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Summary of Contents for AVL 415SE
- Page 1 October 2011 AT4234E, Rev.00 Maintenance Guide AVL 415SE SMOKE METER FROM S/N 7000)
- Page 2 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.
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Page 3: Warnings And Safety Instructions
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 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. - Page 4 Warnings and Safety Instructions AVL 415SE Smoke Meter — Maintenance Guide...
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Page 5: Table Of Contents
Table Of Contents Table Of Contents Warnings and Safety Instructions........................ 3 1 What You Should Know....................7 Safety Instructions ........................7 About the AVL 415SE Smoke Meter ..................7 About this Documentation ......................8 1.3.1 Typografic Conventions ...................... 8 1.3.2 We Want to Hear from You.................... - Page 6 Table Of Contents 4 Parts Lists ........................43 Consumables.......................... 43 Wear Parts..........................43 Spare Parts..........................44 Maintenance Tools ......................... 48 AVL 415SE Smoke Meter — Maintenance Guide...
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Page 7: What You Should Know
Recommendation for repair Required manpower: The required time for an annual maintenance by an AVL Service Engineer is 6 hours. 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). -
Page 8: About This Documentation
About this Documentation The documentation adresses service engineers who perform maintenance tasks 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. -
Page 9: 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! AVL 415SE Smoke Meter — Maintenance Guide... - Page 10 What You Should Know AVL 415SE Smoke Meter — Maintenance Guide...
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Page 11: Maintenance
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. AVL 415SE Smoke Meter — Maintenance Guide... -
Page 12: Service Intervals
Function check and adjustment – port paper mechanism necessary every time spare parts are exchanged. Adjustment of the slip Annually Check the tension and adjustment – clutch if necessary. Ratchet clip Annually Replace. Annually Tab. 1 AVL 415SE Smoke Meter — Maintenance Guide... -
Page 13: Service Engineer - Maintenance Schedule
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... - Page 14 Glue the sealing rings 30 mm. into the clamping device (suction unit) with Adhesive 3M-B20. Check the sealing ring for defects and correct sealing ring position. Tab. 2 AVL 415SE Smoke Meter — Maintenance Guide...
- Page 15 When changing the dirt. dead volume. Necessary: after 1 000 oper- After cleaning the ating hours. device from the soot contamination. After repairing the device. Re-adjustment. Tab. 2 AVL 415SE Smoke Meter — Maintenance Guide...
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Page 16: Components
All appliances have to be treated as hazardous waste. For detailed information on disposal instructions see the AVL 415SE Product Guide. AVL 415SE Smoke Meter — Maintenance Guide... -
Page 17: Paper Feed Mechanism
After (every) approx. 50 paper rolls: – Complete cleaning of all parts of the paper feed mechanism to remove all deposits and re-lubrication of all parts (all rotating and sliding parts; AVL 415SE Smoke Meter — Maintenance Guide... - Page 18 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 then decide if replacement is necessary.
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Page 19: Lubrication Points
Upper clamp piece Clamping block Lifting spring Lower clamp piece Lubricating points Reflectometer head Camshaft Reflectometer head cable Fig. 1 Lubricating points for camshaft, clamping piece and guides of paper transport roll AVL 415SE Smoke Meter — Maintenance Guide... - Page 20 Fastening screw for drive unit Positioning bracket for motor and light barrier Fastening screw for camshaft Pos 050 Pos 060 <<< Housing door >>> Fig. 2 Lubricating points for camshaft bearing and ratched clip roll AVL 415SE Smoke Meter — Maintenance Guide...
- Page 21 Fig. 3 Lubricating points on clamping lever 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. AVL 415SE Smoke Meter — Maintenance Guide...
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Page 22: Blackened Filter Area
Dark spots indicate the formation of condensate or heavy soot deposits: Check the gas path from the sampling probe to the filter paper. Purge frequently. Reduce the sampling volume and/or use the heating option. Always replace the fine filter. AVL 415SE Smoke Meter — Maintenance Guide... -
Page 23: Sampling Probe And Sampling Line
NOTICE Disconnect the probe and line from the AVL 415SE before cleaning them with compressed air. Under no circumstances the gas path from upper clamping piece of the suction unit to direction SAMPLE OUT may be pressurised with compressed air (see Fig. -
Page 24: Suction Unit
Check the clamp piece tracks for easy movement. 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) AVL 415SE Smoke Meter — Maintenance Guide... - Page 25 We recommend ordering this part 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 Fig. 10 Mounting ring 30 mm 4152X41./C00.0 (Available in the eSpares Webshop) AVL 415SE Smoke Meter — Maintenance Guide...
- Page 26 If necessary, lubricate track (ex-works: Teflon lubricant spray - material number HS0058, Teflon lubricant oil - material number HS0064, or Lubricant grease OKS 260 - material number HS0071); see chapter 13 in the Operating Manual. AVL 415SE Smoke Meter — Maintenance Guide...
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Page 27: Reflectometer Head
We recommend replacing the reflectometer head every 2 years: Meas. head N°1 687 224 606 Material number: EZ0104SP Fig. 14 Meas. head N°1 687 224 606 (Available in the eSpares Webshop) AVL 415SE Smoke Meter — Maintenance Guide... -
Page 28: Clamping Lever And Ratchet Clip
Remark: a complete exchange of the rachet clip is recommended. Never clean the elastometer part of the transport roll in an ultrasonic bath. This part can not be cleaned but only replaced. AVL 415SE Smoke Meter — Maintenance Guide... - Page 29 Ratchet clip We recommend replacing the ratchet clip during the annual preventive mainte- nance. Ratchet clip compl. G002 4152W52 Part Number: BO6671SP Fig. 18 Ratchet clip complete G002 4152W52 (Available in the eSpares Webshop) AVL 415SE Smoke Meter — Maintenance Guide...
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Page 30: Camshaft
The camshaft must be replaced if the surface of the tappet is roughened or flat- tened. Check that the resting position of the camshaft is < ±10 deg. Keep in mind that the camshaft bearing in the bearing block must not be chipped. AVL 415SE Smoke Meter — Maintenance Guide... -
Page 31: Fine Filters
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. AVL 415SE Smoke Meter — Maintenance Guide... -
Page 32: Filter Paper Transport And Spool Device
The spool roll is driven by the supply roll by means of a slip clutch and a chain drive; the driving torque of the spool roll is determined by the pre-tensioning of the compression spring on the supply roll axis: AVL 415SE Smoke Meter — Maintenance Guide... -
Page 33: Cooling
Fig. 25 View of the filter mat and the paper transport adjustment The cooling air flows in and out on the underside of the device through filter mats. Clean the mats with compressed air. Replace heavily soiled mats. AVL 415SE Smoke Meter — Maintenance Guide... -
Page 34: Pump
Webshop) 2.3.12 Pump Fig. 27 Back side of the Smoke Meter AVL 415SE Pump noise Depending on the application, due to permanent use at automatic tests, pres- sures at or in the system, pressure pulsations of the exhaust gas, exhaust gas composition and corrosivity of the exhaust gases etc. - Page 35 Fig. 28 Diaphragm pump type 7015ZV/24VDC (Available in the eSpares Webshop) Shop Air We recommend the replacement of the filters once a year. Service Unit Fig. 29 Service unit for option Shop Air AVL 415SE Smoke Meter — Maintenance Guide...
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Page 36: Pressure Reduction
Check Valve Regularly clean/replace one check valve in rotation with the other one. Replace the check valves once a year. Perform a visual check after every assembly and at least once per week. AVL 415SE Smoke Meter — Maintenance Guide... -
Page 37: Checks
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. -
Page 38: Sampling Volume Check Via Terminal
Checks Connect your external measuring equipment to the SAMPLE 1 IN input. Press START on the AVL 4210 to initiate a filter paper feed and zeroing of the pressure sensors. (The system is not under pressure and there is no flow. - Page 39 If both volumes differ around more than 3 %, save the new calculated volume correction factor (only possible when data backup deactivated, see AVL 415S Smoke Meter, Operating Manual, chapter Data Backup). Depending on your software version, continue as follows: SKOR –...
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Page 40: Check The Metering Pipe
Dry gas meter (for a flow measurement range of 8 … 16 l/min) AVL Volume Material number: GH0326SP Tester Material number: TM0415VOLA.01 (GH0326 incl. Deconnex Fluid No. 11 HC0013) Information Delivery restriction may be possible, security data sheet (MSDS) ist available. AVL 415SE Smoke Meter — Maintenance Guide... -
Page 41: Leak Check
– 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. AVL 415SE Smoke Meter — Maintenance Guide... -
Page 42: Leak Check In Service Mode (For Firmware Version 2.10 And Higher)
– If the "FUNCTION TIMEOUT" or the "LEAKAGE EXTREMLY HIGH" error is displayed on the AVL 4210 (or error 10 or 101 is output at the terminal), it could not set up the required low pressure within 5 s (i.e. -
Page 43: Parts Lists
All the consumables, wear parts and spare parts apart from the set of fittings (Material Number TM0415SFIT.01) are available in the Webshop. * These are spare parts considered as “CRITICAL PARTS”. The exchange has to be done by an AVL Service engineer. Consumables Designation... -
Page 44: Spare Parts
Clutch Disc D=45,D=18 4152X47./C00.0 YM3566SP PCK 10 Straight Connection SO 21121-6-1/8 DN1469SP PCK 5 Kink Protection (Sampling Line) EP0377SP PCK 5 Sampling Probe 415 Straight 4152W05./C00.0 BO3144SP Sampling Probe 415 Long 4152W30./C00.0 BO4260SP AVL 415SE Smoke Meter — Maintenance Guide... - Page 45 4152W50 BO6439SP Ratchet Clip complete G002 4152W52 BO6671SP Connecting Cable 5-Pin 4152V51 BV2840SP Connecting Cable 7-Pin 4152V52 BV2841SP Cable Measuring Head 4152V58 BV2900SP T-Piece TS6 DN0812SP PCK 10 T-Piece TS4 DN0813SP PCK 10 AVL 415SE Smoke Meter — Maintenance Guide...
- Page 46 409.01.18 DN0061SP PCK 10 Lock Nut YM1863 Taper Disk YM1864 Hose Nippel with Nut for 415S G01, G02 and 415SE (Stainless Steel) YM3493 Hose Nippel with Nut for 415S G02 and 415SE (Stainless Steel) YM7144 Interface Board BB1718 Controller Board...
- Page 47 Thermo Click 95 °C EV0467 Hose Set BX0891 Pump Module complete BW7568 Flexcover Fitting M20 x 1.5 EP1069 Counternut M20 x 1.5 EP0402 Cable Gland, Adapter EW0354 Counternut M32 x 1.5 Skindicht SN-PE-M EP1070 AVL 415SE Smoke Meter — Maintenance Guide...
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Page 48: Maintenance Tools
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 AVL 415SE Smoke Meter — Maintenance Guide... - 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...