Helsinki 2013/2014. UIS and PLD TESTER STARDEX 1002

Size: px

Start display at page:

Download "Helsinki 2013/2014. UIS and PLD TESTER STARDEX 1002"

Leonard Lamb
5 years ago
Views:

1 Helsinki 2013/2014 UIS and PLD TESTER STARDEX 1002

2 Safety rules for working with STARDEX 1002 device. Before using the device STARDEX 1002 (further the device ) read this manual carefully. The device should be plugged only in a circuit of alternative current mentioned in the passport of the device. In order to power up the device use only supply cable from the delivery kit. Getting of electrical charges on the body of the device is strongly prohibited! Getting of liquid inside the device is strongly prohibited! Device body is constructed to protect its components from mechanical impact while normal operating. Avoid body and front panel damage, do not drop the device and do not put any heavy objects on its cover. At any sign of defects such as smoke, sparking or specific smell, unplug the device immediately and contact the nearest STARDEX service center. All cables connected to the device must be supplied with standard plugs without mechanical damage. There are no self-repairable parts inside of the device. It is strongly prohibited to open the device. Store and use away from children and pets. The device is designed to work with UIS and PLD systems. A user working with the device must understand the structure and principle of operation of injection systems. Incorrect use of the device may lead to breakage of the equipment or user s injury.

3 Specifications and operation directions. STARDEX 1002 Dimensions AC power supply Power consumption in stand-by mode Power consumption in load mode Operating temperature Relative air humidity 450x415x95 mm 100V-240V 47Hz-63Hz 40W 500W from С to С not more than 90% at 25 0 С CamBox Dimensions 430x240x225 mm

4 Purpose and range of application. STARDEX 1002 is a highly professional universal device for testing unit injectors (UIS) and individual pumps (PLD) on the high pressure pump bench, the device is supplied together with CamBox and is intended to work with Bosch, Delphi (Lucas), Cummins, Siemens, Caterpillar, Detroit systems. The device is equipped with its own measuring unit; it speeds up and facilitates operator s work, and makes it suitable for fitting out any high pressure test bench, including the bench without its own measuring unit. It works both with electromagnetic and piezoelectric valves of UIS and PLD. It enables to test current characteristics of an injector displaying the precise diagram on the screen, and enabling to define the state of an electromagnetic coil (solenoid) or piezoelement of an injector. The device is supplied with 8,4" touch-screen, and is controlled by a keyboard and a mouse or by navigating buttons on the front panel. There is possibility to connect the device to an external monitor. The device STARDEX CamBox combined with the test bench is a full-fledged highly professional solution which enables completed test and setting of pumpinjectors and individual pumps according to all necessary parameters in semiautomatic mode while following step-by-step instructions contained in the device in the form of test-plans.

Connectors and control buttons STARDEX 1002. 1 2 3 4 5 6 7 1RPM sensor connector. 2Injection delay sensor connector.

5 Connectors and control buttons STARDEX RPM sensor connector. 2Injection delay sensor connector. 3Power cable connector. 4USB ports. 5Injector universal cable connector. 6Power switch. 7Output for external display.

1 2 3 4 5 6 7 8 9 1Navigation panel arrows to switch measured parameters, a square to select. 2MODE switches modes. 3FLOW resets flowmeter. 4MENU opens the menu of the device. 5On/off button.

6 Navigation panel arrows to switch measured parameters, a square to select. 2MODE switches modes. 3FLOW resets flowmeter. 4MENU opens the menu of the device. 5On/off button. 6Front panel light diode: No light the device is off power. Red light the standby mode. Green light the device is on. 7START/STOP on/off impulse to the injector (stands for the same button on the screen). 8Fuel flowmeter line input. 9Fuel flowmeter line output.

Installing CamBox to the test bench. 1 2 3 4 5 6 7 Place CamBox to the test bench stand and fix it using fasteners from the supply kit 4 and 6. Then fix CamBox coupling 1 in the bench shaft 3.

7 Installing CamBox to the test bench Place CamBox to the test bench stand and fix it using fasteners from the supply kit 4 and 6. Then fix CamBox coupling 1 in the bench shaft 3. Then pour motor oil 10w40 into the scupper filler2 controlling the level according to the indicator5. Connect RPM sensor 7 using the cable from the supply kit into the relevant connector of STARDEX 1001.

8 Setting of pump injector into CamBox Place the tested injector into the proper adaptor 4 and fix it using a cramp with a screw 3.

Fix the pusher 1 according to the type of the injector. Place the adapter with the injector in it to CamBox as shown on the picture and fasten it by screws from the supply kit 5.

9 Fix the pusher 1 according to the type of the injector. Place the adapter with the injector in it to CamBox as shown on the picture and fasten it by screws from the supply kit 5. Fix the injection delay sensor 7 to the injectors nozzle with the proper adaptor 6 connected to it. Connect delivery of the bench supply pump to the input of the adaptor fuel chamber 4, and the backflow from the adaptor to drain into the bench tank. Connect the output 8 from injection delay sensor to the input of STARDEX 1001 flowmeter, and output of the flowmeter to the bench tank. Connect injector to STARDEX 1001 using the cable with the proper cap 2. Switch on the power on the back panel of STARDEX 1001 and run a loading of the device by the button on the front panel (switch off by the same button). Injector cable description The long tale is used for most connections (2 wired injectors). 2 The short tale is used to connect second solenoid valve (Delphi E3).

10 1 2 1

11 STARDEX Start operating. After the loading of the device the window of selection of the tested pump injector manufacturer is displayed. After selecting the injector manufacturer the window for selecting a serial number will open. After selecting the serial number the window for selecting the quantity of the injectors tested will open.

Screen for pump injectors testing. After selecting the manufacturer, the serial number, and the quantity of the injectors tested the window for injectors testing will open.

12 Screen for pump injectors testing. After selecting the manufacturer, the serial number, and the quantity of the injectors tested the window for injectors testing will open Switch on the test bench and set the necessary pressure of the supply pump, commonly 3-4 bar. 2. Fix the bench drive revolutions 16 on the level of target revolutions Push START 11 for delivery of the leading impulse to the injector with the given length 13 and advance angle Within some seconds the delivery of the pump injector will be displayed in the measuring tube 3 in graphical and digital form (in the selected measuring units 4), and two horizontal lines mean a possible limit of declinations which are digitally reflected as well Put down the received delivery result in to the report using STORE button 2 or manually pressing the result window 1. While putting down the delivery result into the report, the results of injection delay 12 will be put down into the report automatically together with BIP signal 10, which are displayed on the diagram 9 in graphical and digital form.

13 6. Proceed to the next test using navigation arrows 6 and repeat the steps from the second to the fifth. Standard injector test includes 5 tests: Air cleaning, High load, Medium load, Low load, Start test. 7. After finishing all the tests stop revolutions of the bench drive, switch off the supply pump and install the next injector into CamBox. 8. With the help of injector selection buttons 8 proceed to testing of the next injector and repeat steps from the first to the eighth. 9. After finishing the injector set test go to the result overview (additional menu on the right of the screen) and print the report. 10. In order to proceed to test of the other injector type, go to the menu of injector selection by pressing the inscription 7. The test-plan for every test has bench revolutions 15, injection impulse length 13, signal advance angle 14, measuring units of the measuring block 4 already specified, but a user is able to change all parameters of the test at his discretion. There is also a possibility to change Volt-Ampere characteristics of the signal, the procedure is described further. Additional menus. There are additional menus in the right part of the screen. Additional menus can vary depending on other connected STARDEX devices or test mode. Current graph Current scale intensity of current in the injector circuit measured in Ampere.

2Time scale time measured in microseconds. 3Navigation between different graphs (current graph, injection delay sensor graph, revolutions uniformity of CamBox axle graph).

14 2Time scale time measured in microseconds. 3Navigation between different graphs (current graph, injection delay sensor graph, revolutions uniformity of CamBox axle graph). 4Return to the previous screen. Injection delay sensor graph Current scale intensity of current in the injector circuit measured in Ampere. 2Time scale time measured in microseconds. 3Navigation between different graphs (current graph, injection delay sensor graph, revolutions uniformity of CamBox axle graph). 4Setting of injection delay sensor sensitivity. 5Return to the previous screen.

Rotation uniformity graph. 2 1 3 1CamBox average revolutions. 2Navigation between different graphs (current graph, injection delay sensor graph, revolutions uniformity of CamBox axle graph).

15 Rotation uniformity graph CamBox average revolutions. 2Navigation between different graphs (current graph, injection delay sensor graph, revolutions uniformity of CamBox axle graph). 3Return to the previous screen. Rotation uniformity graph reflects acceleration and deceleration of CamBox axle rotation depending on loads from injectors. The red circle is the ideal speed per one axle rotation; the white curve shows real rotation speed of the CamBox axle. In the case the white curve varies inside or outside from the red circle (outside acceleration, inside - deceleration) for more then 1/3 of the circle radius, the mass of bench flywheel must be increased.

3Second phase current. 4First phase length.

16 Setting of Volt-Ampere characteristics of the impulse to the injector Signal voltage. 2First phase current. 3Second phase current. 4First phase length. 5Dual-coil injector note while testing Delphi E3. 6Go back to the previous window. General settings

17 1Screen resolution sets resolution of an external monitor. 2Set injector delivery units which are used by default in tests. ml/min milliliters per minute. ml/200str milliliters per 200 cycles. 3Touchscreen calibration. 4Software and hardware version. 5Return return to previous window. 6Quit quit to operation system.

18 Supply kit. Basic STARDEX 1002 simulator CamBox Coupling with fasteners for connecting CamBox to bench drive Adaptor for Volvo (Bosch, Delphi A3), Iveco unit injectors Adaptor for Scania unit injectors Adaptor for Delphi E1, E3 unit injectors Power cable Rotation sensor cable Piezo sensor for injection delay measuring Universal cable for unit injectors Universal cable adaptor Type 1 Universal cable adaptor Type 2 Universal cable adaptor Type 3 Nozzle adaptor 7mm Nozzle adaptor 9mm 2 piece. Fuel pipe 4 m. Fittings for flowmeter line connection Technical description 2 pieces. Cummins unit injector adapter type 1 Cummins unit injector adapter type 2 Additional (supplied separately)

19 Detroit unit injector adapter Volkswagen unit injector adapter type 1 Volkswagen unit injector adapter type 2

20 Warranty and technical support. The equipment has 1 year warranty. The manufacturer is not responsible for the damage due to violation of the operation terms, misuse including unskillful or mistaken personnel actions and if there are traces of mechanical impact. Post-warranty service of device is performed at cost components and the work. The manufacturer reserves the right to design modifications, equipment and the warranty period without advance notice. MANUFACTURED BY: OY STARDEX LTD PULTTITIE HELSINKI FINLAND +358 (0) info@stardex.fi

HELSINKI, FINLAND, 2018 STARDEX 0304 COMMON RAIL PUMP AND INJECTORS TESTER

HELSINKI, FINLAND, 2018 STARDEX 0304 COMMON RAIL PUMP AND INJECTORS TESTER 2018 STARDEX 0304 ENG Safety rules for working with STARDEX 0304 device. Before using the device STARDEX 0304 (further the device