AVL 415SE SMOKE METER
FROM S/N 7000)
October 2011AT4234E, Rev.00
Maintenance Guide
Page 1: ...AVL 415SE SMOKE METER FROM S N 7000 October 2011 AT4234E Rev 00 Maintenance Guide ...
Page 2: ...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 All rights reserved Copyright 2011 AVL List GmbH Graz Austria ...
Page 3: ...the necessary safety precautions All accessories and equipment used with the product must be supplied or approved by AVL The operating prin ciple 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 conditions beyond the control of the manufacturer The results obtained from ...
Page 4: ...Warnings and Safety Instructions 4 AVL 415SE Smoke Meter Maintenance Guide ...
Page 5: ...chanism 17 2 3 2 1 Lubricating and Cleaning Intervals 17 2 3 2 2 Lubrication Points 19 2 3 3 Blackened Filter Area 22 2 3 4 Sampling Probe and Sampling Line 23 2 3 5 Suction Unit 24 2 3 6 Reflectometer Head 27 2 3 7 Clamping Lever and Ratchet Clip 28 2 3 8 Camshaft 30 2 3 9 Fine Filters 31 2 3 10 Filter Paper Transport and Spool Device 32 2 3 11 Cooling 33 2 3 12 Pump 34 2 3 13 Pressure Reduction ...
Page 6: ...Table Of Contents 6 AVL 415SE Smoke Meter Maintenance Guide 4 Parts Lists 43 4 1 Consumables 43 4 2 Wear Parts 43 4 3 Spare Parts 44 4 4 Maintenance Tools 48 ...
Page 7: ...ce Best availability of equipment due to minimized down times Guaranteed service quality through certified engineers Easy budgeting due to transparent maintenance costs Maintenance plans optimized for the used equipment and its applications A typical preventive maintenance procedure comprises the following steps Visual check Performance checks Cleaning Replacing wear parts Calibration and re adjus...
Page 8: ... manual are based on the AVL Instrument Controller IC 4210 If the DUI Device User Interface is used for the maintenance work see also AT3569E 415S Smoke Meter Device User Interface User s Guide 1 3 1 Typografic Conventions Safety messages Additional messages WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTION indicates a haza...
Page 9: ... elements in windows and dialog boxes important text Italics Cross references foreign language or new terms wild card for elements that need to be entered by the user i e characters or text If you read for example macro name you are required to type the name of a macro UPPERCASE LETTERS Operating modes Courier Programming examples source code Times New Roman Formulas Menu Option Description of how...
Page 10: ...What You Should Know 10 AVL 415SE Smoke Meter Maintenance Guide ...
Page 11: ...ements corresponds to 5 10 paper rolls material number HP0153SP do the following Check the reflectometer head Check the sampled volume Clean sampling line tube with ultra clean oil free and water free com pressed air Clean the light gate 1 with ultra clean oil free and water free com pressed air Check filter mat for cooling air Check the ratchet clip and the clamping lever Carry out all the activi...
Page 12: ... paper Annually Check the homogeneous black ening with exactly delineated round contour Sealing ring of the suction unit Annually Check there is no deposit clean if needed Glue the sealing rings into the clamping device suction unit Check the sealing ring for defects and correct sealing ring position Replacement of the sealing rings if damaged Clamping piece rolls axles press fit bush bearing Annu...
Page 13: ...2 years much more often for oil lubricant compressors at least every 1 2 months Check valve Annually Check and replace if necesary Annually Pressure reduction assembly Annually Check After assembly Pressure switch of shop air option Annually Check and adjust if necessary Annually Component Test Lifetime Service interval Maintenance Replacement Tab 1 WARNING Fire hazard When using the required appl...
Page 14: ...y with compressed air Every 2 3 years or after 3 000 oper ating hours Section Camshaft on page 30 Fine filters Every time the filter paper is exchanged Check Following the usage conditions Section Fine Filters on page 31 White value plate Every time the filter paper is exchanged Clean the deposit on the standard with a soft wet cloth Section Clamping Lever and Ratchet Clip on page 28 Filter paper ...
Page 15: ...performed via the shop air purging option Check and clean with compressed air 1 000 2 000 operating hours Section Sampling Probe and Sampling Line on page 23 Filter mat Every 300 oper ating hours of the pump or after 10 000 measurements Visual check and clean if necessary with compressed air Section Cooling on page 33 Check sampled volume Recommended every 300 operating hours of the pump or after ...
Page 16: ... Compressed air supply After each installa tion or once a year Visual check Replace the filters if necessary Filter change once a year for oil free compressors much more often for oil free compressors with oiled air See Fig 29 on page 35 Pressure reduction assembly Once per week or after assembly Check and adjust if necessary Component Test Lifetime Service interval Maintenance Replacement Procedu...
Page 17: ...contamination present in the ambient air Basically the following applies If you notice that lubricant oil or lubricant grease is no longer liquid at the lube points or if the deposits have already turned black or exhibit an almost solid or stiff consistency all moving parts have to be completely cleaned to remove any abrasion deposits residues of lubrication agents etc Furthermore a subsequent re ...
Page 18: ...e entire assembly including axles and rollers see Fig 4 on page 22 Pos 110 to 150 or alternatively replace the entire ratchet clip Perform all activities of step 3 5 After approx 1 000 paper rolls Order an AVL service engineer parts such as the motor camshaft bearings ratchet clip clamping lever suction unit or other worn out component parts have to be checked by an AVL service engineer who will t...
Page 19: ...t grease material number HS0071 or also with lubricant oil or lubricant spray The marking applies for all lube points All marked lube points need to be cleaned on a regular basis too Fig 1 Lubricating points for camshaft clamping piece and guides of paper transport roll Camshaft Lubricating points Lubricating points Lubricating point Lock nut Setting nut Taper hub washer Clamping lever Ratchet cli...
Page 20: ...ft bearing and ratched clip roll Pos 050 Pos 030 Pos 020 Pos 040 Pos 060 Lubricating points Lubricating points Clamping lever Ratchet clip Fastening screw for drive unit Positioning bracket for motor and light barrier Fastening screw for camshaft Housing door Lube point press fit bush Pos 40 ...
Page 21: ...Roll I 2x 5 White value sheet Fig 3 Lubricating points on clamping lever Pos 040 Pos 010 Pos 020 Pos 030 1 1 5 2 3 4 Lube points Lube points Lube points Information These points on the clamping lever only need to be lubricated sparingly approx every 50 paper rolls Please remove any unnecessary or excess oil or grease ...
Page 22: ... Suction Unit on page 24 Local dark spots Dark spots indicate the formation of condensate or heavy soot deposits 1 Check the gas path from the sampling probe to the filter paper 2 Purge frequently 3 Reduce the sampling volume and or use the heating option 4 Always replace the fine filter Fig 4 Lubricating points for ratched clip roll Pos 150 Pos 130 Pos 120 Pos 140 Pos 110 Lubricating point Lubric...
Page 23: ...urging Depending on the operating states of the engine and or the kind of particles deposits in the hose can develop that cannot be removed using compressed air This deposit can filter particles out of the measurement gas and cause measurement deviations NOTICE Disconnect the probe and line from the AVL 415SE before cleaning them with compressed air Under no circumstances the gas path from upper c...
Page 24: ...tely 4 Check the clamp piece tracks for easy movement 5 If necessary lubricate track ex works Teflon lubricant spray part number HS0058 Teflon lubricant oil part number HS0064 or Lubricant grease OKS 260 part number HS0071 Fig 7 Sampling line Information Heavier soot deposits can occur when using new sampling lines for the first time straight from the factory and this can also reduce the recorded ...
Page 25: ...rt for fixing the gasket material number YM3499SP into the suction unit of the clamping and drive mechanism Mounting ring 30 mm 4152X41 C00 0 Material number YM3516SP NOTICE Apply only a thin film of lubrication only into region between the upper and lower clamping piece Fig 8 so that no oil can reach the sealing rings Never clean the elastomer parts sealing rings in an ultrasonic bath Replace the...
Page 26: ...he lock nut see Fig 12 on page 26 If the clearance is too large the retaining ring does not open wide enough and there is a risk that soot will be scraped off If the clearance is too small the leakage factor will be high because the clamping force is insufficient 3 Check the friction in the tracks bearings of the ratchet clip camshaft in rela tion to one another and If necessary lubricate track ex...
Page 27: ...ectometer head housing between the glass area and the end of the reflectometer head It must be even no scratches Measuring head The polymeric material of the measuring head must be clear transparent and colourless no colouring is allowed Replace the measuring head if the polymeric material is coloured yellowish or brownish We recommend replacing the reflectometer head every 2 years Meas head N 1 6...
Page 28: ...t be scratched 2 Clean with a soft wet cloth if necessary or replace white value plate 3 Check the performance of the ratchet clip rolls the surfaces must be clean lubricated and the surface shall look as polished no scratches cuts nuts are allowed see Fig 16 on page 28 4 Otherwise clean all parts of the ratchet clip replace the ratchet clip rolls lubricate all moved parts 1 Clamping lever 2 Ratch...
Page 29: ... is available Alternative transport roll Material number YM6962 Ratchet clip We recommend replacing the ratchet clip during the annual preventive mainte nance Ratchet clip compl G002 4152W52 Part Number BO6671SP NOTICE This roll is not recommended as standard transport roll and shall not replace YM3687 o 1 Transport roll 2 Paper transport roll complete Fig 17 Paper transport roll complete 2 1 Fig ...
Page 30: ...appet is roughened or flat tened 1 Check that the resting position of the camshaft is 10 deg 2 Keep in mind that the camshaft bearing in the bearing block must not be chipped Fig 19 Ratchet clip roll 4152X63 C00 0 Available in the eSparesTM Webshop Fig 20 Clamping lever complete G002 4152W50 Available in the eSparesTM Webshop o 1 Defective camshaft surface 2 Defective ratched clip rolls caused by ...
Page 31: ...nts indicate on Fig 22 below 2 3 9 Fine Filters Check the two fine filters every time the filter paper is exchanged For normal operation We recommend replacing these two fine filters as soon as they become blackened When high hydrocarbon contents as oil and fuel occur in the exhaust We recommend replacing these two fine filters every time the filter paper is exchanged Fig 22 Lubricating points for...
Page 32: ...on spring on the supply roll axis NOTICE Remounting the parts avoid any drilling forces on tubing and upper clamping piece Fig 23 Pre filter Available in the eSparesTM Webshop CAUTION Danger of burns and pinching In heated devices there is a danger of burns The temperature of the compo nents inside a device can reach up to 70 C There is a danger of pinching your fingers in the clamp when inserting...
Page 33: ...sary so that the traction force on the filter paper is kept to a minimum 3 Make sure the roller holder of the used paper spool does not rub against either the supply roller or the paper strip to be spooled onto it The length of a filter paper feed should be between 47 and 53 mm tolerances minimum 43 mm maximum 57 mm 4 Do not lubricate chain and chain wheels in particular the friction surface of th...
Page 34: ...a region between 10 13 l min if system is heated up to 15 lower values related to ambient temperature of 20 C Test with probe line mounted maximum 3 m length clean filter paper inserted inlets and outlets of the flow are at ambient pressure Flow measurement at inlet or outlet of the measuring system A simplified pump function check as well as a check of the flow behaviour in the device is also pos...
Page 35: ... the pump follow the service memo 15 06 Diaphragm pump We recommend replacing the pump every 2 000 to 3 000 operating hours Diaphragm pump type 7015ZV 24VDC Material number MV0207SP Shop Air Service Unit We recommend the replacement of the filters once a year Information With a sampling line with a maximum length of 3 m connected to MV3 or MV4 the flow rate may be reduced by no more than further 1...
Page 36: ...heck valve in rotation with the other one 2 Replace the check valves once a year 3 Perform a visual check after every assembly and at least once per week Fig 30 Compressed air unit for option Shop Air Fig 31 Pressure Reduction Unit Probe for connection into the exhaust duct Probe to Smoke Meter 30 and 70 cm long variants possible Extension for cooling the exhaust gas Extensions for cooling the exh...
Page 37: ... Guide material number AT3803 3 1 1 Sampling Volume Check with AVL 4210 Instrument Controller 1 Enter measurement values 2 Compare measurement values Information In heated devices the calibration should be carried out when the device is heated For this you need the Retrofit Kit material number BO3776 Remark this is a standard part of the AVL 408S Volume Tester if delivered after 1 Jan 2000 Measure...
Page 38: ...measured by the AVL 415SE displayed on the AVL 4210 with the volume measured by the external equipment 4 If the values differ by more than 3 save the correction factor in the AVL 415SE by pressing SAVE on the AVL 4210 3 1 2 Sampling Volume Check via Terminal Information The new correction factor shall be in the interval 0 7 1 3 If the new correction factor is less than 0 7 or greater than 1 3 chec...
Page 39: ...eters 7 Write down the values of date 1 to date 3 1st date dead volume sampling line 1 ml 2nd date dead volume sampling line 2 for two channel measure ment ml 3rd date ambient pressure mbar 4th date old volume correction factor ECPA T1 T2 PU VKF 8 Set calibration parameters 1st date dead volume sampling line 1 ml 2nd date dead volume sampling line 2 for two channel measure ment ml 3rd date ambient...
Page 40: ... careful the orifice plate and O rings might fall out 4 Clean the parts carefully especially the orifice in the plate 5 Reassemble as shown below noting the direction of the orifice bore taper 6 Insert the ratchet clip on tension spring and close the clamping lever 3 1 4 Examples of External Volume Measuring Systems AVL Volume Tester Dry gas meter for a flow measurement range of 8 16 l min AVL Vol...
Page 41: ...ure sensors It switches to SAMPLING MODE and solenoid valve MV3 remains closed The leak check is completed when Ready is displayed again on the AVL 4210 or when the text SRDY is returned in response to the ASTZ status query command via the terminal Fig 34 Volume tester 408S for 415 Information An officially calibrated dry gas meter can only deliver measurement accuracy better than 1 when the flow ...
Page 42: ...switch the device off briefly and then on again to terminate SER VICE MODE That ensures that any error messages that occur are not ignored Information 1 For Smoke Meter systems with mounted versions of the option high pres sure and tests via the service mode add to the above limits this is not checked by the software automatically If the FUNCTION TIMEOUT or the LEAKAGE EXTREMLY HIGH error is displ...
Page 43: ... 597LA 200 m HP0153SP PCK 10 Pre Filter MF0478SP PCK 5 Teflon Lubricant Oil 50 ml HS0064 PCS Tab 3 Designation Material Number Sales Unit Washer Din 988 5 x1 0 x 0 2 DZ0655SP PCK 100 Tube 6 0 x 2 0 Viton Black SS0272SP PCK 15 Tube 4 0 x 2 0 Viton Black SS0271SP PCK 15 Hose Nipple 415X32 C00 0 YM3493SP PCK 10 Gasket 30 mm 4152X38 C00 0 YM3499SP PCK 5 IC MEM 48T02 Zerop Ram Timer EE0336SP PCS Adhesi...
Page 44: ...ver Cap for Appl Plug EU0339 PCS Pl Connection Cover Cap for Appl Socket EU2031 PCS Varistor Module 4152 80 C00 0 BO3613 PCS Push Button 1xS 250 V 1 A Grey ES0419 PCS Supplementary Equipment Set 4080W01 C00 0 BO3776 PCS Fuse 1 6 A 250 V EV0044 PCS Screw Cap 409 08 02 YM0847SP PCS Measuring Head No 1 687 224 606 EZ0104SP PCS Press Fit Bush Bear Clamp Lever Unit DL0066SP PCK 2 Pressure Sensor 26PCCF...
Page 45: ...witch Activator w Roll ES0402SP PCK 2 Power LED N012 01 B07 0 BB1064SP PCS Mounting Ring 30 mm 4152X41 C00 0 YM3516SP PCS Spare Parts Set for Pump 7015 MV0143SP PCS Welding Piece 6 6GW DN1324SP PCS Closing Plug NPT 3 8 DN1373SP PCS PC Interface Cable 4152V34 C00 0 BV2395SP PCS Supply Cable 230 VAC 4390V01 C00 0 BV2166SP PCS Supply Cable 100 115 VAC 4390V31 C00 0 BV2261SP PCS Connecting Cable 15 m ...
Page 46: ... Self Reset EV0246SP PCS Temp Click 120 C Mech Reset EV0247SP PCS 2 2 Way Valve MM0956SP PCS Muffler Filter 2941 1 8 MY0162SP PCK 10 Tube 4 0 x 1 0 Teflon 9 bar 150 C SS0265SP PCK 10 Insulating Mat Heated ZG8447SP PCS Metal Hose NW 5 L 500 4152W49 YM4256SP PCS Gasket 409 01 18 DN0061SP PCK 10 Lock Nut YM1863 Taper Disk YM1864 Hose Nippel with Nut for 415S G01 G02 and 415SE Stainless Steel YM3493 H...
Page 47: ...ble Probe 1 100 115 V BV4634 Cable Probe 2 100 115 V BV4635 Option Special Sampling Sample Out Box BO4557 Fan Cable of Sample Out Box BV4818 Cable Sample Out Box BV4642 Option Pressure Reduction Screw Connection Probe Head DN1564 Back Pressure Valve MM1254 Metal Hose Extension 1 m YM6126 Probe Head Short 30 cm YM6168 Probe Head Long 70 cm YM6169 Thermo Click 95 C EV0467 Hose Set BX0891 Pump Module...
Page 48: ...ray SF01 HK0029 Loctite 222 HD0005 Loctite 577 HD0014 Loctite 245 HD0016 Adhesive 3M B20 HK0056 Spray Adhesive 3M 90 500 ml HK0057 Reflectance Standards 415 BO1941 Volume Tester 408S GH0326SP Soap Concentrate HC0013 Teflon Lubricant Spray HS0058 Teflon Lubricant Oil 50 ml HS0064 Lubricant Grease OKS 260 HS0071 Tab 6 ...
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Page 50: ...FOR FURTHER INFORMATION PLEASE CONTACT AVL List GmbH Hans List Platz 1 8020 Graz Austria Phone 43 316 787 0 Fax 43 316 787 400 eMail info avl com http www avl com ...
