AVL 415SE Operating manual

AVL 415SE SMOKE METER
FROM S/N 7000)
October 2011
AT4234E, Rev.00
Maintenance Guide

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.
Copyright 2011 AVL List GmbH, Graz - Austria

3
Warnings and Safety Instructions
AVL 415SE Smoke Meter — Maintenance Guide
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 applica-
tion which is defined in the instructions. The manual also explains the essential
requirements for the application and operation 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 and safety precautions are not
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 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 this product therefore must be examined by an expert
(e.g. for plausibility) before any action is taken that is based on the results.
All adjustment and maintenance work necessary on instruments when open 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 the test object nor
the testing equipment is operated under conditions that could lead to damage or
injury.

Warnings and Safety Instructions
4
AVL 415SE Smoke Meter — Maintenance Guide

5
Table Of Contents
AVL 415SE Smoke Meter — Maintenance Guide
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
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

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

7
What You Should Know
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 compe-
tent service engineers will carry out inspections and maintenance with technical
professionalism and cost efficiency in mind. Using original spare parts guaran-
tees high system reliability. AVL preventive maintenance assures the highest
possible availability of the system and devices.
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 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-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.

What You Should Know
8
AVL 415SE Smoke Meter — Maintenance Guide
1.3 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.
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:
Additional 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.
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 observing
these instructions could inhibit or impede you from succesfully completing the
tasks described in this documentation.

9
What You Should Know
AVL 415SE Smoke Meter — Maintenance Guide
Standard text styles:
Lists:
1.3.2 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:
[email protected]
We look forward to hearing from you!
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
1.
2. Step-by-step procedures with a given sequence
•One-step instructions


Unordered series of concepts, items or options
–
–

What You Should Know
10
AVL 415SE Smoke Meter — Maintenance Guide

11
Maintenance
AVL 415SE Smoke Meter — Maintenance Guide
2 Maintenance
2.1 Procedure
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 10 000 measurements (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 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.
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.

Maintenance
12
AVL 415SE Smoke Meter — Maintenance Guide
2.2 Service Intervals
2.2.1 AVL Service Engineer - Annual Maintenance Activities
Component / Test Lifetime /
Service interval Maintenance Replacement
Leak check Annually For checks of sample lines and
probes:
supported on SERVICE MODE
only perform with sampling probe &
line
–
Reflectometer head Annually Check and clean or replace if
necessary.
Adjustment if necessary and cali-
bration.
Every 2 years
Light gate 1 Annually Check and clean if necessary. If damaged, replacement
is done by an AVL Service
Engineer.
Camshaft Annually Check and clean or replace if
necessary. Every 2 … 3 years or after 3 000 operating hours.
Fine filters Annually Replace. Annually
White value plate Annually Clean the deposit on the standard. If necessary.
Filter 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
Annually Clean and lubricate all points. If necessary.
Sampling probe,
sampling line Annually Check and clean. 1 000 – 2 000 operating hours.
Filter mat Annually Replace. Annually
Check sampled volume Annually Check. Replacement of the glass
caliber of the volume
tester is necessary when
it is scratched, or contami-
nated with dirt.
Adjustment of the trans-
port paper mechanism Annually Function check and adjustment necessary every time spare parts
are exchanged.
–
Adjustment of the slip
clutch Annually Check the tension and adjustment if necessary. –
Ratchet clip Annually Replace. Annually
Tab. 1

13
Maintenance
AVL 415SE Smoke Meter — Maintenance Guide
2.2.2 Service Engineer - Maintenance Schedule
For the disposal of environmentally sensitive substances, see the AVL 415S
Smoke Meter Operating Manual, chapter Disposal of Environmentally Sensitive
Substances.
Clamping lever Annually Visual check. If damaged or if any part
is bent off.
Pump Annually Check and replace if necesary. Every 2 000 - 3 000 oper-
ating hours.
Nipple & hose connec-
tions Annually Replace. Annually
Cleaning of electronical
boards Annually Clean with high purity compressed air. If necessary or defective.
Filters of shop air filter
unit Annually Check and replace if necessary. once every 1 … 2 years;
much more often for oil
lubricant compressors:
at least: every
1…2months
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 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.

Maintenance
14
AVL 415SE Smoke Meter — Maintenance Guide
Component / Test Lifetime /
Service interval Maintenance Replacement Procedure
Leak check Minimum every day.
After every filter
paper change.
After every manipu-
lation of the paper
transport.
Before & after every
volume tester cali-
bration.
For checks of sample
lines and probes:
supported on
SERVICE MODE only
perform with sampling
probe & line
– Section Leak
Check on page 41
Reflectometer head Every time the filter
paper is exchanged. Check and clean if necessary with a
puffer or a soft brush
or with compressed
air.
Every 2 years Section Reflecto-
meter Head on
page 27
Light gate 1 Every time the filter
paper is exchanged. Check and clean if necessary with
compressed air.
If damaged –
Replacement is
done by an AVL
Service Engi-
neer.
Camshaft Every time the filter
paper is exchanged. Check and clean if necessary 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. SectionFine 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 Every time the filter
paper is exchanged. Check the homoge- neous blackening with
exactly delineated
round contour.
Check the backside of
the filter paper fpr
back flushed particles.
– Section Blackened
Filter Area on
page 22
Sealing ring of the
suction unit Minimum every 5 times of filter paper
exchanged.
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
sealing ring position.
Replacement of
the sealing rings if
damaged; in this
case also order
mounting ring
30 mm.
Section Suction
Unit on page 24
Tab. 2

15
Maintenance
AVL 415SE Smoke Meter — Maintenance Guide
Clamping piece
rolls, axles
press fit bush
bearing
Required after 4-5
exchanges of the
filter paper roll,
or after 10 000
measurements,
or after 300 oper-
ating hours of the
pump.
Clean and lubricate all
points with Teflon
lubricant spray or
Teflon lubricant oil.
If necessary. Section Lubri-
cating and
Cleaning Intervals
on page 17,
section Lubrica-
tion Points on
page 19
Sampling probe,
sampling line For Diesel engine: minimum once a
week,
or after 300 oper-
ating hours of the
pump.
For low meas. emis-
sion:
once a week
For high HC
concentration:
everyday
For measuring
systems with acti-
vated option "Shop
Air" the cleaning
may be omitted or
can be performed
via the shop air
purging option
Check and clean with
compressed air. 1000–2000 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
cleanifnecessarywith
compressed air.
- Section Cooling on
page 33
Check sampled
volume Recommended: every 300 operating
hours of the pump,
or after 10 000
measurements.
Necessary:
after 1 000 oper-
ating hours.
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.
Replacement of
theglasscaliberof
the volume tester
is necessary if it is
scratched or
contaminated with
dirt.
Section Sampling
Volume Check on
page 37
Component / Test Lifetime /
Service interval Maintenance Replacement Procedure
Tab. 2

Maintenance
16
AVL 415SE Smoke Meter — Maintenance Guide
2.3 Components
2.3.1 Disposal Instructions
Adjustment of the
transport paper
mechanism
Every 1 000
operating hours. Function check and adjustment is neces-
sary every time spare
parts are exchanged.
Clean disassembled
partsinultrasonicbath
or replace them.
– Section Suction
Unit on page 24
Adjustment of the
slip clutch Every 1 000 operating hours
or once a year.
Check the tension and
adjust if necessary. – Section Filter Paper Transport
and Spool Device
on page 32
Ratchet clip Every 300 operating
hours.
Every 6 months .
Visual check and
clean if necessary. When ratchet clip rolls damaged or
deformed.
Section Clamping
Lever and Ratchet
Clip on page 28
Pump Every 1 000
operating hours.
Every 2 000 - 3 000
operating hours.
Flow check.
Check and replace if
necessary.
Every
2 000 - 3 000
operating hours.
Section Pump on
page 34
Electrical boards Once a year
or if contaminated. Visual check. Clean with
compressed air.
––
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 Procedure
Tab. 2
NOTICE
Dispose of used filter paper rolls, fine filters, hose connectors and chemical
agents (e.g. bonding agents or sprays) in accordance with the statutory require-
ments applicable in your country.
Remember that hoses and hose connectors contain fluorine. Observe the statu-
tory requirements in your country when you wish to dispose of this product or
components thereof (e.g. directives on the disposal of electronic waste).
Observe the handling instructions, application notes, storage and transport
instructions, instructions for disposal, and safety instructions of the products as
well as the country-specific regulations.
All appliances have to be treated as hazardous waste. For detailed information
on disposal instructions see the AVL 415SE Product Guide.

17
Maintenance
AVL 415SE Smoke Meter — Maintenance Guide
2.3.2 Paper Feed Mechanism
2.3.2.1 Lubricating and Cleaning Intervals
1. After 3 to 4 paper rolls (material number HP0153):
– Lubricate the moving parts of the paper feed mechanism with Teflon
lubricant oil or Teflon lubricant spray, as currently given in the manual.
2. After approx. 5 to 10 paper rolls or after 300 operating hours or every
10,000 measurements (whatever occurs sooner):
– Perform a simple cleaning of the parts of the paper feed mechanism to
remove the coarsest soiling.
– Then lubricate all moving parts (with lubricant grease and/or with lubri-
cant oil or lubricant spray).
3. 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;
NOTICE
The lifetime of the paper feed mechanism components depends heavily on
correct on-site maintenance. If the following activities are not done in time, the
lifetime of the paper feed mechanism will be considerably reduced. The
mentioned intervals are typical, recommended values that might even be shorter
if the system is exposed to additional stress caused by heavy contamination with
particulate matter or by 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-lubrication of the system is
necessary.
A complete cleaning and re-lubrication of all moving parts is also required (immi-
nent danger) if you can hear "squeaky", "rubbing", "grating", "crunching" or
"grinding" noises during paper feed.
Information
In general, the currently defined Teflon lubricant oil can be used in the same way
as it has been used in the past. However, it is absolutely necessary to adhere to
the defined lubricating and cleaning intervals.
Points or system parts for which lubricant grease should preferably be used or
which only require the use of lubricant oil (or lubricant spray) are marked sepa-
rately in the following illustrations.
If the measuring system is not used continously (means approx.5 days a week;
approx. 50 weeks a year) the general use of HS0064 as lubricant agent is
recommended.
Lubricating agents:
Teflon Lubricant Oil (material number HS0064)
Teflon Lubricant Spray (material number HS0058)
Lubricant Grease OKS 260 (material number HS0071);
only for systems which are in permanent use
(7 days a week, > 300 days a year).

Maintenance
18
AVL 415SE Smoke Meter — Maintenance Guide
this also concerns the inside parts of the shafts and rollers that can be
taken apart).
– Check the parts for wear and replace any affected components.
– Perform a complete cleaning of the device to clear any kind of contam-
ination present such as paper fibers, particulate matter or any other
system contamination.
4. After (every) approx. 100 / 300 (200) paper rolls:
– Check and, if required, replace the PU roller and the ratchet clip rollers
(if required, also the 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 then decide if replacement is necessary.
NOTICE
The elastomer roller (Fig. 4 on page 22) on the ratchet clip cannot be cleaned.
This part has to be disassembled before cleaning the other mechanical parts or it
has to be replaced.
After cleaning of all parts they must be lubricated as shown in Fig. 1 to Fig. 4.

19
Maintenance
AVL 415SE Smoke Meter — Maintenance Guide
2.3.2.2 Lubrication Points
Information
Lubrication and cleaning points (Fig. 1-Fig. 4)
Blue frame:
Lubrication only with Teflon lubricant oil (material number HS0064) or Teflon
lubricant spray (material number HS0058).
Red frame:
Lubrication (preferably) with lubricant 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 clip
Upper clamp piece
Clamping block
Lifting spring
Lower clamp piece
Reflectometer head cable
Reflectometer head

Maintenance
20
AVL 415SE Smoke Meter — Maintenance Guide
Fig. 2 Lubricating points for camshaft 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