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1. ASSEMBLAD S r l Costruzioni Elettroniche Sampling SMOKE METER Model OPA 391 and OPA 391 HF Model OPA 391 HD and OPA 391 HDF Model OPA 391 and OPA 391 HF Model OPA 391 HD and OPA 391 HDF USER MANUAL Edition November 2008 Rev V 4 40 ASSEMBLAD Technical office Automotive Division Assemblad s r l OPA 391seies User Manual Marte C anno2008 Manuali Opacim M 391GB 44_01 2008 doc ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual Note ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual TABLE OF CONTENTS LINTRUDODBUCTION cca 6 LISMORE METER FRONT PANT RR OT 7 LISMUREMETER BACK PANEL s a aetati iii i li 8 2ZIEGCHNICAL FEATURES gui 9 21 PHOTODETECTOR TECHNIK AL FEATURES siii iraniana itid 9 22 MEASURING CHAMBER TECHNICAL FEATURES uiid iei ipii atra iii 9 2 5 ELECTRONIC STRUCTURAL FEATURES citt au ao iii a 9 TATON RA a TOTO 10 2a SUPPLEMENTARY PUNC TION oaa 10 LUDITHBERPEATUERES aiiud aaa a creda 10 dI Ere Fh alia MIC 10 SREY PAD AND LEDS oanad iiiad aim ian ini eine 11 4 INFRARED REMOTE CONTROL siii ite e btk ien bar or Mp Ub FEE aa 15 S STARTI
2. For more detailed informations please read the chapter Warranty The smoke meter does its smoke measurements through the sampling method and the measuring chamber is of the specular reflection type The equipment performs measures in conformity with the Italian Ministerial Decree of law n 628 of 23 10 1996 and following modifications as Circular n 88 95 of 6 9 1999 mode L1 and measures in conformity with the Directive 1999 52 CE take in with D M of 7 8 2000 and Circular 6902 604 of 4 8 2000 mode L2 The smokemeter is able to use the communication protocol defined in the technical specification MCTCNET revision 1 0 of 23 06 1999 The smokemeter meets CUNA NC 005 11 standards This manual contains procedures to be performed by both the final user and the technician which is doing service on the equipment Procedures labeled with Must not be undertaken by the final user Note This simbol means that feature or operation which refers to is activated only in OPA 391 HF and OPA 391 HDF but not on other Models of the Smoke meter ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 6 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual 1 1 SMOKE METER FRONT PANEL 1 Smoke value display shows the SMOKE values of the vehicle exhaust gases expressed as percentage from 00 0 to 99 9 and in K from 0 00
3. When the ON LED is lit press the ON OFF key The smoke meter will now switch on and go through a series of selftest and setting procedures automatically The self test series consists of several steps you can see the following ones a All the displays will read 8 All the LEDs are lit b The displays will all read zero except for N TEST that will read 1 The ON CONT C LEDS will remain lit the printer will start a message c The N TEST display will read 2 The two other displays will blink on zero the printer will stop d All the displays will read zero The printer will complete its message e The display will show the chamber temperature if below 45 The smoke display will show a value around zero oscillating by a few units The initial oscillation is due to the intrinsic stabilization of the filament and will continue for a few minutes after the device is turned on Select the unit of measure K key ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 16 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual Select the measurement mode using the MODE key CONT is the default Press the ZERO key to clear the smoke values from the display The display will blink during the automatic clearing phase Clearing may not work the first time therefore repeat the procedure until you get zero the val
4. Alternatively run the installation batch typing A install lt ENTER gt After the installation run the program typing A391 lt ENTER gt from the DOS prompt The menu below described will appear The menu contains all operation you can do on the smoke meter At the top rightmost side the current PC s date and time is displayed Through the up down arrows choose the operation you need to do then press the ENTER key In the last row of the screen you could see a brief description of the currently selected operation The operation displayed in reverse will be undertaken Before starting with any operation with the smoke meter please check if the serial port of your computer is properly configured in A391 In order to do so type the F6 key and the current working parameters will be displayed In particular check if the right COMx port is selected and the working communication parameters are ok The default parameters are the following 8 bit no parity 9600 Baud for software versions higher than or equal to 2 00 ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 37 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual OPA 391 HF SMOKE METER Periodic maintenance utility ASSEMBLAD 15 01 99 19 29 Factory setting data display Workshop customization Customization data displaying Date amp Time setting Current smokem
5. Windows default printer Once the test is finished it s possible to print more than one report until a new test start ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 29 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual 8 MAINTENANCE 8 1 CLEANING THE MEASURING CHAMBER To clean the measuring chamber proceed as follows 1 Switch off the smoke meter and disconnect it from all power supplies 2 Open the hinged cover on top of the smoke meter 3 Remove the cover from the measuring chamber 4 Moisten a piece of cotton with denatured alcohol and clean the mirror 1 and the two glass plates 2 on the photoelectric cell 5 We do not recommend using compressed air to clean the chamber However sometimes it may be necessary to blow some air to remove soot Pressure leaving the gun should never exceed 2 3 bar HIGHER PRESSURES CAN CAUSE PERMANENT DAMAGE TO THE DIFFERENTIAL PRESSURE SENSOR ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 30 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual 8 2 PRINTER To test the printer proceed as follows with the smoke meter switched off press the FEED KEY while keeping it pressed switch on the smoke meter using the ON OFF key The printer will send a mes
6. 10 APPENDIX CONVERSION TABLE smoke readings expressed in percentages and absorption factor k m 1 05 0 10 0 15 0 20 0 25 0 30 0 31 0 32 0 33 0 34 0 35 0 36 0 37 0 38 0 39 0 40 0 41 0 42 0 43 0 Conversion K In 1 N 100 L K 1 m 0 13 0 26 0 41 0 55 0 71 0 89 0 93 0 96 1 00 1 03 1 07 1 11 1 15 1 19 1 23 1 28 1 31 1 36 1 40 44 0 45 0 46 0 47 0 48 0 49 0 50 0 51 0 52 0 53 0 54 0 55 0 56 0 57 0 58 0 59 0 60 0 61 0 62 0 K 1 m 1 45 1 49 1 54 1 59 1 63 1 68 1 73 1 78 1 83 1 89 1 94 2 00 2 05 2 11 2 17 2 23 2 29 2 35 2 42 L length of optical camera 0 4 N value in 63 0 64 0 65 0 66 0 67 0 68 0 69 0 70 0 71 0 72 0 73 0 74 0 75 0 76 0 77 0 78 0 79 0 80 0 90 0 OPA 391seies K 1 m 2 49 2 55 2 62 2 70 2 77 2 85 2 93 3 01 3 09 3 18 3 27 3 37 3 46 3 57 3 67 3 79 3 90 4 02 5 76 ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it User Manual 41 Assemblad s r l OPA 391seies User Manual 11 WARRANTY This device was built with care and carefully inspected before it left the factory It is guaranteed for one year from the date of purchase by the final user To enjoy full rights under this warranty and avoid the risk of invalidation you must mail a copy of the Warranty C
7. pressing the button Find the data related to the instrument will appear in the text fields it s also possible to enter these data manually using the PC keyboard then pressing the button Save these data will be saved Baud Rate Cylinders N of Strokes C 1200 12 C 4 2500 DATA COM Factory and Type 1 N of approval RPM E serial N Check expiry date Oil Temp OFF get RPM Select RPM Set Up to open the window where it s possible to enter the communication parameters for the revolution counter The RPM value can be detected in the following modes Internal RPM set to OFF the keys RPM and Oil Temp referred to an external RPM meter set the COM value equal to the one of smoke meter push the key Find to acquire automatically the instrument data push the key Save to memorize the data and the settings External RPM connected to the RPM connector in the rear panel set to OFF the keys RPM and Oil Temp in the four DATA windows write the instrument data push the key Save to memorize the added data External RPM connected to a PC serial port set the key RPM to ON and the key Oil Temp to ON if you have the oil temperature sensor connected to the external RPM otherwise to OFF set the COM value were is connected the RPM counter push the key Find to acquire automatically the instrument data if they are not received write them in the DATA windows push the key Save to memorize the data and the settings
8. Press ZERO key and wait for the zero resetting cycle The test is favourable when the average of the last 3 measures has a value lower than the limit value settled if the average value is higher than the limit value the test is not considered negative The maximum number of tests is 8 However for the measures procedure and the elaboration of the data please refer to the actual normative If the average of the first 3 measures is greater than 50 of the limit settled the test will be stopped and the negative result will be showed If the Cell Test temperature result lower than 70 C the measure will be interrupted a zero resetting will be performed and the anomaly pointed out A report with the smokemeter data RPM all measures calculated average result environmental data and vehicle data will be printed ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 19 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual 6 4 REVOLUTION COUNTER Introduction Detection of diesel engine rpm is a difficult operation because of the physical nature of the problem without any electrical signal to measure Generally the rpm circuits use a piezoelectric sensor to convert pressure variation on adduction diesel pipe into an electrical signal This system does not guarantee a good performance in all cases for the following reason Impossib
9. Use this key to clear the measurement in progress and recover the initial drift after the pre heating phase Press this key each time you start a new measuring procedure During this phase the smoke meter will clean out gases from the chamber and recheck the settings ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 11 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l PRINT PAPER ADV RPM TEMP F1 F2 F3 OPA 391seies User Manual Press this key to if you want a print out of the results of a measurement If the machine is in the CONT mode you can print at any time If it is in the L1 or L2 mode it will only print after having completed the number of measurements required for the test After printing press the ZERO key for proceed with the next measurement Use this key to advance the printer paper If you keep the key depressed as you press the ON OFF key switching on the smoke meter you will obtain a function TEST of the printer Use this key to select the function for display temperatures or RPM counter When the machine is turned on it goes to chamber temperature mode To calculate engine RPMs multiply the value shown on the display by ten RPM x 10 Function key for settings Settings Using Combinations of Function Keys Here are the key combinations to use for certain settings A plus sign between key designators means tha
10. acceleration and peak acquisition start when the Opacity Limit is exceeded acquisition duration is 4 sec after that the acceleration stop when go back below the Opacity Limit Before run a new acceleration RPM must remain at least 3 sec below RPMmin 4 Time with this selection each acceleration is defined by time You must remain at minimum RPM for 3 sec after that you must go to maximum RPM in 1 sec and remain there for 4 sec in this period there s the peak acquisition Then go back to minimum RPM in 1 sec and maintain it for 3 sec before run a new acceleration 5 Manual with this selection you will pass from an acceleration to another with the button Progress Each measure type has a duration that depends on the test result as described in this manual At the end of each test the result will be displayed in the related field and a final report can be printed The software is continuously improved in this menu may be some others choices ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 27 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual MEASURES In these screen the smokemeter shows the measures performed The Out string means that an over range value has been detected while means that the data is not available If the temperature goes below 70 C the field Cell Temp becomes red SUB FOR
11. the test passed or not ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 38 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual Temperature calibration Through this function authorized technical people can calibrate all smoke meter s temperatures Reinitialise the smoke meter Through this function it s possible to restore the contents of the internal settings of the smoke meter as when it left the factory All internal settings modified in a second time will be lost Analog channels voltage level Shows the electrical level of internal analog channels for diagnostic purpose Create a remote connection On developping Waiting for a remote call On developping Printing a message on the analyzer It simply prints a message on the smoke meter s printer Back to DOS Exit the program ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 39 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual 9 ERRORS During the Autosetting Autotest and measuring phases the smoke meter can and does detect certain problems The system software makes it possible to send the operator warning messages and in serious cases to shut down the machine In some cases the system reports the error and even suggests possible
12. 0496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual 7 3 MENU SECTION Select User and Environmental Data in the Utility menu to set the values that will be written in the report The User data must be set in the installation and when there are some variation The environmental data must be set more times each day With the selection COM Reading in the Utility menu you will enter into the function that can be used to scan for Assemblad instruments connected to the PC and the COM ports available I COM Reading COMI not connected 9 COM2not connected 10 COM3not connected 11 COM4not connected 12 COMSnot connected 13 COMGnot connected 14 COM not connected 15 COMSnot connected 16 COM9not connected COMI Onot connected COMI lnot connected COM12not connected COMI13not connected COMI 4not connected COMI Snot connected 0 0 e e 6 COM16not connected Identification Select Opa Set Up to open the window where it s possible to enter the communication parameters Smoke Meter Baud Rate COM 1200 1 24 9600 DATA Mark N of approval ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 24 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual After the selection of the Baud Rate the COM port number and the instrument model
13. 5 10 FULL ELIGET REBULA MON ica 37 8 11 PROGRAM FOR PERIODIC MAINTENANCE UTILITY cvicisivrerizinezinzeresicosicazonazinia A ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 4 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 5 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual 1 INTRODUCTION The OPA 391 HF and its derivatives are equipments for measuring the opacity of the smoke emitted by Diesel engines Please read carefully this manual before operating on the equipment and follow the instructions when doing any action on it in particular when doing maintenance procedures Open the equipment only when explicitly indicated and after switching off its powering Then at the end of operations close it restoring its original conditions in particular the casing and the flap door before powering it again Be careful of the right hose connections and don t inhale the smoke leaving it flowing outside in free air The manufacturer disclaims any responsibility for any kind of event deriving from a improper use of the equipment or from a procedure not explicitly written on this manual In any case the responsibility is limited to the repair of the instrument
14. ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 25 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual 7 4 SMOKEMETER SECTION em Smoke Analysis OPA 391 HDF TEST RESULT Type of Measure m Continuous Coe Status of acceleration OPACITY In this section the following fields are displayed three windows with the model type the test result and the smokemeter status a field to select the measure type all the measurements performed by the smokemeter an user messages field a final opacity result field 10 intermediate result fields a button to switch OPA 391 in the StandBy or in the Measure mode StandBy a button to proceed with a manual test Progress a button to start and stop the measure Start Measure two buttoms to set the test limits through the button Limits Setting and the vehicle manufacture data through the button Vehicle Data a button to print the test report Print ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 26 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual All functions are available clicking with the mouse on the buttons or through the keyboard pressing ALT the underline lette
15. E MAINTENANCE If the smoke meter is not used for long periods and especially after heavy work cycles the solenoid valve may not open This is due to the fact that after the deposited gases have dried they hold back the seals restraining the core 7 In this case the smoke meter can give an error signal or the display will read zero throughout the various tests A firm tap on the fitting for exhaust gas input see Fig 2 item 2 on the head 9 or on the brass body is usually sufficient to start the solenoid valve working again If this does not work or each time you want to clean the solenoid valve circuits proceed as folows a disconnect the smoke meter from the mains or battery power supply b open the measuring chamber c loosen the 4 screws 8 to access each one rotate the coil 2 on its own axis The coil can only be removed if you first release the cup spring 1 but this is usually not necessary d raise the coil pin unit e clean all the internal parts with a brush and compressed air at medium pressure 1 2 Atm f reassemble 1 Cup spring 2 Coil 3 Guide unit 4 Core return spring 5 Core 6 OR Gasket 7 Seal 8 Screws M4x10 ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 34 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual 8 7 HOW TO CHECK THE CALIBRATION OF THE SMOKEMETER Along wi
16. Ms LIMITS AND VEIHCLE DATA Limitis Setting Vehicle Data ALFA ROMEO RPMmin ooo Factory and Type o JTD RPMmax 3500 Licence plate ARTS3GT Limit Value of K Year of first 2007 registration Opacity 0 15 Threshold 1234567890 15 In the form Limit setting the following values are showed RPMmin in the RPM mode is the maximum value of the engine speed for the minimum rate RPMmax in the RPM mode is the value of the engine speed to go over to start the speed up Opacity Threshold is the opacity limit in the Smoke Limits mode to start the speed up Limit Value of K is the maximum K value of the opacity the average must be lower than this value in order to pass the test In the form Veihicle data the vehicle data can be entered they will be printed in the final report All values and strings can be entered manually selecting the relevant fields with the mouse or with the TAB key and using the keyboard MESSAGE WINDOW In this window are displayed both operative and error messages they enable the interface between the smokemeter and the user The user found here the messages to perform the test ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 28 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual TEST RESULT WINDOW In this window the test result can be read at the end of the measure
17. NG THE SMOKE METEDB cr tia tit ioititi soar eost riae rb ense piis ninna rin 16 Sl POWER SUPPLY CONNECTIONS oriali 16 FRIGO meer RT 16 2 3 PREPARA TION FOR MEASUREMENTS iii iii iaia iii 17 3A MESSA ES ATS TART TUP aaa A TT 17 b SMOKE MEASUREMENTS sscssssssasssscissasasasuasssncsdiascsassisesscsssessuassnssietssbadeivenstatsonssibaaciasaosssuis ea 18 DA CONTINUOUS SMUKE MEASUREMENT spirale dia ideale iii iii 18 6 2 MEASURE OF OPACITY WIH LI PROCEDURE uisa credi pria 18 MEASURE OF OPACITY WITH L2 PROCEDURE lille 19 CF REVOLUTION iia ca a lea eda 20 0S TEMPERATURE READINGS Pane ese en re Oe Pom ua di Ee OE iii 21 6 6 PRESSURE DEPRESSION TEA Sa sissies ba iride aqui in eiie tc 21 ZINFFLUSWINSOETWARE uideat isa erii cort pda d Gn Eb india 22 HW TALLA TION RR a 22 Ta INFPLUS WIN FUNC TION S cunaca aaa A Te 22 TS MENU SECTION colli iii 24 FASI AEREE SEC IUN canonusa rei aa 26 S MAINTENANCE iiie iabekc thi iaia iti A RR RA ARR ed RAI dia 30 5 CLEANING THE MEASURING CHAMBER sirio en o bb e e ots bd Eid nd 30 SL ul dh ol RR NNUS a1 WR ASS cls DT LOCK iii iii rr mon mp LE rina 32 cA REPLACING ELDER a cic dins s TOT 33 5 5 REPLACING THE HALOGEN LAMP strillare ilaria 33 8 6 SMOKE INTERCEPT SOLENOID VALVE MAINTENANCE ii e criereri ta ctas 34 8 7 HOW TO CHECK THE CALIBRATION OF FHESMOKEMETER a is aai EN 8 8 HOW TO RECALIBRATE WITH SAMPLE FILTERS 84 000020 ccena ici 36 9 DARE LEVEL REGULATION nitrico irritare 36
18. OTODETECTOR TECHNICAL FEATURES Ricetransmitter Reflection type Transmitter 6V 10W halogen lamp Color temperature 3000 K Average lamp life 2000 hours Receiver BPW21 photodiode Response corrector filter L I S S passband Periodic settings Neutral density filter supplied 2 2 MEASURING CHAMBER TECHNICAL FEATURES Chamber ventilation Controlled Measuring cell length 198 mm Measuring cell inside diameter 36 mm Length of an exhaust gasspecimen 400 mm Exhaust gas input Balanced Clean air input Balanced Exhaust gas intercept 1 2 inch solenoid value Clean air intercept 1 8 inch solenoid valve Gas discharge By ventilation Pressure depression sensor Differential solid state Measuring chamber Interchangeable Condensate drainage At the base of the chamber Chamber thermostating Over 70 C by microprocessor controlled heaters 2 3 ELECTRONIC STRUCTURAL FEATURES Setting Automatic when switched on Measurement processing Microprocessor controlled Printer Impact 24 columns Smoke display 3 7 segment red colour 20 mm high Temp Rpm display 3 7 segment green colour 20 mm high Test N Display 1 7 segment green colour 14 mm high Measurements displayed Smoke from 00 0 to 99 9 Smoke K m 1 from 0 00 to 9 99 Gas temp from 0 to 180 C Oil temp from 0 to 180 C Chamber temp from 45 to 180 C RPMSs from 0 to 6000 rpm Start up and self test time 1 min normal Ti
19. TEMP RPM display shows the motor oil temperature Make sure that the oil probe is properly connected inside the oil checking rod dip stick and that plug is fitted into the appropriate connector on the back of the device ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 14 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual 4 INFRARED REMOTE CONTROL The ASSEMBLAD cod 801 851936 remote control is a microprocessor based device and it is designed to operate in conjunction with the Smoke meters of both 189 and 391 series It is biased by a 9 Volts alkaline battery installed in the rear side behind the small slide cover Direction of the I R emission MODE ZERO ADV PRINT F5 SEL ENTER 801 851936 pas emhlaq Keys and lamps of remote control Operating notes 1 Press the key SEL One of the five functional LEDs will be lightened in particular the last one selected 2 If the requested function is different from the selected one press again the key SEL until the needed function LED is lightened 3 Press the key ENTER being careful to direct the Infrared emission spot towards the receiver installed in the front of the instrument 4 After few seconds with no key entered the remote control will switch off itself in sleep mode keeping in its memory the last function used If the de
20. antly at 600 Verify electrical connection of rpm cable Verify the correct grounding of the smoke meter If displayed rpm became instable during the acceleration Verify that sensor is positioned on a straight part of pipe with low engine vibrations Tighten strongly the sensor fixing screw ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 20 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual 6 5 TEMPERATURE READINGS The TEMP RPM display can show 3 different temperatures the exhaust gases the measuring chamber and the motor oil Select the temperature you want to see on the display by pressing the RPM TEMP key until the appropriate LED C Chamber temp F4 Gas Temp F5 Oil Temp lights up The gas temperature sensor is an integrated circuit mounted on the inlet duct You can inspect it by removing the two screws that hold the fastening plate in position The chamber temperature sensor is located inside the chamber insulation The oil temperature sensor is part of the probe that has to be put into the oil rod housing and be connected to the device with the fitting on the back of theunit 6 6 PRESSURE DEPRESSION MEASUREMENTS The pressure sensor is of the differential type It detects the difference in pressure between the measuring chamber and the outside environment It is mounted
21. d in K x 100 and its admitted range is from 000 to 490 K from 0 to 4 9 in step of 10 units 0 1 K If the value 000 is entered the printout will leave the user free for handwriting the value The following settings should be used by authorized personnel only and only when the instrument give manifest wrong values for temperatures ZERO F1 COUNT ADV Chamber Temperature Calibration In case of wrong values shown it s possible to recalibrate the sensor by entering the current true value in C measured by means of a reference thermometer placed inside the chamber ZERO F2 COUNT ADV Oil Temperature Calibration In case of wrong values shown it s possible to recalibrate the sensor by entering the current true value in C measured by means of a reference thermometer placed near the probe ZERO F3 COUNT ADV Smoke s Temperature Calibration In case of wrong values shown it s possible to recalibrate the sensor by entering the current true value in C measured by means of a reference thermometer placed near smoke inlet The LEDS ON When this LED is lit the smoke meter is connected to the vehicle s battery or the 220VAC mains power supply If the device is connected to the mains the switch on the back has to be set to ON the smoke meter is ready to be switched on 15 The power supply to the smoke meter is above the rated value if it is not corrected this can damage the smoke meter or impact the resul
22. directly on the chamber output pipe so that vibrations affecting the chamber are damped The pressure sensor does not require any maintenance at all NEVER use compressed air to clean it pressures of only 0 3 Bar can damage the sensor Pressure or depression in the chamber at the time of measure ment is printed on the test results Pressure or depression values exceeding 75 mm H20 are not allowed during the tests if this occurs the control device stops the smoke meter and transmits an error message on the printer ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 21 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual 7 INFPLUSWIN SOFTWARE INFPLUSWIN is a software developed to run on a PC with Windows operative system installed With InfplusWin it is possible to control the instrument and create reports 7 1 INSTALLATION To install the InfplusWin software run the installation file infpluswin exe this file can be downloaded from our web site 75 Setup Infplus Win 1 61 Welcome to the Infplus Win 1 61 Setup Wizard This will install Infplus Win on your computer Itis recommended that you close all other applications before continuing Click Next to continue or Cancel to exit Setup The software will be copied on the hard disk into the default directory InfplusWin or in another directory that can be selec
23. e N TEST display TEST O Wait TEST 1 Year TEST 2 Month TEST 3 Day TEST 4 Hour TEST 5 Minutes F2 Moves the set value ahead one digit at a time for fast advance keep the key pressed down The value is displayed on TEMP RPM Example Press F1 F3 All displays read zero Press F1 Display N TEST 1 year Press F2 Display TEMP from 00 to 99 year Press F1 Confirm preceding step and start next phase Display N TEST 2 month Press F2 Display TEMP from 01 to 12 month Press F1 Confirm Press F1 p US Confirm everything and return to normal functions ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 32 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual 8 4 REPLACING FUSES The smoke meter is equipped with two types of fuses 0 5A 250 5x20 for protections towards the 220VAC mains and 2A 250 5x20 to protect the halogen lamp circuit The 0 5A 250 fuse is located in the filter power switch unit To replace it disconnect the smoke meter from the 220V AC power supply use your finger or a small screwdriver to remove the fusecarrier housing located above the power plug pull out the fuse and replace it with a new one replace the fuse carrier close the snap on cover The 2A 250 fuse is located on the power supply card situated horizontally at the back of the smoke met
24. e internal tests as required by the program Then if everything is in proper order the printer will continue with SELFTEST OK SELFCALIBRATION OK DATE xx xx xx TIME xx xx If any errors or other malfunctions are found the printer will send a message specifying the problem and if possible how to solve it ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 17 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual 6 SMOKE MEASUREMENTS 6 1 CONTINUOUS SMOKE MEASUREMENT When the smoke meter is switched on it is automatically ready to work in this mode Measurements are continuous in the sense that the smoke values of the gases are shown continuously the value on the display is the direct opacity of smoke This type of measurement is particularly useful in bench tests since it shows the smoke values as they rise and fall The print outs of these results do not have any legal value since the reading is an absolute result and not the results of an average of readings taken according to specific standards 6 2 MEASURE OF OPACITY WITH L1 PROCEDURE This method makes it possible to work in accordance with the requirements of the DM 628 To take measurements follow the procedure described below Set the CONT Mode and select the limit value K applicable to the vehicle under test then set the L1 Mode Make the setup setting
25. er to replace it switch off the smoke meter and disconnect it from the power supply raise the hinged door on the cover raise the protective cover removed the blown fuse and replace it with a new one replace the cover 8 5 REPLACING THE HALOGEN LAMP To replace the lamp on the photoelectric cell proceed as follows 1 2 3 O Switch off the smoke meter Open the hinged door on top of the smoke meter Use the 3 mm Allen key supplied with the device to loosen the two screws 7 that support the lamp holder s fastening plate Replace the lamp with another 6V 10W halogen lamp we recommend OSRAM HALO STAR N 64410 or S Insert the lamp into the shoe as centrally as possible Clean the lamp with denatured alcohol before you put it into the photoelectric cell dirt or grease will drastically reduce the service life of all halogen lamps Put the fastening plate back onto the photoelectric cell make sure that the lampholder is properly guided and fastened into position by the two pointed screws their length is preset in the factory and must not be adjusted Replace the two Allen screws and tighten securely Switch on the smoke meter 0 Recalibrate the instrument ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 33 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual 8 6 SMOKE INTERCEPT SOLENOID VALV
26. ertificate to the factory within 10 days of the purchase date The warranty covers all defects in materials The warranty does not cover wiring probes the remote control unit and the accessories These items are subject to wear and their efficiency depends on how they are handled The warranty does not cover damage caused by accidents impact or dropping the instrument or by negligence improper use non compliance with the instructions and improper storage If the device has such defects as to require technical service you must return it to Assemblad or an authorized service centre Shipping charges shall be covered by the customer ASSEMBLAD even supplying support on demand for the first installation of the equipment disclaims any liability for damages and injuries caused even to third parties by an improper installation maintenance defective or unsafe electrical connections Further ASSEMBLAD disclaims any claim for damages from anyone due to a miss utilization of the equipment for any reason The warranty shall immediately become invalid if the device shows any signs of tampering The exclusive court of jurisdiction for any disputes arising from the application and or interpretation of this warranty is the Court of Florence Italy 12 NOTE FOR THE USERS The symbol R of a crossed urban trash bin is stamped on the equipment or on its box and it means that the product must be disposed into the appropriate collecting
27. eter Data amp Time display Entering new expiring date Entering the allowed K limit Temperature calibration Reinitialize the smoke meter Analog channels voltage level Create a remote connection Waiting for a remote call Printing a message on the analyzer Back to DOS Displaying the serial number registered Warning Operations marked with the symbol are protected by password as only authorized personnel is enabled to do them Factory setting data display Shows the factory data of the smoke meter as the serial number and the software version Workshop customisation Allows to write 6 lines of 24 characters containing details about the workshop as the Name Address Telephone and more These data will be printed in the test report by the smoke meter Customisation data displaying Shows the Workshop details currently registered on the smoke meter Date amp Time setting The current PC s date and time will be transferred to the smoke meter Current smokemeter Date amp Time display Shows the current working date and time of the smoke meter Entering new expiring date The smoke meter prints in every report its expiring date Normally the smoke meter should be checked and or recalibrated every 12 months Through this function the technician updates the expiring date after his recalibration Entering the allowed K limit It changes the internal reference of the opacity that the smoke meter uses in order to declare
28. facility at the end of its life The disposal of the equipment will be managed by the producer The user shall contact the producer and follow the method that has been implemented for collecting the appliance at the end of its life A correct waste disposal of the appliance and its subsequent treatment contributes to avoid serious environmental and health damages and allow the recycling of materials used into the equipment An incorrect waste disposal of the product is subject to administrative sanctions In accordance with art 13 D L 25 July 2005 n 151 for the Actuation of European Directives 2002 95 CE 2002 96 CE and 2003 108 CE related to reduction of dangerous substances in the electric appliance and to the waste disposal RoHS RAEE ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 42 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual COPYRIGHT by ASSEMBLAD S r l Via Vittorio Veneto 40 50013 Campi Bisenzio Firenze ITALY Tel 39 055 890485 Fax 39 055 890496 Reproduction and or disclosure prohibited CE EMC CEE 89 336 73 23 CEE EN 50081 1 EN 50082 1 EN 61010 1 are Registered Trademark ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 43 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it
29. if the Continuous mode has not been selected if the test is passed the window background becomes green and the label shows TEST OK while if the test is not passed the window background becomes red and the label shows TEST KO INTERMEDIATE TEST RESULTS WINDOW The peak values for each acceleration are displayed in the bottom part the minimum and maximum RPM values measured during the test are displayed FINAL OPACITY VALUE WINDOW The average value is displayed it represents the final test result STANDBY With the button StandBy the smokemeter goes in the Stand By mode To perform the test the smokemeter must not be in the Stand By mode START MEASURE Pressing the button Start Measure the instrument calibration will begin in the status window is reported Autozeroing when the smokemeter goes back in the measure status in the status window is reported Ready If the Continuous mode has been selected the instrument will read the values continuously without compare them with the limits entered and without peak detection If another mode has been selected after the calibration a test will start accordingly with the mode as described in the paragraph MEASURE SELECTION MANUAL MODE With the button Progress the test will be carried out manually This button is active only in manual mode PRINT A TEST REPORT Its possible to print a test report with the button Print The printout will be sent to the
30. ing operations are needed in order to recalibrate the equipment fig 4 2 Remove the top panel of the smokemeter then the top panel of the measuring chamber and proceed with cleaning all the optical parts Switch on the smokemeter Be careful when operating inside the instrument as there are inside some dangerous voltages Do the dark level tuning then the full light tuning according to their releative paragraphes Wait for the end of the initial drift for about 15 minutes Do an autozeroing using the ZERO key then set the measuring unit as in K nsert in sequence the three sample filters and look at the value shown for the opacity They should indicate the same values written on the filters with a tolerance of 0 1 K then press the key PRINT for getting the calibration report after each insertion n case of a not accurate reading recalibrate the smokemeter through the trimmer 3 then when the match is done remove the filter and do an autozering through the key ZERO waiting for its completion Repeat the same procedure until all the three readings are included in the allowed range Do not make in any case an autozeroing when there s a filter inserted Close the chamber with its panel and set the top cover of the instrument 8 9 DARK LEVEL REGULATION HHH In order to check the right voltage level proceed as follows fig 4 2 Remove the top panel of the smokemeter then the top panel of the measuring chamber pr
31. l or semiautomatic transmission vehicles with the lever in neutral position for the automatic transmission vehicles or according to the manufacturer instructions d Disconnect all parts that can influence the engine rotation at minimum regime except when expressly prohibited by the manufacturer or by regulatory prescriptions e Engine has to be at normal operation temperature oil temperature must be equal to or greater than 80 C f Introduce the probe into exhaust pipe up to 300 mms if it is not possible opportunely prolong the exhaust pipe verifying the airtight of the connection g Press the ZERO key and wait for the zero resetting cycle to be finished Press the COUNT ADV key display will show N 1 Perform a fast full power run by pushing the pedal down in 0 4 sec and maintain it for 2 sec 1 0 then release maintaining the minimum regime for 3 sec 1 0 The opacity display will show the maximum value reached by the opacity in such phase i Press the COUNT ADV key display will show N 2 Perform a fast full power run as described at point h j Repeat instructions at points h and i until pressing the COUNT ADV key you will ear a prolonged sound that means that a favourable test has been reached the average value will be showed on the opacity display k When the test is positive press the PRINT key The printer output will give the result of the calculated average in accordance with the selected normative I
32. le to connect the sensor cause inaccessible diesel pipe and position sensor problem Excessive engine vibration that does not permit to detect correctly the signal No standard engine injection pump Operating mode The RPM value is visualized on RPM TEMP display Verify the correct grounding connection of the electrical power supply connected to smoke meter Push RPM TEMP button until RPM led is on Assure that adduction pipe diameter is equal to the piezo sensor one Positioning the sensor on a straight part of pipe after a accurate cleaning as close as possible to the injection pump tighten strongly the sensor fixing screw Connect the cable fast on connector to the sensor connect the cable crocodile to car battery pole ground connected connect the cable DIN connector to the rpm socket on the back cover of smoke meter Maintain the engine idle verify reading on green display the displayed value is rpm divided by 10 Accelerate verifying the correct value of rpm displayed Proceed to measure according with the selected modality Troubleshooting If displayed rpm remain constantly zero Verify rpm fuse on the back panel of the smoke meter Verify perfect coincidence of the sensor diameter with diesel pipe diameter Move the crocodile connector from car battery to diesel pipe near sensor or to several other ground connections Slack lightly sensor fixing screw If displayed rpm remain const
33. me for operating rates 15 min normal at 25 C Operating temperature 5 to 40 C Humidity range 45 90 Clearing measurement device Automatic press ZERO key ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual 2 4 POWER SUPPLY From mains Single phase 220V 10 50 Hz 2 From battery 13 8 VDC 10 Absorbed power 200VA max for 391 HF and 391 HDF 80 VA max for 391 and 391 HD 2 5 SUPPLEMENTARY FUNCTIONS Remote control Infrared Serial output RS 232 for connection to remote unit PC Calendar clock For dated printouts 2 6 OTHER FEATURES Dimensions weight Std 480 x 300 x 630 mm 29 kg approx Dimensions weight HD 475 x 280 x 480 mm 28 kg approx Exhaust pipe probe 3 different sizes inside diameters of 10 17 and 27 mm to be connected to the hose of probe Ballast 2 kg approx to connect to the hose of probe 2 7 FITTINGS SUPPLIED Standard accessories N 1 Rubber sampling hose N 3 Exhaust pipe connectors N 1 Ballast bag N 1 220 VAC mains lead N 1 Battery mains lead N 1 Calibration filter preinstalled N 1 Infrared remote control device without battery N 1 RPM probe N 1 This manual _ _ lI Optional Accessories Oil temperature probe ASSEMBLAD S r l Costruzioni Elett
34. nel of the smokemeter then the top panel of the measuring chamber proceed being careful when operating inside the instrument as there are inside some dangerous voltages Connect the terminal of a multimeter to the test point TP2 of the measuring board then the terminal to the ground test point TP7 with the multimeter set as for DC Voltages Switch on the smokemeter The LEDs ON CONT and C should be lit Wait for the end of the initial drift for about 15 minutes Do an autozeroing using the ZERO key and wait for its completion Look at the opacity display It should indicate 00 0 or 0 00 1 m If the reading of the multimeter is different from 4 3 regulate the trimmer 1 in such a way to get 4 3 Volts Do an autozeroing using the ZERO key and wait for its completion then check again the indication of the multimeter Do not make in any case an autozeroing when there s a filter inserted Close the chamber with its panel and set the top cover of the instrument 8 11 PROGRAM FOR PERIODIC MAINTENANCE UTILITY The serial port meets the RS 232 standards and permits dialogue between the device and a Personal Computer Some operations are uniquely achievable by Personal Computer running the Periodic Maintenance Utility which is a DOS program In order to install the Periodic Maintenance Utility on your computer please make a new directory named A391 then copy there all the contents of the enclosed diskette
35. oceed being careful when operating inside the instrument as there are inside some dangerous voltages Connect the terminal of a multimeter to the test point TP2 of the measuring board then the terminal to the ground test point TP7 with the multimeter set as for DC Voltages Switch on the smokemeter The LEDs ON CONT and C should be lit Wait for the end of the initial drift for about 15 minutes Doan autozeroing using the ZERO key and wait for its completion nsert the embedded optical filter 4 in the apposite slot 6 as shown in fig 4 1 mentioned as Verifica a Look at the opacity display It should indicate 99 9 or 9 99 1 m fthe reading of the multimeter is lower than 50 mV or greater than 200 mV regulate the trimmer 2 in such a way to get 100 mV then let the filter return back in its idle position Do an autozeroing using the ZERO key and wait for its completion then check again the indication of the multimeter Do not make in any case an autozeroing when there s a filter inserted Close the chamber with its panel and set the top cover of the instrument ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 36 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual 8 10 FULL LIGHT REGULATION In order to check the right voltage level proceed as follows fig 4 2 Remove the top pa
36. r simultaneously To exit from a section click x on the right upper corner using the mouse or press ALT F4 or ESC To select a different measurement type select the corresponding field with the mouse or press TAB until the field is selected select a value using ARROWS KEYS and press SPACE to confirm SMOKEMETER STATUS There is a Status field in the upper right side of the window that describes the status of the smokemeter in the following way Heating Smokemeter in warming StandBy Smokemeter in stand by Autozero Smokemeter in autocalibration Measure Smokemeter in measure mode Error fatal error in the Smokemeter ERROR X error in the Smokemeter X is a number that identify the error type ERROR COM Communication with the Gas Analyzer not available MEASURE SELECTION With this selection it s possible to select the type of measure to carry out There are 5 type of measure 1 Continuous with this selection is possible to carry out diagnosis on the vehicle 2 RPM with this selection is possible to carry out a test where each acceleration start when the RPM lower limit RPMmin is exceeded the peak acquisition start when the RPM upper limit RPMmax is exceeded and the duration is 4 sec after 4 sec the acceleration stops when the RPM come back below RPMmin Before run a new acceleration RPM must remain at least 3 sec below RPMmin 3 Smoke Limits with this selection is possible to carry out a test where each
37. remedies Typical error messages are ERROR Ol LIGHT SENSOR OUT RANGE check the cleaning of the optical parts ERROR 02 EMITTER OUT OF ORDER Check the lamp light sensor and fuse ERROR 03 Measure of smoke is not according to the law Pression in chamber over 75mm H20 ERROR 04 Measure of smoke is not according to the law Depression in chamber over 75mm H20 The first two messages give possible remedies for the other two the problem is caused by gas adduction therefore the sampling point has to be shifted In addition the computer system makes it possible to detect other errors that operator cannot resolve by yourself This type of error sends a message via the printer such as ERROR S A 1 call technical service ERROR S A 2 call technical service etc Function errors are indicated by the letters S A and a progressive number When you call the technical service department give the complete error code with the number NOTE before calling the technical service department switch off the smoke meter and check to make sure that all cables and wires are properly connected Then switch it on again and see if the error signal is still being given If there error signal persists call the technical service department ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 40 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l
38. roniche 50013 Campi Bisenzio Firenze Italy 10 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual 3 KEYPAD AND LEDS Description ON OFF olK MODE COUNT ADV ZERO ASSEMBLAD Figure 5 This key switches the smoke meter on and off It only functions if the ON led is lit The key is timed at about 0 5 seconds to prevent inadvertent switching Each time the instrument is turned on the smoke meter automatically goes through a self test and setting procedure the messages concerning instrument status are either printed or shown on the display Use this key to display smoke values that is in terms of percentage on a 00 0 to 99 9 scale or with the K m 1 factor The form you select is confirmed by the and K LEDs The machine is automatically in the mode when it is switched on Use this key to set the desired measuring mode You can select from CONT L1 or L2 Your selection will be shown on the respective led CONT L1 L2 When measuring in the L1 or L2 modes the MODE key is inhibited by the program it will only be released if you give a clear or PRINT command when measuring is completed The machine is automatically in the CONT mode when it is switched on Use this key to increment measurements in the L1 or L2 modes The measuring increment is timed for 5 seconds to prevent program skips if you do not press the key properly
39. s and measures as described for L2 procedures next paragraph from point b to k When you have reached the stabilized average press the PRINT key the printer will give the data on smoke levels obtained during the measurements performed expressed in the K unit of measure along with the max and the min number of RPMs for each acceleration exhaust gas temperature oil temperature chamber temperature chamber pressure and finally the mean smoke value calculated The test is favourable when the values of last 4 measures has a maximum difference of 0 25 m and the average has a value lower than the limit value settled or if the last 4 measures have values lower then limit value The maximum number of tests is 16 after you can push only the PRINT key to have the values of measure without average ASSEMBLAD S r l Costruzioni Elettroniche 50013 Campi Bisenzio Firenze Italy 18 Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 391seies User Manual MEASURE OF OPACITY WITH L2 PROCEDURE This method allows to operate in accordance with the prescriptions of Directive 1999 52 CE the procedure for carrying out the measure is the following a Set the CONT Mode and select the limit