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Bosch BEA 150 - User Manual

Bosch BEA 150
103 pages
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Repair Instructions
Bosch Emissions Analysis
BEA 150
BEA 250
BEA 350
In conjunction with Service
software for PC

Table of Contents

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Bosch BEA 150 Specifications

General IconGeneral
DisplayLCD
Operating Temperature0-50°C
Dimensions190 x 100 x 35 mm
Weight0.3 kg
Storage Temperature-20-70°C

Summary

1. Important information

1.1 Compulsory calibration

Regulations for exhaust-gas analyzer calibration and service compliance.

2. Testing equipment and settings for the Service software

2.1 Testing equipment

List of required hardware and test connectors for the service software.

2.2 Calibrating gases

Recommended calibrating gas mixtures and their specifications for calibration.

2.3 Settings for the Service software

Procedures for configuring service software settings like interface and language.

2.3.1 Setting the interface for the Service program

Procedure to configure the communication interface for the service software.

2.3.2 Service Software Language Selection

Steps to select the desired language for the service program interface.

2.3.3 Language Selection for RTM 430 Smoke Opacity Module Service Software

Process to change the language settings for the RTM 430 service software.

3. Brief description of unit functions and Servicing the unit

3.1 Exhaust-gas analyzer module

Overview of the analyzer module's measuring ranges and core functions.

3.1.1 Analyzer part (HC, CO and CO2 measurement)

Detailed explanation of the infrared measurement technique for HC, CO, and CO2.

3.2 Servicing the unit

Procedures for essential maintenance tasks performed at regular intervals.

3.2.1 Half-yearly service

Procedures for essential maintenance tasks performed every six months.

3.2.2 Yearly service

Additional maintenance tasks required for annual service by expert personnel.

4. Checking the AMM exhaust-gas analyzer module

4.1 Read operating mode

Displays the current operational status or mode of the exhaust-gas analyzer.

4.2 Leakage test

Manual procedure to check the tightness and integrity of the exhaust-gas analyzer.

4.3 Read measurement values

Displays current measured values for HC, CO, CO2, O2, and air pressure.

4.5 Write parameters

Allows setting country-specific parameters for the analyzer's operation.

4.5.1 Country-specific settings

Table detailing parameter settings for various countries and adjustment data.

4.7 Test functions

Menu for performing various diagnostic tests on the exhaust-gas analyzer module.

4.12 NO-Sensor operations

Menu for monitoring, installing, and checking the NO measuring sensor.

4.12.4 Mounting a new NO-Sensor

Procedure for installing and calibrating a new NO sensor, including connection details.

4.13 Checking opacimeter RTM 430

Guide for checking the functionality and settings of the RTM 430 opacimeter.

5. Checking the PCB and periphery of the BEA control module

5.1 Checking interfaces (DTM, RTM, AMM, OBD)

Procedures to test communication interfaces for DTM, RTM, AMM, and OBD connections.

5.5 Checking the interface for OBD external (without CAN-protocol)

Functional test of the external OBD PCB, including loop test.

5.8 Checking the hard disk (if it installed)

Procedure to test the functionality and integrity of the internal hard disk drive.

5.10 Checking the internal printer

Procedure to test the functionality of the internal printer by performing a test print.

5.14 Display test (Testing TFT display)

Tests for the TFT display, including geometry and full-screen color checks.

5.18 Checking the Foil keypad

Procedure to test the functionality of the foil keypad by pressing individual keys.

5.22 Reading out the Error list

How to access and display the last 20 stored error messages for troubleshooting.

6. Checking the engine-speed and temperature measuring module (DTM)

6.1 Checking oil temperature and engine speed in Diesel Diagnosis

Procedure to check oil temperature and engine speed for diesel engines using the DTM.

6.2 Checking oil temperature and engine speed in Petrol Diagnosis

Procedure to check oil temperature and engine speed for petrol engines using the DTM.

6.3 Checking V-lambda

Steps to perform a V-lambda voltage test using the DTM module.

6.4 Checking the ignition point and dwell angle

Guide for checking ignition timing and dwell angle using the DTM module.

7. Technical information (measuring ranges, resolution and tolerances)

7.1 Exhaust-gas analysis in petrol-driven vehicles

Technical data for exhaust gas components in petrol vehicles.

7.2 Opacity measurement

Technical specifications for opacity measurement, including measuring range and error limits.

7.3 Engine measurement system TDM+

Technical details for the TDM+ system, including temperature and RPM measurements.

8. Trouble-shooting by message number

8.1 Explanations on reference numbers

Explanation of reference numbers displayed during malfunctions and their meaning.

8.2 General messages

Common malfunction messages, their possible causes, and remedies.

8.3 Messages about boot test functions

Troubleshooting guide for error messages encountered during the boot test sequence.

8.4 Messages about software installation functions

Troubleshooting for errors related to software installation and configuration files.

8.5 Messages about printing functions

Troubleshooting common issues related to the printer functions.

8.6 Messages about hardware test functions

Solutions for errors encountered during hardware tests.

8.7 Messages about opacimeter RTM 430

Specific troubleshooting messages and remedies for the RTM 430 opacimeter.

8.9 Messages about EAM exhaust-gas analyzer module

Troubleshooting guide for messages specific to the EAM exhaust-gas analyzer module.

8.11 Reference messages on OBD printed circuit board

Error codes and remedies for the OBD printed circuit board.

8.13 Malfunction messages for testing OBD printed circuit board with KTS115 PC program

Error messages and troubleshooting steps for OBD testing using the KTS115PC program.

9. Adjustment functions

9.1 Setting the Maintenance interval

Procedure to set the interval for scheduled maintenance services in days.

9.2 Setting the calibration interval

Allows setting the interval for recalibration with calibrating gas in days.

9.3 Setting the calibration gas components

Defines which gas measuring channels require recalibration during yearly service.

9.4 Setting the calibration sequence

Defines the BEA's reaction when the calibration interval has elapsed.

9.5 Setting the leakage test interval

Configures whether a leakage test is performed at startup or at set intervals.

9.6 Setting the HC test

Enables or disables the HC residue test before each measurement.

9.7 Setting COvrai

Allows changing the setting for COvrai, prerequisite for configuration.

9.8 National regulation settings

Confirms country-specific settings for the exhaust-gas analyzer module.

9.9 Download

Procedure for downloading new software to the exhaust-gas analyzer module.

10. Repairs

10.1 Adjusting mains voltage for toroidal mains transformer

Steps to check and adjust the mains voltage for the toroidal transformer.

10.2 AC; DC voltage supply to control module PCB

Details voltage supplies to various PCBs and components, including connector pinouts.

10.3 Block circuit diagram of voltage supply

Schematic illustrating the voltage supply distribution throughout the BEA unit.

10.4 View of equipment side of control module PCB

Diagram showing the layout and connections on the control module PCB.

10.5 Visual inspection of measuring bank

Checks for external damage to the measuring bank components.

10.6 Electrical test of measuring bank

Procedures for testing the measuring bank's electrical functionality via LEDs and software.

10.7 Leak test of measuring bank

Method for performing a leak test on the measuring bank using a U-tube gauge.

10.8 Cleaning the lamp reflector

Instructions for cleaning the lamp reflector to ensure optimal performance.

10.9 Cleaning the analysis chambers and windows

Detailed steps for cleaning the internal analysis chambers and windows.

10.10 Replacing the measuring bank

Step-by-step guide for replacing the main measuring bank unit.

10.11 Install new O2 sensor

Procedure for installing and calibrating a new oxygen sensor.

10.12 Checking cross sensitivity

Test to determine the analyzer's sensitivity to water vapor contamination.

10.13 Checking the pump suction power

Method to measure and verify the suction power of the unit's pump.

10.14 Replacing the pump

Instructions for removing and installing a new pump unit.

10.15 Checking the pressure sensor

Procedure to check the pressure sensor's functionality via a leakage test.

10.17 Replacing the pressure sensor

Guide for safely replacing the pressure sensor, including torque specifications.

10.18 Replacing the water separator

Steps to replace the water separator component.

10.19 Replacing the solenoid valve

Procedure for replacing the solenoid valve.

10.20 Replacing the NO sensor

Instructions for replacing the NO sensor and recalibrating the NO channel.

10.21 Replacing the internal printer

Guide for removing and replacing the internal printer unit.

10.22 Replacing the disk drive

Procedure for replacing the unit's disk drive.

10.23 Replacing the TFT display

Steps to remove and install a new TFT display unit.

10.25 Replacing the receiver diode for the remote control

Instructions for replacing the receiver diode used for remote control functionality.

10.26 Replacing the control module PCB

Guide for removing and installing a new control module PCB.

10.27 Replacing the temperature and RPM PCB

Steps to replace the PCB responsible for temperature and RPM measurements.

10.30 Replacing the OBD circuit board

Procedure for replacing the OBD circuit board, including cover plate installation.

10.31 Replacing AWN printed circuit board

Instructions for removing and installing the AWN printed circuit board.

10.29 Replacing the power switch

Steps to replace the unit's power switch.

10.32 Replacing the battery

Guide for replacing the backup battery, recommended every three years.

10.33 Replacing the hard disk

Procedure for replacing the hard disk drive, including compatibility notes.

11. BEA test software OS9

11.1 Hard disk

Testing, identification, and formatting procedures for the BEA's hard disk drive.

11.2 Flash

Information regarding flash operations, noted as not relevant for service.

11.3 Floppy disk

Procedure to test the functionality of the floppy disk drive.

11.4 Language

Allows selection of the language for the BEA test software interface.

12. Overview

12.1 Electrical wiring (Siemens analysis chamber)

Diagram showing the electrical wiring for the Siemens analysis chamber.

12.2 Circuit diagram (Siemens analysis chamber)

Circuit diagram illustrating the electrical connections for the Siemens analysis chamber.

12.3 Wiring diagram (Siemens analysis chamber)

Detailed wiring diagram for the Siemens analysis chamber unit.

12.5 Gas circuit diagram (Siemens analysis chamber)

Schematic illustrating the gas flow and component connections in the Siemens analysis chamber.

12.7 Circuit diagram (Andros analysis chamber)

Circuit diagram detailing the electrical connections for the Andros analysis chamber.

12.8 Wiring diagram (Andros analysis chamber)

Wiring diagram showing the electrical connections for the Andros analysis chamber unit.

12.9 Hosing (Andros analysis chamber)

Diagram illustrating the pneumatic hosing connections for the Andros analysis chamber.

12.10 Gas circuit diagram (Andros analysis chamber)

Schematic of the gas flow and component connections for the Andros analysis chamber.

12.11 Overview of components

Diagram showing the arrangement and interconnections of major components within the unit.

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