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DiGas 4000
AVL DiGas 4000 User Manual
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4000
Periodic Maintenance
Service Manual
1-1
1. Periodic
Maintenance
1.1 General
This Service Manua
l describes the following instruments:
−
A
VL
DiGas 4000
(= A
VL
DiT
est 5400)
−
A
VL
DiSmoke 4000
(= A
VL
DiT
es
t 5430)
−
A
VL
DiCom 4000
(= A
VL
DiT
est 5460)
Some areas ar
e described in detail in the respective Operating Man
ual and therefore n
ot
dealt with in this Service M
anual.
W
e therefore advise always using the Service Manual
together with the respective Operating Manual.
10
12
Table of Contents
Default Chapter
7
Table of Contents
7
1 Periodic Maintenance
11
General
11
Maintenance Plan
12
Minor Maintenance
14
AVL Digas 4000
14
AVL Dismoke 4000
15
AVL Dicom 4000
16
Major Maintenance
18
AVL Digas 4000
18
AVL Dismoke 4000
19
AVL Dicom 4000
20
2 Error Messages and Troubleshooting
23
5-Gas Measuring Instruments Unit
23
Gas Flow Insufficient
23
System Needs Restarting
24
Measuring Chamber Temperature too High
24
Measuring Chamber Pressure Wrong
25
Leak Test Failed
25
Replace O Sensor
26
Replacing the no Sensor
26
Opacity Measuring Chamber
27
Measuring Chamber too Hot/Too Cold
27
Changeover Valve Error
27
Linearity / Opacity Error
28
Opacity Measuring Chamber, Type a
28
Opacity Measuring Chamber, Type 4000
28
3 Software
29
General
29
Self Test
29
Installation of Operating Software (Software Update)
32
4 Evaluation Unit
33
General Description
33
Basic Design
34
Evaluation Unit
35
Pneumatics Rear Panel / 4-/5-Gas Measuring Instruments Unit (5-Gas Option)
36
Hardware Setup
37
Main Board
37
Digital System
37
Analogue Data Acquisition
37
Remote Control Receiver
37
Interfaces
38
Display Control and Softkey Connection
39
Generation of Auxiliary Voltage
39
Board Control
39
Printer Board (Option)
40
Speed / Angle Board with Diagnostics Cable Concept (Option/Installation)
40
Memory Adapter
43
Chamber Adapter (AVL Dicom 4000)
43
Extension Slot
43
Mains Switch Assembly
43
Converting 230 V to 115 V Device
43
Power Supply Unit
43
Fan
44
Dismantling the 4-/5-Gas Measuring Instruments Unit
44
Housing
44
Printer
45
Internal Printer Unit (Option/Installation)
45
External A4 Printer (Option)
46
Lcd
46
Membrane Keypad
46
Fan
46
Main Board
47
Components Location Diagram
47
Circuit Diagrams
48
Speed Angle Board
53
Components Location Diagram
53
Circuit Diagrams
54
Pneumatics Board
58
Components Location Diagram
58
Circuit Diagram
59
Printer Adapter
60
Components Location Diagram
60
Circuit Diagram
61
Memory Adapter
62
Components Location Diagram
62
Circuit Diagram
63
Connector Adapter
64
Components Location Diagram
64
Circuit Diagram
65
Chamber Adapter (Opacity Measuring Chamber Type A)
66
Components Location Diagram
66
Circuit Diagram
67
Receiver Board (Opacity Measuring Chamber Type A)
68
Components Location Diagram
68
Circuit Diagram
69
Selenium Board (Opacity Measuring Chamber Type A)
70
Components Location Diagram
70
Circuit Diagram
71
Chamber Adapter (Opacity Measuring Chamber 4000)
72
Components Location Diagram
72
Circuit Diagram
73
Transmitter Board (Opacity Measuring Chamber 4000)
74
Components Location Diagram
74
Circuit Diagram
75
Receiver Board (Opacity Measuring Chamber 4000)
76
Components Location Diagram
76
Circuit Diagram
77
Fan Board (Opacity Measuring Chamber 4000)
78
Components Location Diagram
78
Circuit Diagram
79
Wiring Diagrams
80
Internal Cabling
83
5-Gas Section
84
Pneumatics Board
84
Multi-Gas Measuring System - General Requirements
84
Service Mode
86
Changing O and no Sensor
86
Gas Calibration
86
5-Gas
86
Diesel - Opacity Measuring Chamber Type a
92
Diesel - Opacity Measuring Chamber 4000
94
5 Gas Measuring Instruments Unit
97
General
97
Gas Analyzer
98
Light Source
99
Motor Unit
99
Measuring Cell
100
Filter/Receiver
100
Pressure Sensor
100
Main Board and Lambda Piggyback
101
Causes of Error
101
Layout of Pneumatics
101
Solenoid
103
Valve Unit
103
Particulate Filter
103
Pump
104
Pressure Sensor
105
Pneumatics Board
105
Power Supply Unit for 4-/5-Gas Measuring Instruments Unit
106
Power Supply Board
106
O 2 Sensor and no Sensor
106
Replacing the O
107
Sensor
107
Replacing the no Sensor
107
Cleaning the Condensate Part of the 4/5-Gas Bench
108
Error Symptom List - Remedies
110
6 Opacity Measuring Chamber Type a
125
System Check with Filter
125
Upgrading an AVL Digas 4000 to an AVL Dicom 4000
127
General Configuration
128
Dismantling the Opacity Measuring Chamber
130
Housing Cover 1 (on Exhaust Gas Outlet Side)
130
Housing Cover 2 (on Exhaust Gas Inlet Side)
131
Half-Shells 1 and 2
133
Fans
136
Heating Blocks and Orifice Plates
137
Changeover Valve with Geared Motor
139
Temperature Sensor
141
Lamp Module (BO1135)
143
Detector (BO1134)
145
Purging Air Panels (YM2691)
147
Electrical Wiring
148
Reassembly of the Opacity Measuring Chamber
156
7 Opacity Measuring Chamber 4000
157
System Check with Filter
157
Upgrading an AVL 4000 Digas to an AVL 4000 Dicom
158
Assembling and Disassembling the Opacity Measuring Chamber
160
Design and Details of Assemblies
161
Fan Unit (BO2189)
161
Measurement Cell (BO2138)
162
Replacing the Temperature Sensor in the Heating System
162
Valve Unit (BO2139)
163
Replacing the Temperature Sensor
163
Transmitter and Detector Unit
164
Checking the Light Sources (Green Leds) and the Receiver
164
Checking the Reference Receiver
164
Assembling the Opacity Measuring Chamber
166
8 Spare Parts Lists
167
General
167
Standard List
168
AVL 4000 with Opacity Measuring Chamber Type a
172
AVL 4000 with Opacity Measuring Chamber Model a France
176
9 Tools for the Service Technician
181
4
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AVL DiGas 4000 Specifications
General
Brand
AVL
Model
DiGas 4000
Category
Test Equipment
Language
English
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