AUTOMOTIVE GAS ANALYZER

KEG-500
OPERATION MANUAL

KOENG Co., Ltd. 1302, DIGITAL EMPIRE, 1130, BEOMAN-RO, GEUMCHEON-GU, SEOUL, KOREA
Tel: +82-2-838-6300 / Fax: +82-2-839-4700 / [email protected]

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 Notes for User

To use this analyzer with safety and effectiveness, please read this
manual before usage.

This manual applies to the product model KEG-500.

1. This manual should be referred with regard to the product design and
safety assurance of the configuration.

2. For the purpose of safe confirmation, this manual should be provided to

the end user at the same time with the supply of the product.

3. Please use only in well-ventilated place.

4. This product should not be washed/polished by volatile or toxic

chemical materials like thinner.

5. Please don't use the printer until the printing paper is prepared.

6. If the equipment is wiped with a piece of moistened gauze, dry the

equipment thoroughly before use. Using the monitor while it is wet may result
in an electric shock.

7. Do not clean the terminals or the AC power inlet. Otherwise, deformation or

corrosion of contacts could occur, which may result in contact failure and/or
malfunction of the equipment.

- The contents of this manual may be changed without notice for the
purpose of functional improvement.

Copyright © KOENG CO., LTD.

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 Contents

Chapter 1. Quality Guarantee Provision ................................................................ 6

1-1 Guarantee provision ........................................................................................................................ 6

1-2 Guarantee claim procedure.......................................................................................................... 6

Chapter 2. Safety Instructions .................................................................................. 7

2-1. Purpose of usage ............................................................................................................................ 7

2-2. Usage condition ............................................................................................................................... 7
2-3. Caution and warning ...................................................................................................................... 7

Chapter 3. Introduction of KEG-500 ........................................................................ 8

3-1 Specification ....................................................................................................................................... 8

3-2 Appearance ........................................................................................................................................ 9
3-3. Front view and description ........................................................................................................ 10
3-4 Rear view and description .......................................................................................................... 12
3-5 Basic accessory .............................................................................................................................. 14

Chapter 4. Circuits of KEG-500 .............................................................................. 16

4-1 Measuring principal ....................................................................................................................... 16

4-2 Guiding diagram ............................................................................................................................. 17
4-3 Electrical circuit diagram ............................................................................................................. 17

Chapter 5. Installation Methods and Notes ......................................................... 18

5-1 Installation ......................................................................................................................................... 18

5-2 Notes ................................................................................................................................................... 20

Chapter 6. Measurement Mode............................................................................... 21

6-1. Warming- Up ................................................................................................................................... 21

Power ON ....................................................................................................................................... 25
6-2. Stand-By ........................................................................................................................................... 25
Zero Calibration ............................................................................................................................. 25

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 Self Diagnosis ................................................................................................................................ 25
6-3. Purge.................................................................................................................................................. 28
6-4. Zero calibration .............................................................................................................................. 29
6-5. Measurement .................................................................................................................................. 31
6-6. Hold .................................................................................................................................................... 32
6-7. Print .................................................................................................................................................... 32

Chapter 7. Selection Mode....................................................................................... 34

7-1. Key functions .................................................................................................................................. 34

7-2. Leak test ........................................................................................................................................... 34
7-3. Remaining HC test ....................................................................................................................... 37
7-4. Selection of fuel ............................................................................................................................. 39
7-5. HCV and OCV setup.................................................................................................................... 40
7-6. PEF Indication ................................................................................................................................ 41
7-7. Program version indication........................................................................................................ 41
7-8. Time setup ....................................................................................................................................... 42
7-9. NOX setup ......................................................................................................................................... 43
7-10. Standard gas calibration .......................................................................................................... 44

Chapter 8. Fault diagnosis and troubleshooting ............................................... 51

Chapter 9. Various Expendables Maintenance .................................................. 52

9-1 Case separation diagram ............................................................................................................ 52

9-2 Probe filter ......................................................................................................................................... 53
9-3 Main filter ........................................................................................................................................... 53
9-4 Printer diagram ................................................................................................................................ 54
9-5 Set of the printing density. .......................................................................................................... 54
9-6 O2 sensor .......................................................................................................................................... 55
9-7 Dust filter ............................................................................................................................................ 56
9-8 Zero filter(Activated charcoal filter) ...................................................................................... 56
9-9 Power fuse ...................................................................................................................................... 57

Chapter 10. Parts List................................................................................................ 58

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 Chapter 1. Quality Guarantee Provision

1-1 Guarantee provision

If the product is handled according to this manual but there occurs a failure with in the
guaranteed period, it will be repaired free of charge by our company. However, the
compensation from the secondary damage and the following cases may not be guaranteed and
repaired without fee:

(1) A damage or fault, which occurs due to mishandling in use and negligence in maintenance
and keeping.
(2) A damage or fault, which originates from a change or reconstruction.
(3) When the parts and consuming materials that naturally wear out become damaged
and needed to be exchanged.
(4) A damage or fault, which originates from an environmental factor such as a fire, earthquake,
storm and flood, or other natural disasters.
(5) A damage or fault, which occurs as the designated pure part is not used.
(6) A mistaken guarantee claim procedure
(for example, absence of type or serial number).

1-2 Guarantee claim procedure

This product is not designed for outdoor installation so that

★
a damage or fault originated from the outdoor installation
Warning
may not be guaranteed.

When you issue a claim against this product in accordance with above provision, please contact
the agent where you purchased:

(1) When you get a fault: Please verify the product by referring Chapter 8. fault diagnosis and
troubleshooting.
(2) Still in bad operation: Please request a repair to the agent where you purchased.
(3) Repair after guaranteed period: After the guaranteed period, the repair cost will be charged.
(4) Repair within guaranteed period: The guaranteed period is for 12 months from the purchase
and within this period the product will be repaired in accordance with our quality guarantee
provision.
(5) For details or questions on the after service, please contact our local agent.
(6) When you contact our local agent, please inform us your product type, serial number, date of
purchasing, and fault conditions in detail.

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 Chapter 2. Safety Instructions

2-1. Purpose of usage

This analyzer is a equipment to measure the gas emission density of an automobile enabling to
diagnose the automobile status and its preventive maintenance so that it can provide a function
to prevent the air pollution in advance.

2-2. Usage condition

(1) No emitted/polluted environment.

(2) Less than 1000m in height and less than 85% in relative humidity.
(3) No direct ray of sunlight, vibration and abrupt temperature change.
(4) Well-ventilated place.
(5) It should be setup at least 25cm from the ground surface.

2-3. Caution and warning

(1) General safety requirement

This item includes some critical contents to prevent safety

★ accident and product damage so that it needs to be read
Warning through and properly understood for correct usage.

① This analyzer should be manipulated only by the trained personnel who well understood the
usage.
② A spot check or periodical check should be executed in accordance with this manual prior to
a measurement.
③ The probe should be installed in a place where not affected by a wind.
④ If there occurs a unusual case during operation, please stop the operation and contact us for
its inspection and verification.

(2) Warning

① This analyzer is designed for the use of AC110V only or AC220V only. Please verify the
power sources prior to the usage.
② The probe is so hot by emitted gas. Therefore, you need to pay high attention not to be
burned during when you insert or remove.
③ During the analysis, please do not stay long in the place to which the gas is being emitted.
④ The emitted gas normally includes the CO, which may induce a fatal damage to a human
body, so that it must be used only in well-ventilated place.

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 Chapter 3. Introduction of KEG-500

3-1 Specification

KEG – 500
CO(carbon monoxide),HC(Hexane), CO2(carbon dioxide),
Measuring item
O2(Oxygen), Lambda(air surplus rate),
AFR, NOX (optional)
Measuring CO, HC, CO2 : NDIR Method
method O2, NOx : Electrochemical Cell
Measuring range 0.00 ~ 9.99% 0 ~ 9999 ppm
Resolution CO 0.01% HC 1 ppm
Display 4 digit 7segment LED 4 or 5 digit 7segment LED
Measuring range 0.0 ~ 20.0% 0.00 ~ 25.00 %
Resolution CO2 0.1% O2 0.01 %
Display 4 digit 7segment LED 4 digit 7segment LED
Measuring range 0 ~ 2.000 0.0 ~ 99.0
Resolution Lambda 0.001 AFR 0.1
Display 4 digit 7segment LED 4 digit 7segment LED
Measuring range 0-5000 ppm
NOx
Resolution 1 ppm
(Option)
Display 4 digit 7segment LED
Repeatability Less than ±2% FS
Response time Within 10 seconds (more than 90%)
Warming up time About 2 ~ 8 minutes
Sample collecting
4 ~ 6 L/min
quantity
Power 220V AC or 110V AC ±10% 50 / 60Hz
Power consumption About 50 W
Operation
0℃ ~ 40℃
temperature
Dimensions 420 (W) × 298 (D) × 180 (H) mm
Weight About 6.9 kg

Probe, Probe hose, Spare fuse, Leak test cap,

Basic accessories Spare filter, Operation manual, Power cord,
RS232, Communication cable, Printer, Printer paper

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 3-2 Appearance

This manual is explaining mainly HOW TO USE 4GAS analyzer. 5GAS analyzer is just
added with NO sensor on 4GAS analyzer. So, for 5GAS analyzer, use this same
manual. You also can use the same manual for motorcycle which emits high density of
HC. Measuring range of the HC is 0 - 20,000 ppm and display window is specially
custom-made in order to indicate 5 digits segments, and for CO, CO2, O2, the display
window is indicating 4 digit segments as in general.

Other features such as the sequence and a series of procedures including GAS
calibration is same as those for 4GAS analyzer. So, you can use the same manuals as
well.

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 3-3. Front view and description

3-3-1 CO display window

This displays the CO density and program proceeding status.

3-3-2 HC display window

This displays the HC density and program proceeding status.

3-3-3 CO2 display window

This displays the CO2 density and program proceeding status.

3-3-4 O2 display window

This displays the O2 density and program proceeding status.

3-3-5 Lambda display window

This displays the Lambda(air over surplus rate) value and program proceeding status.

3-3-6 AFR/NOx display window

This displays the AFR, NOx, and program proceeding status.

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 HOLD
3-3-7 KEY
PRINT

Used in time of holding or printing.

3-3-8 SELECT KEY

Used in choosing a supplementary function.

3-3-9 ▼
KEY
ZERO

Used in time of correcting the datum point or moving a figure or digit.

3-3-10 ▲
KEY
PURGE

Used in time of doing a purge or executing a value increase.

ENT
3-3-11 KEY
MEAS

Used in time of measuring or approving a supplementary function.

ESC
3-3-12 KEY
STAND-BY

Used in time of returning to ready mode.

3-3-13 Internal printer case: The print paper comes out this case.

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 3-4 Rear view and description

3-4-1 CAL(Calibration)
This is a gas inflow gate used in time of standard gas adjustment.

3-4-2 INLET
This is a measuring inlet where one end of the probe mounted into this inlet in time of gas
emission measurement.

3-4-3 WATER OUTLET

This is an emitting outlet where the gas produced in the time of measuring the emitted gas
(4GAS Analyzer) and water to correct the gas is outcome.

3-4-4 MAIN FILTER

This condenses the vapor contained in the automobile emitting gas so that it prevents other
materials from incoming to inside the analyzer at the same time with the water and
measuring gas.

3-4-5 DUST FILTER

This prevents fine dusts and materials from incoming inside the analyzer in the time of
measuring.

3-4-6 ZERO FILTER

This is an activate charcoal filter to purify the analyzer cell in the time of correcting the zero
point.

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 3-4-7 GAS OUTLET
This is a emitting outlet where the emitting gas and standard gas is outcome in the time of
adding the NOx.

3-4-8 OPTION
This is a terminal to be directly connected with a normal PC printer.

3-4-9 RS232 PORT

This is a communication terminal through which a PC can operate the
program.

3-4-10 POWER SWITCH

A power on/off terminal of this analyzer.

3-4-11 FUSE BOX

A fuse terminal which will prevent a damage from external voltage overflow.

3-4-12 POWER SOCKET

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 3-5 Basic accessory

3-5-1 Basic accessory

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 3-5-2 Basic accessory lists

PART
NO. PART NAME Q'TY
NUMBER
1. PROBE QG0-M026 1PC

2. PROBE HOSE QG0-A015 1PC

3. LEAK TEST CAP QG0-A122 1PC
4. OPERATION MANUAL QG4-M071 1 COPY
5. MAIN FILTER QG0-A017 10PC

6. DUST FILTER QG0-A013 5PC

7. ZERO FILTER QG0-A014 2PC

8. PROBE FILTER QG0-A021 10PC

10. FUSE (250V 2A) QG0-E022 2PC

11. POWER CABLE QG0-E019 1PC

14. INNER PRINTER QG4-M026 1PC

PRINTER PAPER
15. QG4-A062 5PC
(ROLL TYPE)
16. COMMUNICATION CABLE QG4-E080 1PC

** As for the standard gas, we recommend you to buy it from local dealers.

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 Chapter 4. Circuits of KEG-500

4-1 Measuring principal

This analyzer is configured to perform a measurement by applying Non Dispersive Infra-Red

(NDIR) method for analyzing CO, HC, and CO2, and electrochemical method for analyzing O2
and NOx. In the NDIR analyzing method, a flashing ramp which flashes the infrared rays is
attached at the one end of the sample cell and at the other end a detecting sensor is attached
so that it can detect the component of a gas and then calculate the gas density.

<NDIR method diagram>

The electrochemical method measures the gas density by using the quantity of electron which
produced in the time of oxidation and reducing reaction of the gas.

<Electrochemical method diagram>

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 4-2 Guiding diagram

4-3 Electrical circuit diagram

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 Chapter 5. Installation Methods and Notes

5-1 Installation

5-1-1 Fit end of the probe hose into the measuring probe and the other end of the hose into the
gas inlet in the rear of the analyzer. If the fitting condition is not good and the air comes
into flow from outside, it may yield an incorrect measured value.
Therefore, please carefully verify the fitting condition before use.

5-1-2 Turn off the power switch and then connect the power cable to the power socket located
in the rear of the analyzer

※ This analyzer supports AC110V only or AC220V only.

(Please confirm the power source to use.)
Warning

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 5-1-3 Verify the fitting conditions of measuring probe filter and various filters located in the rear
of the analyzer.

5-1-4 Verify again the connection status of the analyzer and then turn on the power switch.

5-1-5 Connect the ground cable to GROUND on the rear of the analyzer.

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 5-2 Notes

▶ This analyzer is operated with AC110V only or AC220V only. Please verify the power source
before use. (Note that you can not change power source which is fixed upon supplying this
analyzer.)

▶ The following factors should be considered to properly locate the analyzer body:
━ To be setup in a place of no direct light rays, humidity, vibration and abrupt temperature
change.

━ To be setup in a indoor place where no emitted gas inflows.

━ To be setup in a height higher than 25cm from the ground.

▶ The analyzer should not be moved during the operation. It may cause an
incorrectness in the measured value.

▶ The probe should be located in a place where not affected by the wind.

▶ The probe may be so hot during the operation so that it should be carefully handled not to be
burned in insertion or removal.

▶ It needs to be noted that you should not stay in the gas emitting place during the operation.

▶ The analyzer should be used in a well-ventilated place only because the emitting gas
contains the CO and it can cause a fatal damage to a human body.

▶ This analyzer is Type-approved in accordance with the related government laws so that it is
extremely prohibited to disassemble, change, or rebuild the analyzer and also if you
disassemble the NDIR Module, you may not be guaranteed for the repair.

▶ NDIR module is the core part of the analyzer. Disassembly or assembly work is
possible only by the manufacturer's technician. In any circumstance, you or anyone
else should not attempt to disassemble it. If disassembled or re-assembled, proper
A/S is not going to be possible.

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 Chapter 6. Measurement Mode

6-1. Warming- Up

① Switch the power [ON]. KEG-500 will perform the initialization process for 10 seconds,
displaying the following.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

② KEG-500 will display current set date and time for about five seconds.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

(E.g: May 15th, 2006, PM 1 : 25)

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 ③ After displaying the current date and time, KEG-500 will perform the self-diagnosis in

the order of display window verification, communication, internal sensor, and memory

as follows. If the items diagnosed are normal, KEG-500 will display the [PASS]

message.

(Self-diagnosis execution screen)

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

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 CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

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 ④ Upon completing the self-diagnosis, the screen displays as shown in the figure below.

⑤ The warming-up will be performed while the counter-value decreases by 1 between 120 and

480. ( Perform the warming-up for 2 through 8 minutes according to the neighboring

temperature or the status of equipment use. )

Activate the pump one minute before ending the warming-up and clear up the inside of

equipment with the clean air.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

⑥ The initial calibration is automatically performed once the warming up is over.

The counter-value will decrease by 1 from 20 as shown in the figure below.

Then zero calibration will be performed for 20 seconds.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

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 ⑦ Upon completion of the zero calibration, the following messages will be indicated on the

window showing that KEG-500 is in a ready for measurement.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX
Processing
Processing
Processing
Processing

Processing
Automatic

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 6-2. Stand-By

The standby means when KEG-500 is in a non-measurement state for a long period of time. In

this state, the power is switched [ON] while the suction pump is switched [OFF].

  ESC ENT
HOLD SELECT
ZERO PURGE STAND-BY MEAS
PRINT

Press the ESC key after the measurement or the purge function. And the suction pump will

be deactivated.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

If the window displays as shown above, rdy mode(ready mode) means the stand-by state and

the sign of “gASo” means the selected fuel to calculate the Lambda value.

Please refer to 7-4 and 7-5 to fully understand.

KEG-500 has the power-saving software in it. It operates in a measurement mode and then

turns into a standby mode after 10 minutes as the pump automatically switches itself OFF.

It is also programmed to operate in a purge mode for just 10 minutes and turns to be in a

standby mode automatically.

In this manner, in short term KEG-500 will elongate life cycle of a filter exchange period and in

long term, will elongate the life cycle of pump and other parts as well.

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  

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 6-3. Purge

The [PURGE] mode indicates that the gas remaining in the sample-cell in KEG-500 is being

cleared up with a clean air from the probe.

PURGE mode of KEG-500 cleans the probe for about 120 seconds and internal sample cell for

20 seconds.

  ESC ENT
HOLD SELECT
ZERO PURGE STAND-BY MEAS
PRINT

① Press PURGE key and the following will be displayed. The probe is cleaned for

two minutes.

★ Place the employing end of probe on a clear air.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

② After the probe clearance, zero calibration is automatically performed as follows for

20 seconds, and cleaning process of sample cell starts.

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 CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

③ When zero calibration is finished, it is automatically switched to standby mode.

★Press the PURGE key one more time during the PURGE operation, and the PURGE

function is performed for 30 minutes.

After continuously using the exhaust gas of a vehicle for a long time, there may be lots of

remaining gas in the probe and sample-cell. If the HC value indicates over 10 ppm after the

zero calibration, use this function.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

This preparation process is for the next accurate measurement and for the protection of

sample-cell in the equipment. Therefore, after the continuous operation for a long time, please

clean up the inside of equipment by pressing the PURGE key.

 

6-4. Zero calibration

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 Press the PURGE key to clean the inside of KEG-500 with a clean air before pressing the

Zero key.

  ESC ENT
HOLD SELECT
ZERO PURGE STAND-BY MEAS
PRINT

① Press the ZERO key. The counter values will be decreased by 1 from 20 as shown in the

figure below during the 20-seconds process of the zero calibration.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

② After the zero calibration followed by indicated messages, KEG-500 is in a

measurement ready state.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

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  

 

6-5. Measurement

① Place the probe in the clean air to perform the [ Zero calibration ].

③ Push the probe deep into the exhaust outlet of the vehicle and measure exhaust gas by

pressing measurement key.

  ESC ENT
HOLD SELECT
ZERO PURGE STAND-BY MEAS
PRINT

※ The measurement operates for 10 minutes and the pump is automatically stopped by the
activation of the power-saving mode. Press MEAS key again to measure the exhaust gas
for more than 10 minutes.
③ Pull the probe out of the exhaust outlet of the vehicle. Then clean the inside of KEG-500 with
the clean air by pressing the PURGE key until the measurement values drop to 0.
④ If all the measurements fall close to 0, press ESC key to maintain KEG-500 in a stand-

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 by mode.
⑤ Press the ZERO key for a series of measurement. Then, repeat ②, ③, and ④.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

Example of exhaust gas measurement display

6-6. Hold
This function stops measurement screen temporarily.

This operates only in measuring state.

  ESC ENT
HOLD SELECT
ZERO PURGE STAND-BY MEAS
PRINT

If you press PRINT key once, measurement screen stops.

* If you return to measurements state, press ESC key.

6-7. Print

A function to print out the measurement result of the exhaust gas.

Analyzer's inner printer is thermal printer.

① Turn the printer on, and be ready to print.

② Press PRINT key when measuring value is stabilized.

PRINT key operates only in measurement mode.

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 ③ If the measurement board is in Hold mode, press the PRINT key one more time in the

Hold mode, and the car number registration screen is displayed as shown in the Figure above

and the figure in the highest digit blinks.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

④ Press the ▲ key, and the blinking figure increases. After adjusting the desired figure,

press the ▼ key and the figure in the next digit blinks. After registering the car number

by using the ▼ and ▲ keys, press the PRINT key. Then the print starts.

2012/12/15
PM 01:30

CAR NUMBER : 1234

----------------------------------------------------------

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 Chapter 7. Selection Mode

7-1. Key functions

Key Contents

Use the key to perform the leak test, the PEP value indication, the program

version indication, and the standard gas calibration. Press the [SELECT] key

and KEG-500 will operate as shown below.

SELECT Leak test → Remaining HC test → Used fuel → HCV / OCV

→ PEF value indication → Time set up → NOX measurement set up
→ Gas calibration → Printer set-up
Press the [SELECT] key. KEG-500 will operate according to the contents

▼ , ▲ , ESC , ENT printed on the upper side of each key.

▼ Use this key to change the setup positions.

HOLD When you stops measurement value temporarily, use it

▲ Use this key to increase the setup values.

Use this key to end the selection mode and change into a measurement
ESC
mode.

Use this key to select the present mode indicated, or to execute the number
ENT
substituted.

7-2. Leak test

A function that looks for any possible air leakage from the sample-cell in order to indicate the

result.

  ESC ENT
HOLD SELECT
ZERO PURGE STAND-BY MEAS
PRINT

① Press the SELECT key once in the stand-by mode to select the Leak Test mode.

CO HC

% ppm

CO2 O2

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 % %

AFR
Lambda
NOX

② If the message ‘Leak test’ is indicated on the indication window as shown above, mount the

leak test cap on the front side of the probe.

③Press ENT key. The pump operates and the count values decrease by 1 from 20

during 20 seconds leak test.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

④ If the test turns out normal without any leak after 20 seconds, a message is indicated

as ‘PASS”. If the leak is identified, the message is indicated as ‘FAIL’.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

(When leak test is fine)

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 CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

(When leak is identified)

⑤ KEG-500 returns to the Standby mode automatically unless other keys are pressed

within 30 seconds after the leak test.

 

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 7-3. Remaining HC test

This test measures HC element accumulated in sample extract probe line and inside this

analyzer. The function is to indicate the degree of pollution.

① Press Select key twice in standby mode.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

② Press ENT key. Perform the zero calibration for 20 seconds as shown below.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

③ As the pump starts operating, the counter value is decreased by one from 30 as shown in the

following and the remaining HC test is performed for 30 seconds. During the test, HC density

is displayed.

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 CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

④ If HC value is below 20ppm for 30 seconds, it means normal, and displays ‘PASS’.

If HC value is over 20ppm for 30 seconds, give another try from above ③.

If the result of the second try is over 20ppm, ‘FAIL’ sign is displayed.

⑤ Clean inside this analyzer by pressing the PURGE key when “Fail” is indicated because
remaining gas leaves from the end of the probe to inside this analyzer. But if “Fail“ is
indicated again after the purge mode process, please exchange various expendables filters
to have a remaining HC test again

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 7-4. Selection of fuel

This is the function that selects fuel for testing vehicle. It is used to calculate air surplus rate
(Lambda) and AFR. This analyzer can select the fuel such Gasoline, LPG, CNG, and Alcohol.
GASOLIN  LPG  CNG  ALCOHOL

① Press SELECT key three times from standby mode.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

② Selected fuel is indicated as in the above. Use ▼ , ▲ keys until it indicates the fuel to

select.

③ Press ENT key to setup the selected fuel.

④ For Example, If the “LPG” fuel is selected, the window indicates as shown in the below.

⑤ The selected fuel display will remain as set until the power supply is switched off in the

standby mode. It is programmed to display gASo (gasoline), the most commonly used fuel,

when the power supply is switched off and then on.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

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 7-5. HCV and OCV setup

This is the function that selects ratio between hydrogen and carbon (Hcv) and ratio between
oxygen and carbon (Ocv) for the fuel. This function is used to calculate Lambda value which is
defined by the ratio of actual AFR and theoretical AFR through Brettschneider formula.
Following table is for normal Hcv and Ocv, but there are cases to apply other values depending
on formulation of fuels and country to use. Once Hcv and Ocv values are setup, they are stored
in memory and are maintained even after rebooting.

① Press SELECT key four times from standby mode.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

!
CAUTION

The value of Hcv and Ocv is not possible to change. If it requires to change the value of Hcv
and Ocv due to the difference of molecular structure of the fuel, please contact those whom you
purchased the analyzer from.

Gasoline LPG CNG Alcohol

Hcv 1.8500 2.5000 3.830 3.000

Ocv 0.0000 0.0000 0.000 0.5000

AFR 14.7 15.5 16.9 9.0

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 7-6. PEF Indication

Propane Equivalency Factor (PEF) indication function indicates the figure to convert from the
propane gas into the N-Hexane. The value is the unique constant of relevant measurement cell
and should not be modified or adjusted at random. Multiple the propane density by the PEF
values to convert into the N-Hexane density.

① Press SELECT key for five times. Then, the PEF values are indicated as the

following.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

7-7. Program version indication

It is possible to indicate the version of KEG-500 with this function.

Press the SELECT key six times in the Standby mode. The program and internal sensor

version is indicated as below.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

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 7-8. Time setup

Date and time is displayed and can be set

① Press SELECT key seven times in standby mode. Then current time is displayed as

shown below.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

(E.g.: May 15th, 2006, AM 11:25)

② The values of date and time are set in the order of Year→Month→Day→
 AM/PM→Hour→Minute, and are increased or moved with the ▼ and ▲ keys.
Upon completing the setup, press the ENT key to store it.
The range of setup value is shown in the Table below.

Setup Contents

Year Increase or decrease between three years before and after the set up year.

Month Increase or decrease between Jan ~ Dec.

Day Increase or decrease by one.

AM/PM AM and PM rotates. Select one from both.

Hour Increase or decrease between 1 ~ 12 o’clock.

Minute Increase or decrease by one.

▼ Move the setup location.

▲ Increase the setup value.

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 7-9. NOX setup

It is a function selecting where to attach NO X sensor.

① Press select key for eight times in standby mode.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

(When it is set up to NOX display)

② ▲ key changes display to YES or to NO.

③ Select YES for NOX display mode, NO for non-NOX display mode, then press ENT

※ “A” is attached as shown below in the AFR(Air/fuel rate) display mode and disappears

in the NOx display mode.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

Example of exhaust gas measurement display

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 Indication of NO value on 5GAS analyzer will be as below. Measuring unit of NO value is ppm
and the measuring range of NO value is 0 - 5,000 ppm.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX
ppm

7-10. Standard gas calibration

This analyzer is supplied after accurate calibration with the standard gas (the gas authenticated
by the government-authorized organization). However, it is recommended to adjust the gas at
any time (at least once in every six months) to maintain the accuracy of this analyzer.
This analyzer is designed to prevent any the faulty calibration due to mishandling. Try to fully
understand these manuals and operate KEG-500 according to the specified procedure, for it has
a great influence on accuracy of a standard gas calibration.

7-10-1. Precautions for the standard gas calibration

① The gas used for the standard gas contains poisonous compositions and causes a fatal
damage to human body. Perform the calibration process in a well-ventilated place to
prevent any accident caused by the gas poisoning.
② If the mixed gas that has no test record or that is expired has been on use, the accuracy of
this analyzer can be seriously deteriorated. Therefore, it is recommended to use the
standard gas authenticated by the authorized organization.
③ In the NDIR type analyzer, the change of the pressure and the flow may influence the
measurement values in its principle of measurement. So, the standard gas with its pressure
and flow out of the specified range may lower the accuracy of the equipment.
④ The standard gas calibration process is complicated and may affect measurement values. It
is recommended to request the service center for the process, if possible.

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 7-10-2. Preparatory materials

Items Contents

The standard gas with the attached test record from the authorized
Standard gas
organization
Density range of the
C3H8 : 250∼3000 ppm, CO: 2.00∼6.00 %, CO2 : 10∼15 % N2 balance
standard gas
Recommended
density of the C3H8 : 2000 ppm, CO : 5.00 %, CO2 : 14 % N2 balance
standard gas
Pressure supplied 2GAS : 0.5 kgf/㎠±0.1
(Secondary 4GAS : 0.5 kgf/㎠±0.1
pressure) 5GAS : 0.7 kgf/㎠±0.1
Flow supplied 4∼5 ℓ/min
Use the device with the flow-meter, the flow adjustment valve and the
Pressure controller pressure gauge indicating both the first pressure and the secondary
pressure.

7-10-3. Connection method

7-10-3-1 Connection method by Standard gas Cylinder

① Connect the standard gas cylinder to the CAL (standard gas suction nipple) in the rear of this

analyzer main frame. Be sure to close all the gas valves of the gas tank by turning them in

the [Close] direction to cut off the gas. The standard gas is only to be injected under the

message indicated at this analyzer.

② Unwind the pressure controller counterclockwise to cut off the pressure, and open the valve

of the standard gas cylinder counterclockwise. If the first pressure falls to 10kgf/cm2 or below,

exchange the gas cylinder with a new one.

③ Return the exhaust gas analyzer to its normal measurement state.

④ Close the flow control valve and turn the control adjuster clockwise little by little to adjust the

secondary pressure to 0.5∼1.0 Kgf/㎠.

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 ⑤ Open the flow control valve little by little to control the flow to 4∼5 ℓ/min. Control the flow by

using the pressure controller because the secondary pressure may change during the

minute control of the flow.

[Figure 1]

7-10-4. Standard gas calibration






 


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 ① Set this analyzer in [STAND-BY] mode.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

② Press SELECT key nine times.

  ESC ENT
HOLD SELECT
ZERO PURGE STAND-BY MEAS
PRINT

③ The following message is indicated. KEG-500 operates according to the ▼ ,

▲ , ESC , ENT printed on the upper part of each key.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

④ Press ENT key in the above state. The [Zero calibration] starts automatically for

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 once.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

⑤ When the [Zero calibration] is completed, the values will be indicated on the
indication window as shown and the value in the first digit will blink.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

⑥ The ▲ key makes the blinking number increased. After the setup of the required
number, press ▼ key to move the blinking part to the next field. Use ▼ ,▲
keys to setup to standard gas value of gas cylinder, then press ENT key. The each value
of CO, CO2 and O2 is entered the one displayed on the gas cylinder, but the HC value is
entered the N-Hexane value which is explained in 7-6. For example, HC value = the value is
displayed on the gas cylinder (propane HC value) x PEF value.
If the HC value of the gas cylinder is 1002 ppm, multiply it by 0.5 of PEF value and the
outcome value of 501 ppm is gas calibration.

※ Adjustment of the NO value is just to input the value indicated on cylinder, then it will be

adjusted. When you do this process, you should be very careful and perform it in the area
where it has a good ventilation since NO gas is very toxic and dangerous.

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 If the NO value of the gas cylinder is 234 ppm, value of 234 ppm is gas calibration.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

⑦ Open the valve of the standard gas cylinder to spill the standard gas in a constant pressure.

If the measurement values are in a stable state, press both the ENT key and SELECT
key at the same time to start the gas calibration.

CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

⑧ If the gas calibration is successfully completed, the message [PASS] will be indicated on
each concerned window. If the gas calibration is successfully completed, the message
[PASS] will be indicated on each concerned window. When ENT key is pressed, the
calibrated values indicate on each concerned window. When ENT key is pressed one
more time, this analyzer cleans the calibration line for about 120 seconds and performs the
[Zero calibration] and returns to the standby mode.

⑨ If the gas calibration fails, the message [FAIL] is indicated on each concerned window.
Press the ENT key. KEG-500 will perform the [Zero calibration] and will return to
the standby mode.

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 CO HC

% ppm

CO2 O2

% %

AFR
Lambda
NOX

(It is succeeded in HC and CO2 calibration but failed in CO, O2 calibration.)

* If the [FAIL] is displayed, return to the standby mode and press the PURGE key to
clean the sample-cell with a clean air for two or three minutes. Then perform the gas
calibration again.

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 Chapter 8. Fault diagnosis and troubleshooting
Fault Verification Troubleshooting
Is the power cord
Connect the power cord.
Unable to power switch properly connected?
ON Replace the fuse and check the
Is the fuse cut?
cause of power overflow.
Do you finish the Wait until the rdy mode and
Warming-up? then measure again.
Do you press the Press the measurement key in
measurement key? the rdy mode.
Unable to measure Verify the connection status
Do you properly connect the
(Measuring value stays in between the probe and hose
probe to the analyzer?
"0" and does not move) (gas inlet).
Especially this could openly
Is any of probe, hose or filter happen in the winder due to
Blocked? water-icing. Verify the probes,
hoses, and filters.
COM ERR Is the input power source
Use the other power source.
(Communication error) well purified?
Flow ERR Is any of probe, hose or
Verify the probes, hoses, and filters.
(Flow error) filter blocked?
Mem ERR Is the input power
Turn off the power and reboot.
(Memory error) source well purified?
Press the purge key to clean the
Zero ERR Is remaining gas in
inside of KEG-500 with a clean air
(Zero Calibration error) the analyzer?
for about 2-3minute.
Verify again the connection
Leak Fail Are the probe and hose
status of probes, hoses, and
(Gas leakage fault) properly connected?
filters.
Screen stop Has the analyzer seriously
Turn off the power and reboot.
(unable to press Key) impacted?
Is the connection cord inside Disassemble the case of the
Prt Err
the analyzer is disconnected analyzer and then re-connect
(Printer fault)
or badly connected? the printer connection cord.
Open the printer case and then
Is it lack of printer paper?
exchange the paper.
No printer paper output
Has the paper hung up in the Open the printer case and then
printer? refill the paper.
No letter in the printer Is the ink cartridge used too
Replace the ink cartridge.
paper long and not working?

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 Chapter 9. Various Expendables Maintenance

※ Perform the maintenance basically after turning the power off.

Caution only if there is a necessity to turn the power on, turn it on.

9-1 Case separation diagram

9-1-1 Loosen five screws (four in the side and one in the rear) by using the (+) screwdriver.

9-1-2 After lifting a little the upper cover case of analyzer, pull it back for
dismounting.

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 9-2 Probe filter

9-2-1 If the probe filter contains lots of moisture or is polluted through the visible
verification, replace it.

9-2-2 How to replace the probe filter is as follows; Loosen B counterclockwise for
separation. Then replace the probe filter with new one and assemble it again
in the reverse order of disassembly.

9-3 Main filter

9-3-1 Loosen the main filter housing (A) and (B) counterclockwise.
9-3-2 Replace the first main filter and the second main filter with new ones.
9-3-3 Assemble them in the reverse order of disassembly.

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 9-4 Printer diagram

This analyzer's inner printer is thermal printing method-applying printer.

Replacement of printing paper.

9-4-1. Open the cover of the printer as shown on drawing 1.

When opening the cover of the printer, grab the handle and pull it forward as shown on
drawing. Then the cover opens.

When replacing the printing paper, make sure the correct side, as the printing paper has
pintable side.

9-4-2. Insert the paper as shown on drawing 2. If it inserted oppositely with wrong side of paper,
it won't be printed, since only one side is printable.

9-4-3. When the rubber stick of printer falls off or when replacing the rubber stick, place it with
correct direction to fit to the gear.

CAUTION : When rubber stick and printer parts is moistened or blemished, major parts of
the printer could be damaged. When moistened, dry it before use.
When blemished, clean it before use.

9-5 Set of the printing density.

9-5-1 Prt Set in the SELECT is to adjust the density of the printing letter. It is possible to adjust
the density from 0 to 399. To set the density, press the ▼ and ▲ keys in Prt Set.
Upon completing the setup, press the ENT key to store it.

9-5-2 Normal density is around 100 and depending on the printing material or how much dark
and light printing required, it could be adjusted. (At the time of delivery from factory, it is
set at 100).

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 9-5-3 To set the density too high, it could shorten the printer's life span. So mind to set not too
high.

CAUTION 1: Set Mode is generally used in winter time or very cold area since in cold
temperature the printing is usually produced light. Unless it produces very light,
it is better to keep density value at 100 in set mode.

CAUTION 2: Printing paper is thermal paper which is sensitive to the heat and bright light
such as sunlight, and when it is exposed to such circumstances, the condition of
the paper is turning to unprintable. So when keeping it in storage, store it in
black plastic bag to avoid the contact from the light.
9-6 O2 sensor

9-6-1 It is recommended to replace the O2 sensor at the 12-month cycle.

If the O2 value is severely changed over 5 %, verify the contact defect of connector and
replace the O2 sensor.

9-6-2 Turn the analyzer power off.

9-6-3 Split upper case of analyzer and dismount the O2 sensor connector.

9-6-4 Turn the O2 sensor counterclockwise for splitting.

9-6-5 After verifying that the rubber "O" ring is attached to new O2 sensor, mount it while
matching it with the screw thread.

9-6-6 Perform the mounting in the reverse order of disassembly.

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 9-7 Dust filter

9-7-1 If the dust filter contains lots of moisture or is polluted through the visible verification,
replace it.

9-7-2 Split the filter from B, and split C and D.

9-7-3 After replacing the filter with new one, re-assemble it in the reverse order of disassembly.

9-8 Zero filter(Activated charcoal filter)

9-8-1 It is recommended to replace the zero filter at the 6-month cycle.

9-8-2 Split the filter from B, and split C.

9-8-3 After replacing the filter with new one, re-assemble it in the reverse order of disassembly.

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 9-9 Power fuse

9-9-1 If the analyzer power is not turned on because the fuse is gone, replace it.

9-9-2 Turn the analyzer power off.

9-9-3 Insert the (-) screwdriver or pin to “A” part for dismounting.

9-9-4 After replacing the fuse (250V 2A), re-assemble it in the reverse order of disassembly.

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 Chapter 10. Parts List

Product number
Product name Solid diagram Remarks
Specification: W×D×H(mm)

QG0-M066
Front panel case
420×170×30

QG0-M067
Rear panel case
417×167×20

QG0-M064
Upper cover case
420×140×270

QG0-M065
Bottom case
40×20×34

Main filter QG0-M016

"L" type nipple 21×10×19

Main filter QG0-A009

housing Ø 49×94

QG0-A017
Main filter
Ø 29×33

Main filter
QG0-A019
medium rubber
Ø 22×14
membrane

QG0-A013
Dust filter
Ø 35×81

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 Product number
Product name Solid diagram Remarks
Specification: W×D×H(mm)

Activated
QG0-A014
charcoal filter
Ø 35×81
(Zero filter)

QG0-A021
Probe filter
Ø 23×82

QG0-A006
Check valve
Ø 19×43

QG0-A007
Orifice
Ø 5×6

Printer QG4-M023

Printer case QG0-M006

Printer module QG4-N011

QG4-M062
Printer paper
Ø 48×57

QG4-M070
Rubber stick
Ø 8×64

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 Product number
Product name Solid diagram Remarks
Specification: W×D×H(mm)

QG0-A022
Probe handle
Ø 39×119

QG0-M026
Probe tip
Ø 8×345

Probe
QG0-M027
(stainless steel)

Probe spring QG0-M028

QG0-A015
Probe hose
Ø 6.5×7000

Solenoid QG0-M069

supporter 39×22×9

Solenoid QG0-A002

QG0-E017
Power supply
94×119×40

QG0-E021
Power socket
30×22×49

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 Product number
Product name Solid diagram Remarks
Specification: W×D×H(mm)

QG0-E022
Fuse
(250V 2A)

QG0-E019
Power cable
0.75SQMM×3C

QG0-E002
RS232 port
53×12×15

QG0-E009
Fan
80×25×80

QG0-A001
Pump
80×70×128

QG4-E015
O2 sensor
Ø 29×41

QG4-E016
NOx sensor
Ø 29×42

O2 sensor QG0-MO60

supporter 58×37×22

NDIR module QG4-N001

(Bench) 224×74×102

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 Product number
Product name Solid diagram Remarks
Specification: W×D×H(mm)

QG4-N019
Display PCB
152×18×123

QG4-M006
T-type fitting
Ø 5×31×21

OPERATION
MANUAL

Operation manual QG4-M071

Case handle QG0-M150

Leak test cap QG0-A122

Display pad QG0-M65

Push Button PCB QG4-N020

Main filter QG0-M068

supporter 40×20×34

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 Appendix

1. Lambda (Lambda: air surplus rate) Calculation Formula

Lambda is not the value measured from the vehicle exhaust gas, but is a constant
calculated based on the Bretschineider formula that measures the density of
CO, HC, CO2 and O2 and applies the percentage of H, C, and O of vehicle gasoline.

Bretschineider formula

▶ Enter the density (%) of CO, HC, CO2, and O2.

▶ K1 : Enter constant 6 or 8 for vapor in combustion stroke.

K1 is the constant that converts the value measured by Non Dispersed InfraRed
(NDIR) into the value measured by Flame Ignite Detect (FID) and meets the
specification of 4 gas analyzer manufacturer.

▶Hcv : Rate of C(carbon) to H(hydrogen) of the fuel

▶Ocv : Rate of C(carbon) to O(oxygen) of the fuel

Lambda is the value calculated based on the density of CO, HC, CO2, O2 of
gasoline gas and percentage of gasoline (C8H18) elements. Therefore,
measuring 4 gases accurately is prerequisite to the Lambda calculation.

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