Boston OPA-100 User manual

ENGLISH 1 / 35 CHAP. 1 - GENERAL INFORMATION
OPA-100
Dear Customer,
Thank you for choosing BOSTON for your workshop equipment. We are confident it will
provide you with years of trouble-free operation.
We are proud that over 2000 MoT premises nationwide have chosen our equipment and
to operate what we regard as the best back-up and service team in the country.
Customer satisfaction is very important to us, so if at any time you have suggestions
which you think may improve our service, then please let us know.
Our staff and agents are always on hand to assist, and you can speak to an engineer at
any time by calling our freephone number 0800 085 0620. Our on-line database
provides a wide range of technical literature, and is found at www.boston-ge.com where
you can also check the latest boston product sales information and software downloads.
Assuring you of our best attention at all times
Boston Garage Equipment

CHAP. 1 – GENERAL INFORMATION 2 / 35 ENGLISH
OPA-100
CHAP. 1 - GENERAL INFORMATION
Every care has been taken during the preparation of this manual, however, neither
BOSTON or any other company involved in it’s production and / or equipment
production shall be liable for any damages derived from the use of this documentation.
BOSTON reserves the right to modify or improve its products and literature at any time
without prior notice.
This manual may contain references to, or information about BOSTON products or
services that are not yet available. These references or information in no way mean
that BOSTON intends to make such products available.
This publication may neither be partly nor wholly duplicated, or distributed without prior
authorisation from BOSTON. Requests for further copies of this manual or further
information should be addressed to an authorised agent, a sales representative of
BOSTON or to its e-mail address [email protected]
All technical and sales documentation is available on our Internet website:
http://www.boston-ge.com
BOSTON is a registered trademark owned by BOSTON Garage Equipment, 500 Gale
Street, Dagenham, Essex, RM9 4NU, United Kingdom. Other names of products and
companies mentioned in this manual may be registered trademarks held by their
respective owners.
References to programs under license for use or to other BOSTON products or services
mentioned in this publication does not mean that only these programs and/or products
and/or services may be used. Functionally equivalent products, programs or services
can be used instead of those supplied by BOSTON so long as such action does not
violate the intellectual property rights or other rights of BOSTON. The user is
responsible for evaluating and checking whether other programs and/or products and/or
services can be used, with the exception of those explicitly indicated by BOSTON.
BOSTON may have patents or applications for patents in progress involving the matters
described in this publication. Supply of this publication does not imply that any license to
these has been granted.

ENGLISH 3 / 35 CHAP. 2 - INDEX
OPA-100
CHAP. 2 - INDEX
CHAP. 1 - GENERAL INFORMATION ........................................................................................................ 2
CHAP. 2 - INDEX ......................................................................................................................................... 3
CHAP. 3 - SAFETY CONDITIONS .............................................................................................................. 4
3.1 IMPORTANT INFORMATION CONCERNING PERSONAL SAFETY ...................................... 4
3.2 IMPORTANT INFORMATION ABOUT THE SAFETY OF THE INSTRUMENT ........................ 7
3.3 GENERAL NOTES..................................................................................................................... 8
3.3.1 INSTALLATION .......................................................................................................................... 8
3.3.2 IMPORTANT INFORMATION ABOUT THE BATTERY............................................................. 8
3.3.3 IMPORTANT INFORMATION ABOUT OPERATING SAFETY ............................................... 10
3.3.4 WHEN THE INSTRUMENT IS NOT USED.............................................................................. 11
3.3.5 CLEANING ............................................................................................................................... 11
3.4 SYMBOLS ................................................................................................................................ 12
3.4.1 SAFETY.................................................................................................................................... 12
3.4.2 MARKING ................................................................................................................................. 12
CHAP. 4 - GENERAL DESCRIPTION....................................................................................................... 13
4.1 CONSTRUCTIONAL SPECIFICATIONS OF OPA-100 ........................................................... 13
4.1.1 EXTERNAL ASPECT OF OPA-100 ......................................................................................... 13
4.1.2 SUPPLIED ACCESSORIES..................................................................................................... 14
CHAP. 5 - GENERAL SPECIFICATIONS ................................................................................................. 15
5.1 GENERAL SPECIFICATIONS ................................................................................................. 15
CHAP. 6 - PRELIMINARY OPERATIONS ................................................................................................16
6.1 INSTALLATION ........................................................................................................................ 16
6.2 HOW TO INSTALL THE SOFTWARE ..................................................................................... 18
6.3 INSTALLATION IN THE WINDOWS ENVIRONMENT ............................................................... 18
6.4 SETTINGS................................................................................................................................ 18
6.4.1 GARAGE DATA ENTRY .......................................................................................................... 19
6.4.2 DATE AND TIME SETTING ..................................................................................................... 20
6.4.3 SERIAL PORT SETUP............................................................................................................. 21
6.4.4 REVOLUTION COUNTER SET-UP ......................................................................................... 22
CHAP. 7 - USE OF THE INSTRUMENT.................................................................................................... 23
7.1 PROGRAM USE ON A PERSONAL COMPUTER .................................................................. 23
7.1.1 SMOKE VALUE READING IN CONTINUOUS MODE............................................................. 24
7.1.2 OFFICIAL UK MOT TEST PROCEDURE ................................................................................ 26
7.1.2.1 WEEKLY CALIBRATION CHECK .......................................................................................................... 26
7.1.2.2 VEHICLE DATA ENTRY ......................................................................................................................... 27
7.1.2.3 OIL TEMPERATURE MEASUREMENT.................................................................................................. 28
7.1.2.4 OPACITY READING ............................................................................................................................... 29
7.1.2.5 PRINT-OUT OF RESULTS...................................................................................................................... 30
7.1.2.6 EMISSION LIMITS................................................................................................................................... 30
7.1.3 CHECKING THE CALIBRATION DUE DATE .......................................................................... 31
CHAP. 8 - MAINTENANCE........................................................................................................................ 32
8.1 HOW TO CLEAN THE FILTERING SYSTEM........................................................................................ 32
8.2 ANNUAL RE-CALIBRATION OF THE OPA-100...................................................................... 33
8.3 REPAIRS.................................................................................................................................. 33
CHAP. 9 - ERRORS................................................................................................................................... 34
CHAP. 10 - ACCESSORIES...................................................................................................................... 35

CHAP. 3 - SAFETY CONDITIONS 4 / 35 ENGLISH
OPA-100
CHAP. 3 - SAFETY CONDITIONS
3.1 IMPORTANT INFORMATION CONCERNING PERSONAL SAFETY
DANGER OF ASPHYXIATION
PETROL (GASOLINE) FUELLED ENGINES
The exhaust gas of petrol (gasoline) fuelled engines contains carbon monoxide, a
colourless and odourless gas which can cause serious physical problems if inhaled.
Pay particular attention if you work in a pit as some exhaust gas components are
heavier than air and will deposit at the bottom of the pit itself. Great care should also be
taken with gas fuelled vehicles.
DIESEL ENGINES
The composition of the exhaust gas produced by a Diesel engine is not always the
same. It can change according to: the type of engine, aspiration, the conditions of use
and the composition of the fuel used. Diesel exhaust consists of (CO, CO2, NOX and
HC), gas and particulate (soot, sulphates). The tiny particles of carbon that form the
soot remain suspended in the air and can therefore be inhaled. Small amounts of toxic
components are also present.
SAFETY MEASURES
- Always ensure that the place in which you work is correctly ventilated and that any
fumes are exhausted (particularly in pits).
- Always operate an exhaust extraction system in closed rooms.
DANGER OF BEING CRUSHED
You could be crushed against a work bench unless vehicles are correctly locked in
place by mechanical means.
SAFETY MEASURES
- Make sure that the vehicle is unable to move by applying the hand brake.
- Allow the engine to cool.
- Do not use naked flames or components that produce sparks.
- Do not smoke.
- Clean up any spilt fuel.
- Operate exhaust extraction fans in closed rooms.

ENGLISH 5 / 35 CHAP. 3 - SAFETY CONDITIONS
OPA-100
RISK OF
INJURIES
There are mobile parts in stationary or running engines (belts and so forth) that can
cause serious injury hands and arms. Amongst the various engine components, pay
the greatest attention to electric fans since they can start operating unexpectedly even
when the engine is off.
SAFETY MEASURES
- Never place your hands near moving parts whilst the engine is running
- If you must work near electric fans, first allow the engine to cool and remove the
fan plug from the motor.
- Keep the connection cables of test instruments well away from the moving parts
of the engine.
RISK OF BURNS
Some of the engine components (eg. exhaust gas manifolds) can become very hot, as
can some of the sensors. Take great care to avoid touching these components.
SAFETY MEASURES
- Wear protective gloves.
- Allow the engine and any self-contained accessory heaters to cool down.
- Do not route the connection cables of test instruments over or near hot parts.
- Do not keep the engine running after the tests.
DANGER OF FIRE OR EXPLOSION
There could be a risk of fire outbreak or explosion when work is carried out on the fuel
system (fuel pump, injectors and carburettor, etc.) due to the fuels used and/or the
vapours they create.
SAFETY MEASURES
- Disconnect the ignition system.
- Allow the engine to cool.
- Do not use naked flames or components that produce sparks.
- Do not smoke.
- Clean up any spilt fuel.
- Operate exhaust extraction fans in closed rooms.

CHAP. 3 - SAFETY CONDITIONS 6 / 35 ENGLISH
OPA-100
NOISE LEVEL
The noise level can exceed 90dB when vehicles are tested, particularly at high engine
rates. If a person is subjected to these noise sources for a lengthy period of time, his or
her hearing could be damaged.
SAFETY MEASURES
- If necessary, the user is obliged to protect the work areas near to the places where
tests are carried out.
- The operator must use personal protective equipment if necessary.
DANGEROUS VOLTAGE
There are dangerous voltages in residential, industrial and vehicle electric systems.
When a person comes into contact with test instruments or engine parts to which
voltage is applied, there is a danger of electric shock. This danger exists both in
relation to the primary and secondary side of the ignition system and to the test
instrument connections.
SAFETY MEASURES
- Connect test instruments to a socket that has a protection contact and that is
correctly earthed.
- Only use the supplied cables to connect the test instrument and make sure that the
insulation is not damaged.
- Make sure that the test instrument has been earthed before you turn it on.
- Always disconnect the power (e.g. battery) before you work on the electrical system.
- Make sure that you do not touch live parts of the vehicle when carrying out
inspections and adjustments with the engine running.
DANGER OF INTOXICATION
If subjected to high temperatures, the pipes used to sample exhaust gas release a
highly toxic gas which can be harmful if inhaled.
SAFETY MEASURES
- Immediately consult a physician if you inhale this gas.
- Wear neoprene or PVC gloves to eliminate combustion residues.
- The remains of fire outbreaks can be neutralized with a solution of hydrated lime.
This creates calcium fluoride which can be easily removed with water.

ENGLISH 7 / 35 CHAP. 3 - SAFETY CONDITIONS
OPA-100
3.2 IMPORTANT INFORMATION ABOUT THE SAFETY OF THE INSTRUMENT
The work and operations described below are not permitted when the instrument is
used in certain circumstances, they can endanger persons and lead to permanent
damage to the instrument itself.
- It is forbidden to remove the decals and/or danger
signs affixed to the instrument.
- It is forbidden to cut out the safety devices with
which the instrument is equipped.
- Only use original fuses with the indicated ampere
capacity! The instrument must be immediately
disconnected if the electricity supply is faulty.
Defective fuses must not be repaired or cut out.
They must be replaced with fuses of the same type.
- The electrical components of the instrument must be
inspected/checked at regular intervals. Defects,
such as loosened connections or burnt wires, must
be immediately eliminated.

CHAP. 3 - SAFETY CONDITIONS 8 / 35 ENGLISH
OPA-100
3.3 GENERAL NOTES
3.3.1 INSTALLATION
SERVICE
- Specialized personnel must install the instrument in
strict compliance with the instructions in the
installation manual.
Protect the instrument from the rain and excessive
damp to prevent damage.
3.3.2 IMPORTANT INFORMATION ABOUT THE BATTERY
- Never attempt to dismantle the battery or to modify it in any way.
Damage could result in heat or smoke escaping, leaking liquids, fire
outbreaks and explosion of the battery itself.
- Never allow the positive and negative terminals of the battery to be
connected together. Never transport or store the battery near metal
objects (necklaces, hair clips, etc.) which could cause a short circuit.
Such action could cause the battery to explode, create heat and
fumes, while the object that connects the two terminals could catch
fire.
- Never use or leave the battery near flames, stoves or any other place
where high temperatures could develop (80 °C or higher) as these
could damage the seal of the battery itself. All this could lead to short
circuits, explosion of the holder and fire outbreaks.
- Never wet the battery holder with either fresh water, salt water or any
other liquid. Water can damage the battery causing heat and fumes to
escape, explosion and fire outbreaks.

ENGLISH 9 / 35 CHAP. 3 - SAFETY CONDITIONS
OPA-100
- Never use the battery if its outer part is very damaged or deformed.
Use of a battery in these conditions could cause heat and fumes to
escape, explosion and fire outbreaks.
- Never use the battery for any purpose other than that for which it has
been explicitly designed for. Such action could impair the performance
of the battery, shorten its working life and lead to a power fault which
could damage the battery itself.
- Only use a correct battery charger to carry out recharging. Ensure
adequate space and where the temperature is between 10 °C and 45
°C. The wrong type of charger could overload the battery.
- If battery acid comes into contact with your eyes, do not rub them.
Rinse the affected part with tap water and immediately consult a
physician. Failure to rinse out all the battery acid could seriously
damage the eyes.
- Batteries are considered a hazardous waste and must be disposed of
in the correct way.

CHAP. 3 - SAFETY CONDITIONS 10 / 35 ENGLISH
OPA-100
3.3.3 IMPORTANT INFORMATION ABOUT OPERATING SAFETY
When you work on engines, always protect your face,
hands and feet by wearing adequate clothing. Do not
touch hot components such as spark plugs, radiators,
pipes of the cooling system and exhaust pipes. Catalytic
converters become extremely hot and can cause burns or
fire outbreaks.
- Do not smoke or use naked flames when working on
engines.
- If inhaled, exhaust gas (carbon monoxide) can be lethal or
cause serious damage to health.
- The cooling fan of vehicles can sometimes operate on its
own, even when the engine is turned off. Take the utmost
care when working near this component and disconnect it
if necessary.
- Never move the instrument by pulling the cables to which
it is connected.

ENGLISH 11 / 35 CHAP. 3 - SAFETY CONDITIONS
OPA-100
3.3.4 WHEN THE INSTRUMENT IS NOT USED
- Turn off all the power switches or unplug the power cable when
the instrument is not in use for a long period of time.
3.3.5 CLEANING
- When necessary, clean the outer surfaces of the equipment
with neutral detergents and a soft, slightly damp cloth. Do not
use detergents containing spirits, ammonia or petrol.

CHAP. 3 - SAFETY CONDITIONS 12 / 35 ENGLISH
OPA-100
3.4 SYMBOLS
The safety symbols are described in this section.
3.4.1 SAFETY
ALTERNATE CURRENT
EARTH
CONSULT THE INSTRUCTION MANUAL
DANGER! RISK OF ELECTRIC SHOCK
WARNING! DO NOT REMOVE COVER
(this may only be done by a qualified electrician)
3.4.2 MARKING
CE CONFORMITY MARKING

ENGLISH 13 / 35 CHAP. 4 - GENERAL DESCRIPTION
OPA-100
CHAP. 4 - GENERAL DESCRIPTION
4.1 CONSTRUCTIONAL SPECIFICATIONS OF OPA-100
4.1.1 EXTERNAL ASPECT OF OPA-100
OVERALL VIEW
FRONT PANEL

CHAP. 4 - GENERAL DESCRIPTION 14 / 35 ENGLISH
OPA-100
1) SMOKE INLET
2) ENGINE TEMPERATURE SENSOR INPUT
3) ENGINE RPM SENSOR INPUT
4) SOCKET FOR RS-232 SERIAL LINK
5) 12 Vdc POWER SUPPLY AND COMMUNICATION
4.1.2 SUPPLIED ACCESSORIES
The OPA-100 is supplied with the following accessories:
SMOKE SAMPLING PROBE WITH TUBE REFERENCE FILTER

ENGLISH 15 / 35 CHAP. 5–GENERAL SPECIFICATION
OPA-100
CHAP. 5 - GENERAL SPECIFICATIONS
5.1 GENERAL SPECIFICATIONS
Measuring ranges:
• Opacity from 0 to 99.9 % Res. 0.1
• Opacity from 0 to 9.99 m-1 Res. 0.01
• Revolution counter from 300 to 9990 rpm Res. 10
• Oil temp. from 20 to 150°C Res. 1
• Smoke temp. from 20 to 400°C Res. 1
• Light source with green LED diode
• Photoconductive diode type light receiver
• Automatic pressure monitoring of the measuring chamber
• Measuring chamber temperature stabilization at 99°C
• Automatic monitoring of the slide cleaning system
• Automatic autozero
• Warm up time from cold - 10 minutes.
• Automatic monitoring of dirty slides
• Revolution counter pulse reception via cable or via wireless radio system
• Oil temperature input by direct connection or via wireless radio system
• RS 232 serial link
• 485 serial link in network
• 12 Volt DC power supply
• Consumption 1A DC, 5A DC with heating system active
• Operating temperature from 5 to 40°C
• Dimensions 200 x140 x 430 mm
• Weight 5 Kg

CHAP. 6 - PRELIMINARY OPERATIONS 16 / 35 ENGLISH
OPA-100
CHAP. 6 - PRELIMINARY OPERATIONS
6.1 INSTALLATION
Carefully unpack and remove the OPA-100 from its shipping packaging
If you have a TRO-030 or TRO-010 trolley, place OPA-100 in its appropriate support as
shown in the figures below.

ENGLISH 17 / 35 CHAP. 6 - PRELIMINARY OPERATIONS
OPA-100
PERSONAL COMPUTER
OPA-100 AGS-200
PSI-60

CHAP. 6 - PRELIMINARY OPERATIONS 18 / 35 ENGLISH
OPA-100
6.2 HOW TO INSTALL THE SOFTWARE
The PC software comes as a suite of programs that handle other BOSTON instruments
and is supplied in two formats: Software for use in the Microsoft Windows environment
and Software for use in the DOS environment. The programs operate in exactly the
same way. Only the software for the Windows environment is supplied as standard.
6.3 INSTALLATION IN THE Windows ENVIRONMENT
The software required to operate OPA-100 in the Windows environment is supplied on
CD-ROM.
To install the software, insert the CD-ROM into the drive and open the index.htm file
(this file will be automatically opened if the autorun function is activated). As soon as the
prompt appears, select MANAGER Pro-800 Win and installation will automatically start.
6.4 SETTINGS
Once the software has been installed, there are a few settings that need to be set.
After the BOSTON presentation screen, which can be quit by pressing any key or by
clicking with the mouse, the main menu is displayed. The main menu gives access to all
the attached equipment and all the necessary settings that need to be made.

ENGLISH 19 / 35 CHAP. 6 - PRELIMINARY OPERATIONS
OPA-100
6.4.1 GARAGE DATA ENTRY
Press F7 "SETTINGS” in the main menu and then press F1 "GARAGE DATA"
This page allows the user to enter the company name and address. The information
entered here will be printed on all test reports. Five lines of 24 characters each are
available, plus a line where the test technician's name can be written. Press "ENTER"
to move the cursor to the next field to be edited.
Press F1 to save the data.

CHAP. 6 - PRELIMINARY OPERATIONS 20 / 35 ENGLISH
OPA-100
6.4.2 DATE AND TIME SETTING
Attention ! It is not possible for the operator to change the date. This option
is only available to an authorised engineer.
The time can be adjusted in the following way. Press F7 "SETTINGS” from the main
menu.
Press F8 to select the "TIME SETUP" menu.
This page allows the operator to change the time. Adjust as necessary and press F1 to
save changes.