AVL 439 Opacimeter - Dynamometer World Ltd 439... · 2016-01-25 · AVL 439 Opacimeter As of...

Operat ing Manual

AVL 439 Opac imeter

As of Opac imeter Rev . 03 / SN 1569SW ver . 2 .64 and later (AVL 439)

SW ver . Ox1.25 and later (AVL 4210)

November 2003

AT1307E, Rev. 03

The contents of this document may not be reproduced in any form

or communicated to any third party without the prior written

consent of AVL. While every effort is made to ensure its correctness,

AVL assumes no responsibility neither for errors and omissions

which may occur in this document nor for damage caused by them.

All mentioned trademarks or registered trademarks are owned by

their respective owners.

Printed in Austria at AVL All rights reserved

Copyright 2003 by AVL List GmbH, Graz - Austria

1

This manual contains important warnings and safety instructions to be observed by the user.

The product described in this manual is intended for one specific area of application which is defined in the instructions. The manual also explains the essential requirements for the application and operation of the product as well as safety precautions to ensure smooth operation. AVL can provide no guarantee or accept any liability for applications other than those described in this manual or for applications where the essential requirements and safety precautions are not met.

The product may only be used and operated by qualified personnel capable of observing the necessary safety precautions. All accessories and equipment used with the product must be supplied or approved by AVL. The operating principle of this product is such that the accuracy of the measurement results depends not only on the correct operation and functioning of the product, but also on a variety of peripheral condi-tions beyond the control of the manufacturer. The results obtained from this product therefore must be examined by an expert (e.g. for plausi-bility) before any action is taken that is based on the results.

All adjustment and maintenance work necessary on instruments when open and under voltage must be carried out by a professional techni-cian who is aware of the dangers.

All repairs to the product are to be carried out by the manufacturer or qualified service personnel only.

When the product is in use, an expert must ensure that neither the test object nor the testing equipment is operated under conditions that could lead to damage or injury.

List GmbH

AVL 439 OpacimeterAVL 439 OpacimeterAVL 439 OpacimeterAVL 439 OpacimeterOperating ManualOperating ManualOperating ManualOperating Manual

2

ATTENTION!Connected equipment that uses voltages higher than or equal to 50 V AC or 75 V DC must comply with the Low Voltage Directive 73/23/EEC.

This device must not be used in any environment where there is a danger of explosion. The Opacimeter must not be used to measure explosive exhaust gas mixtures.

Note the device's degree of protection.

To ensure that the risk of electric shock is minimised, the device may only be opened by qualified personnel.

Exhaust gases from internal combustion engines contain toxic substances!

Make sure that the room is properly ventilated and that the exhaust gas is correctly conducted away.

Make sure the probe connections with the exhaust line and the instru-ment are gas-tight.

The probe can become very hot be careful, danger of burning!

Always select "Function off" mode before turning off the Opacimeter!

The gas path of the opacimeter must never be subjected to blasts of compressed air.

Important: To comply with the requirements of the 89/336/EEC Direc-tive on electromagnetic compatibility, only shielded cables with appro-priately shielded plug connections may be used.

Mains connections with standard plugs and the specific cases listed as exceptions do not have to be shielded.

If a foreign body or liquid gets inside the device, disconnect it from the mains and have an expert check it before using it again.

Make sure that the device is supplied with the correct supply voltage.

Only use the supplied network cable with protective ground.

Only connect the network cable to a socket with an earth contact.

Disconnect the equipment from the mains when you change a fuse.

The Opacimeter must not be purged during measurements on exhaust gases with high concentrations of HC, hydrogen or CO, for example, because that can affect the engine.

Ensure that the sampling line travels uphill from the exhaust to the Opacimeter to prevent condensate from forming.

The Opacimeter weighs about 47 kg always use suitable aids there-fore when transporting or moving it.

h t t p : / / w w w . a v l . c o m / e m i s s i o n s

3

Important: Ventilation openings must never be blocked.

Do not set up the Opacimeter in the following places:

near heating systems or hot-air blowers

where it is directly affected by dust, heavy mechanical vibra-tions or impact/shock

in rain or damp conditions

on sloping surfaces (due to risk of tipping over)

Do not place it where it can be affected by sprayed water (e.g. when cleaning the test bed).

If the fuse trips repeatedly, disconnect the mains power supply.

Disconnect the Opacimeter from the power supply and from the exhaust line whenever it is not in use for long periods of time and observe the instructions in Section Maintenance and Storage on page 123.

Only ever use original AVL spare parts.

The instrument specifications can no longer be guaranteed if non-AVL original spare parts are used and

this also invalidates the guarantee.

Note the legal regulations in effect in the respective country, in which the device is operated, for the disposal of the product or its compo-nents (e.g. regulations of the disposal of electronic scrap).


4


Table of Contents 5

Table of Contents

1 What You Should Know............................................................................................... 91.1 Safety Instructions......................................................... 91.2 Intended Application...................................................... 91.3 Application Area............................................................. 91.4 Application Restrictions.............................................. 101.5 Typographic Conventions........................................... 111.6 We Want to Hear from You.......................................... 11

2 Method of Operation.................................................................................................. 132.1 Measurement Principle................................................ 132.2 Beer-Lambert Law........................................................ 132.3 Operating Modes.......................................................... 15

2.3.1 Measurement ............................................................. 162.3.2 Zeroing ....................................................................... 162.3.3 Checking the Zero Point............................................. 162.3.4 Pause......................................................................... 172.3.5 Function off ................................................................ 172.3.6 Linearity Check ("LIN Check").................................... 172.3.7 Calibration .................................................................. 182.3.8 Back-flushing of the Probe......................................... 18

2.4 Function Description ................................................... 192.4.1 Gas Path .................................................................... 192.4.2 Measuring Unit ........................................................... 21

3 Opacimeter Design, Options and Accessories ....................................................... 253.1 Basic Unit...................................................................... 253.2 Options.......................................................................... 30

3.2.1 Sample Lines ............................................................. 303.2.2 AVL 4210 Instrument Controller................................. 323.2.3 PC-Software............................................................... 333.2.4 19" Mounting Frame for AVL 4210 Instrument Controller333.2.5 19" Bench Cabinet for AVL 4210 Instrument Controller343.2.6 ½ 19" Bench Cabinet for AVL 4210 Instrument Controller343.2.7 Wall Mounting Console .............................................. 353.2.8 Trolley ........................................................................ 363.2.9 I/O Cables (Analog Cable) ......................................... 363.2.10 Probe for Open Exhaust Pipe .................................... 36


Table of Contents6

4 Installation .................................................................................................................. 374.1 Commissioning ............................................................ 374.2 Placing the Opacimeter on a Surface......................... 37

4.2.1 General ...................................................................... 384.2.2 Wall Mounting Console Option................................... 394.2.3 Trolley Option............................................................. 40

4.3 Exhaust Gas Routing................................................... 414.3.1 Connections on the Opacimeter................................. 414.3.2 Fitting of Zero Air Valve, Sampling Lines and Probes 424.3.3 Exhaust Gas Recirculation......................................... 484.3.4 Installation Instructions for Tube Fittings.................... 49

4.4 Compressed Air Supply .............................................. 494.5 Power Supply ............................................................... 514.6 Interfaces ...................................................................... 52

4.6.1 Serial Interfaces ......................................................... 534.6.2 Digital Interface ("Digital I/O") .................................... 544.6.3 Analog Measurement Value Output ........................... 584.6.4 Connecting the AVL 4210 Instrument Controller or PC604.6.5 Configuring the AVL 4210 Instrument Controller ....... 60

4.7 DIL Switches................................................................. 63

5 Measurements............................................................................................................ 655.1 Brief Instructions ......................................................... 65

5.1.1 Overview of Opacimeter Functions ............................ 655.1.2 Carrying out a Measurement...................................... 665.1.3 Reading stability......................................................... 675.1.4 Safety Instructions in Special Conditions................... 67

5.2 Setting the Function and Measurement Value Output685.2.1 AVL 4210 Instrument Controller................................. 685.2.2 Control via Serial Interface or Terminal Program of a PC715.2.3 Control via Hybrid Interface ("DIO") ........................... 72

5.3 Switching On and Warming Up Getting the Opacimeter Ready for Measurement735.4 Zeroing .......................................................................... 755.5 Continuous Measurement (Standard Measurement) 785.6 Peak Value Measurement (ECE R24 or EEC 72/306, ELR)80

5.6.1 General ...................................................................... 805.6.2 Example 1: ELR Test ................................................. 835.6.3 Example 2: ECE R24 (EEC72/306) Test ................... 86

5.7 Checking the Zero Point.............................................. 885.8 Setting the Parameters ................................................ 89

5.8.1 Measurement parameters .......................................... 895.8.2 Device Parameters (ambient pressure, spread of analog signal, conditioning temperature and

operating hours counter) ............................................ 92


Table of Contents 7

5.9 Operation with the DIO interface ................................ 945.10 Measurement Value Calculation ................................. 95

5.10.1 Determination of Zero Value ...................................... 955.10.2 Calculation of the Raw Value ..................................... 955.10.3 Filter Calculation ........................................................ 96

6 Calibration and Checking........................................................................................ 1036.1 General........................................................................ 1036.2 Linearity Test ("LIN Check") ..................................... 1046.3 Linearity Check ("Calibration") with "Neutral Density Filters"1066.4 Calibrating the Sensors............................................. 110

7 RS232 Interface / AK Generic Communication Interface ..................................... 1117.1 General........................................................................ 111

7.1.1 Protocol Framework ................................................. 1117.1.2 Operating Mode ....................................................... 1147.1.3 Command Set .......................................................... 114

7.2 General Queries ......................................................... 1157.3 General Control Commands ..................................... 1177.4 Measurement .............................................................. 1177.5 Service ........................................................................ 121

8 Maintenance and Storage........................................................................................ 1238.1 General........................................................................ 1238.2 Changing the Filter Element ..................................... 1248.3 Cleaning the Window Modules ................................. 1278.4 Cleaning the Sampling Lines .................................... 1318.5 1000 Hour Service ...................................................... 1328.6 Storage for Long Periods of Non-Use...................... 133

9 Error Table................................................................................................................ 1359.1 Error codes ................................................................. 1359.2 Causes of Error, Remedies ....................................... 136


Table of Contents8

10 Service ......................................................................................................................14310.1 Function Check .......................................................... 143

10.1.1 Device Parameters................................................... 14310.1.2 Limit Values for the Device Parameters when Instrument Functioning Correctly14510.1.3 Pump Service........................................................... 14610.1.4 Leak Check .............................................................. 14710.1.5 Exchanging Temperature Sensors........................... 14810.1.6 Software Update ...................................................... 151

10.2 Electronics.................................................................. 15210.2.1 Electric Components ................................................ 15210.2.2 Components of the Electronics Board...................... 15310.2.3 Function Check of the Electronics............................ 154

11 Spare Parts List........................................................................................................ 155

12 Technical Data.......................................................................................................... 163

13 Appendix................................................................................................................... 16713.1 Mounting Instructions -

439 Wall Mounting Console ...................................... 16713.2 Mounting Instructions -

Probe for Open Exhaust ............................................ 16813.3 Valve Block (complete).............................................. 16913.4 Measuring Chamber................................................... 17013.5 Probe Heating............................................................. 17213.6 Gas Path...................................................................... 17413.7 Pneumatics ................................................................. 17513.8 Electronics / Assembly.............................................. 17713.9 Block Diagrams, Wiring............................................. 17913.10 Wiring Basic Unit ....................................................... 18013.11 Electronic Wiring Diagram ........................................ 18213.12 Components Location Diagram................................ 18313.13 Circuit Diagrams ........................................................ 18413.14 Comparison Table...................................................... 190


Safety Instructions 9

1 What You Should Know

1.1 Safety Instructions

This documentation contains important warnings and safety instruc-tions to be observed by the user. Smooth operation only is ensured, if the necessary prerequisites and safety measures are kept.

1.2 Intended Application

This product is only intended for the area of application which is described in the instructions. No warranty and/or liability will be granted, if the product is applied in areas other than those described, or if the necessary prerequisites and safety measures are not met.

1.3 Application Area

The AVL 439 Opacimeter is designed for use on engine test beds.

The opacity of the exhaust gas can be determined both in static and in dynamic engine state. This instrument is therefore suitable for use in research, development and manufacturing.

The AVL 439 Opacimeter meets the requirements of the following regulations

EC Council Directive 72/306/EEC resp. ECE R24

EC Council Directive 77/537/EEC incl. Addendum 82/890/EEC

EC Council Directive 1999/96/EEC

The AVL 439 Opacimeter also complies with

NFR 10-025

ISO 11614 (which replaces ISO 3171)

ISO 8178-9


Application Restrictions10

1.4 Application Restrictions

Basically the AVL 439 Opacimeter must not be used to measure explo-sive gas (especially exhaust gas) mixtures because such mixtures could ignite in the measuring cell due to the high temperature of the cell's self-regenerating heated window (approx. 500 600° C). That would irreparably damage the measuring cell and the Opacimeter.

The AVL 439 Opacimeter must not be used to measure emissions of gas mixtures that are flammable or even explosive when mixed with air, as sometimes occur upstream of actively regenerated catalytic converters (e.g. a NOx adsorber catalyst during HCs injection into the exhaust line if the exhaust contains a high oxygen content).

The AVL 439 Opacimeter must not be used to measure exhaust gases with very high hydrogen content (e.g. reformer exhaust gas, even with no residual oxygen in the measurement gas) i.e. greater than 2 % H2 residual content in the measurement gas.

A continuous hydrogen concentration of 2 % or HC concentration of 30000 ppm C1 must not be exceeded if there is overpressure at the sampling point.

The maximum CO concentration should not exceed 6 %.

Even if there is absolutely no danger of explosive mixtures entering the Opacimeter's measuring chamber, the customary and the legal safety precautions for test beds must be observed. In particular, note that no-one may enter the test bed cell while the engine is running. If the Opacimeter is set up outside the test bed cell and it is used in the crit-ical conditions described above, a protective wall must be installed to prevent any possible injury to personnel.

Sampling upstream of an exhaust aftertreatment system

During purge (approx. 90 l/min, 5 times for 2 s, pulsed) ambient air is forced into the exhaust gas via the probe which can affect catalytic converter activity particularly in an actively regenerating exhaust after-treatment system (e.g. NOX adsorber or SCR) due to the oxygen content of the added air.

Back-flushing will affect the control of a lambda controlled engine / catalyst system if the opacimeter is mounted upstream of the catalyst.


Typographic Conventions 11

1.5 Typographic Conventions

This documentation uses the following icons and standard text styles:

1.6 We Want to Hear from You

AVL continually strives to improve its documentation and, with this thought in mind, we would like to hear what you have to say about it.

Whether you want to suggest an improvement to a particular manual, complain that a concept is not explained well enough or point out an error, we want to know.

To this end, we have created the following e-mail address for all docu-mentation-based correspondence:

[email protected]

We look forward to hearing from you!

ATTENTION:

Icon and text indicate a warning of situations or actions that could potentially lead to personal injury, hardware damages and/or signifi-cant data loss.

Important: Icon and text indicate very important information without which you would not be able to successfully finish the actions described in this documentation.

Note: Icon and text refer to further information (tip, literature, etc.)

Example: Describes an example that applies to the current topic.


We Want to Hear from You12


Measurement Principle 13

2 Method of Operation

2.1 Measurement Principle

The AVL 439 Opacimeter measures the opacity of contaminated air, in particular of diesel exhaust emissions.

A measuring chamber of defined measuring length and non-reflecting surface is filled homogeneously with exhaust gas. The loss of light intensity between a light source and a receiver is measured and from it the opacity of the exhaust gas calculated. The calculation is based on the Beer-Lambert law.

2.2 Beer-Lambert Law

As electromagnetic radiation i.e. also visible light propagates through a medium, its intensity decreases along the length of its path.

In our measurement, the light extinction occurs in an exhaust gas charged with soot particulate.

According to Beer-Lambert Law, the light extinction behaves as follows:

I0 intensity of the light at detector without absorbing medium (exhaust gas particulates)

I intensity of the light at detector with absorbing medium (exhaust gas particulates) after travelling the measuring length

k [m-1] absorption coefficientL [m] measuring length (= 0.430 m; see Section Technical Data on page 163).

Fig. 1

kLeII −⋅= 0

Soot particulate

Lamp

II0

Detector

L = Leff


Beer-Lambert Law14

Opacity N [%] is defined by

This gives us the following:

The calculated absorption coefficient is corrected to a standard temperature and atmospheric pressure (in accordance with ISO 11614):

with

Since

the corrected opacity is calculated as follows using the corrected absorption coefficient

kcorr [m-1] corrected absorption coefficientk [m-1] absorption coefficient calculated from measured

opacity valueTGas [K] measured mean gas temperature in the measuring

chamberTNorm [K] standard temperature Opacimeter (373 K)patm [kPa] atmospheric pressurepgem [kPa] pressure in the measuring chamber

Ncorr [%] corrected opacity value

1001

0

NII −=

kLeN −=−100

1

kLN =

−−100

1ln

L

N

k

−−= 100

1ln

( )gem

atm

Norm

GasN

corr pp

TT

Lk ⋅⋅

−−= 1001ln

( )k

L

N=

−− 1001ln

kLeN −=−100

1

( )Lkcorr

correN −−⋅= 1100


Operating Modes 15

Because of the formulas shown above, the opacity must not be temperature- and pressure-corrected directly. It must first be calculated as the absorption coefficient and then converted again to opacity (in per cent).

The procedure for temperature and pressure correction is defined by the equations above.

The AVL 439 Opacimeter has both a pressure sensor and a tempera-ture sensor. The displayed opacity values and absorption coefficients are temperature and pressure-corrected.

2.3 Operating Modes

The Opacimeter has the following operating modes and states:

measurement

zeroing

checking the zero point

pause

function off

as well as the following functions

linearity check

calibration

back-flush of the probe.

When reading the mode descriptions below refer to the diagram of the gas flow (Fig. 2 on page 20). For a detailed description of the gas flow, see Section Gas Path on page 19.

Note:

At a supply voltage of 60 Hz, the pumps run at a higher speed, and the flow is increased by approx. 10 %. This has no impact on the measured values. The instrument automatically recognises the frequency of the supply voltage and adapts the control system limits accordingly.


Operating Modes16

2.3.1 Measurement

The opacity of the exhaust gas is measured as it flows through the Opacimeter.

The sampled gas is conditioned in the sample conditioning tube. Heated compressed air is conducted around the probe line thus ensuring that the temperature of the sample is constant as it enters the Opacimeter.

The opacity is calculated from the detector element signal in accor-dance with Beer-Lambert Law and is available as an output value.

The various types of measurement available are described under Measurements on page 65.

2.3.2 Zeroing

During zeroing, ambient air conditioned to approx. 100 ± 5° C is fed through the measuring chamber. This is achieved when a 3/2-way "zero air" valve is switched, i.e. the zero air valve is switched so that the ambient air is drawn in and no exhaust gas can flow into the Opaci-meter.

The mean value (over 30 s) of the light intensity measured at the detector is then saved as "zero intensity I0" as soon as it fulfils the required stability criteria for sensitive measurements.

After switching on from "Function off" or "Pause" status, the zeroing is carried out automatically after a warm-up and stabilization time. The system displays the maximum time required before it is ready for measurement.

Zeroing takes approx. 1 minute when it is initiated from one of the measuring modes.

2.3.3 Checking the Zero Point

This function is used to switch the zero air valve to ambient air without the system going into "zeroing" mode, i.e. without determining a new zero intensity I0. So the stability of the zero point can be checked.

You can select this mode only during a measurement.


Operating Modes 17

2.3.4 Pause

This mode is designed to save energy. It should only be activated when the Opacimeter is not going to be used for measurements for a while.

The pause state allows the instrument to return as quickly as possible to operational readiness. In this state, there is lower air and energy consumption and less wear (especially on the pumps).

In this mode, the inlet valve and zero air valve are closed to exhaust gas. The measuring chamber heating is switched on and the sample conditioning works at a reduced level.

2.3.5 Function off

This state is triggered by the control software but the Opacimeter continues to be fed with power.

The diaphragm-type pumps stop, all valves are closed (there is also therefore no compressed air consumption) and the heating systems of the window elements, sample conditioning and measuring chamber are switched off. Only the control electronics and the fans are still active.

The Opacimeter can therefore be switched from this state back to other modes from the AVL 4210 Instrument Controller or the test bed host. But remember that the Opacimeter will not be ready for a measure-ment again until after the full warm-up phase.

2.3.6 Linearity Check ("LIN Check")

The LIN check is used to make a quick check of the linearity at an opacity value of approx. 50 %. It can only be called up in zeroing mode.

First the intensity of the two halogen lamps is measured separately and then the intensity of the two lamps together.

The check result is correct when the deviation is ≤ ±0.5 %.

Important: When "Function off" is selected, compressed air continues to flow through the sample conditioning system for two minutes. Do not switch the main power switch off until the solenoid valve in the sample conditioning system has closed.

DANGER!Always select "Function off" before disconnecting the opacimeters power supply!

In the event of a power cut, ensure that either the test engine is shut down or that an alarm is sounded.


Operating Modes18

2.3.7 Calibration

Calibration is used to determine the accuracy, reproducibility and linearity, and also serves as proof of the implementation of a traceable measuring instrument monitoring system with certified test and inspec-tion equipment.

A filter holder with a calibrated absorption filter is inserted in the lamp unit for the calibration. The displayed value must correspond within a certain tolerance to the value of the absorption filter used.

Absorption filters with different opacity values (see Section Linearity Check ("Calibration") with "Neutral Density Filters" on page 106) are available from AVL.

A calibration can only be started in zeroing mode.

2.3.8 Back-flushing of the Probe

Here approx. 90 l/min compressed air is fed through the solenoid valve to back-flush the sampling line and probe line to clear them of deposits. Because the inlet valve upstream of the measuring chamber is closed, no compressed air enters the measuring chamber. The zero air valve is open.

The lines are back-flushed automatically when the Opacimeter is powered up or set ready for measuring from "Function off" state and when the device is switched from "Measurement" or "Zeroing" to "Function Off" state.

DANGER!The Purge function must not be activated in tests involving high concentrations of flammable gases (e.g. HC, H2, CO).

Important: Sampling upstream of an exhaust aftertreatment system

During purge (approx. 90 l/min, 5 times for 2 s, pulsed) ambient air is forced into the exhaust gas via the probe which can affect catalytic converter activity particularly in an actively regenerating exhaust after-treatment system (e.g. NOX adsorber or SCR) due to the oxygen content of the added air.

Back-flushing will affect the control of a lambda controlled engine / catalyst system if the opacimeter is mounted upstream of the catalyst.


Function Description 19

2.4 Function Description

2.4.1 Gas Path

(see Fig. 2 on page 20)

The exhaust gas to be measured (i.e. the sample) follows the path described below:

A probe (typical length 1 m) is mounted in the exhaust line to draw off the sample (see Section Fitting of Zero Air Valve, Sampling Lines and Probes on page 42).

The sample is routed though a pneumatic 3/2-way valve, called the zero air valve, into the conditioning line to the Opacimeter (see Fig. 24 on page 47).

The probe line is surrounded by conditioned air in the sample con-ditioning tube (depending on the temperature of the sample) to ensure that the sample has a temperature of typically 100 ± 5° C when it enters the Opacimeter.

After entering the Opacimeter, the sample is fed through the inlet valve to the measuring chamber where the actual opacity mea-surement is carried out (see Section Measuring Unit on page 21).

The exhaust gas is then conducted through the filter unit and the contained filter element to remove impurities. This is to prevent any damage to the downstream components.

The flow meter checks the flow rate via a metering orifice.

The filter becomes less permeable with time depending on the amount of soot emitted from the engine. That reduces the flow rate which triggers a warning message when it undershoots a cer-tain limit ("Flow Rate Warning"). If the flow rate drops further below a lower limit value, the Opacimeter automatically switches off and outputs an error message ("Flow rate too low").

The exhaust gas then passes through an accumulator into the pump unit which consists of two diaphragm-type pumps.

These two pumps ensures that the gas flows through the mea-surement system at a constant 4049 l/min.

Note:At a supply voltage of 60 Hz, the pumps run at a higher speed, and the flow is increased by approx. 10 %. This has no impact on the measured values. The instrument automatically recognises the frequency of the supply voltage and adapts the control system limits accordingly.


Function Description20

After pumping, the sampled gas flows out of the Opacimeter either through the exhaust gas recirculation system (during a measure-ment) or through the zero air outlet (during zeroing).

That ensures that no ambient air can enter the exhaust system during zeroing.

Gas flow scheme

Fig. 2 SV1 solenoid valve for sample heatingSV2 solenoid valve for purging airSV3 solenoid valve for zero airV4 inlet valve for sample flowZAV1 zero air valve - sampling lineZAV2 zero air valve - zero air outlet

Sample conditioning tube ZAV1

Sampleflow

Control hose

Sample heating

SV3

SV1

SV2

2.5 bar

Pressureregulator

Compressedair supply

Inlet valveV4

Purging air

Detectorunit

Lampunit

Pump unit

Flow meter

FilterAccumulator

Sample feed back

Measuring chamber

Exhaustgas

∆p

*)

*)

*)

*)

4 bar

Zero air outlet

ZAV2

*)



2.4.2 Measuring Unit

The measuring unit comprises the following components:

measuring chamber

light unit

detector unit

As the sample flows into the heated measuring cell in the measuring chamber, it first hits the deflector plate. It then divides and flows both towards the light unit and the detector unit. At the end of the measuring chamber it flows into the exit chambers where it is redirected to flow out of the measuring unit. The light unit is at one end of the measuring cell and the detector unit at the other. Both units are kept separate from the exhaust gas by heated window elements. The distance between the light unit and detector unit window elements is 0.430 m (= measuring length).

The lamp housing in the light unit contains a lamp element that provides the light source necessary for the opacity measurement. It contains two soldered-in halogen lamps and a temperature sensor. The light travels through the measuring cell towards the detector unit via a beam orifice and a heated window element.

A filter holder with a calibrated absorption filter can be inserted in the light unit, if required, to check (calibrate) the Opacimeter.

The light first hits the heated window element of the detector unit. It then travels through the collimating lens, the heat absorption filter and the green filter. Finally it arrives at the detector element.

A thermostatically controlled heating system is also integrated in the detector element to ensure that the components maintain a constant temperature.

The heated window elements of the lamp and detector units ensure that no soot deposits can form on the window.

Caused by production, heating power to heat a window up to 600° C is not the same for all windows. The windows are classified after produc-tion and a pair of windows consuming similar power is installed in the opacimeter.

Important: Only pairs of windows consuming similar power must be installed into the opacimeter - replacing windows must be done in pairs. After replacing windows, the heating power must be set by a service technician.



Measuring unit (BO2694)

Light unit

Fig. 3

Orifice

Heated window element

Sample in Frame

Heated window element

Calibration filter insert

Detector-element Sample out

Sample out Measuring cell

Exit chamber

Sample out

Exit chamber

Orifice

Halogenlamps

Fig. 4

Window unitInsertable calibration filter cartridge

Lamp housing

Halogen lamps

Lamp element(BB0828)

Connector forlamp elementConnector for

window element

Heatedwindow element



Detector unit

Fig. 5

Collimating lensHeat absorption filter

Window unit

Heatedwindow element

Connector forwindow element

Connector fordetector element

Detectorelementwith green filterand controlledheating system(BB0797)

Detector-housing

Important: Lamp unit and detector unit always have to be replaced together (replacement kit for lamp and detector unit BH0215)!


Basic Unit 25

3 Opacimeter Design, Options and Accessories

3.1 Basic Unit

Main view

1 Cabinet hood2 Main cabinet3 Exhaust gas recirculation4 Control connection for zero air valve5 Sample filter unit6 Calibration cover7 Electric box (rear side)8 Status LED9 Sample conditioning tube connector10 Zero air outlet11 Compressed air maintenance unitFig. 6

1

2

3

4

5

6

7

8

9

11

10


Basic Unit26

AVL Opacimeter 439 G004 - 230 V (TM0439G04A.01)

Designation Number

1 AVL Opacimeter 439 G004 GH05641 230 V mains cable (2.5 m) BV21661 compressed air preparation unit (see page 29) BH01711 compressed air tube (5 m, Ø 9 mm) SS03532 tube clips DN13661 RS232 interface cable (15 m) BV18542 cable connectors EU16233 spare filter MF06091 Operating Manual AT1307E

Tab. 1

Important: Please specify your country-specific power supply when ordering.


Basic Unit 27

100 115 V power supplies

This version has an additional transformer which is connected to the power supply on the primary side. The output cable on the secondary side is connected to the AVL 439 and supplies the instrument with 230 V. The transformer housing is mounted on the instruments base plate (see Fig. 7 and Fig. 8 on page 28).

AVL Opacimeter 439 G004 - 100 V Japan (TM0439G04B.01)

AVL Opacimeter 439 G004 - 115 V USA (TM0439G04C.01)

Designation Number

1 AVL Opacimeter 439 G004 GH05641 Autotransformer 230 V / 4 A, 1 phase EI02751 100 / 115 V mains cable (2.5 m) BV22611 compressed air preparation unit (see page 29) BH01711 compressed air tube (5 m, Ø 9 mm) SS03532 tube clips DN13661 RS232 interface cable (15 m) BV18542 cable connectors EU16233 spare filter MF06091 Operating Manual AT1307E

Tab. 2

Designation Number

1 AVL Opacimeter 439 G004 GH05641 Autotransformer 230 V / 4 A, 1 phase EI02751 100 / 115 V mains cable (2.5 m) BV22611 compressed air preparation unit (see page 29) BH01711 compressed air tube (5 m, Ø 9 mm) SS03532 tube clips DN13661 RS232 interface cable (15 m) BV18542 cable connectors EU16233 spare filter MF06091 Operating Manual AT1307E

Tab. 3


Basic Unit28

1 Mains cable 100/115 V ACBV2261

Fig. 7

1 Transformer 100/115 VEI0275

Fig. 8

1

1


Basic Unit 29

Compressed air preparation unit:

Compressed air preparation unit - spare parts

Fig. 9

Designation Number

Compressed air preparation unitincluding:tube coupler for 9 mm diameter tube

BH0171

Tab. 4

Fig. 10

Flow direction

Quick connector 243.01DN1326

Sealing ringDN0645

Quick connector 243.45DN0768

Plug-in nipple 243.50 G1/4 (outside)DN1327

Filter pressure reducer 10 barMY0161


Options30

3.2 Options

3.2.1 Sample Lines

Four different sample lines (different lengths / different materials ) are available. One of these options is necessary to operate the opacimeter.

A constant flow of exhaust gas is drawn from the exhaust pipe through the sample line (welded sample probe) and conditioned sampling hose by means of a diaphragm-type pump pack. The recirculation of the sampled gas via a return line to the exhaust pipe of the test engine ensures constant sample flow also at varying pressure conditions. Due to this feature the AVL 439 can be used for many different applications on the exhaust gas duct while still operating within the instruments normal limits.

In the conditioned sampling line, the sampled gas is fed to the inlet of the measuring chamber at a temperature of approximately 100 °C, i.e. for higher exhaust gas temperatures, (up to 600 °C maximum), the sample is cooled and for cold exhaust gas it is heated.

An important benefit of this temperature conditioning is the reliable signal stability and high signal sensitivity. The AVL 439 G004 uses for the first time a zero-air-valve which provides advantages in economy and safety.

The air pressure consumption will be dramatically reduced and the operating safety regarding damaging and simplification in operation the 439 will be increased.

The sample hose is not part of the AVL 439 basic unit and according to the demands it can now be selected from four different types. Whereby the main difference is the kind of material (silicone or Viton) and the two different lengths (2.5 m or 4 m).

The standard configuration of the sample hose consists always of a flexible sample line with integrated sample probe (total length 1m) as well as the flexible conditioning tube with the length 1.5 m (total length 2.5 m) or with the length 3 m (total length 4 m) and the zero air valve with the control hose. Those mentioned lengths 2.5 m or 4 m are also used for the return sample lines, which are already part of the sample hose articles.

Basically it should be always considered to keep the sample hoses as short as possible, in order to avoid deposits on the tube inner walls and thus to eliminate unwanted variations on the measured values.

Important: All of the Opacimeters specifications, especially the response time, relate to the standard length sampling line (2.5 m).

AVL recommends using the standard tube. The special 4 m length tube should only be used in special circum-stances.


Options 31

Sample lines with zero air valve, complete, Silikon, 2.5 m (TM0439NV25.01)

Sample lines with zero air valve, complete, Silikon, 4 m (TM0439NV40.01)

Sample lines with zero air valve, complete, Viton, 2.5 m (TM0439NV25.02)

Designation ID number

Zero air valve BO5358Conditioning hose, silicone, 1.5 m BO5359Control hose for zero air valve, 1.5 m, PTFE (Teflon)

BO5356

Sampling line G004, 1 m BH0227Return sampling line, complete, silicone, 2.5 m BH0203

Tab. 5


Zero air valve BO5358Conditioning hose, silicone, 3 m BO5353Control hose for zero air valve, 3 m, PTFE (Teflon)

BO5357

Sampling line G004, 1 m BH0227Return sampling line, complete, silicone, 4 m BH0214

Tab. 6


Zero air valve BO5358Conditioning hose, FPM (Viton), 1.5 m BO5354Control hose for zero air valve, 1.5 m, PTFE (Teflon)

BO5356

Sampling line G004, 1 m BH0227Return sampling line, complete, FPM (Viton), 2.5 m

BH0266

Tab. 7


Options32

Sample lines with zero air valve, complete, Viton, 4 m (TM0439NV40.02)

3.2.2 AVL 4210 Instrument Controller

Note: If the AVL Instrument Controller is used to control the AVL 415 Smoke Meter (predecessor of AVL 415S), you need the remote control cable AVL 415 (15 m; ID number BV1908).


Zero air valve BO5358Conditioning hose, FPM (Viton), 3 m BO5355Control hose for zero air valve, 3 m, PTFE (Teflon)

BO5357

Sampling line G004, 1 m BH0227Return sampling line, complete, FPM (Viton), 4 m

BH0267

Tab. 8

Fig. 11

Designation Article number

Remote control 439 (software 439 / 415S) with 409 simulationconsisting of:AVL 4210 Instrument Controller

(SW 439 / 415S)1 combination connecting cable

(RS232 + 24 V DC, 15 m)

TM0439FBRA.02

GH0495

BV2191

Tab. 9


Options 33

3.2.3 PC-Software

Note: Software version 2.60 is required for AVL 439 G004.

3.2.4 19" Mounting Frame for AVL 4210 Instrument Controller


Combination connecting cable (RS232 + 24 V DC, 20 m)

BV2467

Cable for AVL 4210 Instrument Controller soft-ware update

GY0540

Tab. 10


AVL 439 PC softwareProgram for controlling the AVL 439, for data acquisition, recording, and evaluation(software manual included)

TM0439PCA.01

Tab. 11

Fig. 12


19" mounting frameincluding cover panel and mounting screws

TM0439FERA.01

Tab. 12


Options34

3.2.5 19" Bench Cabinet for AVL 4210 Instrument Controller

For mounting the AVL 4210 Instrument Controller in a 19" bench cabinet

3.2.6 ½ 19" Bench Cabinet for AVL 4210 Instrument Controller

For mounting the AVL 4210 Instrument Controller in a ½ 19" bench cabinet

Fig. 13


19" bench cabinet TM0439FTGA.01

Tab. 13


½ 19" bench cabinet TM0439FRGA.01

Tab. 14


Options 35

3.2.7 Wall Mounting Console

Fig. 14

a a

aa460

540 460

423

463

425.

5


Wall mounting consolefor mounting instructions see Appendix(without fittings for wall mounting)

TM0439WMDA.01

Tab. 15


Options36

3.2.8 Trolley

3.2.9 I/O Cables (Analog Cable)

3.2.10 Probe for Open Exhaust Pipe

Fig. 15


Trolley for devices with serial number >500(with instrument mounted, see Appendix)

630 × 950 × 520 mm, W × H × D

TM0439TROA.01

Tab. 16


Cable digital I/O (DIO) 15 m(is also used as analog cable with Opacimeters with serial numbers >1000)

BV2266

Tab. 17


Probe for open exhaust (test bed)(for assembling instructions see Appendix)

TM0439OEA.01

Tab. 18


Commissioning 37

4 Installation

4.1 Commissioning

Remove the instrument from the packaging and prepare it for commis-sioning.

Behind the quick-release locks on the cabinet hood are two screws screwed in from below (see Placing the Opacimeter on a Surface, Pos. 1). They are designed to prevent the quick-release locks from being opened unintentionally. Please note that the defi-nition of the protection class for this instrument is only met when both of these safety screws are fitted.

Front view

4.2 Placing the Opacimeter on a Surface

The Opacimeter can be set up on the following surfaces:

on the floor

Take particular care to ensure that the probes are fitted correctly (see Section Fitting of Zero Air Valve, Sampling Lines and Probes Fitting of Zero Air Valve, Sampling Lines and Probes)!

on a platform

on the wall mounting console option (see Section Wall Mounting Console Option on page 39)

on the instrument trolley option (see Section Trolley Option on page 40)

Fig. 16

1 1


Placing the Opacimeter on a Surface38

4.2.1 General

Make a space of about 1 × 1 m for the AVL 439 Opacimeter to ensure that it has sufficient ventilation.

The surface where it is placed must be as free as possible from vibration.

Make sure that the sampling line travels uphill from the exhaust line to the Opacimeter (to prevent condensate from forming).

The Opacimeter should not be placed in the vicinity of the exhaust line (because of the effect of heat).

Make sure the Opacimeter is easily accessible (e.g. for calibra-tion).

DANGER!Ensure that cables and the compressed air supply hose are laid in compliance with the general safety requirements, i.e. in such a way that they cannot be damaged by excessive temperatures (including any excessive heat from radiating heat sources) and/or mechanical or chemical sources (such as fuel, NOx, SO2, hot steam), which would constitute a safety hazard.

Example: the pressure tolerance of compressed air hoses decreases as the temperature increases! A hose specified for 10 bar at 20° C may burst at 3 bar when the temperature reaches 50° C.


Placing the Opacimeter on a Surface 39

4.2.2 Wall Mounting Console Option

See also mounting instructions in the Appendix.

Mount the wall mounting console on the wall in a suitable position using screw fittings that are capable of taking the weight of the Opacimeter.

Wall mounting console

Remove the four rubber feet. Fit the four feet to the basic unit. Place the Opacimeter on a flat surface and adjust the feet until the instrument is standing horizontally.

Then lift the Opacimeter onto the support plate on the wall mounting console and screw it on tightly from below using the countersunk screws at the feet.

Screw the frame firmly to the wall. Place the support plate and the Opacimeter on it and secure in position by tightening it with the hand screw provided.

The wall mounting console allows the Opacimeter to be swivelled through 90° if necessary for servicing. To do this, undo the hand screw a little to pull the Opacimeter forwards and then swivel it into the required position. Make sure that the signal and supply lines are not damaged when moving the Opacimeter. When work on the Opacimeter is completed, return it to its original position and secure it again.

Fig. 17

a a

aa460

540 46042

3

463

425.

5

DANGER!The wall mounting console is not designed for the Opacimeter to be used permanently in the swivelled position.

Make sure that the sampling line travels uphill from the exhaust line to the opacimeter (to prevent condensate from forming).


Placing the Opacimeter on a Surface40

4.2.3 Trolley Option

Installing the Opacimeter on the trolley:

Position the Opacimeter on the trolley in such a way that the cen-tres of the two rubber feet are above the corresponding holes in the trolley's cover plate.

Fix the Opacimeter to the trolley with the hexagon screws and washers supplied with the trolley.

DANGER!Push the trolley only over smooth floors when the Opacimeter is mounted on it.

If the trolley is pushed too fast over differences in floor levels greater than 3 cm in height, the Opacimeter can tip over.


Exhaust Gas Routing 41

4.3 Exhaust Gas Routing

4.3.1 Connections on the Opacimeter

Connections

The AVL 439 Opacimeter has three connectors for tubes on the front panel and another next to the maintenance unit:

connector for conditioning tube

connector for control hose

connector for return sampling line

connector for zero air outlet

These four connections are couplings that cannot be mixed up and are easily mounted by hand.

1 Exhaust gas feed back tube2 Control hose3 Conditioning tube4 Zero air outletFig. 18

1

2 3

4

Important: When connecting the tubes, make sure the quick connec-tors are pushed onto the probe connectors as far as they will go, otherwise the gas flow will be interrupted.

Secure the conditioning tube connection with the screw on the face.


Exhaust Gas Routing42

4.3.2 Fitting of Zero Air Valve, Sampling Lines and Probes

The system of sampling lines between the Opacimeter and the exhaust line basically consists of:

sampling line (BH0227, Fig. 19 on page 42 top)

zero air valve

conditioning tube

feed back to the exhaust line (Fig. 19 on page 42 bottom).

Probes

Installing the Zero Air Valve

Secure the zero air valve on the test bed by means of e.g. the valve bodys three M4 threads (each offset by 90°) or the four M6 threads at the pressure cylinder.

Makes sure that the entire gas path (including its path through the valve) has a downhill incline toward the exhaust-system branch.

Mount the zero air valve as far away from hot engine components as possible.

General instructions for fitting the sampling lines and probes

Mount the welded-on connecting piece centrally in a straight sec-tion of the exhaust line.

The straight section of the exhaust line in front of the probe should be a length equal to six times the exhaust line diameter, and the section of the exhaust line after the probe should be a length equal to three times the exhaust line diameter.

Fig. 19



Probe positions

There should be as few pulsations in the exhaust gas as possible at the sampling point. The peak pressure at the sampling point must not deviate from the ambient pressure by more than 100 mbar or +400 mbar.

Do not fit the probe anywhere near manifolds or pipe junctions (e.g. exhaust silencers).

The probe feedback into the exhaust line is not absolutely necessary if the pressure at the sampling probe does not deviate from the ambient pressure by more than approx. 30 mbar in any operating state.

Fig. 20

D

6 D ~200 mm 3 D

Exhaust line

Sampling Feed back

DANGER!Engine exhaust gas is noxious!

If the probe gas is not fed back into the exhaust line, it must be prop-erly disposed of, e.g. fed into the test bed air extraction system.

The control hose of the zero air valve may be under pressure! Ensure that it cannot be damaged by excessive temperatures. The pressure tolerance of compressed air hoses becomes lower as the temperature increases! A hose with a spec for 10 bar at 20° C can burst at 2 bar when the temperature increases to 70° C.

When installing the sampling lines and probes, remember that very high concentrations of flammable gases can occur upstream of certain exhaust aftertreatment systems. The restrictions described in Chapter Application Area on page 9 and Section Operating Modes on page 15 therefore apply.

When the AVL 439 Opacimeter is operated in Onboard mode, the exhaust gas is fed out through the zero air outlet - under no circum-stances should it be allowed to flow into the passenger compartment! This connection has the same coupling as the exhaust gas recircula-tion system so you must connect the exhaust recirculation hose to the zero air outlet and feed the exhaust gas out of the vehicle.



Mounting instructions

The exhaust gas is sampled through the probe tube which is a flexible stainless steel corrugated tube, 1 m long (½ m length optional - reduced temperature tolerance), to which the probe pipe is connected at one end and the zero air valve at the other. The probe pipe is inserted into the exhaust line through the welded-on connecting piece and screwed tightly in position.

Fitting the probe

Important: Make sure that the sampling aperture at the tip of the probe is pointing into the exhaust gas flow.

The direction the sampling aperture is pointing can be recognized by the short piece of pipe welded on to the probe pipe.

Fig. 21

XX~16 mm X

Detail "X"

Sampling Feed back

~200 mm

10 × 1 tube 10 × 1 tube

Position indicator forexhaust gas inlet opening Weld connector Weld connector

Exhaust gas Exhaust gas



Favourable probe fitting: angle 30° 60°

Fig. 22

45° incline in exhaust gas line axis against the direction of flow

~6 × D ~3 × D

Straight exhaust line section

Flow direction

M12×1.5

Ø16

D

Important: Lay sampling probe and sampling line as curvature-free as possible and in an ascending order. *)

This helps to prevent condensate and particle deposits as far as possible and optimises measurement accuracy.



*) Contact your AVL representative if it is not possible to lay the sampling line ascending to the Smoke Meter.

Use a 16 mm bit to drill the holes in the exhaust line for the sampling and feed back probes.

Probe line (BH0227, includes couplings)

Fig. 23

Probe corrugated tube 1 m (YM3361) Male coupling(DN1323)

Weld coupling (DN1324)

Position indicator Exhaust gas inlet

Exhaust gas flow



The probe line and zero air valve are connected by a screwed connec-tion with clamp ring. This pneumatic, self-resetting 3/2-way valve is closed to the exhaust gas and not under pressure. The Opacimeter draws in the ambient air in that state (which is known as "zeroing"). The valve is opened when a measurement is carried out. The exhaust gas is thermally conditioned in the conditioning hose so that it has a temperature of 100 °C when it enters the measuring chamber. The control hose for the zero air valve is connected to the appropriate connection on the Opacimeter by means of a rapid-release connector.

Sample conditioning tube, connected to the probe tube

1 Probe tube (YM3361)2 Zero air valve3 Zero air inlet4 Control hose5 Conditioning tubeFig. 24

5

42

1

3

Important: Make sure that the sampling line travels uphill from the sampling point to the opacimeter (to prevent condensate from forming).

Contact your AVL representative if it is not possible to lay the sampling line ascending to the Opacimeter.

Keep the probe line as straight as possible(min. bend radius 300 mm).

DANGER!The maximum permissible sampled gas temperature on entry into the probe is 600° C.

Be careful! Probe and conditioning tube can get very hot! Danger of burning!

You must read the safety instructions at the front of this manual!



Sample conditioning tube 1.5 m or 3.0 m (silicone or Viton)

4.3.3 Exhaust Gas Recirculation

The exhaust line end of the feed back line has a probe (i.e. return sampling line) of a design similar to that of the sampling probe. It is fitted to the exhaust line in the same way.

For the Opacimeter to work without problems, the sampling probe and the feed back probe must be subject to the same exhaust gas pres-sure. In other words, both probes are mounted in the same section of the exhaust line and both of their apertures must be pointing into the exhaust gas flow.

Follow the installation and safety instructions in Section Fitting of Zero Air Valve, Sampling Lines and Probes on page 42.

Exhaust gas recirculation 2.5 m or 4 m (silicone or Viton)

Fig. 25

Conditioning air inlet Safety catch Conditioning air outlet

Opacimeter connection Zero air valve connection

Fig. 26

Opacimeter connectionPosition indicator Exhaust gas out

Exhaust gas flow

Probe corrugated tube(YM3452)

Male coupling (DN1323)

Weld coupling (DN1324)

DANGER!Engine exhaust gas is noxious!

When the AVL 439 Opacimeter is operated in Onboard mode, the exhaust gas is fed out through the zero air outlet - under no circum-stances should it be allowed to flow into the passenger compartment! This connection has the same coupling as the exhaust gas recircula-tion system so you must connect the exhaust recirculation hose to the zero air outlet and feed the exhaust gas out of the vehicle.


Compressed Air Supply 49

4.3.4 Installation Instructions for Tube Fittings

The Parker tube fitting of the sampling and return lines should be fitted as follows:

Insert the tubing into the tube fitting and push until it is in the right position (centre of the exhaust line, see Fig. 21 on page 44).

Make sure in the straight coupling that connects the probe line, the zero air valve and the conditioning line that the tubing rests firmly on the shoulder of the fitting and that the nut is finger-tight-ened.

Before tightening the nut completely, hold the fitting body steady and make a mark on the nut in this position. Then tighten the nut another 1 ¼ turns, i.e. watch the mark, make one complete revo-lution and continue another quarter revolution.

The connection can be undone and done up again quite easily when you need to refit tube couplings. The connection is reliable, safe and leak-proof each time.

Push the tube as far as it will go into the fitting body. Tighten the body with an open-end spanner and tighten the nut to its original position with your hand. Then tighten it a half turn to ensure a leak-proof seal.

4.4 Compressed Air Supply

The AVL 439 Opacimeter needs filtered, oil- and water-free compressed air at 4 10 bar to operate. The maximum compressed air requirement is 90 l/min. If the requisite supply pressure is not main-tained, the Opacimeter automatically switches off and outputs an error message.

Inside the Opacimeter is another pressure reducer and a switch for monitoring the compressed air supply. These elements are set to the Opacimeter's operating pressure (2.5 bar) at the factory and may only be adjusted by AVL service technicians.

Connect the compressed air supply to the AVL 439 Opacimeter(see 1, Fig. 27 on page 50).

Important: Use the AVL 439 Opacimeter only together with the compressed air preparation unit to ensure the quality of the compressed air.

If the compressed air supplied contains oil and/or water, it has to be removed from the condensate container at regular intervals. Check at least once a day whether there is condensate in the container.


Compressed Air Supply50

Side view mains power connection, compressed air preparation unit

DANGER!Ensure that cables and the compressed air supply hose are laid in compliance with the general safety requirements, i.e. in such a way that they cannot be damaged by excessive temperatures (including any excessive heat from radiating heat sources) and/or mechanical or chemical sources (such as fuel, NOx, SO2, hot steam), which would constitute a safety hazard.

Example: the pressure tolerance of compressed air hoses decreases as the temperature increases! A hose specified for 10 bar at 20° C may burst at 3 bar when the temperature reaches 50° C.

1 Zero air outlet2 Compressed air connection on compressed air preparation unit3 Mains power connection4 ON/OFF switchFig. 27

2

3

4

1


Power Supply 51

4.5 Power Supply

The opacimeter is available for different voltages (see Section Basic Unit on page 25).

Plug the mains cable into the AVL 439 Opacimeter (see 1, Fig. 27 on page 50) and connect to an outlet with protective ground. Only use the mains cable supplied.

Note: At a supply voltage of 60 Hz, the pumps run at a higher speed, and the flow is increased by approx. 10 %. This has no impact on the measured values. The instrument automatically recognises the frequency of the supply voltage and adapts the control system limits accordingly.

DANGER!Make sure that the opacimeter is being supplied with the correct mains voltage.

Ensure that the power supply cable is laid in compliance with the general safety requirements, i.e. in such a way that it cannot be damaged by excessive temperatures (including any excessive heat from radiating heat sources) and/or mechanical or chemical sources (such as fuel, NOx, SO0 hot steam), which would constitute a safety hazard.


Interfaces52

4.6 Interfaces

The AVL 439 Opacimeter has the following interfaces for control and data acquisition purposes:

Side view of interfaces

*) Rating plate with supply voltage, serial number, revision, device generation, CE logo

X1 Analog I/OX2 COM1 (RS232 serial interface)X3 COM2 (RS232 serial interface)X4 Digital I/OX5 External (service function)

1 ANALOG I/O2 COM 13 COM 24 Digital I/O5 External6 Rating plate *)7 Screw mounting for potential equalizationFig. 28

1

2

3

4

5

6

7


Interfaces 53

4.6.1 Serial Interfaces

The AVL 439 Opacimeter can be controlled by the AVL 4210 Instru-ment Controller, a PC or a test bed host. Whichever device is connected, COM1 and COM2 are the ports used. Two devices can be connected at the same time.

Interface parameters

RS232 socket

Baud rate: COM1: 9600, can be switched to 4800 COM2: 9600 (can be switched to 4800, software version 2.64 and below only)(see Section DIL Switches on page 63)

Data bits: 8Stop bits: 1Parity: none

Pin 1 RxDPin 2 TxDPin 3 GroundPin 4 Ground power supply for AVL 4210

Instrument ControllerPin 8 +24 V, 0.5 A max.

Tab. 19

Fig. 29

1

2

3

45

67 8


Interfaces54

4.6.2 Digital Interface ("Digital I/O")

Either a trigger switch can be connected here for interval triggering during peak value measurements or a test bed host for operation as a DIO ("hybrid") interface.

The "Trigger type for peak value measurement" measurement param-eter defines the function that is active (see Section Measurement parameters on page 89):

"Internal" DIO interface

"External" trigger input

Digital I/O socket

A cable for DIO connections is available (Cable digital I/O BV2266, see also Section I/O Cables (Analog Cable) on page 36).

DIO cable - pin/colour assignment:

Used as Trigger Input

The trigger switch must be connected to contacts 1 and 6. The jumpers at J23 (controller board, see Fig. 88 on page 181) must be set to positions 1-2 and 3-4 (see Fig. 32 on page 55).

Used as DIO ("Hybrid") Interface

The DIO interface is used together with the analog output. It allows a test bed system that has no serial interface to control the Opacimeter.

Fig. 30

Pin Colour I/O

1 white LATCH2 brown OUT33 green C_OUT/+5V4 yellow IN15 grey IN26 pink VIN+/GND7 blue OUT18 red OUT2

Tab. 20

1

2

3

45

67 8


Interfaces 55

Connection to host - "hybrid" integration

This consists of 3 digital inputs and 3 digital outputs which all have optocouplers. They are therefore electrically separated from the other electronics (but not from one another). The internal power supply can be used when the potential does not need to be separated, e.g. when using relays or optocouplers. This makes the circuitry simpler. Jumpers J23 and J24 on the pcb are used for the switching (Fig. 32 on page 55).

Jumpers J23 and J24

Level and logical states

Since the allocation of level and logical state depend on the circuit, the following applies:

Fig. 31

Fig. 32

Logical "1": optocoupler enabledLogical "0": optocoupler disabled

Test bed host

AVL 439

ANALOG I/O COM1 COM2 DIGITAL

I/O


Interfaces56

Inputs

Circuit with potential separation(Jumper J23: 2-3)

Circuit without potential separation (controlled by potential-free contact)(Jumper J23: 1-2, 3-4)

LATCH (Pin 1) Control input (when trigger = internal, otherwise external trigger input; see Section Measurement parameters on page 89)Activated by a "0" → "1" transition. Switch back to "0" after at least 50 ms.1. Switch to DIO control (when OUT1 = "0").2. Switch to state defined by IN1 and IN2 (when OUT1 = "1").

IN1 (Pin 4),IN2 (Pin 5)

Predefines state to be assumed after LATCH input is activated

IN2 IN1 State

0 0 Off0 1 Pause1 0 Zeroing1 1 Measurement

Tab. 21

VIN+/GND (Pin 6)

Common ground potential for all 3 inputs.In circuits without potential separation: ground

Fig. 33

Fig. 34

6

1, 4, 5

J231 2 3 4

UI

"0": U < 0.5 V"1": U = 4.530 V (Imax = 3 mA)

6

1, 4, 5

J231 2 3 4

+5 V "0": switch open"1": switch closed permissible voltage (Imax = 3 mA)


Interfaces 57

Outputs

Circuit with potential separation(Jumper J24: 2-3)

Circuit without potential separation(Jumper J24: 1-2, 3-4)

OUT1 (Pin 7) Operating mode"0": DIO interface disabled"1": DIO interface active

OUT2 (Pin 8) "Busy" (not ready)During transition from one state to another, this output is set to "1" until the target state is reached.

OUT3 (Pin 2) Error"0": No error"1": Error(error displayed on PC or Instrument Controller)

C_OUT/+5 V (Pin 3)

Signal common for all 3 outputs.In circuits without potential separation: +5 V

Fig. 35

Fig. 36

2, 7, 8

3

J24

UCE

IC

1 2 3 4

"0": IC < 100 µA when UCE < 10 V"1": UCE < 1 V when IC < 5 mA

2, 7, 8

3

J24

U

IC

1 2 3 4

+5 V

"0": IC < 100 µA"1": U > 3.9 V when IC < 5 mA


Interfaces58

4.6.3 Analog Measurement Value Output

The continuous measurement values are available at analog measure-ment output X1 while the measurement is running at four analog measurement value outputs (measurement channels). The output rates correspond to 50 Hz. The measurement channels carry the "filtered measurement value" (pin 1, OUT_A), the "unfiltered measure-ment value" (pin 3, OUT_B), the "U/U0 calculation factor" (pin 5, OUT_C) and the PTcorr correction factor (pin 8, OUT_D).

Both the measurement value quantity (N or k) and the scale (with a spread from 1 to 5-times) can be parameterised for the "filtered measurement value" (also output digitally) and "unfiltered measure-ment value" measurement channels. This parameterisation always applies to both channels so that the unit and scale are the same for both (see Section Device Parameters (ambient pressure, spread of analog signal, conditioning temperature and operating hours counter) on page 92).

The "U/U0" and PTcorr channels are dimension-less calculation quanti-ties which are used for internal measurement value calculations (see Section Measurement Value Calculation on page 95).

Pin Signal

Pin 1

OUT_A

Measurement signal, filtered, 0 10 V DC output

Scaling "times 1": N = 0 100 % or. k = 010 m-1

"times 5": N = 0 20 % or. k = 0 2 m-1

(see Section Device Parameters (ambient pressure, spread of analog signal, condi-tioning temperature and operating hours counter) on page 92)

Pin 2GND

Ground

Pin 3

OUT_B

Measurement signal, not filtered, 0 10 V DC output

Scaling "times 1": N = 0 100 % or. k = 0 10 m-1

"times 5": N = 0 20 % or. k = 0 2 m-1

(see Section Device Parameters (ambient pressure, spread of analog signal, condi-tioning temperature and operating hours counter) on page 92)

Pin 4GND

Ground

Pin 5

OUT_C

U/U0 output

Scaling 0 10 V DC: U/U0 = 0 2Pin 8

OUT_D

PTkorr output

Scaling 0 10 V DC: PTkorr = 0 2

Tab. 22


Interfaces 59

Analog I/O socket

Analog cable - pin/colour assignment:

DIL switch 4 "ON":

DIL switch 4 "OFF":

Fig. 37

Pin Colour I/O

1 white OUT_A2 brown GND3 green OUT_B4 yellow GND5 grey OUT_C6 pink 7 blue 8 red OUT_D

Tab. 23

1

2

3

45

67 8

Important: If DIL switch 4 is set to ON (negative measurement values), zero corresponds to 0.1 V and the end points are also shifted (see table below).

Spread = 1 Spread = 5

Analog Out N k N k

0 V -1 % -01 m-1 -0.2 % -0.02 m-1

0.1 V 0 % 0 m-1 0 % 0 m-1

10 V 99 % 9.9 m-1 19.8 % 1.98 m-1

Tab. 24

Spread = 1 Spread = 5

Analog Out N k N k0 V 0 % 0 m-1 0 % 0 m-1

10 V 100 % 10 m-1 20 % 2 m-1

Tab. 25


Interfaces60

4.6.4 Connecting the AVL 4210 Instrument Controller or PC

The AVL 439 Opacimeter has two serial ports (COM1 and COM2) for connecting the AVL 4210 Instrument Controller and test bed host or PC.

Connect the AVL 439 Opacimeter (preferably COM2 port) to the AVL 4210 Instrument Controller (always COM2 port).

Connection of AVL 4210 Instrument Controller or PC

4.6.5 Configuring the AVL 4210 Instrument Controller

Several settings must be made so that the AVL 4210 Instrument Controller can work with the measuring device which is connected to it.

Fig. 38

Test bed hostor AVL439PC software

FOLLOW THE DIRECTIONS! DON´TOPERATE THIS INSTRUMENT INEXPLOSIVE HAZARDOUS LOCATIONS!THE OPENING OF THIS DEVICE ISPERMITTED ONLY BY AUTHORIZEDTRAINED PERSONNEL!

X1POWER

X2COM 2

X3COM 1

X4EXTERN

X5COM 0

! GRAZAUSTRIA

Type S/NoRev

AVL 439

ANALOG I/O COM1 COM2 DIGITAL

I/O

Important: The displays illustrated are comparative representations which may differ from what you actually see on the screen depending on your system configuration.


Interfaces 61

Turn on the Instrument Controller.

Using the equipment for the first time

If the AVL 4210 Instrument Controller has never been operated before, there will be horizontal lines shown in the dark field, otherwise, it shows the devices for which it has been configured.

Press the MENU key.

You will now see the main menu with the options CONTRAST, LANGUAGE and CONFIGURATION. If the devices have already been configured, a column will appear on the left with menus for the selected devices.

Main menu

Select CONTRAST with the cursor keys and press EXEC.

Adjust the contrast with the cursor keys so that you can easily read the display, and press the ENTER.

You can select the language in the same way.

Fig. 39

Fig. 40


Interfaces62

Selection of Devices and Setting of the Baud Rates

Enter the devices which you have connected.

Select CONFIGURATION and press EXEC and then select SERIAL LINES and press EXEC again.

You can use the menu you now see to enter the devices and tell to which of the three interfaces, COM 0, COM 1 or COM 2, they are connected to, as well as to set their Baud rates. Make sure that these settings match up with the actual settings of each device !

Configuration

When you have made all settings correctly, press SAVE.

Fig. 41


DIL Switches 63

4.7 DIL Switches

The AVL 439 Opacimeter's DIL switches are located on the electronics board (for position see Section Components of the Electronics Board on page 153).

The settings of the DIL switches 1, 2, 5 and 6 are only checked when the equipment is turned on, changes of DIL switch settings 3 and 4 take effect immediately.

DIL switch Function Setting Comment

1 Baud rate COM1 OFF 9600 baud

ON 4800 baud2 Firmware version 2.64:

baud rate COM2OFF 9600 baud

ON 4800 baud

Firmware version ≥2.65:duration of zeroing

OFF Long zeroing (55 s)ON Short zeroing (25 s)

3 Test mode OFF Test mode off

ON Test mode on (status LED flashes permanently)

no purging after turning on the equipment

no temperature and stability criteria

no flashing when errors occur

No compressed air is needed in test mode it may only be used for demonstration purposes.

Under no circumstances may exhaust gas be sampled in test mode (for presentations only)!

4 Output of negative measurement values(see Section Analog Measurement Value Output on page 58)

5 Onboard application OFF Test bed mode

ON Onboard diagnostics

6 Zero air valve OFF Operation with zero air valveON Operation without zero air valve

Tab. 26

DANGER!Under no circumstances may exhaust gas be sampled in test mode (for presentations only)!


DIL Switches64


Brief Instructions 65

5 Measurements

5.1 Brief Instructions

5.1.1 Overview of Opacimeter Functions

The measurement, all the settings and the calibration and service func-tions are called up by simple commands. The measurement function usually required is the standard or "continuous" measurement. The diagram below shows the functions and the order they are in. Here you can also see the functions from which one can call up the calibration and service routines.

Block diagram of Opacimeter functions

Fig. 42

Modes: On/Offswitch

Functionoff

Zeroing Measurement(continuous)

Checkingthe zero point

Pause Peak valuemeasurement

Functions: Leaktest

Purging LIN check Calibration

Important: Typical procedure for parametrising and carrying out measurements:

Power up the instrument first thing in the morning and call up the zeroing function.

It will only deliver reliable values when properly warmed up (see Section Switching On and Warming Up Getting the Opacimeter Ready for Measurement).


Brief Instructions66

The Opacimeter takes up to 30 min (though normally 20 min) to warm up from "Function off" mode and 10 15 min from "Pause" mode. When it is switched to Zeroing from "Function off" or "Pause " mode, it displays the maximum time left until a stable state is reached (i.e. measurement readiness).

5.1.2 Carrying out a Measurement

As shown in , the following steps are necessary after powering up to set the instrument to measuring mode:

Check that the power and compressed air supplies are working properly.

Switch on the Opacimeter and the control unit

Input: zeroing to get instrument ready for measuring (Section Zeroing on page 75)

Wait until the Opacimeter has reached thermal stability and "Ready" is displayed (takes about 20 to 30 min).

Set parameters (Section Setting the Parameters on page 89)

If necessary

LIN check (Section Linearity Test ("LIN Check") on page 104)

calibration (Section Linearity Check ("Calibration") with "Neutral Density Filters" on page 106)

Input: continuous measurement (standard measurement, Section Continuous Measurement (Standard Measurement) on page 78)

The Opacimeter continuously delivers opacity or absorption mea-surement values that can be queried and recorded.

If required: Start peak value measurement (Section Peak Value Measurement (ECE R24 or EEC 72/306, ELR) on page 80)

Always call up the zeroing function (Section Zeroing on page 75) when no measurement data is to be queried.

DANGER!Always select "Function off" mode before turning off the Opacimeter! The inlet valve is not closed until "Function Off" status.


Brief Instructions 67

5.1.3 Reading stability

The measurement variation and drift of the instrument's zero point is 0.1 % opacity, or 0.0025 m-1, according to the specifications. Thus it is also possible to measure low opacity values. At high exhaust levels, the measurement variation is considerably higher due to varying engine emissions.

Additionally, in new measuring cells, another effect has to be taken into consideration: soot deposition in the measuring cell leads to a decrease in internal reflection. Although reflection is minimised by the internal blackening of the measuring cell, it cannot be eliminated completely by normal means. However, through soot deposition in the measuring cell, reflections can be practically eliminated. Therefore, in new measuring cells, a drift of the zero point by a few percent has to be expected, especially if exhaust gas with high soot concentration flows through the measuring cell. As a rule of thumb, we could say that this drift is complete when exhaust gas with an opacity of 20 % has flowed through the measuring cell for one hour. At low opacities, this drift can take correspondingly longer, but is then much smaller within each measurement sequence. Hence, for new measuring cells, zero point correction is recommended after measuring periods of no more than 30 minutes.

5.1.4 Safety Instructions in Special Conditions

No inflammable gas or exhaust mixtures may ever be measured with the AVL 439 Opacimeter. The high temperature of the self-regener-ating heated windows of the measurement cell (to approx.500 600 °C) could cause such gas mixtures to ignite in the measurement cell which would destroy both the cell and the device. For further details, see Chapter Application Area on page 9.

If it is not possible to ensure that absolutely no inflammable mixture can flow into the measuring chamber, at least you should ensure that the customary safety precautions for test beds are taken. In particular entry to the test cell when the engine is running is prohibited. If the Opacimeter is set up outside the test bed and operated under the crit-ical conditions described above, a protective wall should be built to prevent any possible injury to test bed personnel.


Setting the Function and Measurement Value Output68

5.2 Setting the Function and Measurement Value Output

For a measurement to be carried out, the AVL 439 Opacimeter must be connected to a control unit via a serial or a digital hybrid interface as described in Section Interfaces on page 52. The control unit can be the AVL 4210 Instrument Controller or a higher-order computer system, e.g. a terminal, a PC or the test bed control system.

The measurement values are output via the serial interface or the analog measurement signal connection.

Parametrising and carrying out the measurement is simple. It can be even simpler, especially for commissioning, if you take advantage of the clear guidance of the AVL 4210 Instrument Controllers user inter-face.

5.2.1 AVL 4210 Instrument Controller

The Instrument Controller is a universal controller for the AVL 415 Smoke Meter, the AVL 733S Fuel Meter and the AVL 439 Opacimeter. Two of these instruments can be controlled by the Instrument Controller depending on the firmware installed. If the Opacimeter is controlled by the Instrument Controller it must be configured accord-ingly (see Section Configuring the AVL 4210 Instrument Controller on page 60).

The AVL 4210 Instrument Controller has to be connected to one of the Opacimeters serial ports (COM1 or COM2). The Opacimeter is controlled from the AVL 4210 Instrument Controller by the menu keys and the ↑ ↓ keys. To activate a measurement function, first press "F1" to call up the MENU and then select the first function, usually "Contin-uous measurement". All other functions can then be called up with the function keys and are described in the relevant sections below.

Software title screen

Fig. 43


Setting the Function and Measurement Value Output 69

Operating the AVL 4210 Instrument Controller

The screens are designed to be self-explanatory. The title of the screen is found in the upper left corner, and to the right you see the code of the device and the software version.

Continuous measurement screen

The operating mode and the state of the device are shown in the second line. The operating mode tells from where the device is being controlled:

INST.CON.: controlled by the AVL 4210 Instrument Controller

REMOTE: controlled by the test bed computer or PC

You can only communicate actively with the devices, i.e. adjust param-eters, start measurements, etc., when in INST.CON. mode.

You can change to INST.CON. mode by pressing the button READY.

The state of the device tells if the device is in a ready state, if a proce-dure is currently running, if an error has occurred, etc. Which functions can be carried out is dependent on this state.

The last line describes the function of the keys. In different pictures the keys usually correspond to different functions. The button to the far left, however, always brings you back to the next higher menu.

The line above the key functions is reserved for messages.

Fig. 44

Important: When you press READY, all currently running procedures will be aborted, even if they were started from the test bed computer or from a PC!



Menu Choices and Settings

Menu options can be chosen and values adjusted using the cursor keys. The selected options are displayed in reverse video. It will be activated by pressing the EXEC key.

Changing the settings:

Select the corresponding field and press SET.

The value is displayed in a frame.

You can either choose an option from a list using the cursor keys or enter a number manually.

When entering a number, you can select a digit using the < and > keys.

Press ENTER to end the input.

If the SAVE key is displayed, it must be pressed to save the set-tings.

Important: Settings which were not saved before leaving the screen will be lost.


Setting the Function and Measurement Value Output 71

5.2.2 Control via Serial Interface or Terminal Program of a PC

The Opacimeter is simplest to control from a VT100 terminal or the VT100 emulation of a PC terminal program.

The necessary interface parameters are described in Section Interfaces on page 52. The protocol framework (AK generic communication interface) and the commands are described in detail in Section RS232 Interface / AK Generic Communication Interface on page 111. For the sake of clarity, Sections Measurements on page 65 and Calibration and Checking on page 103 describe the commands only briefly, without any detailed description of the parameters.

Example: Performing configuration and leak check via terminal

Connect the PC to the COM1 (X2) port of the AVL 439.

Configure the PCs terminal program:

1 start bit, 1 stop bit, 8 data bits, 9600 baud, no parity, no hand-shake

N.B. If necessary, configure the terminal program in such a way that the control key (Ctrl) is used for the terminal and not for Win-dows. Under Microsoft HyperTerminal, for example, call up the Properties option in the File menu and then Settings. Then select "Terminal".

Input in terminal mode must be in UPPERCASE LETTERS!

N.B. In the example below, <Ctrl+B> means that you press and hold down the control key (Ctrl) and then press B.

Fig. 45

Terminal Answer

Initialisation:

<Ctrl+B> SREM<Ctrl+C> SREM 0Requesting measurement parameters(see Sections and )

<Ctrl+B> APAR<Ctrl+C> APAR 0 1 2 3 0.800 0Settings according ECE-R24 filtering with internal trigger (see Sections and )

<Ctrl+B> EPAR 1 2 3 0.8 0<Ctrl+C> EPAR 0

Tab. 27



5.2.3 Control via Hybrid Interface ("DIO")

The hybrid interface permits the AVL 439 Opacimeter to be controlled by test bed systems where a RS232 connection is not possible. The relevant parameters must be set before a measurement is started (e.g. via a terminal) (see Section Control via Serial Interface or Terminal Program of a PC on page 71 and Measurement parameters on page 89). The measurement values must them always be output via the analog output (and a suitable data acquisition system).

Only measurement modes can be set via the DIO interface (see Section Overview of Opacimeter Functions on page 65). No service functions (Section Digital Interface ("Digital I/O") on page 54) can be set. No peak value measurements as described in Section Peak Value Measurement (ECE R24 or EEC 72/306, ELR) on page 80 are possible because the results are only output to the serial interface. When the DIO interface is used, the peak value can be read off from the measurement data that is continuously recorded in analog mode.

When the system is controlled via the hybrid interface, "internal" must always be selected as the trigger mode.

The set parameters are stored when the system is powered down.


Switching On and Warming Up Getting the Opacimeter Ready for Measurement 73

5.3 Switching On and Warming Up Getting the Opacimeter Ready for Measurement

When the mains ON/OFF switch is switched on the green status LED is continuously illuminated. (If the status LED flashes this indicates a user or system error, e.g. the compressed air is not connected). The Opacimeter runs a self-test and purges the sampling lines with clean air (5 purges, approx. 2 s each). However, the instrument stays in "Function off" mode, until a command is input and all functions, including the heating systems, are deactivated.

This is because the Opacimeter has to be cold for various service operations, e.g. calibrating the temperature sensors. It is therefore not desirable for the instrument to go straight into warmed-up state ready for measurements.

The zeroing function must be called up before the Opacimeter is ready for measurements.

This heating systems and pumps are then switched on and the measuring chamber is purged with clean air. ("forward purge"). It takes about 30 minutes (typ. 20 minutes) for the system to reach a steady temperature. Only when a steady temperature is reached (i.e. measuring chamber temperature TCha, exhaust gas temperature TG and lamp temperature TL) can the Opacimeter deliver stable measure-ment values with no zero drift. No measurement can be started unltil thermal stability is reached.

Necessary conditions for zeroing

Precondition: standard setpoint values:

Preparing ready status from the Instrument Controller

Switch on Opacimeter and Instrument Controller.After title screen is displayed briefly, the Instrument Controller usually goes straight to the "Continuous measurement" screen, as indicated at the top left of the screen. If another measurement screen is active (if, for example, another status is defined by the other interface), the "Continuous measurement" screen can be called by pressing MENU (key F1), selecting "Continuous mea-surement" and confirming with EXEC. (key F6).

Detector temperature ≥ 49° CMeasuring chamber and gas temperature ≥ 99° CWindow heating power ≥ ±0.5 W of setpoint

valueLamp temperature drift ≤ 0.5° C / minuteDetector signal drift ≤ 40 LSB (= 3 mV) in 5 s

Tab. 28


Switching On and Warming Up Getting the Opacimeter Ready for Measurement74

After powering up, the Instrument Controller is in monitor mode, recognizable by the word REMOTE displayed top left. The user has to tell the Opacimeter that it is to be controlled from the Instru-ment Controller: READY (key F3) - INST: CON. is then displayed top left.

This is necessary because another controller might be active at the other interface that can only be deactivated by user input.


The systems warm-up phase then begins and the stabilization time still left is displayed top right. The Opacimeter must be in "Function off" or "Pause" mode for at least five minutes for this value to be reliable.

During stabilization time the system counts down in one minute steps. It can happen that the display of the remaining stabilization time does not display every minute in the right order - this is a reg-ular behaviour during this phase.

If zeroing is not activated from "Function off" or "Pause" mode (e.g. between two measurements), it takes about 1 minute.

The "Zero, ready" state in the AVL 439 combines three functions or states:

the Opacimeter is ready for measurement

"Zero" - the brightness value (N = 0 %) is determined

"Forward purge" clean zero air flows through measuring cell and sampling line.

Fig. 46


Zeroing 75

These three functions are called up from the Instrument Controller when ZERO is pressed. The AVL 439 itself therefore has no com-mand for "Stand-by" and "Forward purge".

When "Ready" is displayed, the system will accept the "measure-ment" command: MEAS (key F4).

The OFF (F2), ZERO (F4) and SET (F6) functions are also avail-able.

Preparing ready status from the serial interface

AK command: STBY

Error 14 ("not ready") is displayed until a steady temperature is reached. The Opacimeter is not ready for measurement until the error message disappears.

5.4 Zeroing

"Zeroing" must be carried out before a measurement. The measuring chamber is filled with clean air and the relevant sensor signal is regis-tered internally as the zero value (or light value). N = 0 % represents the zero value while N = 100 % is the dark value.

The AVL 439 Opacimeter has only a small zero drift but for precision measurements at low opacity, zeroing is nevertheless necessary not only immediately after powering up and warm-up but also periodically during the measurement (approximately every half-hour).

As of firmware Version 2.65 you can set the length of time that zeroing takes (see DIL Switches on page 63). The long zeroing (duration approx. 55 s) ensures that the absolute zero point remains stable because the data is statistically evaluated over a long period of time. The short zeroing (duration approx. 25 s) should only be used when longer zeroing is not possible because of a test run.

If you issue the "Zeroing" command when the Opacimeter is in the "Function off" or "Pause" state, it warms up to a steady temperature and forward-purges the measuring cell.

"Zeroing" mode includes forward purging of the measuring cell and conditioning line. Generally, the whole line should only be back-purged when the Opacimeter is switched on and off, but can also be performed in "Zeroing" state. It can therefore only be called up from the "Function off", "Pause", and "Zeroing" states.

Important: The Opacimeter indicates that zeroing is necessary after 30 minutes of uninterrupted measurements. You can carry out zeroing then if you wish, but you do not have to, i.e. you can carry on running measurements without zeroing.

If you run the Opacimeter for a long time without zeroing, however, the zero point may start to drift.


Zeroing76

The measurement parameters, i.e. the selection of the filter algorithm and the output value (opacity N or absorption coefficient k), should be set from the zeroing function or in other words, before going into measurement mode (see Section Setting the Parameters on page 89)

The "Linearity test" (Section Linearity Test ("LIN Check") on page 104) and "Calibration" (Section Linearity Check ("Calibration") with "Neutral Density Filters" on page 106) calibration functions must be called up from "zeroing, ready" state.

Zeroing can be called up from the measurement functions (standard or peak value measurement), as well as from "Pause" and "Function off".

When zeroing is initiated from the "Pause" or "Function off" modes, the stabilization conditions for the transition to zeroing mode must be fulfilled first (see Section Switching On and Warming Up Getting the Opacimeter Ready for Measurement on page 73). Only then does the actual zeroing routine start and run as it does when zeroing is called up from a measurement function:

Important: If no measurement values are to be recorded but the instrument is needed in ready state, switch to zeroing (not Pause!)

Carry out zeroing every half-hour or more frequently if possible.


Zeroing 77

Checking of measuring chamber and exhaust temperature

Checking of temperature drift

Long zeroing: Determination of mean value of detector voltage over 10 s, then filter 1st Order over 30 s

Short zeroing: Determination of mean value of detector voltage over 10 s

Checking of stability of (smoothed) detector voltage

Checking that the detector signal has not drifted by more than 2 % since the last zeroing.

This function is not called up when zeroing is initiated from "Pause" or "Function off" mode. It ensures that the zero air valve is tightly closed and that only ambient air and no exhaust gas can be drawn in.

If the detector signal has drifted by more than 2 %, Error 13 (no zeroing) is output (the other things that Error 13 indicate are only relevant in measurement mode). When this happens, investigate the cause of the drift (see Section Causes of Error, Remedies on page 136).

The checks are made internally every 10 s and the complete zeroing process takes at least 50 s (long zeroing) or 20 s (short zeroing). The zero air valve switches several times to help deposits to work them-selves free. Then a new zeroing process is started. If the process is still unsuccessful after five attempts, the Opacimeter switches itself to "Function OFF". If all the checks are positive, the system is "Ready" and signal smoothing with 30 s-filter 1st Order is resumed until the measurement function is called up again.

Instrument Controller

From "Pause" or "Function off" state: as described in Section AVL 4210 Instrument Controller

From measurement status: ZERO (key F4)

Control via serial interface

AK command: STBY


Continuous Measurement (Standard Measurement)78

5.5 Continuous Measurement (Standard Measurement)

As soon as the Opacimeter is "Ready" which means that zeroing is complete the system will accept the "measurement" command. This puts it into standard measurement mode. The zero air valve switches to continuous exhaust gas sampling function and the Opacimeter continuously delivers the opacity or absorption values, N [%] or k [m-1], respectively. These values are standardised to measuring chamber temperature 100° C and atmospheric pressure (see also Section Beer-Lambert Law on page 13) as required by the relevant regulations.

Note: See Section Reading stability on page 67 for information about measurement value stability.

The standard measurement status is set as follows:


When the status (displayed top right) is "Ready":

Press MEAS (F4)

The Instrument Controller continuously displays the measurement value.


The measurement data and the filter algorithm are displayed in addi-tion to the measurement value (N or k).

Fig. 47


Continuous Measurement (Standard Measurement) 79


AK protocol: SMGA

The system continuously outputs data that can be queried.

Analog values: 50 Hz data rate

Digital interfaces: query command AKON. One measure-ment value is transmitted per query in accordance with the AK generic communications interface.

Requesting measurement data: AMDT

The display of exhaust gas flow rate through the measuring cell (Q_Gas), pressure in the measuring chamber (p_Cha) and temperature of the sampled gas at the inlet to the mea-suring cell (T_Gas) allows you to check that the Opacimeter is functioning properly (see also Section Service on page 143).

The measurement parameters, i.e. the selection of the filter algorithm and the output value (opacity N or absorption coefficient k) should be set from the zeroing function but can also be set in measurement mode (see Section Setting the Parameters on page 89).


Peak Value Measurement (ECE R24 or EEC 72/306, ELR)80

5.6 Peak Value Measurement (ECE R24 or EEC 72/306, ELR)

5.6.1 General

The peak value measurement registers the highest measured value during a measurement period. The measurement is prescribed for certain statutory test cycles for engine certification or testing, e.g. for free acceleration in accordance with ECE R24 (EEC 72/306) or the "ELR" test ("Load Response Tests") of the EURO III HD Regulation.

The peak value can only be output via the serial interface and not the analog or digital one.


Call up the Menu (key F1). Select the measurement screen for the required peak value measurement (ECE R24 or ELR or free acceleration peak value measurement) and confirm with F6.

The correct parameters are already programmed for the statutory test runs and do not have to be set. For the free acceleration peak value measurement: set parameters as described in Section Checking the Zero Point.

When a peak value measurement is called up, the trigger type (i.e. measurement period "Start" and "Stop") is set to "internal", i.e. the measurement period is controlled by pressing function keys TRIG (F3) and STOP (F6). This is displayed at the right of the fourth line. If an external trigger is to be used, which is actually preferable, the parameter has to be set in the usual way:

Select the variable to be set with the ↑ ↓ keys (your selec-tion is then inversely highlighted).

When you press SET (F6), the inverse highlighting changes to a normal display and is enclosed in a box. INPUT appears above F6. Use the ↑ ↓ keys to change the parameter and confirm by pressing INPUT (F6).

You will find more information about trigger types on the following pages.

The "peak value measurement" mode now has to be initialised by pressing the MEAS key (F4).

The measurement period is started by pressing the TRIG function key F3 and terminated by pressing STOP (key F6). If key F3 is pressed a second time before key F6 is pressed, the previous measurement window is automatically terminated and a new one started. The measurement window can also be defined by digital input when the Instrument Controller is being used (see below).


Peak Value Measurement (ECE R24 or EEC 72/306, ELR) 81

The highest measurement values between each start and stop, i.e. the peak values, are displayed on the screen.

Free acceleration peak value measurement screen


The peak value measurement is generally started from "contin-uous measurement" mode (see Section Continuous Measure-ment (Standard Measurement)).

Set the output and filter parameters as in the standard measure-ment - see Section Checking the Zero Point.

AK command: SMFA

This command starts the measurement window for the peak value measurement and SMFE terminates it.

The measurement window is also terminated if the SMFA trigger is issued a second time via the serial interface (before SMFE) and a new window is started.

The last peak value can be queried with the AMES command on completion of each measurement window

Fig. 48



Triggering the measurement windows

The measurement window can be defined in different ways.

The type of trigger is defined by the parameter setting command, EPAR (see Section Setting the Parameters on page 89).

Trigger types:

External trigger (digital interface, see Section Digital Interface ("Digital I/O") on page 54)

The measurement window is defined by:

"Level" The measurement window is active As long as the contact is closed

or

"Start edge" The measurement window is started when the contact is closed and terminated by the next Start edge.

Internal trigger, Instrument Controller function keys or AK com-mand via serial interface

SMFA: starts measurement window

SMFE: ends measurement window

Trigger types

Fig. 49

SMFA

SMFE

Signal curve Measured peak value

Measurementinterval

External trigger Edge

Level

internal trigger



5.6.2 Example 1: ELR Test

ELR test

Fig. 50

(S)

TT

TT

T(S

)S/

T(S

)(S

)T

TT

T(S

)(S

)S/

TD

(S)

TT

TT

T(S

)S

(S)

(S)

TT

TT

S(S

)(S

)S/

TD

S/T

060

120

180

240

300

360

t [s]

≥ 50

ms

>4.5

V

<0.5

V

>4.5

V

<0.5

V

D D

A AA

2500

2000

1500

1000 50

0 0

[min

-1]

[Nm

]

0.8

0.6

0.4

0.2 0

k [m

-1]

Inst

rum

ent

Con

trolle

r onl

y

exte

rnal

trig

ger

"leve

l", q

=1

exte

rnal

trig

ger

"edg

e", q

=2

seria

lin

terfa

ce

Spee

d A

Spee

d B

Spee

d C

Spee

d

Torq

ue



The ELR test consists of three additional loads on the engine (with peak value measurement) at each of three (or optionally four) speeds A, B, C (D). The mean value of the three peak values has to be deter-mined for each of the speed blocks and a weighted total measurement value calculated from the first three blocks (see relevant European Council Directive).

An example of this is shown in Fig. 49 on page 82 where the sequence control for the various trigger types can also be seen.

Here:

When the Instrument Controller is used, the last peak value is displayed after each stop (S). If the Opacimeter is being controlled via the serial interface, it has to be queried using the AMES AK command. If S is not used, the value is displayed each time after the next T.

S/T: S or T must be input to terminate a speed block (from the Instru-ment Controller) or the entire measurement (from the serial interface).

A in Fig. 50 on page 83 defines the time the ELR test is started from the Instrument Controller (see Section General on page 80).

EURO 3 measurement screen

T Start measurement periodInstrument Controller: F3Serial interface: SMFA

S Stop measurement periodInstrument Controller: F6Serial interface: SMFES may be omitted.

Fig. 51



The tester may also add a freely defined fourth speed block D to the additional load on the engine at the three defined speed blocks. The Instrument Controller "assumes" that the fourth additional load test will take place. If there is no fourth test and a new ELR test is required instead, the test must be started anew by pressing ZERO (F4) and MEAS (F3).

When the Instrument Controller is used, a screen can be called up by pressing DATA (F6) where the mean values of the speed blocks, the deviations within the blocks and the weighted total mean value are displayed.

EURO 3 results

N.B. Although the timing of the ELR test is defined, the tolerance for the phases (±10 %) is too large to make the triggering of the AVL 439 Opacimeter for each additional load on the engine independent of the test bed host sequence control.

ELR sequence control with test bed control

The start and stop points of the measurement period coincide with characteristic times of the engine control system and can therefore easily be integrated in the test sequence plan for the ELR test. To do this, of course, the test bed control system must be suitably linked to the AVL 439 Opacimeter by serial or digital connection.

Fig. 52



5.6.3 Example 2: ECE R24 (EEC72/306) Test

ECE R24 test

Fig. 53

Opa

city

Spee

d

nstru

men

tC

ontro

ller o

nly

exte

rnal

trig

ger

leve

l", q

=1

exte

rnal

trig

ger

"edg

e", q

=2

seria

lin

terfa

ce

k [m

-1]

ST

TT

TS

SS

SS

TT

ST

TT

TS

SS

SST

OP

TT

>4.5

V

<0.5

V

>4.5

V

<0.5

V

min

-1



In the ECE R24 "free acceleration" test, the engine is freely acceler-ated at least six times. The first two accelerations are not evaluated. The next four are valid if the measurement values lie within a scatter band of 0.25 m-1. If they do not, the free accelerations are continued until this criterion is fulfilled.

The order of the sequence control for the various trigger types is shown in Fig. 53 on page 86.

Here:

When the Instrument Controller is used, the last peak value is displayed after each stop (S). If the Opacimeter is being controlled via the serial interface, it has to be queried using the AMES AK command. If S is not used, the value is displayed each time after the next T.

ECE R24 measurement screen

The peak values of the last four free accelerations are displayed each time on the Instrument Controller as well as the mean value and devia-tion. It can easily be seen therefore whether the current measurement series is valid or whether another free acceleration is required.

ECE R24 sequence control with test bed control:

The start and stop points of the measurement period coincide with characteristic times of the engine control system and can therefore easily be integrated in the test sequence plan for the ECE R24 test. To do this, of course, the test bed control system must be suitably linked to the AVL 439 Opacimeter by serial or digital connection.

T Start measurement periodInstrument Controller: F3Serial interface: SMFA

S Stop intervalInstrument Controller: F6Serial interface: SMFES may also be omitted.

Fig. 54


Checking the Zero Point88

5.7 Checking the Zero Point

This function switches the zero air valve to allow ambient air to be drawn in. Measurement values are still displayed continuously, however, and they should be around zero (otherwise zeroing is neces-sary).

This mode can only be selected during a measurement, during peak value measurements only when no trigger is active.


Press 0 GAS function key (F5).


AK command: SNGA

Permitted: during measurement (SMGA)

Back to measurement with SMGA.


Setting the Parameters 89

5.8 Setting the Parameters

5.8.1 Measurement parameters

The parameters can be set in any mode. If the preprogrammed statu-tory regulation is called up by the Instrument Controller, the correct parameters are set automatically and act then as permanent defaults (see Tab. 29 on page 89).

Parameters that can be set:

the measurement unit for the output (N or k)

filter algorithm and time:moving average, 2nd order Bessel filter, or 1st order low pass

whether filter to be applied to N or k, or the "Hardridge" simulated filtering (0.35 s Bessel filter over k, then filtering of N using moving average, 1st order low pass or Bessel filter) "kN"

trigger mode for peak value measurement(see Section Peak Value Measurement (ECE R24 or EEC 72/306, ELR))(digital/serial, edge/level)

Parameters for statutory regulations

Bessel filtering is carried out in such a way that the rise time τ (10-90) of a jump function is the "filter time" (see Tab. 29 on page 89). The algorithms used to attain this within a given physical rise time are spec-ified in the relevant regulations and illustrated with examples.

*) For the R 24 test, the AVL 439 Opacimeter has to simulate a device that has a physical rise time (or gas exchange time) of 0.4 s and a galvanometer instrument with a 1 s low-pass filter characteristic. Comparative tests showed that first a 2nd order (Bessel) filtering over 0.35 s and then a 1st order low pass filter over 0.8 s has to be applied.

Physical requirements at opacimeters

ECE-R24 ELR ISO 8178-9 SAE J1667

Output unit k k k k or NUnit to be filtered kN *) k k kFilter algorithm Low pass

1st order *)Bessel 2nd order

Bessel 2nd order

Bessel 2nd order

Filter time 0.8 s *) 1 s 1 s 0.5 s

Tab. 29

ECE-R24 ELR ISO 8178-9 SAE J1667

Max. physical rise time 0.4 s 0.2 s 0.2 s 0.2 sElectronic rise time 1.0 s 0.01 s 0.01 s 0.01 s

Tab. 30


Setting the Parameters90


All measurement parameters can be set during zeroing, contin-uous measurement and free acceleration peak value measure-ment provided the instrument is in ready state. (In continuous measurement mode, the measurement parameters can even be set during the measurement itself.) Trigger mode can be selected if ECE R24 or EURO III is selected.

SET function key (F6)

The settable parameters are displayed on the screen in each mode. First use the ↑ ↓ keys to select the parameter to be changed. The "current" parameter is inversely highlighted (white against a black background).

When you press SET (F6), the inverse highlight changes into a normal display and the data is enclosed in a box. "INPUT" appears above F6. Use the ↑ ↓ keys to change the parameter and press INPUT (F6) to confirm.

"SET" then appears again above F6 and the ↑ ↓ keys can be used to select another parameter to be changed.

The signal available at the analog measurement value output "A" is output in the unit and with the filter set in the "Measurement parame-ters".

Important: When you have set all the parameters as required, save the configuration by pressing SAVE (F2).

Example: Settings according ECE-R24 filtering with internal trigger

Output unit = k

Unit to be filtered = kN

Filter algorithm = low pass 1st order

Filter time = 0.8 s

Trigger = internal




AK command: EPAR u v f T q

u: output measurement unit0 = N [%], 1 = k [m-1]

v: measurement unit that is filtered0 = N, 1 = k, 2 = "kN" (0.35 s Bessel filter over k, then filtering of N using moving average, 1st order low pass or Bessel filter)

f: type of filter0 = no filter (at the same time has the effect that u is equal to v)1 = moving average2 = Bessel filter of the 2nd order3 = 1st order low pass

T: rise time [s] (real)moving average, 1st order low pass:

T = T0-100 (0.02 10.00)

Bessel: T = T10-90 (0.2, 0.35, 0.5, 1.0, 1.077, 1.5, 2.0)

1st order low pass: T = T0-90 (0.2 2)q: Trigger type for peak value measurement (see Section Peak

Value Measurement (ECE R24 or EEC 72/306, ELR))(0 = internal, 1 = external/level, 2 = external/edge)

Example: Settings according ECE-R24 filtering with internal trigger

EPAR 1 2 3 0.8 0


Setting the Parameters92

5.8.2 Device Parameters (ambient pressure, spread of analog signal, conditioning temperature and operating hours counter)

Device parameters that can be set:

Ambient pressure

Input of current ambient pressure (see Section Calibrating the Sensors on page 110).

Spread of the analog signal (only channels A and B)

There are two scales for the analog output: "times 1" and "times 5". This means that the voltage signal 010 V corresponds to the following measurement values:

"times 1" means N = 0 100 % where u = 0or k = 0 10.0 m-1 where u = 1

"times 5" means N = 0 20 % where u = 0or k = 0 2.0 m-1 where u = 1

Conditioning temperature

Setting range: 70 120° C (in 1° steps)

Conditioning temperatures other than 100 ° C can be set for spe-cial applications - but it should be remembered that conditioning to temperatures other than 100 °C does not comply with the statu-tory requirements.

If the conditioning temperature is lower, condensate will probably form after the measuring chamber. Where HC condensate forms in particular, the device is likely to be more heavily soiled (thus shortening the maintenance intervals).

Deletion of the second operating hours counter

The Opacimeter has two operating hours counters, the second of which can be reset (only by service technician, requires download dongle, article number BV2601). The first counter ("total") always displays the total number of operating hours (zeroing/measure-ment, pump operating time) the instrument has been run. The second ("last") shows the operating time since the last reset.


Call up "Menu" screen (F1) and select "Parameters".

The parameters that can be set are displayed on the screen.

Function key Delete (F5) sets the second operating hours counter ("last") to 0. The first operating hours counter ("total") cannot be set to 0.



The variable to be set is selected with the ↑ ↓ keys (your selection is then inversely highlighted); ambient pressure, spread analog signal, and conditioning temperature).

When you press SET (F6), the inverse highlight changes to the normal display with the data framed in a box and "INPUT" appears above F6. The ↑ ↓ keys can be used to change the parameter which must then be confirmed by pressing INPUT (F6).

"SET" then appears again over F6 and another parameter can be selected for changing with the ↑ ↓ keys.


Spread of analog signal

AK command EMBE x y

x = 1: "times 1"x = 5: "times 5"y = 0

Delete the second counter (service personnel only)

AK command: SBST

Adjusting the pressure to ambient pressure

AK command ELDR x

x = 800 1100 mbar

Input of conditioning temperature

AK command ESMK x

x = 70 120° C

Important: When you have set all the parameters as required, save the configuration by pressing SAVE (F2).


Operation with the DIO interface94

5.9 Operation with the DIO interface

Settings (i.e. measurement parameters etc.) must be made on a PC or the Instrument Controller. The "Internal" trigger type must be set to enable the DIO interface to take over control (see Section Measurement parameters on page 89).

When a signal is applied to the LATCH input, the Opacimeter switches to DIO control. This is indicated by the fact that the OUT1 output is set to "1". In this state, the Opacimeter cannot be controlled via COM1 and COM2.

The bit pattern for the required state should be applied to IN1 and IN2 (see Fig. 30 on page 54):

The action is executed when the LATCH input is subsequently acti-vated. Output OUT2 ("Busy") is set to "1" and as soon as that state is reached it is set to "0" again.

The Opacimeter automatically carries out a 13 second back-purge during the transition from MEASUREMENT or ZEROING to PAUSE status.

IN2 IN1 State

0 0 Off0 1 Pause1 0 Zeroing1 1 Measurement

Tab. 31

Important: The MEASUREMENT mode can only be requested when the Opacimeter is in ZEROING mode and OUT2 is set to "0".

All other states can also be requested when OUT2 = "1".


Measurement Value Calculation 95

5.10 Measurement Value Calculation

The final measurement value that is output is determined by various calculation levels of the Opacimeter software. The value on which the calculations are primarily based is the measured detector voltage, from which the opacity or absorption is calculated based on Beer-Lambert Law (see Section Beer-Lambert Law on page 13). The calculation of the final value runs through the following modules, depending on the parameters set (see Tab. 34 on page 100).

Determination of zero value (zeroing)

Calculation of raw value

Filter calculations (filter type and filtered unit)

Calculation of output unit (N [%] or K [m-1])

5.10.1 Determination of Zero Value

Zero value, U0, is calculated during zeroing as the mean value of the detector voltages (see Section Zeroing) and N = 0 % and k = 0 m-1 are equated. The zero value recalculated during each zeroing is calculated by means of averaging (filter floating mean over 10 s or in addition for a long zeroing, Bessel filter for t = 30 s) (see Section Zeroing on page 75).

5.10.2 Calculation of the Raw Value

The internal raw value Sk is calculated in the first calculation module based (U/U0, analog output "C") on Beer-Lambert Law (see Section Beer-Lambert Law on page 13) and standardised by means of the correction factor PTcorr (analog output "D") to standard tempera-ture (100° C) and ambient pressure.

The raw value ("unfiltered measurement value", see Section Analog Measurement Value Output on page 58) output via the analog output "B" corresponds to the pressure and temperature-compensated value calculated using Beer-Lambert Law.

The raw value that is output is transmitted continuously to the measurement channel of the "unfiltered measurement value" analog output "B". The selected filters (filter type, filter time) are not consid-ered for the raw value.

Depending on the output unit, the result is::

for k: Leff = 0.43 m

for N:

eff

k

LSk =

NSN =


Measurement Value Calculation96

5.10.3 Filter Calculation

The following parameters can be set for the filter calculation:

filtered unit (N, k or kN)

filter type and filter time (floating mean value, Bessel or 1st order filter)

Filtered Unit

The Opacimeter offers the option of using the measurement quantities N, k or kN as the base value for the filter.

The filter based on (kN) is an algorithm that was especially developed for the R24 peak value measurement and imitates an Opacimeter with a physical rise time of 0.35 s and an analog measurement value display (linear N-scale). Such an Opacimeter is the familiar Hartridge MK3. The algorithm contains a filter first using Bessel (0.35 s) based on (k). The result is then converted to (N) and filtered with the set filter type.

Filter Types and Filter Times

The Opacimeter can filter the raw values (N, k or kN) by means of 3 different filter types for which different filter times can be set.

The following filter types are implemented:

Floating Mean

An imaginary window is placed over the last (n) measurement values in which all the measurement values are averaged. The size of this floating window is set by the filter time (T0-100 = 0.02 10 s). The calculation algorithm creates the mean value with

n includes all the values inside the time window

=

=n

iiSn

S0

1



Bessel Filter

The Bessel filter has the characteristic of a 2nd order low pass which is described by the following formula:

The Bessel constants depend on the rise time (T10-90) (0.1 s for the AVL 439 Opacimeter) and the sampling frequency of the unfiltered signal (50 Hz internally for the AVL 439 Opacimeter), i.e. Bessel filtering of a signal with the same rise time but which was recorded with a different sampling frequency, needs different filter constants.

The constants (E, K) are specified below for a data rate of 50 Hz.

Data rate = 50 Hz

Low pass of the 1st order

This filter filters the raw value with a filter characteristic of a 1st order low pass which is described by the following formula:

The low pass filter constant (C) can be calculated from the following formula:

The sampling frequency corresponds to the data rate of the measure-ment (Opacimeter, internal = 50 Hz), τ90 corresponds to filter rise time T0-90.

Y calculation results X measurement valuesE, K Bessel constants which determine the T10-90 time

)()42( 212211 −−−−−− −∗+−++∗+= iiiiiiii YYKYXXXEYY

Time

Constant 0.2 s 0.35 s 0.5 s 1 s 1.077 s 1.5 s 2 sE 1.9383e-2 5.8148e-3 2.8362e-3 7.2038e-4 6.2236e-4 3.2358e-4 1.8298e-4

K 0.4995 0.7302 0.8127 0.9063 0.91296 0.93737 0.95296

Tab. 32

CXcYY iii ⋅+−⋅= − )1(1

)10ln(90

1

1⋅⋅−= τfrequency SamplingeC



Example: Recalculation of ELR measurement data based on measured analog values (U/U0) and (PTcorr)

In this example, the absorption (k) [m-1] is calculated based on the measured analog values of the (U/U0) and (PTcorr) channels (see Section Analog Measurement Value Output on page 58).

According to the ELR Test, the signal has to be filtered with a 1 s Bessel filter based on (k) and with the final value output in (k) [m-1]. The data rate for this example should be 50 Hz.

1. Scaling of the measured analog values (see Section Analog Measurement Value Output on page 58) based on a measure-ment value.

Scaling of analog output: 0 10 V equals 0 2 for U/U0

Scaling of analog output: 0 10 V equals 0 2 for PTcorr

2. Raw value (Sk) is calculated from:

3. 1 s Bessel filter based on raw value (Sk):

Yi, Yi-1, Yi-2 calculation results

Xi, Xi-1, Xi-2 calculated raw values (Sk, Sk-1, Sk-2)

E 7.2038e-4

K 0.9063

4. Calculation of output value (k):

Yi filter calculation results

Leff 0.43 m optical length

9956.05978.4

0==

UU

0322.15161.5 ==korrPT

corrk PTUUS ⋅

−=

0ln

)()42( 212211 −−−−−− −∗+−++∗+= iiiiiiii YYKYXXXEYY

eff

i

LYk =



The table below contains an example of data for a short measurement calculated based on the above criteria and formulas.

Note: Each filter calculation includes the last measured or calculated values (Sk) or (Yi) in the calculation. The initialisation value (0) is used for missing values at the start of a filter calculation.

U/U0measured in V

PTcorrmeasured in V

U/U0(Scale Section Analog Mea-surement Value Out-put on page 58)

PTcorr(Scale Section Analog Mea-surement Value Out-put on page 58)

Raw valueSk

Yi after 1 s Bessel filter of Skr

Finaly value (k) in m-1

4.978 5.161 0.9956 1.0322 0.00455 0.000003 0.0000084.978 5.160 0.9956 1.0320 0.00455 0.000016 0.0000374.977 5.160 0.9954 1.0320 0.00476 0.000041 0.0000954.978 5.160 0.9956 1.0320 0.00455 0.000077 0.0001794.976 5.160 0.9952 1.0320 0.00497 0.000123 0.0002864.975 5.161 0.9950 1.0322 0.00517 0.000178 0.0004154.978 5.161 0.9956 1.0322 0.00455 0.000243 0.0005654.978 5.162 0.9956 1.0324 0.00455 0.000314 0.0007314.981 5.162 0.9962 1.0324 0.00393 0.000391 0.0009094.981 5.162 0.9962 1.0324 0.00393 0.000471 0.0010964.979 5.162 0.9958 1.0324 0.00435 0.000554 0.001289

Tab. 33



Flow diagram for measurement value calculation

After the Opacimeter is powered up: Udark = signal (lamps off)U = detector signal - Udark Zeroing: U0 = mean value (U)

Calculate raw value

(PTcorr pressure and temperature correction)

only calculated when filter = N and output = NFiltering

N k kN(first k is filtered,

then conversion into N)S = SN S = Sk S1 = Bessel

Filter typewithout smoothing moving average Bessel filter 1st order low pass

S = S S = mov.av. (S) S = BE (S) S = 1stLP (S)Output

N kwhen filtering when filtering

N oder kN k N oder kN kN = S

Tab. 34

[ ][ ] pressure chamber tmeasuremenK373

pressure ambientK etemperatur chamber tmeasuremen⋅

⋅=korrPT

corrUU

k PTS ⋅−=0

ln

( )kSN eS −−⋅= 1100

( )SeN −−⋅= 1100 ( )eff

S

Lk 1001ln −−

=effLSk =



Analog measurement value output

Pin Measurement value Output N Output k

1 Final value, filtered N k3 Final value, not filtered SN

5

8 PTkorr PTkorr PTkorr

Tab. 35

effkL

SkS =

0UU

0UU

0UU


General 103

6 Calibration and Checking

6.1 General

Opacimeters have two well defined calibration points (see Section Zeroing on page 75):

the light value at N = 0 % and the dark value at N = 100 %.

These two points are determined in the AVL 439 Opacimeter as it goes into ready mode:

The dark value that corresponds to the signal from the sensor when no light falls on it, is determined internally shortly after the instrument is switched on while the light units are deactivated. (It is usually less than 10 mV.)

The light value is determined during zeroing (the associated sensor signal is 24 V). The light value has to be determined anew periodically, i.e. approximately every half-hour. The Opaci-meter prompts the user to do this. The scale between light value, N = 0 %, and dark value, N = 100 %, is graduated linearly to the sensor signal.

During calibration the system checks that the graduation of the N-scale is linear to the incident light intensity. This is done by reducing the transmitter light intensity by a precisely defined amount, say by 40 %. The display should then show an opacity of N = 40 % in accordance with the definitions and formulas of Section Method of Operation on page 13.

A calibration can be performed in one of two ways on the AVL 439 Opacimeter:

1. with the patented "Linearity Test"

2. with calibrated filters "of neutral optical density"(i.e. grey glass discs that reduce the light of each wave length to approximately the same extent in the observed optical spectral range.)

Important: Calibrating the AVL 439 Opacimeter with the linearity test or with neutral optical density filters is only used to check the sensor linearity - it has no effect on the display of measurement values.


Linearity Test ("LIN Check")104

6.2 Linearity Test ("LIN Check")

The light source in the AVL 439 Opacimeter consists of two nearly identical halogen lamps. If lamp 1 only is switched on, about half as much light is incident on the detector as when both lamps are switched on. The same applies when lamp 2 only is switched on. The example in Fig. 55 on page 104 shows that the detector signal is D1=1900 mV when lamp 1 is switched on and D2=2100 mV when lamp 2 is switched on. D1 + D2 is 4000 mV and should ideally be the same as the value measured when both lamps, D1+2, are switched on. Assuming the measured value is D1+2=3996 mV, the linearity deviation is:

The relevant standards and statutory regulations generally require less than 1 % deviation. In our experience the linearity test deviation is less than 0.5 %. Larger deviation can only be caused by a faulty detector element. If the deviation is > 0.5 % the detector element must be replaced (see Section Service on page 143).

This kind of linearity check is RW TÜV-approved.

The system must be in "Zeroing", "Ready" state. The maximum devia-tion is 0.5 %.

Graphic representation of the LIN check

% 0.1% 10021

1221 −=⋅−−

=∆+

+

DDDD

D

Fig. 55

I1

I2

I1 + I2

I = I0 = 100 %, N = 0 %

D1 D2

D1 + D2

D1+2

linearitydeviation

real curveideal curve

light intensity I

dete

ctor

sig

nal D


Linearity Test ("LIN Check") 105


The "Linearity test" measurement screen can be selected from the Menu screen (by pressing F1) and confirmed with EXEC. (F6).

As soon as the "Linearity test" screen appears and the equipment is ready for measurement, start the procedure by pressing START (F4).

The linearity test is carried out automatically after each "START" and the results displayed after 20 sec.

Zeroing is automatically carried out after the test. You can inter-rupt it by pressing ZERO (F4) or you can start a new linearity test by pressing START.


The AK command for executing the LIN check is:SLCH

The result can be called up by

ALCH x1 x2 x3 x4 w1 w2

x1: signal lamp 1 (real)x2: signal lamp 2 (real)x3: signal both lamps (real)

(all results in mV)x4: linearity = ((x1+x2)-x3)/x3 *100

(real)w1: 0 = OK, 1= warning (lamp current drift)

Caution: The lamp currents were not constant during the linearity test due to thermal instability. The test can be repeated after a short stabilisation period.

w2: 0 = OK, 1= warning (drift in dark value voltage)

Caution: The dark value has changed since the Opacimeter was switched on. This unusual situation can be remedied by switching the Opacimeter off then on again and following the (shortened) procedure for putting it into ready state.


Linearity Check ("Calibration") with "Neutral Density Filters"106

6.3 Linearity Check ("Calibration") with "Neutral Density Filters"

"Neutral density filters" are available from various optics companies. They are normally supplied, however, with only an approximate absorption value (±5 %, possibly ±2 %) and have to be calibrated. Ready-calibrated filters are available for the AVL 439 Opacimeter under the following order numbers:

For calibration of the device with certified neutral density filters, usually one filter will be enough, preferably with an absorption of 50 %. For engine certification of commercial vehicles according to guideline 1999/96/EU ("commercial vehicles regulation Euro 3/4"), filters with an absorption of 10, 20 and 40 % are required.

The opacity values specified on the filters should be treated as guide-lines only. The pricise, calculated absorption value is printed on the first page of the calibration protocols of the company Swarovski.

In a few special cases, Calibration Certificates from the BEV (Bunde-samt für Eich- and Vermessungswesen = Federal Office for Calibration and Measurement) are supplied with the equipment and not the Cali-bration Report from Swarovski. These calibration certificates show the transmission values of the filters as a function of the wave length [400 800 nm], from which the precise calibration value can be calculated. The transmission factors indicate the filter's permeability to light of different wavelengths (usually from 400 nm to 800 nm). The transmis-sion that is effective for the AVL 439 Opacimeter is obtained by multi-plying and standardizing these values by the standardized emission and sensitivity of the detector unit. The Excel spreadsheet "Filter_Cal.xls" can be used for an exact calculation. A simpler calcula-tion, which experience has shown to produce the effective transmis-sion (or opacity, see below) to better than 0.5 %, is described below.

The AVL 439's detector unit is designed in such a way that its highest spectral sensitivity is between 550 nm and 570 nm (in accordance with the statutory requirements). It is the transmission values around 550 nm therefore that are particularly significant in the filter's calibra-tion certificate. Approximated absorption value can be determined from the weighted mathematical mean of three values (see below).

Absorption [%] Order no.

10 BH018320 BH018240 BH018150 BH0177

Tab. 36


Linearity Check ("Calibration") with "Neutral Density Filters" 107

Absorption value N is therefore N = 100 % - 48.7 % = 51.3 %

The value displayed on the AVL 439 was 50.8 % and is therefore within tolerance (see below).

The calculated value for the ≈50 % absorption filter, used for calibration according to ECE R24 (EEC 72/306), must agree with the value displayed on the AVL 439 to within ±1 % opacity.

For the ELR test according to the directive 1999/96/EU ("commercial vehicles regulation Euro 3/4") and for the standards ISO 8178-9, ISO 11614 and SAE 1667, calibration with filters of lower absorption are required. The limit of agreement in these regulations and standards is ±2 % opacity. The acceptance of a larger tolerance in these regula-tions and standards is based on the fact that neutral density filters with low absorption show larger deviations: the values given by the opaci-meter are usually lower than the calibration value. This is due to well-understood physical principles ("multireflexions") and does not indicate any deficiency or non-linearity in the actual smoke density measurement. It accounts for the fact that the absorption by neutral density filter is optically not comparable to the absorption in the smoke cell. (For the same reason the calibration is usually carried out with the "opacity" value N [%], not the "absorption" value k [1/m]).

Example: Transmission values (from the calibration certificate of a calibration filter)

Wave-length

Transmission T Weighting W T × W

500 nm 0.485 1 0.485560 nm 0.494 3 1.482600 nm 0.476 2 0.952Weighted mean value

2.919/6=0.487

Tab. 37

DANGER!The absorption value of a filter decreases as the temperature rises! Do not leave the calibration filter in the unit for longer than 1 min!

Absorption filters are precision components never touch the surface! If the surface is touched, this changes the absorption value even if the filter is meticulously cleaned. Once touched, a filter must be officially calibrated again!


Linearity Check ("Calibration") with "Neutral Density Filters"108

With careful handling the absorption value of the filters changes only slightly (<<1 %). For a calibration at an official certification according to 1999/96/EU it is necessary that the filter is not longer used than one year. After that, a recalibration is required. You can have your device recalibrated by AVL or by an approved national inspection agency.

The neutral density discs are mounted in a calibrating filter cartridge.

For the calibration, the calibrating filter cartridge is inserted in the light unit (on the right of the measuring unit) instead of the cartridge without glass discs. The cartridge can be accessed by undoing the screwed coupling on the Opacimeter cover using a spanner (NW 58). It is then easy to remove and replace.

Carrying out the calibration with neutral density filter

The system must be in "Zeroing", "Ready" state.


Select the calibration measurement screen from the Menu screen (key F1) and confirm with EXEC(key F6).

The "calibration" screen is displayed but the system is still in "Zeroing" mode.

Press START (key F4) to start the calibration

The calibration is carried out in the sequence described below. The corresponding measurement value is displayed after each calibrating filter is inserted.

Press ZERO (key F4) to return to zeroing.


AK command: SKAL

You can call up the result withAKAL x

Fig. 56


Linearity Check ("Calibration") with "Neutral Density Filters" 109

Calibration sequence

The system prompts the user to insert or remove the calibration filter cartridge as required by making the status LED flash slowly.

This is necessary because for calibration, the system must reach stable values before the procedure can be continued, i.e. before the calibrating filter can be removed again. Not only that but it may be advisable to repeat the calibration using several different filter cartridges one after the other. In that case, insertion or removal is also prompted by slow flashing.

1. Before calling up the calibration procedure: make sure that the cartridge without glass discs is fully inserted.

2. Call up the calibration procedure (from the Instrument Controller or terminal, see above).

3. Status LED flashes slowly:

remove the cartridge (without calibrating filter

and insert the calibrating filter cartridge

4. Status LED is illuminated constantly again as soon as the filter cartridge is inserted.

5. When a stable value is measured for N (or k), it is displayed (on the Instrument Controller) or can be called up with AK commands.

6. Status LED flashes slowly

7. If another calibration value is required, remove the calibrating filter and insert the next one. Repeat the procedure from d).

If the calibration is finished, insert the cartridge without glass discs. The system recognizes this cartridge by the fact that when inserted there is less than 5 % opacity. The system checks inter-nally whether the zero value reaches better than 0.5 % opacity within 10 sec. If it doesnt, a warning is output.

8. The calibration process is terminated when the user calls up the "Zeroing" function.

A maximum of 7 calibrations can be performed in succession. The status LED switches off for 5 s to indicate when the seventh cali-bration value is reached.

Important: When the status LED flashes slowly, it means the calibra-tion filter cartridge should be changed.


Calibrating the Sensors110

6.4 Calibrating the Sensors

By calibration in the real sense, we mean that the displayed measure-ment value from a sensor is compared with an officially calibrated reference value. Setting the displayed measurement value to be the same as the officially calibrated reference is more correctly called "adjusting".

The AVL 439 Opacimeter measurement value (N or k) can also now be calibrated (or "adjusted") see Section Linearity Check ("Calibration") with "Neutral Density Filters" on page 106 and Linearity Test ("LIN Check") on page 104.

It is pointless to calibrate the temperature and pressure sensors of the AVL 439 Opacimeter without adjusting them as well. Below the term "calibration" therefore is always used in the sense of "calibration and adjustment".

The following sensor values can be calibrated:

measuring chamber temperature sensor

temperature sensor for the inflowing gas sample (valve block gas in)

pressure sensor in the measuring chamber

gas sample flow rate sensor (i.e. differential pressure sensor)

Zero point and end point of the analog outputs

The absolute pressure transducer is a special device. The value should be checked once a week and if necessary recalculated. The calibration must carried out approx. 5 min after power-up (allowing for the electronics to warm up, "Function off" status) and before the device warms up (balancing).

The air pressure is input in the "Parameters" screen with the Instru-ment Controller (see Section. Device Parameters (ambient pressure, spread of analog signal, conditioning temperature and operating hours counter) on page 92).

All sensors are calibrated at the factory. Recalibration is a service task that should only be carried out by trained personnel. It is absolutely essential also to carry out this calibration whenever the controller board is replaced.

A separate "Calibration and Adjustment Procedure" for the AVL 439 Opacimeter (ID number AT0685E) is available.

Important: The intervals between the calibration of sensors and cali-bration tools depend on the guidelines on maintenance of test instru-mentation applicable for the user.

AVL recommends annual calibration.


General 111

7 RS232 Interface / AK Generic Communication Interface

7.1 General

This chapter contains information for programmers who have to inte-grate the AVL 439 Opacimeter into automation systems.

The communication via the RS232 interface is based on the AK generic communication interface that is standard in exhaust emissions measurement technology.

You will find references to the interface parameters in chapter Serial Interfaces on page 53.

7.1.1 Protocol Framework

Command message

Byte Function

1 <STX>2 Is ignored3 6 Function code

SXXX control commands

EXXX setting commands

AXXX query commands7 Blank8 K9 Channel number (always 0). Data (variable)

Can also be omitted (depends on function code)..nth byte <ETX>

Tab. 38


General112

Acknowledgement message

Acknowledgement when function code unknown

<STX> ???? n<ETX>

n error status

General comments and possible acknowledgements in the event of error

The command message must begin with <STX> and end in <ETX>. The first nine bytes must always be present.

When entering commands via keyboard, <STX> can be entered by pressing and holding down the control key (Ctrl) and then pressing B (also known as <Ctrl+B>), <ETX> can be entered by pressing <Ctrl+C>.

Blanks are used as separators.

The variable-length floating decimal format is used to display numerical values. There is no decimal point with integers. The sign is only specified in front of negative values. Physi-cally meaningless digits are omitted.

If no data is available in response to a query, the piece of data is replaced by # in the acknowledgement.

Data that is only conditionally valid is prefixed with a #.

Byte Function

1 <STX>2 Is ignored3 6 Function code (same as command)7 Blank8 Error status

0 no error1 9 error (counted in cycles)

. Data (variable)Can also be omitted (depends on function code)

.

.nth byte <ETX>

Tab. 39


General 113

If a control or setting command is transmitted in SMAN oper-ating state (which only permits query commands), it is acknowledged as follows:

<STX> XXXX n K0 OF<ETX>

XXXX function code

n error status

OF offline

If a command is transmitted that cannot be executed in the current status or due to an unremedied error, it is acknowl-edged as follows:

<STX> XXXX n K0 BS<ETX>

XXXX function code

n error status

BS busy

If a command message contains a syntax error (e.g. too few or too many parameters), it is acknowledged as follows:

<STX> XXXX n K0 SE<ETX>

XXXX function code

n error status

SE syntax error

If a parameter value is outside the permissible range, it is acknowledged as follows:

<STX> XXXX n K0 DF<ETX>

XXXX function code

n error status

DF data error


General114

7.1.2 Operating Mode

The Opacimeter has two RS232 interfaces (COM1 and COM2) and one digital port (Digital I/O) which has the same status as the two RS232 interfaces as far as the operating mode is concerned. Each of the three interfaces can be either in control or monitor mode, but only one can be in control mode at a time.

All three interfaces are in monitor mode after power-up and after a reset.

7.1.3 Command Set

The command set is arranged according to function groups. Only the function code and parameters are listed. The full string complies with the conventions of the AK generic communication interface.

In query commands (which start with A), the returned parameters are specified after the function code. AKEN k v therefore signifies that when AKEN was transmitted, the response was AKEN k v.

Numerical format

The format is integer unless otherwise specified.

Control mode (SREM): All commands are accepted.Monitor mode (SMAN): Only query commands are accepted and

control command SREM.


General Queries 115

7.2 General Queries

AKEN k v

Device ID and firmware version

ABST t1 t2

Operating hours counter (operating time of pump, window heating system)

ASTZ z1 z2...

Status

The statuses are the same as their function code if they are triggered by control commands.

ASTF

Error status

Shows the numbers of the current errors (see next page).

k: 439 (= device ID)v: firmware version

t1: total operating time [h]t2: operating time [h] since the last reset (SBST)


General Queries116

Error codes

1 Detector Signal < 1500 mV2 Halogen lamps Current < 350 mA or > 500 mA3 Detector heating system Temperature does not increase when heating switched

on4 Measuring chamber heating system Temperature does not increase when heating switched

on5 Probe heating system Temperature does not increase when heating switched

on6 Compressed air Pressure < 2 bar

(= pressure switch setting)7 Window heating system window resistance too low (< 4 W)

or too high (setpoint not reached)

Window heating fuse (F4) faulty/blown8 Gas temperature sensor Ruptured sensor or short circuit.

The probe heating system is switched off.9 Measuring chamber temperature

sensorRuptured sensor or short circuit.The measuring chamber heating system is switched off.

10 Calibration Signal drift during calibration(N > 0.3 or < -0.3 %)

11 Flow rate alarm Flow rate < 30

12 Flow rate warning Flow rate < 35 or > 60 13 Zeroing warning Zeroing has not been carried out for more than 30

minutes.14 Not ready (= status information) Target temperatures not reached yet

(during PAUSE)

Signal stability not yet reached(during STANDBY)

Pump run-on time (when switching back to PAUSE or OFF)

15 Lamps/detector overheating Lamp or detector temperature > 90° C16 Exhaust gas overtemperature Exhaust gas inlet temperature > 150° C17 Measurement parameters checksum error

18 Analog output calibration checksum error

19 Operating hours counter checksum error20 Sensor calibration checksum error21 Setpoint values checksum error22 Limit values checksum error23 Maintenance will be required soon Operating hours counter > 950 hours

Tab. 40

minl

minl


General Control Commands 117

7.3 General Control Commands

SRES

ResetAll active functions are aborted and the system is reset.

SREM

Switch to control mode

SIDL

"Function off"

SPAU

Pause

STBY

Zeroing

SBST

Reset operating hours

7.4 Measurement

SMGA

Start measurement (charge of measurement gas)

Permitted: Zeroing (STBY) and Checking the zero point (SNGA)

AKON x

Measurement value

x: Opacity N or absorption k, as set with EPAR (real).


Measurement118

AMDT TG p Q t

Measurement data

AMES x

Result of peak value measurement

SMFA

Peak value measurement: start of measurement window

Permitted: during measurement (SMGA) provided that the trigger type = internal (set with EPAR)

The command can also be transmitted several times (without SMFE in between). It then acts like an edge trigger.

SMFE

Peak value measurement: end of measurement window

Permitted: during measurement (SMGA) provided that the trigger type = internal (set with EPAR)

SNGA

Checking the zero point

Permitted: during measurement (SMGA)

Back to measurement with SMGA

EPAR u v f T q

Measurement parameters

TG: Gas temperature [°C]p: Measuring chamber pressure [mbar]Q: Gas flow rate [l/min]t: time remaining until Opacimeter is ready for measure-

ment (see Section Switching On and Warming Up Getting the Opacimeter Ready for Measurement on page 73)# Zeroing is in progress or "Ready" (see Section Zeroing on page 75)

x: Peak value of last measurement window (real)


Measurement 119

APAR u v f T q

SKAL

Calibration

Permitted: Zeroing (STBY)

AKAL x

Calibration result

in N [%] or k [m-1], as set with EPAR (real)

SLCH

Linearity test ("LIN check")

Permitted: Zeroing (STBY)

u: measurement value that is output0 = N [%]1 = k [m-1]

v: measurement value that is filtered0 = N1 = k2 = kN

f: type of filter0 = no filter1 = floating mean2 = Bessel filter of the 2nd order3 = 1st order low pass

T: rise time [s] (real)floating mean: T = T0-100 (0.02 10.00)Bessel: T = T10-90 (0.2, 0.35, 0.5, 1, 1.077, 1.5, 2)1st order low pass: T = T0-90 (0.02 10)

q: trigger type for peak value measurement0 = internal1 = external/level2 = external/edge


Measurement120

ALCH x1 x2 x3 f w1 w2

Linearity test result

SLEC

Leak test

Duration: 10 20 s

Permitted: Off (SIDL)

ALEC x

Leak test result

x = 0: test passed

x = 1: test failed

EMBE x y

Scaling of analog output

AMBE x y

ELDR x

Air pressure [mbar]

ALDR x

Permitted: Off (SIDL), Pause (SPAU)

x = 500 1100

x1: Signal from lamp 1 [mV] (real)x2: Signal from lamp 2 [mV] (real)x3: Signal from both lamps [mV] (real)f: Linearity error [%] (real)w1: 0 = OK, 1= warning: lamp currents differentw2: 0 = OK, 1= warning: drift in dark value voltage

x=1: times 1(10 V = 100 % or 10 m-1)

x=5: times 5(10 V = 20 % or 2 m-1)

y=0


Service 121

SRUC

Purging

Permitted: Off (SIDL), Pause (SPAU), Zeroing (STBY)

Continuous purging, can be stopped with SIDL, SPAU or STBY.

SPRG

Purging

Permitted: Off (SIDL), Pause (SPAU), Zeroing (STBY)

Purging for 13 s, then switching back to the operating mode SPRG was called from.

7.5 Service

Switch commands contain parameter z which can be 0 or 1.

0 off / close

1 on / open

ASPA UD TD TMK TG p Q I1 I2 TL P1 P2

Service measurement values

ELMP n z

Switch halogen lamp n (n = 1, 2; 0 [both])

EPMP z

Switch pumps

UD: Detector signal [mV]TD: Detector temperature [°C]TMK: Measuring chamber temperature [°C]TG: Gas temperature [°C]p: Measuring chamber pressure [mbar]Q: Gas flow rate [l/min]I1: Halogen lamp 1 current [mA]I2: Halogen lamp 2 current [mA]TL: Lamp temperature [°C]P1: Heat output window 1 [W] (real)P2: Heat output window 2 [W] (real)


Service122

EVLV n z

Switch valve n (n = 1 4)

ASST L1 L2 p v1v4

Switch states

Lamps, pumps, valves

ESMK x

Setpoint value for conditioning temperature (service technician only)

ASMK x

(70 ≤ x ≤ 120° C)

EANA x

Checking analog output

AANA x

This command affects all four analog outputs.

After checking the analog outputs, reset them using the EANA 0 command.

x=0: Measurement valuex=1: Zero value (0 V)x=2: End value (10 V)


General 123

8 Maintenance and Storage

8.1 General

The AVL 439 Opacimeter is designed in such a way that it requires little maintenance even when in use for long periods. This is due in particular to the heated measuring chamber window, the sample condi-tioning and the automatic purge function. Only the filter element in the exhaust gas sampling path has to be changed from time to time depending on the degree to which it is used. The Opacimeter indicates when the filter needs changing (flow measurement).

When the Opacimeter has been in operation for a long time, we recom-mend cleaning it periodically because residues can build up in the lines and measuring chamber, especially if it has been used for exhaust gases with high particulate concentrations. Such residual deposits can become dislodged during operation due to thermal or mechanical influ-ences and cause an effect that looks like soot peaks or zero drift.

We therefore recommend cleaning the Opacimeter, particularly before measurements on low-emission engines. You should clean the following components approximately every 100 operating hours:

Window modules and window elements

Sampling lines

Measuring chamber

DANGER!The gas path of the opacimeter must never be subjected to blasts of compressed air.


Changing the Filter Element124

8.2 Changing the Filter Element

The filter element is situated between the measuring chamber outlet and the pump inlet. It consists of filter paper with a nominal perme-ability of 5 µm and a filter area of about 2800 cm2. The filter element guarantees long pump life and consistent operational reliability during its operational life.

The AVL 439 Opacimeter has an integral flowmeter. The filter becomes less permeable with time depending on the amount of soot emitted from the engine. That reduces the flow rate which triggers a warning message when it undershoots a certain limit ("Flow Rate Warning"). If a measurement is running when this message is output, it can still be completed. When the flow rate drops below the lower limit, the Opaci-meter switches to pause mode and outputs an error message.

However, we recommend changing the filter element before the error message is output. Change the filter before switching the instrument on, i.e. before the parts through which the exhaust gas flows get hot.

The filter can be changed easily, quickly and cleanly:

Make sure that the Opacimeter is switched off or in pause mode.

Unscrew the filter cover at the front of the Opacimeter.

Remove the filter element from the filter housing together with the cover.

"Snap" the used filter element out of the cover by pressing it to the side and then let it fall out.

This way there is no need to touch the filter element that is loaded with diesel particulate.

Fig. 57


Changing the Filter Element 125

Insert a new filter element into the cover. You can hear when it is sitting correctly by the sound it makes as it fits into place in the cover.

Check the O-ring in the cover for any signs of damage and replace if necessary.

To reassemble, insert the filter element into the filter housing, centre the sealing collar and push it carefully onto the internal guide. As soon as you can feel that it is correctly positioned, press the filter element together with the cover until it is resting on the

Fig. 58

Fig. 59

Fig. 60


Changing the Filter Element126

threaded guides.

You can feel when the cover fits into the threaded guides by turning it counterclockwise while gently pushing it. Then tighten the cover moderately by hand.

The Opacimeter is ready for use again.

Fig. 61

DANGER!Do not operate the Opacimeter without the filter elements supplied by AVL and do not use any other brand, otherwise operational reliability cannot be guaranteed.

Important: Dispose of used filters in accordance with the regulations stipulated by your company.


Cleaning the Window Modules 127

8.3 Cleaning the Window Modules

The heated windows which separate the optical elements from the exhaust gas in the measuring chamber are designed to automatically burn off soot deposits and to keep the optical passage clean. However, after being in operation for a very long time for measurements where the smoke density is high, various exhaust gas components can soil the windows (e.g. unburned engine oil residues, etc.).

The windows must be cleaned when the transmitted light intensity is reduced to the extent that the received detector voltage falls below ~1500 mV. When it falls below this threshold, an error message is output during zeroing. The measured detector voltage can be displayed using the service functions.

The sequence for cleaning the windows is described below.

Make sure that the Opacimeter is switched off and disconnect it from the mains.

Open the instrument and remove the cabinet hood.

DANGER!The components of the Opacimeter may still be hot from previous use - be careful not to burn yourself!


Cleaning the Window Modules128

Remove the light unit and detector unit.

To do this open both quick-release locks (1) and pull the entire unit out carefully in the axial direction (2).

Screw off the two connectors for the supply line and the signal line.

Fig. 62

Fig. 63

12


Cleaning the Window Modules 129

Place the light and detector units on a suitable work surface with the windows facing upwards.

Cleaning instructions for window modules

Carefully remove particulate deposits around the windows using compressed air or suction.

Fig. 64

Fig. 65

DANGER!When carrying out this work, make sure that no exhaust gas is entering the Opacimeter via the return line. The gas could escape through the opened measuring chambers - risk of poisoning!


Cleaning the Window Modules130

Cleaning instructions for the window elements of the detector and lamp unit

Clean the window elements first with a soft cloth

Only use the Cleaning Set (Ident. No. HY0028) for stubborn soiling to remove any residual deposits:

Wet the wooden cleaning stick with water

Dab a little cleaning powder onto the wet stick (the powder should then become pasty).

Remove deposits using circling movements of the stick.

Using a soft cloth wipe the window elements first clean (possibly using liquid) and then dry.

Switch the detector and lamp unit on briefly to allow any residual moisture or cleaning agent to evaporate.

Wipe the window elements again with a soft cloth when they have cooled down.

Before reassembling, check the O-rings for any signs of damage and replace if necessary.

After cleaning the windows reconnect the supply and signal lines and fit the light and detector units back into position.

Replace the cabinet hood and close it properly.

Restart the Opacimeter. Once it is ready for operation, check the detector voltage using the service function.

DANGER!Only ever clean the elements when they have cooled down (i.e. are warm to the touch)!

Do not touch the window elements with your fingers.

The windows are made of laminated 1 mm thick quartz.

Mind the limited shock resistance of the windows, especially when using pointed equipment.


Cleaning the Sampling Lines 131

8.4 Cleaning the Sampling Lines

The conditioning hose, the zero air valve and the probe line are back-flushed with compressed air every time the AVL 439 Opacimeter is switched off. Nevertheless when the Opacimeter is in use for a long period of time, and particularly at high particulate loads, residues can still become deposited in the lines. If such deposits become dislodged during operation due to thermal or mechanical influences, it causes an effect that looks like an emission peak.

That is why we recommend using compressed air to blow clean the conditioning hose and zero air valve, especially in measurements on low-emissions engines. The particulate deposits from the lines should not be blown into the ambient air. The following procedure is therefore recommended:

Switch the Opacimeter to "Function off" mode.

Zero air valve open path into exhaust line

Instrument Controller:

Set V3 to "1" and all other values to "0" in the Service menu (see Section Device Parameters on page 143).

AK command:

EVLV 3 1

Disconnect conditioning hose from the Opacimeter input.

Blow compressed air into the conditioning hose in short bursts while shaking the hose so that any particulate deposits can work loose.

Repeat the process several times.

If, despite this cleaning, there are still depositis in the line, you can clean them out with the cleaning brush (Ident. No. WH0065).


1000 Hour Service132

8.5 1000 Hour Service

Those parts of the AVL 439 Opacimeter which are regularly contami-nated with exhaust gas can wear within a short period of time and might cause leakage.

Due to this, AVL recommends the exchange of these components after 1000 operating hours (operating-hour check in software) with original AVL spare parts according to AVL requirements.

After 950 operating hours, the AVL 439 Opacimeter outputs an message to the effect that a 1000 h service will soon be necessary. This message is not an error message. You can still continue to carry out measurements without any problem (the message is reset during the 1000 h service).

The total operating hours can be read out with the AVL 4210 Instrument Controller (sub menu "Parameters") or with the AVL 439 PC Software. The download dongle (Article No. BV2601) is also needed to reset the operating hours counter.

For comparison, an example : 1000 h operating hours correspond to approx. 50.000 to 100.000 km driven.

All service related actions should be performed by a trained (AVL) service engineer.

For detailed information see "1000 Hours Service" Operating Instructions(Article No. AT1004E).

DANGER!All components should be exchanged only with approved and speci-fied AVL spare parts!

With defects and troubles which are caused by disregarding AVL, no warranty on the defective hardware can be claimed. This relates also to the accuracy and specifications of the system.


Storage for Long Periods of Non-Use 133

8.6 Storage for Long Periods of Non-Use

If the Opacimeter is not to be used for a long period, it must be discon-nected from the exhaust system and also from the supply lines. When stored for long periods, it must be kept in a dry, well-ventilated place.

Before long-term storage, make the following preparations:

In "Function off" mode, activate the purge function.

Disconnect the sample line and feed back line from the exhaust line and let the Opacimeter run for about an hour in "Zeroing" mode.

This ensures that any deposits or residual condensate is removed.

Switch the Opacimeter off.

Replace the filter element with an unused one (see Section Changing the Filter Element on page 124).

Clean the windows (see Section Cleaning the Window Modules on page 127).

Carry out a short function test and then disconnect the connection lines.

Drain any condensate that has collected in the compressed air preparation unit.


Storage for Long Periods of Non-Use134


Error codes 135

9 Error Table

9.1 Error codes

Query command ASTF indicates the number of the current error:

1 Detector error Detector voltage too low2 Lamp error Lamp current too low3 Error at detector heating Detector temperature TD: temperature does not

increase when heating switched on (setpoint value not reached)

4 Error at chamber heating Measuring chamber temperature TMK: temperature does not increase when heating switched on (setpoint value not reached)

5 Error at probe heating Gas temperature TG: temperature does not increase when heating switched on (setpoint value not reached)

6 No compressed air Insufficient pressure at pressure switch7 Error at window heating Px setpoint value not reached because window resis-

tance too low (< 4 Ω) or too high8 Error at gas temp. sensor Gas temperature sensor defective9 Error at chamber temp. sensor Measuring chamber sensor defective10 Calibration error Zeroing cannot be carried out sensibly because the

detector voltage is drifting.11 Flow rate too low Flow rate alarm: flow rate < 30 l/min12 Flow rate warning Flow rate warning: flow rate < 35 l/min or > 60

l/min13 Zeroing warning Measurement mode: The zero point may no longer be

correct check it, or carry out Zeroing again (see Section Causes of Error, Remedies on page 136).

Zeroing: Intensity drift since last zeroing (see Section Zeroing on page 75).

14 The device has not reached the requested state or the current action is not yet finished, e.g. setpoint tempera-tures (measuring chamber temperature TMK, gas temperature TG, lamp temperature TL) or signal stability not yet reached or zeroing not yet finished.

15 Overtemp. det./lamps Detector temperature TD or lamp temperature TL too high (> 100° C)

16 Overtemperature gas Gas temperature TG higher than 150° C17 Measurement parameters checksum error18 Analog output calibration checksum error19 Operating hours counter checksum error20 Sensor calibration checksum error21 Setpoint values checksum error

Tab. 41


Causes of Error, Remedies136

9.2 Causes of Error, Remedies

22 Limit values checksum error23 Maintenance will be required soon Operating hours counter > 950 hours

Error Possible cause Check Remedy

1 One lamp defective Ix = 0 (x = 1; 2) Replace lamp element (ID number: BB0828)

Windows soiled Check windows visually Clean windows

Detector defective Replace detector element (ID number: BB0797)

2 One lamp defective Ix = 0 (x = 1; 2) Replace lamp element (ID number: BB0828)

3 Detector heating defective TD < TD (setpoint), not increasing

Replace detector element (ID number: BB0797)

4 Sensor for TMK defective Error 9 is output See error 9No voltage in heating system Check voltage at plug

X14, pin 1 and 4Repair contact if faulty or replace solid-state relay REL2 (Sect. Compo-nents of the Electronics Board on page 153)

Measuring chamber heating system defective

TMK < 100°C,disconnect plug X14, measure resistance R (pin 1 and 2)

If R < 10 Ω or R > 1000 Ω:Replace measuring chamber, send old one in for repair

Measuring chamber over-heated, overtemperature switch responded

Disconnect plug X14, measure resistance R overtemperature switch EV0176, pin 3 and 4 (see Appendix, Section Measuring Chamber)

If R < 10 Ω or R > 1000 Ω:Replace heating element

Find reason for overheating:solid-state relay REL2 defective? (see Layout of Electronic Board, Section Components of the Elec-tronics Board on page 153)

Tab. 42

Tab. 41


Causes of Error, Remedies 137

5 Sensor for TG defective Error 8 is output See error 8

Heating element burnt out TG < 100°C,disconnect plug X15, measure resistance R between pin 1 and 2

If R < 10 Ω or R > 1000 Ω:Cool the measuring chamber, reset overtemperature switch.Find reason for overheating:

Overtemperature switch EV0170 defective?

Solid-state relay REL1 defective? (see Layout of Electronic Board, Section Components of the Elec-tronics Board on page 153)

TG sensor defective (see above)?

No voltage in the heating system

Check voltage at plug X15, pin 1 and 4

Repair contact if faulty or replace solid-state relay REL1 (Section Components of the Elec-tronics Board on page 153)

Overtemperature switch broken

Let heating element cool down, disconnect plug X15, measure resis-tance between pin 3 and 4

If R > 1 Ω: Replace overtemperature switch EV0177

6 Compressed air supply inad-equate

Check pressure indicator Ensure adequate supply of com-pressed air. There must be a pressure of > 1.8 bar at the inlet even when 100 N l/min is removed

7 Heating layer defective

Contact error

Heating layer overheating

P_window < 21.5 W,measure window resis-tance RF (plug J6, pins 1+2 and 5+6)

The window element must be replaced, if not 10 Ω ≤ RF ≤ 100 Ω Note that the window elements must be replaced in pairs!

Electronics problem 10 Ω ≤ RF ≤ 100 Ω Check electronics8 PT-100 sensor for measuring

TG (at measuring chamber inlet) is defective

The sensor is delivering unacceptable values

Replace the sensor (or the entire valve block)

9 Temperature sensor for TMK defective

The sensor is delivering unacceptable valuesSetpoint resistance: 50 kΩ 160 kΩ at room temperature

Replace the sensor (or the entire measuring chamber)


Tab. 42



10 Zero values before and after calibration differ by more than ± 0.3 %

Check zero stability without exhaust gas in measuring mode

Was the "zero" cali-brating filter cartridge inserted completely before and after the cali-bration?

Zeroing stabilise the Opacimeter until sufficient zero stability is observed in measurement mode without exhaust gas. (Drift < 0.3 % in 10 min)

Repeat calibration properly.

11 Filter element soiled Alarm deactivated when new filter inserted

Replace filter element

Pump failure Alarm active despite new filter element

Pump service (see below)

Limit value wrong Check limit value(terminal program)

Set valid limit value(terminal program)

12 Filter element soiled see error 11Pump soiled see error 11Limit value wrong see error 11


Tab. 42




13 Opacimeter has been contin-uously used for measure-ments for more than 30 minutes without zeroing

Carry out zeroing as soon as your test sequence permits

The device measures values less than zero (< -1 % opacity)

Check the zero point (Section Checking the Zero Point on page 88). Enable Negative Output Values (Sections Inter-faces on page 52 and DIL Switches on page 63)

Zero drift, Opacimeter is not stable during zeroing

Let the Opacimeter stabilise, carry out Zeroing again

Switchover to Bessel filter can cause negative over-shoot

Generally speaking, not critical.In calibration mode: switch to Bessel filter before switching to calibration mode

Temperature sensor and/or pressure sensor failure wrong correction factor

Check temperature sensor and pressure sensor values for plausi-bility

Replace the sensors

If error 13 is displayed in Zeroing: detector voltage has changed significantly since the last zeroing.Window dirty Check if window is dirty Switch Opacimeter off and clean

window

Zero air valve stuck Actuate valve V3 in Service mode (see Section Service on page 143) and watch the action of the zero air valve

Clean zero air valve (clean with com-pressed air when removed from the Opacimeter) or replace it

14 Opacimeter not yet warm TG and/or TMK < 100° C, but rising

Wait until the Opacimeter is warm

A heating system is defec-tive

TG and/or TMK <100° C after 20 min warm-up

See error 4 and/or 5

TL not yet stably TL rises by more than 0.5 °C/min

Wait for TL to stabilize

Requested mode not yet reached

Wait until the requested mode is reached

Tab. 43



15 Opacimeter ventilation system failure

TL > 90° C

Open Opacimeter cover (CAREFUL! mains voltage!), check fans

Replace fans

Detector heating control defective

TD > 90° C Replace detector module

Venting apertures of the housing blocked

Clean venting apertures

16 Exhaust gas temperature more than 600° C

Mount the sampling probe in a cooler place in the exhaust line

PT-100 sensor for measuring TG (at measuring chamber inlet) is defective

The sensor is delivering unacceptable values

Replace the sensor (or the entire valve block)

Heating element overheated TG > 110° C Check solid-state relay REL1, replace if necessary

17 Battery in memory module is empty

Measurement parame-ters change every time AVL 439 is turned on

Replace module, new calibration of AVL 439 necessary (service techni-cian)

Microprocessor failure Check measurement parameters

Replace electronics board, new cali-bration of AVL 439 necessary (service technician)

Microprocessor: electromagnetic interference

Check measurement parameters

Set new measurement parameters (filter, output unit, trigger setting)


Scaling of analog out-puts wrong (Section Analog Mea-surement Value Output on page 58)


Microprocessor failure Scaling of analog out-puts wrong (Section Analog Mea-surement Value Output on page 58)


Microprocessor:electromagnetic interference

Scaling of analog out-puts wrong (Section Analog Mea-surement Value Output on page 58

Calibrate analog output (service technician)


Read operating hours counter


Microprocessor failure Read operating hours counter



Read operating hours counter

Set operating hours counter again (service technician)


Tab. 43




Check all sensor values Replace module, new calibration of AVL 439 necessary (service techni-cian)

Microprocessor failure Check all sensor values Replace electronics board, new cali-bration of AVL 439 necessary (service technician)


Check all sensor values Calibrate sensors (service technician)


Check all setpoint values Replace module, new calibration of AVL 439 necessary (service techni-cian)

Microprocessor failure Check all setpoint values Replace electronics board, new cali-bration of AVL 439 necessary (service technician)


Check all setpoint values Enter setpoint values (setpoint value of window heating may also have changed) (service technician)


Check all limit values Replace module, new calibration of AVL 439 necessary (service techni-cian)

Microprocessor failure Check all limit values Replace electronics board, new cali-bration of AVL 439 necessary (service technician)


Check all limit values Set limit values (service technician)

23 Maintenance will be required soon

Operating hours counter > 950 hours

Perform recommended 1000 hour service (service technician)


Tab. 43



Operating errors without error codes


No response from system

Communication error Check the communica-tion protocol, see Section RS232 Inter-face / AK Generic Com-munication Interface on page 111

Set up correct communication pro-tocol

Microprocessor error Check electronics board,

see Section Function Check of the Electronics on page 154

Replace microprocessor or elec-tronics board (service)

Linearity test error

Detector defective Linearity test error > 0.5%

Replace detector element

TD > setpoint

Room temperature too high TD > TD(setpoint) Set setpoint temperature higher while carrying out measurements at high room temperature TD (setpoint) to T(room) + 10° C

Room temperature higher than 50° C (specification limit)

Switch cooling fans on in test bed room

Tab. 44


Function Check 143

10 Service

10.1 Function Check

10.1.1 Device Parameters

When the Opacimeter displays an error, e.g. when the green status LED flashes, or when the measurement results suggest a system error, it is advisable to carry out a function check.

Additional device parameters (spread of analog signal, operating hours counter, ambient pressure) are described in Section Device Parame-ters (ambient pressure, spread of analog signal, conditioning tempera-ture and operating hours counter) on page 92.


The following screen appears when you call up the "Service" menu.

Service screen on the Instrument Controllers

The screen displays all the systems measurement parameters and the switch states of the lamps, pumps and valves.

You can also switch the lamps, pumps and valves using the service function to check that they are working properly. To do this, press OFF (F2) to set the Opacimeter to "Function off" mode.

When the Opacimeter is in ready mode (i.e. "Pause" and "Measure-ment" functions), the following switch states must be displayed:

Fig. 66


Function Check144

x: 1 for "Measurement", 0 for "Zeroing"

AK Generic Communication Interface

the following parameter supplies all the device parameters:

ASPA UD TD TMK TG p Q I1 I2 TL P1 P2

Service measurement values

The states of the lamps, pumps and valves can be checked using the query command ASST. They can be set using switch com-mands (see Section Service on page 121).

The operating hours counter can be queried with the ABST com-mand (see Section General Queries on page 115).

Code L1 L2 P V1 V2 V3 V4

Signifying Lamp 1 Lamp 2 Pumps Conditioning air Purging air

Zero air Measure-ment gas

State 1 1 1 1 0 x 1

Tab. 45

DANGER!V2 (purging valve) and V4 (inlet valve) must never both be on 1 at the same time!

UD: Detector signal [mV]TD: Detector temperature [°C]TMK: Measuring chamber temperature [°C]]TG: Gas temperature [°C]p: Measuring chamber pressure [mbar]Q: Gas flow rate [l/min]I1: Halogen lamp 1 current [mA]I2: Halogen lamp 2 current [mA]TL: Temperature in area of lamps [°C]P1: Window 1 heat output [W] (real)P2: Window 2 heat output [W] (real)


Function Check 145

10.1.2 Limit Values for the Device Parameters when Instrument Functioning Correctly

The parameters must lie within the following range::

UD: 800 2200 mV for L1 = 1 or L2 = 11500 4500 mV for L1 = 1 and L2 = 1

TD: Setpoint value ± 1 °C. The setpoint is usually 50° C unless specified otherwise in the ETDT command.

TMK: Setpoint value ± 5°C (default setting: setpoint value = 100° C)

TG: Setpoint value ± 5°C (default setting: setpoint value = 100° C)TG may briefly deviate from the setpoint by up to 10° C during sudden changes in exhaust gas temperature and during power-up.

p: When pump switched off: ambient air pressure.When pump running: 30 to 60 mbar below the pressure at the beginning of the probe tube (pressure p-exhaust gas in the exhaust line).

Caution: p-exhaust gas may lie between - 100 mbar and +400 mbar according to the specifications.

Q: Permissible range: 60 35 l/minWarning range: 35 30 l/min or

> 60 l/minAlarm range < 30 l/minAt a supply frequency of 60 Hz higher limits apply.

I1, I2: ~0 when Lx = 0430 470 mA, when Lx = 1

TL: Maximum value: 100° CThe device is ready for measuring (thermally stabilised), if TL changes by less than 0.5 . When selecting zero point adjustment after starting up, this condition is in general achieved last (after approx. 20 min).

P1, P2: The setpoint is usually 14 W. It is labelled on all window elements.Tolerance: ± 0.5 W of setpoint value

minC°


Function Check146

10.1.3 Pump Service

Check the pumps during the 1000 hour service. The diaphragms in 7015 diaphragm-type pumps must be renewed depending on use. It is advisable to replace the valves at the same time (part of the "Spare parts set for pump 7015", article number MV0143).

To do this, remove the head screws.

The pump head and chamber can now be lifted out and separated from one another.

Unscrew the central diaphragm screw and lift the diaphragms out. Release the top and bottom diaphragm plates.

Insert the new diaphragms and screw in well ("finger-tight").

Remove the valves (valve/seal) from the pump chamber and replace with new ones

Place the pump head on the chamber making sure that the lug fits into the groove.

Position the cover plate on top and push the entire assembly over the diaphragms. Make sure that the diaphragms slide properly into the bore.

Replace the four head screws and tighten them gradually in a diagonal sequence.


Function Check 147

10.1.4 Leak Check

Each device is leak checked before shipping. In general re-testing is not necessary. The leak check should only be carried out after any disassembly of the exhaust gas ducting, to check for correct mounting of all parts and connections.

For the leak check, the sample conditioning tube must be separated from the probe tube, and the exhaust inlet of the sample conditioning tube must be manually closed with an appropriate plug (e.g. Swage-lock drain plug SS-10M0-P, AVL ID number DN0228).

Make sure that the filter cover of the filter housing is closed prop-erly:

When selecting leak check, the whole system is evacuated to approx. 700 mbar absolute pressure, and the rate of pressure increase is measured. If this measured rate of pressure increase is less than 1 % of standard sample flow of 40 l/min, the test is passed.

The option leak check is accessible from the condition "Function off":


Call up the Menu (F1),

select Leak Check,

press START (F4).


AK command: SLEC

The leak check is performed (duration approx. 20 s).

Requesting test result using ALEC.

Result: ALEC x

x = 0: test passedx = 1: test failed

Fig. 67


Function Check148

10.1.5 Exchanging Temperature Sensors

Temperature sensor - measuring chamber

Disconnect sensor cable (plug X18)

Socket spanner (Item. 1, material number BH0219) for removing and installing the temperature sensor in the measuring chamber (Item. 2, material number BV2170)

Fig. 68

Fig. 69

1

2


Function Check 149

Temperature sensor - valve block

Disconnect sensor cable (plug X12)

Remove cable of temperature sensor for the valve block (material number BV2208) from the sensor body using pliers (sensor body remains in the valve))

Fig. 70

Fig. 71


Function Check150

Insert the extractor tool (Item. 1, material number BH0218) in the centre of sensor body and screw in applying moderate pressure.

Remove the sensor body with the extractor tool.

Fig. 72

Fig. 73

1


Function Check 151

Assembly:

Clean the bore making sure that no dirt gets into the valve body!

Coat the metal housing of the new temperature sensor with liquid Teflon (e.g. Loctite 572) and press it into the valve housing as far as it will go (using a small screwdriver if necessary).

Re-connect the temperature sensor cable at slot X12.

See also "Exchanging Temperature Sensors" quick reference (article number AT0955).

10.1.6 Software Update

New firmware can be installed using a PC and a serial interface.

This functionality is only available to a service technician. The down-load dongle is required to carry this out (Article No. BV2601).

Fig. 74

Important: After installing a new firmware, a calibration according to the Calibration and Adjustment Procedure (article number AT0685E) has to be performed


Electronics152

10.2 Electronics

10.2.1 Electric Components

Rear view of electric box

Fig. 75

J1

J3

J13 J14

J28

Power supply unit

Controller Board(BB1101)

Toroidal coretransformer

On/Off switch

Mains connection

Mains filter Fuse block

Cooling air fan


Electronics 153

10.2.2 Components of the Electronics Board

Fig. 76

Flow measurementpressure sensor

Measuring chamberpressure sensor

LED 7 self test

LED 8SV sampleheating

LED 9SV purgingair

LED 10SV zero air

REL3 pumps

LED 5operatingstate

DILswitches

LED 4measuringchamberheating

LED 1probeheating

REL1probeheating

REL2measuringchamberheating

EPROMwithfirmware


Electronics154

10.2.3 Function Check of the Electronics

Function displays

When the On/Off switch is switched on, the following function dis-plays are illuminated indicating that they are in a functional state (see Section Components of the Electronics Board on page 153 for position of the LEDs):

The status LED (Fig. 76 on page 153) is continuously on.

LED no. 1 (red) lights up when probe heating is on

LED no. 4 (red) lights up when chamber heating is on

LED no. 5 (green) flashes at a frequency of about 2 Hz (indicating that the microprocessor is functioning properly)

LED no. 7 (red) lights up during the self test (approx. 5 s after On/Off switch is switched on) and then goes off. This LED also lights up when the Opacimeter is in not ready state.

LED no. 8 (red) lights up when the solenoid valve for the sample heating is active

LED no. 9 (red) lights up when the solenoid valve for purging air is active

LED no. 10 (red) lights up when the solenoid valve for zero air is active


155

11 Spare Parts List

Important: When ordering spare parts consider the serial number of the opacimeter (see following table).

In the following spare parts tables some parts are marked with a generation designation (G001 to G004) - spare parts without genera-tion designation can be used for all opacimeters.

Generation Designation Serial number

1 G001 111 3442 G002 511 10003 G003 1011 15004 G004 > 1511

Tab. 46


156

Mechanical Components


Tube 6.0 × 2.0 Viton black (per meter) SS0272Polyamid filter cover H 145 H-8, S80x3 (for filter housing) MF0610O-ring 73.5 × 3.5 (for Polyamid filter cover MF0610) DA0415Measuring chamber, complete BO2694Locking ring DIN 471 28x1.5 mm (stainless)(stainless version for measurement chamber tube see 1000 Hour Service)

DZ0637

Pressure spring type KM-2286-174 mm lang (stainless)(stainless version for measurement chamber tube see 1000 Hour Service)

DF0148

Diaphragm-type pump 7015 ZVD/230 V (for 50 and 60 Hz power supply systems)

MV0141

Spare parts set for pump 7015 (contains spare parts to service a single pump!) MV0143Inlet valve complete (V4 inlet valve) G001 BO2716

G002 BO4084

G003, G004 BO4814Cable motor valve (motor for V4 inlet valve) G001, G002 BV2204

G003, G004 BV2587Solenoid valve (SV1, SV2, SV3) G001 G003 MM0589Solenoid valve (SV3) G004 MM0251Air preparation unit for compressed air BH0171Hose set, inside (for 1000 hour service) BO4460Upgrade kit fan (cooling air fan, electric box)

G001, G002 BH0269

Fan (cooling air fan, electric box) BV2342Pressure reducer 0.5 10 bar R1/4" M004-R00 (mounted internally) MM0584Pressure switch 1 10 bar (mounted internally) EZ0222

Tab. 47


157

Sampling Unit


Zero air valve G004 BO5358Sealing cone for zero air valve G004 YM3679Sample conditioning tube 1.5 m (silicone) G001 G003 BH0169Conditioning tube 1.5 m SI (silicone) G004 BO5359Conditioning tube 1.5m FPM (Viton) G004 BO5354Control hose for zero air valve 1.5 m PTFE (Teflon) G004 BO5356Return sampling line 2.5 m G001 G003 BH0203Return sampling line 2.5 m FPM (Viton) G004 BH0266Sample conditioning tube 3.0 m G001 G003 BH0170Conditioning tube 3 m SI (silicone) G004 BO5353Conditioning tube 3m FPM (Viton) G004 BO5355Control hose for zero air valve 3 m PTFE (Teflon) G004 BO5357Clip conditioning tube - control hose G004 BO4548Return sampling line 4.0 m G001 G003 BH0214Return sampling line 4.0 m FPM (Viton) G004 BH0267Sampling line (incl. fittings, 0.5 m) G001 G003 BH0220

G004 BH0227Sampling line (incl. fittings, 1 m) G001 G003 BH0173

G004 BH0228Probe (corrugated tube 0.5 m, without fittings),can be used as feed back pipe

YM3452

Probe (corrugated tube 1 m, without fittings),can be used as feed back pipe

YM3361

Male connector DN1323Drain plug for leak check DN0228

Welding piece 6-6GW DN1324

Closing plug for welding piece DN1373Straight connector DN1320

Probe for open exhaust(For test bed use only, not for testing on the road!)

TM04390EA.01

O-ring 10.82 × 1.78 mm, viton (for sample conditioning tube) DA0355O-ring 29.74 × 3.53 mm, viton (for sample conditioning tube) DA0356

Tab. 48


158

Electrical Components


Probe heating BO2717Temperature switch 180° C (for probe heating) EV0177

Temperature switch 135° C (for measuring chamber heating) EV0176Temperature sensor - measuring chamber BV2170Temperature sensor - valve block BV2208

O-Ring 3.68 x 1.78 mm, Viton (for BV2170 and EV0176) DA0207Controller board (main board) BB1101

Power supply 5 V/8 A, 24 V/2 A, ±15 V/2.5 A EN0321

Toroidal core transformer 240 VA prim. 2×115 V / sec. 2×24 V (for window heating)

EI0248

Signal lamp complete, green G001 EL0264Light bulb 24 V, 2.6 W, BA9S socket (for signal lamp)) G001 EL0259Cable kit 5 (contains all cables of the electric box)

(includes the following cables: BV2192, BV2193, BV2194, BV2195, BV2390, BV2198, BV2585/1, BV2585/2, BV2585/3, BV2207)

G003, G004 BV2585

Cable kit 6 (contains all cables of the main cabinet)

(includes the following cables: BV2203, BV2164, BV2205, BV2206, BV2163, BV2165, BV2586/1, BV2162, BV2209, BV2421)

G003, G004 BV2586

Cable kit 3 (contains all cables of the electric box)

(includes the following cables: BV2192, BV2193, BV2194, BV2195, BV2390, BV2198, BV2391, BV2200, BV2202, BV2207)

G002 BV2420


(includes the following cables: BV2203, BV2164, BV2205, BV2206, BV2163, BV2165, BV2167, BV2162, BV2209, BV2421)

G002 BV2421

Cable kit 1 (contains all cables of the electric box)

(includes the following cables: BV2192, BV2193, BV2194, BV2195, BV2390, BV2198, BV2391, BV2200, BV2201, BV2202, BV2207)

G001 BV2330


(includes the following cables: BV2203, BV2164, BV2205, BV2206, BV2163, BV2165, BV2167, BV2162, BV2209)

G001 BV2331

Fuse F1 sec. 3.15 AT EV0047Fuse F2 prim. 1 ATT EV0192

Fuse F3 and F4 6.3 AT EV0051Fuse F5 1 AT EV0039Fuse for option 100/115 V 10 AT EV0052

Tab. 49


159

Optical Components

Accessories

Consumption Parts


Exchange set windows(lamp unit and detector unit for exchange - paired unit)

BH0215

Lamp element BB0828Detector element BB0797

O-ring 50.00 x 2.00 mm, Viton (for lamp and detector unit) DA0369

Locking ring DIN 472 50x2 mm(stainless, for lamp and detector unit 1000 hour service)

DZ0638

Sliding part (neutral, without calibration filter insert) YM3340

Tab. 50


Analog cable 10 m G001, G002 BV1740Analog cable 15 m G001, G002 BV1763Cable digital I/O (DIO) 15 m(is also used as analog cable with G003 and G004)

BV2266

RS232 PC interface cable 15 m (e.g. connecting AVL 439 and PC) BV1854

RS232 PC interface cable 20 m (e.g. connecting AVL 439 and PC) BV2395Download dongle G003, G004 BV2601Connecting cable for AVL Instrument Controller, 15 m BV2191

Connecting cable for AVL Instrument Controller, 20 m BV2467

Condensate trap (including documentation) BH0193

Tab. 51


Filter insert (package consists of 6 pcs. filter insert plus an O-ring DA0415) MF0609Cleaning set for heated windows HY0028

Tab. 52


160

Calibration Equipment

Tools

Documentation


Calibration kit 439 (for service technician)(includes: floppy disk with calibration software, calibration device for temperature sensor GAS IN, documentation)

TM0439KALA.01

Transmission filter 50 % BH0177

10 % BH018320 % BH0182

40 % BH0181

Tab. 53


Service Tool Kit for 439(includes: cleaning brush, extractor tool and socket spanner for temperature sensors, stopper for leak check, cleaning set for heated windows, documentation)

TM0439WZK.01

Cleaning brush for measuring chamber and sampling line WH0065

Tab. 54


Operating Manual AVL 439 (English) AT0525E

AT1196EAT1307E

PC Software Manual AVL 439 (English) AT0602E

Calibration Procedure AVL 439 (English) AT0685EPUMA Integration 439 (English)VersaDos integration into PUMA5 and PUMA Open

AT0909E

On Board Diagnosis (German) AT0970D

Cleaning Set for Window Elements (English) AT0952Exchanging Temperature Sensors (English) AT0955Exchange Set Heated Windows (lamp adjustment) (English) AT0907

Condensate Trap (English) AT0713E1000 Hour Service (English) AT1004EPressure-filled Mode (English) AT1005E

Manual "upgrade kit" (English / German) AT1284Mounting instructions for upgrade kit "fan" AT1160

Tab. 55


161

Miscellaneous

Operating Manual AVL Instrument Controller (English) AT0993E

Exchange Controller Board (English / German) AT1534


Plug connection 8p cable plug 6 mm (suitable for AVL 439 plugs) EU1623Hose 9.0 × 3.0 PVC + fabric transparent (for compressed air tube) per meter SS0353

Clamp for tube 16.5 RER for compressed air tube DN1366

Tab. 56


Tab. 55


162


163

12 Technical Data

Measurement value output

Opacity N [%] or absorption k [m-1]

Measurement range

N = 0 100 % or k = 0 10 m-1

Measurement value resolution

0.1 % opacity or 0.0025 m-1 (10 s mean value)

Zero stability

0.1 % or 0.0025 m-1 / 30 min (drift with zero gas)

Rise time

0.1 s (at flow rate 40 l/min)

Inputs/outputs

Analog outputs 0 10 V (filtered, not filtered, calculation factors)

Serial RS232C interface, 9600 baud

Serial interface for connecting the optional AVL 4210 Instrument Controllers

Digital input/output: 3 inputs, 3 outputs; potential separated by optocoupler(see Section Digital Interface ("Digital I/O") on page 54)

Sampling rate for opacity signal

50 Hz

Output rates

Electronic measurement value filter (parametrisable)

Exhaust gas temperature

0 600° C

Exhaust gas pressure

-100 mbar + 400 mbar (incl. pulsation peaks)

Serial interfaces up to 2 Hz using the AK generic communication interface(required by protocol)

Analog output (50 Hz)

Moving average 0.02 10 sBessel filter of 2nd order (0.2, 0.35, 0.5, 1.0, 1.077, 1.5, 2 s)1st order low pass 0.02 10 sNot filtered


164

Protection type

IP 24

Ambient temperature

5 50° C

Power supply

230 V (100/115 V optional) ± 10 %, 5060 Hz

Power consumption

1 kVA (max.)

Compressed air supply/consumption

Required:

max. 100 l/min, non-oiled, dry and filtered

input pressure regulated to 410 bar

Dimensions

650 × 420 × 450 mm (W × H × D)

Weight

approx. 47 kg


165

CE Compliance

89/336/EEC Electromagnetic Compatibility Directive complied with by virtue of compliance with the following standard:

EN 61326:97/A1:98/A2:01 Electrical Equipment for Measurement, Control and Laboratory Use. EMC Requirements

73/23/EEC Low Voltage Directive complied with by virtue of compli-ance with the following standard:

EN 61010-1:93/A2:95 Safety Requirements for Electrical Equip-ment for Measurement, Control and Laboratory Use

The conformity to the Pressure Equipment Directive 97/23/EC is evidenced by an assessment showing that the range according to "article 3 / paragraph (3)" is not exceeded with this product / assembly.


166


Mounting Instructions - 439 Wall Mounting Console 167

13 Appendix

13.1 Mounting Instructions - 439 Wall Mounting Console

Fig. 77

460

425.5

Ø 1

2

463

540

AVL

439

Opa

cim

eter

10.5

DIN

125

M10

x12

DIN

7991

DIN

633

6 M

10x2

5 63

Ø

Use

fixi

ng m

ater

ials

th

at a

re s

uita

ble

for t

he ty

pe o

f wal

l

Wal

l mou

ntin

g co

nsol

e

Wal

l

Gru

ndpl

atte


Mounting Instructions - Probe for Open Exhaust168

13.2 Mounting Instructions -Probe for Open Exhaust

For measurements at the open end of an exhaust pipe, e.g. test runs on a roll test bed

Fig. 78

Exhaust gas sampling

Sampling probeTM04390EA.01

Zero air valve

Probe tube

Probe for open exhaust pipe, TM0439OEA.01, consisting of:- Adapter (YM3389)- Tube for exhaust probe Diesel (YM2733)- Clamp for exhaust probe (BO1179)

Exhaust gas feed back

Exhaust gas extraction system Exhaust gas feed back

Exhaust system


Valve Block (complete) 169

13.3 Valve Block (complete)

(Ident. no. BO4814)

Fig. 79

X12

Pos. Ident. no. Designation

0020 BV2587 Motor valve + cable0090 DN1336 Screwed angle fitting0110 BV2208 Temperature sensor

Tab. 57


Measuring Chamber170

13.4 Measuring Chamber

Fig. 80

0010

0020

0030

0040

0060

0070

0080

0100

0110

0050

0100

0090

0110

0180

0150

0140

0120

0130

0190

0190

0200

0180

0200

0050

0210

0190

0190

0205

0205

cool end

long

end

30

0090

21 cool end

X14

X18


Measuring Chamber 171


0010 YM3333 Measuring cell0020 YM3334 Outer tube0030 YM3335 Deflector plate0040 YM3336 Inlet tube0050 YM3337 Support dics0060 BV2503 Measuring cell heating 125 W0070 BV2170 Measuring cell sensor0080 EV0176 Temperature switch 140° C0090 DA0357 O-ring 23.47 × 2.620100 DA0353 O-ring 53.7 × 1.780110 DZ0637 Retaining ring DIN471 28 × 1.50120 DS1041 Oval head screw DIN7985 M40130 DZ0287 Disc DIN67970140 DN0199 Connector cal input 1511-6/4-1/8"0150 DN1319 Seal ring, 2651-1/8", Alu0160 DZ0549 Disc 4.10170 EU1019 Faston connector 6.30180 EW0116 Cable guide0190 HB0213 Glass fabrics tape 0.19 mm white0200 DA0207 O-ring 3.68 × 1.780205 DF0148 Spring0210 BV2210 Temp. switch + cable

Tab. 58


Probe Heating172

13.5 Probe Heating

Fig. 81


0290 EV0177 Temperature switch 180° C

Tab. 59

290

1

30

5090

30

2 3 4

brblrt/sw

sw

brblrd/b

k

bk

X15


Probe Heating 173

Fig. 82

PCB

Prob

e he

atin

g

Hea

ting

Res

ista

nce:

app

rox.

100

Ω

δ =

240°

CTh

erm

oclic

k

Switc

hes

off a

t 180

° C

and

on a

gain

at a

ppro

x. 1

65° C

Sock

et o

r pl

ug (c

able

's s

ide)

Solid

sta

te re

lay


Gas Path174

13.6 Gas Path

(for further details see Operating Instructions "1000 Hour Service", AT1004E)

Fig. 83

0250

025002

80

Main board

0280

0370

0370

P+

PT2

PT1

Q+

Valv

e bl

ock

com

plet

e

Filte

rho

usin

g

Zero

air

valv

eZe

ro a

ir ou

tlet


250 ZG2179 Pump air guide

280 MV0141 Diaphragm type pump370 DN1331 Connector ¼, exthaust gas return

Tab. 60


Pneumatics 175

13.7 Pneumatics

Fig. 84

Set pressureat zero point adjustment:2.5 bar

static set pressure:1 bar

Teflonschlauch 4.0 × 1

V2V1V3

0100

0080

0120

0135

0130

017001700170 0160 0160

0200

0135

0135

0140

231

0150


Pneumatics176


0080 DN1327 Nipple ¼"

0100 MM0584 Pressure reducer 0.510 bar R ¼"0120 DN0647 cross piece ¼"0135 DN1215 Male connector

0140 DN1328 T-connector0150 EZ0222 Pressure switch 110 bar0160 MM0589 Solenoid valve0170 MM0251 Solenoid valve

0200 DN1826 Box 1/8"

Tab. 61


Electronics / Assembly 177

13.8 Electronics / Assembly

Fig. 85

ZFu

se a

nd c

onne

ctor

blo

ckC

onne

ctor

for p

oten

tial e

qual

izat

ion

0090

0100

0110

0040

0020

0070

Z

F1 F4


Electronics / Assembly178

Pos. Ident. no. Designation0020 BB1101 Controller Board0040 ES0360 Cam switch0070 EU0013 Connector. 3-p.0080 EN0321 Power supply0090 EI0148 Mains filter 230 V, 10 A0100 EI0248 Toroidal core transformer 240 VA0110 BV2342 Cooling air fan

Tab. 62


Block Diagrams, Wiring 179

13.9 Block Diagrams, Wiring

Fig. 86

M =

Prob

e H

eatin

gPu

mps

Lam

p U

nit

Mea

surin

g C

ham

ber

Det

ecto

r Uni

tFa

n

Con

nect

ing

SUPP

LY 2

30V

AC

Filte

r

PO

WE

R/E

RR

OR

Com

pres

sed

Air

MV4

Pt10

0

Tem

p. M

eas.

Cha

mbe

r

Tem

p. G

as

X15

X16

X14

X13

X18

X17

X11

X12

X1 X2 X3 X4

BV21

94BV

2195

BV23

90

BV24

21 J

12

BV25

85/1

BV25

86/1

BV22

03BV

2164

BV25

87BV

2205

BV21

63BV

2165

BV22

06

BO27

17

BV21

62BV

2162

BV22

10

BO29

38BO

2938

BV21

70

Pane

l

BV21

61

X5

M12 M

MM

POW

ER S

1

DC

AC

V1V2

V3

Prob

e

P

Tem

p. A

UX

X7BV

2166

BV21

92BV

2193

BV21

98BV

2585

/3BV

2585

/2BV

2207

ANAL

OG

I/0

XT1

Con

trolle

rJ9

J5J8

J11

J2J6

J4J1

0J7

J15

J14

J1J3

J12

J13

BV22

08

~~

CO

M 1

CO

M 2

DIG

ITAL

I/0

Exte

rnal

LINE

LOAD

==2

1

J28

BV23

42Fa

n


Wiring Basic Unit180

13.10 Wiring Basic Unit

Fig. 87

CO

NTR

OLL

ER B

OAR

D

J2

BV21

65

J7

BV21

64

J6

BV21

63BV

2163

X11

X12

X13

J11

BV22

06

BO

2938

J4

BV22

05

BV2

205

J15

BV22

03

BV21

62

PT10

0

BV2

208

J10

BV22

04B

V216

7

J8

LAM

P U

NIT

ETEC

TOR

UN

IT

PU

MP

FAN

FAN

BV22

09

Z

Det

ail Z

Det

ail Y

swrt/

sw

X14

X16

X15

BV

2206

BV2

203

BV22

10

BV

2209

MV4

BV2

161

X17

X18

BO

2938

BV2

162

BO

2717

PU

MP

BV2

170

BV22

09

BV2

209

Y

swrt/

sw pos

1010

,102

0

pos

1030

J12

BV24

21


Wiring Basic Unit 181

Fig. 88

BV21

92

BV21

93

BV25

85/2

BV21

98 V1V2

V3

BV22

02

J13

J14

BV22

07

BV21

94

BV21

95

LINE

LOAD

Con

trolle

r Boa

rd

J1 J3

BV22

01

BV23

90

1 212

ws sw

414

818

11rt gr bl gr

1

br

bl1

919

313

717

5 615 16

BV25

85/1

BV23

42

J28


Electronic Wiring Diagram182

13.11 Electronic Wiring Diagram

Fig. 89

BV21

92BV

2390

0070

0090

0040

F3 6

.3AT

F4 6

.3AT

0110

0120

2 x

2 x

X7SU

PPLY

230

V AC

S1PO

WER

XT1

0140

2 x

1 x

EU08

44

P N

1 2

bk /

sw

bk /

swLI

NE

LOAD

sw /

bk

sw /

bk42

1 3

sw /

bk

sw /

bk

7 8

17 18

sw /

bk

sw /

bk

BV21

93

BV21

94BV

2195

155

br bl

br blbl gr1

166

0080

0020

XT1

199

BV21

98AC

DC

J14

ye/g

nge

/gn

BV22

07

BV2585/2

ye/g

nge

/gn

J3 J1

XT1

F1 3

.15A

T

0110

0180

wh

/ ws

1 11

2 12

2 x

EU08

43

bk /

sw 3 13

rd /

rt

br

BV2585/1bk /

sww

h / w

s

115V

24V

115V

24V

14

gr bl1

XT1

F2 1

ATT

0110

0170

EI02

48bl

4

gr1

Con

trolle

rBo

ard

XT1

BV23

42

M =


Components Location Diagram 183

13.12 Components Location Diagram

Fig. 90


Circuit Diagrams184

13.13 Circuit Diagrams

Fig. 91


Circuit Diagrams 185

Fig. 92


Circuit Diagrams186

Fig. 93



Fig. 94


Circuit Diagrams188

Fig. 95



Fig. 96


Comparison Table190

13.14 Comparison Table

The table below shows the correlation between opacity N [%] and the light absorption coefficient k [m-1]. This table is based on an effective measuring length of 0.430 m.

Opacity N[%]

Absorption k[m-1]

Opacity N[%]

Absorption k[m-1]

Opacity N[%]

Absorption k[m-1]

12345

0.020.050.070.090.12

3132333435

0.860.900.930.971.00

60.461626364

2.152.192.252.312.38

678910

0.140.170.190.220.25

3637383940

1.041.071.111.151.19

6566676869

2.442.512.582.652.72

1112131415

0.270.300.320.350.38

4142434445

1.231.271.311.351.39

7071727374

2.802.882.963.043.13

1617181920

0.410.430.460.490.52

4647484950

1.431.481.521.571.61

7576777879

3.223.323.423.523.63

2122232425

0.550.580.610.640.67

5152535455

1.661.711.761.811.86

8081828384

3.743.863.994.124.26

2627282930

0.700.730.760.800.83

5657585960

1.911.962.022.072.13

858687888990

4.414.574.744.935.135.35

Tab. 63


Index 191

Index

AAAAabsorption coefficient 13AK command

AANA 122AKAL 119AKON 117ALCH 120ALDR 120ALEC 120AMBE 120AMDT 118AMES 118APAR 119ASMK 122ASPA 121ASST 122ASTF 115ASTZ 115EANA 122ELDR 120ELMP 121EMBE 120EPAR 118EPMP 121ESMK 122EVLV 122SBST 117SIDL 117SKAL 119SLCH 119SLEC 120SMFA 118SMFE 118SMGA 117SNGA 118SPAU 117SPRG 121SREM 117SRES 117SRUC 121STBY 117

AK Generic Communication Interface 111

AVL 4210 Instrument Controller 68

Menu Choices and Settings 70Operating the AVL 4210 Instrument

Controller 69

BBBBBack-flushing of the Probe 18Basic Unit 25Beer-Lambert law 13Bessel Filter 97Bessel filtering 89Block Diagrams, Wiring 179

CCCCCalibration

Calibrating the Sensors 110General 103Linearity Check ("Calibration") with

"Neutral Density Filters 106Linearity Test ("LIN Check") 104

calibration 18calibration points

dark value 103light value 103

changing the filter 124Checking the Zero Point 88checking the zero point 16Circuit Diagrams 184commissioning 37Comparison Table 190Components Location Diagram

183Continuous Measurement

(Standard Measurement) 78

DDDDdark value 103detector 13Determination of Zero Value 95Device Parameters

Ambient pressure 92Conditioning temperature 92Reset of the second operating hours

counter 92Spread of the analog signal 92

DIL Switch 63

EEEEECE R24 87electromagnetic radiation 13Electronic Wiring Diagram 182Electronics Assembly 177ELR test 84Error Table

Causes of Error, Remedies 136Error codes 135

FFFFFilter Calculation 96filter element 124filter type

Bessel Filter 97Floating Mean 96Low pass of the 1st order 97

Floating Mean 96Function off 17

GGGGGas Path 174Getting the Opacimeter Ready for

Measurement 73

HHHHHybrid Interface ("DIO") 72

IIIIInstallation 37

Analog Measurement Value Output 58

commissioning 37Compressed Air Supply 49Connecting the AVL 4210

Instrument Controller or PC 60Connections on the Opacimeter 41Digital Interface ("Digital I/O") 54DIL Switches 63Exhaust Gas Recirculation 48Exhaust Gas Routing 41Fitting of Zero Air Valve, Sampling

Lines and Probes 42General 38Installation Instructions for Tube

Fittings 49Interfaces 52Power Supply 51Serial Interfaces 53Trolley Option 40Wall Mounting Console Option 39

intensity of the light 13Interface 52, 60

Analog 58Digital 54Serial 53

LLLLlight extinction 13light value 103LIN check 17linearity 17Linearity Check 17Linearity Check ("LIN Check") 17low pass filter constant 97Low pass of the 1st order 97

MMMMMaintenance and Storage

1000 Hour Service 132Changing the Filter Element 124Cleaning instructions for the window

elements of the detector and lamp unit 130

Cleaning the Sampling Lines 131Cleaning the Window Modules 127General 123Storage for Long Periods of

Non-Use 133measurement 16Measurement parameters 89Measurement Principle 13measurement variation 67



Index192

MeasurementsAVL 4210 Instrument Controller 68Brief Instructions 65Calculation of the Raw Value 95Carrying out a Measurement 66Checking the Zero Point 88Continuous Measurement

(Standard Measurement) 78Control via Hybrid Interface ("DIO")

72Control via Serial Interface or

Terminal Program of a PC 71Determination of Zero Value 95Device Parameters 92ECE R24 87ELR test 84Filter Calculation 96Measurement parameters 89Measurement Value Calculation 95Operation with the DIO interface 94Overview of Opacimeter Functions

65Peak Value Measurement 80Reading stability 67Safety Instructions in Special

Conditions 67Setting the Function and

Measurement Value Output 68

Setting the Parameters 89Switching On and Warming Up

Getting the Opacimeter Ready for Measurement 73

Zeroing 75measuring cell 67Measuring Chamber 170measuring chamber 13measuring unit

detector unit 21light unit 21measuring chamber 21

Mounting Instructions 439 Wall Mounting Console 167

Mounting Instructions Probe for Open Exhaust 168

NNNNNeutral density filter 106

OOOOOpacimeter Design 25Opacimeter Functions

Overview 65opacity 13operating mode

checking the zero point 16Function off 17measurement 16pause 17zeroing 16

option½ 19" Bench Cabinet for AVL 4210

Instrument Controller 3419" Bench Cabinet for AVL 4210

Instrument Controller 3419" Mounting Frame for AVL 4210

Instrument Controller 33AVL 4210 Instrument Controller 32I/O Cables (Analog Cable) 36PC-Software 33Probe for Open Exhaust Pipe 36Sample Lines 30Trolley 36Wall Mounting Console 35

PPPPpause 17Peak Value Measurement 80Pneumatics 175Power Supply 51Probe Heating 172

RRRRReading stability 67RS232 Interface

Command Set 114General 111General Control Commands 117General Queries 115Measurement 117Operating Mode 114Protocol Framework 111Service 121

SSSSsafety instruction 2, 17, 18, 38,

40, 43, 48, 50, 51, 66, 123, 126, 127, 130, 132, 144

sensor value 110Service

Components of the Electronics Board 153

Electric Components 152Exchanging Temperature Sensors

148Function Check Device Parameters

143Function Check Leak Check 147Function Check Limit Values for the

Device Parameters when Instrument Functioning Correctly 145

Function Check of the Electronics 154

Function Check Pump Service 146Software Update 151

spare parts 155

Spare Parts List 155Accessories 159Calibration Equipment 160Consumption Parts 159Documentation 160Electrical Components 158Mechanical Components 156Miscellaneous 161Optical Components 159Tools 160

stateBack-flushing of the Probe 18Calibration 18Linearity Check ("LIN Check") 17

TTTTTechnical Data 163

VVVVValve Block (complete) 169

WWWWWiring Basic Unit 180

ZZZZZeroing 75zeroing 16


AVL List GmbH

Hans-List-Platz 1, A-8020 Graz, Austria

Phone: +43 316 787-0, Fax: +43 316 787-400

http://www.avl.com

AVL 439 Opacimeter - Dynamometer World Ltd 439... · 2016-01-25 · AVL 439 Opacimeter As of...

Documents

Transcript of AVL 439 Opacimeter - Dynamometer World Ltd 439... · 2016-01-25 · AVL 439 Opacimeter As of...