Soft. rev. 3.

1 and later
March 2000

By
NALIZZATORE OMOLOGATO SECONDO D.M 628/9

INFRARED GAS ANALYSER

USER’S MANUAL
Soft. rev. 3.1 and later
Cod. 71105410

Via di Prato, 74
50041 CALENZANO
FIRENZE - ITALY
( ++39 055 8878151
2 ++39 055 8878152
: www.protechspa.it

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1. CARES, CALIBRATION AND DISCLAIMER.................................................... 1-1

2. INTRODUCTION ............................................................................................... 2-1

2.1. GENERAL FEATURES ......................................................................................... 2-2
2.2. FRONT PANEL ......................................................................................................... 2-3
2.2.1. Displays ..................................................................................................................... 2-3
2.2.2. Keyboard.................................................................................................................... 2-5
2.2.3. Printer ........................................................................................................................ 2-5
2.3. REAR PANEL ........................................................................................................... 2-8
2.4. FLUX 4005 PROBES ............................................................................................. 2-10

3. STARTING PROCEDURE AND USE................................................................ 3-1

3.1. USE CARES ............................................................................................................. 3-1
3.2. PRELIMINARY OPERATIONS ..................................................................................... 3-1

4. HOW TO PERFORM A QUICK TEST OF EXHAUST GASES ......................... 4-1

5. HOW TO PERFORM EXHAUST GASES TEST ACCORDING TO THE CHINESE

PROCEDURE.......................................................................................................... 5-1

6. SPECIAL FUNCTIONS ..................................................................................... 6-0

6.1. LEAK CHECK TEST ................................................................................................... 6-0
6.2. RESIDUAL HC TEST ................................................................................................. 6-1
6.3. CATALYST EFFICIENCY TEST ................................................................................... 6-2
6.4. HOW TO SET INTERNAL REAL TIME CLOCK ................................................................ 6-4
6.5. HOW TO SET RPM READING .................................................................................... 6-5

7. MESSAGES ...................................................................................................... 7-1

8. MAINTEINANCE ............................................................................................... 8-1

8.1. HOW TO CLEAN THE FIRST INTAKE FILTER................................................................. 8-1
8.2. CONDENSATE DRAINAGE PUMP MAINTENANCE.......................................................... 8-3
8.3. PRINTER PAPER ROLL REPLACEMENT....................................................................... 8-3
8.4. PRINTER RIBBON CARTRIDGE REPLACEMENT ............................................................ 8-4
8.5. OXYGEN TRANSDUCER REPLACEMENT ..................................................................... 8-5
8.6. NO SENSOR REPLACEMENT ..................................................................................... 8-6

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 8.7. CHARCOAL FILTER REPLACEMENT ........................................................................... 8-7

9. TECHNICAL SPECIFICATION.......................................................................... 9-1

Index of illustrations

PICTURE 1- FRONT PANEL OF 5 LED VERSION....................................................................... 2-6

PICTURE 2 - FRONT PANEL OF 6 LED VERSION...................................................................... 2-7

PICTURE 3 – REAR PANEL......................................................................................................... 2-9

PICTURE4 - INDUCTIVE CLAMP............................................................................................... 2-10

PICTURE5 - THERMOCOUPLE TEMPERATURE PROBE ........................................................ 2-10

PICTURE6 - GAS DRAWING PROBE ........................................................................................ 2-10

PICTURE7 - LOW VOLTAGE PROBE (*)................................................................................... 2-11

PICTURE8 - RPM COM PROBE (*)............................................................................................ 2-11

PICTURE9 – LAMBDA PARAMETER.......................................................................................... 6-2

PICTURE10 – POLLUTANTS REDUCTION RATE....................................................................... 6-3

PICTURE11 – INTAKE FILTER .................................................................................................... 8-2

PICTURE12 – PRINTER RIBBON REPLACEMENT..................................................................... 8-4

PICTURE13 - OXYGEN TRANSDUCER REPLACEMENT ........................................................... 8-5

PICTURE14 - NO TRANSDUCER REPLACEMENT..................................................................... 8-6

PICTURE15 - CHARCOAL FILTER REPLACEMENT .................................................................. 8-7

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1. CARES, CALIBRATION AND DISCLAIMER

This manual describes the correct use and maintenance of FLUX 4005. The manufacturer
recommends to follow the instructions contained in this manual. The manufacturer does not grant any
guarantee when damages, due to misuse of this instrument, can be found. The manufacturer does not
accept any liability for any personal injury or damage to third parties arising from the misuse of the
instrument or from use for which it is not designed.

The measuring and checking methods you find here are intended as a general guide only.
Always follow legislation, if applicable, or the vehicle manufacturer’s recommendations for the
particular vehicle or system under test. Damage can result if the correct procedures are not followed.

AVOID THE RISK OF FUMES INHALATION

Fuel and exhaust fumes are harmful; always work in a well-ventilated area. Never start
engines in closed sites. Refer to local legislation.

PAY ATTENTION TO MOVING PARTS

Be careful not to get hands, hair or clothing near fan blades and belts, pulleys,
transmission and throttle linkage etc. Do not wear ties, loose clothing, jewellery,
watches or other loose articles when working on a vehicle; these can be caught in
moving parts and can also cause short circuits

AVOID ELECTRICAL SHOCK AND BURNS

High voltages are present in the ignition coil, distributor cap, High Voltage leads and
spark plug. Avoid direct contact and beware of involuntary movements, use insulated
pliers when repairing and tuning. Avoid contact with battery acid; it can burn your
skin, eyes and clothing. Avoid contact with hot gas exhaust systems, radiators and
hoses. Never remove the radiator cap whilst the engine is hot; escaping coolant
under pressure could scald you.

AVOID THE RISK OF EYE DAMAGE

Always wear eye protection when working on a Vehicle to protect against battery
acid, fuel, dirt, dust, oil and backfires.

CAR CHECKS
When working on a vehicle, ensure it is securely parked with the brake on and gear in
neutral position. To raise the vehicle use suitable equipment (not the wheel change
jack supplied with the vehicle) and double check that it cannot slip.

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 WARNING!
The internal parts of the instrument don’t require maintenance. Opening it will cause
guarantee decay.

WARNING!
Always disconnect power supply before removing the analyser lid.

Each instrument before delivery has been previously tested and calibrated by PROTECH S.p.A.

is a registered trademark of PROTECH S.p.A. - Florence - Italy..

NOTE
All information, illustrations, and specifications contained in this manual are based on
the latest information available at the time of publication. PROTECH S.p.A. reserves
the right to make changes at any time without further notice to any of its products to
improve reliability, functions, design or whatever can be thought suitable.

NOTE
Items indicated with (*) are optional

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2. INTRODUCTION

FLUX 4005 gas analyser is a complete measuring station of emissions coming from cars using petrol
engines. Concentration of the following gases can be analysed:

q CO (CARBON MONOXIDE)
q CO2 (CARBON DIOXIDE)
q HC (HYDROCARBONS)
q O2 (OXYGEN)
q NO (*) (NITROGEN OXIDE)
q NOX (*) (NITROGEN n- OXIDE)

FLUX 4005 uses an internal proprietary optical bench, designed and released by PROTECH S.p.A,
using a NDIR (non-dispersive infrared) technique for gas analysis.

FLUX 4005 can also measure:

q RPM rate
q Oil temperature
q Air /fuel ratio (AFR)
q Lambda

A powerful 32-bit microprocessor system is responsible of global management of the instrument.

Thanks to its features FLUX 4005 can be considered a modern and complete measuring instrument
and, at the same time, an efficacious remedy against air pollution. FLUX 4005 complies with the most
severe international legislations such as OIML Class I, BAR 90.

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2.1. GENERAL FEATURES

1. CO (carbon monoxide), CO2 (carbon dioxide) e HC (hydrocarbons) by means of "NDIR" infrared

method. It is also available a "corrected" CO value as measured parameter.

2. O2 (oxygen), NO (*) (nitrogen oxide) measurement.

3. NOx measurement. This parameter is calculated as NO% x 1.1.

4. Lambda value and air/petrol ratio (AFR) are obtained measuring exhaust gases. These
parameters are needed to test catalyst and modern fuel feeding systems.

5. RPM rate measurement with three different kind of probes, inductive clamp, low voltage probe (*)
and RPM COM (*), in order to cover the whole body of circulating Otto-cycle engine powered
vehicles.

6. Oil temperature measurement with a thermocouple probe.

7. Catalyst efficiency test with graphic representation of polluting gases reduction.

8. All measured values printed by a 24-columns impact printer. Print out personalization available
(*).

9. Watch/calendar with back-up battery, fully compliant with year 2000 and followings.

10. RS-232 serial interface for connection with portable terminal (*).

11. RS-232 serial interface for connection with external PC.

12. Automatic condensate drainage system to prevent damages from steam. Condensed water is
continuously drained by a separate pump automatically operated each time the aspiration pump
is working.

13. Temperature and pressure compensating system to ensure measuring stability in the presence of
environmental changing conditions.

14. Membrane keyboard to protect keys from dust, oil and moisture.

15. External gas filters mounted on the rear panel and the gas drawing probe in order to provide an
easy maintenance.

16. High efficiency red LEDs display.

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 2.2. FRONT PANEL

2.2.1. Displays

The front panel of FLUX 4005 presents four displays each one showing concentrations of the
following gases: CO, CO2, HC and O2.There are, besides, a multi-functional display and two warning
lights.

POWER warning light goes on when the instrument comes into operation.

PUMP warning light is on when pump is working.

FUNC key is on the right of the multi-functional display and allows operator to select the desired
quantity or function.

The multi-functional display is made up of:

- a seven digit ultra-bright display

- five or six LEDs showing the meaning of measures appearing on the display according to the
following tables:

INFORMATIONS SHOWN ON MULTI-FUNCTIONAL DISPLAY

Quantities displayed LEDs Status Format

2ND LAMB NOX RPM T. OIL/AFR COCORR
CO Corr. petrol X.XXX
CO Corr. LPG X.XXX
CO Corr. methane X.XXX
Lambda petrol X.XXX
Lambda LPG X.XXX
Lambda methane X.XXX
AFR XX.XX
Oil temperature XXX.X
RPM 4 strokes XXXX
RPM 2 strokes XXXX
NOx XXXX
NO XXXX

Symbols meaning

= LED OFF = LED ON = LED FLASHING

CO %VOL display, during measurement, shows CO (carbon monoxide) concentration in % vol.

By 2-3
CO2 %VOL display, during measurement, shows CO2 (carbon dioxide) concentration in % vol.

HC ppm VOL display, during measurement, shows HC (hydrocarbons) concentration in n-exane ppm
units. When HC concentration value is greater than 9999 ppm, the four points of the display are ON,
meaning that the digit 1 must be placed before the number displayed (es. “2.5.2.7” is equal to 12527
ppm).

O2 %VOL display, during measurement, shows O2 (oxygen) concentration in % vol.

Moreover:

• At the beginning of the measuring phase displays show "MEAS CAL" (Measure calibration)
message.

• If an error occurs, displays show the corresponding message.

• While instrument is in standby, “Protech” message runs on superior displays and "4005"
message is shown on HC display.

• After a Standby period of one minute, multi-functional display shows the current hour.

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2.2.2. Keyboard

FLUX 4005 keyboard presents three keys, each one with a specific function.

After warm-up, during normal operating mode, the front panel keys have the following meaning:

1. MEASURE key starts or stops the measuring routine. Before each measurement an auto-
zeroing phase is automatically performed ("MEA(S) CAL" displayed). The instrument gets out
of measure status when MEASURE key is pressed or after 15 min. of uninterrupted work, in
order to prevent internal mechanisms from unnecessary wear. The instrument keeps the
pump running for a few seconds to clean the pneumatic circuit.

2. FUNC key allows operator to select the quantity shown on the multi-functional display.
Press this key to go to the next parameter.

3. PRINT key, while the pump is running, starts printing all measured and/or calculated
quantity together with the garage data, if the print out personalization option (*) is installed.
Printing starts after two seconds. If this key is kept pressed for more than one second, in
Standby mode, the paper is fed without printing. Use this functionality to perform the
printer paper roll replacement.

2.2.3. Printer

FLUX 4005 has a built in 24 columns impact printer. Printer paper roll and ribbon cartridge are easily
and quickly replaceable, being accessible from the cover placed on the front panel of the instrument.

NOTE
Printing is disabled when the intake pump is not running. The printing report always shows
all measured and calculated parameters (being displayed or not) and the garage data (*), if
stored.

WARNING!
Under no circumstances pull out paper while the printer is working. Doing so may
cause damages to printing heads. Such problems are not covered by instrument
warranty.

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By

CO2 display HC printer cover

CO display
display

CO %VOL CO2 % VOL HC PPM VOL

O2 display

FLUX
INFRARED MULTIGAS ANALYSER
multi-functional O2 % VOL

display

PUMP POWER
FUNC MEASURE PRINT

LAMBDA AFR RPM T.OIL CO.CORR

function pump on measure power on print key

key LED key LED
2-6

PICTURE 1- FRONT PANEL OF 5 LED VERSION

By

CO2 HC printer
CO
display display cover
display

CO %VOL CO 2 % VOL HC PPM VOL

O2
display

FLUX
multi-functional O2 % VOL
INFRARED MULTIGAS ANALYSER
display

PUMP POWER
FUNC MEASURE PRINT

ND
2 LAMB NOX RPM T.OIL/AFR CO. CORR

pump on measure power on print

function key
LED LED key
key
PICTURE 2 - FRONT PANEL OF 6 LED VERSION
2-7
2.3. REAR PANEL

On the rear panel of FLUX 4005, the following devices are recognizable (see picture on next page):

1. The Oxygen sensor with its cover;

2. The NO sensor (*) with its cover;

3. The charcoal filter;

4. The gas filtering system (composed of two filters);

5. The gas intake;

6. The power switch and the fuse holder;

7. The RPM probe connector;

8. The oil temperature probe connector;

9. The RS-232 standard interface connectors (‘TERMINAL’ to connect to the hand held terminal
EXTERM and ‘DATA’ to connect to a PC);

10. The cooling fan;

11. The gas outlet;

12. The zeroing gas intake;

13. The calibration gas intake;

14. The automatic condensate drainage system which intakes condensed water from the first filter
and discharges it from the water outlet.

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By

calibration gas
gas intake 40µ m
RPM probe NO oxygen intake
filter
connector sensor sensor

charcoal
filter
oil paper
temperature filter
connector

gas
exhaust

power
switch

condensate
filter

FLUX 4005
label data RPM probe condensate
hand held terminal drain
interface (PC) label
interface PICTURE 3 – REAR PANEL
2-9
2.4. FLUX 4005 PROBES

PICTURE4 - INDUCTIVE CLAMP

Use
1. Switch off the instrument.

2. Plug connector to the RPM interface on the rear panel of

FLUX 4005, taking care to fasten it tightly.

3. Hook the probe round a HT lead of a spark plug.

4. If readings are not stable, turn the probe upside down,

letting the opposite site of the probe to face spark plug.

PICTURE5 - THERMOCOUPLE
TEMPERATURE PROBE

Use
1. Switch off the instrument.

2. Plug connector to the oil temperature

interface on the rear panel of FLUX
4005, taking care to fasten it tightly.

3. Extract the oil level dipstick from its

housing and use its lenght as
reference to set the conic stop in
order to avoid it touching engine
moving parts and prevent oil spillage.

PICTURE6 - GAS DRAWING PROBE

Use
1. Connect the end of the probe, opposite to the
clamp, to the gas intake on the rear panel of FLUX
4005.
2. Insert the other end in the exhaust pipe of the
vehicle, fastening it with its clamp.

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 PICTURE7 - LOW VOLTAGE PROBE (*)

Use
1. Switch off the instrument.
2. Plug connector to the RPM interface on the
rear panel of FLUX 4005, taking care to
fasten it tightly.
3. Connect the black clamp to ground.
4. Connect the red clamp to RPM terminal of
vehicle diagnosis connector (refer to vehicle
technical manual) or to the positive terminal of
the LT ignition circuit.

PICTURE8 - RPM COM PROBE (*)

Use
Refer to user’s manual supplied with the
probe.

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3. STARTING PROCEDURE AND USE
Remove the instrument from its package, place it on a trolley and perform the following connections:

NOTE
Please, refer to previous pages, describing front and rear panel, to correctly carry out
connections.

ü the gas sampling probe to the gas hose;

ü the other end of the gas hose to the gas intake of the instrument;

ü the inductive probe to its proper connector on the rear panel;

ü the temperature probe to its proper connector on the rear panel;

ü the Exterm (*), if present, to ‘TERMINAL’ connector on the rear panel;

It is advisable to keep all fittings connected to the instrument, whether it is working or not.

3.1. USE CARES

WARNING!
Carefully follow instructions of this manual in order to avoid problems due to
moisture. Any trouble related to such negligence is not covered by the instrument
warranty.

q Periodically check intake filters status; keep them clear following instructions in MAINTEINANCE
chapter (pay attention to the filter mounting direction).

q It is advisable to daily clear the exhaust sampling probe: disconnect it from the instrument and
blow compressed air in the direction of the sampling probe.

q Lambda and AFR parameters may show "----" message. This means that these parameters are
out of the measuring field.

q Never pull out paper while the printer is working. Doing so may cause damages to printing heads.

q During tests, make sure that the RPM probe connector is correctly screwed to its interface and
that the probe is not placed too near to other HT leads.

q Make sure that the spark plug symbol printed on the inductive clamp is oriented toward the spark
plug. If readings are not stable, try to reverse the probe.

q If the inductive probe is not able to measure the RPM rate correctly, low voltage probe (*) or RPM
COM (*) may be needed.

q During measures, a continuous flow of condensed water is given out by the condensate drain.
Take care not to damage other equipments, particularly electrical devices.

q Place the instrument so that the necessary ventilation is ensured.

3.2. PRELIMINARY OPERATIONS

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Connect the power cord and the available probes as previously showed and switch on the instrument.
FLUX 4005 will print Protech logo.

The instrument starts warming up. Five minutes are needed to reach the operating temperature.
During this phase the instrument shows the time elapsed on the upper displays.

At the end of the warming up phase FLUX 4005 enters the standby mode and is ready for use.

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4. HOW TO PERFORM A QUICK TEST OF EXHAUST GASES
This section describes the operations needed to perform a quick test of exhaust gases coming out
from a petrol engine.

1. Press MEASURE key to start measurements: the automatic zeroing phase begins and the
message "MEA(S) CAL" is displayed. When the message goes out, the instrument start
measuring gases concentrations. User can select, pressing the FUNC key, parameter to be
shown on the multi-functional display.

2. Insert the end of the gas drawing probe into the vehicle exhaust pipe, connect the RPM probe to a
HT lead of a spark plug, making sure that the spark plug symbol printed on the inductive clamp is
oriented toward the spark plug and insert the temperature probe in the oil level dipstick housing,
with its stop properly set.

3. Pressing FUNC key, display oil temperature parameter and wait until it reaches 60 °C in order
to make sure of the regular working of the engine.

4. Make sure that the RPM idle rate displayed is equal the one declared by the manufacturer. If no
RPM values are displayed or readings are unstable, use the switch positioned on the clamp to
select the best working position, or turn the probe upside down, letting the opposite site of the
probe to face spark plug.

5. When gas values are stable, press PRINT key to print data.

6. Press MEASURE key to exit measurement, whenever you want. FLUX 4005 switches off the
intaking pump after 15 minutes of continuous work, to avoid useless wear.

Compare the following data with those declared by the vehicle manufacturer or those expected:

q CO
q CO2
q HC
q O2
q CO corr.
q Lambda
q AFR
q NO (*)
q NOx (*)

For Co corr. and Lambda, values are displayed for three different kind of fuel, petrol, LPG and
methane, while the two RPM rates refer to four and two strokes engines.

CO corr. value is calculated with the following formulas:

petrol engines:

15 ×CO%
CO corr. = ____________

CO%+CO2%

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LPG engines:

14 × CO%
CO corr. = ____________

CO%+CO2%

methane engines:
.
12 × CO%
CO corr. = ____________

CO%+CO2%

In most cases, if CO corr. value is significantly different from CO value, probably gas is escaping
from a leak in the vehicle exhaust pipe. In that case, CO corr. value indicates the “real" CO value,
that is the value obtainable without leaks.

Lambda parameter is calculated with the Brettschneider formula, as requested by car manufacturers
and modern legislations. This method is the best way to test three way catalysts with lambda probe

Here is the complete formula to calculate Lambda value:

   
   
 [CO ] Hcv 3.5 
21 ×  [CO 2 ] + + [O 2 ] +  × − 0.00877  × ([CO ] + [CO 2])
 2  4 [CO ] 

 3.5 + 
  [CO 2]  
λ =
 [CO ] 
 
 21 + [CO 2]   Hcv 0.01754 
0.5628 × × 1 + +  × ([CO ] + [CO 2 ] + [HC ] × 0.0006)
 [CO ]   4 2 
 3.5 + 
 [CO 2] 

Hcv parameter has the following values:

1.85 – for petrol engines

2.57 – for LPG engines
4.00 – for methane engines

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AFR (Air to Fuel Ratio) is another parameter calculated by FLUX 4005, in the following way:

AFR = Lambda × 14.7

AFR represents ratio between air weight and fuel weight in the combustion chamber.

NO (*) concentration parameter is measured by the optional electrochemical transducer.

NOx parameter is calculated according to the following formula:

NOx = NO × 1.1

Eventually, after repairing or adjustments on the vehicle, executing and printing results of a new
measurement on the exhaust gases will certify the correctness of the work done.

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5. HOW TO PERFORM EXHAUST GASES TEST ACCORDING TO THE
CHINESE PROCEDURE

1. Connect the RPM probe to a HT lead of a spark plug, making sure that the spark plug symbol
printed on the inductive clamp is oriented toward the spark plug and insert the temperature probe
in the oil level dipstick housing, with its stop properly set.

2. In stand-by state, press MEASURE key when “PrOC” (Measurement Procedure) is shown on
the FUNC display, to start measurements: the automatic zeroing phase begins and the message
"PrOC CAL" is displayed.

3. The message “FUEL tyPE” is displayed, while on the HC display flashes the actual entry. Set the
proper fuel among “Petr” (Petrol), “LPG” and “MetH” (Methane) using FUNC key to toggle
between entries and PRINT to store selection.

4. The message “EnG StrO” (Engine strokes) is displayed, while on the HC display flashes the
actual entry. Set the proper strokes number between “4” and “2” using FUNC key to toggle
between entries and PRINT to store selection.

5. The message “RPM 3500” is displayed, while on the HC display a 60 seconds countdown is
shown (it is possible to skip this phase, pressing the PRINT key). Run the engine at 3500 RPM
for the displayed time.

6. The message “EXt PIPE” (Exhaust pipes) is displayed, while on the HC display is shown the
actual entry. Set the proper exhaust pipes number among “1”, “2” and “4” using FUNC key to
toggle between entries and PRINT to store selection.

7. The message “RPM 2500 Ins Prob” is displayed while on the multi-functional display is shown
the pipe where the intake probe is to be inserted: “P” (Pipe) and “x”, where x is the pipe number.
After inserting the probe in the proper pipe, run the engine at 2500 RPM.

8. The gas concentrations values are displayed for 30 seconds (for the meaning of the information
displayed please refer to par. 2.2.1). During this phase the engine rate must be kept at 2500 RPM.
The instrument periodically acquires the gas values and calculates the average during the 30 secs.
period.

9. The message “Idle” is displayed, let the engine idle.

10. The gas concentrations values are displayed for 15 seconds (for the meaning of the information
displayed please refer to par. 2.2.1). During this phase the engine rate must be kept at idle. The
instrument periodically acquires the gas values and calculates the average during the 30 secs.
period.

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11. At the end of the measuring phase the instrument automatically prints the concentration averages
just acquired and calculated. If the vehicle has more than one exhaust pipe, the measurement
procedure is repeated goes on from point 7 to 10 for each exhaust pipe. At last, the engine
parameters, date and hour of measurement are printed.

Note: During each phase of the measurement procedure, press the MEASURE key to
abort the procedure.

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6. SPECIAL FUNCTIONS

6.1. LEAK CHECK TEST

Execute this test to make sure that there are no leaks in the pneumatic system.

NOTE
Once this test is started going back to standby position is possible only if the test is
passed.

1. Starting from standby position, press FUNC key to toggle to “Lch” message on multi-functional

display then press MEASURE key to enter this function (“FUn” flashing message on multi-

functional display, “LCh” on CO display);

2. Close the end of the exhaust sampling probe with its cap and keep it close until the end of
the test;

3. Press FUNC key to begin testing;

4. While the intaking pump runs, upper displays show "LCh run" message;

5. When the pump stops, "LCh test" message is shown for the whole duration of the test (about 30
seconds);

6. If no leaks are pointed out the instrument automatically goes back to standby position and the
sampling probe can be cleared;

7. If, on the contrary, FLUX 4005 discovers a leak “LCh FAIL” message will appear on upper
displays while the flashing “FUn” message will suggest to repeat the test. The instrument will not
allow to exit this procedure until this test is passed.

After more than one failure is advisable to switch off the instrument and carefully check the external
pneumatic circuit of FLUX 4005.

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6.2. RESIDUAL HC TEST

Before measuring any gas concentration, is advisable to check if HC residues (more than 20ppm) are
still in the instrument gas intaking system.

NOTE
Once this test is started, only passing the test will allow to go back to standby
position.

To execute this test, you must take an ambient air sample through the sampling probe in the following
way:

1. Take the sampling probe out of the vehicle exhaust pipe.

2. Press FUNC key to toggle to “rES” message on multi-functional display, press MEASURE key
to start residual HC check: the instrument begins a zeroing routine during which “rES CAL"
message is shown on upper displays.

3. At the end of the routine, FLUX 4005 shows HC value on HC display and "Hi" message (high) (if
residual HC concentration is higher than 20 ppm) or "Lo" (low) (if residual HC concentration is
lower than 20 ppm) CO2 display.

4. The instrument goes on intaking ambient air for about 30 seconds.

5. If, at the end of this period, HC value is "Lo" FLUX 4005 goes back to standby position, ready to
perform new measurements, if, on the contrary, level is "Hi", test is not passed and the
instrument remains in the residual HC test routine.
It is possible to perform the test again pressing FUNC key ("Con" message is shown on O2
display), or, overseeing HC concentration reading, it may be enough to wait until value goes under 20
ppm thanks to natural loss.

If several tests in a row are not passed, you will have to check filters:

ü Remove the sampling probe hose from the instrument and blow compressed air in the direction of
the probe to clean the probe filter
ü Clean the condensate filter with water and neutral soap. Accurately rinse and blow compressed
air from the inner to the outer part of the filter
ü Replace the inlet paper filter positioned after the condensate filter

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6.3. CATALYST EFFICIENCY TEST

This test allows to check catalyst efficiency in two different ways:

- Lambda parameter calculation.

- pollutants reduction rate calculation.

Perform this test according to the following instructions:

1. From standby position, toggle to "EFF" message on multi-functional display pressing FUNC key.

2. Press MEASURE key to start this test.

3. “EFF CAL” message shows the lasting of the calibration routine.

4. At the end of the routine the multi-functional display “-A-“ message (after the catalyst).

5. Place the sampling probe in the vehicle exhaust pipe.

6. When readings are stable, press PRINT key and the instrument will store data and go to the next
measurement.

7. Multi-functional display shows “-b-“ message (before the catalyst).

8. Place the sampling probe in the sampling hole provided before the catalyst (if the hole is not
available, remove catalyst).

9. When readings are stable, press PRINT key. Now the instrument prints the test report.

Report is arranged as follows:

q First section: Lambda and AFR (Air to Fuel Ratio) parameters. Lambda value of a three-way
catalyst equipped vehicle with O2 sensor must vary between 0.97 and 1.04 (while AFR value
between 14.2 and 15.1). In such case, lambda graphic representation will be inside the "OK" area

FLUX 4005 print

PICTURE9 – LAMBDA PARAMETER

q Second section: pollutants reduction rate. Each vehicle equipped with a catalyst should perform a
pollutants reduction rate not lower than 50%. The report will show the chart of reduction rate for
CO and HC compared with the limit line of 50%.

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 PICTURE10 – POLLUTANTS REDUCTION RATE

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6.4. HOW TO SET INTERNAL REAL TIME CLOCK
FLUX 4005 has a built in RTC, which is set after assembly
.
User is able to display and set current date and hour.

This functionality is started pressing FUNC key to toggle to “dAt” message on multi-functional
display and entering the procedure pressing MEASURE key.

The following messages will be shown:

CO CO2 MEANING
Yr xx year
Mon xx month
dAy xx day
Ho xx hour
Min xx minute
End - procedure end

ü MEASURE key increases actual value

ü PRINT key decreases actual value

ü FUNC key goes to next step

After setting minutes procedure enters the final state (“End” message). Press PRINT to store data

or FUNC key to go back to setting routine.

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.

6.5. HOW TO SET RPM READING

FLUX 4005 can be equipped with different RPM probes. Each one has its own peculiarity and setting.
The inductive probe picks up the ignition secondary circuit discharge from the HT lead of a spark
plug, the low voltage probe gets the ignition signal from the ignition primary circuit or from a digital
line while the RPM COM probe is able to catch the electro-magnetic radiation emitted by the ignition
secondary circuit discharge. Whichever the probe used may be, the structure of the engine and the
quality of the electric shields applied to sparking plugs, distributors, ignition coils and wires may
require to set a corrective coefficient. For, anyway, the displayed value, before the setting, is a
multiple of the correct RPM rate, the corrective coefficient is an integer divisor.

For example, monitoring a four cylinder engine with a traditional ignition system, an idle rate of 800
RPM gives a value of 3200 RPM, before introducing the dividing factor of 4.
To set the proper corrective coefficient perform the following steps:

1. With FLUX 4005 in standby mode press FUNC key to toggle to “CIL” message on multi-
functional display, then press MEASURE key to enter the RPM setting procedure

2. “nCIL“ message flashes on CO display, while on HC display appears the RPM value obtained
using the divisor factor shown on O2 display.
3. Press MEASURE key to increase and FUNC key to decrease divisor factor

4. Press PRINT key to store the selected value.

5. A high beep points out the storing of the value and the analyzer goes back in standby mode

Coming back to the previous example, after setting 4 as divisor factor the RPM reading will be 800.

Note
RPM setting is stored by the instrument and is used until a new setting is performed

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7. MESSAGES
When the instrument notices a functioning anomaly, an error message is displayed. All possible error
messages and their meanings are reported in this section.

1. "End" message on O2 display, during measurement mode: oxygen transducer is worn-out,

replace as shown at p. 8-5

2. “no FLO” message on upper displays, during measurement mode: no flow in the intaking system.
Possible causes are:

ü the cap of the sampling probe has not been removed;

ü the sampling probe is obstructed by dirt particles;
ü the sampling probe hose if filled with condensed water;
ü the sampling probe hose is kinked or flattened;
ü filters are dirty.

3. "Err xx" message, where xx goes from 1 to 15 according to the following table:

Error code Signal out of standard on channel:

CO CO2 HC REF
1 •
2 •
3 • •
4 •
5 • •
6 • •
7 • • •
8 •
9 • •
10 • •
11 • • •
12 • •
13 • • •
14 • • •
15 • • • •

4. "Err 16" message: the gas outlet is occluded. After a few seconds, the instrument will
automatically switch the gas pump off to avoid damaging the optical bench. Switch it off and
remove the occlusion, if visible, otherwise contact the technical service.

Report the error code to technical service

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8. MAINTEINANCE

8.1. HOW TO CLEAN THE FIRST INTAKE FILTER

Refer to PICTURE11 – intake filter”, in the next page.

The intake filtering system is composed of a metal filter with 40 µm pores placed in a bowl like
housing from which condensate is pumped out and a second disposable paper filter.
Periodically inspect and clean the first filter to allow a correct gas intake. Remove and clean the filter
as described in the following instructions and blow compressed air through it to dry it up before
refitting.

Remember that a proper maintenance of the filtering system is fundamental for the analyzer life.

To clean filter proceed as follows:

ü unscrew the bowl

ü remove it
ü unscrew the cartridge bearing
ü wash the cartridge using gasoline or similar solvent or soap, accurately rinse cartridge with water
ü blow compressed air from the inside to the outside of the filter
ü refit the cartridge in its bearing and place it in its original position
ü refit the bowl

After cleaning the first filter it is advisable to substitute the paper filter. Before placing the new filter,
blow it with compressed air, in the direction of the arrow impressed on the filter, to eliminate dust and
processing residuals.

NOTE
Once the cleaning procedure is over, perform a leak check test can control pneumatic
circuit integrity.

Another disposable paper filter is provided as spare part. Please, periodically check and, if necessary,
substitute this filter.

by 8-1
40 µ m filter

bowl

PICTURE11 – INTAKE FILTER

by 8-2
8.2. CONDENSATE DRAINAGE PUMP MAINTENANCE
If condensed water is drained with difficulty (particularly after an inactivity period) the drainage pump
will have to be cleaned from dirty deposits.

Proceed as follows:

ü remove the bowl of the first filter (40 µm) (see PICTURE11);

ü fill the bowl using clean water;

ü with the instrument on, press MEASURE key to activate the pump and let it work until the bowl
is empty

ü refit the bowl

NOTE
After this procedure, a leak check test can control pneumatic circuit integrity.

8.3. PRINTER PAPER ROLL REPLACEMENT

To replace the printer paper roll unscrew the retaining screw and open the printer flap; place the new
paper roll in the printer recess and then feed the paper into the slot of the printing heads. With the
instrument in standby status, keep the PRINT key pressed (paper feed command) until the paper
starts coming out of the printer top.
Never pull the paper with your hands in order to avoid possible damage of the printing heads.

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8.4. PRINTER RIBBON CARTRIDGE REPLACEMENT

To replace the ribbon cartridge undo the retaining screw and open the printer flap; remove the old
cartridge by pressing it with your finger in the position shown in the picture below, then remove it
completely. Place the new cartridge starting from the side you have previously pushed, then press the
other side to engage the cartridge properly. It may be that the ribbon is not completely aligned with
the printing head; if so turn the small button on the cartridge in the direction indicated by the arrow
until it is properly aligned.

push Ribbon feed

PICTURE12 – PRINTER RIBBON REPLACEMENT

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8.5. OXYGEN TRANSDUCER REPLACEMENT

WARNING!
Be sure the instrument is switched off before carrying out this operation. We advise
you anyway to contact our distributor before performing this operation.

When the oxygen transducer is worn-out, the analyzer, during measurement, shows “End” message
on O2 display.
To replace the oxygen transducer proceed as follows:

ü Remove the NO/O2 cover from the rear panel.

ü Unplug the sensor connector

ü Unscrew the oxygen sensor

ü Write the replacement date on the sticker of the new transducer

ü Install the new transducer screwing it in its holder and properly plug its connector
ü Reinstall the oxygen transducer with its cover.

NOTE
Spare parts are only available through PROTECH S.p.A and distributed by authorised
dealers only.

O2 sensor
holder Rear cover
O2 sensor

Plug

PICTURE13 - OXYGEN TRANSDUCER REPLACEMENT

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8.6. NO SENSOR REPLACEMENT

WARNING!
Be sure the instrument is switched off before carrying out this operation.
We advise you anyway to contact our distributor before performing this operation.

To replace the NO transducer proceed as follows:

ü Remove the NO/O2 cover from the rear panel

ü Remove the transducer by unscrewing the screws on its cover.

ü Disconnect the electrical wires and the silicon hose.

ü Connect now the new transducer with the connector taking care of the connector polarity.

ü Refit the silicon hose.

ü Write the replacement date on the transducer.

ü Refit the transducer with its screws on the cover and make sure that the wires and the silicon hose
are correctly placed inside the instrument.
ü Refit the NO/O2 cover.

PICTURE14 - NO TRANSDUCER REPLACEMENT

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8.7. CHARCOAL FILTER REPLACEMENT

NOTE
Be sure the instrument is switched off before carrying out this operation

The charcoal filter should be changed at every periodical service calibration.

To replace the charcoal filter proceed as follows (see next page):

ü Unplug the filter from the holder on rear panel taking care of flow direction.

ü Unplug hose from the filter.

ü Write the replacement date on the new filter.

ü Refit hose on the new filter taking care of flow direction.

ü Refit the charcoal filter into the holder.

charcoal filter

NOTE
Spare parts are only available through PROTECH S.p.A and distributed by authorised
dealers only.

PICTURE15 - CHARCOAL FILTER REPLACEMENT

Note
The shape of the charcoal filter may vary depending on different supplies. Anyway,
the filter is always recognizable by its position, the inscription on rear panel and its
distinctive contents.

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9. TECHNICAL SPECIFICATION
Ranges of measurements and display resolutions:
CO: 0 to 9.99 % vol. resolution 0.01 %
CO2: 0 to 19.9 % vol. resolution 0.1 %
HC: 0 to 19990 ppm resolution 1 ppm
O2 : 0 to 25 % vol. resolution 0.01 %
NO (*): 0 to 2000 ppm resolution 1 ppm
RPM: 400 to 9990 RPM resolution 10 RPM
Oil temp : 2 to 599 °C resolution 0.1 °C

Ranges and display resolution of computed data:

CO corr. 0 to 9.99 % vol. resolution 0.01 %
AFR: 7.00 to 23.00 % vol. resolution 0.01 %
Lambda: 0.50 to 1.50 % vol. resolution 0.001 %
NOx (*): 0 to 2100 ppm resolution 1 ppm

Display: High efficiency seven segment display. LED indicator

Keyboard: 3 membrane protected keys

Printer: 24 column impact printer with optional print out

personalization

Serial interfaces: 2 RS-232 standard interfaces for connections with other

equipments

Other functions: Flow absence warning message on display.

Automatic zeroing, before each measuring procedure

Automatic condensate drainage system

RPM measurement

Oil temperature measurement

Date/hour adjustment
Leak check test procedure
HC residuals test procedure

Response time: Approx. 12 sec. (6 mt. sampling hose)

Warming up time: 5 min.

Operating temperature: 5 to 40 °C.

Storage temperature: -10 to 60 °C.

Power supply: 220-240 Vac + 10% / -15%, 45/55 Hz 100 VA

Power consumption: Approx. 100 W

Fuse: 220 Vac – 1 A - T

Dimensions and weight: 290 x 200 x 420 mm Kg. 15 approx.

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