AVL 439 Opacimeter Operating Manual

AVL 439 Opacimeter
As of Opacimeter Rev. 03 / SN 1569

SW ver. 2.64 and later (AVL 439)
SW ver. Ox1.25 and later (AVL 4210)
November 2003
AT1307E, Rev. 03
Operating Manual
Copyright 2003 by AVL List GmbH, Graz - Austria
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.
Printed in Austria at AVL All rights reserved

1
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 application 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 principle 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 condi-
tions beyond the control of the manufacturer. The results obtained from
this product therefore must be examined by an expert (e.g. for plausi-
bility) 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 techni-
cian 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.
List GmbH
AVL 439 Opacimeter

Operating Manual
2
ATTENTION!
Connected equipment that uses voltages higher than or equal to
50 V AC or 75 V DC must comply with the Low Voltage Directive
73/23/EEC.
This device must not be used in any environment where there is a
danger of explosion. The Opacimeter must not be used to measure
explosive exhaust gas mixtures.
Note the device's degree of protection.
To ensure that the risk of electric shock is minimised, the device may
only be opened by qualified personnel.
Exhaust gases from internal combustion engines contain toxic
substances!
Make sure that the room is properly ventilated and that the exhaust
gas is correctly conducted away.
Make sure the probe connections with the exhaust line and the instru-
ment are gas-tight.
The probe can become very hot – be careful, danger of burning!
Always select "Function off" mode before turning off the Opacimeter!
The gas path of the opacimeter must never be subjected to blasts of
compressed air.
Important: To comply with the requirements of the 89/336/EEC Direc-

tive on electromagnetic compatibility, only shielded cables with appro-
priately shielded plug connections may be used.
Mains connections with standard plugs and the specific cases listed
as exceptions do not have to be shielded.
If a foreign body or liquid gets inside the device, disconnect it from the
mains and have an expert check it before using it again.
Make sure that the device is supplied with the correct supply voltage.
Only use the supplied network cable with protective ground.
Only connect the network cable to a socket with an earth contact.
Disconnect the equipment from the mains when you change a fuse.
The Opacimeter must not be purged during measurements on
exhaust gases with high concentrations of HC, hydrogen or CO, for
example, because that can affect the engine.
Ensure that the sampling line travels uphill from the exhaust to the
Opacimeter to prevent condensate from forming.
The Opacimeter weighs about 47 kg – always use suitable aids there-
fore when transporting or moving it.
http://www.avl.com/emissions
3
Important: Ventilation openings must never be blocked.

n Do not set up the Opacimeter in the following places:
– near heating systems or hot-air blowers
– where it is directly affected by dust, heavy mechanical vibra-
tions or impact/shock
– in rain or damp conditions
– on sloping surfaces (due to risk of tipping over)
n Do not place it where it can be affected by sprayed water (e.g.
when cleaning the test bed).
n If the fuse trips repeatedly, disconnect the mains power supply.
n Disconnect the Opacimeter from the power supply and from the
exhaust line whenever it is not in use for long periods of time and
observe the instructions in Section “Maintenance and Storage”
on page 123.
n Only ever use original AVL spare parts.
– The instrument specifications can no longer be guaranteed
if non-AVL original spare parts are used and
– this also invalidates the guarantee.
Note the legal regulations in effect in the respective country, in which
the device is operated, for the disposal of the product or its compo-
nents (e.g. regulations of the disposal of electronic scrap).
AVL 439 Opacimeter

Operating Manual
4
Table of Contents 5
Table of Contents
1 What You Should Know............................................................................................... 9

1.1 Safety Instructions......................................................... 9
1.2 Intended Application...................................................... 9
1.3 Application Area............................................................. 9
1.4 Application Restrictions.............................................. 10
1.5 Typographic Conventions........................................... 11
1.6 We Want to Hear from You.......................................... 11
2 Method of Operation .................................................................................................. 13

2.1 Measurement Principle................................................ 13
2.2 Beer-Lambert Law........................................................ 13
2.3 Operating Modes.......................................................... 15
2.3.1 Measurement ............................................................. 16
2.3.2 Zeroing ....................................................................... 16
2.3.3 Checking the Zero Point............................................. 16
2.3.4 Pause ......................................................................... 17
2.3.5 Function off ................................................................ 17
2.3.6 Linearity Check ("LIN Check").................................... 17
2.3.7 Calibration .................................................................. 18
2.3.8 Back-flushing of the Probe ......................................... 18
2.4 Function Description ................................................... 19
2.4.1 Gas Path .................................................................... 19
2.4.2 Measuring Unit ........................................................... 21
3 Opacimeter Design, Options and Accessories ....................................................... 25

3.1 Basic Unit...................................................................... 25
3.2 Options.......................................................................... 30
3.2.1 Sample Lines ............................................................. 30
3.2.2 AVL 4210 Instrument Controller................................. 32
3.2.3 PC-Software............................................................... 33
3.2.4 19" Mounting Frame for AVL 4210 Instrument Controller33
3.2.5 19" Bench Cabinet for AVL 4210 Instrument Controller34
3.2.6 ½ 19" Bench Cabinet for AVL 4210 Instrument Controller34
3.2.7 Wall Mounting Console .............................................. 35
3.2.8 Trolley ........................................................................ 36
3.2.9 I/O Cables (Analog Cable) ......................................... 36
3.2.10 Probe for Open Exhaust Pipe .................................... 36
AVL 439 Opacimeter

Operating Manual
6 Table of Contents
4 Installation .................................................................................................................. 37
4.1 Commissioning ............................................................ 37
4.2 Placing the Opacimeter on a Surface......................... 37
4.2.1 General ...................................................................... 38
4.2.2 Wall Mounting Console Option................................... 39
4.2.3 Trolley Option............................................................. 40
4.3 Exhaust Gas Routing................................................... 41
4.3.1 Connections on the Opacimeter................................. 41
4.3.2 Fitting of Zero Air Valve, Sampling Lines and Probes 42
4.3.3 Exhaust Gas Recirculation......................................... 48
4.3.4 Installation Instructions for Tube Fittings.................... 49
4.4 Compressed Air Supply .............................................. 49
4.5 Power Supply ............................................................... 51
4.6 Interfaces ...................................................................... 52
4.6.1 Serial Interfaces ......................................................... 53
4.6.2 Digital Interface ("Digital I/O") .................................... 54
4.6.3 Analog Measurement Value Output ........................... 58
4.6.4 Connecting the AVL 4210 Instrument Controller or PC60
4.6.5 Configuring the AVL 4210 Instrument Controller ....... 60
4.7 DIL Switches................................................................. 63
5 Measurements ............................................................................................................ 65
5.1 Brief Instructions ......................................................... 65
5.1.1 Overview of Opacimeter Functions ............................ 65
5.1.2 Carrying out a Measurement...................................... 66
5.1.3 Reading stability......................................................... 67
5.1.4 Safety Instructions in Special Conditions ................... 67
5.2 Setting the Function and Measurement Value Output68
5.2.1 AVL 4210 Instrument Controller................................. 68
5.2.2 Control via Serial Interface or Terminal Program of a PC71
5.2.3 Control via Hybrid Interface ("DIO") ........................... 72
5.3 Switching On and Warming Up – Getting the Opacimeter Ready for Measurement73
5.4 Zeroing .......................................................................... 75
5.5 Continuous Measurement (Standard Measurement) 78
5.6 Peak Value Measurement (ECE R24 or EEC 72/306, ELR)80
5.6.1 General ...................................................................... 80
5.6.2 Example 1: ELR Test ................................................. 83
5.6.3 Example 2: ECE R24 (EEC72/306) Test ................... 86
5.7 Checking the Zero Point.............................................. 88
5.8 Setting the Parameters ................................................ 89
5.8.1 Measurement parameters .......................................... 89
5.8.2 Device Parameters (ambient pressure, spread of analog signal, conditioning temperature and
operating hours counter) ............................................ 92
Table of Contents 7
5.9 Operation with the DIO interface ................................ 94

5.10 Measurement Value Calculation ................................. 95
5.10.1 Determination of Zero Value ...................................... 95
5.10.2 Calculation of the Raw Value ..................................... 95
5.10.3 Filter Calculation ........................................................ 96
6 Calibration and Checking........................................................................................ 103

6.1 General........................................................................ 103
6.2 Linearity Test ("LIN Check") ..................................... 104
6.3 Linearity Check ("Calibration") with "Neutral Density Filters"106
6.4 Calibrating the Sensors............................................. 110
7 RS232 Interface / AK Generic Communication Interface ..................................... 111

7.1 General........................................................................ 111
7.1.1 Protocol Framework ................................................. 111
7.1.2 Operating Mode ....................................................... 114
7.1.3 Command Set .......................................................... 114
7.2 General Queries ......................................................... 115
7.3 General Control Commands ..................................... 117
7.4 Measurement .............................................................. 117
7.5 Service ........................................................................ 121
8 Maintenance and Storage........................................................................................ 123

8.1 General........................................................................ 123
8.2 Changing the Filter Element ..................................... 124
8.3 Cleaning the Window Modules ................................. 127
8.4 Cleaning the Sampling Lines .................................... 131
8.5 1000 Hour Service ...................................................... 132
8.6 Storage for Long Periods of Non-Use...................... 133
9 Error Table ................................................................................................................ 135

9.1 Error codes ................................................................. 135
9.2 Causes of Error, Remedies ....................................... 136
AVL 439 Opacimeter

Operating Manual
8 Table of Contents
10 Service ...................................................................................................................... 143

10.1 Function Check .......................................................... 143
10.1.1 Device Parameters................................................... 143
10.1.2 Limit Values for the Device Parameters when Instrument Functioning Correctly145
10.1.3 Pump Service........................................................... 146
10.1.4 Leak Check .............................................................. 147
10.1.5 Exchanging Temperature Sensors........................... 148
10.1.6 Software Update ...................................................... 151
10.2 Electronics.................................................................. 152
10.2.1 Electric Components ................................................ 152
10.2.2 Components of the Electronics Board...................... 153
10.2.3 Function Check of the Electronics............................ 154
11 Spare Parts List........................................................................................................ 155
12 Technical Data.......................................................................................................... 163
13 Appendix................................................................................................................... 167
13.1 Mounting Instructions -
439 Wall Mounting Console ...................................... 167
Probe for Open Exhaust ............................................ 168
13.3 Valve Block (complete).............................................. 169
13.4 Measuring Chamber................................................... 170
13.5 Probe Heating............................................................. 172
13.6 Gas Path...................................................................... 174
13.7 Pneumatics ................................................................. 175
13.8 Electronics / Assembly.............................................. 177
13.9 Block Diagrams, Wiring............................................. 179
13.10 Wiring Basic Unit ....................................................... 180
13.11 Electronic Wiring Diagram ........................................ 182
13.12 Components Location Diagram................................ 183
13.13 Circuit Diagrams ........................................................ 184
13.14 Comparison Table...................................................... 190
Safety Instructions 9
1 What You Should Know
1.1 Safety Instructions

This documentation contains important warnings and safety instruc-
tions to be observed by the user. Smooth operation only is ensured, if
the necessary prerequisites and safety measures are kept.
1.2 Intended Application

This product is only intended for the area of application which is
described in the instructions. No warranty and/or liability will be
granted, if the product is applied in areas other than those described,
or if the necessary prerequisites and safety measures are not met.
1.3 Application Area

The AVL 439 Opacimeter is designed for use on engine test beds.
The opacity of the exhaust gas can be determined both in static and in
dynamic engine state. This instrument is therefore suitable for use in
research, development and manufacturing.
The AVL 439 Opacimeter meets the requirements of the following
regulations
n EC Council Directive 72/306/EEC resp. ECE R24
n EC Council Directive 77/537/EEC incl. Addendum 82/890/EEC
n EC Council Directive 1999/96/EEC
The AVL 439 Opacimeter also complies with
NFR 10-025
n ISO 11614 (which replaces ISO 3171)
n ISO 8178-9
AVL 439 Opacimeter

Operating Manual
10 Application Restrictions
1.4 Application Restrictions

Basically the AVL 439 Opacimeter must not be used to measure explo-
sive gas (especially exhaust gas) mixtures because such mixtures
could ignite in the measuring cell due to the high temperature of the
cell's self-regenerating heated window (approx. 500 … 600° C). That
would irreparably damage the measuring cell and the Opacimeter.
The AVL 439 Opacimeter must not be used to measure emissions of
gas mixtures that are flammable or even explosive when mixed with
air, as sometimes occur upstream of actively regenerated catalytic
converters (e.g. a NOx adsorber catalyst during HCs injection into the
exhaust line if the exhaust contains a high oxygen content).
The AVL 439 Opacimeter must not be used to measure exhaust gases
with very high hydrogen content (e.g. reformer exhaust gas, even with
no residual oxygen in the measurement gas) i.e. greater than 2 % H2
residual content in the measurement gas.
A continuous hydrogen concentration of 2 % or HC concentration of
30000 ppm C1 must not be exceeded if there is overpressure at the
sampling point.
The maximum CO concentration should not exceed 6 %.
Even if there is absolutely no danger of explosive mixtures entering the
Opacimeter's measuring chamber, the customary and the legal safety
precautions for test beds must be observed. In particular, note that
no-one may enter the test bed cell while the engine is running. If the
Opacimeter is set up outside the test bed cell and it is used in the crit-
ical conditions described above, a protective wall must be installed to
prevent any possible injury to personnel.
Sampling upstream of an exhaust aftertreatment system
During purge (approx. 90 l/min, 5 times for 2 s, pulsed) ambient air is
forced into the exhaust gas via the probe which can affect catalytic
converter activity particularly in an actively regenerating exhaust after-
treatment system (e.g. NOX adsorber or SCR) due to the oxygen
content of the added air.
Back-flushing will affect the control of a lambda controlled engine /
catalyst system if the opacimeter is mounted upstream of the catalyst.
Typographic Conventions 11
1.5 Typographic Conventions

This documentation uses the following icons and standard text styles:
ATTENTION:
Icon and text indicate a warning of situations or actions that could
potentially lead to personal injury, hardware damages and/or signifi-
cant data loss.
Important: Icon and text indicate very important information without

which you would not be able to successfully finish the actions
described in this documentation.
Note: Icon and text refer to further information (tip, literature, etc.)
Example: Describes an example that applies to the current topic.
1.6 We Want to Hear from You

AVL continually strives to improve its documentation and, with this
thought in mind, we would like to hear what you have to say about it.
Whether you want to suggest an improvement to a particular manual,
complain that a concept is not explained well enough or point out an
error, we want to know.
To this end, we have created the following e-mail address for all docu-
mentation-based correspondence:
docu@avl.com
We look forward to hearing from you!
AVL 439 Opacimeter

Operating Manual
12 We Want to Hear from You
Measurement Principle 13
2 Method of Operation
2.1 Measurement Principle

The AVL 439 Opacimeter measures the opacity of contaminated air, in
particular of diesel exhaust emissions.
A measuring chamber of defined measuring length and non-reflecting
surface is filled homogeneously with exhaust gas. The loss of light
intensity between a light source and a receiver is measured and from it
the opacity of the exhaust gas calculated. The calculation is based on
the Beer-Lambert law.
2.2 Beer-Lambert Law

As electromagnetic radiation – i.e. also visible light – propagates
through a medium, its intensity decreases along the length of its path.
In our measurement, the light extinction occurs in an exhaust gas
charged with soot particulate.
According to Beer-Lambert Law, the light extinction behaves as
follows:
I = I 0 ⋅ e − kL
I0 … intensity of the light at detector without absorbing medium

(exhaust gas particulates)
I … intensity of the light at detector with absorbing medium (exhaust
gas particulates) after travelling the measuring length
k [m-1] … absorption coefficient
L [m] … measuring length (= 0.430 m; see Section “Technical Data” on
page 163).
Soot particulate
I0 I
Lamp Detector
L = Leff
Fig. 1
AVL 439 Opacimeter

Operating Manual
14 Beer-Lambert Law
Opacity N [%] is defined by

I N
= 1−
I0 100
This gives us the following:

N
1− = e −kL
100
æ N ö
− lnç1 − ÷ = kL
è 100 ø
æ N ö
− lnç1 − ÷
è 100 ø
k=
L
The calculated absorption coefficient is corrected to a standard

temperature and atmospheric pressure (in accordance with
ISO 11614):
k corr =
( N
− ln 1 − 100 ) ⋅ TGas ⋅
p atm
L TNorm p gem
with
( N
− ln 1 − 100 )=k
L
kcorr [m-1] corrected absorption coefficient

k [m-1 ] absorption coefficient calculated from measured
opacity value
TGas [K] measured mean gas temperature in the measuring
chamber
TNorm [K] standard temperature Opacimeter (373 K)
patm [kPa] atmospheric pressure
pgem [kPa] pressure in the measuring chamber
Since
N
1− = e −kL
100
the corrected opacity is calculated as follows using the corrected

absorption coefficient
(
N corr = 100 ⋅ 1 − e − kcorr L )
Ncorr [%] corrected opacity value
Operating Modes 15
Because of the formulas shown above, the opacity must not be

temperature- and pressure-corrected directly. It must first be calculated
as the absorption coefficient and then converted again to opacity (in
per cent).
The procedure for temperature and pressure correction is defined by
the equations above.
The AVL 439 Opacimeter has both a pressure sensor and a tempera-
ture sensor. The displayed opacity values and absorption coefficients
are temperature and pressure-corrected.
2.3 Operating Modes

The Opacimeter has the following operating modes and states:
n measurement
n zeroing
n checking the zero point
n pause
n function off
as well as the following functions
n linearity check
n calibration
n back-flush of the probe.
When reading the mode descriptions below refer to the diagram of the
gas flow (Fig. 2 on page 20). For a detailed description of the gas flow,
see Section “Gas Path” on page 19.
Note:
At a supply voltage of 60 Hz, the pumps run at a higher speed, and the
flow is increased by approx. 10 %. This has no impact on the
measured values. The instrument automatically recognises the
frequency of the supply voltage and adapts the control system limits
accordingly.
AVL 439 Opacimeter

Operating Manual
16 Operating Modes
2.3.1 Measurement
The opacity of the exhaust gas is measured as it flows through the
Opacimeter.
The sampled gas is conditioned in the sample conditioning tube.
Heated compressed air is conducted around the probe line thus
ensuring that the temperature of the sample is constant as it enters the
Opacimeter.
The opacity is calculated from the detector element signal in accor-
dance with Beer-Lambert Law and is available as an output value.
The various types of measurement available are described
under “Measurements” on page 65.
2.3.2 Zeroing
During zeroing, ambient air conditioned to approx. 100 ± 5° C is fed
through the measuring chamber. This is achieved when a 3/2-way
"zero air" valve is switched, i.e. the zero air valve is switched so that
the ambient air is drawn in and no exhaust gas can flow into the Opaci-
meter.
The mean value (over 30 s) of the light intensity measured at the
detector is then saved as "zero intensity I0" as soon as it fulfils the
required stability criteria for sensitive measurements.
After switching on from "Function off" or "Pause" status, the zeroing is
carried out automatically after a warm-up and stabilization time. The
system displays the maximum time required before it is ready for
measurement.
Zeroing takes approx. 1 minute when it is initiated from one of the
measuring modes.
2.3.3 Checking the Zero Point

This function is used to switch the zero air valve to ambient air without
the system going into "zeroing" mode, i.e. without determining a new
zero intensity I0. So the stability of the zero point can be checked.
You can select this mode only during a measurement.
Operating Modes 17
2.3.4 Pause
This mode is designed to save energy. It should only be activated
when the Opacimeter is not going to be used for measurements for a
while.
The pause state allows the instrument to return as quickly as possible
to operational readiness. In this state, there is lower air and energy
consumption and less wear (especially on the pumps).
In this mode, the inlet valve and zero air valve are closed to exhaust
gas. The measuring chamber heating is switched on and the sample
conditioning works at a reduced level.
2.3.5 Function off

This state is triggered by the control software but the Opacimeter
continues to be fed with power.
The diaphragm-type pumps stop, all valves are closed (there is also
therefore no compressed air consumption) and the heating systems of
the window elements, sample conditioning and measuring chamber
are switched off. Only the control electronics and the fans are still
active.
The Opacimeter can therefore be switched from this state back to other
modes from the AVL 4210 Instrument Controller or the test bed host.
But remember that the Opacimeter will not be ready for a measure-
ment again until after the full warm-up phase.
Important: When "Function off" is selected, compressed air continues

to flow through the sample conditioning system for two minutes. Do
not switch the main power switch off until the solenoid valve in the
sample conditioning system has closed.
DANGER!
Always select "Function off" before disconnecting the opacimeter‘s
power supply!
In the event of a power cut, ensure that either the test engine is shut
down or that an alarm is sounded.
2.3.6 Linearity Check ("LIN Check")

The LIN check is used to make a quick check of the linearity at an
opacity value of approx. 50 %. It can only be called up in zeroing mode.
First the intensity of the two halogen lamps is measured separately and
then the intensity of the two lamps together.
The check result is correct when the deviation is ≤ ±0.5 %.
AVL 439 Opacimeter

Operating Manual
18 Operating Modes
2.3.7 Calibration
Calibration is used to determine the accuracy, reproducibility and
linearity, and also serves as proof of the implementation of a traceable
measuring instrument monitoring system with certified test and inspec-
tion equipment.
A filter holder with a calibrated absorption filter is inserted in the lamp
unit for the calibration. The displayed value must correspond within a
certain tolerance to the value of the absorption filter used.
Absorption filters with different opacity values (see Section “Linearity
Check ("Calibration") with "Neutral Density Filters"” on page 106) are
available from AVL.
A calibration can only be started in zeroing mode.
2.3.8 Back-flushing of the Probe

Here approx. 90 l/min compressed air is fed through the solenoid valve
to back-flush the sampling line and probe line to clear them of deposits.
Because the inlet valve upstream of the measuring chamber is closed,
no compressed air enters the measuring chamber. The zero air valve
is open.
The lines are back-flushed automatically when the Opacimeter is
powered up or set ready for measuring from "Function off" state and
when the device is switched from "Measurement" or "Zeroing" to
"Function Off" state.
DANGER!
The Purge function must not be activated in tests involving high
concentrations of flammable gases (e.g. HC, H2, CO).
Important: Sampling upstream of an exhaust aftertreatment system

During purge (approx. 90 l/min, 5 times for 2 s, pulsed) ambient air is
forced into the exhaust gas via the probe which can affect catalytic
converter activity particularly in an actively regenerating exhaust after-
treatment system (e.g. NOX adsorber or SCR) due to the oxygen
content of the added air.
Back-flushing will affect the control of a lambda controlled engine /
catalyst system if the opacimeter is mounted upstream of the catalyst.
Function Description 19
2.4 Function Description
2.4.1 Gas Path

(see Fig. 2 on page 20)
The exhaust gas to be measured (i.e. the sample) follows the path
described below:
n A probe (typical length 1 m) is mounted in the exhaust line to draw
off the sample (see Section “Fitting of Zero Air Valve, Sampling
Lines and Probes” on page 42).
n The sample is routed though a pneumatic 3/2-way valve, called
the zero air valve, into the conditioning line to the Opacimeter (see
Fig. 24 on page 47).
The probe line is surrounded by conditioned air in the sample con-

ditioning tube (depending on the temperature of the sample) to
ensure that the sample has a temperature of typically 100 ± 5° C
when it enters the Opacimeter.
n After entering the Opacimeter, the sample is fed through the inlet
valve to the measuring chamber where the actual opacity mea-
surement is carried out (see Section “Measuring Unit” on
page 21).
n The exhaust gas is then conducted through the filter unit and the
contained filter element to remove impurities. This is to prevent
any damage to the downstream components.
n The flow meter checks the flow rate via a metering orifice.
The filter becomes less permeable with time depending on the

amount of soot emitted from the engine. That reduces the flow
rate which triggers a warning message when it undershoots a cer-
tain limit ("Flow Rate Warning"). If the flow rate drops further
below a lower limit value, the Opacimeter automatically switches
off and outputs an error message ("Flow rate too low").
n The exhaust gas then passes through an accumulator into the
pump unit which consists of two diaphragm-type pumps.
These two pumps ensures that the gas flows through the mea-
surement system at a constant 40…49 l/min.
Note:
At a supply voltage of 60 Hz, the pumps run at a higher speed,
and the flow is increased by approx. 10 %. This has no impact on
the measured values. The instrument automatically recognises
the frequency of the supply voltage and adapts the control system
limits accordingly.
AVL 439 Opacimeter

Operating Manual
20 Function Description
n After pumping, the sampled gas flows out of the Opacimeter either
through the exhaust gas recirculation system (during a measure-
ment) or through the zero air outlet (during zeroing).
That ensures that no ambient air can enter the exhaust system
during zeroing.
Gas flow scheme
Sample conditioning tube ZAV1
Control hose Sample

flow
*)
SV3
4 bar
*) Sample heating
SV1
Exhaust
gas
SV2
Purging air *)
Inlet valve 2.5 bar
V4
Compressed
Pressure
air supply
Detector Measuring chamber Lamp regulator
unit unit
Sample feed back
Pump unit
ZAV2
Flow meter *)
*)
Filter ∆p
Accumulator Zero air outlet
Fig. 2
SV1 solenoid valve for sample heating
SV2 solenoid valve for purging air
SV3 solenoid valve for zero air
V4 inlet valve for sample flow
ZAV1 zero air valve - sampling line
ZAV2 zero air valve - zero air outlet
2.4.2 Measuring Unit

The measuring unit comprises the following components:
n measuring chamber
n light unit
n detector unit
As the sample flows into the heated measuring cell in the measuring
chamber, it first hits the deflector plate. It then divides and flows both
towards the light unit and the detector unit. At the end of the measuring
chamber it flows into the exit chambers where it is redirected to flow
out of the measuring unit. The light unit is at one end of the measuring
cell and the detector unit at the other. Both units are kept separate from
the exhaust gas by heated window elements. The distance between
the light unit and detector unit window elements is 0.430 m (=
measuring length).
The lamp housing in the light unit contains a lamp element that
provides the light source necessary for the opacity measurement. It
contains two soldered-in halogen lamps and a temperature sensor.
The light travels through the measuring cell towards the detector unit
via a beam orifice and a heated window element.
A filter holder with a calibrated absorption filter can be inserted in the
light unit, if required, to check (calibrate) the Opacimeter.
The light first hits the heated window element of the detector unit. It
then travels through the collimating lens, the heat absorption filter and
the green filter. Finally it arrives at the detector element.
A thermostatically controlled heating system is also integrated in the
detector element to ensure that the components maintain a constant
temperature.
The heated window elements of the lamp and detector units ensure
that no soot deposits can form on the window.
Caused by production, heating power to heat a window up to 600° C is
not the same for all windows. The windows are classified after produc-
tion and a pair of windows consuming similar power is installed in the
opacimeter.
Important: Only pairs of windows consuming similar power must be

installed into the opacimeter - replacing windows must be done in
pairs. After replacing windows, the heating power must be set by a
service technician.
AVL 439 Opacimeter

Operating Manual
Measuring unit (BO2694)
Calibration filter insert

Sample in Frame
Orifice
Heated window element Heated window element
Exit chamber Exit chamber Halogen

Detector- lamps
element Sample out Sample out
Sample out Measuring cell
Orifice
Fig. 3
Light unit
Window unit
Insertable calibration filter cartridge
Lamp housing
Halogen lamps
Heated
window element
Lamp element
(BB0828)
Connector for
Connector for lamp element
window element
Fig. 4
Detector unit
Heat absorption filter

Collimating lens Window unit
Detector-
housing
Heated
window element
Detector
element
with green filter
and controlled
heating system
(BB0797)
Connector for Connector for

detector element window element
Fig. 5
Important: Lamp unit and detector unit always have to be replaced

together (replacement kit for lamp and detector unit BH0215)!
AVL 439 Opacimeter

Operating Manual
Basic Unit 25
3 Opacimeter Design, Options and

Accessories
3.1 Basic Unit

Main view
1 6
2 8
3 9
4 10
11
5
1 Cabinet hood
2 Main cabinet
3 Exhaust gas recirculation
4 Control connection for zero air valve
5 Sample filter unit
6 Calibration cover
7 Electric box (rear side)
8 Status LED
9 Sample conditioning tube connector
10 Zero air outlet
11 Compressed air maintenance unit
Fig. 6
AVL 439 Opacimeter

Operating Manual
26 Basic Unit
AVL Opacimeter 439 G004 - 230 V (TM0439G04A.01)
Designation Number
1 AVL Opacimeter 439 G004 GH0564
1 230 V mains cable (2.5 m) BV2166
1 compressed air preparation unit (see page 29) BH0171
1 compressed air tube (5 m, Ø 9 mm) SS0353
2 tube clips DN1366
1 RS232 interface cable (15 m) BV1854
2 cable connectors EU1623
3 spare filter MF0609
1 Operating Manual AT1307E
Tab. 1
Important: Please specify your country-specific power supply when

ordering.
Basic Unit 27
100 … 115 V power supplies

This version has an additional transformer which is connected to the
power supply on the primary side. The output cable on the secondary
side is connected to the AVL 439 and supplies the instrument with
230 V. The transformer housing is mounted on the instrument’s base
plate (see Fig. 7 and Fig. 8 on page 28).
AVL Opacimeter 439 G004 - 100 V Japan (TM0439G04B.01)
Designation Number
1 Autotransformer 230 V / 4 A, 1 phase EI0275
1 100 / 115 V mains cable (2.5 m) BV2261
2 tube clips DN1366
Tab. 2
AVL Opacimeter 439 G004 - 115 V USA (TM0439G04C.01)
Designation Number
1 Autotransformer 230 V / 4 A, 1 phase EI0275
1 100 / 115 V mains cable (2.5 m) BV2261
2 tube clips DN1366
Tab. 3
AVL 439 Opacimeter

Operating Manual
28 Basic Unit
1 Mains cable 100/115 V AC

BV2261
Fig. 7
1
1 Transformer 100/115 V
EI0275
Fig. 8
Basic Unit 29
Compressed air preparation unit:
Fig. 9
Designation Number
Compressed air preparation unit BH0171
including:
tube coupler for 9 mm diameter tube
Tab. 4
Compressed air preparation unit - spare parts
Flow direction
Quick connector 243.01 Sealing ring Quick connector 243.45

DN1326 DN0645 DN0768
Plug-in nipple 243.50 G1/4 (outside)

DN1327
Filter pressure reducer 10 bar

MY0161
Fig. 10
AVL 439 Opacimeter

Operating Manual
30 Options
3.2 Options
3.2.1 Sample Lines

Four different sample lines (different lengths / different materials ) are
available. One of these options is necessary to operate the opacimeter.
A constant flow of exhaust gas is drawn from the exhaust pipe through
the sample line (welded sample probe) and conditioned sampling hose
by means of a diaphragm-type pump pack. The recirculation of the
sampled gas via a return line to the exhaust pipe of the test engine
ensures constant sample flow also at varying pressure conditions. Due
to this feature the AVL 439 can be used for many different applications
on the exhaust gas duct while still operating within the instruments
normal limits.
In the conditioned sampling line, the sampled gas is fed to the inlet of
the measuring chamber at a temperature of approximately 100 °C, i.e.
for higher exhaust gas temperatures, (up to 600 °C maximum), the
sample is cooled and for cold exhaust gas it is heated.
An important benefit of this temperature conditioning is the reliable
signal stability and high signal sensitivity. The AVL 439 G004 uses for
the first time a zero-air-valve which provides advantages in economy
and safety.
The air pressure consumption will be dramatically reduced and the
operating safety regarding damaging and simplification in operation the
439 will be increased.
The sample hose is not part of the AVL 439 basic unit and according to
the demands it can now be selected from four different types. Whereby
the main difference is the kind of material (silicone or Viton) and the
two different lengths (2.5 m or 4 m).
The standard configuration of the sample hose consists always of a
flexible sample line with integrated sample probe (total length 1m) as
well as the flexible conditioning tube with the length 1.5 m (total length
2.5 m) or with the length 3 m (total length 4 m) and the zero air valve
with the control hose. Those mentioned lengths 2.5 m or 4 m are also
used for the return sample lines, which are already part of the sample
hose articles.
Basically it should be always considered to keep the sample hoses as
short as possible, in order to avoid deposits on the tube inner walls and
thus to eliminate unwanted variations on the measured values.
Important: All of the Opacimeter’s specifications, especially the

response time, relate to the standard length sampling line (2.5 m).
AVL recommends using the standard tube.
The special 4 m length tube should only be used in special circum-
stances.
Options 31
Sample lines with zero air valve, complete, Silikon, 2.5 m

(TM0439NV25.01)
Designation ID number
Zero air valve BO5358
Conditioning hose, silicone, 1.5 m BO5359
Control hose for zero air valve, 1.5 m, PTFE BO5356
(Teflon)
Sampling line G004, 1 m BH0227
Return sampling line, complete, silicone, 2.5 m BH0203
Tab. 5
Sample lines with zero air valve, complete, Silikon, 4 m

(TM0439NV40.01)
Conditioning hose, silicone, 3 m BO5353
Control hose for zero air valve, 3 m, PTFE BO5357
(Teflon)
Return sampling line, complete, silicone, 4 m BH0214
Tab. 6
Sample lines with zero air valve, complete, Viton, 2.5 m

(TM0439NV25.02)
Conditioning hose, FPM (Viton), 1.5 m BO5354
Control hose for zero air valve, 1.5 m, PTFE BO5356
(Teflon)
Return sampling line, complete, FPM (Viton), BH0266
2.5 m
Tab. 7
AVL 439 Opacimeter

Operating Manual
32 Options
Sample lines with zero air valve, complete, Viton, 4 m

(TM0439NV40.02)
Conditioning hose, FPM (Viton), 3 m BO5355
Control hose for zero air valve, 3 m, PTFE BO5357
(Teflon)
Return sampling line, complete, FPM (Viton), 4 BH0267
m
Tab. 8
3.2.2 AVL 4210 Instrument Controller
Fig. 11
Designation Article number

Remote control 439 (software 439 / 415S) with TM0439FBRA.02
409 simulation
consisting of:
AVL 4210 Instrument Controller GH0495
(SW 439 / 415S)
1 combination connecting cable BV2191
(RS232 + 24 V DC, 15 m)
Tab. 9
Note: If the AVL Instrument Controller is used to control the AVL 415
Smoke Meter (predecessor of AVL 415S), you need the remote control
cable AVL 415 (15 m; ID number BV1908).
Options 33

Combination connecting cable BV2467
(RS232 + 24 V DC, 20 m)
Cable for AVL 4210 Instrument Controller soft- GY0540
ware update
Tab. 10
3.2.3 PC-Software

AVL 439 PC software TM0439PCA.01
Program for controlling the AVL 439,
for data acquisition, recording, and evaluation
(software manual included)
Tab. 11
Note: Software version 2.60 is required for AVL 439 G004.
3.2.4 19" Mounting Frame for AVL 4210 Instrument Controller
Fig. 12

19" mounting frame TM0439FERA.01
including cover panel and mounting screws
Tab. 12
AVL 439 Opacimeter

Operating Manual
34 Options
3.2.5 19" Bench Cabinet for AVL 4210 Instrument Controller
Fig. 13
For mounting the AVL 4210 Instrument Controller in a 19" bench

cabinet

19" bench cabinet TM0439FTGA.01
Tab. 13
3.2.6 ½ 19" Bench Cabinet for AVL 4210 Instrument Controller

For mounting the AVL 4210 Instrument Controller in a ½ 19" bench
cabinet

½ 19" bench cabinet TM0439FRGA.01
Tab. 14
Options 35
3.2.7 Wall Mounting Console
a a
423
425.5
463
a a
460
540 460
Fig. 14

Wall mounting console TM0439WMDA.01
for mounting instructions see Appendix
(without fittings for wall mounting)
Tab. 15
AVL 439 Opacimeter

Operating Manual
36 Options
3.2.8 Trolley
Fig. 15

Trolley for devices with serial number >500 TM0439TROA.01
(with instrument mounted, see Appendix)
630 × 950 × 520 mm, W × H × D
Tab. 16
3.2.9 I/O Cables (Analog Cable)

Cable digital I/O (DIO) 15 m BV2266
(is also used as analog cable with Opacimeters
with serial numbers >1000)
Tab. 17
3.2.10 Probe for Open Exhaust Pipe

Probe for open exhaust (test bed) TM0439OEA.01
(for assembling instructions see Appendix)
Tab. 18
Commissioning 37
4 Installation
4.1 Commissioning
Remove the instrument from the packaging and prepare it for commis-
sioning.
n Behind the quick-release locks on the cabinet hood are two
screws screwed in from below (see Placing the Opacimeter on a
Surface, Pos. 1). They are designed to prevent the quick-release
locks from being opened unintentionally. Please note that the defi-
nition of the protection class for this instrument is only met when
both of these safety screws are fitted.
Front view
1 1
Fig. 16
4.2 Placing the Opacimeter on a Surface

The Opacimeter can be set up on the following surfaces:
n on the floor
Take particular care to ensure that the probes are fitted correctly
(see Section Fitting of Zero Air Valve, Sampling Lines and Probes
Fitting of Zero Air Valve, Sampling Lines and Probes)!
n on a platform
n on the wall mounting console option (see Section “Wall Mounting
Console Option” on page 39)
n on the instrument trolley option (see Section “Trolley Option” on
page 40)
AVL 439 Opacimeter

Operating Manual
38 Placing the Opacimeter on a Surface
4.2.1 General
n Make a space of about 1 × 1 m for the AVL 439 Opacimeter to
ensure that it has sufficient ventilation.
n The surface where it is placed must be as free as possible from
vibration.
n Make sure that the sampling line travels uphill from the exhaust
line to the Opacimeter (to prevent condensate from forming).
n The Opacimeter should not be placed in the vicinity of the exhaust
line (because of the effect of heat).
n Make sure the Opacimeter is easily accessible (e.g. for calibra-
tion).
DANGER!
Ensure that cables and the compressed air supply hose are laid in
compliance with the general safety requirements, i.e. in such a way
that they cannot be damaged by excessive temperatures (including
any excessive heat from radiating heat sources) and/or mechanical or
chemical sources (such as fuel, NOx, SO2, hot steam), which would
constitute a safety hazard.
Example: the pressure tolerance of compressed air hoses decreases

as the temperature increases! A hose specified for 10 bar at 20° C
may burst at 3 bar when the temperature reaches 50° C.
Placing the Opacimeter on a Surface 39
4.2.2 Wall Mounting Console Option

See also mounting instructions in the Appendix.
n Mount the wall mounting console on the wall in a suitable position
using screw fittings that are capable of taking the weight of the
Opacimeter.
Wall mounting console
a a
423
425.5
463
a a
460
540 460
Fig. 17
n Remove the four rubber feet. Fit the four feet to the basic unit.
Place the Opacimeter on a flat surface and adjust the feet until the
instrument is standing horizontally.
n Then lift the Opacimeter onto the support plate on the wall
mounting console and screw it on tightly from below using the
countersunk screws at the feet.
n Screw the frame firmly to the wall. Place the support plate and the
Opacimeter on it and secure in position by tightening it with the
hand screw provided.
The wall mounting console allows the Opacimeter to be swivelled
through 90° if necessary for servicing. To do this, undo the hand screw
a little to pull the Opacimeter forwards and then swivel it into the
required position. Make sure that the signal and supply lines are not
damaged when moving the Opacimeter. When work on the Opacimeter
is completed, return it to its original position and secure it again.
DANGER!
The wall mounting console is not designed for the Opacimeter to be
used permanently in the swivelled position.
Make sure that the sampling line travels uphill from the exhaust line to
the opacimeter (to prevent condensate from forming).
AVL 439 Opacimeter

Operating Manual
40 Placing the Opacimeter on a Surface
4.2.3 Trolley Option

Installing the Opacimeter on the trolley:
n Position the Opacimeter on the trolley in such a way that the cen-
tres of the two rubber feet are above the corresponding holes in
the trolley's cover plate.
n Fix the Opacimeter to the trolley with the hexagon screws and
washers supplied with the trolley.
DANGER!
Push the trolley only over smooth floors when the Opacimeter is
mounted on it.
If the trolley is pushed too fast over differences in floor levels greater
than 3 cm in height, the Opacimeter can tip over.
Exhaust Gas Routing 41
4.3 Exhaust Gas Routing
4.3.1 Connections on the Opacimeter

Connections
2 3
1 Exhaust gas feed back tube
2 Control hose
3 Conditioning tube
4 Zero air outlet
Fig. 18
The AVL 439 Opacimeter has three connectors for tubes on the front
panel and another next to the maintenance unit:
n connector for conditioning tube
n connector for control hose
n connector for return sampling line
n connector for zero air outlet
These four connections are couplings that cannot be mixed up and are
easily mounted by hand.
Important: When connecting the tubes, make sure the quick connec-
tors are pushed onto the probe connectors as far as they will go,
otherwise the gas flow will be interrupted.
Secure the conditioning tube connection with the screw on the face.
AVL 439 Opacimeter

Operating Manual
42 Exhaust Gas Routing
4.3.2 Fitting of Zero Air Valve, Sampling Lines and Probes

The system of sampling lines between the Opacimeter and the exhaust
line basically consists of:
n sampling line (BH0227, Fig. 19 on page 42 top)
n zero air valve
n conditioning tube
n feed back to the exhaust line (Fig. 19 on page 42 bottom).
Probes
Fig. 19
Installing the Zero Air Valve

n Secure the zero air valve on the test bed by means of e.g. the
valve body’s three M4 threads (each offset by 90°) or the four M6
threads at the pressure cylinder.
n Makes sure that the entire gas path (including its path through the
valve) has a downhill incline toward the exhaust-system branch.
n Mount the zero air valve as far away from hot engine components
as possible.
General instructions for fitting the sampling lines and probes
n Mount the welded-on connecting piece centrally in a straight sec-
tion of the exhaust line.
n The straight section of the exhaust line in front of the probe should
be a length equal to six times the exhaust line diameter, and the
section of the exhaust line after the probe should be a length
equal to three times the exhaust line diameter.
Probe positions
Sampling Feed back

Exhaust line
6D ~200 mm 3D
Fig. 20
n There should be as few pulsations in the exhaust gas as possible

at the sampling point. The peak pressure at the sampling point
must not deviate from the ambient pressure by more than
–100 mbar or +400 mbar.
n Do not fit the probe anywhere near manifolds or pipe junctions
(e.g. exhaust silencers).
The probe feedback into the exhaust line is not absolutely necessary if
the pressure at the sampling probe does not deviate from the ambient
pressure by more than approx. 30 mbar in any operating state.
DANGER!
Engine exhaust gas is noxious!
If the probe gas is not fed back into the exhaust line, it must be prop-
erly disposed of, e.g. fed into the test bed air extraction system.
The control hose of the zero air valve may be under pressure! Ensure
that it cannot be damaged by excessive temperatures. The pressure
tolerance of compressed air hoses becomes lower as the temperature
increases! A hose with a spec for 10 bar at 20° C can burst at 2 bar
when the temperature increases to 70° C.
When installing the sampling lines and probes, remember that very
high concentrations of flammable gases can occur upstream of certain
exhaust aftertreatment systems. The restrictions described in
Chapter “Application Area” on page 9 and Section “Operating Modes”
on page 15 therefore apply.
When the AVL 439 Opacimeter is operated in Onboard mode, the
exhaust gas is fed out through the zero air outlet - under no circum-
stances should it be allowed to flow into the passenger compartment!
This connection has the same coupling as the exhaust gas recircula-
tion system so you must connect the exhaust recirculation hose to the
zero air outlet and feed the exhaust gas out of the vehicle.
AVL 439 Opacimeter

Operating Manual
Mounting instructions
The exhaust gas is sampled through the probe tube which is a flexible
stainless steel corrugated tube, 1 m long (½ m length optional -
reduced temperature tolerance), to which the probe pipe is connected
at one end and the zero air valve at the other. The probe pipe is
inserted into the exhaust line through the welded-on connecting piece
and screwed tightly in position.
Important: Make sure that the sampling aperture at the tip of the
probe is pointing into the exhaust gas flow.
The direction the sampling aperture is pointing can be recognized by
the short piece of pipe welded on to the probe pipe.
Fitting the probe
Detail "X"
Sampling Feed back
~200 mm
10 × 1 tube 10 × 1 tube
~16 mm X X
Position indicator for
exhaust gas inlet opening Weld connector Weld connector
Exhaust gas Exhaust gas
Fig. 21
Favourable probe fitting: angle 30° … 60°
M12×1.5
45° incline in exhaust

gas line axis against
the direction of flow
D
Ø16
~6 × D ~3 × D
Straight exhaust line section
Flow direction
Fig. 22
Important: Lay sampling probe and sampling line as curvature-free

as possible and in an ascending order. *)
This helps to prevent condensate and particle deposits as far as
possible and optimises measurement accuracy.
AVL 439 Opacimeter

Operating Manual
*)Contact your AVL representative if it is not possible to lay the

sampling line ascending to the Smoke Meter.
Use a 16 mm bit to drill the holes in the exhaust line for the sampling
and feed back probes.
Probe line (BH0227, includes couplings)
Probe corrugated tube 1 m (YM3361) Male coupling Weld coupling

(DN1323) (DN1324)
Exhaust gas flow
Position indicator Exhaust gas inlet
Fig. 23
The probe line and zero air valve are connected by a screwed connec-
tion with clamp ring. This pneumatic, self-resetting 3/2-way valve is
closed to the exhaust gas and not under pressure. The Opacimeter
draws in the ambient air in that state (which is known as "zeroing").
The valve is opened when a measurement is carried out. The exhaust
gas is thermally conditioned in the conditioning hose so that it has a
temperature of 100 °C when it enters the measuring chamber. The
control hose for the zero air valve is connected to the appropriate
connection on the Opacimeter by means of a rapid-release connector.
Sample conditioning tube, connected to the probe tube
2
3
4
1 Probe tube (YM3361)

2 Zero air valve
3 Zero air inlet
4 Control hose
5 Conditioning tube
Fig. 24
Important: Make sure that the sampling line travels uphill from the
sampling point to the opacimeter (to prevent condensate from
forming).
Contact your AVL representative if it is not possible to lay the
sampling line ascending to the Opacimeter.
Keep the probe line as straight as possible
(min. bend radius 300 mm).
DANGER!
The maximum permissible sampled gas temperature on entry into the
probe is 600° C.
Be careful! Probe and conditioning tube can get very hot! Danger of
burning!
You must read the safety instructions at the front of this manual!
AVL 439 Opacimeter

Operating Manual
Sample conditioning tube 1.5 m or 3.0 m (silicone or Viton)
Conditioning air inlet Safety catch Conditioning air outlet
Opacimeter connection Zero air valve connection
Fig. 25
4.3.3 Exhaust Gas Recirculation

The exhaust line end of the feed back line has a probe (i.e. return
sampling line) of a design similar to that of the sampling probe. It is
fitted to the exhaust line in the same way.
For the Opacimeter to work without problems, the sampling probe and
the feed back probe must be subject to the same exhaust gas pres-
sure. In other words, both probes are mounted in the same section of
the exhaust line and both of their apertures must be pointing into the
exhaust gas flow.
n Follow the installation and safety instructions in Section “Fitting of
Zero Air Valve, Sampling Lines and Probes” on page 42.
Exhaust gas recirculation 2.5 m or 4 m (silicone or Viton)
Male coupling Weld coupling

Probe corrugated tube (DN1323) (DN1324)
(YM3452)
Exhaust gas flow

Opacimeter connection
Position indicator Exhaust gas out
Fig. 26
DANGER!
Engine exhaust gas is noxious!
When the AVL 439 Opacimeter is operated in Onboard mode, the
exhaust gas is fed out through the zero air outlet - under no circum-
stances should it be allowed to flow into the passenger compartment!
This connection has the same coupling as the exhaust gas recircula-
tion system so you must connect the exhaust recirculation hose to the
zero air outlet and feed the exhaust gas out of the vehicle.
Compressed Air Supply 49
4.3.4 Installation Instructions for Tube Fittings

The Parker tube fitting of the sampling and return lines should be fitted
as follows:
n Insert the tubing into the tube fitting and push until it is in the right
position (centre of the exhaust line, see Fig. 21 on page 44).
n Make sure in the straight coupling that connects the probe line,
the zero air valve and the conditioning line that the tubing rests
firmly on the shoulder of the fitting and that the nut is finger-tight-
ened.
n Before tightening the nut completely, hold the fitting body steady
and make a mark on the nut in this position. Then tighten the nut
another 1 ¼ turns, i.e. watch the mark, make one complete revo-
lution and continue another quarter revolution.
n The connection can be undone and done up again quite easily
when you need to refit tube couplings. The connection is reliable,
safe and leak-proof each time.
n Push the tube as far as it will go into the fitting body. Tighten the
body with an open-end spanner and tighten the nut to its original
position with your hand. Then tighten it a half turn to ensure a
leak-proof seal.
4.4 Compressed Air Supply

The AVL 439 Opacimeter needs filtered, oil- and water-free
compressed air at 4 … 10 bar to operate. The maximum compressed
air requirement is 90 l/min. If the requisite supply pressure is not main-
tained, the Opacimeter automatically switches off and outputs an error
message.
Inside the Opacimeter is another pressure reducer and a switch for
monitoring the compressed air supply. These elements are set to the
Opacimeter's operating pressure (2.5 bar) at the factory and may only
be adjusted by AVL service technicians.
n Connect the compressed air supply to the AVL 439 Opacimeter
(see 1, Fig. 27 on page 50).
Important: Use the AVL 439 Opacimeter only together with the
compressed air preparation unit to ensure the quality of the
compressed air.
If the compressed air supplied contains oil and/or water, it has to be
removed from the condensate container at regular intervals. Check at
least once a day whether there is condensate in the container.
AVL 439 Opacimeter

Operating Manual
50 Compressed Air Supply
DANGER!
Ensure that cables and the compressed air supply hose are laid in
compliance with the general safety requirements, i.e. in such a way
that they cannot be damaged by excessive temperatures (including
any excessive heat from radiating heat sources) and/or mechanical or
chemical sources (such as fuel, NOx, SO2, hot steam), which would
constitute a safety hazard.
Example: the pressure tolerance of compressed air hoses decreases

as the temperature increases! A hose specified for 10 bar at 20° C
may burst at 3 bar when the temperature reaches 50° C.
Side view – mains power connection, compressed air preparation unit
1 2
1 Zero air outlet
2 Compressed air connection on compressed air preparation unit
3 Mains power connection
4 ON/OFF switch
Fig. 27
Power Supply 51
4.5 Power Supply

The opacimeter is available for different voltages (see Section “Basic
Unit” on page 25).
n Plug the mains cable into the AVL 439 Opacimeter (see 1, Fig. 27
on page 50) and connect to an outlet with protective ground. Only
use the mains cable supplied.
DANGER!
Make sure that the opacimeter is being supplied with the correct
mains voltage.
Ensure that the power supply cable is laid in compliance with the
general safety requirements, i.e. in such a way that it cannot be
damaged by excessive temperatures (including any excessive heat
from radiating heat sources) and/or mechanical or chemical sources
(such as fuel, NOx, SO0 hot steam), which would constitute a safety
hazard.
Note: At a supply voltage of 60 Hz, the pumps run at a higher speed,

and the flow is increased by approx. 10 %. This has no impact on the
measured values. The instrument automatically recognises the
frequency of the supply voltage and adapts the control system limits
accordingly.
AVL 439 Opacimeter

Operating Manual
52 Interfaces
4.6 Interfaces
The AVL 439 Opacimeter has the following interfaces for control and
data acquisition purposes:
X1 Analog I/O
X2 COM1 (RS232 serial interface)
X3 COM2 (RS232 serial interface)
X4 Digital I/O
X5 External (service function)
Side view of interfaces
6
7
1 ANALOG I/O
2 COM 1
3 COM 2
4 Digital I/O
5 External
6 Rating plate *)
7 Screw mounting for potential equalization
Fig. 28
*)
Rating plate with supply voltage, serial number, revision, device
generation, CE logo
Interfaces 53
4.6.1 Serial Interfaces

The AVL 439 Opacimeter can be controlled by the AVL 4210 Instru-
ment Controller, a PC or a test bed host. Whichever device is
connected, COM1 and COM2 are the ports used. Two devices can be
connected at the same time.
Interface parameters
Baud rate: COM1: 9600, can be switched to 4800

COM2: 9600 (can be switched to 4800,
software version 2.64 and below only)
(see Section “DIL Switches” on page 63)
Data bits: 8
Stop bits: 1
Parity: none
Pin 1 RxD
Pin 2 TxD
Pin 3 Ground
Pin 4 Ground power supply for AVL 4210
Pin 8 Instrument Controller
+24 V, 0.5 A max.
Tab. 19
RS232 socket
7 8 6
3 1
5 2 4
Fig. 29
AVL 439 Opacimeter

Operating Manual
54 Interfaces
4.6.2 Digital Interface ("Digital I/O")

Either a trigger switch can be connected here for interval triggering
during peak value measurements or a test bed host for operation as a
DIO ("hybrid") interface.
The "Trigger type for peak value measurement" measurement param-
eter defines the function that is active (see Section “Measurement
parameters” on page 89):
n "Internal" DIO interface
n "External" trigger input
Digital I/O socket
7 8 6
3 1
5 2 4
Fig. 30
A cable for DIO connections is available (Cable digital I/O BV2266, see
also Section “I/O Cables (Analog Cable)” on page 36).
DIO cable - pin/colour assignment:
Pin Colour I/O

1 white LATCH
2 brown OUT3
3 green C_OUT/+5V
4 yellow IN1
5 grey IN2
6 pink VIN+/GND
7 blue OUT1
8 red OUT2
Tab. 20
Used as Trigger Input

n The trigger switch must be connected to contacts 1 and 6. The
jumpers at J23 (controller board, see Fig. 88 on page 181) must
be set to positions 1-2 and 3-4 (see Fig. 32 on page 55).
Used as DIO ("Hybrid") Interface
n The DIO interface is used together with the analog output. It
allows a test bed system that has no serial interface to control the
Opacimeter.
Interfaces 55
Connection to host - "hybrid" integration
AVL 439
ANALOG DIGITAL
COM1 COM2
I/O I/O
Test bed host
Fig. 31
This consists of 3 digital inputs and 3 digital outputs which all have
optocouplers. They are therefore electrically separated from the other
electronics (but not from one another). The internal power supply can
be used when the potential does not need to be separated, e.g. when
using relays or optocouplers. This makes the circuitry simpler. Jumpers
J23 and J24 on the pcb are used for the switching (Fig. 32 on page 55).
Jumpers J23 and J24
Fig. 32
Level and logical states

Since the allocation of level and logical state depend on the circuit, the
following applies:
Logical "1": optocoupler enabled

Logical "0": optocoupler disabled
AVL 439 Opacimeter

Operating Manual
56 Interfaces
Inputs
LATCH (Pin 1) Control input (when trigger = internal,

otherwise external trigger input; see
Section “Measurement parameters” on page 89)
Activated by a "0" → "1" transition.
Switch back to "0" after at least 50 ms.1. Switch to
DIO control (when OUT1 = "0").
2. Switch to state defined by IN1 and IN2 (when
OUT1 = "1").
IN1 (Pin 4), Predefines state to be assumed after LATCH input
IN2 (Pin 5) is activated
IN2 IN1 State

0 0 Off
0 1 Pause
1 0 Zeroing
1 1 Measurement
Tab. 21
VIN+/GND (Pin Common ground potential for all 3 inputs.

6) In circuits without potential separation: ground
Circuit with potential separation

(Jumper J23: 2-3)
1 2 3 4
J23
"0": U < 0.5 V
6
I "1": U = 4.5…30 V
(Imax = 3 mA)
U
1, 4, 5
Fig. 33
Circuit without potential separation (controlled by potential-free

contact)
(Jumper J23: 1-2, 3-4)
1 2 3 4
J23
+5 V "0": switch open
6
"1": switch closed
permissible voltage
1, 4, 5
(Imax = 3 mA)
Fig. 34
Interfaces 57
Outputs
OUT1 (Pin 7) Operating mode

"0": DIO interface disabled
"1": DIO interface active
OUT2 (Pin 8) "Busy" (not ready)
During transition from one state to another, this
output is set to "1" until the target state is reached.
OUT3 (Pin 2) Error
"0": No error
"1": Error
(error displayed on PC or Instrument Controller)
C_OUT/+5 V Signal common for all 3 outputs.
(Pin 3) In circuits without potential separation: +5 V
Circuit with potential separation

(Jumper J24: 2-3)
2, 7, 8
IC
UCE "0": IC < 100 µA when U CE < 10 V
3
"1": UCE < 1 V when IC < 5 mA
J24
1 2 3 4
Fig. 35
Circuit without potential separation

(Jumper J24: 1-2, 3-4)
2, 7, 8 IC
"0": IC < 100 µA

U
"1": U > 3.9 V when IC < 5 mA
3
+5 V
J24
1 2 3 4
Fig. 36
AVL 439 Opacimeter

Operating Manual
58 Interfaces
4.6.3 Analog Measurement Value Output

The continuous measurement values are available at analog measure-
ment output X1 while the measurement is running at four analog
measurement value outputs (measurement channels). The output
rates correspond to 50 Hz. The measurement channels carry the
"filtered measurement value" (pin 1, OUT_A), the "unfiltered measure-
ment value" (pin 3, OUT_B), the "U/U0 calculation factor" (pin 5,
OUT_C) and the PTcorr correction factor (pin 8, OUT_D).
Both the measurement value quantity (N or k) and the scale (with a
spread from 1 to 5-times) can be parameterised for the "filtered
measurement value" (also output digitally) and "unfiltered measure-
ment value" measurement channels. This parameterisation always
applies to both channels so that the unit and scale are the same for
both (see Section “Device Parameters (ambient pressure, spread of
analog signal, conditioning temperature and operating hours counter)”
on page 92).
The "U/U0" and PTcorr channels are dimension-less calculation quanti-
ties which are used for internal measurement value calculations (see
Section “Measurement Value Calculation” on page 95).
Pin Signal
Pin 1 Measurement signal, filtered, 0 … 10 V DC output
OUT_A Scaling "times 1": N = 0 … 100 % or. k = 0…10 m-1
"times 5": N = 0 … 20 % or. k = 0 … 2 m-1
(see Section “Device Parameters (ambient pressure, spread of analog signal, condi-
tioning temperature and operating hours counter)” on page 92)
Pin 2 Ground
GND
Pin 3 Measurement signal, not filtered, 0 … 10 V DC output
OUT_B Scaling "times 1": N = 0 … 100 % or. k = 0 … 10 m-1
"times 5": N = 0 … 20 % or. k = 0 … 2 m-1
(see Section “Device Parameters (ambient pressure, spread of analog signal, condi-
tioning temperature and operating hours counter)” on page 92)
Pin 4 Ground
GND
Pin 5 U/U0 output
OUT_C Scaling 0 … 10 V DC: U/U0 = 0 … 2
Pin 8 PTkorr output
OUT_D Scaling 0 … 10 V DC: PTkorr = 0 … 2
Tab. 22
Interfaces 59
Analog I/O socket
7 8 6
3 1
5 2 4
Fig. 37
Analog cable - pin/colour assignment:
Pin Colour I/O

1 white OUT_A
2 brown GND
3 green OUT_B
4 yellow GND
5 grey OUT_C
6 pink –
7 blue –
8 red OUT_D
Tab. 23
Important: If DIL switch 4 is set to ON (negative measurement

values), zero corresponds to 0.1 V and the end points are also shifted
(see table below).
DIL switch 4 "ON":
Spread = 1 Spread = 5
Analog Out N k N k
0V -1 % -01 m-1 -0.2 % -0.02 m-1
0.1 V 0% 0 m-1 0% 0 m-1
10 V 99 % 9.9 m-1 19.8 % 1.98 m-1
Tab. 24
DIL switch 4 "OFF":
Spread = 1 Spread = 5
Analog Out N k N k
0V 0% 0 m-1 0% 0 m-1
10 V 100 % 10 m-1 20 % 2 m-1
Tab. 25
AVL 439 Opacimeter

Operating Manual
60 Interfaces
4.6.4 Connecting the AVL 4210 Instrument Controller or PC

The AVL 439 Opacimeter has two serial ports (COM1 and COM2) for
connecting the AVL 4210 Instrument Controller and test bed host or
PC.
Connect the AVL 439 Opacimeter (preferably COM2 port) to the AVL
4210 Instrument Controller (always COM2 port).
Connection of AVL 4210 Instrument Controller or PC
AVL 439
ANALOG DIGITAL
COM1 COM2
I/O I/O
Test bed host

or AVL439
PC software
X1 X2 X3 X4 X5
POWER COM 2 COM 1 EXTERN COM 0
! GRAZ
AUSTRIA
FOLLOW THE DIRECTIONS! DON´T
OPERATE THIS INSTRUMENT IN
Type S/No
EXPLOSIVE HAZARDOUS LOCATIONS!
THE OPENING OF THIS DEVICE IS Rev
PERMITTED ONLY BY AUTHORIZED
TRAINED PERSONNEL!
Fig. 38
4.6.5 Configuring the AVL 4210 Instrument Controller

Several settings must be made so that the AVL 4210 Instrument
Controller can work with the measuring device which is connected to it.
Important: The displays illustrated are comparative representations

which may differ from what you actually see on the screen depending
on your system configuration.
Interfaces 61
n Turn on the Instrument Controller.

Using the equipment for the first time
Fig. 39
If the AVL 4210 Instrument Controller has never been operated before,
there will be horizontal lines shown in the dark field, otherwise, it shows
the devices for which it has been configured.
n Press the MENU key.
You will now see the main menu with the options CONTRAST,
LANGUAGE and CONFIGURATION. If the devices have already been
configured, a column will appear on the left with menus for the selected
devices.
Main menu
Fig. 40
n Select CONTRAST with the cursor keys and press EXEC.

n Adjust the contrast with the cursor keys so that you can easily
read the display, and press the ENTER.
You can select the language in the same way.
AVL 439 Opacimeter

Operating Manual
62 Interfaces
Selection of Devices and Setting of the Baud Rates

n Enter the devices which you have connected.
n Select CONFIGURATION and press EXEC and then select
SERIAL LINES and press EXEC again.
You can use the menu you now see to enter the devices and tell to
which of the three interfaces, COM 0, COM 1 or COM 2, they are
connected to, as well as to set their Baud rates. Make sure that these
settings match up with the actual settings of each device !
Configuration
Fig. 41
n When you have made all settings correctly, press SAVE.
DIL Switches 63
4.7 DIL Switches

The AVL 439 Opacimeter's DIL switches are located on the electronics
board (for position see Section “Components of the Electronics Board”
on page 153).
DIL switch Function Setting Comment

1 Baud rate COM1 OFF 9600 baud
ON 4800 baud
2 Firmware version 2.64: OFF 9600 baud
baud rate COM2
ON 4800 baud
Firmware version ≥2.65: OFF Long zeroing (55 s)
duration of zeroing ON Short zeroing (25 s)
3 Test mode OFF Test mode off
ON Test mode on (status LED flashes permanently)
n no purging after turning on the equipment

n no temperature and stability criteria
n no flashing when errors occur
No compressed air is needed in test mode – it may
only be used for demonstration purposes.
Under no circumstances may exhaust gas be

sampled in test mode (for presentations only)!
4 Output of negative measurement values
(see Section “Analog Measurement Value Output” on page 58)
5 Onboard application OFF Test bed mode
ON Onboard diagnostics
6 Zero air valve OFF Operation with zero air valve
ON Operation without zero air valve
Tab. 26
The settings of the DIL switches 1, 2, 5 and 6 are only checked when
the equipment is turned on, changes of DIL switch settings 3 and 4
take effect immediately.
DANGER!
Under no circumstances may exhaust gas be sampled in test mode
(for presentations only)!
AVL 439 Opacimeter

Operating Manual
64 DIL Switches
Brief Instructions 65
5 Measurements
5.1 Brief Instructions
5.1.1 Overview of Opacimeter Functions

The measurement, all the settings and the calibration and service func-
tions are called up by simple commands. The measurement function
usually required is the standard or "continuous" measurement. The
diagram below shows the functions and the order they are in. Here you
can also see the functions from which one can call up the calibration
and service routines.
Block diagram of Opacimeter functions
On/Off Function Zeroing Measurement Checking

Modes: (continuous) the zero point
switch off
Pause Peak value

measurement
Functions: Leak Purging LIN check Calibration

test
Fig. 42
Important: Typical procedure for parametrising and carrying out

measurements:
n Power up the instrument first thing in the morning and call up the
zeroing function.
n It will only deliver reliable values when properly warmed up (see
Section Switching On and Warming Up – Getting the Opacimeter
Ready for Measurement).
AVL 439 Opacimeter

Operating Manual
66 Brief Instructions
The Opacimeter takes up to 30 min (though normally 20 min) to warm

up from "Function off" mode and 10 … 15 min from "Pause" mode.
When it is switched to Zeroing from "Function off" or "Pause " mode, it
displays the maximum time left until a stable state is reached (i.e.
measurement readiness).
DANGER!
Always select "Function off" mode before turning off the Opacimeter!
The inlet valve is not closed until "Function Off" status.
5.1.2 Carrying out a Measurement

As shown in , the following steps are necessary after powering up to
set the instrument to measuring mode:
n Check that the power and compressed air supplies are working
properly.
n Switch on the Opacimeter and the control unit
n Input: zeroing to get instrument ready for measuring (Section
“Zeroing” on page 75)
n Wait until the Opacimeter has reached thermal stability and
"Ready" is displayed (takes about 20 to 30 min).
n Set parameters (Section “Setting the Parameters” on page 89)
n If necessary
– LIN check (Section “Linearity Test ("LIN Check")” on
page 104)
– calibration (Section “Linearity Check ("Calibration") with
"Neutral Density Filters"” on page 106)
n Input: continuous measurement (standard measurement, Section
“Continuous Measurement (Standard Measurement)” on page 78)
The Opacimeter continuously delivers opacity or absorption mea-

surement values that can be queried and recorded.
If required: Start peak value measurement (Section “Peak Value

Measurement (ECE R24 or EEC 72/306, ELR)” on page 80)
n Always call up the zeroing function (Section “Zeroing” on
page 75) when no measurement data is to be queried.
Brief Instructions 67
5.1.3 Reading stability

The measurement variation and drift of the instrument's zero point is
0.1 % opacity, or 0.0025 m-1, according to the specifications. Thus it is
also possible to measure low opacity values. At high exhaust levels,
the measurement variation is considerably higher due to varying
engine emissions.
Additionally, in new measuring cells, another effect has to be taken into
consideration: soot deposition in the measuring cell leads to a
decrease in internal reflection. Although reflection is minimised by the
internal blackening of the measuring cell, it cannot be eliminated
completely by normal means. However, through soot deposition in the
measuring cell, reflections can be practically eliminated. Therefore, in
new measuring cells, a drift of the zero point by a few percent has to be
expected, especially if exhaust gas with high soot concentration flows
through the measuring cell. As a rule of thumb, we could say that this
drift is complete when exhaust gas with an opacity of 20 % has flowed
through the measuring cell for one hour. At low opacities, this drift can
take correspondingly longer, but is then much smaller within each
measurement sequence. Hence, for new measuring cells, zero point
correction is recommended after measuring periods of no more than
30 minutes.
5.1.4 Safety Instructions in Special Conditions

No inflammable gas or exhaust mixtures may ever be measured with
the AVL 439 Opacimeter. The high temperature of the self-regener-
ating heated windows of the measurement cell (to approx.
500 … 600 °C) could cause such gas mixtures to ignite in the
measurement cell which would destroy both the cell and the device.
For further details, see Chapter “Application Area” on page 9.
If it is not possible to ensure that absolutely no inflammable mixture
can flow into the measuring chamber, at least you should ensure that
the customary safety precautions for test beds are taken. In particular
entry to the test cell when the engine is running is prohibited. If the
Opacimeter is set up outside the test bed and operated under the crit-
ical conditions described above, a protective wall should be built to
prevent any possible injury to test bed personnel.
AVL 439 Opacimeter

Operating Manual
68 Setting the Function and Measurement Value Output
5.2 Setting the Function and Measurement Value

Output
For a measurement to be carried out, the AVL 439 Opacimeter must be
connected to a control unit via a serial or a digital hybrid interface as
described in Section “Interfaces” on page 52. The control unit can be
the AVL 4210 Instrument Controller or a higher-order computer
system, e.g. a terminal, a PC or the test bed control system.
The measurement values are output via the serial interface or the
analog measurement signal connection.
Parametrising and carrying out the measurement is simple. It can be
even simpler, especially for commissioning, if you take advantage of
the clear guidance of the AVL 4210 Instrument Controller‘s user inter-
face.
5.2.1 AVL 4210 Instrument Controller

The Instrument Controller is a universal controller for the AVL 415
Smoke Meter, the AVL 733S Fuel Meter and the AVL 439 Opacimeter.
Two of these instruments can be controlled by the Instrument
Controller depending on the firmware installed. If the Opacimeter is
controlled by the Instrument Controller it must be configured accord-
ingly (see Section “Configuring the AVL 4210 Instrument Controller” on
page 60).
The AVL 4210 Instrument Controller has to be connected to one of the
Opacimeter’s serial ports (COM1 or COM2). The Opacimeter is
controlled from the AVL 4210 Instrument Controller by the menu keys
and the ↑ ↓ keys. To activate a measurement function, first press "F1"
to call up the MENU and then select the first function, usually "Contin-
uous measurement". All other functions can then be called up with
the function keys and are described in the relevant sections below.
Software – title screen
Fig. 43
Setting the Function and Measurement Value Output 69
Operating the AVL 4210 Instrument Controller

The screens are designed to be self-explanatory. The title of the screen
is found in the upper left corner, and to the right you see the code of the
device and the software version.
Continuous measurement screen
Fig. 44
The operating mode and the state of the device are shown in the
second line. The operating mode tells from where the device is being
controlled:
INST.CON.: controlled by the AVL 4210 Instrument Controller
REMOTE: controlled by the test bed computer or PC
You can only communicate actively with the devices, i.e. adjust param-
eters, start measurements, etc., when in INST.CON. mode.
You can change to INST.CON. mode by pressing the button READY.
Important: When you press READY, all currently running procedures

will be aborted, even if they were started from the test bed computer
or from a PC!
The state of the device tells if the device is in a ready state, if a proce-
dure is currently running, if an error has occurred, etc. Which functions
can be carried out is dependent on this state.
The last line describes the function of the keys. In different pictures the
keys usually correspond to different functions. The button to the far left,
however, always brings you back to the next higher menu.
The line above the key functions is reserved for messages.
AVL 439 Opacimeter

Operating Manual
Menu Choices and Settings

Menu options can be chosen and values adjusted using the cursor
keys. The selected options are displayed in reverse video. It will be
activated by pressing the EXEC key.
Changing the settings:
n Select the corresponding field and press SET.
The value is displayed in a frame.

n You can either choose an option from a list using the cursor keys
or enter a number manually.
When entering a number, you can select a digit using the < and >
keys.
n Press ENTER to end the input.
n If the SAVE key is displayed, it must be pressed to save the set-
tings.
Important: Settings which were not saved before leaving the screen
will be lost.
Setting the Function and Measurement Value Output 71
5.2.2 Control via Serial Interface or Terminal Program of a PC

The Opacimeter is simplest to control from a VT100 terminal or the
VT100 emulation of a PC terminal program.
The necessary interface parameters are described in
Section “Interfaces” on page 52. The protocol framework (AK generic
communication interface) and the commands are described in detail in
Section “RS232 Interface / AK Generic Communication Interface” on
page 111. For the sake of clarity, Sections “Measurements” on page 65
and “Calibration and Checking” on page 103 describe the commands
only briefly, without any detailed description of the parameters.
Example: Performing configuration and leak check via terminal
n Connect the PC to the COM1 (X2) port of the AVL 439.
n Configure the PC’s terminal program:
1 start bit, 1 stop bit, 8 data bits, 9600 baud, no parity, no hand-
shake
N.B. If necessary, configure the terminal program in such a way

that the control key (Ctrl) is used for the terminal and not for Win-
dows. Under Microsoft HyperTerminal, for example, call up the
Properties option in the File menu and then Settings. Then select
"Terminal".
Fig. 45
– Input in terminal mode must be in UPPERCASE LETTERS!

N.B. In the example below, <Ctrl+B> means that you press and hold
down the control key (Ctrl) and then press B.
Terminal Answer
Initialisation:
<Ctrl+B> SREM<Ctrl+C> SREM 0
Requesting measurement parameters
(see Sections and )
<Ctrl+B> APAR<Ctrl+C> APAR 0 1 2 3 0.800 0
Settings according ECE-R24 filtering with
internal trigger (see Sections and )
<Ctrl+B> EPAR 1 2 3 0.8 0<Ctrl+C> EPAR 0
Tab. 27
AVL 439 Opacimeter

Operating Manual
5.2.3 Control via Hybrid Interface ("DIO")

The hybrid interface permits the AVL 439 Opacimeter to be controlled
by test bed systems where a RS232 connection is not possible. The
relevant parameters must be set before a measurement is started (e.g.
via a terminal) (see Section “Control via Serial Interface or Terminal
Program of a PC” on page 71 and “Measurement parameters” on
page 89). The measurement values must them always be output via
the analog output (and a suitable data acquisition system).
Only measurement modes can be set via the DIO interface (see
Section “Overview of Opacimeter Functions” on page 65). No service
functions (Section “Digital Interface ("Digital I/O")” on page 54) can be
set. No peak value measurements as described in Section “Peak Value
Measurement (ECE R24 or EEC 72/306, ELR)” on page 80 are
possible because the results are only output to the serial interface.
When the DIO interface is used, the peak value can be read off from
the measurement data that is continuously recorded in analog mode.
n When the system is controlled via the hybrid interface, "internal"
must always be selected as the trigger mode.
n The set parameters are stored when the system is powered down.
Switching On and Warming Up – Getting the Opacimeter Ready for Measurement 73
5.3 Switching On and Warming Up – Getting the

Opacimeter Ready for Measurement
When the mains ON/OFF switch is switched on the green status LED
is continuously illuminated. (If the status LED flashes this indicates a
user or system error, e.g. the compressed air is not connected). The
Opacimeter runs a self-test and purges the sampling lines with clean
air (5 purges, approx. 2 s each). However, the instrument stays in
"Function off" mode, until a command is input and all functions,
including the heating systems, are deactivated.
This is because the Opacimeter has to be cold for various service
operations, e.g. calibrating the temperature sensors. It is therefore not
desirable for the instrument to go straight into warmed-up state ready
for measurements.
The zeroing function must be called up before the Opacimeter is
ready for measurements.
This heating systems and pumps are then switched on and the
measuring chamber is purged with clean air. ("forward purge"). It takes
about 30 minutes (typ. 20 minutes) for the system to reach a steady
temperature. Only when a steady temperature is reached (i.e.
measuring chamber temperature TCha, exhaust gas temperature TG
and lamp temperature TL) can the Opacimeter deliver stable measure-
ment values with no zero drift. No measurement can be started unltil
thermal stability is reached.
Necessary conditions for zeroing
Precondition: standard setpoint values:
Detector temperature ≥ 49° C

Measuring chamber and gas temperature ≥ 99° C
Window heating power ≥ ±0.5 W of setpoint
value
Lamp temperature drift ≤ 0.5° C / minute
Detector signal drift ≤ 40 LSB (= 3 mV) in 5 s
Tab. 28
n Preparing ready status from the Instrument Controller
Switch on Opacimeter and Instrument Controller.

After title screen is displayed briefly, the Instrument Controller
usually goes straight to the "Continuous measurement" screen, as
indicated at the top left of the screen. If another measurement
screen is active (if, for example, another status is defined by the
other interface), the "Continuous measurement" screen can be
called by pressing MENU (key F1), selecting "Continuous mea-
surement" and confirming with EXEC. (key F6).
AVL 439 Opacimeter

Operating Manual
74 Switching On and Warming Up – Getting the Opacimeter Ready for Measurement
After powering up, the Instrument Controller is in monitor mode,

recognizable by the word REMOTE displayed top left. The user
has to tell the Opacimeter that it is to be controlled from the Instru-
ment Controller: READY (key F3) - INST: CON. is then displayed
top left.
This is necessary because another controller might be active at

the other interface that can only be deactivated by user input.
Fig. 46
n The system’s warm-up phase then begins and the stabilization

time still left is displayed top right. The Opacimeter must be in
"Function off" or "Pause" mode for at least five minutes for this
value to be reliable.
During stabilization time the system counts down in one minute

steps. It can happen that the display of the remaining stabilization
time does not display every minute in the right order - this is a reg-
ular behaviour during this phase.
If zeroing is not activated from "Function off" or "Pause" mode

(e.g. between two measurements), it takes about 1 minute.
The "Zero, ready" state in the AVL 439 combines three functions
or states:
– the Opacimeter is ready for measurement
– "Zero" - the brightness value (N = 0 %) is determined
– "Forward purge" – clean zero air flows through measuring
cell and sampling line.
Zeroing 75
n These three functions are called up from the Instrument Controller

when ZERO is pressed. The AVL 439 itself therefore has no com-
mand for "Stand-by" and "Forward purge".
When "Ready" is displayed, the system will accept the "measure-

ment" command: MEAS (key F4).
The OFF (F2), ZERO (F4) and SET (F6) functions are also avail-
able.
n Preparing ready status from the serial interface
AK command: STBY
Error 14 ("not ready") is displayed until a steady temperature is

reached. The Opacimeter is not ready for measurement until the
error message disappears.
5.4 Zeroing
"Zeroing" must be carried out before a measurement. The measuring
chamber is filled with clean air and the relevant sensor signal is regis-
tered internally as the zero value (or light value). N = 0 % represents
the zero value while N = 100 % is the dark value.
The AVL 439 Opacimeter has only a small zero drift but for precision
measurements at low opacity, zeroing is nevertheless necessary not
only immediately after powering up and warm-up but also periodically
during the measurement (approximately every half-hour).
Important: The Opacimeter indicates that zeroing is necessary after

30 minutes of uninterrupted measurements. You can carry out zeroing
then if you wish, but you do not have to, i.e. you can carry on running
measurements without zeroing.
If you run the Opacimeter for a long time without zeroing, however, the
zero point may start to drift.
As of firmware Version 2.65 you can set the length of time that zeroing
takes (see “DIL Switches” on page 63). The long zeroing (duration
approx. 55 s) ensures that the absolute zero point remains stable
because the data is statistically evaluated over a long period of time.
The short zeroing (duration approx. 25 s) should only be used when
longer zeroing is not possible because of a test run.
If you issue the "Zeroing" command when the Opacimeter is in the
"Function off" or "Pause" state, it warms up to a steady temperature
and forward-purges the measuring cell.
"Zeroing" mode includes forward purging of the measuring cell and
conditioning line. Generally, the whole line should only be back-purged
when the Opacimeter is switched on and off, but can also be
performed in "Zeroing" state. It can therefore only be called up from the
"Function off", "Pause", and "Zeroing" states.
AVL 439 Opacimeter

Operating Manual
76 Zeroing
The measurement parameters, i.e. the selection of the filter algorithm

and the output value (opacity N or absorption coefficient k), should be
set from the zeroing function or in other words, before going into
measurement mode (see Section “Setting the Parameters” on
page 89)
The "Linearity test" (Section “Linearity Test ("LIN Check")” on
page 104) and "Calibration" (Section “Linearity Check ("Calibration")
with "Neutral Density Filters"” on page 106) calibration functions
must be called up from "zeroing, ready" state.
Important: If no measurement values are to be recorded but the

instrument is needed in ready state, switch to zeroing (not Pause!)
Carry out zeroing every half-hour or more frequently if possible.
Zeroing can be called up from the measurement functions (standard or

peak value measurement), as well as from "Pause" and "Function off".
When zeroing is initiated from the "Pause" or "Function off" modes, the
stabilization conditions for the transition to zeroing mode must be
fulfilled first (see Section “Switching On and Warming Up – Getting the
Opacimeter Ready for Measurement” on page 73). Only then does the
actual zeroing routine start and run as it does when zeroing is called up
from a measurement function:
Zeroing 77
n Checking of measuring chamber and exhaust temperature

n Checking of temperature drift
n Long zeroing: Determination of mean value of detector voltage
over 10 s, then filter 1st Order over 30 s
n Short zeroing: Determination of mean value of detector voltage
over 10 s
n Checking of stability of (smoothed) detector voltage
n Checking that the detector signal has not drifted by more than 2 %
since the last zeroing.
This function is not called up when zeroing is initiated from

"Pause" or "Function off" mode. It ensures that the zero air valve
is tightly closed and that only ambient air and no exhaust gas can
be drawn in.
If the detector signal has drifted by more than 2 %, Error 13 (no

zeroing) is output (the other things that Error 13 indicate are only
relevant in measurement mode). When this happens, investigate
the cause of the drift (see Section “Causes of Error, Remedies” on
page 136).
The checks are made internally every 10 s and the complete zeroing
process takes at least 50 s (long zeroing) or 20 s (short zeroing). The
zero air valve switches several times to help deposits to work them-
selves free. Then a new zeroing process is started. If the process is still
unsuccessful after five attempts, the Opacimeter switches itself to
"Function OFF". If all the checks are positive, the system is "Ready"
and signal smoothing with 30 s-filter 1st Order is resumed until the
measurement function is called up again.
n Instrument Controller
From "Pause" or "Function off" state: as described in

Section AVL 4210 Instrument Controller
From measurement status: ZERO (key F4)

n Control via serial interface
AK command: STBY
AVL 439 Opacimeter

Operating Manual
78 Continuous Measurement (Standard Measurement)
5.5 Continuous Measurement (Standard Measurement)

As soon as the Opacimeter is "Ready" – which means that zeroing is
complete – the system will accept the "measurement" command. This
puts it into standard measurement mode. The zero air valve switches
to continuous exhaust gas sampling function and the Opacimeter
continuously delivers the opacity or absorption values, N [%] or k [m-1],
respectively. These values are standardised to measuring chamber
temperature 100° C and atmospheric pressure (see also
Section “Beer-Lambert Law” on page 13) as required by the relevant
regulations.
Note: See Section “Reading stability” on page 67 for information about
measurement value stability.
The standard measurement status is set as follows:
When the status (displayed top right) is "Ready":
Press MEAS (F4)

The Instrument Controller continuously displays the measurement
value.
Fig. 47
The measurement data and the filter algorithm are displayed in addi-
tion to the measurement value (N or k).
Continuous Measurement (Standard Measurement) 79
Control via serial interface

AK protocol: SMGA
The system continuously outputs data that can be queried.
– Analog values: 50 Hz data rate
– Digital interfaces: query command AKON. One measure-
ment value is transmitted per query in accordance with the
AK generic communications interface.
– Requesting measurement data: AMDT
The display of exhaust gas flow rate through the measuring

cell (Q_Gas), pressure in the measuring chamber (p_Cha)
and temperature of the sampled gas at the inlet to the mea-
suring cell (T_Gas) allows you to check that the Opacimeter
is functioning properly (see also Section “Service” on
page 143).
The measurement parameters, i.e. the selection of the filter algorithm
and the output value (opacity N or absorption coefficient k) should be
set from the zeroing function but can also be set in measurement mode
(see Section “Setting the Parameters” on page 89).
AVL 439 Opacimeter

Operating Manual
80 Peak Value Measurement (ECE R24 or EEC 72/306, ELR)
5.6 Peak Value Measurement

(ECE R24 or EEC 72/306, ELR)
5.6.1 General
The peak value measurement registers the highest measured value
during a measurement period. The measurement is prescribed for
certain statutory test cycles for engine certification or testing, e.g. for
free acceleration in accordance with ECE R24 (EEC 72/306) or the
"ELR" test ("Load Response Tests") of the EURO III HD Regulation.
The peak value can only be output via the serial interface and not the
analog or digital one.
Call up the Menu (key F1). Select the measurement screen for
the required peak value measurement (ECE R24 or ELR or free
acceleration peak value measurement) and confirm with F6.
n The correct parameters are already programmed for the statutory
test runs and do not have to be set. For the free acceleration peak
value measurement: set parameters as described in
Section Checking the Zero Point.
n When a peak value measurement is called up, the trigger type
(i.e. measurement period "Start" and "Stop") is set to "internal", i.e.
the measurement period is controlled by pressing function keys
TRIG (F3) and STOP (F6). This is displayed at the right of the
fourth line. If an external trigger is to be used, which is actually
preferable, the parameter has to be set in the usual way:
– Select the variable to be set with the ↑ ↓ keys (your selec-
tion is then inversely highlighted).
– When you press SET (F6), the inverse highlighting changes
to a normal display and is enclosed in a box. INPUT appears
above F6. Use the ↑ ↓ keys to change the parameter and
confirm by pressing INPUT (F6).
n You will find more information about trigger types on the following
pages.
The "peak value measurement" mode now has to be initialised by
pressing the MEAS key (F4).
The measurement period is started by pressing the TRIG function key
F3 and terminated by pressing STOP (key F6). If key F3 is pressed a
second time before key F6 is pressed, the previous measurement
window is automatically terminated and a new one started. The
measurement window can also be defined by digital input when the
Instrument Controller is being used (see below).
Peak Value Measurement (ECE R24 or EEC 72/306, ELR) 81
The highest measurement values between each start and stop, i.e. the
peak values, are displayed on the screen.
Free acceleration peak value measurement screen
Fig. 48

n The peak value measurement is generally started from "contin-
uous measurement" mode (see Section Continuous Measure-
ment (Standard Measurement)).
n Set the output and filter parameters as in the standard measure-
ment - see Section Checking the Zero Point.
n AK command: SMFA
This command starts the measurement window for the peak value
measurement and SMFE terminates it.
The measurement window is also terminated if the SMFA trigger

is issued a second time via the serial interface (before SMFE)
and a new window is started.
The last peak value can be queried with the AMES command on
completion of each measurement window
AVL 439 Opacimeter

Operating Manual
Triggering the measurement windows

The measurement window can be defined in different ways.
The type of trigger is defined by the parameter setting command,
EPAR (see Section “Setting the Parameters” on page 89).
Trigger types:
n External trigger (digital interface, see Section “Digital Interface
("Digital I/O")” on page 54)
The measurement window is defined by:

– "Level" The measurement window is active As long as the
contact is closed
or
– "Start edge" The measurement window is started when the
contact is closed and terminated by the next Start edge.
n Internal trigger, Instrument Controller function keys or AK com-
mand via serial interface
SMFA: starts measurement window
SMFE: ends measurement window

Trigger types
Measurement
interval
Signal curve Measured

peak value
External trigger Edge
Level
internal trigger
SMFA
SMFE
Fig. 49
0.8
k [m -1]
Fig. 50
5.6.2
0.6
0.4
0.2
0 2500
Speed C [min -1] Speed
2000
Speed B
Speed A
Example 1: ELR Test
1500
ELR test
Operating Manual
1000
AVL 439 Opacimeter

500
[Nm] Torque
0
0 60 120 180 240 300 t [s] 360
Instrument
Controller only A T (S) T (S) T S/T T (S) T (S) T S/T T (S) T (S) T S/T D
external trigger >4.5 V

"level", q=1
A D
<0.5 V
≥50 ms
external trigger >4.5 V
"edge", q=2 A D
<0.5 V
serial
interface T (S) T (S) T S T (S) T (S) T S T (S) T (S) T S/T D
Peak Value Measurement (ECE R24 or EEC 72/306, ELR)
83
The ELR test consists of three additional loads on the engine (with
peak value measurement) at each of three (or optionally four) speeds
A, B, C (D). The mean value of the three peak values has to be deter-
mined for each of the speed blocks and a weighted total measurement
value calculated from the first three blocks (see relevant European
Council Directive).
An example of this is shown in Fig. 49 on page 82 where the sequence
control for the various trigger types can also be seen.
Here:
T … Start measurement period

Instrument Controller: F3
Serial interface: SMFA
S … Stop measurement period
Serial interface: SMFE
S may be omitted.
When the Instrument Controller is used, the last peak value is

displayed after each stop (S). If the Opacimeter is being controlled via
the serial interface, it has to be queried using the AMES AK command.
If S is not used, the value is displayed each time after the next T.
S/T: S or T must be input to terminate a speed block (from the Instru-
ment Controller) or the entire measurement (from the serial interface).
A in Fig. 50 on page 83 defines the time the ELR test is started from
the Instrument Controller (see Section “General” on page 80).
EURO 3 measurement screen
Fig. 51
The tester may also add a freely defined fourth speed block D to the
additional load on the engine at the three defined speed blocks. The
Instrument Controller "assumes" that the fourth additional load test will
take place. If there is no fourth test and a new ELR test is required
instead, the test must be started anew by pressing ZERO (F4) and
MEAS (F3).
When the Instrument Controller is used, a screen can be called up by
pressing DATA (F6) where the mean values of the speed blocks, the
deviations within the blocks and the weighted total mean value are
displayed.
EURO 3 results
Fig. 52
N.B. Although the timing of the ELR test is defined, the tolerance for
the phases (±10 %) is too large to make the triggering of the AVL 439
Opacimeter for each additional load on the engine independent of the
test bed host sequence control.
ELR sequence control with test bed control
The start and stop points of the measurement period coincide with
characteristic times of the engine control system and can therefore
easily be integrated in the test sequence plan for the ELR test. To do
this, of course, the test bed control system must be suitably linked to
the AVL 439 Opacimeter by serial or digital connection.
AVL 439 Opacimeter

Operating Manual
86
Fig. 53
Opacity
5.6.3
k [m -1]
Speed
min -1
nstrument
T S T S T S T S T S T S
Controller only
>4.5 V
ECE R24 test
external trigger
level", q=1
<0.5 V
Peak Value Measurement (ECE R24 or EEC 72/306, ELR)
>4.5 V
Example 2: ECE R24 (EEC72/306) Test
external trigger
"edge", q=2
<0.5 V
serial
interface T S T S T S T S T S T STOP
In the ECE R24 "free acceleration" test, the engine is freely acceler-
ated at least six times. The first two accelerations are not evaluated.
The next four are valid if the measurement values lie within a scatter
band of 0.25 m-1. If they do not, the free accelerations are continued
until this criterion is fulfilled.
The order of the sequence control for the various trigger types is
shown in Fig. 53 on page 86.
Here:
T … Start measurement period

Serial interface: SMFA
S … Stop interval
Serial interface: SMFE
S may also be omitted.
When the Instrument Controller is used, the last peak value is

displayed after each stop (S). If the Opacimeter is being controlled via
the serial interface, it has to be queried using the AMES AK command.
If S is not used, the value is displayed each time after the next T.
ECE R24 measurement screen
Fig. 54
The peak values of the last four free accelerations are displayed each
time on the Instrument Controller as well as the mean value and devia-
tion. It can easily be seen therefore whether the current measurement
series is valid or whether another free acceleration is required.
ECE R24 sequence control with test bed control:
The start and stop points of the measurement period coincide with
characteristic times of the engine control system and can therefore
easily be integrated in the test sequence plan for the ECE R24 test. To
do this, of course, the test bed control system must be suitably linked
to the AVL 439 Opacimeter by serial or digital connection.
AVL 439 Opacimeter

Operating Manual
88 Checking the Zero Point
5.7 Checking the Zero Point

This function switches the zero air valve to allow ambient air to be
drawn in. Measurement values are still displayed continuously,
however, and they should be around zero (otherwise zeroing is neces-
sary).
This mode can only be selected during a measurement, during peak
value measurements only when no trigger is active.
Press 0 GAS function key (F5).

AK command: SNGA
Permitted: during measurement (SMGA)
Back to measurement with SMGA.
Setting the Parameters 89
5.8 Setting the Parameters
5.8.1 Measurement parameters

The parameters can be set in any mode. If the preprogrammed statu-
tory regulation is called up by the Instrument Controller, the correct
parameters are set automatically and act then as permanent defaults
(see Tab. 29 on page 89).
Parameters that can be set:
n the measurement unit for the output (N or k)
n filter algorithm and time:
moving average, 2nd order Bessel filter, or 1st order low pass
n whether filter to be applied to N or k, or the "Hardridge" simulated
filtering (0.35 s Bessel filter over k, then filtering of N using moving
average, 1st order low pass or Bessel filter) "kN"
n trigger mode for peak value measurement
(see Section Peak Value Measurement
(ECE R24 or EEC 72/306, ELR))
(digital/serial, edge/level)
Parameters for statutory regulations
ECE-R24 ELR ISO 8178-9 SAE J1667

Output unit k k k k or N
Unit to be filtered kN *) k k k
Filter algorithm Low pass Bessel Bessel Bessel
1st order *) 2nd order 2nd order 2nd order
Filter time 0.8 s *) 1s 1s 0.5 s
Tab. 29
Bessel filtering is carried out in such a way that the rise time τ (10-90)
of a jump function is the "filter time" (see Tab. 29 on page 89). The
algorithms used to attain this within a given physical rise time are spec-
ified in the relevant regulations and illustrated with examples.
*) For the R 24 test, the AVL 439 Opacimeter has to simulate a device
that has a physical rise time (or gas exchange time) of 0.4 s and a
galvanometer instrument with a 1 s low-pass filter characteristic.
Comparative tests showed that first a 2nd order (Bessel) filtering over
0.35 s and then a 1st order low pass filter over 0.8 s has to be applied.
Physical requirements at opacimeters
ECE-R24 ELR ISO 8178-9 SAE J1667

Max. physical rise time 0.4 s 0.2 s 0.2 s 0.2 s
Electronic rise time 1.0 s 0.01 s 0.01 s 0.01 s
Tab. 30
AVL 439 Opacimeter

Operating Manual
90 Setting the Parameters
All measurement parameters can be set during zeroing, contin-

uous measurement and free acceleration peak value measure-
ment provided the instrument is in ready state. (In continuous
measurement mode, the measurement parameters can even be
set during the measurement itself.) Trigger mode can be selected
if ECE R24 or EURO III is selected.
SET function key (F6)
The settable parameters are displayed on the screen in each

mode. First use the ↑ ↓ keys to select the parameter to be
changed. The "current" parameter is inversely highlighted (white
against a black background).
When you press SET (F6), the inverse highlight changes into a
normal display and the data is enclosed in a box. "INPUT"
appears above F6. Use the ↑ ↓ keys to change the parameter
and press INPUT (F6) to confirm.
"SET" then appears again above F6 and the ↑ ↓ keys can be

used to select another parameter to be changed.
Important: When you have set all the parameters as required, save
the configuration by pressing SAVE (F2).
The signal available at the analog measurement value output "A" is

output in the unit and with the filter set in the "Measurement parame-
ters".
Example: Settings according ECE-R24 filtering with internal trigger

Output unit = k
Unit to be filtered = kN
Filter algorithm = low pass 1st order
Filter time = 0.8 s
Trigger = internal

AK command: EPAR u v f T q
u: output measurement unit

0 = N [%], 1 = k [m-1]
v: measurement unit that is
filtered
0 = N, 1 = k, 2 = "kN" (0.35 s
Bessel filter over k, then
filtering of N using moving
average, 1st order low pass or
Bessel filter)
f: type of filter
0 = no filter (at the same time
has the effect that u is equal to
v)
1 = moving average
2 = Bessel filter of the 2nd order
3 = 1st order low pass
T: rise time [s] (real) T = T0-100 (0.02 … 10.00)
moving average, 1st order low
pass:
Bessel: T = T10-90 (0.2, 0.35, 0.5,
1.0, 1.077, 1.5, 2.0)
1st order low pass: T = T0-90 (0.2 … 2)
q: Trigger type for peak value measurement (see Section Peak
Value Measurement (ECE R24 or EEC 72/306, ELR))
(0 = internal, 1 = external/level, 2 = external/edge)
Example: Settings according ECE-R24 filtering with internal trigger

EPAR 1 2 3 0.8 0
AVL 439 Opacimeter

Operating Manual
92 Setting the Parameters
5.8.2 Device Parameters (ambient pressure, spread of analog

signal, conditioning temperature and operating hours
counter)
Device parameters that can be set:
n Ambient pressure
Input of current ambient pressure (see Section “Calibrating the

Sensors” on page 110).
n Spread of the analog signal (only channels A and B)
There are two scales for the analog output: "times 1" and "times
5". This means that the voltage signal 0…10 V corresponds to the
following measurement values:
"times 1" means N = 0 … 100 % where u = 0

or k = 0 … 10.0 m-1 where u = 1
"times 5" means N = 0 … 20 % where u = 0

or k = 0 … 2.0 m-1 where u = 1
n Conditioning temperature
Setting range: 70 … 120° C (in 1° steps)
Conditioning temperatures other than 100 ° C can be set for spe-

cial applications - but it should be remembered that conditioning to
temperatures other than 100 °C does not comply with the statu-
tory requirements.
If the conditioning temperature is lower, condensate will probably

form after the measuring chamber. Where HC condensate forms
in particular, the device is likely to be more heavily soiled (thus
shortening the maintenance intervals).
n Deletion of the second operating hours counter
The Opacimeter has two operating hours counters, the second of

which can be reset (only by service technician, requires download
dongle, article number BV2601). The first counter ("total") always
displays the total number of operating hours (zeroing/measure-
ment, pump operating time) the instrument has been run. The
second ("last") shows the operating time since the last reset.
Call up "Menu" screen (F1) and select "Parameters".
The parameters that can be set are displayed on the screen.
Function key Delete (F5) sets the second operating hours counter
("last") to 0. The first operating hours counter ("total") cannot be
set to 0.
The variable to be set is selected with the ↑ ↓ keys (your selection is

then inversely highlighted); ambient pressure, spread analog signal,
and conditioning temperature).
When you press SET (F6), the inverse highlight changes to the normal
display with the data framed in a box and "INPUT" appears above F6.
The ↑ ↓ keys can be used to change the parameter which must then
be confirmed by pressing INPUT (F6).
"SET" then appears again over F6 and another parameter can be
selected for changing with the ↑ ↓ keys.
Important: When you have set all the parameters as required, save
the configuration by pressing SAVE (F2).
Control via serial interface

– Spread of analog signal
AK command EMBE x y
x = 1: "times 1"
x = 5: "times 5"
y=0
– Delete the second counter (service personnel only)
AK command: SBST
– Adjusting the pressure to ambient pressure
AK command ELDR x
x = 800 … 1100 mbar

– Input of conditioning temperature
AK command ESMK x
x = 70 … 120° C
AVL 439 Opacimeter

Operating Manual
94 Operation with the DIO interface
5.9 Operation with the DIO interface

n Settings (i.e. measurement parameters etc.) must be made on a
PC or the Instrument Controller. The "Internal" trigger type must
be set to enable the DIO interface to take over control (see
Section “Measurement parameters” on page 89).
n When a signal is applied to the LATCH input, the Opacimeter
switches to DIO control. This is indicated by the fact that the
OUT1 output is set to "1". In this state, the Opacimeter cannot be
controlled via COM1 and COM2.
n The bit pattern for the required state should be applied to IN1 and
IN2 (see Fig. 30 on page 54):
IN2 IN1 State

0 0 Off
0 1 Pause
1 0 Zeroing
1 1 Measurement
Tab. 31
The action is executed when the LATCH input is subsequently acti-

vated. Output OUT2 ("Busy") is set to "1" and as soon as that state is
reached it is set to "0" again.
Important: The MEASUREMENT mode can only be requested when

the Opacimeter is in ZEROING mode and OUT2 is set to "0".
All other states can also be requested when OUT2 = "1".
The Opacimeter automatically carries out a 13 second back-purge

during the transition from MEASUREMENT or ZEROING to PAUSE
status.
Measurement Value Calculation 95
5.10 Measurement Value Calculation

The final measurement value that is output is determined by various
calculation levels of the Opacimeter software. The value on which the
calculations are primarily based is the measured detector voltage, from
which the opacity or absorption is calculated based on Beer-Lambert
Law (see Section “Beer-Lambert Law” on page 13). The calculation of
the final value runs through the following modules, depending on the
parameters set (see Tab. 34 on page 100).
n Determination of zero value (zeroing)
n Calculation of raw value
n Filter calculations (filter type and filtered unit)
n Calculation of output unit (N [%] or K [m-1])
5.10.1 Determination of Zero Value

Zero value, U0, is calculated during zeroing as the mean value of the
detector voltages (see Section Zeroing) and N = 0 % and k = 0 m-1 are
equated. The zero value recalculated during each zeroing is calculated
by means of averaging (filter floating mean over 10 s or in addition for
a long zeroing, Bessel filter for t = 30 s) (see Section “Zeroing” on
page 75).
5.10.2 Calculation of the Raw Value

The internal raw value Sk is calculated in the first calculation module
based (U/U0, analog output "C") on Beer-Lambert Law (see
Section “Beer-Lambert Law” on page 13) and standardised by means
of the correction factor PTcorr (analog output "D") to standard tempera-
ture (100° C) and ambient pressure.
The raw value ("unfiltered measurement value", see Section “Analog
Measurement Value Output” on page 58) output via the analog output
"B" corresponds to the pressure and temperature-compensated value
calculated using Beer-Lambert Law.
The raw value that is output is transmitted continuously to the
measurement channel of the "unfiltered measurement value" analog
output "B". The selected filters (filter type, filter time) are not consid-
ered for the raw value.
Depending on the output unit, the result is:
:
for k: Leff = 0.43 m

Sk
k=
Leff
N = SN
for N:
AVL 439 Opacimeter

Operating Manual
96 Measurement Value Calculation
5.10.3 Filter Calculation

The following parameters can be set for the filter calculation:
n filtered unit (N, k or kN)
n filter type and filter time (floating mean value, Bessel or 1st order
filter)
Filtered Unit
The Opacimeter offers the option of using the measurement quantities
N, k or kN as the base value for the filter.
The filter based on (kN) is an algorithm that was especially developed
for the R24 peak value measurement and imitates an Opacimeter with
a physical rise time of 0.35 s and an analog measurement value
display (linear N-scale). Such an Opacimeter is the familiar
Hartridge MK3. The algorithm contains a filter first using Bessel
(0.35 s) based on (k). The result is then converted to (N) and filtered
with the set filter type.
Filter Types and Filter Times
The Opacimeter can filter the raw values (N, k or kN) by means of 3
different filter types for which different filter times can be set.
The following filter types are implemented:
Floating Mean
An imaginary window is placed over the last (n) measurement values
in which all the measurement values are averaged. The size of this
floating window is set by the filter time (T0-100 = 0.02 …10 s). The
calculation algorithm creates the mean value with
n
1
S =
n åS
i =0
i
n … includes all the values inside the time window
Bessel Filter
The Bessel filter has the characteristic of a 2nd order low pass which is
described by the following formula:
Yi = Yi −1 + E ∗ ( X i + 2 X i −1 + X i − 2 − 4Yi − 2 ) + K ∗ (Yi −1 − Yi − 2 )
Y… calculation results
X… measurement values
E, K … Bessel constants which determine the T10-90 time
The Bessel constants depend on the rise time (T10-90) (0.1 s for the
AVL 439 Opacimeter) and the sampling frequency of the unfiltered
signal (50 Hz internally for the AVL 439 Opacimeter), i.e. Bessel
filtering of a signal with the same rise time but which was recorded with
a different sampling frequency, needs different filter constants.
The constants (E, K) are specified below for a data rate of 50 Hz.
Data rate = 50 Hz
Time
Constant 0.2 s 0.35 s 0.5 s 1s 1.077 s 1.5 s 2s
E 1.9383e-2 5.8148e-3 2.8362e-3 7.2038e-4 6.2236e-4 3.2358e-4 1.8298e-4
K 0.4995 0.7302 0.8127 0.9063 0.91296 0.93737 0.95296
Tab. 32
Low pass of the 1st order

This filter filters the raw value with a filter characteristic of a 1st order
low pass which is described by the following formula:
Yi = Yi −1 ⋅ (1 − c ) + X i ⋅ C
The low pass filter constant (C) can be calculated from the following
formula:
1 ⋅ln(10)
C = 1 − e Sampling frequency⋅τ 90
The sampling frequency corresponds to the data rate of the measure-

ment (Opacimeter, internal = 50 Hz), τ90 corresponds to filter rise time
T0-90.
AVL 439 Opacimeter

Operating Manual
Example: Recalculation of ELR measurement data based on

measured analog values (U/U0) and (PTcorr)
In this example, the absorption (k) [m-1] is calculated based on the
measured analog values of the (U/U0) and (PTcorr) channels (see
Section “Analog Measurement Value Output” on page 58).
According to the ELR Test, the signal has to be filtered with a 1 s
Bessel filter based on (k) and with the final value output in (k) [m-1].
The data rate for this example should be 50 Hz.
1. Scaling of the measured analog values (see Section “Analog
Measurement Value Output” on page 58) based on a measure-
ment value.
U 4.978
= = 0.9956
U0 5
Scaling of analog output: 0 … 10 V equals 0 … 2 for U/U0

5.161
PTkorr = = 1.0322
5
Scaling of analog output: 0 … 10 V equals 0 … 2 for PTcorr

2. Raw value (Sk) is calculated from:
æU ö
S k = − lnçç ÷ ⋅ PTcorr
÷
èU0 ø
3. 1 s Bessel filter based on raw value (Sk):
Yi = Yi −1 + E ∗ ( X i + 2 X i −1 + X i − 2 − 4Yi − 2 ) + K ∗ (Yi −1 − Yi − 2 )
Yi, Yi-1, Yi-2 … calculation results

Xi, Xi-1, Xi-2 … calculated raw values (Sk, Sk-1, Sk-2)
E … 7.2038e-4
K … 0.9063
4. Calculation of output value (k):
Yi
k=
Leff
Yi … filter calculation results

Leff … 0.43 m optical length
The table below contains an example of data for a short measurement

calculated based on the above criteria and formulas.
U/U0 PTcorr U/U0 PTcorr Raw value Yi after 1 s Finaly value

measured measured (Scale (Scale Sk Bessel filter of (k) in m-1
in V in V Section “An Section “An S kr
alog Mea- alog Mea-
surement surement
Value Out- Value Out-
put” on put” on
page 58) page 58)
4.978 5.161 0.9956 1.0322 0.00455 0.000003 0.000008
4.978 5.160 0.9956 1.0320 0.00455 0.000016 0.000037
4.977 5.160 0.9954 1.0320 0.00476 0.000041 0.000095
4.978 5.160 0.9956 1.0320 0.00455 0.000077 0.000179
4.976 5.160 0.9952 1.0320 0.00497 0.000123 0.000286
4.975 5.161 0.9950 1.0322 0.00517 0.000178 0.000415
4.978 5.161 0.9956 1.0322 0.00455 0.000243 0.000565
4.978 5.162 0.9956 1.0324 0.00455 0.000314 0.000731
4.981 5.162 0.9962 1.0324 0.00393 0.000391 0.000909
4.981 5.162 0.9962 1.0324 0.00393 0.000471 0.001096
4.979 5.162 0.9958 1.0324 0.00435 0.000554 0.001289
Tab. 33
Note: Each filter calculation includes the last measured or calculated

values (Sk) or (Yi) in the calculation. The initialisation value (0) is used
for missing values at the start of a filter calculation.
AVL 439 Opacimeter

Operating Manual
Flow diagram for measurement value calculation
After the Opacimeter is powered up: Udark = signal (lamps off)

U = detector signal - Udark Zeroing: U0 = mean value (U)
Calculate raw value
measuremen t chamber temperatur e [K ] ⋅ ambient pressure

PTkorr =
373[K ] ⋅ measuremen t chamber pressure
S k = − ln UU ⋅ PTcorr
0
(PTcorr … pressure and temperature correction)
(
S N = 100 ⋅ 1 − e − Sk )
only calculated when filter = N and output = N
Filtering
N k kN
(first k is filtered,
then conversion into N)
S = SN S = Sk S1 = Bessel
Filter type
without smoothing moving average Bessel filter 1st order low pass
S=S S = mov.av. (S) S = BE (S) S = 1stLP (S)
Output
N k
when filtering when filtering
N oder kN k N oder kN k
N=S
(
N = 100 ⋅ 1 − e − S ) k=
( S
− ln 1 − 100 ) k=
S
Leff Leff
Tab. 34
Analog measurement value output
Pin Measurement value Output N Output k

1 Final value, filtered N k
3 Final value, not filtered SN
Sk
Sk = Leff
5
U U U
U0 U0 U0
8 PTkorr PTkorr PTkorr

Tab. 35
AVL 439 Opacimeter

Operating Manual
General 103
6 Calibration and Checking
6.1 General
Opacimeters have two well defined calibration points (see
Section “Zeroing” on page 75):
the light value at N = 0 % and the dark value at N = 100 %.
These two points are determined in the AVL 439 Opacimeter as it goes
into ready mode:
n The dark value that corresponds to the signal from the sensor
when no light falls on it, is determined internally shortly after the
instrument is switched on while the light units are deactivated. (It
is usually less than 10 mV.)
n The light value is determined during zeroing (the associated
sensor signal is 2…4 V). The light value has to be determined
anew periodically, i.e. approximately every half-hour. The Opaci-
meter prompts the user to do this. The scale between light value,
N = 0 %, and dark value, N = 100 %, is graduated linearly to the
sensor signal.
During calibration the system checks that the graduation of the N-scale
is linear to the incident light intensity. This is done by reducing the
transmitter light intensity by a precisely defined amount, say by 40 %.
The display should then show an opacity of N = 40 % in accordance
with the definitions and formulas of Section “Method of Operation” on
page 13.
A calibration can be performed in one of two ways on the AVL 439
Opacimeter:
1. with the patented "Linearity Test"
2. with calibrated filters "of neutral optical density"
(i.e. grey glass discs that reduce the light of each wave length to
approximately the same extent in the observed optical spectral
range.)
Important: Calibrating the AVL 439 Opacimeter with the linearity test
or with neutral optical density filters is only used to check the sensor
linearity - it has no effect on the display of measurement values.
AVL 439 Opacimeter

Operating Manual
104 Linearity Test ("LIN Check")
6.2 Linearity Test ("LIN Check")

The light source in the AVL 439 Opacimeter consists of two nearly
identical halogen lamps. If lamp 1 only is switched on, about half as
much light is incident on the detector as when both lamps are switched
on. The same applies when lamp 2 only is switched on. The example
in Fig. 55 on page 104 shows that the detector signal is D1=1900 mV
when lamp 1 is switched on and D2=2100 mV when lamp 2 is switched
on. D1 + D2 is 4000 mV and should ideally be the same as the value
measured when both lamps, D1+2, are switched on. Assuming the
measured value is D1+2=3996 mV, the linearity deviation is:
D1+ 2 − D 2 − D1
∆D = ⋅ 100 % = −0.1 %
D1+ 2
The relevant standards and statutory regulations generally require less

than 1 % deviation. In our experience the linearity test deviation is less
than 0.5 %. Larger deviation can only be caused by a faulty detector
element. If the deviation is > 0.5 % the detector element must be
replaced (see Section “Service” on page 143).
This kind of linearity check is RW TÜV-approved.
The system must be in "Zeroing", "Ready" state. The maximum devia-
tion is 0.5 %.
Graphic representation of the LIN check
detector signal D
linearity
deviation
D1+2
ideal curve
real curve
D1 + D 2
D1 D2
I1 light intensity I
I2
I1 + I2
I = I0 = 100 %, N = 0 %
Fig. 55
Linearity Test ("LIN Check") 105
The "Linearity test" measurement screen can be selected from the

Menu screen (by pressing F1) and confirmed with EXEC. (F6).
As soon as the "Linearity test" screen appears and the equipment

is ready for measurement, start the procedure by pressing START
(F4).
The linearity test is carried out automatically after each "START"

and the results displayed after 20 sec.
Zeroing is automatically carried out after the test. You can inter-
rupt it by pressing ZERO (F4) or you can start a new linearity test
by pressing START.
The AK command for executing the LIN check is:

SLCH
The result can be called up by
ALCH x1 x2 x3 x4 w1 w2
x1: signal lamp 1 (real)

x2: signal lamp 2 (real)
x3: signal both lamps (real)
(all results in mV)
x4: linearity = ((x1+x2)-x3)/x3 *100
(real)
w1: 0 = OK, 1= warning (lamp current drift)
Caution: The lamp currents were not constant during the
linearity test due to thermal instability. The test can be
repeated after a short stabilisation period.
w2: 0 = OK, 1= warning (drift in dark value voltage)
Caution: The dark value has changed since the Opacimeter
was switched on. This unusual situation can be remedied by
switching the Opacimeter off then on again and following the
(shortened) procedure for putting it into ready state.
AVL 439 Opacimeter

Operating Manual
106 Linearity Check ("Calibration") with "Neutral Density Filters"
6.3 Linearity Check ("Calibration") with "Neutral Density

Filters"
"Neutral density filters" are available from various optics companies.
They are normally supplied, however, with only an approximate
absorption value (±5 %, possibly ±2 %) and have to be calibrated.
Ready-calibrated filters are available for the AVL 439 Opacimeter
under the following order numbers:
Absorption [%] Order no.

10 BH0183
20 BH0182
40 BH0181
50 BH0177
Tab. 36
For calibration of the device with certified neutral density filters, usually
one filter will be enough, preferably with an absorption of 50 %. For
engine certification of commercial vehicles according to guideline
1999/96/EU ("commercial vehicles regulation Euro 3/4"), filters with an
absorption of 10, 20 and 40 % are required.
The opacity values specified on the filters should be treated as guide-
lines only. The pricise, calculated absorption value is printed on the first
page of the calibration protocols of the company Swarovski.
In a few special cases, Calibration Certificates from the BEV (Bunde-
samt für Eich- and Vermessungswesen = Federal Office for Calibration
and Measurement) are supplied with the equipment and not the Cali-
bration Report from Swarovski. These calibration certificates show the
transmission values of the filters as a function of the wave length [400
… 800 nm], from which the precise calibration value can be calculated.
The transmission factors indicate the filter's permeability to light of
different wavelengths (usually from 400 nm to 800 nm). The transmis-
sion that is effective for the AVL 439 Opacimeter is obtained by multi-
plying and standardizing these values by the standardized emission
and sensitivity of the detector unit. The Excel spreadsheet
"Filter_Cal.xls" can be used for an exact calculation. A simpler calcula-
tion, which experience has shown to produce the effective transmis-
sion (or opacity, see below) to better than 0.5 %, is described below.
The AVL 439's detector unit is designed in such a way that its highest
spectral sensitivity is between 550 nm and 570 nm (in accordance with
the statutory requirements). It is the transmission values around
550 nm therefore that are particularly significant in the filter's calibra-
tion certificate. Approximated absorption value can be determined from
the weighted mathematical mean of three values (see below).
Linearity Check ("Calibration") with "Neutral Density Filters" 107
Example: Transmission values (from the calibration certificate of a

calibration filter)
Wave- Transmission T Weighting W T×W

length
500 nm 0.485 1 0.485
560 nm 0.494 3 1.482
600 nm 0.476 2 0.952
Weighted 2.919/6=0.487
mean value
Tab. 37
Absorption value N is therefore N = 100 % - 48.7 % = 51.3 %

The value displayed on the AVL 439 was 50.8 % and is therefore within
tolerance (see below).
The calculated value for the ≈50 % absorption filter, used for calibration
according to ECE R24 (EEC 72/306), must agree with the value
displayed on the AVL 439 to within ±1 % opacity.
For the ELR test according to the directive 1999/96/EU ("commercial
vehicles regulation Euro 3/4") and for the standards ISO 8178-9, ISO
11614 and SAE 1667, calibration with filters of lower absorption are
required. The limit of agreement in these regulations and standards is
±2 % opacity. The acceptance of a larger tolerance in these regula-
tions and standards is based on the fact that neutral density filters with
low absorption show larger deviations: the values given by the opaci-
meter are usually lower than the calibration value. This is due to
well-understood physical principles ("multireflexions") and does not
indicate any deficiency or non-linearity in the actual smoke density
measurement. It accounts for the fact that the absorption by neutral
density filter is optically not comparable to the absorption in the smoke
cell. (For the same reason the calibration is usually carried out with the
"opacity" value N [%], not the "absorption" value k [1/m]).
DANGER!
The absorption value of a filter decreases as the temperature rises!
Do not leave the calibration filter in the unit for longer than 1 min!
Absorption filters are precision components – never touch the surface!
If the surface is touched, this changes the absorption value even if the
filter is meticulously cleaned. Once touched, a filter must be officially
calibrated again!
AVL 439 Opacimeter

Operating Manual
108 Linearity Check ("Calibration") with "Neutral Density Filters"
With careful handling the absorption value of the filters changes only
slightly (<<1 %). For a calibration at an official certification according to
1999/96/EU it is necessary that the filter is not longer used than one
year. After that, a recalibration is required. You can have your device
recalibrated by AVL or by an approved national inspection agency.
The neutral density discs are mounted in a calibrating filter cartridge.
For the calibration, the calibrating filter cartridge is inserted in the light
unit (on the right of the measuring unit) instead of the cartridge without
glass discs. The cartridge can be accessed by undoing the screwed
coupling on the Opacimeter cover using a spanner (NW 58). It is then
easy to remove and replace.
Fig. 56
Carrying out the calibration with neutral density filter

The system must be in "Zeroing", "Ready" state.
Select the calibration measurement screen from the Menu screen

(key F1) and confirm with EXEC(key F6).
The "calibration" screen is displayed but the system is still in

"Zeroing" mode.
Press START (key F4) to start the calibration
The calibration is carried out in the sequence described below.

The corresponding measurement value is displayed after each
calibrating filter is inserted.
Press ZERO (key F4) to return to zeroing.

AK command: SKAL
You can call up the result with

AKAL x
Linearity Check ("Calibration") with "Neutral Density Filters" 109
Calibration sequence
The system prompts the user to insert or remove the calibration filter
cartridge as required by making the status LED flash slowly.
Important: When the status LED flashes slowly, it means the calibra-
tion filter cartridge should be changed.
This is necessary because for calibration, the system must reach

stable values before the procedure can be continued, i.e. before the
calibrating filter can be removed again. Not only that but it may be
advisable to repeat the calibration using several different filter
cartridges one after the other. In that case, insertion or removal is also
prompted by slow flashing.
1. Before calling up the calibration procedure: make sure that the
cartridge without glass discs is fully inserted.
2. Call up the calibration procedure (from the Instrument Controller
or terminal, see above).
3. Status LED flashes slowly:
remove the cartridge (without calibrating filter
and insert the calibrating filter cartridge

4. Status LED is illuminated constantly again as soon as the filter
cartridge is inserted.
5. When a stable value is measured for N (or k), it is displayed (on
the Instrument Controller) or can be called up with AK commands.
6. Status LED flashes slowly
7. If another calibration value is required, remove the calibrating filter
and insert the next one. Repeat the procedure from d).
If the calibration is finished, insert the cartridge without glass

discs. The system recognizes this cartridge by the fact that when
inserted there is less than 5 % opacity. The system checks inter-
nally whether the zero value reaches better than 0.5 % opacity
within 10 sec. If it doesn’t, a warning is output.
8. The calibration process is terminated when the user calls up the
"Zeroing" function.
A maximum of 7 calibrations can be performed in succession. The

status LED switches off for 5 s to indicate when the seventh cali-
bration value is reached.
AVL 439 Opacimeter

Operating Manual
110 Calibrating the Sensors
6.4 Calibrating the Sensors

By calibration in the real sense, we mean that the displayed measure-
ment value from a sensor is compared with an officially calibrated
reference value. Setting the displayed measurement value to be the
same as the officially calibrated reference is more correctly called
"adjusting".
The AVL 439 Opacimeter measurement value (N or k) can also now be
calibrated (or "adjusted") – see Section “Linearity Check ("Calibration")
with "Neutral Density Filters"” on page 106 and “Linearity Test ("LIN
Check")” on page 104.
It is pointless to calibrate the temperature and pressure sensors of the
AVL 439 Opacimeter without adjusting them as well. Below the term
"calibration" therefore is always used in the sense of "calibration and
adjustment".
The following sensor values can be calibrated:
n measuring chamber temperature sensor
n temperature sensor for the inflowing gas sample (valve block gas
in)
n pressure sensor in the measuring chamber
n gas sample flow rate sensor (i.e. differential pressure sensor)
n Zero point and end point of the analog outputs
The absolute pressure transducer is a special device. The value
should be checked once a week and if necessary recalculated. The
calibration must carried out approx. 5 min after power-up (allowing for
the electronics to warm up, "Function off" status) and before the device
warms up (balancing).
The air pressure is input in the "Parameters" screen with the Instru-
ment Controller (see Section. “Device Parameters (ambient pressure,
spread of analog signal, conditioning temperature and operating hours
counter)” on page 92).
All sensors are calibrated at the factory. Recalibration is a service task
that should only be carried out by trained personnel. It is absolutely
essential also to carry out this calibration whenever the controller
board is replaced.
A separate "Calibration and Adjustment Procedure" for the AVL 439
Opacimeter (ID number AT0685E) is available.
Important: The intervals between the calibration of sensors and cali-

bration tools depend on the guidelines on maintenance of test instru-
mentation applicable for the user.
AVL recommends annual calibration.
General 111
7 RS232 Interface / AK Generic

Communication Interface
7.1 General
This chapter contains information for programmers who have to inte-
grate the AVL 439 Opacimeter into automation systems.
The communication via the RS232 interface is based on the AK
generic communication interface that is standard in exhaust emissions
measurement technology.
You will find references to the interface parameters in chapter “Serial
Interfaces” on page 53.
7.1.1 Protocol Framework

Command message
Byte Function
1 <STX>
2 Is ignored
3…6 Function code
SXXX … control commands
EXXX … setting commands
AXXX … query commands

7 Blank
8 K
9 Channel number (always 0)
. Data (variable)
. Can also be omitted (depends on function code)
.
nth byte <ETX>
Tab. 38
AVL 439 Opacimeter

Operating Manual
112 General
Acknowledgement message
Byte Function
1 <STX>
2 Is ignored
3…6 Function code (same as command)
7 Blank
8 Error status
0 no error
1 … 9 error (counted in cycles)
. Data (variable)
Can also be omitted (depends on function code)
.
.
nth byte <ETX>
Tab. 39
n Acknowledgement when function code unknown
<STX> ???? n<ETX>
n … error status
n General comments and possible acknowledgements in the event
of error
– The command message must begin with <STX> and end in
<ETX>. The first nine bytes must always be present.
– When entering commands via keyboard, <STX> can be
entered by pressing and holding down the control key (Ctrl)
and then pressing B (also known as <Ctrl+B>), <ETX> can
be entered by pressing <Ctrl+C>.
– Blanks are used as separators.
– The variable-length floating decimal format is used to display
numerical values. There is no decimal point with integers.
The sign is only specified in front of negative values. Physi-
cally meaningless digits are omitted.
– If no data is available in response to a query, the piece of
data is replaced by # in the acknowledgement.
– Data that is only conditionally valid is prefixed with a #.
General 113
– If a control or setting command is transmitted in SMAN oper-

ating state (which only permits query commands), it is
acknowledged as follows:
<STX> XXXX n K0 OF<ETX>
XXXX … function code
n … error status
OF … offline
– If a command is transmitted that cannot be executed in the
current status or due to an unremedied error, it is acknowl-
edged as follows:
<STX> XXXX n K0 BS<ETX>
n … error status
BS … busy
– If a command message contains a syntax error (e.g. too few
or too many parameters), it is acknowledged as follows:
<STX> XXXX n K0 SE<ETX>
n … error status
SE … syntax error
– If a parameter value is outside the permissible range, it is
acknowledged as follows:
<STX> XXXX n K0 DF<ETX>
n … error status
DF … data error
AVL 439 Opacimeter

Operating Manual
114 General
7.1.2 Operating Mode

The Opacimeter has two RS232 interfaces (COM1 and COM2) and
one digital port (Digital I/O) which has the same status as the two
RS232 interfaces as far as the operating mode is concerned. Each of
the three interfaces can be either in control or monitor mode, but only
one can be in control mode at a time.
Control mode (SREM): All commands are accepted.

Monitor mode (SMAN): Only query commands are accepted and
control command SREM.
All three interfaces are in monitor mode after power-up and after a
reset.
7.1.3 Command Set

The command set is arranged according to function groups. Only the
function code and parameters are listed. The full string complies with
the conventions of the AK generic communication interface.
In query commands (which start with A), the returned parameters are
specified after the function code. AKEN k v therefore signifies that
when AKEN was transmitted, the response was AKEN k v.
Numerical format
The format is integer unless otherwise specified.
General Queries 115
7.2 General Queries
AKEN k v
Device ID and firmware version
k: 439 (= device ID)

v: firmware version
ABST t1 t2
Operating hours counter (operating time of pump, window heating
system)
t1: total operating time [h]

t2: operating time [h] since the last reset (SBST)
ASTZ z1 z2...
Status
The statuses are the same as their function code if they are triggered
by control commands.
ASTF
Error status
Shows the numbers of the current errors (see next page).
AVL 439 Opacimeter

Operating Manual
116 General Queries
Error codes
1 Detector Signal < 1500 mV

2 Halogen lamps Current < 350 mA or > 500 mA
3 Detector heating system Temperature does not increase when heating switched
on
4 Measuring chamber heating system Temperature does not increase when heating switched
on
5 Probe heating system Temperature does not increase when heating switched
on
6 Compressed air Pressure < 2 bar
(= pressure switch setting)
7 Window heating system n window resistance too low (< 4 W)
or too high (setpoint not reached)
n Window heating fuse (F4) faulty/blown
8 Gas temperature sensor Ruptured sensor or short circuit.
The probe heating system is switched off.
9 Measuring chamber temperature Ruptured sensor or short circuit.
sensor The measuring chamber heating system is switched
off.
10 Calibration Signal drift during calibration
(N > 0.3 or < -0.3 %)
l
11 Flow rate alarm Flow rate < 30 min
l
12 Flow rate warning Flow rate < 35 or > 60 min
13 Zeroing warning Zeroing has not been carried out for more than 30
minutes.
14 Not ready (= status information) Target temperatures not reached yet
(during PAUSE)
Signal stability not yet reached
(during STANDBY)
Pump run-on time (when switching back to PAUSE or

OFF)
15 Lamps/detector overheating Lamp or detector temperature > 90° C
16 Exhaust gas overtemperature Exhaust gas inlet temperature > 150° C
17 Measurement parameters checksum error
18 Analog output calibration checksum error
19 Operating hours counter checksum error
20 Sensor calibration checksum error
21 Setpoint values checksum error
22 Limit values checksum error
23 Maintenance will be required soon Operating hours counter > 950 hours
Tab. 40
General Control Commands 117
7.3 General Control Commands
SRES
Reset
All active functions are aborted and the system is reset.
SREM
Switch to control mode
SIDL
"Function off"
SPAU
Pause
STBY
Zeroing
SBST
Reset operating hours
7.4 Measurement
SMGA
Start measurement (charge of measurement gas)
Permitted: Zeroing (STBY) and Checking the zero point (SNGA)
AKON x
Measurement value
x: Opacity N or absorption k, as set with EPAR (real).
AVL 439 Opacimeter

Operating Manual
118 Measurement
AMDT TG p Q t
Measurement data
TG: Gas temperature [°C]

p: Measuring chamber pressure [mbar]
Q: Gas flow rate [l/min]
t: time remaining until Opacimeter is ready for measure-
ment
(see Section “Switching On and Warming Up – Getting
the Opacimeter Ready for Measurement” on page 73)
# … Zeroing is in progress or "Ready" (see
Section “Zeroing” on page 75)
AMES x
Result of peak value measurement
x: Peak value of last measurement window (real)
SMFA
Peak value measurement: start of measurement window
Permitted: during measurement (SMGA) provided that the trigger type
= internal (set with EPAR)
The command can also be transmitted several times (without SMFE in
between). It then acts like an edge trigger.
SMFE
Peak value measurement: end of measurement window
Permitted: during measurement (SMGA) provided that the trigger type
= internal (set with EPAR)
SNGA
Checking the zero point
Permitted: during measurement (SMGA)
Back to measurement with SMGA
EPAR u v f T q
Measurement parameters
Measurement 119
APAR u v f T q
u: measurement value that is output

0 = N [%]
1 = k [m-1]
v: measurement value that is filtered
0=N
1=k
2 = kN
f: type of filter
0 = no filter
1 = floating mean
2 = Bessel filter of the 2nd order
3 = 1st order low pass
T: rise time [s] (real)
floating mean: T = T0-100 (0.02 … 10.00)
Bessel: T = T10-90 (0.2, 0.35, 0.5, 1, 1.077, 1.5, 2)
1st order low pass: T = T0-90 (0.02 … 10)
q: trigger type for peak value measurement
0 = internal
1 = external/level
2 = external/edge
SKAL
Calibration
Permitted: Zeroing (STBY)
AKAL x
Calibration result
in N [%] or k [m-1], as set with EPAR (real)
SLCH
Linearity test ("LIN check")
Permitted: Zeroing (STBY)
AVL 439 Opacimeter

Operating Manual
120 Measurement
ALCH x1 x2 x3 f w1 w2
Linearity test result
x1: Signal from lamp 1 [mV] (real)

x2: Signal from lamp 2 [mV] (real)
x3: Signal from both lamps [mV] (real)
f: Linearity error [%] (real)
w1: 0 = OK, 1= warning: lamp currents different
w2: 0 = OK, 1= warning: drift in dark value voltage
SLEC
Leak test
Duration: 10 … 20 s
Permitted: Off (SIDL)
ALEC x
Leak test result
x = 0: test passed
x = 1: test failed
EMBE x y
Scaling of analog output
AMBE x y
x=1: times 1
(10 V = 100 % or 10 m-1)
x=5: times 5
(10 V = 20 % or 2 m-1)
y=0
ELDR x
Air pressure [mbar]
ALDR x
Permitted: Off (SIDL), Pause (SPAU)
x = 500 … 1100
Service 121
SRUC
Purging
Permitted: Off (SIDL), Pause (SPAU), Zeroing (STBY)
Continuous purging, can be stopped with SIDL, SPAU or STBY.
SPRG
Purging
Permitted: Off (SIDL), Pause (SPAU), Zeroing (STBY)
Purging for 13 s, then switching back to the operating mode SPRG
was called from.
7.5 Service
Switch commands contain parameter z which can be 0 or 1.
0 … off / close
1 … on / open
ASPA UD TD TMK TG p Q I1 I2 TL P1 P2
Service measurement values
UD: Detector signal [mV]

TD: Detector temperature [°C]
TMK: Measuring chamber temperature [°C]
I1: Halogen lamp 1 current [mA]
TL: Lamp temperature [°C]
P1: Heat output window 1 [W] (real)
P2: Heat output window 2 [W] (real)
ELMP n z
Switch halogen lamp n
(n = 1, 2; 0 [both])
EPMP z
Switch pumps
AVL 439 Opacimeter

Operating Manual
122 Service
EVLV n z
Switch valve n
(n = 1 … 4)
ASST L1 L2 p v1…v4
Switch states
Lamps, pumps, valves
ESMK x
Setpoint value for conditioning temperature (service technician only)
ASMK x
(70 ≤ x ≤ 120° C)
EANA x
Checking analog output
AANA x
x=0: Measurement value

x=1: Zero value (0 V)
x=2: End value (10 V)
This command affects all four analog outputs.

After checking the analog outputs, reset them using the EANA 0
command.
General 123
8 Maintenance and Storage
8.1 General
The AVL 439 Opacimeter is designed in such a way that it requires
little maintenance even when in use for long periods. This is due in
particular to the heated measuring chamber window, the sample condi-
tioning and the automatic purge function. Only the filter element in the
exhaust gas sampling path has to be changed from time to time
depending on the degree to which it is used. The Opacimeter indicates
when the filter needs changing (flow measurement).
When the Opacimeter has been in operation for a long time, we recom-
mend cleaning it periodically because residues can build up in the lines
and measuring chamber, especially if it has been used for exhaust
gases with high particulate concentrations. Such residual deposits can
become dislodged during operation due to thermal or mechanical influ-
ences and cause an effect that looks like soot peaks or zero drift.
We therefore recommend cleaning the Opacimeter, particularly before
measurements on low-emission engines. You should clean the
following components approximately every 100 operating hours:
n Window modules and window elements
n Sampling lines
n Measuring chamber
DANGER!
The gas path of the opacimeter must never be subjected to blasts of
compressed air.
AVL 439 Opacimeter

Operating Manual
124 Changing the Filter Element
8.2 Changing the Filter Element

The filter element is situated between the measuring chamber outlet
and the pump inlet. It consists of filter paper with a nominal perme-
ability of 5 µm and a filter area of about 2800 cm2. The filter element
guarantees long pump life and consistent operational reliability during
its operational life.
The AVL 439 Opacimeter has an integral flowmeter. The filter becomes
less permeable with time depending on the amount of soot emitted
from the engine. That reduces the flow rate which triggers a warning
message when it undershoots a certain limit ("Flow Rate Warning"). If a
measurement is running when this message is output, it can still be
completed. When the flow rate drops below the lower limit, the Opaci-
meter switches to pause mode and outputs an error message.
However, we recommend changing the filter element before the error
message is output. Change the filter before switching the instrument
on, i.e. before the parts through which the exhaust gas flows get hot.
The filter can be changed easily, quickly and cleanly:
n Make sure that the Opacimeter is switched off or in pause mode.
n Unscrew the filter cover at the front of the Opacimeter.
Fig. 57
n Remove the filter element from the filter housing together with the
cover.
n "Snap" the used filter element out of the cover by pressing it to the
side and then let it fall out.
This way there is no need to touch the filter element that is loaded
with diesel particulate.
Changing the Filter Element 125
Fig. 58
Fig. 59
n Insert a new filter element into the cover. You can hear when it is
sitting correctly by the sound it makes as it fits into place in the
cover.
Fig. 60
n Check the O-ring in the cover for any signs of damage and
replace if necessary.
n To reassemble, insert the filter element into the filter housing,
centre the sealing collar and push it carefully onto the internal
guide. As soon as you can feel that it is correctly positioned, press
the filter element together with the cover until it is resting on the
AVL 439 Opacimeter

Operating Manual
126 Changing the Filter Element
threaded guides.
Fig. 61
n You can feel when the cover fits into the threaded guides by
turning it counterclockwise while gently pushing it. Then tighten
the cover moderately by hand.
n The Opacimeter is ready for use again.
DANGER!
Do not operate the Opacimeter without the filter elements supplied by
AVL and do not use any other brand, otherwise operational reliability
cannot be guaranteed.
Important: Dispose of used filters in accordance with the regulations

stipulated by your company.
Cleaning the Window Modules 127
8.3 Cleaning the Window Modules

The heated windows which separate the optical elements from the
exhaust gas in the measuring chamber are designed to automatically
burn off soot deposits and to keep the optical passage clean. However,
after being in operation for a very long time for measurements where
the smoke density is high, various exhaust gas components can soil
the windows (e.g. unburned engine oil residues, etc.).
The windows must be cleaned when the transmitted light intensity is
reduced to the extent that the received detector voltage falls below
~1500 mV. When it falls below this threshold, an error message is
output during zeroing. The measured detector voltage can be
displayed using the service functions.
The sequence for cleaning the windows is described below.
n Make sure that the Opacimeter is switched off and disconnect it
from the mains.
n Open the instrument and remove the cabinet hood.
DANGER!
The components of the Opacimeter may still be hot from previous use
- be careful not to burn yourself!
AVL 439 Opacimeter

Operating Manual
128 Cleaning the Window Modules
n Remove the light unit and detector unit.

n To do this open both quick-release locks (1) and pull the entire unit
out carefully in the axial direction (2).
1
2
Fig. 62
Fig. 63
n Screw off the two connectors for the supply line and the signal
line.
Cleaning the Window Modules 129
Fig. 64
Fig. 65
n Place the light and detector units on a suitable work surface with
the windows facing upwards.
DANGER!
When carrying out this work, make sure that no exhaust gas is
entering the Opacimeter via the return line. The gas could escape
through the opened measuring chambers - risk of poisoning!
Cleaning instructions for window modules

n Carefully remove particulate deposits around the windows using
compressed air or suction.
AVL 439 Opacimeter

Operating Manual
130 Cleaning the Window Modules
Cleaning instructions for the window elements of the detector and

lamp unit
DANGER!
Only ever clean the elements when they have cooled down (i.e. are
warm to the touch)!
Do not touch the window elements with your fingers.
The windows are made of laminated 1 mm thick quartz.
Mind the limited shock resistance of the windows, especially when
using pointed equipment.
n Clean the window elements first with a soft cloth

Only use the Cleaning Set (Ident. No. HY0028) for stubborn soiling to
remove any residual deposits:
n Wet the wooden cleaning stick with water
n Dab a little cleaning powder onto the wet stick (the powder should
then become pasty).
n Remove deposits using circling movements of the stick.
n Using a soft cloth wipe the window elements first clean (possibly
using liquid) and then dry.
n Switch the detector and lamp unit on briefly to allow any residual
moisture or cleaning agent to evaporate.
n Wipe the window elements again with a soft cloth when they have
cooled down.
n Before reassembling, check the O-rings for any signs of damage
and replace if necessary.
n After cleaning the windows reconnect the supply and signal lines
and fit the light and detector units back into position.
n Replace the cabinet hood and close it properly.
n Restart the Opacimeter. Once it is ready for operation, check the
detector voltage using the service function.
Cleaning the Sampling Lines 131
8.4 Cleaning the Sampling Lines

The conditioning hose, the zero air valve and the probe line are back-
flushed with compressed air every time the AVL 439 Opacimeter is
switched off. Nevertheless when the Opacimeter is in use for a long
period of time, and particularly at high particulate loads, residues can
still become deposited in the lines. If such deposits become dislodged
during operation due to thermal or mechanical influences, it causes an
effect that looks like an emission peak.
That is why we recommend using compressed air to blow clean the
conditioning hose and zero air valve, especially in measurements on
low-emissions engines. The particulate deposits from the lines should
not be blown into the ambient air. The following procedure is therefore
recommended:
n Switch the Opacimeter to "Function off" mode.
n Zero air valve – open path into exhaust line
Instrument Controller:
– Set V3 to "1" and all other values to "0" in the Service menu
(see Section “Device Parameters” on page 143).
AK command:
– EVLV 3 1
n Disconnect conditioning hose from the Opacimeter input.
n Blow compressed air into the conditioning hose in short bursts
while shaking the hose so that any particulate deposits can work
loose.
n Repeat the process several times.
If, despite this cleaning, there are still depositis in the line, you can
clean them out with the cleaning brush (Ident. No. WH0065).
AVL 439 Opacimeter

Operating Manual
132 1000 Hour Service
8.5 1000 Hour Service

Those parts of the AVL 439 Opacimeter which are regularly contami-
nated with exhaust gas can wear within a short period of time and
might cause leakage.
Due to this, AVL recommends the exchange of these components after
1000 operating hours (operating-hour check in software) with original
AVL spare parts according to AVL requirements.
After 950 operating hours, the AVL 439 Opacimeter outputs an
message to the effect that a 1000 h service will soon be necessary.
This message is not an error message. You can still continue to carry
out measurements without any problem (the message is reset during
the 1000 h service).
n The total operating hours can be read out with the AVL 4210
Instrument Controller (sub menu "Parameters") or with the
AVL 439 PC Software. The download dongle (Article No. BV2601)
is also needed to reset the operating hours counter.
For comparison, an example : 1000 h operating hours correspond to
approx. 50.000 to 100.000 km driven.
DANGER!
All components should be exchanged only with approved and speci-
fied AVL spare parts!
With defects and troubles which are caused by disregarding AVL, no
warranty on the defective hardware can be claimed. This relates also
to the accuracy and specifications of the system.
n All service related actions should be performed by a trained (AVL)

service engineer.
n For detailed information see "1000 Hours Service" Operating
Instructions(Article No. AT1004E).
Storage for Long Periods of Non-Use 133
8.6 Storage for Long Periods of Non-Use

If the Opacimeter is not to be used for a long period, it must be discon-
nected from the exhaust system and also from the supply lines. When
stored for long periods, it must be kept in a dry, well-ventilated place.
Before long-term storage, make the following preparations:
n In "Function off" mode, activate the purge function.
n Disconnect the sample line and feed back line from the exhaust
line and let the Opacimeter run for about an hour in "Zeroing"
mode.
This ensures that any deposits or residual condensate is

removed.
n Switch the Opacimeter off.
n Replace the filter element with an unused one (see
Section “Changing the Filter Element” on page 124).
n Clean the windows (see Section “Cleaning the Window Modules”
on page 127).
n Carry out a short function test and then disconnect the connection
lines.
n Drain any condensate that has collected in the compressed air
preparation unit.
AVL 439 Opacimeter

Operating Manual
134 Storage for Long Periods of Non-Use
Error codes 135
9 Error Table
9.1 Error codes

Query command ASTF indicates the number of the current error:
1 Detector error Detector voltage too low

2 Lamp error Lamp current too low
3 Error at detector heating Detector temperature TD: temperature does not
increase when heating switched on (setpoint value not
reached)
4 Error at chamber heating Measuring chamber temperature TMK: temperature
does not increase when heating switched on (setpoint
value not reached)
5 Error at probe heating Gas temperature TG: temperature does not increase
when heating switched on (setpoint value not reached)
6 No compressed air Insufficient pressure at pressure switch
7 Error at window heating Px setpoint value not reached because window resis-
tance too low (< 4 Ω) or too high
8 Error at gas temp. sensor Gas temperature sensor defective
9 Error at chamber temp. sensor Measuring chamber sensor defective
10 Calibration error Zeroing cannot be carried out sensibly because the
detector voltage is drifting.
11 Flow rate too low Flow rate alarm: flow rate < 30 l/min
12 Flow rate warning Flow rate warning: flow rate < 35 l/min or > 60 l/min
13 Zeroing warning Measurement mode: The zero point may no longer be
correct – check it, or carry out Zeroing again (see
Section “Causes of Error, Remedies” on page 136).
Zeroing: Intensity drift since last zeroing (see

Section “Zeroing” on page 75).
14 The device has not reached the requested state or the
current action is not yet finished, e.g. setpoint tempera-
tures (measuring chamber temperature TMK, gas
temperature TG, lamp temperature TL) or signal
stability not yet reached or zeroing not yet finished.
15 Overtemp. det./lamps Detector temperature TD or lamp temperature TL too
high (> 100° C)
16 Overtemperature gas Gas temperature TG higher than 150° C
17 Measurement parameters checksum error
18 Analog output calibration checksum error
19 Operating hours counter checksum error
20 Sensor calibration checksum error
21 Setpoint values checksum error
Tab. 41
AVL 439 Opacimeter

Operating Manual
136 Causes of Error, Remedies
22 Limit values checksum error

23 Maintenance will be required soon Operating hours counter > 950 hours
Tab. 41
9.2 Causes of Error, Remedies

Error Possible cause Check Remedy
1 One lamp defective Ix = 0 (x = 1; 2) Replace lamp element
(ID number: BB0828)
Windows soiled Check windows visually Clean windows
Detector defective Replace detector element
(ID number: BB0797)
2 One lamp defective Ix = 0 (x = 1; 2) Replace lamp element
(ID number: BB0828)
3 Detector heating defective TD < TD (setpoint), not Replace detector element
increasing (ID number: BB0797)
4 Sensor for TMK defective Error 9 is output See error 9
No voltage in heating system Check voltage at plug Repair contact if faulty or replace
X14, pin 1 and 4 solid-state relay REL2 (Sect. “Compo-
nents of the Electronics Board” on
page 153)
Measuring chamber heating TMK < 100°C, If R < 10 Ω or R > 1000 Ω:
system defective disconnect plug X14, Replace measuring chamber, send
measure resistance R old one in for repair
(pin 1 and 2)
Measuring chamber over- Disconnect plug X14, If R < 10 Ω or R > 1000 Ω:
heated, overtemperature measure resistance R Replace heating element
switch responded overtemperature switch
EV0176, pin 3 and 4 Find reason for overheating:
(see Appendix, Section solid-state relay REL2 defective? (see
Measuring Chamber) Layout of Electronic Board,
Section “Components of the Elec-
tronics Board” on page 153)
Tab. 42
Causes of Error, Remedies 137

5 Sensor for TG defective Error 8 is output See error 8
Heating element burnt out TG < 100°C, If R < 10 Ω or R > 1000 Ω:
disconnect plug X15, Cool the measuring chamber, reset
measure resistance R overtemperature switch.
between pin 1 and 2 Find reason for overheating:
Overtemperature switch EV0170

defective?
Solid-state relay REL1 defective?
(see Layout of Electronic Board,
Section “Components of the Elec-
TG sensor defective
(see above)?
No voltage in the heating Check voltage at plug Repair contact if faulty or replace
system X15, pin 1 and 4 solid-state relay REL1
(Section “Components of the Elec-
Overtemperature switch Let heating element cool If R > 1 Ω:
broken down, disconnect plug Replace overtemperature switch
X15, measure resis- EV0177
tance between pin 3 and
4
6 Compressed air supply inad- Check pressure indicator Ensure adequate supply of com-
equate pressed air. There must be a pressure
of > 1.8 bar at the inlet even when
100 N l/min is removed
7 Heating layer defective P_window < 21.5 W, The window element must be
measure window resis- replaced, if not
Contact error
tance RF (plug J6, pins 10 Ω ≤ RF ≤ 100 Ω
Heating layer overheating 1+2 and 5+6) Note that the window elements must
be replaced in pairs!
Electronics problem 10 Ω ≤ RF ≤ 100 Ω Check electronics
8 PT-100 sensor for measuring The sensor is delivering Replace the sensor (or the entire
TG (at measuring chamber unacceptable values valve block)
inlet) is defective
9 Temperature sensor for TMK The sensor is delivering Replace the sensor (or the entire
defective unacceptable values measuring chamber)
Setpoint resistance:
50 kΩ … 160 kΩ at room
temperature
Tab. 42
AVL 439 Opacimeter

Operating Manual

10 Zero values before and after Check zero stability Zeroing – stabilise the Opacimeter
calibration differ by more without exhaust gas in until sufficient zero stability is
than ± 0.3 % measuring mode observed in measurement mode
without exhaust gas.
Was the "zero" cali-
(Drift < 0.3 % in 10 min)
brating filter cartridge
inserted completely Repeat calibration properly.
before and after the cali-
bration?
11 Filter element soiled Alarm deactivated when Replace filter element
new filter inserted
Pump failure Alarm active despite new Pump service (see below)
filter element
Limit value wrong Check limit value Set valid limit value
(terminal program) (terminal program)
12 Filter element soiled see error 11
Pump soiled see error 11
Limit value wrong see error 11
Tab. 42

13 Opacimeter has been contin- — Carry out zeroing as soon as your test
uously used for measure- sequence permits
ments for more than
30 minutes without zeroing
The device measures values Check the zero point
less than zero (< -1 % (Section “Checking the
opacity) Zero Point” on page 88).
Enable Negative Output
Values (Sections “Inter-
faces” on page 52 and
“DIL Switches” on
page 63)
Zero drift, Opacimeter is not Let the Opacimeter stabilise, carry out
stable during zeroing Zeroing again
Switchover to Bessel filter Generally speaking, not critical.
can cause negative over- In calibration mode: switch to Bessel
shoot filter before switching to calibration
mode
Temperature sensor and/or Check temperature Replace the sensors
pressure sensor failure – sensor and pressure
wrong correction factor sensor values for plausi-
bility
If error 13 is displayed in
Zeroing: detector voltage
has changed significantly
since the last zeroing.
Window dirty Check if window is dirty Switch Opacimeter off and clean
window
Zero air valve stuck Actuate valve V3 in Clean zero air valve (clean with com-
Service mode (see pressed air when removed from the
Section “Service” on Opacimeter) or replace it
page 143) and watch the
action of the zero air
valve
14 Opacimeter not yet warm TG and/or TMK Wait until the Opacimeter is warm
< 100° C, but rising
A heating system is defec- TG and/or TMK <100° C See error 4 and/or 5
tive after 20 min warm-up
TL not yet stably TL rises by more than Wait for TL to stabilize
0.5 °C/min
Requested mode not yet Wait until the requested mode is
reached reached
Tab. 43
AVL 439 Opacimeter

Operating Manual

15 Opacimeter ventilation TL > 90° C Replace fans
system failure
Open Opacimeter cover
(CAREFUL! mains
voltage!), check fans
Detector heating control TD > 90° C Replace detector module
defective
Venting apertures of the Clean venting apertures
housing blocked
16 Exhaust gas temperature Mount the sampling probe in a cooler
more than 600° C place in the exhaust line
PT-100 sensor for measuring The sensor is delivering Replace the sensor (or the entire
TG (at measuring chamber unacceptable values valve block)
inlet) is defective
Heating element overheated TG > 110° C Check solid-state relay REL1, replace
if necessary
17 Battery in memory module is Measurement parame- Replace module, new calibration of
empty ters change every time AVL 439 necessary (service techni-
AVL 439 is turned on cian)
Microprocessor failure Check measurement Replace electronics board, new cali-
parameters bration of AVL 439 necessary (service
technician)
Microprocessor: Check measurement Set new measurement parameters
electromagnetic interference parameters (filter, output unit, trigger setting)
18 Battery in memory module is Scaling of analog out- Replace module, new calibration of
empty puts wrong AVL 439 necessary (service techni-
(Section “Analog Mea- cian)
surement Value Output”
on page 58)
Microprocessor failure Scaling of analog out- Replace electronics board, new cali-
puts wrong bration of AVL 439 necessary (service
(Section “Analog Mea- technician)
on page 58)
Microprocessor: Scaling of analog out- Calibrate analog output
electromagnetic interference puts wrong (service technician)
(Section “Analog Mea-
on page 58
19 Battery in memory module is Read operating hours Replace module, new calibration of
empty counter AVL 439 necessary (service techni-
cian)
Microprocessor failure Read operating hours Replace electronics board, new cali-
counter bration of AVL 439 necessary (service
technician)
Microprocessor: Read operating hours Set operating hours counter again
electromagnetic interference counter (service technician)
Tab. 43

20 Battery in memory module is Check all sensor values Replace module, new calibration of
empty AVL 439 necessary (service techni-
cian)
Microprocessor failure Check all sensor values Replace electronics board, new cali-
bration of AVL 439 necessary (service
technician)
Microprocessor: Check all sensor values Calibrate sensors
electromagnetic interference (service technician)
21 Battery in memory module is Check all setpoint values Replace module, new calibration of
cian)
Microprocessor failure Check all setpoint values Replace electronics board, new cali-
technician)
Microprocessor: Check all setpoint values Enter setpoint values (setpoint value
electromagnetic interference of window heating may also have
changed) (service technician)
22 Battery in memory module is Check all limit values Replace module, new calibration of
cian)
Microprocessor failure Check all limit values Replace electronics board, new cali-
technician)
Microprocessor: Check all limit values Set limit values (service technician)
electromagnetic interference
23 Maintenance will be required Operating hours counter Perform recommended 1000 hour
soon > 950 hours service (service technician)
Tab. 43
AVL 439 Opacimeter

Operating Manual
Operating errors without error codes

No Communication error Check the communica- Set up correct communication pro-
response tion protocol, see tocol
from Section “RS232 Inter-
system face / AK Generic Com-
munication Interface” on
page 111
Microprocessor error Check electronics board, Replace microprocessor or elec-
tronics board (service)
see Section “Function
Check of the Electronics”
on page 154
Linearity Detector defective Linearity test error Replace detector element
test error > 0.5%
TD > Room temperature too high TD > TD(setpoint) Set setpoint temperature higher while
setpoint carrying out measurements at high
room temperature TD (setpoint) to
T(room) + 10° C
Room temperature higher Switch cooling fans on in test bed
than 50° C (specification room
limit)
Tab. 44
Function Check 143
10 Service
10.1 Function Check
10.1.1 Device Parameters

When the Opacimeter displays an error, e.g. when the green status
LED flashes, or when the measurement results suggest a system error,
it is advisable to carry out a function check.
Additional device parameters (spread of analog signal, operating hours
counter, ambient pressure) are described in Section “Device Parame-
ters (ambient pressure, spread of analog signal, conditioning tempera-
ture and operating hours counter)” on page 92.
The following screen appears when you call up the "Service"

menu.
Service screen on the Instrument Controllers
Fig. 66
The screen displays all the system’s measurement parameters and the
switch states of the lamps, pumps and valves.
You can also switch the lamps, pumps and valves using the service
function to check that they are working properly. To do this, press OFF
(F2) to set the Opacimeter to "Function off" mode.
When the Opacimeter is in ready mode (i.e. "Pause" and "Measure-
ment" functions), the following switch states must be displayed:
AVL 439 Opacimeter

Operating Manual
144 Function Check
Code L1 L2 P V1 V2 V3 V4
Signifying Lamp 1 Lamp 2 Pumps Conditioning air Purging Zero air Measure-
air ment gas
State 1 1 1 1 0 x 1
Tab. 45
x: 1 for "Measurement", 0 for "Zeroing"
DANGER!
V2 (purging valve) and V4 (inlet valve) must never both be on 1 at the
same time!
n AK Generic Communication Interface

– the following parameter supplies all the device parameters:
ASPA UD TD TMK TG p Q I1 I2 TL P1 P2
Service measurement values
UD: Detector signal [mV]

TD: Detector temperature [°C]
TMK: Measuring chamber temperature [°C]]
TL: Temperature in area of lamps [°C]
P1: Window 1 heat output [W] (real)
P2: Window 2 heat output [W] (real)
n The states of the lamps, pumps and valves can be checked using
the query command ASST. They can be set using switch com-
mands (see Section “Service” on page 121).
n The operating hours counter can be queried with the ABST com-
mand (see Section “General Queries” on page 115).
Function Check 145
10.1.2 Limit Values for the Device Parameters when Instrument

Functioning Correctly
The parameters must lie within the following range:
:
UD: 800 … 2200 mV for L1 = 1 or L2 = 1

1500 … 4500 mV for L1 = 1 and L2 = 1
TD: Setpoint value ± 1 °C. The setpoint is usually 50° C
unless specified otherwise in the ETDT command.
TMK: Setpoint value ± 5°C (default setting: setpoint value =
100° C)
TG: Setpoint value ± 5°C (default setting: setpoint value =
100° C)
TG may briefly deviate from the setpoint by up to 10° C
during sudden changes in exhaust gas temperature and
during power-up.
p: When pump switched off: ambient air
pressure.
When pump running: 30 to 60 mbar
below the pressure at the beginning
of the probe tube (pressure p-exhaust
gas in the exhaust line).
Caution: p-exhaust gas may lie
between - 100 mbar and +400 mbar
according to the specifications.
Q: Permissible range: 60 … 35 l/min
Warning range: 35 … 30 l/min or
> 60 l/min
Alarm range < 30 l/min
At a supply frequency of 60 Hz higher limits apply.
I1, I2: ~0 when Lx = 0
430 … 470 mA, when Lx = 1
T L: Maximum value: 100° C
The device is ready for measuring
°C
(thermally stabilised),
if TL changes by less than 0.5 min . When selecting
zero point adjustment after starting up, this condition is
in general achieved last (after approx. 20 min).
P1, P2: The setpoint is usually 14 W. It is labelled on all window
elements.
Tolerance: ± 0.5 W of setpoint value
AVL 439 Opacimeter

Operating Manual
146 Function Check
10.1.3 Pump Service

Check the pumps during the 1000 hour service. The diaphragms in
7015 diaphragm-type pumps must be renewed depending on use. It is
advisable to replace the valves at the same time (part of the "Spare
parts set for pump 7015", article number MV0143).
n To do this, remove the head screws.
n The pump head and chamber can now be lifted out and separated
from one another.
n Unscrew the central diaphragm screw and lift the diaphragms out.
Release the top and bottom diaphragm plates.
n Insert the new diaphragms and screw in well ("finger-tight").
n Remove the valves (valve/seal) from the pump chamber and
replace with new ones
n Place the pump head on the chamber making sure that the lug fits
into the groove.
n Position the cover plate on top and push the entire assembly over
the diaphragms. Make sure that the diaphragms slide properly
into the bore.
n Replace the four head screws and tighten them gradually in a
diagonal sequence.
Function Check 147
10.1.4 Leak Check

Each device is leak checked before shipping. In general re-testing is
not necessary. The leak check should only be carried out after any
disassembly of the exhaust gas ducting, to check for correct mounting
of all parts and connections.
For the leak check, the sample conditioning tube must be separated
from the probe tube, and the exhaust inlet of the sample conditioning
tube must be manually closed with an appropriate plug (e.g. Swage-
lock drain plug SS-10M0-P, AVL ID number DN0228).
n Make sure that the filter cover of the filter housing is closed prop-
erly:
Fig. 67
When selecting leak check, the whole system is evacuated to approx.

700 mbar absolute pressure, and the rate of pressure increase is
measured. If this measured rate of pressure increase is less than 1 %
of standard sample flow of 40 l/min, the test is passed.
The option leak check is accessible from the condition "Function off":
Call up the Menu (F1),
select Leak Check,
press START (F4).

– AK command: SLEC
The leak check is performed (duration approx. 20 s).
Requesting test result using ALEC.
Result: ALEC x
x = 0: test passed
x = 1: test failed
AVL 439 Opacimeter

Operating Manual
148 Function Check
10.1.5 Exchanging Temperature Sensors

Temperature sensor - measuring chamber
n Disconnect sensor cable (plug X18)
Fig. 68
Socket spanner (Item. 1, material number BH0219) for removing and

installing the temperature sensor in the measuring chamber (Item. 2,
material number BV2170)
Fig. 69
Function Check 149
Temperature sensor - valve block

n Disconnect sensor cable (plug X12)
Fig. 70
n Remove cable of temperature sensor for the valve block (material

number BV2208) from the sensor body using pliers (sensor body
remains in the valve))
Fig. 71
AVL 439 Opacimeter

Operating Manual
150 Function Check
n Insert the extractor tool (Item. 1, material number BH0218) in the

centre of sensor body and screw in applying moderate pressure.
Fig. 72
n Remove the sensor body with the extractor tool.
Fig. 73
Function Check 151
Assembly:
n Clean the bore making sure that no dirt gets into the valve body!
n Coat the metal housing of the new temperature sensor with liquid
Teflon (e.g. Loctite 572) and press it into the valve housing as far
as it will go (using a small screwdriver if necessary).
n Re-connect the temperature sensor cable at slot X12.
Fig. 74
See also "Exchanging Temperature Sensors" quick reference (article

number AT0955).
10.1.6 Software Update

New firmware can be installed using a PC and a serial interface.
This functionality is only available to a service technician. The down-
load dongle is required to carry this out (Article No. BV2601).
Important: After installing a new firmware, a calibration according to

the Calibration and Adjustment Procedure (article number AT0685E)
has to be performed
AVL 439 Opacimeter

Operating Manual
152 Electronics
10.2 Electronics
10.2.1 Electric Components

Rear view of electric box
Cooling air fan
Power supply unit J1
J3
Controller Board
(BB1101)
J28
Toroidal core
transformer
On/Off switch
J13 J14
Mains connection
Mains filter Fuse block
Fig. 75
Electronics 153
10.2.2 Components of the Electronics Board
LED 5
operating
state
Flow measurement
pressure sensor
Measuring chamber
pressure sensor
EPROM
with
firmware
LED 7
self test DIL
switches
LED 4
measuring
chamber
heating
LED 1
probe
heating
REL1
probe
heating
REL2
measuring
chamber
heating
LED 8 LED 9 LED 10 REL3 pumps

SV sample SV purging SV zero air
heating air
Fig. 76
AVL 439 Opacimeter

Operating Manual
154 Electronics
10.2.3 Function Check of the Electronics

n Function displays
When the On/Off switch is switched on, the following function dis-
plays are illuminated indicating that they are in a functional state
(see Section “Components of the Electronics Board” on page 153
for position of the LEDs):
– The status LED (Fig. 76 on page 153) is continuously on.
– LED no. 1 (red) lights up when probe heating is on
– LED no. 4 (red) lights up when chamber heating is on
– LED no. 5 (green) flashes at a frequency of about 2 Hz
(indicating that the microprocessor is functioning properly)
– LED no. 7 (red) lights up during the self test (approx. 5 s after
On/Off switch is switched on) and then goes off. This LED
also lights up when the Opacimeter is in not ready state.
– LED no. 8 (red) lights up when the solenoid valve for the
sample heating is active
– LED no. 9 (red) lights up when the solenoid valve for purging
air is active
– LED no. 10 (red) lights up when the solenoid valve for zero
air is active
155
11 Spare Parts List
Important: When ordering spare parts consider the serial number of

the opacimeter (see following table).
In the following spare parts tables some parts are marked with a
generation designation (G001 to G004) - spare parts without genera-
tion designation can be used for all opacimeters.
Generation Designation Serial number

1 G001 111 … 344
2 G002 511 … 1000
3 G003 1011 … 1500
4 G004 > 1511
Tab. 46
AVL 439 Opacimeter

Operating Manual
156
Mechanical Components
Tube 6.0 × 2.0 Viton black (per meter) SS0272
Polyamid filter cover H 145 H-8, S80x3 (for filter housing) MF0610
O-ring 73.5 × 3.5 (for Polyamid filter cover MF0610) DA0415
Measuring chamber, complete BO2694
Locking ring DIN 471 28x1.5 mm (stainless) DZ0637
(stainless version for measurement chamber tube – see 1000 Hour Service)
Pressure spring type KM-2286-174 mm lang (stainless) DF0148
(stainless version for measurement chamber tube – see 1000 Hour Service)
Diaphragm-type pump 7015 ZVD/230 V MV0141
(for 50 and 60 Hz power supply systems)
Spare parts set for pump 7015 (contains spare parts to service a single pump!) MV0143
Inlet valve complete (V4 inlet valve) G001 BO2716
G002 BO4084
G003, G004 BO4814
Cable motor valve (motor for V4 inlet valve) G001, G002 BV2204
G003, G004 BV2587
Solenoid valve (SV1, SV2, SV3) G001 … G003 MM0589
Solenoid valve (SV3) G004 MM0251
Air preparation unit for compressed air BH0171
Hose set, inside (for 1000 hour service) BO4460
Upgrade kit fan G001, G002 BH0269
(cooling air fan, electric box)
Fan (cooling air fan, electric box) BV2342
1
Pressure reducer 0.5 … 10 bar R /4" M004-R00 (mounted internally) MM0584
Pressure switch 1 … 10 bar (mounted internally) EZ0222
Tab. 47
157
Sampling Unit
Zero air valve G004 BO5358
Sealing cone for zero air valve G004 YM3679
Sample conditioning tube 1.5 m (silicone) G001 … G003 BH0169
Conditioning tube 1.5 m SI (silicone) G004 BO5359
Conditioning tube 1.5m FPM (Viton) G004 BO5354
Control hose for zero air valve 1.5 m PTFE (Teflon) G004 BO5356
Return sampling line 2.5 m G001 … G003 BH0203
Return sampling line 2.5 m FPM (Viton) G004 BH0266
Sample conditioning tube 3.0 m G001 … G003 BH0170
Conditioning tube 3 m SI (silicone) G004 BO5353
Conditioning tube 3m FPM (Viton) G004 BO5355
Control hose for zero air valve 3 m PTFE (Teflon) G004 BO5357
Clip conditioning tube - control hose G004 BO4548
Return sampling line 4.0 m G001 … G003 BH0214
Return sampling line 4.0 m FPM (Viton) G004 BH0267
Sampling line (incl. fittings, 0.5 m) G001 … G003 BH0220
G004 BH0227
Sampling line (incl. fittings, 1 m) G001 … G003 BH0173
G004 BH0228
Probe (corrugated tube 0.5 m, without fittings), YM3452
can be used as feed back pipe
Probe (corrugated tube 1 m, without fittings), YM3361
can be used as feed back pipe
Male connector DN1323
Drain plug for leak check DN0228
Welding piece 6-6GW DN1324
Closing plug for welding piece DN1373
Straight connector DN1320
Probe for open exhaust TM04390EA.01
(For test bed use only, not for testing on the road!)
O-ring 10.82 × 1.78 mm, viton (for sample conditioning tube) DA0355
O-ring 29.74 × 3.53 mm, viton (for sample conditioning tube) DA0356
Tab. 48
AVL 439 Opacimeter

Operating Manual
158
Electrical Components
Probe heating BO2717
Temperature switch 180° C (for probe heating) EV0177
Temperature switch 135° C (for measuring chamber heating) EV0176
Temperature sensor - measuring chamber BV2170
Temperature sensor - valve block BV2208
O-Ring 3.68 x 1.78 mm, Viton (for BV2170 and EV0176) DA0207
Controller board (main board) BB1101
Power supply 5 V/8 A, 24 V/2 A, ±15 V/2.5 A EN0321
Toroidal core transformer 240 VA prim. 2×115 V / sec. 2×24 V EI0248
(for window heating)
Signal lamp complete, green G001 EL0264
Light bulb 24 V, 2.6 W, BA9S socket (for signal lamp)) G001 EL0259
Cable kit 5 (contains all cables of the electric box) G003, G004 BV2585
(includes the following cables: BV2192, BV2193, BV2194, BV2195,
BV2390, BV2198, BV2585/1, BV2585/2, BV2585/3, BV2207)
Cable kit 6 (contains all cables of the main cabinet) G003, G004 BV2586

BV2163, BV2165, BV2586/1, BV2162, BV2209, BV2421)
Cable kit 3 (contains all cables of the electric box) G002 BV2420

BV2390, BV2198, BV2391, BV2200, BV2202, BV2207)
Cable kit 4 (contains all cables of the main cabinet) G002 BV2421
BV2163, BV2165, BV2167, BV2162, BV2209, BV2421)
Cable kit 1 (contains all cables of the electric box) G001 BV2330

BV2390, BV2198, BV2391, BV2200, BV2201, BV2202, BV2207)
Cable kit 2 (contains all cables of the main cabinet) G001 BV2331

BV2163, BV2165, BV2167, BV2162, BV2209)
Fuse F1 sec. 3.15 AT EV0047
Fuse F2 prim. 1 ATT EV0192
Fuse F3 and F4 6.3 AT EV0051
Fuse F5 1 AT EV0039
Fuse for option 100/115 V 10 AT EV0052
Tab. 49
159
Optical Components
Exchange set windows BH0215
(lamp unit and detector unit for exchange - paired unit)
Lamp element BB0828
Detector element BB0797
O-ring 50.00 x 2.00 mm, Viton (for lamp and detector unit) DA0369
Locking ring DIN 472 50x2 mm DZ0638
(stainless, for lamp and detector unit – 1000 hour service)
Sliding part (neutral, without calibration filter insert) YM3340
Tab. 50
Accessories
Analog cable 10 m G001, G002 BV1740
Analog cable 15 m G001, G002 BV1763
Cable digital I/O (DIO) 15 m BV2266
(is also used as analog cable with G003 and G004)
RS232 PC interface cable 15 m (e.g. connecting AVL 439 and PC) BV1854
RS232 PC interface cable 20 m (e.g. connecting AVL 439 and PC) BV2395
Download dongle G003, G004 BV2601
Connecting cable for AVL Instrument Controller, 15 m BV2191
Connecting cable for AVL Instrument Controller, 20 m BV2467
Condensate trap (including documentation) BH0193
Tab. 51
Consumption Parts
Filter insert (package consists of 6 pcs. filter insert plus an O-ring DA0415) MF0609
Cleaning set for heated windows HY0028
Tab. 52
AVL 439 Opacimeter

Operating Manual
160
Calibration Equipment
Calibration kit 439 (for service technician) TM0439KALA.01
(includes: floppy disk with calibration software, calibration device for temperature
sensor GAS IN, documentation)
Transmission filter 50 % BH0177
10 % BH0183
20 % BH0182
40 % BH0181
Tab. 53
Tools
Service Tool Kit for 439 TM0439WZK.01
(includes: cleaning brush, extractor tool and socket spanner for temperature sensors,
stopper for leak check, cleaning set for heated windows, documentation)
Cleaning brush for measuring chamber and sampling line WH0065
Tab. 54
Documentation
Operating Manual AVL 439 (English) AT0525E
AT1196E
AT1307E
PC Software Manual AVL 439 (English) AT0602E
Calibration Procedure AVL 439 (English) AT0685E
PUMA Integration 439 (English) AT0909E
VersaDos integration into PUMA5 and PUMA Open
On Board Diagnosis (German) AT0970D
Cleaning Set for Window Elements (English) AT0952
Exchanging Temperature Sensors (English) AT0955
Exchange Set Heated Windows (lamp adjustment) (English) AT0907
Condensate Trap (English) AT0713E
1000 Hour Service (English) AT1004E
Pressure-filled Mode (English) AT1005E
Manual "upgrade kit" (English / German) AT1284
Mounting instructions for upgrade kit "fan" AT1160
Tab. 55
161

Operating Manual AVL Instrument Controller (English) AT0993E
Exchange Controller Board (English / German) AT1534
Tab. 55
Miscellaneous
Plug connection 8p cable plug 6 mm (suitable for AVL 439 plugs) EU1623
Hose 9.0 × 3.0 PVC + fabric transparent (for compressed air tube) per meter SS0353
Clamp for tube 16.5 RER for compressed air tube DN1366
Tab. 56
AVL 439 Opacimeter

Operating Manual
162
163
12 Technical Data
Measurement value output
Opacity N [%] or absorption k [m-1]
Measurement range
N = 0 … 100 % or k = 0 … 10 m-1
Measurement value resolution
0.1 % opacity or 0.0025 m-1 (10 s mean value)
Zero stability
{0.1 % or 0.0025 m-1} / 30 min (drift with zero gas)
Rise time
0.1 s (at flow rate 40 l/min)
Inputs/outputs
Analog outputs 0 … 10 V (filtered, not filtered, calculation factors)
Serial RS232C interface, 9600 baud
Serial interface for connecting the optional AVL 4210 Instrument
Controllers
Digital input/output: 3 inputs, 3 outputs; potential separated by
optocoupler
(see Section “Digital Interface ("Digital I/O")” on page 54)
Sampling rate for opacity signal
50 Hz
Output rates
Serial interfaces up to 2 Hz using the AK generic

communication interface
(required by protocol)
Analog output (50 Hz)
Electronic measurement value filter (parametrisable)
Moving average 0.02 … 10 s

nd
Bessel filter of 2 order (0.2, 0.35, 0.5, 1.0, 1.077, 1.5, 2 s)
1st order low pass 0.02 … 10 s
Not filtered
Exhaust gas temperature

0 … 600° C
Exhaust gas pressure
-100 mbar … + 400 mbar (incl. pulsation peaks)
AVL 439 Opacimeter

Operating Manual
164
Protection type
IP 24
Ambient temperature
5 … 50° C
Power supply
230 V (100/115 V optional) ± 10 %, 50…60 Hz
Power consumption
1 kVA (max.)
Compressed air supply/consumption
Required:
max. 100 l/min, non-oiled, dry and filtered
input pressure regulated to 4…10 bar
Dimensions
650 × 420 × 450 mm (W × H × D)
Weight
approx. 47 kg
165
CE Compliance
89/336/EEC Electromagnetic Compatibility Directive complied with by
virtue of compliance with the following standard:
n EN 61326:97/A1:98/A2:01 Electrical Equipment for Measurement,
Control and Laboratory Use.
EMC Requirements
73/23/EEC Low Voltage Directive complied with by virtue of compli-
ance with the following standard:
n EN 61010-1:93/A2:95 Safety Requirements for Electrical Equip-
ment for Measurement, Control and Laboratory Use
The conformity to the Pressure Equipment Directive 97/23/EC is
evidenced by an assessment showing that the range according to
"article 3 / paragraph (3)" is not exceeded with this product / assembly.
AVL 439 Opacimeter

Operating Manual
166
460
Fig. 77
Use fixing materials
that are suitable
13.1
AVL 439 Opacimeter
for the type of wall
463
425.5
13 Appendix
Wall mounting
console
Grundplatte
Ø 12
Wall 540
Operating Manual
AVL 439 Opacimeter
Mounting Instructions -
10.5 DIN 125
M10x12 DIN7991
439 Wall Mounting Console
DIN 6336 M10x25 63 Ø

Mounting Instructions - 439 Wall Mounting Console
167
168 Mounting Instructions - Probe for Open Exhaust

Probe for Open Exhaust
For measurements at the open end of an exhaust pipe, e.g. test runs
on a roll test bed
Exhaust gas sampling
Zero air valve
Exhaust system
Sampling probe Probe tube

TM04390EA.01
Probe for open exhaust pipe, TM0439OEA.01, consisting of:

- Adapter (YM3389)
- Tube for exhaust probe Diesel (YM2733)
- Clamp for exhaust probe (BO1179)
Exhaust gas feed back
Exhaust gas extraction system Exhaust gas feed back
Fig. 78
Valve Block (complete) 169
13.3 Valve Block (complete)

(Ident. no. BO4814)
X12
Fig. 79
Pos. Ident. no. Designation

0020 BV2587 Motor valve + cable
0090 DN1336 Screwed angle fitting
0110 BV2208 Temperature sensor
Tab. 57
AVL 439 Opacimeter

Operating Manual
170
X14 2 1
Fig. 80
13.4
X18
30
cool end
cool end
Measuring Chamber
0210
0110 0090 0100 0050 0010 0080 0200 0205 0020 0120 0030 0205 0060 0180 0070 0200 0100 0090 0110
0130
Measuring Chamber
long end
0050
0190 0180 0190 0040 0190 0140 0190

0150
Measuring Chamber 171

0010 YM3333 Measuring cell
0020 YM3334 Outer tube
0030 YM3335 Deflector plate
0040 YM3336 Inlet tube
0050 YM3337 Support dics
0060 BV2503 Measuring cell heating 125 W
0070 BV2170 Measuring cell sensor
0080 EV0176 Temperature switch 140° C
0090 DA0357 O-ring 23.47 × 2.62
0100 DA0353 O-ring 53.7 × 1.78
0110 DZ0637 Retaining ring DIN471 28 × 1.5
0120 DS1041 Oval head screw DIN7985 M4
0130 DZ0287 Disc DIN6797
0140 DN0199 Connector cal input 1511-6/4-1/8"
0150 DN1319 Seal ring, 2651-1/8", Alu
0160 DZ0549 Disc 4.1
0170 EU1019 Faston connector 6.3
0180 EW0116 Cable guide
0190 HB0213 Glass fabrics tape 0.19 mm white
0200 DA0207 O-ring 3.68 × 1.78
0205 DF0148 Spring
0210 BV2210 Temp. switch + cable
Tab. 58
AVL 439 Opacimeter

Operating Manual
172 Probe Heating
13.5 Probe Heating
30
290
90
50
rd/bk rt/sw
sw
br
bl
30
bk
br
bl
1
3
2
4
X15
Fig. 81

0290 EV0177 Temperature switch 180° C
Tab. 59
PCB Probe heating
Fig. 82
Heating
Resistance: approx. 100 Ω
δ = 240° C
Thermoclick
Solid state relay
Switches off at 180° C

and on again at approx. 165° C
Operating Manual
AVL 439 Opacimeter
Socket or
plug (cable's side)
Probe Heating
173
174 Gas Path
13.6 Gas Path

(for further details see Operating Instructions "1000 Hour Service",
AT1004E)
0370
Valve block
0370
housing
complete
Filter
Zero air outlet

Zero air valve
0280
0250
0280
0250
PT1
PT2
Main board
P+
Q+
Fig. 83

250 ZG2179 Pump air guide
280 MV0141 Diaphragm type pump
370 DN1331 Connector ¼, exthaust gas return
Tab. 60
Pneumatics 175
13.7 Pneumatics
0130
0200
0170 0160 0170 0160 0170
Set pressure
at zero point adjustment:
2
V3 3 V1 V2 2.5 bar
1
0100
0150
static set pressure:

1 bar
0080
0135
0140
0120
0135
0135
Teflonschlauch 4.0 × 1
Fig. 84
AVL 439 Opacimeter

Operating Manual
176 Pneumatics

0080 DN1327 Nipple ¼"
0100 MM0584 Pressure reducer 0.5…10 bar R ¼"
0120 DN0647 cross piece ¼"
0135 DN1215 Male connector
0140 DN1328 T-connector
0150 EZ0222 Pressure switch 1…10 bar
0160 MM0589 Solenoid valve
0170 MM0251 Solenoid valve
0200 DN1826 Box 1/8"
Tab. 61
Electronics / Assembly 177
13.8 Electronics / Assembly
0070
Connector for potential equalization

0020
0110
Z
F1
F4
0090
Z…Fuse and connector block

0040
0100
Fig. 85
AVL 439 Opacimeter

Operating Manual
178 Electronics / Assembly

0020 BB1101 Controller Board
0040 ES0360 Cam switch
0070 EU0013 Connector. 3-p.
0080 EN0321 Power supply
0090 EI0148 Mains filter 230 V, 10 A
0100 EI0248 Toroidal core transformer 240 VA
0110 BV2342 Cooling air fan
Tab. 62
Probe Heating Pumps Lamp Unit Measuring Chamber Detector Unit Fan
1 2 2 1
Fig. 86
13.9
M M Temp. Meas. Chamber M M
~ ~ = =
MV4
BV2162 BV2162 BV2161 Temp. Gas BV2170 BO2938 BO2938
Pt100
BO2717
BV2210 BV2208
Connecting
X15 X13 X16 X14 X12 X18 X11 X17
Panel
BV2587 BV2205 BV2163 BV2165
Compressed Air
BV2203 BV2164 BV2206 BV2586/1
P
Temp. AUX
Operating Manual
ANALOG I/0 X1 J15 J7 J10 J4 J6 J2 J11 J8 J5
Block Diagrams, Wiring
AVL 439 Opacimeter

COM 1 X2
COM 2 X3 Controller J9 Probe
DIGITAL I/0 X4
External X5 J28 J1 J14 J3 J12 J13
BV2207 BV2585/1
BV2342 Fan BV2585/2
DC
M BV2198 BV2421 J12 BV2585/3
= AC
SUPPLY 230V AC POWER S1
LINE
LOAD
Filter XT1 V1 V2 V3
BV2166 X7 BV2192 BV2194 BV2195 BV2390 POWER/ERROR

BV2193
Block Diagrams, Wiring
179
180
Fig. 87
CONTROLLER BOARD
J2 J11 J4 J15 J10 J8 J6 J12 J7

Wiring Basic Unit
BV2421
BV2205 BV2203 BV2204 BV2167
BV2206
BV2165 BV2163 BV2163 BV2164
FAN FAN
BV2209
ETECTOR UNIT LAMP UNIT

Z Y
13.10 Wiring Basic Unit
Detail Z Detail Y
MV4 BV2206 BV2170
BV2210
BV2161
X11 BV2203 X17

X14 X15
X13 X16
X12 X18
BV2209 BO2938
BV2209 BO2938
BV2162 BV2205 BO2717 BV2162
BV2209
PT100
pos 1030
PUMP BV2208 PUMP
sw rt/sw rt/sw sw
pos 1010,1020
Fig. 88
BV2585/2
J1
BV2585/1
J3
BV2198
J28
BV2342
Operating Manual
AVL 439 Opacimeter
BV2201
ws
1 11
sw
rt 2 12
br
BV2195
bl1
3 13
gr
4 14 BV2390
bl
5 15
gr1
6 16
7 17
8 18
9 19
V1 V2 V3
Controller Board
BV2194
BV2192
LINE
LOAD
J13
J14
Wiring Basic Unit
BV2193 BV2207 BV2202

181
182
EI0248
bl bk / sw
XT1 115V 24V XT1
0110
0110 gr rd / rt
4 0180
3
Fig. 89
0170 F1 3.15AT
F2 1ATT
14 bl1 br 13
115V 24V
gr1 wh / ws
0070 0090 0040 2x 0110 2 x 0140

wh / ws bk / sw
2 x 0120 1 x EU0844
2 x EU0843
1 2
BV2192 BV2194 BV2195 BV2390
XT1
11 12
Electronic Wiring Diagram
F3 6.3AT br bl
P 1 bk / sw
15 5
sw / bk 2 1 sw / bk 7 17 sw / bk br
LINE
BV2585/1
N 2 bk / sw 0020
LOAD
Controller
sw / bk 4 3 sw / bk 8 18 sw / bk gr1 Board J3
BV2207
16 6 J14
bl bl
J1
F4 6.3AT
BV2193 ye/gn 19 9 ye/gn
BV2342
ge/gn ge/gn
M
=
BV2585/2
X7 S1
SUPPLY 230V AC POWER XT1 XT1
0080
13.11 Electronic Wiring Diagram
AC
BV2198
DC
Components Location Diagram 183
13.12 Components Location Diagram
Fig. 90
AVL 439 Opacimeter

Operating Manual
184 Circuit Diagrams
13.13 Circuit Diagrams
Fig. 91
Circuit Diagrams 185
Fig. 92
AVL 439 Opacimeter

Operating Manual
Fig. 93
Fig. 94
AVL 439 Opacimeter

Operating Manual
Fig. 95
Fig. 96
AVL 439 Opacimeter

Operating Manual
190 Comparison Table
13.14 Comparison Table

The table below shows the correlation between opacity N [%] and the
light absorption coefficient k [m-1]. This table is based on an effective
measuring length of 0.430 m.
Opacity N Absorption k Opacity N Absorption k Opacity N Absorption k

[%] [m-1] [%] [m-1] [%] [m-1]
1 0.02 31 0.86 60.4 2.15
2 0.05 32 0.90 61 2.19
3 0.07 33 0.93 62 2.25
4 0.09 34 0.97 63 2.31
5 0.12 35 1.00 64 2.38
6 0.14 36 1.04 65 2.44
7 0.17 37 1.07 66 2.51
8 0.19 38 1.11 67 2.58
9 0.22 39 1.15 68 2.65
10 0.25 40 1.19 69 2.72
11 0.27 41 1.23 70 2.80
12 0.30 42 1.27 71 2.88
13 0.32 43 1.31 72 2.96
14 0.35 44 1.35 73 3.04
15 0.38 45 1.39 74 3.13
16 0.41 46 1.43 75 3.22
17 0.43 47 1.48 76 3.32
18 0.46 48 1.52 77 3.42
19 0.49 49 1.57 78 3.52
20 0.52 50 1.61 79 3.63
21 0.55 51 1.66 80 3.74
22 0.58 52 1.71 81 3.86
23 0.61 53 1.76 82 3.99
24 0.64 54 1.81 83 4.12
25 0.67 55 1.86 84 4.26
26 0.70 56 1.91 85 4.41
27 0.73 57 1.96 86 4.57
28 0.76 58 2.02 87 4.74
29 0.80 59 2.07 88 4.93
30 0.83 60 2.13 89 5.13
90 5.35
Tab. 63
Index 191
Index
A C H
absorption coefficient 13 Calibration Hybrid Interface ("DIO") 72
AK command Calibrating the Sensors 110
AANA 122 General 103 I
AKAL 119 Linearity Check ("Calibration") with
AKON 117 "Neutral Density Filters 106 Installation 37
ALCH 120 Linearity Test ("LIN Check") 104 Analog Measurement Value Output
ALDR 120 calibration 18 58
ALEC 120 calibration points commissioning 37
AMBE 120 dark value 103 Compressed Air Supply 49
light value 103 Connecting the AVL 4210
AMDT 118
changing the filter 124 Instrument Controller or PC 60
AMES 118
Checking the Zero Point 88 Connections on the Opacimeter 41
APAR 119
checking the zero point 16 Digital Interface ("Digital I/O") 54
ASMK 122
Circuit Diagrams 184 DIL Switches 63
ASPA 121
commissioning 37 Exhaust Gas Recirculation 48
ASST 122
Comparison Table 190 Exhaust Gas Routing 41
ASTF 115 Fitting of Zero Air Valve, Sampling
ASTZ 115 Components Location Diagram
Lines and Probes 42
EANA 122 183
General 38
ELDR 120 Continuous Measurement Installation Instructions for Tube
ELMP 121 (Standard Measurement) Fittings 49
EMBE 120 78 Interfaces 52
EPAR 118 Power Supply 51
EPMP 121 D Serial Interfaces 53
ESMK 122 Trolley Option 40
dark value 103
EVLV 122 Wall Mounting Console Option 39
SBST 117
detector 13
Determination of Zero Value 95 intensity of the light 13
SIDL 117 Interface 52, 60
Device Parameters
SKAL 119 Analog 58
Ambient pressure 92
SLCH 119 Digital 54
Conditioning temperature 92
SLEC 120 Reset of the second operating hours Serial 53
SMFA 118 counter 92
SMFE 118 Spread of the analog signal 92
SMGA 117 L
DIL Switch 63
SNGA 118 light extinction 13
SPAU 117 light value 103
SPRG 121 E LIN check 17
SREM 117 ECE R24 87 linearity 17
SRES 117 electromagnetic radiation 13 Linearity Check 17
SRUC 121 Electronic Wiring Diagram 182 Linearity Check ("LIN Check") 17
STBY 117 Electronics Assembly 177 low pass filter constant 97
AK Generic Communication ELR test 84 Low pass of the 1st order 97
Interface 111 Error Table
AVL 4210 Instrument Controller Causes of Error, Remedies 136 M
68 Error codes 135
Maintenance and Storage
Menu Choices and Settings 70
Operating the AVL 4210 Instrument 1000 Hour Service 132
Controller 69
F Changing the Filter Element 124
Filter Calculation 96 Cleaning instructions for the window
filter element 124 elements of the detector and
B filter type lamp unit 130
Back-flushing of the Probe 18 Bessel Filter 97 Cleaning the Sampling Lines 131
Basic Unit 25 Floating Mean 96 Cleaning the Window Modules 127
Beer-Lambert law 13 Low pass of the 1st order 97 General 123
Bessel Filter 97 Floating Mean 96 Storage for Long Periods of
Bessel filtering 89 Function off 17 Non-Use 133
Block Diagrams, Wiring 179 measurement 16
Measurement parameters 89
G Measurement Principle 13
Gas Path 174 measurement variation 67
Getting the Opacimeter Ready for
Measurement 73
AVL 439 Opacimeter

Operating Manual
192 Index
Measurements option Spare Parts List 155

AVL 4210 Instrument Controller 68 ½ 19" Bench Cabinet for AVL 4210 Accessories 159
Brief Instructions 65 Instrument Controller 34 Calibration Equipment 160
Calculation of the Raw Value 95 19" Bench Cabinet for AVL 4210 Consumption Parts 159
Carrying out a Measurement 66 Instrument Controller 34 Documentation 160
Checking the Zero Point 88 19" Mounting Frame for AVL 4210 Electrical Components 158
Continuous Measurement Instrument Controller 33 Mechanical Components 156
(Standard Measurement) 78 AVL 4210 Instrument Controller 32 Miscellaneous 161
Control via Hybrid Interface ("DIO") I/O Cables (Analog Cable) 36 Optical Components 159
72 PC-Software 33 Tools 160
Control via Serial Interface or Probe for Open Exhaust Pipe 36 state
Terminal Program of a PC 71 Sample Lines 30 Back-flushing of the Probe 18
Determination of Zero Value 95 Trolley 36 Calibration 18
Device Parameters 92 Wall Mounting Console 35 Linearity Check ("LIN Check") 17
ECE R24 87
ELR test 84 P
Filter Calculation 96
T
pause 17 Technical Data 163
Measurement parameters 89
Peak Value Measurement 80
Pneumatics 175
Operation with the DIO interface 94 V
Power Supply 51
Overview of Opacimeter Functions Valve Block (complete) 169
65 Probe Heating 172
Peak Value Measurement 80
Reading stability 67 R W
Safety Instructions in Special Reading stability 67 Wiring Basic Unit 180
Conditions 67 RS232 Interface
Setting the Function and Command Set 114
Measurement Value Output
Z
General 111
68 Zeroing 75
General Control Commands 117
Setting the Parameters 89 General Queries 115
zeroing 16
Switching On and Warming Up Measurement 117
Getting the Opacimeter Ready
Operating Mode 114
for Measurement 73
Protocol Framework 111
Zeroing 75
Service 121
measuring cell 67
Measuring Chamber 170
measuring chamber 13 S
measuring unit safety instruction 2, 17, 18, 38,
detector unit 21 40, 43, 48, 50, 51, 66,
light unit 21 123, 126, 127, 130, 132,
measuring chamber 21 144
Mounting Instructions 439 Wall sensor value 110
Mounting Console 167 Service
Mounting Instructions Probe for Components of the Electronics
Open Exhaust 168 Board 153
Electric Components 152
N Exchanging Temperature Sensors
148
Neutral density filter 106 Function Check Device Parameters
143
O Function Check Leak Check 147
Opacimeter Design 25 Function Check Limit Values for the
Opacimeter Functions Device Parameters when
Instrument Functioning
Overview 65
Correctly 145
opacity 13 Function Check of the Electronics
operating mode
checking the zero point 16
154
Function Check Pump Service 146
Function off 17
Software Update 151
measurement 16
pause 17
spare parts 155
zeroing 16
AVL List GmbH
Hans-List-Platz 1, A-8020 Graz, Austria
Phone: +43 316 787-0, Fax: +43 316 787-400
http://www.avl.com

AVL 439 Opacimeter Operating Manual

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AVL 439 Opacimeter Operating Manual

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AVL 439 Opacimeter

As of Opacimeter Rev. 03 / SN 1569

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