Manual for GASBOARD-6010

Opacity Meter

Components

Smoke Head
 Light source panel
 Detector panel
 Cell Temperature sensor
 Heating Component
 Gas Temperature sensor
 Gas Input valve
 Smoke measurement chamber
 Exhaust fan

Display Unit
Sampling Pipe
Sample Probe and Handle
Communication Line
Data Line

Operating Instruction

Equipment Assembly
1. Fix exhaust probe clamp
device on to the stainless
steel probe.
2. Insert the end of the
stainless steel probe into
the red rubber hose and
securely tighten the
clamp.
3. Connect the other end of
the red rubber hose to the
smoke inlet tube on the
smoke head and securely
tighten the clamp to prevent any gas from leaking.
4. Connect the communication cable between the smoke head and display unit and
tighten the connector screws securely.
5. Connect the power cord from the smoke head to an electrical outlet. Ensure that the
unit is switched of before plugging the power cord in.
6. Connect the oil temperature probe (optional extra) to the smoke head.
7. Ensure that all electrical power supplies are properly grounded to ensure operator and
equipment safety.

Warm-up
 1. Warm up time is 15 minutes
2. Do not connect the sample probe to the vehicles exhaust during warm up. It should be
kept in clean air, well away from any exhaust emissions in order or the opacity meter
to perform its automatic calibration correctly.
3. When the detector temperature reaches 45 C and the sample tube temperature reaches
78 C, the warm up indicator disappears and the opacity meter is now ready to perform
test.
Real-time Measurement
1. Assemble the equipment according to the instructions. Switch the smoke head and
display units on and wait for it to complete the warm up cycle.
2. Real-time measurement
K = real-time light absorption coefficient; m-1
N = Dynamic Opacity Degree; %
RPM = Engine Revolution; revolution per minute
Oil = Oil Temperature; C
3. The vehicles engine must be running and be at normal operating temperature.
4. Enter button to allow the opacity meter to perform a calibration. The sample probe
should be kept in clean air, well away from any exhaust emissions in order for the
opacity meter to perform its automatic calibration correctly to avoid inaccurate test
results.
5. Depress the accelerator two to three times in quick succession to clear any remaining
exhaust gas from the exhaust system.
6. Connect the sample probe to the vehicle exhaust pipe. The probe shall be inserted at
least 30 cm into the exhaust pipe. If this is not possible, insert the sample probe as
deep as it can go without touching the wall of the exhaust pipe.

7. During the real-time (continuous) test, the maximum value reached, will remain
unchanged.
8. After completing the measurement, remove the sample probe from the exhaust pipe
9. Print result

Emission Control
What is Emission Control System?
Emission Control system reduces the emission produced by automobile.
Emission control system reduces the emissions, which are harmful to the Environment
and human being produced by automobile.

Exhaust Emissions are produced by cars, buses, and motorcycles.

Four basic types of exhaust emissions:
1. Hydrocarbons (HC)
 Resulting from the release of unburned fuel into the atmosphere
 Produced by incomplete combustion or by fuel evaporation.
 Mostly related to ignition problems.
 Effect could be eye,
 throat, and lung irritation, and, possibly cancer.
2. Carbon monoxides (CO)
 Extremely toxic emission resulting from the release of partially burned fuel
(incomplete combustion of petroleum-based fuel).
 CO prevents human blood cells from carrying oxygen to body tissue
 Symptoms are headaches, nausea, blurred vision, and fatigue.
 A rich air-fuel would increase CO; lean air-fuel mixture would lower CO
emissions.
3. Oxides of nitrogen (NOx)
 Produced by extremely high temperatures during combustion.
 Air consist of about 79% nitrogen and 21% oxygen
 With enough heat (above 2500ºF / 1370ºC), nitrogen and oxygen in air-fuel
mixture combines to form NOx emissions.
 An engine with high compression ratio, lean air-fuel mixture, and high-
temperature thermostat will produce high combustion heat, resulting in
formation of NOx.
4. Particulates

SOURCES OF VEHICLE EMISSONS

Engine Crankcase Blow-by Fumes (20%) – heating oil and

burning of fuel that blows past piston rings and into the
crankcase.

Fuel Vapour (20%) – chemicals that enter the air as fuel

evaporate.
Engine Exhaust (60%)- blown out the tailpipe when engine
burns a hydrocarbon based fuel.

Engine Modification Related to Emission Control

Lower Compression Ratios

• Use of unleaded gasoline that permits use of catalytic
converters and burns
completely to lower HC emissions.
• Lower combustion temperature = Lower NOx
emissions.

Smaller Combustion Chamber Surface Volume

• Reduce HC emissions.
• Lowers the amount of heat dissipation out of the fuel mixture.
• Reduce the chance of fuel condensation.

Reduce Quench Areas in the Combustion Chambers

• Lower HC and CO emissions.
• Quench areas- movement of piston too close to the cylinder head.
• If too close, it tends to quench (put out) combustion and increase emissions
due to unburned fuel.

Vehicle Emission Control System

PCV (Positive Crankcase Ventilation System)

• Uses engine vacuum to draw blow-by
gases into the intake manifold for
reburning in the combustion chamber.
• At idle, high manifold vacuum pulls
the plunger for minimum vapour flow
(prevents a lean air-fuel mixture).
• During acceleration, intake manifold
decreases. This allows the PCV valve
to move to a center position for
maximum flow.
• With engine off, a spring pushes the
valve against its seat, closing the valve.
A backfire will also close the valve.

Evaporative Emission Control Systems (EVAP)

 Prevents toxic fuel system vapours from entering the atmosphere

Exhaust Gas Recirculation (EGR)

• Allows burned gases to enter the engine intake manifold to help reduce NOx
• When exhaust gases are added to air-fuel mixture, they decrease peak
combustion temperatures.
 • Vacuum operated (Throttle Vacuum) When accelerated the throttle plate
opens, engine vacuum is applied to EGR, opening the diaphragm. Engine
exhaust can enter the intake manifold and combustion chamber.

• Electronic EGR Valve uses one or more solenoids to open/close exhaust

passages.

EGR System Service

• System malfunction can cause stalling, rough idle, detonation, and poor fuel
economy.
 • If stuck open, it will cause a lean air-fuel mixture, engine will run rough at
idle, or stall.
• If stuck closed, higher combustion temperatures can cause abnormal
combustion and knocking, raising NOx.
EGR System Service (Vacuum Type)
• Allow the engine to warm up, increase the engine speed to 2000-3000 rpm
very quickly, the EGR valve stem should move.
• Idle the engine, connect a vacuum pump, when vacuum is applied the engine
should miss or stall.
EGR System Service (Electronic Type)
• Most problems can be located by a
scan tool.
• Symptoms will be similar to the
vacuum type EGR.

Air Injection System

 • Forces fresh air into the exhaust ports or catalytic converter to reduce HC/CO.
• Oxygen from the air injection system causes the unburned fuel to burn in the
exhaust system or the catalytic converter.

Catalytic Converter
• Oxidizes (burns) the remaining HC and CO emissions that pass into the
exhaust system.
• Extreme heat (1400°F/760°C) ignites these emissions and change them into
carbon dioxide (CO2) and water (H2O).
• Catalyst is a substance that speeds a chemical reaction without itself being
changed (coated with ceramic honey comb).
• Catalyst Substance: Platinum and Palladium treats HC and CO emissions;
Rhodium acts on the NOx emissions.

Types of Converters
Mini Catalytic Converter is placed close to the
engine exhaust manifold.
Two-way Catalytic Converter can only reduce
HC & CO (Platinum).

Types of Converters
Three-way Catalytic Converter reduces HC, CO & NOx (Platinum and Rhodium).
Dual-bed Catalytic Converter normally has both a three-way (reduction) and a
two-way (oxidation) catalyst.
• Mixing chamber is provided between the two.
Air is forced into the mixing chamber to help burn the HC and CO emissions

Catalytic Converter Service

A clogged converter can increase exhaust back pressure, decreasing engine performance
(rotten egg smell).
Catalytic Converter Service
Exhaust back pressure test will check for a clogged catalytic converter.
• Remove the front oxygen sensor and install a pressure gauge.
• Start engine, read pressure at idle and at high speeds.
• If gauge reads too high, there is a restriction in the exhaust system.
• Remove one part at a time to isolate problem.

Electronic Computer Control System

An Engine which utilizes a microprocessor to control various engine functions. This results in
a reduction in exhaust gas emissions and improves engine performance with a reduction in
fuel consumption.
Purpose of ECCS Development
 Improved engine performance
 Improved driveability
 Reduced exhaust emissions
 Improved starting in cold weather
 Reduction in fuel consumption