Omitec OmiSmoke Operating Instructions Manual

OmiSmoke

Operating Instructions

Part Number - I311592

English

Issue 2

© Omitec 2003

Part Number - I311592
English - Issue 2

© Omitec 2003

Contents

Introduction

Introduction ............................................................................................ 5

OmiSmoke Components........................................................................ 6

Handset ............................................................................................. 6

Smokemeter ...................................................................................... 8

Sample hose.................................................................................... 10

Inserting sample hose probe ........................................................... 11

Engine oil temperature sensor probe .............................................. 12

Setting the sensor probe depth gauge ............................................ 13

Safety Precautions............................................................................... 14

Getting Started

PC Based Systems .............................................................................. 15

System requirements....................................................................... 15

Loading software ............................................................................. 15

Battery Charging .................................................................................. 15

Emissions Testing Using the Handset ................................................. 16

Emissions Testing Using the PC ......................................................... 17

PC Navigation Short-cut Buttons ......................................................... 18

Test Procedures

Preparation of Vehicle Prior to Tests ................................................... 19

Checks on Vehicle Before Tests ..................................................... 19

Visual Test ........................................................................................... 19

Metered Smoke Test ........................................................................... 19

MOT FAS Test Procedure ................................................................... 20

Category of Vehicle ......................................................................... 21

RPM Probe ...................................................................................... 21

Smart Card ...................................................................................... 22

Test Type......................................................................................... 23

Reduced Pollution Certificate (RPC) - (Category B only) ................ 24

Oil Temperature Measurement (Category A only)........................... 24

Insert Pipe into Exhaust................................................................... 26

FAS Test Procedure ........................................................................ 27

Fast Test (Category A only)............................................................. 27

Results and Print ............................................................................. 28

3

Contents

Peak Test ............................................................................................. 30

Peak Test Quick Summary of Events .............................................. 31

Continuous Test ................................................................................... 32

Continuous Test Quick Summary of Events .................................... 33

Linearity Test (Calibration Verification Check) ..................................... 34

Diagnostics........................................................................................... 36

Smoke Head Info ............................................................................. 36

Smoke Readings ............................................................................. 38

Smoke Raw Data............................................................................. 39

Printer Test ...................................................................................... 40

Clock Setup Mode................................................................................ 41

Calibration ............................................................................................ 42

Cleaning and Maintenance

Cleaning ............................................................................................... 43

Cleaning the smokemeter ................................................................ 43

Cleaning the handset....................................................................... 43

Cleaning the linearity check filter ..................................................... 43

Cleaning Optics ............................................................................... 44

Maintenance......................................................................................... 45

Calibration........................................................................................ 45

Replacing the printer paper ............................................................. 45

Replacing the battery ....................................................................... 45

Troubleshooting

OmiSmoke Error and Warning Messages............................................ 46

Parts List

Spares.................................................................................................. 49

Option Accessories .............................................................................. 49

4

Introduction

Introduction

Introduction

The OmiSmoke diesel smoke meter (DSM) is an exhaust smoke analyser for diesel
vehicles and is available as both a stand-alone and PC-based unit. It is an opacimeter
device working on the partial flow principle.

The OmiSmoke is approved by the Vehicle Inspectorate Executive Agency for MOT
testing on the following classes of vehicle:

• Category A - Cars and Light Commercial Vehicles (MOT classes 4 and 7)

• Category B - Public Service Vehicles, Private Buses and Heavy Goods Vehicles

(MOT Class 5 and 6)

OM0378

OmiSmoke consists of two portable units; the smokemeter, which contains the
measurement electronics, and the handset, which is equipped with a 4 button keypad,
LCD display and a printer. The two units are connected by a single 7 meter cable.

The smokemeter is designed to run for intermittent operation on an internal 12V
200W battery, or using the AC adapter if prolonged supply operation is required. The
smokemeter can be charged when not in use by leaving the AC adapter connected.

5

Introduction

OmiSmoke Components

Handset

The handset displays the results from each test on the LCD. Progress through the
tests is indicated on the LCD, while the 4 buttons allow for menu navigation and option
selection.

1 3

4

2

6

5

OM0381

1. Test results printer

2. LCD

3. ‘Up’ Navigation button

4. ‘Down’ navigation button

5. ‘Accept’ button

6. ‘Reject’ button

6

There are 5 connectors located on the sides of the handset:

Introduction

OM0379

123

1. Engine oil temperature sensor connector

2. Engine RPM sensor (OmiSpeed) BNC connector

3. 9-pin D type VI Card reader input

OM0380

12

1. Smokemeter 5-pin XLR connector

2. USB port

7

Introduction

Smokemeter

The smokemeter houses the measurement components of OmiSmoke.

1 73

OM0382

2 4 5

1. Receiver optics cover

2. Air intake

3. 4-pin XLR power connector

4. 5-pin XLR handset connector

5. Fuse

6. Power switch

7. Transmitter optics cover

8. Carry handle

9. Exhaust measuring chamber

8

9

6

8

Introduction

3

3

OM0383

1. Exhaust smoke outlet

2. Exhaust sample probe input

3. Air knife vents

Do not obstruct the air knife vents whilst running the OmiSmoke

smokemeter.

Note: The battery access cover is located on the underside of the smokemeter.

1 2

9

Introduction

Sample hose

OM0384

The exhaust probe collects gas samples from the test vehicle exhaust, which are then
analysed by OmiSmoke.

Take care to avoid contact with the exhaust system when inserting or

removing the sample hose. The exhaust system will be hot and severe
burns could occur.

10

Inserting sample hose probe

Place the probe into the exhaust following the quick guide below:

OM0478

Introduction

The probe should never be placed directly behind a bend in the exhaust pipe or close
to the silencer or expansion box. It should attach using the securing clamp, which will
ensure a minimum insertion.

11

Introduction

Engine oil temperature sensor probe

OM0373

Category A tests prefer the measurement of the test vehicle’s engine temperature.

The engine temperature sensor probe measures engine oil temperature in the sump
of the test vehicle, providing an accurate reading of the temperature of the engine.

The probe connects to the OmiSmoke handset using the Oil Temperature Probe
socket.

To monitor the engine temperature of the vehicle after it’s warm-up period, prior to an
emissions test, the sensor probe must be inserted into the engine oil dipstick
aperture. First remove and clean the engine oil dipstick of the vehicle.

NEVER insert the probe into the dipstick aperture without first setting the

depth gauge, and take care not to insert the probe any further than the
gauge allows. Serious damage to the engine could result.

12

Introduction

Setting the sensor probe depth gauge

OM0375

The sensor probe is fitted with a depth gauge to prevent the probe from being inserted
too far (which could cause serious damage to the engine). Move the rubber sleeve on
the probe, so that the distance between it and the end of the probe, is equal to the
length of the dipstick (see illustration). Insert the probe (up to the depth gauge) into
the dipstick aperture.

Do not attempt to insert the engine temperature probe while the engine is

running. Moving engine parts may cause personal injury or come in
contact with the probe, or its cable, resulting in damage to the probe and
to the engine.

Take care not to come into contact with hot engine parts when inserting or

removing the engine temperature probe from the engine oil dipstick
aperture - serious burns may occur.

Take care when removing the engine temperature probe after an

emissions test. The probe may be extremely hot and could cause serious
burns.

Remove the oil temperature probe prior to carrying out an emission test.

Do not rev/accelerate the engine with the temperature probe inserted into

sump. Increased vibration may cause it to move and cause damage.

NOTE: Always clean the probe after use and clean the dipstick before re-inserting into
the engine.

13

Introduction

Safety Precautions

Exhaust gases are poisonous and contain carbon monoxide, which can

cause unconsciousness and can be fatal - NEVER start or leave the test
vehicle engine running in an unventilated area.

•

DO NOT handle the OmiSmoke exhaust probe tip, or place the exhaust probe
on plastic or combustible surfaces after the test procedure. The probe may
become extremely hot during the test and could cause burns and a risk of
fire.

•

Take care when handling the Oil Temperature probe after the test procedure.
The probe’s metal sheath may become extremely hot during the test and
could cause burns.

•

Prolonged contact with engine oil may cause serious skin disorders,
including dermatitis and cancer of the skin. Avoid unnecessary contact with
engine oil and wash thoroughly after contact.

•

When fitting or removing the engine speed measuring device, ensure that
the engine is switched off and allow the engine to cool. Be aware that on
some vehicle’s the engine cooling fan may commence operating AFTER the
engine has been switched off.

•

Ensure that any test leads will not foul any moving part of the engine. Also
keep leads away from engine cooling fans and any hot engine components.

•

Take care with the vehicle electric systems when using an Ignition Pulse
Speed measurement probe, as many modern high energy ignition systems
are potentially dangerous.

14

Getting Started

Getting Started

PC Based Systems

System requirements

The minimum PC system requirements to load the OmiGas/OmiSmoke Techcenter
software are:

• Windows 98, ME, 2000 or XP

• Pentium 133 processor or higher

• 32 MB RAM

• 10 MB of free disk space

• 1024 X 768 minimum screen resolution

• CD ROM drive

• Serial com port capable of 115200 baud rate

• USB 1.1 or later

Loading software

Full instructions on loading the software are included with the software CD.

To load the software onto your machine, first insert the CD into the drive. The program
should then auto-run. If it doesn’t, select ‘Run’ from the ‘Start’ menu and browse to
the appropriate CD drive and select the file ‘Setup.exe’ to start the installation
process. Follow the on-screen instructions to complete the loading sequence, then
reboot when prompted.

Battery Charging

The smokemeter is designed to run for intermittent operation on an internal 12V
200W battery, or using the AC adapter if prolonged supply operation is required. The
smokemeter can be charged when not in use by leaving the AC adapter (battery
charger) connected.

1. Ensure charger is switched off before connection to the smokemeter.

2. Connect the charger power lead to the battery charger XLR socket.

3. Connect the charger to the mains supply and switch on.

4. After charging, ensure the battery charger is switched off before disconnecting.

Note: The battery charger is designed to revert to a ‘trickle’ charge mode after the
battery has been fully charged. It is safe, therefore to leave the charger attached
during a normal working day.

Do not leave the AC adapter/ battery charger connected for prolonged

periods.

15

Getting Started

Emissions Testing Using the Handset

OmiSmoke emissions testing can be undertaken by using the handset or a PC (using
the OmiGas/OmiSmoke Techcenter software).

Navigation through the emissions test software using the handset is assisted by the
on-screen information and prompts which are displayed throughout the testing
procedure. To scroll up and down through the menus press the ‘Up and ‘Down’
buttons until the required option is highlighted. To select the highlighted option, press
the ‘Tick’ button, or to reject press the ‘Cross’ button. Each successive menu
displayed on the handset will provide a number of options from which the technician
may choose.

During a test procedure, the handset will display screens which inform the technician
what the OmiSmoke analyser is currently doing. These screens do not provide
options for the technician to select and are simply a commentary on the procedure.

16

Getting Started

Emissions Testing Using the PC

OmiSmoke emissions testing can be undertaken by using a PC (using the
OmiGas/OmiSmoke Techcenter software) or the handset.

OmiSmoke can be added to the PC based OmiGas/OmiTechcenter system at any
time, simply by connecting the ‘combo’ cable (OM1500/10) between the OmiSmoke
handset socket and the auxiliary serial interface socket on the rear of the OmiGas unit
(OM4500/1).

The PC system will need to recognise new hardware for the OmiSmoke. To achieve
this, return to the main menu and select ‘ABORT’. The software will then re-establish
communication and the message ‘Configuring Analyser - Please Wait’ will appear.
This will then bring up the new ‘Combined Menu’, where the Smokemeter button will
be added.

Navigation through the emissions test software using the PC, is assisted by the
on-screen information and prompts which are displayed throughout the testing
procedure. Each successive menu displayed on the PC will provide a number of
options from which the technician may choose, using the ‘virtual’ buttons on the
screen. Selecting an option is achieved by pointing to the relevant button with the
mouse cursor and pressing the left hand mouse button to select.

During a test procedure, the PC will display screens which inform the technician what
the OmiSmoke analyser is currently doing. These screens do not provide options for
the technician to select and are simply a commentary on the procedure.

17

Getting Started

OmiSmoke Main Menu

PC Navigation Short-cut Buttons

In the top right of the PC display, there are five short-cut buttons to aid the technician
with software navigation. These buttons function as follows:

Select to view the screen last displayed.

Select to return to the current screen if you have used the ‘back’ button to

view a previous screen.

Select to print the data for the current emissions test.

Select to access the OmiSmoke help files, if you need assistance or

clarification during an emissions test.

Select to close the OmiSmoke Techcenter program. An emissions test can

still be carried out, but only by using the handset.

18

Test Procedures

Test Procedures

Preparation of Vehicle Prior to Tests

This is a guidance note, similar to that which will be found in the Vehicle and Operator
Services Agency (VOSA) inspection manual.

Checks on Vehicle Before Tests

As a general precaution, check:

1. That the vehicle has enough engine oil.

2. The coolant level is correctly topped up.

3. There is sufficient fuel to carry out the test.

4. There are NO defects or suspected faults. It is advised to seek advice from a

qualified automotive service engineer and have them rectify any faults in
advance of the test.

5. Confirm the engine is at normal operating temperature.

For cars and light commercial vehicles (Category A) it is preferred to use an oil
temperature probe inserted into the dipstick tube of the engine.

6. There are no obvious signs that the fuel injection pump governor has been
tampered with (e.g. seals are in place).

7. The condition of the camshaft belt (where visible).

8. Raise engine to around 2500 rpm or half the maximum engine speed, if it is

lower. Hold it steady for 30 seconds to ensure the system is properly purged.

9. Raise engine speed slowly to establish operation of governor, by monitoring
engine speed and its stabilised maximum.

Visual Test

Applies to all cars and light commercial vehicles up to and including 3500 Kg, first
used before 1st August 1979 (Category A).

The test will be a visual one, it does not require a diesel smoke meter test. Follow the
visual inspection outlined in the VOSA inspection manual.

Metered Smoke Test

Applies to all cars and light commercial vehicles up to and including 3500 Kg, first
used after 1st August 1979 (Category A). This also applies to all heavy goods vehicles
and large passenger vehicles.

The vehicle must be tested using a metered smoke test.

19

Test Procedures

MOT FAS Test Procedure

Before carrying out a MOT FAS test or any other FAS test, the engine must

first be verified safe and sound to proceed, and be running at normal
operating temperature. See section ‘Preparation of Vehicle Prior to Tests’
for suggested full checks.

The MOT FAS TEST is a procedure that follows the statutory requirements of the
Diesel Exhaust emission test as described in the current Vehicle and Operator
Services Agency Inspection Manual, and is approved for testing the following:

(a) Car and Light Commercial Vehicle testing (Class II, IV & VII) CAT A
(b) Private bus testing (Class V) CAT B
(c) Public Service Vehicle (Class VI) CAT B
(d) Heavy Goods Vehicle CAT B
(e) Single Vehicle approval CAT A

The MOT FAS test also offers Reduced Pollution Certificate (RPC) testing within the
Category B menu.

The OmiSmoke will measure the Free Acceleration Smoke (FAS) output over the
whole speed range of an engine (no load from idle up to cut-off speed) where the
engine is accelerated against its own inertia.

A schedule of up to 6 accelerations will be prompted, leaving a gap of 10 seconds
between each. The engine should be at idle before the start of each test.

The OmiSmoke will automatically calculate a Pass or a Fail and print the result.

From the Main Menu, the operator can select which test is required, by scrolling down
the menu using the up and down buttons, and confirming the selection by pressing
the tick key.

20

Test Procedures

Category of Vehicle

Select Category A for the following vehicle types:

• Car or light commercial (Inc. MOT class IV, VII and single approval scheme
vehicles).

Select category B for the following vehicle types:

• Public service vehicles

• Private bus (Inc. MOT class V and VI).

• Heavy Goods Vehicle of which Reduced Pollution Certificate (RPC) testing is also

available.

RPM Probe

An RPM probe (analyser) can be used to establish engine speed and recognise a
FAS test in progress. This is normally optional but may be necessary in some testing.
OmiSpeed, part no. OM1600 is available from Omitec.

Select from the following menu:

21

Test Procedures

Smart Card

VI INTERFACE RPM OIL PROBE

OM0479

The introduction of MOT computerisation requires the use of a Smart Card to pass
data to the OmiSmoke. A Smart Card reader is connected to the socket on the side
of the handset, market ‘VI Interface’(9 pin D type).

On the ‘Insert Smart Card’ screen, press the tick key to confirm. Data will then be read
from the smart card to the OmiSmoke.

Press the cross key if a smart card is not used. If ‘No Card’ is selected move on to
‘Test Type’ section.

9 pin D type

‘Enter VRM or Test Number’ will appear on the screen.

VRM = Vehicle Registration Number

Test number = MOT test number

22

Test Procedures

Using the up and down buttons start by scrolling through to find the character required
for the first position.

This will scroll 0-10 followed by A-Z with the up button or the reverse with the down
button.

Fill the entire fieldbox ‘[ ]’ to progress. Press the tick key to enter a blank. Spaces can
be entered by also pressing the tick key.

The data will be confirmed ‘Reading vehicle data - Please wait’. The display will then
prompt the user to ‘KEEP TEST TYPE’ followed by ‘Turbo’ or ‘Non Turbo’.

Press the tick key for YES or the cross key for change.

Test Type

Select ‘Turbo’ or ‘Non Turbo’ as required for vehicle under test.

23

Test Procedures

Reduced Pollution Certificate (RPC) - (Category B only)

The RPC menu is only shown if category B has been selected previously. Select RPC
1, 2, 3, 4 or No RPC for standard MOT tests. RPC limits for 1, 2, 3 and 4 are explained
in relevant RPC test instruction manual.

Oil Temperature Measurement (Category A only)

This selection ‘Measure Oil Temp’ will only appear on Category A tests. The MOT
FAS test prefers that Oil Temperature is measured.

Press the tick key for YES.

Follow the instructions given in section ‘Engine Oil Temperature Sensor Probe’
paying particular attention to the use of the probe and the relevant warnings.

WARNING: Incorrect use may result in damage to both user and vehicle.

The minimum oil temperature required for the test to proceed is 60°C, however the
user has the option to wait for a higher temperature before proceeding. Once oil
temperature is recorded the user is prompted to remove the probe, replace the
dipstick and confirm this before the test will continue.

WARNING: Do not rev/accelerate the engine with the temperature probe
inserted into sump as increased vibration may cause it to move and cause
damage.

24

Test Procedures

Press the cross key for NO.

By selecting ‘NO’ the OmiSmoke will impose a 40 second time penalty, showing a
clear count down to this on the display.

This period can be used to purge the engine and effectively prepare for the test.

NOTE: By selecting ‘NO’ the test report will state ‘No engine temperature taken’.

The OmiSmoke will now check that the engine is at operating temperature. The user
may have to wait for temperature to reach 70°C, check itself for contamination and
finally ‘ZERO CHECK’ the optics.

Once ready the user is prompted to ‘Insert Pipe into Exhaust’.

25

Test Procedures

Insert Pipe into Exhaust

Place the probe into the exhaust following the quick guide below:

OM0478

The probe should never be placed directly behind a bend in the exhaust pipe or close
to the silencer or expansion box. It should attach using the securing clamp, which will
ensure a minimum insertion.

26

Test Procedures

FAS Test Procedure

The user will be prompted with the correct FAS test procedure.

During each FAS test fully depress the accelerator quickly but not violently in under
one second.

Press the tick key to acknowledge and proceed.

The display will show the smoke measurement and a 10 second count down.

The user should now be seated in the drivers seat with a handset or the PC screen in
viewing distance, and follow the automated instructions:

A schedule of up to 6 accelerations is automatically progressed by the OmiSmoke
with automatic calculation of pass / fail status. It may also request another repeated
acceleration if insufficient data was recorded.

Fast Test (Category A only)

After the 1st acceleration, on category A vehicles only, a reading of less than or equal
to the fast pass smoke limit (currently 1.5 K (m-1)) will automatically produce a fast
pass and as such will terminate the schedule at this point with a pass status. The test
results and print out will state ‘Fast Pass Result’.

For all other conditions the schedule will continue prompting the user to accelerate
and release until the arithmetic mean of the latest 3 readings is within the pass limit.
The schedule of tests up to a maximum of 6 will continue automatically.

27

Test Procedures

Results and Print

Once the OmiSmoke has achieved a result it will inform the user of ‘Waiting for smoke
to disperse’.

Fail result with oil temp. at >60°C and <80°C

A fail report after a category A test and an oil temperature of greater than 60°C but
less than 80°C, will not be produced and the user will be informed to raise the engine
oil temperature to 80°C and a retest will be offered.

Pass or Fail Result

The display will inform the user of the results. Scroll through with the up and down
buttons to check the conclusion (Pass or Fail).

28

Test Procedures

Print

All results must be printed, the user will be prompted to check the printer has paper
and proceed. Press the tick key and the display will show ‘Printed Results - Please
Wait...’ The print should take approximately 10-15 seconds. A second set of results
will be offered.

The OmiSmoke will return to the main menu once the user has confirmed sufficient
prints.

29

Test Procedures

Peak Test

The OmiSmoke will make a continuous smoke reading and report the Peak K value.
A reset button (X) is offered to reset the peak value during the diagnostic period. This
test is useful for engine analysis during service repair or diagnostic work and can be
of use prior to the MOT FAS test. The Peak test result will NOT produce the same K
value that would be achieved in the MOT FAS test procedure, it is for relative
performance use only.

Select ‘Peak Test’ from the main menu and follow the on-screen instructions.

On ‘RPM Probe Check’ menu, confirm you have a RPM probe (OmiSpeed)
connected by pressing the tick key. If you do not have a RPM probe, press the cross
key.

The OmiSmoke then goes through a warm-up procedure, an automatic contamination
check and a zero check before the smoke measurement screen is displayed. Insert
the sample probe as requested, start the vehicle and confirm by pressing the tick key.

The ‘K Peak Value’ is displayed on the ‘Smoke Peak’ screen. The smoke peak can
be reset by simply pressing the cross button. Once the smoke measurement is
complete, turn off the vehicle, remove the probe and the press the tick button to
confirm. The OmiSmoke performs another zero check and returns to the main menu.

30

Peak Test Quick Summary of Events

• Connect RPM - yes or no

• Tube warm up to 70°C

• Contamination - bench reset and optic zero check

• Insert pipe into exhaust

• Smoke peak reading given

• Reset peak reading or Finish

• Remove pipe from exhaust

• Smoke disperse and zero check

• Return to main menu

Test Procedures

31

Test Procedures

Continuous Test

The OmiSmoke will make a continuous smoke reading and report the K value on a
continuous basis. This test is useful for engine analysis during service repair or
diagnostic work and can be of use over the whole engine speed range. This test will
not hold the peak K value as would the Peak test.

The continuous test result will NOT produce the same K value that would be achieved
in the MOT FAS test procedure as it is used for relative performance only.

Select ‘Continuous Test’ from the main menu and follow the on-screen instructions.

On ‘RPM Probe Check’ menu, confirm you have a RPM probe (OmiSpeed)
connected by pressing the tick key. If you do not have a RPM probe, press the cross
key.

The OmiSmoke then goes through a warm-up procedure, an automatic contamination
check and a zero check before the smoke measurement screen is displayed. Insert
the sample probe as requested, start the vehicle and confirm by pressing the tick key.

The ‘K Value’ is displayed on the ‘Smoke Continuous’ screen. Once the smoke
measurement is complete, turn off the vehicle, remove the probe and the press the
tick button to confirm. The OmiSmoke performs another zero check and returns to the
main menu.

32

Continuous Test Quick Summary of Events

• Connect RPM - yes or no

• Tube warm up to 70ºC

• Contamination - bench reset and optic zero check

• Insert pipe into exhaust

• Smoke continuous reading given

• Finish

• remove pipe from exhaust

• Smoke disperse and zero check

• Return to main menu

Test Procedures

33

Test Procedures

Linearity Test (Calibration Verification Check)

The ‘Calibration Validation Check’, known as ‘Linearity Check’ on the OmiSmoke,
needs to be carried out every 7.5 days. The OmiSmoke prompts the user to carry out
a ‘Linearity Check’ when calibration is due, alternatively the user can carry out the
check on demand.

Note: If the ‘Linearity Check’ is carried out on demand by the user, OmiSmoke will
automatically calculate a new 7.5 default.

Once ‘Linearity Test’ is selected from the main menu, The OmiSmoke automatically
performs a tube warm up procedure followed by a contamination check and a smoke
bench reset before the ‘Linearity Check’ screen is displayed.

OM0396

The message ‘Please insert filter’ appears on the ‘Linearity Check’ screen. Insert the
filter into the sample probe port in the back on the smokemeter, ensuring the filter is
inserted fully and in the correct orientation (see illustration).

Once the filter is inserted correctly, confirm by pressing the tick key.

34

Test Procedures

If the linearity check fails, check the correct filter is being used and is inserted
correctly before trying again. If repeat failure occurs, check filter is clean - See
‘Cleaning and Maintenance’ section. Once the linearity check is completed
successfully, remove the filter and press the tick key to return to the main menu.

35

Test Procedures

Diagnostics

Diagnostics for the OmiSmoke are provided to help the user check over the status of
the equipment as part of routine maintenance or as part of Helpdesk diagnostics
should a problem be encountered.

Smoke Head Info

The ‘Smoke Head Details’ screen displays the following information, some of which
you may want to record in the user notes section.

36

Heading Description User Notes

Serial # Serial number of

smoke head

Customer code Customer code

Test Procedures

Part List Rev. Build parts list revision

Manufacturer
Date

Program Location Location of program

S/Ware # Software number in

S/W rev Software revision

LIN date Due linearity check

CAL date Due calibration date -

(issue number)

Manufacturer Date

smoke head

(issue number)

date - every 7.5 days

every 12 months

37

Test Procedures

Smoke Readings

The ‘Smoke Readings’ screen displays the calculated K reading, percentage of
opacity, acceleration detection, engine speed, battery voltage, tube temperature,
heater status and the fan status.

The following information is mainly for use in Helpdesk diagnostic.

Reading Description User Notes

Calculated K K value reading - 0.00

Opacity % Opacity within sample

Accel. Det. Signal from acoustic

Engine RPM Reading from RPM

unless filter inserted or
fault

chamber of
Smokemeter

sensor in smoke
chamber (typ. 0.00 with
no signal)

signal input

Battery V Battery voltage

Tube
Temperature

Heater Status Sample chamber

Fan Status Purge air fan status.

Oil Temp °C Reading from oil

(Approx. 12V)

Sample chamber tube
temperature (80°C
max)

heater status - On or
Off

One in each optic box ­On or Off

temperature input

38

Test Procedures

Smoke Raw Data

The ‘Smoke Raw Data’ screen displays the opacity reading, tube temperature and
battery voltage.

Reading Description User Notes

Opacity 3 digit number -

Tube Temp 3 digit number -

Battery 3 digit number -

typically 444 with no
filter or fault

typically 300 but can
vary with tube
temperature

typically 295 for battery
of 12 volt - will vary
depending on charge
status

39

Test Procedures

Printer Test

The ‘Printer Test’ screen displays text under the ‘Print Data’ tab to enable the operator
to check the printer for correct operation.

This is automatic on selection and will print out the following as means of checking
the operation of the printer.

• Smoke readings

• Customer address

• Model No.

This can be useful for testing after insertion of a new paper roll.

40

Test Procedures

Clock Setup Mode

The Clock Setup Mode allows the user to change the internal clock to the correct time.

Select ‘Clock Setup Mode’ from the main menu.

The Clock Setting mode displays the current time in the main window. To change the
time, press the tick key.

The hour can be set by pressing the up or down arrow to display the correct hour, then
confirming by pressing the tick key.

The minutes can be set by pressing the up or down arrow to display the correct minute
then confirming by pressing the tick key.

Note: There is NO adjustment to the date. If the date is incorrect - contact the service
help desk.

41

Test Procedures

Calibration

The calibration menu is only available for use by authorised service/calibration
engineers.

42

Cleaning and Maintenance

Cleaning and Maintenanc e

Cleaning

Cleaning the smokemeter

The smokemeter can be cleaned with a non-aggressive cleaner and a soft cloth.

DO NOT immerse in water or use sprays of any kind.

Ensure that the unit is switched off and disconnected before carrying out any cleaning
on the smokemeter.

Cleaning the handset

The handset can be cleaned with a non-aggressive cleaner and a soft cloth.

DO NOT immerse in water or use sprays of any kind.

Ensure that the handset is disconnected before carrying out any cleaning.

Cleaning the linearity check filter

The linearity check filter is a precision reference tool and must be treated with care.

DO NOT touch the glass of the filter. Grease, dirt, oil etc. can render the filter useless.

Clean the filter by wiping gently with clean, dry cotton wool or an optical lens cloth.

DO NOT press on the glass.

43

Cleaning and Maintenance

Cleaning Optics

Cleaning the optics is a necessary part of periodic routine maintenance. The amount
of time between cleaning the optics will depend a lot on how dirty the vehicles under
test are and how frequent the OmiSmoke is used. The OmiSmoke will automatically
inform the user when the optic signal is below recommended limits which will normally
indicate that the optics will need cleaning.

The optics consist of a transmitter LED and a receiver LED, these are mounted on
small PCB’s within the end covers – See Introduction section.

This cleaning procedure is the most critical for your Smoke meter and should be
carried out on a clean bench and should be carried out by a competent technician.

1. Remove screws from end face of optics covers – these are usually socket screws
of 2 different sizes.

2. Locate the LED mounted in the centre of the PCB facing the smoke chamber –
it is situated between 2 hexagonal mounts.

Note: Be very careful not to knock this assembly as optical alignment is critical
for normal operation.

3. Using a cotton bud clean the domed lens of the LED removing black soot. If the
surface is particularly contaminated, the cotton bud can be moistened in tap
water to remove soot and then dried off with a clean dry cotton bud to finish.

Note: DO NOT use solvents to clean LEDs.

4. Before replacing cover, check that the PCB and its mounts have not been
knocked or have come loose. If you suspect they have DO NOT tighten the
assembly – report to service help desk as these fixings are tightened to a torque
limit.

5. Replace cover carefully ensuring seal is in place around perimeter.

6. Tighten fixing screws. Ensure both halves of cover create a good seal to prevent

light and water ingress.

Important: It is advised that a linearity test is performed after cleaning optics to

ensure operation and calibration are correct.

44

Cleaning and Maintenance

Maintenance

Calibration

It is a requirement that the OmiSmoke is calibrated once a year, or as directed from
time to time by the Vehicle inspectorate Executive Agency in the United Kingdom.

This calibration must be carried out by UKAS approved engineers.

For further information, please contact your supplier or the manufacturer.

Replacing the printer paper

The part number for replacement paper is PE2008A, however the printer paper can
be replaced with any thermal printer paper roll which is between 57-58 mm wide and
has a maximum diameter of 49.5 mm.

To replace the printer paper:

1. Lift green release clip and open paper compartment lid.

2. Remove old paper cartridge.

3. Insert new paper roll.

4. Feed a short length of paper through and close paper compartment lid.

Replacing the battery

Rechargable batteries have a limited life, and eventually need replacing. If the
smokemeter’s battery needs replacing follow this procedure:

1. Carefully place the smokemeter on it’s back and locate the battery compartment
cover on the base of the unit.

2. Remove two screws to release battery compartment.

3. Slide out battery compartment and release battery leads.

4. Remove battery from battery compartment.

Note: Ensure the battery is disposed of in accordance with current rules and
regulations applicable and enforced in your area.

5. Fit new battery in battery compartment and fit battery leads to terminals.

Note: Ensure the battery leads are fitted to the correct battery terminals.

6. Replace battery compartment and secure with screws.

7. Charge battery (see Information section).

45

Troubleshooting

Troubleshooting

OmiSmoke Error and Warning Messages

Symptom/ Fault Message Cause Action

Blank handset
screen

Self test fail WARNING Battery

Linearity check fail Use Correct Filter

Oil probe failure Remove Oil Probe

EEPROM failure Unable to

Smoke comms.
error

N/A Battery voltage

too low or power
not received by
handset

Batter level below

Low. Connect

10.5V
power supply to
avoid shutdown.

Error 1010 Limits
not set

Error 1000
Incorrect Filter
Val ues

Error 1002 Fan

Limits are not set
up EEPROM

Filter values in
EEPROM are
invalid

Fan control fault Contact Omitec
Control Returned
Error State

Failed LIN check Contact Omitec
or Check Filter

Oil probe failure

-Bypass Oil

Te m p

- Cancel Test

during oil

temperature

measurement

Unable to acces
read/write to the

the EEPROM
EEPROM. Press

to continue.

No response
Received. Check
the cable.

No response

came back from

the smoke head

- Reset

- Retry

Smoke Head
reported illegal
data value.

Smoke head

received illegal

data value

- Reset

- Retry

Battery may
require charging.
Attach external
power supply/
charger. Check
fuse and cable.

Attach external
power supply/
charger.

Contact Omitec
Helpdesk

Contact Omitec
Helpdesk

Helpdesk

Helpdesk
Check oil probe

cabling

Contact Omitec
Helpdesk

Check the
handset cable

Contact Omitec
Helpdesk

46

Troubleshooting

Symptom/ Fault Message Cause Action

Smoke comms.
error

Fan control error Fan control

Tube heater fault Tube temperature

Contamination
check

Smoke checks WARNING.

Print results Printer Error. Print

Smoke Head
reported bad
command mode.

- Reset

- Retry

Communications
fault with the
smoke head.

- Reset

- Retry

returned error
state

out of range

Tube NOT
warming up

Failed check hose
or filter is not
inserted

Failed. Please
clean optics

Battery Low.
Connect power
supply to avoid
shutdown.

results again?

- No - Yes

Smoke head
received bad
command

Communications
problem with the
smoke head

Fans are not
functioning
properly

Tube temperature
sensor is reporting
a temperature
which is too
low/high

The tube
temperature is not
increasing when
the heater is on.
Tube heater may
be damaged.

Contamination
check has failed

After retrying, the
contaminatin
check has failed
again.

Battery voltage at
the start of an
MOT test is below

10.5V

Printer has timed
out.

Contact Omitec
Helpdesk

Check the
handset cable

Contact Omitec
Helpdesk

Contact Omitec
Helpdesk

Contact Omitec
Helpdesk

Remove hose and
filters

Clean optics. (See
Maintenance
section). If unit
continues to fail,
contact the
Omitec Helpdesk.

Attach external
power supply/
charger.

-

47

Troubleshooting

Symptom/ Fault Message Cause Action

Smart card error Smart card reader

NOT detected.
Check
connections.

Smart card error.
report failure to
helpdesk.

Software error.
Report failure to
meter
manufacturer

Check details and
that you are
logged on
correctly

Smart card NOT
detected.

- Cancel

- Retry

Smart card reader

was not detected

Data on the smart

card is faulty.

Smart card

received incorrect

message from

smoke meter

Incorrect VRM or

test number used

to interrogate

smart card

No smart card

detected

Check smart card
reader is switched
on. Check cable to
handset.

Please contact the
smart card/ reader
helpdesk.

Contact Omitec
Helpdesk.

Insert smart card
or check that card
reader is powered
and correctly
connected to
handset.

48

Parts List

Parts List

Spares

The OmiSmoke has a number of spare parts and optional extras available from the
manufacturer.

Part Description Part Number

Air Inlet Fan Filter FL5400A
Battery BA1003A
Category A Sample Probe and Hose OM1500/6
Category A Sample Probe Only PB1007A
Category B Add-On Kit (Includes Extension Hose) OM1500/9
Category B Sample Probe and Hose OM1500/9A
Category B Sample Hose (2.5 m extension) OM1500/9B
Category B Sample Probe Only PB1106A
Combo Cable (Connection to OmiGas) OM1500/10
DC Power Up Cable OM1500/14
Handset Cable (7 m standard) OM1500/4
Handset Cable (10 m special) OM1500/15
Handset Cover OM1500/13
Linearity Check Filter Kit OM1500/7
Oil Temperature Probe P308359
Operators Manual I311592
Power Adapter Kit OM1500/12
Printer Paper PE2008A
Wall Bracket OM1500/3

Option Accessories

Part Description Part Number

RPM sensor - OmiSpeed (for all engine types) OM1600
Trolley - houses OmiSmoke and OmiGas OM2500

49

Omitec Instrumentation Ltd

Hopton Industrial Estate

London Road

Devizes

Wiltshire

SN10 2EU

United Kingdom

Tel: [phone]
Fax: [phone]
email: [e-mail]

Web: www.omitec.com