USER MANUAL
Contents
1. ASSEMBLAD S r l Costruzioni Elettroniche Sampling SMOKE METER Model OPA 198 USER MANUAL Oct 2006 Rev V 2 2 0 ASSEMBLAD Engineering Departement Automotive division Assemblad s r l OPA 198 User Manua ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 198 User Manua Note ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 198 User Manua TABLE OF CONTENTS T INTRODUCTION nl i 5 2 TECHNICAL FEATURES carita 6 2 1 PHOTODETECTOR TECHNICAL FEATURES ii 6 2 2 MEASURING CHAMBER TECHNICAL FEATURES i 6 2 35 ELECTRONIC STRUGTURAE FEATURES 6 24 POWER SUPPLY agile ppi aaa 7 2 95 OTHER FEATURE A O A A AA AE 7 2 6 FITTINGS SUPPLIED ati AAA edilizia 7 3 STARTING THE SMOKE METER 5 oca 8 3 1 POWER SUPPLY CONNECTIONS cinc Ai 8 3 2 PREPARATION FOR MEASUREMENTS ssssseseeene eene nnne nenne 8 4 INFPEUSWIN SOFTWARE osos aspira IALIA RALE 9 4 1 Features of the ale iatale ms 9 AROS ANS RE AA LEIA aaa 9 l SRunning IMPIUS WI cnt 10 44 SOU SOMO do2. ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it 28 Assemblad s r l WARRANTY Basis and or Generic for all our products 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 Certificate to the factory within 10 days of the purchase date The warranty covers all defects in materials The warranty does not cover external cables probes the remote control unit pumps motors and the external accessories These items are subject to wear and their efficiency depends on how they are handled or treated 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 center 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
3. ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti 13 Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 r a Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 198 User Manua COM Reading Fig 6 COM identifier Baud Rate is 9600 ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 r a Fax 055 890496 E mail info assemblad it Web www assemblad it 14 Assemblad s r l OPA 198 User Manua 4 5 Smoke Meter section Smoke Analysis OPA 105 TEST RESULT Measure i Block of the smoke e i Type of Measure Continuous Status of acceleration Esc Fig 9 Smoke Meter section This section shows an Assemblad device type window the smoke meter s status type of Block of the Smoke only for OPA 105 a box for setting the type of measure all measurements made by the Smoke Meter two sub forms containing the test limits available by Limits Setting command and the vehicle manufacturer s data available by Vehicle Data command a message window a test result window a intermediate test result window the smoke test is from minimum of three to a maximum of eight accelerations a final opacity re
4. ERROR X Smoke Meter is in error X it s a number and identify the type of error ERROR COM Communication with Smoke Meter impossible 4 6c Type of Block of the Smoke only for OPA 105 On the top right side under the Status window a label is present in which is brought back the type of device used in order to block the smoke in the phase of auto zero In the window are brought back various indications according to the type of device Elect Valv if you used an electro valve Sled Opened or Sled Closed if it s present a Sledge Not Present if the devices are not present 4 6d Setting the type of measurement With this box you can select the type of measure There are five types of measurements 1 Continuous with this selection you can perform a diagnosis of the emissions of the vehicle 2 RPM by this selection we can perform a test in which every acceleration starts when the lower RPM limit is crossed RPMmin The peak acquisition starts after the upper RPM limit is crossed and it lasts for 4 secs after the 4 secs if we came back under RPMmin the acceleration over Before you could pass to the next acceleration you must stay under RPMmin at least 3 secs ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti 16 Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 r a Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 1
5. CHECK THE CALIBRATION OF THE SMOKEMETER 27 APPENDIX toa lada 28 WARRANTY liane 29 ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti 4 Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 198 User Manua 1 INTRODUCTION The OPA 198 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 For more detailed informations please read the chapter Warranty The smoke meter does its smoke measurements through the sampling method and the measuring chamber i
6. User Manua SS Analyser Ea Smoke Meter Baud Rate Baud Rate COM COM 105 C 1200 C 1200 224 jj 9600 9600 DATA Find DATA 4 Mark JASSEMBLAD Mark A SSEMBLAD N of approval Save N of approval JowoosaebNET a b RPM ix y Baud Rate N of Cylinders of Strokes C 1200 2 o 9600 DATA t 2 1 N of approval 9 RPM Lom serial N Check A Oil Temp epey ona RPM Fig 5 Sub form for communication setting a Analyser b Smoke Meter c RPM After to have chosen the Baud Rate the communication port COM and the Type of instrument pressing the commando Find will appear data about the instruments in the text boxes it s possible to write data through the keyboard from PC pushing after the commando Save such data and setting will come save to you Sub form RPM contains two buttons in order to qualify the acquisition of the Turns and the oil Temperature RPM and Oil Temp during the phase of measure directly from RPM 405 connected to the PC With User and Environmental command buttons the sub forms will be opened the sub forms will be filled by the values and strings used in the test and written in the test report With COM Reading you enter in a user window which recognizes the Assemblad instruments and the COM ports connected to the PC
7. displayed rom remain constantly at 600 Verify electrical connection of rpm cable Verify the correct grounding of the smoke meter If displayed rom 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 Servizio Assistenza Tecnica Clienti 22 Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 r a Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 198 User Manua 5 2 TEMPERATURE READINGS The TEMP RPM display can show 3 different temperatures the exhaust gases the measuring chamber SS and the motor oil SS 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 SS 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 5 3 PRESSURE DEPRESSION MEASUREMENTS The pressure sensor is of the differential type It detects the difference in p
8. 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 ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 r a Fax 055 890496 E mail info assemblad it Web www assemblad it OPA 198 User Manua 29 Assemblad s r l OPA 198 User Manua COPYRIGHT by ASSEMBLAD S r l Via Marzabotto 4 50013 Campi Bisenzio Firenze ITALY Tel 39 055 890485 Fax 39055 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 Servizio Assistenza Tecnica Clienti 30 Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 r a Fax 055 890496 E mail info assemblad it Web www assemblad it
9. will be copied on your hard disk in the default directory named InfplusWin or in any other directory you can choose during the installation ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti 9 Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 r a Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 198 User Manua To run the program execute InfplusWin150 exe from the directory InfplusWin or click on the icon named InfplusWin150 that by the setup software appears on the desktop Sh Risorse di ret Cestino Documenti La Dragon Serial_Poll MCTCNet ___InfplusWin Collegamento a opaled ht Fig 2 InfplusWin start icon on desktop 1 3 Running InfplusWin Before running InfplusWin check the connection between the PC s RS232 COMx port and the instrument to ensure the correct operating of COMx port When running InfplusWin will appear a main menu with 5 command buttons the language selection and the ASSEMBLAD logo ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti 10 Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 r a Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 198 User Manua Start men a EI English Fig 3 Start Men InfplusWin is provided with these default communication se
10. 12 4 5 Smoke Meter SOCIO Nr AAA AR AAA EA ARANA NAAA RARA 15 4 00 of AA ae 16 4 6b Smoke Meter s status ii 16 4 6c Type of Block of the Smoke only for 105 16 4 6d Setting the type of measurement rennen 16 4 00 Measurements ae etie oon c en ee 17 4 6f Sub form of test limits and manufacturer s 18 A OG Message WING OW desconoce dide AIDA 18 4 6h TOS ERE SEMI COW iu aS Rx eu t aa ae wag RR dua a Ru ROM HR d 19 4 6i Intermediate test result window nennen nnns 19 4 61 Final opacity result 19 4 6m Starting the MOISES tst c detenta breuitate Und 19 4 6n Going in manual measurement seien nnn nnn nnne nnns nna 19 4 60 Printing a test report oce ne x eee ER vi ag n PR ERR E 19 4 7RPM seclionia eer AE ans E ia 21 9 MEASURES aa 22 Sil REVOLUTION COUNTER trail 22 5 2 TEMPERATURE READINGS 2 25 2 A D Ope te emo Satis 23 5 3 PRESSURE DEPRESSION MEASUREMENTS i 23 6 MAINTENANCE at 24 6 1 CLEANING THE MEASURING CHAMBER i 24 p z REPLACING USE Sua ti A A ea 25 6 3 REPLACING THE HABEOGEN LAMP soria A 25 6 4 SMOKE INTERCEPT SOLENOID VALVE MAINTENANCE 26 6 5 HOW TO
11. 98 User Manua 3 Smoke Limits by this selection we can perform a test in which every acceleration and peak acquisition start when the Opacity Threshold is crossed The acquisition lasts for 4 secs after the 4 secs if we are back under the Opacity Threshold then the acceleration is over Before you could pass to the next acceleration you must stay under Opacity Threshold for at least 3 secs 4 Time in this modality every steps of acceleration is managed by the time as indicated by several messages appearing in the window We must stay at minimum rate for 3 secs after we must rise to the maximum rate in 1 sec and to maintain for 4 secs this is the time of the peak acquisition After the acquisition we are back to the minimum rate in 1 sec and we stay at the minimum for 3 secs before passing to another acceleration 5 Manual by this selection we pass from an acceleration to the other by the Progress command 6 Single only for Opa 105 with this modality it is possible to carry out a Single accelerated with the same modalities of measure RPM and to print the result diagram see following figure SINGLE ACCELERATION 180 70 E TE EE SES ET E E ETE ER EET mt tte Opacity x 10 k a o oa i i i as a EE E ES EIE E Ed BEND esp pes en em s o0L Md gt 18107 spes sposi Ex CERE E ET C
12. GE TO THE DIFFERENTIAL PRESSURE SENSOR ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti 24 Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 r a Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 198 User Manua 6 2 REPLACING FUSES The smoke meter is equipped with two fuses 1A 250 5x20 for protections towards the 220VAC mains 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 6 3 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 pro
13. RT E ES ES ER ESI C see MAR RZ ne BEER per ph E E Ee ENI E ES E Eee gt em SUI End of Test Speed Up for a new test S Fig 10 Result diagram of the Single test In all modalities the test has a duration according to the test results as described in the Smoke Measurements Section of the Service and User Manual pag 18 At the end of every test it is possible to find the test results in the result window and it is possible to print a report 4 6e Measurements ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti 17 Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 r a Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 198 User Manua Smoke Meter is showing here its measurements A string Out means that an over range situation has been detected A string means no data available When it is used a pre heating smoke meter if the Cell Temperature is above 70 C the window will became red 4 6f Sub form of test limits and manufacturer s data Limitis Setting Fig 11 The two form Limits Setting and Vehicle Data The Limits Setting form is filled with the following test limits RPMmin it s the lower limit for the RPM test RPMmax it s the upper limit for RPM test Opacity Threshold it s the smoke threshold in Smoke Limits test for starting the acqu
14. and maximum RPM measured during the test 4 61 Final opacity result window Here it s possible to read the average value calculated during the test This is the final test result 4 6m Starting the measurement With the command Measure we can start a calibration and after the calibration the Smoke Meter will be in Ready State If it was selected the Continuous mode the instrument will collect the values of measure continuously without comparing these values with the selected limits If we are in one of the other modes after the calibration a test starts with the modalities described into paragraph 1 6c 4 6n Going in manual measurement By the Progress command we advance in Manual measure After we have selected Manual measurement this command is not enabled until we aren t in Ready State and it came back to not enabled if we select a different Type of measure 4 60 Printing a test report A test report can be printed by pushing Printing command The printout will be printed on the default Windows printer When a test is finished we can print the report of this test several times until new test It is possible to print two types of report ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti 19 Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l Linee di rev
15. hamber Connect the other end of the hose onto the vehicle s exhaust pipe using one of the three metal fittings supplied with the instrument small probe with the conical fitting for pipes with diameters up to 35 mm medium probe for pipes with diameters of 35 to 80 mm big probe for exhaust pipes with diameters exceeding 80 mm Use the ballast to prevent engine s vibrations from shaking the hose loose during testing ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti 8 Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 r a Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 198 User Manua 4 INFPLUSWIN Software 4 1 Features of the program InfplusWin is a WINDOWS program which is able to connect to ASSEMBLAD equipments through their serial ports to take control to display and print the measured data InfplusWin has also the capability of generating several statistical and or analytical reports 4 2 Installation To install InfplusWin on your computer execute the file infpluswin150 exe that you find in the diskette and follow the instructions 15 Setup Infplus Win 1 50 Welcome to the Infplus Win 1 50 Setup Wizard This will install Infpluswin on your computer It is recommended that you close all other applications before continuing Click Next to continue or Cancel to exit Setup Fig 1 Setup page The software
16. iameter 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 Measurements displayed Smoke from 00 0 to 99 996 Smoke K m 1 from 0 00 to 9 99 Gas temp from 0 to 180 C Oil temp from 0 to 180 C SS Chamber temp from 45 to 180 C SS RPMs from 0 to 6000 rpm Start up and self test time 1 min normal Time for operating rates 15 min normal at 25 C Operating temperature 5 to 40 C Humidity range 4596 9096 Clearing measurement device Automatic Serial output RS 232 for connection to remote unit PC ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 r a Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l 2 4 POWER SUPPLY From mains Absorbed power 2 5 OTHER FEATURES Dimensions weight Std Exhaust pipe probe Ballast 2 6 FITTINGS SUPPLIED Sta
17. isione Green line N of approval TM dem M Year of first registration Temperature m C Pressure kPa Relative Humidity ana serial N Factory and Type Engine turns at min girismin Engine turns max girismin 6 Ml 5 AVERAGE OF THE VALUES Agency Linee di revisione Green line DMI A Year of first registration Sy Temperature Ls RG Pressure 43080 kPa Relative Humidity ts Engine turns at min girimin Temp engine oil C RPMmin 100 Opacity Threshold 615 Engine turns max giri min 1 Umm RPMmax 3500 Limtvaueotk BT N of approval 1 2 3 4 5 6 7 8 ur OF THE VALUES K RPM TEST RESULT ER date 2515 start measure PERRA end measure Agency Name ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 r a Fax 055 890496 E mail info assemblad it Web www assemblad it OPA 198 User Manua 20 Assemblad s r l OPA 198 User Manua Fig 13 Report B 4 7 RPM section Fig 14 RPM section This section shows one window in order to visualize the value of RPM or the oil Temperature a command for the selection the type of measure that you want to visualize o
18. isition of the peak Limit Value of K it s the limit for the K factor see User Manual pag 40 you must stay above this limit for pass the test The Vehicle Data form is filled by the information about the vehicle under test These information will be printed in the test report All values and string can be entered selecting the respective box by the mouse and then writing inside or selecting the box by TAB key from keyboard and then writing inside the box 4 6g Message window ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti 18 Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 r a Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 198 User Manua In this window operating messages and error messages are shown to allow the correct interface between the Smoke Meter and the operator In this window the operator can watch at any helpful message to carry out the test 4 6h Test result window In this window the test result is written at the end of every test if it wasn t chosen Continuous measure If the test is ok the back of the window becomes green and the label is TEST OK If the test is not ok not passed the back is red and the label is TEST KO 4 6i Intermediate test result window This window shows in the upper part the peak value for each acceleration done during the test and in the lower part the minimum
19. lowing reason Impossible 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 rom socket on the back cover of smoke meter Maintain the engine idle verify reading on green display the displayed value is rom divided by 10 Accelerate verifying the correct value of rpm displayed Proceed to measure according with the selected modality Troubleshooting If displayed rom 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
20. ndard accessories N 1 Rubber sampling hose N 3 Exhaust pipe connectors N 1 Ballast bag N 1 220 VAC mains lead N 1 Calibration filter preinstalled N 1 RPM probe N 1 This manual N 1 Oil temperature probe Optional Accessories ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti OPA 198 User Manua Single phase 220V 10 50 Hz 2 200VA max 660 x 545 x 255 mm 23 kg approx different sizes inside diameters of 10 17 and 27 mm to be connected to the hose of probe 2 kg approx to connect to the hose of probe Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 r a Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 198 User Manua 3 STARTING THE SMOKE METER 3 1 POWER SUPPLY CONNECTIONS Select the power supply for the smoke meter Usually 220 VAC mains power is used If it is not available connect the smoke meter to the battery of the vehicle being tested or to a fully charged shop battery MAINS POWER SUPPLY Connect the smoke meter to a 220 VAC outlet using the cable supplied with the device set the switch on the back to ON The ON LED on the keypad with will light up if you set the switch to OFF the LED will go out very slowly 3 2 PREPARATION FOR MEASUREMENTS Bring the engine to its normal operating temperature Fit the hose into the 19 mm fitting on the back of the measuring c
21. ne box for the selection and visualization of the Number of Cylinders one box for the selection of the Number of Strokes In order to change the type of measure you press with the mouse the button with the RPM icon or the Thermometer icon Otherwise to press TAB until the button is highlighted and after to press Enter in order to vary the selection In order to vary the Number of Cylinders you push with mouse the buttons or or to highlight them with TAB and to press Enter In order to select the Number of Strokes you press with mouse the wished choice or through keyboard you press at the same time ALT the underlined number In order to go out from the section you press with the mouse the x in the right hand corner or press the keys of keyboard ALT F4 or ESC ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti 21 Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 r a Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 198 User Manua 5 MEASURES 5 1 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 fol
22. never clear the smoke meter with the filter inserted gt 0 B 1 Full light regulation 2 Dark level regulation 3 Mean level regulation 4 Embedded optical filter 5 Light sensor device 6 Filter housing 7 Lamp holder ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti 27 Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l 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 198 User Manua K 1 m 2 49 2 55 2 62 2 70 2 17 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
23. perly 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 O Recalibrate the instrument ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti 25 Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 r a Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 198 User Manua 6 4 SMOKE INTERCEPT SOLENOID VALVE 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 usuall
24. ressure between the measuring chamber and the outside environment It is mounted 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 Servizio Assistenza Tecnica Clienti 23 Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 r a Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 198 User Manua 6 MAINTENANCE 6 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 of the smoke meter 3 Moisten a piece of cotton with denatured alcohol and clean the mirror 1 and the two glass plates 2 on the photoelectric cell 4 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 DAMA
25. s 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 ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti 5 Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 198 User Manua 2 TECHNICAL FEATURES 2 1 PHOTODETECTOR 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 d
26. sult window a command for start the measure Measure command a command to go on with the test in manual measure Progress command a command for printing a test report Print command ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 r a Fax 055 890496 E mail info assemblad it Web www assemblad it 5 Assemblad s r l OPA 198 User Manua All command buttons can pushed by a mouse click or by keyboard pushing together the ALT key the letter underscored To Exit from the section with mouse push the x in the upper right corner of the section or push the keys on the keyboard ALT F4 or ESC To change type of device type of fuel number of strokes and type of measure select the box of your choice with the mouse or push TAB until the box starts to be lighted and by the ARROW KEYS perform the selection and confirmation by the SPACE BAR 4 6a Type of device In this box it s possible to see the Smoke Meter that you have connected 4 6b Smoke Meter s status There is a Status window at the right top of the section describing the current Smoke Meter s status as Check Smoke Meter is checking itself Only for OPA391xxx Heating Smoke Meter is heating Auto zeroing Smoke Meter is calibrating itself Ready Smoke Meter is measuring Error Smoke Meter is in unrecoverable error
27. ttings Port COM1 Baud Rate 9600 Word 8 bits Stop 1bit Parity None If the default port COM1 or default Baud Rate don t match with your PC s port you have to switch the configured port or Baud Rate entering in the set up section using the Set Up command ATTENTION All the other parameters are fixed Now you can enter the gas analyzer section pushing on the Gas Analysis command If an error message will appear or the system respond very slowly please check again the wire connections as well as the communication parameters in use ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti 11 Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 r a Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 198 User Manua 4 4 Set Up section Fig 4 Start page of the Set Up section In this section you can set the communication parameters and instrument details mark and number of approval if required for Gas Analyser and Smoke Meter respectively into the Analyser sub form into the Smoke Meter and the RPM sub form that can reached by clicking the reference command buttons ASSEMBLAD S r l Costruzioni Elettroniche Servizio Assistenza Tecnica Clienti 12 Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 r a Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 198
28. y 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 Servizio Assistenza Tecnica Clienti 26 Via Marzabotto 4 50013 Campi Bisenzio Firenze Italia Tel 055 890485 Fax 055 890496 E mail info assemblad it Web www assemblad it Assemblad s r l OPA 198 User Manua 6 5 HOWTO CHECK THE CALIBRATION OF THE SMOKEMETER Along with the smoke meter an embedded optical filter with a well known absorption factor is supplied In order to check the proper operation of the equipment proceed as follows Clean all optical parts with care Switch on the equipment After that the following indicators must be lightened ON 96 CONT C Wait for the end of the initial drift for about 15 minutes Do a zeroing Look at the opacity display and verify this value against the nominal value of the filter as written in the calibration certificate issued along with the manual The maximum allowed deviation is of the 1 0 96 If a bigger deviation is found the Technical Service must be invoked as the recalibration with three sample filters is required Introducing the embedded filter till the position referred as A should generate an opacity value of 99 9 IMPORTANT
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