USER MANUAL
Contents
1. serrerre eee rie nie sie nie nie 33 9 WARRANTY ccccccoccocceccscceccsccsccsccsccsccscscescescescescescescescescestescescescescescescescescescestesceseeses 34 10 SAPPEND UG n en Genie eerta iode ie eS iet Nao IM E B D iU iE 35 ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 3 www assemblad it info assemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual 1 GENERAL The smokemeter OPA 105 is an instrument for the measure of light absorption of diesel engine exhaust fumes Before use read carefully this manual and follow the instructions to carry out any kind of measure and in particular for the maintenance operations Open the equipment only for operation where it is clearly requested after having switched it off close the instrument and put it in the original configuration before switch on again in particular be sure the cover has been locked with the screws Pay attention to the correct tubes connection avoid breathing fumes and make sure they can be dispersed in an open ambient The manufacturer decline every responsibility in case of an incorrect use or a use not expressly specified in this manual the responsibility is anyhow limited to the equipment s repair operation with the exclusion of any other direct or indirect damage For more information please read the chapter Warranty condition For technical support or spare parts requests contact Assemblad Tech2. a and aZ eemblad are Assemblad S r l trade marks ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia www assemblad it infoGQassemblad it 40
3. az eemblad SMOKE METER OPA 105 OPA 105 LCD OPA 105 PCB USER MANUAL Edition May 2010 Vers 3 01 ASSEMBLAD Technical office Automotive Division atan VM105 105LCD 105PCB GB301 01 2010 doc amp pdf M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual Note ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual INDEX A GENERAL osi ea eus nn a n a n ra na aa 4 2 TECHNICAL DATA ai oui sd woutin foi ina it Pn enn c a a ka c n lr v 5 2 1 OPERATIONAL CHARACTERISTIC cccccccccessesccssecescesccssseccssssessessessesscsscsucsucsuceuceuens 5 2 2 BASIC AND OPTIONAL FUNCTIONS cali e e alla 5 2 3 LIGHT REFLECTION SENSOR trente dnte teda atra teda ara teda sra teda a dran aaa 5 2 4 MEASURE BENCH FEATURES nie ei 6 25 ACCESSORIES uo Aria band ea Cr i ri antico 6 2 6 FRONT PANEL OPA 105 LCD tea ovaoeaoeareaoeaoeaoaaoeareareaoeaoeaoeooeasen 7 OFT REY BOA Diced ares cd estan i A e n dice 8 2 8 REAR PANEL OPA 105 LCD uecccccccccccocceccecccccccceccccsecsecsevsecsecsecseusecsausecseusevsensavsevevsuees 9 2 9 CONNECTOR PANEL OPA 105 treten tenter tentes trs nrc 10 2 10 CONNECTOR PANEL OPA 105 PCB entrer treten 10 2 11 DISPLAY AND MENU eee eee eee eee eee eee eee 11 212 THE SMOK
4. except for normal maintenance which Customer should get done at regular intervals d ASSEMBLAD can refuse to replace or repair defective parts until the Customer has fulfilled all his obligations as to ASSEMBLAD All repaired and replaced parts will be guaranteed like any new product f ASSEMBLAD obligation of warranty service is intended only with respect to the repair and or the replacement of the defective parts and covers only the parts not subject to wear i e the warranty does not cover external cables probes 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 is in any case limited to the price of the defective part stated on ASSEMBLAD invoice ASSEMBLAD is absolved from any other liability of any kind and for any reason unless specifically settled by the Italian Law D P R 24 05 1988 No 244 and under the terms set forth by the same Law ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 34 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual 10 APPENDIX Flow diagram of vehicle test procedure PERFORM 3 ACCELERATIONS AVERAGE lt LIMIT YES TEST PASSED PRINTOUT OF THE 3 VALUES NO J AVERAGE 2 150 OF LIMIT YES TEST NOT PASSED PRINTOUT OF THE 3 VALUES l l NO L PERFORM THE 4 ACCELERATION AVERAGE OF L
5. 1 Op K 2 Op 5 K 3 Toil 4 Rpm IT 0745 OPA 105LCD Prova RPM 1 Op K 2 0p 5 KS 00 03 3 Toil 4 Rpm OOO a2 4210 TEST OK OPA 105LCD Prova RPM 1 Op K 2 0p 3 03 00 00 00 0 TE 3 Toil 4 Rpm OSIO 0792 During the test phase the following data will be displayed Testtype 4 windows with measured value To select different parameters press the numeric key use arrows keys to select the required parameters press OK to confirm The measures made during the test and the final result QUAUSWNHE pp obo ud 1 2 3 rom 5 6 de Bo ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 16 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual 2 12 THE SMOKE METER PROBE Luce nz iii MA ANANA LA The smoke meter probe is composed with the follow parts 1 Terminal probe for exhaust pipe connection 2 Grip 3 Extension probe 60 cm 4 Extension probe 100 cm The terminal probe 1 must be inserted in the exhaust pipe of the diesel vehicle in the final side there is a spring to avoid a position near the side of exhaust pipe In the other side there is a junction to be connected to the smoke meter It is possible prolong the terminal probe with 1 or 2 extension probes 3 4 the smoke meter is homologated for the use with all the extensions supplied The grip 2 is useful to avoid to touch hot and dirty parts moreover the tongs can be
6. 6 Single with this selection it s possible to run a single acceleration in the same way as in the RPM mode and print the result graphic see picture below SINGLE ACCELERATION wda 00L 7 Aide DH HIS MIU SES E IEEE EET Ez E Ed ES E ER Ed Ec Eos 0 pa sh sus 2 muy os ae i A do wm p dms ov nus So ches qu Time sec Opacity RPM RPM RPMmin B d 601 nina Fig 10 Single test result graph 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 ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 29 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance 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 the field Cell Temp becomes red SUB FORMS LIMITS AND VEIHCLE DATA Limitis Setting Vehicle Data ALFA ROMEO RPMmin foco Factory and Type o UTD RPMmax 3500 Licence plate ARISIGT Limit Value of K Opacity 0 15 a Threshold i 1234567890 15 Year of first registration Fig 10 the
7. Firenze Italia 31 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual 6 STANDARD MAINTENANCE The following maintenance operations can be performed directly by the end user In case of calibration or non standard maintenance have to be carried out contact an Authorized Technical Service that will fix problems or will give instructions where to send the equipment for repair 6 1 VERIFY MEASURE WITH OPTICAL FILTER An optical filter with a certain absorption factor is supplied with the instrument it can be used to verify periodically the measures and calibration To check opacity values perform the following steps clean the protection screens insert the one on the connector side only the probe must be disconnected Switch on the smokemeter and wait 5 minutes select the Continua mode and perform an autozeroing by pressing the Start button insert the filter read the opacity value and compare it with the one written on the certificate supplied with the filter the difference between the two values must be within 0 05 K in case the difference is greater than 0 05 K the Technical Service must be contacted to perform an instrument calibration 6 2 INSTRUMENT AND PROBE CLEANING Before proceeding with the instrument cleaning disconnect the power supply Clean external parts using a wet cloth use water and not solvents or chemical products Do not
8. GB301 01 2010 doc amp paf Operation and Maintenance Manual 5 3 MENU SECTION Start men DER ASSEMBLAD Integrated System of Gas amp Smoke Analysis Fig 4 Menu section Selecting Opa you will go to the sub form where it s possible to enter the communication parameters Smoke Meter Baud Rate C 1200 9600 DATA Mak TT N of approval Fig 5 Sub form for smokemeter communication After the selection of the Baud Rate the COM port number and the instrument model 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 ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 25 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual With RPM User and Environmental data you will enter into the related sub forms to set values and information s used during the test and also printed in the final report With the button COM Reading you will enter into the utility menu that can be used to scan for Assemblad instruments connected to the PC and the COM ports available COM Reading COMI not connected COM2not connected COM3not connected COM4not connected COMSnot connected COM6not connected COMTnot connected COMBnot connected COM9not conne
9. InfplusWin or in another directory that can be selected during the installation Once the installation has been completed run InfplusWin161 exe in the InfplusWin directory or click on InfplusWin161 icon on the desktop 5 2 INFPLUS WIN FUNCTIONS Before run InfplusWin check that the connection between the serial port COMx of the personal computer and the instrument make sure the serial port COMx works properly When InfplusWin start a Main Menu will appear with 4 control keys the menu selection and the ASSEMBLAD logo ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 23 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual Start men Infra Mesi Rpm Language Utility Fig 3 Main Menu InfplusWin has the following default communication parameters set Port COM1 Baud Rate 9600 Word 8 bits Stop 1 bit Parity None If the default serial port number or the baud rate value are not the ones used by the PC serial port change them entering in the set up section with the F4 command ATTENTION other parameters cannot be changed It s possible to enter in the smokemeter section with the command OPA If an error message appears or the system responds very slowly check again the serial connection and the parameters ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 24 www assemblad it infoGQassemblad it M105 105LCD 105PCB
10. Operation and Maintenance Manual AMBIENT DATA AMBIENT DATA 1 Temperature 20 C 2 Amb pressure 1000hP 3 Rel humidity 355 4 Wind speed 0m s Use this menu to enter ambient data These data must be read from a dedicated instrument and they will be printed onto the test result report Press ESC to go back to the main menu LIMITS SETTING LIMITS SETTING Max RPM at minimum rate 1000 rpm Min RPM at accel rate 3500 rpm Min opacity e Oslo cK Max opacity t 255 oK Acceptable limits of the test are set in accordance with the vehicle data entered It is possible to edit the limits pressing the corresponding key delete the present limit enter a new value and press OK to confirm The limits 1 and 2 are used in the RPM test the limit 3 is used in the test Smoke test Press ESC to go back to the main menu ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 12 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual INSTRUMENTS INSTRUMENTS 1 ANALYSER 2 SMOKEMETER 3 RPM 4 5 SPEED TESTER REMOTE Press the corresponding numeric key to select the instrument you want to use then press OK to confirm If you need to connect and or control the equipment with a PC you must select REMOTE With this selection the PC will be able to communicate with the internal gas analyser
11. any kind of cracks Do not leave the instrument directly exposed to the sun light or under the rain Do not put the smokemeter over dusty and dirty surfaces or over whatever material can be suctioned by the lower fans Avoid crushes unstable positions vibrations and falls Do not pull probes or connection cables to avoid instrument falls Leave the smokemeter in a dry ambient and if possible at a normal ambient temperature Keep the reference optical filter in the original package and do not get it dirty ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 18 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual 4 OPERATION PUMA smokemeter is an instrument for the measurement of light absorption of Diesel engine emission smokes Measurement consists on verifying the attenuation of a light beam due to the absorption of the fume gases concentration in exam The smoke enters into the measurement cell maintained at a constant temperature where it is analyzed with a reflection transceiver The analyzed smoke then goes out through the fans positioned on the bottom part of the equipment An optical filter is supplied with the instrument and it can be used to verify the equipment functionality The smokemeter performs measure of exhaust fumes taken with the partial flow method connecting the steel probe to the exhaust pipe of the vehicle under test Make sure t
12. vehicles the battery connection and the positioning of the sensor are very easy and quick operations After connection the display will lighting select the number of strokes and the number of cylinders verify the correct reading on the display with motor at idle and with the acceleration Look for a place on the motor with good vibrations place the sensor in a steady position if there are not steel parts use a clamp verify the correct reading on the display Make attention to don t put the vibration sensor in hot places and to don t pull the cable to avoid irreparable damages If the sensor don t work properly select the battery impulses with the middle key If the rates are not regular try to switch on the lights of the vehicle in order to receive a better signal from battery With a little training on different kind of vehicles this operations will be fast and easy See the RPM 405 for details The RPM 405 is connected with a cable to the input RPM connector of the smoke meter with the instrument OPA 105 LCD is possible to connect the RPM 405 to the specific serial port ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 21 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual 4 5 BLUETOOTH CLASS 1 DEVICE The smoke meter must be connected to a PC to work normally this connection is made with a wire supplied that connect the RS232 port of the instrument wi
13. 2 forms Limits setting and Vehicle data In the form Limit setting the following values are showed RPMmin is the lower limit of the engine speed in the RPM mode RPMmax is the upper limit of the engine speed in the RPM mode Opacity Threshold is the opacity limit in the Smoke Limits mode to start the peak acquisition 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 both operative and error messages are displayed they enable the interface between the smokemeter and the user The user can read there important messages to perform the test ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 30 www assemblad it info assemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual TEST RESULT WINDOW In this window the test result can be read at the end of the measure 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 TE
14. A 105 LCD has a display to show the menu and the measurement Some part may be not enabled some other reserved for technical service The same menu is present in the gas analyzer INFRAGAS 205 when it is selected the instrument smoke meter MAIN MENU 26 10 09 OPA 105 LCD VEHICLE DATA AMBIENT DATA LIMITS SETTING INSTRUMENTS MAINTENANCE LANGUAGE This menu is displayed when we turn on the instrument and when we come back from other menu In the high left corner is showed the data in the upper centre is reported the selected instrument to operate the choice push the key number After a short time the backlight is switched off push the ESC key to restore Use the arrow keys to set the contrast of the LCD this function work only in this menu VEHICLE DATA VEHICLE DATA Plate Reg date dd mm yyyy Fuel type Diesel Chassis Vehicle typ Press the corresponding key number to select the value you want to set use the alphanumerical keys to enter a value then press OK to confirm The key delete previous character the key insert a space Before entering the registration date delete dd mm yyyy then enter the correct date The slash symbol will be automatically entered Press ESC to go back to the main menu ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 11 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf
15. AST 3 ACCELERATIONS lt LIMIT YES TEST PASSED l IS THE AVERAGE OF LAST 3 VALUES NO L PERFORM THE 5 ACCELERATION AVERAGE OF LAST 3 ACCELERATIONS lt LIMIT YES TEST PASSED l IS THE AVERAGE OF LAST 3 VALUES NO L PERFORM THE 6 ACCELERATION AVERAGE OF LAST 3 ACCELERATIONS lt LIMIT YES TEST PASSED IS THE AVERAGE OF LAST 3 VALUES l NO L PERFORM THE 7 ACCELERATION AVERAGE OF LAST 3 ACCELERATIONS lt LIMIT YES TEST PASSED l IS THE AVERAGE OF LAST 3 VALUES NO L AVERAGE OF LAST 4 ACCELERATIONS lt LIMIT YES TEST PASSED l IS THE AVERAGE OF LAST 4 VALUES NO L AVERAGE OF LAST 5 ACCELERATIONS lt LIMIT YES TEST PASSED IS THE AVERAGE OF LAST 5 VALUES l NO L PERFORM THE 8 ACCELERATION AVERAGE OF LAST 3 ACCELERATIONS lt LIMIT YES TEST PASSED IS THE AVERAGE OF LAST 3 VALUES l NO L AVERAGE OF LAST 4 ACCELERATIONS lt LIMIT YES TEST PASSED l IS THE AVERAGE OF LAST 4 VALUES NO L AVERAGE OF LAST 5 ACCELERATIONS lt LIMIT YES TEST PASSED l IS THE AVERAGE OF LAST 5 VALUES NO J TEST NOT PASSED PRINTOUT OF 8 VALUES THE RESULT IS THE AVERAGE OF LAST 3 VALUES ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia www assemblad it infoGQassemblad it PRINTOUT OF THE 4 VALUES THE RESULT PRINTOUT OF THE 5 VALUES THE RESULT PRINTOUT OF THE 6 VALUES THE RESULT PRINTOUT OF THE 7 VALUES THE RESULT PRINTOUT OF THE 7 VALUES THE RE
16. E METER PROBE clic 17 3 INSTALLATION AND TRANSPORTATION s csscosscsescosscceccesseseccerseseccarsesecearsnseces 18 zA CONNECTIONS qa m trm sesh eats ce kane AOL Em e o eo n orta 18 3 2 OPERATIONS TO AVOID eee ee eee eee eee erica 18 4 0OPERMION Galati 19 ad 3SET UP VEHIGEE tirati tina ARA a LARA LARA LIRA ARAN 19 4 2 MEASURE Lillian aiar 20 4 3 TEMPERATURE MEASURE ene ea 21 dA RENE uA oer tutor n LLL d AA 21 4 5 BLUETOOTH CLASS 1 DEVICE i 22 4 6 BATTERY PACK FOR OPA 105 AND OPA 105 LCD ii 22 AT Cod P sc S ome i Meier E mE AE LEE EE triti 22 4S8 WNC Ti NE le amd e rm essc iss eS tata n A n tic E ved td c ete 22 5 INFPLUS WIN SOFTWARE coded SO ee dt 23 E INSTALLATIONE ss lol at EM ERARIALI CRIME EM 23 5 2 INFPLUS WIN FUNCTIONS f rroan nananana na anane Eanan EEEE E aaan E Enaren aran 23 BS MENU SECTION toti ae ea ka avoy NA SOA N A Si 25 54 SMOKEMETER SECTION ete kata a oo a aa a cte e ano klib a 27 6 STANDARD MAINTENANCE cccrrerie rie rie eee rie eee iene viene iene iene eee 32 6 1 VERIFY MEASURE WITH OPTICAL FILTER e 32 6 2 INSTRUMENT AND PROBE CLEANING trenes 32 6 3 FUSE REPLACEMENT ccccccccsceccescescecescceccecssccscsssssecsessessessessessessessessessesecsecseesseses 32 7 TROUBLESHOOTING MM MM MM Moore o reo eee iaia eee iene eee 33 8 INFORMATION DIRECTIVE RAEE 9
17. ST 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 Remove the probe from the exhaust pipe pressing the button Start Measure the instrument calibration will begin when the smokemeter goes back in the measure status insert again the probe into the exhaust pipe 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 not active if the smokemeter is not in active or if another mode has been selected PRINT A TEST REPORT Its possible to print a test report with the button Print The printout will be sent to the Windows default printer Once the test is finished it s possible to print more than one report until a new test start It s possible to print 2 different kind of report ASSEMBLAD S r l 50013 Campi Bisenzio
18. SULT PRINTOUT OF THE 7 VALUES THE RESULT PRINTOUT OF THE 8 VALUES THE RESULT PRINTOUT OF THE 8 VALUES THE RESULT PRINTOUT OF THE 8 VALUES THE RESULT Co 5 M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual CONVERTION TABLE BETWEEN OPACITY VALUES IN PERCENTAGE 96 AND K ABSORPTION FACTOR 1 m K m K 1 m K 1 m 00 0 0 00 21 0 0 98 52 0 3 06 01 0 0 04 22 0 1 04 540 3 24 02 0 0 08 23 0 1 09 56 0 3 42 03 0 0 13 540 1 14 58 0 3 61 040 017 25 0 1 20 60 0 3 82 05 0 0 21 26 0 1 25 62 0 4 03 06 0 0 26 270 ON 64 0 4 26 07 0 0 30 28 0 1 37 66 0 4 50 08 0 0 35 29 0 1 43 68 0 4 75 09 0 0 39 30 0 1 49 70 0 5 02 10 0 0 44 31 0 1 55 72 0 5 30 11 0 0 49 32 0 1 61 74 0 5 61 12 0 0 53 34 0 1 73 76 0 5 95 13 0 0 58 36 0 1 86 78 0 6 31 14 0 0 63 38 0 1 99 80 0 6 71 15 0 0 68 40 0 2 13 82 0 7 14 16 0 0 73 420 2 27 84 0 7 64 17 0 0 78 44 0 2 42 86 0 8 19 18 0 0 83 46 0 2 57 88 0 8 83 19 0 0 88 48 0 2 72 90 0 9 59 20 0 0 93 50 0 2 89 90 9 9 99 Formula K In 1 N 100 L L bench optical length 0 24 m N value in TEST AMBIENT CONDITIONS DM 628 dated 23 10 96 The barometric pressure variations have influence on smokemeter test results for this reason it s important to know the real pressure value The ambient pressure must be within 850 and 1025 mbar When
19. al RPM counter data will be entered Press the corresponding numeric key to modify a value delete present value using key enter a new value and press OK to confirm With the selection RPM Enab Yes the measure will go on only if the RPM value is according with the RPM limit setting and the RPM value will be written in the report With the selection RPM Ext Yes the RPM value is acquired from the RPM meter connected to the serial port on the rear panel with the selection NO the RPM value is detected from the smoke meter Press ESC to go back to the previous menu INSTRUMENT DATA INSTRUMENT DATA Manuf ASSEMBLAD Model OPA 105 LCD Approv 0M00000b NET S N BEO70001 Exp data 03 06 2007 SW Ver 2342000 In this menu it is possible to read the information of the instrument connected Data cannot be modified read only they are acquired from the instrument Press ESC to go back to the previous menu AUTOZERO SCREEN In this screen is displayed the vehicle plate ant the opacity max from limits setting With F3 key is possible to select the follows type of measures Cont Test RPM Test Smoke Test Manual Test For detail see the paragraph MEASURE SELECTION ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 15 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual MEASUREMENT SCREEN Accelerate PPA 105LCD RPM Test
20. and with the connected smoke meter and RPM MAINTENANCE MAINTENANCE Date time setup Garage data RPM meter data Services Set Up Instrument data Leak test From this menu it is possible to enter on assistance and service functions Assistance and Set Up are restricted to authorized technical personnel only and the access require a password ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 13 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual SET DATE TIME DATE TIME SETUP 1 Year 6 2 Month 6 3 Day 26 4 5 Hour I S Minutes 56 Press the corresponding numeric key to modify a value delete present value using key enter a new value and press OK to confirm Press ESC to go back to the previous menu WORKSHOP DATA GARAGE DATA OPERATOR Press the corresponding numeric key to modify a value delete present value using key enter a new value and press OK to confirm max 24 character per line Press ESC to go back to the previous menu ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 14 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual RPM DATA Manuf ASSEMBLAD Model RPM 405 Approv 0M00539F NET S N ZA050001 Exp data 03 06 2007 RPM Enab Yes RPM Ext No In this menu the extern
21. asure and print the report 4 8 MCTC NET The smoke meter OPA 105 to communicate with a PC use the protocol MCTCNet RSSE the default address is 1 if there are some error the instrument sent a COD answer with the following meaning 1 Measure chamber has not reach the minimum operative temperature 2 Optical length dirty clean the 2 shields 3 Irrecoverable error restart the instrument if the error repeat call service 4 Led emitter is off 6 Command received cannot be executed in the present status 7 Measure chamber temperature is too high turn off the smoke meter ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 22 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual 5 INFPLUS WIN SOFTWARE INFPLUSWIN is a software developed to run on a PC with Windows operative system installed With Infplus Win it is possible to control the instrument and create reports 5 1 INSTALLATION To install the Infplus Win software run infpluswin exe from the disk and follow the instruction showed 15 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 Fig 1 Setup screen The software will be copied on the hard disk into the default directory
22. ata Alphanumerical data cancellation LCD contrast setting Choice of data to be displayed ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual 2 8 REAR PANEL OPA 105 LCD Main items on the rear panel of OPA 105 LCD Power on switch Instrument fuse Power supply plug External RPM Counter connection Oil temperature probe connection Led Gas input Shield 1 Shield 2 10 PC serial connection 11 Gas analyser serial connection 12 Speedometer serial connection 13 Universal RPM counter Serial connection OONOQOXHON ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf 2 9 CONNECTOR PANEL OPA 105 2 10 CONNECTOR PANEL OPA 105 PCB Operation and Maintenance Manual Main items on the connector panel of OPA 105 PCB 1 Power on switch 2 Instrument fuse 3 Power supply plug 4 External RPM Counter connection 5 Oil temperature probe connection 6 Led 10 PC serial connection 14 Battery fuse ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia www assemblad it infoGQassemblad it 10 M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual 2 11 DISPLAY AND MENU The smoke meter OP
23. cted COMI Onot connected COMI lnot connected COMI 2not connected COMI 3not connected COMI 4not connected COMI Snot connected COMI 6not connected Fig 6 COM Reading The Baud Rate for scanning is 9600 ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia www assemblad it infoGassemblad it 26 M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual 5 4 SMOKEMETER SECTION Smoke Analysis TEST RESULT E ES e ES e Id do E ES e ESS e en en L aa io men men Fig 9 SMOKEMETER SECTION In this section the following fields are displayed the model type the smokemeter status the Smoke stop device type a field to select the measure type all the measurements performed by the smokemeter two sub forms with the test limits through the button Limits Setting and the vehicle manufacture data through the button Vehicle Data an user messages field a test result field 10 intermediate result fields a final opacity result field a button to switch OPA 105 in the StandBy or in the Measure mode StandBy a button to start and stop the measure Start Measure a button to proceed with a manual test Progress a button to print the test report Print ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 27 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Ope
24. finished insert the probe into the exhaust pipe for at least 300 mm In the event that due to the exhaust pipe shape this is not possible extend the exhaust pipe with an additional tube verifying that there are no leaks On instruments supplied with the smoke stop valve the probe can be inserted at the beginning of the test setting the smokemeter in standby ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 19 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual 4 2 MEASURE Select the type of measure if RPM work properly is preferred to select it so the acquisition of opacity peak will be done in the correct range and the report will have the RPM values Otherwise it is possible to select the smoke limits with this method the acceleration counter will be increased when it is detect an increment of smoke this mode can have problem with vehicle with very low opacity values The time mode is practical but the operator must perform the operations accelerations and decelerations exactly when they are requested With manual mode the operator must have the PC near the operating site because he increments the acceleration counter with mouse or keyboard Engine and any turbocharger fitted to be at idle before the start of each free acceleration cycle Start the test The throttle pedal must be fully depressed quickly and continuously but not violently in less t
25. goods b All items manufactured by ASSEMBLAD will be repaired or replaced at its irrevocable option as promptly as possible when found and proved defective for vice of material or manufacturing or considerably prejudiced in their function within a 1 year from the date of delivery The defective parts must be returned to ASSEMBLAD factory or to an authorized service center entirely at Customer s expenses Eventual defects must be notified to ASSEMBLAD by letter within 8 eight days from their discovery otherwise any right will be forfeited In case of apparent defects the finish the treating of zinc colored or anyhow treated surfaces and all what is apparent the term of 8 eight days will run from the date of receipt of the goods The parts ASSEMBLAD replaces will become its property The present warranty does not include consumption parts i e nuts washers sleeves and so on c ASSEMBLAD obligation of warranty service will decay in the following cases whenever the installation has been made improperly or erroneously or not perfectly if the product has been improperly and carelessly used or put under unusual and excessive stress when the defect comes from having used the wrong tools or materials during installation or wrong use of the product as well as from chemical electrochemical and electrical effects whenever works repairs modifications or tampering have been made without ASSEMBLAD prior written authorization
26. han 0 4 second so as to obtain maximum delivery from the injection pump maintain that position for a period of 2 sec 1 0 and release maintain the engine at minimum running speed for a period of 3 sec 1 0 The opacity display will indicate the maximum opacity value reach in this phase In the monitor will be show the operation to do Repeat the accelerations until a stabilized average has been reached At the end of test print the report The test is passed when the average of the last 3 measures has a value lower than the K limit inserted if the average is greater other measures are requested The maximum number of tests is 8 for the measures method and data calculation refer to the applicable laws If the average of the last 3 measures is greater than the 50 of the limit value inserted the test will be stopped without asking for other cycles and the test will be considered NOT passed If the bench cell temperature is lower than 70T the test will be stopped and the instrument will go in the warm up status The test report will include smokemeter data measures performed calculated average results ambient data vehicle data and RPM data ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 20 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual 4 3 TEMPERATURE MEASURE The smoke temperature sensor is positioned on the T joint at the bench cell
27. hat the probe is properly inserted using the dedicated mechanism to avoid it can come out from the exhaust pipe when running the engine The probe can be connected to the short probe instrument interconnecting pipe or to the long one or with a combination of these depending on the needs 4 1 SET UP VEHICLE Visual inspect the relevant parts of the motor vehicle s emission system to check that there are no leaks e g cap the exhaust pipe when the engine run at minimum speed to find leaks verify that the interconnecting pipe from the probe to the instrument has a climbing gradient and it goes straight Insert the oil temperature probe Run the engine Make the vehicle data registration verify the K value limit applicable to the vehicle under test Disconnect all the devices that can have influence to the engine minimum running speed except for the ones expressly required by the vehicle manufacturer or by law If it is available the external RPM connect it to the vehicle battery set the number of cylinders verify if the RPM value can be detected from battery otherwise use the vibration sensor see the RPM chapter for details Insert the oil temperature probe wait for the motor normal operating temperature typical over 80C Make three or more free accelerations the throttle pedal must be fully depressed quickly and continuously wait some seconds from an acceleration to the next one Perform the zeroing of the instrument when it is
28. input It can be checked by removing the instrument cover The bench cell temperature sensor is mounted on the bench itself inside the insulation cover The oil temperature sensor is into the oil probe that must be inserted into the dipstick hole and must be connected to the lateral side of the instrument If it is used the external RPM it is possible to detect the oil temperature with the sensor of this instrument to use this sensor enable it in the setup page of the external RPM after this selection the oil probe connected to the smoke meter will not be read 4 4 RPM The measure of diesel engine RPM it s a difficult operation due to the fact that electric signals are missing The easiest solution is based on a piezoelectric sensor positioned on the fuel supply tube that converts the pressure variation in an electric signal The piezo sensor is connected to the connector placed in the smokemeter side This system does not guarantee a good result in all the situations for the following reasons The sensor cannot be put on the fuel supply tube because of lack of space Excessive engine vibrations that cannot make the signal available Engines that do not use a standard injection pump e g common rail A better method is to use an external RPM counter RPM 405 that measures the engine speed through the engine vibration and or through the alternator voltage residual peak the system that use these 2 techniques works with almost all
29. lable or contact the Technical Service The INFPLUSWIN software can display the following error type ERROR 1 the bench cell does not reach the minimum operative temperature ERROR 2 optical path dirty verify and clean the optical parts in the bench cell ERROR 3 fatal error switch off the equipment and search for the fault cause ERROR 4 Led switched off or burned ERROR 6 operation not allowed in the present status of the equipment ERROR 7 bench cell temperature gt 95 switch off the instrument 8 INFORMATION Directive RAEE The symbol RK stamped on the equipment means that when the product will be at the end of its operative life it shall be consider as a special refusal and shall be a special dismantle For this reason the user shall take it to a Dismantle Center authorized by Local Authority or to an authorized distributor for purchasing a new equivalent equipment European Directives 2002 95 CE 2002 96 CE and 2003 108 CE ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 33 www assemblad it info assemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual 9 WARRANTY a ASSEMBLAD products are manufactured with care and carefully inspected before they left the factory To have full rights of warranty and avoid the risk of invalidation the Customer must mail a signed copy of the Warranty Certificate to ASSEMBLAD within 10 days from the receiving of the
30. nical Support The smokemeter performs measure of exhaust fumes with a partial flow the measure bench cell is a reflection type The equipment performs measure in accordance with the European Directive 1999 52 CE and the Italian D M del 7 Agosto 2000 and Circolare 6902 604 del 4 Agosto 2000 The smokemeter is approved for the communication protocol defined by the technical specifications MCTCNET version 1 0 dated 23 06 1999 and subsequent integrations ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 4 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf 2 TECHNICAL DATA Operation and Maintenance Manual 2 1 OPERATIONAL CHARACTERISTIC Calibration Measures execution Measure presentation Measures range Warming time Operational temperature Operational humidity Dimensions Weight Exhaust pipe connection Power supply Power Automatic at power up Controlled by microprocessor and PC Monitor or control unit Opacity 96 00 0 100 res 0 1 96 Opacity K 1 m 0 00 99 99 res 0 01 K Fumes Temp 0 0 150 0 res 0 1 C Oil Temp 0 0 150 0 res 0 1 C Internal Temp 0 0 100 0 res 0 1 C RPM 400 9999 res 1 rpm 5 minutes T amb 25 C 0 445 C lt 90 Yo 263 x 84 x 155 mm OPA 105 Ixwxh 275 x 166 x 155 mm OPA 105 PCB 344 x 270 x 160 mm OPA 105 LCD 2 Kg without pipes 4 7 Kg OPA 105 PCB without pipes 4 0 Kg OPA 105 LCD without pipe
31. ration and Maintenance Manual All functions are available clicking with the mouse on the buttons or through the keyboard pressing ALT the underline letter 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 INSTRUMENT TYPE In this field it is showed the smokemeter model connected to the PC 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 SMOKE STOP DEVICE TYPE Below the Status field there is an indication of which kind of Smoke stop device is currently used during the auto zeroing phase The indication depends on the type of device Elect Valve if an electric valve is used Sled Opened or Sled Close if a sledge is present Not Present if there s no device MEASURE SELECTION With this selection it s possible to select the type of measure to ca
32. rry 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 ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 28 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual 3 Smoke Limits with this selection is possible to carry out a test where each 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
33. s Auto adapting with flexible joint 10 5 15 Vcc max 3A 110 220 Vca with external power supply 40 W max 2 2 BASIC AND OPTIONAL FUNCTIONS Controls Oil temperature probe Internal temperature probe Fumes temperature probe Communication Interface RPM Continuous measure Official measure through control unit or PC connected to the equipment Integrated Integrated RS232 internal 19200 8 N 1 RS232 external 9600 8 N 1 Bluetooth optional external RPM connection or piezo sensor optional for power bench test in accordance with Directive 1999 52 CE 2 3 LIGHT REFLECTION SENSOR Type Transmitter Receiver Function check reflection Green Led 550 570 nm Photo diode amplified Optical filter N D ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia www assemblad it info assemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual 2 4 MEASURE BENCH FEATURES Bench Ventilation controlled flow Length of measure bench 120 mm Internal diameter of measure bench 20 mm Real length of the exhaust fume sample 240 mm Fume input Balanced Fume output normal Pressure sensor Barometric solid Measure bench Interchangeable Bench mechanics Inspectionable Bench temp 70T 2 5 ACCESSORIES The following accessories are supplied with the smokemeter N 2 reinforced Teflon tubes for fumes input N 1 probe terminal for exhaust pipe connection N 1 12 Vcc cable with ba
34. th the one of the computer this wire connection can be replace with a radio link that works under the standard of blue tooth it is composed of two parts the blue tooth interface is connected to the RS232 port of the OPA 105 the blue tooth key is connected to an USB port of the computer The PC must be setup for the use of the key and it communicates with the smoke meter like any other blue tooth instrument it assign a communication port number that must be reported in the communication setup of the smokemeter program The instrument don t need of any initialization The characteristic and performance of this link are conformed to the blue tooth class 1 4 6 BATTERY PACK FOR OPA 105 AND OPA 105 LCD Battery Pack 105 is an optional device that provides power supply to smoke meter OPA 105 in absence of an electrical network in order to use the equipment everywhere Usually it is fixed under the smoke meter using 4 screws becoming unique equipment very compact and easy to use After use switch off the smokemeter and recharge always the battery Fully recharge if not used for a long period at least once per month Read the specific manual for details 4 7 GAS ANALYSER The OPA 105 LCD can manage the measure on vehicle with spark engines with a gas analyzer like INFRAGAS 109 The gas analyzer can be connected to the specific serial connection in the main menu select instrument gas analyzer OPA 105 LCD is able to control all the me
35. the smokemeter is operated with an ambient pressure between 945 mbar and 850 mbar the measured value is reduced by 0 25 1 m This has to be checked if possible in absence of wind in any case the vehicle and the smokemeter exhausts must not be against the wind ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 36 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Note ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia www assemblad it infoGQassemblad it Operation and Maintenance Manual 37 M105 105LCD 105PCB GB301 01 2010 doc amp paf Note ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia www assemblad it infoGQassemblad it Operation and Maintenance Manual 38 M105 105LCD 105PCB GB301 01 2010 doc amp paf Note ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia www assemblad it infoGQassemblad it Operation and Maintenance Manual 39 M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual COPYRIGHT by ASSEMBLAD S Via V Veneto 40 50013 Campi Bisenzio Firenze Italia Tel 39 055 89 04 85 Fax 39 055 89 04 96 http www assemblad it E mail info assemblad it Reproduction and or disclosure prohibited All rights reserved di C This object is in conformity with the requirements of the following documents 2004 108 CE 2006 95 CE Standards EN 61326 1 EN 61010 1
36. ttery clamps N 1 serial cable 5 m N 2 protection shields N 1 optical filter N D for function check N 1 maintenance and operational manual N 1 power supply AC DC 220 12 Vcc or battery charg er The following optional can be supplied with the smokemeter N 1 external universal RPM counter N 1 bluetooth class 1 device N 1 battery pack for OPA 105 N 1 elbow joint for vertical discharge N 1 12 Vcc cable with cigarette lighter plug N 1 oil temperature probe AD N 1 oil temperature probe for trucks AD N 1 RPM probe with piezo sensor ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual 2 6 FRONT PANEL OPA 105 LCD o i Main items on the front panel of OPA 105 LCD 1 Display LCD 2 Keyboard 3 Thermal printer ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual 2 7 KEYBOARD Keyboard OPA 105 LCD Key MEAS Key OK PRINT Key F3 Key ESC Key 0 9 Key Arrows Start measure Confirm entered data Print results when test is finished Force test to continue or end also in case of non positive data Stop test execution and go back to main menu Go back of one level when into a menu Alphanumerical data input mobile phone style Choice of set up d
37. use compressed air Remove the probe and using compressed air blow into the probe from the side that is usually connected to the instrument not into the terminal side Water with detergent can be used but make sure the probe is not wet before using it again Do not use compressed air into the smokemeter connection joint 6 3 FUSE REPLACEMENT The fuse is placed on the lateral side it has a value of 3A 5x20 replace the fuse as follow Disconnect the power supply Unscrew the fuse cap Remove the fuse replace it and screw the fuse cap Do not use fuse with a different value If the fuse will burn immediately after the replacement do not perform any action and contact the Technical Service ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 32 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual 7 TROUBLESHOOTING During start up calibration and measure phases the smokemeter could detect some faults The software will display a message to the user and in case of fatal error it will stop operations In some case the software advise also for the corrective action Before carry out a repair switch off the instrument and inspect internally verifying that all cables and plugs are correctly inserted after that switch on the smokemeter again to check the fault is disappear If the fault is still there follow the specific error instruction if avai
38. used to close the terminal probe with the exhaust pipe ASSEMBLAD S r l 50013 Campi Bisenzio Firenze Italia 17 www assemblad it infoGQassemblad it M105 105LCD 105PCB GB301 01 2010 doc amp paf Operation and Maintenance Manual 3 INSTALLATION AND TRANSPORTATION Installation is easy and can be performed by the user or if required by Assemblad authorized personnel Due to the small dimensions of the equipment transportation can be done by hand pay attention to avoid crashes or falls damages caused for these reasons are not covered by warranty 3 1 CONNECTIONS The smokemeter works with a nominal 12 Vcc power supply Use the power supply cable to connect it to a battery or use the external supply to connect it to the power network a cable with a cigarette lighter plug can be requested as an optional If the instrument has a battery connect this one to the charger pay attention to don t discharge completely the battery Connect the smokemeter to the serial port of a personal computer using the RS232 input the connection can be replaced with the Bluetooth link in this case connect the Bluetooth interface to the smokemeter serial port and the Bluetooth key to the PC Connect the probe terminal to the smokemeter joint using one or two tubes Press the lateral power button to switch on the instrument and verify that the led come on 3 2 OPERATIONS TO AVOID Do not bend or stress excessively the fume input tube and avoid
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