SPECIFICATION Emissionsbench AMA 4000 and AMA 4000 Advanced
(Colours and Details on Pictures may de slightly different to the Supplied Hardware)
1.GENERAL INFORMATIONS (3)
1.1.A MBIENT CONDITIONS (4)
2.SERVICES REQUIRED (5)
2.1.P OWER: (5)
2.2.C ABINET VENTILATION: (7)
2.3.E XHAUST VENTILATION: (8)
2.4.C OMPRESSED A IR: (9)
2.5.C ONDENSATE D RAIN: (9)
3.SAMPLE INLET (10)
3.1.H EATED SAMPLE UNIT (HSU): (10)
3.2.R AW GAS MEASUREMENT (11)
4.GASES REQUIRED (13)
4.1.O PERATION GASES (13)
4.2.C ALIBRATION GASES (14)
4.2.1. E XAMPLES EPA/CFR P ART 86: (16)
4.2.2. E XAMPLES ECE: (17)
4.3.S PECIAL GASES (18)
5.INSTALLATION MATERIAL AMA 4000 (20)
5.1.P IERBURG I NSTRUMENTS SCOPE OF SUPPLY (20)
5.2.O UR SCOPE OF SUPPLY DOES NOT INCLUDE (20)
APPENDIX 1: GUIDELINE FOR THE INSTALLATION OF HEATED HOSES (21)
APPENDIX 2: SPECIFICATION OF CALIBRATION GASES (24)
1. G eneral information
Qty. Type Pos. Application
AMA 4000
Dimensions: 665 * 900 * 2000 mm (W * D * H)
Weight: approx. 450 kg
(depending on the actual system configuration)
Colours:
front and back covers: RAL 9006 white aluminium frame and side plates: RAL 5002 ultramarine blue
Bench control unit BCU 4000:
Operating system Windows NT 4.0
Screen 15" TFT Touch screen
Host communication LAN (TCP/IP)
RS 232 (AK-SAMT)
Analyser control unit ACU 4000:
Operating system 32 Bit
Real time operating system (RTKernel-32)
Internal communication LAN (TCP/IP)
CAN-Bus (CANOpen)
Loss of heat: approx. 2-3 kW (depending on the actual system configuration)
1.1. A mbient conditions
Temperature: 10-35°C [50-95°F]
Ambient Pressure: 800-1050 mbar [11,6-15,2 psi], absolute, constant
(pressure change during measurement <50 mbar [0,72 psi])
Humidity: m ax. 80% rel. humidity (N O C ONDENSATION!)
Clean and dry ambient conditions!
?The system is equipped with fans for removing the heat from the cabinet.
The air stream of these fans should not be restricted under any circumstances .
In order to ensure that there must be a minimum distance of about 20 cm to walls sur-rounding the bench and the ceiling (see f ig. 5, page 7).
A minimum distance to a wall of 50 cm is recommended for the backside for service. ?The location should be chosen to enable easy access to the system.
The surface must be a even so that it is possible to pull out the GPU easily (see fig. 1, page 4). This is very important for service and installation.
?The location must be free from vibrations.
?The location must not be draughty or windy.
fig. 1
AMA 4000 with pulled out GPU for service
2. S ervices required
2.1. P ower:
The system is equipped with a 5 meter power cable and a mounted CEE plug for 32A.
fig. 2
CEE Plug
Power system:Three-phase current with centre neutral (L1, L2, L3 – N – PE). Stable power supply without any interruptions is required.
Nominal voltage : 3 x 400 VAC ±10% Phase L1: m ax 16 A (3.68 kVA) Phase L2: m ax 16 A (3.68 kVA) Phase L3: m ax 16 A ( 3.68 kVA) Frequency: 50 Hz ±2% (Standard)
60 Hz ±2% (Option)
The socket has to be within a distance of 5m to the AMA 4000
ATTENTION: It is not allowed to use a 50 Hz-Bench at 60 Hz and reciprocal because some components are only for one frequency.
fig. 3
example: location of gas panel
gaspanel
The cabinet is equipped with fans for removing the heat from the cabinet and in case of a damaged gas line to prevent hydrogen from gathering in the cabinet. Therefore it is impor-tant and absolutely necessary to use a ventilation system to remove the warm air stream out of the room.
The air stream volume of the fans is: 7,5m3/min (one measuring line) … 15m3/min (two measuring lines)
The recommended capacity for a ventilation system is min. 15m3/min … 25m3/min. (de-pending on the configuration)
f ig. 4
example: ventilation system
fig. 5
top view of AMA 4000
ceiling fans
After passing through the analysers the gases are discharged via the central extraction (see fig. 7, page 8). The AMA 4000 will be delivered with 10m PVC spiral hose, inner di-ameter 32 mm) connected to the central outlet.
The customer shall provide a external ventilation system with a recommended flow of approx. 3-4 m3/h; max. 8 m3/h
Depressure at the point of withdrawal: max. 10 mbar (0.14 PSI)
To prevent the hose of any damaging, it is recommended to lay it in a duct. The hose must not be bended or squeezed at any point.
ATTENTION:
Due to partial toxicity, all bench exhaust gases must be ventilated by a suitable extracting system. The Bench may not be operated unless the ventilation system is running.
fig. 6 fig. 7
rear side AMA 4000 central outlet
2.4. C ompressed Air:
If the AMA 4000 is equipped with a heated FID (H-FID) compressed air is required for operation.
Supply pressure approx. 3 bar [43.5 psi] (min. 2 bar [29 psi], max. 6 bar [87 psi]) Clean, dry and oil free.
Quality grade according PNEUROP-recommendation 6611/1984 or DIN ISO 8573-1
Max. size of particulate: 0,1 μm class 1
Max. density of particulate: 0,1 mg/m 3
class 1
Max. oil content: 0,01 mg/m 3
class 1 Dew point: -20°C [-4°F] class 3
Consumption: approx. 250 l/h (if the system is equipped with one H-FID). For each additional H-FID250 l/h have to be added to the consumption.
2.5. C ondensate Drain:
The condensate (approx. 100 ml/h) will be conducted to a hose connector at the bottom of the rear side of the AMA 4000. From there a 10m PU 6x1mm hose will lead the conden-sate to the customers collecting site.
N OTE : T HIS IS HAZARDEOUS WASTE ! P LEASE DISPOSE ACCORDINGLY !
fig. 9
condensate drain
fig. 8
3. S ample Inlet
3.1. H eated sample unit (HSU):
The heated sample line from the HSU is connected to the AMA 4000 from the rear. (See fig. 10, page.10)
fig. 10 connecting block for HSU
connecting block
for HSU
3.2. R aw gas measurement
A stainless steel tube (suitable for 8 mm ferrule fitting) to protect the heated line against overheat and vibrations, should be installed between tailpipe and heated sample line (see fig. 11 and f ig. 12 (page 11/12) ).
Maximum inlet gas temperature stainless steel hose: 600°C [1112°F]!
Maximum inlet gas temperature heated sample line: 200°C [392°F]!
To prevent condensation the temperature of the heated sample line should
not be lower than 191°C [376°F] for diesel and
not be lower than 120°C [248°F] for gasoline engines
The customer has to provide an appropriate bracket to support the heated line as shown in fig. 11 and f ig. 12 (page 11/12) pos. TENSION RELIEF.
The diameter of the end caps is 45 mm and of the insulation approx. 40 mm.
The heated sample lines has to be installed according to the “Guideline for the installation of heated hoses” (see Appendix 1, page 21).
fig. 11
drawing tailpipe connection (all dimension in mm) ?45 approx. ?40
tension relief (customer supply)
stainless steel hose (option)
heated sampleline X
sample probe
tailpipe exhaust gas
to AMA interface tailpipe
connection
fitting
X
fig. 12
example: tailpipe connection
An external prefilter unit is recommended.
For diesel-, 2 stroke-, offroad-, and special applications an external prefilter unit is highly recommended.
tension relief (customer suply)
stainless steel hose (option)
raw gas sample probe
exhaust pipe
heated sample line
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AMA 4000 spec. 1.1.DOC
Date: 25.02.2005
EOP
4. G ases required
For connection of the AMA 4000 to the gas cylinders the customer should supply a gas panel equipped with shutoff valves (6 mm ferrule fitting). The panel has to be nearby (within a distance of 3 m) the AMA 4000 (the connections for the span- and operation gases are at the rear side of the bench. (see fig. 13 and fig. 14, page 19).
4.1. O peration gases
Operation gases are required for running the emissions bench. For proper operation of the AMA 4000 the provided gases should meet the specifications.
OPERATION GASES #
Gas
Analyser Conc. Quality Supplypress. [bar] Location 1
Quantity 2
Required 3
1 Synthetic Air (SA)
Operating Gas FID 20% O2
80% N2 5.0 HC-free 2-3 BU 50 l
X 2 Hydrogen / Helium H2 / He Operating Gas FID
40% H2 60% He
5.7/5.6
2-3 BU 50 l
X 3 Compressed air Operating Gas H-FID See chapter 2.4: compressed air
4 O2
Operating Gas
CLD (PI, RAI) 100% 4.5 2-3 BU
50 l
X
Table 1 / Gases required – OPERATION GASES
Connections:
6 mm ferrule fitting
PFA or Stainless Steel piping (hoses)
1 Location: BU: AMA 4000 basic unit / SU: external sampling unit
2
Specified quantity required for commissioning / 50 liters (10 liters) cylinders – 200 bar [2900 psi] (150 bar [2175 psi] ) 3
Only the gases marked with “X” in column “required” are necessary for application
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AMA 4000 spec. 1.1.DOC
Date: 25.02.2005
EOP
4.2. C alibration gases
CALIBRATION GASES # Gas
Analyser Conc. Accuracy Supplypress.
[bar] Location 4
Quantity 5 Required 6
1 CO2/N
2 Span gas NDIR CO2 * **
2-3 BU 50 l 2 CO2/N2 Span gas NDIR CO2 EGR * ** 2-3 BU 50 l 3 CO2/N2 Span gas NDIR CO2 TRACER * ** 2-3 BU 50 l 4 CO/N2 Span gas NDIR ULCO * ** 2-3 BU 50 l 5 CO/N2 Span gas NDIR LCO * ** 2-3 BU 50 l 6 CO/N2 Span gas NDIR HCO * ** 2-3 BU 50 l 7 O2/N2 Span gas FRPMD O2 * ** 2-3 BU 50 l 8 SA Span gas FRPMD O2 20% O2
80% N2
5.0 HC-free 2-3
BU 50 l 9 NO/N2 Span gas (W)CLD * ** 2-3 BU 50 l 10 C3H8/SA Span gas (H)FID THC * ** 2-3 BU 50 l 11 C3H8/SA Span gas Cutter FID * ** 2-3 BU 50 l 12 CH4/SA Span gas Cutter FID * ** 2-3 BU 50 l 13 SO2/N2 Span gas DUV-RAS SO2 * ** 2-3 BU 50 l 14
N2
Span gas
All, except FID 100%
5.0
2-3
BU
50 l
Table 2 / Gases required – CALIBRATION GASES
N2 must be free of HC(<1ppmC1) if it is used as Zero gas for the FID.
*Concentration of calibration gases depend mainly on the specification of the engine and the requirements of the user. Definition of calibration gas concentrations: See Appendix 2: Specification of calibration gases (page 24)
** Accuracy of the of the span- resp. calibration gases must be chosen according to the regulation that fits to the customers application:
Connections:
4 Location: BU: AMA 4000 basic unit / SU: external sampling unit 5
Specified quantity required for commissioning 6
Only the gases marked with “X” in column “required” are necessary for application
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AMA 4000 spec. 1.1.DOC Date: 25.02.2005 EOP
6 mm ferrule fitting
PFA or stainless steel piping (hoses)
4.2.1. E xamples EPA/CFR Part 86:
Subpart B (LD) 86.114-94
calibration gases (for linearisation) (not including methanol) :+/- 1%
span gases (for zero/span adjust) (not including methanol) :+/- 2%
Fuel for FIDs and HFIDs and the methane analyser shall be a blend of 40±2 percent hydrogen with the balance
being helium. The mixture shall contain less than one ppm equivalent carbon response.
98 to 100 percent hydrogen fuel may not be used with Pierburg Analysers.
Subpart D (HD-Raw gas) 86.308-79
calibration gases (for linearisation) :+/- 2%
span gases (for zero/span adjust) :+/- 3%
Fuel for FIDs and HFIDs shall contain 40±2 percent hydrogen. The balance shall be helium. The mixture shall contain less than
2 ppmC hydrocarbon.
Subpart N (HD-diluted) 86.1314-94
calibration gases (for linearisation) (not including methanol) :+/- 1%
span gases (for zero/span adjust) (not including methanol) :+/- 2%
Fuel for FID’s and HFID’s and methane analysers shall be a blend of 40 ±2 percent hydrogen with the balance being helium. The mixture shall contain less than 1 ppm equivalent carbon response. 98 to 100 percent hydrogen fuel may not be used.
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4.2.2. E xamples ECE:
R49 (HD-Euro2) Annex IV Appendix 2 2.1 and 2.2:
The true concentration of a calibration and span gas must be within +/-2% of the nominal value
R83 (LD-Euro2) Annex IV 4.5.1 and 4.5.2:
The true concentration of a calibration and span gas must be within +/-2% of the nominal value
1999/96/EC (HD-Euro3) Annex III 1.2.1and 1.2.2:
The true concentration of a calibration and span gas must be within +/-2% of the nominal value
1998/69/EC (LD-Euro3): Annex VI 4.8.1 and 4.8.2
The true concentration of a calibration and span gas must be within +/-2% of the nominal value
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AMA 4000 spec. 1.1.DOC Date: 25.02.2005 EOP
4.3. Special gases
Special gases are used for particular tests and depend on the type of AMA 4000.
SPECIAL GASES
#
Gas
Analyser Conc. Accuracy Supplypress.
[bar] Location 7
Quantity 8
Required 9
1 NO/N
2 NOx Converter Check
NOx CLD *
2% 2-3 BU 10 l X 2 C3H8 CFO Check (CVS Propane injection check)
100% 0,5% 8-10
CFO Kit 10 l 3 C2H6/SA
Cutter efficiency Check
Cutter FID
≈ 50ppm
2%
2-3
BU
10l
Table 3 / Gases required – SPECIAL GASES
*according to measuring range of Nox analyser. Usually about 100ppm.
**Concentration of calibration gases depend mainly on the specification of the engine and the requirements of the user. Definition of calibration gas concentrations: See Appendix 2: Specification of calibration gases (page 24)
Connections:
6 mm ferrule fitting
PFA or stainless steel piping (hoses)
7 Location: BU: AMA 4000 basic unit / SU: external sampling unit 8
Specified quantity required for commissioning 9
Only the gases marked with “X” in column “required” are necessary for application
The gases (span, zero and operating gases) required for calibration and operation of the analysers are fed into the system via the gas interface on the back of gas distribution unit GDU 4000. (See fig. 13, page 19)
fig. 13
rear side GSU 4000
gas interface
fig. 14
rear side AMA 4000
5. INSTALLATION MATERIAL AMA 4000
5.1. PIERBURG INSTRUMENTS SCOPE OF SUPPLY
5 m cable 5x2,5 mm2 with CEE plug 32A.
10m PFA hose 4x1 mm for each span gas- and operation gas connection
10m PU hose 6x1 mm for compressed air supply
10m PU hose 6x1 mm for condensate draining
10m PVC spiral hose D i=32 mm for exhaust extraction
If not expressly mentioned in the contract:
5.2. OUR SCOPE OF SUPPLY DOES NOT INCLUDE
Supply of ventilation and drainage system
Interface: VENT OUT
Interface: CONDENSATE DRAIN PTFE hose 6x1 (suitable for D=8mm hose fitting) Supply of compressed air to AMA 4000
Interface: PU hose 6x1 mm with QC (suitable for R3/8” thread in shutoff valve) Supply of gases required for operation of AMA 4000
Interface: PFA hose 4x1 mm (suitable for 6mm hose fitting)
Sample probe or special adapters for connection of sample line to tailpipe
All modifications to the building, such as holes required...