser. Select, using the operating

speed key, the “TTL” mode. The display appears automatically.

« Battery » : The battery option is composed of an electronic card installed inside the

CAP3201, a cable for data and for power supply from the cigar lighter to the case, and a

cable for data and for power supply from the battery. This option is a battery-driven

tachometer which allows operating speed to be measured on all vehicles - petrol, diesel

and LPG.

Connect the cable on the CAP3201 (RPM BAT); select the “battery” mode

using the operating speed key. After three seconds, the operator must choose and

confirm the number of cylinders. If the battery cable is correctly connected, the

system carries out an initialization phase. After this phase the operating speed is

displayed.

ATTENTION: In the event of a problem, the headlights of the vehicle should

be turned on, and everything else shut off.


44

See section VI.

II.5.5. Preparation for measurement

- Tachometer

Install the sensor, then press the operating speed key to determine the

appropriate mode. This mode is automatically saved. The value of the operating speed

must immediately appear. (see paragraph II.5.4).

- Oil temperature

Remove the oil level dipstick and replace it in the tube with the oil

temperature probe. Adjust the length so that the probe dips in the oil when the

sealing cone acts as a stopper for the dipstick tube. The engine must be warm before

any measurement takes place, which corresponds to an oil temperature greater than

80 °C.

- Gas measurement

Insert the sampling probe as far as possible in the exhaust gas exit tube. The

minimum depth, when the layout allows it, is 30 cm. If this condition cannot be

fulfilled, it is necessary to use a collector tube that acts as an exhaust system

extension.

In exhaust systems with a single exhaust pot, but provided with two exit

tubes, it is necessary to use a collector tube into which the probe is inserted.

For analysis of the gases upstream of the catalytic converter, the entire length

of the flexible sampling tube must be used.

Start the measurement by pressing the PUMP key (if the pumps are not

running).

Start the engine (if the engine is running before the probe is inserted, it is

preferable to activate the pumps and to wait for zeroing to finish before inserting the

sampling probe as indicated above).

II.5.6. Analysis and measurement

Automatic calibration is then engaged for a period of 50 seconds. The pump

starts running and the following message is displayed on the screen: “ZERO IN

PROGRESS”.

After this period, the LCD screen contains the message: “Measurement in

progress,” the results of each measurement appear on the displays, the


45

system is ready to carry out a measurement (concentrations must be similar

to those in air: 0% for CO, CO2, 0 ppm vol. for HC, 20.9% for O2.)

The machine is ready to be used. It is recommended that a seal integrity test

be performed in order to verify that the probe is correctly installed and that

the equipment has not be damaged in transport (refer to paragraph V.5.4).


46

Operating diagram

Activating the pump has the effect of triggering automatic calibration. This

phase lasts xx seconds and is launched as soon as the pump is started. While this

procedure is in progress, the message “auto-zero in progress” is displayed in the

message box.

When the message disappears, measurement operations become available

on the screen. Automatic zeroing occurs every 30 minutes if the analyser is in

ON/OFF Automatic

system

check

Warmup period < 5 min

Time remaining is displayed

The pumps are running

Calibration,

auto-zero check

Wait mode. Pumps resting,

no measurements

No gas

measurements for a

certain time >

standby time

Key

Auto-zero

Pumps active

Key

Elapsed time > 30 min. and no

measurement in progress.

OR values drifting.


R P M

M E A S U R E I N P R O G R E S S


47

measurement mode. If a measurement is in progress, the analyser will await the end

of the measurement operation before launching calibration. Before carrying out a

zeroing operation, the analyser performs a check of the air intake.

Note that if a field contains no value and remains in the “----“ state, the

associated measurement is not available. We note the following cases:

The temperature probe is not connected to the analyser; oil temperature measurement is

not available.

The NOx option is not present; NOx measurement is not available.

Concentrations of HC, CO, CO2 and O2 give values for LAMBDA which are out of bounds;

LAMBDA is not available.

One of the gas measurements is invalid.

NOTICE:

At any time during this phase, it is possible to stop the pumps by pressing

the mode key and put the machine in the resting state. However, in order to avoid dirt

accumulation, it is recommended that the machine be rinsed with clean air by letting

the pumps run 1 minute with the probe removed from the exhaust pipe. It is possible

to so configure the machine that after a certain time has elapsed without exhaust gas

measurement, it automatically goes into standby (see paragraph V.5.1).

II.5.7. Printing results

Printing of values displayed on screen is accomplished by simply pressing the

PRINT key .

It is possible to print the results of measurements at two test points (for

example, idle measurement and measurement under high-speed running). Pressure

on the MEMORY key allows storage of a first series of results. During printing,

both the values retained in memory and the current values will appear.

Sending the report to a central storage set erases the values stored in

memory.

Printing is accomplished by simply pressing the PRINT key while the analyser

is in measurement mode (pumps activated and auto-zero complete).

ATTENTION: The operator has a choice of several print modes, the internal

mode which allows the use of the thermal printer furnished with the machine, in this

mode the user has nothing to do and the system is autonomous. On the other hand, if

the external mode is activated, for the system to work correctly the printer must be

turned on and ON LINE, that is, the green indicator light located on the SELECT ON


48

LINE button of the printer must be lit. If this is not the case, press this button; the

indicator lights if paper is installed (see. paragraph I.4.2.2).

Measure 1,2,3 are the memorize measure.

Measure 4 is the currently measure.


49

II.6. OFFICIAL TESTING

For technical tests, it is possible to obtain a printout of a test report giving a

breakdown of the polluting status of the vehicle in relation to its registration date and

current legislation.

In the main menu, select the technical test menu.

This action gives access to a menu for selecting one of the three categories.

Using the up and down keys, scroll through the selection. Press OK or ENTER

when the selection is made. It appears a client data entry window (see above), then

the procedure starts.

Vehicles are divided into 4 categories:

1) Vehicles placed in service before 01/10/86.

Only testing of corrected CO at idle is required.

The measurement must not exceed 4.50 %vol.

2) Vehicles placed in service between 02/10/86 and 31/12/92 and

utility vehicles placed in service between 02/10/86 and 30/09/94.

Only testing of corrected CO at idle is required.


3) Vehicles that began operating after 01/01/93 and

utility vehicles that began operating after 01/10/94 until 01/07/2002.

These vehicles are required to be equipped with catalytic converters.

V E H I C L E 3 0 / 0 9 / 8 6

V E H I C L E 0 1 / 1 0 / 8 6

C A T A L Y S T V E H I C L E

B E F O R E 0 1 / 0 7 / 2 0 0 2


C A T A L Y S T V E H I C L E

A F T E R 0 1 / 0 7 / 2 0 0 2


50

Measurement of CO and LAMBDA must be carried out at fast idle

(between 2500 and 3000 rpm).

CO must not exceed 0.30% vol. and LAMBDA (l) must lie between 0.97

and 1.03.

CO must also be measured at idle.


4) Catalyst vehicles registered after 01/07/2002.

II.6.1. Vehicle registered before 1 October 1986

Limit of corrected CO at idle: 4.5 %vol.

Operator guide: NO.

One single measurement carried out at idle.

If CO2 concentration is lower than 9.0 % vol., it is necessary to

perform a leak test of the exhaust, and if necessary a leak test of the analyser.

If a leak is detected in the exhaust line, the vehicle must be rejected and the

measurement invalidated.

Press the print key to validate the measurement and print it out.

II.6.2. Vehicle registered before 1 January 1993

Limit of corrected CO at idle: 3.5 %vol.

Operator guide: NO.

One single measurement carried out at idle.

If CO2 concentration is lower than 9.0 % vol., it is necessary to

perform a leak test of the exhaust, and if necessary a leak test of the analyser.

If a leak is detected in the exhaust line, the vehicle must be rejected and the

measurement invalidated.

Press the print key to validate the measurement and print it out.

II.6.3. Catalyst vehicle registered before 01/07/2002

Fast idle measurement:

Fast idle CO limit: 0.3 %vol.


51

Lambda between 0.97 and 1.03 at fast idle.

Measurement at idle:

CO limit at idle: 0.5 %vol.

No LAMBDA test at idle.

Operator guide: YES.

The guide allows the measurement to be carried out according to

French standard NF R 10-018. This standard describes the various steps

necessary to measure CO and Lambda of a vehicle equipped with a catalytic

converter.

The user is guided by following instructions readable on the liquid

crystal screen. When a phase is limited to time, the analyser indicates on the

NOx display (lower right) the time remaining in seconds until the phase

terminates.


52

Testing a Catalyst-Equipped Vehicle

No Phase Messages Observations Duration Advancing to the

following step

1 Zéro ZERO IN PROGRESS Takes place only if no zero

has occurred in the last 3

minutes

10 S. Automatic

2 Preparation of the vehicle PRECONDITIONING VEHICLE Preparation for

measurement

Not Timed If oil > 80 °C or if ENTER is

pressed

INSERT GAS MEASUREMENT

PROBE

30 mm depth min.

INSERT ENGINE OIL PROBE Optional if another

thermometer is present

CONNECT OPERATING SPEED

SENSOR

Optional if vehicle has on-

board tachometer

WAIT FOR OIL > 80 °C OR

PRESS ENTER

If oil temperature measured

by analyser, advancing to

the next stage is automatic

when temperature > 80°C

3 Temperature conditioning

of the exhaust line

MAINTAIN SPEED BETWEEN

2500 and 3000

Speed stable. Use the

tachometer for assistance

60 S. Automatic

4 Fast idle measurement FAST IDLE MEASUREMENT Start of 1st measurement 2 Min. Max. After 2 minutes or as soon

as measurement CO < 0.3

and 0.97< <1.03 during 5

second.

MAINTAIN SPEED BETWEEN

2500 and 3000

Speed always between 2500

and 3000 rpm.

If a value stored in memory

is bad:

5 Return to stable idle

condition

RETURN TO IDLE AND WAIT Release the accelerator and

wait for the expiration of

the 20 sec.

20 S.

6 Idle measurement IDLE MEASUREMENT Start of 2nd measurement 15 S. Max. if CO<0.5 during 5 second.

7 Measurement results TEST RESULTS: Results are displayed Not Timed

Test report, ex.:

“VEHICLE REJECTED LAMBDA

> 1.03”

Vehicle accepted or

rejected.

Displays bad value(s).

If the result is bad with oil

temperature not measured,

repeat the test while

measuring oil temperature.


53

II.6.4. Catalyst vehicle registered before 01/07/2002:

This is the same procedure than in paragraph II.6.3 with the following limits:

Fast idle measurement:

Fast idle CO limit: 0.2 %vol.

Lambda between 0.97 and 1.03 at fast idle.

Measurement at idle:

CO limit at idle: 0.3 %vol.

No LAMBDA test at idle.

Operator guide: YES.


54

II.6.5. Printing results:

V e hi c le s p lac e d in s e r v i c e be for e

0 1 / 1 0 / 8 6

V e hic le s p lac e d in s e r v i c e be tw e e n 0 2 / 1 0 / 8 6 and 3 1 / 1 2 / 9 2 and ut i l i t y v e h ic le s p lac e d in s e r v i c e be tw e e n

0 2 / 1 0 / 8 6 and 3 0 / 0 9 / 9 4

C ata ly s t v e h ic le s


55

II.7. LIST OF FAULT REPORT MESSAGES AND FAULT

TRACING

Error

number Message displayed

Call

Maintenance

Do it yourself Explanation in section

1 Leak present YES II.6.1.1

2 Data invalid YES II.6.1.2

3 HC out of bounds YES II.6.1.3

4 CO out of bounds YES II.6.1.4

5 CO2 out of bounds YES II.6.1.5

6 O2 out of bounds YES II.6.1.6

7 NOx out of bounds - - II.6.1.7

8 Lowflow detected YES II.6.1.8

9 Out of paper YES II.6.1.9

10 Lever open YES II.6.1.10

11 Printer problem YES II.6.1.11

12 HC residue in gas inlet YES II.6.1.12

13 MB com. Error YES II.6.1.13

14 Adjustment necessary YES II.6.1.14

15 Change O2 sensor YES II.6.1.15

16 Condensation: wait YES II.6.1.16

17 Heating problem YES II.6.1.17


56

II.7.1. Leak present

Repeat the test, disconnecting the probe from the device and

plugging the gas entry port on the separator. If the problem disappears, the

leak is in the probe tubing.

Otherwise, it affects the machine. Check the filter connections. Check

that the separator is correctly installed and adequately tightened.

Test the various parts of the pneumatic circuit with leak tests,

moving the plug progressively upstream, up to the pumps.

Open the machine and perform a visual check of the pneumatic

circuit.

Replace the leaking portion of the pneumatic circuit.

II.7.2. Data invalid

Adjustment necessary.

II.7.3. HC out of bounds

Out of range.

Check that the ambient air is not polluted and re-zero.

Perform a further adjustment if the problem persists.

II.7.4. CO out of bounds

Out of range.



II.7.5. CO2 out of bounds

Out of range.



57


II.7.6. O2 out of bounds

Out of range.


Check sensor connections.

II.7.7. NOx out of bounds

Out of range.

Check NOx sensor connections (optional).

Replace the NOx sensor if the message persists after several

attempts to zero.

II.7.8. Flow too low

Check that the flexible tubes located at the rear of the machine are

connected in accordance with the sketch in paragraph I.2.4. Check that they

are not kinked, twisted or plugged.

Disconnect the sampling probe to see whether the problem is

connected with it, or persists.

1) If the probe is disconnected, the message is no longer active:

Check that the sampling tube is not crushed by an external mass.

Clean the probe and the flexible sampling tube with compressed air

in accordance with paragraph I.4.4.1.

2) If the probe is disconnected, the message remains active:

Check the flow with a flowmeter.

If the flow is between the minimum flow and the nominal flow, it is

necessary for Maintenance to open the machine to check the pressure switch

and if necessary calibrate it using a pressure sensor at a trigger pressure of

160 mbar, or even to replace it.


58

If on the other hand the flow is outside the acceptable range

indicated at the rear of the machine, it is necessary to open the machine to

check what, in the pneumatic circuit, is reducing flow. If no flexible tube

seems twisted, kinked or plugged, check the electrovalves and finally replace

the pump diaphragms if necessary.

II.7.9. Out of paper

Put in a new ream of paper in accordance with paragraph I.4.2.

II.7.10. Lever open :

The printer thermal lever is open.

II.7.11. PB IMPR

Printer fault, save the error code and call maintenance.

II.7.12. HC residue in gas inlet

When a measurement is carried out on ambient air, if the CO2

concentration is below 2% by volume for more than twenty seconds while the

HC measurement gives more than 20 ppm, it is assumed that hydrocarbon

residues are present in the inlet tract.

These residues may also be in the ambient air. One must therefore

ensure that the work area is well ventilated. It may be necessary to clean the

probe. If the problem appears again, clean the separator.

If the HC measurement drops back to a level below 20 ppm for more

than 20 seconds, this message disappears, a zero operation is carried out and

the message “measurement in progress” appears.

II.7.13. com. error

Check that the device is grounded. Extensions for the power supply

cable are absolutely required to include a ground connector as well as the

power supply plug.

Communication between the main card and the test set is defective.

First, check that the power supply and communication cables are correctly

connected and that the “happy LEDs” are blinking. Connect the infrared set to


59

a computer and check that it is communicating correctly with the

maintenance program. Next, check that at the Tx pin of the main card, a

signal is regularly transmitted. Depending on the problem encountered,

replace the defective component.

II.7.14. Adjustment necessary

Call Maintenance; adjustment with the help of a calibration gas is

necessary. This message indicates excessive drift in the machine.

II.7.15. Change O2 sensor

During a zero operation, the system associates the oxygen

concentration in air (20.9%) with the corresponding potential at the terminals

of the oxygen sensor. This potential must lie between –2.15V and –1.95V. If

the potential is not in this range, the message “Change O2 sensor” appears.

This means that the oxygen sensor is defective or incorrectly connected.

Replace it and follow the procedure indicated by the analyser.

II.7.16. Condensation: wait

This message may appear during the start-up phase. In this case, one

need only wait for the machine to be warmed up and ready to carry out

measurements.

If on the other hand this message appears in the course of a

measurement and persists, it is necessary to carry out a check of the

following points:

Check that the separator is correctly connected.

Check the flow at the condensate exhaust connector.

Check the internal parameters in the maintenance menu.

Perform a leak test.

Depending on the results obtained, notify Maintenance, which will

undertake the replacement of the defective part.


60

II.7.17. Heating problem

If the estimated start-up time of the machine (elapsed time between the time the machine is

turned on and the time when measurements are possible) is greater than 15 minutes, this

message appears.

If the temperature is below 5°C, it is necessary to move the machine to a less cold space and

restart it.

II.7.18. Other :

a) RPM out of range

This is manifested on screen by a “----“ display.

If this message appears, it means that the measurement of operating

speed is greater than 9999 rpm. Check that in the Operating Speed menu, the

correct sensor has been chosen and the information concerning the engine to

be tested are correct and have been entered.

b) TMP. Out of range

This is manifested on screen by a “----“ display.

If the ambient temperature is less than 0°C or if a measurement is in

progress on a vehicle, this means that the measured value is outside the

range 0-150°C.

If neither of these is the case, check that the oil temperature probe is

correctly connected to the connector assigned to it. If this is not the case,

replace the sampling probe.


61

III. THE OPACIMETER:

(DIESEL VEHICLES)


62

III.1. PRINCIPLE OF OPERATION

In the composition of the exhaust gas emitted by diesel engines, the pollutant

component is considered to be carbon in suspension. A polluting vehicle emits on acceleration

a puff of gas that is darker (and thus more opaque) than a vehicle in good condition. The partial

flow opacimeter is used to establish a measure of this phenomenon based on a given unit of

measure, the K(m-1).

The principle of opacity measurement is the following: a beam of light (emitter aimed

at a receiver, with a constant distance between the two) is passed through a sample of gas. The

fraction of incident light which reaches the receiver is inversely proportional to the

concentration of particles in suspension in the gas.

The measurement obtained is digitally corrected.

The opacity of a vehicle is the maximum opacity value measured during acceleration.

Several accelerations are needed to obtain a reliable measurement. The number of

accelerations to be carried out for the opacity measurement of a given vehicle is defined by

standard NF R 10-025.

1- Emitter

2- Receiver

3- Chamber temperature sensor


63

4- Heating elements

5- Gas temperature sensor

6- Gas inlet

7- Measurement chamber

8- Exhaust fan

F unc t iona l s c he m at ic o f the m e as ur e m e nt c ham be r .

The opacimeter depends on the interactive operation of two sub-systems. The first is

composed of the cell. This is what establishes the opacity measurement. The electronic system

of this cell contains a microprocessor which makes it possible, on the basis of several

temperature and pressure sensors, to regulate the system, to detect bad operating conditions

and to correct the measurement. All this information is directly taken into account by the

central unit which is responsible for detecting maximum opacity, displaying the results on an

LCD screen, printing to a thermal printer or an external A4 format printer and guiding the

operator throughout the procedure.

According to current regulation, the periodic testing of opacimeters is not compulsory.

These devices, may, however later become subject to this type of inspection.

All the devices manufactured under reference number CAP3201 have been subjected

after manufacture to a test that verifies the correct operation of the device and the validity of

the measurement.


64

III.2. OPERATING CONDITIONS

The opacimeter automatically checks the parameters that have an influence

on the measurement. If at least one of these parameters is out of bounds, hence

threatening to metrologically alter the results, the opacimeter disables itself and

prevents any measurement from occurring until operating conditions have been re-

established.

The following problems result in the system being disabled:

Detector temperature out of bounds (limits extending from 41 C to 55°C)

Chamber temperature out of bounds (limits extending from 70°C to 110 C)

Supply voltage out of bounds

Fan speed too low (limits extending from 2100 rpm to 2900 rpm)

Computer to cell communication problem

Windows need to be cleaned

Problem with a temperature sensor


65

III.3. TECHNICAL CHARACTERISTICS

Power supply: 1,5 A / 115 VAC 0,9 A / 230 VAC (+10%-15%) 50-60

Hz (+-2%).

Effective length of the measuring chamber: 215 mm +-0.05 cm.

Preheating time: from 3 to 6 min depending on ambient temperature.

Zero adjustment and calibration before use: automatic.

Control of zero adjustment: automatic by electrical filter centred at 50%.

Ambient temperature range for operation: +5 to +40°C.

Humidity: 30% to 90%.

Storage temperature: -32°C to +55°C.

Measurement range of the measured value:

Opacity: 0.00 to 9.99 m-1.

Resolution 0.01 m-1.

Maximum relative error:

Under standard conditions (temperature +20 °C, atmospheric pressure 1013 hPa,

relative humidity 60% +/-15%), opacity error below 0.15 m-1.

Measurement range of influencing factors (which allow correction of the opacity value):

Temperature of the gas being measured: 0-256 C (resolution 1°C)

Physical response time 10% to 90%: less than 0.2 sec. for gas at 75L/min.

Electrical response time: 0.9 sec.


66

III.4. INSTALLATION AND PRECAUTIONS

DURING OPERATION

III.4.1. Installation, start-up :

Each CAP3201 is inspected before delivery by a representative of the

measuring instruments service, who affixes a stamp mark on the plate attached to the

rear of the machine.

Check that the opacity cell is correctly connected to the station and

connect it to the 230 VAC 50 Hz mains.

Press the Stop/Start switch on the station.

Press the Stop/Start switch of the cell.

III.4.2. Cleaning and precautions during operation

The opacity gauge is designed to function without maintenance. The only

components requiring periodic maintenance are certain components of the cell.

Occasionally, large carbon particles enter the chamber while the engine is

being tested. The great inertia of these particles will cause them to be thrown against

the windows located on either side of the chamber. A periodical monthly inspection is

recommended to determine whether the two windows have an excessive coating.

A carbon deposit may also be deposited in the measurement chamber. It is

sufficient to sweep out the tube to eliminate the soot using the brush supplied with

the opacimeter.

Where the windows are concerned, a dry cotton rag is the proper tool for

cleaning these two surfaces.

DO NOT USE ANY CLEANING FLUID.

It is not necessary to open the cell to carry out these maintenance operations.


67

III.5. OPACITY TESTING PROCEDURE

This procedure allows a determination, for a given vehicle, of whether or not its

opacity is lower than the current limit.

Select in the main menu the

opacimeter application, then the opacity

testing procedure. A series of phases will then

take place in sequence. It is important to

follow the instructions just as they appear on

the screen and to observe the directions in the

user manual.

III.5.1. Client information entry

As soon as the test procedure is launched, the user may, if he wishes, enter

information about the client and his car (name of client, make, mileage and registration

number). These data will then appear on the test report.

The client entry procedure is the same as for the garage header (voir paragraphe V.3).

The entry window with keyboard option appears this way:

O P A C I T Y C H E C K


O P A C I T Y A N A L Y S I S

S M O K E M E T E R

C U S T O M E R :


V E H I C L E :

P L A T E :

M I L E S :

N O T E S :


68

III.5.2. The engine :

The software then asks you about the type of engine to be tested. This lets it know the

limit of opacity that may not be exceeded.

First, it asks you whether the vehicle has a

naturally aspirated engine (maximum

authorized limit = 2.5 m-1) or a turbocharged

engine (permissible limit = 3 m-1).

Select the corresponding type using the UP arrow and the DOWN arrow and confirm

the selection using the OK key.

III.5.3. Description of the graphic interface:

This graphic interface is composed of several elements:

The tachometer:

Current opacity

Tachometer

Oil temperature

Gas temperature

Interval timer

Message box

A T M O S P H . V E H I C L E

T U R B O V E H I C L E

O P A C I T Y C H E C K

R P M O P A C I T Y

O I L G A S

T U R B O V E H I C L E


69

The tachometer reading may run from 0 to 9999 rpm. In addition, a

graphic element allows the trend in engine operating speed to be quickly

visualized.

Only one of the sensors allowing the engine speed to be acquired is

needed for reading the rotation speed (in revolutions per minute), see

paragraph IV.4.2..

The oil temperature:

The oil temperature gauge has been installed in the vehicle’s oil

dipstick well for the preliminary phase. The user can therefore monitor this

temperature in the window provided for this purpose.

Current opacity:

This value constantly shows the current opacity; it is expressed with

two opacity units. One is given per meter (m-1) and the other in percent. In

addition, a graphic element allow rapid visualization of opacity between 0 and

99.9%.

The message box:

It directs the operator through the procedure. Messages displayed

here are of two types:

Error messages. Every detected error or timeout results either in

cancellation of the procedure or invalidation of the free acceleration. In one

case, the message window contains the type of error that caused the

problem.

Explanatory messages. During the procedure, several different

phases follow one another in sequence. The message window indicates to the

operator what he must do and what the opacimeter is doing. This allows easy

understanding of the procedure and gives effective guidance to the operator.

At any moment in the procedure, press “DYS” if you detect the slightest

problem regarding the control of engine speed or a leak in the exhaust line.

You can print a test report with the annotation “unacceptable result”.

The «operating speed mode » key:

Allows the operating speed mode to be selected depending on the sensor

type used at the input (see paragraph III.5.2.).


70

The “print” key:

This key allows the results to be printed or transferred to a central computer

in a technical testing centre for example.

III.5.4. Displays the selected operating speed mode:

Each time the opacity program is launched, the operator knows the operating

speed mode that is selected; he may therefore change this mode by pressing

the key or leave it in the displayed mode.


71

MEASURE IN

PROGRESS

RPM touch

Display the rpm

mode in progress

RPM touch

3 s

YES

Induction

Induction/2

Piezo

E.O.B.D.

TTL

3 s

3 s

3 s

3 s

3 s

YES

Battery3 s

Cylinder number?

Initialization

Organization chart:


72

“Induction”: Sensor operation:

The induction clip allows detection of the moment that ignition occurs in a cylinder. Placed

around the ignition lead of a cylinder, it generates a signal by inductive effect at the moment of

ignition. At the rate of one spark per revolution for 2-stroke engines and 1 spark for two

revolutions when a 4-stroke is involved, the induction clip allows the operating speed of a

petrol engine to be measured.

Connect the induction clip cable to the CAP3201 input connector for the induction clip (an icon

indicates its location), then selection the “induction” mode using the operating speed key. The

operating speed display appears automatically.

“Induction/2”: The procedure is identical to the preceding one, only the value is divided by

two.

“Piezoelectric”: Sensor operation:

The piezoelectric sensor allows detection of the moment of injection on a diesel

engine. Placed around an injection tube, it detects the dilation caused by the variations of

internal pressure caused by injection. The electric signal supplied by the sensor allows the

operating speed of a diesel engine to be measured (one dilation of the tube for two engine

revolutions).

Procedure:

STEP ACTION COMMENT

1 Clean the injection tube locally with

sandpaper.

2 Place the piezoelectric sensor on the

cleaned part and tighten it firmly by hand.

Connect the cable to the sensor.

Ensure that the piezoelectric sensor is of

the same diameter as the injection tube.

All diameters are available as options.

3 Connect the ground clamp, preferably to

the same tube.

The tachometer is installed and it should

be possible to read the operating speed

of the engine on the screen.

Note: We recommend that the tachometer, when it is used, be connected at

the beginning of the test, that is before launching the testing or opacity value

measurement procedure.


73

Connect the sensor cable to the CAP3201, then select the “piezo” mode using the operating

speed key. The operating speed display appears automatically.

“E.O.B.D.”: This mode allows the engine speed to be read from the data sent to us by the

computer on board a vehicle (see part V). This option consists of an electronic card installed inside

the CAP3201. All vehicles equipped with E.O.B.D. have operating speed readout.

Connect the cable to the vehicle’s computer; the plug provided for this purpose is usually

located near the fusebox. Then connect the other end to the CAP3201. Select, using the

operating speed key, the “E.O.B.D.” mode. The display appears automatically.

“TTL”: This mode makes it possible to read an engine speed sensor with a TTL output. Connect the

cable to the induction clip input of the analyser. Select, using the operating speed key, the “TTL”

mode. The display appears automatically.

“Battery”: The battery option is composed of an electronic card installed inside the CAP3201, a

cable for data and for power supply from the cigarette lighter to the case, and a cable for data and

for power supply from the battery. This option is a battery-driven tachometer which allows

operating speed to be measured on all vehicles - petrol, diesel and LPG.

Connect the cable on the CAP3201 (RPM BAT); select the “battery” mode using the operating speed

key. After three seconds, the operator must choose and confirm the number of cylinders. If the battery

cable is correctly connected, the system carries out an initialization phase. After this phase the

operating speed is displayed.

ATTENTION: In the event of a problem, the headlights of the vehicle should

be turned on, and everything else shut off.

See section VI.

III.5.5. Detecting the cell

At the beginning of the test, the presence of the cell is verified.

After a few seconds, the cell is detected.

If the contrary is true, the following message is displayed:

In this case, check whether the cell is plugged in and properly connected.

C O M M U N I C A T I O N

P R O B L E M

P R O C E D U R E I N T E R R O M P U

P R E S S E S C

T H E N R E S T A R T


74

III.5.6. Auto-zero and error checking

Following the phase which consists of preparing the vehicle for measurement

and ensuring that it is operating correctly, the opacimeter needs to perform an auto-

zero. This is an internal procedure in the measurement cell that allows it to calculate

the sensitivity of the detect such that an invisible gas is assigned an opacity of 0.00 m-

1. This procedure is carried out automatically; it is vital, however, to check the

following point:

DURING THE AUTO-ZERO OPERATION, THE SAMPLING PROBE MUST NEVER BE

INSERTED INTO THE EXHAUST LINE OF A RUNNING ENGINE.

Before this procedure is launched, a general check of all the parameters of

the cell is automatically carried out.

Three cases could then occur:

1°) The opacimeter was just started and the preheating phase is still active. In this

case, it is necessary to wait for the measuring chamber to reach its operating temperature. A

message to this effect is displayed on the screen: It provides information on the progress of the

percentage of preheating of the cell.

2°) The opacimeter refuses to operate because it has detected an error or a

breakdown. These errors are listed in III.8.1. For certain errors, it is possible to recover by

carrying out the prescribed operations (cleaning the measurement cell windows, for example);

for others, action by the Maintenance service is required.

3°) The opacimeter is ready.

The auto-zero operation will take place as soon as the opacimeter is assured

of the normality of its current condition. During auto-zero, this message will be posted

on the screen.

The auto-zero operation is a procedure which, taking ambient air as a

reference, establishes the signal levels for zero opacity. It is therefore important not to

put the measurement probe into the exhaust line before the software requests it.

W A R M U P = 9 0 %

Z E R O I N P R O G R E S S

P L E A S E W A I T


75

III.5.7. Insertion of the probe and sensors

Once the auto-zero operation is carried out, the following messages appear

on the screen:

Now is the time to put the sampling probe, the oil temperature sensor and

the tachometer in place:

III.5.7.1. The probe:

To do this, move the cell near the exhaust pipe outlet.

The probe must be inserted to a depth at least equal to 5 cm. If the layout of

the exhaust line allows it, it is preferable to insert it as deep as possible. Ensure that

the probe is not kinked, which might alter the flow of gas arriving at the measuring

chamber.

The sliding clip on the probe allows the probe to be affixed to the exhaust

pipe.

Only the original probe, bearing the CAP10 reference label, allows valid

results to be achieved. This probe may not be extended or modified.

III.5.7.2. The oil temperature sensor:

It is necessary to insert the oil temperature sensor in the dipstick tube. Do not insert

the probe too deeply. One solution consists of adjusting the rubber stopper on the probe so as

to insert the probe to the same depth as the dipstick.

III.5.7.3. Connecting the tachometer:

See paragraph (III.5.2.)

I N S E R T T H E P R O B E I N T O T H E

E X H A U S T

I N S T A L L T H E O I L

T E M P E R A T U R E S E N S O R

C O N N E C T T H E T A C H O M E T E R


76

After inserting the probe and the sensors, with the engine still running, it is

necessary to notify the opacimeter that all is ready. To do this, press the OK key to

move on to the following phase.

III.5.8. Preliminary checks

Before undertaking any measurement, the operator must satisfy himself that

the engine is operating correctly. Opacity measurement being a rather demanding

procedure for the engines, it is imperative that this step be carefully followed to avoid

engine damage and to obtain a valid opacity measurement. If an obvious malfunction

is detected on the vehicle, press the “MAL” key. This will have the effect of rejecting

the vehicle test and printing a test report specifying that the vehicle cannot be

checked due to its poor condition.

The following points are to be observed:

The vehicle exhaust line must be gas-tight. This check can be carried out

by partially blocking the exhaust while the engine is at idle. No leak must

be observed.

The gearbox must be in neutral, with the clutch engaged, for vehicles with

manual or semi-automatic transmissions; the selector should be in neutral

for vehicles with automatic transmissions or in accordance with the

instructions of the vehicle manufacturer.

Accessories and optional equipment that influence the engine speed at

idle must not be activated, barring manufacturer’s instructions or

regulation to the contrary.

The engine must be at normal operating temperature, that is with an oil

temperature at least equal to 80°C.

To satisfy this preliminary check, the following page is then displayed:

The opacimeter may be configured in what is called the “P.L.” mode (see

Configuration - opacimeter). One can then move on to the following phase without having to

W A I T F O R O I L > 8 0 ° C


77

perform an oil temperature measurement or even connecting the probe. Simply press the OK

key to escape this blocking phase. In this mode, the following message is activated:

In the so-called “V.L.” mode, required for technical inspections, oil temperature

measurement is indispensable.

No test can be carried out as long as the probe has not reached a temperature of

80 °C, the oil temperature at which the engine is considered to be at its operating temperature

and in no danger of deterioration during the test procedure. If, for certain vehicles, the

manufacturer recommends a higher temperature, it is necessary to wait for this temperature

to be reached before carrying out the first acceleration.

On the page, the oil temperature is displayed. It must increase while the engine is

running and reach 80 °C after a certain time. If this is not the case, check that the probe is

correctly inserted and in contact with the engine oil.

This page also contains a tachometer window (located at the upper right).

III.5.9. Conditioning the engine:

Faced with this message, the operator has ten seconds or so to get into the

vehicle, and is charged with carrying out the two preliminary phases of the procedure:

1°) Establish a preliminary check to verify the correct operation of the

vehicle.

2°) Test governor operation for one minute.

For a period of 60 seconds, the engine governor operation must be checked

in the following manner:

Check the normality of no-load governor operation by carrying out a series of

accelerations, step by step, up to the governing level given by the vehicle

manufacturer.

If the duration of the check of the normality of no-load governor operation is

less than 60 seconds, the balance of the time must be used to maintain the engine at a

C H E C K G O V E R N O R

O P E R A T I O N

D E R E G U L A T I O N

O R P R E S S O K


78

stabilized operating speed around 40 to 60% of the maximum no-load speed, or

approximately:

- 3000 rpm for a vehicle with an authorized gross weight less than 3.5 T;

- 1500 rpm for a vehicle with an authorized gross weight greater than 3.5 T;

It is recommended to use the tachometer to reliably check engine governor

operation.

The operator must follow along with the following messages:

This vehicle preparation is indispensable; it may not be skipped.

III.5.10. Free acceleration

Definition according to standard NF R 10-025:

Acceleration achieved, with the engine initially at idle, by rapidly but not

violently operating the accelerator control in such a way as to obtain maximum

injection pump output. This position is maintained until the maximum operating speed

of the engine is attained and the governor goes into action.

The accelerator must therefore be pushed down all the way in order to

advance from idle speed to maximum speed in the shortest possible time. This

operation is an essential feature of the procedure, since the opacity that is recorded is

the maximum opacity measured during free acceleration. In order to obtain a valid

measurement, it is indispensable to undertake this operation so that the opacity is a

maximum (maximum injection pump output). It is possible to detect that maximum

speed has been reached, either by ear or using the tachometer. The pedal is then

released to return to idle speed.

As soon as free acceleration is to be carried out, messages indicate when to

accelerate and when to release the accelerator pedal. The software analyses the

opacity curve recorded during free acceleration to detect its maximum and establish

the validity of the acceleration.

A C C E L E R A T E S T E P B Y S T E P

G O T O M A X S P E E D

M A I N T A I N S P E E D

A T 5 0 % O F M A X


79

III.5.11. Two non-measured accelerations in succession

A series of two accelerations will now be requested. The following screen

appears:

Faced with this screen, the user must push the accelerator down all the way.

The following message should then appear:

After a few seconds the following message appears:

The operator must release the accelerator pedal so that the engine speed

returns to idle speed.

This operation is requested once again.

These two accelerations are indispensable for cleaning out the exhaust

system and thus avoiding excessive and meaningless opacity measurements.

Two accelerations not counting toward the test are therefore carried out, and

we move on to the test proper.

III.5.12. Opacity measurement phase

After the engine preparation phase, the operator is now occupying

the driver’s seat of the vehicle. He now had nothing to do but concentrate on

the message box, which dictates to him when to press the accelerator pedal

and when to return to idle. Depending on the vehicle and the results, the

operator will need to carry out two to five accelerations.

The opacity of each acceleration is displayed on the left side of the

page (the window assigned to the first acceleration being named K1, that

assigned to the second called K2 and so forth).

C L E A N O U T N o 1

C L E A N O U T I N P R O G R E S S

R E T U R N T O I D L E


80

III.5.13. Display of the results of each acceleration

The acceptance decision is made in the following manner:

If the result of the two accelerations is below the current limit

(2.50 m-1 for naturally aspirated engines and 3.00 m-1 for turbocharged

engines), the procedure is terminated and the vehicle is accepted. Likewise, if

the results are 1.5 times higher than the limit, the vehicle is rejected.

Otherwise, 3 more accelerations are carried out and the results

compared to the current limit. The result is considered acceptable if the mean

value obtained is below the limit. Again, the operator has no calculation to

perform and need only concern himself with responding to the orders given

him by the software. If the result given by this procedure judges the opacity

of the vehicle to be unacceptable, the vehicle will have to be subjected to the

opacity value determination procedure (see paragraph IV.5).

When the test is finished, the user may print or transfer the report

by pressing the key corresponding to the icon.

A new message appears:

It indicates whether the user wishes to print a report (F1) or transfer

the same to a central data store (F2) or return to the previous message (ESC).

F 1 : P R I N T

F 2 : T R A N S M I T


81

III.5.14. Printing results

III.5.14.1. Measurement to standard

A c c e ptab le r e s u l t c as e

U nac c e ptab le r e s u l t c as e

U nac c e ptab le r e s u l t c as e , due to obv ious m al func t ion

Indications on the printout ticket :

- Garage header,

- Customer informations,

- Date/time,

- type (PL or VL),

- The procedure name,

- If the measurement is in conformity with the standard (NFR 10-025),

- Serial number,

U N A C C E P T A B L E R E S U L T

M A L F U N C T I O N O F T H E

V E H I C L E

R E S U L T FOR INFORMATION


82

- Oil temperature information,

- The engine (atmosphéric or turbo),

- Opacity limit,

- Speed engine min./max,

- Oil temperture max.,

- Results,

- the decision concerning acceptance of the vehicle.

Finally, if the result of an acceleration is shown in the form “-.--”, it means that the

acceleration was not detected.

III.5.14.2. Measurement not to standard

When a free acceleration is carried out and the temperature of the gases

entering the chamber is less than 40°C, the measurement is considered not to

standard. The measurement is not rejected and the result is given for the sake of

information.


83

The test report indicates that the measurement is not in conformity with the

standard (NFR 10-025) and that the result displayed is for information only. In the

ticket examples, the absence of a cross in the third column of the measurement table

indicates that the temperature is below 40 °C.

..




84

III.6. OPACITY VALUE DETERMINATION

PROCEDURE

This test must be performed on vehicles whose results from the opacity check

procedure have been judged unacceptable. It repeats the same steps as the opacity check

procedure. This procedure, however, is longer but more accurate in that the number of free

accelerations may go as high as 16 and measurements are taken into account only when the

results of successive free accelerations are stabilized. This test is identical to the opacity check

procedure, but conditions for termination are different and free acceleration results start to be

processed beginning with acceleration number 4. The software continues to order free

accelerations as long as the results of successive accelerations do not converge to a stable

value. If after 16 accelerations the values are not stable enough, the procedure stops and

indicates unstable opacity.

The UP and DOWN arrows allow scrolling of values when there are more than 5 of them. All

the other buttons have the same characteristics as in the opacity check procedure.


R P M R P M O P A C I T Y

O I L G A S



85

T he m ac h ine g iv e s the ar i thm e t ic m e an o f the las t four ac c e le r at ions .

T he v a lue s hav e not s tab i l i ze d a f te r

1 6 ac c e le r at ion ; the m ac h ine ind ic ate s uns tab le opac i ty .

T he v a lue s hav e not s tab i l i ze d a f te r

1 6 ac c e le r at ion ; the m ac h ine ind ic at e s uns tab le opac i ty . W hat i s m or e , the ac c e le r at ions hav e a gas

te m pe r atur e <4 0 ° C , he nc e the r e s u l t i s on ly fo r in for m at ion .

Indications on the printout ticket are identical to the opacity control procedure; only the

termination criteria are different.

U N S T A B L E O P A C I T Y

R E S U L T F O R I N F O R M A T I O N


86

III.7. OPACITY ANALYSIS

This page is dedicated to the repairman who wants to analyse the opacity curves of a

vehicle without the constraints of the official procedure.

Enable/Erase:

Press K1 and/or K2 to enable. When an acceleration is detected, the curve is drawn on the

screen. To erase curve 1 and/or 2 simply press ERA K1 or/and ERA K2. To draw a new curve,

enable again.

Print:

Printing the opacity curves.

Auto-zero:

Recalibrates the instrument; the probe must not be in the exhaust when the function

is requested.

Operating speed mode:

Allows the operating speed mode to be selected depending on the sensor type used at

the input (Voir paragraphe III.5.2.).

O P A C I T Y A N A L Y S I S

R P M

O I L

G A S


87

III.8. OPACIMETER MESSAGES

III.8.1. Error messages

III.8.1.1. «Zero in progress»

This message should disappear after a few seconds at the end of the auto-

zero operation. Maximum duration, 4 seconds. It is not an error; it means

that the procedure for resetting opacity to zero is in progress. Wait.

III.8.1.2. « Mains voltage out of bounds »

The cell input voltage should be between 195 and 253 VAC.

Beyond that, the cell cannot operate correctly. Have the mains power

checked.

III.8.1.3. « Windows dirty »

You must shut off the machine and proceed with cleaning the cell lenses as

described in the maintenance chapter of this manual.

III.8.1.4. « Fan is defective »

The air flow system is unable to ensure a constant effective length. Call the

Maintenance service.

III.8.1.5. « EEPROM out of service »

This should not appear. Call Maintenance, which will come and reinitialize

your cell. The measurements carried out are not valid.

III.8.1.6. « Sensor problem »

A temperature sensor is defective; call the Maintenance service.


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III.8.1.7. « Preheating »

Tube temperature must be 80°C. It is therefore necessary to carry out a

warmup operation which varies from 3 to 6 minutes in length.

III.8.1.8. « Detector temp. out of bounds »

The temperature of the optical detector must be between 25 ºC and 45 ºC.

After a preheating period, this error resolves itself. Wait.

III.8.1.9. « Time exceeded »

If no acceleration was detected within the prescribed interval, this message

appears.

III.8.1.10. « Probe connected?»

This message appears right after the preceding one, because in general non-

detection of an acceleration is caused by an incorrectly inserted probe.

III.8.1.11. « Measurement invalid »

The opacity curve contains several peaks, making it impossible to determine

opacity. Use more vigorous foot pressure on the accelerator.

III.8.1.12. « Press ESC and start again »

This message appears when an error threatens to impede the proper

operation of the test. The test in progress is therefore interrupted, and it is

necessary to quit the test by pressing ESC, then start over.

III.8.2. User guidance messages

III.8.2.1. « Acceleration No. X »

This message indicates the beginning of a new acceleration.


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The user must therefore push the accelerator pedal all the way down as soon

as this message is displayed.

III.8.2.2. « Measurement in progress »

Acceleration has been detected; the accelerator pedal must be kept pushed

to allow acquisition of opacity during the current acceleration.

III.8.2.3. « Return to idle »

Starting with this message, the accelerator pedal must be released and the

cell sends to the central unit information on the vehicle’s opacity.


90

IV. OBD SCANTOOL

On Board Diagnostic

or

Universal on-board diagnostic reader


91

IV.1. GENERAL

The Scantool is a tool allowing access to the internal data of on-board systems. It

connects to the OBDII autodiagnostic plug (SAE J1962 standard) of the vehicle and scans the

information stored in memory or current data made available and accessible by one of the 5

standardized protocols.

- ISO 11519-4 (SAE J1850) at 41.6 Kbps PWM (FORD).

- ISO 11519-4 (SAE J1850) at 10.4 Kbps VPW (CHRYSLER- GM).

- ISO 9141-2 at 10.4 Kbps (European vehicles).

- ISO 14230-1.2 to 10.4 Kbps or Keyword 2000 (CAN equipped vehicles).

- CAN (Controller Area Network; Keyword 2000 layer) (system which will be

applied generally to European vehicles in the coming years).

Since 1 January 2000, all petrol vehicles sold in Europe must compulsorily be equipped

with an on-board computer controlling engine and drivetrain operation and capable of

communicating its internal information to diagnostic devices according to at least one of the 4

protocols cited earlier.

The European Directive aims to universalise access to information necessary for repair.

This concept answers to the name of EOBD (European On Board Diagnostic).

This technology is already implemented on American (Ford, GM, Chrysler) and Asian

(Honda, Toyota, …) vehicles. European makes are the last to benefit from these functions.

Since 1 January 2000, costly and manufacturer-specific equipment is obsolete. The

same is true for the cartridge-based multi-brand systems.

IV.2. PRINCIPLE

The Scantool is not a measuring instrument. All information displayed on the screen is

only information transmitted by the computer.

Information available varies according to each model.

Connected to the vehicle, the Scantool asks questions of the computer and displays

the answers. Answers are information which can be classified by family:

Fault codes stored in memory (injection, emission test, air conditioning, brakes,

gearbox, body, chassis, network…),

Codes for current faults,


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Current measurements,

Fixed arrays (snapshots of internal measurements at the time a fault occurs),

Data on oxygen probes (measurements on lambda probes),

Specific internal data (air conditioning, ABS, passenger cabin, engine and drive train

control peripherals not provided for in the standard, ex. anti-slip control),

Test procedures,

Reinitialization procedure (erases faults stored in memory, turns off indicator lights

on the dashboard and resets the oil change indicator to zero),

Vehicle information (serial number, model, ...)

IV.3. MEASUREMENT AND TESTING

IV.3.1. Connection

The Scantool connects directly to the EOBD connector of the vehicle.

This connector allows communication with, and power supply to the

computer.

Generally this connector is located under the dashboard on the

driver’s side, in the glove compartment or under the main ashtray.

It is therefore easy to make measurement while staying, the Scantool

in hand, inside the vehicle. This is especially appreciated in the context of

measurements carried out on the road.

Attention:

Certain vehicles manufactured between 1996 and 2000 are equipped

with this connector. Everything appears to show that they are equipped with

OBD. That is not so. For a vehicle bought in France before 2000, only those of

VOLVO brand as well as imported American vehicles satisfy this standard.


93

IV.3.2. EOBD data

IV.3.2.1. Measurements

a) Service 01 – Current measurements

This service gives access to current measurements carried out by the

computer on the engine/drive train assembly, the digital inputs and outputs

and the system states.

A number, called PID, is associated with each type of measurement.

For each measurement that is available, the screen displays:

- the PID,

- the value,

- the unit of measure (if required),

- the measurement heading.

The list of measurements displayed depends on the individual vehicle

model.

b) Service 05 – Lambda probe measurements and testing

This service gives access to all the oxygen probe parameters. For

systems with several lines or with several sensors per line, it is necessary to

select from the list the sensor that is to be checked.

The values measured correspond to the following information

relating to the oxygen probe signal.

[Insert Lambda probe diagram...]

IV.3.2.2. Fault codes

a) Service 03 – Fault codes stored in memory

This is the most complete service

Destined for the long term to replace emission test checks in

technical inspections, the OBD is an on-board computer that constantly


94

analyses the operation of the engine. At the slightest anomaly, the OBD

system detects the source of the malfunction, establishes a diagnostic

procedure and determines the most representative fault code.

This fault code is stored in the computer’s memory.

Service 03 allows reading and display of fault codes stored in

memory in the computer. When a fault code is in memory, an indicator (MI)

lights up on the dashboard.

Reading a fault code never erases it from memory. To erase a fault

code after display, use service 04 (Erase / reinitalize computer).

It is possible that the computer might have a code still in memory

even thought the fault is no longer present (fault due to particular conditions,

repair completed).

The fault codes taken from the EOBD standard are limited to

monitoring engine and drive train operation or any component capable of

generating pollution in the event of a malfunction.

In the long term, the European program seeks to replace current

emission test checks by a simple readout of fault codes from memory, a

vehicle without functional faults stored in memory being a vehicle that does

not pollute.

It is recommended that the description of a fault by the OBD system

not be taken literally. In fact, a fault on a given sensor could be generated by

several types of trouble. These faults are not always linked to the sensor

itself:

- Problem in the circuit connecting the sensor to the computer,

- Electronic fault at the signal conditioning stage,

- Out of bounds measurement due to a problem not upstream of the

system.

b) Service 02 – Fixed arrays

This service allows access to fixed arrays. A fixed array is a snapshot

of current measurements or of a part of the current measurements at a given

moment. Very generally, a fixed array may be stored in memory when a fault

code is generated following a malfunction. Thus, this allows the conditions

under which the problem appeared to be known.


95

Ex.:

Readout of the fault codes displays the following message:

P0302 “Ignition misfire detected, Cylinder 2”

After becoming aware of this problem, I will read the fixed array

associated with it. I will for example be able to say that the ignition misfire

took place at 195 km/h and that the engine was running at 4,200 rpm.

This service is particularly valuable when an intermittent fault is

involved. It thus allows knowledge of the conditions under which the fault

occurred.

Storage of a fixed array in memory does not occur systematically

every time a fault code is stored in memory.

c) Service 07 – Current fault codes

For certain malfunctions, the computer decides to generate a fault

code in memory if this fault persists through several driving cycles. Service 03

gives access to persistent faults, while service 07 gives a list of malfunctions

that are active at the moment the request is made.

This service is particularly helpful for car mechanics. In fact, after

repair and erasure of the fault codes, it is possible for him to verify that the

malfunction is no longer present and that the problem is resolved.

If the problem continues to persist, its fault code is displayed by this

service. If, after two driving cycles, the fault code is still active, the MI

indicator lights up and the fault code is stored in memory and thus becomes

accessible to service 03.

d) Service 04 - Erase / reinitialize computer

When a fault is in memory, the repairman must attempt to

determine the source of the fault and repair it.

Once he thinks he has resolved the problem, it is imperative that he

erase the fault in memory, because repairing a malfunction never erases the

fault code in memory that is associated with it.

Service 04 is responsible for carrying out this memory cleaning

operation.


96

After launching this service, it is advisable to check that the faults

have been erased from memory by returning to the preceding service.

IV.3.2.3. Tests not continuously performed

a) Service 08 - Launching a specific test procedure

Certain components are not continuously monitored. Verification of

the correct functioning of such systems can only be carried out by launching a

test using the diagnostic tool. This test will be launched by the user and will

stop by itself. At present, only the emission vapour leak test is available. Early

addition of a catalyst test is planned, but this function will be the subject of a

future update.

b) Service 06 - Systems not constantly monitored

This service has the purpose of displaying the results of monitoring

tests by the on-board diagnostics of specific components/systems which are

not continuously monitored (these tests are activated by the service). The

results of the tests are displayed without interpretation. In fact, the

information is specific to each vehicle. It is therefore necessary to obtain

information from a database or from the manufacturer to understand these

results.

IV.3.2.4. The information

a) Service 09 – Information about the vehicle

This screen gives access to all information relative to the vehicle (VIN,

calibration identification, CVN…).

b) Computer information

This screen gives complete information on the type of computer

providing the OBD function. It provides information on the type of OBD

(American, European, Asian) and the type of protocol, as well as the functions

that are provided because an OBD system cannot provide the full range of

measurements described in this manual.


97

IV.3.2.5. The full report

This function gives a complete diagnostic on the vehicle in less than 1 minute.

It is only necessary to be connected to a computer or a printer and to launch the test.

The CAP4100 will extract the full set of information and send to the printer or

computer all that is made available by the computer.

IV.3.3. Printing results

It is possible to print what is on the screen at any time by pressing the print

key.


98

IV.4. LIST OF DATA

IV.4.1. List of available measurements in the table «

current measurements » and « freezed frame ».

Number

of

function

Measurement unit Measurement name

$01 Number of fault codes of the powerplant relative to

the emissions

$01 Active/Inactive Status of control systems

$01 Active/Inactive Status of MI

$02 Pxxxx Fault code which caused the storage of the required

freezed frame

$04 xxx.x % Calculated load value

$05 xxx °C Engine coolant temperature

$06 xx.x % Short term fuel trim – bank 1

$07 xx.x % Long term fuel trim – bank 1

$08 xx.x % Short term fuel trim – bank 2

$09 xx.x % Long term fuel trim – bank 2

$0A xxx kPa Fuel pressure gauge

$0B xxx kPa Intake manifold absolute pressure

$0C xxxxx RPM Engine speed

$0D xxx km/h Vehicle speed

$0E xx.x ° Ignition timing advance

$0F xxx °C Intake air temperature

$10 xxx.xx g/s Air flow rate from MAF sensor

$11 xxx.x % Absolute throttle position

$12 Commanded secondary air status

$14-$1B x.xxx V Output voltage of the sensor


99

xxx.x % Long term fuel trim associated to sensor

$1C OBD requirements to which vehicle is designed

$1D Active/Inactive Location of oxygen sensors

$1E Active/Inactive Status of the power take-off (PTO)

$1F xx.xxx sec Time Since Engine Start

$21 xxxxx Km Distance travelled while MI is activated

$22 xxxx.xx KPa Fuel Rail Pressure relative to manifold vacuum

$23 xxxxxx Kpa Fuel Rail Pressure

$24-$2B xxx.xxx Equivalence Ratio (lambda)

xxx.xxx V Oxygen Sensor Voltage

$2C xxx.xxx % Commanded EGR

$2D xxx.x % EGR Error

$2E xxx.x % Commanded Evaporative Purge

$2F xxx.x % Fuel Level Input

$30 xxx Number of warm-ups since diagnostic trouble codes

cleared

$31 xxxxx Km Distance since diagnostic trouble codes cleared

…

…

…

$4E xxxx hrs, xx min Time since diagnostic trouble codes cleared


100

IV.4.2. EXEMPLE OF DTC (DATA TROUBLE CODE) :

The CAP4100 contains more than 3000 DTC. The following is a part of this DTC.

Group of DTC

#define P0xxx "- P0xxx Powertrain system groupings"

#define P01xx "- Px1xx Fuel and air metering"

#define P02xx "- Px2xx Fuel and air metering"

#define P03xx "- Px3xx Ignition system or mifire"

#define P04xx "- Px4xx Auxiliary emission controls"

#define P05xx "- Px5xx vehicle speed, idle control, and auxiliary inputs"

#define P06xx "- Px6xx Computer and auxiliary outputs"

#define P07xx "- Px7xx Transmission"



#define P0Axx "- P0Axx Hybrid propulsion"

#define P10xx "- P10xx Manufacturer controlled fuel and metering and auxiliary emission controls"

#define P11xx "- P11xx Manufacturer controlled fuel and air metering"

#define P12xx "- P12xx Manufacturer controlled fuel and air metering"

#define P13xx "- P13xx Manufacturer controlled ignition system or misfire"

#define P14xx "- P14xx Manufacturer controlled auxiliary emission controls"

#define P15xx "- P15xx Manufacturer controlled vehicle speed, idle control, and auxiliary inputs"

#define P16xx "- P16xx Manufacturer controlled computer and auxiliary outputs"

#define P17xx "- P17xx Manufacturer controlled transmission"



#define P20xx "- P20xx Fuel and air metering and auxiliary emission controls"



#define P23xx "- P23xx Ignition system or misfire"

#define P24xx "- P24xx Auxililary Emission Controls"

#define P25xx "- P25xx Auxiliary Inputs"


101

#define P26xx "- P26xx Computer & Auxiliary Output"

#define P27xx "- P27xx Transmission"





#define P33xx "- P33xx Ignition system or misfire"

#define P34xx "- P34xx Cylinder Deactivation"

#define U00xx "- U00xx Network Electrical"

#define U01xx "- U01xx Network Comunication"

#define U02xx "- U02xx Network Communication"

#define U03xx "- U03xx Network Software"

PRECISION :

P0001 "Fuel Volume Regulator Control Circuit/Open"

P0002 "Fuel Volume Regulator Control Circuit Range/Performance"

P0003 "Fuel Volume Regulator Control Circuit Low"

P0004 "Fuel Volume Regulator Control Circuit High"

P0005 "Fuel Shutoff Valve Control Circuit/Open"

P0006 "Fuel Shutoff Valve Control Circuit Low"

P0007 "Fuel Shutoff Valve Control Circuit High"

P0008 "Engine Position System Performance [Bank1]"

P0009 "Engine Position System Performance [Bank2]"

P0010 "'A' camshaft position actuator circuit [Bank1]"

P0011 "'A' camshaft position - timing over - advanced or system performance - [Bank1]"

P0012 "'A' camshaft position - timing over - retarded - [Bank1]"

P0013 "'B' camshaft position actuator circuit - [Bank1]"

P0014 "'B' camshaft position - timing over - advanced or system performance - [Bank1]"

P0015 "'B' camshaft position - timing over - retarded - [Bank1]"

P0016 "Crankshaft Position-Camshaft Position Correlation[Bank 1 Sensor A]"

P0017 "Crankshaft Position-Camshaft Position Correlation[Bank 1 Sensor B]"


102

P0018 "Crankshaft Position-Camshaft Position Correlation[Bank 2 Sensor A]"

P0019 "Crankshaft Position-Camshaft Position Correlation[Bank 2 Sensor B]"

P0020 "'A' camshaft position actuator circuit - [Bank2]"

P0021 "'A' camshaft position - timing over - advanced or system performance - [Bank2]"

P0022 "'A' camshaft position - timing over - retarded - [Bank2]"

P0023 "'B' camshaft position actuator circuit - [Bank2]"

P0024 "'B' camshaft position - timing over - advanced or system performance - [Bank2]"

P0025 "'B' camshaft position - timing over - retarded - [Bank2]"

P0026 "Intake Valve Control Solenoid Circuit Range/Performance[Bank1]"

P0027 "Exhaust Valve Control Solenoid Circuit Range/Performance[Bank1]"

P0028 "Intake Valve Control Solenoid Circuit Range/Performance[Bank2]"

P0029 "Exhaust Valve Control Solenoid Circuit Range/Performance[Bank2]"

P0030 "HO2S heater control unit [Bank1 Sensor1]"

P0031 "HO2S heater control unit low [Bank1] Sensor1]"

P0032 "HO2S heater control unit high [Bank1 Sensor1]"

P0033 "Turbo charger bypass valve control circuit"

P0034 "Turbo charger bypass valve control circuit low"

P0035 "Turbo charger bypass valve control circuit high"


P0037 "HO2S heater control unit low [Bank1 Sensor2]"


P0039 "Turbo/Super Charger Bypass Valve Control Circuit Range/Performance"

P0040 "O2 Sensor Signals Swapped Bank 1 Sensor 1/ Bank 2 Sensor 1"

P0041 "O2 Sensor Signals Swapped Bank 1 Sensor 2/ Bank 2 Sensor 2"




P0045 "Turbo/Super Charger Boost Control Solenoid Circuit/Open"

P0046 "Turbo/Super Charger Boost Control Solenoid Circuit Range/Performance"

P0047 "Turbo/Super Charger Boost Control Solenoid Circuit Low"

P0048 "Turbo/Super Charger Boost Control Solenoid Circuit High"

P0049 "Turbo/Super Charger Turbine Ovespeed"


103




P0053 "HO2S Heater Resistance [Bank 1 Sensor 1]"












P0065 "Air assisted injector control range / performance"

P0066 "Air assisted injector control circuit low"

P0067 "Air assisted injector control circuit high"

P0068 "MAP/MAF - Throttle Position Correlation"

P0069 "Manifold Absolute Pressure - Barometric Pressure Correlation"

P0070 "Ambient air temperature sensor circuit"

P0071 "Ambient air temperature sensor range / performance"

P0072 "Ambient air temperature sensor circuit low"

P0073 "Ambient air temperature sensor circuit high"

P0074 "Ambient air temperature sensor circuit intermittent"

P0075 "intake valve control solenoid circuit [Bank1]"

P0076 "intake valve control solenoid circuit low [Bank1]"

P0077 "intake valve control solenoid circuit high [Bank1]"

P0078 "exhaust valve control solenoid circuit [Bank1]"

P0079 "exhaust valve control solenoid circuit low [Bank1]"

P0080 "exhaust valve control solenoid circuit high [Bank1]"

P0081 "intake valve control solenoid circuit [Bank2]"

P0082 "intake valve control solenoid circuit low [Bank2]"

P0083 "intake valve control solenoid circuit high [Bank2]"


104

P0084 "exhaust valve control solenoid circuit [Bank2]"



P0087 "Fuel Rail/System Pressure - Too Low"

P0088 "Fuel Rail/System Pressure - Too High"

P0089 "Fuel Pressure Regulator 1 Performance"

P0090 "Fuel Pressure Regulator 1 Control Circuit"

P0091 "Fuel Pressure Regulator 1 Control Circuit Low"

P0092 "Fuel Pressure Regulator 1 Control Circuit High"

P0093 "Fuel System Leak Detected - Large Leak"

P0094 "Fuel System Leak Detected - Small Leak"

P0095 "Intake Air Temperature Sensor 2 Circuit"

P0096 "Intake Air Temperature Sensor 2 Circuit Range/Performance"

P0097 "Intake Air Temperature Sensor 2 Circuit Low"

P0098 "Intake Air Temperature Sensor 2 Circuit High"

P0099 "Intake Air Temperature Sensor 2 Circuit Intermittent/Erratic"

P0100 "Mass or volume air flow circuit malfunction"

P0101 "Mass or volume air flow circuit range / performance problem"

P0102 "Mass or volume air flow circuit low input"

P0103 "Mass or volume air flow circuit high input"

P0104 "Mass or volume air flow circuit intermittent"

P0105 "Manifold absolute pressure / barometric pressure circuit malfunction"

P0106 "Manifold absolute pressure / barometric pressure circuit range / performance problem"

P0107 "Manifold absolute pressure / barometric pressure circuit low input"

P0108 "Manifold absolute pressure / barometric pressure circuit high input"

P0109 "Manifold absolute pressure / barometric pressure circuit intermittent"

P0110 "Intake air temperature circuit malfunction"

P0111 "Intake air temperature circuit range / performance problem"

P0112 "Intake air temperature circuit low input"

P0113 "Intake air temperature circuit high input"

P0114 "Intake air temperature circuit intermittent"

P0115 "Engine coolant temperature circuit malfunction"

P0116 "Engine coolant temperature circuit range / performance problem"

P0117 "Engine coolant temperature circuit low input"


105

P0118 "Engine coolant temperature circuit high input"

P0119 "Engine coolant temperature circuit intermittent"

P0120 "Throttle / pedal position sensor / switch 'A' circuit malfunction"

P0121 "Throttle / pedal position sensor / switch 'A' circuit range / performance problem"

P0122 "Throttle / pedal position sensor / switch 'A' circuit low input"

P0123 "Throttle / pedal position sensor / switch 'A' circuit high input"

P0124 "Throttle / pedal position sensor / switch 'A' circuit intermittent"

P0125 "Insufficient coolant temperature for closed loop fuel control"

P0126 "Insufficient coolant temperature for stable operation"

P0127 "Intake air temperature too high"

P0128 "coolant thermostat (coolant temperature below thermostat regulating temperature)"

P0129 "Barometric Pressure Too Low"

P0130 "O2 sensor circuit malfunction [Bank 1 Sensor 1]"

P0131 "O2 sensor circuit low voltage [Bank 1 Sensor 1]"

P0132 "O2 sensor circuit high voltage [Bank 1 Sensor 1]"

P0133 "O2 sensor circuit slow response [Bank 1 Sensor 1]"

P0134 "O2 sensor circuit no activity detected [Bank 1 Sensor 1]"

P0135 "O2 sensor heater circuit malfunction [Bank 1 Sensor 1]"













P0148 "Fuel delivery error"

P0149 "Fuel timing error"




106

















P0168 "Fuel temperature too high"

P0169 "Incorrect fuel composition"

P0170 "Fuel trim malfunction [Bank 1]"

P0171 "System too lean [Bank 1]"

P0172 "System too rich [Bank 1]"

P0173 "Fuel trim malfunction [Bank 2]"

P0174 "System too lean [Bank 2]"

P0175 "System too rich [Bank 2]"

P0176 "Fuel composition sensor circuit malfunction"

P0177 "Fuel composition sensor circuit range / performance"

P0178 "Fuel composition sensor circuit low input"

P0179 "Fuel composition sensor circuit high input"

P0180 "Fuel temperature sensor 'A' circuit malfunction"

P0181 "Fuel temperature sensor 'A' circuit range / performance"

P0182 "Fuel temperature sensor 'A' circuit low input"

P0183 "Fuel temperature sensor 'A' circuit high input"

P0184 "Fuel temperature sensor 'A' circuit intermittent"

P0185 "Fuel temperature sensor 'B' circuit malfunction"

P0186 "Fuel temperature sensor 'B' circuit range / performance"


107

P0187 "Fuel temperature sensor 'B' circuit low input"

P0188 "Fuel temperature sensor 'B' circuit high input"

P0189 "Fuel temperature sensor 'B' circuit intermittent"

P0190 "Fuel rail pressure sensor circuit malfunction"

P0191 "Fuel rail pressure sensor circuit range / performance"

P0192 "Fuel rail pressure sensor circuit low input"

P0193 "Fuel rail pressure sensor circuit high input"

P0194 "Fuel rail pressure sensor circuit intermittent"

P0195 "Engine oil temperature sensor malfunction"

P0196 "Engine oil temperature sensor range / performance"

P0197 "Engine oil temperature sensor low input"

P0198 "Engine oil temperature sensor high input"

P0199 "Engine oil temperature sensor intermittent"

P0200 "Injector circuit malfunction"

P0201 "Cylinder 1 - injector circuit malfunction"












P0213 "Cold start injector 1 malfunction"

P0214 "Cold start injector 1 malfunction"

P0215 "Engine shut-off solenoid malfunction"

P0216 "Injection timing control circuit malfunction"

P0217 "Engine overtemperature condition"

P0218 "Transmission overtemperature condition"

P0219 "Engine overspeed condition"

P0220 "Throttle / pedal position sensor / switch 'B' circuit malfunction"


108

P0221 "Throttle / pedal position sensor / switch 'B' circuit range / performance"

P0222 "Throttle / pedal position sensor / switch 'B' circuit low input"

P0223 "Throttle / pedal position sensor / switch 'B' circuit high input"

P0224 "Throttle / pedal position sensor / switch 'B' circuit intermittent"

P0225 "Throttle / pedal position sensor / switch 'C' circuit malfunction"

P0226 "Throttle / pedal position sensor / switch 'C' circuit range / performance"

P0227 "Throttle / pedal position sensor / switch 'C' circuit low input"

P0228 "Throttle / pedal position sensor / switch 'C' circuit high input"

P0229 "Throttle / pedal position sensor / switch 'C' circuit intermittent"

P0230 "Fuel pump primary circuit malfunction"

P0231 "Fuel pump secondary circuit low"

P0232 "Fuel pump secondary circuit high"

P0233 "Fuel pump secondary circuit intermittent"

P0234 "Engine overboost condition"

P0235 "Turbocharger boost sensor 'A' circuit malfunction"

P0236 "Turbocharger boost sensor 'A' circuit range / performance"

P0237 "Turbocharger boost sensor 'A' circuit low"

P0238 "Turbocharger boost sensor 'A' circuit high"

P0239 "Turbocharger boost sensor 'B' circuit malfunction"

P0240 "Turbocharger boost sensor 'B' circuit range / performance"

P0241 "Turbocharger boost sensor 'B' circuit low"

P0242 "Turbocharger boost sensor 'B' circuit high"

P0243 "Turbocharger wastegate solenoid 'A' malfunction"

P0244 "Turbocharger wastegate solenoid 'A' range / performance"

P0245 "Turbocharger wastegate solenoid 'A' low"

P0246 "Turbocharger wastegate solenoid 'A' high"

P0247 "Turbocharger wastegate solenoid 'B' malfunction"

P0248 "Turbocharger wastegate solenoid 'B' range / performance"

P0249 "Turbocharger wastegate solenoid 'B' low"

P0250 "Turbocharger wastegate solenoid 'B' high"

P0251 "Injection pump fuel metering control 'A' malfunction (cam / rotor / injector)"

P0252 "Injection pump fuel metering control 'A' range / performance (cam / rotor / injector)"

P0253 "Injection pump fuel metering control 'A' low (cam / rotor / injector)"

P0254 "Injection pump fuel metering control 'A' high (cam / rotor / injector)"

P0255 "Injection pump fuel metering control 'A' intermittent (cam / rotor / injector)"


109

P0256 "Injection pump fuel metering control 'B' malfunction (cam / rotor / injector)"

P0257 "Injection pump fuel metering control 'B' range / performance (cam / rotor / injector)"

P0258 "Injection pump fuel metering control 'B' low (cam / rotor / injector)"

P0259 "Injection pump fuel metering control 'B' high (cam / rotor / injector)"

P0260 "Injection pump fuel metering control 'B' intermittent (cam / rotor / injector)"

P0261 "Cylinder 1 injector circuit low"

P0262 "Cylinder 1 injector circuit high"

P0263 "Cylinder 1 contribution / balance fault"

























110











P0297 "Vehicule Overspeed Condition"

P0298 "Engine Oil Over Temperature"

P0299 "Turbo/Super Charger Underboost"

P0300 "Random / multiple cylinder misfire detected"

P0301 "Cylinder 1 misfire detected"












P0313 "Misfire Detected With Low Fuel"

P0314 "Single cylinder misfire (cylinder not specified)"

P0315 "Cranshaft Position System Variation Not Learned"

P0316 "Engine Misfire Detected On Startup (First 1000 Revolutions)"

P0317 "Rough Road Hardware Not Present"

P0318 "Rough Road Sensor A Signal Circuit"

P0319 "Rough road Sensor B"


111

P0320 "Ignition / distributor engine speed input circuit malfunction"

P0321 "Ignition / distributor engine speed input circuit range / performance"

P0322 "Ignition / distributor engine speed input circuit no signal"

P0323 "Ignition / distributor engine speed input circuit intermittent"

P0324 "Knock Control System Error"

P0325 "Knock sensor 1 circuit malfunction [Bank 1 ou 1 Sensor]"

P0326 "Knock sensor 1 circuit range / performance [Bank 1 ou 1 Sensor]"

P0327 "Knock sensor 1 circuit low input [Bank 1 ou 1 Sensor]"

P0328 "Knock sensor 1 circuit high input [Bank 1 ou 1 Sensor]"

P0329 "Knock sensor 1 circuit intermittent [Bank 1 ou 1 Sensor]"

P0330 "Knock sensor 2 circuit malfunction [Bank 2]"

P0331 "Knock sensor 2 circuit range / performance [Bank 2]"

P0332 "Knock sensor 2 circuit low input [Bank 2]"

P0333 "Knock sensor 2 circuit high input [Bank 2]"

P0334 "Knock sensor 2 circuit intermittent [Bank 2]"

P0335 "Crankshaft position sensor 'A' circuit malfunction"

P0336 "Crankshaft position sensor 'A' circuit range / performance"

P0337 "Crankshaft position sensor 'A' circuit low input "

P0338 "Crankshaft position sensor 'A' circuit high input "

P0339 "Crankshaft position sensor 'A' circuit intermittent"

P0340 "Camshaft position sensor 'A' circuit malfunction [Bank1]"

P0341 "Camshaft position sensor 'A' circuit range / performance [Bank1]"

P0342 "Camshaft position sensor 'A' circuit low input [Bank1]"

P0343 "Camshaft position sensor 'A' circuit high input [Bank1]"

P0344 "Camshaft position sensor 'A' circuit intermittent [Bank1]"

P0345 "Camshaft position sensor 'A' circuit malfunction [Bank2]"

P0346 "Camshaft position sensor 'A' circuit range / performance [Bank2]"

P0347 "Camshaft position sensor 'A' circuit low input [Bank2]"

P0348 "Camshaft position sensor 'A' circuit high input [Bank2]"

P0349 "Camshaft position sensor 'A' circuit intermittent [Bank2]"

P0350 "Ignition coil primary /secondary circuit malfunction"

P0351 "Ignition coil 'A' primary /secondary circuit malfunction"

P0352 "Ignition coil 'B' primary /secondary circuit malfunction"


112

P0353 "Ignition coil 'C' primary /secondary circuit malfunction"

P0354 "Ignition coil 'D' primary /secondary circuit malfunction"

P0355 "Ignition coil 'E' primary /secondary circuit malfunction"

P0356 "Ignition coil 'F' primary /secondary circuit malfunction"

P0357 "Ignition coil 'G' primary /secondary circuit malfunction"

P0358 "Ignition coil 'H' primary /secondary circuit malfunction"

P0359 "Ignition coil 'I' primary /secondary circuit malfunction"

P0360 "Ignition coil 'J' primary /secondary circuit malfunction"

P0361 "Ignition coil 'K' primary /secondary circuit malfunction"

P0362 "Ignition coil 'L' primary /secondary circuit malfunction"

P0363 "Misfire Detected - Fueling Disabled"

P0365 "Camshaft position sensor 'B' circuit malfunction [Bank1]"

P0366 "Camshaft position sensor 'B' circuit range / performance [Bank1]"

P0367 "Camshaft position sensor 'B' circuit low input [Bank1]"

P0368 "Camshaft position sensor 'B' circuit high input [Bank1]"

P0369 "Camshaft position sensor 'B' circuit intermittent [Bank1]"

P0370 "Timing reference high resolution signal 'A' malfunction"

P0371 "Timing reference high resolution signal 'A' too many pulses"

P0372 "Timing reference high resolution signal 'A' too few pulses"

P0373 "Timing reference high resolution signal 'A' intermittent / erratic pulses"

P0374 "Timing reference high resolution signal 'A' no pulses"

P0375 "Timing reference high resolution signal 'B' malfunction"

P0376 "Timing reference high resolution signal 'B' too many pulses"

P0377 "Timing reference high resolution signal 'B' too few pulses"

P0378 "Timing reference high resolution signal 'B' intermittent / erratic pulses"

P0379 "Timing reference high resolution signal 'B' no pulses"

P0380 "Glow plug / heater circuit 'A' malfunction"

P0381 "Glow plug / heater indicator circuit malfunction"

P0382 "Glow plug / heater circuit 'B' malfunction"

P0385 "Crankshaft position sensor 'B' circuit malfunction"

P0386 "Crankshaft position sensor 'B' circuit range / performance "

P0387 "Crankshaft position sensor 'B' circuit low input"

P0388 "Crankshaft position sensor 'B' circuit high input"

P0389 "Crankshaft position sensor 'B' circuit intermittent"


113

P0390 "Camshaft position sensor 'B' circuit malfunction [Bank2]"

P0391 "Camshaft position sensor 'B' circuit range / performance [Bank2]"

P0392 "Camshaft position sensor 'B' circuit low input [Bank2]"

P0393 "Camshaft position sensor 'B' circuit high input [Bank2]"

P0394 "Camshaft position sensor 'B' circuit intermittent [Bank2]"

P0400 "Exhaust gas recirculation flow malfunction"

P0401 "Exhaust gas recirculation flow insufficient detected"

P0402 "Exhaust gas recirculation flow excessive detected"

P0403 "Exhaust gas recirculation circuit malfunction"

P0404 "Exhaust gas recirculation circuit range / performance"

P0405 "Exhaust gas recirculation sensor 'A' circuit low"

P0406 "Exhaust gas recirculation sensor 'A' circuit high"

P0407 "Exhaust gas recirculation sensor 'B' circuit low"

P0408 "Exhaust gas recirculation sensor 'B' circuit high"

P0409 "Exhaust gas recirculation sensor 'A' circuit"

P0410 "Secondary air injection system malfunction"

P0411 "Secondary air injection system incorrect flow detected"

P0412 "Secondary air injection system switching valve 'A' circuit malfunction"

P0413 "Secondary air injection system switching valve 'A' circuit open"

P0414 "Secondary air injection system switching valve 'A' circuit shorted"

P0415 "Secondary air injection system switching valve 'B' circuit malfunction"

P0416 "Secondary air injection system switching valve 'B' circuit open"

P0417 "Secondary air injection system switching valve 'B' circuit shorted"

P0418 "Secondary air injection system relay 'A' circuit malfunction"

P0419 "Secondary air injection system relay 'B' circuit malfunction"

P0420 "Catalyst system efficiency below threshold [Bank1]"

P0421 "Warmup catalyst efficiency below threshold [Bank1]"

P0422 "Main catalyst efficiency below threshold [Bank1]"

P0423 "Heated catalyst efficiency below threshold [Bank1]"

P0424 "Heated catalyst temperature below threshold [Bank1]"

P0425 "Catalyst temperature sensor [Bank1]"

P0426 "Catalyst temperature sensor range / performance [Bank1]"

P0427 "Catalyst temperature sensor low input [Bank1]"

P0428 "Catalyst temperature sensor high input [Bank1]"

P0429 "Catalyst heater control unit [Bank1]"


114

P0430 "Catalyst system efficiency below threshold [Bank2]"

P0431 "Warmup catalyst efficiency below threshold [Bank2]"

P0432 "Main catalyst efficiency below threshold [Bank2]"

P0433 "Heated catalyst efficiency below threshold [Bank2]"

P0434 "Heated catalyst temperature below threshold [Bank2]"

P0435 "Catalyst temperature sensor [Bank2]"

P0436 "Catalyst temperature sensor range / performance [Bank2]"

P0437 "Catalyst temperature sensor low input [Bank2]"

P0438 "Catalyst temperature sensor high input [Bank2]"

P0439 "Catalyst heater control unit [Bank2]"

P0440 "Evaporative emission control system malfunction"

P0441 "Evaporative emission control system incorrect purge flow"

P0442 "Evaporative emission control system small leak detected"

P0443 "Evaporative emission control system purge control valve circuit malfunction"

P0444 "Evaporative emission control system purge control valve circuit open"

P0445 "Evaporative emission control system purge control valve circuit shorted"

P0446 "Evaporative emission control system vent control circuit malfunction"

P0447 "Evaporative emission control system vent control circuit open"

P0448 "Evaporative emission control system vent control circuit shorted"

P0449 "Evaporative emission control system vent valve / solenoid circuit malfunction"

P0450 "Evaporative emission control system pressure sensor malfunction"

P0451 "Evaporative emission control system pressure sensor range / performance"

P0452 "Evaporative emission control system pressure sensor low input"

P0453 "Evaporative emission control system pressure sensor high input"

P0454 "Evaporative emission control system pressure sensor intermittent"

P0455 "Evaporative emission control system important leak detected"

P0456 "Evaporative emission control system small leak detected"

P0457 "Evaporative emission control system leak detected - fuel cap lost or off"

P0458 "Evaporative Emission System Purge Control Valve Circuit Low"

P0459 "Evaporative Emission system Purge control Valve Circuit High"

P0460 "Fuel level sensor circuit malfunction"

P0461 "Fuel level sensor circuit range / performance"

P0462 "Fuel level sensor circuit low input"


115

P0463 "Fuel level sensor circuit high input"

P0464 "Fuel level sensor circuit intermittent"

P0465 "Purge flow sensor circuit malfunction"

P0466 "Purge flow sensor circuit range / performance"

P0467 "Purge flow sensor circuit low input"

P0468 "Purge flow sensor circuit high input"

P0469 "Purge flow sensor circuit intermittent"

P0470 "Exhaust pressure sensor malfunction"

P0471 "Exhaust pressure sensor range / performance"

P0472 "Exhaust pressure sensor low"

IV.4.3. List of available measurements in

« Measurements and control of the lambda probes ».

Number

of

function


$01 x.xxx V [0-1.275] Rich to lean sensor threshold voltage

$02 x.xxx V [0-1.275] Lean to rich sensor threshold voltage

$03 x.xxx V [0-1.275] Low sensor voltage for switch time calculation

$04 x.xxx V [0-1.275] High sensor voltage for switch time calculation

$05 x.xxx s [0-1.02] Rich to lean sensor switch time

$06 x.xxx s [0-1.02] Lean to rich sensor switch time

$07 x.xxx V [0-1.275] Minimum sensor voltage for test cycle

$08 x.xxx V [0-1.275] Maximum sensor voltage for test cycle

$09 x.xxx s [0-1.02] Time between sensor transitions


116

IV.4.4. List of recoverable and possible information in

the table « Information about the vehicle ».

Number

of

function


$02 Chain of 17

characters

VIN number

(identification of the vehicle)

$04 Chain of 16

characters

Sampling identification

$06 Chain of characters CVN number

(checking of the sampling)

$08 Chain of characters In-use Performance Tracking (IPT)


117

IV.4.5. List of data composing the table « Computer

information ».

Name

Type of communication supported by the

computer

Type of OBD regulation for which the

vehicle is designed

List of supervised systems

Location of the oxygen sensors


118

IV.4.6. TABLE OF ABBREVIATIONS

MI Malfunction Indicator

PID Parameter Identification

DTC Diagnostic Trouble Code

PTO

RAM Random Access Memory

ROM Read Only Memory

KAM Keep Alive Memory

EGR Exhaust Gas Recirculation

MAF

A/C

CYL.

CVN

VIN

EOBD European On-Board Diagnostic

OBD On Board Diagnostic


119

IV.4.7. TERMS AND DEFINITIONS

Throttle absolute position sensor

Value to represent the throttle opening. The throttle position at idle speed is mainly

above 0 % and the full-opened position indicates generally less than 100 %.

Bank

The group of cylinders which powers the oxygen sensor. Bank 1 contains the cylinder

number 1.

Fuel prevision base

The sampled prevision of programmed fuel in the command module of the

transmission or in the programmable ROM when manufacturing or when updating via an

external source, before every automatic correction.

Calculated load value

It is the exact air flow on peak air flow (at the level of the sea) multiplied by the

atmospheric pressure ratio at the level of the sea on barometric pressure multiplied by one

hundred.

Continuous supervising

Updated information at rhythm superior or equal to 2 measurements by second.

Fuel adjustment

Loop adjustment of the fuel prevision basis. The basic fuel adjustment refers to

dynamic or instantaneous adjustments.

Service

An exchange of information initiated by the service technician so that to ask

for a diagnosis information and so that to modify its behaviour for diagnostic

requirements. It is also a testing mode in which are collected type of information and

means to communicate with the computer.


120


121

V. CONFIGURATIONS


122

V.1. GENERAL:

To launch this application, select the “Configuration” line in the main menu.

The following screen appears:

This is a scrolling menu made of several

options.

Each option allows access to a parameter-

setting window.

All such windows are described below.

V.2. TIME/DATE:

Allows the CAP3201’s time and date to be updated.

The field must be selected using the OK key; to

change the value, press on the UP and DOWN

arrows. Finally, to save the new values, you

must press OK.

T I M E / D A T E

G A R A G E H E A D E R

O P E R A T O R


O P A C I M E T E R

C E N T R A L C O N T R O L

P R I N T I N G

S C R E E N

O P T I O N S

D E F A U L T P A R A M E T E R S

I N F O R M A T I O N

Y E A R

M O N T H

D A Y

D A Y

T I M E

M I N U T E

M O N D A Y

T I M E / D A T E


123

V.3. GARAGE HEADER:

This application allows information related to the garage to be entered and personalized. This

information appears at the beginning of the test report. The entry window has the form shown

below.

To type the data, one must use either:

The five keys located below the screen; in case the keyboard option is not installed

or non-existent. The UP and DOWN arrows allow rapid scrolling of numbers and

figures. The >> button allows advancing to the next character, and conversely <<

allows a return to the preceding character. Finally, OK allows a change of entry

zone, up to the NOTES zone. After this zone, the program leaves the client entry

procedure.

The alphanumeric keyboard is supplied as an option (see Configurations—

Keyboard). The UP, DOWN arrows allow a change of entry zone. To erase a

character, use the key located at the upper right of the keyboard, or the LEFT

arrow. To move to the following phase, you need only press the OK key (5-key pad)

or type ENTER.

The printer touch allow to print the garage header.

This touch allow to change the range of character.

G A R A G E H E A D E R


124

V.4. OPERATOR:

This window allows entry of up to 9 operator names. The principle is identical to the

entry of the garage header and client entry.

In the main menu, the name of the current user is displayed; to change it, simply

press, if the keyboard option is active, on the number 1 for the first operator, 2 for the second

and so on; if the user does not have the keyboard option he can change using the “Op+” icon.

This name will be inscribed in the test report at the end of a test.

V.5. GAS ANALYSIS

This gives access to a submenu that allows selection of the standby interval of the gas

analysis module, display of Lambda and CO to 3 or 2 decimal places; it also allows evaluation of

the oxygen sensor’s condition, execution of a leak test, display of routine control and access to

the secure menu.

O P E R A T O R


125

V.5.1. Standby

For standby, select the standby tab, then press OK. The time remaining until the gas

analysis component is placed on standby is displayed in the dialog box. Using the UP and

DOWN arrow, you can enter the time suited to your needs.

V.5.2. Digit CO, Lambda

The DIGIT CO and DIGIT LAMBDA submenus allow selection of the number of figures

after the decimal that you want to have when CO and LAMBDA are displayed.

IMPORTANT: If you choose CO at 3 DIGITS, the gas analyser is in high resolution for

the CO and also for HC. So, the measurement range in high resolution is for the HC to –13 at

2000 ppm with 1 ppm of accuracy and in normal resolution the range resolution is to –13 at

20000 ppm with 10 ppm of accuracy.

V.5.3. O2 sensor condition

This window provides information on the condition of the oxygen sensor. The

CAP3201 performs a diagnostic on the sensor and gives its opinion of the wear condition of the

sensor. The state of wear is graduated from 0 to 100%, 100% corresponding to the most

satisfactory state of wear.


S T A N D B Y

D I G I T C O , L A M B D A

O 2 S E N S O R C O N D I T I O N


L E A K T E S T

R O U T I N E C H E C K

P R O T E C T E D A C C E S S


126

V.5.4. Leak test

The leak test is a procedure allowing the detecting of any seal problems that might

occur in the pneumatic circuit. It is imperative to carry out this test at least once every three

months. It is also preferable that it be carried out at least once per month by the user. The

presence of a leak involves immediate maintenance work.

This test is guided throughout. The operator must attentively follow the instructions

given on the screen.

Test upstream of the pump:

The following message appears: “Plug the inlet”. Blocking of the inlet is automatically

detected by the analyser. The pumps then shut off and the following message appears: “Test in

progress.” It is necessary to keep the inlet hermetically shut. This phase lasts at most 11

seconds. At the end of this phase, a diagnosis of “Leak present” or “Leak absent” is given.

Press the key to continue the test, otherwise .

Test downstream of the pump:

The following message appears: “Plug the exhaust”. Blocking of the exhaust is

automatically detected by the analyser. The pumps then shut off and the following message

appears: “Test in progress.” It is necessary to keep the inlet hermetically shut. This phase lasts

at most 8 seconds. At the end of this phase, a diagnosis of “Leak present” or “Leak absent” is

given.

Stop test and exit:

The presence of a leak disables measurement so long as a new test has not been

carried out with a final result of “Leak absent”.

V.5.5. Routine check

This window is made up of 2 pages (PG1 and PG2). They provide information in real

time on the condition of the gas analysis module, indicate the date and the name of the

participants, and finally indicate the BENCH software version and its serial number.


127

V.5.6. Protected access

Type the 5-key secret code. Then .

The machine asks for entry of the user name “Carried out by:”; this name can contain

between 3 to 15 characters. This information will be retained in memory and is not erasable.

This part of the program is reserved for persons charged with periodic inspection of

the machine.

V.5.6.1. HC index:

This gives access to a submenu allowing display of HC in propane equivalent or

hexane equivalent.

H C I N D E X

C A L I B R A T I O N

A M B A C C E S S


A M B I E N T T E M P .

G A S P R E S S U R E

L A M P T E M P .

D E T E C T O R L A M P

R O U T I N E C H E C K R O U T I N E C H E C K

b f 1 0


128

PEF being variable, it is preferable, when

calibrating with a cylinder containing propane,

to go to propane mode and to read the

measured value directly as propane. Note that

the PEF displayed by the machine is the PEF

for a value of HC propane near 2000 ppm vol.

V.5.6.2. Calibration:

The second menu allows the machine to be calibrated; it is composed of several options:

a) CO, HC, CO2 adjustment procedure:

Adjusting calibration gas concentrations:

Note that for the oxygen concentration (air/oxygen ratio), it is imperative to leave the

value set to 20.90%. This is the value used whenever the machine is re-zeroed. This value has

no influence on the per-gas adjustment of the three infrared channels.

IMPORTANT: HC must be entered in propane equivalent.

Recall that the cylinder containing the gas required for analyser adjustment contains

the following concentrations:

CO: 3.50 % vol.

CO2: 14.0 % vol.

H C I N D E X


C A L I B R A T E C O - H C - C O 2

O 2 I N T I A L I Z A T I O N

N O X I N I T I A L I Z A T I O N



129

HC: 2000 ppm propane by vol.

Balance N2

The operator must enter the values of the CO, CO2 and HC gas concentrations. To advance to

the following step, OK or ENTER must be pressed.

Launching the adjustment procedure:

The operator is guided throughout the procedure by messages indicating to him the

various steps that the CAP3201 carries out during an adjustment procedure.

b) O2 initialization:

This tab is used for installing a new O2 sensor. It is necessary to follow the procedure,

which requires changing the O2 sensor first, then pressing OK. Once this step is completed, the

CAP3201 initializes the sensor for 1 minute. This consists of recovering the reference voltage of

the new sensor.

c) NOx initialization:

Same as O2 initialization.

V.5.6.3. AMB access:

The final menu allows access to MICROBENCH, using a computer via an RS232 connection. The

operator may carry out all the adjustment operations previously mentioned.

When this window is activated, the user can

communicate with the gas analysis set.

Quit to return to measurement mode:

A C C E S S A M B

C O N N E C T T H E C O M P U T E R

O N C O M 1


130

V.6. SMOKEMETER:

When the user selects “Opacimeter” the following window is activated:

V.6.1. VL/PL:

The VL/PL selection list allows a choice of mode: either VL - in this mode, the

operator is required to measure an oil temperature of at least 80°C. In the other

mode, type PL, he can free himself of the need to measure temperature by validating

manually. (see paragraph IV.4.6.).

V.6.2. Engine speed and Oil temperature:

The ENGINE SPEED and OIL TEMP selection list allow a choice whether

information concerning the engine speed and the oil temperature will be printed on

the test report.

V.6.3. Routine check:

The “routine check” program allows the user to check the opacimeter for correct

operation.

This page lists opacimeter faults. It is made of up 3 pages (PG1, PG2 and PG3).

V L / P L

E N G I N E S P E E D

O I L T E M P .

S M O K E M E T E R




131

This window show the cell current data.

Example : the ambient temperature is correct

if it’s locate between 0°C and 50°C.

This page gives the last current data.

Moreover, it shows the cell currently opacity

in % and /m.

Finally, this page gives the result of optical

attenuation test.

The page 3 gives a few temperatures, cell

power supply, and fan speed.

CK and CN filters are the electrical filters used

by the cell.

Finally, the page shows the software version

and the serial number

Two functions are also available:

a) Auto-zero:

This key launches the automatic auto-zero procedure.



Ambient temp. out of range

Detector temp. out of range

Tube temp. out of range

Power supply out of range

Fan stop

Opacity out of range Cell in stand-by mode Zero running Sooting of the lenses Sampling armed

GAS temp.

TUBE temp. DET. temp. EXT. temp.

Power supply

Fan speed (rpm)

Serial number Software version

Cell :


Trigger armed

Fault of the fans

Gas temp. out of range

Faulty EEPROM

Fault on sensor

OPACITY OPACITY

OPACITYcorr. OPACITYcorr.

Measure = 1.39/m

Variation = 0.01/m

Filter used = 1.38 /m

Smokemeter OK ! ! ! !


132

As long as the value read in the opacity field is not in the neighbourhood of zero,

relaunch the auto-zero function.

b) Evaluation of the error in opacity measurement. « TEST »

This is an automatic check by electrical filter centred at 50%, allowing the

accuracy of measurements to be verified. The error is considered acceptable if its

evaluation gives a result less than 5%. To carry out this evaluation, press the TEST key.

The result is displayed on page 2; it shows the measurement obtained, the filter

employed and the gap between the two values.

A window appears giving an opinion of the credibility of the measurements

carried out. If this opinion is negative “opacimeter out of spec”, clean the cell and

restart the test.

V.6.4. Protected access:

This part of the program is reserved for CAPELEC personnel. It gives access to a

submenu that allows the filter coefficients used in carrying out measurements to be selected.

V.7. CENTRAL CONTROL:

A central testing station must be able to connect a measuring device, the

CAP3201 in this case, with a computer at the central technical testing station. There

are different standard protocols allowing information exchange between devices of

different makes.

This window allows the operator to choose the type of communication

protocol in order to be able to store all information on a central computer.


133

V.7.1. GIEG-NET protocol:

At the GIEGNET protocol level, the CAP3201 follows rigorously the

specifications of the “GIEGNET PROTOCOL” Version 1.06.01. Thus the dialog is always

initiated by the computer. It can be carried out directly with the measuring device

(GIEG-NET MONO PROTOCOL diagram A) or via a multiplexer combining various

measuring devices (GIEG-NET MULTI PROTOCOL diagram B).

To transmit the desired results, it is necessary to first press the key.

A new keyboard layout is loaded and the message box invites you to either:

F1: PRINT

F2: SEND DATA

Diagram A:

Diagram B:

Multiplexer

Pressing this key displays in the message window.

Opa .

String

Gas

Opa .

Multiplexer Computer

String

Gas Computer


134

Press F2 for send data.

V.7.1.1. GIEG-NET MONO :

In this configuration, only the car’s measurements can be saved, without having

any registration information. If the centre’s computer does not request the measurements

before doing another car, the old measurements will be overwritten by the new ones.

V.7.1.2. GIEG-NET MULTI :

In this configuration, the measurements must be accompanied by the

registration of the vehicle. Thus the client entry portion is no longer the same and the following

appears:

1111 www 34 is the registration number of a car sent by the centre’s computer to the CAP3201

station. The hour indicates when the measurements are saved and if the field shows “--:-- “ that

means that the user has not yet carried out a test on that registration. The car is awaiting test.

IMPORTANT: If the registration number already has values, it is possible to store new ones by

selecting that plate and sending measurements.

OTHER allows the user to carry out a test with a registration number other than that sent by the

centre’s computer. It will later be added to the list of registration number whose results have

not been requested by the centre’s computer.

F 1 : P R I N T

F 2 : S E N D D A T A



135

It is possible to modify a registration number by pressing the MODI button while the

registration number is displayed in reverse type. The data entry keyboard then appears and you

will be able to carry out the desired modifications. To confirm the modifications, you must press

the OK button. It the registration field is blank when this operation takes place, it is removed

from the list, along with the accompanying measurements.

V.7.2. PC protocol:

Allows communication with the gas analysis or opacity software on the PC.

When this protocol is selected, as soon as the computer is started and communicates with the

CAP3201, the CAP3201 display will automatically position itself on the multi-gas analysis page,

no matter where the user is in the menu.

V.7.3. MAHA protocol:

When this protocol is selected, while results are being printed, if the user presses F2 for

transmission, the CAP3201 will send the data via its COM2 in MAHA format for processing by a

MAHA set.

V.8. PRINTING:

This menu is made up of two submenus:

“Number of tickets”: Allows 1, 2 or 3 reports to be automatically printed after each test

sequence.

“Printer”: The operator can select either an external A4 format printer or the internal thermal

printer furnished with the machine.

N U M B E R O F T I C K E T S

P R I N T E R

P R I N T I N G

O N E

T W O

T H R E E

N U M B E R O F T I C K E T S


136

V.9. SCREEN:

The machine’s screen can be configured; to do this, choose either NORMAL mode

(normal operating mode of the screen), or the INVERSE mode (mode in which display is the

exact inverse of the normal mode). Finally, it is sufficient to press OK to confirm one’s choice.

The screen sets itself automatically to the chosen mode.

V.10. OPTIONS :

This part of the program is reserved for persons charged with installing new

functions. This page is protected by a 5-digit code.

To install a new component, the Configuration tab must be selected.

This window allows a quick survey of the functions and options already installed.

Each component needs a code to be installed; press the INS key and type in the

applicable code. If the code is correct, the new component is automatically active.

To display the preceding code, press VIEW.

V.11. DEFAULT PARAMETERS:

ATTENTION: This window should be used with caution; it allows all the configuration

values previously mentioned to be reinitialized.

C O N F I G U R A T I O N

S E R I A L N U M B E R

O P T I O N S


137

V.12. INFORMATION:

This window includes the coordinates of the manufacturer, the time and the date. For

more information on our products, consult our Internet site: www.capelec.fr.


138

VI. PETROL AND DIESEL TACHOMETER


139

VI.1. OPERATING PRINCIPLE

The tachometer operates by analysing noise frequencies at the battery terminals.

Certain peripheral devices in the vehicle, such as the alternator, have a direct effect on the

voltage across the battery terminals. When the engine is running, this voltage does not remain

perfectly steady. When studied more closely, one sees that the battery voltage oscillates

slightly in proportion to the engine speed.

By analysing these disturbances, the tachometer is able to calculate the engine speed

and transmit it to your pollution checking equipment as an analog or digital signal.

VI.2. TECHNICAL CHARACTERISTICS

Measurement characteristics

Automatic initialisation

Measurement range: : 400 - 9 999 rpm.

Maximum error: <20

rpm at speeds below 2000 rpm

o <2 % in other cases

Response time: <1 second

Measurement update rate: 10 times per second

Initialisation time: <17 seconds

VI.3. LIST OF KIT CONTENTS

One battery connection cable.

One cigar lighter connection cable.

VI.4. CONNECTING THE TACHOMETER

Connected to the cigar lighter


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This is the simplest solution. It lets you measure the engine speed with no need to

open the vehicle bonnet. On some vehicles, however, the engine speed measurement

may be less accurate than with the unit connected directly to the battery.

Connect the cable ( 1 ) to the INPUT socket RPM BAT. Remove the cigar lighter from its

socket on the dashboard


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Connected to the battery

Connect the cable ( 2 ) to the INPUT socket (RPM BAT) on the du CAP3201 and use the

clips to connect it to the battery terminals, taking care not to invert the polarity.

NOTE:

The tachometer is connected to the vehicle's DC power supply for two reasons –

to power the unit and to perform the engine speed measurements. It is therefore

essential to connect the unit to the battery on the vehicle being tested, and not to

a spare battery.

Cigarette lighter

Connector (1)

Battery clamp

( 2 )


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VI.5. MEASURING THE ENGINE SPEED

Pressing this key displays the speed mode currently in use. On the other

hand, if the user again presses the operating speed key, a new speed mode displays the new

selection. Select the rpm mode call battery. After three seconds, the message box request a

cylinder number. This number corresponding to 4 stroke engine. If you want to measure a 2

stroke engine, see the figure:

Troubleshooting:

On some vehicles, measurements may be inconsistent. There can be several

causes for this. In the event of a problem (unstable or imprecise readings), minimise

the risk of error as follows:

- The battery should be slightly discharged. Better results will be obtained if

the headlights are left on for a few minutes before starting the motor.

- During the measurement procedure, switch on the headlights to boost

power consumption.

- If measurements were made from the cigar lighter, try measuring directly

on the battery.

If, after initialisation, the tickover speed is stable, but incorrect (e.g. double the actual speed), change

the cylinder number setting until the correct value appears.

12

10

8

6

5

4

3

2

1

4

2

1

4 stroke 2 stroke

Cylinder number


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VII. PREMIUM VERSION WIN3201


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VII.1. INSTALLATION AND SET-UP

The software WIN3200 automaticaly starts when the PC starts to run.

If you don’t want to launch this software automaticaly under Windows 98/XP, go to the

menu Start, Programs, Startup, click with the right button of the mouse on the icon

WIN3200 and click with the left button of the mouse to delete it.

Main menu:

By the main menu you can launch six programs :

Gas analyzer (keyboard short cut : touch F1)

Smokemeter (keyboard short cut : touch F2)

EOBD (keyboard short cut : touch F3)

Setup (keyboard short cut : touch F4)

Save Reports (keyboard short cut : touch F5)


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Wingieg : centralization software (keyboard short cut : touch F6)

When putting into the service the equipment, you have to go in the window " Setup " :

Setup:

You may not use the mouse and for that you have to press the key TAB.

The setup window allows to setup your PC.

You first have to select the serial COM port where you have connected the

CAP3201.

If you need to centralize your test reports, select the type of centralisation

(Giegnet, maha…), and the COM port.

Enter your header

To validate the changes, press F1.


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VII.2. GAS ANALYZER

VII.2.1. Launching of the procedure

The choice of the procedure is the same than for the CAP3201 alone, for further

information please see chapter II.6.

When you are ready, click on OK or type Enter.

Be Careful : if the touch OK remains lighted, you have to check if the

connection with the CAP3201. The gas analyzer CAP3201 must be set up on

PC, for that you have to go into the menu “CONFIGURATION”

“CENTRALISATION” then select PC.

If the connection is correct between the PC and the gas analyzer, the WIN 3200 loads a

second page (see below).


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You can anytime come back on the garage header by pressing F11.

The information F1, F2… meet with the keyboard short cuts.

Icons are the same than on the gas analyzer, please see chapter II.5.

VII.2.2. Limit values :

The key F9 corresponds to a window of « limit values ».


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You can save the limit values with the key F1.

Thus, during the gas analysis, if the bargraph located below the value in red, it means

that the value measured is out of range.

VII.2.3. Print out preview

When the operator presses F1, the software gets back the gas analyser ticket :


149

The user can then :

Print out the ticket with the short cut key F1.

IMPORTANT : when the operator prints out a report, this one is automaticaly saved. It

is not necessary to press F2 for that purpose.

Save the report with the short cut key F2.

Send the values to a centralisation bench with F3.

ATTENTION if this key is greyed, that means that the operator has not chosen

any centralisation (NO PORT) in the window “Setup”.

Quit the window with ESC


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VII.3. SMOKEMETER :

VII.3.1. Launching of the procedure :

The choice of the procedure is the same than for the stand-alone CAP3201, for further

information please see chapter III.5 .

When you are ready, click on OK or type Enter.

If the connection is correct between the PC and the gas analyzer, the WIN 3200 loads a

second page (see below).


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You can anytime come back on the garage header by pressing F11.

The information F1, F2… meet with the keyboard short cuts.

Icons are the same than on the gas analyzer, please see chapter II.5.

VII.3.2. Print out preview :



152

The user can then :










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VII.3.3. Opacity Analysis

To launch the procedure, please press the F5 key. Once launched, the message box

shows “ACCELERATION No 1”. From now, you can make the acquisition of a curve.

This procedure enables to measure up to 5 curves. They are displayed in different

colours. They can deleted independently the ones from the others thanks to the small

buttons dedicated to each colour (located above the bargraph).

Or with the F8 key, the curves will be all together deleted.


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VII.4. EOBD

VII.4.1. Launching of the procedure

To go into the EOBD procedure EOBD, please click on the « EOBD SCANTOOL » icon

or press F3 from the main menu.

You can enter the customer’s name.


155

VII.4.2. Print out preview


The user can then :









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VII.5. LOOKING INTO THE TESTS :

You can get back the saved tests from the main menu. Please press the F4 key.

When you open an exploration window, please double-click on the folder « GAS » to

get back the gas analyzer measurements or double-click on the folder « SMOKE » to

get back the smokemeter measurements.

.


157

The measuremets are classified by month/year, double-click on the month of your

choice :

The measurements are classified by the number of the report followed by the registered

plate number. Double-click on the report that you want to get back. Windows is going to

open up Internet Explorer. You can print out this report by going to file/print out.


158

After sales Service

Warranty card

Equipment covered:

Customer No.:

Type: CAP3201

Serial No.:

Date placed in service:

Owner:

Name:

Address:

Signature and stamp:

Technician performing start-up procedure:

Name:

Date:

Signature:


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Start-up tag

TO BE RETURNED TO THE FOLLOWING ADDRESS WITHIN 8 DAYS TO HAVE THE BENEFIT OF

THE WARRANTY:

CAPELEC S.A.R.L.

1130 rue des Marels

Parc Eurêka

F-34000 Montpellier

Phone: +(33)0 467.156.156

Fax: +(33)0 467.224.224

Equipment covered:

Customer No.:

Type: CAP3201

Serial No.:

Date placed in service:

Owner:

Name:

Address:

Signature and stamp:

Technician performing start-up procedure:

Name:

Date:

Signature:


160


161

Anomaly Tag

(Make a copy and fill out the sheet for each problem or suggested improvement to the

software. Please return it to the address given below.)

Date: .......................................................................

Name of garage: .....................................................

Address: ..................................................................

Serial number: ........................................................

TYPE OF REQUEST: (check the box that best fits your request)

ANOMALY IN OPERATION:

ANOMALY IN DESIGN:

SUGGESTION FOR UPDATE:

Description of the anomaly:

............................................................................................................................................................

............................................................................................................................................................

............................................................................................................................................................

...

Circumstances in which the anomaly occurred:

............................................................................................................................................................

............................................................................................................................................................

............................................................................................................................................................

...

Suggestions:

............................................................................................................................................................

............................................................................................................................................................

...........................................................................................................................................................


162

Send to:

CAPELEC S.A.R.L.

1130 rue des Marels

Parc Eurêka

F-34000 MONTPELLIER

Phone: 04-67-156-156

Fax: 04-67-224-224

This symbol indicates that, in accordance with directive DEEE

(2002/96/CE) and with the regulation of your country, this product

should not be thrown with the household refuse. You must deposit it in

a place of collecting envisaged to this end, for example, an official site

of collection of the electric components and electronics (EEE) for their

recycling or a terminal point of products authorized which is accessible

when you acquire of a new product of the same type as the old one.

Any deviation compared to these recommendations of elimination of

this type of waste can have negative effects on the environment and

the public health because these products EEE generally contain

substances which can be dangerous. In parallel, your whole co-

operation with the good reject of this product will support a better use

of the natural resources. To obtain more information on the points of

collection of the equipment to be recycled, contact your town hall, the

service of collection of waste, approved plan DEEE or the service of

garbage collection domestic.

emission station - autoequip.rouser’s manual for ap3201 2 t a b l e o f c o n t e n t s i. i....

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