EPA-460/3-77-OI4
July 1977
VEHICLE EXHAUST EMISSION
INSTRUMENTS EVALUATION
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Mobile Source Air Pollution Control
Emission Control Technology Division
Ann Arbor, Michigan 48105
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EPA-460/3-77-014
VEHICLE EXHAUST EMISSION
INSTRUMENTS EVALUATION
by
Steve N. Schlingmann
Olson Laboratories, Inc.
421 East Cerritos Ave.
Anaheim, California 92805
Contract No. 68-03-2353
EPA Project Officer: D. Harold Davis
Prepared for
ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Mobile Source Air Pollution Control
Emission Control Technology Division
Ann Arbor, Michigan 48105
July 1977
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This report is issued by the Environmental Protection Agency to report
technical data of interest to a limited number of readers. Copies are
available free of charge to Federal employees, current contractors and
grantees, and nonprofit organizations - in limited quantities - from the
Library Services Office (MD-35), Research Triangle Park, North Carolina
27711; or, for a fee, from the National Technical Information Service,
5285 Port Royal Road, Springfield, Virginia 22161.
This report was furnished to the Environmental Protection Agency
by Olson Laboratories, Inc., 421 East Cerritos Ave. , Anaheim,
California, in fulfillment of Contract No. 68-03-2353. The contents
of this report are reproduced herein as received from Olson
Laboratories. The opinions, findings, and conclusions expressed
are those of the author and not necessarily those of the Environmental
Protection Agency. Mention of company or product names is not
to be considered as an endorsement by the Environmental Protection
Agency.
Publication No. EPA-460/3-77-014
ii
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FOREWORD
Periodic motor vehicle exhaust emissions inspection and maintenance has
shown itself to be an effective tool to minimize the contribution of vehicle
exhaust emission to total air pollution.
Proper engine tune-up and operation is vitally important in the fight
against air pollution. In addition to tune-up, vehicle inspection and excessive
exhaust emission detection are necessary for a continuing program of emission
control.
Individual vehicle owners have a responsibility to maintain their vehicles
in optimum condition to minimize emissions. Government agencies have recently
become involved in vehicle maintenance through the initiation of periodic
vehicle emission inspection requirements carried out at state or local levels.
The key element in all vehicle engine maintenance, inspection and emission
detection is the exhaust emission analyzer. Exhaust emission analyzers are
presently available in many different designs, offering various detection
capabilities over a broad price range. The objective of this study is to
survey the market and identify all exhaust emission analyzer manufacturers
whose product could be used in vehicle inspection/maintenance (I/M) programs.
A representative group of instruments was selected and a series of tests were
conducted to evaluate instrument performance.
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ABSTRACT
Government agencies have become involved in vehicle maintenance
through the initiation of periodic vehicle emission inspection requirements
carried out at State or local levels. The key element in all vehicle engine
maintenance inspection and emission detection is the exhaust emission analyzer.
Exhaust emission analyzers are presently available in many different designs,
covering a broad price range and offering various capabilities and features.
The objective of this study was to survey the market and identify all exhaust
emission analyzer manufacturers, whose product could be used in vehicle
inspection/maintenance (I/M) programs. Consequently, a representative group
of instruments was selected and a series of tests were conducted to evaluate
instrument performance.
Major findings of this program:
1. A significant number of HC/CO I/M emission analyzers are presently
available.
2. The vast majority of HC/CO instruments use an infrared absorption
operating principle.
3. The hydrocarbon response characteristics of the HC/CO instruments
generally showed greatest sensitivity to isobutylene, followed by
toluene, methane, and ethylene. The units demonstrate essentially
no sensitivity to acetylene and benzene.
iv
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CONTENTS
Foreword ill
Abstract iv
Figures vii
Tables ix
1 INTRODUCTION 1-1
1.1 Major Findings 1-2
1.2 State of the Art 1-3
2 INSTRUMENT SURVEY, SELECTION, AND PROCUREMENT 2-1
2.1 Information Sources 2-1
2.2 Selection Criteria 2-9
2.3 Survey Results 2-9
2.4 Selected Instruments 2-18
3 LABORATORY TESTS 3-1
3.1 Instrument Warm Up 3-3
3.2 Instrument Calibration 3-3
3.3 Instrument Zero Drift 3-3
3.4 Instrument Gas Interference 3-5
3.5 Instrument Accuracy Determination 3-5
3.6 Response and Recovery 3-5
3.7 Voltage Variation 3-6
3.8 Hydrocarbon Response 3-6
3.9 Repeatability Tests 3-6
3.10 Facilities 3-7
4 VEHICLE TESTS 4-1
4.1 Instrument Warm Up 4-1
4.2 Instrument Calibration 4-1
4.3 Loaded Steady-State 4-1
4.4 Lean Loaded Steady-State 4-1
4.5 Calibration Check 4-4
4.6 Instrument Hang-Up 4-4
4.7 Rich Loaded Steady-State 4-4
4.8 Instrument Recalibration 4-4
4.9 Diagnostic Emission Measurements 4-4
4.10 EPA Analysis Bench and Calibration Gases 4-5
4.11 EPA Instrument Calibration 4-5
5 DURABILITY TESTS 5-1
5.1 Scope 5-1
5.2 Service 5-1
5.3 Instrument Failure 5-1
5.4 Vibration and Shock Tests ' 5-4
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CONTENTS (CONT'D)
5.5 Data 5-6
5.6 Exposure Rating 5-6
5.7 Service Data 5-6
5.8 Durability Span Drift 5-6
6 GENERALIZED DATA PRESENTATION AND RATINGS 6-1
6.1 Observed Performance Data 6-1
6.2 Objective Ratings 6-1
7 INDIVIDUAL INSTRUMENT REPORTS 7-1
7.1 Horiba Mexa 300A Infrared Exhaust Analyzer. . 7-1
7.2 Barnes 8335C Emission Analyzer 7-17
7.3 Scott IIIC Exhaust Emission Analyzer 7-34
7.4 Marquette 42-160 Infrared Emissions Analyzer 7-51
7.5 Beckman 590 HC/CO Tester. 7-67
7.6 Stewart Warner 3161 Infrared Gas Analyzer 7-83
7.7 Sun EPA 75 Exhaust Performance Analyzer 7-100
7.8 Mopar IIIC Exhaust Emission Analyzer 7-116
7.9 Sears 713.21022 HC-CO Analyzer 7-133
7.10 Kal Equip 4094-D Infrared Emissions Analyzer. 7-148
7.11 Pulsar 662 Infrared Analyzer 7-164
7.12 Autoscan 710C HC/CO Analyzer 7-180
7.13 Allen 23-160 CA CO/CH Infrared Exhaust Emission Analyzer. . 7-196
7.14 Autosense 200 Engine Diagnostic and Exhaust Emission
Analyzer 7-213
7.15 Horiba Mexa 240 Infrared Analyzer 7-231
7.16 Thermo Electron 8A NO Analyzer 7-247
7.17 IBC N322 W/SC-400 Nitrogen Oxide Analyzer 7-262
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FIGURES
Number Page
3-1 Laboratory Test Sequence 3-2
3-2 Sample Warm-up Time Plot 3-4
3-3 Repeatability Test 3-8
3-4 Environmental Chamber 3-9
3-5 Environmental Chamber with Calibration Gases 3-10
3-6 Environmental Chamber, Interior 3-11
3-7 Instruments Inside Environmental Chamber 3-12
3-8 Olson Laboratories, Inc., High Altitude Test Facility -
Big Bear Lake, California 3-13
4-1 Vehicle Test Sequence 4-2
4-2 EPA Analytical System 4-6
4-3 Vehicle Test Setup 4-7
4-4 Common Sampling Manifold 4-8
5-1 Durability Test Setup 5-2
5-2 Vehicle Test in Progress 5-3
5-3 Vibration Test Platform 5-5
7-1 Horiba Mexa 300A Infrared Exhaust Analyzer 7-14
7-2 Horiba Mexa 300A Infrared Exhaust Analyzer (Back) 7-15
7-3 Horiba Mexa 300A Infrared Exhaust Analyzer (Left Side). . . 7-16
7-4 Barnes 8335C Emission Analyzer 7-30
7-5 Barnes 8335C Emission Analyzer (Back) 7-31
7-6 Barnes 8335C Emission Analyzer (Left Side) 7-32
7-7 Barnes 8335C Emission Analyzer (Right Side and Probe) . . . 7-33
7-8 Scott IIIC Exhaust Emission Analyzer 7-48
7-9 Scott IIIC Exhaust Emission Analyzer (Back) 7-49
7-10 Scott IIIC Exhaust Emission Analyzer (Left Side and
Probe) 7-50
7-11 Marquette 42-160 Infrared Emissions Analyzer 7-64
7-12 Marquette 42-160 Infrared Emissions Analyzer (Left Side). . 7-65
7-13 Marquette 42-160 Infrared Emissions Analyzer (Back) .... 7-66
7-14 Beckman 590 HC/CO Tester 7-80
7-15 Beckman 590 HC/CO Tester (Back) 7-81
7-16 Beckman 590 HC/CO Tester (Left Side) 7-82
7-17 Stewart Warner 3161 Infrared Gas Analyzer 7-97
7-18 Stewart Warner 3161 Infrared Gas Analyzer (Back) 7-98
7-19 Stewart Warner 3161 Infrared Gas Analyzer (Right Side). . . 7-99
7-20 Sun EPA 75 Exhaust Performance Analyzer 7-113
7-21 Sun EPA 75 Exhaust Performance Analyzer (Back) 7-114
7-22 Sun EPA 75 Exhaust Performance Analyzer (Right Side and
Probe) 7-115
7-23 Mopar IIIC Exhaust Emission Analyzer 7-130
7-24 Mopar IIIC Exhaust Emission Analyzer (Back) 7-131
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FIGURES (CONT'D)
Number Page
7-25 Mopar IIIC Exhaust Emission Analyzer (Left Side and
Probe) 7-132
7-26 Sears 713.21022 HC-CO Analyzer 7-145
7-27 Sears 713.21022 HC-CO Analyzer (Back and Probe) 7-146
7-28 Sears 713-21022 HC-CO Analyzer (Right Side and Probe) . . . 7-147
7-29 Kal Equip 4094-D Infrared Emissions Analyzer. . . 7-161
7-30 Kal Equip 4094-D Infrared Emissions Analyzer (Back and
Probe) 7-162
7-31 Kal Equip 4094-D Infrared Emissions Analyzer (Left Side). . 7-163
7-32 Pulsar 662 Infrared Analyzer 7-177
7-33 Pulsar 662 Infrared Analyzer (Back) 7-178
7-34 Pulsar 662 Infrared Analyzer (Left Side and Probe) 7-179
7-35 Autoscan 710C HC/CO Analyzer 7-193
7-36 Autoscan 710C HC/CO Analyzer (Back) 7-194
7-37 Autoscan 710C HC/CO Analyzer (Right Side, Probe, and
Span Gas Container) 7-195
7-38 Allen 23-160 CA CO/HC Infrared Exhaust Emission Analyzer. . 7-209
7-39 Allen 23-160 CA CO/HC Infrared Exhaust Emission Analyzer
(Back) 7-210
7-40 Allen 23-160 CA CO/HC Infrared Exhaust Emission Analyzer
(Right Side) 7-211
7-41 Allen 23-160 CA CO/HC Infrared Exhaust Emission Analyzer
(Probe) 7-212
7-42 Autosense 200 Engine Diagnostic and Exhaust Emission
Analyzer (Front) 7-227
7-43 Autosense 200 Engine Diagnostic and Exhaust Emission
Analyzer (Back) 7-228
7-44 Autosense 200 Engine Diagnostic and Exhaust Emission
Analyzer (Right Side) 7-229
7-45 Autosense 200 Engine Diagnostic and Exhaust Emission
Analyzer (Control Unit) . 7-230
7-46 Horiba Mexa 240 Infrared Analyzer 7-244
7-47 Horiba Mexa 240 Infrared Analyzer (Back) 7-245
7-48 Horiba Mexa 240 Infrared Analyzer (Left Side and Probe) . . 7-246
7-49 Thermo Electron 8A NO Analyzer 7-259
7-50 Thermo Electron 8A NO Analyzer (Back) 7-260
7-51 Thermo Electron 8A NO Analyzer (Right Side and Probe) . . . 7-261
7-52 IBC N322 W/SC-400 Nitrogen Oxide Analyzer 7-275
7-53 IBC N322 W/SC-400 Nitrogen Oxide Analyzer (Back). ..... 7-276
7-54 IBC N322 W/SC-400 Nitrogen Oxide Analyzer (Left Side) . . . 7-277
7-55 IBC N322 W/SC-400 Nitrogen Oxide Analyzer - Sampler
Control Module 7-278
7-56 IBC N322 W/SC-400 Nitrogen Oxide Analyzer - Sampler
Control Module (Back and Probe) 7-279
7-57 IBC N322 W/SC-400 Nitrogen Oxide Analyzer - Sampler
Control Module (Right Side and Probe) . 7-280
viii
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TABLES
Number
2-1 List of State and Local Government Agencies . 2-3
2-2 List of Prospective Manufacturers, Assemblers or
Distributors 2-6
2-3 Prospective Instruments with Manufacturer Cross Index . . . 2-10
2-4 Advertised Performance Specifications 2-16
4-1 Loaded Steady-State Horsepower Values for Loaded
Vehicle Test 4-3
6-1 Observed Performance Data Table 6-2
6-2 Warmup Time: (Temperature and Humidity - Quickest
Warmup Time to Slowest) 6-3
6-3 Zero Drift (Temperature and Humidity) 6-4
6-4 Accuracy Determination (Temperature and Humidity) - (Most
Accurate to Least Accurate) - Overall Accuracy Rating . . 6-5
6-5 Accuracy Determination (Temperature and Humidity) - (Most
Accurate to Least Accurate) - High Range NO 6-6
6-6 Accuracy Determination - High Altitude 6-7
6-7 Response and Recovery (Temperature and Humidity Cycles) -
(Quickest to Slowest) 6-8
6-8 Gas Interference Laboratory Tests (Least Response to
Most Response) 6-9
6-9 Voltage Profile (Least Influenced to Most Influenced) . . . 6-10
6-10 Vehicle Tests Accuracy (Most Accurate to Least Accurate)
(Overall Accuracy Rating) 6-11
6-11 Vehicle Tests Accuracy (Most Accurate to Least Accurate)
(Standard Mode) 6-12
6-12 Diagnostic Vehicle Tests (Most Accurate to Least
Accurate) - (HC and CO) 6-13
6-13 Diagnostic Vehicle Tests (Most Accurate to Least
Accurate) - (NO) 6-14
6-14 Durability Tests 6-15
6-15 Instrument Service Requirements 6-16
6-16 Durability Tests (Life, Span Drift, Service and Shock
Failure Parameters) 6-17
7-1 Horiba Mexa 300A Data Composite - Laboratory Test 7-5
7-2 Horiba Mexa 300A Data Composite - Repeatability Test. . . . 7-8
7-3 Horiba Mexa 300A Vehicle Test Accuracy Determination -
Exhaust Gas 7-10
7-4 Horiba Mexa 300A Diagnostic Test 7-12
7-5 Horiba Mexa 300A Durability Test Data 7-13
7-6 Barnes 8335C Data Composite - Laboratory Test 7-21
7-7 Barnes 8335C Data Composite - Repeatability Test 7-24
7-8 Barnes 8335C Vehicle Test Accuracy Determination -
Exhaust Gas 7-26
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TABLES (CONT'D)
Number Page
7-9 Barnes 8335C Diagnostic Test 7-28
7-10 Barnes 8335C Durability Test Data 7-29
7-11 Scott IIIC Data Composite - Laboratory Test 7-39
7-12 Scott IIIC Data Composite - Repeatability Test 7-42
7-13 Scott IIIC Vehicle Test Accuracy Determination -
Exhaust Gas 7-44
7-14 Scott IIIC Diagnostic Test 7-46
7-15 Scott IIIC Durability Test Data 7-47
7-16 Marquette 42-160 Data Composite - Laboratory Test 7-55
7-17 Marquette 42-160 Data Composite - Repeatability Test. . . . 7-58
7-18 Marquette 42-160 Vehicle Test Accuracy Determination -
Exhaust Gas 7-60
7-19 Marquette 42-160 Diagnostic Test 7-62
7-20 Marquette 42-160 Durability Test Data 7-63
7-21 Beckman 590 Data Composite - Laboratory Test 7-71
7-22 Beckman 590 Data Composite - Repeatability Test 7-74
7-23 Beckman 590 Vehicle Test Accuracy Determination -
Exhaust Gas . 7-76
7-24 Beckman 590 Diagnostic Test 7-78
7-25 Beckman 590 Durability Test Data 7-79
7-26 Stewart Warner 3161 Data Composite - Laboratory Test. . . . 7-88
7-27 Stewart Warner 3161 Data Composite - Repeatability Test . . 7-91
7-28 Stewart Warner 3161 Vehicle Test Accuracy Determination -
Exhaust Gas 7-93
7-29 Stewart Warner 3161 Diagnostic Test 7-95
7-30 Stewart Warner 3161 Durability Test Data 7-96
7-31 Sun EPA 75 Data Composite - Laboratory Test 7-104
7-32 Sun EPA 75 Data Composite - Repeatability Test 7-107
7-33 Sun EPA 75 Vehicle Test Accuracy Determination -
Exhaust Gas 7-109
7-34 Sun EPA 75 Diagnostic Test 7-111
7-35 Sun EPA 75 Durability Test Data 7-112
7-36 Mopar IIIC Data Composite - Laboratory Test 7-121
7-37 Mopar IIIC Data Composite - Repeatability Test 7-124
7-38 Mopar IIIC Vehicle Test Accuracy Determination -
Exhaust Gas 7-126
7-39 Mopar IIIC Diagnostic Test 7-128
7-40 Mopar IIIC Durability Test Data 7-129
7-41 Sears 713.21022 Data Composite - Laboratory Test 7-136
7-42 Sears 713.21022 Data Composite - Repeatability Test .... 7-139
7-43 Sears 713.21022 Vehicle Test Accuracy Determination -
Exhaust Gas 7-141
7-44 Sears 713.21022 Diagnostic Test 7-143
7-45 Sears 713.21022 Durability Test Data 7-144
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TABLES (CONT'D)
Number Page
7-46 Kal Equip 4094-D Data Composite - Laboratory Test 7-152
7-47 Kal Equip 4094-D Data Composite - Repeatability Test. . . . 7-155
7-48 Kal Equip 4094-D Vehicle Test Accuracy Determination -
Exhaust Gas 7-157
7-49 Kal Equip 4094-D Diagnostic Test 7-159
7-50 Kal Equip 4094-D Durability Test Data 7-160
7-51 Pulsar 662 Data Composite - Laboratory Test 7-168
7-52 Pulsar 662 Data Composite - Repeatability Test 7-171
7-53 Pulsar 662 Vehicle Test Accuracy Determination -
Exhaust Gas 7-173
7-54 Pulsar 662 Diagnostic Test 7-175
7-55 Pulsar 662 Durability Test Data 7-176
7-56 Autoscan 710C Data Composite - Laboratory Test 7-184
7-57 Autoscan 710C Data Composite - Repeatability Test 7-187
7-58 Autoscan 7IOC Vehicle Test Accuracy Determination -
Exhaust Gas 7-189
7-59 Autoscan 710C Diagnostic Test 7-191
7-60 Autoscan 710C Durability Test Data 7-192
7-61 Allen 23-160CA Data Composite - Laboratory Test 7-200
7-62 Allen 23-160CA Data Composite - Repeatability Test 7-203
7-63 Allen 23-160CA Vehicle Test Accuracy Determination -
Exhaust Gas 7-205
7-64 Allen 23-160CA Diagnostic Test 7-207
7-65 Allen 23-160CA Durability Test Data 7-208
7-66 Autosense 200 Data Composite - Laboratory Test 7-218
7-67 Autosense 200 Data Composite - Repeatability Test 7-221
7-68 Autosense 200 Vehicle Test Accuracy Determination -
Exhaust Gas 7-223
7-69 Autosense 200 Diagnostic Test 7-225
7-70 Autosense 200 Durability Test Data 7-226
7-71 Horiba Mexa 240 Data Composite - Laboratory Test 7-235
7-72 Horiba Mexa 240 Data Composite - Repeatability Test .... 7-238
7-73 Horiba Mexa 240 Vehicle Test Accuracy Determination -
Exhaust Gas 7-240
7-74 Horiba Mexa 240 Diagnostic Test 7-242
7-75 Horiba Mexa 240 Durability Test Data 7-243
7-76 Thermo Electron 8A Data Composite - Laboratory Test .... 7-250
7-77 Thermo Electron 8A Data Composite - Repeatability Test. . . 7-253
7-78 Thermo Electron 8A Vehicle Test Accuracy Determination -
Exhaust Gas 7-255
7-79 Thermo Electron 8A Diagnostic Test 7-257
7-80 Thermo Electron 8A Durability Test Data 7-258
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TABLES (CONT'D)
Number Page
7-81 IBC N322 W/SC-400 Data Composite - Laboratory Test 7-266
7-82 IBC N322 W/SC-400 Data Composite - Repeatability Test . . . 7-269
7-83 IBC N322 W/SC-400 Vehicle Test Accuracy Determination -
Exhaust Gas 7-271
7-84 IBC N322 W/SC-400 Diagnostic Test 7-273
7-85 IBC N322 W/SC-400 Durability Test Data 7-274
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Section 1
INTRODUCTION
This report documents the results of the Inspection of Vehicle Exhaust
Emission Instruments Evaluation, EPA Contract 68-03-2353. This contract
consisted of a survey of all available inspection/maintenance (I/M) type
exhaust emission instruments and an assessment and selection for testing of
approximately 20 instruments. Laboratory tests, vehicle exhaust gas response
tests and instrument durability tests were conducted for each instrument. The
final phase of the contract consisted of reports relating to work accomplished,
comparative ratings of the instruments and recommendations/comments.
The purpose of this project was to assemble and collect information
pertaining to availability, function, operation, performance, appearance,
quality and relative test rating of I/M exhaust gas analyzers.
The scope of this project included a survey of all available I/M exhaust
gas analyzers. The survey was used to develop a list of instruments to be
procured for test evaluation. Following procurement of the instruments, a
specified sequence of laboratory, vehicle and durability tests were conducted
on each instrument. Relative performance ratings were determined based upon
test results.
The survey that was conducted identified essentially all vehicle exhaust
emission instruments from established instrument manufacturers that would be
eligible for use in an I/M program. A table was constructed listing the
instruments by application (HC, CO, NO ), manufacturer, model, operating
principle, range, specification (claimed or established, cost and availability.
The final selection of instruments for procurement and testing was made in
accordance with those instruments rated highest on the table and with additional
requirements as delineated in the contract.
The final selection of instruments consisted of 17 units, three of which
were NO analyzers.
Omissions of a specific instrument from this study does not, by itself,
imply rejection of that instrument.
The scope of activities in this program is similar in some respects to
ongoing or newly created I/M exhaust analyzer programs in various state and
local government agencies. These programs range from simple review of manu-
facturing literature to complete operational checkout performed either by
state government laboratories or by outside contractors. At present, California,
New Jersey, Colorado, Arizona, and Nevada are active in I/M instrument review,
with New York State and Rhode Island having programs in the planning stages.
New York City also conducts an I/M instrument review.
1-1
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Most state and local government Instrument review programs require instru-
ment manufacturer participation prior to sale for use in I/M programs in the
respective state or locality.
All testing performed under this contract was carried out at the Anaheim,
California facilities of Olson Laboratories, Inc., between June of 1976 and
January of 1977, except for the high altitude test sequences. The high altitude
test sequences were performed at Olson Laboratories' High Altitude Test Lab-
oratory located in the City of Big Bear Lake, California, at an altitude of
6,750 feet.
1.1 MAJOR FINDINGS
The major findings of this program presented in generalized terms are as
follows:
o A significant number of HC/CO I/M emission analyzers are presently
available.
o Many different brands of instruments use common analytical benches
with cosmetic changes for marketing purposes.
o Many HC/CO instruments include or are included in electronic engine
diagnostic analyzers.
o The vast majority of HC/CO instruments are of an infrared absorption
operating principle.
o General instrument designs have obviously been structured and influ-
enced by state and local review agencies.
o Only two instruments with display/printout are available and both
incorporate electronic diagnostic capability.
o Display and control design varies greatly and the ease of operation
and use is different and correlates with design.
o There are very few NO instruments presently available for I/M use.
2x
o Limited availability of NO instruments is probably due to very
limited market demand.
o The majority of HC/CO instruments in this survey were adequate for
I/M use.
o Most HC/CO instruments showed limited ability to handle the high
volume of moisture, particulates, and heat encountered in loaded
steady-state tests.
o In general, all I/M instruments tested met their respective advertised
specifications.
1-2
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In general, all instruments were very insensitive to a +10 percent
change in input voltage. The maximum sensitivity observed on any
instrument was 1 percent full scale.
The hydrocarbon response characteristics of the HC/CO instruments
generally showed greatest sensitivity to isobutylene followed by
toluene, methane and ethylene. The units demonstrate essentially no
sensitivity to acetylene and benzene.
Instrument performance in actual vehicle testing showed that most
instruments were capable of delivering acceptable exhaust concentra-
tion values in idle and loaded steady-state testing.
Exhaust concentration variation during idle and loaded steady-state
tests requires response time correlation when comparing the indica-
tions on two or more instruments. Instrument response time variation,
noted in early response time tests, caused real-time sample correla-
tion problems under dynamic vehicle exhaust conditions.
Prolonged loaded steady-state testing caused early filter degradation
on some instruments. Water accumulation in some lines occurred
during these tests. The water accumulation indicated, in general,
that if an instrument is to be used for a significant time in loaded
steady-state or high rpm testing, an auxiliary sample conditioning
or water removal system should be utilized to achieve maximum
instrument performance.
Instrument durability in sampling service, demonstrated in the
durability tests, ranged from early failure to completion of approx-
imately 1,000 hours of exposure to exhaust gases. Long-term use
under exhaust conditions generally resulted in repetitive filter
replacement, sample system degradation and blockage, water accumula-
tion and analyzer degradation resulting in loss of response, increased
response times, increasing drift and instability. Analyzer and
sample system designs were most accurately characterized by perfor-
mance observation during durability tests.
1.2 STATE OF THE ART
The instruments selected for this study represent the current state of
the art in I/M emission analyzers. Typically, they provide adequate levels of
repeatability in measuring exhaust gas emissions.
General analyzer cabinet design is sturdy and able to properly protect
the analyzer package from typical environmental effects encountered in a
garage environment. Ease of operation, calibration and mobility are directly
related to cabinet design and control/meter layout. Several instruments
exhibited design deficiencies that resulted in increased user effort and time-
consuming delays in use and/or calibration.
Instrument mobility is greatly influenced by human factors engineering.
The correct placement of handles and wheels with relation to human body size
was apparent in many instruments but an apparent lack of regard to mobility
1-3
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was noted in some units. Wheel sizes ranged between 3 inches and 8 inches,
arranged in two- or four-wheel combinations. During movement, the instrument/
cart center of gravity (C.G.) plays an important role in the "feel of stability"
or ease of mobility of each instrument.
Portable instruments were generally small and light enough to be used in
a mobile mode of operation. HC/CO analyzer accuracy, using precision calibra-
tion gases and also when simultaneously sampling exhaust in parallel with an
EPA-type analyzer bench is, in general, better than +3 percent of full scale.
This value is consistent with most state requirements for HC/CO analyzers.
NO instruments tend to be more accurate than HC/CO instruments while analyzing
precision gases. Their accuracy is on the order of ^1 percent of full scale.
When sampling automotive exhaust, NO instruments tend to be much more sensitive
to moisture contamination and this tends to degrade operational accuracy.
The operation of some HC/CO analyzers can be severely impaired by exposure
to high temperature environments. In many cases, span and/or zero adjustment
at high temperatures is insufficient for correct calibration. Typical failures
appear to be a result of electronic malfunction due to overheating. Most
instruments exhibiting malfunctions at high temperatures will recover to
normal when operated again at room temperature. Low temperature operation
tends to cause the same type of problem but the incidence is much lower.
Humidity variation affects the output of most HC/CO instruments. Varia-
tions of +10 percent RH can cause a significant change in output level.
Operation at high altitude cause malfunctions on some instruments resulting in
symptoms similar to malfunctions at high temperatures. The principle detri-
mental operational effect of high altitude is insufficient zero/span adjustment
to achieve correct calibration. Altitude compensation has apparently not been
successfully implemented by all manufacturers.
The interference effects of various noninterest gases can be quite signif-
icant at specific temperatures, and carbon monoxide are the most dominant
interference gases. Some analyzers exhibit cross-sensitivity between their HC
and CO channels.
In general, most instruments showed response times of up to 30 seconds
under extreme temperature and humidity conditions.
In some cases, the response time was a function of the specific design or
sampling operation of the instrument. The general trend in response time
indicated a range from slightly less than 10 seconds to approximately 30 seconds
for 100 percent final reading.
Instrument zero drift at normal operating temperatures for a period of
4 hours, in many cases, can exceed +3 percent of full scale. Temperature
extremes generally serve further to degrade zero drift performance.
Instrument warm up times at normal room temperature were generally less
than 30 minutes. Most state specifications require 30-minute warm up times
for all temperature and humidity conditions. Both high and low temperature
tests indicated longer warm up times than those at 70 F for most instruments.
Temperature-related drift at the extremes may account for the apparent increased
warm up times by masking the warm up performance with meter drift.
1-4
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Section 2
INSTRUMENT SURVEY, SELECTION, AND PROCUREMENT
This program was initiated by conducting a general survey to identify all
manufacturers, assemblers or distributors of vehicle exhaust emission instru-
ments that would be eligible for use in an I/M vehicle test program. I/M
vehicle test programs typically utilize "garage-type" HC/CO or NO instrumenta-
tion, or second generation instruments based upon "garage-type" units.
"Garage-type" instruments have achieved their own identity in the marketplace
and, because of expansion and refinement of this type of product, they can
easily be distinguished from so called "laboratory-type" instruments.
"Laboratory-type" instruments are usually not well suited for usage in a
harsh environment. External and/or additional sample handling and conditioning
systems are usually required when using "laboratory-type" instruments. "Garage-
type" instruments usually incorporate all necessary sample handling and condi-
tioning equipment.
In general, "laboratory-type" instruments demonstrate accuracies in the
range of +1 percent full scale. The requirements of inspection and maintenance
of automobiles do not necessitate such a high degree of accuracy. Typical
"garage-type" instruments demonstrate accuracies in the range of +3 percent
full scale.
The survey concerned itself only with established instrument manufacturers.
It specifically excluded those manufacturers who only had prototype equipment
available at the time of the survey. A specific requirement of the instrument
survey was that the instruments identified must be readily available to the
general public at the time of the survey.
Out of the 113 manufacturers contacted, 21 were found to have instruments
available and applicable to this program. Combined, these 21 manufacturers
produced 129 distinct HC/CO or NO I/M instruments.
2.1 INFORMATION SOURCES
The survey was structured as a literature search, followed by a general
mailing and telephone survey.
The literature search utilized all available periodicals, trade journals
and professional papers. The most productive sources for instrument manufac-
turers names were:
Automotive Engineering Magazine, May 1974 Issue.
(Special Issue on Instrumentation)
2-1
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Instrumentation for Environmental Monitoring, Environmental Instrumentation
Group, Lawrence Berkeley Laboratory, University of California, Berkeley,
California, Volume I
Pollution Equipment News, Rimbach Publishing Company, 8550 Babcock Boulevard,
Pittsburgh, Pennsylvania 15237. Various Volumes
Instruments and Control Systems, Chilton Company, Chilton Way, Radnor,
Pennsylvania 19089. Various Volumes
Industrial Research, Dun Donnelley, 666 Fifth Avenue, New York, New York
10019. Various Issues
Pollution Engineering, Technical Publishing Company, 35 Mason Street, Greenwich,
Connecticut 06830 . Various Issues
Motor, The Hearst Corporation, 1790 Broadway, New York, New York 10019.
Various Issues
International Automotive Industries, Chilton Company, Chilton Way, Radnor,
Pennsylvania 19089. Various Issues
Mandatory Vehicles Emission Inspection and Maintenance, Volume III, Prepared
under Contract ARB1522 with State of California Air Resources Board by Northrop
Corporation in association with Olson Laboratories, Inc., May 31, 1971
Environmental Science and Technology, American Chemical Society, 20th and
Northampton Streets, Easton, Pennsylvania 18042. Various Issues
Thomas Register, Thomas Publishing Company, 461 Eight Avenue, New York, New
York 10001
Instrument Accreditation Data Files, Olson Laboratories, Inc.
To supplement the literature search, appropriate state and local govern-
ment agencies were identified and included in a general mail survey requesting
manufacturers names known to them. The sources for state and local government
agencies were:
Where to Find State Plans to Clean the Air. U.S. Environmental Protection
Agency, Washington, D.C. 20460
Governmental Air Pollution Agencies. 1973-1974 Directory, Published by the Air
Pollution Control Association, 4400 Fifth Avenue, Pittsburgh, Pennsylvania
15213
Table 2-1 lists all state and local government agencies on the mailing
list.
Out of 58 letters sent to various agencies, ten replies were received.
The results of the literature search and the agency mailing was compiled
to produce a list of prospective manufacturers (Table 2-2). A general mailing
was initiated based upon the prospective manufacturer's list. After a
2-2
-------
Table 2-1.
LIST OF STATE AND LOCAL GOVERNMENT AGENCIES
Alabama Department of Health
State of Alaska, Department of
Environmental Conservation
Division of Air Pollution Control
Arizona
Arkansas Department of Pollution
Control and Ecology
Air Resources Board, California
Bay Area Air Pollution Control,
District, San Francisco
Los AngeUs County Air Pollution
Di strict
Riverside County Air Pollution
Control District
San Bernardino County Air
Pollution Control District
Air Pollution Control Division
Colorado Department of Health
San Diego County Air Pollution
Control District
Air Compliance Section
Dept. of Environmental
Protection, Connecticut
Delaware Department of Natural
Resources & Environmental Control
District of Columbia Dept. of
Environmental Services
Department of Pollution Control,
Florida
Environmental Protection Div.
Dept. of Natural Resources,
Georgia
Air Sanitation Branch Division
of Environmental Health, Hawaii
Department of Environmental &
Community Services, Idaho
Environmental Protection Agency,
IIlinoi s
City of Chicago Dept. of
Environmental Control
Indiana State Board of Health
Air Quality Management Div.
Iowa Dept. of Environmental
Quality
Kansas State Dept. of Health
Division of Air Pollution
Kentucky Dept. for Natural
Resources & Environmental
Protection
Air Control Section, Bureau of
Environmental Health Louisiana
Health & Social Rehabilitation
Department of Environmental
Protection, Bureau of Air
Pollution Control, State House,
Maine
Bureau of Air Quality Control
Maryland State Department of
Health & Mental Hygiene
2-3
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Table 2-1. LIST OF STATE AND LOCAL GOVERNMENT AGENCIES (Cont'd)
Division of Air Pollution Control
Michigan Department of Natural
Resources
Division of Air Quality
Minnesota Pollution Control
Agency
Mississippi Air & Water
Pollution Control Commission
Missouri Air Conservation
Commission
Montana State Dept. of Health
& Environmental Sciences
Division of Air Pollution
Control Department of
Environmental Control, Nebraska
Bureau of Environmental Health,
Nevada
New Hampshire Air Pollution
Control Agency
New Jersey Bureau of Air
Pollution Control Division of
Environmental Quality Dept. of
Environmental Protection
Environmental Improvement Agency,
New Mexico
New York State Dept, of Environmental
Conservation
Dept. of Natural & Economic
Resources, North Carolina
North Dakota State Dept. of Health
State Capitol
Ohio Environmental Protection
Agency
Air Pollution Control Div.
Environmental Health Services
Oklahoma State Department
of Health
Department of Environmental
Quality,Oregon
Bureau of Air Quality &
Noise Control Dept of
Environmental Resources
Commonwelath of Pennsylvania
Rhode Island Division of Air
Pollution Control
South Carolina Department
of Health & Environmental
Control
South Dakota Dept. of
Environmental Protection
Division of Air Pollution
Control Tennessee Dept. of
Public Health
Texas Air Control
Utah State Division of Health
Agency of Environmental
Conservation Air Pollution
Control , Vermont
State Air Pollution Control
Board, Virginia
Washington State Dept. of
Ecology
West Virginia Air Pollution
Control Commission
Wisconsin Dept. of Natural
Resources Bureau of Air
Pollution Control & Solid
Waste Disposal
2-4
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Table 2-1. LIST OF STATE AND LOCAL GOVERNMENT AGENCIES (Cont'd)
Air Quality Division Department of
Environmental Quality, Wyoming
Environmental Quality Board,
Puerto Rico
2-5
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Table 2-2.
LIST OF PROSPECTIVE MANUFACTURERS, ASSEMBLERS OR DISTRIBUTORS
Allen Testproducts Div. Edmund Scientific Co.
Autoscan Baganoff Associates, Inc.
Barnes Engineering Co. Baird-Atomic, Inc.
Beckman Instruments, Inc. Bendix Corp.
Chrysler Motors Corp. Canadian Research Institute
Div. of Criterion Instruments
Horiba Instruments Inc.
Catalytic Products Int'l Inc.
Kal Equipment
CEA Instruments
Applied Power, Inc.
Celesco Industries
Peerless Instrument Co.
Cenco Instrument Corp.
Robert Bosch Corp.
Clayton Manufacturing Co.
Stewart-Warner Alemite Sales Co.
Cleveland Controls, Inc.
Sun Electric Corp.
Comspace Corp.
Snap-On Western Division
Del Electronics, Corp.
Acurex Corp.
Devco Engineering Inc.
AEG-Telefunken Corp.
Drew Chemical Corp.
Anacon Inc.
Drexelbrook Engineering Co.
Analabs, Inc.
Dynasciences Corp.
Analog Devices, Inc.
E. I. Du Pont Co.
Analytical Instrument
Development Ecologic Instrument Corp.
Antex Instruments, Inc. Edmac Associates, Inc.
Austron, Inc. Scientific Technology, Inc.
2-6
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Table 2-2. LIST OF PROSPECTIVE MANUFACTURERS,
ASSEMBLERS OR DISTRIBUTORS (Cont'd)
Scott Research Laboratories, Inc.
Siemens Corp.
Systron-Donner Corp.
Technicon Industrial Systems
Thermo Electron Corp.
Thermo-Lab Instruments, Inc.
Thermotron Corp.
Tracer, Inc.
United Electric Controls Co.
United Systems Corp.
Hamilton Standard
ADI Div. of Contamination
Control Inc.
Andros Inc.
Automotive Environmental
System, Inc.
Varian Associates
Weathermeasure Corp.
Wemco Instrumentation Co.
Wilks Scientific Corp.
Crystal-X Corp.
Environmental Data Corp.
National Environmental
Instruments Inc.
Purad Inc.
World Marketing Corp.
Sylvania
Panametric Inc.
Lear Siegler Inc.
Teledyne Analytical Instruments
Sears,Roebuck & Co.
Bacharach Instrument Co.
Joy Manufacturing Co.
EMP Telemetry
Energetics Science Inc.
Environmetrics, Inc.
Fisher Scientific Co.
Fluidynamic Devices Ltd.
Forte Engineering Div.
Frankling Gno Corp.
Gam Rad, Inc.
GCA Precision Scientific
General Devices, Inc.
Instrumentaion Div.
General Dynamics
Electronics Div.
Gulton Measurement & Control
Systems Div.
2-7
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Table 2-2. LIST OF PROSPECTIVE MANUFACTURERS,
. ASSEMBLERS OR DISTRIBUTORS (Cont'd)
Heusser Instrument Co.
Infrared Industries, Inc.
International Light, Inc.
Intertech Corp.
ITT Barton
Kontes
Lab Glass, Inc.
Laboratory Data Control
McMillan Electronics Corp.
Meloy Laboratories, Inc.
Theta Sensors
Mettler Instrument Corp.
MG Scientific
Mine Safety Appliances Co.
Monitor Labs, Inc.
Perkin-Elraer Corp.
Philco Ford Corp.
Philips Electronic Instruments Inc.
Photobell Co. Inc.
Phys-Chemical Research Corp.
Process & Instruments, Inc.
Process Computer Systems, Inc.
Raeco, Inc.
REM Scientific Inc.
Research Appliance Co.
Royco Instruments, Inc.
Sara Scientific Co.
Scanivalve, Inc.
Science Spectrum, Inc.
2-8
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reasonable time period had elapsed, a telephone follow-up survey was initiated
to attempt to contact all manufacturers not responding to the mailing. In
all, 113 manufacturers were contacted in the survey. Not all manufacturers
contacted had instruments that would be applicable to the specific application
in question.
All data collected during the survey was compiled and all products meeting
the general requirements of an I/M instrument were identified and a preliminary
instrument list was developed (Table 2-3).
2.2 SELECTION CRITERIA
The 129 distinct models represent, in reality, packing or optional feature
variations of a much more limited number of basic instruments. The scope of
this program only allowed the acquisition of a limited number of these instru-
ments. With the intent of acquiring a representative cross section of all
identified instruments, a selection criteria was established based upon the
optical bench utilized by each unit. Using the optical bench as the basis of
selection, Table 2-4 was generated.
Selection within optical bench subgroups was aimed at identifying the
simplest and/or most economical instrument incorporating all available emission
testing features. Table 2-4 then, includes a representative of each optical
bench sytle or design identified from Table 2-3. Table 2-4 lists more than
one model for a few manufacturers. In these cases, the differences between
models are packaging- or accessory-oriented. More than one model was presented
to allow flexibility in choice of packaging and to increase the chances of
immediate availability.
Some instruments were excluded during the selection period due to unavail-
ability of product. Specifically, Andros and Robert Bosch Corporation were
unable to supply units due to discontinuance of production or lack of stock.
Mine Safety Appliance was excluded due to lack of applicable product at time
of selection. McMillan Electronics was excluded due to a prohibitive delivery
schedule. World Marketing Corporation could not be located nor were they ever
contacted by telephone. Their inclusion in the initial survey was based upon
information gathered in the government agency general mailing.
Table 2-3 listed all instruments that were considered as candidates for
testing. A subjective elimination of many instruments discovered in the
survey was made based upon their complexity and unsuitability for use in the
subject application. Although some instruments discovered in the survey could
be utilized for the measurement of raw automotive emissions, their intended
application was not consistent with the specific application as presented in
the contract. Use of these instruments in the subject application would
require extensive sample handling systems and higher operator skills not
consistent with the intent of I/M level activity.
2.3 SURVEY RESULTS
The results of this survey indicate that with the exception of Horiba
Instruments, Inc., no manufacturers are marketing NO instruments for the
2-9
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Table 2-3.
PROSPECTIVE INSTRUMENTS
WITH MANUFACTURER CROSS INDEX
Manufacturer's Name
Andros Instruments for Life
Allen -
Instrument Model
Allen
Allen
Allen
Allen
Allen
Allen
Allen
Allen
Allen
Allen
Amserv
Amserv
Amserv
Amserv
Amserv
Amserv
Amserv
Amserv
Amserv
Amserv
Model 218
23-060-CA
23-070-CA
23-080-CA
23-160-CA
23-170-CA
23-180-CA
18-090-CA
18-150-CA
18-190-CA
18-250-CA
23-067-CA
23-077-CA
23-087-CA
23-167-CA
23-177-CA
23-187-CA
18-097-CA
18-157-CA
18-197-CA
18-297-CA
2-10
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Table 2-3. PROSPECTIVE INSTRUMENTS WITH
MANUFACTURER CROSS INDEX (Cont'd)
Manufacturer's Name
Instrument Model
Allen -
MTSE 23-0660CA
MTSE 23-076-CA
MTSE 23-086-CA
MTSE 23-166-CA
MTSE 23-176-CA
MTSE 23-186-CA
MTSE 18-096-CA
MTSE 18-156-CA
MTSE 18-196-CA
MTSE 18-296-CA
Rotunda
Rotunda
Rotunda
Rotunda
Rotunda
Rotunda
Rotunda
Rotunda
Rotunda
23-065-CA
23-075-CA
23-085-CA
23-165-CA
23-175-CA
18-095-CA
18-155-CA
18-195-CA
18-255-CA
Triple - A
Commercial Electronics #715
Autoscan -
Autoscan
Autoscan
700 HC/CO
705
2-11
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Table 2-3. PROSPECTIVE INSTRUMENTS WITH
MANUFACTURER CROSS INDEX (Cont'd)
Manufacturer's Name
Instrument Model
Autoscan -
Autoscan
Autoscan
Autoscan
Series
705-C
710
710-C
4000 IR-C
Rotunda
Rotunda
Rotunda
LIRE 705
LIRE 710
LIRE 4000 IR
Barnes -
Barnes
Barnes
Barnes
Christie
Christie
King
King
Texaco
Fox
Mi lex
Milex
1836C
8335C
8335T
EA-74C
EA-74
770C
770
8335T
1800
1805
1856
Beckman •
Chrysler
Beckman
Chrysler
Chrysler
Chrysler
590
IIIC
23-066
23-076
2-12
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Table 2-3. PROSPECTIVE INSTRUMENTS WITH
MANUFACTURER CROSS INDEX (Cont'd)
Manufacturer's Name
Instrument Model
Chrysler -
Chrysler
Chrysler
Chrysler
23-086
18-096
18-156
Chrysler Master Technician
HCE-211C
Mopar
MTSE
Scott
Sun
IIIC
IIIC
IIIC
1-300C
Emission Control Instruments
IBC Celesco
Hamilton Test Systems
Sears
HTS
HT
Autosense
713.21022
N322W/SC-400 (NO)
759464-2
200067
200
Horiba Instruments, Inc.
GSM
GSM
GSM
MEXA
MEXA
MEXA
300
300A
300CA
300
300A
240 (NO)
2-13
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Table 2-3. PROSPECTIVE INSTRUMENTS WITH
MANUFACTURER CROSS INDEX (Cont'd)
Manufacturer's Name
Instrument Model
Kal Equip Company -
Kal Equip
Kal Equip
Bal Kamp
Bal Kamp
Poweready
Poweready
Poweready
AC
AC
4094C
4094D
14-4787C
14-47870
370-400
370-400C
370-400D
ST-500
ST-500A
Marquette Manufacturing
Company
Marquette
Marquette
Marquette
Marquette
Marquette
42-159
42-153
40-222
40-225
42-160
Rotunda
Rotunda
BRE 42-732
BRE 42-730
Atlas
Atlas
Atlas
Atlas
Atlas
AET-345
AET-340
ADC-120 CMAE
ADC-120 CME
AET-330
2-14
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Table 2-3. PROSPECTIVE INSTRUMENTS WITH
MANUFACTURER CROSS INDEX (Cont'd)
Manufacturer's Name
McMillan Electronics -
Mine Safety Appliance -
MEC
Instrument Model
2300 (NO)
Model 303
Peerless Instrument Company -
Pulsar
Model 660
Model 660C
662
Robert Bosch
EFAW
289
Snap-On Tools Corp.
(Marquette)
MT-495
MT-496
MT-496S
Stewart-Warner
Sun Electric Corp.
Atlas
Thermo Electron
3160-AC
3160-ACI
3161 Mfg. by Kal Equip
EPA-75
EET-910-1
U-912-1
EET-947
EET-945
2001
AET-330
Model 8-A (NO)
World Marketing Corp.
EIR-101 Marc 1
2-15
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PAGE NOT
AVAILABLE
DIGITALLY
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specific application of I/M automotive emission testing. Because of this
fact, present NO instruments are typically sold to be installed in consoles or
rack-mounted and are plumbed into an analytical bench sample system. As a
result, price quotations from the NO instrument manufacturers were developed
based upon the requirement that their instrument must "stand alone;" i.e.,
must have their own sample delivery and sample conditioning system. The
quoted prices reflect that requirement. All NO instruments recommended for
acquisition were production units readily available to any customer. The
sample systems supplied are based upon the recommendations of the manufacturer
and also would be readily available to anyone with the specific application of
I/M automotive emission testing.
All HC/CO instruments recommended for testing were priced with standard
sample handling packages typically included with purchase.
With reference to Table 2-4, the letters "NC" are used to mean that the
manufacturer makes no claim or that the information was not available.
The NO instruments recommended for purchase included instruments using
NDIR, chemiluminescence and electro-mechanical detection techniques. The
HC/CO instruments recommended for purchase and testing included both NDIR
single-beam and dual-beam with gas charged detectors, thermocouple or thermopile
detectors, and selective combustion detection techniques.
Only two units, the Sun Model 2001 and the Hamilton Test Systems Model 200
Autosense, incorporate direct computer interface with the exhaust emission
analyzer. Because of the relative high cost of these two instruments and to
maximize the total number of subject instruments, only one computer interface
instrument was recommended for purchase. The Sun Model 2001 uses the same
analytical bench as the Sun EPA 75 which was recommended for purchase. There-
fore, the Hamilton Test Systems Model 200 Autosense was recommended for purchase.
This instrument does not share the same analytical bench with any other instru-
ment in Table 2-4. Purchase of the Model 200 Autosense would allow acquisition
of data on the performance of a computer interface exhaust emission analyzer,
in addition to another distinct analyzer bench.
2.4 SELECTED INSTRUMENTS
The final selection of instruments included the following:
o HC/CO
Horiba Mexa 300A
Barnes 8335C
Scott 3C
Marquette 42-160
Beckman 590
Stewart Warner 3161
Sun EPA 75
Mopar 3C
Sears 713.21022
Kal Equip 4094-D
Pulsar 662
Autoscan 710C
2-19
-------
Allen 23-160CA
Autosense 200
o NO
Horiba Mexa 240
Thermo Electron 8A
IBC N322 W/SC-400
The initial checkout of instruments for stable operation and hardware
integrity was made at the time of instrument delivery. One instrument, Kal
Equip, was returned upon this initial inspection due to shipping damage.
It was later replaced by the distributor. By late June of 1976, all the
test instruments had been received and the laboratory test sequence was started.
2-20
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Section 3
LABORATORY TESTS
Figure 3-1 depicts the sequential steps that were followed in the labora-
tory test program. The test sequence up to and including the response and
recovery step was performed once daily for a period of 4 days. Upon completion
of the response and recovery phase on the fourth day, all instruments were
subjected to the voltage profile step prior to shut down.
Each test cycle was performed under carefully controlled temperature and
humidity conditions. The first day the tests were conducted at ambient room
temperature which was 21 C (70°F) at 50 percent relative humidity. The second
day the tests were conducted at 43 C (110°F) at 70 percent relative humidity.
The third-day tests were conducted at 2°C (35°F) at 85 percent relative humidity.
The fourth-day tests were conducted at 21°C (70 F) at 85 percent relative
humidity.
Following the voltage profile test, the instruments were subjected to a
test to determine the effects of nonalkane hydrocarbons on their response.
After the completion of the hydrocarbon response test, the barometric pressure
test was performed.
The effects of barometric pressure were tested by relocating the test
instruments to a high altitude test facility located approximately 6,750 feet
above sea level. Olson Laboratories' emission lab in Analhim is approximately
300 feet above sea level.
The instruments were grouped in threes and fours for testing. Group
determination was based upon the similarity between various instruments'
scales and the ability to use the same calibration gases to set up a complete
group of instruments.
Calibration gases used for this program were all purchased from the same
gas supplier. The certified analytical accuracy of gas concentration was
+2 percent. The calibration gases were referenced by the supplier to either
EPA-standard gases or National Bureau of Standards gases, depending upon their
availability. Zero reference gas for all testing was dry nitrogen.
In addition to the analytical accuracy statement and naming of the specific
gas blends by the gas supplier, Olson Laboratories used on-site equipment to
specifically read each calibration gas and reference it to our in-house standard
gases. Any gases that were found to be out of the +2 percent analytical
accuracy tolerence would be excluded from the program or carefully identified.
(No gases were actually found to be out of this accuracy range.)
The specific description of each test in this program is presented below.
3-1
-------
WARM-UP
I
CALIBRATION
i
ZERO DRIFT
I
GAS INTERFERENCE
ACCURACY
DETERMINATION
i
RESPONSE AND RECOVER
i
VOLTAGE PROFILE
I
HYDROCARBON RESPONSE
BAROMETRIC PRESSURE
ONE CYCLE PER DAY
FOR FOUR CYCLES
Figure 3-1. LABORATORY
TEST SEQUENCE
CYCLE
1
2
3
4
TEMPERATURE
70°F
110°F
35QF
70°F
RELATIVE HUMIDITY
50%
70%
85%
85%
3-2
-------
3.1 INSTRUMENT WARM UP
The instrument warm up tests were performed based upon the instrument
manufacturer's recommendations for warm up. Typically, power was applied to
the instruments by front panel toggle switches or rotary switches. Input
power for all instruments was controlled by front panel switches except for
the Beckman 590.
The Beckman 590 has two front panel switch positions, "On" and "Standby."
In the "Standby" position the instrument draws power but the operation's
manual does not explain which devices in the analyzer are actually operating
or are on a "Standby" mode. The Beckman 590 can only be turned off completely
by unplugging the power cord. Warm up tests were performed on this instrument
by switching the front panel toggle switch from the "Standby" to the "On"
position. Prior to the start of the warm up test, all instruments, including
the Beckman 590, were plugged into or connected to their appropriate power
supply for a period in excess of 2 hours.
Warm up times were determined by taking successive meter readings at
30-second intervals after the instruments were turned on. When successive
readings indicated stabilized operation, the data was backtracked to the
beginning of the stabilized operation point. The time from initial power-on
to the stabilized operating point was reported as the net warm up time. All
instruments were set at mid-scale 1 minute after start. Meter deviation from
the mid-scale set point was recorded as ppm for HC meter and percent for CO
meter. Figure 3-2 shows a typical warm up time plot for an EC/CO instrument.
Determination of stabilized operation was hampered by the occurrence of
zero drift. Some instruments exhibited significant zero drift in a stabilized
condition (warmed up). It was observed that the occurrence of this significant
zero drift tended to mask the initial point of stabilized operation for some
instruments during the warm up test.
3.2 INSTRUMENT CALIBRATION
Following the warm up test, the instruments were calibrated in accordance
with the manufacturer's instructions and rechecked with precision gases. Zero
reference gas was dry nitrogen. The calibration points were recorded.
3.3 INSTRUMENT ZERO DRIFT
Instrument zero drift was noted every 30 minutes for a period of 4 hours
during each test cycle. At the time of data collection, dry nitrogen was
applied to the instrument. No adjustments were made on the instrument during
the zero drift test. Data was reported as the maximum zero drift encountered
during the 4-hour test, presented as percent of full scale. All zero drift
tests were run on the lowest range available, since higher signal amplification
is required for lower concentration measurements and any inherent drift will
be more apparent.
3-3
-------
KLUFFII- » CSSCR CO.
otson LNBomronas. ma
—-i v_ -J:
-------
3.4 INSTRUMENT GAS INTERFERENCE
The instruments were tested to determine their response to various gases
and various moisture contents which they might encounter in normal service (in
either an engine idle or loaded mode testing situation), but which they were
not designed to analyze. By exposing the instruments to these various gases
and moisture levels, the actual response of the instrument to these gases
could be noted and recorded.
The following gases were used in the interference test: blend of 15 per-
cent C0_, background nitrogen; 1,600 ppm hydrocarbon (as hexane), background
nitrogen; 10 percent CO, background nitrogen; 3 percent H20 vapor in air
(saturated), 2,000 ppm NO, background nitrogen; and 10 percent 0 , background
nitrogen. Gas interference tests were run on all instruments in their lowest
range. The 1,600 ppm hydrocarbon in N. sample used for gas interference
testing was blended as 3,344 ppm propane. (With a propane equivalency factor
of 0.52, the hexane equivalent would be 1,739 ppm.) Water vapor (H20) in air
was generated with a bubbler under controlled temperature conditions. The
data was reported as response (percent of full scale deflection) to each gas
constituent.
3.5 INSTRUMENT ACCURACY DETERMINATION
A series of known, blended precision gases containing only analyzed
amounts of HC, CO and NO with background nitrogen, were applied to each instru-
ment. The instrument's response and measurement of the constituent for which
it was designed was observed and used as a basis for its accuracy determination.
Accuracy determinations were made on all available ranges for all instru-
ments. The data is presented as percent absolute error, calculated by compar-
ing the instrument's reading to the known sample gas value. Percent full
scale error was calculated by computing the variation of the instrument's
reading from the sample gas value, then comparing with the full scale value of
the instrument range in question.
All accuracy data was presented for three conditions on each range (35 per-
cent, 70 percent and 100 percent of full scale). The fourth point in the
accuracy determination, zero, is not reported since rezeroing was always
accomplished prior to accuracy determination.
Accuracy determination was made for all four temperatures and relative
humidity test cycles, plus the barometric pressure test.
3.6 RESPONSE AND RECOVERY
This test was run to determine the response time of each instrument.
Using a switching valve, alternate applications of a span gas of known concen-
tration followed by a zero gas was made. The sample gas was introduced into
the instrument's exhaust sampling probe (tail pipe probe). Observed instrument
response time represented the total analyzer and sample system response time
for each instrument.
3-5
-------
The data was reported as the average of two runs for each component of
interest. High range was used on all instruments during all response tests.
The corrected concentration of HC represents the hexane equivalent of 3,300 ppm
propane in nitrogen gas sample. The instrument's propane equivalency factor
was used to calculate the corrected concentration.
The time span was measured on each instrument from the time the switching
valve was turned to the sample gas to the time when the instrument response
leveled off. The data was reported as response time in seconds and was the
average of two runs. This response time represents time required for full
scale readings and is not consistent with various advertised ratings that call
out response time to 90 percent full scale reading.
3.7 VOLTAGE VARIATION
This test demonstrates the effects of line voltage fluctuation. It was
executed by applying calibration gases of known concentration to the instrument
while varying its input voltage plus and minus 10 percent from nominal.
Voltage profile tests were run with the instruments in the highest available
range. Supply voltages of 115 VAC and 13.6 VDC were varied plus 10 percent
and minus 10 percent using variable power supplies.
The HC and CO analyzers were supplied 3,300 ppm propane and 8.1 percent
CO sample gas. The NO analyzers were supplied 3,400 ppm NO sample gas. The
data was presented as reading variation in percent of full scale.
3.8 HYDROCARBON RESPONSE
Most hydrocarbon instruments specifically designed for automotive inspec-
tion or maintenance testing are designed and sensitized to read total hydrocar-
bons. Thus, the response of instruments to specific hydrocarbon groups was
tested.
Various other gases found in automotive exhaust emissions, including both
aliphatic and aeromatic hydrocarbons, were introduced into the instrument.
The specific gases used were acetylene, benzene, ethylene, isobutylene, methane
and toluene, (all approximately 300 ppm in nitrogen).
Hydrocarbon response tests were run on each HC/CO instrument at altitudes
of 300 feet and also at the high altitude laboratory located at 2,057.4 meters
(6,750 feet).
All instruments except the Sears were run on low range. Because of the
Sears higher response to various hydrocarbons, it was necessary to run the
Sears unit on high range.
The data for hydrocarbon response was presented as hydrocarbons in ppm.
3.9 REPEATABILITY TESTS
Following the Laboratory Barometric Pressure Tests, the instruments were
subjected to a series of repeatability tests. These tests consisted of the
3-6
-------
following laboratory test sequence steps: warm up, calibration, zero drift,
gas interference, accuracy determination, and response and recovery. The
instruments were cycled through these sequence steps four times. All testing
was accomplished at laboratory ambient temperature and humidity. The data
generated indicates the instrument's level of repeatability (see Figure 3-3).
3.10 FACILITIES
The laboratory test sequence of warm up through response and recovery was
carried out utilizing the environmental chamber in Olson Laboratories' emissions
lab. This environmental chamber allows close control of temperature and
humidity. The temperature range capability of this environmental chamber is
approximately 0°C to 54.4°C (32°F to 130°F). The humidity control range is
approximately 5 percent RH to 95 percent RH. Control capability is in the
order of +1.1°C (+2°F) and +5 percent RH. Figures 3-4, 3-5, 3-6, and 3-7
show various views of the environmental chamber.
The double-pane sliding glass doors allow complete visual observation of
the instrument operation during the test sequence. All calibrations, adjust-
ments and data acquisition were accomplished with the instrument technician
inside the environmental chamber. Calibration gas control was achieved by
utilizing a push button panel mounted inside the chamber, controlling gas
solenoids mounted on the outer wall. These, in turn, were connected to the
sample gas tanks.
All laboratory test sequences, except hydrocarbon response and barometric
pressure tests, were accomplished inside the environmental chamber. The
barometric pressure test was conducted at Olson Laboratories' high altitude
facility located at an elevation of 2,057.4 meters (6,750 feet) in the City of
Big Bear Lake, California. These tests took place in a controlled ambient
temperature of approximately 21°C (70°F). Prior to testing at high elevation
and also at the high altitude test site, the instruments were calibrated with
the same precision gases used at Olson Laboratories' Anaheim facility (approx-
imately at sea level). Figure 3-8 shows a plot plan of the high altitude test
facility.
3-7
-------
WARM-UP
1
CALIBRATION
I
ZERO DRIFT
I
GAS INTERFERENCE
i
ACCURACY
DETERMINATION
1
RESPONSE AND RECOVERY
ONE CYCLE PER DAY
FOR FOUR CYCLES
Figure 3-3. REPEATABILITY TEST
(All cycles conducted at laboratory ambient temperature and humidity)
3-8
-------
3-4T ENVIRONMENTAL, CHAMBER
-------
Figure 3-5. ENVIRONMENTAL CHAMBER WITH CALIBRATION GASES
-------
Figure 3-6. ENVIRONMENTAL CHAMBER, INTERIOR
-------
'igure 3-7. INSTRUMENTS INSIDE ENVIRONMENTAL CHAMBER
-------
1
-©-
-39 FEET-
EXISTINQ BUILOINO
DOUBLE DOORS
( 2 PAIR I
HEATER AND FAN
O
O
c
0
w
III
O
O
D
INSTRUMENT TEST AREA
1 liVAC
: W 4X
to*
in VAC
1* 4X -
10A
BOTTLE STORAGE
QA8
CONTROL PANEL
30 FEET
EXHAUST PAN
Figure 3-8
OLSON LABORATORIES INC. HIGH ALTITUDE TEST FACILITY
BIO BEAR LAKE CALIFORNIA
ELEVATION 0780 FEET
3-13
-------
Section 4
VEHICLE TESTS
After completion of the laboratory test phase, the instruments were
tested on a vehicle dynamometer to simulate typical operating conditions. In
these tests an EPA-type analytical bench was used as the standard to determine
instrument performance. Automotive exhaust gases were analyzed simultaneously
by the EPA bench and test instruments, and these readings were compared. The
vehicle test sequence is shown in Figure 4-1. A description of each test step
follows.
4.1 INSTRUMENT WARM UP
The instruments were warmed up in accordance with the manufacturer's
instructions. Typical warm up times were on the order of 1 hour to assure
that all instruments were completely stable. The test vehicle was warmed up
on the dynamometer and was run at 48.28 kph (30 mph) at a pre-set loaded
steady-state road load for 15 minutes (Table 4-1). The EPA analytical bench
was warmed up for approximately 2 hours.
4.2 INSTRUMENT CALIBRATION
The instruments were calibrated using zero and laboratory span gases as
specified by the instrument manufacturer. The span gases were +2 percent
analysis. The zero gas was dry nitrogen. The zero and span gas values and
the calibration points for each instrument were recorded.
4.3 LOADED STEADY-STATE
The test vehicle was run on the dynamometer under loaded conditions at
72.42 kph (45 mph), 48.28 kph (30 mph) and idle (Table 4-1).
The loaded steady-state test was run with the vehicle engine in its
normal, properly adjusted condition. No modifications were made at this
point. Tail pipe emissions were sampled simultaneously using the EPA analytical
system and the test instruments. The test instrument reading was then compared
to the reading of the EPA analytical system.
4.4 LEAN LOADED STEADY-STATE
Prior to running the lead loaded steady-state test, the test vehicle
carburetor was adjusted for a lean air/fuel mixture at idle. The EPA analytical
system was used to monitor CO. A reading of 0.5 to 1.5 percent CO was the
adjustment target. After adjustment, the vehicle was tested under loaded
conditions at 72.42 kph (45 mph), 48.28 kph (30 mph), and idle (Table 4-1).
4-1
-------
VEHICLE TTST SEQUENCE
WARM-UP
I
CALIBRATION
STD. KEY MODE TEST
i
KEY-MODE TEST, LEAN
i
CALIBRATION CHECK
i
HANG-UP
KEY-MODE TEST, RICH
4 CYCLES
RE-CALIBRATION
i
DIAGNOSTIC EMISSION
MEASUREMENTS
Figure 4-1. Vehicle
Test Sequence
CYCLE
1-4
TEMPERATURE
70°F + 5°F
RELATIVE HUMIDITY
50% + 10%
4-2
-------
Table 4-1.
LOADED STEADY STATE HORSEPOWER VALUES FOR LOADED VEHICLE TEST
VEHICLE
WEIGHT
2800-3800
LOW CRUISE HIGH CRUISE
SPEED (KPH/MPH)
48.28/30
LOAD (WATTS/HP)
6711/9
SPEED (KPH/MPH)
72.42/45
LOAD (WATTS/HP)
17,151/23
I
U)
-------
Emissions were tested simultaneously at the tail pipe with the EPA system and
the test instrument. The readings were then compared.
4.5 CALIBRATION CHECK
Immediately following the lean loaded steady-state test, the test instru-
ment probe was removed from the vehicle exhaust pipe.
Zero calibration and span calibration was checked and the results recorded.
The zero gas used for this check was dry nitrogen. The span gas used was
+2 percent analysis and was based upon the manufacturer's recommendations for
concentration.
4.6 INSTRUMENT HANG-UP
Following the calibration check, the instrument hang-up time was determined.
To perform the hang-up response a sparkplug wire was removed from the test
vehicle. This immediately caused the HC emissions to increase significantly.
The instrument sample probe was inserted in the exhaust stream of test
vehicle. After a reading was generated, the probe was quickly removed. The
time required for the instrument meter to return to zero was recorded as hang-
up time. The data is reported as the average of two tests.
4.7 RICH LOADED STEADY-STATE
After the hang-up test, the test vehicle carburetor was adjusted to
achieve a rich air/fuel mixture at idle. The EPA analytical system was used
to set the air/fuel mixture. Exhaust emissions were sampled simultaneously
with the test instrument and the EPA system with the vehicle running at 72.42 kph
(45 mph), 48.28 kph (30 mph), and idle (Table 4-1). The readings of both
systems were then compared.
The entire sequence from Instrument Calibration, (4.2) through Rich
Loaded Steady-State (4.7) was repeated three times without turning off the
instrument's vehicle or dynamometer and was reported as cycles one, two, three
and four.
4.8 INSTRUMENT RECALIBRATION
Following the final fourth cycle of rhe Rich loaded steady-state test,
each instrument was recalibrated as in Section 4.2.
4.9 DIAGNOSTIC EMISSION MEASUREMENTS
The distributor timing in the test vehicle was retarded by disconnecting
the line to the vacuum advance mechanism. This altered the vehicle exhaust
emission composition. The test instrument probe was inserted in the exhaust
manifold connected to the test vehicle. While the test vehicle engine was
4-4
-------
idling, the exhuast emissions were measured and recorded simultaneously with
the EPA system.
The vacuum line to the distributor vacuum advance was then reconnected
and the vehicle exhaust emissions remeasured. Following this, a sparkplug
wire was disconnected and idle emissions again recorded. A large increase in
HC concentration was observed. Following this, the engine was put back into
normal operating condition and the idle emissions again were measured and
recorded. This diagnostic emission measurement sequence was performed only
once, immediately following the fourth and final cycle of the vehicle test
sequence.
4.10 EPA ANALYSIS BENCH AND CALIBRATION GASES
The EPA-Approved Analysis System for HC/CO and NO was constructed and
assembled per 85.774-13 of the Federal Register, Volume 37, No. 221, November 15,
1972. The analytical bench assembled for use in this program consisted of two
Beckman 315 NDIR analyzers for measuring HC and CO and a Horiba AIA-2 analyzer
for measuring NO . The outputs for these analyzers were recorded on a Horiba
Labocorder R-4T r"our-pen recorder. The analysis and sample handling system
was modeled after the general flow schematic contained in the Federal Register.
Figure 4-2 shows the front view of the EPA analytical system with the
four-pen recorder at the upper left. Figure 4-3 and 4-4 show the special
exhaust manifold used for both the vehicle tests, and later for the diagnostic
and durability tests. Both the probe for the EPA analytical system and the
probe for the test instrument were inserted into the special exhaust manifold
during testing.
4.11 EPA INSTRUMENT CALIBRATION
Calibrations were performed on the three analyzers using calibration
gases with an analysis of +2 percent as specified in the Federal Register.
Propane was used for the HC analyzer, and the hexane equivalent was determined
by using 0.52 as the propane equivalency factor. The 0.52 value was extracted
from the calibration procedures included in the Federal Register under the
applicable section.
The EPA instrument assembly was subjected to full calibration after each
30-day use. The same flow rate was used for calibration that was used for
sampling exhaust gases. The 30-day calibrations were accomplished by shooting
ten calibration gases plus a zero gas (10 points plus zero). A polynomial
regression was used for the curve fit.
Daily calibrations utilized one up-scale gas per range plus zero. Before
and after each cynamic test sequence, an up-scale gas plus zero was shot on
each analyzer.
Dryer changes in the NO sample line were accomplished prior to each test
sequence. The common sample manifold as shown in Figures 4-2 and 4-3 was
constructed to supply exhaust sample to all the instruments simultaneously
during the vehicle tests and the durability tests. Multiple sample ports were
4-5
-------
Figure 4-2. EPA ANALYTICAL SYSTEM I
-------
Figure 4-3. VEHICLE TE.ST SETUP
-------
Figure 4-4. COMMON SAMPLING MANIFOLD
-------
built into this sample manifold to allow the instrument probe's access to the
exhaust stream.
All instrument probe positions were varied within the sample manifold
ports on a daily basis during the durability tests. The size and shape of the
sample manifold tended to allow significant exhaust mixing in the manifold.
This, in turn, tended to reduce the concentration variations and spikes in the
exhaust gases. The constituent make-up of the exhaust gases was not adversely
affected by the sample manifold.
However, since the sample manifold tended to be cooler than the exhaust
system on the vehicle, significant water fallout did occur in the manifold.
This water fall-out indicated that the instruments may have been exposed to a
slightly lower moisture level than they would have encountered in actual use
when their probes were placed in the tail pipe of a vehicle. Modifications or
special conditioning of the sample must be approached carefully so as not to
alter the sample concentration in any way that would result in exhaust samples
that are not truly representative of the exhaust stream in question.
. Although special procedures and sample modification techniques do exist,
these procedures and tactics tend to condition the sample for ease of detection
or analysis but may make the sample unrepresentative of the true exhaust
composition.
The goal in automobile measurement is, of course, a true representation
of the exhaust composition. To achieve this goal and, at the same time,
enhance the ability to correctly analyze and time-correlate composition mea-
surements, some form of special conditioning may be required.
The time-correlation problem is probably most severe in this area. In
addition to the test instruments and the EPA standard bench having different
response times, these respone times tend to vary slightly from test to test
for both instrument systems. Thus, under dynamic sample analysis conditions,
time-correlation of instrument readings becomes very difficult.
4-9
-------
Section 5
DURABILITY TEST
The instruments that successfully passed the laboratory tests and the
vehicle exhaust tests and that generally showed results within the manufac-
turer's specifications were subjected to 3 months of durability testing (or
until instrument failure occurred).
5.1 SCOPE
The durability test consisted of cycling the instruments for 50 minutes
on undiluted exhaust from an idling gasoline engine, followed by 10 minutes of
exposure to outside air. This cycle was conducted for 16 hours a day and then
shut down for 8 hours. Tests were conducted 5 days per week and shut down for
2 days. All instrument probes in this test were simultaneously inserted into
a common manifold for exhaust sampling.
5.2 SERVICE
Normal servicing as recommended by the manufacturer's literature was
performed on each instrument during the durability test. This was done either
per the manufacturer's recommendations on maintenance frequency or when
Immediate attention was required. The scope of this contract between the EPA
and Olson Laboratories, Inc., did not provide for any repairs to be performed
by Olson Laboratories, Inc., on the instruments that failed during the durab-
ility test sequence. This is, of course, exclusive of any required normal
service.
5.3 INSTRUMENT FAILURE
Failure in the durability test was defined as either a loss of response
of the instrument to exhaust or sample gas, or a significant degradation in
the instrument's ability to properly measure specific concentrations of analyzed
gases. Additionally, uncontrolled meter variation or loss of stability consti-
tuted failure.
Figure 5-1 shows the durability test set up. In the center of the picture
is the common exhaust manifold. Behind the manifold is the laboratory test
engine. The laboratory technician is seen placing the various instrument
probes in the ports of the exhaust manifold. Figure 5-2 shows another view of
the common exhaust manifold.
The instruments were rezeroed and spanned each morning before the start
of the day's durability test. Zero and span calibrations were performed
according to the manufacturer's specifications.
5-1
-------
Figure 5-1. DURABILITY TEST,SETUP
-------
Figure 5-2. VEHICLE TEST IN PROGRESS
-------
5.4 VIBRATION AND SHOCK TESTS
The instruments were then subjected to a vibration and shock test. This
test simulated rolling the instrument over a rough garage floor. The shock
test simulates a rolling instrument which collides with a wall or other fixed
object.
The test floor was 6 feet by 10 feet expanded metal grating, with diamond
shaped openings of approximately 1 inch by 3.75 inches. The test floor grating
was elevated 2 inches off of the laboratory floor by utilizing a sub-frame.
The test instruments, while operating, were rolled over the grating in the
direction of the "short way of the diamond." At the end of the grating, the
instruments were rolled off the end and dropped 2 inches to the test floor.
After one traverse of the grating, the instruments were checked for any
shift in zero or span setting. Any variation from the previous set points was
recorded. If necessary, the instruments were then rezeroed and respanned.
Figure 5-3 shows the vibration test in progress.
After zeroing and spanning, the position of the instrument's probe in the
common manifold was changed and recorded.
Vibration tests were run only on those instruments that incorporated a
cabinet and some form of wheel arrangement for mobility. No attempt was made
to run vibration tests on those instruments not equipped with wheels.
The shock transferred to an instrument while rolling along the ground or
over rough surfaces is determined by the size and geometry of the instrument's
wheels. Since the size and geometry is different for each instrument in
question, each instrument's ability to resist shock impact will differ.
It would not be realistic to equip an instrument with a special test
cabinet or special test wheels and then run that equipment in the vibration
tests. If an instrument was specially equipped by a test laboratory with a
test cabinet and wheels, the results of the vibration test might not be indica-
tive of the instrument's ability to resist shock. It might instead be a
direct function of the wheel size and geometry.
Where manufacturers have made a decision on wheel size and geometry and
have packaged their instrument accordingly, vibration tests are realistic.
Where the manufacturer had made no attempt to equip the instrument with wheels,
wheel size and geometry selection on the part of the testing agency would be
inappropriate and may, in fact, unfairly compare that instrument in these
tests.
Normal usage of a nonwheeled instrument would result in the typical level
of shock and vibration exposure occurring during pick up and placement opera-
tions. Since these instruments were always moved during the durability test,
it is felt that the shock and vibration encountered by the nonwheeled instru-
ments is quite representative of the shock and vibration they would see in the
real operating environment of a garage or inspection facility.
The performance in the vibration and shock test was reported as the
number of days that any span or zero reading varied greater than 3 percent
5-4
-------
Figure 5-3. VIBRATION TEST PLATFORM
-------
from known calibration gas values, immediately after the test was administered.
5.5 DATA
The data recorded for the durability tests consisted of the number of
hours each instrument operated before failing to calibrate, or when the instru-
ment started to display a permanent, obvious malfunction. This data is
presented as time to failure in hours.
5.6 EXPOSURE RATING
The typical level of gas concentration for HC, CO and NO experienced by
the instruments during durability testing was recorded. This level was recorded
as an average value determined by comparing the concentration notations made
during each test time period. This data is then converted into an exposure
value by combining the concentration level with the time to failure. The data
is reported as ppm-hours for HC and NO and percent-hours for CO.
5.7 SERVICE DATA
All incidences of service were recorded by type as follows:
A. Filter change
B. Drain hose
C. Re-zero
D. Repair sample system
E. Other
Each incidence of service was recorded by the technician. The total
number of incidences of each service was then normalized by dividing by its
time to failure in hundreds of hours.
5.8 DURABILITY SPAN DRIFT
The daily span drift was recorded and the absolute percentage of drift
was calculated by comparing it to the span gas concentration.
5-6
-------
Section 6
GENERALIZED DATA PRESENTATION AND RATINGS
6.1 OBSERVED PERFORMANCE DATA
Table 6-1 represents a compilation of the most representative data recorded
for each instrument during the laboratory tests. This compilation serves as a
quick reference to be used when making generalized comparisons of various test
instruments. A complete performance data listing for all tests is included in
each instrument report section.
6.2 OBJECTIVE RATINGS
Tables 6-2 through 6-16 present an objective performance listing for all
instruments based upon their demonstrated performance in the Laboratory,
Repeatability, Vehicle and Durability tests. Typical rating placement runs
from best performance to worst performance. Normalized rating totals are
given for some categories and are presented to allow appreciation of relative
ranking with respect to the best performing instrument.
These ratings are presented to be utilized only as a generalized relative
performance rating. Specific instrument performance data is included in each
instrument report section.
6-1
-------
Table 6-1. OBSERVED PERFORMANCE DATA TABLE
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-------
Table 6-2.
WARMUP TIME: (TEMPERATURE AND HUMIDITY - QUICKEST
WARMUP TIME TO SLOWEST)
HC/CO
Cycle 1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
1.
2.
3.
Barnes ) ®
s?
Kal EquipA
Stewart"^
Warner C,®
Autosense)
Horiba"^
1 Cl)
Allen >•*
Sears J
Sun "^o>
PulsarJ
Scott "? 0
^^•r|
V ^^
Mopar x
Marquett^
Beckman S ^
Autoscan
NO
Cycle 1
Horiba
IBC
Thermo Elec
Electron
HC/CO
Cycle 2
Autosense
Kal Equip
Horiba ^\
Stewart Warner
s
Pulsar x**"^
Beckman "^ ^
>Tj
Autoscan X^
Scott^
Co
Sun ^jj
Mopar ^
Barnes
Marquette
Allen
Sears
NO
Cycle 2
Horiba
IBC
Thermo
Electron
HC/CO
Cycle 3
Autosense
Kal Equip
r Pulsar
Q) «— • »w
H Scott ^ o
Stewart Warner)
Mopar
Autoscan
Sun
Beckman
Barnes
Marquette
Horiba
Allen
Sears
NO
Cycle 3
Horiba
IBC
Thermo
Electron
HC/CO
Cycle 4
Kal Equip^
j£o>
Pulsar _5-$
Autosense
Stewart"N
Warner/ a;
l^ 1 *
Sun \
•^
Autoscan
Beckman
Horiba^
&
Allen Jj^
Barnes
Scott "Xj
Marquette)
Mopar
Sears
NO
Cycle 4
Horiba
IBC
Thermo
Electron
OVERALL
HC/CO
Kal Equip
Autosense
Stewart
Warner
Pulsar
Horiba^
f Q)
V 'H
Sun ^ ^
Barnes
Autoscan
Beckman
Scott
Mopar
Allen
Marquette
Sears
NO
OVERALL
Horiba
IBC
Thermo
Electron
6-3
-------
Table 6-3.
ZERO DRIFT (TEMPERATURE & HUMIDITY)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
1.
2.
3.
HC/CO
Cycle 1
Horiba^X
Sun /
>v 0)
Mopar (S
\
AUenJ
Marquette^g
AutosenseN
Stewart y
Warner C, o
Kal Equipj
Barnes
Scott
BeckmaiTl
Pulsar S
Sears
Autoscan
NO
Cycle 1
Horiba
Thermo^N
Electron^ o
1-M
IBC J
^^r
HC/CO
Cycle 2
Stewart Warner
Marquette
Kal Equip
Horiba
Pulsar
Beckman
Allen
Scott
Mopar
Barnes ^^N
Sun f
Sears \ *»
Autoscan \
Autosense)
NO
Cycle 2
Horiba
IBC
Thermo Electron
HC/CO
Cycle 3
Sun
Autosense
Kal Equip
Autoscan
Stewart Warner
Horiba~\
Barnes C 0
>C
Beckman \
Pulsar J
Marquette
Allen
Mopar
Scott
Sears
NO
Cycle 3
Horiba
Thermo Electron
IBC
6-4
HC/CO
Cycle 4
Horiba "? «
7»>iH
V +»
Autosense)
Marquette
Kal Equip
Barnes
Stewart Warner
Beckmany
ju
C'Z
Sun \
Autoscan
Pulsar
Allen
Mopar
Scott
Sears
NO
Cycle 4
Horiba
Thermo
Electron
IBC
HC/CO
Overall
Horiba
Kal Equip
Stewart
Warner
Autosense^
Q ;
Marquettej
Sun
Allen
Beckman
Barnes
Pulsar
Mopar
Autoscan
Scott
Sears
NO
Overall
Horiba
Thermo
Electron
IBC
-------
Table 6-4.
ACCURACY DETERMINATION (TEMPERATURE & HUMIDITY)
(MOST ACCURATE TO LEAST ACCURATE)
OVERALL ACCURACY RATING
Normalized
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
HC-High
Overall
Horiba
Mopar
Marquette
Scott
Barnes
Sun
Beckman
Allen
Pulsar
Stewart
Warner
Kal Equip
Autoscan
Autosense
Sears
HC-Low
Overall
Allen
Horiba
Sun ^ «
Autos ens^
Mopar^X
Beckmanj
Barnes
Pulsar
Scott ~^)
^f
Marquette)
Stewart
Warner
Kal Equip
Autoscan
Sears
CO-High
Overall
Marquette
Horiba
Kal Equip
Beckman
Sun
Pulsar
Barnes
Allen
Scott
Mopar
Stewart
Warner
Autosense
Autoscan
Sears
CO- Low
Overall
Scott
Marquette
Autosense
Beckman
Horiba
Mopar
Pulsar
Sun
Stewart
Warner
Barnes
Allen
Autoscan
Kal Equip
Sears
HC/CO
Overall
Horiba
Marquette
Beckman
Sun
Mopar^
Scott 5"
Allen
Barnes
Pulsar
Autosense
Kal Equip
Stewart
Warner
Autoscan
Sears
Rating
Total
1.0
1.5
2.05
2.25
2.35
2.35
2.8
2.9
3.0
3. 15
3.9
4.1
5.0
5.6
6-5
-------
Table 6-5
ACCURACY DETERMINATION (TEMPERATURE & HUMIDITY) -
(MOST ACCURATE TO LEAST ACCURATE)
HIGH RANGE NO
1.
2.
NO
Cycle 1
Horiba
Thermo Electron
NO
Cycle 2
Horiba
me
NO
Cycle 3
Horiba
me
NO
Cycle 4
Horiba
Thermo
Electron
NO High
Range
Overall
Horiba
Thermo"sS
Electron/
3. me
Thermo Electron
(malfunction)
Thermo Electron IBC
IBC
s
LOW RANGE NO
NO
Cycle 1
NO
Cycle 2
NO
Cycle 3
NO
Cycle 3
NO Low
Range
Overall
1. Horiba
2. Thermo Electro
3. IBC
Horiba IBC
IBC
Horiba
Thermo Electron Thermo
Electron
Thermo Electron Horiba
(malfunction)
IBC
Horiba
Thermd"N
Electron/
IBC
£.
I -1
J
OVERALL ACCURACY RATINGS
NO High
Range
Overall
NO Low
Range
Overall
1. Horiba Horiba
2. Thermo Electro^ Thermo Electron!
^••1-1
0)
3. IBC
IBC
NO
Overall
Horiba
Thermo Electron
me
6-6
-------
Table 6-6.
ACCURACY DETERMINATION - HIGH ALTITUDE
HC
High
HC
Low
CO
High
CO
Low
HC/CO
Overall
9. Stewart Warner
Stewart Warner
Beckman
(malfunction)
Beckman
(malfunction)
NO
High
1. Horiba
2. IBC
3. Thermo Electron
NO
Low
NO
Overall
Horiba £jjj Horiba
Thermo Electron Thermo Electron
IBC IBC
6-7
-------
Table 6-7.
RESPONSE & RECOVERY (TEMPERATURE & HUMIDITY CYCLES) -
(QUICKEST TO SLOWEST)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
1.
2.
HC/CO
Cycle 1
Beckman
Scott
Mopar
Horiba
Allen
Sun
Barnes
Marquette
Pulsar
Sears
Kal Equip
Stewart Warner
Autosense
Autoscan
(malfunction)
NO
Cycle 1
IBC
Horiba
HC/CO
Cycle 2
Horiba
Beckman
Allen
Scott
Mopar
Marquette
Pulsar
Kal Equip
Stewart Warner
Barnes~X
Sun /
Sears f „
AutoscanX
Autosense)
NO
Cycle 2
IBC
Horiba
HC/CO
Cycle 3
Horiba
Mopar
Sun
Scott
Allen
Beckman
Pulsar
Autoscan
Barnes
Marquette
m
Stewart Warne
_^
&
Kal Equip ^£
Autosense
Sears
NO
Cycle 3
Horiba
IBC
HC/CO
Cycle 4
Scott
Mopar
Beckman
Pulsar
Barnes
Allen
Sun
Horiba
Autoscan
Marquette
^ Kal Equip
)
> Autosense
Stewart Warner
Sears
NO
Cycle 4
IBC
Horiba
HC/CO
Overall
Scott
Beckmarft
£ V
1 r I *H
Mopar \ -*->
Horiba
Allen
Pulsar
Sun
Barnes
Marquette
Kal Equip
Autoscan
Stewart
Warner
Autosense
Sears
NO
Overall
3. Thermo Electron Thermo Electron
(malfunction)
Thermo Electron Thermo Electron
6-8
-------
Table 6-8.
GAS INTERFERENCE LABORATORY TESTS
(LEAST RESPONSE TO MOST RESPONSE)
HC/CO
Overal1
(All 6 Gases)
Normalized
Rating
Total
NO
Overall
(All 6 Gases)
Normalized
Rati ng
Total
Autosense
Marquette
Autoscan
Mopar
Barnes
Scott
Allen
Pul sar
Horiba
Sun
Beckman
Kal Equip
Sears 1 «u
> iH
1 4-1
Stewart Warner 1
1 Thermo Electron 1
1.14 IBC 1.34
1.34 Horiba 1.73
1.37
1.39
1.42
1.43
1.44
1.47
1.58
1.73
1.96
2.96
2.96
6-9
-------
Table 6-9.
VOLTAGE PROFILE (LEAST INFLUENCED TO MOST INFLUENCED)
HC + 10%
HC - 10%
CO+ 10%
CO - 10%
HC/CO
Overall
14. Autosense
-------
Table 6-10.
VEHICLE TESTS ACCURACY
(MOST ACCURATE TO LEAST ACCURATE)
OVERALL ACCURACY RATING
HC/CO
Overall Normalized
(Al1 3 Modes) Rating Total
Autoscan 1
Marquette 1.15
Horiba 1.39
Beckman 1.52
Allen 1.54
Scott 1.57
Sun 1.89
Pulsar 2.02
Barnes 2.13
Mopar 2.16
Kal Equip 2.39
Stewart Warner 2.98
Sears > „, 3.8
I **
AutosenseJ w 3.8
6-11
-------
Table 6-11.
VEHICLE TESTS ACCURACY
(MOST ACCURATE TO LEAST ACCURATE)
(STANDARD MODE)
NO NO NO NO
Cycle 1 Cycle 2 Cycle 3 Cycle 4
NO Normalized
Overall % Rate
Horiba
IBC
Horiba
IBC
Horiba
IBC
Horiba
IBC
Horiba
IBC
1
2
Thermo Thermo Thermo Thermo Thermo
Electron Electron Electron Electron Electron
(LEAN MODE)
IBC
Horiba
Horiba
IBC
Horiba
IBC
Horiba
IBC
Horiba
IBC
1
1.4
Thermo Thermo Thermo Thermo Thermo
Electron Electron Electron Electron Electron
2.4
(RICH MODE)
Horiba
IBC
Horiba
IBC
Horiba
IBC
Horiba
IBC
Horiba
IBC
1
2
Thermo Thermo Thermo Thermo Thermo
Electron Electron Electron Electron Electron
6-12
-------
Table 6-12.
DIAGNOSTIC VEHICLE TESTS
(MOST ACCURATE TO LEAST ACCURATE)
Ignition Retard
HC
CO
Autosense
Autoscan
Marquette
Mopar
Allen
Kal Equip
Beckmen
Stewart
Warner
Horiba
Pulsar
Sun
Scott
Barnes
Sears
Horiba
Autoscan
Autosense
Allen
Mopar
Scott
Sun
Pulsar
Stewart
Warner
Beckman
Marquette
Kal Equip
Sears **) a,
J-H
4J
Sparkplug Shorted
HC CO
Ignition Advance
Sun
Mopar
Allen
Autoscan
Scott
Autosense
Beckman
Stewart
Warner
Kal Equip
Horiba
Marquette
Pulsar
Sears
Barnes
HC
Is
•J"
Autoscan
Autosense
Hori ba
Allen
Pulsar
Mopar
Sun
Scott
Stewart
Warner
Beckman
Marquette
Kal Equip
Sears ^ o>
I-H
I W
BarnesJ
CO
Beckman
Scott
Autosense
Autoscan
Allen
Marquette
Stewart
Warner
Sun
Pulsar
Horiba
Kal Equip
Mopar
Sears") «
I w
BarnesJ
Autoscan
Horiba
Allen
Autosense
Mopar
Pulsar
Scott
Stewart
Warner
Sun
Beckman
Marquette
Kal Equip
Sears") ^
f-H
Barnes]w
6-13
-------
Table 6-13.
DIAGNOSTIC VEHICLE TESTS
(MOST ACCURATE TO LEAST ACCURATE)
Ignition Retard Sparkplug Shorted Ignition Advance
NO NO NO
Horiba Horiba Horiba
IBC IBC IBC
Thermo Electron Thermo Electron Thermo Electron
6-14
-------
Table 6-14.
DURABILITY TESTS
(LEAST DRIFT TO
MOST DRIFT)
(MOST HRS. TO LEAST HRS,
960 HRS. MAXIMUM)
AVERAGE DAILY
SPAN DRIFT
HC
Beckman
Scott
Autoscan
Mopar
Sun
Allen
Autosense
Marquette
Horiba
Kal-Equip
Pulsar
Barnes*!
I Q)
f "tJ
Sears 1
CO
Beckman
Mopar
Scott
Autosense
Sun
Autoscan
Horiba
Marquette
Allen
Pulsar
Kal-Equip
Stewart
Warner ^
)-H
t-U
HOURS
OPERATION
HC/CO
Scott |^
-------
Table 6-15.
INSTRUMENT SERVICE REQUIREMENTS
A
CHANGE FILTER
(PER 100 HRS.)
BARNES ")
SCOTT C -H
MOPAR \ u
PULSAR J
MARQUETTE
STEWART WARNER
SUN
AUTOS CAN
ALLEN
AUTOSENSE
KAL-EQUIP
SEARS
IBC
HORIBA
THERMO
ELECTRON
B
DRAIN HOSE
(PER 100 HRS.)
SUN *) cu
KAL-EQUIPt-H
AUTOS CAN J w
STEWART WARNER
AUTOSENSE
SCOTT
MARQUETTE
ALLEN
BECKMAN
\0)
•H
BARNESJ w
09
PULSAR*V -n
HORIBA J *
SEARS
IBC -L3
HORIBA> w
THERMO
ELECTRON
C
RE ZERO
(PER 100 HRS.)
BARNES -\
SCOTT 1
BECKMAN ( „
SUN f «
MOPAR \
PULSAR 1
AUTOS CANX
AUTOSENSE
ALLEN
STEWART WARNER
KAL-EQUIP
0)
HORIBA ^-H
MARQUETTE/*'
SEARS
NO INSTRUMENTS
IBC
HORIBA
THERMO
ELECTRON
D
SAMPLING SYST.
(PER 100 HRS.)
BARNES "N
SCOTT I
BECKMAN V £
MOPAR f "
PULSAR V
AUTOS CAN j
AUTOSENSE/
ALLEN
HORIBA
SUN
KAL-EQUIP
STEWART WARNED
MARQUETTE J
SEARS
IBC "") o>
HORIBA J£
THERMO
ELECTRON
E
OTHER
(PER 100 HRS.)
BARNES "*>
HORIBA V
SCOTT N^"
BECKMAN [u
SUN \
MOPAR J
AUTOS CAN j
ALLEN ^/
^^
PULSAR
AUTOSENSE
STEWART WARNER
^KAL-EQUIP
•rl
W
SEARS
IBC
HORIBA
THERMO
ELECTRON
6-16
-------
Table 6-16.
DURABILITY TESTS
(LIFE, SPAN DRIFT, SERVICE AND SHOCK FAILURE PARAMETERS)
OVERALL
PERFORMANCE
(ALL 4 PARAMETERS
EQUALLY WEIGHTED)
SCOTT
MOPAR
BECKMAN
AUTOS CAN
SUN
ALLEN
AUTOSENSE
MARQUETTE
HORIBA
PULSAR
STEWART WARNER
BARNES
KAL EQUIP
SEARS
NORMALIZED
RATE
TOTAL
1
1.52
2. 10
2. 67
2.67
3.24
3.24
3.48
4. 10
4. 19
4.57
5.33
5.38
6.52
6-17
-------
Section 7
INDIVIDUAL INSTRUMENT REPORTS
The following sections in this report contains 17 "Mini Reports," each
concerned with a specific instrument.
The "Mini Reports" present a detailed physical description of each instru-
ment covering electronics, displays, control panels, construction, sample
systems, theory of operation, and other pertinent information necessary to
fully describe and understand each unit. A subjective operational performance
evaluation is presented along with a general data review with comments. Each
report includes a complete composite of all test data collected for each
instrument during the tests. An explanation of the data presentation and the
respective tests is contained in Sections 3, 4 and 5 of this report. Following
the "Mini Report" data presentation, are appropriate instrument photographs
depicting instrument configuration and sample probe design.
7.1 HORIBA MEXA 300A
Manufacturer - Horiba Instruments, Inc.
Description - EC/CO exhaust analyzer configured as a bench top analyzer
incorporating an optional four-wheel mobile cart. The cart has a
built-in gas calibration system. Incorporates readout of both HC
and CO on separate meters.
Dimensions -
Analyzer: Weight - 43 Ibs.
Height - 12-1/2 inches
Width - 21 inches
Depth - 16-1/2 inches
Cart: Weight - 63 Ibs.
Height - 31 inches
Width - 24 inches
Depth - 16-1/2 inches
The cart holds gas calibration equipment and incorporates
additional read access storage space.
Material of Construction - Main analyzer cabinet and cart - heavy walled
plastic molding with sheet metal on analyzer face, cart front and
shelves.
Color - Red with silver front panels.
7-1
-------
Mobility - Four, 4-inch wheels; two at front corners stationary, two at
rear corners rotate for steering. The two rear wheels incorporate
wheel locks.
Accessories - Tail pipe probe, flexible 24-foot sample hose, particulate
filters, water separator.
Control Package -
Front Access - Mode select switch (five-position)
1. Standby
2. Sample (with indicator light)
3. Zero
4. Span check
5. Calibration gas
HC - zero knob
HC - span knob
HC - high range adjustment (screw)
CO - zero knob
CO - span knob
CO - high range adjustment (screw)
ON/OFF - toggle switch with indicator light
Range select toggle switch with high range
Indicator light
Flow alarm light
2 amp fuse cartridge
Cart Control Panel - Push button calibration gas valve. Calibration gas
cylinder pressure gauge.
Meters - Dual 8", 90° swing. Black figures on white background.
Ranges - HC - 2000 ppm in 50 ppm increments
400 ppm in 10 ppm increments
CO - 10% in 0.10% increments
2% in 0.05% increments
The HC meter showed sensitivity to static electricity. (Needle
moved up-scale and sticks when cloth brushed against meter face.)
This indicates the need for the use of an antistatic coating on the
HC meter cover. The CO meter showed no sensitivity to static elec-
tricity. Meter visibility and readability is rated as good.
Altitude Compensation - Internal electronic (no manual reset)
Probe - Braided flexible tube with perforated hard tube tip, hard tube
extension to plastic handle.
Filters and Sample Handling - Water trap with paper filter cartridge,
particulate "cigarette filter" cartridges for sample and drain.
Gal Gas Inlet - Rear of analyzer.
Power Requirements - 115 VAC (60HZ) 150VA
7-2
-------
Operating Principles - Dual beam nondispersive infrared with chopper.
Luft-type, gas-charged detectors, positive filter, parallel cell hot
wire sources.
Calibration - Electro-mechanical with swinging arm span checker. Provi-
sions are incorporated for gas calibration (both internal and
external).
Operation and Calibration - Straightforward, explanation included in
operator's manual.
1. Power up and warm up
2. Zero set
3. Gas calibration
4. Test
(Electro-mechanical span check applicable after initial gas
calibration.)
7.1.1 Operational.Performance Comments
In general, this unit was easy to use and easy to calibrate. The mobility
of the cart was good and the locking feature on the rear wheels worked well.
The display showed good response and stability. Calibration pot adjustment
was fine enough to afford easy meter setting. The rear panel incorporated
four ports (vent, air/ext gas, cal gas, drain). Gas calibration using these
ports posed no severe problem, although the nomenclature, air/ext gas and cal
gas, was moderately confusing.
The sample handling system presented the only real problem encountered
with this instrument. Under durability test conditions, the paper filter in
the external water trap repeatedly became wet causing the restricted flow
indication light to come on. With the condition of reduced flow, the sample
hose quickly filled with water. This problem may be compounded by the uphill
routing of the sample aspirator outlet. In addition, the filter tip in the
aspirator outlet may have contributed to this problem. The maintenance required
by this problem consisted of changing the paper filter in the aspirator and
draining the sample hose.
In the laboratory tests, this instrument showed reasonable warm up times
under all temperature conditions. The zero drift for all temperature conditions
showed the best performance of all instruments. In accuracy determination,
the Horiba high and low range HC showed the best combined performance. High
range CO was second best of all instruments, low range CO was fifth best.
Overall, the Horiba showed the best sample gas accuracy of all HC/CO instruments.
In high altitude performance, the overall Horiba accuracy was sixth best,
indicating an apparent accuracy degradation with altitude.
At normal laboratory temperature, the unit showed essentially no response
to interference gases. Both high and low temperature extremes produced signif-
icant interference response from various gases. The Horiba showed no HC
response to acetylene, benzene or ethylene. The unit was most responsive to
isobutylene, followed by toluene and methane.
7-3
-------
The Horiba unit was not sensitive to input voltage variation. Instrument
repeatability was rated good and quite acceptable for I/M application.
The Horiba analyzer was rated third best overall in the vehicle tests.
Actual percentage errors in exhaust analysis were sometimes quite high.
Response time variation may have contributed to this problem. As in the
vehicle test, the percentage error values achieved by the Horiba in the diag-
nostic test were quite high but, overall, the unit correlated third best of
all instruments with the EPA Bench.
In the durability test the Horiba ran 272 hours out of a total of 960 hours.
This corresponded to an HC exposure of 257,040 ppm-hours and CO exposure of
443 percent-hours. The instrument failed because the HC scale could not be
zeroed after prolonged exposure to exhaust gases.
This problem occurred gradually and crept up for several days. The unit
would exhibit fairly good recovery early in a test day but by midafternoon,
the HC reading on air would begin to climb. Failure was identified when the
HC indicator remained up-scale and could not be brought down within acceptable
limits. During the durability test, the Horiba failed the shock and vibration
test only two times. Both failures occurred on the HC zero mode. This is a
failure rate of 0.12 failures per day and indicates that the instrument has
very good resistance to shock. Average daily span drift of this instrument
measured from test-day to test-day was 5.75 percent for HC and 4.54 percent
for CO. This was an acceptable value but it indicates that span adjustment is
required more frequently than on a daily basis.
The Horiba required a total of 54 filter changes (19.9 per 100 hours)
during the durability test, and the sample hose required draining 71 times (26
per 100 hours). Compared to the other units, this unit required significantly
more maintenance to continue proper operation.
The tail pipe probe supplied with this unit showed no significant deter-
ioration at the end of testing.
Other than the high system maintenance requirement, this unit demonstrated
good performance with no problems or breakdowns until the final durability
test.
Test data for Horiba Mexa 300A Infrared Exhaust Analyzer are shown in
Tables 7-1 through 7-5.
Photographs of the instrument are shown in Figures 7-1, 7-2, and 7-3.
7-4
-------
Attachment (1)
Table 7-1. DATA COMPOSITE - LABORATORY TEST
INSTRUMENT: HORIBA MEXA 300A
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
(CYCLE 1)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
(CYCLE 1)
9
9
(CYCLE 1)
0
0
15%
C02/N2
0.75
0
(CYCLE 2)
10
10
MAXIf
(CYCLE 2)
2.5
0
(CYCLE 3)
(CYCLE 4)
29
29
IUM ZERO DRIFT % FT
(CYCLE 3)
2.5
ISOOppm 10%
HC/N2 CO/N2
0.
25
0
COMPARISON
CONDITION % FS
35
70
100
35
70
100
35
70
100
35
70
100
% ERROR
ABSOLUTE
+ 0
- 1
- 0
- 0
+ 1
+ 1
+ 1
- 3
+ 0
- 2
+ 0
.14
.41
.11
.95
.23
.37
.74
.39
.06
.86
.41
0
3%
H20/AIR
0
0
H
0
12
12
.5
.5
JLL SCALE
(CYCLE 4)
0
2000ppm
NO/N2
1.25
0
C
% ERROR
FS
+ 0.15
- 1.00
- 0.10
- 0.25
+ 0.75
+ 1.25
+ 0.60
- 2.4
+ 0.05
- 0.75
+ 0.25
0
0
10%
02/N2
0.5
0.5
C(
% ERROR
ABSOLUTE
+ 0.81
+ 3.08
+ 0.11
+10.15
+ 0.95
- 2.25
- 1.88
+ 1.54
+ 3.26
+ 4.35
0
0
D
% ERROR
FS
+ 0.30
+ 2.0
+ 0.1
+ 3.5
+ 0.5
- 2.0
- 0.70
+ 1.00
+ 3.00
+ 1.5
0
0
I
Ul
-------
HORIBA
Table 7-1. DATA COMPOSITE - LABORATORY TEST (Cont'd)
MEXA 300 A
Attachment (1)
CYCLE 3
CYCLE 4
HIGH
ALTITUDE
RESPONSE &
RECOVERY
HYDROCARBOfc
RESPONSE
300 Feet
Altitude
6750 Feet
Altitude
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
RANGE
HIGH
HIGH
•RANGE
LOW
LOW
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SCALE
HC
CO
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
CORRECTED
CONCENTRATION
1716
8.1
INSTRUMElS
287 ppm 323 ppm
ACETYLENE BENZENE
0 0
0 5
+ 1.
- 1.
+ o.
- 2.
- 1.
+ 1.
+ 0.
- 2.
+ 0.
74
98
06
86
64
65
29
33
66
0
- 3.
+ 1.
+ 0.
- 3.
+ 0.
+ 0.
- 1.
- o.
INSTRUMEN'
(CYCLE 1)
10.5
9.65
69
65
29
39
06
95
64
28
+ 0
- 1
+ 0
- 0
- 1
+ 1
+ 0
- 1
+ 0
.60
.40
.05
.75
.00
.50
.10
.65
.05
0
- 2.25
+ 1
+ 0
- 2
+ 0
+ 0
- 1
- 0
I RESPONSE TI
(CYCLE 2)
5.25
6.3
PT RESPONSE TO \t
322 ppm
ETHYLENE
0
11
.50
.10
.40
,05
.25
.00
.25
+ 1.61
+ 1.54
0
+ 1.45
- 0.95
- 1.71
- 1.88
0
0
+14.49
+ 9.52
0
- 3.23
+ 1.54
+ 4.35
+10.15
- 0.95
+ 2.86
ME (SEC) (AVERA
(CYCLE 3)
5.55
5.7
rARIOUS HYDROCAF
385 ppm
ISOBUTYLENE
62
120
+ 0.60
+ 1.00
0
+ 0.50
- 0.50
- 1.50
- 0.70
0
0
+ 5.00
+ 5.00
0
- 1.20
+ 1.00
+ 4.00
+ 3.5
- 0.50
+ 2.50
GE OF 2 RUNS)
(CYCLE 4)
18.5
17.8
.SONS AS ppm
337 ppm 329 ppm
METHANE TOLUENE
5
20
26
58
-------
Attachment (1)
Table 7-1. DATA COMPOSITE - LABORATORY TEST (Cont'd)
HORIBA MEXA 300A
VOLTAGE
PROFILE
POWER
115V
115V
RANGE
HIGH
HIGH
SCALE
HC
CO
READING VARIAT:
VARYING LINE
+ 10%
0
0
ION AS FUNCTION OF
VOLTAGE ± 10%
- 10%
0
0
-------
INSTRUMENT:
Table 7-2. DATA COMPOSITE - REPEATABILITY TEST
HORIBA MEXA 300A
00
WARMUP
TIME (Min.)
1
ZERC DRIFT
GAS
INTERFERENCE
(% of FS)
CYCLE 1
GAF
INTERFERENCE
(% of FS)
CYCLE 2
GAS
INTERFERENCE
(% of FS)
CYCLE 3
GAS
INTERFERENCE
(•-- of FS)
CYCLE 4
>- -
i — —
R;
! «—
RANGE
LOW
LOW
RANGE
_LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
. .=
i
i
SCALE 1 (CYCLE 1) (CYCLE 2) (CYCLE 3) (CYCLE 4)
HC > 9 25 9 15
CO , 8 18 9 12
SCALE i MAXIMUM ZERO DRIFT % FULL SCALE !
; (CYCLE 1) (CYCLE 2) (CYCLE 3) (C^CLE 4) '
HC ! 2.5 5.0 1.75 2 0 i
co • 3.5 1.6 3.5 10 i
SCALE ' 15'/c .
j CC,/N2
HC | 0
CO i 1.0
SCALE ! 15~.
i C02/N2.
HC ! 0
co ! o
SCALE i 15'%
! ' C02/N2
HC i 1.0
CO j 0.5
SCALE i 15°- ,
i C02/N2
HC \ 0
CO | 1.0
CORRECTED
"-^ CONCE NTRATI ON
1600ppm 10%
HC/No j CO/N-,
^ 1 . •*•
2.5
1.5
IGOOppir. 10%
HC/N2 CO/N2
0
0
1
HC/N2" j CO/K2
1.25
0 0
HC/>-2 i CO/N2
1.25
0 i 0
3% 2000ppm
K?0/AIR NO/N-*
0 0
0 • 1.0
3% .2000ppm
K20/AIR NO/NJ"
0 0
0.4 • 0
H-O/AIR NOA%"
•^ £.
1.25 1.25
0 0
3% 2000ppm
HnO/AIR NO/N-,"
- i -
1.25 i 0
0 0
10% I
0
0.5
10%
0
0
10%
02/N2
o !
0 ;
"A,
0
0.5 i
INSTRUJ.1SNT RESPONSE TIME (SEC) (AVERAGE OF 2 RUNS)
(CYCLE 1) j (CYCLE 2) j (CYCLE 3} j (CYCLE -^
RLSFONSE i HIGH HC 1716 i 21 ! 11.5 ; 6 5 i 5 5
-E,0v-; HIGH CO 8.1 17.5 j 11.5 i 5 5 J 5 0
-------
HORIBA MEXA 300A
Table 7-2. DATA COMPOSITE - REPEATABILITY TEST (Cont'd)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
RANGE
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
COMPARISON
CONDITION -/I FS
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
i 70
100
! 35
i 70
100
35
70
100
H
% ERROR
ABSOLUTS
+0.29
-4.72
-1.62
2.86
-1.64
0
+ 1.74
-3.03
+0.61
-0.95
-2.05
+0.82
+1.74
-1.97
+ 1.17
-1.90
-2.05
+1.10
+1.87
-1.55
+1.17
-12.38
-4.1
+1.37
C
% ERROR
73 '
+0.10
-3.35
-1.45
+0.75
+1.00
0
+0.6
-2.15
'. +0.55
! -0.2
-1.0
+0.6
+0.60
-1.4
+1.05
-0.50
-1.25
+ 1.00
+0.65
-1.1
+1.05
-3.25
i -2.50
i +1.25
w
% ERROR
ABSOLUTE
-3.23
+1.54
0
+10.14
-0.95
+2.86
-1.88
0
0
+13.04
0.0
+1.14
-1.88
-0.77
-2.72
+10.14
+4.76
+3.43
-1.08
+1.54
+2.07
+14.49
0
+2.86
t*\
u
-'= ERROR
FS
-1.20
+1.00
0
+3.5 j
-0.5 '
+2.5 i
-0.7
0
0
+3.6
0
+0.8
-0.70
-0.50
-2.5
+3.5
+2.5
+3.00
h -0.40
+1.00
+1.90
+5.0
0
+2.50
-J
•e
-------
Table 7-3. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS
HORIBA MEXA 300 A
KEY MODE
CYCLE #•
•!
% ERROR
FS
- 7.58
- 11.23
- 31.85
- 2.8
- 5.85
- 18.93
- 0.55
- 1.88
- 10.25
+ 1.33
+ 0.05
- 8.33
- 1.03
- 2.03
+ 3.72
- 2.85
- 3.. 53....
+ 5.0
- 1.38
+ 3.08
- 5.86
+ 4.33
+ 1.93
- 24.83
Ci
% ERROR
ABSOLUTE
+ 11.11
+ 15.38
+ 7.14
- 6.78
- 14.49
- 10.62
- 13.79
0
- 10.71
+ 57.14
+1100.0
+ 18.64
+ 7.14
+ 25.0
- 47.37
- 15.09
0
0
- 10.71
+ 33.33
0
+ 13.64
+400.0
+ 66.67
3
% ERROR
PS
+ 2-5
+ 1.0
+ 2.0
2.0
1.0
+ 6.0
4.0
0
4.5
+ 10.0
+ 5.5 |
+ 11.0 i
+ 2.0
+ 1.5
4.5
4.0
0
o '
3.0
+ 1.5
0
+ 3.0
+ 4.0
+ 7.0
I
h-'
o
-------
Table 7-3. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS (Cont'd)
HORIBA MEXA 300 A
KEY MODE
CYCLE #
RICH MODE
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
RANGE
PPM/%
400/?
400/2
400/10
400/2
400/2
400/10
400/2
400/2
400.10
400/2
400/2
400/10
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SPEED
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
HC
% ERROR-
ABSOLUTE
+ 56.4
- 38.1
- 11.43
+ 16.96
+ 10.82
1 - 7.77
- 28.79
- 28.79
+ 5.62
- 20.72
- 24.17
- 19.85
% ERROR
FS
+ 14.88
- 12.0
- 9.68
T 4.35
+ 3.05
- 5.9
- 7.08
- 7.08
+ 3.73
- 4.58
- 6.38
- 13.0
CO
% ERROR
ABSOLUTE
- 7.69
- 25.0
+ 1.55
- 10.71
- 14.29
+ 3.02
- 9.09
0
+ 9.47
- 37.5
- 23.08
- 16.67
% ERROR
PS
- 2.5 !
- 2.5 ':
+ 0.7 1
- 3.0
- 1.0 '!
+ 1.2 !
- 2.5
o
+ 3.2
- 12.0
- 1.5 j
- 6.0 !
-------
HORIBA MEXA 300 A
Table 7-4. DIAGNOSTIC TEST
IEST
IGNITION ADVANCE
IGNITION RETARD
^
400
10%
400
10%
400
10%
400
10%
SCALE
HC
CO
HC
CO
HC
CO
HC
CO
PPM NO, PPM HC, % CO
TEST INSTRUMENT
875
1.90
340
1.8
325
2.10
325
2.4
EPA BENCH
1142
2.08
374
2.01
374
2.18
358
2.45
HC/CO/NO
% ABSOLUTE
ERROR
- 23.38
8.65
9.09
- 10.45
- 13.1
3.67
9.22
2.04
% ERROR
- 13.35
- 1.8
- 8.5
- 2.1
- 12.25
- 0.8
- 8.25
- 0.5
«vl
I—'
NJ
-------
Table 7-5. DURABILITY TEST DATA
INSTRUMENT: HORIBA MEXA 300 A
INSTRUMENT TIME TO FAILURE AND GAS EXPOSURE
TIME TO FAILURE (HRS.)
HC EXPOSURE (PPM-HRS.)
CO EXPOSURE (%-HRS.)
NO EXPOSURE (PPM-HRS.)
272
275,040
443
28,016
INSTRUMENT STABILITY
TOTAL NO. DAYS SHOCK TEST FAILURE
(3% Variation) 1 or More of 4 Modes
SHOCK TEST FAILURE RATE
(Failure/Day %)
INCIDENCE OF FAILURE IN EACH MODE
HC ZERO
HC SPAN
CO ZERO
CO SPAN
AVERAGE DAILY SPAN DRIFT
HC%
CO% (
N0%
2
11.76
2
0
0
0
5.75
4.54
—
INSTRUMENT SERVICE REQUIREMENTS
A CHANGE FILTER
TOTAL
PER 100 HRS.
B DRAIN HOSE
TOTAL
PER 100 HRS.
C REZERO
TOTAL
PER 100 HRS.
D. SAMPLING SYSTEM
TOTAL
PER 100 HRS.
E. OTHER
TOTAL
PER 100 HRS.
54.00
19.80
71.0
26.1
3.0
1.1
2.00
0.74
—
7-13
-------
1 2 3
H C
Ml »»Nt f MUIV<1 F N T
INFRARED
EXHAUST ANALYZER
Figure 7-1. HORIBA MEXA 300A INFRARED EXHAUST ANALYZER
7-14
-------
Figure 7-2. HORIBA MEXA 300A INFRARED EXHAUST ANALYZER (BACK)
7-15
-------
Figure 7-3. HORIBA MEXA 300A INFRARED EXHAUST ANALYZER (LEFT SIDE)
7-16
-------
7.2 BARNES 8335C EMISSION ANALYZER
Manufacturer - Barnes Engineering Company.
Description - HC/CO exhaust analyzer configured as a bench top analyzer
physically connected to a cart. The unit could be used without the
cart if desired. The cart incorporates one low shelf for storage.
Dimensions -
Analyzer: Height - 12 ''inches
Width - 20 inches
Depth - 16 inches
Weight - 45 Ibs.
Analyzer Height - 46 inches
on Cart: Width - 22 inches
Depth - 23 inches
The cart shelf is 22 inches wide and 20 inches deep, with a
1-inch lip. The shelf is 5 inches from the floor.
Material of Construction - Main analyzer cabinet and cart are sheet
metal. Cabinet and cart are welded and screwed together.
Color - Analyzer - Black case with yellow front. Cart - Yellow shelves
with black legs.
Mobility - Two, 4-inch diameter nonsteerable wheels in rear, solid legs
in front. This unit has the handle on the front and wheels at the
rear.
Accessories - Tail pipe probe, 20-foot hose, rollaway cart, particulate
filter (0.6 micron), operator's manual.
Control Package -
Front access - Mode select switch (four positions)
1. Off
2. Standby
3. Calibrate
4. Run
HC zero knob
HC HI/LO toggle switch
CO zero knob
CO zero knob
CO HI/LO toggle switch
Test button (electronic calibration)
Filter light (red) indicates restriction
ON light
C02 light (indicates presents of CO- in exhaust stream)
Side Access - (Recess in right side of cabinet)
HC span knob
7-17
-------
HC test adjust screw (used for gas calibration)
CO span knob
CO test adjust screw
Rear Panel Access
2.5 amp fuse cartridge
HC and CO recorder outputs
Meters - 8", 90° swing
High scale - red figures
Low scale - flue figures
Graduations - Black
Meter visibility and readability is rated as good.
Ranges - HC - 2000 ppm in 50 ppm increments
400 ppm in 10 ppm increments
CO - 10% in 0.2% increments
2% in 0.05% increments
These meters were very sensitive to static electricity caused
by brushing against the clear meter lens. The application of an
antistatic coating on the meter lens is definitely needed.
Altitude Compensation - Manual set with HC and CO test adjustment screws.
0- to 7,000-foot scales on HC and CO meter faces.
Probe - Convoluted flexible tube with sealed tip and perpendicular sample
holes. Tail pipe clamp used to keep probe in exhaust pipe.
Filter and Sample Handling - External particulate (0.6 micron) filter in
water separator. Dual-head pump moves sample through one head with
the other head removing water from separator through a particulate
filter to the drain hose. Water particulate filter protects the
pump head.
Cal Gas Inlet - Rear of analyzer.
Power Requirements - 115 VAC/60HZ 300 watts
Operating Principles - Multi-channel infrared interference photometer
with solid state electronics. Mechanical filter wheel with EC/CO
reference/CO- optical filter windows. Solid state detector, hot
wire source.
Calibration - Electronic signal by test button on front panel. Altitude
of site set on front meter faces. Original factory gas calibration
at zero elevation. On-site gas calibration through rear port with
mode switch in calibrate.
Operation and Calibration - Straightforward. Operation and calibration
data on analyzer side panel and in manual.
1. Set to standby
2. Warm up
7-18
-------
3. Set in calibrate
4. Adjust zero
5. Set altitude of test site (test button depressed)
6. Ready for use
Gas calibration can be performed with mode switch in standby
and span knob adjustment. Calibration instructions on instrument
side panel.
7.2.1 Operational Performance Comments
The most obvious problem encountered while using this instrument was the
very awkward mobility that this specific cabinet and cart design produced.
The unit has an extremely high C.G. and with the present handle location and
rear wheel position, it is difficult to move around.
Operationally, this unit was easy to use and calibrate.
The meters were front-lighted and this enhanced meter visibility.
The HC and CO meters could be set to high or low ranges individually with
their own range toggle switch. This was a nice feature except that there were
no range identification lights so the toggle switch's position was the only
visual range indication. This lead to a slight degree of confusion during
vehicle testing.
The electronic test button (calibration button) worked well and gave a
quick indication of calibration.
This unit is equipped to detect CO. and displays CO. presence with a
front panel light. The intended use of this feature is to identify valid tail
pipe exhaust readings by indicating high CO- levels. Low C0_ levels would
indicate exhaust dilution and, thus, invalid tail pipe exhaust readings. This
feature worked very well during the vehicle tests. The CO meter on this unit
was the only one that was linear. The unit incorporates an eight-point linear-
ized circuit to achieve this linear output. When used in conjunction with an
auxiliary recorder, this would be a very useful feature. For the tests run in
this program this feature had negligible effect.
Gas calibration using the rear panel calibration gas port was simple.
Altitude correction with the scales on the front meter faces was also easy.
In the laboratory tests, this instrument showed reasonable warm up times.
Zero drift was good at medium and low temperatures. During the high temperature
test, the unit failed to operate properly. The CO meter could not be zeroed.
The lowest obtainable reading at the end of the zero pot was 0.5 percent. The
HC channel appeared to function normally. Upon returning the instrument to
70 F, the CO channel resumed normal operation. Additionally, later in the
diagnostic tests, the instrument stopped responding to sample gas altogether.
This failure was identified and attributed to a solenoid valve stuck in the
calibration position. Due to the multiple failures in the temperature test
sequences, the Barnes was found to be the eighth most accurate instrument
overall. Exclusive of the test failures, the actual demonstrated accuracy of
the instruments was generally well within +3 percent full scale except for the
7-19
-------
35 percent full scale CO tests. The low CO scale consistently showed positive
errors of 4 to 5 percent full scale. Operation at high altitude showed no
significant degradation in accuracy.
The Barnes unit showed reasonable and fairly consistent response times.
This unit was not sensitive to acetylene or benzene. It was most sensitive
to isobutylene, followed by toluene, methane and ethylene. Input voltage
variation caused essentially no signal level change.
In general, the Barnes showed effects of interference gases to be on the
order of approximately 1 percent or less. This is an acceptable level. No
significant interference problem was noted.
The unit showed slightly below average correlation with the EPA bench
during the vehicle exhaust tests. The low range CO and low range HC values
showed larger errors, especially during idle mode.
In
to a HC
the durability tests, the Barnes ran only 16 hours. This corresponds
exposure of 16,160 ppm-hours and CO exposure of 33 percent-hours.
This early failure was indicated by radical and uncontrollable up-scale
meter deflections (both scales). Unfortunately, failure occurred too early in
the durability test to draw reasonable conclusions with regard to maintenance
requirements. During the time it did run though, the instrument appeared to
have a slight moisture handling problem complicated by the fact that the
various filters on this unit are relatively difficult to service and filter
changing is time-consuming. In the short time period of operation, the probe
and sample hose showed no degradation.
Test data for Barnes 8335C Emission Analyzer are shown in Tables 7-6
through 7-10.
Photographs of the instrument are shown in Figures 7-4 through 7-7.
7-20
-------
Attachment (1)
INSTRUMENT:
Table 7-6. DATA COMPOSITE - LABORATORY TEST
BARNES 8335 C
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
(CYCLE 1}
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
(CYCLE 1)
7
7
(CYCLE 1)
1.25
0
15%
CO2/N2
1.0
0
(CYCLE 2) (CYCLE 3)
13 26
13 26
MAXIMUM ZERO DRIFT % Fl
(CYCLE 2) (CYCLE 3)
INSTRUMENT 1.25
MALFUNCTION 2.5
(CYCLE 4)
13
12
JLL SCALE
(CYCLE 4)
0.5
0
IGOOppm 10% 3% 2000ppm 10%
HC/N2 CO/N2 H20/AIR NO/N2 °2/N2
1.25 0 0 0
0.5 0-0 0
COMPARISON
CONDITION % FS
35
70
100
35
70
100
35
70
100
35
70
100
H
% ERROR
ABSOLUTE
0
- 2.84
- 1.21
+ 1.87
+ .80
+ 1.80
INSTRUMENT
C
% ERROR
FS
0
- 2.05
- 1.1
+ 0.5
+ 0.5
+ 1.0
MALFUNCTIO
C
% ERROR
ABSOLUTE
- 1.88
+ 1.54
+ 1.09
+ 7.25
+ 1.90
- 0.57
tf
0
% ERROR
FS
- 0.7
+ 1.0
+ 1.0
+ 2.5
+ 1.0
- 0.5
I
ro
-------
BARNES
Table 7-6.
8335C
DATA'COMPOSITE - LABORATORY TEST (Cont'd)
Attachment (1)
CYCLE 3
CYCLE 4
HIGH
ALTITUDE
RESPONSE &
RECOVERY
HYDROCARBON
RESPONSE
300 Feet
Altitude
6750 Feet
Altitude
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
RANGE
HIGH
HIGH
RANGE
LOW
LOW
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SCALE
HC
CO
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
CORRECTED
CONCENTRATION
1716
8.1
INSTRUME*
287 ppm 323 ppm
ACETYLENE BENZENE
0 0
0 0
0
- 1.
- 0.
80
16
0
+ .40
+ 1.
+ 2.
08
0
- 0.41
L + 0.
+ 2.
+ 0.
+ 0.
93
80
40
32
0
- 3.
- 0.
18
71
0
- o.
+ 2.
INSTRUMEN1
(CYCLE 1)
11.95
11.8
4
16
0
- 1.
- 0
.3
15
0
+ 2.
+ 1.
.5
.0
+ 0.7
- 0.3
+ .85
+ .75
+ .25
+ .25
0
- 2.
- 0.
3
65
0
- o.
+ 2.
I RESPONSE TI
(CYCLE 2)
INSTRUMENT
FAILED No D;
IT RESPONSE TO \
322 ppm
ETHYLENE
5
8
25
0
- .54
+ 1.54
- 1.09
+15.94
+ .95
+ .57
+ 1.88
+ 4.62
+ 0.11
+14.49
+ 0.95
- 0.57
- .54
+ 1.85
- 0.22
+14.49
+ 0.95
- 0.57
ME (SEC) (AVERA
(CYCLE 3)
17.5
,TA 22.5
CARIOUS HYDROCAE
385 ppm
ISOBUTYLENE
84
85
- 0.2
+ 1.0
- 1.0
+ 4.4
+ 0.5
+ 0.5
+ 0.7
+ 3.0
+ 1.0
+ 5.0
+ 0.5
- 0.5
- 0.2
+ 1.2
- 0.2
+ 5.0
+ 0.5
- 0.5
GE OF 2 RUNS)
(CYCLE 4)
16.3
15.9
BONS AS ppm
337 ppm 329 ppm
METHANE TOLUENE
11
16
31
39
-------
I
N3
U>
Attachment (1)
Table 7-6. DATA COMPOSITE - LABORATORY TEST (Cont'd)
BARNES 8335C
VOLTAGE
PROFILE
POWER
115V
115V
RANGE
HIGH
HIGH
SCALE
HC
CO
READING VARIAT3
VARYING LINE
+ 10%
0
0.5
ION AS FUNCTION OF
VOLTAGE ± 10%
- 10%
0
0
-------
Table 7-7. DATA COMPOSITE - REPEATABILITY TEST
INSTRUMENT: BARNES 8335C
^J
1
N)
*•
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
CYCLE 1
GAS
INTERFERENCE
(% Of FS)
CYCLE 2
GAS
INTERFERENCE
(% of FS)
CYCLE 3
' GAS
INTERFERENCE
(% of FS)
CYCLE 4
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
LOW.
RANGE
LOW
RANGE
i
LOW
j
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
(
RANGE SCALE (
I
RESPONSE S HIGH | HC
RECOVERY | £Q
j (CYCLE 1) (CYCLE 2) (CYCLE 3) (CYCLE 4)
! 9 20
110 20
11 15
15 15
MAXIMUM ZERO DRIFT % FULL SCALE '
\ (CYCLE 1) (CYCLE 2) (CYCLE 3) (CYCLE 4) !
1.25 1.7R 3.5 0.5 !
i 1.5 1.0
15%
C02/N2
2.5
1.5
15%
C02/N2
0.75
! o
15%
C02/N2
0.5
0
15%
CO7/N2
0.5
ISOOppm
HC/N2*
1.0
1600ppm
HC/N2
__
0
1600opm
HC/N2*
--
0
IGOOpprr.
HC/N0
2.5 0.5 !
10%
CO/N2
0.5
3%
H20/AIR
0.5
I 1.0
10%
CO/N2
2.5
3%
H20/AIR
0
2000ppir,
NO/N"
^ '-\
0
• 0.5
.2000ocm
NO/K^"
0
Jo i • o
10%
CO/N2
1 .0
3°-
K90/AIR
0
2000ppm
NO,/N2
0
10%
02/N2
0
0
10%
0 /N2
4 ^
0
o
10%
02/N2
0
o ! o i o
10% | 3%
CO /No i Ho 0 /AIR
f. ; ^
1.5
0 j 0
:ORRECTED
CONCENTRATION
2000ppm
NO.A%"
0 0
*-- i o
- o
10%
02/N2
0
1.0
INSTRUMENT RESPONSE TIME (SEC) (AVERAGE OF 2 RUNS)
(CYCLE 1) j (CYCLE 2) j (CYCLE 3) ] (CYCLE 4)
1749 19.5
8.1 j 19.5
! 19.5 1 8 i 7.5
i 19.5 ! 7 f 6.5 i
-------
Table 7-7. DATA COMPOSITE - REPEATABILITY TEST (Cont'd)
to
BARNES 8335C
ACCURACY
DETERMINATION
CYCLZ 1
CYCLE 2
CYCLE 3
CYCLE 4
RANGE
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
JC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
IHC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
COMPARISON
CONDITION % FS
35
70
TOO
35
70
100
35
70
100
35
70
100
35
70
100
35
70
1 00
35
70
100
35
70
100
H
% ERROR
ABSOLUTE
+ 2.00
- 3.87
- 1.26
+ 8.41
+ 1.21
+ 2.16
+ 5.56
- 2.49
- 0.17
+ 6.54
+ 0.40
0
+ 4.14
- 1.80
- 0.16
0
- 2.81
+ 1 .08
+ 2.43
- 1.94
0
+ 5.61
0
+ 1.08
C
% ERROR
FS
+ 0.70
- 2.80
- 1.15
+ 2.25
+ 0.75
+ 2.0
+ 1.95
- 1.8
- 0.15
+ 1.75
+ 0.25
0
+ 1.45
- 1.30
- 0.15
0
- 1.75
+ 1.00
+ 0.85
- 1.40
0
+ 1.50
0
+ 1.00
C
% ERROR
ABSOLUTE
+ 2.15
+ 3.85
- 1.08
+1 8 . 84
+ 6.67
+ 2.29
+ 1.61
+ 2.31
- 2.17
+ 7.25
+ 2.85
- 1.71
- 0.54
+ 3.08
- 0.54
+ 4.35
- 8.57
- 0.57
- 2.15
+ 1.85
- 0.98
+ 15.94
+ 1.90
- 1.71
i
0
% ERROR
FS
+ 0.80
+ 2.50
- 1.00
+ 6.50
+ 3.50
+ 2.00
+ 0.6
+ 1.5
- 2.0
+ 2.5
+ 1 .5
- 1.5
- 0.20
+ 2.00
- 0.50
+ 1 .50
- 4.50
- 0.50
- 0.80
+ 1.20
- 0.90
+ 5.50
+ 1 .0
- 1.50
-------
Table. 7-8. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS
BARNES 8335C
KEY MODE
CYCLE #
STANDARD MODE
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
LEAN MODE
CYCLE 1
CYCLE 2.
CYCLE 3
CYCLE 4
RANGE
PPM/%
400/2
400/2
2000/2
400/2
400/2
400/2
400/2
400/2
400/2
400/2
400/2
400/2
400/2
400/2
2000/2 -
400/2
400/2
5000/2
400/2
400/2
2000/2
400/2
400/2
2000/2
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HP/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SPEED
50
30
IDLE
50
30
IDLE
50
30r
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
H
% ERROR
ABSOLUTE
+ 0.2
+ 2.4
+ 23.1
+ 14.89
+ 3.32
1 + 12.86
+ 26.1
+ 12.21
+ 8.78
+ 7.71
+ 14.69
- 12.06
+ 30.8
+ 24.19
+ 56.96
+ 3.75
+ 6.16
+ 36.13
+ 13.35
+ 39.06
- 1.07
+ 26.04
+ 27.73
+ 64.62
C
% ERROR
FS
+ 0.05
+ 0.65
+ 4.03
+ 3.5
+ 0.9
+ 7.98
+ 5.95
+ 3.4
+ 5.65
+ 1.95
+ 3.86
- 7.2
+ 6.48
+ 5.6
+ 18.16
+ 0.98
+ 1.62
+ 11.28
+ 3.48
+ 8.06
+ 5.48
+ 6.03
+ 10.8
C
% ERROR
ABSOLUTE
- 7.69
+ 33.33
+ 38.89
- 2.3
+ 71.43
+ 35.42
+ 17.65
+109.09
+ 36.23
+ 57.41
+130.0
+ 52.63
- 2.78
+ 15.38
+ 43.75
+ 14.04
+100.0
+ 78.95
+ 29.03
+120.0
- 0.33
+ 32.08
+100.0
+257.14
0
% ERROR
PS
- 2.5
+ 2.0
+ 7.0
- 1.0
+ 5.0
+ 17.0
+ 6.0
+ 6.0
+ 12.5
+ 15.5
+ 6.5
+ 25.0
- 1.0
+ 1.0
i
+ 3.5
+ 4.0
+ 6.0
+ 7.5
+ 9.0
+ 6.0
+112.5
+ 8.5
+ 5.0
+ 18.0
-------
Table 7-8. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS (Cont'd)
HARMED H.< •!-. r; _
KEY MODE
CYCLE #.
RICH MODE
CYCLE 1
CYCLE £•
CYCLE 3
CYCLE 4
RANGE
400/2
400/2
4nn/io
400/2
4QQ/2
400/10
AQQ/5
400/2
400/10
400/2
400/10
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HP /CO
HG/CO
HC/CO
HC/CO
HC/CO
HC/CO
SPEED
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
7 1
H<
% ERROR-
ABSOLUTE
+ 56.4
- 38.1
- 11.43
+ 10.47
+ 15.25
+ 16.73
+ 23,56
+ 32.25
+ 34.7
+ 20.04
+ 27.96
+ 34.03
^i
% ERROR
FS
+ 14.88
- 12.0
- 9.68
+ 2.73
+ 4.3
+ 12.83
+ 5.63
+ 7.93
+ 21.13
+ 4.93
+ 7.38
+ 21.9
CC
% ERROR
ABSOLUTE
- 7.69
- 25.0.
+ 1.55
+ 29.03
+ 78.57
+ 21.69
+ 7.14
+ 91.67
+ 30.84
'+ 26.47
4- 91.67
+ 26.07
)
% ERROR
- 2.5
- 2.5
+ 0.7 i
+ 9.0
+ 5.5 _
+ 8.2 .
+ 2.5
+ 5.5
+ 9.9
+ 9.0
+ 5.5
+ 9.1
•^J
I
-------
Table 7-9. DIAGNOSTIC TEST
BARNES 8335 C ,
TEST
SPARKPLUG SHORTED
NORMAL IDLE
IGNITION ADVANCE
IGNITION RETARD
RANGE
SCALE
PPM NO, PPM HC, % CO
TEST INSTRUMENT
INOPEI
INOPEI
INOPEI
INOPEI
EPA BENCH
ATIVE
ATIVE
ATIVE
[ATIVE
HC/CO/NO
% ABSOLUTE
ESROR
% ERROR
FS
-------
Table 7-10. DURABILITY TEST DATA
INSTRUMENT: BARNES 8335C
INSTRUMENT TIME TO FAILURE AND GAS EXPOSURE
_TIME TO FAILURE (HRS.)
HC EXPOSURE (PPM-HRS.)
CO EXPOSURE (%-HRS.)
16
16,160
33
NO EXPOSURE (PPM-HRS.)
1,664
INSTRUMENT STABILITY
TOTAL NO. DAYS SHOCK TEST FAILURE
(3% Variation) 1 or More of 4 Modes
NO TEST DATA
SHOCK TEST FAILURE RATE
(Failure/Day %)
NO TEST DATA
INCIDENCE OF FAILURE IN EACH MODE
NO TEST DATA
HC ZERO
HC SPAN
CO ZERO
CO SPAN
AVERAGE DAILY SPAN DRIFT
HC%
NO TEST DATA
C0%
INSTRUMENT SERVICE REQUIREMENTS
A
B
C
~D.~
E.
CHANGE FILTER
TOTAL
PER 100 HRS.
DRAIN HOSE
TOTAL
PER 100 HRS.
REZERO
TOTAL
PER 100 HRS.
SAMPLING SYSTEM
TOTAL
PER 100 HRS.
OTHER
TOTAL
PER 100 HRS. ;
—
1
6.;
—
—
—
7-29
-------
Figure 7-4. BARNES 8335C EMISSION ANALYZER
7-30
-------
gure 7-5. BARNES 8335C EMISSION AilALYZER (BACK)
7_31 w
-------
Figure 7-6. BARNES 8335C EMISSION ANALYZER (LEFT SIDE)
™" 7-32
-------
Figure 7-7
BARNES 8335C EMISSION AHALYZER (RIGHT SIDE AND PROBE)
7-33
-------
7.3 SCOTT IIIC EXHAUST EMISSION ANALYZER
Manufacturer - Chrysler Corporation
Description - HC/CO analyzer configured as a bench to unit but available
with a two-wheel cart. The analyzer can be used with or without the
cart with equal ease. The cart incorporates storage areas.
Dimensions -
Analyzer: Height - 9 inches
Width - 13 inches
Depth - 10 inches
Weight - 20 Ibs.
Cart: Height - 38 inches
Width - 15 inches
Depth - 15 inches
Weight - 30 Ibs.
The cart incorporates a top drawer and a lower storage area
with a snap-closing door.
Material of Construction - Main analyzer cabinet is aluminum sheet. Cart
is sheet metal. Method of joining - welding and screws.
Color - Analyzer - Blue with silver front. Cart - red.
Mobility - Two, rear-mounted, 7-inch wheels. Round tube cart handle is
at top rear of instrument. Mobility and stability of this combination
is very good. Low C.G. gives very stable feel.
Accessories - Tail pipe probe with 25-foot sample hose (two pieces),
water trap, operator's manual.
Control Package -
Front access -
HC - course zero adjust (screw)
HC - fine zero adjust (knob)
HC - span adjust (screw)
HC - cal adjust (screw)
HC - range switch (two-position toggle)
CO - course zero adjust (screw)
CO - fine zero adjust (knob)
CO - span adjust (screw)
CO - cal adjust (screw)
CO - range switch (two-position toggle)
POWER - push button incorporating indicating lame
Calibrate Check - push button
• Low Flow - light
No external fuses or breakers (external housing must be removed to
replace lamp fuse)
7-34
-------
Rear Access -
Recorder jack
Meters - 6-inch, 90 swing
High scale - green graduations - black figures
Low scale - red graduations - black figures
White background.
Ranges - HC - 2000 ppm in 50 ppm increments
300 ppm in 50 ppm increments
CO - 10% in 0.2% increments
0.5% in 0.01% increments
Meter visibility and readability rated as good. The HC meter
on this instrument was sensitive to static electricity (soft cloth
rubbed against lens).
Altitude Compensation - On chart contained in operator's manual. Requires
use of correction factor. Correction not needed if gas calibration
used at altitude in question.
Probe - Three-foot, convoluted tube with sealed end and perpendicular gas
entrance holes. Tube has handle at mid-span and adjustable tail
pipe clamp.
Filters and Sample Handling - No filters are used. Steel water trap is
used in sample hose as water drop-out. It requires periodic emptying.
Internal pump moves sample from vehicle to analyzer bench.
Cal Gas Inlet - Front mount, same as sample inlet.
Power Requirements - 115 VAC 60HZ 100 watts
Operating Principles - Nondispersive single beam infrared instrument
using narrow band infrared optical filters. Incorporates a sample
cell reference filter to cancel the effects of dust, particulates
and smoke in the sample cell.
Calibration - Electronic reference signal by "calibrate check" button on
front panel and calibration reference points on meter faces. Gas
calibration through front panel port utilizing span adjustment
screws on front panel.
Operation and Calibration - Very easy. Operating and calibrating instruc-
tions on analyzer and cart.
1. Warm up
2. Set zero
3. Push calibration check button
4. If OK, ready for use
5. If not, gas calibration through front port using HC and CO span
screws.
6. Adjust calibrate check points
7. Ready for use
7-35
-------
7.3.1 Operational Performance Comments
This unit is identical to the Mopar IIIC except for the logo. This unit
was tested as an alternate to the unavailable Andros unit. The relative
degree of interinstrument correlation was demonstrated by the Scott and
Mopar IIIC tests.
This unit has excellent mobility while on its cart, due to C.G. location,
handle placement and wheel size. In addition, the unit is very handy used as
a bench top model due to its small size. The analyzer fits freely but tightly
into a tilted recess at the top of the cart. The analyzer is equipped with a
top-mount, strap-carrying handle that facilitates removal from the cart for
portable use. The cart contains a top-mounted drawer that is handy for manual
storage and a bottom storage cabinet with snap closing door. This cabinet
works very well for probe, trap and sample hose storage, although hose hangers
are mounted on the cart side and rear.
This analyzer uses a turbine-type sample pump differing from the typical
diaphragm pump found on other analyzers. This results in a very low level of
both noise and vibration.
This unit, without benefit of any form of particulate filter, has an
unusual sample handling system that appears to be relatively unsusceptible to
water and particulate accumulation.
This system uses only a single metal cooling tube in its sample hose to
collect moisture. This tube acts as a system low point and collects condensed
sample moisture which must be dumped out periodically. The probe used on this
unit is a convoluted tube approximately 3 feet long. It was noted that the
end plug on this sample tube broke off at the weld during durability testing.
The sample hose, made of clear unreinforced plastic tubing, periodically
filled with water during durability testing. When the flow restriction light
indicated low flow, the hose was drained and sampling returned to normal. The
material used for this hose was susceptible to melting when placed against a
hot exhaust pipe.
This unit, in general, was very easy to use and demonstrated exceptional
dependability. The analytical system on this unit consisted of a single
sample cell and rotating filter wheel. This unit demonstrated fast response
during the laboratory tests and vehicle test sequences. The response time
deteriorated badly by the end of the durability tests. The cause of this
deterioration might have been contamination or pump degradation.
This unit and Mopar IIIC incorporated lower ranges than any other instru-
ment tested. Because of its extremely low range, it is more applicable for
use with catalytic converter-equipped cars than the other instruments.
This instrument had a minimum number of controls and the simplest and
most straightforward operation and calibration procedures.
A single front panel gas port was used for both sample and calibration
gases. Range selection was made through the use of individual HC and CO
toggle switches. Range indication, other than switch position, was not utilized,
and this was the only negative aspect to the control/display function.
7-36
-------
In the laboratory tests, this unit showed acceptable warm up times. Zero
drift performance at normal laboratory temperature was reasonable considering
the low ranges incorporated in this unit. Zero drift for CO at high temperature
was 70 percent full scale indicating extreme stability sensitivity to high
temperatures. Low temperature zero drift was greater than that at normal
temperatures, but an order of magnitude lower for CO than that at high temper-
atures. (NOTE: both Scott II1C and Mopar IIIC showed the same zero drift
temperature sensitivity.)
The Scott IIIC showed good analytical accuracy tying with the Mopar IIIC
for fifth most accurate overall in the accuracy determination tests. In the
high altitude tests, the CO accuracy readings slipped significantly, most
prominently during high range tests. (The Mopar IIIC showed the same tendency.)
Instrument response time was fast, on the order of 10 seconds or less and
was relatively consistent during laboratory tests.
This instrument was not responsive to acetylene and only marginally
responsive to benzene. It was most responsive to isobutylene, followed by
toluene, methane and ethylene.
Voltage variation caused 1/2 percent full scale or less meter reading
variation.
The HC scale was noted to be slightly responsive to CO- and CO. The CO
meter showed 3 percent full scale response to the C0? sample and 1.6 to 4 per-
cent full scale response to the NO sample during the repeatability tests. The
HC scale response was not very repeatable but the CO scale response was rela-
tively repeatable, indicating possible excessive CO response to C0_ and NO.
The CO. response pattern was also seen in the Mopar IIIC but the NO response
was not as clear.
In the vehicle tests, the Scott IIIC was found to correlate sixth best of
all instruments with the EPA bench. HC correlation seemed to cause the most
trouble, especially on low range during the standard and lean modes.
This unit survived the durability test to the conclusion ending 960 hours
of operation.
This corresponds to exposure levels of 809,280 ppm-hours and 528 percent-
hours. The instrument showed relatively good day-to-day stability in the
durability test, with an average daily span drift of 1.92 percent full scale
for HC and 2.65 percent full scale for CO. Resistance to vibration and shock
was good with only 3 days of shock test failure (resulting in 73 percent full
scale meter variation) noted for the total durability test. This corresponds
to 0.05 failures per day.
This instrument required no maintenance other than hose and trap draining
during the duration of all tests. During the durability tests, the hose
required draining 14 times. This corresponds to a rate of 1.46 servicings per
100 hours of operation. This was the lowest total maintenance requirement of
all instruments tested.
7-37
-------
The only detrimental effect of the durability test on this instrument was
the aforementioned loss in response time.
Test data for Scott IIIC Exhaust Emission Analyzer are shown in Tables 7-11
through 7-15.
Photographs of this instrument are shown in Figures 7-8, 7-9, and 7-10.
7-38
-------
Attachment (1)
Table 7-11. DATA COMPOSITE - -LABORATORY TEST
INSTRUMENT:
SCOTT 111C
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
(CYCLE 1)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
(CYCLE 1)
18
16
(CYCLE 1)
0
2.0
15%
C02/N2
0.66
0
(CYCLE 2)
12
11
MAXI1V
(CYCLE 2)
5.0
70.0
(CYCLE 3)
21
21
(CYCLE 4)
15
15
IUM ZERO DRIFT % F\
(CYCLE 3)
9.33
1600ppm 10%
HC/N2 CO/N2
0.33
2.0
COMPARISON
CONDITION % FS
35
70
100
35
70
100
35
70
100
35
70
100
% ERROR
ABSOLUTE
6.0
3%
H20/AIR
0
0
H
+ 3.03
- 1.54
+ 0.23
- 0.99
- 2.0
+ 1.71
0
- 5.95
- 3.85
- 3.96
- 4.0
- 1.36
JLL SCALE
. (CYCLE 4)
5.33
1.80
2000ppm
NO/N2
0
• 4.0
C
% ERROR
FS
+ 10
- 1.05
+ 0.2
- 0.33
- 1.33
+ 1.67
0
- 3.05
- 3.3
- 1.3
- 2.67
- 1.3
10%
02/N2
0
0
C
% ERROR
ABSOLUTE
0.0
+ 3.08
+ 3.26
+ 1.25
+ .07
0.0
0
+ 4.62
+ 3.26
+ 0.06
- 0.28
+ 2.0
0
% ERROR
FS
0
+ 2.0
+ 3.0
+ 4.2
+ .04
0
0
+ 3.0
+ 3.0
+ 0.2
- .16
+ 2.0
•vl
I
OJ
-------
Table 7-11. DATA. COMPOSITE - -LABORATORY TEST (Cont'd)
Attachment (1)
SCOTT 111C
CYCLE 3
CYCLE 4
HIGH
ALTITUDE
RESPONSE &
RECOVERY
HYDROCARBON
RESPONSE
300 Feet
Altitude
6750 Feet
Altitude
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
RANGE
HIGH
HIGH
RANGE
LOW
LOW
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SCALE
HC
CO
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
CORRECTED
CONCENTRATION
1647
8.1
INSTRUME1S
287 ppm 323 ppm
ACETYLENE BENZENE
0 2
0 0
+ 4.54
- 2.65
- 0.93
- .99
0
+ 2.05
+ 4.54
- 1.18
+ .23
+ 3.96
0
+ 4.10
- 1.51
- 8.15
- 6.76
- 1.98
- 1.0
+ 0.68
INSTRUMEN
(CYCLE 1)
10.1
9.5
+ 1.
- 1.
- 0.
50
8
8
- .33
0
+ .20
+ 1.
- 0.
+ 0.
+ 1.
50
8
2
33
0
+ 4.
- 0.
- 5.
- 5.
0
5
55
8
- .67
- .67
+ .67
T RESPONSE TI
(CYCLE 2)
9.75
9.5
IT RESPONSE TO V
322 ppm
ETHYLENE
7
7
- 1.88
+ 1.54
+ 2.17
+ 1.25
+ .76
+ 2.0
- .54
+ 3.08
+ 2.17
+ 1.25
+ 0.41
+ 1.0
-16.66
-16.92
-18.48
-11.85
-17.18
-12.0
ME (SEC) (AVERA
(CYCLE 3)
8.25
7.0
rARIOUS HYDROCAF
385 ppm
ISOBUTYLENE
86
78
- 0.7
+ 1.0
+ 2.0
+ .42
+ .44
+ 2.0
- 0.2
+ 2.0
+ 2.0
+ .42
+ .24
+ 1.0
- 6.2
-11
-17
- 3.98
- 9.96
-12.0
,GE OF 2 RUNS)
(CYCLE 4)
6.05
6.0
.BONS AS ppm
337 ppm 329 ppm
METHANE TOLUENE
16
13
38
38
-------
Attachment (1)
Table 7-11. DATA COMPOSITE - LABORATORY TEST (Cont'd)
SCOTT IIJC
VOLTAGE
PROFILE
POWER
115V
115V
RANGE
HIGH
HIGH
SCALE
HC
CO
READING VARIATION AS FUNCTION OF
VARYING LINE VOLTAGE + 10%
+ 10%
0.5
0
- 10%
0
0
-------
Table 7-12. DATA COMPOSITE - REPEATABILITY TEST
INSTRUMENT: SCOTT 111C
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
CYCLE 1
GAS
INTERFERENCE
(% of FS)
CYCLE 2
GAS
INTERFERENCE
(% of FS)
CYCLE 3
GAS
INTERFERENCE
(% of FS) ,
CYCLE 4
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
(CYCLE 1) (CYCLE 2)
15 29
12 27
(CYCLE 3) (CYCLE 4)
25 25
27 22
MAXIMUM ZERO DRIFT % FULL SCALE
(CYCLE 1) (CYCLE 2) 1 (CYCLE 3) (CYCLE 4)
5.0 ! 12.6
2.4 2.0
15%
C02/N2
0
3.0
15%
C02/N2
0
3.0
15%
C02/N2
! 0
3.6
15%
C02/N2
HC 0
LOW CO
RANGE SCALE ,
(
i RESPONSE i HIGH HC
RECOVERY [HIGH co
1 C\
:ORRECTSD
:ONCENTRATION
3.66 1.6
4.6 1.0
1600ppm 10%
HC/N," CO/N?
fc ' <-•
1 0.67
2.0 | -
1600ppm i 10%
HC/N2 CO/N2
0
H20/AIR
0.0
0.0
3%
K20/AIR
0
o j -
leOOppm 10%
HC/N? CO/N2
0
0
leOOppm 10%
HC/N9" CO/N2
0.3
-
0
H90/AIR
2000Dpn>.
NO/N2*
0.0
• 4.0
.2000ppm
NO/N2
0
2.0
2GOOppm
NO/K2*
0 | 0
0
• 1.6
3% 1 2000ppm
""2 " ' " 2
10%
0.0
1.0
10%
0
0 i
10%
02/N2
0
0
10%
0 ! 0 i 0
0 2.4
0
INSTRUJ-1ENT RESPONSE TIME (SEC) (AVERAGE OF 2 RUNS)
CYCLE 1) j (CYCLE 2) j (CYCLE 3) ) (CYCLE 4)
1647 I 21.5 !
8.1 21.5 j
13.5 I 9 i 10.5
13.5 j 7 ! 8.5
-p-
to
-------
SCOTT me
Table 7-12. DATA COMPOSITE.- REPEATABILITY TEST (Cont'd)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
RANGE
HIGH
HIGH
HIGH
LCW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
COMPARISON
CONDITION % FS
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
H
% ERROR
ABSOLUTE
+3.03
-2.65
+0.23
+1.98
-0.50
+1.02
+6.06
-1.91
+0.23
+1.98
+0.5
+2.38
+6.82
-1.54
+1.11
0
-0.5
+ 2.05
+6.82
-1.54
+0.52
-0.99
-1.00
+1.71
C
% ERROR
FS
+1.00
-1.80
+0.20
+0.67
-0.33
+1.00
+2.0
-1.3
+0.2
+0.6
+0.3
+2.3
+2.25
-1.05
+0.95
0
-0.33
+2.0
+2.25
-1.05
+0.45
-0.33
-0.67
+1.67
C
% ERROR
ABSOLUTE
-1.88
+1.54
+2 . 17
+4.23
+0.07
+2.00
-1.88
+1.54
+3.26
+1.19
-0.62
+2.0
-3.23
+1.54
+1.09
+0.66
-0.62
+0.6
-2.69
+ 1.85
+2.17
-5.36
-5.52
-2.00
0
% ERROR
FS
-0.70
+1.00
+2.00
+1.42
+0.04
+2.00
-0.7
-1.0
+3.0
+0.4
-0.36
+2.0
-1.2
+1.0
+ 1.0
+0.22
-0.36
+0.6
-1.00
+ 1.20
+2.0
-1.80
-3.20
-2.0
-J
fc.
-------
Table 7-13. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST
SCOTT 111C
VPV Mnr>"P
CYCLE #
C rnAKTTlTi'DTl MOTJT*1
CYCLE 1
/"VPT.'F ")
CVPT.'P 3
CYCLE 4
LEAN MODE
CYCLE 1
CYCLE 2.
CYCLE 3
OVfT V 4.
O A KT*™1 1?
KnL.No.Ci
PPM/%
300/10
300/.5
300/10
300/.5
300/.5
300/10
300/.5
300/.5
300/10
300/10
300/.5
2000/5
300/10
300/.5
300/10
300/10
300/.5
300/10
300/10
300/.5
300/10
300/10
300/.5
2000/10
Cf £ T 7?
EC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
nr/co
HC/CO '
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
CDT?T?r\
50
30
IDLE
50
30
IDLE
50
30-
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
H
% ERROR
ABSOLUTE
- 30.82
- 30.85
- 5.21
- 21.05
- 31.74
1 - 10.09
- 11.50
- 0.48
+ 12.66
- 33.65
- 30.85
- 28.17
- 38.83
- 37.05
+ 13.71
- 19.5
- 16.58
+ 22.73
- 1.96
- 1.8
- 6.35
- 37-flfi
- 38.06
- 5.1
C
% ERROR
FS
- 10.1
- 11.6
- 3.67
- 6.4
- 12.4
- 8.6
- 3.77
- 0.17
+ 7.87
- 11.83
- 11.6
- 24.83
- 14.fi
- 11.97
+ 4.07
- 6.3
- 5.43
+ 4.26
- 0.63
- 0.6
- 9.0
- T*.^
- 14.13
- 0.94
C
% ERROR
ABSOLUTE
- 10.45
- 28.57
+ 7.14
- 13.79
- 46.88
- 1.79
- 16.67
- 35.71
+ 13.92
- 14.71
+ 13.64
+ 3.17
- fi.7R
- 26.92
- 19.05
+ 7.14
- 10.0
+ 16.67
- 11.69
- 16.67
+ 27.66
- 14.06
- 29.17
- 5.26
D
% ERROR
FS
- 0.7
- 8.0
+ 1.0
- 0.8
- 15.0
- 0.2
- 1.0
- 10.0
+ 2.2
- 1.0
+ 3.0 j
+ 0.4
- 0.4
- 7.0
- 8.0
+ 0.4 I
- 2.0
+10.0 :
- 0.9
- 4.0
+ 1.3
" 0.9
- 7.0
- 4.0
•t-
-------
Table 7-13. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS (Cont'd)
SCOTT 1 1 1C
KEY MODE
CYCLE #
pTr'M winm?
PVCT.F 1
CYCLE 2
CYCLE 3
CYCLE 4
RANGE
PPM/%
300/10
300/.5
300/10
300/10
300/.5
300/10
300/10
300/.5
300/10
300/10
300/.5
2000/10
SCALE
EC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
we /no
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SPEED '
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
H
% ERROR-
ABSOLUTE
- 1.96
- 6.28
- 2.67
+ 3.2
- 2.21
•f 4.02
- 4.67
- 11.35
- 2.16
- 7.11
- 14.24
- 10.05
C
% ERROR
FS
- 0.63
- 2.3
- 2.3
+ 1.03
- 0.8
+ 3.8
- 1.67
- 4.27
- 2.1
- 2.5
- 5.7
- 1.57
C
% ERROR
ABSOLUTE
0
- 12.5
+ 5.92
- 6.78
- 29.17
+ 14.86
- 11.29
+ 50.0
+ 12.27
- 18.18
+ 15.38
+ 6.64
3
^ ERROR
PS
I
0
- 3.0
+ 1.9
- 0.4
- 7.0
+ 5.5
- 0.7
+ 10.0
+ 4.7
- 1.0
+ 4.0
+ 2.8
•vl
i
in
-------
Table 7-14. DIAGNOSTIC TEST
SCOTT 1 1 1 C — — — —~ 1
TEST
SPARKPLUG SHORTED
NORMAL IDLE
IGNITION ADVANCE
IGNITION RETARD
RANGE
2000
10%
300
10%
2000
10%
300
10%
SCALE
HC
CO
HC
CO
HC
CO
HC
CO
PPM NO, PPM HC, % CO
TEST INSTRUMENT
1025
2.60
270
2.60
310
2.70
250
2.80
EPA BENCH
1131
2.11
390
2.14
349.1
2.19
365.9
2.43
i
HC/CO/NO
% ABSOLUTE
ERROR
- 9.37
+ 23.22
- 30.77
+ 21.50
- 11.20
+ 23.29
- 31.68
+ 15.23
% ERROR
FS
- 5.3
+ 4.9
- 4.0
+ 4.6
- 1.96
+ 5.1
- 38.63
+ 3.7
-------
Table 7-15. DURABILITY TEST DATA
INSTRUMENT: SCOTT 111C
INSTRUMENT TIME TO FAILURE AND GAS EXPOSURE
TIME TO FAILURE (HRS.)
HC EXPOSURE (PPM-HRS.)
CO EXPOSURE (%-HRS.)
NO EXPOSURE (PPM-HRS.)
960
809^280
528
114,240
INSTRUMENT STABILITY
TOTAL NO. DAYS SHOCK TEST FAILURE
(3% Variation) 1 or More of 4 Modes
SHOCK TEST FAILURE RATE
(Failure/Day %)
INCIDENCE OF FAILURE IN EACH MODE
HC ZERO
HC SPAN
CO ZERO
CO SPAN
AVERAGE DAILY SPAN DRIFT
HC%
CO% ,
N0%
3
5.0
2
0
0
1
1.92
2.65
__
INSTRUMENT SERVICE REQUIREMENTS
A CHANGE FILTER
TOTAL
PER 100 HRS.
B DRAIN HOSE
TOTAL
PER 100 HRS.
C REZERO
TOTAL
PER 100 HRS.
D. SAMPLING SYSTEM
TOTAL
PER 100 HRS.
E. OTHER
TOTAL
PER 100 HRS.
—
14
1.46
—
—
—
7-47
-------
Figure 7-8. SCOTT IIIC EXHAUST EMISSION ANALYZER
7-48
-------
Figure 7-9. SCOTT IIIC EXHAUST EMISSION ANALYZER (BACK)
7-49
-------
Figure 7-10. SCOTT IIIC EXHAUST EMISSION ANALYZER (LEFT SIDE AND PROBE)
7-50
-------
7.4 MARQUETTE 42-160 INFRARED EMISSIONS ANALYZER
Manufacturer - Marquette Manufacturing Division Applied Power Industries
Description - HC/CO exhaust analyzer configured as a bench top unit
supplied with a four-wheel cart for mobile use. This unit also
incorporated a 0 to 3,000 rpm electronic tachometer and ignition
probe.
Dimensions -
Analyzer: Height - 17-3/4 inches
Width - 13-1/2 inches
Length - 23-5/8 inches
Weight - 80 Ibs.
Cart: Height - 34 inches
Width - 19 inches
Length - 27-1/2 inches
Weight - 50 Ibs.
Cart has one lower shelf for storage and a side-mounted hanger
for the sample hose.
Material of Construction - Analyzer - Sheet metal. Cart - Sheet metal
and steel tubing. Joints are welded and/or screwed together.
Color - Analyzer - Red with black front. Cart - Red with gold handle and
chrome tube legs.
Mobility - Four steerable, 4-inch diameter wheels. Front wheels incor-
porate locks. Mobility is good with stable feel during movement.
Accessories - Tail pipe probe, flexible 20-foot sample hose, weighted
shot bag (to hold probe in tail pipe), tachometer probe wire, operat-
or's manual.
Control Package -
Front Access - Test mode switch (four positions)
1. Tach, CO-LO
2. CO/HC HI
3. CO/HC LO
4. Span
HC Air adjust - knob (zero)
HC Span adjust - knob
CO Air adjust - knob (sero)
CO Span adjust - knob
Pump Switch - ON/OFF toggle
Detector Switch -ON/OFF toggle
Pump On Indicator - light
Detector On Indicator - light
Tach Check - push button
Fuse Cartridge - 4A slo bio
7-51
-------
Side Access -
HC - Span (scale) - screw
HC - High (scale) - screw
CO - Span (scale) - screw
CO - High (scale) - screw
Located on right panel under a small plate attached with two
screws.
Mode Switch - (pneumatic) - 2-position - sample, air/cal gas (located
on left panel)
Flow indicator - mechanical
Air/cal gas inlet
Meters - 7-3/4" wide x 4-5/8" high, 100° swing
Black figures and increments on white background Figures on
meter faces were large giving very good long range readability. HC
meter incorporates 0 to 3,000 rpm tach scale on bottom of meter.
HC scale - 0 - 2000 ppm in 20 ppm increments
0 - 1000 ppm in 10 ppm increments
CO scale - 0 - 10% in 0.20% increments
0 - 5% in 0.10% increments
These meters did not appear to be sensitive to static electricity
(soft cloth rubbed across meter face).
Altitude Compensation - On chart in operator's manual. No scale on meter
faces. Not needed if gas calibrated at altitude used.
Probe - "S" curved tubing with a spiral flex section welded on the top of
the tube. A convoluted tube is inserted into the flexible section.
The sampling tip is on the end of the convoluted tube.
Filters and Sample Handling - Pump aspirated water trap (self draining)
with level routing of water outlet. A large accordion-type circular
paper filter cartridge was in series with water trap. Mechanical
flow indicator.
Cal Gas Inlet - Side panel near flow mode switch.
Power Requirements - 120 volts 60HZ 360 watts
Operating Principles - Dual beam nondispersive infrared with chopper,
positive filters, solid-state detectors, and hot wire sources.
Calibration - Electronic span adjust on meter faces with mode switch in
span. Gas calibration with side port and side-mounted adjustment
screws. Multiple turn pots for zero and span give good range and
resolution.
Operation and Calibration - Fairly straightforward, but combined range
and function switch was slightly confusing.
7-S2
-------
1. Set air adjust (zero)
2. Check mechanical span
3. Run low and then high range gases using front span adjust and
side "High" pots
4. Using side "Span" pots adjust span set point
5. Push tach check button - needle to tach set dot
6. Ready for use
7.4.1 Operational Performance Comments
The analyzer and cart combination is relatively heavy. The analyzer sets
freely on the top of the cart and is configured as a bench top unit, but at
80 pounds it is really too heavy to be a practical bench top analyzer. The
lower shelf on the cart works well for storage of the probe and sample hose.
The engine rpm function included on this unit could be a very useful accessory.
The control of this function with the same mode switch used for emission
measurements was slightly confusing.
From a functional standpoint, the sample system and, specifically, the
paper filter cartridge was probably the best filter design of all units tested
that used filters. It presented the fewest maintenance problems of all filters.
The mechanical flow indicator used in this unit gave better progressive indica-
tion of flow degradation than the on/off light types, although the mechanical
indicator was not as obvious as a light.
There were good operating instructions on the instrument case but they
were located in a relatively awkward position on the left side panel of the
unit. There were no calibration instructions on the unit, but they were
included in the operator's manual.
This instrument utilized a relatively stiff sample hose that exhibited
ply separation at both ends by the conclusion of the durability test. In
addition, during the durability test, the probe failed at the beginning of the
flex section. The spiral flex section broke near its weld.
In the laboratory tests this unit showed fairly long warm up times at
normal temperatures. This unit demonstrated extreme up- and down-scale zero
drift for several hours after warm up. Due to the test data collection tech-
nique (one data point taken every 30 minutes for 4 hours), this phenomenon was
not terribly apparent. Many times the meter needle position at data collection
time was near zero while, in reality, the needle subject to randomly occurring
erratic zero and span shifts during the laboratory tests. Poor performance in
some tests can be attributed to this phenomenon. This phenomenon was somewhat
similar to accelerated zero or span drift. Zero drift performance indicated
by the data showed 3 percent full scale drift on HC as the worst case.
Gas interference showed 1 percent full scale or less meter deflection for
all gases.
The Marquette was second only to Horiba in overall accuracy. Its overall
accuracy was very good. In high altitude accuracy tests the Marquette scored
highest of all HC/CO analyzers.
7-53
-------
The general response time for this unit was slow, ranging up to 30 seconds.
Pump sizing or sample system design may have been at fault.
This unit showed no HC response to acetylene or benzene. It was most
responsive to isobutylene followed by toluene. It was marginally responsive
to ethylene and methane. Voltage fluctuation caused 1 percent full scale or
less meter deflection.
In the repeatability drift test, the random erratic shifts noted early
can be seen to detrimentally affect the performance data.
In the vehicle tests, the Marquette was found to correlate second best to
the EPA bench. No real problem areas were evident in exhaust correlation.
This instrument survived the durability tests to the end. It endured 960 hours
of operation. This corresponded to an exposure level of 809,280 ppm-hours for
HC and 528 percent-hours for CO. Although it finished the test, its operation
was deteriorating rapidly at the end.
The design of this instrument's sample system incorporates a restrictor
plug in the aspirator near the water outlet. This restrirtor plug stopped up
often, requiring shut down, removal of sample hose, water trap top cover and
other miscellaneous hoses and subsequent cleaning.
Durability tests indicated that the paper filter used on this unit had a
long, trouble-free life. Maintenance of this filter was quick and simple due
to its external location.
In the shock and vibration test, the unit totalled 11 test days when
3 percent variation was noted during this test. This indicates moderate
sensitivity to shock. This corresponds to 0.18 failures per day.
The average daily span drift noted during durability tests was 5.7 percent
full scale for HC and 4.9 percent full scale for CO indicating that span set
adjustments are needed more often than on a daily basis.
In general, overall service requirements for this unit were about average
considering all test units.
Test data for Marquette 42-160 Infrared Emission Analyzer are shown in
Tables 7-16 through 7-20.
Photographs of this instrument are shown in Figures 7-11, 7-12, and
7-13.
7-54
-------
Table 7-16. DATA COMPOSITE - LABORATORY TEST
Attachment (1)
INSTRUMENT:
MARQUETTE 42-160
1
Ln
Oi
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
(CYCLE 1)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
(CYCLE 1)
23
23
(CYCLE 1)
0.5
0
15%
C02/N2
0
0
(CYCLE 2)
14
14
MAXII*
(CYCLE 2)
2.0
1.0
(CYCLE 3)
27
27
1UM ZERO DRIFT % Fl
(CYCLE 3)
3.0
1600ppm 10%
HC/N2 CO/N2
o:.2
0
COMPARISON
CONDITION % FS
35
70
100
35
70
100
35
70
100
35
70
100
% ERROR
ABSOLUTE
+ 3.
- 0.
+ 0.
- 1.
- o.
- 2.
+ 9.
- 2.
- 0.
- 0.
70
65
23
12
44
60
63
23
80
56
0.4
3%
H20/AIR
0
0
H
- 2.22
- 7.
57
(CYCLE 4)
15
9
JLL SCALE
(CYCLE 4)
0
0.2
2000ppm
NO/N2
0
• 0
C
% ERROR
FS
+ 1.25
- 0.45
+ 0.20
- 0.40
- 0.30
- 2.2
+ 3.25
- 1.55
- 0.70
- 0.20
- 1.50
- 6.40
10%
02/N2
0
0
C
% ERROR
ABSOLUTE
+ 1.61
+ 1.69
- 0.98
+ 2.86
- 0.96
- 0.96
+ 2.15
+ 2.31
0
+ 0.57
+ 3.21
+ 5.78
0
% ERROR
FS
+ 0.60
+ 1.10
- 0.90
+ 1.00
- 0.60
- 0.80
+ 0.8
+ 1.5
0
+ 0.20
+ 2.00
+ 4.80
-------
Table 7-16.
MARQUETTE 42-160
DATA COMPOSITE - LABORATORY TEST (Cont'd)
Attachment (1)
CYCLE 3
CYCLE 4
HIGH
ALTITUDE
RESPONSE &
RECOVERY
HYDROCARBON
RESPONSE
300 Feet
Altitude
6750 Feet
Altitude
HIGH
HIGH
HIGH
LOW
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
RANGE
HIGH
HIGH
.RANGE
LOW
LOW
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SCALE
HC
CO
35
70
100
35
70
70
100
36
70
100
35
70
100
35
70
100
35
70
CORRECTED
CONCENTRATION
1683
8.1
INSTRUMEK
287 ppm 323 ppm
ACETYLENE BENZENE
0 0
0 0
+ 6.
- 0.
+ 0.
+ 2.
+ 2.
+ 2.
- 1.
+ 0.
- o.
+ 0.
- 0.
- 0.
- 3.
+ 3.
- 2.
+ 0.
- 1.
- 0.
INSTRUMEN'
(CYCLE 1)
14.45
14.9
67
07
23
24
22
22
89
74
79
34
56
74
07
07
23
34
96
74
+ 2
- 0
- 0
+ 0
-f 1
+ 1
- 1
+ 0
- 0
+ 0
- 0
- 0
- 2
+ 1
- 1
+ 0
- 0
- 0
I RESPONSE TI
(CYCLE 2)
11.5
12.75
rr RESPONSE TO \
322 ppm
ETHYLENE
5
5
.25
.05
.20
.80
.50
.50
.60
.25
.55
.3
.20
.50
.60
.25
.55
.30
.70
.50
+ 0.81
+ 1.54 _J
+ 0.54
- 2.86
+ 0.96
+ 0.96
0
- 0.54
+ 1.54
- 1.09
- 1.14
- 0.64
- 1.21
- 1.88
0
- 1.09
- 1.7.1
+ 0.96
ME (SEC) (AVERA
(CYCLE 3)
30.0
28.5
rARIOUS HYDROCAF
385 ppm
ISOBUTYLENE
78
84
+ 0.30
+ 1.00
+ 0.50
- 1.00
+ 0.60
+ 0.60
0
- 0.20
+ 1.0
- 1.0
- 0.40
- 0.40
- 1.00
- 0.70
0
- 1.00
- 0.60
+ 0.60
GE OF 2 RUNS)
(CYCLE 4)
25.0
26.5
,BONS AS ppm
337 ppm 329 ppm
METHANE TOLUENE
5
20
21
28
-------
Ul
Attachment (1)
Table 7-16. DATA COMPOSITE - LABORATORY TEST (Cont'd)
MARQUETTE 42-160
VOLTAGE
PROFILE
POWER
115V
115V
RANGE
HIGH
HIGH
SCALE
HC
CO
READING VARIATION AS FUNCTION OF
VARYING LINE VOLTAGE + 10%
+ 10%
0.65
1.0
- 10%
0.65
1.0
-------
INSTRUMENT:
Table 7-17. DATA COMPOSITE - REPEATABILITY TEST
MARQUETTE 42-160
1
!
i
1
Ui
oo
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
CYCLE 1
GAS
INTERFERENCE
(% of FS)
CYCLE 2
GAS
INTERFERENCE
(% of FS)
CYCLE 3
! GAS
INTERFERENCE
(:•_- of FS)
CYCLE 4
RANGE
LOW
LOW
RANGE
SCALE
HC
CO
SCALE
LOW i HC
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
JLOW
RANGE
i
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
I
i (CYCLE 1) (CYCLE 2
8 28
: 8 27
MAX
j (CYCLE 1) (CYCLE 2
15.0 8.4
i 0.6 0.6
15%
CO2/N2
o.o
0.2
15%
C02/N2
0
i 0.4
I 15%
1 _ C02/N?
1600ppm 1
T?C /TV~ s~*
~ i **
1.0
) (CYCLE 3)
24
17
IMUM ZERO DRIFT %
) (CYCLE 3)
4.4
0.2
0% 3%
O/N2 HO 0 /AIR
.5 0.0
(CYCLE 4)
20 j
14 i
FULL SCALE i
i
(CYCLE 4) !
5.9 j
0.2 ' !
2000ppm
NO/N""
0.0
j -0.0
IGOOopm 10% 3%
HC/N~7 CO/N2 H20/AIR
0
0
.5 I 0 •
i o !
IGOOppm 10% 3%
HC /N 7 CO/N o K o 0 /AI R
; o | - o
! 0.4
i 15%
1 C02/N2
LOW ! HC J 0
!LOW
CO
RANGE SCALE
i L '
j TT-r/-»TJ TT/"1
' RESFONSE i JHJ-GH Ht_
! RECOVERY (HIGH co
1 °
CORRECTED
CONCENTRATION
0
j 0
i o
1600cpra 10% j 3%
HC/'N o " CO /N 2 H 2 0 /AI R
0190 j 0 j
0
i o
"NO/NJ"
0
10%
02/N2
0.0
0.0
10%
02/N2
0
•0 | 0.2 _. _j
2GOOppm
NO/NO
0
•0
NO/^~
10% '•
0 ;
0
! 10%
O AT
22
o i o
.02
0
INSTRUMENT RESPONSE TIME (SEC) (AVERAGE OF 2 RUNS)
(CYCLE 1) | (CYCLE 2) (CYCLE 3) j (CYCLE 4)
1683 i 20 !
8.1 \ 21 j
27.5 11.5 i 13.5
25 j 10.5 ! 8.5
-------
Table 7-17. DATA COMPOSITE - REPEATABILITY TEST (Cont'd)
MARQUETTE 42-
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
160
RANGE
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO .
COMPARISON
CONDITION % FS
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
H
% ERROR
ABSOLUTE
+5.19
-0.07
-0.23
-0.56
-2.22
-8.98
+8.15
-1.87
-0.23
+3.08
+2.22
-3.31
+11.11
+2.80
+1.48
+2.24
+1.04
-1.89
+4.44
-2.59
+ 0.34
+1.40
+0.74
-4.49
C
% ERROR
FS
+1.75
-0.05
-0.20
-0.20
-1.50
-7.60
+2.75
-1.3
-0.2
+1.1
+1.5
-.2.8
+3.75
+1.95
1.3
+0.80
+0.70
-1.50
+1.50
-1.80
+0.30
+0.50
+0.50
-3.80
C
% ERROR
ABSOLUTE
-5.91
-3.08
-5.43
+2.29
+4.17
+3.13
+2.15
0
-2.17
-2.86
+2.88
+3.13
+2.69
+3.85
-0.54
-3.43
-1.28
0
-3.23
-1.54 n
i
0
% ERROR
FS
-2.20
-2.00 j
-5.00
+0.80
+2.60
+2.60
+0.8
0
-2.0
-1.0
+1.8
+2.6
+1.00
+2.50
-0.50
-1.20
-0.80
0
-1.20
-1.0
-1.63 | -1.50
-1.71
+1-.28
+0.48
-0.60
+0.80
+0.40
-J
I
VO
-------
Table 7-18. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS
MARQUETTE 42-160
~J
1
o
KEY MODE
CYCLE #
STANDARD MODE
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
LEAN MODE
CYCLE 1
CYCLE 2
CYCLE 3
CYCLF 4
RANGE
PPM/0/
/o
1000/5
1000/5
1000/5
100C/5
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO '
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SPEED
50
30
IDLE
50
30
IDLE
50
30-^
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
H
% ERROR
ABSOLUTE
+ 16.99
+ 21.5
+ 6.95
- 1.32
- 7.75
• - 4.92
+ 20.61
+ 18.48
- 33.28
+ 4.17
+ 5.21
+ 2.09
+ 10.58
+ 12.39
+ 25.31
+ 4.27
+ 56.7
+ 6.35
+ 23.22
+ 51.15
+ 21.88
+ 18.91
+ 18.91
- 1.49
C
% ERROR
FS
+ 1.67
+ 2.7
+ 1.95
- 0.12
- 0.84
- 1.19
+ 1.88
+ 1.95
- 7.74
+ 0.38
+ 0.52
+ 0.4
+ 0.89
+ 0.99
+ 16.16
+ 0.45
+ 0_._5.9 .
+ 3.61
+ 2.45
+ 4.23
+ 11.49
+ 1.59
+ 1.67
- 0.53
C
% ERROR
ABSOLUTE
-. 20.fi3
- 25.0
+ 11.11
- 9.09
- 35.71
+ 25.0
+ 16.07
- 25.0
+ 30.14
+ 20.0
+700.0
+ 20.69
+ 3.45
- 18.18
- 36.84
- 1.79
- 20.0
+ 19.05
+ 14.55
- 15.0
- 22.22
+ 31.0 i
+700.0
+ 71043
0
% ERROR
FS
- 2.6
- 0.6
+ 1.0
- 1.2
- 1.0
+ 5.2
+ 1.8
- 0.6
+ 4.4
+ 2.0
+ 1.4
+ 4.8
+ 0.4
- 0.4
- 1.4 j
- 0.2
- 0.4 •
+ 0.8 :
+ 1.6 ;
- 0.3
- O.R
+ 1. -6
+ 1.4
+ 3.0
-------
Table 7-18. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS (Cont'd)
MARQUETTE 42-160
KEY MODE
CYCLE #
RICH MODE
fVfT P 1
t
CYCLE 2
CYCLE 3
CYCLE 4
P2XTJ/7T!1
PPM/%
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
1000/5
cpAT P
EC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
Wd/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
COPTT^ '
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
H
% ERROR
ABSOLUTE
- 11.21
- 3.69
+ 18.1
+ 28.46
+ 37.44
1 + 27.83
4- 13.25
+ 23.84
+ 14.18
+ 9.65
+ 9.00
- 25.57
C
% ERROR
FS
- 1.2.
- 0.46
+ 6.13
+ 2.88
+ 3.95
+ 8.49
+ 1.17
+ 2.31
+ 3.54
H- 0.88
+ 0.95
- 6.7
C(
% ERROR
ABSOLUTE
4- P 11
- 40.74
- 31.03
+ 1.69
- 28.57
+ 19.35
4- 7.14
-.25.0
+ 9.28
+ 2.94
- 38.46
- 27.78
D
%' ERROR
T^q
i
4 3.^2
r- 2.2
- 28.8
f 0-2
- 0.8
^ 15.4
»- nTn
- 0.6
i- 6.2
K 0.4
- 1 .0
- 20.0
-------
MARQUETTE 42-160
Table 7-19. DIAGNOSTIC TEST
TEST
SPARKPLUG SHORTED
NORMAL IDLE
IGNITION ADVANCE
IGNITION RETARD
RANGE
1000
5%
1000
5%
1000
5%
1000
5%
SCALE
HC
CO
HC
CO
HC
CO
HC
CO
PPM NO, PPM HC, % CO
TEST INSTRUMENT
1025
2.70
740
2.70
700
2.80
520
2.75
EPA BENCH
1131
2.17
669
2.20
660
2.22
496
220
HC/CO/NO
% ABSOLUTE
E^ROR
- 19.64
+ 24.42
+ 10.61
+ 22.73
+ 6.06
+ 26.13
+ 4.84
+ 2.5
% ERROR
FS
+ 22.0
+ 10.6
+ 7.1
+ 10.0
+ 4.0
+ 11.6
+ 2.4
+ 11.0
-------
Table 7-20. DURABILITY TEST DATA
INSTRUMENT: MARQUETTE 42-160
INSTRUMENT TIME TO FAILURE AND GAS EXPOSURE
TIME TO FAILURE (HRS.)
HC EXPOSURE (PPM-HRS.)
CO EXPOSURE (%-HRS.)
960
809,280
528
NO EXPOSURE (PPM-HRS.)
114,240
INSTRUMENT STABILITY
TOTAL NO. DAYS SHOCK TEST FAILURE
(3% Variation) 1 or More of 4 Modes
11
SHOCK TEST FAILURE RATE
(Failure/Day %)
18.33
INCIDENCE OF FAILURE IN EACH MODE
HC ZERO
11
HC SPAN
CO ZERO
CO SPAN
0
AVERAGE DAILY SPAN DRIFT
HC%
5.65_
4.86
NO%
INSTRUMENT SERVICE REQUIREMENTS
A CHANGE FILTER
TOTAL
PER 100 HRS.
B DRAIN HOSE
TOTAL
PER 100 HRS.
REZERO
TOTAL
PER 100 HRS.
D. SAMPLING SYSTEM
TOTAL
PER 100 HRS.
E. OTHER
TOTAL
PER 100 HRS.
6
0.63
21
2.19
54
5.63
17
1.77
51*
5.31
* SWITCHED TO AIR INLET TO BLOW OUT WATER TRAP
7-63
-------
Figure 7-11,
1IARQUETTE 42-160 INFRARED EMISSIONS ANALYZER
7-64
-------
Figure 7-12. MARQU
42-160 INFRARED EMISSIONS ANALYZER (LEFT SIDE)
7-65
-------
Figure 7-13. 1IARQUET1E 42-160 INFRARED EMISSIONS ANALYZER (BACK)
7-66
-------
7.5 BECKMAN 590 HC/CO TESTER
Manufacturer - Beckman Instruments, Inc.
Description - HC/CO exhaust analyzer configured as a bench top analyzer
secured to a four-wheeled cart. The analyzer could be used with or
without the cart with equal ease. The cart incorporates two shelves
for storage.
Dimensions -
Analyzer - Height - 10 inches
Width - 20 inches
Depth - 20 inches (with water trap)
Cart - Height - 45 inches
with Width - 23 inches
Analyzer Depth - 17 inches
Weight - Analyzer - 85 Ibs. Cart - 45 Ibs.
Analyzer is mounted on 30 angle on cart top.
Material of Construction - Analyzer cover - sheet aluminum. Analyzer
front - brushed sheet metal. Cart shelves - steel tubing welded and
screwed together.
Color - Analyzer - Orange with silver brushed steel front panel. Cart -
Orange top shelf, black bottom shelf, chrome legs.
Mobility - Four, 5-inch, swiveling wheels. Front wheels incorporate
mechanical locks. Mobility and stability are rated excellent.
Accessories - Sample probe, 25-foot sample hose, operator's manual.
Control Package -
Front Access - HC range and mode switch (three-position)
1. 2000 ppm
2. 400 ppm
3. Calibrate
HC zero - knob (with locking ring)
HC calibration - knob (with locking ring)
CO range and mode switch (three-position)
1. 10%
2. 2%
3. Calibrate
CO zero - know (with locking ring)
CO calibration (knob) (with locking ring)
Sample Mode Valve (two-position)
1. Container
2. Probe
On/Standby switch (toggle)
Flow Indicator (mechanical)
7-67
-------
Side Access -
2% CO set - screw
CO cal - screw
400 ppm set - screw
HC cal - screw
Rear Access recorder jacks (TB)
Meters - 8", 90° swing
Black figures and scale graduations on white background.
Ranges - HC - 2000 ppm in 50 ppm increments
400 ppm in 10 ppm increments
CO - 10% in 0.2% increments
2% in 0.05% increments
Altitude scales on meter faces
Meters were not sensitive to static electricity (soft cloth
rubbed over face of meter).
Altitude Compensation - Scales on meter faces used in conjunction with
HC/CO cal pots (side access). Not needed with gas calibration at
altitude of use.
Probe - Convoluted tubing with capped and perforated end, nonmetallic
handle, tail pipe clamp.
Filters and Sample Handling - Water trap with 50 micron-sintered metal
filter, dual head pump (water aspiration, sample transport), 25-foot
sample hose, flow indicator.
Cal Gas Inlet - Unlabeled, on rear analyzer panel.
Power Requirements - 115 BAG 60/50HZ 275 watts
Operating Principles - Dual channel nondispersive infrared analyzer with
optical filters, solid-state thermistor detector, hot wire sources,
chopper wheel.
Calibration - Electronic reference signal using calibrate position of
HC/CO mode switches. Altitude of test site set on meter faces. Gas
calibration using rear panel port.
Operation and Calibration - Straightforward operation and sample system
service directions are attached to the cart by a short chain. No
gas calibration instructions are on analyzer or cart but are included
in operator's manual.
Procedure -
1. Plug in and warm up (optical bench is powered up whenever
instrument is plugged in)
2. Zero
7-68
-------
3. Set altitude
4. Use
5. Optional gas calibration
7.5.1 Operational Performance Comments
Based upon the results of usage during these tests, this unit was judged
to have the best overall cabinet and cart design. Mobility and stability
during movement were excellent. This was attributed to the C.G. location,
sturdy construction and utilization of large wheels. The cart is equipped
with two large shelves that are used for power cord and sample hose storage.
The tubular steel outer framework of the cart serves to protect the analyzer
from damage. The only problem area for possible impact damage is the rear-
mounted plastic water trap which protrudes approximately 3/4 inches past the
rear steel tubes. The steel tubing also interferes with side access to the HC
and CO calibration and set pots.
The fact that the rear calibration gas port was unlabeled caused slight
confusion. The operator's manual does not identify this port.
One nice feature found on this instrument was the locking mechanism on
the zero and calibration knobs. If properly used, these locks prevented
accidental setting changes due to objects (hands) brushing against the knobs.
The on/standby switch function should be described more completely in the
operator's manual. It is not immediately clear that this instrument has no
real off position unless the plug is pulled. The on/standby switch does not
completely control all electrical functions in the unit. In the standby mode,
certain components are powered up. In the on position, all components are
powered up. During the warm up time tests, this unit was "switched on" by
plugging in the cord with the switch in standby position.
The mechanical flow indicator appeared to be not quite sensitive enough
for this application. This unit gave a progressive indication of flow degrada-
tion not available on those units equipped with flow indication lights. This
progressive indication was easy to follow with good visibility due to the
red/green color scheme and the front panel location of the indicator. Unfortu-
nately, the performance of the unit would markedly degrade indicating flow
blockage prior to flow restriction indicator operation. An increase in sensi-
tivity would be worthwhile.
Operation of this unit reveals a moderately high level of noise and
vibration due to the sample pump selection and mounting.
During various tests a random unpredictable drift pattern was observed.
This interfered with some of the test readings. In the repeatability tests,
cycles two, three and four, for zero drift showed the effects of this random
drift phenomenon.
The print on the meters was relatively fine and might not be bold enough
for use in less than optimum lighting conditions. The meters were not lighted
on this unit. Additionally, no range indication lights were used. .The range
position switch was the only range indication and under certain lighting
conditions, this switch position was hard to read.
7-69
-------
In the laboratory tests, the unit demonstrated relatively long warm up
times.
Zero drift in the laboratory and repeatability tests was large for the HC
scale especially at high temperature. CO zero drift was 2 percent full scale
or less under normal temperature and 3 percent full scale at high temperature.
The only repeatable gas interference was 1 to 2 percent full scale CO response
to C0_.
In the accuracy determination tests, the Beckman was found to be third
most accurate overall. During high altitude accuracy tests, the Beckman could
not be adjusted for correct CO span while gas calibrating. High range gas was
used and the CO "Calibration" pot was turned to its upper limit but the CO
span gas value could not be reached.
The instrument showed fairly quick sampling response time and was rela-
tively repetitive.
This unit was unresponsive to acetylene, benzene and ethylene. It was
most responsive to isobutylene, followed by toluene and methane.
The Beckman 590 was essentially insenstive to voltage fluctuation.
The Beckman was fourth fest in overall EPA bench correlation during the
vehicle tests.
This unit completed only 50 hours of testing in the durability sequence.
This corresponds to 50,500 ppm-hours for HC and 102 percent-hours for CO.
Failure resulted when both CO and HC meter readings went off scale (high end).
The meters would not recover regardless of what corrective action was taken.
In the area of maintenance, during the durability tests, the 50 micron-
sintered metal filter in the water trap repeatedly plugged requiring frequent
attention. The sample hose and probe caused no problems.
Test data for Beckman 590 HC/CO Tester are shown in Tables 7-21 through
7-25.
Photographs of this instrument are shown in Figures 7-14, 7-15, and
7-16.
7-70
-------
Attachment (1)
Table 7-21. DATA COMPOSITE - LABORATORY TEST
INSTRUMENT:
BECKMAN 590
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
(CYCLE 1)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
EC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
(CYCLE 1}
23
23
(CYCLE 1)
2.5
0
15%
C02/N2
0.5
1.0
(CYCLE 2)
11
11
MAXIJ'
(CYCLE 2)
15.0
3.0
(CYCLE 3)
25
25
(CYCLE 4)
11
11
IUM ZERO DRIFT % Fl
(CYCLE 3)
2.5
1.0
leOOppm 10% 3%
HC/N2 CO/N2 H20/AIR
0.5 0
0
COMPARISON
CONDITION % FS
35
70
100
35
70
100
35
70
100
35
70
100
0
H
% ERROR
ABSOLUTE
+ 7.70
+ 1.25
- 0.58
- 0.94
- 2.4
- 0.54
+ 6.99
- 3.87
- 1.54
- 3.74
- 2.01
- 2.16
JLL SCALE
(CYCLE 4)
0.5
1.0
2000ppm
NO/N2
0
- 0
C
% ERROR
FS
+ 2.7
+ 0.55
- 0.55
- 0.25
- 1.50
'- 0.50
+ 2.45
- 1.3
- 1.4
- 1.0
- 1.25
- 2.0
10%
02/N2
0
0
C
% ERROR
ABSOLUTE
- .54
+ 1.67
- 0.61
+ 1.45
+ 0.95
- 1.14
- 3.23
+ 1.54
+ 2.17
+ 7.25
0
0
3
% ERROR
FS
- 0.2
+ 1.0
- 0.6
+ 0.50
+ 0.50
- 1.0
- 1.2
+ 1.0
+ 2.0
+ 2.5
0
0
-------
Table 7-21.
BECKMAN 590
DATA COMPOSITE - LABORATORY TEST (Cont'd)
Attachment (1)
CYCLE 3
CYCLE 4
HIGH
ALTITUDE
RESPONSE &
RECOVERY '
HYDROCARBON
RESPONSE
300 Feet
Altitude
6750 Feet
Altitude
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
LOW
LOW
LOW
LOW
RANGE
HIGH
HIGH
RANGE
LOW
LOW
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SCALE
HC
CO
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
CORRECTED
CONCENTRATION
1749
8.1
INSTRUMElS
287 ppm 323 ppm
ACETYLENE BENZENE
0 0
0 0
+ 4.
+ 1.
- 0.
+ 2.
- 3.
- 0.
+ 6.
- 2.
- 1.
2.
- 2.
14
80
71
80
62
54
99
49
26
80
81
- .54
+ 0.
- 3.
- 0.
+ 0.
- 3.
- 0.
INSTRUMEN1
(CYCLE 1)
9.7
10.0
14
18
71
94
62
27
+ 1.
+ 1,
- 0.
+ 0,
- 2.
- 0.
.45
,30
65
.75
25
50
+ 2.45
— 1
J- 4
- 1.
+ 0.
- 1.
- 0.
+ 0.
_ 2
- 0.
+ o.
- 2.
- 0.
r RESPONSE TI
(CYCLE 2)
7.0
8.15
FT RESPONSE TO V
322 ppm
ETHYLENE
0
5
8
15
75
75
5
05
30
65
25
25
25
- 0.54
+ 1.54
0
+ 8.70
+ 4.76
+ 1.71
+ 2.15
+ 2.31
+ 2.17
+ 8.70
+ 0.95
- 0.57
INSTRUMENT
M
ii
ii
M
n
- 0.20
+ 1.0
0
+ 3.0
+ 2.5
+ 1.5
+ 0.80
+ 1.50
_ 2.00
+ 3.0
+ 0.5
- 0.8
MALFUNCTION
n
n
n
M
II
ME (SEC) (AVERAGE OF 2 RUNS)
(CYCLE 3) (CYCLE 4)
11.25 15.0
12.45 14.5
rARIOUS HYDROCAF
385 ppm
ISOBUTYLENE
65
75
BONS AS ppm
337 ppm 329 ppm
METHANE TOLUENE
8 9
8 22
I
-^1
N:
-------
Attachment (1)
Table 7-21. DATA COMPOSITE - LABORATORY TEST (Cont'd)
BECKMAN 590
VOLTAGE
PROFILE
POWER
115V
115V
RANGE
HIGH
HIGH
SCALE
HC
CO
READING VARIATION AS FUNCTION OF
VARYING LINE
+ 10%
0
0
VOLTAGE ± 10%
- 10%
0
0.2
-J
I
-------
Table 7-22. DATA COMPOSITE - REPEATABILITY TEST
INSTRUMENT:
BECKMAN 590
WARMUP
TIME (Min.)
RANGE
LOW
LOW
i
SCALE j (CYCLE 1)
HC i 8
CO i 7
(CYCLE 2)
18
18
(CYCLE 3)
30
25
(CYCLE 4) j
19
13
-J
I
ZERO ijR±JrT
GAS
INTERFERENCE
(% of FS)
CYCLE 1
1 GAS
INTERFERENCE
(% of FS)
CYCLE 2
GAS
INTERFERENCE
(% of FS)
CYCLE 3
I GAS
INTERFERENCE
(% of FS)
CYCLE 4
RANGE
SCALE
LOW j HC
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
i
RANGE
LOW
(LOW
RANGE
LOW
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC .
LOW ! CO
RANGE SCALE
R^3-0\-SE i 1 HIGH HC
RECOVERY | HIGH CO
!
! (CYCLE 1) 1 [CYC!
j 2.0 6.75
i 1.0 2.0
15%
C02/N2
0.0
1.0
i 15%
C02/N2
3.75
2.0
i 15%
1 C02/N2
0
1.0
! 15%
C02/N2
2.25
i 1.5
CORRECTED
CONCENTRATION
IGOOppm
HC/N2*
1.0
IGOOrcpm
HC/N^
—
1.5
IGOOpprc
HC/N2~
MAXIMUM ZERO DRIFT % FULL SCALE
E 2) (CYCLE 3} (CYCLE 4) !
5.0 8.0
1.5 1.0
10%
CO/N2
0.0
-
10%
CO/N2
5.25
-
j 10%
CO/N2
i i
0
IGOOppm
HC/N-,
10%
; 4.
i 0
1.0
0
•?c' ;
K20/AIR
0.0
2000ppm
NO/N2
0.0
0.5 ( -0.0
3C-
H^O/AIR
2.0
2000ppm
0
1.0 j 0.5
•3C/
K20/AIR
0
0
3%
H20/AIR
2000ppm
NO./N-,
3.0
• 0
2000ppir.
2.0 j 0
( 1.0
0
10%
0.0
0.5
10%
02/N2
2.0
0.75
10%
0
0
10%
02/N2 '
0
0.5
INSTRUMENT RESPONSE TIME (SEC) (AVERAGE OF 2 RUNS)
(CYCLE 1) ] (CYCLE 2) ! (CYCLE 3) } (CYCLE 4)
1749 i 16
8.1
16
1 12.5 ! 8.5 15
1 12.5 ! 11 ! 7
-------
BECKMAN 590
Table 7-22. DATA.-COMPDSITE - REPEATABILITY TEST (Cont'd)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
RANGE
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
tow
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
SCALE
:
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
I HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
COMPARISON
CONDITION % FS
35
70
100
35
70
100
L 35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
H
Y, ERROR
ABSOLUTS
+6.99
-8.71
-1.26
+7.48
+2.41
+2.43
+8.42
-1.80
+0.11
-6.54
+0.40
-0.27
+16.98
+2.35
+3.68
0
-3.61
+3.23
+7.28
-1.11
+0.05
+0.93
I +4.02
! +0.54
C
% ERROR
FS
+2.45
-6.30
-1.15
+ 2.00
+1.50
+2.25
+2.95
-1.30
+0.10
-1.75
+0.25
-0.25
+5.95
+1.70
+3.35
0
-2.25
+3.00
+2.55
-0.80
+0.05
! +0.25
+2.50
i +0.50
.-»
% 2RROR
ABSOLUTE
!
-1.88
+4.62
+1.63
+8.70
+0.95
+1.14
-0.54
+3.08
+1.09
+10.14
-0.95
-0.57
-1.88
-0.77
0
+7.25
0
+0.57
-3.23
+1.69
-1.30
+13.04
+0.95
+2.29
0
•': 2RRCR
FS i
-0.70
+3.00
+1.50 !
+3.00 i
+0.50
+1.00
-0.20 >
+2.0 |
+1.0
+3.50
-0.50 !
-0.50
-0.70
-0.50
0
+2.5
0
+0.50
-1.20
i +1.10
i -1.20
! +4.50
+0.50
+ 2.0
>J
in
-------
Table 7-23. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS
BECKMAN 590
KEY MODE
CYCLE #
STANDARD MODE
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
LEAN MODE
CYCLE 1
CYCLE 2.
CYCLE 3
CYCLE 4
RANGE
PPM/%
400/2
400/2
400/2
400/2
400/2
400/2
400/2
400/2
400/2
400/2
400/2
400/2
400/2
400/2
2000/2
400/2
400/2
2000/2
400/2
400/2
400/2
400/2
400/2
2000/2
SCALE
EC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
wr/co
HC/CO i
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SPEED
50
30
IDLE
50
30
IDLE
50
30-"
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
H
% ERROR-
ABSOLUTE
- 21.84
- 14.72
- 2.84
- 10.99
- 15.3
• - 19.87
- 9.95
+ 3.75
+ 9.09
- 26.07
- 11.74
+ 27.5
- 33.88
- 29.82
+ 39.88
- 28.08
+ ^,71
+ 48.7
+ 4.27
+ 3.32
- 17.48
- 14.21
- 18.11
- 1.34
C
% ERROR
FS
- 5.45
- 4.1
- 1.5
- 2.63
- 4.43
- 12.4
- 2.63
+ 0.95
+ 4.38
- 6.88
- 3.23
+ 10.3
- 8.33
- 7.23
+ 14.26
- 0.65
-t- 13
+ 10.24
+ 1.13
+ 0.88
- 17.48
- 3.85
- 4.98
- 0.31
C
% ERROR
ABSOLUTE
+ 2.74
- 7.14
+ 16.33
+ 23.08
- 6.25
+ 26.21
+ 16.44
+ 7.14
+ 26.87
+ 34.33
+ 36.36
+ 13.64
- 5.48
- 14.29
0
+ 17.74
+ fin n
+ 37.93
+ 7.14
+ 60.0
+ 42.86
+ 6.67
+ 8.33
+ 29.63
O
% ERROR
PS
+ 0.01
- 0.5
+ 0.12
+ 0.75
- 0.5
+ 13.5
+ 6.0
+ 0.5
+ 18.0
+ 11.5
+ 2.0
+ 9.0
- 2.0
- 1.0
i
0
+ 5.5
j. •} n
-•+• J , U .
+ 5.5 ;
+ 3.0
+ 3.0
+ 9.0
+ 2.5
+ 0.5
+ 4.0
-------
Table 7-23. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS (Cont'd)
BECKMAN 590
KEY MODE
CYCLE #
RICH MODE
CYCLE 1
I
CYCLE 2
CYCLE 3
CYCLE 4
RANGE
PPM/*
400/2
400/2
400/10
400/2
400/2
400/10
400/2
400/2
400/10
400/2
400/2
400/10
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
w./cn
EC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SPEED '
50
30
IDLE
50
30
IDLE
«;o
30
IDLE
50
30
IDLE
HC
% ERROR
ABSOLUTE
+ 17.02
+ 13.74
+ 10.72
+ 10.92
+ 27.96
+ 6.94
+ 17.02
+ 13.74
+ 10.72
- 6.28
+ 4.27
- 17.58
% ERROR
FS
+ 4.0
+ 3.63
+ 6.9
+ 3.2
+ 7.38
+ 4.95
+ 4.0
+ 3.63
+ 6.9
- 1.73
+ 1.13
- 13.28
CO
% ERROR
ABSOLUTE
+ 29.03
+ 50.0
+ 19.12
+14.52
+ 25.0
+ 11.11
+ 29.03
+.50.0 _
+ 19.12
- 2.94
+ 7.69
+ 1.60
"A ERROR
^c;
+ 9.0
+ 3.0
+ 6.1
+ 4.5 !
+ 1.5 ;
+ 4.1
+ 9.0
+ 3.0
+ 6.1
- 1.0
+ 0.5 _,
+ 0.6 !
-------
Table 7-24. DIAGNOSTIC TEST
BFCKMAN 590
TEST
SPARKPLUG SHORTED
NORMAL IDLE
IGNITION ADVANCE
IGNITION RETARD
RANGE
2000
10%
2000
10%
2000
10%
2000
10%
SCALE
HC
CO
HC
CO
HC
CO
HC
CO
PPM NO, PPM HC, % CO
TEST INSTRUMENT
1340
2.90
400
2.90
400
2.90
625
3.18
EPA BENCH
1120
2.15
458.4
2.06
365.9
2.14
490.5
2.40
HC/CO/NO
% ABSOLUTE
ERROR
+ 19.64
+ 34.88
- 12.74
+ 40.78
-f- 9.32
+ 35.51
+ 27.42
+ 32.5
% ERROR
+ 11.0
+ 7.5
- 292
+ 8.4
+ 1.71
+ 7.6
+ 6.73
+ 7.8
-------
Table 7-25. DURABILITY TEST DATA
INSTRUMENT: BECKMAN 590
INSTRUMENT TIME TO FAILURE AND GAS EXPOSURE
INS
TIME TO FAILURE (HRS.)
HC EXPOSURE (PPM-HRS.)
CO EXPOSURE (%-HRS.)
NO EXPOSURE (PPM-HRS.)
50
50,500
102
5,200
FRUMENT STABILITY
TOTAL NO. DAYS SHOCK TEST FAILURE
(3% Variation) 1 or More of 4 Modes
SHOCK TEST FAILURE RATE
(Failure/Day %)
INCIDENCE OF FAILURE IN EACH MODE
HC ZERO
HC SPAN
CO ZERO
CO SPAN
AVERAGE DAILY SPAN DRIFT
HC%
C0% ,
N0%
0
0
0
0
0
0
n.RQ
0.63
—
INSTRUMENT SERVICE REQUIREMENTS
A CHANGE FILTER
TOTAL
PER 100 HRS.
B DRAIN HOSE
TOTAL
PER 100 HRS.
C REZERO
TOTAL
PER 100 HRS.
D. SAMPLING SYSTEM
TOTAL
PER 100 HRS.
E. OTHER
TOTAL l
PER 100 HRS.
3
6
2
4
—
—
—
7-79
-------
Figure 7-14. BECK-IAN 590 HC/CO TESTER
7-80
-------
gure 7-15. BECKMAN 590 HC/CO TESTER (BACK)
•IB ~*WiMH
-------
IL_
16. BECKHAH 590 EC/CO TEST! .LEFTSIDE)
7-82
-------
7.6 STEWART WARNER 3161 INFRARED GAS ANALYZER
Manufacturer - Kal Equip
Description - Dual chamber nondispersive infrared exhaust analyzer.
Single source with mirrors, single solid-state detector with mirrors
multiplying circuit keyed to chopper wheel. Rotating optical filters.
This is not a bench top unit. It can only be used in conjunction
with its cart.
Dimensions -
Overall
Height - 43-1/4 inches
Width - 22-5/8 inches
Depth - 18-1/2 inches
Weight - 58 Ibs.
Cart has no storage areas. Rear of cabinet equipped with
hanger for power cord.
Overall package is best described as a rectangular analyzer
box, mounted on a sheet-metal pedestal.
Material of Construction - Sheet-metal cabinet with plastic back panel.
Cabinet is welded and screwed together.
Color - White with brown face and brown base.
Mobility - Two rear, nonswiveling, 8-inch diameter wheels, with two sheet
metal legs in front. The handle is mounted on the rear of the unit.
Mobility is generally good with the large wheels, although the C.G.
is relatively high.
Accessories - Probe, 12-foot sample hose, calibration pot tools, operator's
manual.
Control Package -
Front Access - Function selector (five-position)
1. Off
2. Zero
3. Set mark
4. Hi scale
5. Lo scale
HC zero - knob
HC - 1 (set mark adjust) - Hexagonal screw
HC - 2 (Hi scale) - Hexagonal screw
HC - 3 (Lo scale) - Hexagonal screw
CO zero - knob
CO calibrate - knob
CO - 1 (set mark adjust) - Hexagonal screw
CO - 2 (Hi scale) - Hexagonal screw
7-83
-------
CO - 3 (Lo scale) - Hexagonal screw
Change filter - indicator light
Range indicator lights - on meter faces
Rear Panel - Calibration valve (two-position)
1. Internal
2. External
Span gas inlet port.
Meters - 8-1/2", 90° swing
Figures and division - black on white background
Ranges - HC - 2000 ppm in 50 ppm increments
500 ppm in 10 ppm increments
CO - 10% in 0.2% increments
2.5% in 0.1% increments
These meters were not sensitive to static electricity (soft
cloth rubbed across meter lens).
Altitude Compensation - Set mark on meter face used in conjunction with
chart in operator's manual. Not needed if gas calibration is per-
formed at test site.
Probe - Steel tubing with flexible tip. A filter screen is located in
the flexible tip end to remove large particles. A wooden handle is
used on the probe and a spring assembly holds the probe in the tail
pipe.
Filters and Sample Handling - This unit incorporates a primary particulate
screen in the probe tip, a secondary particulate filter in the probe
handle, a water trap (air dryer), and an air-cooled water separator
assembly for further moisture collection.
Gal Gas Inlet - On rear of instrument
Power Requirements - 11-15.7 VDC 8.5 amps
Operating Principles - Single-cell, rotating optical filters, chopper
modulates infrared energy and synchronizing windows in chopper wheel
picks appropriate HC and CO circuit.
Calibration - Basically straightforward except that Lo and Hi scales have
their own span adjustments resulting in four "span" related pots for
each circuit. With function selector and span pots, this unit is
more complicated to calibrate than some other units.
Operation and Calibration - Operating instructions are printed on the
front of the instrument. Calibration procedures are on back panel.
7-84
-------
Operations -
1. Place "function selector" in zero position
2. Warm up
3. Zero
4. Calibrate adjust to set marks
5. Ready for use
6. Optional gas calibration
7.6.1 Operational Performance Comments
The unit utilized range identification lights which were found to be very
helpful during instrument use.
The unit incorporated a "change filter" indicator light on the front
panel. The indicator worked very well during all tests.
The lack of a sample hose hanger on this unit was very inconvenient. In
addition, the sample hose was extremely stiff and relatively hard to manipulate.
.The 12-foot length of the hose was considered too short for general use,
especially when the hose stiffness was taken into account.
The gas calibration port and gas selection valve, located on the rear
panel, were inconvenient. The hexagonal span pot tool was hard to use during
calibration and the blind holes in the cabinet face made span pot adjustment
difficult. The selector valve was easy to set incorrectly without detection.
This unit operated on 12 VDC power and was subject to the limitation of
frequent on/off cycling by the user, resulting in insufficient warm up and
poor stability, accuracy and repeatability. It is recognized that the use of
12 VDC power may circumvent problems related to electrical testing laboratory
approval and various agency acceptance criteria.
There was no over-voltage protection built into the instrument, thus a
malfunctioning charging system in an automobile could damage components in the
instrument even though the manufacturer rates the instrument for operation on
DC voltages between 11 VDC and 15.7 VDC.
The sample handling system presented some problems in the area of mainte-
nance. A heat sink cooling tube was located on the interior of the analyzer
housing and was difficult to remove during servicing. The secondary particulate
filter could only serviced by disassembling the sample probe handle. Repeated
changing of this fiber cartridge filter caused the connections in the probe
housing to loosen. Located at the bottom of the pedestal stand was a small
water trap with a downward pointed outlet. This water trap presented no
problems during tests.
In the laboratory tests, this unit showed relatively short warm up times;
on the order of 8 to 10 minutes. At low temperatures, the warm up time increased
two-fold. Zero drift performance was very good at all temperatures, never
exceeding 1.2 percent full scale. The effects of interference gases were
minimal. Slight interscale sensitivity was noted but the effects did not
exceed 1.6 percent full scale. NO interference caused 1.2 percent full scale
fluctuation in the CO meter.
7-85
-------
In span gas accuracy, the Stewart Warner was twelfth most accurate with
the most apparent problem seen in the low CO scale. High altitude accuracy
was not significantly different than low altitude tests.
Response test performance indicated relatively slow times although rela-
tively consistent.
This unit was not responsive to acetylene or benzene. It was most respon-
sive to isobutylene, followed by methane, toluene and ethylene.
Voltage fluctuation caused slight HC meter response but caused 1.0 percent
full scale CO meter response for both plus and minus 10 percent voltage
variations.
This unit experienced an electronic failure during repeatability tests.
The unit was returned to the local service facility where repairs were made.
Diagnosis discovered intermittent circuits on a circuit board and a number of
bad I.C's. After repair, the instrument was returned for further tests but all
repeatability tests were missed.
In the vehicle test sequence, the Stewart Warner correlated twelfth best
with the EPA instrument.
The unit demonstrated very poor exhaust correlation during the vehicle
test. Instrument failure occurred three times during the vehicle tests. Each
failure occurred in the fourth cycle of each loaded steady-state mode. At the
beginning of each fourth cycle, both meters gave full scale needle indications
and could not be returned to zero. There was no water visible in the water
trap or clear tubing in the system. The "change filter" light did not
illuminate.
On the front panel of this instrument there is a sticker which states the
following: "Caution use of this instrument on an engine which is not at
operating temperature may cause moisture to deposit internally. If this
occurs both meter pointers may go to full scale and stay there. This condition
can be corrected by operating unit for ten (10) minutes or more with function
selector switch in zero position." After each of the three cycle failures,
the instrument was run for an extended period of time in the zero position.
The unit recovered satisfactorily each time. It must be concluded that internal
water accumulation was the problem. It is noted that during interference gas
tests, this instrument did not indicate sensitivity to water vapor.
It is possible that the poor exhaust correlation performance is at least
partly attributable to water vapor interference. Apparently, this specific
sampling system cannot handle the moisture level encountered in prolonged
loaded steady-state tests.
During the durability test, the sample probe broke at the junction between
the flexible spiral tubing and the hard tube extension. This unit completed
276 hours of durability testing. This corresponds to 227,424 ppm-hours of HC
exposure and 218 percent-hours of CO exposure. Failure occurred when both
meters gave high zero readings that would not respond to zeroing attempts. A
zero position dry-out mode of operation brought the meters back to near normal
operation. The next day during calibration, the HC scale could not be zeroed
and would not respond to a zero position dry-out mode.
7-86
-------
Upon internal observation, it was noted the optical bench and sample
system used on this unit is almost identical with that used on the Kal
Equip 4094D. The most obvious difference between the two units is in packaging;
the Stewart Warner housed in a mobile sheet metal enclosure, and the Kal Equip
configured as a molded plastic encased portable unit. There are other slight
physical and operational differences between the two units but, in general,
comparison of the two units can be considered as a package variation of the
same basic bench. It is interesting to note that although the Kal Equip is
not supplied with a bowl-type water trap, using only the air-cooled tube, it
never experienced total failure attributable to internal water accumulation.
The Kal Equip did show the same pattern of poor exhaust correlation
during the vehicle tests as seen in the Stewart Warner.
Test data for Stewart Warner 3161 Infrared Gas Analyzer are shown in
Tables 7-26 through 7-30.
Photographs of this instrument are shown in Figures 7-17, 7-18 and 7-19.
7-87
-------
Attachment (1)
INSTRUMENT:
Table 7-26. DATA COMPOSITE - LABORATORY TEST
STEWART WARNER 3161
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
(CYCLE 1)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
(CYCLE 1)
8
8
(CYCLE 1)
1.0
1.2
15%
C02/N2
0
0.4
(CYCLE 2)
10
10
MAXI*
(CYCLE 2)
1.0
0.8
(CYCLE 3)
21
21
IUM ZERO DRIFT % F1
(CYCLE 3)
1.2
1600ppm 10%
HC/N2 CO/N2
1
.0
1.6
COMPARISON
CONDITION % FS
35
70
100
35
70
100
35
70
100
35
70
100
% ERROR
ABSOLUTE
- 4
- 4
+ 0
.07
.80
.06
0.4
3%
H20/AIR
0
0
H
- 1.13
+ 4
+ 0
- 6
- 1
+ 0
- 9
+ 1
+ 2
.40
.40
.25
.62
.06
.61
.65
.20
(CYCLE 4)
9
9
JLL SCALE
(CYCLE 4)
0.6
0
2000ppro
NO/N2
0
- 1.2
C
% ERROR
FS
- 1.40
- 3.40
+ 0.05
- 0.40
+ 3.20
+ 0.40
- 2.15
- 1.15
+ 0.05
- 3.40
+ 1.20
+ 2.20
10%
0
0
C
% ERROR
ABSOLUTE
+ 2.15
- 1.54
- 2.17
+ 0.95
- 2.29
0
+ 1.88
+ 1.54
+ 3.26
- 4.76
- 1.14
- 6.82
0
% ERROR
FS
+ 0.80
- 1.00
- 2.00
+ 0.40
- 1.60
0
+ 0.70
+ 1.00
+ 3.00
- 2.00
- 0.80
- 6.00
t
00
00
-------
. Table 7-26. DATA COMPOSITE - LABORATORY TEST (Cont'd)
STEWART WARNER 3161
Attachment (1)
CYCLE 3
CYCLE 4
HIGH
ALTITUDE
RESPONSE &
RECOVERY
HYDROCARBON
RESPONSE
300 Feet
Altitude
6750 Feet
Altitude
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
RANGE
HIGH
HIGH
RANGE
LOW
LOW
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SCALE
HC
CO
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
CORRECTED
CONCENTRATION
1716
8.1
INSTRUME1S
287 ppm 323 ppm
ACETYLENE BENZENE
0 0
5 0
- 5.
- 4.
+ o.
- 4.
+ 4.
+ 1.
- 5.
- 4.
+ 0.
- 3.
+ 4.
+ 2.
- 6.
™" J *
52
80
06
52
12
20
52
09
62
96
12
20
98
50
0
- 2.
+ 1.
+ 2.
INSTRUMEN1
(CYCLE 1)
28.5
32.5
26
92
20
- 1
- 3
+ 0.
- 1
+ 3.
+ 1
- 1
- 2
+ 0
- 1
+ 2
+ 2
- 2
- 3
.90
.40
.05
.60
.00
.20
.9
.9
.55
.4
.8
.2
.4
.9
0
- 0
+ 1,
+ 2.
I RESPONSE TI
(CYCLE 2)
37.0
36.5
IT RESPONSE TO \t
322 ppm
ETHYLENE
5
5
.40
.40
.2
+ 2.15
- 1.54
- 3.26
+ 3.81
+ 2.86
- 4.55
+ 2.15
- 1.54
- 3.26
- 4.76
- 8.57
-18.18
- 0.54
- 3.08
+ 1.09
+ 1.91
- 1.71
- 6.82
ME (SEC) (AVERA
(CYCLE 3)
35.5
36.5
rARIOUS HYDROCAF
385 ppm
ISOBUTYLENE
55
60
+ 0.80
- 1.00
- 3.00
+ 1.60
+ 2.00
- 4.00
+ 0.80
- 1.00
- 3.0
- 2.00
- 6.00
-16.00
- 0.20
- 2.00
+ 1.00
+ 0.80
- 1.20
- 6.00
GE OF 2 RUNS)
(CYCLE 4)
43.5
41.5
.BONS AS ppm
337 ppm 329 ppm
METHANE TOLUENE
10
10
5
12
00
VO
-------
I
VD
o
Attachment (1)
Table 7-26. DATA COMPOSITE - LABORATORY TEST (Cont'd)
STEWART WARNER 3161
VOLTAGE
PROFILE
POWER
13.6V
13.6V
RANGE
HIGH
HIGH
SCALE
HC
CO
READING VARIAT:
VARYING LINE
+ 10%
0.80
1.00
iON AS FUNCTION OF
VOLTAGE _+ 10%
- 10%
0.45
1.00
-------
INSTRUMENT:
Table 7-27. DATA COMPOSITE - REPEATABILITY TEST
STEWART WARNER 3161
VO
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
CYCLE 1
GAS
INTERFERENCE
(% of FS)
CYCLE 2
GAS
INTERFERENCE
(% of FS)
CYCLE 3
GAS
INTERFERENC
(% of FS)
CYCLE 4
RESPONSE &
RECOVERY
E
RANGE
RANGE
RANGE
RANGE
RANGE
RANGE
RANGE
SCALE
SCALE
SCALE
SCALE
SCALE
SCALE
SCALE
(CYCLE 1)
INST
(CYCLE 1)
INST
15%
CO2/N2
U
15%
C02/N2
U
15%
C02/N2
IN
15%
C02/N2
IN
CORRECTED
CONCENTRATION
IN
(CYCLE 2)
IUMENT MALFUH
MAXI1"
(CYCLE 2)
IUMENT MALFUr
1600ppm
HC/N2
STRUMENT h
1600ppm
HC/N2
STRUMENT V
(CYCLE 3) (CYCLE 4)
CTION
- - 1
1UM ZERO DRIFT % FULL SCALE
(CYCLE 3) (CYCLE 4) j
CTION
i
1
10%
CO/N2
ALFUNCTIOr
. 10%
CO/N2
ALFUNCTIOr
1600ppm 1 10%
HC/N2 CO/N2
STRUMENT MALFUNCTION
IGOOppm
HC/N2
10%
CO/N2
STRUMENT MALFUNCTION
r
INSTRUMEN1
(CYCLE 1)
iTRUMENT MALF
3%
H20/AIR
3%
H20/AIR
3%
H20/AIR
3%
H20/AIR
I RESPONSE TI
(CYCLE 2)
UNCTION
2000ppm
NO/N2
2000opni
NO/N2
2000ppm
NO/N2
2000ppm
NO/N2"
10%
02/N2
10%
02/N2
i
10%
02/N2
o°%2
ME (SEC) (AVERAGE OF 2 RUNS)
(CYCLE 3) j (CYCLE 4)
i
1
-------
STEWART WARNER 3161
Table 7-27. DATA. COilPOSlTE - REPEATABILITY TEST (Confd)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
RANGE
SCALE
COMPARISON
CONDITION % FS
INSTRUMEN'
INSTRUMENT
INSTRUMENT
H
% ERROR
ABSOLUTE
MALFUNCTION
MALFUNCTION
MALFUNCTION
INSTRUMENt MALFUNCTION
•
c
% ERROR
FS
C
% ERROR
ABSOLUTE
0
% ERROR
FS
..
I
MD
SJ
-------
Table 7-28.
STEWART WARNER 3161
VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS
KEY MODE
CYCLE #
STANDARD MODE
CYCLE 1
•
CYCLE 2
CYCLE 3
CYCLE 4
LEAN MODE
CYCLE 1
CYCLE 2.
CYCLE 3
CYCLF 4
RANGE
PPM/%
2000/10
2000/10
2000/10
2000/10
2000/10
2000/10
2000/10
2000/10
2000/10
2000/10
2000/10
2000/10
500/2.5
500/2.5
500/2.5
500/2.5
500/2.5
500/2.5
500/2.5
500/2.5
500/2.5
500/2
500/2.5
500/2.5
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
trr/ro
HC/CO i
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SPEED
50
30
IDLE
50
30
IDLE
50
30-
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
H
% ERROR
ABSOLUTE
- 47.16
- 52.35
- 18.49
- 38.36
- 40.7
• - 39.65
- 60.44
- 57.59
- 47.99
- 44.16
- 49.97
- 38.64
- 40.31
45.33
- 41.63
- 48.58
- 49.26
+ 21.33
C
% ERROR
FS
- 14.28
- 15.38
- 11.34
- 11.58
- 12.08
- 21.02
- 15.28
- 14.94
- 25.84
FAILED
FAILED
FAILED
- 12.18
- 14.98
- 25.82
- 11.48
- 13.6
- 29.96
- 12.28
- 12.62
+ 4.5
FA I
FA I
FAI
C(
% ERROR
ABSOLUTE
+ fiQrni
+ 81.82
+ 61.76
+ 61.29
+166.67
+ 58.16
+118.75
+100.0
+ 20.97
+ 42.86
+ 50.0
+ 45.45
+ 52.54
+127.27
+ 60.0
+ 35.87
+100.0
+ 12.9
LED
[jED
LED
•)
% ERROR
PS
+ 19 6
+ 3.6
+ 16.8
+ 15.2
+ 8.0
+ 22.8
+ 22.8
+ 5.2
+ 10.4
t
1
+ 10.8
+ 2.4
+ 10.0
+ 12.4
+ 5.6
+ 12.0
+ 13.2
+ 5.6
+ 3.2
VO
-------
Table 7-28. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS (Cont'd)
STEWART WARNER 31
t
KEY MODE
CYCLE #
RICH MODE
CYCLE 1
rvrT/F 2
fVfT T? T
CYCLE et
61
RANG XL
PPM/%
500/2.5
500/2.5
500/10
500/2.5
500/2.5
500/10
400/2.5
400/2.5
400/10
Cf~
-------
STEWART WARNER 3161
Table 7-29. DIAGNOSTIC TEST
TEST
SPARKPLUG SHORTED
NORMAL IDLE
IGNITION ADVANCE
TT^VT T OnT^^ftr O ^*M7V TD^^
•L \j!N JL X A^/IN X% JLj ±r*t\is
RANGE
2000
10%
2000
10%
2000
10%
2000
10%
SCALE
HC
CO
HC
CO
HC
CO
HC
CO
PPM NO, PPM HC, % CO
TEST INSTRUMENT
1300
3.5
650
3.50
550
3.70
550
3.80
EPA BENCH
1550
2.95
713
3.05
680
3.11
706
3.09
HC/CO/NO
% ABSOLUTE
ERROR
- 16.13
+ 18.64
- 8.84
+ 14.75
- '9.12
+ 18.97
- 22.10
+ 22.98
% ERROR
- 12.5
+ 5.5
- 3.15
+ 4.5
- 6.5
+ 5.9
- 7.8
+ 7.1
-------
Table 7-30. DURABILITY TEST DATA
INSTRUMENT:STEWART WARNER 3161
INSTRUMENT TIME TO FAILURE AND GAS EXPOSURE
TIME TO FAILURE (HRS.)
HC EXPOSURE (PPM-HRS.)
CO EXPOSURE (%-HRS.)
NO EXPOSURE (PPM-HRS.)
276
227,424
218
26,772
INSTRUMENT STABILITY
TOTAL NO. DAYS SHOCK TEST FAILURE
(3% Variation) 1 or More of 4 Modes
SHOCK TEST FAILURE RATE
(Failure/Day %)
INCIDENCE OF FAILURE IN EACH MODE
HC ZERO
HC SPAN
CO ZERO
CO SPAN
AVERAGE DAILY SPAN DRIFT
HC%
C0% (
N0%
5
27.78
0
1
0
4
6.65
11.44
—
INSTRUMENT SERVICE REQUIREMENTS
A CHANGE FILTER
TOTAL
PER 100 HRS.
B DRAIN HOSE
TOTAL
PER 10.0 HRS.
C REZERO
TOTAL
PER 100 HRS.
D. SAMPLING SYSTEM
TOTAL
PER 100 HRS.
E . OTHER
TOTAL
PER 100 HRS.
6
2.17
1
0.36
1
0.36
4
1.45
2
0.72
7-96
-------
Figure 7-17. STEWART WARNER 3161 INFRARED GAS ANALYZER
7-97
-------
.•Hfeffi
...
_ «*-;£ "* *J
Figure 7-18. STEWART WARNER 3161 INFRARED GAS ANALYZER (BACK)
7-98
-------
Figure 7-19. STEWART WARNER 3161 INFRARED GAS ANALYZER (RIGHT SIDE)
7-99
-------
7.7 SUN EPA 75 EXHAUST PERFORMANCE ANALYZER
Manufacturer - Sun Electric Corporation
Description - EC/CO exhaust analyzer configured as a bench-type unit,
mounted (quick disconnect swivel mount) on a four-wheeled cart
equipped with two shelves. The analyzer can be used without the
cart as a bench top unit. It is not equipped with a top handle so
use and movement as a bench top unit would be somewhat more difficult
than with the cart.
Dimensions -
Analyzer - Height - 12-1/4 inches
Width - 20-1/4 inches
Depth - 20-1/2 inches
Analyzer - Height - 48 inches
and Cart Width - 24 inches
Depth - 21 inches
Total Weight - 90 Ibs.
The mounting hardware that connects the analyzer to the cart
allows 30° of the analyzer tilt for best viewing; five steps of
angle selection are available.
Material of Construction - Sheet metal cabinets and cart shelves with
molded plastic front panel. Cart frame is chrome-plated, round
steel tubing.
Color - Blue with red front panel
Mobility - Four, 3-inch diameter swiveling wheels. Left side wheels
incorporate manual locks. Mobility is very good. Unit is very
stable when in motion due to basic design and C.G. location. Small
diameter wheels cause slight problems on rough floors.
Accessories - Sample probe, 25-foot sample hose, operator's manual,
chained operating instructions attached to analyzer cabinet.
Control Package -
Front Access - Mode control - four push buttons
1. Off
2. Test
3. Zero
4. Span
CO - HI - push button
CO - LO - push button
CO - Zero - knob
CO - Span - knob
HC - HI - push button
HC - LO - push button
7-100
-------
HC - Zero - knob
HC - Span - knob
Low Flow - light
Rear Access -
Operate mode/Gas cal mode - toggle switch
Circuit Breaker - push button - 5 amp
Cal gas inlet
Meters - 8", 90° swing
Ranges - HC - 2000 ppm in 20 ppm increments
500 ppm in 10 ppm increments
CO - 10% in 0.20% increments
2.5% in 0.10% increments
Both HC and CO meters are back-lighted.
High-range figures and divisions are blue on white background.
Low-range figures and divisions are red on white background.
These meters are sensitive to static electricity (soft cloth rubbed
over face of meter).
Altitude Compensation - None
Probe - Thirty-inch long convoluted tube with sealed end and perforated
sample entrance holes. Circular spring around end of sample line
acts as probe handle. Tail pipe clamp used to secure probe.
Filters and Sample Handling - Primary stainless steel particulate filter
in primary water trap. Secondary paper element particulate filter
in secondary water trap. Primary water trap automatically aspirated
by sample pump. Secondary water trap aspirated manually when needed.
Cal Gas Inlet - Rear panel
Power Requirements - 120 VAC 60HZ 4 amps
Operating Principles - Dual cell, single source, dual solid-state detector
nondispersive infrared. Chopper modulates infrared and controls
reference and signal sychronization LED devices.
Calibration - Span reference button attenuates HC and CO signals. Span
set knob used to trim needles to respective set points. Calibration
gas can be used but only as a reference test. No span or set pots
are available to operator to adjust instrument response to cal gas.
Operator's manual indicates acceptable tolerances for both meters.
If reading on span gas is outside tolerance, the instrument must be
returned to service center for calibration.
Operation and Calibration - Operation instructions located on card chained
to the cart. Operation is very simple and straightforward. Rear-
mounted gas mode control switch is the only device that can be used
incorrectly during operation.
7-101
-------
Procedure -
1. Plug in
2. Depress test button
3. Warm up
4. Depress zero button and set zero
5. Depress span button and set to span set
6. Depress test button and use
7.7.1 Operational Performance Comments
The overall layout of this instrument was very good and resulted in a
very "useable" instrument. The cart construction and shelf layout were good.
The tilt feature incorporated in the cart allowing various analyzer front face
angles was very useful and it was noted that this was the only analyzer incor-
porating this feature. There were no hangers on the unit for the power cord
or sample hose but the two cart shelves held both items easily.
The sample hose and probe are of sturdy construction and worked very well
during all tests.
Although no range indicator lights were used, the meter scales and range
buttons were of a color that, at a distance, was somewhat difficult to determine
the range buttons' position and, thus, determination the proper scale to read.
On this unit, the meter scales were printed on the clear meter lens cover
and the pointer moved behind the lens, but in front of the back lighted white
background translucent lens. This arrangement accentuated the meter parallax
problem.
The "Low Flow" indicator light worked well during all tests and seemed to
pass the proper sensitivity to indicate flow restriction prior to reading
degradation.
The operation and "calibration" of this instrument was greatly simplified
by the single span control knob. At no time during laboratory testing did the
Sun instrument exceed the manufacturer's span variation specifications for
span gas calibration (HC reading within +60 ppm HC on 2,000 range, and CO
reading within +0.3 percent CO on 10 percent range) . It did exceed +3 percent
full scale readings when sampling gases on the low CO range during accuracy
determination. Using only span calibration gases and monitoring electronic
inter-range correlation, the instrument continually met the manufacturer's
specification and, thus, no other span adjustment was indicated. To attempt
to achieve highly precise measurements, additional span adjustments would be
needed; but for the anticipated accuracy requirements of I/M inspection, this
instrument seems to meet the requirements without additional adjustment capabil-
ity after factory calibration.
In the laboratory tests, this instrument showed warm up times of 9 to
12 minutes except at cold temperatures where it required 24 minutes.
This unit showed zero drift during cycles one and three and 1 percent HC
drift with zero CO drift for cycle four. The unit malfunctioned in cycle two
during the drift test. At the high test temperature, the unit failed to
respond to span gas. It also would not respond to the internal span device.
7-102
-------
After returning to normal temperature, the instrument resumed proper
operation.
The instrument was found to be the fourth most accurate HC/CO unit in the
accuracy determination tests. The specific problem area was the low range CO
where 4 percent variations were noted.
High altitude performance indicated, essentially, the same degree of
accuracy with the same low range CO problem.
Instrument response times were relatively fast, in the range of 10 to
17 seconds.
This instrument was not sensitive to acetylene or benzene. It showed the
highest sensitivity to isobutylene of all instruments. Following isobutylene,
it was most sensitive to toluene, methane, and ethylene, in descending sensi-
tivity.
Voltage fluctuation caused 0.2 percent full scale meter deflection for HC
and 1.0 percent full scale meter deflection for CO for both +10 percent voltage
change.
The repeatability tests showed 0.8 to 1.6 percent full scale. CO sensi-
tivity to the CO- sample gas and 1 to 2 percent full scale. HC sensitivity to
the CO sample gas. Additionally, the CO channel indicated a steady 0.4 percent
full scale sensitivity to the HC sample gas.
In the vehicle tests, the Sun correlated seventh best with the EPA instru-
ment. No clear pattern of problems was noted. Correlation for low scale HC
and CO were generally the same overall with no general deficient areas.
In the durability tests, the Sun completed 101 hours of use. This cor-
responds to 102,010 ppm-hours of HC exposure and 206 percent-hours of CO
exposure.
The failure experienced by this instrument was described as both meters
going off-scale (at the high end). The meters could not be rezeroed.
The greatest problem encountered during durability testing was the fre-
quency of changing the secondary paper filter cartridge in the secondary water
trap. This filter repeatedly became saturated with water during durability
tests. For shorter periods of idle testing or during nonloaded engine testing,
the frequency of filter change was greatly reduced. The unit required three
filter changes in 101 hours of operation and one manual dumping of the secondary
water trap. The primary water trap with atuomatic aspiration worked very
well.
The average daily span drift was found to be 3.11 percent full scale for
HC and 3.23 percent full scale for CO. These were less than the manufacturer's
claim of +5 percent full scale for 24 hours.
Test data for Sun EPA 75 Exhaust Performance Analyzer are shown in
Tables 7-31 through 7-35.
Photographs of this instrument are shown in Figures 7-20, 7-21, and
7-22.
7-103
-------
Attachment (1)
Table 7-31. DATA COMPOSITE - LABORATORY TEST
INSTRUMENT:
SUN EPA 75
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% Of FS)
(CYCLE 1)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
(CYCLE 1)
12
12
(CYCLE 1)
0
0
15%
C02/N2
0.4
1.2
(CYCLE 2)
12
12
MAXiy
(CYCLE 2)
INSTRUMENT
MALFUNCTION
(CYCLE 3)
24
24
IUM ZERO DRIFT % F
(CYCLE 3)
0
IGOOppm 10%
HC/N2 CO/N2
0.4
0
COMPARISON
CONDITION % FS
35
70
100
35
70
100
35
70
100
35
% ERROR
ABSOLUTE
0
(CYCLE 4)
9
9
ULL SCALE
(CYCLE 4)
1%
0
3% 2000ppm
H20/AIR NO/N2
0 0
0 • 0
H
+ 3.65
+ .58
- .64
+ 1.7
+ 1.4
+ 0.2
INSTRUMENT :
C
% ERROR
FS
+ 1.25
+ 0.25
- 0.6
+ 0.6
+ 1.0
+ 0.20
1ALFUNCTION
10%
02/N2
- 2.0
0.4
C
% ERROR
ABSOLUTE
- .54
+ 1.67
- .91
+ 1.4
+ 1.1
- 4.5
0
% ERROR
FS
- 0.2
+ 1.0
- 0.9
+ 0.4
+ 0.8
- 4.0
-J
I
-------
Table 7-31. DATA COMPOSITE - LABORATORY TEST (Cont'd)
Attachment (1)
SUN EPA 75
CYCLE 3
CYCLE 4
HIGH
ALTITUDE
RESPONSE &
RECOVERY
HYDROCARBON
RESPONSE
300 Feet
Altitude
6750 Feet
Altitude
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
RANGE
HIGH
HIGH
RANGE
LOW
LOW
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SCALE
HC
CO
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
CORRECTED
CONCENTRATION
1709
8.1
INSTRUME^
287 ppm 323 ppm
ACETYLENE BENZENE
0 0
0 0
+ 1
+ 0
+ 0
- 1
+ 0
- 0
+ 7
- 0
+ 0
+ 2
+ 1
+ 0
+ 4
- 1
.7
.14
.05
.12
.27
.2
.56
.56
.06
.26
.3
.2
.65
.97
- .50
- 2
.82
+ .27
+ .20
INSTRUMENT
(CYCLE 1)
11.4
10.6
+ o.
+ o.
+ 0.
- 0.
+ o.
- 0.
+ 2.
- 0.
rf 0.
+ o.
+ 1.
+ 0.
-1- 1.
- 1.
- 0.
- 1.
+ o.
+ 0.
I RESPONSE TI
(CYCLE 2)
INSTRUMENT
MALFUNCTION '
rr RESPONSE TO v
322 ppm
ETHYLENE
8
5
6
1
05
4
2
2
6
4
5
8
0
2
6
4
45
0
2
2
' - 0.54
+ 1.54
-
- 2.85
+ 0.57
+ 0.45
- 0.53
+ 1.5
- 0.54
- 4.7
- 4.7
- 4.5
- .54
+ 3.1
+ 1.1
- 4.8
- 5.7
- 4.5
ME (SEC) (AVERA
(CYCLE 3)
8.05
7.6
rARIOUS HYDROCAF
385 ppm
ISOBUTYLENE
90
72
- 0.2
+ 1.0
-
- 1.2
+ 0.4
+ 0.4
- 0.2
+ 1.0
- 0.5
-20
- 4.0
- 4.0
- 0.2
+ 2.0
+ 1.0
- 2.0
- 4.0
- 4.0
GE OF 2 RUNS)
(CYCLE 4)
16.0
17.35
IBONS AS ppm
337 ppm 329 ppm
METHANE TOLUENE
15
12
38
35
o
Ul
-------
I
H—
o
Attachment (1)
Table 7-31. DATA COMPOSITE - LABORATORY TEST (Cont'd)
SUN EPA 75
VOLTAGE
PROFILE
POWER
115V
115V
RANGE
HIGH
HIGH
SCALE
HC
CO
READING VARIAT3
VARYING LINE
+ 10%
.2
1.0
ION AS FUNCTION OF
VOLTAGE ± 10%
- 10%
.2
1.0
-------
Table 7-32. DATA COMPOSITE - REPEATABILITY TEST
INSTRUMENT: SUN
EPA 75
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
CYCLE 1
GAS
INTERFERENCE
(% of FS)
CYCLE 2
GAS
INTERFERENCE
(% of FS)
CYCLE 3
GAS
INTERFERENC
(% of FS)
CYCLE 4
RESPONSE &
RECOVERY
E
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
HIGH
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
(CYCLE 1) (CYCLE 2)
7 16
6 16
MAXiy
(CYCLE 1) (CYCLE 2)
0 0
0.4 0.8
15%
C02/N2
0
0.8
15%
C02/N2
0.8
0.8
15%
CO2/N2
0
1.6
15%
CO2/N2
1.0
1.2
CORRECTED
CONCENTRATION
1709
8.1
IGOOppm
HC/N2
--
0.4
IGOOppm
HC/N2
--
0.4
IGOOppm
HC/N2
_ _
0.4
IGOOppm
HC/N2
0.4
(CYCLE 3) (CYCLE 4)
7
7
10
10
IUM ZERO DRIFT % FULL SCALE
(CYCLE 3) (CYCLE 4)
2.
4.
10%
CO/N2
0
--
10%
CO/N2
2.0
10%
CO/N2
1 .0
10%
CO/N2
0.2
--„
2 2.0
4 0.4
3%
H20/AIR
0
0
3%
H20/AIR
1.
0
0
3%
H20/AIR
0
0
3%
H20/AIR
1.
0.
INSTRUMENT RESPONSE TI
(CYCLE 1) (CYCLE 2)
20.5 15
20 16
0
8
2000ppm
NO/N2
0
. 0.4
.2000ppm
NO/N2
2.0
• 3.6
2000ppm
NO/N2
0
- 0
2000ppm
NO/N2
0
• o
ME (SEC) (AVERA
(CYCLE 3)
8.5
8
10%
02/N2
0
0.4
10%
02/N2
3.0
1.2
10%
02/N2
0
0
10%
0
0
GE OF 2 RUNS)
(CYCLE 4)
9
7
-------
SUN EPA 75
Table 7-32. DATA COMPOSITE - REPEATABILITY TEST (Cont'd)
ACCURACY
DETERMINATION
CYCLE 1
i
CYCLE 2
CYCLE 3
CYCLE 4
RANGE
HIGH
HIGH
HIGH
LOW
LOU
LOW
HIGH
HIGH
HIGH
LOW
SCALE
COMPARISON
CONDITION % ITS ]'
^
HC
ERROR f< ERROR
B SOLUTE FS
HC/CO 35' + 5.84 + 2.00
% ERROR
ABSOLUTE
- 3.23
HC/CO ! 70 ! - 0.92 ! - 0.65 + 1.54
HC/CO 100 - 0.11 - 0.10
HC/CO 35
2.82 + 1.00
HC/CO 70 - 0.83 - 0.60
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
LOW 1 HC/CO
LOW | HC/CO
HIGH
HIGH
HIGH
100
2.41 - 2.40
35 + 7.30 + 2.50
7n - I
100 +
35 (
70 - 1
100 1 -
HC/CO !' 35 + ,
HC/CO
70 - (
3.21 - 0.15
3.45 1 + 0.40
3 I 0
3.83 - 0.60
1.41 | - 1.40
7.30 +2.50
0
- 4.76
- 8.57
- 9.09
+ 0.81
+ 1.54
- 1.09
0
- 2.29
- 2.27
+ 0.81
3.92 - 0.65 + 2.31 i
HC/CO | 100 - 0.11 - 0.10 0 i
LOW HC/CO ! 35 +
LOW
LOW
HIGH
HIGH
1 .70 + 0.60
+ 0.95
HC/CO ! 70 i - 0.83 ! - 0.60 0 i
HC/CO 100 i - 3.16 - 3.20
HC/CO 35 + 8.76 | + 3.00
HC/CO 70 ' + 0.42 j + 0.30
HIGH HC/CO
LOW
LOW
LOW
100
o ;
- 1.08 i
+ 1 .85 !
1.23 +1.10 0 :
HC/CO 35 - 3.39 ! - 1.20 +1.90 !
HC/CO
70
1.10 1-0.80
HC/CO j 100 ! - 3.42 < - 3.40
- 1.71
- 0.93
0
:- ERROR
FS
- 1.20
+ 1.00
0
- 2.0
- 6.0
- 8.0
+ 0.30 !
+ 1.0 -
- 1.0
0
- 1.60
- 2.0
+ 0.30
+ 1.5
0
+ 0.40
0
0
- 0.40
+ 1.20
0
+ 0.80
- 1.20
- 0.80
o
CXI
-------
Table 7-33. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS
SUN EPA 75
KEY MODE
CYCLE #'
STANDARD MODE
CYCLE 1
•
CYCLE 2
CYCLE 3
CYCLE 4
LEAN MODE
CYCLE 1
CYCLE 2.
CYCLE 3
CYCLE 4
RANGE
PPM/%
500/2.5
500/2.5
500/2 . 5
500/2.5
500/2 . 5
500/2.5
500/2.5
500/2 . 5
500/2.5
500/2.5
50.0/2.5
500/2.5
500/2.5
500/2.5
2000/2.5
500/2.5
^nn/9_*
2000/2
500/2.5
500/2.5
2000/2.5
qnp/9.5
500/2.5
500/2.5
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HCVCO
HC/CO '
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CQ
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SPEED
50
30
IDLE
50
30
IDLE
50
30-
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
H
% ERROR
ABSOLUTE
+ 6.82
+ 4.64
- 8.56
+ 29.39
+ 16.7
+ 1.01
+ 26.1
+ 1.55
- 6.83
+ 51.83
+ 59.09
+52.35
+ 53.75
+ 31.58
+ 29.38
+ 21.33
4- 99. Qf;
+ 4.46
+ 21.33
+ 42.68
+ 0.22
+ ROT17
+ 69.88
+ 91 _m
C
% ERROR
FS
+ 1.34
+ 1.02
- 5.62
+ 5.36
+ 3.72
+ 0.52
+ 4.76
+ 0.4
- 3.96
+ 9.9
+ 11.96
+ 20.96
+ 8.74
+ 5.76
+ 10.22
+ 4.5
+ 4.78
+ 1.5
+ 4.5
+ 7.06
+ 0.07
+ n,9fi
+ 12.34
+ 17.9
Cl
% ERROR
ABSOLUTE
+ 22.81
+ 23.08
+ 48.65
+ 29.03
+ 21.43
+ 27.55
+ 18.64
+ 50.0
+ 33.8
+ 45.83
+ 63.64
+ 69.9
+ 7.69
+ 15.38
+ 47.06
+ 40.0
+ 25.0
+ 47.37
+ 12.9
+ 66.67
+ 52.94
4- 7Q. 7"*
+ 63.64
+163-16
3
% ERROR
PS
+ 5.2
+ 1.2
+ 7.2
+ 7.2
+ 1.2
+ 10.8
+ 4.4
+ 2.4
+ 9.6
+ 8.8
+ 2.8
+ 28.8
+ 2.0
+ 0.8
+ 3.2
+ 8.0
+ 1.2
+ 3.6 :
+ 3.2 !
+ 2.4
+ 3.6
•*• 11 5
+ 2.8
+ 12.4
o
VO
-------
Table 7-33. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS (Cont'd)
SUN EPA 75
KEY MODE
CYCLE TT
RICH MODE
CYCLE 1
r'vr'T "P ")
V_ 1 1— i-li-/ t-
CYCLE 3
CYCLE 4
RANGE
PPM/^
500/2.5
500/2.5
500/10
500/2.5
500/2.5
500/10
500/2.5
500/2^5
500/10
500/2.5
500/2.5
500/10
SCALE
HC/CO
EC/CO
HC/CO
HC/CO
HC/CO
HC/CO
JHC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SPEED
50
30
IDLE
50
30
IDLE
^n
30
IDLE
50
30
IDLE
H
% ERROR-
ABSOLUTE
+ 18.69
+ 17.65
+ 15.09
+ 60.82
+ 55.14
+ 30.77
+ 15.07
+ 13.52
+ 24.6
+ 31.31
+ 32.7
+ 35.98
f!
% ERROR
FS
+ 4.0
+ 4.5
+ 10.36
+ 12.48
+ 12.44
+ 19.06
+ 2.62
+ 2.62
+ 12.28
+ 5.98
+ 6.9
+ 18.52
C(
% ERROR
ABSOLUTE
+ 1Q.79
+ 4.17
+ 13,79
+ 29.31
+ 35.71
+ 23.71
+ 25.0
+ 41.67
+ 24.26
+ 19.72
+ 3fi.Afi
- 63.56
3
% ERROR
^q
+ 5.6
p- 0.4
f 6.3
f 6.8
f 2.0
f 9.2
f fi.n
f 2-0
f 8.2
*•' .5.6
t. 9,n
- 21.8
I
H-
I—
o
-------
Table 7-34. DIAGNOSTIC TEST
SUN EPA 75
TEST
NORMAL IDLE
T PWT TTOKT A Ttt/A WP P
IGNITION RETARD
RANGE
500
10%
500
10%
500
10%
500
10%
SCALE
HC
CO
HC
CO
HC
CO
HC
CO
PPM NO, PPM HC, % CO
TEST INSTRUMENT
1100
2.50
380
2.55
325
2.70
380
2.95
EPA BENCH
1133
2.15
358
2.04
358
2.08
316
2.39
HC/CO/NO
% ABSOLUTE
ERROR
- 2.91
+ 16.28
+ 6.15
+ 25.0
- 9.22
+ 29.81
+ 20.25
+ 23.43
% ERROR
FS
- 1.65
-I- 3.5
+ 4.4
+ 5.1
- 6.6
+ 6.2
+ 12.8
+ 5.6
-------
Table 7-35. DURABILITY TEST DATA
INSTRUMENT: SUN EPA 75
INSTRUMENT TIME TO FAILURE AND GAS EXPOSURE
TIME TO FAILURE (HRS.)
HC EXPOSURE (PPM-HRS.)
GO EXPOSURE (%-HRS.)
NO EXPOSURE (PPM-HRS.)
101
102,010
206
10,504
INSTRUMENT STABILITY
TOTAL NO. DAYS SHOCK TEST FAILURE
(3% Variation) 1 or More of 4 Modes
SHOCK TEST FAILURE RATE
(Failure/Day %)
INCIDENCE OF FAILURE IN EACH MODE
HC ZERO
HC SPAN
CO ZERO
CO SPAN
AVERAGE DAILY SPAN DRIFT
HC%
CO% (
N0%
0
0
0
0
0
0
3.11
3.23
—
INSTRUMENT SERVICE REQUIREMENTS
A CHANGE FILTER
TOTAL
PER 100 HRS.
B DRAIN HOSE
TOTAL
PER 100 HRS.
C REZERO
TOTAL
PER 100 HRS.
D. SAMPLING SYSTEM
TOTAL
PER 100 HRS.
E. OTHER
TOTAL ,
PER 100 HRS.
3
2.97
—
—
1
0.99
*••"—
7-112
-------
Figure 7-20. SUN EPA 75 EXHAUST PERFORMANCE ANALYZER
7-113
-------
Figure 7-21. SUN EPA 75 EXHAUST PERFORMANCE ANALYZER (BACK)
7-114
-------
Figure 7-22. SUN EPA 75 EXHAUST PERFORMANCE ANALYZER (RIGHT SIDE AND PROBE)
7-115
-------
7.8 MOPAR IIIC EXHAUST EMISSION ANALYZER
Manufacturer - Chrysler Corporation
Description - HC/CO exhaust analyzer configured as a bench to unit, but
available with a two-wheel cart. The analyzer can be used with or
without the cart with equal ease. The cart incorporates storage
areas.
Dimensions -
Analyzer - Height - 9 inches
Width - 13 inches
Depth - 10 inches
Weight - 20 Ibs.
Cart - Height - 38 inches
Width - 15 inches
Depth - 15 inches
Weight - 30 Ibs.
The cart incorporates a top drawer and a lower storage area
with a snap closing door.
Material of Construction - Main analyzer cabinet is aluminum sheet. Cart
is sheet metal. Method of joining welding and screws.
Color - Analyzer - Blue with silver front - Cart - red
Mobility - Two rear-mounted, 7-inch wheels. Round tube cart handle is at
top rear of instrument. Mobility and stability of this combination
is very good. Low C.G. gives very stable feel.
Accessories - Tail pipe probe with 25-foot sample hose (two pieces),
water trap, operator's manual.
Control Package -
Front Access -
HC - course zero adjust (screw)
HC - fine zero adjust (knob)
HC - span adjust (screw)
HC - Cal adjust (screw)
HC - range switch (two-position toggle)
CO - course zero adjust (screw)
CO - fine zero adjust (knob)
CO - span adjust (screw)
CO - cal adjust (screw)
CO - range switch (two-position toggle)
POWER - push button incorporating indicating lamp
CALIBRATE CHECK - push button
LOW FLOW - light
7-116
-------
No external fuses or breakers (external housing must be removed
to replace lamp fuse)
Rear access -
Recorder jack
Meters - 6-inch, 90° swing
High scale - green graduations - black figures
Low scale - red graduations - black figures
White background
Meter visibility and readability is rated as good
Ranges - HC - 2000 ppm in 50 ppm increments
300 ppm in 50 ppm increments
CO - 10% in 0.2% increments
0.5% in 0.01% increments
The meters on this instrument were not sensitive to static
electricity (soft cloth rubbed against lens).
Altitude Compensation - On chart contained in operator's manual. Requires
use of correction factor. Correction not needed if gas calibration
used at altitude in question.
Probe - Three-foot convoluted tube with sealed end and perpendicular gas
entrance holes. Tube has handle at mid-span and adjustable tail
pipe clamp.
Filters and Sample Handling - No filters are used. Steel water trap
requiring periodic emptying. Internal pump moves sample from vehicle
to analyzer bench.
Cal Gas Inlet - Front mount, same as sample inlet
Power Requirements - 115 BAC 60HZ 100 watts
Operating Principles - Nondispersive single beam infrared instrument
using narrow-band infrared optical filters. Incorporates a sample
cell reference filter to cancel the effects of dust, particulate and
smoke in the sample cell.
Calibration - Electronic reference signal by "calibrate check" button on
front panel and calibration reference points on meter faces. Gas
calibration through front panel port utilizing span adjustment
screws on front panel.
Operation and Calibration - Very easy operating and calibrating instruc-
tions on analyzer cart.
1. Warm up
2. Set zero
3. Push calibration check button
7-117
-------
4. If OK, ready for use
5. If not, gas calibration through front port using HC and CO span
screws
6. Adjust calibrate check points
7. Ready for use.
7.8.1 Operational Performance Comments
This unit is identical to the Scott IIIC except for the logo. The relative
degree of inter-instrument correlation was demonstrated by the Scott and
Mopar IIIC tests.
This unit has excellent mobility while on its cart due to C.G. location,
handle placement and wheel size. In addition, the unit is very handy used as
bench top model due to its small size. The analyzer fits freely but tightly
into a tilted recess at the top of the cart. The analyzer is equipped with a
top-mount strap carrying handle that facilitates removal from the cart for
portable use. The cart contains a top-mounted drawer that is handy for manual
storage and a bottom storage cabinet with snap closing door. This cabinet
works very well for probe, trap and sample hose storage, although hose hangers
are mounted on the cart and rear.
This analyzer uses a turbine-type sample pump differing from the typical
diaphragm pump found on other analyzers. This results in a very low level of
both noise and vibration.
This unit, without benefit of any form of particulate filter, has an
unusual sample handling system that appears to be relatively unsusceptible to
water and particulate accumulation.
This system uses only a single metal cooling tube on its sample hose to
collect moisture.
This tube acts as a system low point and collects condensed sample moisture
which must be dumped out periodically. The probe used on this unit is a
convoluted tube approximately 3 feet long.
The sample hose, made of clear unreinforced plastic tubing, periodically
filled with water during durability testing. When the flow restriction light
indicated low flow, the hose was drained and sampling returned to normal. The
material used for this hose was susceptible to melting when placed against a
hot exhaust pipe.
This unit, in general, was very easy to use and demonstrated exceptional
dependability.
The analytical system on this unit consisted of a single sample cell and
rotating filter wheel.
This unit demonstrated fast response during the laboratory tests and
vehicle test sequences.
This unit and Scott IIIC incorporated lower ranges than any other instru-
ment tested. Because of its extremely low range, it is more applicable for
use with catalytic converter-equipped cars than the other instruments.
7-118
-------
This instrument had a minimum number of controls and the simplest and
most straightforward operation and calibration procedures.
A single front panel gas port was used for both sample and calibration
gases. Range selection was made through use of individual HC and CO toggle
switches. Range indication other than switch position was not utilized and
this was the only negative aspect to the control/display function.
In the laboratory tests, this unit showed acceptable warm up times. Zero
drift performance at normal laboratory temperatures was reasonable considering
the low ranges incorporated in this unit. Zero drift for CO at high temperature
was 80 percent full scale, indicating extreme stability sensitivity to high
temperatures. Low temperature zero drift was greater than that at normal
temperatures but an order of magnitude lower for CO than that at high tempera-
ture. (NOTE: Both the Scott IIIC and Mopar IIIC showed the same zero drift
temperature sensitivity.)
The Mopar IIIC showed good analytical accuracy tying with the Scott IIIC
for fith most accurate overall in the accuracy determination tests.
In the high altitude tests, the CO accuracy readings slipped significantly,
most prominently during high range tests. (The Scott IIIC showed the same
tendency.)
Instrument response time was fast, on the order of 11 seconds or less and
was relatively consistent during laboratory tests.
This instrument was not responsive to acetylene and only marginally
responsive to benzene. It was most responsive to isobutylene, followed by
toluene, methane and ethylene.
Voltage variation caused no meter reading variation.
The HC scale was noted to be responsive to C02 ranging from 0.67 to
3.33 percent full scale meter deflection. The CO meter showed essentially no
response to the CO- sample in the repeatability test cycle.
The CO meter indicated a range of response of 0.4 to 2 percent full scale
to the HC sample during the repeatability cycles. NO response was slightly
less significant than that seen on the Scott IIIC.
The CO- response pattern was also seen in the Scott IIIC but the NO
response was more dominant.
In the vehicle tests, the Mopar IIIC was found to correlate tenth best of
all instruments with the EPA bench. HC correlation seemed to cause the most
trouble, especially on low range during the standard and lean modes. CO
correlation was poor during rich modes. This unit survived the durability
test for 528 hours of operation.
This corresponds to HC exposure levels of 470,976 ppm-hours and CO exposure
of 227 percent-hours. The instrument showed relatively good day-to-day sta-
bility in the durability test with an average daily span drift of 2.3 percent
full scale for HC and 1.3 percent full scale for CO. Resistance to vibration
7-119
-------
and shock was good with only 2 days of shock test failure (resulting in 73 per-
cent full scale meter variation) noted for the total durability test. This
corresponds to 6.06 failure per day. CO span failure dominated.
This instrument required no maintenance other than hose and water trap
draining during the duration of all tests.
During the durability tests, the hose required draining 26 times. This
corresponds to a rate of 4.92 servicings per 100 hours of operation. During
the durability tests, failure resulted from the CO reading becoming totally
unreliable. After additional testing, the CO reading remained up-scale during
attempted rezeroing. The failure seemed to be of an electrical nature and
could be related to a meter failure. No loss in response time was noted as
seen in the Scott, but total test time and exposure for the Mopar was signi-
ficantly less.
Test data for Mopar IIIC Exhaust Emission Analyzer are shown in
Tables 7-36 through 7-40.
Photographs of this instrument are shown in Figures 7-23, 7-24, and
7-25.
7-120
-------
Attachment (1)
Table 7-36. DATA COMPOSITE - LABORATORY TEST
INSTRUMENT:
MOPAR II 1C
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
(CYCLE 1)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
(CYCLE 1)
18
16
(CYCLE 1)
0
0
15%
C02/N2
3.33
4.0
(CYCLE 2)
12
12
MAXIN
(CYCLE 2)
3.3
80.0
(CYCLE 3)
22
22
1UM ZERO DRIFT % Fl
(CYCLE 3)
2.0
6.0
1600ppm 10% 3%
HC/N2 CO/N2 H20/AIR
0.33 0
10.0
COMPARISON
CONDITION % FS
35
70
100
35
70
100
35
70
100
35
70
100
0
H
% ERROR
ABSOLUTE
+ 4.29
- 1.49
- 0.29
0
0
+ 3.45
+ 2.76
- 2.6
- 0.12
+ 1.0
+ 0.51
+ 1.72
(CYCLE 4)
17
15
JLL SCALE
(CYCLE 4)
4
2
2000ppm
NO/N2
0
- 10.0
C
% ERROR
FS
+ 1.4
- 1.0
- .25
0
0
+ 3.33
+ 0.9
- 1.75
- 0.1
-I- 0.33
+ 0.5
+ 1.67
.0
.2
10%
02/N2
0
0
C
% ERROR
ABSOLUTE
- 0.54
+ 2.3
+ 2.17
+ 1.25
+ .07
-20
- 3.23
+ 1.54
+ 2.17
- 4.11
- 3.38
0
0
% ERROR
FS
- 0.2
+ 1.5
+ 2
+ 4.2
+ .04
- 2.0
- 1.2
+ 1.0
+ 2.0
- 1.30
- 1.96
0
-------
Table 7-36. DATA. COMPOSITE - LABORATORY TEST (Cont'd)
Attachment (1)
MOPAR I 11C
CYCLE 3
CYCLE 4
HIGH
ALTITUDE
RESPONSE &
RECOVERY
HYDROCARBON
RESPONSE
300 Feet
Altitude
6750 Feet
Altitude
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
RANGE
HIGH
HIGH
RANGE
LOW
LOW
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SCALE
HC
CO
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
CORRECTED
CONCENTRATION
1627
8.1
INSTRUMEl*
287 ppm 323 ppm
ACETYLENE BENZENE
0 3
0 0
+ 4.
- 1.
29
15
+ .12
+ 2.
0
0
+ 0.34
+ 4.
- 2.
23
6
0
+ 2.
- 2.
0
54
+ 2.41
+ .31
- 3.35
- 0.35
0
- 3.
+ 0.
INSTRUMEN'
(CYCLE 1)
10.1
9.5
55
69
+ 1.
- 0.
+ 0.
4
75
1
+ .67
0
+ .33
+ 1.
- 1.
4
75
0
+ 0.
- 1.
+ 2.
67
67
33
+ .1
- 2.
- 0.
25
3
0
- 2.
+ o.
I RESPONSE TI
(CYCLE 2)
11.5
10.0
IT RESPONSE TO V
322 ppm
ETHYLENE
6
9
33
67
- 0.54
+ 1.54
+ 3.26
+ 4.23
- .96
+ 2.0
- 1.88
+ 1.54
+ 3.26
-10.66
- 1.66
+ 2.0
-18.35
-16.92
-18.48
- 1.73
- 5.11
- 2.0
ME (SEC) (AVERA
(CYCLE 3)
7.25
7.25
rAR!OUS HYDROCAF
385 ppm
ISOBUTYLENE
88
82
- 0.2
+ 1.0
+ 3.0
+ 1.42
- .56
+ 2.0
- 0.7
+ 1.0
+ 3.0
- 3.58
- 0.96
+ 2.0
- 7.2
-11.0
-17.0
- 0.58
- 2.96
- 2.0
GE OF 2 RUNS)
(CYCLE 4)
6.5
6.25
J30NS AS ppm
337 ppm 329 ppm
METHANE TOLUENE
17
15
42
40
I
I—'
N>
-------
I
I—"
to
Attachment (1)
Table 7-36. DATA COMPOSITE - LABORATORY TEST (Cont'd)
MOPAR 111C
VOLTAGE
PROFILE
POWER
115V
115V
RANGE
HIGH
HIGH
SCALE
HC
CO
READING VARIAT3
VARYING LINE
+ 10%
0
0
:ON AS FUNCTION OF
VOLTAGE + 10%
- 10%
0
0
-------
Table 7-37. DATA COMPOSITE - REPEATABILITY TEST
INSTRUMENT:
MOPAR 111C
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
CYCLE 1
GAS
INTERFERENCE
(% of FS)
CYCLE 2
GAS
INTERFERENCE
(% of FS)
CYCLE 3
GAS
INTERFERENCE '
(% of FS)
CYCLE 4
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
RESPONSE & HIGH
RECOVERY
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
rn
SCALE
HC
CO
SCALE
HC
CO
(CYCLE 1)
14
12
(CYCLE 1)
K n
3.4
15%
C02/N2
0
0
15%
C02/N2
3.33
0
15%
CO2/N2
1.67
0
15%
CO2/N2
0.67
0.4
CORRECTED
CONCENTRATION
1627
8.1
(CYCLE 2)
29
29
MAXI^
(CYCLE 2)
4 33
2.0
leOOppm
HC/N2
--
2.0
1600ppm
HC/N2
--
0.4
IGOOppm
HC/N2
--
0
leOOppm
HC/N2
1.0
(CYCLE 3) (CYCLE 4)
28
25
23
22
:UM ZERO DRIFT % FULL SCALE
(CYCLE 3) (CYCLE 4)
7.n 0.67
4.0 0.2
10%
CO/N2
0
--
10%
CO/N2
0
10%
CO/N2
0
--
10%
CO/N2
1.67
3%
H20/AIR
0
0
3%
H20/AIR
0
0
3%
H20/AIR
0
0
3%
H20/AIR
0
0
2000ppm
' NO/N2
0.04
• o
.2000ppm
NO/N2
0
•• 1.0
2000ppm
NO/N2
0
•0
2000ppm
NO/N2
0.67
-2.0
INSTRUMENT RESPONSE TIME (SEC) (AVERA
(CYCLE 1) (CYCLE 2) } (CYCLE 3)
15
15.5
12
12
8.5
5
10%
02/N2
0
2.0
10%
02/N2
0
0
10%
02/N2
0
0
10%
02/N2
0
0.6
GE OF 2 RUNS)
(CYCLE 4)
9.5
7
-------
Table 7-37. DATA COMPOSITE - REPEATABILITY TEST (Cont'd)
MOPAR me .
ACCURACY
DETERMINATION
, CYCLE 1
CT'CLS 2
CYCLE 3
CYCLE 4
-
RANGE
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
i
SCALE
HC/CO
HC/CO !
HC/CO
HC/CO !
HC/CO '
HC/CO I
HC/CO
HC/CO i
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
i
" COMPARISON j
CONDITION ;•• 7S |
35 *
70
100 i
35 i
70 !
100 i
35
70
100
35
70
100
35
70
100
35
70
100
35
! 70
i 100
1 35
70
100
,
H(
'.i ERROR
ABSOLUTE !
- + 1.23 i
- 5.20 !
- 2.77 |
+ 2.0
+ 1.52
+ 3.45
+ 4.29 i
- 1.86
+ 0.24
+ 1 .0
+ 0.51
+ 2.41
+ 5.83
+ 0.83
0
0
+ 3.10
- 1 .49
+ 5.83
- 0.37
+ 1.42
0
+ 2.54
j + 2.07
i
-'. -roopn
•J «i^v.blW«\
T? C
+ 0.40
- 3.50 i
- 2.35
+ 0.67
+ 1 .00
+ 3.33
+ 1.40
- 1.25
+ 0.20
+ 0.33
+ 0.33
+ 2.33
+ 1 .9
+ 0.7
0
0
+ 3.0
- 1.0
i +1.90
! - 0.25
+ 1 .20
: 0
; + 1 .67
. + 2.00
%• ERROR
ABSOLUTS
- 0.54
+ 2.31 i
+ 1.63
+ 1.85
- 1.66
+ 2.0
- 3.23
0
+ 1.09
0
- 0.28
+ 4.0
- 1 .88
+ 0.54
+ 0.66
- 0.62
j + 1.6
+ 1.54
- 2.69
+ 0.77
+ 0.54
- 1.19
- 1.72
0
«K
FS
- 0.20
+ 1.50
+ 1.50
+ 0.62
- 0.96
+ 2.00
- 1.20
o
+ 1.0
0
- 0.16
+ 4.0
- 0.7
, + 0.5
• + 0.22
- 0.36
; +1.6
i + i.o ;
i - 1.00
1 . j
i +0.50
i + 0.50
; - 0.40
i - 1.00
0 i
-J
I
NJ
-------
Table 7-33. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS
MOPAR 111C
KEY MODE
CYCLE #
STANDARD MODE
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
LEAN MODE
CYCLE 1
CYCLE 2 .
CYCLE 3
CYCLE 4
RANGE
PPM/%
300/10
300/.5
300/10
300/.5
300/.5
300/10
300/10
300/.5
300/10
300/10
300/.5
300/10
300/10
300/.5
300/10
300/.5
300/.5
300/10
300/10
300/.5
300/10
300/10
300/.5
300/10
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
WP /CO
HC/CO '
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SPEED
50
30
IDLE
50
30
IDLE
50
30-
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
H
% ERROR
ABSOLUTE
- 39.81
- 40.55
- 29.72
- 42.18
- 43.16
1 - 39.65
- 34.29
- 47.33
- 30.43
- 45.51
- 64.87
- 42.53
- 35.91
- 39.33
- 26.16
- 42.42
- 39.35
- 31.5
- 53.74
- 60.98
- 46.57
- 54 _]
- 67.53
- 31 -??
C
% ERROR
PS
- 18.3
- 20.47
- 23.97
- 18.97
- 20.63
- 35.03
- 14.27
- 20.97
- 22.6
- 18.93
- 27.7
- 33.3
- 18.3
- 19.67
- 4.96
- 20.13
- 1&.47
- 5.34
- 23.23
- 26.03
- 8.72
- 21TQ7
- 27.73
- 3f).?7
C
% ERROR
ABSOLUTE
+ 12.70
+ 3.17
- 5.17
0
- 9.90
+ 2.8
+ 50.0
+ 7.69
+ 17.19
- 14.86
+ 42.86
+ 15.38
+ 4.84
- 1.64
+ 18.64
- 15.38
- 9.09
+ 13.21
+ 4.94
+ 92.31
+ 25.0
•*• ^ 8^
+ 53.85
+ «7r cj
0
% ERROR
PS
+ 0.8
+ 0.8
- 0.6
0
- 2.0
+ 0.3
+ 2.0
+ 2.0
+ 2.2
- 1.0
+ 12.0 I
T v H
+ 1.6
+ 6.0
- 0.02
+ 2.2
- 1.0 i
-2.0
+ 0.7 :
+ 0.4 i
+ 2.4
+ 1.3
-i- i A n
+ 14.0
I
K^
S3
-------
Table 7-38. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS (Cont'd)
MOPAR 111C
KEY MODE
CYCLE #
RICH MODE
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
RANGE.
PPM/%
300/10
300/.5
2QOO/10
300/10
300/ 5
2000/10
•snn/i n
3IJI.I/ 1 »
3QQ/.5
2000/10
300/10
300/.5
2000/10
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SPEED
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
^
H<
% ERROR-
ABSOLUTE
- 29.03
- 30.67
- 58.9
- 43.04
- 53.74
- 24.41
- 24.84
- 33.65
- 23.18
- 12.18
- 17.25
- 1.31
•^
% ERROR
PS
- 13.63
- 15.33
- 22.22
- 18.13
- 23.23
- 3.96
- 10.47
- 14.37
- 3.62
- 5.13
- 7.37
- 0.21
CC
% ERROR
ABSOLUTE.^—
- 5.66
- 48.42
+153.09
+ 5.26
+ 50.0
+ 17.98
- 11.76
. 0
+ 7.14
-' 5.80
- 21.43
+ 15.26
3
% ERROR
PC;
I
- 0.3
- 18.4
+ 24.8 ;
+ 0.4
+ 14.0
+ 6.4 .
- 0.8
0
+ 2.4 ;
. 1
- 0.4 j
- 6.0
+ 4.9
I
t-'
to
-------
Table 7-39. DIAGNOSTIC TEST
MOPAR 111C
TEST
SPARKPLUG SHORTED
NORMAL IDLE
IGNITION ADVANCE
Tf^NTTTDNT PPTTVRFl
RANGE
2000
10%
2000
10%
300
10%
2000
10%
SCALP
HC
CO
HC
CO
HC
CO
HC
CO
PPM NO, PPM HC, % CO
TEST INSTRUMENT
1100
2.40
380
2.40
250
250
400
2.78
EPA BENCH
!
1142
2.13
467
2.11
365.9
2.15
449.9
2.46
HC/CO/NO
% ABSOLUTE
ERROR
+ 16.28
+ 12.68
- 18.63
+ 13.74
- 31.68
+ 16.28
- 11.09
+ 13.01
% ERROR
FS
+ 3.5
+ 2.7
- 4.35
+ 2.9
- 38.63
+ 3.5
- 2.50
+ 3.2
I
V—
oo
-------
INSTRUMENT:
Table 7-40. DURABILITY TEST DATA
MOPAR 111C
INSTRUMENT TIME TO FAILURE AND GAS EXPOSURE
TIME TO FAILURE (HRS.)
HC EXPOSURE (PPM-HRS,)
CO EXPOSURE (%-HRS.)
NO EXPOSURE (PPM-HRS.)
528
470,976
227
55,440
TNSTRUMENT STABILITY
TOTAL NO. DAYS SHOCK TEST FAILURE
(3% Variation) 1 or More of 4 Modes
SHOCK TEST FAILURE RATE
(Failure/Day %)
INCIDENCE OF FAILURE IN EACH MODE
HC ZERO
HC SPAN
CO ZERO
CO SPAN
AVERAGE DAILY SPAN DRIFT
HC%
CO%
N0%
2
6.06
0
0
0
2
2.3
1.3
—
INSTRUMENT SERVICE REQUIREMENTS
A CHANGE FILTER
TOTAL
PER 100 HRS.
B DRAIN HOSE
TOTAL
PER 100 HRS.
C REZERO
TOTAL
PER 100 HRS.
D. SAMPLING SYSTEM
TOTAL
PER 100 HRS.
E . OTHER
TOTAL
PER 100 HRS.
VB ^
26
4.92
—
• — —
— —
7-129
-------
Figure 7-23. HOPAR,IIIC EXHAUST EMISSION ANALYZER-
7-130
-------
Figure 7-24. MOPAR IIIC EXHAUST EMISSION ANALYZER (BACK)
7-131
-------
Figure 7-25. MDPAR IIIC EXHAUST EMISSION ANALYZER (LEFT SIDE AND PROBE)
7-132
-------
7.9 SEARS 713.21022 HC-CO ANALYZER
Manufacturer - Emission Control Instruments Inc. (Sun Electric)
Description - HC/CO analyzer configured as a small portable bench top
unit. No cart or stand is available for this unit.
Dimensions -
Height - 9 inches
Width - 15 inches
Depth - 6-1/2 inches
Weight - 10-1/4 Ibs.
Material of Construction - Aluminum extrusion on top, molded plastic side
panels, aluminum extrusion control panel, balance of parts are
sheet metal. All parts jointed by grooves, slots and screws.
Color - Black sides, rear panels and meter frames; balance of parts are
silver.
Mobility - Portable bench top unit.
Accessories - Sample probe, hose, filter material, operator's manual.
Control Package -
Front Access - Operation Mode switch (three-position)
1. Standby (with indicator light)
2. Run
3. Test
HC range switch (three-position)
1. Off
2. Hi
3. Lo
HC set - knob (zero)
CO range switch (three-position)
1. Off
2. Hi
3. Lo
CO set - knob (zero)
Bottom Access
Unlabeled - HC span - screw
Unlabeled - CO span - screw
Meters - 5-1/2", 100° swing
Ranges - HC - 0-2000 ppm in 50 ppm increments
0-500 ppm in 25 ppm increments
7-133
-------
CO - 0-10% in 0.2% increments
0-2.5% in 0.1% increments
Air fuel ratio - 14.2-10.2 (on CO meter)
High ranges - Figures red on white background
Low ranges - Figures blue on white background
Meter visibility and readability is poor at moderate distance.
Altitude Compensation - None
Probe - Flowthrough T-shape constructed of spiral, flexible tube. The
exhaust sample is pulled from the center of the probe. The majority
of the exhaust sample passes through the probe and out the end.
Filters and Sample Handling - Glass fiber filter packed in a small plastic
housing. No water trap. Small diameter sample house was soft but
worked well.
Cal Gas Inlet - Sample hose used for calibration.
Power Requirements - 12 volts DC.
Operating Principles - Selective combustion utilizing vandia catalyst,
charcoal stripper and dual thermocouples.
Calibration - Proper warm up indicated with HC range switch in off position
and mode switch in test position. HC meter scale must be at blue
set point (80 percent full scale) or above. No other calibration
procedures are included in the operator's manual. Unlabeled factory
span pots are accessible through bottom of instrument.
Operation and Calibration - Operation is simple but manual is somewhat
confusing in its presentation.
Procedure -
1. Attach 12 V battery clips
2. Turn mode switch to standby
3. Check warm up
4. Set zero positions with switches in off position
5. Ready for use
7.9.1 Operational Performance Comments
In general, this instrument is not a precision measurement device
nor is it advertised as such. It is an inexpensive instrument intended for
home hobby use where relative test-to-test readings are the intended use.
This unit is not intended to compete with other instruments in attempting to
identify absolute sample gas values. This intended application explains the
lack of calibration controls. Factory calibration is deemed adequate for this
specific application.
7-134
-------
This unit is designed to be primarily sensitive to exhaust gas
components other than those characterized as hexane. Factory calibration
utilizes a span gas composed of Butene-1 as the primary hydrocarbon and so its
sensitivity to hexane or propane tends to differ dramatically from the typical
sensitivity seen in other HC and CO analyzers.
The design of the sample probe was interesting in that it would tend
to minimize the instrument's exposure to particulate accumulation. The sample
probe was not used sufficiently to comment on its durability.
Instrument failure occurred repeatedly during testing but the follow-
ing was determined. Warm up time appeared to be approximately 10 minutes.
Zero drift of 5 percent full scale and 2 percent full scale were seen in cycle
one tests of the HC and CO meters, respectively. The unit did not appear to
be significantly sensitive to any of the interference gases.
In the accuracy tests, the HC meter showed essentially no response
propane. Improper CO calibration resulted in the loss of cycle one CO accuracy
data. Cycle four showed a maximum CO error on high scale of 3 percent and on
low scale 10 percent.
Instrument response time was approximately 24 seconds. The hydro-
carbon response pattern of the HC meter is apparent in the high altitude
accuracy data, indicating very close correlation with benzene, but twice the
anticipated isobutylene reading, and over three times the toluene reading.
Methane response was slightly below the actual value. The unit showed no
response to ethylene and minimal response to acetylene.
The unit experienced a sample pump failure during the laboratory
test sequence. Due to problems encountered during attempts to replace the
sample pump, a large number of laboratory tests were missed. Prior to the
vehicle test phase, the instrument experienced a failure that rendered it
inoperative. Attempts were made to notify the manufacturer of this failure
but the manufacturer was involved in relocating operations to the east coast.
The inability to secure repairs on this instrument caused the unit to miss
most of the test cycles in the vehicle test and durability test phases.
Test data for Sears 713.21022 HC-CO Analyzer are shown in Tables 7-41
through 7-45
Photographs of the instrument are shown in Figures 7-26, 7-27, and
7-28.
7-135
-------
A-tt aclune nt
INSTRUMENT:
Table 7-41.
SEARS 713.21022
DATA COMPOSITE - LABORATORY TEST
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
(CYCLE 1)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2 ,
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
(CYCLE 1)
10
10
(CYCLE 1)
5.0
2.0
15%
C02/N2
0
0
(CYCLE 2)
INSTRUMENT
MAXI1"
(CYCLE 2)
INSTRUMENT
(CYCLE 3)
(CYCLE 4}
MALFUNCTION
IUM ZERO DRIFT % FT
(CYCLE 3)
MALFUNCTION
leOOppm 10% 3%
HC/N2 CO/N2 H20/AIR
2.0 0
0-0
COMPARISON
CONDITION % FS
35
70
100
35
70
100
35
70
100
35
70
100
H
% ERROR
ABSOLUTE
INSTRUMEff
RESPONSIV
PROPANE
NO
INSTRUMENT
JLL SCALE
(CYCLE 4)
2000ppm
NO/N2
0
0
C
% ERROR
FS
T NOT
2 TO
-
DATA
FAIL!
10%
02/N2
0
0
C
% ERROR
ABSOLUTE
INSTRUME
CALIBRAT
INVALID
ID NO
0 :
% ERROR
FS
HT NOT
3D -
DATA
DATA
I
I_J
-------
SEARS
Table 7-41.
713,21022
DATA COMPOSITE - LABORATORY TEST (Cont'd) Attachment (1)
CYCLE 3
CYCLE 4
HIGH
ALTITUDE
RESPONSE &
RECOVERY
HYDROCARBON
RESPONSE
300 Feet
Altitude
6750 Feet
Altitude
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
RANGE
HIGH
HIGH
RANGE
LOW
LOW ;
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SCALE
HC
CO
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
CORRECTED
CONCENTRATION
3300ppm Propane
8.1
INSTRUMElv
287 ppm 323 ppm
ACETYLENE BENZENE
INSTRUJ
50 350
NOT SENSIT
FOR
PROPAN
OR HEXANE
INSTRUMEN'
(CYCLE 1)
24.5
24.0
INSTRUMEI
NO
INSTRUMI
NO
:ZED
jt
I RESPONSE TI
(CYCLE 2)
INSTRUMENT
?AILED NO DA^
W RESPONSE TO V
322 ppm
ETHYLENE
ENT MALI
0
rr FAILED
DATA
NT FAILED
DATA
+ 7.53
+ 4.62
0
+ 4.76
+ 9.71
+11.36
ME (SEC) (AVERA
(CYCLE 3)
II
A
'ARIOUS HYDROCAF
385 ppm
ISOBUTYLENE
UNCTION
700
+ 2.8
+ 3.0
0
+ 2.0
+ 6.8 i
+10.0
GE OF 2 RUNS)
(CYCLE 4)
11
II
IBONS AS ppm
337 ppm 329 ppm
METHANE TOLUENE
250
1100
I
H—
UJ
-------
Attachment (1)
Table 7-41. DATA COMPOSITE - LABORATORY TEST (Cont'd)
SEARS 713.21022
VOLTAGE
PROFILE
POWER
13 -.6V
13.6V
RANGE
HIGH
HIGH
SCALE
HC
CO
READING VARIATION AS FUNCTION OF
VARYING LINE VOLTAGE + 10%
+ 10%
INSTRUMENT
MALFUNCTION
- 10%
u>
CO
-------
Table 7-42. DATA COMPOSITE - REPEATABILITY TEST
INSTRUMENT: SEARS 713.21022
1
I—1
u>
VO
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
CYCLE 1
GAS
INTERFERENCE
(% of FS)
CYCLE 2
GAS
INTERFERENCE
(% of FS)
CYCLE 3
GAS
INTERFERENCE
(% of FS)
CYCLE 4
RESPONSE &
RECOVERY
RANGE
RANGE
RANGE
RANGE
RANGE
RANGE
RANGE
SCALE
SCALE
SCALE
SCALE
SCALE
SCALE
SCALE
(CYCLE 1)
INSTRUI
(CYCLE 1)
INSTRUI
15%
C02/N2
INST
15%
C02/N2
INST
15%
CO2/N2
INST
15%
C02/N2
INST
CORRECTED
CONCENTRATION
INST1
(CYCLE 2)
1ENT MALFUNCT
MAXI^
(CYCLE 2)
ENT MALFUNCT
1600ppm
HC/N2
RUMENT MAL
1600opm
HC/N2
WMENT MAL
1600ppm
HC/N2
IUMENT MAL
IGOOppm
HC/N2
IUMENT MAL
(CYCLE 3) (CYCLE 4)
CON
IUM ZERO DRIFT % FULL SCALE
(CYCLE 3) (CYCLE 4)
CON
10%
CO/N2
FUNCTION
10%
CO/N2
FUNCTION
10%
CO/N2
;1UNCTION
10%
CO/N2
'UNCTION
INSTRUMEN1
(CYCLE 1)
UMENT MALFUN
3%
H20/AIR
3%
H20/AIR
. 3%
H20/AIR
3%
H20/AIR
T RESPONSE TI
(CYCLE 2)
2TION
2000ppm
NO/N2
•
.2000ppm
NO/N2
2000ppm
NO/N2
2000ppm
NO/N2
10%
02/N2
10%
02/N2
10%
°2/N2
10%
02/N2
ME (SEC) (AVERAGE OF 2 RUNS)
(CYCLE 3) (CYCLE 4)
-------
SEARS 713.21022
Table 7-42. DATA COMPOSITE - REPEATABILITY TEST (Cont'd)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
RANGE
SCALE
COMPARISON
CONDITION >5 ITS
INSTRUMENT ti
H
;'= ERROR
ABSOLUTS
ALPUNCTION
c
% ERROR
FS
i :• i
i ;
i
INSTRUMENT N
INSTRUMENT ^
ALPUNCTION
<
i
[ALFUNCTION
. CO
% ERROR -::- ERROR
ABSOLUTE FS
j
i
i
i
i
l
INSTRUMENT MALFUNCTION
• i ' 1
1
i
i
i
i
1 :
i
1 !
!
1
j
i
-------
Table 7-43. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS
SEARS 713.21022
KEY MODE
CYCLE #
QTAVrnART) MODE
CYCLE 1
CYCLE 2
CYC1.E 3
CYCLE 4
LEAN MODE
CYCLE 1
CYCLE 2.
CYCLE 3
/""Vf~*T T? A.
L.JCL..U.& 4
PAWfSF
PPM/%
CpAT.F
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
Hr/no
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
nq/co
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
CD"PT?T^
50
30
IDLE
50
30
IDLE
50
30 -
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
HI
% ERROR
ABSOLUTE
r
•t
% ERROR
PS
FAI
._
FAI
FAr
FAI
FAI
FAI
FAl!
PAT
CC
% ERROR
ABSOLUTE
JED
f-
\
JED
tim
LED
LED
LED
LED
LED
T.-p;n
)
% ERROR
PS
1
I
1
)
i
1
\
:
•
I
H-
*-
-------
Table 7-43. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST G'AS (Cont1 d)
SEARS 713.21022
KEY MODE
CYCLE #
RICH MODE
CYCLE 1
CYCLE 2
CYCLE 3
(
CYCLE 4
RANGE
PPM/%
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
He/no
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SPEED'
50
30
IDLE
50
30
IDLE
SO
30
IDLE
50
30
IDLE
i
EC
% ERROR-
ABSOLUTE
% ERROR
FS
FAIL
FA II
FAII
FAII
CO
% ERROR
ABSOLUTE
ED
ED
ED
ED
^ ERROR
^S
!
~
.>
S3
-------
Table 7-44. DIAGNOSTIC TEST
SEARS 713.21022
TEST
SPARKPLUG SHORTED
NORMAL IDLE
IGNITION ADVANCE
IGNITION RFTARD
RANGE
SCALE
PPM NO, PPM HC, % CO
TEST INSTRUMENT
INOPE
INOPE
INOPE
INOPE
EPA BENCH
NATIVE
RATIVE
RATIVE
RATIVE
HC/CO/NO
% ABSOLUTE
E^ROR
% ERROR
PS
-------
Table 7-45.
INSTRUMENT: SEARS 713.21022
DURABILITY TEST DATA
INSTRUMENT TIME TO FAILURE AND GAS EXPOSURE NO TEgT DATA
TIME TO FAILURE (HRS.)
HC EXPOSURE (PPM-HRS.)
CO EXPOSURE (%-HRS.)
NO EXPOSURE (PPM-HRS.)
INSTRUMENT STABILITY fjn TRST nA-na
TOTAL NO. DAYS SHOCK TEST FAILURE
(3% Variation) 1 or More of 4 Modes
SHOCK TEST FAILURE RATE
(Failure/Day %)
INCIDENCE OF FAILURE IN EACH MODE
HC ZERO
HC SPAN
CO ZERO
CO SPAN
AVERAGE DAILY SPAN DRIFT
HC%
CO%
NO%
NO TEST DATA
NO TEST DATA
INSTRUMENT SERVICE REQUIREMENTS NO TEST DATA
A CHANGE FILTER
TOTAL
PER 100 HRS.
B DRAIN HOSE
TOTAL
PER 100 HRS.
C REZERO
TOTAL
PER 100 HRS.
D. SAMPLING SYSTEM
TOTAL
PER 100 HRS.
E. OTHER
TOTAL
PER 100 HRS.
7-144
-------
--J
I
01
Figure 7-26. SEARS 713.21022 HC-CO ANALYZER
-------
Figure 7-27. SEARS 713.21022 HC-CO ANALYZER (BACK AND PROBE)
-------
I
I
I
]
Figure 7-28. SEARS 713.21022 HC-CO ANALYZER (RIGHT SIDE AND PROBE)
-------
7.10 KAL EQUIP 4094-D INFRARED EMISSIONS ANALYZER
Manufacturer - Kal Equip Company
Description - HC/CO analyzer configured as a bench top unit not supplied
or available with wheels or cart. Molded plastic case has integral
handle at top.
Description -
Height - 28-3/4 inches
Width - 11-1/4 inches
Depth - 15 inches
Weight - 18 Ibs.
Material of Construction - Molded plastic housing.
Color - Grey with black trim.
Mobility - Portable.
Accessories - Sample probe, sample hose (20 feet) operator's manual,
hexagonal span tool.
Control Package -
Front Access - Test selector (five-position)
1. Off
2. Zero
3. Span
4. High
5. Low
6. HC zero - knob
7. HC span - knob
8. HC 1 - Hexagonal pots
9. HC 2 - Hexagonal pots
10. HC 3 - Hexagonal pots
11. CO zero - knob
12. CO span - knob
13. CO 1 - Hexagonal pots
15. CO 3 - Hexagonal pots
16. Change filter - light
17. High HC - Hi CO - light (range)
18. Low HC - Lo CO - light (range)
Rear Access - Calibration valve (two-position)
1. Internal
2. External
3. Span gas inlet
Meters - Both meters on same face and unconventional in appearance, 6-
inch, 100 swing. All figures black on white background.
7-148
-------
Ranges - HC - 0-2000 ppm in 50 ppm increments
- 0-500 ppm in 10 ppm increments
CO - 0.10% in 0.2% increments
- 0.2.5% in 0.1% increments
These meters were insenstive to static electricity. Readability was
fair at moderate distance. Range identification with lights was easy to
distinguish.
Altitude Compensation - Included on chart in operator's manual. Used in
conjunction with set points on meter faces. Not needed if gas
calibrated at altitude of use.
Probe - The probe consisted of spiral flex tubing connected to a solid
tube. Tail pipe spring and wooden handle were also included.
Filters and Sample Handling - Two filters, primary particulate type
located in the sample probe, secondary particulate type located
downstream of condensing tower, condensing tower (on instrument rear
panel) used to remove sample moisture.
Gal Gas Inlet - Rear panel.
Power Requirements - 12 VDC 8.5 amps (no fuses or breakers).
Operating Principles - Single cell, rotating optical filters, chopper
modulates infrared energy, and synchronizing windows in chopper
wheel picks appropriate HC or CO circuit.
Calibration - Basically straightforward except that Lo and Hi scales have
their own span adjustments resulting in four "span" related pots for
each circuit. With function selector and numerous span pots, this
unit is more complicated to calibrate than some other units.
Operation and Calibration - Operating instructions and calibration instruc-
tions were on stickers on the rear of the instrument. These rear
panel stickers peeled loose during testing.
Operation -
1. Place "function selector" in zero position
2. Warm up
3. Zero
4. Calibrate - adjust to set marks
5. Ready for use
6. Optional gas calibration
7.10.1 Operational Performance Comments
The general control and display layout on this unit was moderately
inconvenient. The operation and calibration of this instrument was complicated
by the fact that the zero and span knobs were very close together and easy to
confuse or bump. The infrared and electronics systems of the Kal Equip are
very similar to those of the Stewart Warner. The meters were unconventional
in appearance. They were small, and had nonlinear scales with poor resolution
7-149
-------
at the high end. The meters were built into one large module with the range/
function switch. The meter needles rotated in opposite directions from the
approximate center of this module, with the meter scales increasing in value
from the bottom of the plate to the top. Range indicating lights were included
on the meter face.
The hex socket adjustments, covered by rubber plugs and used for
correlation of electronic span, were awkward to use. They were completely
discussed in the instructions. Both the rubber plugs and the hex tool was
easy to lose. In addition, the pots requiring this hex socket tool were
deeply recessed in both this instrument and the Stewart Warner. It was some-
times very difficult to engage these pots during calibration. The sample
handling equipment for the Kal Equip was very similar to that supplied with
the Stewart Warner. However, there was no external bowl type water trap on
the Kal Equip. This instrument had the sample hose connected inside the case.
Sample hose service or replacement would require complete shutdown and case
disassembly.
This unit demonstrated very slow nontypical response that seemed
almost to step. Its stability was also relatively poor. The nomenclature
internal/external used on the span gas control valve was somewhat confusing
and did not clearly relate to its function.
This unit operated on 12 VDC power and was subject to the limitation
of frequent on/off cycling by the user resulting in sufficient warm up, poor
stability, accuracy and repeatability.
There was no over-voltage protection built into the instrument, thus
a malfunctioning charging system in an automobile could damage internal
components.
In the sampling system, the primary filter in the probe handle was
relatively easy to change but the secondary filter near the cooling tower was
very difficult and time-consuming to change due to its specific placement and
securing method.
The maintenance required for this instrument was similar to that
required on the Stewart Warner except that there was -no maintenance requirements
for the water trap. The in-line primary filter cartridge required changing
more often.
In the laboratory tests this unit showed warm up times of 6 to
9 minutes except at cold temperatures, where it required 19 minutes.
Zero drift at normal laboratory temperatures and low temperature was
1.2 percent full scale or less. At high temperature, the HC drift climbed to
2.4 percent full scale but the CO drift was still only 0.8 percent full scale.
Gas interference tests indicated CO meter sensitivity of up to 2 percent full
scale to HC gas and CO senstivity of up to 2 percent full scale to NO gas. No
other repeatable sensitivities were noted.
The Kal Equip was eleventh most accurate of all HC/CO instruments.
Both low and high ranges of HC and CO showed significant error in analysis.
High altitude operation actually showed an increase in both high scale HC and
CO accuracy.
7-150
-------
This phenomenon has not been totally explained by the balance of the
data. In response and recovery, the unit consistently showed slow response
time on the order of 25 seconds or greater.
The Kal Equip was not sensitive to acetylene, benzene or toluene and
only marginally sensitive to ethylene and methane. It was most responsive to
isobutylene. Voltage fluctuation caused very slight HC meter response but
1.0 percent full scale CO response for both plus and minus 10 percent voltage
change.
In the vehicle tests the Kal Equip correlated eleventh best with the
EPA bench. The unit demonstrated significant correlation problems, especially
on the hydrocarbon scale.
This instrument failed during the repeatability test when the hydro-
carbon scale could not be zeroed. The service Watsline, as specified in the
operation's manual, was called several times daily for a period of 10 days;
getting either a busy signal or no answer at all. The local service organiza-
tion was contacted but seemed very reluctant to come out and service the
instrument. They suggested laying the unit on its side and running air through
it for a few hours. This procedure did not alleviate the problem. The service
organization then insisted on verifying the warranty status with the factory
before finally coming out and repairing the unit.
During the durability test the sample probe broke at the junction of
the solid tube and the spiral flex tube. Later in the durability test, the
filter light came on, indicating that a filter change was needed. Even though
the filter was replaced the light stayed on for 5 to 10 minutes. This reoccurred
numerous times. This unit completed 164 hours of durability testing. This
represents 129,888 ppm-hours of HC exposure and 59 percent-hours of CO exposure.
Prior to failure, the instrument demonstrated an average daily span drift of
7.9 percent full scale for HC and 11.14 percent full scale for CO. Final
failure in the durability test resulted from the inability to zero the hydro-
carbon scale, followed by the lack of response of the hydrocarbon scale to
calibration gas.
Judging from our testing this unit needs much more zero adjustment
range.
Test data for Kal Equip 4094-D Infrared Emissions Analyzer are shown
in Tables 7-46 through 7-50.
Photographs of this instrument are shown in Figures 7-29, 7-30,
and 7-31.
7-151
-------
Attachment (1)
INSTRUMENT:
Table 7-46. DATA COMPOSITE - LABORATORY TEST
KAL EQUIP 4094-D
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% Of FS)
(CYCLE 1)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
(CYCLE 1)
7
7
(CYCLE 1)
1.2
0.8
15%
C02/N2
0
6.0
(CYCLE 2)
9
7
MAXIf
(CYCLE 2)
2.4
0.8
(CYCLE 3)
19
19
IUM ZERO DRIFT % Fi
(CYCLE 3)
1.0
0.4
ISOOppm 10% 3%
HC/N2 CO/N2 H20/AIR
1.0 0
0
COMPARISON
CONDITION % FS
35
70
100
35
70
100
35
70
100
35
70
100
0
H
% ERROR
ABSOLUTE
- 4.
- 4.
- 0.
18
45
05
+ 2.09
+ 0.
- 5.
26
17
- 5.53
- 5.
- 0.
- 8.
- 1.
+ 1.
11
05
38
79
29
(CYCLE 4)
6
6
ULL SCALE
(CYCLE 4)
0
0.4
2000ppm
NO/N2
0
2.0
C
% ERROR
FS
- 1.55
- 3.4
- 0.05
+ 0.8
+ 0.2
- 4.8
- 2.05
- 3.9
- 0.05
- 3.2
- 1.4
+ 1.2
10%
02/N2
0
0
C
% ERROR
ABSOLUTE
+ 2.15
- 1.54
0.0
0.0
- 3.43
- 9.09
+ 2.15
0.0
+ 2.17
+ 2.86
- 2.86
- 6.82
1
0
% ERROR
FS
+ 0.8
- 1.0
0.0
0.0
- 2.4
- 8.0
+ 0.8
0.0
+ 2.0
+ 1.2
- 2.0
- 6.0
-------
Table 7-46. DATA COMPOSITE - LABORATORY TEST (Cont'd) Attachment (1)
KAL EQUIP 40-94-D
CYCLE 3
CYCLE 4
HIGH
ALTITUDE
RESPONSE &
RECOVERY
HYDROCARBOi;
RESPONSE
300 Feet
Altitude
6750 Feet
Altitude
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
RANGE
HIGH
HIGH
RANGE
LOW
LOW
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SCALE
HC
CO
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
CORRECTED
CONCENTRATION
1848
8.1
INSTRUMEIS
287 ppm 323 ppra
ACETYLENE BENZENE
0 0
0 0
- 4.18
- 5.11
- 0.31
- 7.85
- 0.77
+ 1.29
- 5.53
- 5.11
0.0
- 8.38
- 0.51
+ 2.37
-10.93
- 7.07
- 0.83
-11.00
- 3.06
+ 0.22
- 1.55
- 3.9
- 0.3
- 3.0
- 0.6
+ 1.2
- 2.05
- 3.9
0.0
- 3.2
- 0.4
+ 2.2
- 4.05
- 5.40
- 0.80
- 4.2
- 2.4
+ 0.2
+ 4.84
- 3.08
- 2.17
+ 4.76
- 2.86
- 6.82
+ 1.88
+ 1.54
- 1.09
- 3.81
- 7.43
-11.36
+ 0.81
0
0
+ 4.76
- 5.71
- 9.09
+ 1.8
- 2.0
- 2.0
+ 2.0
- 2.0 n
- 6.0
+ 0.7
+ 1.0
- 1.0
- 1.6
- 5.2
-10.0
+ 0.3
0
0
+ 2.0
- 4.0
- 8.0
INSTRUMENT RESPONSE TIME (SEC) (AVERAGE OF 2 RUNS)
(CYCLE 1) (CYCLE 2) (CYCLE 3) (CYCLE 4)
26.5 31.0 36.5 38.5
25.0 30.0 34.0 37.0
IT RESPONSE TO VARIOUS HYDROCAF
322 ppm 385 ppm
ETHYLENE ISOBUTYLENE
5 65
10 70
IBONS AS ppm
337 ppm 329 ppm
METHANE TOLUENE
10 0
15 11
tl/1
Co
-------
Attaclunent (1)
Table 7-46. DATA COMPOSITE - LABORATORY TEST (Cont'd)
KAL EQUIP 4094-D
VOLTAGE
PROFILE
POWER
13.6V
13.6V
RANGE
HIGH
HIGH
SCALE
HC
CO
READING VARIAT3
VARYING LINE
+ 10%
0.15
1.0
.ON AS FUNCTION OF
VOLTAGE ± 10%
- 10%
0.20
1.0
-------
INSTRUMENT:
Table 7-47. DATA COMPOSITE - REPEATABILITY TEST
KAL EQUIP 4094-D
r
WARKUP
TIME (Min.)
!
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
CYCLE 1
! s^ c
INTERFERENCE
("/: Of FS)
CYCLE 2
i
GAS
INTERFERENCE
(% of FS)
CYCLE 3
GAS
INTERFERENCE
(>i of rs)
CYCLE 4
RANGE
LOW
LOW .
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
i RESPONSE & HIGH
RECOVERY HIGH
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
(CYCLE 1)'
7
7
(CYCLE 1)
1.0
0.8
15%
CO2/N2
4.0
3.6
15%
C02/N2
0
0
15%
C02/N2
0
3.2
15%
C02/N2
INSTRUM
INSTRUM
CORRECTED
CONCENTRATION
1848
8.1
(CYCLE 2) (CYCLE 3) (CYCLE 4)
17 17
23 14
13
13
MAXIMUM ZERO DRIFT % FULL SCALE
(CYCLE 2) (CYCLE 3) (CYCLE 4)
4.4 3.0
1.2 1.2
leOOppm
HC/N2
-
6.0
ISOOppm
HC/N2
-
0
1600ppm
HC/N2
-
0
1600ppm
HC/N2
jJNT ''MALFU
3NT MALFU
109T
CO/N2
2.0
-
10%
CO/N2
1.0
• -
10%
CO/N2
1.0
-
10%
CO/N2
ACTION
ACTION
MALFUNCTION
MALFUNCTION"
3%
H20/AIR
1.0
-
3%
H20/AIR
0
0
3%
H20/AIR
0.4
0
3%
H20/AIR
INSTRUMENT RESPONSE TI
(CYCLE 1) (CYCLE 2)
29 20
25 20.5
2000ppm
NO/N2
1.0
-0.8
,2000ppm
NO/N2
0
-2.0
2000ppm
NO/N2
0
•0.8
2000ppm
NO/NJ
ME (SEC) (AVERA
(CYCLE 3)
16
16.5
10%
02/N2
0
0.4
10%
02/N2
0
0
10%
02/N2
0
0
10%
02/N2
GE OF 2 RUNS)
(CYCLE 4)
MALFUNCTION
MALFUNCTION
Ul
Ul
-------
Table 7-47. DATA COMPOSITE - REPEATABILITY TEST (Cont'd)
V
I—*
Ul
KAL EQUIP 4094-D
ACCURACY
DETER:-!! NATION
CrrCT ^ "*
CYCLE 2
CYCLE 3
CYCLE 4
RANGE
Of ^ T ""^
HIGH ! HC/CO
HIGH HC/CO
HIGH i HC/CO
LOW ! HC/CO
LOW
HC/CO
LOW i HC/CO
HIGH
HIGH
HIGH
HC/CO
HC/CO
HC/CO
LOW j HC/CO
LOW
LOW
HIGH
HIGH
HIGH
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
LOW HC/CO
LOW
HC/CO
LOW HC/CO
HIGH
HIGH
HC/CO
HC/CO
HIGH j HC/CO
LOW I HC/CO
LOW
LOW
HC/CO
HC/CO
'
t y
' COMPARISON !
CONDITION :' 7S : ;'= ERROR
! ABSOLUTE'
1
35 ! -5.86
70 -5.11
100 i +0.21
35 i -11.00
70 i -8.16
100 ; -6.68
35 : -5.53
70 i -6.74
100 I +1.25
35 I -3.14
70 i -0.51
100 j -3.02
35 j -0.13
70 1 -0.52
100 i +2.28
35 : -25.65
70 ! -3.57
100 ' -3.Q6
35
70 " i
100 1
35 !
C
-1 ERROR '
ri ERROR
AS SOLUTE
-2.05 -0.54
-3.90 -3.08
+0.20 -2.17
-4.20
-6.40
+4.76
-1.71
-6.20 -9.09
-2.05 +10.22
-5.15
+1.20
-1.20
-0.40
-2.80
-0.50
+3.08
+2.17
+3.81
-1.14
-6.36
+6.18
-0.40 +4.62
+2.20 +6.52
-9.80
+8.57
-2.80 -5.14
-3.60 -10.0
INGTPWfflMT
i
MALjFUNCtlON
70 j
100 !
- 5
-0.20
-2.00
-2.00
+2.00
-1.20
-8.00
+3.80
+ 2.00
+2.0
+1.60
-0.80
-5.60 ;
+2.30
+3.00
+6.00
+3.60
-3.60
-8.80
!
i
-------
Table 7-48. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS
KAL EQUIP 4094-
KEY MODE
CYCLE #
STANDARD MODE
CYCLE 1
•
CYCLE 2
CYCLE 3
CYCLE 4
LEAN MODE
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
•D
RANGE
PPM/%
500/2.5
500/2.5
500/2.5
500/2.5
500/2.5
500/2.5
5OO/2 . 5
500/2.5
500/2.5
500/2.5
500/2.5
500/2.5
500/2.5
500/2.5
500/2.5
-------
Table 7-43. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS (Cont'd)
KAL EQUIP 4094-D
KEY MODE
CYCLE #
RICH MODE
CYCLE 1
CYCLE 2
pvnt.p 3
r"»V/T T7 A
CYUJbr/ •*
TJ 7\ VT/-" T?
PPM/%
500/2.5
500/2.5
500/10
500/2.5
500/2.5
500/10
500/2.5
500/2.5
500/10
500/2.5
500/2.5
500/10
QOAT T?
HC/CC
HC/CO
EC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
copT^n '
50
30
IDLE
50
30
IDLE
so
30
IDLE
50
30
IDLE
H
% ERROR-
ABSOLUTE
- 57.87
- 60.76
- 51.23
- 57.08
- 34.46
- 36.10
- 32.77
- 42.16
- 54.46
- 22.88
- 29.71
- 34.38
•»
% ERROR
FS
- 16.48
- 18.58
- 42.02
- 23.94
- 8.94
- 23.16
- 8.29
- 10.93
- 33.48
- 5.93
- 7.61
- 21.48
C(
% ERROR
ABSOLUTE
+ AQ ni
- 4.76
- 15.18
+ n . 1 3
4- 27.40
- 0.28
+ 10.95
+ 27.40
- 16.92
+ 13.48
+ 32.35
+ 2.84
D
r/< ERROR
PS
-+ 10.64
- 0.4
- 5.6
4- O.OA
+ 0.16
.- 0.1
+ 2.96
+ 0.16
- 5.5
+ 3.8
+ 1.76
+ 0.91
I
H-t
00
-------
Table 7-49. DIAGNOSTIC TEST
KAT, EQUIP 4094 -D
TEST
«™™
IGNITION RETARD
RANGE
500
2.5
500
2.5%
500
2.5%
500
2.5%
SCALE
HC
CO
HC
CO
HC
CO
HC
CO
PPM NO, PPM HC, % CO
TEST INSTRUMENT
340
1.10
190
1.20
175
1.15
150
1.0
EPA BENCH
406.15
1.955
217.89
2.223
134.53
1.864
131.29
1.934
HC/CO/NO
% ABSOLUTE
ERROR
- 16.29
- 43.73
- 12.80
- 46.02
+ 30.08
- 38.30
+ 14.25
- 48.29
% ERROR
FS
- 13.23
- 34.2
- 5.58
- 40.92
+ 16.19
- 28.56
+ 3.74
- 37.36
^J
I
I—
Ui
VO
-------
Table 7-50. DURABILITY TEST DATA
INSTRUMENT: KAL EQUIP 4094-D
INSTRUMENT TIME TO FAILURE AND GAS EXPOSURE
TIME TO FAILURE (HRS.)
HC EXPOSURE (PPM-HRS.)
CO EXPOSURE (%-HRS.)
NO EXPOSURE (PPM-HRS.)
164
129,888
59
16,236
INSTRUMENT STABILITY
TOTAL NO. DAYS SHOCK TEST FAILURE
(3% Variation) 1 or More of 4 Modes
SHOCK TEST FAILURE RATE
(Failure/Day %)
INCIDENCE OF FAILURE IN EACH MODE -
HC ZERO
HC SPAN
CO ZERO
CO SPAN
AVERAGE DAILY SPAN DRIFT
HC%
C0% ,
N0%
NOT APPLICABLE
NOT APPLICABLE
NOT APPLICABLE
7.9
11.14
—
INSTRUMENT SERVICE REQUIREMENTS
A CHANGE FILTER
TOTAL
PER 100 HRS.
B DRAIN HOSE
TOTAL
PER 100 HRS. .
C REZERO
TOTAL
PER 100 HRS.
D. SAMPLING SYSTEM
TOTAL
PER 100 HRS.
E . OTHER
TOTAL
PER 100 HRS.
13
7.98
—
1
0.61
2
1.22
3
1.83
7-160
-------
Figure 7-29. KAL EQUIP 4094-D INFRARED EMISSIONS ANALYZER
7-161
-------
Figure 7-30. KAL EQUIP 4094-D INFRARED EMISSIONS ANALYZER (BACK AND PROBE)
7-162
-------
Figure 7-31. KAL EQUIP 4094-D INFRARED EMISSIONS ANALYZER (LEFT SIDE)
7-163
-------
7.11 PULSAR 662 INFRARED ANALYZER
Manufacturer - Peerless Instrument Company
Description - HC/CO exhaust analyzer configured as separate, bench top
sample handling/analysis and readout/control modules fitted to a
compartmentalized two-wheel cart. The modules can be used without
the cart.
Dimensions -
Height - 13 inches
Width - 8-5/8 inches
Depth - 14-1/2 inches
Readout/Control Module
Height - 12-1/2 inches
Width - 8-5/8 inches
Depth - 7-1/2 inches
Cart -
Height - 36-1/4 inches
Width - 20-1/2 inches
Depth - 18-3/4 inches
Material of Construction - Sheet metal, joined by welding and screws .
Color - Cart is gold with black trim, modules are black with gold trim.
Mobility - Two, rear-mounted, 8-inch diameter wheels, front sheet metal
legs. Handle is mounted at top rear of unit. Mobility is good with
well placed C.G.
Accessories - Sample probe, sample hose, module interconnect cable,
operator's manual, chain-connected to cart for instructions.
Control Package - All functions in both modules are controlled from the
readout/control module.
Front Access - Mode control (four push buttons)
1. Standby
2. Calibration zero
3. Calibration span
4. Test
5. Main power - toggle on/off
6. Flow blocked - indicator light
7. HC span - knob
8. HC zero - knob
9. Range - toggle - high/low
10. CO span - knob
11. CO zero - knob
12. Range - toggle - high/low
13. 15 amp breaker
7-164
-------
Meters - 5-1/2", 90° sweep
Black characters on white background
Red bar for high scales
Gold bar for low scales
Span marks on meter faces
Air fuel ratio markings on CO meter face (14.7 to 10.5 afr).
Ranges - HC - 0-2000 ppm in 50 ppm increments
0-400 ppm in 10 ppm increments
CO - 0-10% in 0.20% increments
0-2% in 0.05% increments
Meters were not sensitive to static electricity.
Altitude Compensation - Chart in operator's manual used during electronic
calibration. Not needed when gas calibration used at test site.
Probe - Flexible braided metallic hose connected to rigid tubing. Handle
and tail pipe clamp are one piece. Metallic screen in probe tip.
Filters and Sample Handling - Primary metallic screen in probe tip acts
as course particulate filter. A water trap is located immediately
upstream of the entrance to sample module. Water trap also incor-
porates a 100 mesh stainless steel filter element.
Cal Gas Inlet - Injection port on top of water trap.
Power Requirements - 12 volt DC 9.5 amps
Operating Principles - Dual cell nondispersive infrared, dual hot wire
source dual detector (thermopile) chopper blade, band pass optical
filters.
Calibration - Straightforward - both electronic and span gas calibration
uses same span pots. No external ability to set individual ranges
or adjust inter-range correlation.
Operation and Calibration - Fairly straightforward but complicated by
operating mode push buttons.
Operation -
1. Connect 12 volt power clips
2. Warm up with main power on and standby button pushed
3. Electronic zero and span set
4. Ready for use (push test button)
5. Optional gas calibration
7.11.1 Operational Performance Comments
The mechanical package for this unit consisted of an electronic
module and a sample processing module, connected by an electrical cable. Both
of the modules fit into a cabinet equipped with two wheels and two stationary
feet. The cabinet had a vertical storage space with one hangar inside of the
hose and power cord. This storage area had a hinged door on the front.
7-165
-------
The sampling system utilized a braided probe. During the test
sequences no fraying of this probe was noted, but the metallic screen in the
tip of the probe disintegrated. The sample hose was short and made of soft,
large diameter rubber tubing. During durability testing, this hose continually
filled with water. The hose was attached by a slip-on tubular connector. Its
integrity is questionable. The water trap contained a series of screens
acting as a particulate filter.
The unit was interesting from a design standpoint, due to its modular
separation of the sample handling and analysis function from the control and
readout function.
In use, the sample handling and analyzing module was located near
the rear of the test vehicle, while the control and readout module was located
near the front. Interconnection was achieved through the use of a multicon-
ductor electrical cable. There appeared to be no clear advantage in function
separation except reduction in sample transit time (response time). In reality,
this separation merely added one more piece of equipment to be moved and
positioned. Due to the short sample hose length, the modules could not effect-
ively be used for "underhood" work while installed in the cart.
The infrared section of the Pulsar uses two tubes which are spilt
horizontally, with the lower section for the sample and the upper section for
reference. It was noted that this instrument had nontypical response charac-
teristics. The unit appeared to be very unstable; the readings exhibiting
continual up and down drift. It was noted that both the HC and CO meters
"slipped" when the cycling fan came on in the sample module.
The Pulsar had the lowest meter height (above floor level when in
cart) of all the console-type instruments tested. In addition to the standard
CO meter scales, an air/fuel ratio scale was inscribed on the CO meter. The
correct CO range selection for use with this air/fuel ratio scale was not
specified on the instrument.
The zero and span knobs were very close together on the instrument
face. They were easy to mistake or bump. The power switch was easy to mistake
for the HC range switch.
Calibration gas input required fitting a hose adaptor to the calibra-
tion port. The calibration port was located at the bottom front of the sample
handling module on top of the water traps.
Operating instructions for the instrument were on a plastic card
attached by a chain to the stand. The calibration instructions on the back of
the card was judged to be incomplete.
In the laboratory tests, this unit showed warm up times of 12 minutes
or less, except at low temperatures, where 20 minutes were required.
Zero drift was typically 2.5 percent full scale or less with the
exception of high temperature tests. Zero drift climbed to 10 percent full
scale for HC and 5 percent full scale for CO indicating sensitivity to high
temperatures.
7-166
-------
Gas interference tests indicated slightly more than 1 percent full
scale repeatable HC response to CO. In addition, the CO meter showed 0.8 per-
cent to 2.0 percent full scale response to NO.
In accuracy determination, the Pulsar was rated ninth overall with
no clear pattern of weakness. High altitude tests showed slightly better
accuracy overall. The response time of this instrument was very consistent
for HC and only slightly less consistent for CO. Times varied between 12 and
18 seconds.
The Pulsar was not sensitive to acetylene, benzene or ethylene and
only marginally sensitive to methane. It was most sensitive to isobutylene,
follwed by toluene. Voltage fluctuation caused essentially no meter response.
During the repeatability tests, cycle four, the HC meter refused to zero.
Operation on air for 3 hours caused the meter to resume normal operation. The
problem was never diagnosed.
In the vehicle test, the Pulsar correlated eighth best overall with
the EPA instrument. Generally, the HC scale showed significantly more error
than the CO scale.
In the durability tests, the Pulsar completed 309 hours of operation.
This corresponds to 288,297 ppm-hours of HC exposure and 454 percent-hours of
CO exposure.
The unit was moderately sensitive to shock and vibration; experiencing
7 days of testing when the shock test caused more than 3 percent full scale
meter variation.
This unit showed significant average daily span drift on the order
of 16.3 percent full scale and 9.9 percent full scale for CO. The particulate
filter required cleaning 13 times during the durability tests.
In the area of maintenance, the sample hose continually filled with
water, blocking the sample flow. The sample hose required very frequent
draining during durability testing. During the vibration test on this instru-
ment, the axle retaining cap fell off, allowing one of the wheels to slip off
the end of the axle. In the durability test, failure resulted when the HC
meter could not be rezeroed with an air input.
Test data for Pulsar 662 Infrared Analyzer are shown in Tables 7-51
through 7-55.
Photographs of this instrument are shown in Figures 7-32, 7-33,
and 7-34.
7-167
-------
Attachment (1)
Table 7-51. DATA COMPOSITE - LABORATORY TEST
INSTRUMENT:
PULSAR 662
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
(CYCLE 1)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
HIGH
HIGH
HIGH
LOW
LOW
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
LOW IHC/CO
HIGH IHC/CO
HIGH HC/CO
HIGH JHC/CO
LOW |HC/CO
LOW JHC/CO
LOW |HC/CO
(CYCLE 1)
12
9
(CYCLE 1)
2.5
2.5
15%
C02/N2
0
0.5
(CYCLE 2)
10
8
MAXI*<
(CYCLE 2)
10.0
5.0
(CYCLE 3)
20
20
IUM ZERO DRIFT % PI
(CYCLE 3)
2.5
1.0
IGOOppm 10% 3%
HC/N2 CO/N2 H20/AIR
0.01 0
0-0
COMPARISON
CONDITION % FS
35
70
100
35
70
100
35
70
100
35
70
100
H
% ERROR
ABSOLUTE
- 7.56
- 8.39
4- 5.69
- 1.1
- 1.42
- 1.59
- 2.52
- 3.5
- 1.49
-16.48
-10.38
- 6.35
(CYCLE 4)
6
6
ULL SCALE
(CYCLE 4)
1.
25
0
2000ppm
NO/N2
0
-1.0
C
% ERROR
FS
- 2.25
- 5.15
-1- 4.4
- 0.25
- 0.75
- 1.25
- 0.75
- 2.15
- 1.15
- 3.75
- 5.5
- 5.0
10%
02/N2
0
0
C
% ERROR
ABSOLUTE
+ 2.15
+ 4.62
-I- 1.09
+15.94
0.0
+ 2.86
- 3.23
+ 1.54
+ 1.09
+ 8.7
- 0.95
0.0
o
% ERROR
FS
+ 0.8
+ 3.0
+ 1.0
+ 5.5
0.0
+ 2.5
- 1.2
+ 1.0
+ 1.0
+ 3.0
- 0.5
0.0
I
I—«
Ou
-------
Table 7-51. DATA COMPOSITE - LABORATORY TEST (Cont'd) Attachment (1)
PULSAR 662
CYCLE 3
CYCLE 4
HIGH
ALTITUDE
RESPONSE &
RECOVERY
HYDROCARBON
RESPONSE
300 Feet
Altitude
6750 Feet
Altitude
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
RANGE
HIGH
HIGH
RANGE
LOW
LOW
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SCALE
HC
CO
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
CORRECTED
CONCENTRATION
1485
8.1
INSTRUMEIS
287 ppm 323 ppm
ACETYLENE BENZLNE
0 0
0 0
- 2.52
- 4.72
- 2.46
0.0
- 3.3
0.0
- 0.84
- 3.1
- 0.52
+10.99
- 2.52
- 1.27
- 0.84
+ 9.94
- 1.16
- 2.20
- 5.66
- 1.59
INSTRUMEN1
(CYCLE 1)
16.5
16.5
- 0.75
- 2.9
- 1.9
0.0
- 1.75
0.0
- 0.25
- 1.9
- 0.4
+ 2.5
- 0.75
- 1.0
- 0.25
+ 6.1
- 0.90
- 0.50
- 3.0
- 1.25
- 3.23
+ 2.31
+ 2.17
+ 8.7
- 0.95
+ 2.29
- 3.25
+ 1.54
+ 1.09
+10.15
- 3.23
+ 4.0
- 5.91
- 3.08
- 2.17
+ 8.70
- 0.95
+ 1.71
T RESPONSE TIME (SEC) (AVERA
(CYCLE 2) (CYCLE 3)
18.5 16.25
15.5 12.0
rr RESPONSE TO \
322 ppm
ETHYLENE
0
5
rARIOUS HYDROCAF
385 ppm
ISOBUTYLENE
51
60
- 1.2
+ 1.5
+ 2.0
+ 3.0
- 0.5
+ 2.0
- 1.2
+ 1.0
+ 1.0
+ 3.5
- 1.2
+ 3.5
- 2.2
- 2.0
- 2.0
+ 3.0
- 0.5
+ 1.5
GE OF 2 RUNS)
(CYCLE 4)
16.0
12.5
LBONS AS ppm
337 ppm 329 ppm
METHANE TOLUENE
8
7
21
29
I
NO
-------
Attacliment (1)
Table 7-51. DATA COMPOSITE
PULSAR 662
- LABORATORY TEST (Cont'd)
VOLTAGE
PROFILE
POWER
13.6V
13.6V
RANGE
HIGH
HIGH
SCALE
HC
CO
READING VARIATION AS FUNCTION OF
VARYING LINE VOLTAGE + 10%
+ 10%
0
0.50
- 10%
0.25
0
>
K-
o
-------
Table 7-52. DATA COMPOSITE - REPEATABILITY TEST
INSTRUMENT: PULSAR 662
WAR.MUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
CYCLE 1
GAS
INTERFERENCE
(% of FS)
CYCLE 2
GAS
INTERFERENCE
(% of FS)
CYCLE 3
GAS
INTERFERENCE
(% of FS)
CYCLE 4
RESPONSE i
RECOVERY
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
SCALE
HC
GO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
i
SCALE
i
1 (CYCLE 1) (CYCLE 2) (CYCLE 3) (CYCLE 4)
! 10 22 19 15
11 17 17 13
1 MAXIMUM ZERO DRIFT % FULL SCALE
] (CYCLE 1) (CYCLE 2) (CYCLE 3) (CYCLE 4) {
! 5.0 3.75 1.5 0.75
1.0 0.5 1.0 0.50
! 15%
C02/N2
0.5
1.0
15%
C02/N2
! i.s
1 0.5
15%
C02/N2
0
1.0
15%
C02/N2
HC j 0
CO
(
RANGE SCALE (
31 GH HC
HIGH ! HC |
1.5
ZORRECTSD
lONCENTRATION
1485
8.1
IGOODpm
HC/N2
- ' •
0.5
1600ppm
HC/N2
-
0
HC/N2*
Ml
10%
CO/N2
1.25
-
10%
CO/N2
1.25
-
• 10%
CO/N2
0.75
0 }
IGOOppra
HC/N2
-
0
10%
CO/N2
0
3%
K20/AIR
0
0
3%
K20/AIR
0
0
3%
H20/AIR
1.25
0.5
3%
H20/AIR
0.5
1 o
NO/N2"
0.5
• 1.0
,2000ppin
0
0
2000ppm
0
- 0
2000DDIT1
NO/KJ"
0
0
10%
02/N2
0
1.0
10%
02/N2
0
0
10%
02/N2
0
0 >
10% i
02/N2
0
0
INSTRUMENT RESPONSE TIME (SEC) (AVERAGE OF 2 RUNS)
(CYCLE 1) | (CYCLE 2) ] (CYCLE 3) | (CYCLE 4)
21 ! 15 i 9.5 j 9
21.5 j 15 ! 9 ! 6.5
-------
Table 7-52. DATA COMPOSITE - REPEATABILITY TEST (Cont'd)
PULSAR 662 , . . , •
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
RANGE
SCALE
COMPARISON
CONDITION :- 7S
i
HIGH JHC/CO 35
HIGH
HC/CO i 70
HIGH HC/CO 100
LOW HC/CO
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
35
HC/CO ! 70
HC/CO 100
HC/CO
HC/CO
HC/CO
35
70
100
HC/CO 35
HC/CO
HC/CO
HC/CO
70
100
35
HC/CO 70
HC/CO
LOW 'HC/CO
100
35
LOW i HC/CO ! 70
LOW HC/CO : 100
HIGH | HC/CO j 35
HIGH
HC/CO 70
HIGH | HC/CO
LOW
LOW
LOW
100
HC/CO 35
HC/CO
HC/CO
70
100
«
f= ZRROR
ABSOLUTE
-0.84
-3.10
-1.49
-1.10
-1.89
-0.95
-6.72
-6.43
-8.91
0
-0.95
+0.95
+3.36
-1.47
-1.81
0
-5.19
+0.95
+4.37
-3.91
-1.81
-9.87
-0.94
+1.59
C
'A ERROR
F5
-0.25
o
w
•• ERROR
ABSOLUTE
+1.88
-1.90 i +3.85
-1.15 i +1.09
-0.25
+10.15
-1.00 I -1.91
-0.75
0
-2.0 +0.81
-3.95
-6.90
0
' -0.50
+0.75
+1.54
+3.26
+13.04
+2.86
+3.43
+1.00 -3.23
-0.9 i 0
-1.40 1 +7.61
o
+10.14
-2.75 i 0
+0.75 j +0.57
+1.30 | +2.15
-2.40 i +10.77
-1.40
-2.25
-0.50
-6.52
+1.45
-4.76
+1.25 -2.86
W
•;< SRRC?. •
FS
+0.70
+2.50
+1.00
+3.50
-1.00 !
0 j
+0.30 i
+1.00 i
+3.0
+4.50 !
+1.54
+3.0 i
-1 2
J. «
-------
PULSAR 662
Table 7-53. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS
KEY MODE
CYCLE #
STANDARD MODE
CYCLE 1
•
CYCLE 2
CYCLE 3
CYCLE 4
LEAN MODE
CYCLE 1
CYCLE 2.
CYCLE 3
CYCLE 4
RANGE
PPM/%
400/2
400/2
400/2
400/2
400/2 1
400/2
400/2
400/2
400/2
400/2
400/2
400/2
400/2
400/2
400/2
400/2
400/2
400/2
400/2
400/2
400/2
-------
Table 7-53.
PULSAR 662
VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS (Cont'd)
b
KEY MODE
CYCLE #
RICH MODE
CYCLE 1
CYCLE 2
rVTT,F 3
CYCLib ^
RANGE
PPM/0/
/o
400/2
400/2
2000/10
400/2
400/2
400/10
400/2
400/2'
400/10
400/2
400/2
400/10 .
Q/-IT\ T "C*
bL-AJ-ib
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
WC /CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
CDTTTTT^ '
Oir^lUJ
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
H
% ERROR-
ABSOLUTE
- 34.74
- 41.22
- 42.5
- 27.22
- 28.8
- 29.65
- 41.22
- 30.61
- 23.1
- 38.29
- 28.01
- 25.33
C
% ERROR
FS
- 11.98
- 15.6
- 8.69
- 8.6
- 9.1
- 24.03
- 15.6
- 9.93
- 17.38
- 12.1
- 8.85
- 19.68
C(
% ERROR
ABSOLUTE
- 2.14
- 55.0
•f 5.34
-2.44
- 36.17
+ 6.51
+ 4.65
- 31.51
+ 5.74
- 3.85
+ 27.66
+ 5.43
D
% ERROR
^S
- 0.6
- 5.5
+ 1.9
\- 1.0
- 2.55
f 2.2
4- 1.6
- 2.3
+ 1.9
- 1.3
+ 19.5
+ 1.7
-------
Table 7-54. DIAGNOSTIC TEST
PULSAR 662
TEST
»«».
T fiTO T T1 TOM AHX7 A NP-P
IGNITION RETARD
RANGE
400
10%
400
10%
400
10%
400
10%
SCALE
HC
CO
HC
CO
HC
CO
HC
CO
PPM NO, PPM HC, % CO
TEST INSTRUMENT
240
2.20
116
2.60
100
2.40
97
2.70
EPA BENCH
401.1
1.97
231.1
1.90
147.5
2.03
134.5
2.06
HC/CO/NO
% ABSOLUTE
ESROR
- 40.16
- 11.68
- 49.81
- 36.84
- 32.2
- 18.23
- 27.88
- 31.07
% ERROR
- 40.28
- 2.3
- 28.78
- 7.0
- 11.88
- 3.7
- 9.38
- 6.4
-------
Table 7-55.
INSTRUMENT: PULSAR 662
DURABILITY TEST DATA
INSTRUMENT TIME TO FAILURE AND GAS EXPOSURE
TIME TO FAILURE (HRS.)
HC EXPOSURE (PPM-HRS.)
CO EXPOSURE (%-HRS.)
NO EXPOSURE (PPM-HRS.)
309
288,297
454
32,136
INSTRUMENT STABILITY
TOTAL NO. DAYS SHOCK TEST FAILURE
(3% Variation) 1 or More of 4 Modes
SHOCK TEST FAILURE RATE
(Failure/Day %)
INCIDENCE OF FAILURE IN EACH MODE
HC ZERO
HC SPAN
CO ZERO
CO SPAN
AVERAGE DAILY SPAN DRIFT
HC%
CO%
N0%
7
35.0
1
5
0
1
16.28
9.86
—
INSTRUMENT SERVICE REQUIREMENTS
A CHANGE FILTER
TOTAL
PER 100 HRS.
B DRAIN HOSE
TOTAL
PER 100 HRS.
C REZERO
TOTAL
PER 100 HRS.
D. SAMPLING SYSTEM
TOTAL
PER 100 HRS.
E. OTHER
TOTAL
PER 100 HRS.
__
60
19.42
~"
—
1
0.32
7-176
-------
Figure 7-32. PULSAR 662 INFRARED ANALYZER
7-177
-------
Figure 7-33. PULSAR 662 INFRARED ANALYZER (BACK)
7-178
-------
Figure 7-34. PULSAR 662 INFRARED ANALYZER (LEFT SIDE AND PROBE)
7-179
-------
7.12 AUTOSCAN 710C HC/CO ANALYZER
Manufacturer - FMC Corporation
Description - HC/CO exhaust analyzer configured as a console model with
two wheels. The analyzer cannot be used independent of the cart.
Dimensions -
Height - 48 inches
Width - Base - 19-1/2 inches Analyzer - 10 inches
Depth - 21-1/2 inches
Weight - 81 Ibs.
Material of Contraction. - Sheet metal cabinet - welded aluminum trim.
Color - Blue with black base and front panel - sliver trim.
Mobility - Two, rear-mounted, 5-inch diameter wheels, front sheet metal
support pad. Top, rear-mounted handle. Mobility is good. Feeling
during movement is slightly heavy.
Accessories - Sample probe with shot bag, sample hose (25 feet) gas
calibration kit, operator's manual.
Control Package -
Front Access - Operation mode switches (four push buttons, all lighted)
1. Standby
2. High (scale)
3. Low (scale)
4. Cal
5. Change filter - indicator light
6. HC zero - knob
7. HC cal - knob
8. CO zero - knob
9. CO cal - knob
Rear Access -
Power on - toggle
2.5 amp breaker
HC course zero - knob
CO course zero - knob
Calibration Mode - (two-position slider switch)
1. Electronic
2. Gas
Self test switch (nine positions)
Calibration gas inlet
Unlabeled HC and CO span adjustments (screws recessed behind
blind holes in rear panel - used for factory calibration)
Meters - 8-inch, 90 sweep
Black characters on white background.
7-180
-------
Ranges - HC - 0-2000 ppm in 50 ppm increments
- 0-500 ppm in 10 ppm increments
CO - 0-10% in 0.20% increments
- 0-2.0% in 0.02% increments
Air fuel ratio - 14.6 to 11 AFR
Altitude Compensation - Chart on rear panel used during electronic cali-
bration not needed when gas calibrated at test site.
Filters and Sample Handling - Flexible braided tube with rigid tube tip
insert, connected to rigid tube with handle. Heavy shot bag chained
to probe to hold it in the tail pipe.
Cal Gas Inlet - On rear of unit - automatic cal gas shot with cal button
actuation.
Power Requirements - 115 VAC 60 HZ
Operating Principles - Nondispersive infrared, dual cell, optical filter,
chopper modulated, dual source, dual solid-state detectors.
Calibration - Normal mode uses automatic calibration gas shot, electronic
calibration feature serves as back up system. HC and CO cal knobs
used to trim readings to "cal" mark on meters during gas and elec-
tronic calibrations. Calibrate mode switch on rear panel selects
type of calibration desired.
Operation and Calibration - Very straightforward.
Operation -
1. Plug in and push standby button
2. Set zero
3. Push cal button and set to marks
4. Push high or low button
5. Ready for use
7.12.1 Operational Performance Comments
The mechanical package of this unit consists of a tall, narrow,
integral cabinet and stand on a triangular base with wheels at two corners.
The unit is slightly top-heavy but the large base, with the calibration gas
package located at the bottom, prevents tipping over from being a real problem.
There is a hanger attached to the rear of the unit for power cord and sample
hose, but there is not additional storage space for instrument manuals or
other accessories.
The sample hose is constructed of gray, flexible, reinforced tubing
and worked very well during all tests. The unit is designed with a sintered
bronze filter located in the aspirated water trap. The water trap configuration
presented an uphill flow for any water or particulates in the output line.
An air/fuel ratio scale was included on the CO meter, but the correct
CO range for its use was not specified.
7-181
-------
Calibration of the instrument with laboratory gases requires removing
a threaded cap and fitting a hose adapter to the calibration gas inlet. There
are very brief operation and calibration instructions on a plastic card attached
to the handle on the back of the unit.
Changing the filter on this unit was awkward because of its location.
It was noted during operation that the braided sample probe frayed slightly.
The quick disconnect sample hose is a good idea, conducive to easy cleaning
and draining.
The instrument incorporates a novel self diagnosis switch that can
be used by the customer to help pin point problems prior to calling a service
facility. A diagnostic routine is followed while changing switch positions
(nine total). The results of these tests are then telephoned to the factory
representative who advises on service.
It was noted that meter span set points and interscale correlation
are not intended as customer adjustment, although the HC and CO span pots are
accessible through unlabeled holes in the rear panel. The manufacturer depends
upon initial gas calibration for set point and interscale correlation. Factory
service is recommended if span adjustment is needed.
In the laboratory tests, the unit showed warm up times of 9 to
12 minutes except during cold temperature tests, which required 23 minutes.
During the zero drift tests, cycle one and two, the unit experienced
an electronic failure causing erratic meter readings. The problem was diagnosed
as a faulty data PC board. It was replaced by the service representative and
the instrument returned to normal. Cycle three and four indicated a slightly
increased low CO error at 35 percent of meter full scale. High altitude
operation demonstrated the same general pattern.
Response times for this instrument appeared to range from 16 to
slightly more than 19 seconds.
This unit was not responsive to acetylene or benzene. It was most
responsive to isobutylene, followed by toluene, methane and ethylene.
The Atuoscan showed no significant repeatable gas interference
effects on either scale although the CO scale showed a tendency toward NO
sensitivity.
In the vehicle tests, the Autoscan 7IOC showed the best overall
correlation of all instruments.
In the durability test, the Autoscan ran 193 hours before failure
(195,700 ppm-hours-HC, 398 percent-hours-CO).
It experienced three test days when the shock test caused greater
than a 3 percent meter variation.
The Autoscan average daily span drift was noted to be 1.96 percent
full scale HC and 4.5 percent full scale CO.
7-182
-------
The filter element was serviced six times during durability tests
(3.1 times per 100 hours of operation).
During the durability test, the unit failed when the HC meter was
pegged up-scale. The filter light came on and could not be turned off even by
removing the hose and filter.
Test data for Autoscan 710C HC/CO Analyzer are shown in Tables 7-56
and through 7-60.
Photographs of this instrument are shown in Figures 7-35, 7-36,
and 7-37.
7-183
-------
Attachment (1)
INSTRUMENT:
Table 7-56. DATA COMPOSITE - LABORATORY TEST
AUTOSCAN 7IOC
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
(CYCLE 1)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
RANGE
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
(CYCLE 1)
12
MALFUNCTION
(CYCLE 1)
INSTRUMENT
MALFUNCTION
15%
C02/N2
INSTRUMENT
MALFUW
(CYCLE 2)
11
9.5
MAXI!-
(CYCLE 2)
INSTRUMENT
MALFUNCTION
IGOOppm
HC/N2
JTION
COMPARISON
CONDITION % FS
35
70
100
35
70
100
35
70
100
35
70
100
(CYCLE 3)
23
23
IUM ZERO DRIFT % Fl
(CYCLE 3)
1.0
10%
CO/N2
% ERROR
ABSOLUTE
0.5
3%
H20/AIR
H
(CYCLE 4)
9
10
JLL SCALE
(CYCLE 4)
1.2
0.5
2000ppm 10%
-
C
% ERROR
FS
INSTRUME
NO
INSTRUME
NO
C
% ERROR
ABSOLUTE
95? FAILED
DATA
OT FAILED
DATA
0
% ERROR
FS
~J
H-1
CO
-------
Table 7-56.
AUTO SCAN 7IOC
DATA COMPOSITE - LABORATORY TEST (Cont'd)
Attachment (1)
CYCLE 3
CYCLE 4
HIGH
ALTITUDE
RESPONSE &
RECOVERY
HYDROCARBON
RESPONSE
300 Feet
Altitude
6750 Feet
Altitude
H'GH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
RANGE
HIGH
HIGH
RANGE
LOW
LOW
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SCALE
HC
CO
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
CORRECTED
CONCENTRATION
1627
8.1
INSTRUMEK
287 ppm 323 ppm
ACETYLENE BENZENE
0 0
0 0
+ 1
- 4
- 0
- 0
+ 1
+ 2
+ 0
- 3
- 0
- 6
.23
.09
.94
.62
.45
.54
.46
.35
.35
.83
- 3.77
- 1
+ 1
-• 3
- 0
.69
.84
.35
.94
0
- 0
+ 1
INSTRUMEN1
(CYCLE 1)
INSTRUMENT
FAILED NO D
.86
.45
+ 0.4
.- 2
.75
- 0.8
- 0.2
+ 1.0
+ 2.4
+ 0.15
- 2.25
- 0.3
- 2.2
- 1.6
- 1.6
+ 0.6
- 2.25
- 0.8
0
- 0.4
+ 1.0
r RESPONSE TI
(CYCLE 2)
11
VTA "
rr RESPONSE TO v
322 ppm
ETHYLENE
10
5
- 8.6
- 1.54
- 2.17
+10 . 14
0.0
- 1.71
- 1.88
+ 1.54
0.0
+13.04
+ 0.95
+ 0.57
- 0.54
+ 1.54
0
+13.04
- 2.86
- 0.57
ME (SEC) (AVERA
(CYCLE 3)
17.0
16.0
rARIOUS HYDROCAT
385 ppm
ISOBUTYLENE
80
75
- 3.2
- 1.0
- 2.0
+ 3.5
0.0
- 1.5
- 0.7
+ 1.0
0.0
+ 4.5
+ 0.5
+ 0.5
- 0.2
+ 1.0
0
+ 4.5
- 1.5
- 0.5
GE OF 2 RUNS)
(CYCLE 4)
19.5
19.25
IBONS AS ppm
337 ppm 329 ppm
METHANE TOLUENE
12
10
35
30
I
h—
oo
-------
Attachment (1)
Table 7-56
AUTOSCHN 710C
DATA COMPOSITE - LABORATORY TEST (Cont'd)
VOLTAGE
PROFILE
POWER
115V
115V
RANGE
HIGH
HIGH
SCALE
HC
CO
READING VARIATI
VARYING LINE
+ 10%
0.35
0.0
ON AS FUNCTION OF
VOLTAGE ± 10%
- 10%
0.0
1.0
I
H-»
03
-------
Table 7-57. DATA COMPOSITE - REPEATABILITY TEST
INSTRUMENT: AUTOSCAN 710C
WARKUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
CYCLE 1
1 GAS
INTERFERENCE
(% of FS)
CYCLE 2
GAS
INTERFERENCE
(% of FS)
CYCLE 3
GAS
INTERFERENCE
(:-. of rs)
CYCLE 4
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
RESPONSE i HIGH
RECOVERY HIGH
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
(
SCALE (
HC
CO
\ (CYCLE 1) (CYCLE 2) (CYCLE 3) (CYCLE 4)
! 13 24 29 20
! 13 24 29 20
MAXIMUM ZERO DRIFT % FULL SCALE
t
! (CYCLE 1) (CYCLE 2) (CYCLE 3) (CYCLE 4) !
! 1-2 2.0 3.0 2.4
I 5.0 75.0 6.0 0.5
15%
C02/N2
1.0
0.75
15%
j C02/N2
0
0
15%
C02/N2
0
0
15%
CO9/N2
0
0.5
:ORRECTED
ZONCENTRATION
leOOocm
HC/N2"
-
1.0
ISOOppm
HC/N2
—
10%
CO/N2
0.4
_
10%
CO/N2
5.0
o I -
1600ppm
HC/N2"
0
10%
CO/No
^
0
_
ISOOppin 10%
HC/N0 CO/N2
—
0
0
-
3%
K20/AIR
0
1.0
3%
H20/AIR
0
0
3P-
H90/AIR
0
0
3%
K20/AIR
2000ppm
NO/N2
0
• 1.0
.2000ppm
NO/N^
0
4.5
2000ppm
NO/N2
0
• o
2000ppin
NO/N,"
0 0
0
1.0
10%
02/N2
0
0.5
10%
02/N2
1.0
0.5
10%
02/N2
0
o !
10% i
o2/N2 ;
o :
1
0
INSTRUMENT RESPONSE TIME (SEC) (AVERAGE OF 2 RUNS)
(CYCLE 1) | (CYCLE 2) | (CYCLE 3) | (CYCLE 4)
1627 j 30 j ' 21.5 i 10.5 i 9
8.1
30 j 20 1 . 10 J8
VJ
I
oo :
•>J
-------
Table 7-57. DATA COMPOSITE - REPEATABILITY TEST (Cont'd)
AUTOSCAN 710C
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
~? 1 VflT
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
i
cp- T ~?
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
I ..
' COMPARISON j
ririvnTriiTn'vr ~~ ~?~ I "' "RRCT3
1 ABSOLUTE
i
35 i +0.46 i
70 -4.83
100 ! -1.53
35 i -6.83
70 ! -4.35
100 1 -2.20
35 i +3.53
70 i -1.71
100 i -0.35
35 i +8.70
70 i 0
100 t +0.42
35 i +8.90
70 ! -0.37
100 { +0.83
35 ! +3.11
70 1 +0.58
100 ' +3.32
35 : +3.99
! 70 " i -1.86
100 i +0.29
35 ! -0.62
70 j +2.03
100 ! +3.59
C
-'- ^"^^C^ '
- O
+0.15
-3.25
-1.30
-2.20
-3.00
+2.86
+1.15
-1.25
-0.30
+ 2.80
0
+0.40
+2.90
-0.25
+0.70
+1.00
+0.40
+3.20
+1.30
-1.25
+0.25
-0.20
+1.40
+3.40
f^
-'.. ERROR
ABSOLUTE
-5.91
-3.08
-3.26
+15.94
+4.76
+2.86
-0.54
+0.77
-1.09
+13.04
+2.86
+2.86
+3.49
+4.62
+2.17
+14.49
-3.81
+ 1.14
-2.96
+1.38
+1.74
+14.49
+0.95
+1.14
-'. r"?'?.->r>
FS
-2.20
-2.00
-3.00
+5.50
+2.50
+2.50
-0.20
+0.50
-1.0
+4.50
+1.50
+2.50
+1.30
+3.00
+2.00
+5.0
-2.00
+1.00
-1.10
+0.90
+ 1.60
+5.0
+0.50
+ 1.0 ]
-si
f
I—1
oo
oo
-------
Table 7-58. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS
Aypnpr'a^f 7 \ nr>
KEY MODE
CYCLE #
STANDARD MODE
CYCLE I
•
CYCLE 2
CYCLE 3
CYCLE 4
LEAN MODE
CYCLE 1
CYCLE 2.
CYCLE 3
CYCLE 4
RANGE
PPM/*
500/2
500/7
500/2
500/2
500/2
500/2
snn/9
500/2
500/2
500/2
500/2
500/2
500/2
500/2
2000/2
500/2
unn/o
500/2
500/2
500/2
500/2
500/2
500/2
500/2
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
wr/r-n
HC/CO '
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SPEED
50
30
IDLE
50
30
IDLE
50
30r*
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE.
H
% ERROR
ABSOLUTE
- 52.03
- 9.57
+ 4.06
+ 1.06
- 6.66
1 + 3,8
- 3.94
+ 5.67
+ 10.82
- 11.85
- 7.54
- 6.59
- 6.41
- 4.81
+ 22.02
+ 5.83
+ 6.82
+ 2.9
+ 9.95
+ 3.2
- 3.79
- 3.74
- 1.73
+ 6.02
C
% ERROR
FS
- 18.44
- 2.16
+ 1.64
+ 0.2
- 1.54
+ 1.72
- 0.82
+ 1.18
+ 4.1
- 2.5
- 1.6ft
- 2.82
- 1.26
- 0.96
+ 7.3
+ 1.08
+ ;U34
+ 2.62
+ 1.9
+ 0.62
- 2.52
- 0.8
- 0.38
+ 5.68
C
% ERROR
ABSOLUTE
- 15.07
- 32.31
- 1.34
- 3.23
- 40.0
+ 14.29
- 8.33
- 35.71
- 4.76
+ 17.74
+ 16.67
+ 21.21
- 10.77
- 64.29
- 21.05
- 1.64
- 1.50
+ 3.7
- 10.26
- 41.67
- 4.76
+ 13.85
+ 16.67
+ 17.65
0
% ERROR
PS
- 5.5
- 2.1
- 1.0
- 1.0
- 3.0
+ 7.5
- 3.0
- 2.5
- 3.5
+ . 5.5
+ .1.0
+ 14.0
- 3.5
- 4.5
- 2.0
- 0.5 !
- 0.75 i
+ 0.5
-4.0 j
- 2.5
- 1.0
+ 4.5
+ 1.0
+ 3.0
I
h-•
00
-------
Table 7-58. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS (Cont'd)
AUTOSCAN 7IOC
KEY MODE
CYCLE #
RICH MODE
CYCLE 1
CYCLE 2
PVPT "P ?
CYC Lib **
•n A vrr* "P
rvrt.i\olj
PPM/0/
/o
500/2
500/2
500/10
500/2
500/2
500/10
500/2
500/2
500/10
500/2
500/2
500/10
cr*ZiT *p
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HG/CO
HC/CO
HC/CO
HC/CO
HC/CO
CPPT7FI '
50
30
IDLE
50
30
IDLE
sn
30
IDLE
50
30
IDLE
H
% ERROR-
ABSOLUTE
- 1.96
+ 6.16
+ *>-&?
L + 11.90
+ 9.0
- 1.27
- 5.21
- 11.35
- 1.11
- 5.21
- 4.25
+ 4.20
r*
% ERROR
FS
- 0.3R
+ 1.3
-1- ^QO
+ 2.34
+ 1.9
- 0.72
- 1.1
- 2.56
- 0.64
- 1.1
- 1.02
+ 2.5
C
% ERROR
ABSOLUTE
4. 7 04
+ 8.33
+ 10.49
- 8.93
- 8.33
+ 0.27
+ Q.flfi
+.36.36
+ 17.81
- 3.23
+ 8.33
+ 13.21
D
"A ERROR
i^.q
-^ 3rrQ
4- n.=i
+ 3,4
- 2.5
- 0.5
+ 0.1
+ 3.B-
+ 2.0
+ 6.5
- 1.0
+ 0.5
+ .4.9
10
o
-------
Table 7-59. DIAGNOSTIC TEST
AUTOSCAN 710 C
TEST
SPARKPLUG SHORTED
NORMAL IDLE
IGNITION ADVANCE
IGNITION RETARD
RANGE
2000
10%
2000
10%
500
10%
500
10%
SCALE
HC
CO
HC
CO
HC
CO
HC
CO
PPM NO, PPM HC, % CO
TEST INSTRUMENT, EPA BENCH
1090
2.20
560
2.15
475
2.10
475
2.30
993
2.11
535
2.04
490
2.07
483
2.23
HC/CO/NO
% ABSOLUTE
ERROR
+ 9.77
+ 4.27
+ 4.67
+ 5.39
- 3.06
+ 1.45
- 1.66
+ 3.14
% ERROR
+ 4.85
+ 0.9
+ 1.25
+ 1.1
- 3.0
+ 0.3
- 1.6
+ 0.7
-------
Table 7-60.
INSTRUMENT: AUTOSCAN 7IOC
DURABILITY TEST DATA
INSTRUMENT TIME TO FAILURE AND GAS EXPOSURE
TIME TO FAILURE (HRS.)
HC EXPOSURE (PPM-HRS.)
CO EXPOSURE (%-HRS.)
NO EXPOSURE (PPM-HRS.)
193
_..195-,-7£UQ - -
398
20,070
TNSTRUMENT STABILITY .
TOTAL NO. DAYS SHOCK TEST FAILURE
(3% Variation) 1 or More of 4 Modes
SHOCK TEST FAILURE RATE
(Failure/Day %)
INCIDENCE OF FAILURE IN EACH MODE
HC ZERO
HC SPAN
CO ZERO
CO SPAN
AVERAGE DAILY SPAN DRIFT
HC%
C0%
N0%
3
25.0
1
1
n
1
1.96
4.5
—
INSTRUMENT SERVICE REQUIREMENTS
A CHANGE FILTER
TOTAL
PER 100 HRS.
B DRAIN HOSE
TOTAL
PER 100 HRS.
C REZERO
TOTAL
PER 100 HRS.
D. SAMPLING SYSTEM
TOTAL
PER 100 HRS.
E. OTHER
TOTAL
PER 100 HRS.
6
3.11
—
mm —
7-192
-------
Figure 7-35. AUTOSCAN 710C HC/CO ANALYZER
4 7-193
-------
Figure 7-36. AUTOSCAN 7 IOC HC/CO ANALYZER (BACK)
7-194
-------
Figure 7-37. AUTOSCAN 710C HC/CO ANALYZER (RIGHT SIDE, PROBE, AND SPAN
GAS CONTAINER)
7-195
-------
7.13 ALLEN 23-160 CA CO/HC INFRARED EXHAUST EMISSION ANALYZER
Manufacturer - Allen Testproducts Division, The Allen Group Inc.
Description - HC/CO exhaust analyzer configured as a console instrument.
The instrument cart is equipped with two wheels.
Dimensions -
Height - 41 inches
Width - 19-1/2 inches
Depth - 17-1/2 inches
Material of Construction - Sheet steel, welded and screwed together.
Handle is extruded aliminum tubing.
Color - White with wood-grain front panel.
Mobility - Two, rear-mounted, 6-inch diameter wheels. Front-mounted
steel legs. Top rear handle location. Mobility is good with good
C.G. location.
Accessories - Sample probe, 25-foot sample hose, tail pipe clamp and
operator's manual.
Control Package -
Front Access - Off/On - Range switch (three positions)
1. Off
2. High
3. Low
Mode Control Switch - (three-position)
1. Cal
2. Norm
3. Span
4. Flow indicator (light
5. Pump on/off (Rocker switch)
6. CO zero - double know (course external, fine internal)
7. CO Cal 1 - Sunken screw
8. CO Cal 2 - Sunken screw
9. CO Span - Sunken screw
10. HC zero - double knob (course external, fine internal)
11. HC span - Sunken screw
12. HC Cal 1 - Sunken screw
13. HC Cal 2 - Sunken screw
14. Range indicator lights - two per meter
Rear Access -
3 amp breaker
Cal gas inlet
Meters - 8-inch, 90° sweep - unlighted
Black characters on white face with red band across graduations.
7-196
-------
Ranges - HC - 0-2000 ppm in 20 ppm increments
- 0-500 ppm in 10 ppm increments
CO - 0-10% in 0.2% increments
- 0-2.5% in 0.1% increments
Span (altitude correction) scales on both HC and CO meters.
Meters were not sensitive to static electricity.
Altitude Compensation - Chart in operator's manual used in conjunction
with "span" graduations on meters. Adjustment using Cal 1 pots not
needed when gas calibrated at test site.
Probe - Short section of flexible spiral tubing attached to longer rigid
tube fitted with handle. Fine mesh screen located at probe tip.
Filters and Sample Handling - Two series-connected water traps with
internal-sintered bronze filters. Air-cooled moisture condenser is
internal. Secondary water trap is self-draining.
Cal Gas Inlet - Rear panel
Power Requirements - 115 VAC 60 HZ.
Operating Principles - Dual cell, nondispersive infrared using hot wire
sources, solid-state detectors, optical filters and chopper wheel.
Calibration - Operation and calibration instructions printed on rear
panel. Internal electronic calibration and gas calibration as back
up. Span adjustment requires screwdriver.
Operation and Calibration - Fairly straightforward. Unit is warmed up
with pump on.
Operation -
1. Plug in
2. Select High or Low range
3. Turn pump on
4. Warm up
5. Set in Norm or Cal position
6. Set zero or high or low scale
7. Turn to span position
8. Set span (altitude)
9. Turn to Norm, ready for use
10. Optional gas calibration
7.13.1 Operational Performance Comments
The mechanical package for this unit has the meter housing located
on the top of the unit, tilted back slightly for better visibility. The meter
housings are attached to the rear handle loop of the two-wheeled cabinet. The
cabinet is fully enclosed with no doors or storage space except for a desk-
like platform below the meters. The unit is equipped with hangers for both
the sample hose and the power line.
7-197
-------
The sample system consists of a probe that has a short section of
flexible spiral tubing on the end. This probe presented no problems during
use except that the screen located at the tip of the probe came loose. This
unit utilized a well designed flexible reinforced sample hose, gray in color.
The sample hose was connected to the water trap, and did not incorporate a
quick disconnect. The two water traps on this unit use bronze filters. The
first water trap is manually drained. The second water trap is aspirated by
the sample pump. The unit had its sample inlet mislabeled as "outlet."
During normal operation of the Allen analyzer, the FLOW indicating
light was on. This light was red, and it would be less confusing if it were
green, since when lighted it indicates a normal condition. A burned out lamp
is easier to detect with this system, but lamp failure will likely occur more
often. The fact that the light goes out during flow restriction is somewhat
confusing.
The Allen analyzer uses two sample tubes and two reference tubes in
its infrared section. This utilizes two 8-inch meters equipped with range
indicating lights. The meters had altitude correction numbers imprinted on
their face. In using this instrument it was noted that the needless on the
meters oscillated. Readings would also change slightly from time to time
without explanation. There were very good operating, calibration and service
instructions printed on the unit. However, they are located on the rear panel
behind the hose hanger making them somewhat difficult to see.
This unit had a generally good control layout except for the span
and calibration adjustments vehicles were slotted pots located inside of holes
on the front panel and-somewhat difficult to adjust. The calibration gas
inlet was inconveniently located at the bottom of the rear panel.
In the laboratory tests, the Allen showed warm up time variation
form 8 to 12.5 minutes under normal temperatures. During high temperature
tests, the warm up time increased to 15 minutes, and under cold temperatures
the warm up significantly increased to 40 minutes. Zero drift performance for
CO scale was very good for all temperature conditions hitting a maximum of
2 percent full scale at 110°F. This indicated definite temperature sensitivity.
This unit showed essentially no response to any of the interference
gases.
The Allen was rated seventh most accurate in the accuracy determina-
tion tests. Low scale CO appeared to be the most obvious problem area.
Additionally, operations at 110°F indicated generally poor accuracy performance.
Again, high altitude tests indicated low scale CO gas correlation problems.
The response times for this instrument varied between 8 and 16 seconds.
This unit was essentially, not responsive to acetylene, benzene,
ethylene and methane. It was most sensitive to isobutylene, followed by
toluene.
Voltage flunctuation caused essentially no meter response. In the
repeatability tests, the warm up times showed long warm up during cycle two.
The large change in time cannot be completely explained.
7-198
-------
In the vehicle tests, the Allen was fifth best overall in correlation
with the EPA bench. The most prevalent problem appeared to be low scale HC
readings at idle.
In the durability test, the Allen completed 384 hours of operation.
This corresponds to 338,688 ppm-hours of HC exposure and 242 percent-hours of
CO exposure. During durability tests, the Allen experienced 8 days when the
shock tests caused more than 3 percent meter variation. The instrument demon-
strated an average daily span drift of 4.48 percent full scale for HC and
5.23 percent full scale for CO. This unit required 15 filter changes during
durability tests (3.9 changes per 100 hours).
With regard to maintenance, it was noted that in normal operation
the primary water trap became approximately half full of water. The second
water trap aspirated any additional water from the sample line. The bronze
filters on this unit are of moderate pore size. They needed less frequent
service than other bronze filters of a finer pore size. During the durability
test phase, servicing of the water traps and filters resulted in breakage of
the plastic filter mount. It was subsequently replaced.
The Allen analyzer failed and durability test when the CO meter
began intermittently dropping to zero. Eventually the CO Meter no longer
responded to calibration gas.
Test data for Allen 23-160CA CO/HC Infrared Exhaust Emission Analyzer
are shown in Tables 7-61 through 7-65.
Photographs of this instrument are shown in Figures 7-38 through
7-41.
7-199
-------
Attachment (1)
INSTRUMENT:
ALLEN
Table 7-61.
23 160 CA
DATA COMPOSITE -'LABORATORY TEST
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
(CYCLE 1)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
LOW
LOW
RANGE
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
(CYCLE 1)
9
8
(CYCLE 1)
0
0
15%
C02/N2
0
0
(CYCLE 2)
15
15
MAXIJi
(CYCLE 2)
18.0
2.0
(CYCLE 3)
40
40
1UM ZERO DRIFT % Fl
(CYCLE 3)
4.0
1600ppm 10%
HC/N2 CO/N2
0
0
COMPARISON
CONDITION % FS
35
70
100
35
70
100
35
70
100
35
70
100
% ERROR
ABSOLUTE
0
(CYCLE 4)
12
.5
10
LJLL SCALE
(CYCLE 4)
2.0
0
3% 2000ppm
H20/AIR NO/N2
0 0.6
0 - 0
H
+ 6.1
- 0.28
- 0.61
- 1.13
+ 0.27
+ 0.49
+ 6.83
+19.89
- 1.06
+ 2.82
+ 3.02
> +22.0
C
% ERROR
FS
+ 2.1
- 0.2
- 0.55
- 0.4
+ 0.2
+ 0.4
+ 2.35
+14.1
- 0.95
+ 1.0
+ 2.2
> +16.0
10%
02/N2
0
0
C
% ERROR
ABSOLUTE
0.0
+ 3.85
0.0
+10.14
- 2.86
- 4.55
- 7.26
- 4.62
- 0.54
-12.38
- 7.43
- 7.27
0
% ERROR
FS
0.0
+ 2.5
0.0
+ 2.8
- 2.0
- .4.0
- 2.7
- 3.0
- 0.5
- 5.2
- 5.2
- 6.4
••J
I
N5
O
O
-------
ALLEN 23-160 CA
Table 7-61. DATA COMPOSITE - LABORATORY TEST (Cont'd)
Attachment (1)
CYCLE 3
CYCLE 4
HIGH
ALTITUDE
RESPONSE &
RECOVERY
HYDROCARBON
RESPONSE
300 Feet
Altitude
6750 Feet
Altitude
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
RANGE
HIGH
HIGH
RANGE
LOW
LOW
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SCALE
HC
CO
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
CORRECTED
CONCENTRATION
1716
8.1
INSTRUME1S
287 ppm 323 ppm
ACETYLENE BENZENE
0 0
0 0
+ 1.74
- 1.27
- 2.74
- 1.13
- 0.55
- 0.4
+ 4.65
- 1.27
- 1.34
- 1.13
+ 1.65
+ 0.73
+ 7.56
- 1.27
- 0.2
2
+ 2.82
+ 1.65
+ 4.21
INSTRUMEN1
(CYCLE 1)
10.8
10.9
+ 0.6
- 0.9
- 2.45
- 0.4
- 0.4
- 0.4
+ 1.6
- 0.9
- 1.2
- 0.4
+ 1.2
+ 0.6
+ 2.6
- 0.9
- 0.2
+ 1.0
+ 1.2
+ 4.2
r RESPONSE TI
(CYCLE 2)
8.25
7.55
rr RESPONSE TO \
322 ppm
ETHYLENE
0
5
-12.63
+ 1.54
0.0
- 2.86
- 5.71
- 4.55
+ 2.15
0.0
0.0
- 4.76
- 8.57
- 4.55
+ 1.61
- 1.54
+ 2.17
- 4.76
- 5.71
- 6.82
ME (SEC) (AVERA
(CYCLE 3)
11.4
11.25
rARIOUS HYDROCAI
385 ppm
ISOBUTYLENE
75
80
- 4.7
+ 1.0
0.0
- 1.2
- 4.0
- 4.0
+ 0.8
0.0
0.0
- 2.0
- 6.0
- 4.0
+ 0.6
+ 1.0
+ 2.0
- 2.0
- 4.0
- 6.0
GE OF 2 RUNS)
(CYCLE 4)
16.25
16.5
IBONS AS ppm
337 ppm 329 ppm
METHANE TOLUENE
5
10
25
25
I
NS
O
-------
Attachment (1)
Table 7-61. DATA COMPOSITE - LABORATORY TEST (Cont'd)
ALLEN 23-160 CA
VOLTAGE
PROFILE
POWER
115V
115V
RANGE
HIGH
HIGH
\
SCALE
HC
CO
READING VARIAT:
VARYING LINE
+ 10%
0
0
ION AS FUNCTION OF
VOLTAGE ± 10%
- 10%
0.55
0
ro
O
-------
INSTRUMENT:
Table 7-62. DATA COMPOSITE - REPEATABILITY TEST
ALLEN 23-160 CA
WART.UP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% Of FS)
CYCLE 1
' GAS
INTERFERENCE
(% of FS)
CYCLE 2
GAS
INTERFERENCE
(% of FS)
CYCLE 3
GAS
INTERFERENCE
(:. of FS)
CYCLE 4
RANGE
LOW
!
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
LOW
SCALE j (CYCLE 1) (CYCLE 2) (CYCLE 3) (CYCLE 4)
HC j 8 28 9 19 ]
CO 1 6 26 9 10 i
0_.TT, ! MAXIMUM ZERO DRIFT % FULL SCALE
ol-rU-i.h |
! (CYCLE 1) (CYCLE 2) (CYCLE 3) (CYCLE 4)
HC ! 1.2 2.0 3.0 2.4
CO i 5.0 75.0 6.0 0.5
SCALE ' C02/N2
HC 0
CO | 0.08
CCJVT.F • 15/c
SCALE ! C02/N2
HC j 0
CO ! 0.4
C/"*^TT • — D/C
SCrtLE | C02/N2
HC i 1.6
CO ! 0
SCALE j ™t%
HC i 1.0
CO 1 0
CORRECTED
RANGE SCALE CONCENTRATION
IGOOppm
HC/N2
--
1.2
1600ppm
HC/N,
0.8
leOOnpin
HC/N2
— — ~
0
10%
CO/N2
0
--
10%
CO/N2
1.0
«•••••
^.,
CO/N2
0.6
___
n G* c\ c\ T™\ V^T^T n r\c '
HC/N^" CO/N2
0
3%
K20/AIR
0
0
2%
H20/AIR
0
0
2000ppm
NO/N2
2.0
• 0
.2000ppm
NO/N2"
1.0
3.6
3% j 2000cprn
K90/AIR NO/N2"
2.0
0
3%
K20/AIR
0
-o
2000ppir
NO/N!,"
o ! o
0.8
0.8
10%
02/N2
0
0
10%
02/N2
0
0 . .
10%
02/N2
o
0
10%
0
1.2
INSTRUMENT RESPONSE TIME (SEC) (AVERAGE OF 2 RUNS)
(CYCLE 1) | (CYCLE 2) ] (CYCLE 3) \ (CYCLE 4)
R-S-GNSE i HIGH ! HC 1716 ! 22.5 ! 20 i 6.5 i 7
RECOVERY | CO 8.1 22.5 j 17.5 ! 6.5 i 7.5
10
O
u>
-------
Table 7-62. DATA COMPOSITE ..- REPEATABILITY TEST (Cont'd)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
RANGE
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
*-« /^ — T -^
i(-t-JLuu.
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
1
COMPARISON i •-,
CONDITION v'= FS i ;'- ERROR
| ABSOLUTE
35 i - 1.16
70 ! - 6.91
100 i - 6.09
35 ! -12.43
70 ! - 9.34
100 1 - 4.81
35 1 + 7.56
70 i - 1.27
100 i +1.17
35 I - 3.95
70 i - 2.47
100 1 - 0.80
35 i +11.92 ,
70 1+2.26
100 i +1.73
35 : - 5.09
70 i - 0.55
. 100 ; - 2.00
i 35 ; +10.47
! 70 i + 0.14
j 100 I + 0.62
i 35 ! - 1.70
70 i - 0.82
j 100 ! - 1 .00
C
:i ERROR
FS
- 0.40
- 4.90
- 5.45
- 4.40
- 6.80
- 4.80
+ 2.60
- 0.90
+ 1.05
1.40
- 1.80
- 0.80
+ 4.10
-i- 1.60
+ 1.55
- 1.80
- 0.40
- 2.00
+ 3.60
+ 0.10
+ 0.55
- 0.60
- 1.00
- 1.00
ri- ERROR
ABSOLUTE
+ 4.84
+ 5.39
+ 5.44
+ 1.91
+ 0.57
+ 0.46
+10.22
+ 4.62
+ 8.70
- 2.86
- 5.14
- 2.27
+ 0.24
+ 5.39
+ 3.80
- 3.81
+ 0.57
- 3.18
+ 1 .61
- 1.54
- 0.22
+ 3.81
+ 0.57
- 0.93
~
-/ -7^ *^ ("^^
FS
+ 1.80
+ 3.50
+ 5.00
+ 0.80
+ 0.40
+ 0.40
+ 3.80
+ 3.0
+ 8.0
- 1.20
- 3.60
- 0.01
+ 0.80
+ 3.50
+ 3.50
- 1.60
+ 0.40
- 2.80
+ 0.60
- 1.0
- 0.20
+ 1.60
+ 0.40
- 0.80
to
o
-------
Table 7-63. VEHICLE TEST ACCURACY DETERMINATION - EXHA.UST GAS
ALLEN 23-160 CA
KEY MODE
CYCLE #
STANDARD MODE
CYCLE 1
i
CYCLE 2
CYCLE 3
CYCLE 4
LEAN MODE
CYCLE 1
CYCLE 2.
CYCLE 3
CYCLE 4
FIANCE
PPM/%
500/2.5
500/2.5
500/2.5
500/2.5
500/2.5
500/2.5
*nn/? R
500/2.5
500/2.5
500/2.5
500/2.5
500/2.5
500/2.5
500/2.5
2000/2.5
500/2.5
500/2.5
500/2.5
500/2.5
500/2.5
500/2.5
^r\ri/-> ^
500/2.5
500/2.5
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
wr/r-n
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SPEED
50
30
IDLE
50
30
IDLE
50
30-
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
H
% ERROR-
ABSOLUTE
- 11.07
- 2.48
- 8.55
- 14.89
- 9.57
+ 15.29
- 8.44
+ 7.21
+ 35.21
- 3.32
- 5.75
+., 2.54
+ 6.82
+ 12.80
+ 12.56
+ 7.99
+ 9.95
+ 12.76
+ 37.17
+ 32.35
+ 7.42
+ 3.32
+ 0.09
+ 4.64
C
% ERROR
FS
- 2.24
- 0.56
- 3.74
- 2.8
- 2.16
+ 7.16
- 1.66
+ 1.48
+ 13.02
- 0.7
- 1.28
+ 1.04
+ 1.34
+ 2.52
+ 4.13
+ 1.48
+ 1,9
+ 11.28
+ 7.1
+ 6.34
+ 5.24
+ 0.7?
+ 0.02
+ 3.94
C
% ERROR
ABSOLUTE
- 1.32
- 14.29
+ 19.15
+ 20.0
- 33.33
+ 27.36
0
- 21.43
+ 37.68
+ 20.97
0
+ 18.32
+ 12.90
- 7.69
+ 15.00
+ 31.58
+ 20.0
+ 20.69
+ 16.44
+ 9.09
+ 37.5
+ 4.4R
- 14.29
+ 25.0
0
% ERROR
PS
- 0.4
- 0.8
+ 10.8
+ 4.8
- 2.0
+ 11.6
0
- 1.2
+ 20.8
+ 5.2
o 1
+ 9.6 !
+ 3.2
- 0.4
+ 1.2
+ 7.2
+ 0.4 '
+ 2.4 :
+ 4.8 ••
+ 0.4
+ 6.0
+ 1.2
- 0.8
+ 3.2
in
-------
Table 7-63. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST &AS (Cont'd)
ALLEN 23-150 CA
KEY MODE
CYCLE #
RICH MODE
/"•V/^T T? 1
(_ XL-ij£< J.
CYCLE 2
CYCLE 3
fYCTjF 4
RATtf^F
PPM/%
500/2.5
500/2.5
500/10
500/2.5
500/2.5
500/10
500/2.5
500/21.5
500/10
500/2.5
500/2.5
500/10
crAT-P1
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
WC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
cpppn •
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
H
% ERROR-
ABSOLUTE
- 1.96
- 1.87
+ 25.1
+ 1.73
+ 9.19
+ 21.21
+ 3.14
+ 1.95
+ 24.57
- 12.8
- 16.74
+ 9.78
C
% ERROR
FS
- 0.38
- 0.4
+ 12.84
+ 0.34
+ 2.02
+ 11.9
-f- 0.68
+ 0.44
+ 16.04
- 2.7
- 4.02
+ 6.06
C
% ERROR
ABSOLUTE
-H 15.38
- 8.33
+ 11.82
+ 15.25
+ 8.33
+ 9.59
+ 4.17
0
+ 16.09
+19.40
0
+ 13.40
0
^ ERROR
PS
+ 4.0
- 0.4
+ 3.7
+ 3.6
+ 0.4
+ 3.5
+ 1 T?
0
+ 6.1
+ 5.2
0
f 5.2
I
NJ
O
ON
-------
Table 7-64. DIAGNOSTIC TEST
ALLEN 23-160 CA
TEST
SPARKPLUG SHORTED
MORMAT, TDT.F
TCJNTTION ADVANCE
TOIMTTtTriKT "D fPTk "DT\
XGNX 1 J.UJN K.h J.AKU
RANGE
2000
10%
2000
10%
2000
10%
2000
10%
SCALE
HC
CO
HC
CO
HC
CO
HC
CO
PPM NO, PPM HC, % CO
TEST INSTRUMENT
3.300
2.40
700
2.60
580
2.50
540
2.50
EPA BENCH
1217
2.21
677
2.47
502
2.33
488
2.32
HC/CO/NO
% ABSOLUTE
ERROR
+ 6.82
+ 8.6
+ 3.4
+ 5.26
+ 15.54
+ 7.3
+ 10.66
+ 7.76
% ERROR
FS
+ 4.15
+ 1.9
+ 1.15
+ 1.3
+ 3.9
+ 1.7
+ 2.6
+ 1.8
-------
INSTRUMENT:
Table 7-65. DURABILITY TEST DATA
ALLEN 23-160 CA
INSTRUMENT TIME TO FAILURE AND GAS EXPOSURE
TIME TO FAILURE (HRS.)
HC EXPOSURE (PPM-HRS.)
CO EXPOSURE (%-HRS.)
NO EXPOSURE (PPM-HRS.)
384
338,688
242
39,168
INSTRUMENT STABILITY
TOTAL NO. DAYS SHOCK TEST FAILURE
(3% Variation) 1 or More of 4 Modes
SHOCK TEST FAILURE RATE
(Failure/Day %)
INCIDENCE OF FAILURE IN EACH MODE
HC ZERO
HC SPAN
CO ZERO
CO SPAN
AVERAGE DAILY SPAN DRIFT
HC%
COP/o
N0%
9
39.13
2
2
0
7
4.48
5.23
—
INSTRUMENT SERVICE REQUIREMENTS
A CHANGE FILTER
TOTAL
PER 100 HRS.
B DRAIN HOSE
TOTAL
PER 100 HRS.
C REZERO
TOTAL
PER 100 HRS.
D. SAMPLING SYSTEM
TOTAL
PER 100 HRS.
E. OTHER
TOTAL
PER 100 HRS.
15
3.91
9
2.34
1
0.26
1
0.26
—
i
7-208
-------
CO/HC INFRA-RED
EXHAUST EMISSION
ANALYZER
IALLENI
Figure 7-38. ALLEN 23-160 CA CO/HC INFRARED EXHAUST EMISSION ANALYZER
7-209
-------
Figure 7-39. ALLEN 23-160 CA CO/HC INFRARED EXHAUST EMISSION ANALYZER (BACK)
7-210
-------
Figure 7-40. ALLEN 23-160 CA CO/HC INFRARED EXHAUST EMISSION ANALYZER (RIGHT SIDE)
7-211
-------
Figure 7-41. ALLEN 23-160 CA CO/EC INFRARED EXHAUST EMISSION ANALYZER (PROBE)
7-212
-------
7.14 AUTOSENSE 200 ENGINE DIAGNOSTIC AND EXHAUST EMISSION ANALYZER
Manufacturer - Hamilton Test Systems
Description - An integrated package consisting of engine parameter sensors,
HC/CO emissions analyzer, computer, tape cassette unit, hand-held
controller and printer.
Dimemsions -
Analyzer -
Width - 47 inches
Height - 41 inches
Depth - 26 inches
Weight - 250 Ibs
Hand-Held Controller -
8" x 9-5/8 x 1-3/8"
Weight - 3 Ibs
Connecting cable length - 30 feet
Material of Construction - Welded sheet steel cabinet, square tube steel
handles on each end.
Color - Light blue with white top.
Mobility - Four, 4-inch wheels, two wheels on printer end swivel. Mobility
is relatively good considering the weight of this unit.
Accessories - Exhaust probe, sample hose (30 feet) miscellaneous diagnostic
sensors, miscellaneous cassettes with diagnostic programs, printer
paper. Operator's manual and miscellaneous support documentation.
Control Package -
Front Access -
"Power" button (On/Off)
Side Interior Access -
HC span screw
CO span screw
Hand-held Control -
Enter/verify/print - Push button
1-9 and 0 - Push buttons
(-) - Push button
Start - Push button
- Push button
Clear - PUsh button
Diagnosis - Push button
Spec On/Off - Push button
Aid No - Test No - Led Display
Test Data - min. limit - Diag. code
7-213
-------
Test Condition - max. limit
Enter Aid Number - Small Red Light
Enter Test Number - Small Red Light
Enter Test Data - Small Red Light
Out of Limit - Small Red Light
Sequence Testing - Small Red Light
Diagnostic Code - Small Red Light
Error - Small Red Light
Print Ready - Small Red Light
Meters - Located on hand-held controller .
Three 1-3/4 x 1/2" Led Display
Middle Display - HC - Digital - Four Digital
Bottom Display - CO - Digital - Four Digital
Top Nonemission-related - procedural information identifying
operation programs.
Teletype paper printer on left side of analyzer console.
Ranges - HC - 0-2000 ppm
CO - 0-10%
Altitude Compensation - None, must be calibrated at altitude of use.
Probe - "S" curve rigid tube with a convoluted tube end piece. Convoluted
tube was fitted with tail pipe clamp; rigid tube was fitted with
handle. Sample entrance through side hole in convoluted tube.
Filters and Sample Handling - Fine mesh porous bronze filter located in
the automatically aspirated primary water trap. Secondary paper
cartridge filter in the secondary, manually drained, water trap.
Cal Gas Inlet - Internal cabinet access left side near front panel. Very
careful calibration gas pressure and flow regulation was required.
Power Requirements - 115 VAC 60HZ 6 amps
Operating Principles - Dual cell, nondispersive infrared solid-state
detector, hot wire source, band pass optical filters, chopper wheel -
digital signal conversion.
Calibration - Automatic zero during each measurement cycle. No manual
zero possible. Gas calibration only, no electronic calibration
available. Gas calibration is relatively time-consuming and usually
requires more than one procedural cycle.
Operation and Calibration - With regard to operation and calibration, the
unit required extensive instruction for operator use and a significant
amount of experience to interpret the output displays. The unit
incorporates an auto-zeroing function that complicates the calibration
procedure and makes calibration time-consuming. Calibration of this
unit required internal disconnection of the sample input line and
connection of the cal gas hose through a precision regulator and an
7-214
-------
in-line plenum damper. Calibration of this unit required over-
compensation of the span adjustments, which were located inside
holes in a very awkward location on the interior of the instrument.
In general, we found calibration of this instrument to be a very
difficult and time-consuming effort.
Calibration Procedure -
1. Power on, warm up for 30 minutes
2. Teletype will print "NO of CYL"
3. Using hand controller enter "8"
4. Teletype will print 8 CYL
5. Teletype will then ask for AID number (Vehicle Identification)
6. Using hand controller enter 934
7. Hand controlled middle and bottom displays will read percent
8. Disconnect sample time and connect span gas, pressure regulator,
magnihelic
9. Turn on span gas
10. Adjust meters by use of HC or CO screw pot. (Adjustment should
be three times observed deviation; i.e., if gas is 1,600 ppm HC
and meter read 1,550, set meter at 1,600 + (3 x 50) + 1,750 ppm.)
11. Push clear
12. Hand control reads 0-0
13. Enter 934
14. Read span gas values on controller
15. If not correct, repeat step 10 through 14 until acceptable
reading is achieved.
This overshooting technique saves time but calibration is still very
time-consuming.
7.14.1 Operational Performance Comments
The mechanical configuration of this unit was very different from
the other units in this program. It has a very large, heavy cabinet that also
incorporates a printer and engine diagnostic unit. Operation of this unit was
accomplished by using a remote, hand-held display and pushbutton panel. This
display served both the engine analyzer and emissions functions. The cabinet
was equipped with four wheels, two swiveling and two fixed. Only lateral
movement was possible with this configuration.
The engine diagnostic functions required a large number of input
cables and hoses, which were a storage problem when not in use.
The sample system on this unit utilized a probe that was a double-
curve rigid tube with a convoluted end section. The sample hose was relatively
stiff and was difficult to manipulate. This unit incorporated a fine porous
bronze filter in the aspirated primary water trap, and a back-up paper cartridge
filter in the manually drained secondary water trap.
In the emissions-measuring mode, this unit had slow response and
also demonstrated some problems in reading stability.
7-215
-------
In the area of maintenance, it was found that filter service was
relatively difficult. The bronze porous filter in this unit had excessively
fine pores, thus requiring frequent changes. In addition, the specific bronze
filter required for this instrument is available only from the manufacturer
and acquisition of spare filters required 6 weeks from time of order. The
secondary paper filter cartridge collects moisture easily and needed frequent
service, especially during the durability test.
During the laboratory test, high temperature cycle (cycle 2), this
unit experienced failure in its electrical system. The failure appeared to be
confined to the optical bench. The optical bench was returned to the manufac-
turer and they were advised that during the high temperature test the HC
channel became completely inoperative. The channel would not respond at all
and the LED display indicated a constant zero reading. The CO channel appeared
to function properly but did require recalibration at the high temperature.
Upon return of the optical bench, the service representative advised
this laboratory that the PC board was the problem and that the board had been
cleaned and was now functioning properly. However, upon examination it was
discovered that the optics in the system had been altered and that a new
conversion factor sticker had been applied to the unit. The prior conversion
factor of 0.596 had been changed to 0.587.
Also, during the laboratory test, the hand-held controller showed
erratic display behavior and input to the computer became unpredictable. The
controller was checked and a solder bridge was discovered on its circuit
board. The bridge was removed and the controller and analyzer returned to
proper operation.
In the laboratory tests, the Autosense showed warm up times of 7 to
8 minutes at normal temperatures. At low temperatures, the unit required
15 minutes to achieve stable zero. In the repeatability tests it indicated
stabilized operation after only 2 minutes of operation in cycle 3.
With the automatic zero function, the unit showed essentially no
zero drift during laboratory tests.
This unit was totally insensitive to the interference gases.
In the accuracy determination tests, this unit was tenth most accurate
showing greatest errors at 100 percent scale values. This instrument was
single range for both HC anc CO. Accuracy tests were run with span gas values
of 100 percent, 70 percent, 35 percent, 20 percent, 10 percent, and 5 percent
full scale gas values for both HC and CO scales. High altitude operation
showed the same error pattern.
The response time of this instrument indicated a wide variation in
CO and HC response times. Times varied between 12.5 seconds for CO to 55 seconds
for HC. Generally, CO response was shorter than HC response. This response
time variation is apparently a function of the cyclic sampling operation of
the unit. The computer "looks" at a 7-second sample of HC and CO and then
processes this information for display. Response time will be affected by the
sampling rate and frequency.
7-216
-------
Unfortunately, hand-controller failure (solder bridge) prevented low
altitude gas interference tests from being run, but the same tests at high
altitude indicated no response to any of the HC gases. This indicated very
high specificity to propane or hexane gases. This high specificity to propane
and hexane was not observed for any other EC/CO instrument.
The Autosense was out for repair during the entire vehicle test
sequence so no exhaust gas correlation data is available.
The limited data available for the diagnostic tests indicate that,
in general, the Autosense showed exhaust gas correlation of better than 2 per-
cent. During the spark plug shorted test, the HC scale showed 10.5 percent
full scale error, but showed 2 percent full scale or less error for the balance
of the tests.
The Autosense ran 432 hours until failure in the durability tests
(corresponding to 387,504 ppm-hours HC exposure and 173 percent-hours CO
exposure). The unit experienced 6 days when the shock test produced more than
3 percent full scale readout variation. Average daily span drift was 5.17 per-
cent full scale for HC and 2.76 percent full scale for CO. The unit required
18 filter changes corresponding to 4.2 changes per 100 hours of operation.
During the durability test, it was noted that the flow blockage
error code indicated on the remote display/control was not explicit, and its
appearance did not necessarily indicate a blocked filter. This same error
code could indicate an internal electronic problem. It was also observed
during testing that the remote display module was very susceptible to shock.
When the hand-held control received a shock or jolt, it sometimes shut down
the unit until the instrument start-up was recycled.
The unit failed the durability test in a multi-faceted manner.
First, span readings began to creep progressively higher. Later in the testing,
the readouts would not zero on air. Finally, the remote display/control
indicated a flow error which could not be cleared.
Test data for Autosense 200 Engine Diagnostic and Exhaust Emission
Analyzer are shown in Tables 7-66 through 7-70.
Photographs of this instrument are shown in Figures 7-42 through
7-45.
7-217
-------
At t acTune nt (1)
INSTRUMENT:
Table 7-66. DATA COMPOSITE - LABORATORY TEST
AUTOSENSE 200
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
(CYCLE 1)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
RANGE
SINGLE
RANGE
..
RANGE
SINGLE
RANGE
II
RANGE
g^LE
ii
RANGE
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC
CO
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
(CYCLE 1) (CYCLE 2) (CYCLE 3)
8 7 15
8 7 15
MAXIMUM ZERO DRIFT % F1
(CYCLE 1) (CYCLE 2) (CYCLE 3)
0.5 ^MALFUNCTION 0
000
(CYCLE 4)
7
7
JLL SCALE
(CYCLE 4)
0
0
15% 1600ppm 10% 3% 2000ppm
C02/N2 HC/N2 CO/N2 H20/AIR NO/N2
0 0 00
0 0 - 0-0
COMPARISON
CONDITION % FS
35
70
100
5
10
20
35
70
100
5
10
20
H
% ERROR
ABSOLUTE
+ 5.2
+ 0.88
+ 4.97
0.0
- 3.57
- 4.08
INSTRUMENT
FAILED
NO
C
% ERROR
FS
+ 2.05
+ 0.8
+ 4.95
0.0
- 0.5
- 0.85
-
DATA
10%
02/N2
0
0
C
% ERROR
ABSOLUTE
- 8.6
+ 1.08
- 0.11
-15.94
-24.76
-18.29
-22.04
+ 0.77
+ 0.44
+ 0.45
-13.3
-10.29
0 •
% ERROR
FS .
- 3.2
+ 0.7
- 0.1
- 1.1
- 2.6
- 3.2
- 8.2
+ 0.5
+ 0.4
+ 0.1
- 1.4
- 1.8
I
I-O
00
-------
Table 7-66.
AUTOSENSE 200
DATA COMPOSITE - LABORATORY TEST (Cont'd) Attachment (1)
CYCLE 3
CYCLE 4
HIGH
ALTITUDE
RESPONSE &
RECOVERY
HYDROCARBON
RESPONSE
300 Feet
Altitude
6750 Feet
Altitude
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
RANGE
HIGH
HIGH
RANGE
SINGLE
RANGE
II
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SCALE
HC
CO
35
70
100
5
10
20
35
70
100
5
10
20
35
70
100
5
10
20
CORRECTED
CONCENTRATION
1750
8.1
INSTRUMEls
287 ppm 323 ppm
ACETYLENE BENZENE
INSTRUMENT
0 0
+ 3.93
+ 1.99
+ 4.47
0.0
+ 3.57
+ 3.12
+ 3.93
+ 0.33
+ 3.97
- 8.33
- 7.14
- 4.08
+ 2.66
+ 2.70
+ 4.97
+ 8.33
+ 3.57
+ 6.72
INSTRUMEN'
(CYCLE 1)
44
21.5
+ 1.
+ 1.
+ 4.
0.
+ o.
+ o.
+ 1.
+ 0.
+ 3.
- 0.
- 1.
- 0.
+ 1.
+ 2.
+ 4.
+ o.
+ 0.
+ 0.
T RESPONSE TI
(CYCLE 2)
MALFUNCTION
22.5
IT RESPONSE TO V
322 ppm
ETHYLENE
MALFUNCTIC
0
55
8
45 -
0
5
65
55
3
95
5
0
85
05
45
95
50
50
15
+ 1.08
+ 3.45
- 0.44
+ 4.35
-10.48
- 6.29
- 4.84
+ 1.69
+ 0.54
- 7.25
-14.29
- 9.71
- 0.54
+ 1.85
+ 0.44
+ 4.35
-11.43
-12.00
ME (SEC) (AVERA
(CYCLE 3)
39.5
23.0
rARIOUS HYDROCAF
385 ppm
ISOBUTYLENE
>N
0
+ 0.4
+ 2.3
- 0.4
+ 0.3
- 1.1
- 1.1 J
- 1.8
+ 1.1
+ 0.5
- 0.5
- 1.5
- 1.7
- 0.20
+ 1.20
+ 0.40
+ 0.30
- 1.20
- 2.10
GE OF 2 RUNS)
(CYCLE 4)
42.5
19.5
IBONS AS ppm
337 ppm 329 ppm
METHANE TOLUENE
0
0
I
N>
i—•
VO
-------
-J
S3
o
Attachment (1)
Table 7-66. DATA COMPOSITE - LABORATORY TEST (Cont'd)
AUTOSENSE 200
VOLTAGE
PROFILE
POWER
115V
115V
RANGE
SINGLE
RANGE
ii
SCALE
HC
CO
READING VARIAT3
VARYING LINE
+ 10%
HC CHANNEL BAD
0
ION AS FUNCTION OF
VOLTAGE ± 10%
- 10%
0
-------
INSTRUMENT:
Table 7-67. DATA COMPOSITE - REPEATABILITY TEST
AUTOSENSE 200
NJ
KJ
t— •
WARMUP
TIME (Min.)
ZERO DRIFT
[RANGE
INGLE
AN6E
GAS
INTERFERENCE
(% of FS)
CYCLE 1
GAS
INTERFERENCE
(% of FS)
CYCLE 2
GAS
INTERFERENCE
(% of FS)
CYCLE 3
GAS
INTERFERENCE
('.- of FS)
CYCLE 4
RESPONSE Sc
RECOVERY
RANGE
SINGLE
RANGE
RANGE
SINGLE
RANGE
RANGE
SINGLE
RANGE
RANGE
SINGLE
IANGE
RANGE
SINGLE
RANGE
RANGE
HIGH
SCALE |
HC
CO
(CYCLE 1) (CYCLE 2) (CYCLE 3) (CYCLE 4)
6 16 2 4
I 6 16 2 4 !
SCALE
!
HC
CO
MAXIMUM ZERO DRIFT % FULL SCALE •
(CYCLE 1) (CYCLE 2) (CYCLE 3) (CYCLE 4)
0 0 0 0.5 ....... 1
o n o o
SCALE
HC
CO
SCALE
HC
CO
15%
C02/N2
0
0
15%
C02/N2
0
0
C02/B2
HC
0
CO
SCALE
HC
SCALE
HC
CO
0
15%
CO2/N2
0
0
CORRECTED
CONCENTRATION
1724
8.1
1600DDIT1
HC/Nj*
_ _ _ _
0
1600ppm
HC/N2
_ _
0
leOOoom
HC/N2~
--
0
10%
CO/N2
0
_ .
10%
CO/N2
0
- -
10%
CO/N2
0
--
leooppm i 10%
HC/NT . CO/N2
0.5
0
--
3%
H20/AIR
0
0
3%
H20/AIR
0
0
OC-^
K20/AIR
0
0
3%
H20/AIR
2000ppm
NO/N2
0
0
.2000ppm
"NO/NJ"
0
0
2000ppm
NOA\'
0
0
2000ppm
NO/N!"
^
0.5 0
0
0
10%
02/N2
0
o
10%
02/N2
0
0
10%
02/N2
0
0
10%-
02/N2
0
0
INSTRUMENT RESPONSE TIME (SEC) (AVERAGE OF 2 RUNS)
(CYCLE 1) | (CYCLE 2) | (CYCLE 3) \ (CYCLE 4)
52.5 sec 1 55 ! 26 1 17
52.5 sec ! 42.5 i 21 | 12.5
-------
Table 7-67. DATA COMPOSITE - REPEATABILITY TEST (Cont'd)
AUTOSENSE 200 .
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
RANGE
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
SCALE '
I
HC/CO
HC/CO i
HC/CO
HC/CO i
HC/CO i
HC/CO i
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
I
COMPARISON !
CONDITION ;'= 7S i ;= ERROR
| ABSOLUTE
35 I + 4.25
70 ; - 1.46
100 1+3.01
35 i - Z.56
70 i - 9.42
100 1-2.68
35 I + 4.25
70 1 * ' <34
100 t +5.05
35 j + 9.24
70 j + 1.45
100 ! -5.11
35 i + 4.25
70 1+0.34
100 1 +3.01
35 : - 7.56
70 I - 9. 42
100 ' - 2.68
I 35 + 4.25
70 " . + 1 .90
100 i +5.56
(35 I 7.56
70 j - 2.17
100 ! - 0.24
,
c
'•'= ERROR
FS
+ 1.65
- 1.34
+ 2.95
- 0.45
- 1.30
- 0.55
+ 1.65
j + 1.20
+ 4.95
'•• + 0.55
i + 0.20
- 1.05
+ 1.65
! + 0.30
i + 2.95
- 0.45
! - 1.30
i - 0.55
i + 1 .65
! + 1.70
+ 5.45
! - 0.45
; - 0.30
, - 0.05
•/-• ERROR
ABSOLUTE
0
+ 3.85 :
+ 0.87
+ 7.25
- 2.86
- 2.86
0
+ 1 .54
+ 1.96
+ 4.35
- 4.76
- 5.14
- 3.50
0
- 1.63
+ 1.45
- 3.81
- 5.14
- 0.81
+ 3.69
0
+10.15
- 1.91
- 0.57
?s
0
+ 2.50
+ 0.80
+ 0.50
- 0.30
- 0.50
0
+ 1 .0
+ 1.80
+ 0.30
- 0.50
- 0.90
- 1.30
0
- 1.5
+ 0.10
- 0.40
- 0.90
- 0.30
+ 2.40
0
+ 0.70
, - 0.20
- 0.10
I
to
fO
-------
Table 7-68. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS
AUTOSENSE 200
KEY MODE
CYCLE #
STANDARD MODE
CYCLE 1
•
CYCLE 2
CYCLE 3
CYCLE 4
LEAN MODE
CYCLE 1
CYCLE 2.
CYCLE 3
CYCLE 4
RANGE
PPM/%
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
H<-/<-O
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SPEED
50
30
IDLE
50
30
IDLE
50
30r
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
H
% ERROR
ABSOLUTE
C
% ERROR
FS
OUT
OUT
OUT
OUT
OUT
OUT
OUT
OUT
C
% ERROR
ABSOLUTE
FOR REPAIR
FOR REPAIR
FOR REPAIR
FOR REPAIR
FOR REPAIR
FOR REPAIR
FOR REPAIR
FOR REPAIR
0
% ERROR
FS
i
t
i
-------
Table 7-68. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS (Cont'ci)
AUTOSENSE 200
KEY MODE
CYCLE #
RICH MODE
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
RANGE
PPM/%
SCALE
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
| HC/po
HC/CO
HC/CO
HC/CO
HC/CO
HC/CO
SPEED '
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
HC
% ERROR
ABSOLUTE
% ERROR
FS
0
i
•
o
0
CO
% ERROR
ABSOLUTE
CJT FOR REPAIR
JT FOR REPAIR
TT FPP P EPA IP
CJT FOR REPAIR
7t ERROR
i
i
:
i
i
'
I
NJ
NJ
-------
Table 7-69. DIAGNOSTIC TEST
AUTOSENSE 200
TEST
SPARKPLUG SHORTED
NORMAL IDLE
IGNITION ADVANCE
Tr'MTT'TOM OPT^Cn
-LolN J. 1 J.VJ1N KLiinKU
RANGE
2000
10%
2000
10%
2000
10%
2000
10%
SCALE
HC
CO
HC
CO
HC
CO
HC
CO
PPM NO, PPM HC, % CO
TEST INSTRUMENT
1100
2.14
550
2.09
550
1.98
450
1.98
EPA BENCH
1310
2.30
576
2.25
590
2.20
479
2.10
HC/CO/NO
% ABSOLUTE
ERROR
- 16.03
- 6.96
- 4.51
- 7.11
- 6.78
- 10.00
- 6.05
- 5.71
% ERROR
FS
- 10.5
- 1.6
i
- 1.3
•
- 1.6
- 2.0
- 2.2
- 1.45
- 1.2
-------
Table 7-70. DURABILITY TEST DATA
INSTRUMENT: AUTOSENSE 200
INSTRUMENT TIME TO FAILURE AND GAS EXPOSURE
TIME TO FAILURE (HRS.)
HC EXPOSURE (PPM-HRS.)
CO EXPOSURE (%-HRS.)
NO EXPOSURE (PPM-HRS.)
432
387,504
173
41,040
INSTRUMENT STABILITY
TOTAL NO. DAYS SHOCK TEST FAILURE
(3% Variation) 1 or More of 4 Modes
SHOCK TEST FAILURE RATE
(Failure/Day %)
INCIDENCE OF FAILURE IN EACH MODE
HC ZERO
HC SPAN
CO ZERO
CO SPAN
AVERAGE DAILY SPAN DRIFT
HC%
C0% (
N0%
6
22.22
6
6
5
7
5.17
2.76
—
INSTRUMENT SERVICE REQUIREMENTS
A CHANGE FILTER
TOTAL
PER 100 HRS.
B DRAIN HOSE
TOTAL
PER 100 HRS.
C REZERO
TOTAL
PER 100 HRS.
D. SAMPLING SYSTEM
TOTAL
PER 100 HRS.
E . OTHER
TOTAL
PER 100 HRS.
18
4.17
4
0.93
1
0.23
_»
2
0.46
7-226
-------
SJ
' I
1
Figure 7-42. AUTOSENSE 200 ENGINE DIAGNOSTIC AND EXHAUST EMISSION ANALYZER (FRONT)
-------
Figure 7-43. AUTOSENSE 200 ENGINE DIAGNOSTIC AND EXHAUST EMISSION ANALYZER (BACK)
-------
Figure 7-44.
AUTOSEWSE 200 ENGINE DIAGNOSTIC AND EXHAUST
EMISSION ANALYZER (RIGHT SIDE)
7-229
-------
ENTER AID NUMBER
ENTER TEST NUMBER
ENTER TEST DATA
SEQUENCE TESTING
DIAGNOSTIC CODE
ERROR
Figure 7-45.
AUTOSENSE 200 ENGI\7F niArvnc-
F-rfTQc-rrvT ArTI7\ DIAGNOSTIC AND EXHAUST
H ANALYZER (CONTROL UNIT)
7-230
-------
7.15 HORIBA MEXA 240 INFRARED ANALYZER
Manufacturer - Horiba Instruments, Inc.
Description - NO analyzer configured in a portable cabinet used as a
bench top or floor-mounted unit. The unit is not equipped with
wheels but is designed with a wide base to enhance stability.
Dimensions -
Height - 25 inches
Width - 9-1/2 inches
Depth - 8 inches
Weight - 27 Ibs.
Material of Construction - Sheet steel main frame with sheet aluminum
cover.
Color - Grey with silver cover plates.
Mobility - Portable.
Accessories - Sample probe, 8-1/2 foot, sample hose, operator's manual.
Control Package -
Front (Top) Access -
Power On/Off - toggle
Pump/On - toggle
Ranch switch - high/low - toggle
Zero adjust - knob
Span adjust - knob
Front (Bottom) Access -
Dust filter - cartridge
Span gas port
Sample in port
Sample out port
Rear Access -
Fuse
Recorder outputs (+, -)
Recorder output adjust (screw)
Recorder range adjust (screw)
Meters - 3-3/4" , 90° sweep
Ranges - NO - 0-4000 ppm in 100 ppm increments
- 0-1000 ppm in 20 ppm increments
Black characters on white background. The meter was not
sensitive
to static electricity.
7-231
-------
Altitude Compensation - NO provision, gas calibration only.
Probe - 1/4-inch rigid copper tube pinched shut on end and cross-drilled
for sample entry. Probe incorporates a prefilter assembly in its base.
Filters and Sample Handling - Prefilter paper cartridge particulate
filter in sample probe, small internal water trap, secondary "cigarette
filter" type particulate filter, ball type flow indicator.
Gal Gas Inlet - Front panel
Power Requirements - 115 VAC 60HZ 45 watts
Operating Principles - Nondispersive infrared, positive optical filter,
dual cell, dual source, gas charged luft-type detector.
Calibration - Gas calibration only using zero and span knobs on front of
case.
Operation and Calibration - Simple and straightforward operation and
calibration.
Procedure -
1. Turn on and warm up
2. Set zero with front knob
3. Introduce span gas
4. Set span using front span adjust knowb
5. Ready for use
7.15.1 Operational Performance Comments
The unit was equipped with quick release covers to facilitate service
access.
In the sampling handling system, this unit had a relatively short
sample hose (8-1/2 feet), with a 1/4-inch O.D. tube probe.
This hose was too short for diagnostic work but would be acceptable
for inspection operations. The probe incorporated an in-line filter in a
small plenum behind the probe and immediately prior to the sample hose. This
plenum held a small push-on paper element which was easy to service. On the
front panel, the instrument incorporated a cigarette tip type filter for
additional protection.
This unit utilized vibrating diaphragm pumps and a small internal
water trap. A ball-type flow indicator was recessed in the front panel of
this unit and was difficult to see. When it became wet it would stick, indica-
ting high flow. This occurred throughout the durability test.
In the area of the analytical system and display, this unit had a
small meter than was extremely difficult to see at a distance. The meter
incorporated two scales; 1,000 ppm and 4,000 ppm. For most of the vehicle and
durability testing, a lower scale would have been more useful.
7-232
-------
In the area of operation and calibration, this unit was by far the
most useful of the three NO units. In spite of the flow meter problem and the
distance visibility limitation in reading the instrument output meter, the
unit was basically simple to operate, highly reliable and appeared to be
unaffected by exhaust gases with regard to degradation of operation. Typically,
the meter readings were found to be very stable and consistent, showing very
little drift.
The Horiba had simple controls; however, calibration was somewhat
difficult because the manual spring-loaded valve at the calibration gas port
had to be held in by hand during calibration.
In the laboratory tests, this unit showed relatively consistent warm
up times of less than 11 minutes. Cold temperature operation required 14 minutes
of warm up to reach stabilization.
This unit consistently showed 1 percent full scale or less zero
drift under all test conditions.
In the gas interference tests, this unit showed significantly sensi-
tivity to HC and CO and, to a lesser degree, CO . CO interference was most
significant followed by HC and C0_.
In the accuracy determination tests, the Horiba 240 was shown to be
the overall most accurate instrument tested in this program. The greatest
sample gas inaccuracy noted for this instrument at any test point was 1.6 per-
cent full scale. This far extends the consistent demonstrated accuracies of
all other test instruments. High altitude tests indicated the same high
accuracy. Response time variation ranged from 10 seconds to 33 seconds,
indicating a substantial sample transport and analysis time variation.
Voltage fluctuation had no effect on the meter signal level.
In the vehicle tests, the Horiba 240 was easily the most accurate NO
instrument tested. In general, the unit showed excellent correlation with the
EPA bench. Based upon its laboratory test performance in accuracy deter-
mination and response and recovery tests, it is reasonable to assume that
large inaccuracies noted in the vehicle tests could be related to response
time variation and, thus, sample time correlation.
In the durability tests, the Horiba 240 survived to the conclusion
of testing with no obvious or apparent problems. No obvious degradation in
analysis quality was noted nor did the analyzer experience any malfunctions
during the tests.
This unit required frequent changing of the in-line filter, but its
twist-lock housing made this operation very quick and easy. The cigarette tip
filter also required relatively frequent service but, again, this service was
very quick and easy. This unit demonstrated an average daily span drift of
2.84 percent full scale.
Filter servicing was required 31 times during testing. Test duration
was 960 hours (114,240 ppm NO-hours). The filter service requirement was 3.7
service per 100 hours of operation.
7-233
-------
In general, this NO analyzer was judged to be the only unit that
meets the specific requirements of I/M analysis.
Test data for Horiba Mexa 240 Infrared Analyzer are shown in
Tables 7-71 through 7-75.
Photographs of this instrument are shown in Figures 7-46, 7-47,
and 7-48.
7-234
-------
INSTRUMENT:
Table 7-71. DATA COMPOSITE - LABORATORY TEST
HORIBA MEXA 240
Attachment (1)
WARMUP
TIME. (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
(CYCLE 1)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
SCALE
NO
SCALE
NO
SCALE
NO
SCALE
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
(CYCLE 1)
6
(CYCLE 1)
0
15%
C02/N2
1.5
(CYCLE 2)
5
MAXI*
(CYCLE 2)
0.5
(CYCLE 3)
14
IUM ZERO DRIFT % F
(CYCLE 3)
0.3
leoOppm 10% 3%
HC/N2 CO/N2 H20/AIR
0.3 2.
8 0
COMPARISON
CONDITION % FS
35
70
100
35
70
100
35
70
100
35
70
100
N
% ERROR
ABSOLUTE
+ 2.
- 0.
- 1.
0.
- 0.
+ 0.
+ 0.
+ 0.
+ 0.
- 0.
0.
+ 0.
04
13
03
0
21
26
29
26
52
99
0
78
(CYCLE 4)
6
JLL SCALE
(CYCLE 4)
0.6
2000ppro
NO/N2
-
•
0
% ERROR
FS
-1- 0.7
- 0.1
- 1.0
0.0
- 0.13
+ 0.25
+ 0.1
+ 0.2
+ 0.5
- 0.25
0.0
+ 0.75
10%
02/N2
0
% ERROR
ABSOLUTE
,
% ERROR
FS
I
M
W
Ln
-------
HORIBA
Table 7-71. DATA COMPOSITE - LABORATORY TEST (Cont'd)
MEXA 240 NO
Attachment (1)
CYCLE 3
CYCLE 4
HIGH
ALTITUDE
RESPONSE &
RECOVERY
HYDROCARBON
RESPONSE
300 Feet
Altitude
6750 Feet
Altitude
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
RANGE
HIGH
RANGE
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
SCALE
NO
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
CORRECTED
CONCENTRATION
3400
INSTRUME1S
287 ppm 323 ppm
ACETYLENE BENZENE
+ 4.65
+ 0.
13
- 0.52
+ 0.
5
0.0
+ 0.
26
+ 1.74
+ 0.39
- 0.41
0.0
- 0.
+ 0.
+ 1.
+ 0.
- 0.
0.
- 0.
+ o.
INSTRUMEN
(CYCLE 1)
20.5
21
78
74
26
10
0
21
26
+ 1.
+ 0.
- 0.
+ 0.
0.
+ 0.
+ o.
+ 0.
- 0.
0.
- 0.
+ 0.
+ 0.
+ o.
- 0.
0.
- 0.
+ 0.
I RESPONSE TI
(CYCLE 2)
34.3
FT RESPONSE TO \
322 ppm
ETHYLENE
6
1
5
13
0
25
6
3
4
0
13
75
60
20
10
0
13
25
ME (SEC) (AVERA
(CYCLE 3)
28.9
rARIOUS HYDROCAF
385 ppm
ISOBUTYLENE
l
GE OF 2 RUNS)
(CYCLE 4)
20.5
,BONS AS ppm
337 ppm 329 ppm
METHANE TOLUENE
I
to
-------
Attachment (1)
Table 7-71. DATA COMPOSITE - LABORATORY TEST (Cont'd)
HORIBA MEXA 240
VOLTAGE
PROFILE
POWER
115V
RANGE
HIGH
SCALE
NO
READING VARIATH
VARYING LINE
+ 10%
0
ION AS FUNCTION OF
VOLTAGE ± 10%
- 10%
0
to
-------
Table 7-72. DATA COMPOSITE - REPEATABILITY TEST
INSTRUMENT: HORIBA MEXA 240
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
CYCLE 1
GAS
INTERFERENCE
(% of FS)
CYCLE 2
GAS
INTERFERENCE
(% of FS)
CYCLE 3
GAS
INTERFERENCE
(% of FS)
CYCLE 4
RESPONSE &
RECOVERY
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
HIGH
SCALE
NO
SCALE
NO
SCALE
NO
SCALE
NO
SCALE'
NO
SCALE
NO
SCALE
NO
(CYCLE 1) (CYCLE 2)
8 16
MAXI*<
(CYCLE 1) (CYCLE 2)
0 0
15%
CO2/N2
3.5
15%
C02/N2
0
15%
C02/N2
1.0
15%
CO2/N2
0.6
CORRECTED
CONCENTRATION
3400
1600ppm
HC/N2
2.1
IGOOppm
HC/N2
1.5
1600ppm
HC/N2
2
leOOppm
HC/N2
2.2
1
(CYCLE 3) (CYCLE 4) j
6
11
IUM ZERO DRIFT % FULL SCALE
(CYCLE 3) (CYCLE 4) {
1.0
o
1
10%
CO/N2
6.
2
10%
CO/N2
0
10%
CO/N2
2.
8
10%
CO/N2
3.0
3%
H20/AIR
1.0
3%
H20/AIR
0
3%
H20/AIR
0
3%
H20/AIR
1.0
2000ppm
NO/N2*
—
•
.2000npm
NO/N^*
-
2000ppm
NO/N^"
—
2000ppiT!
NO/N^,"
_
10%
02/N2
2.0
10%
02/N2
0 i
10%
02/N2
0
10"i
02/N2 '
0.7
INSTRUMENT RESPONSE TIME (SEC) (AVERAGE OF 2 RUNS)
(CYCLE 1) (CYCLE 2) | (CYCLE 3) j (CYCLE 41
33.5
10.5
11.25 i 19
i
10
00
00
-------
HORIBA MEXA 240
Table 7-72. DATA COMPOSITE - REPEATABILITY TEST (Cont'd)
-«J
1
LO
VO
ACCURACY
DETERMINATION
CYCLZ 1
CYCLE 2
CYCLE 3
CYCLE 4
i
RANGE
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
SCALE
!
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
| NO
NO
NO
NO
NO
NO
NO
NO
COMPARISON
CONDITION :'= FS
i
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
i 70
1 100
35
70
100
1 35
70
100
£
','-. ERROR
ABSOLUTS
+3.20
+0.90
0
+0.49
0
-0.52
-1.16
-2.31
-1.55
0
+2.27
-0.78
+3.20
-0.39
-0.52
0
+2.27
+0.52
+1.74
-0.39
-0.52
0
! +2.27
-1.03
ro
;': ERRQR
ITS
+1.10
+0.70
0
+0.13
0
-0.50
-0.40
-1.80
-1.50
0
; +1.37
-0.75
+1.10
1 -0.30
-0.50
0
+1.36
+0.50
+0.60
! -0.30
-0.50
0
+1.38
-1.0
7i ZRRCR '• ERROR i
ABSOLUTE FS !
i
; .
i
•
J
1
1
I
i
i
1
1 •
-------
Table 7-73. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS
HORIBA MEXA 240
KEY MODE
CYCLE #
STANDARD MODE
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
LEAN MODE
r'vr'T t? 1
\~i\*ijd JL
CYCLE 2
CYCLE 3
CYCLE 4
RANGE
PPM
4000
4000
1000
4000
4000
1000
4000
4000
1000
4000
4000
1000
4000
4000
1000
4000
4000
1000
4000
4000
1000
4000
4000
1000
SCALE
NO
NO
NO
NO
NO
NO
NO
NO .
NO
NO
NO
NO
NO
NO
NO
NO
No
NO
NO
NO
NO
NO
NO
NO
SPEED
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
N(
% ERROR
ABSOLUTE
- 7.72
- 9.47
+ 1.78
- 3.04
- 3.57
+ 4.33
- 2.98
1 - "4.13 ~
- 3.79
- 13.76
- 16,43
- 10.94
- 7.58
- 8.77
- 0.65
- 3.82
- 4.13
- 4.68
- 4.89
- s.d
- in.nq
- 5.97
- 6.66
- 24.64
D
% ERROR
FS
- 4.63
- 3.4
+ 0.21
- 1.73
- 1.25
+ 0.51
- 1.65
i - 1.4
- 0.48
- 8.18
- 5.65
- 1.29
• - 4.33
- 3.13
- n,n«
- 2.13
- 1.4
- 0.58
....- ....2.73 -.-
_ n Q2
_ 1.13
- 3.34
- 2.3
- 3.27
-------
Table 7-73. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS (Cont'd)
HORIBA MEXA 240
KEY MODE
CYCLE #
P TPR MOnP
! CYCLE 1
CYCLE 1
CYCLE 3
CYCLE 4
RANGE
PPM
4000
4000
1000
4000
4000
1000
4000
4000
1000
4000
4000
1000
SCALE
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
SPEED
"50
30
TD"LE~ '
50
30
IDLE
50
30
IDLE
50
30
IDLE
N(
% ERROR
ABSOLUTE
-
- 4.87
- 5.5
+ 5.17
- 2.65
- 3.44
+ 8.7
- 1.7
- 4.69
+ 6.02
- 1.45
- 5.21
+ 24.58
3
% ERROR
. FS
- 2.75
- 1.95
+ 0.61
- 1.5
- 1.18
+ 1.0
- 0.95
- 1.6
H- 0.71
- 0.83
- 1 -fl
+ 7r17
-------
Table 7-74. DIAGNOSTIC TEST
HORIBA MEXA 240
TEST
SPARKPLUG SHORTED
NORMAL IDLE
IGNITION ADVANCE
IGNITION RETARD
RANGE
1000
1000
1000
1000
SCALE
NO
NO
NO
NO
PPM NO, PPM HC, % CO
TEST INSTRUMENT
110
112
115
118
EPA BENCH
147
147
132
132
HC/CO/NO
% ABSOLUTE
ERROR
- 25.17
- 23.81
- 12.88
- 10.61
% ERROR
FS
- 3.7
- 3.5
- 1.7
- 1.4
-------
Table 7-75. DURABILITY TEST DATA
INSTRUMENT: HORIBA MEXA 240
INSTRUMENT TIME TO FAILURE AND GAS EXPOSURE
TIME TO FAILURE (HRS.)
HC EXPOSURE (PPM-HRS.)
CO EXPOSURE (%-HRS.)
NO EXPOSURE (PPM-HRS.)
960
809,280
528
114,240
INSTRUMENT STABILITY
TOTAL NO. DAYS SHOCK TEST FAILURE
(3% Variation) 1 or More of 4 Modes
SHOCK TEST FAILURE RATE
(Failure/Day %)
INCIDENCE OF FAILURE IN EACH MODE
HC ZERO
HC SPAN
CO ZERO
CO SPAN
AVERAGE DAILY SPAN DRIFT
HC%
C0% (
NO%
NOT APPLICABLE
NOT APPLICABLE
NOT APPLICABLE
—
—
2.84
INSTRUMENT SERVICE REQUIREMENTS
A CHANGE FILTER
TOTAL
PER 100 HRS.
B DRAIN HOSE
TOTAL
PER 100 HRS.
C REZERO
TOTAL
PER 100 HRS.
D. SAMPLING SYSTEM
TOTAL
PER 100 HRS.
E. OTHER
TOTAL
PER 100 HRS.
31
3.73
—
36
3.75
—
1
0.1
7-243
-------
Figure 7-46. HORIBA MEXA 240 INFRARED ANALYZER
7-244
-------
Figure 7-47. HORIBA MEXA 240 INFRARED ANALYZER (BACK)
7-245
-------
Figure 7-48. HORIBA MEXA 240 INFRARED ANALYZER (LEFT SIDE AND PROBE)
7-246
-------
7.16 THERMO ELECTRON 8A NO ANALYZER
Manufacturer - Thermo Electron Corporation
Description - Portable chemiluminescent NO analyzer configured as a bench
top unit. All sample handling equipment incorporated in or on
analyzer case. No optional cart or wheels available.
Dimensions -
Height - 10 inches
Width - 8-1/4 inches
Depth - 16-inches
Weight - 32-1/2 Ibs.
Material of Construction - Sheet metal case and face plate welded and
screwed together.
Color - Blue with white front.
Mobility - Portable
Accessories - Sample probe with water trap/prefilter, sample hose (10
feet long 1/4-inch Teflon tube), operator's manual.
Control Package -
Front Panel Access -
Range switch (three-position)
1. 500 ppm
2. 1,000 ppm
3. 5,000 ppm
Zero adjust - multi turn vernier scale with lock
Span adjust - multi turn vernier scale with lock
Power on - Lighted push button
Pressure Gauges (2) - Linear scale with needle
1. Air
2. Sample
Bypass flowmeter - adjustable
Rear Access -
Sample flow regulator - knob
Air flow regulator - knob
Pump vent switch - push button
Inlet air dryer
Sample port
Exhaust outlet charcoal filter (for excess ozone)
5 amp fuse cartridge
Meters - 5-inch, 100 sweep
Black characters on white background.
7-247
-------
Three Ranges - NO - 0-500 ppm in 10 ppm increments
0-1000 ppm in 20 ppm increments
0-5000 ppm in 100 ppm increments
The meter was not sensitive to static electricity.
Altitude Compensation - None, gas calibration only at site of test.
Probe - 1/4-inch OD stainless steel tubing, 3 feet long with cooling coil
at probe vase. A paper filter cartridge is contained in the probe-
mounted water trap. Probe is equipped with a handle.
Filter and Sample Handling - Primary particulate (paper cartridge) filter
in probe handle. Internal water trap.
Gal Gas Inlet - Sample port is used
Power Requirements - 115 VAC 60HZ 224 watts
Operating Principles - Chemiluminescent reaction of NO and ozone employing
a pulsed ozonator method to generate ozone from dry air.
Calibration - Gas calibration on each range of operation with electronic
reference calibration check using "check" button. Reference calibra-
tion is based upon results of gas calibration so gas calibration
must be performed first.
Operation and Calibration - Moderately difficult with many critical
pressure and flow setting requirements, in addition to span and zero
adjustments. Operation and calibration requirements are judged to
be more difficult than the level deemed acceptable for I/M instrumen-
tation and diagnostic application.
7.16.1 Operational Performance Comments
The mechanical package for this unit consisted of a relatively small
bench top cabinet, which incorporated all sample handling equipment. Everything
that was required was included in one package. The sample pickup system
consisted of a 1/4-inch diameter rigid probe with a 10-foot sample hose. The
instrument incorporated an internal water trap, which appeared to be ineffective
for the conditions of this evaluation testing.
The operator's manual recommends additional externally plumbed cold
traps and/or particulate filters if the sample contained excessive moisture or
particulate matter. Based upon test results, the unit would require at least
an additional cold trap to function in an I/M test environment.
This analyzer used the chemiluminescence method for sample detection.
In sample gas analysis, correlation between HDIR and chemiluminescence
methods could be expected to be relatively poor. In fact, this instrument
demonstrated very good accuracy and correlation except on the highest scale
(0 to 5,000).
7-248
-------
The display on this instrument a single 5-1/2-inch meter that demon-
strated slow response to automotive exhaust and generally unstable readings.
It was relatively easy to read at short distances. After using this instrument,
it was agreed that it was not totally applicable for garage operation or
automotive inspection and maintenance in its present form.
The adjustments for this instrument seemed to work backwards, giving
changes in readings that were the reverse of those anticipated. The response
to the adjustment controls was very delayed and hard to anticipate.
In the area of maintenance, it was noted that this unit appeared to
be unreliable in this application, as its performance could not be accurately
predicted. This unit appears to be more a laboratory-type unit not speci-
ficially intended for the automotive environment of this test.
The unit failed to calibrate during the high temperature cycle of
the laboratory test sequence. It required return to the factory for repair.
The high voltage transformer was found to be defective. During the laboratory
repeatability test, the readings were extremely intermittent and generally
unreliable. After this problem was encountered the local service representative
was notified. No successful diagnosis was ever made and no further repair was
attempted.
This intermittent problem of instability caused the unit to miss
many of the tests in the vehicle test phase and the entire durability test
phase.
In the durability tests, this unit showed no complete inability to
handle the high moisture content of the exhaust gas. Additional cold traps or
auxiliary sample handling accessories are definitely needed to use this instru-
ment in an I/M application.
Test data for Thermo Electron 8A NO Analyzer are shown in Tables 7-76
through 7-80.
Photographs of this instrument are shown in Figures 7-49, 7-50,
and 7-51.
7-249
-------
At t achme nt (1)
INSTRUMENT:
Table 7-76. DATA COMPOSITE - LABORATORY TEST
THERMO ELECTRON 8A
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
(CYCLE 1)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
LOW
LOW
LOW
HIGH
HIGH
HIGH
LCW
LOW
LOW
HIGH
HIGH
HIGH
SCALE
NO
SCALE
NO
SCALE
NO
SCALE
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
(CYCLE 1)
15
(CYCLE 1)
1.0
15%
C02/N2
0
(CYCLE 2)
20
MAXI*
(CYCLE 2)
MALFUNCTION
(CYCLE 3)
22
IUM ZERO DRIFT % Fl
(CYCLE 3)
0.4
IGOOppm 10%
HC/N2 CO/N2
0 0
COMPARISON
CONDITION % FS
35
70
100
35
70
100
35
70
100
35
70
100
3%
H20/AIR
0
NC
% ERROR
ABSOLUTE
+ 2.27
' +0.58
- 1.0
+20.0
- 4.39
-
INSTRUMENT
NO
(CYCLE 4)
12
ULL SCALE
(CYCLE 4)
0.
8
2000ppm
NO/N2
—
)
% ERROR
FS
+ 0.8
+ 0.4
- 1.0
+ 7.0
- 3.4
-
FAILED
DATA
10%
02/N2
0
% ERROR
ABSOLUTE
•
% ERROR
FS
-------
Table 7-76.
THERMO ELECTRON 8A
DATA COMPOSITE - LABORATORY TEST (Cont'd)
Attachment (1)
CYCLE 3
CYCLE 4
HIGH
ALTITUDE
RESPONSE &
RECOVERY
HYDROCARBON
RESPONSE
300 Feet
Altitude
6750 Feet
Altitude
LOW
^LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
RANGE
HIGH
RANGE
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
SCALE
NO
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
CORRECTED
CONCENTRATION
3400
INSTRUMEK
287 ppm 323 ppm
ACETYLENE BENZENE
+ 2.
-1- 0.
- 1.
+22.
- 1.
27
87
2
86
81
-
+ 0.
+ 1.
+ 0.
+ 22.
+ 3.
57
45
4
86
36
-
+ 1.
+ 1.
+ 0.
+ 22.
- 1.
14
74
40
84
16
-
INSTRUMEN1
(CYCLE 1)
43.5
+ 0.
+ 0.
- 1.
+ 8.
- 1.
8
6
2
0
4
-
+ 0,
+ 1.
+ o.
+ 8.
+ 2.
2
0
4
0
6
-
+ 0.
+ 0.
+ o.
+ 8.
- 0.
4
6
4
0
9
-
I RESPONSE TI
(CYCLE 2)
LJNSTKUJ^ltiJN'J.1
FAILED MO PA1
[T RESPONSE TO V
322 ppm
ETHYLENE
ME (SEC) (AVERS
(CYCLE 3)
43.8
rARIOUG HYDROCAB
385 ppm
ISOBUTYLENE
X3E OF 2 RUNS)
(CYCLE 4)
47.5
.BONS AS ppm
337 ppm 329 ppm
METHANE TOLUENE
ISJ
-------
I
N5
U1
Attachment (1)
Table 7-76. DATA COMPOSITE - LABORATORY TEST (Cont'd)
THERMO ELECTRON
VOLTAGE
PROFILE
POWER
115V
RANGE
HIGH
SCALE
NO
READING VARIATION AS FUNCTION OF
VARYING LINE VOLTAGE + 10%
+ 10%
INSTRUMENT MALFUNCTION
- 10%
-------
Table 7-77. DATA COMPOSITE - REPEATABILITY TEST
INSTRUMENT: THERMO ELECTRON 8A
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
CYCLE 1
GAS
INTERFERENCE
(% of FS)
CYCLE 2
GAS
INTERFERENCE
(% of FS)
CYCLE 3
GAS
INTERFERENCE
(% of FS)
CYCLE 4
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
LOW
SCALE
NO
SCALE
NO
SCALE
NO
SCALE
NO
SCALE
NO
SCALE
NO
(CYCLE 1) (CYCLE 2) (CYCLE 3) (CYCLE 4)
MALFUNCTION 33 9 11
MAXIMUM ZERO DRIFT % FULL SCALE
(CYCLE 1) (CYCLE 2) (CYCLE 3) (CYCLE 4)
8.0 0.8 0.4 0
'
15%
C02/N2
0
15%
C02/N2
0
15%
C02/N2
0
15%
C02/N2
0
CORRECTED
RANGE SCALE CONCENTRATION
RESPONSE & H1011 N0 340°
RECOVERY
1600ppm
HC/N2
0
IGOOppm
HC/N2
0
1600ppm
HC/N2
0
IGOOppm
HC/N2
0
10%
CO/N2
0
10%
CO/N2
0
10%
CO/N2
0
10%
CO/N2
38.0
3%
H20/AIR
0
3%
H20/AIR
0
3%
H20/AIR
0
3%
H20/AIR
0
2000ppm
NO/N2
-
.2000ppm
NO/N2
-
•
2000ppm
NO/N2
—
.-
2000ppm
NO/N2
-
10%
02/N2
0
10%
02/N2
0
10%
02/N2
0
10%
02/N2
0
INSTRUMENT RESPONSE TIME (SEC) (AVERAGE OF 2 RUNS)
(CYCLE I) (CYCLE 2) (CYCLE 3) | (CYCLE 4)
41 13.5 ' 12 25.5
1
Ui
VJ
-------
THERMO ELECTRON 8A
Table 7-77. DATA COMPOSITE - REPEATABILITY TEST (Cont'd)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
RANGE
LOW
LOW
LOW
MEDIUM
MEDIUM
MEDIUM
LOW
LOW
LOW
MEDIUM
MEDIUM
MEDIUM
LOW
LOW
LOW
MEDIUM
MEDIUM
MEDIUM
LOW
LOW
LOW
MEDIUM
MEDIUM
MEDIUM
SCALE
NO
NO
NO
NO
__ NO
NO
NO
NO
NO
NO
NO
NO
NO
NO -
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
COMPARISON
CONDITION % FS
35
70
L 100
35
70
100
35
70
100
35
70
100
35
70
100
35
70 ;
100 '
35 i
70 ' i
100 !
35
70
100
N
;'= ERROR
ABSOLUTS
+5.11
+3.20
-0.40
+10.47
-1.03
-3.09
+7.95
+ 1.74
-7.19
+6.10
+9.25
o
-9.09
+ 2.62
-5.19
+13.37
-8.10
-5.15
+0.57
+ 1.16
-5.19
+9.01
-5.78 •
-14.43
O
k s
+1.80
+2.20
-0.40
+3.60
-0.80
-3.0
+ 2.80
+1.20
-7.20
+ 2.10
+7.20
o
-3.20
+1.80
-5.20
+4.60
-6.30
-5.00
+0.20
+0.80
-5.20
+3.10
-4.30
-14.0
'
i
-1 ZRROR -i ERROR
ABSOLUTE ?S
;
'
'
1
1
i
t
i
i
i
t
i
i
i
I
i
«vl
I
-------
Table 7-78
THERMO ELECTRON 8A
VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS
KEY MODE
CYCLE #
STANDARD MODE
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
LEAN MODE
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
1 ...
RANGE
PPM
SCALE
NO
NO
NO
NO
NO
NO
NO
NO
NO
NQ
NO
NO
NO
NO
NO
NO
WO
NO
NO
NO
SPEED
50
30
IDLE
50
30
IDLE
50
NO
% ERROR
ABSOLUTE
OUT FOR R
OUT FOR R
% ERROR
FS
SPAIR
1PATR
OUT FOR REPAIR
•an
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50 _
30
NO IDLE
NO
NO
NO
50
30
IDLE
I
OUT FOR REPAIR
i
OUT FOR R
OUT FOR R
... OUT. FOR R:
OUT FOR Rl
.
3PAXR-.
3PAIR . -
IPAIR
]PAIR
-------
Table 7-78. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS (Cont'd)
NJ
Ui
THERMO ELECTRO
THERMO ECT V
KFY MODE
CYCLE #
•n Tfirj M/^TM?
KJ.L.H JMUDrj
i CYCLE 1
CYCLE ?
CYCLE 3
CYCLE 4
:
N 8A
•*•' j
RANGE
PPM
SCALE
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
SPEED
50
30
' IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
N<
% ERROR
ABSOLUTE
-
OUT FOR F
OUT FOR I
OUT FOR I
OUT FOR 1
D
% ERROR
. FS
EPAIR
EPAIR
EPAIR
EPAIR
-------
Table 7-79. DIAGNOSTIC TEST
THERMO ELECTRON 8A
TEST
SPARKPLUG SHORTED
NORMAL IDLE
TRWTTTOW ADVANCE
.
IGNITION RETARD
RANGE
SCALE
PPM NO, PPM HC, % CO
TEST INSTRUMENT,' EPA BENCH
INOPI
INOPI
INOP:
INOPI
RATIVE
IRATIVE
IRATIVE
3RATIVE
HC/CO/NO
% ABSOLUTE
ERROR
% ERROR
-------
Table 7-80. DURABILITY TEST DATA
INSTRUMENT: THERMO ELECTRON 8A
INSTRUMENT TIME TO FAILURE AND GAS EXPOSURE NO TEST DATA
TIME TO FAILURE (HRS.)
HC EXPOSURE (PPM-HRS.)
CO EXPOSURE (%-HRS.)
NO EXPOSURE (PPM-HRS.)
INSTRUMENT STABILITY
TOTAL NO, DAYS SHOCK TEST FAILURE
(3% Variation) 1 or More of 4 Modes
SHOCK TEST FAILURE RATE
(Failure/Day %)
INCIDENCE OF FAILURE IN EACH MODE
HC ZERO
HC SPAN
CO ZERO
CO SPAN
AVERAGE DAILY SPAN DRIFT
HC%
C0% ,
NO%
NOT APPLICABLE
NOT. APPLICABLE
NOT APPLICABLE
NO TEST DATA
INSTRUMENT SERVICE REQUIREMENTS NO TEST DATA
A CHANGE FILTER
TOTAL
PER 100 HRS.
B DRAIN HOSE
TOTAL
PER 100 HRS.
C REZERO
TOTAL
PER 100 HRS.
D. SAMPLING SYSTEM
TOTAL
PER 100 HRS.
E. OTHER
TOTAL
PER 100 HRS.
7-258
-------
Figure 7-49. THE3HO ELECTRON 8A NO ANALYZER
7-259
-------
Figure 7-50. THER110 ELECTRON 8A NO ANALYZER (BACK)
7-260
-------
Figure 7-51. THERIIO ELECTRON 8A NO ANALYZER (RIGHT SIDE AND PROBE)
7-261
-------
7.17 IBC N322 N/SC-400 NITROGEN OXIDE ANALYZER
Manufacturer - International Bio Physics Corporation (Selesco)
Description - NO analyzer using specific eletro-chemical detection method.
The analyzer is configured as a portbale bench top unit. In this
application, it is used with a portable sample/control module.
(Model SC-400).
Dimensions -
Analyzer -
Height - 6-1/2 inches
Width - 12-3/4 inches
Depth - 12-3/4 inches
Weight - 14 Ibs.
Sample/Control Module -
Height - 8 inches
Width - 7-1/2 inches
Depth - 11 inches
Height - 12-3/4 Ibs
Material of Construction - Sheet metal'cabinets and face panels welded
and screwed together.
Color -
Analyzer - Brown with tan face
Sampler - Blue with light blue face
Mobility - Both modules are portable
Accessories - Sample probe, 15-foot sample hose, operator's manual.
Control Package -
Analyzer Front Access - Mode switch (six positions)
1. Calibrate NO
2. Calibrate NO
3. Sample NO X
4. Sample NO*
5. Sample NO
NO null adjust - multi turn pot with lock
NO calibrate - multi turn pot with lock
NO» null adjust - multi turn pot with lock
W0~ calibrate - multi turn pot with lock
NO ratio trim - screw
•v
NO ratio trim - screw
Analyzer power on - rocks switch
Heater Power on - rocks switch
7-262
-------
Rear Access -
Analog output plug (NO -NO)
Analog output plug (NO^)
NO - NO analog adjust (screw)
NO* analog adjust (screw)
NO outlet port
NOX inlet port
NO* outlet port
NO- inlet port
1/5 analyzer fuse
2A heater fuse
Sampler - Control Module Front Access -
Mode switch (cal gas) (three-position)
1. Cal gas-B
2. Cal gas-A
3. Purge
Mode Switch (sample) (three-position)
1. Sample-B
2. Sample-A
3. Purge
Cal Gas Flow Controls (2) -
1. Cal gas-A
2. Cal gas-B
Flow meter (adjustable)
Power switch (toggle)
Power on light
Rear Access -
Sample and cal gas ports (9)
1. P-4
2. P-3
3. P-2
4. To analyzer
5. Cal gas-A
6. P-l
7. Sample-A
8. Cal gas-B
9. Sample-B
Meters - 4-1/2", 100° sweep (one meter)
Black characters on white background
Three ranges for each sample mode (NO, N02, NO )
0-500 ppm in 5 ppm increments
0-1000 ppm in 10 ppm increments
0-5000 ppm in 50 ppm increments
The meter was only slightly sensitive to static electricity.
7-263
-------
Altitude Compensation - None. Gas calibration required at test site.
Probe - 1/2-inch diamter copper tube pinched closed on end with cross-
drilled holes for sample entrance. Probe has handle and tail pipe
clamp.
Filters and Sample Handling - Glass fiber-filled tube used for particulate
filtering. Water drop-out trap with no drain. Both units enclosed
in sampler/control module.
Gal Gas Inlet - Read of sampler/control module.
Power Requirements - Analyzer 115 VAC 60HZ 2 1/4 amp Sampler 115 VAC 60HZ
2 amp.
Operating Principles - Specific electro-chemical analysis using "Faristor"
cartridges mounted in rear of analyzer cabinet.
Calibration - Gas calibration only utilizing sampler/control module.
Calibration is time-consuming and involved.
Operation and Calibration - The operation and calibration of this instru-
ment required manipulation and interpretation of the switching and
control module which was much too complex for an I/M application.
The IBC has both NO and NO capability, which adds more complexity.
The sample detection technique employed by this analyzer uses a
special sensor which provides an electrical signal output from
catalytic oxidation of the gas sample.
7.17.1 Operational Performance Comments
This unit was found to be a laboratory-type instrument, with a
separate module incorporating switching valves and a flow meter. It was
determined after initial testing that the intent of this instrument was probably
not consistent with an automotive I/M application. The unit allows detection
of NO, NO , and NO in ranges of 500, 1,000, and 5,000 ppm utilizing two
specific Faristor modules.
In the sample handling area, this unit utilized a copper tube probe
with black tygon tubing for sample hose. The instrument used glass fibers as
a filter, and a simple manually-drained plenum in-the probe for water removal.
In general, this unit had stable meter readings. However, the NO
concentration values indicated on the meter were not reliable due to oxides of
carbon interference problem.
This unit was much too responsive to CO to be usable as an auto
exhaust analyzer in its present form, and it is too susceptible to degradation
from water intake. It required higher and higher span control adjustments to
calibrate, as its exposure to exhaust samples with high water content increased.
The unit finally ran out of range capability on the span control and failure
in the durability test resulted.
7-264
-------
It was judged that this unit would need a more effective water
removal system for this specific application, it would require an in-line
scrubber for CO and C09, and its operation would have to be simplified for the
end user.
Test data for IBC N322 W/SC-400 Nitrogen Oxide Analyzer are shown in
Tables 7-81 through 7-85.
Photographs of this instrument are shown in Figures 7-52 through
7-57.
7-265
-------
At t achme nt (1)
INSTRUMENT:
Table 7-81.
IBC N322 W/SC-400
DATA COMPOSITE - LABORATORY TEST
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
(CYCLE 1)
ACCURACY
DETERMINATION
CYCLE 1
CYCLE 2
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
SCALE
NO
SCALE
NO
SCALE
NO
SCALE
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
(CYCLE 1)
9
(CYCLE 1)
1.0
15%
CO2/N2
0
(CYCLE 2)
9
MAXI1Y
(CYCLE 2)
1.0
(CYCLE 3)
21
IUM ZERO DRIFT % Fl
(CYCLE 3)
0.8
1600ppm 10% 3%
HC/N2 CO/N2 H20/AIR
0 40 . 0 0
COMPARISON
CONDITION % FS
35
70
100
35
70
100
35
70
100
35
70
100
K
% ERROR
ABSOLUTE
- 3
+ 1
0
0
- 0
.41
.16
.0
.0
.26
-
- 2
+ 1
.84
.45
+ 0.8
- 0
- 0
.06
.52
-
(CYCLE 4)
8
DLL SCALE
(CYCLE 4)
1.0
2000ppm
NO/N2
-
ro
% ERROR
FS
- 1.2
+ 0.8
0.0
0.0
- 0.2
-
- 1.0
+ 1.0
+ 0.8
- 0.02
- 0.4
-
10%
0
% ERROR
ABSOLUTE
% ERROR
FS
-------
Table 7-81. DATA COMPOSITE - LABORATORY TEST (Cont'd) «uuav.t«»i«. Vx,
IBC N322 W/SC-400
CYCLE 3
CYCLE 4
HIGH
ALTITUDE
RESPONSE &
RECOVERY
HYDROCARBON
RESPONSE
300 Feet
Altitude
6750 Feet
Altitude
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
LOW
LOW
LOW
HIGH
HIGH
HIGH
RANGE
HIGH
RANGE
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
SCALE
NO
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
0
+ 0
- 0
+ 0
+ 0
.0
.58
.6
.06
.26
-
- 3
- 0
- 1
- 1
+ 0
.53
.58
.6
.71
.52
-
- 3
+ 0
- 1
0
- 0
.41
.29
.20
.0
.13
-
CORRECTED INSTRUMEN1
CONCENTRATION (CYCLE 1)
3400 12.5
0
+ 0
- 0
+ 0
+ 0
.0
.4
.6
.02
.2
-
- 1
- 0
- 1
- 0
+ 0
.2
.4
.6
.6
.4
-
- 1
+ 0
- 1
0
- 0
.20
.20
.20
.0
.10
-
I RESPONSE TI
(CYCLE 2)
27.0
INSTRUMENT RESPONSE TO V
287 ppm 323 ppm 322 ppm
ACETYLENE BENZENE ETHYLENE
ME (SEC) (AVERA
(CYCLE 3)
29.75
'ARIOUS HYDROCAI
385 ppm
ISOBUTYLENE
GE OF 2 RUNS)
(CYCLE 4)
16.5
IBONS AS ppm
337 ppm 329 ppm
METHANE TOLUENE
-------
Attaclunent (1)
Table 7-81
IBC N322 W/SC-400
DATA COMPOSITE - LABORATORY TEST (Cont'd)
VOLTAGE
PROFILE
POWER
115V
RANGE
HIGH
SCALE
NO
READING VARIAT]
VARYING LINE
+ 10%
3445
ION AS FUNCTION OF
VOLTAGE ±10%
- 10%
3450
^J
N3
00
-------
INSTRUMENT:
Table 7-82. DATA COMPOSITE - REPEATABILITY TEST
IBC N322 W/SC-400
WARMUP
TIME (Min.)
ZERO DRIFT
GAS
INTERFERENCE
(% of FS)
CYCLE 1
GAS
INTERFERENCE
(% of FS)
CYCLE 2
GAS
INTERFERENCE
(% of FS)
CYCLE 3
GAS
INTERFERENCE
(% of FS)
CYCLE 4
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
LOW
RANGE
RESPONSE & HIGH
RECOVERY
SCALE
NO
SCALE
NO
SCALE
NO
SCALE
NO
SCALE
NO
SCALE
NO
SCALE
NO •
(CYCLE 1) (CYCLE 2) (CYCLE 3) (CYCLE 4)
9 17
10
14
MAXIMUM ZERO DRIFT % FULL SCALE
(CYCLE 1) (CYCLE 2) (CYCLE 3) (CYCLE 4)
0 2.0
0.2
0.4
f
15%
C02/N2
0
15%
C02/N2
0
15%
C02/N2
0
15%
CO2/N2
0
CORRECTED
CONCENTRATION
3400
ISOOppm
HC/N2
0.4
1600ppm
HC/N2
0
IGOOppm
HC/N2
0
1600ppm
HC/N2
0
10%
CO/N2
33.0
10%
CO/N2
36.0
10%
CO/N2
36
10%
CO/N2
0
INSTRUMEN'
(CYCLE 1)
23.5
3%
H20/AIR
1.0
3%
H20/AIR
0
3%
H20/AIR
0
3%
H20/AIR
0.8
I RESPONSE TI
(CYCLE 2)
8.75
2000ppm
NO/N2
-
.2000ppm
NO/N2 '
-
•
2000ppm
NO/N2
-
•
2000ppm
NO/N2
-
10%
02/N2
3.0
10%
02/N2
4.0
10%
02/N2
0
10%
02/N2.
0
ME (SEC) (AVERAGE OF 2 RUNS)
(CYCLE 3) (CYCLE 4)
'10.5 11
-------
Table 7-82.
IBC N322 W/SC-400
DATA COMPOSITE - REPEATABILITY TEST (Cont'd)
ACCURACY
DETERMINATION
CYCLE 1
•
CYCLE 2
CYCLE 3
CYCLE 4
1
RANGE
LOW
LOW
LOW
MEDIUM
MEDIUM
MEDIUM
LOW
LOW
LOW
MEDIUM
MEDIUM
MEDIUM
LOW
LOW
LOW
MEDIUM
MEDIUM
MEDIUM
LOW
LOW
LOW
MEDIUM,
MEDIUM
MEDIUM
SCALE ;
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO -
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
COMPARISON
CONDITION =/3 FS
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
35
70
100
1
':'-. ERROR
ABSOLUTE
+2.27
-0.58
-2.20
+1.45
+1.29
+2.06
-4.55
-1.74
-0.50
-1.16
-0.39
+2.06
+3.41
-0.87
-3.19
+3.20
+4.88
+1.55
-7.39
+0.58
-1.60
-1.16
+1.54
+5.16
TO
-'-. ERROR
FS
+0.80
-0.40
-2.20
+0.50
+1.0
+ 2.0
-1.60
-1.20
-0.60
-0.40
-0.30
+ 2.0
-1.20
-0.60
-3.20
+1.10
+3.80
+1.50
-1.40
+0.40
-1.60
-0.40
+1.20
+5.00
1
% 3RROR •< ERROR I
ABSOLUTE FS
',
;
i
i
!
•
'
;
i
t
i
i
1
to
-------
Table 7-83. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS
IBC N322W/SC-400
trpv MODfi
CYCLE #
STANDARD MODE
CYCLE 1
CYCLE 2
^"*T7yiT t? *3
CYCIicI J
CYCT.P 4
LEAN MODE
CYCLE 1
CYCLE 2
CYCLE 3
t
CYCLE 4
i
RANGE
PPM
5000
5000
500
5000
5000
500
5000
5000
500
5000
5000
500
5000
5000
500
5000
5000
500
5000
5000
500
5000
5000
500
SCALE
NO
NO
NO
NO
NO
NO
NO
NO
NO
MO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
SPEED
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
50
30
IDLE
N
% ERROR
ABSOLUTE
- 1.88
- 7.8
+ 53.52
+ 3.57
0
+120.53
+ 3.79
- 0.44
: + 23.03
+ 3.07
+ 1,79
+ 39.95
- 2.54
- 8.77
- 1.42
+ 5.62
+ 3.24
+ 0.97
+ 4.31
- 0.22
27.91
+ 3.98
+ 1.3
+ 43.18
0
% ERROR
FS
- 0.9
- 2.2
+ 12.62
+ 1.62
' 0
+ 28.42
+ 1.68
I - 0.12
i + 5.84
+ 1.46
+ 0.5
+ 9.42
.- 1.16
- 2.5
- 0.36
+ 2.5
+ 0.88
+ 0.24
+ 1.92
- 0.06
- 6.58
+ 1.8
+ 0.36
+ 11.46
••J
NJ
-------
Table 7-83. VEHICLE TEST ACCURACY DETERMINATION - EXHAUST GAS (Cont'd)
IBC N322 W/SC-400
NJ
•~J
1-0
K"PV MOHF
CYCLE #
RICH MODE
CYCLE 1
CYCLE 2
CYCLE 3
CYCLE 4
RANGE
PPM
5000
5000
500
5000
5000
1000
5000
5000
1000
5000
5000
1000
SCALE
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
SPEED
"50 1
30
' IDLE i
50
30
IDLE
50
30
IDLE
50
30
IDLE
N(
% ERROR
ABSOLUTE
+ 3.98
- 1.27
+222.31
+ 3.98
+ 2.41
+334.78
+ 5.0
+ 2.64
+391.94
+ 51.12
- 3.04
+607. ffl
)
% ERROR
. FS
+ 1.8
- 0.36
+ 52.42
+ 1.8
+ 0.66
+ 77.0
+ 2.24
+ 0.72
+ 92.42
+ 23.34
n.R4
-t- t^,K7
-------
Table 7-84. DIAGNOSTIC TEST
IBC N322 W/SC-400
TEST
SPARKPLUG SHORTED
NORMAL IDLE
IGNITION ADVANCE
IGNITION RETARD
j RANGE
500
500
500
500
SCALE
NO
NO
NO
NO
PPM NO, PPM HC, % CO
TEST INSTRUMENT
295
310
262
224
EPA BENCH
147
147
132
132
HC/CO/NO
% ABSOLUTE
ERROR
+100.68
+110.88
+ 98.48
+ 69.7
% ERROR
FS
+ 29.6
+ 32.6
+ 26.00
+ 18.4
-------
INSTRUMENT:
Table 7-85. DURABILITY TEST DATA
N322 W/SC-400
INSTRUMENT TIME TO FAILURE AND GAS EXPOSURE
TIME TO FAILURE (HRS.)
HC EXPOSURE (PPM-HRS.)
CO EXPOSURE (%-HRS.)
NO EXPOSURE (PPM-HRS.)
176
183,040
373
18,832
INSTRUMENT STABILITY •-
TOTAL NO. DAYS SHOCK TEST FAILURE
(3% Variation) 1 or More of 4 Modes
SHOCK TEST FAILURE RATE
(Failure/Day %)
INCIDENCE OF FAILURE IN EACH MODE
HC ZERO
HC SPAN
CO ZERO
CO SPAN
AVERAGE DAILY SPAN DRIFT
HC%
C0% ,
N0%
NOT APPLICABLE
NOT APPLICABLE
NOT APPLICABLE
—
—
17.68
INSTRUMENT SERVICE REQUIREMENTS
A CHANGE FILTER
TOTAL
PER 100 HRS.
B DRAIN HOSE
TOTAL
PER 100 HRS.
C REZERO
TOTAL
PER 100 HRS.
D. SAMPLING SYSTEM
TOTAL
PER 100 HRS.
E . OTHER
TOTAL .
PER 100 HRS.
—
__
1
0.57
— —
—
7-274
-------
Figure 7-52. IBC N322 W/SC-400 NITROGEN OXIDE ANALYZER
7-275
-------
Figure 7-53. IBC N322 W/SC-400 NITROGEN OXIDE ANALYZER (BACK)
7-276
-------
FiRure 7-54. IBC H322 W/SC-400 NITROGEN OXIDE ANALYZER (LEFT SIDE)
7-277
-------
.
00
Figure 7-55. IBC N322 W/SC-400 NITROGEN OXIDE ANALYZER -
SAMPLER CONTROL MODULE
-------
(S3
Figure 7-56.
IBC N322 W/SC-400 NITROGEN OXIDE ANALYZER -
SAMPLER CONTROL MODULE (BACK AND PROBE)
-------
I
I
I '
•
'
Figure 7-57. IBC N322 W/SC-400 NITROGEN OXIDE ANALYZER -
SAMPLER CONTROL MODULE (RIGHT SIDE AND PROBE)
-------
TECHNICAL REPORT
^(Please read Insmtctions on the reverse
DATA
before completing}
1. REPORT NO.
EPA-460/3-77-014
3. RECIPIENT'S ACCESSIOWNO.
PB-224 316/AS
I. TITLE AND SUBTITLE
Vehicle Exhaust Emissic n
Instruments Evaluation
5. REPORT DATE
July 1977
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
8. PERFORMING ORGANIZATION REPORT NO.
Steve N. Schlingmann
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Olson Laboratories Inc.
421 East Cerritos Ave.
Anaheim, CA 92805
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
Contract No.
68-03-2353
12. SPONSORING AGENCY NAME AND ADDRESS
U.S. Environmental Protection Agency
2565 Plymouth Rd
Ann Arbor, MI 48105
13. TYPE OF REPORT AND PERIOD COVERED
Final
14. SPONSORING AGENCY CODE
200/05
15. SUPPLEMENTARY NOTES
16. ABSTRACT - ' ' ~"
Government agencies have become involved in vehicle maintenance through the
initiation of periodic vehicle emission inspection requirements carried out at
State or local levels. The key element in all vehicle engine maintenance,
inspection and emission detection is the exhaust emission analyzer. Exhaust emissioi
analyzers are presently available in many different designs, covering a broad price
range and offering various capabilities and features. The objective of this study
was to survey the market and identify all exhaust emission analyzer manufacturers,
whose product could be used in vehicle inspection/maintenance (I/M) programs.
Consequently, a representative group of instruments was selected and a series of
tests were conducted to evaluate instrument performance.
Major findings of this program:
1. A significant number of HC/CO I/M emission analyzers are presently available.
2. The vast majority of HC/CO instruments use an infrared absorption operating
principle.
3. The hydrocarbon response characteristics of the HC/CO instruments generally
showed greatest sensitivity to isobutylene, followed by toluene, methane,
and ethylene. The units demonstrate essentially no sensitivity to acetylene and
benzene.
7.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
c. COS AT I Field/Group
Air Pollution
Inspec t ion/Maintenance
Garage-type Instruments
13B
8. DISTRIBUTION STATEMENT
19. SECURITY CLASS (ThisReport)
Unclassified
21. NO. OF PAGES
320
Unlimited
20. SECURITY CLASS (Thispage}
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
------- |