AVL 415SE Maintenance Manual
October 2011
AT4234E, Rev.00
Maintenance Guide
AVL 415SE SMOKE METER
FROM S/N 7000)
Copyright 2011 AVL List GmbH, Graz - Austria
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.
All rights reserved.
Warnings and Safety Instructions
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 operatio n 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 an d safety precautions are no t
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 conditions beyond the control of the manufacturer .
The results obtained from this prod uct the refo re must be exa mined by an e xper t
(e.g. for plausibility) before any action is taken that is based on the results.
All adjustment and maintenance work necessary on instrument s when ope n and
under voltage must be carried out by a professional technician 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 th e test object nor
the testing equipment is operated under conditions that could lead to damage or
injury.
Warnings and Safety Instructions
3
AVL 415SE Smoke Meter — Maintenance Guide
4
Warnings and Safety Instruct ions
AVL 415SE Smoke Meter — Maintenance Guide
Table Of Contents
Table Of Contents
Warnings and Safety Instructions................................................................................................................ 3
1 What You Should Know.................................................................................................... 7
1.1 Safety Instructions.................................................................................................................... 7
1.2 About the AVL 415SE Smoke Meter........................................................................................ 7
1.3 About this Documentation ........................................................................................................ 8
1.3.1 Typografic Conventions......................................................................................................8
1.3.2 We Want to Hear from You.................................................................................................9
2 Maintenance .................................................................................................................... 11
2.1 Procedure............................................................................................................................... 11
5
2.2 Service Intervals..................................................................................................................... 12
2.2.1 AVL Service Engineer - Annual Maintenance Activities....................................................12
2.2.2 Service Engineer - Maintenance Schedule.......................................................................13
2.3 Components........................................................................................................................... 16
2.3.1 Disposal Instructions.........................................................................................................16
2.3.2 Paper Feed Mechanism....................................................................................................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 ..........................................................................................................36
3 Checks..............................................................................................................................37
3.1 Sampling Volume Check........................................................................................................37
3.1.1 Sampling Volume Check with AVL 4210 Instrument Controller........................................37
3.1.2 Sampling Volume Check via Terminal..............................................................................38
3.1.3 Check the Metering Pipe...................................................................................................40
3.1.4 Examples of External Volume Measuring Systems..........................................................40
3.2 Leak Check............................................................................................................................. 41
3.2.1 Leak Check in SERVICE MODE (for Firmware Version 2.10 and Higher).......................42
AVL 415SE Smoke Meter — Maintenance Guide
6
Table Of Contents
4 Parts Lists ........................................................................................................................43
4.1 Consumables.......................................................................................................................... 43
4.2 Wear Parts.............. ... .... ... ....................................... ... ... ... ....................................... ............... 43
4.3 Spare Parts............................................................................................................................. 44
4.4 Maintenance Tools................................................................................................................. 48
AVL 415SE Smoke Meter — Maintenance Guide
1 What You Should Know
1.1 Safety Instructions
This documentation contains important Warnings and Safety Precautions
which should be observed by the user. Only by careful observance of these
requirements and safety precautions, a smooth operation can be guaranteed.
1.2 About the AVL 415SE Smoke Meter
Minimize your system downtimes by means of proactive measures. Our competent service engineers will carry out inspections and maintenance with technical
professionalism and cost efficiency in mind. Using original spare parts guarantees high system reliability. AVL preventive maintenance assures the highest
possible availability of the system and devices.
What You Should Know
7
Your benefits at a glance:
Best availability of equipment due to minimized down times
Guaranteed service quality through certified engineers
Easy budgeting due to transparent maintenance cost s
Maintenance plans optimized for the used equipment and its applications
A typical preventive maintenance proc ed ur e co mp r i ses the follow ing steps:
Visual check
Performance checks
Cleaning
Replacing wear parts
Calibration and re-adjustment
Calibration protocols
Failure diagnostics
Recommendation for repair
Required manpower:
The required time for an annual maintenance by an AVL Service Engineer is
6hours.
Obviously, this time might depend of the usage and the environment conditions
of the device.
The frequency we recommend in this document is based on normal operating
hours (8 hours/working day).
Information
This manual refers to the maintenance of a Smoke Meter 415SE.
Handling and actions are mainly the same as for the 415S Smoke Meter, but the
spare parts can be different.
AVL 415SE Smoke Meter — Maintenance Guide
8
What You Should Know
1.3 About this Documentation
The documentation adresses service enginee rs who perform ma intenance t asks
of the AVL 415SE Smoke Meter. All relevant tasks are described, all necessary
wear and spare parts are listed.
Detailed knowledge about the device and the relevant safety regulations is
essential.
For detailed information on the AVL 415SE Smoke Meter see the corresponding
manuals:
AT1240E 415S Smoke Meter, Operating Manual
AT3648E 415SE Smoke Meter, Product Guide
AT3803E 415SE Smoke Meter, Calibration Manual
The descriptions in this 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:
WARNING
WARNING indicates a hazardous situation which – if not avoided – could result
in death or serious injury.
CAUTION
CAUTION indicates a hazardous situation which – if not avoided – could result in
minor or moderate injury.
Additional messages:
NOTICE
This text indicates situations or operation errors which could result in property
damage or data loss.
Information
This text indicates important information or operating instructions. Not observ ing
these instructions could inhibit or impede you from succesfully completing the
tasks described in this documentation.
AVL 415SE Smoke Meter — Maintenance Guide
What You Should Know
Standard text styles:
Bold Parameters; control 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 to select a menu item from a
given menu
Lists:
9
1.3.2
1.
2.
• One-step instructions
–
–
We Want to Hear from You
Your comments and suggestions help us to improve the quality and practical
relevance of our manuals.
If you have any suggestions for improvement, please send them to:
docu@avl.com
We look forward to hearing from you!
Step-by-step procedures with a given sequence
Unordered series of concepts, items or options
AVL 415SE Smoke Meter — Maintenance Guide
10
What You Should Know
AVL 415SE Smoke Meter — Maintenance Guide
2 Maintenance
2.1 Procedure
NOTICE
For permanent operation of the measuring device (fully automated endurance
runs, 24 h/day, 6 … 7 days/week), a service is recommended every 3 weeks.
A full service or replacing the pump is recommended every 3 months.
When the device is put to average use, we recommend:
1. Each time the paper is changed, perform the following steps:
– Inspect the reflectometer head - clean if necessary (do not forget to
clean also the light gate 1).
– Inspect the two fine filters and replace if there are any signs of soiling.
– Inspect the blackened filter area.
– Perform a leak check.
– Check white value disk for soiling and clean if necessary.
– Lubricate moving parts of the camshaft and the ratchet clip by using
Teflon lubricant oil (material number: HS0064) or Teflon lubricant spray
(material number: HS0058).
2. After 300 operating hours or 10 00 0 measurement s (correspo nds 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 activities described in the following sections.
– Replace all fine filters.
– Clean and lubricate moving parts of camshaft and ratched clip using
Teflon lubricant spray (material number HS0058) or Teflon lubricant oil
(material number HS0064).
– Check pump noise and check nominal pump flow.
Maintenance
11
AVL 415SE Smoke Meter — Maintenance Guide
12
Maintenance
2.2 Service Intervals
2.2.1
Component / Test Lifetime /
Leak check Annually For checks of sample lines and
Reflectometer head Annually Check and clean or replace if
Light gate 1 Annually Check and clean if necessary. If damaged, replacement
Camshaft Annually Check and clean or replace if
Fine filters Annually Replace. Annually
White value plate Annually Clean the deposit on the standard. If necessary.
Filter paper Annually Check the homogeneous black-
Sealing ring of the
suction unit
Clamping piece
rolls, axles
press fit bush
bearing
Sampling probe,
sampling line
Filter mat Annually Replace. Annually
Check sampled volume Annually Check. Replacement of the glass
Adjustment of the transport paper mechanism
Adjustment of the slip
clutch
Ratchet clip Annually Replace. Annually
AVL Service Engineer - Annual Maintenance Activities
Maintenance Replacement
Service interval
probes:
supported on SERVICE MODE
only perform with sampling probe &
line
necessary.
Adjustment if necessary and cali-
bration.
necessary.
ening with exactly delineated round
contour.
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.
Annually Clean and lubricat e all po ints. If necessary.
Annually Check and clean. 1 000 – 2 000 operating
Annually Function check and adjustment
necessary every time spare parts
are exchanged.
Annually Check the tension and adjustment
if necessary.
–
Every 2 years
is done by an A VL Service
Engineer.
Every 2 … 3 years or after
3 000 operating hours.
–
Replacement of the
sealing rings if damaged.
hours.
caliber of the volume
tester is necessary when
it is scratched, or contaminated with dirt.
–
–
Tab. 1
AVL 415SE Smoke Meter — Maintenance Guide
Maintenance
13
Component / Test Lifetime /
Service interval
Clamping lever Annually Visual check. If damaged or if any part
Pump Annually Check and replace if necesary. Every 2 000 - 3 000 oper-
Nipple & hose connections
Cleaning of electronical
boards
Filters of shop air filter
unit
Check valve Annually Check and replace if necesary. Annually
Pressure reduction
assembly
Pressure switch of shop
air option
Tab . 1
Annually Replace. Annually
Annually Clean with high purity compressed
air.
Annually Check and replace if necessary. once every 1 … 2 years;
Annually Check. After assembly.
Annually Check and adjust if necessary. Annually
Maintenance Replacement
is bent off.
ating hours.
If necessary or defective.
much more often for oil
lubricant compressors:
at least: every
1…2months
2.2.2
Service Engineer - Maintenance Schedule
WARNING
Fire hazard
When using the required appliances like sprays, mounting pastes, lubricants,
always observe the relevant handling instructions and safety measures of the
various products.
All sprays used are a fire hazard and highly inflammable. Installation work using
the appliances on and inside measurement devices and on test beds must only
be carried out on cooled-down parts and in well ventilated areas.
NOTICE
The compressed air used to clean, has to be absolutely free from oil, water, and
particles.
For the disposal of environmentally sensitive substances, see the AVL 415S
Smoke Meter Operating Manual, chapter Disposal of Environmentally Sensitive
Substances.
AVL 415SE Smoke Meter — Maintenance Guide
14
Maintenance
Component / Test Lifetime /
Service interval
Leak check Minimum every day.
After every filter
paper change.
After every manipulation of the paper
transport.
Before & after every
volume tester calibration.
Reflectometer head Every time the filter
paper is exchanged.
Light gate 1 Every time the filte r
paper is exchanged.
Camshaft Every time the filter
paper is exchanged.
Fine filters Every time the filter
paper is exchanged.
White value plate Every time the filter
paper is exchanged.
Filter paper Every time the filter
paper is exchanged.
Sealing ring of the
suction unit
Minimum every 5
times of filter paper
exchanged.
Maintenance Replacement Procedure
For checks of sample
lines and probes:
supported on
SERVICE MODE only
perform with sampling
probe & line
Check and clean if
necessary with a
puffer or a soft brush
or with compressed
air.
Check and clean if
necessary with
compressed air.
Check and clean if
necessary with
compressed air.
Check. Following the
Clean the deposit on
the standard with a
soft, wet cloth.
Check the homogeneous blackening with
exactly delineated
round contour.
Check the backside of
the filter paper fpr
back flushed particles.
Check if there is no
deposit, clean if
necessary with a soft
or a damp cloth.
Glue the sealing rings
into the clamping
device (suction unit)
with Adhesive
3M-B20.
Check the sealing ring
for defects and correct
ling ring position.
sea
– Section Leak
Check on page 41
Every 2 years Section Reflecto-
meter Head on
page 27
If damaged –
Replacement is
done by an AVL
Service Engineer.
Every 2-3 years or
after 3 000 operating hours.
usage conditions.
– Section Clamping
– Section Blackened
Replacement of
the sealing rings if
damaged; in this
case also order
mounting ring
30 mm.
Section Camshaft
on page 30
Section Fine Filters
on page 31
Lever and Ratchet
Clip on page 28
Filter Area on
page 22
Section Suction
Unit on page 24
Tab. 2
AVL 415SE Smoke Meter — Maintenance Guide
Maintenance
15
Component / Test Lifetime /
Service interval
Clamping piece
rolls, axles
press fit bush
bearing
Sampling probe,
sampling line
Required after 4-5
exchanges of the
filter paper roll,
or after 10 000
measurements,
or after 300 operating hours of the
pump.
For Diesel engine:
minimum once a
week,
or after 300 operating hours of the
pump.
For low meas. emission:
once a week
For high HC
concentration:
everyday
Maintenance Replacement Procedure
Clean and lubricate all
points with Teflon
lubricant spray or
Teflon lubricant oil.
Check and clean with
compressed air.
If necessary. Section Lubri-
cating and
Cleaning Intervals
on page 17,
section Lubrica-
tion Points on
page 19
1000 – 2000
operating hours.
Section Sampling
Probe and
Sampling Line on
page 23
For measuring
systems with activated option "Shop
Air" the cleaning
may be omitted or
can be performed
via the shop air
purging option
Filter mat Every 300 oper-
ating hours of the
pump,
or after 10 000
measurements
Check sampled
volume
Recommended:
every 300 operating
hours of the pump,
or after 10 000
measurements.
Necessary:
after 1 000 operating hours.
Visual check and
clean if necessary with
compressed air.
Check recommended
after:
Installing/reinstalling
the device on the test
bed.
When changing the
dead volume.
After cleaning the
device from the soot
contamination.
After repairing the
device.
Re-adjustment.
- Section Cooling on
page 33
Replacement of
the glass caliber of
the volume tester
is necessary if it is
scratched or
contaminated with
dirt.
Section Sampling
Volume Check on
page 37
Tab . 2
AVL 415SE Smoke Meter — Maintenance Guide
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