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HL036(EN) Issue 1

World Leaders in Diesel Fuel Injection Test Equipment.

Smokemeter 4

Users Manual

THIS IS AN UNCONTROLLED DOCUMENT downloaded by Lukas Matuska on 16 Feb 2016Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.

YDA309 SMOKEMETER 4 HARTRIDGE LIMITED

HL036(EN) Issue 1 1

CONTENTS 1 THE AREA OF APPLICATION & SAFETY WARNINGS................................................ 3 2. THE SMOKEMETER PARTS......................................................................................... 4 3. ASSEMBLY & CONNECTION OF PARTS..................................................................... 6 4. THE OPERATOR CONTROLS .................................................................................... 10 5 VEHICLE/DRIVER PREPARATION............................................................................. 10 6 PERFORMING A TEST ............................................................................................... 10 7. ERROR MESSAGES ................................................................................................... 16 8. THE PRINTOUT AND PRINTER ................................................................................. 18 9. NAME AND ADDRESS ENTRY................................................................................... 21 10. ROUTINE MAINTENANCE.......................................................................................... 21 11. REPAIR , ADJUSTMENT, and CHECKS..................................................................... 21 12. FAULT FINDING .......................................................................................................... 24 13. PRINCIPLE OF OPERATION ...................................................................................... 26 14. SPECIFICATION.......................................................................................................... 27 15 USER SERVICED PARTS........................................................................................... 28 16 STORAGE & RETRIEVAL OF TEST RESULTS.......................................................... 29 17 HSU TO K (m-1) CONVERSION CHART ..................................................................... 30 18 PARTS LIST................................................................................................................. 31


HARTRIDGE LIMITED YDA309 SMOKEMETER 4

2 HL036(EN) Issue 1

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HL036(EN) Issue 1 3

1 THE AREA OF APPLICATION & SAFETY WARNINGS 1.1 The YDA309 measures the opacity and coefficient of light absorption of diesel smoke. It is

optimised for free acceleration testing from the tailpipe of road vehicles. If it is used with an engine testbed additional equipment may be needed to protect the

smokemeter and to ensure a good measurement. The following points should be considered:

• Protection of the smokemeter against high pressures and entry of smoke when

powered down. • Protection of the smokemeter against high smoke temperatures. Note that the flexible

silicone hose supplied has a maximum temperature for intermittent use of 250 °C. • Condensation can be a significant problem from hot exhausts; a water trap may be

necessary. • Pulsations of pressure can interfere with exhaust sampling; a damping unit may be

necessary. • Adjustment of pressure may be necessary to ensure good sampling.

1.2 Beware of hot parts, in particular the probe which has been in the vehicle exhaust pipe. 1.3 Avoid breathing diesel fumes. Do not use the equipment indoors without exhaust extraction

equipment or adequate ventilation. 1.4 Switch off the engine when fitting speed and oil temperature sensors. Make sure trailing

leads do not make contact with moving parts of the engine. 1.5 Make sure the vehicle is securely parked with the handbrake on and gear in neutral before

making the connections and performing the test. 1.6 Do not use the power unit outside; it should remain inside near a power socket.



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2. THE SMOKEMETER PARTS

YDA309 Smokemeter with 10m of power lead. printer/keypad unit(135-11-01), and handset display unit.(135-06-11). This part number also includes: 4m flexible hose 134-86-71 10mm probe assembly YDA 128 16mm probe assembly YDA 129 3 printer paper rolls and 1 ribbon Cleaning brush User manual YDA123 Power Unit (200 to 240V AC).

Converts 240V AC supply to 24VAC for the smokemeter (50/60Hz)

YDA182 Power Unit (100 to 130V AC).

Converts 120V AC supply to 24VAC for the smokemeter (50/60Hz)

134-86-71 Flexible silicon hose to connect the

smokemeter to the exhaust probe. 4m long.

YDA128 10mm diameter exhaust probe with clamp.

YDA129 16mm diameter exhaust probe with clamp

135-05-46 25mm diameter exhaust probe with clamp

135-05-42 Speed box with 10m of cable to connect clamp-on speed transducer lead (or optical sensor) and the oil temperature sensor to the smokemeter.

134-98-29 Clamp-on sensor cable. 8887404 Clamp-on sensor (for 6mm pipe) YDA131 Oil temperature sensor (1.5m insertion length) SM99 Cleaning brush HL036(EN) User manual



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2 HV048 Optical pickup Complete with 5m reel of reflective tape. A clamping and adjustment mechanism is provided. Requires 135-05-42 for connection to the smokemeter. 135-05-48 Vertical Exhaust Extension Pole

A telescopic pole which accepts the standard 10 and 16mm exhaust probe assemblies. Quick fitting allows the probe assembly`to be inserted at 45º the flexible hose.

134-98-43 Oil temperature sensor 3m insertion length

For commercial vehicles with very long dipsticks. Requires YDA 138 for connection

to the smokemeter. 8687404 Clamp on speed sensor for 6mm pipes 8687405 Clamp on speed sensor for 4.5mm pipes 8687406 Clamp on speed sensor for 8mm pipes 124-01-10 Handset extension cable, 15m long 135-05-60 Communication cable, 10m long

HV033 Trolley 8684298 printer paper roll-pack of 20 8684297 printer ribbon- pack of 5 8689146 12V Halogen lamp



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3. ASSEMBLY & CONNECTION OF PARTS Refer to assembly illustrations 1 to 8 when setting up. Illustrations 9 & 10 identify connection points.



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3.1 Attach the printer to the smokemeter, using the thumbscrew located under the printer lid.

See illustration 1 3.2 Attach the smokemeter to the trolley using the handwheel See illustration 2. 3.3 Connect the printer cable to the smokemeter. See illustration 3. 3.4 Connect the handset cable to the connector on the front of smokemeter. The handset can be parked on the lip to the right of the printer when not in use. See illustration 4 Do not leave the handset in direct hot sunlight. The display darkens and may become

difficult to read when hot. 3.5 Position the power unit near a power socket if possible. Try to avoid long trailing extension cables which can be a safety hazard. Do not use the power unit where it may get wet. Connect the smokemeter power cable to the terminals under the power unit lid, and position the

rubber boot on the cable in the exit slot. Fasten down the lid. See illustration 5 If the smokemeter is to be powered from a vehicle, connect the red lead to battery positive. If the

battery is 24V, use the 24V, not a 12V tapping. Start the engine before switching on the smokemeter. 3.6 Connect the flexible hose to the smokemeter. See illustration 3 3.7 Select the correct probe for the exhaust. Generally, use the 10mm diameter probe for exhausts with a diameter less than 50mm. Connect the probe to the flexible hose. 3.8 If a vertical exhaust pipe is to be monitored, insert the probe handle into the clamp at the end of

telescopic pole and tighten the handwheel to lock. One of two positions can be selected; for angled or for vertical exhaust pipes.

Position the flexible hose in the guide as shown in illustration 6. Note that the telescopic pole is an optional extra. 3.9 If used indoors, a waste pipe can be connected to the smokemeter outlet to direct smoke to an

extraction system. A 30mm diameter 2m long pipe can be used. A direct connection to the extraction system must not be made; a vacuum break must be included.

3.10 An optical filter is provided to allow a check of the optical system to be made. See section 11 for details on its use. The filter is stored under a hood on the side of the light sensor box. It is attached by a thumb

screw. It is important that the filter is in place and the screw done up tight when using the smokemeter.

An indication of low pressure during the test may otherwise result.



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3.11 If speed or oil temperature is required, connect the speed unit cable to the front of the

smokemeter, and position the box in the engine compartment where it will not foul any moving parts. See illustration 7. For oil temperature measurement, remove the dipstick and use it to set the insertion depth of the probe by sliding along the adjustable position stop.

Use the locking screw to fix the adjustment. Insert the oil temperature probe into the dipstick hole,and connect the cable to the box. See illustration 7.

For speed measurement with clamp-on sensor, connect the correct size sensor to the high pressure pipe as shown in illustration 7.

See section 12.5 for more advice on using clamp-on sensors. Connect the clamp-on sensor to the box using the lead provided. If the optical sensor is to used for speed measurement, connect it to the box in place of the

clamp-on sensor lead. Stick a reflective patch to the engine crankshaft pulley. Position and clamp the optical sensor to point at the reflective patch. An indicator on the sensor body flashes on when the patch is seen, as an aid to correct alignment.

Take care to avoid cables and items of clothing coming into contact with moving parts. 3.12 Position the smokemeter near the vehicle exhaust so that it is not enveloped in smoke when

used. When the probe is inserted, bend the pipe away from the exhaust flow to avoid unnecessary heating and contamination of the flexible hose. See illustration 8.



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Identification points

1) 48 button keypad for data entry 2) Portable handset (clips to the

smokemeter) 3) Message display (2 lines of 20

characters) 4) Push button for control 5) Protective cover for the handset 6) 10m of cable for connection of the handset 7) Test filter in its storage position 8) Speed unit cable connection 9) Handset cable connection 10) On/Off switch 11) Power on indicator 1) Speed unit connector 2) Test filter in its storage position 3) Handset connector 4) Foot/carrying handle 5) Slot to insert the test filter 6) Waste smoke/air outlet 7) Smoke inlet 8) Printer cable connection 9) 10m power cable 10) Communication connector



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4. THE OPERATOR CONTROLS The smokemeter is very simple to operate with an ON/OFF switch on the front and a push button

on the handset. Instructions and results are displayed on the handset. The handset has 10m of cable so that the operator can view the display and control the

smokemeter whilst sitting in the driving seat. (An extension cable is available if 10m is not long enough) For control of the smokemeter, two handset push button actions are recognised; CLICK and HOLD. CLICK means press and release the button in less than half of one second. HOLD means press and hold the button until the display changes (longer than 1 second). The flowcharts below show when CLICK or HOLD are required. A keypad is supplied to allow entry of data for the printout. Note that a test can be performed without using the keypad; data entry is an optional part of the

sequence.

5 VEHICLE/DRIVER PREPARATION 5.1 Check that the vehicle has sufficient oil in the sump. 5.2 Check that the engine has no known problems, and has been properly maintained. 5.3 Check that the exhaust system has no significant leaks. 5.4 Check that the vehicle is parked on approximately level and firm ground. 5.5 Check that the parking brake is on and the engine out of gear. 5.6 Check that the vehicle engine is warm. 5.7 If the vehicle driver is to perform the accelerations, make sure that he understands when to press

and when to release the accelerator pedal and that the accelerator pedal must be pressed to the floor rapidly, but not violently.

6 PERFORMING A TEST Refer to flowcharts 1, 2, and 3. 6.1 Prepare for the test as described in section 3 6.2 Switch on the smokemeter, and wait for the 3 to 4 minute warmup time. The date/time can be checked and set if required. See flowchart 1. The selected units (m-1 or HSU) are displayed for 4 seconds. Click to change if required. The probe should not be inserted into the exhaust during the warmup. When the display shows PULL OUT THE PROBE/CLICK, click for the start of test sequence

message F1 = DATA ENTRY. 6.3 If DATA ENTRY is not required, click the handset button to start the test procedure. If DATA ENTRY is required, press the F1 button on the keypad to get the message DATA

ENTRY/ NEW.



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See flowchart 2 for details of data entry. To enter new data, press the ↵ button. REGISTRATION No: is displayed, and the data can be entered if required or skipped by directly

pressing the ↵ button. Pressing ↵ moves down the list of entries, and eventually to exit, sending to the smokemeter

any data which has been entered ready for the printout Alternatively, click the handset button at any time during DATA ENTRY to abort the procedure. In

this case, any data entered will not be sent for inclusion on the printout. 6.4 Click when PULL OUT THE PROBE/ CLICK is displayed to perform an automatic zero for smoke

measurement. The probe must not be inserted into the exhaust during the zero operation. If an error message is displayed, see section 7 ERROR MESSAGES. The message INSERT THE PROBE/ THEN CLICK indicates a successful zero operation. Insert

the probe into the exhaust. 6.5 At this stage a choice exists. Either CLICK to carry out a standard sequenced test. Or HOLD to enter VEHICLE DIAGNOSTIC MODE described in 6.12. 6.6 Click the button to display CLICK = NON-TURBO 2.5/ HOLD = TURBO 3.0. Click the handset button if the vehicle has a normally aspirated engine.

Otherwise hold the button until the display changes. The appropriate smoke limit will be selected. This selection is not displayed if a smoke limit is entered

during the DATA ENTRY 6.7 The message WHEN MOTOR IS HOT/ THEN CLICK is displayed. If an oil temperature probe is connected, the oil temperature will also be displayed. Click to confirm that the engine is warm. Remember that rapid acceleration of a cold engine can cause damage. 6.8 CHECK MAX SPEED/ RPM=xxxx THEN CLICK is displayed. xxxx is the speed of the engine if a speed sensor is connected. Slowly increase the speed of the engine to maximum over a period of 5 to 10 seconds. Stop immediately if any problem is detected, or if the speed reading exceeds the maximum for the engine. . Release the accelerator to return to low idle.

Click to continue. If a message PRESSURE LOW/HIGH is displayed, the smokemeter indicates that the pressure of the smoke sample is not correct for a good measurement. Check that the probe is in the exhaust pipe.

Click to return to the CHECK MAX SPEED test and repeat. If the error message repeats, see the section ERROR MESSAGES. 6.9 The wait/accelerate/decelerate loop of between 4 and 10 tests has now started. A five seconds

wait period between accelerations is indicated by the countdown from 5. Rapidly press down the accelerator pedal as soon as the message indicates, and hold down for a maximum of 4 seconds, or until the message to return to idle is displayed. The captured peak smoke value is briefly displayed, then the wait countdown.

A minimum of 4 accelerations must be performed. If after this the results are stable (the last 4 with a spread of less than 0.5m-1 (or 10HSU) and the average of the last 4 is less than the limit, then the test is ended.

Otherwise one more test is requested, and the above conditions rechecked. This process is repeated until a maximum of 10 tests have been performed. 6.10 Click when the message PULL OUT THE PROBE/ THEN CLICK is displayed. The results will now be automatically printed.




If there has been drift of the zero in the test a warning message is displayed. Click to acknowledge this to start print.

If the handset button is held instead of clicked at the above message, then the individual results will be displayed in turn on the display, this can be useful if a printout is not required.

One copy of the results will be printed, with 3 possible conclusions; pass, fail, or unstable readings.

Further copies of the printout can be obtained by pressing the R button on the keypad (until either the handset button or F1 on the keypad is pressed).

The smokemeter is now ready to perform the next test. 6.11 Note that the following actions are available from the keypad: · press P on the keypad for paper feed · press and hold F1 for greater than 2 seconds to stop a printout 6.12 VEHICLE DIAGNOSTIC MODE allows the results of single free accelerations to be displayed

and printed (one line for each test). As many accelerations as are required can be done, with display and printout of the peak opacity reading. In addition the engine speed, oil temperature, and smoke pressure in the smokemeter are continuously displayed.

Operation is as follows: 1) When ready to do a test, CLICK the handset button. 2) When instructed (2 seconds later), press down the accelerator pedal. 3) Hold down the accelerator pedal for 3 seconds, then release. 4) The display shows the peak opacity in units m-1 under Kmax.. 5) CLICK to repeat, HOLD to exit this mode.

Note that measurement time is 4 seconds from the accelerate message, so it is necessary to accelerate immediately after the message is displayed.

During these 4 seconds, waveform data for opacity and speed are output via the COMMUNICATION connector on the printer. With a suitable computer (IBM PC) and connecting cable, (135-05-60), it is possible to observe the waveforms as they happen, or collect data for later analysis.




Flowchart 1: Warmup This sequence is followed everytime the smokemeter is switched on. To change time or date ... Display of software VERSION 1AdA Hold the button until the version for 5 seconds asterisk is under the number at switch on. to change. Click to increment the number. Display of time/date for 5 seconds. 14:03 21/08/96 14:03 21/08/96 * Click to change if CLICK TO CHANGE * required. To exit... Hold the button until the 2 Current selected units m-1 asterisks are in line, then are displayed for 4 sec. CLICK TO CHANGE release. Click to alternate between m-1 and HSU. Wait 3 minutes while PULL OUT THE PROBE the smokemeter warms WARMUP WAIT ... 162 up. The probe should not yet be put in the exhaust. PULL OUT THE PROBE This display will show blank CLICK to start the test CLICK if the supply volts is low. sequence. click (For example if operation is from HOLD to perform a filter a nearly discharged battery.) test. F1 = DATA ENTRY OTHERWISE CLICK CLICK means ... HOLD means ... Press and release the handset Press and hold the handset button button in less than a half second. until the display changes. (about 1 second)




Flowchart 2: Data Entry Press F1 on the keypad to select DATA ENTRY when the display message is: F1 = DATA ENTRY. CLICK the handset button to ignore or exit DATA ENTRY. NEW is selected to enter all new data ( Press ↵ , the bottom right button, to select). EXISTING is selected to display the last data entered,which can then be editted if required. (Press F1, then ↵ to select) EXIT/LOAD is selected when data entry is complete, to send the data to the smokemeter. (Press F1, then ↵ to select) All entered values, which have been sent to the smokemeter, will be included on the printout. In addition, if a non-zero value is entered for smoke limit, then this value will be used as the pass limit in place of the default values. Note that the * is used to toggle between upper and lower case letters.

F1 = DATA ENTRYOTHERWISE CLICK

F1

DATA ENTRYNEW

DATA ENTRY EXISTING

DATA ENTRYEXIT/LOAD

WAIT...

PULL OUT THE PROBECLICK

REGISTRATION NO.:

MANUFACTURER:

ENGINE NO.:

CHASSIS NO.:

MILEAGE:

SMOKE LIMIT:

F1

F1

F1

Maximum 16caracters

Maximum 16caracters

Maximum 12caracters

Maximum 20caracters

Maximum 7digits

Return to test sequence after 2 seconds




Flowchart 3: Test sequence F1 = DATA ENTRY restart of sequence OTHERWISE CLICK click PULL OUT THE PROBE ERROR 2/3/4 xxx hold THEN CLICK CLICK ZEROING ... after 2 sec VEHICLE DIAGNOSTIC MODE PUSH IN THE PROBE hold RPM Otp PRES Kmax hold 0.00 m-1 THEN CLICK 870 78 01 1.23 CLICK = NON TURBO 2.5 HOLD = TURBO 3.0 WHEN MOTOR IS HOT hold 75 ºC THEN CLICK CHECK MAXIMUM SPEED RPM=870 THEN CLICK click PRESSURE LOW 02 hold if pressure error CLICK WAIT ... 5 hold after 5 sec ACCELERATE 1 hold after 3 to 8 sec RETURN TO IDLE Kmax = 1.63 m-1 when a pass is obtained or after a maximum of 10 repeat test . Rotating results PULL OUT THE PROBE hold 3) 1.54 m-1 click THEN CLICK CLICK TO RESTART

click AVERG=1.57 m-1 PASS

PRINTING ... when AVERG=3.45m-1 FAIL printing PRINTING ... complete UNSTABLE READINGS PRINTING ...




7. ERROR MESSAGES

If a message is displayed indicating a problem, follow the action described in this section to try to rectify the problem.

7.1 ERROR 1 107 This indicates a calibration failure during warmup. CLICK Switch off, then on again after 10 seconds. If the fault repeats, report it to your service organisation. 7.2 ERROR 2 745 This indicates unstable readings whilst performing a CLICK zero operation .

• Click twice to repeat. If the message repeats: • Check that the probe is out of the exhaust. • Check for no visible flickering of the lamp. • Check for anything in the smoke chamber which could

obstruct the light. • Report the fault, together with the number displayed. • Note how that number changes over a time of 10 seconds.

7.3 ERROR 3 304 This indicates that there is insufficient light to CLICK perform a zero.

• Clean the lamp and light sensor • Check that the lamp is operating. • Check for anything in the smoke chamber which could

obstruct the light, including the test filter. Adjust the sensitivity of the light sensor (see section 11.5)

7.4 ERROR 4 999 This indicates that there is too much light to perform a CLICK zero. This may be displayed after a new bulb has been fitted.

• Adjust the sensitivity of the light sensor (see section 11.5) 7.5 PRESSURE LOW 00 This indicates that not enough smoke was entering CLICK the smokemeter to give a valid sample.

• CLICK to repeat, checking that the probe has not fallen out of the exhaust pipe, and that the engine is accelerated to maximum speed for at least 2 seconds.

• Move the position of the probe backwards, away from any bend in the exhaust pipe.

• Use a larger probe if possible. • HOLD to exit, and repeat from the start of the sequence.

Make sure that the probe is out of the exhaust pipe when indicated.

• Make sure that the filter is screwed firmly in place to avoid a leak from the light sensor box.

• Check for air leaks between the assemblies. • Note the value of the number on the display, (with the

error message showing) when at idle and when at maximum speed




7.6 PRESSURE HIGH 16 This indicates that too much smoke was entering the CLICK smokemeter. Rapid contamination of the optics is likely.

• Use a smaller probe. 7.7 ERROR 9 Indicates a fault with the smoke chamber CLICK temperature detector.

• Switch off, then on again after 10seconds. If the fault repeats, report it to your service organisation.




8. THE PRINTOUT AND PRINTER 8.1 Printer use. To get access to the paper roll and ribbon, lift the printer cover. (A clip on the right hand side acts to keep the cover firmly closed) Check that the paper is located in its holder under the lid. (to ensure that the paper feeds squarely into the printer) Check that the cover is firmly pressed down. (to prevent the paper curling back up into the printer) Tear off the paper downwards for a clean cut. 8.2 Printer controls. The printout comes automatically at the end of the sequence. Repeat copies can be obtained by pressing ‘R ‘ on the keypad.

Note that a repeat copy cannot be obtained once the handset button or the F1 key on the keypad have been pressed to start a new test. (but see section 16)

Paper can be fed continuously by holding down ‘P’ on the keypad ( but not in DATA ENTRY mode)

Printing can be aborted by holding down the F1 key on the keypad for at least 2 seconds. 8.3 The printout contents. The printout is made up of the following parts. THE HEADER This describes that it is a diesel free acceleration test according to a standard. The type and serial number of the smokemeter are printed. OPERATOR NAME and ADDRESS

Using the keypad, the operator can enter up to 7 lines of 24 characters of text. This text can be changed if required. See section NAME & ADDRESS ENTRY.

TIME and DATE

The time and date of the test are included. If the time /date is incorrect it can be set after switching on the smokemeter.

DATA ENTRY INFORMATION This is information specific to the vehicle under test.

If the optional keypad data entry is skipped at the start of a test, then the headings are printed without entries. These can be written in by hand if required.

With one exception, this information does not affect the test procedure. The exception is SMOKE LIMIT, which becomes the pass/fail limit if entered. If not entered, the default values of 2.5/3.0 for non-turbo/turbo are used. TEST SELECTION DATA

The printout records the selections during the sequence for which probe size was used, whether the vehicle was turbo or non-turbo, and whether oil temperature measurement or an operator assessment of warm vehicle was performed.

THE READINGS Between 4 and 10 sets of readings are printed. The low idle, maximum speed (if measured) and peak smoke value are detailed.




The * at the start of a line indicates that these results are used in the calculation of a valid average.

THE AVERAGE The average of the last 4 readings if they were sufficiently stable to allow a calculation. THE LIMIT This is the value used to compare with the average to decide if the result is a pass or fail. THE CONCLUSION Pass, fail or results too unstable to calculate a result. SIGNATURE Space for the operator to sign, or stamp.

8.4 Fitting a roll of paper See illustration 11 1) Use a pair of scissors to cut away 2 turns of the

new roll. 2) Place the roll in its holder so that the paper feeds

from the bottom of the roll. 3) Feed the paper into the printer, using the manual

feed knob. until it emerges through the case. 4) Check that the paper passes above the printer

ribbon. 8.5 Fitting a printer ribbon. 1) Carefully pull the paper back out of the printer. 2) Pull the old ribbon forwards to unclip, and

remove. 3) Clip the new ribbon in place. 4) Reload the paper as described above.




8.6 Example printouts

Illustrates . . . Full data entry. No oil or speed measurement. A PASS after 5 accelerations with the tests in the average marked with an asterisk. Measurement in m-1.

Illustrates . . Entry of Registration No. only. Oil and speed measurement. UNSTABLE RESULTS after 10 accelerations(no 4 consecutive results within 10%). The zero after the test printed because it exceeds 3%. Measurement in HSU

Illustrates . . . No data entry Oil and speed measurement. A FAIL after 10 accelerations because the average is greater than the limit. Tests in the average are marked with an asterisk. Measurement in m-1.




9. NAME AND ADDRESS ENTRY Switch on the smokemeter. When the display shows VERSION (after a few seconds), press and hold the F1 button on the

keypad until NAME AND ADDRESS is displayed, then release. HOLD again to repeat if it is not selected the first time.

Press the ↵ button (bottom right on the keypad) to get EXISTING. Press the ↵ button to bring back any previous text for editting. If any existing text is to be cleared, CLICK F1 twice to get NEW, then press ↵ to start. Up to 7 lines of 24 characters can be entered. Use the ↵ button to move down to the next line. Use the UP ARROW to move back up one line. Use the LEFT/RIGHT ARROWS to move the cursor left or right. Use the DEL key to delete a character. To change to lower case, press ‘*’ button. (Each new line reverts to upper case) When complete, CLICK F1 to get EXIT/LOAD. Press ENTER to get a test printout showing the name and address entered. If a change is required, switch off, then on again to repeat the above sequence.

10. ROUTINE MAINTENANCE Perform these checks weekly, or more often for heavy use. 10.1 Disconnect the probes and hose from the smokemeter. Blow out any deposits of soot from the probes and hose with low pressure compressed air (maximum 2 bar pressure). 10.2 Check the probes and hose for signs of excessive wear. Replace if worn. 10.3 Clean the lamp and light sensor with a clean lint free cloth. If a cleaning fluid is necessary, use

iso-propyl alcohol. 10.4 Check for visible gaps between the end boxes containing the lamp and light sensor and the

smokemeter body. If necessary, adjust the clips using a 2mm hex key to get a tight fit. (See section REPAIR AND ADJUSTMENT)

11. REPAIR , ADJUSTMENT, and CHECKS 11.1 Removing and fitting assemblies. The smokemeter is made out of 4 assemblies which are clipped together with simple nylon clips.

Each clip has a locking tab to keep it closed. To release the clip, pull back the locking tab while lifting the clip off the catch. See illustration 12 When refitting the end boxes, make sure that the temperature probe goes into the smoke chamber without catching on the side.

Align all 4 clips before latching. Push down the clips firmly until the locking tab clicks into place.




11.2 Changing a clip 1) Use a 2mm hex key to unscrew the 2 M3 screws. 2) Remove the screws, keeper plate and nut bar. 3) Fit the new clip. Align with its mating piece, with a gap of 1.5mm, before tightening. 4) Readjust and tighten if necessary to give about 1mm compression of the sealing strip Note that the clip screws must be tight to stop the clip slipping when closed. 11.3 Changing a box seal. Each box assembly has a special sealing gasket for electrical protection and air sealing. A set of 3 gaskets is available for replacement, if a seal no longer provides an air tight join. 1) Completely remove the old seal 2) Remove the protective backing from the self adhesive surface, and attach to the end box. Position the edge about 2mm in from the edge to avoid it protruding when compressed. 11.4 Changing the lamp 1) Switch off the smokemeter 2) Undo the clips attaching the lamp box, and pull away. 3) Release the electrical connector by pressing together its side lugs, and pulling away. 4) Remove the circuit board from the box , first removing the fixing nuts. 5) Using a small screwdriver, undo the screws attaching the lamp. 6) Fit the new lamp, ensuring it is pushed well down whilst tightening the screws 7) Refit the circuit board, then end box. 8) Note that adjustment of the light level may be necessary after lamp change. See below. 11.5 Adjusting the light level This should be done if ERROR 4 has been displayed, or after fitting a new lamp. 1) Clean the lamp and light sensor. 2) Switch on the smokemeter. 3) When the warmup countdown is 120, CLICK the handset button. 4) After 3 seconds, HOLD the handset button to display the diagnostic screen with headings Otp

OPAC Stp VLT PRS Note the number under OPAC If it is below 600 or above 900, the following adjustment should be made. Unclip the light sensor end box.

With a small screwdriver, rotate the adjustment control shown in illustration 13. (This can be safely done with the smokemeter powered)

Turn approximately 10 degrees clockwise to increase, or anticlockwise to decrease Align the end box on its clips (without latching) and note the OPAC reading.




Repeat this adjustment until the reading lies between 700 and 800. Latch the end box in position and recheck the value still lies between 700 and 800. 5) Switch off, then on again to return to normal operation.

11.6 Testing the air pressure system This test checks the overall air pressure system, including excessive leaks, operation of the

blower, and calibration of the pressure measurement system. 1) Check that the filter is screwed firmly in place and that the end box latches are closed. 2) Follow steps 2 to 4 of 11.5 to select the diagnostic screen. CLICK the handset button, and note that the number under PRS goes to 00 (-01 to +01 allowed). 3) Block the waste outlet at the back of the smokemeter( it is sufficient to use the hand), and note

the number under PRS. The value should be between 11 and 18 If the value is low, examine the smokemeter for leaks. 4) Switch off, then on, to return to normal operation. 11.7 Testing the optical system with the supplied filter. An optical filter is provided with the smokemeter (stored on the light sensor box). It is labelled with the opacity of the filter in percent. This filter allows a check to be made at the end of warm up, to confirm that the optical measuring

system reads accurately about the mid point of light intensity. This test is optional. To perform the test: 1) Switch on the smokemeter and wait for warm up to end 2) HOLD the handset button until the message ZEROING ...is displayed. 3) Unscrew the filter and insert into the slot. 4) Check that the reading is within 1% of the value written on the filter. 5) If necessary, remove the filter and CLICK to rezero. 6) HOLD to exit, and refit the filter to block the slot




12. FAULT FINDING 12.1 Smokemeter will not power up (Blower does not run, handset does not display)

If the power unit is being used, check that the on/off switch is illuminated to indicate 220V is present.

Check the protective trip on the front of the power unit is pushed in. If a voltmeter is available, check for 20 to 24V AC on the power supply terminals If a battery is being used, check for 12V DC at its terminals. 12.2 The blower runs, but the handset does not display and the printer will not paper feed when ‘P’ is

pressed on the keypad. Check the fuse located under the light sensor box.

Remove the light sensor box and unscrew the fuse located on the smokemeter end, below the exit hole for the cable.

The fuse is a 20 by 5mm 5 or 6A antisurge. Replace if faulty. 12.3 The handset does not display, or will only display LUCAS ATS DIESEL SMOKEMETER Check that the handset connector is fully inserted. If available, try with another handset.

Perform the following test on the printer. If this printer test is successful, then the fault almost certainly lies with handset or its cable, not in the smokemeter.

Switch on the smokemeter. After 4 seconds, press the F1 button on the keypad. Then press the ENTER button on the keypad 10 times. If a printout is produced, the smokemeter is correctly functioning. 12.4 Printer problems. Check that the printer connector is fully inserted. The print mechanism can be checked by performing a self test. HOLD the F1 button on the keypad whilst switching on. A self test pattern similar to that illustrated should be produced. This test only requires power from the smokemeter (no signals). Failure on this test indicates a problem in the printer

Self test printout




12.5 Speed reading problems with piezo clamp-on sensors. Check that the following advice is being followed. · Use the correct size sensor for the pipe.

· Remove paint, dirt, and grease from the pipe. If necessary, use abrasive paper to get clean smooth finish.

· Tighten the sensor firmly, but do not use a tool. · Connect the earth clip near the sensor on the same pipe.

· Check that the metal clip of the sensor (to which the cable connects) does not touch any metalwork.

· Position the sensor on a straight section of pipe, but not on a long section which may vibrate.

· Rotating the sensor on the pipe may improve the signal (but never rotate the sensor without first slackening the screw. Rotating a clamped sensor will damage it)

· Do not power the smokemeter from a 12V tapping of a 24V battery. The speed sensor may not function if this is done. Connect the smokemeter power to the 24V in this case.

· Keep spare sensors to allow quick identification of a defective sensor. . If access to the high pressure pipes is difficult, or a good signal cannot be obtained,

consider using an optical pickup. · Check low idle and maximum speeds using the USER DIAGNOSTIC TEST position

before starting the official test.




13. PRINCIPLE OF OPERATION

See illustration 14. A smoke sample from the vehicle exhaust enters the smokemeter via a smoke probe and flexible hose. Smoke enters at the centre of a heated smoke chamber, and flows towards each end. The air pressure system produces an ‘air curtain’ at both ends of the chamber, which directs the smoke away from the optics and into the smoke box. The mixture of air and smoke then leaves the smoke box via the waste outlet. The smokemeter is fitted with a light source (1) and a light sensor (2), which measure the light absorption in the chamber. The light sensor, smoke temperature sensor, and amplifiers are located on a circuit board in the light sensor box. The smokemeter contains 2 circuit boards, one for power supplies, the other to provide the measurement and sequence logic.




14. SPECIFICATION Dimensions See illustration 15

Weight Smokemeter,printer and handset (excluding trolley, hose etc) 14kg Storage temperature -20 to +60 ºC Operating temperature 0 to +40 ºC Electrical At the smokemeter power lead clips 11.5 to 28V DC supply or 20 to 24V AC at 15amps To the power unit YDA 123 230V AC 50Hz -15% , +10% Opacity Range (k scale) 0 to 10 m-1

measurement Resolution 0.01 m-1

Range (HSU scale) 0 to 100 % Resolution 0.1 %

Speed Range (RPM) 200 to 6000 RPM measurement Resolution 10 RPM (optical/clamp-on Accuracy 1% + 10 RPM sensors) Oil temperature Range ( ºC) 1 to 120 ºC Resolution 1 ºC Accuracy 2 ºC for 20 to 100 ºC Optical System Light Source type Halogen lamp 12V 12/20W Light source colour temperature 2900 ºC Light sensor Silicon photodiode with added green filter to EEC 72/306 etc Effective optical path length 430mm Optical system accuracy 1% of full scale




Response time Physical response time less than 0.4 sec Electrical response time exponential 0 to 90% in 1 sec (in response to a step input) (as EEC 72/306) Printer Epson ink ribbon, 24 column 57.5mm plain paper roll Powered by the smokemeter at 12V DC Interface 1200baud RS232 with ready/busy handshaking. Communications RS 232 duplex at 2400 baud from 9 way ‘D’ connector located on the printer. 8 bit, no parity, 1 start, 1 stop bit. Transmit from pin3, receive to pin2, ground pin 5. Can be connected to a PC for the recording/viewing of transients. Also for calibration and diagnostic of the smokemeter. Environmental The smokemeter and printer (but not the power unit) can be used outside under wet conditions. Electromagnetic Compatibility Tested to IEC 801-1 (short term power reduction) IEC 801-2 (voltage bursts from mains) IEC 801-3 (electrostatic discharge) IEC 801-4 (electromagnetic fields)

15 USER SERVICED PARTS It is recommended that the user holds the following parts. Rolls of paper Printer ribbons Halogen lamp

Clamp-on sensors (if using speed measurement)




16 STORAGE & RETRIEVAL OF TEST RESULTS The smokemeter automatically stores the last 4 test results including data entered on the keypad. Data can be recalled for viewing or printing. The stored test results can be erased. The results are kept stored when the smokemeter is not powered. Details are: To select a test result: When the display shows F1= DATA ENTRY / OTHERWISE CLICK press the * on the keypad. If any test results are stored the second line of the display will change to: 1) XXXXXXXXXXXXXXXX where XXXXXXXXXXXXXX is the Registration number entered for the vehicle of the last test. Press the * again to display: 2) XXXXXXXXXXXXXXXX where XXXXXXXXXXXXX is the Registration number entered for the previous test. Each press of * will bring back the data for the next previous test. When the * is pressed after the last stored test (or after a maximum of 4) then the display shows: R = CLEAR RESULTS If R is pressed, then the stored results are cleared. If * is pressed, then the first result is display again. To print the test result: Press the R key on the keypad To view the test result: Hold the handset button until the results are displayed. To start a new test: Press the F1 key on the keypad for DATA ENTRY




17 HSU TO K (m-1) CONVERSION CHART

Note that HSU (Hartridge Smoke Unit) is the percentage opacity measurement for a column of smoke 430mm in length. k is the coefficient of light absorption, a measure of ‘blackness’ of the smoke which is independent of the measurement length.

HSU k HSU k HSU k 0 0 33 0.93 66 2.51 1 0.02 34 0.97 67 2.58 2 0.05 35 1.00 68 2.65 3 0.07 36 1.04 69 2.72 4 0.09 37 1.07 70 2.80 5 0.12 38 1.11 71 2.88 6 0.14 39 1.15 72 2.96 7 0.17 40 1.19 73 3.04 8 0.19 41 1.23 74 3.13 9 0.22 42 1.27 75 3.22 10 0.25 43 1.31 76 3.32 11 0.27 44 1.35 77 3.42 12 0.30 45 1.39 78 3.52 13 0.32 46 1.43 79 3.63 14 0.35 47 1.48 80 3.74 15 0.38 48 1.52 81 3.86 16 0.41 49 1.57 82 3.99 17 0.43 50 1.61 83 4.12 18 0.46 51 1.66 84 4.26 19 0.49 52 1.71 85 4.41 20 0.52 53 1.76 86 4.57 21 0.55 54 1.81 87 4.74 22 0.58 55 1.86 88 4.93 23 0.61 56 1.91 89 5.13 24 0.64 57 1.96 90 5.35 25 0.67 58 2.02 91 5.60 26 0.70 59 2.07 92 5.87 27 0.73 60 2.13 93 6.18 28 0.76 61 2.19 94 6.54 29 0.80 62 2.25 95 6.97 30 0.83 63 2.31 96 7.49 31 0.86 64 2.38 97 8.15 32 0.90 65 2.44 98 9.10 99 10.71




18 PARTS LIST 18.1 LIGHT SENSOR BOX

Ref Description Part No. 1 Complete assembly 135-04-11 2 Sealing gasket set (set of 3 for the whole smokemeter) 134-95-69/70 3 Circuit PCB 135-04-13 4 Optical test filter 135-04-08 5 Latch kit HS168 6 Thermocouple 135-04-21 Metal box 135-04-05




18.2 LAMP BOX

134-95-12 134-95-69/ 70 137-65-00 8689146 HS168 135-04-21 134-86-07

Complete assembly Sealing gasket set (set of 3 for the whole smokemeter) Circuit PCB Lamp 12V/20W Latch kit Metal box

1 2 3 4 5

PART No. DESCRIPTION REF




18.3 ELECTRONICS ENCLOSURE

8686451 118-18-00 9842615 YDA170 134-95-17 134-86-89 135-04-04 135-11-03 135-11-04 9842596 134-86-53 134-86-60 134-98-01 135-05-51 135-05-50 134-86-25

Blower Power PCB 15A fuse On/Off switch Lamp cable 10m power cable Printer loom Logic PCB Programmed microcomputer 5A fuse 20x5mm( pack of 5) Light sensor cable Transformer Loom to blower box Electronic enclosure box Cover Blower cover

1 2 3 4 5 6 7 8 9 10 11 12 13





18.4 SMOKE BOX AND CHAMBER ASSEMBLY

134-86-93 135-05-09 134-86-30 YDA168 134-95-69/ 70 134-86-03 7733F 134-86-01

Heated smoke chamber assembly. Thermistor Smoke inlet boss Latch kit Sealing gasket set (set of 3 for the whole smokemeter) Handle Cap Metal box

1 2 3 4 5 6 7





18.5 PRINTER UNIT

REF DESCRIPTION PART No 1 2 3

Key pad mounted on the cover Connector with loom Circuit PCB + mechanism + programmed chip Print/PLB Programmed chip Print Printer Mechanism alone Printer unit complete Ribbon Paper Roll

135-03-11 134-96-03 135-11-05 135-11-06 8684285 135-11-01 8684297 8684298


World Leaders in Diesel Fuel Injection Test Equipment

The Hartridge Building, Network 421, Radclive Road Buckingham, MK18 4FD, United Kingdom Tel: +44(0) 1280 825 600 Fax: +44(0) 1280 825 601 Email: [email protected] www.hartridge.com

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