Sun Microsystems DGA 5000 Operator's Manual
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Sun Microsystems DGA 5000 Operator's Manual

Diagnostic gas analyser
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HIGH TECH SECURES YOUR FUTURE
EMISSIONS DIAGNOSTIC
PLATFORM
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Operator's Manual

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Summary of Contents for Sun Microsystems DGA 5000

  • Page 1 HIGH TECH SECURES YOUR FUTURE EMISSIONS DIAGNOSTIC PLATFORM • Operator’s Manual...
  • Page 3 Operator’s Manual EMISSIONS DIAGNOSTIC PLATFORM Software Version V 5.X.X.X Models: DGA5000, Geogas5000 Diagnostic Gas Analyser Copyright 2002 - 2016 Snap-on UK Holdings Ltd. All rights reserved Part number : ZEEEAGB132A 30-J-164 UK Rev.:G...
  • Page 4 DISCLAIMER OF WARRANTIES AND LIMITATIONS OF LIABILITIES Whilst the authors have taken due care in the preparation of this manual, nothing contained herein: • modifies or alters in any way the standard terms and conditions of the purchase, lease or rental agreement under the terms of which the equipment to which this manual relates was acquired, •...

  • Page 6: Table Of Contents

    Product Specification ............5 General ....................5 Gas Bench ..................5 2.2.1 SGM II .................. 5 Introduction ..............7 The DGA 5000 ................... 8 Maintenance ..................8 Options ....................8 Functional Description ............. 9 Platform Layout .................. 9 Gas Module Layout ................9 4.2.1...
  • Page 7 The Gas Analyser Maintenance Menu ..........19 Gas Analyser Maintenance Menu Options ........20 Gas Analyser System Settings ............21 Gas Analyser System Information ........... 22 Print ....................24 Preparatory Steps…………………………………………26 Connections ..................26 6.1.1 Power Connections ............26 6.1.2 Data Connections ..............
  • Page 8 Storing Data in the Data Buffers ............48 The Print Preview Window ............... 50 Printing Test Results ................ 51 9 Maintenance ..............52 System Checks ................52 Leak Check (Vacuum) ................ 52 Leak Check (Gas) ................55 Gas Calibration Check ..............58 Check and/or Install the O2 Cell ............

  • Page 10: Safety

    Safety All Safety Precautions relevant to the unit are described in the Safety Precautions book, part number: EAZ0007E04A Figure 1-1 part number: EAZ0007E04A The Safety Precautions book should be fully understood by every operator. We suggest that (a copy of) of the Safety Precautions book be stored near the unit, in sight of the operator.

  • Page 11: Safety Signal Words

    C H A P T E R 1 1.1 Safety Signal Words All safety messages contain a safety signal word that indicates the level of the hazard. An icon, when present, gives a graphical description of the hazard. Safety Signal words are: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury to the operator or to bystanders.

  • Page 12: Read All Instructions

    ONVENTIONS Before using the unit, always refer to and follow safety messages and applicable test procedures provided by the manufacturer of the vehicle or equipment being tested. Use equipment only as described in the manual. 1.2.1 Read all Instructions Read, understand and follow all safety messages and instructions in the Safety Precautions book, this manual and on the unit.
  • Page 13 C H A P T E R 1...

  • Page 14: Product Specification

    Product Specification 2.1 General This section provides details of the power supply and dimensions of the Diagnostic Platform and the minimum PC specifications. 2.2 Gas Bench 2.2.1 SGM II Table 2-1 Operation & Storage Operating Conditions Max. ambient temp. +40 °C Min.
  • Page 15 C H A P T E R 2...

  • Page 16: Introduction

    - An exhaust probe and hose assembly, used for the collection of the gas sample from the vehicle tailpipe. The DGA 5000\Geogas 5000 forms part of the Emissions Diagnostic Platform System. Specific software versions will be available for performing the emissions tests specified by separate national or international jurisdictions.

  • Page 17: Maintenance

    C H A P T E R 3 Note: In cases where a EOBD Device is connected to the analyser, rpm and oil temperature data will be obtained via the OBD device. - CO corrigé (CO ) may be displayed using a formula corrected for fuel type.

  • Page 18: Functional Description

    Functional Description 4.1 Platform Layout This section provides details of the Diagnostic Platform general layout. 4.2 Gas Module Layout 4.2.1 Gas Module Layout - SGMII Figure 4-2 The Gas Module - Side & Bottom Panels 1. USB connection for PC interface 2.
  • Page 19 UNCTIONAL ESCRIPTION C H A P T E R 4 7. Gas Sample inlet (connection point for exhaust probe/ sample hose assembly). 8. Gas sample outlet (outlet for gas sample from gas bench) 9. Water outlet (connect a tube to this outlet to drain water from the water removal system) 10.

  • Page 20: Common Program Elements

    C H A P T E R 4 UNCTIONAL ESCRIPTION 4.3 Common Program Elements For details of program elements that are common across the Emissions Diagnostic Platform system, refer to the following sections of the Emissions Diagnostic Platform Operator‟s Manual: •...
  • Page 21 NALYSER CONS Table 4-1 Gas Analyser Toolbar Icons Icon Name Description Use this button to place the unit in standby Standby mode. Zero- Use this button to manually initiate a zero- „Zero-calibration‟). calibration calibration (see 6.2.4: Indicates that limit set 1 is currently applied; click 8.2: „Free to toggle to limit set 2;...
  • Page 22 C H A P T E R 4 UNCTIONAL ESCRIPTION Table 4-2 Gas Analyser Menu Icons Icon Name Description Maintenance Selects the Gas Analyser Maintenance Menu Settings Selects the Gas Analyser System Settings Gas Analyser System Selects Gas Analyser System Information Information Gas analyser Allows updated software to be...
  • Page 23 NALYSER CONS Table 4-2 Gas Analyser Menu Icons Icon Name Description Gas Calibration Initiates the Gas Calibration Check Check maintenance procedure. Check/install Initiates the Check and/or Install the O2 Cell Cell maintenance procedure.
  • Page 24 C H A P T E R 4...

  • Page 25: System And Gas Analyser General Screens

    General Screens This Chapter contains: • A description of the DGA 5000 Gas Analyser System Screens. Gas Analyser System Screens are defined as being screens shown by the DGA 5000 that do not relate to a specific test procedure. These Screens comprise: (5.1: „Gas Analyser...

  • Page 26: Gas Analyser Menu

    C H A P T E R 5 5.1 Gas Analyser Menu Figure 5-1 Gas Analyser Menu Screen Figure 5-2 Free Measure Menu Screen Figure 5-3 Maintenance Menu Screen • To access the Gas Analyser Menu , select the “Gas Analyser” option from The SUN Diagnostic Startup Screen (see the Emissions...
  • Page 27 NALYSER The Gas Analyser Maintenance Menu allows operator maintenance functions to be initiated, gas analyser system settings to be made, gas analyser system information to be consulted and updates to the 5.2: „The Gas Analyser gas analyser software to be loaded. Refer to System Menu‟...

  • Page 28: The Gas Analyser Maintenance Menu

    C H A P T E R 5 5.2 The Gas Analyser Maintenance Menu Figure 5-4 The Gas Analyser Maintenance Menu • To access the Gas Analyser Maintenance Menu , select the “Petrol” option from the Gas Analyser Menu (see 5.1 , 5.3).

  • Page 29: Gas Analyser Maintenance Menu Options

    NALYSER AINTENANCE • Press “Back” or the “Gas Analyser” toolbar icon button to return to the Gas Analyser Menu. 5.3 Gas Analyser Maintenance Menu Options Figure 5-5 The Gas Analyser Maintenance Menu The Maintenance procedures that can be initiated from the Gas Analyser Maintenance Menu are: Leak Check (Vacuum) (see 10.2).

  • Page 30: Gas Analyser System Settings

    C H A P T E R 5 • To Check and/or Install the O2 Cell, select the O Sensor Check Option. Details of the procedures for these checks are to be found in „Maintenance‟. 5.4 Gas Analyser System Settings Figure 5-6 The Gas Analyser System Settings Screen To access the Gas Analyser System Settings Screen, select the “System...

  • Page 31: Gas Analyser System Information

    NALYSER YSTEM NFORMATION • Use the LPG Composition drop-down menu to specify the appropriate ratio of Butane (C ) to Propane (C ) in the LPG fuel used by the test vehicle. The available range is from 100% Butane to 100% Propane in 10% increments.
  • Page 32 C H A P T E R 5 • To open the Gas Analyser System Information Window, select the “System Information” option from the The Gas Analyser System Menu (see 5.2). The Gas Analyser System Information Window comprises six tabs: - System Information (includes application versions, checksums etc.).

  • Page 33: Print

    The “Notes” Dialog Box 1 Figure 5-8 Note: The DGA 5000 uses the same “Print” procedure to provide a printout of all gas analyser test results. The following description is, therefore, applicable irrespective of whether the Free Measurement or Country Specific test procedure is employed.
  • Page 34 C H A P T E R 5 A typical sample results printout is illustrated below.. • Press “Cancel” to abort the print instruction and return to the test procedure. Note: Calculated values will be shown for either Lambda or AFR depending on the setting made in the Gas Analyser System Settings Screen (see 5.4).

  • Page 35: Preparatory Steps

    Gas Module side panel. Note: If the DGA 5000 is used in conjunction with an EOBD Device, the unit will derive rpm and oil temperature data direct from the test vehicle engine management system via the EOBD unit. In this case the use of the ROTI Module is unnecessary.

  • Page 36: Gas Module Pneumatic Connections

    Menu (see 5.1). Note: The body of this manual concerns the operation of the DGA 5000 in Gas Analyser mode only. Information concerning the use of the unit in conjunction with the Diesel Smoke Meter, EOBD Device menu options will be provided as separate documentation.

  • Page 37: Gas Analyser Start-Up

    TART 6.2.2 Gas Analyser Start-up At start-up, the analyser will automatically perform the following functions in sequence: - Warm up. - Zero-calibration. - HC residue check. While these functions are being performed, “pop-up” windows will be automatically displayed showing the status of the unit. These windows will automatically close when the function has been successfully completed.

  • Page 38: Zero-Calibration

    C H A P T E R 6 6.2.4 Zero-calibration Zero-calibration, which allows the Gas Module to determine the correct zero reference and gain settings. During this time: - The zero-calibration pop-up screen will be displayed showing the elapsed calibration time. An zero-calibration may be triggered in three ways: - As part of the start-up procedure or on return from standby mode (initial zero-calibration).

  • Page 39: Daily Leak Check

    AILY HECK Note: During zero-calibration the DGA 5000 derives the zero reference point settings from the atmospheric conditions of the environment in which it is operated. If the operating environment is poorly ventilated, or if sources of atmospheric pollution (e.g. petrol soaked rags etc.) are present in close proximity to the unit, this may lead to the zero reference points being set too high.

  • Page 40: Hc Residue Check

    C H A P T E R 6 6.4 HC Residue Check A HC residue check will follow every initial or manually triggered zero- calibration. The HC residue check will be aborted or postponed if a maintenance function is selected (e.g. in order to perform a leak check) The residue check will be resumed when the maintenance function is exited.

  • Page 41: Settings

    • Select and apply the Speed Factor as described in 8: „Operation - The Free Measurement Procedure‟ 6.5.3 Lambda/AFR Selection The DGA 5000 calculates and can display either Lambda () or Air Fuel Ratio (AFR). To select Lambda or AFR: • Open the Gas Analyser System Settings screen (see 5.4).

  • Page 42: Vehicle Connections

    C H A P T E R 6 6.6 Vehicle Connections Route the rpm pick-up lead and oil temperature probe clear of any hot or moving engine parts. 6.6.1 RPM Pick-Up Refer to the Emissions Diagnostic Platform Operator‟s Manual (6.2: „RPM Measurement and Speed Factor Selection‟) for details of rpm pick-up connection.

  • Page 43: Operation - General

    Operation - General The following sections contain general information applicable to all test procedures. Specific information relating to the performance of tests 8: „Operation using the Free Measurement Procedure may be found in - The Free Measurement Procedure‟. Information necessary to conduct country specific tests (MOT, AU, APK etc.) will be provided in separate documentation.

  • Page 44: Measurement Procedure

    During testing, engine exhaust gas samples are continuously gathered by means of the Exhaust Sample Probe inserted into the vehicle‟s exhaust tail pipe. The DGA 5000 continuously determines the amount of CO, CO , HC and O present in the exhaust sample. In the Free Measuring Procedure these values are continuously displayed in the parameter windows together with the values for CO corrigè, engine speed and oil...

  • Page 45: Shut Down Procedure

    ROCEDURE After all necessary settings and connections have been made, proceed as follows: • Start the vehicle engine and allow the oil temperature to come up to normal operating temperature (see Note above). • Insert the sample probe fully into the vehicle tailpipe. Note: On exhaust systems having twin tail pipes that exit a common resonator or muffler the exhaust gas sample may be diluted by ambient air...
  • Page 46 C H A P T E R 7...

  • Page 47: Operation - The Free Measurement Procedure

    Operation - The Free Measurement Procedure The Free Measurement program allows the DGA 5000 to be used as a diagnostic tool for the investigation of the fuel, ignition and emission control systems of a vehicle without applying the limits and procedures specified in any local, national or international test.

  • Page 48: The Free Measurement Screen

    C H A P T E R 8 In testing emission control devices any of the following tests may be performed as necessary, applicable or useful: - Exhaust Gas Recirculation Valve. - Positive Crankcase Ventilation (PCV) Valve. - Air Pump - Carburetor Adjustments for Vehicles Without Feedback Systems, - Lean-misfire Adjustment.
  • Page 49 EASUREMENT CREEN • To open the Free Measurement Screen, select the “Free Measurement” option from the Gas Analyser Menu (see section 5.1). - If the ROTI Rpm and Temperature selection in the General Settings screen is set to “Standard”, the Free Measurement screen will be shown immediately.

  • Page 50: Engine Speed Measurement Setup

    C H A P T E R 8 • To manually initiate an Zero-calibration, press the “Zero-calibration” button (see 6.2.4). • To toggle between limit sets, press the “Toggle Limit Sets” button (see 8.6: „Storing Data in the Data Buffers‟). •...

  • Page 51: Free Measurement Vehicle Setup

    EASUREMENT EHICLE ETUP The Engine Speed Measurement Setup screen displays: - Instructions for setting up engine speed measurement. - The current status of the 8520 measurement device. - A scale for the selection of the number of cylinders in the engine. - The currently recorded engine speed.
  • Page 52 C H A P T E R 8 In the Free Measurement Vehicle Setup Screen it is possible to: - Specify the vehicle fuel type. - Save the current set-up to file. - Load a previous set-up from file - Load the SUN default set-up. - Enable/disable limit sets.

  • Page 53: Saving And Loading Vehicle Setups

    AVING AND OADING EHICLE ETUPS • Use the “Limits” button to enable or disable the Limit Sets. Pressing the “Limits” button will change the status of the limit sets from ON to OFF and vice versa. The “Limits” button will be Green when the limits are switched ON and Red when the limits are switched OFF.
  • Page 54 C H A P T E R 8 • To cancel, click the “Cancel” button or press the”Esc” key. The Save Limits File box will be closed without storing the setup. To load a previously saved setup: • Press the “Load Setup” button. The Load Limits File dialog box will be displayed).

  • Page 55: Editing Limit Sets

    DITING IMIT 8.4 Editing Limit Sets Figure 8-6 The Edit Limit Sets Window To alter any or all of the limit values currently shown in the Vehicle Setup Screen: • Press the “Edit Limit Set” button corresponding to the Limit Set to be edited.

  • Page 56: Free Measurement Test Procedure

    C H A P T E R 8 8.5 Free Measurement Test Procedure Note: The following description of the Free Measurement Test Procedure assumes that the Limit Sets are applied and that gas readings are required at both high and low engine revolutions. This may not be the case in all circumstances.

  • Page 57: Storing Data In The Data Buffers

    TORING ATA IN THE UFFERS After the test data for Limit Set 2 has been stored the “Toggle Limit Sets” button will show that Limit Set 1 has been automatically reselected and the indicator bands will change accordingly. A figure “2”...
  • Page 58 C H A P T E R 8 The “Freeze” button will be replaced by the “Store” and “Undo” buttons. The “Store” button will be automatically selected (indicated by a Green background – see Figure 8-9). • Press “Store” to store the data or “Undo” to unfreeze the data and return to continuous measurement..

  • Page 59: The Print Preview Window

    RINT REVIEW INDOW • Press “Store” to store the Limit Set 2 data or “Undo” to unfreeze the data and return to continuous measurement. Figure 8-11 Store Limit Set 2 Readings The number “2” will appear alongside the number “1” in the toolbar indicating that data is now stored in both buffers.

  • Page 60: Printing Test Results

    C H A P T E R 8 • To open the Print Preview Window, press the “Print Preview” toolbar button on the The Free Measurement Screen toolbar. The Print Preview Window will be displayed. The window shows the measurements stored in the data buffers (1 & 2) together with the limit values applied.

  • Page 61: Maintenance

    (see Leak Check‟). If the DGA 5000 is configured for an approval type that requires such a daily leak check, the appropriate settings will be made at the time of the installation of the test software. In this case the unit will not commence normal operation unless a satisfactory leak check has been carried out.
  • Page 62 C H A P T E R 10 The Leak Check (Vacuum) screen will be displayed instructing the operator to block the sample probe inlet. Figure 9-1 Leak Check (Vacuum) Initialization • Block the probe inlet using the Probe Sealing Tool (p/n 7009E9317- 46) supplied with the unit.
  • Page 63 HECK ACUUM Figure 9-2 Leak Check (Vacuum) Measurement After the elapse of the decay measurement period the screen will indicate either a successful or unsuccessful test result Figure 9-3 Leak Check (Vacuum) Result • If the leak check is successful, unblock the probe tip, store the Probe Sealing Tool in a safe place until it is required again and press “Continue”...

  • Page 64: Leak Check (Gas)

    C H A P T E R 10 • If the leak check is unsuccessful, check all filter and hose connections for tightness and ensure that the sample hose is not damaged. 9.6.3: „Sample Probe Repeat the Leak Check (Vacuum). Refer to Hose‟) for information on how to isolate possible leaks in the sampling system (Probe, Hose and Gas Filter).
  • Page 65 HECK Figure 9-4 Leak Check (Gas) Initialization • Start the vehicle engine (if not already running) and insert the sample probe fully into the exhaust tailpipe. The unit will collect an exhaust gas sample from the vehicle and the CO concentration will be continuously measured and displayed.
  • Page 66 C H A P T E R 10 Figure 9-5 Leak Check (Gas) - Block Probe Tip • Remove the sample probe from the vehicle exhaust, block the probe tip and press the “Continue” button to proceed. After the “Continue” button is pressed, the pump will re-start and the unit will enter the measurement phase in which the decay in the concentration of CO will be determined.

  • Page 67: Gas Calibration Check

    The Gas Calibration Check should not be confused with the full gas calibration that should only be carried out by a SUN Service Engineer. The DGA 5000 system may be set to specify that a full gas calibration be performed at specified intervals (normally once every 12 months). If such a setting has been entered into the system, the unit will give a warning that a full gas calibration is required.

  • Page 68: Check And/Or Install The O2 Cell

    C H A P T E R 10 Figure 9-7 Gas Calibration Check The available options are: H8 (Propane) (Hexane) - CH (Methane) - LPG (Liquefied Petroleum Gas). The default setting is HC represents C (Hexane). • Connect the calibration gas bottle to the calibration gas inlet on the gas module rear panel, set the flow to 5 liters/min and turn on the gas.
  • Page 69 O2 C HECK AND NSTALL THE Due to the chemical processes within the O2 cell it has a limited life. The current status of the cell may be derived from its output voltage which is monitored by the unit software. If the output voltage falls below 7.5 mV the unit will display a warning that the cell will soon require replacement (“Pre-warning –...
  • Page 70 C H A P T E R 10 Figure 9-9 O2 Sensor Status Check - Result Note: Once “Continue” is pressed the installation procedure must be completed even if a new cell is not installed. If the old cell remains in situ the software will see the existing cell as a new cell and will require that the auto-calibration referred to below be performed.
  • Page 71 O2 C HECK AND NSTALL THE Figure 9-10 O2 Sensor Replacement - Auto-calibration The unit will initiate the auto-calibration and the auto-calibration pop-up window will appear showing the auto-calibration countdown. At the end of the auto-calibration the screen will show the message “Installation complete”...

  • Page 72: Routine Maintenance Procedures

    C H A P T E R 10 Routine Maintenance Procedures The maintenance and service procedures presented in this section are those that the operator may perform. All other service procedures should only be carried out by an authorised sun service representative.

  • Page 73: Sample Probe And Hose

    OUTINE AINTENANCE ROCEDURES More frequent filter service will be required when: - The analyser is in constant use. - Testing vehicles not warmed up to normal operating temperature. - Testing vehicles with very high emissions. 9.6.3 Sample Probe and Hose Periodically check the inlet holes at the probe tip for dirt and debris.

  • Page 74: Test Leads

    C H A P T E R 10 b. If the test is successful, install a new hose and repeat the leak test to check for other leaks. c. If the test still fails, continue with step 4. 4. Pinch off the tube connected to the gas filter with a small vise grip or needle nose style pliers.

  • Page 75: General

    Error, Warning and System Status Messages The DGA 5000 system gives error, warning and system status messages in two ways: - By means of automatic pop-up windows. - By means of the “Error/Warning” button on the toolbar.
  • Page 76 C H A P T E R 10 Figure 9-11 Warm-up Figure 9-12 Zero Calibration Figure 9-13 HC Residue Check Each of the above statuses is represented by its own automatically displayed pop-up window, showing the status concerned together with a countdown of the time remaining in that status.

  • Page 77: The Error/Warning Button

    Error/Warning codes and messages may be of two types: Messages relating to the DGA 5000 system. - Messages relating to the gas bench The possible error codes are show by the tables below.
  • Page 78 C H A P T E R 10 AINTENANCE Table 9-1 Gas Bench Error Codes SGMII Error Code Description Detector temp O.O.R Ambient temp O.O.R Pressure O.O.R Calibration required Calibration in progress Warm-up in progress Zero required Zero in progress Vacuum O.O.R Rpm O.O.R Oil temp O.O.R...
  • Page 79 SUN System E RROR Codes Table 9-2 SUN System Error Codes Error Code Description Change O2 Cell Pre_Warning Change O2 Cell Temperature limit exceeded Water Detected Sibench errors Auto zero calibration pending Condensation in Sibench Detected Low Flow Vacuum Error Temperature Error Co2 too high while HC-residue check active Gasbench driver error...

  • Page 80: Maintenance Parts

    AINTENANCE ARTS Maintenance Parts The following maintenance parts are available for Operator Maintenance Procedures: Table 9-4 Operator Maintenance Parts Part No. Description 7096E9321-25 Exhaust Probe Assembly 7009E9317-46 Exhaust Probe Sealing Tool 7096E9061-02 Water Filter 7096E9061-54 Charcoal Filter 7096E4060-31 Oxygen Sensor 1-32981A Water Bowl Coalescing Filter 1-33081A...
  • Page 81 C H A P T E R 10 AINTENANCE...

  • Page 82: Index

    Fuel Type Selection In Free Measurement Daily Leak Check, see Start-up Fuel Type Selection, see Setup Data Buffers 4 8 DGA 5000 8 Basic Configuration 8 Gas Analyser Menu 1 7 Gas Module Layout 9 Gas Analyser System Information 22...
  • Page 83 Standby Mode 18 Sample Hose & Probe 64 Start-up Test Leads 65 Daily Leak Check Requirement 30 Measurement Procedure 35 DGA 5000 2 7 Measurements Gas Analyser 2 7 Accuracy 5 HC Residue Check 31 Parameters 5 Warm up 28...

This manual is also suitable for:

Geogas 5000

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