Stargas 1

mod 898 BOX

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9001328

Operating instructions

Rel. 3 11/07
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14 e
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21 f
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24
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42 40 26 g
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38 h
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32 f 58
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Dear garage owner,

Thank you for having chosen one of our instruments for your workshop. We are
certain that it will give the utmost satisfaction and be a notable help on the job.

Please become fully familiar with the instructions in this user’s manual. It should
be kept ready to hand for consultation whenever required.

The STARGAS BOX analyser ranks at the top of the last generation of gasoline engine
exhaust gas analysers and allows to provide the repairer with a reliable guide to the
analysis procedure.

STARGAS adds to the gas analyser functions - the analysis of CO, CO2, HC, O2, NO
(optional), of Lambda coefficient, of engine revolutions (RPM) and of temperature -
the Lambda probe operation and the relative probe-central unit system
control.

The analyser is nowadays absolutely necessary for a good engine tuning, and for the
diagnosis of possible operation drawbacks aimed at limiting the vehicle polluting
emissions.

If the emission values are not correctly adjusted it will be absolutely impossible to
obtain a good operation of engines, especially of electronic injection fuel ones.

Moreover, as to vehicles equipped with catalytic muffle and Lambda probe it is

important to have the possibility of detecting the oxygen content (O2) and the Lambda
coefficient value too.

OPERATING INSTRUCTIONS 1
• It is forbidden to even partially this handbook in any way unless prior written authorisation has
been obtained from the manufacturer.

• The data and characteristics indicated in this handbook are not binding. The manufacturer reserves
the right to make all those modifications as are considered necessary without being obliged to give
advance warning or make replacements.

• All the names of brands and products and the trade marks are the property of the respective
owners.

TTPR - November 2007

__________________________________________________________________________ STARGAS BOX 

INDEX

GENERAL RULES FOR THE SAFETY OF THE OPERATOR 5

When operating on engines or other parts of the vehicle it is necessary: 5
When working on batteries it is necessary to remember: 6
When working with a mains voltage fed equipment it is necessary: 6
GENERAL INFORMATION FOR THE USER 7
Disposing of equipment 7
Disposing of batteries 7
FOR A CORRECT USE OF THE STARGAS BOX 8
1.0 - DESCRIPTION OF STARGAS BOX 9
1.1 - Tool rear view 9
2.0 - HOW TO CONNECT THE STARGAS BOX 11
3.0 - USE OF THE STARGAS BOX 12
3.1 - Test Conditions 12
3.2 - Temperature Measurement 13
3.3 - Revolution counter use 13
4.0 - GAS ANALYSIS 21
4.1 - Installation and uninstallation of the VISA PLAnet Suite 21
4.2 - Hardware key protection 23
4.3 - Powering 23
4.4 - Serial port setting 23
4.5 - Use of the programme 24
5.0 - STANDARD TEST 25
5.1 - Print 27
5.2 - Graphic Printing 27
5.3 - Automatic Zero Set 27
5.4 - Lambda coefficient 28
5.5 - Values exhaust gases 29
6.0 - CURVES 32
7.0 - HISTOGRAMS 33
8.0 - LAMBDA PROBE TEST 34
8.1 - Analysis 34
8.2 - Diagnosis 36
8.3 - Simulation 36
8.4 - Rich mixture 37
8.5 - Lean mixture 37
9.0 - CONFIGURATION 38

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10.0 - AUTOMATIC CONTROLS 40

10.1 - Pump ON/OFF 40
10.2 - Flow Control 40
10.3 - Supply Voltage 41
11.0 - CONTROLS 42
11.1 - Features of the sample gases 42
11.2 - Gas bottle connection 43
11.3 - Calibration 43
11.4 - Leak Test 43
11.5 - Residual HC 45
12.0 - MAINTENANCE 46
12.1 - Replacement of the standard cartridge/filter 46
12.2 - Cleaning of the condensate separating filter 46
12.3 - Replacement of the actived carbon filter 46
12.4 - Replacement of the O2 sensor 47
12.5 - Cleaning of the external transparent precleaner 47
12.6 - Cleaning of the pick-up pipe 47
12.7 - Replacement of the filtering baffle 47
13.0 - TECHNICAL FEATURES 48
14.0 - SPARE PARTS 51
14.1 - Lambda cables list - option 52

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GENERAL RULES FOR THE SAFETY OF THE OPERATOR

Read carefully the instructions for the installation, use and maintenance contained in
the operative manual.

Do not allow unskilled personnel to use this equipment, in order to avoid accidents to
the people or damages to the equipment.

The work place must be dry, sufficiently bright and well aired.

Particularly, vehicle diagnosis operations involving engine ignition must be carried out in
a room provided with an exhaust fan.

We remind you that inhalation of carbon oxide (which is odourless) causes serious
health damages.

When operating on engines or other parts of the vehicle it is necessary:

• To wear suitable clothes and to keep a proper attitude in order to prevent

accidents.

• Before going on with the test, to make sure that the car gear is in neutral position
(or in parking position if the vehicle is an automatic transmission one), to put on
the emergency or parking brake in the vehicle which is going to be tested and to
verify if the wheels are locked.

• To protect face, hands and feet and avoid any contact with hot surfaces such as
sparking plugs, exhaust pipes, radiators, cooling system connections.

• Not to smoke and not to light flames when working on the vehicle.

• To check that all electrical connections are insulated and firm.

• Not to look directly and at a close distance into the carburettor suction pipe when
the engine is on.

• To keep one's hands and hair off the moving parts. Never to wear ties, large
clothes, wrist pieces of jewellery and watches when working on a vehicle,
especially if the engine is on.

• To keep off the fan; the cooling fan is controlled by a thermal switch which is
linked to the coolant temperature: thus disconnect the fan cable when working on
a still hot engine, in order to prevent the fan from starting to work suddenly even
if the engine is off.

• Not to pour fuel directly in to the carburettor in order to ease the engine starting.

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• Not to unscrew the radiator plug before the engine temperature and consequently
the cooling system pressure have lowered.

• Not to touch the high voltage cables when the engine is on.

• To handle portable lamps carefully and use only the ones that are provided with
metallic protection.

• To wear protective glasses in order to protect the eyes from gasoline, dust or
metals.

• To remember that the catalytic muffler reaches very high temperatures that can
cause serious burns or fires.

• Hence check that near the muffler there are no oil stains, wipers, paper or other
easily inflammable materials.

When working on batteries it is necessary to remember:

Car batteries contain sulphuric acid and produce explosive gases; hence pay attention
to the following instructions:

• Always wear protective glasses.

• Never leave tools onto the battery since they could cause accidental contacts.

• Before carrying out the test or the recharge, cover with a wet wiper the battery
openings so as to choke the explosive gases.

• Avoid the sparking when connecting the cables to the battery.

• Avoid electrolyte sprinkles on the skin, on the eyes and on cloths, since it is a
corrosive and highly toxic compound.

When working with a mains voltage fed equipment it is necessary:

• To verify if the equipment is earthed.

• To avoid touching it with wet hands.

• To work beeing insulated from earth.

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GENERAL INFORMATION FOR THE USER

Disposing of equipment

• Do not dispose of this equipment as miscellaneous solid municipal waste but

arrange to have collected separately.

• The re-use or correct recycling of the electronic equipment (EEE) is important in

order to protect the environment and the wellbeing of humans.

• In accordance with European Directive WEEE 2002/96/EC, special collection points

are available to witch to deliver waste electrical and electronic equipment.

• The public administration and producers of electrical and electronic equipment are
involved in facilitating the processes of the re-use and recovery of waste electrical
and electronic equipment through the organisation of collection activities and the
use of appropriate planning arrangements.

• Unauthorised disposal of waste electrical and electronic equipment is punishable by

law with appropriate penalties.

Disposing of batteries

• Batteries must be recycled or disposed of properly. Do not throw batteries

away as part of normal refuse disposal.
• Do no throw batteries into open flame!

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FOR A CORRECT USE OF THE STARGAS BOX

In order to use the STARGAS BOX gas analyser safely it is necessary to comply with
the following rules:

• The analyser must be used in dry places. Its exposure or use near sources of heat
or polluting emissions (stoves, ovens, etc...) must also be avoided.

• In order to connect the analyser to the feeding mains make sure that the mains
voltage/frequency corresponds to the ones which are suggested for the analyser.

• Do not expose the analyser to shocks.

• Do not wet the analyser with water or other liquids.

• Avoid to touch it with wet hands.

• Replace the burnt fuses with fuses having the same features.

• Do not lean objects on the supply cable and never bend it sharply.

8 OPERATING INSTRUCTIONS
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1.0 - DESCRIPTION OF STARGAS BOX

1.1 - Tool rear view

11. Main switch: to turn on and off the tool if plugged to the mains supply.

12. Main switch: to turn on and off the tool if plugged to a battery.

13. Filter-holder with internal cooling air filter that can be washed.

14. Group filter bowl: It holds the standard cartridge/filter.

15. Standard cartridge/filter: It allows to separate the impurities from the exhaust
gases.

16. Certification plate: All of the technical features can be found there.

17. Connector of connecting cable to the oxygen sensor.

18. Oxygen Sensor: It measures the oxygen percentage which is contained in the
exhaust gases.

19. COM1 Port: serial port for the connection to the autodiagnosis interface.

20. COM2 Port: serial port for the connection to the autodiagnosis interface.

21. PARALLEL port: Port for the connection to a 80-column standard printer.

22. USB Port: Port for the connection of a 80-column external printer and for
software update.

23. Port for special activations by electronic key.

24. RS485 port: Port for industrial standard serial connection.

25. RPM Socket: Socket for the connection of the RPM clamp from battery or of
induction clamp (option).

26. TEMP Socket: Socket for the connection of the oil temperature probe.

27. Ambient sensors: Sensors to detect environment data (relative humidity and
temperature).

28. λ Socket: Socket for the connection of the lambda probe 1 Volt/5 Volt.
29. COM port: Port for the vehicle ground connection; battery negative.

30. Oscilloscope connector BNC: It allows the inlet of the measured signal through
the relevant wire connection.

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31. VGA port: Port for the connection to a standard monitor or to a TV color
(PAL/NTSC systems).

32. RS232/PC port: Port for the connection to a Personal Computer.

33. SMOKEMETER port: Port for the connection to a partial flow smoke analysis cell
combined with external supplier.

34. Tightness Test Plugs: They verify the internal and external pneumatic circuit
tightness.

35. Group filter bowl: It holds the condensate separating filter.

36. Condensate Separating Filter: It allows to separate the condensate from the
exhaust gases.

37. Outlet connection of the analysed gases.

38. Inlet connection of the exhaust gases.

39. Fuse compartment with a 5A quick fuse.

40. Mains Socket: Tool power supply socket by the connection of the relevant cable
to the power mains.

41. Battery Socket: Tool power socket by the connection of the relevant battery
cable (12 Volt).

42. Actived Carbon Filter: It separates the air that is sucked up for the internal
pneumatic circuit cleaning from unburnt hydrocarbons and impurities.

43. It is used for the connection of the sample gas bottle.

44. Condensate outlet connection of the analysed gases.

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2.0 - HOW TO CONNECT THE STARGAS BOX

The STARGAS BOX analyzer, is managed through the connection to a multi-function

center of series VISA or to a Personal Computer.

ATTENTION:
Remove the protection plugs which have been inserted in
the external connections.
It is necessary to keep the plugs because in case that a
new package is needed for the forwarding to the
laboratory (calibration, overhaul, repair), they assure a
suitable protection to the whole internal pneumatic
circuit.

For the connections proceed in the following way:

• Insert the special pipe (49) into the condensate outlet connection
OUT WATER (44) so as to convey the condensate far from the analyser.
• Set up the gas pick-up system according to the following rules:
Insert the sampling gas probe (54) in the 6m piping (48-b).
Connect to the piping the external prefilter which is equipped with its
80cm pipe (48-a).
Insert the above-mentioned assemblage into the inlet gas connection (38).
• Connect the RPM battery cable (62) or in case of use the antenna system, connect
the relevant cables (69) o (70), to the RPM socket (25).
• Connect the ground cable (60) to the COM port (29). Such cable doesn’t have
to be connected, in case of use the aerial system for RPM surveying.
• Connect the temperature probe (61) to the TEMP. °C tap (26).

• Connect the extension (58) to the λ tap (28) to check the effectiveness of the
Lambda probe/central unit.
• Attach to the extension (58) the SHUNT cable (57) or the connecting cable of
the test prod clamp (56) with the prod (55).
• Connect the serial cable (71) to COM2 (20) or COM1 (19) port of the
STARGAS BOX and to one of the port presents on the PC. The configuration of the
communication port on the STARGAS BOX happens in automatic mode.
• Connect the sample gas bottle if required by the rules in force to the coupler (43).
• Attach the battery supply cable (59) to the battery socket (41) and to the tested
vehicle battery (in case the vehicle is not already supplied by the mains cable).
• Attach the mains cable (63) to the mains socket (40) and to the supply source
of the power mains (in case the vehicle is not already supplied by battery cable).

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• For the connection to the feeding mains, make sure that the tap has the same
VOLTAGE/FREQUENCE features as those that are written on the plate which is
located on the analyser back side. The earthing is absolutely necessary.

ATTENTION:
The oxygen sensor (18) is one of chemical kind and it has to be replaced
when it is no longer possible to obtain the automatic span. To replace the
exhausted sensor it is necessary to ask for the intervention of the authorised
technical service. Not to alter the test results, let the gas outlet flow coupler
free (37).

3.0 - USE OF THE STARGAS BOX

Error messages are displayed on the monitor simultaneously to the emission of a sound
warning.

3.1 - Test Conditions

Once the connections have been performed, before starting the test check:

• The ambient temperature ranges between +5°C and +40°C (degrees

Centigrades).
• The exhaust pipe of the vehicle is tight. This condition has to be checked by
hermetically occluding the exhaust pipe while the engine is idling; in such a
condition no gas leakages from the pipe joints should be detected.
• The following car parameters are correct, as per the manufacturer’s indications.
IDLING
DWELL ANGLE (DWELL)
IGNITION ANGLE (ADVANCE)
PLAY OF THE VALVES
• The engine oil temperature, beeing measured through the probe the analyser is
equipped with, is higher than 80°C.
• The cold starting devices (automatic and manual) are disconnected.

ATTENTION:
During the outdoor gas analysis tests be sure the gas sampling facility is not
directly exposed to sun rays. As a matter of fact, a temperature increase of
piping/filter can cause a steam accumulation inside the analyser thus
affecting measurements.

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3.2 - Temperature Measurement

During the carrying out of the tests the engine temperature is displayed on the
TEMP. °C box, after beeing measured through the probe the analyser is equipped with.

The temperature measuring range ranges between 5°C and 200°C.

5°C are the lowest threshold in compliance with the minimum ambient temperature at
which the instrument must be able to work in temperature.

The temperature (61) probe has to be introduced at the place of the oil dipstick.
In order to introduce it deeply enough, adjust the rubber plug by using as a reference
the original dipstick length.

ATTENTION:
When introducing the temperature probe, do not bring the connecting cable
near sources of strong interferences (coil, spark plug cables, distributor).
Moreover do not twist the cables inside the engine compartment.

3.3 - Revolution counter use

While carrying out the gas analysis test, it is also necessary to make sure that the
VEHICLE IS IDLING and at ACCELERATED SPEED (manufacturer’s data).

Battery mode

To measure the rpm you can use the internal revolution counter of the tool that
processes a signal from the battery positive terminal and detects the rpm.
That is set for 4-cylinder engines, but also 1, 2, 3, 5, 6, 8, 10, 12 cylinder can be set.

Connect cables as follows:

• Connect the RPM cable from battery (62) to the battery positive pole.

• Connect the ground cable (60) to the vehicle chassis.

• Start the engine, the RPM case on the LCD will read the rpm.

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NOTA BENE:
If the programme displays the RPM RANGE SELECTION page, usually when the engine
rpm number is lower than 700 RPM or when it exceeds 900 RPM, it is necessary to
select the RPM value being nearest to that of the tested engine. The programme
processes the data by setting as predefined value the measure it deems to be more
correct.
After carrying out the relevant checks the operator shall select the most reliable
measure (by using the cursor shifting keys) and confirm by ENTER.

If during the tests the rpm is unstable (anomalous values) the problems are due to the
generator charge pulses or to the charge current pulses interfering with the continuous
current of the electrical system. These currents cause a voltage drop on the electrical
system lines that can be measured by the tool revolution counter.

In case you have problems during tests check:

• Measuring the speed functions better with a partially discharged battery than with
a fully charged one. It is, therefore, worthwhile switching on several loads for a
few minutes before starting the engine.

• During measurement switch on several loads such as the lights, rear window
heating etc.

• Once the engine is on, press down fully on the accelerator, the generators
regulator can only be activated through this.

• Be sure that the V-belt used to drive the generator does not slip off, otherwise
faulty measurements could occur whilst the engine is accelerating.

• In some vehicles a switched on fan can distort measurement. In this case, switch
off the fan.

The rpm reading can be carried out by using the RPM cable from the electric lighter
(option) or the cable with induction clamp (option).
The latter is set to 4-time engines, but can be set to 2-time/DIS engines too.

ATTENTION:
At the end of measurement disconnect the RPM cable from the battery and
short circuit the clamps one another to avoid the display of a wrong rpm due
to the high sensitivity of the system. If a RPM cable from car lighter is used
(option) short circuit it through the special hook connected to it.

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Induction clamp mode

If during the tests with induction clamp the revolution number is unstable (showing a
trend towards anomalous values), probably some parasitic signals or some other signals
coming from the ignition system of the other non concerned cylinders get into the
induction clamp.

The reasons for these drawbacks are numerous, for instance:

• Spark plug contacts blinked with an excessive resistance.

• Coil high output.

• Excessive distance of the spark plug electrodes.

• Spark plug cables too close one another and non perfectly insulated.

• Humidity of the cables, of the spark plugs, etc...

ATTENTION:
Check that no electrical discharges occur between the spark plug cable and
the clamp, which could seriously damage the analyser.

Antenna mode

An antenna positioned near by the vehicle, picks up from ignition peaks that are
opportunely processed.

Intervals between the peaks give the number of revolutions.

This system is predisposed for 1, 2, 3, 4, 5, 6-cylinders engines.

To use antenna system:

• Position the antenna (69) or (70), according to that one that thinks more adapted
for the measure, near to the engine;

• start the engine in order to visualize into the RPM square, the RPM number.

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FLEXIBLE ANTENNA (69)

This kind of antenna was designed to use the instrument with the four-cylinder engines
that are typical of road motorcycles. It is advisable to use it both in the case of ignition
coils separated from spark plugs, and in the case of ignition systems that have no spark
plug high voltage cable. This antenna is also suitable for gasoline engines of vehicles
with head coils and common rail diesel engines (for the correct positioning and fixation
see antenna mode with common rail engines).

REVOLVING ANTENNA (70)

The use of this kind of antenna is suggested for the measurement of rpm of all vehicles
and motor vehicles except for those described above.

POSITIONING OF THE ANTENNA - 1-CYLINDER ENGINES

Use the revolving antenna by positioning it at about 50cm – 1m from the spark plug or
from the coil.

POSITIONING OF THE ANTENNA - 2-CYLINDER ENGINES

Use the revolving antenna by positioning it near one cylinder only so as to enable the
instrument to receive the correct signal only.

NOTA BENE:
For this kind of engines the rpm measurement can often turn out to be easier by using
the induction clamp.

POSITIONING OF THE ANTENNA - 3-CYLINDER ENGINES

Use the revolving antenna and position it near the coil unit (ex. BMW motorcycles).

POSITIONING OF THE ANTENNA - 4-CYLINDER ENGINES

Mainly use the flexible antenna by positioning it at exactly the same distance from the
spark plugs and as near as possible to them. In case of engines having no spark plug
high–voltage cable, position the antenna as near as possible to the coil-spark plugs
assembly (see figure).

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OPERATING INSTRUCTIONS 17
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SENSIBILITY ADJUSTMENT

• See chapter 5.0 for the following image visualization.

Selecting the Antenna mode, in the angle on the left the bar chart is visualized.
It indicates the power of the signal in entrance to the measure circuit.

If the indicator bar is positioned between the half and the maximum, the signal
received presents an optimal power for the measure. In contrary case approach mainly
the antenna at the source of the signal.

NOTA BENE:
The signal power decreases with the increase in the rpm number.

The cylinder number preset by the tool is 4; modifying the cylinders number, the
following chosen will be displayed:

2 time : engine with one spark every 2 driving shaft revolutions;

2 time/DIS : engine with one spark every driving shaft revolutions and
DIS system engine;
2 time-2 sparks : engine with two sparks every driving shaft revolutions
(typical of a motorcycle such as VESPA PK-SPECIAL).

• Position the selection level with suitable choice to the type of measure that must
be executed.

NOTA BENE:
The motorcycles type VESPA 125 PRIMAVERA ET3 are characterised by anomalous
signals such as 1S every driving shaft revolutions (2 time/DIS selection) when the
engine is idling and 2S every driving shaft revolutions (2 time-2 sparks selection) when
the engine is accelerated.

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The sensitivity value preset by the tool is 200.
This value must not be modified if the tool shows the correct and stable rpm.

If the rpm is not correct, follow the procedures below:

• Gradually lower sensitivity until reaching a correct rpm value, in case the displayed
rpm is higher than the true one.

• Gradually increase sensitivity or take the antenna near the signal source, in case
the displayed rpm is lower than the true one.

To modify the sensibility value, follow the procedures below:

• Press F4 to increase the sensibility.

• Press F5 to lower the sensibility.

NOTA BENE:
Always check the rpm value also at the accelerated idle speed.

Approximately, the values of rpm number, at idling, are those that are listed in the
following table.

Displacement Number of cylinders RPM Number

50cc 1 1500 - 1600rpm
250cc 1 1500rpm
600cc 1 1300 - 1400rpm
750cc 2 1200 - 1300rpm
750cc – 1000cc 4 900 - 1100rpm

ATTENTION:
The cellular telephones can disturb the ANTENNA MODE measure.

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Antenna mode with common rail engines

The common rail engines revolution speed can be measured by an antenna system
thanks to the injectors electromagnetic emissions.

1
1

To carry out the measurement follow instructions below:

• Use the flexible antenna (2) with antenna grippers (1).

• Place the antenna parallel to injectors as close as possible to them, as shown in
the picture.
• Use antenna grippers (1) to fix the flexible antenna (2) by bending it as desired to
reach the correct position.
• Set the tool in the antenna mode.
• The signal power is shown on the display: search for the antenna positioning
allowing best power for measurement.
• Select cylinder number.
• Check the measure at idle and fast idle:
If the displayed rpm value is lower than the true value the sensitivity has to be
increased by means of the relevant keys (see sensitivity adjustment).
If the displayed rpm value is higher than the true value the sensitivity has to be
decreased.

ATTENTION:
Do not attach the antenna grippers to the positive pole and/or
negative pole of the battery.

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4.0 - GAS ANALYSIS

Tecnotest equipment is provided with different software for PCs with Windows OS.

4.1 - Installation and uninstallation of the VISA PLAnet Suite

An auto-install CD-ROM is provided for the installation of the VISA PLAnet software.
PC minimum requirements PC:
Pentium MMX 233 MHz
128 MB RAM
10 GB Hard Disk
Windows 98 Second Edition
1 Port USB
1 Port LPT
CD-ROM drive
Mouse
Keyboard
1 RS232 serial port for each connected device.

PC recommend requirements:
Pentium Celeron 850 MHz
128 MB RAM
40 GB Hard Disk
Windows 98 Second Edition
2 Port USB
1 Port LPT
CD-ROM drive
Mouse
Keyboard
1 RS232 serial port for each connected device.

Software prerequisites (if the following programmes are not installed on the PC, they
are automatically installed from the CD-ROM):
Java 2 Runtime Environment or higher.
Microsoft Internet Explorer 5.02 or higher.
.NET Framework 1.1.
.NET Framework 2.0.

To install Java 2 Runtime Environment, select the typical option.

To install Microsoft Internet Explorer 6.0, accept all the default settings.
To install.NET Framework, the page with the software conditions of use is displayed: to
continue with the installation, press Accept.

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VISA PLAnet software installation

The user interface is conforming to the Windows applications standard; once the
VISA PLAnet installation has started, the user shall press Next on each screen page.

After the prerequisites (if needed) have been installed, the VISA PLAnet installation
starts, displaying a page with the installation confirmation request.

The installation starts automatically and ends some seconds after a message for the
user is displayed

• Press Close to end the procedure completely.

VISA software uninstallation

• Open the Control Panel, verify the installation (VISA PLAnet) and, if needed,
remove it, just like any other programme installed on the PC.

During the removal procedure, all the folders and files that have been copied on the PC
during the installation are cancelled. Files containing customized configurations will not
be removed. These files can be cancelled manually.

NOTA BENE:
The first time that each VISA PLAnet suite application is launched, the relevant license
contract is displayed. The contract shall be read and accepted before the software can
be used.

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4.2 - Hardware key protection

• Make sure that the hardware key is inserted in way corrected in one door USB of
the PC.

• Make sure that the red light on the key is ignited.

• In order to verify the correct operation of the hardware key supplied with suite
VISA PLAnet, enter in menu the UTILITIES of the MAIN MENU and select
VERSIONS SOFTWARE.

The utilities program recalled, will control the presence of the hardware key and will
suggest to the customer like resolving eventual problems.

4.3 - Powering

• Press the (11) or (12) switch located on the back side of the analyser next to the
mains supply tap.

NOTA BENE:
To start the VISA2 central unit or the Personal Computer, please refer to the specific
operational manual.

4.4 - Serial port setting

To set the serial port on the VISA2, please refer to the specific operational manual of
the multioperational unit.

For the correct functioning of the gas analyser connected to a Personal Computer,
the serial port setting is required.

• Select F6 from GAS ANALYSIS page, to accede to CONFIGURATION page.

• Select the Protocol properties page and set the serial port to be used in the
analyser SERIAL PORT section.

• Once the setting has been completed, quit and restart the program.

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4.5 - Use of the programme

• Select EXHAUST GASES function from MAIN MENU page and afterwards
GAS ANALYSIS.

The waiting message WAIT PLEASE is displayed and subsequently you enter the
GAS ANALYSIS programme.

The following functions will be displayed on the monitor:

F1-MEASUREMENT: to carry out the controls of exhaust gases in agreement to

norm OIML.
F2-CURVES: to display the exhaust gas variation graphically.
F3-HISTOGRAMS: to display graphically the comparison among the exhaust
gases.
F5-LAMBDA PROBE TEST: to check the Lambda probe efficiency and the correct
functioning of the injection unit.
F6-CONFIGURATIONS: service function allowing to carry out calibrations and/or
controls on the analyser.
ESC-TO EXIT: This function allows to interrupt the test at any time and to quit
the programme you are working in.

Warming up Time

After to have selected one of the tests available in the programme, the WARMING UP
message is displayed; it signals the analyser warming up phase which can last till a
maximum of 60 seconds.

Automatic Zero Set

The analyser automatically starts the zero setting phase. The AUTOZERO IN
PROGRESS message is displayed.
At the end of this phase the analyser is ready to be used.

At every AUTOZERO the instrument automatically carries out a calibration of the

O2 value (according to the parameters it has memorised).

In case some calibration errors occur (for instance due to a defective or exhausted
sensor) the message REPLACE O2 SENSOR will be displayed.

If the drawback persists it is necessary to apply to the technical assistance

service.

24 OPERATING INSTRUCTIONS
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5.0 - STANDARD TEST

• Select MEASURE function from GAS ANALYSIS page.

• Press F4 to select the type of fuel. Make sure the chosen fuel is displayed in the
box.

To carry out the value measurement it is necessary to:

• Perform two rapid idle accelerations and bring the engine back to the slow
running.
• Introduce the gas sampling probe into the exhaust pipe as deep as possible, and
anyway at a depth of at least 300mm.
• If the exhaust pipe extremity does not allow to introduce the probe completely, it
is necessary to add a special extension assuring the tightness in the joint area.

The analyser displays the values of the single gases, the Lambda coefficient, the
revolution number and the engine temperature value.

• Press F5 to display RPM COUNTER CONFIGURATION page.

OPERATING INSTRUCTIONS 25
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To carry out settings (in case they differ from those of default) follow the instructions
below:

• Select the type of revolution cable used to carry out the test by mouse.
• Select the engine times (Strokes N.) of the tested engine (2, 4 times or 2 times
2 sparks), only in case the induction clamp or the antenna system with a different
number of cylinders from that 4 cylinders preset, is used.
• In case the battery cable or antenna system is used, press many times the F2 key
until displaying the number of cylinders of the tested vehicle.

To calibrate the rpm (only in case the battery cable is used) follow instructions below:

• Select the RPM COUNTER CONFIGURATION page and connect the revolution cable
from the battery (see chapter 3.3).
• The light on the RPM COUNTER CONFIGURATION page is usually red
(no calibration performed), while when the tool starts calibration it turns yellow.
• At the end of calibration the light becomes green and the RPM box indicates the
revolution number.
• If at the end of automatic calibration the value is not correct, select F1 key to
carry out a second calibration.

NOTA BENE:
In the case an adapter model 2033 is used, select the INDUCTION CLAMP mode and
lower sensibility from 200 (default value) to 120.
To carry out a correct measure of the rpm number refer to the use of the rpm counter
(see chapter 3.3).

26 OPERATING INSTRUCTIONS
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• Press the F3 key to store the new settings and quit the RPM COUNTER
CONFIGURATION page.
• Select the ESC function to quit the RPM COUNTER CONFIGURATION page without
storing the new settings.

5.1 - Print

• Select PRINT function from the MEASURE page.

• Enter the make of the vehicle, the model, the registration number, the frame
number, the car mileage and the tester’s name, and than press the F2 key, to
cancel the data previously inserted.
• Select 80-column function in order to print through the 80-column printer the
machinery is equipped with.

At the end of the printing the GAS ANALYSIS page is displayed again.

• Compare the retrieved values with the data that have been specified by the car
maker and if it is necessary correct them by means of the special adjustment
systems (screw on the carburettor, screw on the flow meter, screw on the central
unit etc...).

5.2 - Graphic Printing

• Select GRAPHIC PRINTING function in order to print through the 80-column

printer.

5.3 - Automatic Zero Set

The autozero function allows the machinery to zero the values. The autozero message
is automatically displayed either according to the preset parameters or every time the
user selects the function.

• In order to zero the values select the F3 function.

The AUTOZERO message is displayed.

Every time the machinery proceeds to an automatic zero setting it also automatically
carries out an O2 value calibration.
If any calibration of the sensor O2 error intervenes (for instance defective or exhausted
sensor) the REPLACE O2 SENSOR message is displayed.
After this message, measurement of oxygen and of Lambda coefficient will be inhibited
until proper functioning conditions are restored replacing the depleted sensor with a
new one.

If the drawback persists it is necessary to apply to the technical assistance

service.

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5.4 - Lambda coefficient

The Lambda coefficient shows the stoichiometric ratio, that is the ratio between the air
and petrol quantities in the combustion chamber.

When this value is very close to 1 it means that the combustion inside the chamber is
as near perfect as can be expected.

Lambda coefficients are calculated using a mathematical formula according to the

selected fuels.

The Lambda coefficient calculating formula is the following one:

⎡ ⎛ ⎞ ⎤
⎢ ⎜∗ ⎟ ⎥
CO Hcv 3,5
21× ⎢CO 2 + + O2 + ⎜ × − 0,0087 ⎟ × (CO 2 + CO)⎥
⎢ 2 ⎜ 4 CO ⎟ ⎥
⎢ ⎜ 3,5 + ⎟ ⎥
⎣ ⎝ CO 2 ⎠ ⎦
λ =
⎡ CO ⎤
⎢ CO 2 ⎥ ⎡ ∗
Hcv 0,01754 ⎤
⎢21 + 0,5628 × ⎥ × ⎢1 + − ⎥ × [CO 2 + CO+ HC× 6 × 10 ]
−4

⎢ CO ⎥ ⎣ 4 2 ⎦
3,5 +
⎢ CO ⎥
⎣ 2 ⎦

Gasoline fed engines = 1,85 CO, CO2 and O2 = % vol.

*Hcv LPG fed engines = 2,525 HC = ppm vol
Methane fed engines = 4

(Lambda Coefficient) λ < (lower) than 1.000: rich mixture

(Lambda Coefficient) λ > (higher) than 1.000: lean mixture

28 OPERATING INSTRUCTIONS
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5.5 - Values exhaust gases

The value of the single gases (CO, CO2, O2) is expressed in percentage-volume.
The unburnt hydrocarbons (HC) and Azote oxide values (NOX) are expressed in
PPM VOL (Parts Per Million-Volume).

The corrected CO indicates the CO when the following conditions are satisfied
simultaneously:

CO ≠ 0 (different from zero)

CO + CO2 < 15* % (lower than 15%)
CO2 ≥ 6 % (greater or equal to 6 %)

(CO × 15∗ )
The applied formula is the following one: CO corr =
(CO+CO2)

(*) 14 for LPG-powered vehicles.

(*) 12 for METHANE (CH4) powered vehicles.

The corrected CO is always printed (if CO2 ≥ 6%) together with CO. The percentage
value has to be taken into consideration only when the corrected CO value turns out to
be different from the CO value.

The corrected CO indicates the value of the CO which is emitted by the engine even
when the vehicle exhaust system is not tight.
As a matter of fact the gas values are diluted by the air suction hence they are not
reliable.

The lambda coefficient is always calculated with the CO value.

The corrected CO is printed with larger fonts, as provided for by the law in force.

The corrected CO value must be taken into consideration only when the measured gas
values are stabilized.

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DIAGRAM OF COMPARISON
AMONG THE 4 ANALYSED GASES (CO, CO2, HC, O2)
ON A SAMPLE OF 100 FUEL INJECTION VEHICLES
ALIMENTATI AD INIEZIONE
IN GOOD MAINTENANCE CONDITIONS

In order to read the diagram correctly, consider the CO (Carbon Monoxide) as the
reference gas.

30 OPERATING INSTRUCTIONS
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Possible causes for CO - CO2 - HC and O2 wrong values

• Wrong carburation adjustment

• Dirty or obstructed air filter
• Defective enrichment of the heating phase
CO • Defective enrichment of the acceleration
• Defective spark plugs
• Defective pressure regulator

• IGNITION LEAKAGES:
Defective reducer contacts
Defective spark plug cables
Wrong advance
Defective spark plugs

HC • INCOMPLETE COMBUSTION:
Lean mixture
Defective suction circuit tightness
• MECHANICAL DEFECTS
Insufficient compression
Valves that are not tight

CO2 • Exhaust system tightness

• Exhaust system tightness

O2 • Rich mixture
• Defective Lambda Probe

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6.0 - CURVES

• Select CURVES from the page GAS ANALYSIS in order to display the exhaust gas
variation graphically.

1 2 3

The graph which is visualised on the display indicates the measured gases progress.

The values correspondents to every single gas (1), are displayed in their respective
boxes.

• Press with the mouse on the key (2) in order to interrupt the values of the
selected gas acquisition.

• With the mouse carry the cursor (3) in the point of the acquired curve that is
wanted to be inspected, while the relevant gas values are displayed.

• Press with the mouse again to resume the acquisition of the value.

32 OPERATING INSTRUCTIONS
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7.0 - HISTOGRAMS

• From the GAS ANALYSIS page select HISTOGRAMS in order to visualise

graphically the comparison among the exhaust gases.

This kind of visualisation proves to be very useful because it allows both to adjust the
CO value rapidly and without errors, and to check immediately if also CO2, HC and O2
are within the limits that have been specified by the Car Makers.

During these two graphic tests the diagrams will display the gases only if they do not
exceed the most significant preset limit values.
This is done in order to obtain a good resolution thus enabling to single out even very
little variations of the measured gases.

The values are always precisely displayed in their respective boxes, although they are
not graphically visualised.

OPERATING INSTRUCTIONS 33
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8.0 - LAMBDA PROBE TEST

This test allows to check the Lambda probe efficiency and the correct functioning of the
injection unit being connected to the probe.

The test is divided into the following phases:

• ANALYSIS
• SIMULATION

The analyser is equipped with an electronic protection to avoid erroneous connections

which might damage the tool.

8.1 - Analysis

This test allows to check the Lambda probe efficiency.

Before carrying out any operation on the tested vehicle, check the type of Lambda
probe and its wiring.

Two different types of lambda probe are currently being used: heated probe
(usually with 3 or 4 wires) and non-heated probe (usually with 1 or 2 wires).

In case of heated probe, before any operation, check the resistance and its power
supply using an ordinary multimeter, whereas in case of probe without heating
resistance, check the signal.

Once the type of probe has been identified, prepare the suitable connection in relation
to the type of vehicle being testes, as indicated on the following page.

• Connect the analyser to the Lambda probe, by means of the Lambda probe
extension cable (58) and the Shunt cable (57), or using other specific cables, if
needed.

Connections can be established both when the tool is turned off and on; in any case,
start the analyser for the preparation of the test.

Now warm up the engine as you would normally do by covering at least 3Km at a speed
such as to allow for the probe to attain the correct temperature, if non-heated, and
especially for both types of probes, to eliminate possible residues deposits due to
regular use; in some case, it is advisable to keep the engine accelerated, for
some minutes, between 2500 and 3000rpm during the test as well.

After warming up the engine as required, in the garage, immediately check the
efficiency of the lambda probe signal, through the connection previously prepared, and
insert the gas sampling probe into the vehicle’s exhaust pipe to check (alternatively) the
exhaust gas reading as well.

If the probe status is DEPLETED, immediately check the wiring through a simulation
test.

34 OPERATING INSTRUCTIONS
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If the status is immediately signalled as EFFICIENT, you make sure this status is
maintained by carrying out other tests.

If efficiency decreases up to the DEPLETED condition, the possible causes can be the
following:

• Engine with relatively high unburnt hydrocarbons emissions (HC) which, often,
cannot be detected at the exhaust pipe due to the additional reduction by the
catalytic converter and/or the emission of carbon residues.
• Non-heated Lambda probe not attaining (at idling) a working temperature
sufficient to issue a correct signal to the electronic central unit.
• Lambda probe (heated) not working properly; using a multimeter, measure and
verify the voltage (12V) in parallel to the heater, as well as the correct resistance
value (2÷10Ω values when engine is cool) according to the type of probe.

NOTA BENE:
The lambda probe diagnosis is very accurate thanks to parameters developed through
tests and studies carried out for the German market during the AU type approval.

• Select LAMBDA PROBE TEST from GAS ANALYSIS page.

The LAMBDA PROBE ANALYSIS page, is displayed.

• Select ANALYSIS function.

• Press F1 to start ANALYSIS function.

After the 10 seconds required to display the complete graph, F1 can be selected to
repeat the test.

OPERATING INSTRUCTIONS 35
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8.2 - Diagnosis

The DIAGNOSIS function within the ANALYSIS test allows for the assessment of the
probe efficiency through a graphic indication.

• Select the DIAGNOSIS function, after the 10 seconds of the previous graph
(wave-shaped) display.

A bar indicating the probe condition is displayed, starting from the DEPLETED status up
and stopping at the point indicating that condition (DEPLETED –MEDIUM –EFFICIENT).

The space ranging between the depleted area and the efficient area is
regarded as medium.

• Press ESC key to return to the ANALYSIS LAMBDA PROBE page.

8.3 - Simulation

Through this test, the analyser simulates the functioning of the Lambda probe,
replacing it.
The maximum duration of each test is 60 seconds, to ensure that the
ecu-catalytic converter system of the vehicle being tested is not damaged.

Through the simulation, the analyser checks the functioning of the ecu and of the
relevant wirings in the connection to the Lambda probe.

ATTENTION:
Improper use of the analyser can cause damage; carefully follow the
instructions.

• Select SIMULATION function to visualize LAMBDA PROBE SIMULATION page.

• Select F1 to start the test.

• Select F2 SIM. λ < 1 to enrich the mixture after starting the test.

• Select F3 SIM. λ > 1 to weaken the mixture after starting the test.

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8.4 - Rich mixture

On the LAMBDA PROBE SIMULATION page, in the box on the lower left-hand side, the
CO values and the lambda factor correspond to those measured by means of the gas
sampling probe.

The box indicating the lambda factor will change colour when the value is comprised
between 0,97 and 1,03 (ideal carburation).

• Select SIM. λ < 1 function.

8.5 - Lean mixture

The function λ > 1 allows for the simulation of a weakening of the mixture; in the
WEAK MIXTURE box, the CO values and the lambda factor are displayed.

The graph displays the curve transforming into a straight line tending to a value close
to 1 Volt. After about 15 seconds, by selecting the function λ > 1 once again, check the
correct variation of the CO values and lambda factor.

In the WEAK MIXTURE box, the saved values remain displayed.

In the box on the lower left-hand side, make sure the normal working values of the
system have been restored, starting from the saved data in the WEAK MIXTURE box.

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9.0 - CONFIGURATION

• Select F6 from GAS ANALYSIS page to accede to CONFIGURATION page.

• Enter the garage data (the fields for the entry of the Garage Data are enabled only
if set on local mode in the Configuration Type) and set the language to be used for
printing and for the test.

ATTENTION:
The CONFIGURATION TYPE, MODE, LOGO and TEST PROCEDURE
functions are protected by a password and can thus be used
exclusively by the Technical Assistance personnel.

• Select the Protocol property to display the following page.

• Select the serial port used for the connection of the gas analyser.

38 OPERATING INSTRUCTIONS
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• Select the RPM meter properties page to display the RPM COUNTER
CONFIGURATION page. To carry out a correct measure of the rpm number refer to
the use of the rpm counter (see chapter 3.3).

• Select the Analyzer property to display the following page.

On this page, the selection of the type of gas analyser being used can be displayed.

ATTENTION:
The ANALYZER MODEL function, is protected by a password and can
thus be used exclusively by the Technical Assistance personnel.

• Select the License property in order to visualize and eventually to print the
relative contract.

ATTENTION:
The PROTECT SERVICES function, is protected by a password and can
thus be used exclusively by the Technical Assistance personnel.

OPERATING INSTRUCTIONS 39
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10.0 - AUTOMATIC CONTROLS

The machinery automatically checks the state of the parameters being necessary for a
good operation.

10.1 - Pump ON/OFF

The pump turning off is visualised on the display by the respective symbol.

• In order to enable the pump again select PUMP ON.

10.2 - Flow Control

The machinery automatically controls the gas flow by checking the vacuum value inside
the suction circuit.

Insert the probe into the analyser so as to guarantee that the flow control is
carried out correctly.

VACUUM LOW

In such a condition, carry out the following operations:

• Carry out a leakage test

• Check if the ring nut of the water trap is tightened
• Check if the ring nut of the standard cartridge/filter is tightened
• Verify if the O-Rings are in their housings and in good conditions

VACUUM HIGH

In such a condition, carry out the following operations:

• Make sure that the probe pipe is not obstructed

• Make sure that the external precleaner is not obstructed
• Make sure that the condensate separator is not dirty
• Replace the standard cartridge/filter

NOTA BENE:
For a correct reading of the flow, never remove the tube (6 meters).

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10.3 - Supply Voltage

The supply voltage is very important for the correct analyser operation.

It is hence necessary to provide for suitable systems signalling a wrong supply.

In case the voltage exceeds the allowed limits (±15% of the supply voltage value), the
error is signalled by the displaying of two messages:

• LOW MAINS VOLTAGE

• HIGH MAINS VOLTAGE

In case one of these messages is displayed while the test is being carried out, it is
necessary to repeat the test when the machinery supply voltage is regular again.

NOTA BENE:
If the supply voltage should keep being unstable or exceeding the allowed thresholds, it
is suggested to use a mains voltage stabiliser (provided with earthing), suitable for the
specific features that are written on the approval plate which is located on the back side
of the analyser.

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11.0 - CONTROLS

• Select the Advanced properties page, from the CONFIGURATIONS page, to

display CONTROLS.

Inside CONTROLS page it is possible to select:

F1-CALIBRATION
F2-LEAK TEST
F3-RESIDUAL HC
F4- SERIAL NUMBER

11.1 - Features of the sample gases

The values of the sample gases contained in the gas bottle must range between the
following concentrations:

Carbon Monoxide (CO) 0,500% ÷ 15,000%

Carbon Dioxide (CO2) 1,00% ÷ 20,00%
Unburnt Hydrocarbons (HC) 100ppm ÷ 30000ppm
Nitrogen oxide (NO) 100ppm ÷ 5000ppm

The above-mentioned values refer to a gas bottle containing HEXANE.

If a PROPANE gas bottle is used, in order to obtain the corresponding HC value
relating to HEXANE, it is necessary to multiply the HC value referring to PROPANE by
the P.E.F. (Propane/Hexane/Factor).

Example:

Gas bottle with HC value (PROPANE) = 2718ppm

Analyser P.E.F. = 0,539

HC (PROPANE) × P.E.F. = HC (EXANE)

2718 × 0,539 = 1465 HC Value for the gas bottle
data setting

NOTA BENE:
The P.E.F. value for this bench can vary. The bench is highly accurate since it complies
with the BAR 97 California standard and is OIML CLASS 0 type-approved.

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11.2 - Gas bottle connection

The gas bottle must be connected to the coupler (43) which is located in the back side
of the analyser.

NOTA BENE:
It is compulsory to adjust the sample gas flow, by means of a reducer/adjuster, at a
value of 3,5 litres per minute in free air before connecting the pipe to the
connection (43), in order to prevent too a high pressure from damaging the analyser.

11.3 - Calibration

The calibration can only be carried out by the AUTHORIZED TECHNICAL

SERVICE.

The calibration operation becomes necessary after ascertaining (through standard gas)
that the analyser does not carry out correct measurements.

A periodical calibration too (every twelve months) can be necessary if it is requested

by the rules that are now in force.

During the test, bottle sample gases values are controlled. They are necessary for one
corrected calibration.

11.4 - Leak Test

The leak test is necessary to make sure that in the whole analyser suction circuit there
are no air infiltrations, which could alter the gas analysis result.

1st TEST

• Introduce the sampling gas probe extremity (54) set up like gas pick-up system
(see chapter 2.0), in the leak test plug (34) which is located on the analyser back
side.
• Select LEAK TEST function from the CONTROLS page and press F1 to proceed.

The pump is on for 30 seconds, after which the vacuum electronic circuit checks the
tightness of the internal pneumatic system.

In case no leakage is detected, the LEAK TEST CORRECT message is displayed.

OPERATING INSTRUCTIONS 43
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On the contrary, if a leakage is detected, the LEAK TEST NOT CORRECT message is
displayed.

At this point it is possible to carry out a second leak test.

2 st TEST

• Insert directly the leak test plug (34) directly into the gas inlet port (38).

In case no leakage is detected, the LEAK TEST CORRECT message is displayed.

In such a case check the gas sampling device conditions in order to eliminate the
external leakage.

On the contrary, if a leakage is detected, the LEAK TEST NOT CORRECT message is
displayed.

In case even after the second leakage test the LEAK TEST NOT CORRECT message is
displayed, go on according to the following instruction.

3 st TEST

• Carry out the leak test again according to the second test procedure.
• Introduce the second tightness plug in the out water (44) connection when the
pump stops operating.

Only if in this last case too the LEAK TEST NOT CORRECT message is displayed,
make sure that:

• The ring nuts of the condensate trap and of the standard cartridge/filter are
screwed tight
• The tightness gaskets of the filter plugs are fit in their slots and in good conditions.

IF THE DRAWBACK PERSISTS IT IS NECESSARY TO APPLY TO THE

AUTHORIZED TECHNICAL SERVICE.

44 OPERATING INSTRUCTIONS
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11.5 - Residual HC

The RESIDUAL HC test allows to check if in the analyser pneumatic circuit there are
hydrocarbons which could alter the reading.

ATTENTION:
The gas sampling probe must not be introduced in the exhaust pipe.

• Select the RESIDUAL HC function from CONTROLS page.

The HC-TEST IN PROGRESS or RESIDUAL HC-TEST IN PROGRESS message

keeps being displayed throughout the test.

After the AUTOZERO phase, the unburnt hydrocarbons value (HC in ppm) is measured.

If the analyser detects any impurities in the pneumatic circuit, the HC-TEST NOT
CORRECT or RESIDUAL HC-TEST NOT CORRECT message is displayed.

In case of negative result, please refer to the tool’s MAINTENANCE illustrative pages, in
the paragraphs concerning the cleaning operations on the pipe and gas sampling probe
through the replacement of the external filters.

In case no impurities are detected, the HC-TEST CORRECT or RESIDUAL HC-TEST

CORRECT message is displayed.

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12.0 - MAINTENANCE

12.1 - Replacement of the standard cartridge/filter

The white cartridge/filter (15) cannot be cleaned but it must be replaced any time
it looks blackened or when the VACUUM HIGH message is displayed.

12.2 - Cleaning of the condensate separating filter

The condensate separating filter (36) has to be cleaned on average every two
replacements of the standard cartridge/filter (15) or whenever it is obstructed. In order
to clean it wash it with suds, hence rinse and dry it with compressed air. On the
contrary the separating filter has to be replaced if after the cleaning it appears to be
equally deteriorated.

NOTA BENE:
The wire gauze filter is provided with 2 different colour gaskets (blue/black) according
to the different filter sections where they have to be inserted.
When the filter is no longer in good conditions it is necessary to replace it with a new
one provided with new gaskets.

12.3 - Replacement of the actived carbon filter

The actived carbon filter has to be replaced on average every two years.
This operation is easily carried out by extracting it out of the pipe to which it is
connected.

In the cases in which during function ZERO SET it did not aspire perfectly, it is
concurred the use of a small screwdriver in order to free the dirt plug that has been
deposited in the income of the filter.

ATTENTION:
Mount the new filter with the arrow towards the ZERO GAS IN connection.

46 OPERATING INSTRUCTIONS
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12.4 - Replacement of the O2 sensor

When the oxygen sensor (18) is no longer effective it is necessary to replace it

according to the following procedure:

• Disconnect the connector (17);

• Unscrew the sensor in counter clock wise.
• Screw the new sensor clockwise by connecting the connector which had previously
been disconnected.

12.5 - Cleaning of the external transparent precleaner

The external transparent precleaner (52) must be cleaned or even replaced if the
cleaning is no longer enough. To clean the precleaner wash it with suds, hence rinse
and dry with compressed air.

12.6 - Cleaning of the pick-up pipe

The cleaning of the pick-up pipe has to be periodically carried out to clear the pipe from
possible carbon residues or condensate which have deposited inside of it.
Before blowing down in the pick-up pipe disconnect it from the connection.

ATTENTION:
Do not blow compressed air in the analyser.

12.7 - Replacement of the filtering baffle

The filtering baffle (51) allows to the analyser to work in dusty environments
preventing this working condition from causing troubles to the analyser correct
operation in the long term.

One cleaning periodic is advised to be carried out with water and soap. In case that
also after the washing is not succeeded to clean up the filter is necessary to replace it.

In order to replace the filtering baffle carry out the following procedure:

• Remove the filter-holder (13) on the back of the STARGAS BOX, to the inside of
which the filter (51) is positioned.

• Carry out the cleaning or eventually the substitution of the filter.

• Place again the filter to the inside of the filter-holder and subsequently insert the
all in the appropriate lodging making pressure with the hands.

OPERATING INSTRUCTIONS 47
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13.0 - TECHNICAL FEATURES

CONTROL UNIT

Power supply:
Supply options:
Mains 90 ÷ 270V, 50 ÷ 60Hz
Battery 10 ÷ 16 Volt (5 [A] F fuse).
Mains supply voltage (110/220/240 Volt), automatic indication with print out of the
error code for variations > -15% +10%.
Max power 70W.

6-Way miniDIN socket:

For special enablings with electronic key

Serial port:
COM1 - COM2 for connection to the autodiagnosis interface
SMOKEMETER for connection to partial flow smoke cell combined with external
supplier
standard serial port RS232/PC for connection to a PC or to other diagnosis
stations
RS485 standard industrial serial connection

Printer port:
PARALLEL for connection to 80-column standard printer (colour too)
USB for connection to 80-column standard printer

Socket video:
VGA for connection to standard monitor or to a TV color (PAL - NTSC system)

Socket COM:
grounding of the tested vehicle (battery negative pole) for revolution counter
signals from battery, lambda prove and oscilloscope

Tested environment parameters measurement:

automatic measurement of:
ambient temperature -40 ÷ +60°C res. 1
ambient pressure 75.0 ÷ 106.0hPa res. 1
ambient relative humidity 0 ÷ 100% res. 1

48 OPERATING INSTRUCTIONS
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Operation temperature:
+5°C ÷ +40°C

Stocking temperature:
Min. -25 Max. +70°C

Dimensions:
400 × 180 × 450mm

Weight:
8,6kg (approximately)

GAS ANALYSER

Measuring range:
CO 0 ÷ 15,000 % Vol. res. 0,001
CO2 0 ÷ 20,00 % Vol. res. 0,01
HC 0 ÷ 30000 ppm Vol. res. 1
O2 0 ÷ 25,00 % Vol. res. 0,01
NO 0 ÷ 5000 ppm Vol. res. 1 (optional)
Lambda 0,5 ÷ 2,000 [-] res. 0,001

Induction revolution counter:

0 ÷ 10000rpm res. 10 (with battery connection)
0 ÷ 20000rpm res. 10 (with induction clamp)
0 ÷ 15000rpm res. 10 (with antenna system)

Thermometer:
5 ÷ 200°C res. 1

Pressure automatic compensation:

from 750mB to 1060mB

Tested gas suction:

10l/min (approximately)

Flow control:
Internal and automatical

Leak test:
Automatical

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Condensate drainage:
Continual and automatical

Response time:
<10 sec. (Probe length 3m.)

Heating time:
Max. 60 seconds

Zero setting:
Electronic and automatical

Calibration:
Electronic and automatical (only with the gas bottle the analyser is equipped)

Socket λ:
socket allowing:
Lambda probes analysis (1 Volt/5 Volt) with performance automatic calculation
Simulation to evaluate the correct operation of the control unit wiring

50 OPERATING INSTRUCTIONS
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14.0 - SPARE PARTS

18. O2 sensor 3105008

42. Actived Carbon Filter 5123016
45. Lighter socket RPM cable (option) 2303159
46. Lighter supplying cable (option) 2303151
47. NO sensor (option) 3105043
48. Sampling Gas Pipes SL11001
VITON Sampling Gas Pipes (optional) SL11001/V
49. ZENIT hose for stream drain 1103004
50. Spare filters kit SL51043
c. Nylon Wire Gauze Filter SL51044
d. N. 2 Standard cartridge/filter 5123012
51. N. 2 Filters for fan 5119031
52. N. 2 Transparent external filters 5123008
53. Group filter
e. Group filter bowl 0115315
f. O-ring 1107065
g. O-ring 1107066
h. Condensate separating filter support 5117450
54. Sampling probe SL51003
55. Undercable detecting clamp 3119064
56. Test prod connecting cable SL21771
57. Shunt cable SL21409
58. Lambda probe extension cable 2303153
59. Battery supply cable 2303152
60. Ground cable 2303155
5m ground cable (option) 2303155/5
61. Temperature Probe SL51080
62. Battery RPM cable 2303154
5m battery RPM cable (option) 2303154/5
63. Mains cable 3119066
64. Induction clamp (option) SL06033

OPERATING INSTRUCTIONS 51
 STARGAS BOX ___________________________________________________________________________

65. STARGAS-2033 adapter cable (option) 2303189

66. RPM/SUPPLY/ECUreader shunt electric lighter cable (option) 2303171

67. STARGAS aluminium case (option) 4101036

68. RPM Counter adapter (optional) 2035

69. 0,6m flexible antenna (optional) SL51117

70. Revolving antenna (optional) SL51116

71. 4m STARGAS/PC serial connection cable 2303240

12m STARGAS/PC serial connection cable (optional) 2303240/12

72. STARGAS/PC USB connection cable (optional) 2303280

73. Antenna support clamp (option) SL31362

14.1 - Lambda cables list - option

The optional cables are equipped with wiring for the 12V supply voltage and Lambda
probe heating resistance control.
To carry out these two measures (Volt-Ohm) use any multimeter.

1. Probe Test Cable VOLKSWAGEN - SEAT SL21552

2. Probe Test Cable MERCEDES (3 PINS) SL21553

3. Probe Test Cable MERCEDES (4 PINS) SL21554

4. Probe Test Cable BMW SL21555

5. Probe Test Cable HONDA (1 PIN) SL21579

6. Probe Test Cable SAAB - VOLVO (3/4 PINS) SL21560

7. Probe Test Cable HONDA (4 PINS) SL21580

8. Probe Test Cable SUZUKI SL21570

9. Probe Test Cable NISSAN SL21586

10. Probe Test Cable OPEL - RENAULT SL21556

52 OPERATING INSTRUCTIONS