Leak Detector Technology
It's not always easy to find a leak in an air conditioning system, but leak detector technology and products are constantly improving, and at least one industry leader feels even better products will be forthcoming in the near future.

There are three basic technologies in use today for leak detection:

• Corona Discharge,
• Heated Diode and
• Ultra Violet (UV).

The most common and fairly inexpensive method of leak detection is the Corona Discharge method, which uses an electric current to detect leaks. Anytime something crosses that current and breaks the current it sounds an alarm, thus detecting the leak. This technology is relatively inexpensive and can be reliable depending on the conditions under which it is used. The price to the end user for this technology is usually in the $150 to $200 range. The drawback to this technology is that it can give false readings.

Heated Diode technology is more refrigerant sensitive. This technology uses a sensor that is looking for a specific type of component of refrigerant to set off an alarm. A pump is required to draw in the substance and because it is controlled by heat there is a certain amount of time required for warm-up. Among advantages of this technology, it is more accurate and more refrigerant specific. Among disadvantages, the user level cost ranges from $450 to $500 and there is additional time required for warm-up.

The Ultra Violet light method for detecting leaks requires a special lamp designed for using ultra violet or black light that is looking for an oil-based dye that is highly active when the light shines on the dye. The dye is a compressor oil-based dye that is injected into an air conditioning system and circulated through the system via operation. If a leak is present, the dye will mist through at that point. Among advantages of this type of leak detection are even hard-to-find leaks will be noticeable and the dependability is better (there is no highly sophisticated technology to break down). Among disadvantages, injecting the dye can be sloppy and create false leak impressions, and not all the Original Equipment Manufacturers (OEMs) have approved the leak-detecting dyes for use with their components. The user price will vary from $300 to $400, depending on the type of kit purchased. Replacement dyes must also be purchased as needed because they are a disposable item.

David Gentit, product manager for the SPX Corporation's Robinair Division, which is headquartered in Montpelier, Ohio, says his firm offers two of the three technologies discussed above. According to Gentit, Robinair's 16500 halogen leak detector that uses the Corona Discharge method for leak detection and its "Tracker" UV leak detection system offer the most advanced formulas and features that you will find on the market today. Robinair is constantly pursuing new technologies in this field, says Gentit, and is confident it will have something new in the near future.

Says Gentit: "If you asked the industry today what the top priority would be to improve the service of air conditioning systems in the automotive industry, a better method of leak detection would probably be on everyone's top-three list. Many technicians today have more than one method of leak detection and many have several models of the same method of leak detection. The reason is that none of the available technologies are 100 percent accurate 100 percent of the time. I believe that in the very near future there will be a product or products available that will be far superior to all of the methods currently in use. The market is asking for this and with today's technological advances it will be accomplished."

Standard Motor Products' Four Seasons Division, headquartered in Coppel, Texas, offers the "Professional Flourescent A/C Leak Detection Kit," which utilizes UV light and flourescent dyes to detect leaks.

Spectronics Corporation's Tracer Products Division, which is headquartered in Westbury, N.Y., offers a device it says will add fluorescent leak detection dyes into automotive air conditioning and refrigeration systems with only one hookup. Tracer says its Tracerline¬ EZ-Ject» multi-dose dye injection system adds a precise amount of dye into an air conditioning system with a simple turn of a handle. According to company officials, there is nothing to measure, pour or spill, no hoses to repurge or evacuate, and no refrigerant required to add the dye.

Refrigerant equipment
Neutronics Inc., Exton, Pa., released the first and only automatic air-purge tool for air-conditioning (A/C) systems and cylinders at the 1998 MACS Convention & Trade Show in Orlando, Fla., according to Joy Hlavacek Mossholder, Neutronics' marketing manager. The Air-Radicator will automatically purge or "burp" the air from an A/C system or bulk refrigerant storage cylinder without having to evacuate the refrigerant first. This tool will only purge air from pure (98 percent +) R-12 or R-134a.

The technology is basically the same, and is covered under the same U.S. patent number, as the Neutronics Refrigerant Identifier's technology, according to Mossholder. The instrument uses non-dispersive infrared to measure the gases within a system or cylinder. The software that the Air-Radicator uses, however, is different (trade secret). Neutronics was able to take the same technology currently used in more than 20,000 of its refrigerant identifiers and find a promising new application, purging air.

Never before has an automotive technician been able to resolve the problem of excess air in an A/C system or cylinder without using a recovery/recycling machine, she said. Gary Halpern, Neutronics' vice president, sales and marketing, said, "The value of this tool is immeasurable in both the time saved by a technician and the money saved from not having to tie up a recovery/recycling machine."

"The typical evacuation of a 32-ounce system [approximate size of a vehicle's A/C system], along with an air purge using the recovery/recycling machine, can take a minimum of 45 minutes," said Halpern. "That's why we are so excited about this product. It's the first time we can sell the immediate financial benefits of a product - where time saved truly equals money saved!"

Halpern estimates that the average purge using the Air-Radicator will take three minutes, a time-savings of over 40 minutes. Use the Air-Radicator just five times and the tool pays for itself. According to Mossholder, traditionally to purge the air from an A/C system, a technician must first identify what type of refrigerant is in a vehicle, then completely evacuate the A/C system of all refrigerant by using a recovery/recycling machine. The storage cylinder attached to the recovery/recycling machine which contains that refrigerant must then temperature stabilize; this process can take from 30 minutes to a day depending on ambient conditions. Once the stabilization has occurred, the technician must manually open a valve to release the air then recheck the pressure of the gas to determine if there is any air remaining in the cylinder. This method is referred to as the pressure/temperature method and can take hours to complete.

Existing technology in the air conditioning market will typically utilize temperature and pressure measurements to determine air purge need and control, according to Mossholder. Errors inherent in this technology are due to the difficulties of accurately measuring liquid refrigerant temperature and vapor refrigerant pressure at all times during the purging procedure. With the Air-Radicator, purging of air is achieved through a direct measurement and is not dependent upon pressure or temperature measurements.

Another form of technology currently used in the air conditioning market is the use of an air detection instrument which is an "oxygen sensor" based analyzer. The use of an oxygen sensor in this type of application can lead to inaccurate air readings due to the reaction of certain refrigerants with the "chemistry" of the oxygen sensor. The oxygen sensor is an electrochemical fuel cell which, over time, will lose its ability to provide accurate readings and will need to be replaced - very similar to the technology used in an alkaline battery. Finally, this oxygen sensor based analyzer can only test for air directly from an A/C system but is unable to purge it.

With Neutronics' product, the cooling of refrigerant during venting does not affect the instrument's performance. In fact, the Air-Radicator is not affected by temperature of the source refrigerant in any manner. Purging procedures can begin at any time and no time period is required for the refrigerant storage vessel to come to a temperature equilibrium. All purging procedures are automatically performed by the Air-Radicator, removing the chance for human error.

Snap-on Tools Company has incorporated the Air-Radicator technology into its new Deluxe Refrigerant Identifier, the only portable refrigerant identifier available that combines advanced refrigerant contaminate measurement technology with an automatic air-purge capability to remove air from pure R-12 and R-134a refrigerants.

Snap-on's new identifier has four infrared sensors capable of identifying trace amounts of contaminants and assures 98 percent purity of R-12 and R-134a refrigerants, and automatically purges air from systems and cylinders in minutes without the use of recovery and recycling equipment.

Robinair has also incorporated infrared optical technology, created by Texas Instruments, into its new PrismPro Series of identifiers. PrismPro's optics analyze the refrigerant sample and compare it to programmed ranges for R-12, R-134a, and two alternative blends - FRIGC and Freeze 12.

PrismPro Series identifiers display a refrigerant type when the refrigerant is identified only if it's pure enough to recover or recharge. For the PrismPro, the refrigerant must be at least 90 percent R-12 or R-134a to be displayed. For the PrismPro-OE, the refrigerant must be at least 98 percent R-12, R-134a, FRIGC or Freeze 12. On both PrismPro units, anything less pure will be identified as "unknown."

Color Matching Tools
With the evolution of increasingly complex paint systems, it is sometimes impossible for a person to match color exactly. Today's color matching tools are keeping pace with the paint systems and are now at the point where the electronic eye, in the form of the spectrophotometer, has virtually replaced the human eye.

"In the past, color matching was left to the experience and eye of the painter. But with the continuous changes in automotive color trends such as the use of micas, pearls, tri-coats and tinted clearcoats, it's no longer practical to attempt to match color by the seat of your pants," said Jim Rees, the vice president of sales for Sherwin-Williams Automotive Finishes Corp.

Bill Mays, the director of sales at NAPA/Martin-Senour Automotive Finishes agrees, saying, "In my opinion, the refinishing business has become too sophisticated for body shops to think in terms of spraying test panels to get a color match. No matter how good your eye is, it's a subjective process - a process that has room for error which inevitably leads to a waste of time and money.

"Clearly, the sophisticated refinishes of today need an equally sophisticated means to measure and identify color," Mays said.

The computer spectrophotometer is sophisticated enough to "see" color in its exact state. However, the earliest models have not been portable and many are not easy to use. Sherwin-Williams has introduced the Color Eye, a five-pound computer housed in a "gun" that you hold against the car to get an accurate color formula in less than a minute.

"Being a stand-alone unit means the user doesn't have to download the color reading into a desktop computer to retrieve the color formula. The correct formula is quickly displayed on the Color Eye's LCD panel," Rees said. "The time savings and accuracy result in increased productivity and cost reduction and are an immediate benefit for body shops and jobbers who use it."

NAPA/Martin-Senour's Color Dominator is designed for precise color measurement of all automotive finishes. The unit is capable of capturing the "deep flop" that is so critical in matching many of today's finishes, Mays said.

According to Mays, other technological advancements incorporated into the Color Dominator include three pressure sensors which allow for accurate measurement on all sections of a car - curved or flat; 100,000 watt xenon illumination for accurate measurement in any lighting condition; and sensors that will automatically request recalibration if required.

"Just about anyone can use the unit. It simply has to be pressed against a car's surface with one hand and steadied by the other to provide accurate color measurements in less than one minute," Mays said.

Last year, Akzo Nobel introduced Mixit2, a computerized color formula retrieval system that runs on Windows 95 software. Mixit2 offers its user the ability to track costs, VOC content and inventory right at the scale, which helps save money and streamlines inventory, said Lisa Boughner, public relations representative for Akzo Nobel.

Painters can queue mixing jobs in the morning and mix all jobs at once, Boughner said. Mixit2 features more than 40,000 colors, including fleet and competitor formulas; it recalculates for tinting and overpour/underpour, making it faster and easier to get the perfect match - without wasting paint; and it saves custom colors to enable exact future matches.

Motor Oils
While automobiles themselves are becoming more technologically advanced with improved mechanical components, the enhancements made to vital automotive fluids - such as motor oil - are also helping to ensure more efficient, longer lasting engines.

One of the recent advancements in motor oil technology relates to the further refining of conventional base oils by removing virtually all contaminants and impurities. Progress has also been made with synthetic blends, which are formulated from combinations of conventional and synthetic base oils.

Pennzoil Products Company's Multiviscosity Motor Oil is blended with PureBase, a new proprietary base oil. "Pennzoil is the only motor oil to use this ultra-pure base oil in all of its multiviscosity motor oils," Courtneye B. Wolf, coordinator of marketing communications for Pennzoil, said.

Base oil, the primary ingredient in engine oils, is refined from crude oil through a series of separation and purification processes. One of the most important steps performed during refining, according to Wolf, is increasing the base oil's stability. In a refinery, base oils are stabilized by processes that increase the degree of saturation and remove sulfur and nitrogen compounds. There are two major stabilization processes currently in use today: solvent extraction and hydrocracking.

Solvent extraction is an older, less effective process than hydrocracking, Wolf said. "This process involves mixing the oil with a special solvent that is not soluble in the oil, but does dissolve some of the contaminants and impurities common to all crude oil: namely, unsaturated nitrogen and sulfur compounds. The major drawback has been that the solvent extraction process only partially removes contaminants and impurities. Typically, about 78 percent of the resulting oil is pure, while the remaining 22 percent is composed of contaminants and impurities."

The process used to manufacture PureBase, hydrocracking, involves heating the crude oil to more than 700 degrees Fahrenheit in the presence of 3000 psi of hydrogen gas and a catalyst. Hydrocracking removes sulfur and nitrogen, opens carbon rings into straight chains and saturates the oil. The result is a base oil that is 97 percent pure, with virtually all contaminants and impurities removed, according to Wolf. The PureBase is then blended with Pennzoil's proprietary Z-7 additive package to make Pennzoil Motor Oil. Since PureBase is virtually free of contaminants, said Wolf, the additives are more effective because they are not depleted by contaminants and impurities found in conventional base oil.

Semi-synthetic motor oils (synthetic blends) represent the next significant improvement in motor oil, according to Valvoline. Conventional oils, lubricate moving metal parts, hold contaminants from the combustion process in check and disperse heat. Valvoline contends that synthetics, which are man-made, do an even better job by increasing horsepower and fuel economy through reduced friction; they also reduce wear by flowing better when an engine is first started.

Synthetic blends combine the best of both worlds, according to Valvoline, whose synthetic blend DuraBlend has many of the benefits of full synthetics but costs roughly 40 percent less per quart. Introduced in 1994, DuraBlend is formulated with a combination of conventional and advanced formula synthetic base oils. It is available in several grades, including 5w30, 10w30, 10w40, 15w40 and 20w50.

Texaco has its Havoline Formula3 Synthetic Blend SAE 10W-30, which it recommends for engines operated under conditions expected to generate high engine oil temperatures or for engines operated under extremely low ambient temperature conditions.

Some car models already require the use of synthetic blend motor oils, and Valvoline predicts that more models will need semi-synthetics as the years progress.

Welding Equipment
Welding technology has improved for small tungsten inert gas (TIG) welding power sources and for plasma cutting machines. Significant improvements have also been made with squeeze-type resistance spot welders.

The Lincoln Electric Company's Square Wave TIG 175 features Lincoln's patented Square Wave Technology, which controls the waveform and enables users to produce a more superior weld, according to Lorilynn Valderrama, account executive with Lincoln's public relations company, Robert Falls & Co. PR. "The unit also offers lower amperages capabilities (down to 12 amps) for welding on the lightweight materials found in the automotive industry."

Another of Lincoln's new machines, the Pro-Cut 55, is a versatile plasma cutting machine that can cut materials up to three-fourths of an inch thick quickly and easily. Its PCT 80 plasma torch operates without high frequency and incorporates new technology that virtually eliminates any operating delay when the trigger is depressed or the arc is re-ignited after the torch leaves the plate, according to Valderrama, which means no waiting for the end user. The arc is able to re-ignite within 50 milliseconds. No other torch operating without high frequency can match this capability, she said.

Dual Winding technology provides for a cutting arc that transfers quickly and forcefully to the work piece, she said. This means that the Pro-Cut 55 has the smoothest, easiest starting plasma cutting arc in the industry to get through the plate sooner and with less dross buildup.

The Pro-Cut 55's "cousin" product, the Pro-Cut 20, offers cutting ability for plate up to one-fourth of an inch and weighs only 19.8 pounds. New VORTECH technology consumables in both the Pro-Cut 55 and Pro-Cut 20 generate tight cutting arcs which yield excellent cutting speeds, low dross levels, unparalleled ease of use and extended consumable life, according to Valderrama.

Squeeze-type resistance spot welding has been used by the car manufacturers since 1940 as a technique for welding sheet metal, according to Lennart Naslund, president of Data Welder, Saratoga, Calif. He added that only 2 percent of body shops in North America use this type of welder while 80 percent of body shops in Europe and Japan use electric spot welders.

"The spot welding equipment of today is not to be confused with the old panel spotters of yesteryear," according to Naslund. "The new welders run off three-phase electricity and have much more amperage. The current is converted from an amplified current to a direct current. The most powerful welder today can run 20,000 amps."

Naslund said that besides the higher power, there are three more functions that set aside the modern spot welder from the other makes:

• Built-in sensors - There is a direct current circuit that is critical for welding through painted surface. This circuit indicates when the proper current passes through the welding tips and will start the main current and weld for the set time. This means the welding time will be the same for each weld despite what it will take for the hot tips to melt through the non-conductive primer.
• Soft start and pre-heating function - The latest improvements are the soft start and pre-heating function or "slope function." The welding cycle includes a 0.3 second pre-heating pulse with 50 percent of maximum current and the regular 0.5-0.7 second welding pulse with 100 percent of current set. This function will prevent heavy sparks and possibly burn-throughs. It will weld 100 percent penetration every time and easily weld through primer without any grinding between the panels. This function is specially designed for collision repair shops where there is welding of electro-zinc coated replacement panels or painted surfaces.
• Overheat shut off system - To prevent damage of the transformer from overheating, there is a built-in shut off system. The most common cause of overheating is allowing the tip diameter to be too large before dressing them down. The tips should be around one-fourth of an inch (6 mm) in diameter.

Naslund said shops should use modern spot welders because technicians can now spot weld through the e-coating between the panels, keeping the lifetime corrosion protection intact; the zinc coating seals around the welding nugget in between the panels and the zinc form brass together with the copper electrode on the outside spot surfaces. He also said, "Repairers can now produce a pre-accident factory-type weld with far less hazardous fumes than MIG welding."

He added that spot welding is four-to-five times faster than MIG welding.

Electronic Repair Information
Mitchell Repair Information Company recently announced that its automotive repair information system, ON-DEMAND, will be available June 1 on a single Digital Versatile Disc (DVD). It will be the first industry information system available on the DVD medium.

"DVD represents the ultimate in convenience for ON-DEMAND customers," said David Peterson, Mitchell Repair senior vice president of marketing. This new technology will enable technicians to access repair data faster than is currently possible. Because all the information fits on one disc, DVD eliminates the need for service professionals to swap discs when accessing repair information.

Peterson said the new DVD technology will save shops "a significant amount of time on each repair by being able to access the data faster than ever before."

A DVD has more than 10 times the capacity of a CD-ROM disc. Shops that choose the DVD option will need a DVD drive, which is similar in size and appearance to a CD-ROM drive.

Mitchell's release of the DVD option will coincide with their release of ON-DEMAND 4.

CCI/Triad recently introduced RepairSource as a companion electronic repair reference to be used in conjunction with their ServiceExpert product.

ServiceExpert, introduced three years ago, is a shop management system that allows shops to generate estimates, work orders and invoices electronically.

This Windows software product provides parts and labor information for virtually all makes of vehicles, enabling the user to not only generate estimates, but to also access vehicle and customer histories, manage inventory and order parts electronically.

The new RepairSource provides technicians with diagnosis, repair and maintenance information. The electronic database includes thousands of technical service bulletins; NHTSA and EPA recall notices; maintenance service schedules for 2,500 vehicles; diagrams of parts and part locations; subsystem wiring diagrams; and worksheets and checklists for diagnosing and fixing driveability problems.

Alexander Sherwood, CCI/Triad's product marketing director, said using ServiceExpert and RepairSource in tandem helps foster good customer relations.

"When the customer comes into a shop, he or she can describe the problematic symptoms to the technician. The technician, then, can access RepairSource for the technical service bulletin which will outline both the problem and how to fix it," Sherwood said.

Once the diagnosis is complete, the technician can look up the repair procedure in RepairSource, and then access ServiceExpert to look up parts and labor hours necessary to make the repair. Lastly, the shop can print an estimate for the customer and work order for the technician.

"By using these two products together, the shop owner or technician can build credibility with the customer. Because RepairSource describes every step involved in making the repair, it is beneficial for showing customers why a repair that they believe should be simple is sometimes very complex and costly," Sherwood said. "And, customers who can walk away with a detailed computer-generated printout of a repair procedure will feel better about the work and spending the money than they would with an abbreviated hand-written description."

Any information that helps the customer understand what's required to ensure a quality repair likely helps improve relations between the shop and consumer.

Diagnostic Tools
As vehicles are becoming increasingly more electronically sophisticated, diagnostic tools are incorporating new technology to make them faster, more powerful and with expanded capabilities.

Fluke Corporation has a number of new technology offerings for the automotive technician, according to Corey Glassman, national accounts manager, Automotive Products Division, Fluke. The new Fluke 87 Series III has a much larger display and better internal electrical shielding, he said.

"But the best part is an increase in glitch detect speed; four times faster than the older 87 (1 millisecond), it is now 250 microseconds," said Glassman.

The Fluke 98 Series II Automotive ScopeMeter is one of the most powerful diagnostic tools available, according to Glassman. "We have just released a new version of operating firmware, making the 98 even faster and more powerful."

OTC's Perception hand-held, two-channel lab scope/multimeter is designed to keep pace with changes in technology and vehicle systems, according to Robert Remker, manager, sales and development training, OTC.

With the Perception, technicians can easily capture elusive "glitches" that occur. Recognizing the difference between normal and unusual signal patters, the OTC Perception will store and save the data for detailed analysis and repair. In addition, the Perception has a vehicle-specific database holding information about almost every domestic and imported vehicle on the road.

Accessing the database allows the technician to review wiring diagrams with wire colors, function and pin numbers. The OTC Perception permits testing and comparing two signals simultaneously. The split screen function displays any two modes at once: multimeter and graph, graph and scope, or scope and multimeter. Updates will be available over the Internet from the OTC Bulletin Board.

The Fluke DIS90 is a distributorless ignition parade adapter that allows a display of all ignition patterns at the same time. The adapter has been specially designed to work with the Fluke 98-2 for finding problems on the road or in the bay. This adapter works extremely well to find intermittents and defective ignition components.

OTC's hand-held ABS Reader is the first and only tool on the market with GM-approved software to offer bi-directional control on Delco VI and III anti-lock braking systems, according to Remker. It also offers data stream troubleshooting capabilities on other systems such as Bosch, Teves and MECS used on Ford and GM vehicles and several imports. Coverage of Chrysler systems will be available later in 1998.

OTC's Accuracy hand-held battery tester gives users the "charge it up or junk it" answer in barely 17 seconds, even on batteries down to as low as one volt. A dual load tester, Accuracy features unique technology for which a patent has been applied, according to Remker. "A major battery manufacturer ran evaluation tests on the unit, knowing ahead of time the condition of each battery in the testing program. The Accuracy lived up to its name, scoring a 99 percent accuracy rating. Capable of testing both 6 volt and 12 volt automotive and marine (deep cycle) batteries, Accuracy has a test range of 50 to 2,000 cold cranking amps, 1.0 to 14 volts."

Some of the enhancements made to automotive diagnostic tools come from technological improvements made in other industries. "Fluke's products are developed for a wide range of applications in the calibration, networks and electrical markets," said Glassman. "Technology developed for these other markets is used to enhance all of Fluke's automotive products."

Glassman said, "Vehicles are incorporating more electronics than ever before. Test equipment requires greater sophistication than previous years to enable complete and accurate diagnosis. The end user pays less with our products for incorporation of this new technology due to the synergy of development."

Air Supply and Tools
One of the newest introductions in air supply products is SAS Safety Corporation's Pure-Air 2000, a belt mounted breathing air filtration unit that provides both monitored, purified Grade D breathing air and shop air for spray equipment from one single inlet air source.

When used with approved SAS Safety respirators, the Pure-Air 2000 meets OSHA requirements for supplying Grade D air, said Ken Watson, vice president of SAS. "One of the most beneficial attributes of this new product is that it eliminates the need for a painter to drag around two hoses. Air for both breathing and shop air are delivered by the same hose."

A single replaceable filter that utilizes a carbon based filtration process purifies shop air for breathing, providing protection against organic vapors and gases with acidic and basic chemical properties, including carbon dioxide, chlorine, hydrogen chloride, sulfur dioxide and others, Watson said. Additionally, the Pure-Air 2000 has an optional carbon monoxide (CO) monitor that alerts its user of dangerous CO levels.

Kaeser Compressors Inc. recently introduced a "complete and compact" compressed air system that includes its Kaeser Sigma Rotary Screw Compressor, Refrigerated Air Dryer and optional Filter Package mounted on a horizontal receiver tank.

"The KRD-Series CFC-free refrigerated dryer delivers a consistent pressure dew point as low as 35 degrees Fahrenheit to deliver the dry air you need," said Kaeser's Harold Wagner. "The package can be customized with filters that remove particles as small as .01 micron, oil aerosols and even oily smell or taste from the compressed air."

The units deliver 20 percent more air per horsepower than previous Kaeser compressors and, Wagner said, the only steps required to have a fully operational compressed air system is to simply connect their new compressors to the power source and the air line.

Kaeser has also just introduced new filters that offer improved performance. "Contaminated compressed air systems increase operating costs by robbing the air system of useful power," Wagner said. "This results in reduced efficiency and higher maintenance and repair costs."

The new filters are designed with housings that have larger flow areas to ensure low pressure drop and to provide easy installation, operation and maintenance. For the shop, Wagner said, that results in consistent air quality with minimal operating costs.

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