Tse0202

Transcript

Common Rail System Driver STARDEX® 0202 1. Security information Read the instructions carefully before using STARDEX 0202 (the device). Power supply of the device is performed from car battery 12-24 V or from 220 V 50 Hz outlet with the adaptor from the delivery kit. The device must be connected to power supply only with the cable from the delivery kit. Getting of electrical charges on the equipment is strictly prohibited! Getting liquids inside the device is strictly prohibited! Device body is constructed to protect its components from mechanical impact while operating. Avoid body and front panel damage, do not drop the device and do not put heavy objects on the top of it. In case of defect (smoke, sparks, specific smell) immediately unplug it and send to the service center. All cables from the delivery kit must be supplied with standard plugs and do not have mechanical damage. The device does not contain self repairable parts inside. Do not let children play with the device. The device is designed to work with Common Rail system. The user must understand the structure and working principle of injection systems. Incorrect use of the device may cause damage or injury. Do not operate the device with damaged cords. 2. Technical requirements and operation directions Dimensions AC power supply Power from vehicle battery 250-190-75mm 220V 50Hz or 110V 60Hz 12-24V Power consumption 10W Power consumption 150W Maximum load current 9A Operating temperature from -100С to + 500С Relative humidity no more 90 % at 250С 3. General Description STARDEX 0202 is 3 channel electromagnetic valve pulse simulator that controls pressure in Common rail system of various manufacturers such as Bosch, Delphi, Denso, Siemens, Cummins. The product allows to perform:  Quick and accurate on-vehicle diagnostics of fuel pressure regulators and fuel pressure sensors in Common Rail system  On-vehicle express diagnostics of Common Rail pump efficiency  Full testing and settings control of Common Rail pump on the test bench and compare the data with the attached reference values (test-plans)  Cleaning up of pressure valves in different modes  There are more than 300 test-plans on CD for Common Rail Bosch, Delphi, Denso, Siemens pumps testing on the test bench.  Connected to STARDEX 0302 with interface cable STARDEX 0202 is a complete, highly professional kit with the possibility of a full testing and setting of any Common Rail Bosch, Delphi, Denso, Siemens pumps and injectors according to all required parameters in semi-automatic mode, following step by step instructions contained in the test plans of the device.  This kit is suitable for upgrading any test bench including test benches without measuring unit. 4. Interface and control buttons description Duty cycle Control buttons Current Start\Stop button Real pressure Target pressure Indicator of the controlled parameter Mode Info window Stop Power supply Frequency Status indicator Menu Connectors on the front panel of the device: CH1 – the first channel. CH2 – the second channel. CH3 – the third channel. SENSOR – pressure sensor. POWER – supply from AC outlet or from vehicle battery. Duty cycle – duty cycle value on the channel. Current – measured intensity of current on the channel. Frequency – the frequency of modulated signal on the channel. Indicator of the controlled parameter – two triangular arrows located on the screen to the right from the controlled parameter. Status indicator – triangle (Play) shows that the channel is turned on and square (Stop) means that the channel is turned off. Real pressure – signal indication from the pressure sensor. Target pressure – pressure that will be automatically controlled by the first channel of the device. Mode – the mode of automatic pressure control on the first channel. Power supply – indicates the power voltage. Info window – displays warnings on the screen. Stop button – is used for emergency shutdown of all channels. Control buttons – up arrow increases the value of the controlled parameter, and the down arrow decreases. Start / Stop button – turns on / off modulated signal on the channel. Menu button – displays main menu. 5. Main Menu To enter main menu press Menu button. Navigation in the menu is performed by first channel buttons – up/down selection, menu item selection is accomplished with START/STOP button, and the change of the parameters values is performed with control buttons of the second channel - up/down. Ch 1 Config – configuration mode of the first channel. Ch 2 Config – configuration mode of the second channel. Ch 3 Config – configuration mode of the third channel. Sensor type – type of pressure sensor. Max pressure – all channels will automatically shut off, when the max pressure is reached. Max current – channel will automatically shut off, when the max current is reached. Clean – mode for regulator cleaning in ultrasonic bath. 6. Channels configuration menu. (Ch Config) Return – return to the main menu. Mode – operating modes of the channel: Current – current control. Pwm – pulse width modulation control. Cp3 – pressure control on vehicle for Bosch CP3 systems. Delphi – pressure control on vehicle for Delphi systems. Bench – pressure control on the test bench. PWM Frequency – frequency of modulated signal. 7. Clean menu (Clean) Return – return to the main menu. Speed – speed of duty cycle changes. Max duty – a range of work. Time – timer of clean mode. Run – run cleaning mode. In cleaning mode duty cycle on all 3 channel of the device is increasing from 0% to Max Duty and is back with value mentioned in Speed parameter causing rhythmic movement of the piston in the pressure regulator which is placed in cleaning solution or ultrasonic bath. While using conductive liquids, do not immerse in it electric connector which is connected to the pressure regulator. 8. Main principles of work with different types of pressure regulators Pressure regulators in Common Rail system can be divided into several groups according to structure and principles of work. There are two main groups: pressure control valves (PCV) and stream control valves (SCV). The main difference between them is that PCV by-passes fuel from high pressure section to low pressure section keeping the predetermined pressure in fuel rail (PCV is installed in high pressure section). SCV in Common Rail system by-passes fuel at the stage of filling in pump elements in such a way controlling the quantity of fuel that flows to pump elements (SCV is installed in low pressure section). There are two kinds of SCV: normally opened and normally closed. Normally opened SCV without control signal by-passes all fuel to pump elements and with gradual increase in strength of current SCV gradually closes decreasing the fuel quantity that flows to pump elements. Normally closed SCV without control signal by-passes all fuel to pump back leak and with gradual increase in strength of current SCV gradually opens increasing the fuel quantity that flows to pump elements. All kinds of PCV in Common Rail systems is constructed in such a way that all fuel that flows to high pressure section without control signal to the valve by-passes to low pressure section and with gradual increase of strength of current, PCV gradually closes decreasing the quantity of fuel that by-passes from high pressure section to low pressure section in such a way increasing pressure in high pressure section. 9. CR pumps checking on test bench with STARDEX 0202 Install Common Rail pump on the test bench. Connect test oil supply from the test bench to the pump inlet. Install six injector fuel rail on the test bench and connect it with pump high pressure outlet using high pressure tube. Close the rest fuel rail outlets by special plugs. Connect return flow of pump and fuel rail to measuring unit (ex. Measuring unit of the test bench or STARDEX 0101). Connect pressure sensor of fuel rail to STARDEX 0202. Connect pressure regulator of fuel rail to the fist channel of STARDEX 0202. Connect pump pressure regulators (if exists) to the second and third channels of STARDEX 0202. Turn on STARDEX 0202. Select manufacturer and serial number of the tested pump in the program installed on CD from the delivery kit. Follow step by step instructions of the program. Conceptual connection pattern 10. On vehicle pressure sensor testing Find signal wire in the fuel pressure sensor cable. To do it, turn the ignition on and measure voltage in each wire in reference to the minus of the battery without removing connector from pressure sensor. Voltage of signal wire is 0,5 V. With ignition off, turn the device on from the car battery with the supplied cable. Pierce signal wire of pressure sensor with the probe and connect it to SENSOR connector at the back panel of the device. Turn on the ignition. Make sure that the pressure sensor shows voltage from 0 to 30 bar. Start the car and make sure that the pressure is from 200 to 350 bar, and when you press accelerator pedal the pressure increases. 11. Checking the efficiency of Bosch CP3/CP1H, Delphi pumps and injectors on vehicle With ignition off, turn on the device from the car battery with the supplied cable. Pierce signal wire (0.5 V) of pressure sensor with the probe and connect it to SENSOR connector at the back panel of the device. Disconnect camshaft sensor or injectors wires (for car not to start). Connect pressure regulator of the pump to CH1 connector. Set solenoid emulator into disconnected pressure regulator connector on a car. Select PWM mode in configuration of the first channel. Depending on the type of pressure regulator set 0 or 50% duty cycle. Press START/STOP button of the first channel and turn the ignition key in start position. There must be about 600 bar pressure for Bosch system and 800 bar for Delphi system. If the enough pressure is not reached, make express check of the injectors by performing the back leak test and pump express check with the help of one injector fuel rail. 12. Checking the efficiency of Bosch CP1K pump and injectors on vehicle With ignition off, turn the device on from the car battery with the supplied cable. Pierce signal wire (0.5 V) of pressure sensor with the probe and connect it to SENSOR connector at the back panel of the device. Disconnect camshaft sensor or injectors wires (for car not to start). Pressure regulator of the pump connect to CH1 connector. Set solenoid emulator into disconnected pressure regulator connector on a car. In configuration of the first channel select PWM mode. Set 50% pulse width of the first channel. Press START/STOP button and turn the ignition key in start position. There must be about 600 bar pressure for this system. If the enough pressure is not reached, make an express check of the injectors by performing the back leak test and pump express check with help of one injector fuel rail. Pressure regulator must be checked on the test bench. 13. Checking the efficiency of Siemens pump and injectors on vehicle With ignition off, turn the device on from the car battery with the supplied cable. Pierce signal wire (0.5 V) of pressure sensor with the probe and connect it to SENSOR connector at the back panel of the device. Disconnect camshaft sensor or injectors wires (for car not to start). Pump pressure regulator which is located in high pressure circuit connect to СН1 connector of device. Pump pressure regulator which is located in low pressure circuit (at supply pump) connect to СН2 connector of device. Set solenoid emulators into pressure regulators connectors on a car. In configuration of the first and second channels select PWM mode. Set duty cycle on the channels in such a way that the current is 1,2 A in each channel. Press START/STOP button on the first and second channels and turn the ignition key in start position. There must be about 700 bar pressure in the system. If the enough pressure is not reached, make an express check of the injectors by performing the back leak test and pump express check with help of one injector fuel rail. 14. Pump express diagnostics with the help of one injector fuel rail. With ignition off, turn the device on from the car battery with the supplied cable. Connect high pressure tube to the pump on the one side and to one injector fuel rail on the other side. Close the second outlet of fuel rail with special plug from the delivery kit. Connect pressure sensor of fuel rail to SENSOR connector of device. Control pressure regulators according to the instructions for on-vehicle pump efficiency checking. Turn the ignition key into start position for a few seconds. The pressure must be no less than 1200 bar. If the pressure isn’t reached, check the pump on the test bench. 15. Diagnostics of Common Rail injectors on the test bench with STARDEX 0202 + STARDEX 0302 Install Common Rail pump on the test bench. Connect test oil supply from the test bench to the pump inlet. Install six injectors fuel rail on the test bench and connect it with pump high pressure outlet using high pressure tube. Return flow of pump and fuel rail connect to tank inlet of the test bench. Connect Common Rail injectors to fuel rail with high pressure tubes. Delivery and return flow of injectors connect to measuring unit (ex. Measuring unit of the test bench). Connect pressure sensor of fuel rail to STARDEX 0202. Connect pressure regulator of fuel rail to the fist channel of STARDEX 0202. Connect STARDEX 0302 to injectors with the appropriate cable from the delivery kit. Connect STARDEX 0202 and STARDEX 0302 with interface cable from the delivery kit. Turn on STARDEX 0202 and STARDEX 0302. Set the connection to STARDEX 0202 in the menu of STARDEX 0302. Select Bench tab in STARDEX 0302 and set Injector mode. Select manufacturer and serial number of the tested injectors. In STARDEX 0302 activate the connected injectors by injector select buttons according to the numbered cables. Follow the step by step instructions in information window of STARDEX 0302. Conceptual connection pattern While working at the high pressure test bench, use the protective clothes, to avoid injury in case of emergency situations! 16. Diagnostics of Common Rail pumps on the test bench with STARDEX 0202 + STARDEX 0302 Install Common Rail pump on the test bench. Connect test oil supply from the test bench to the pump inlet. Install six injector fuel rail on the test bench and connect it with pump high pressure outlet using high pressure tube. Close the rest fuel rail outlets by special plugs. Connect return flow of pump and fuel rail to measuring unit (ex. Measuring unit of the test bench or STARDEX 0101). Connect pressure sensor of fuel rail to STARDEX 0202. Connect pressure regulator of fuel rail to the fist channel of STARDEX 0202. Connect pump pressure regulators (if exists) to the second and third channels of STARDEX 0202. Connect STARDEX 0202 and STARDEX 0302 with interface cable from the delivery kit. Turn on STARDEX 0202 and STARDEX 0302. Select Bench tab in STARDEX 0302 and set Pump mode. Select manufacturer and serial number of the tested pump in STARDEX 0302. Follow the step by step instructions in information window of STARDEX 0302. Conceptual connection pattern Note: While testing some Bosch CP1 pumps where pressure regulator is similar to pressure regulator in six injectors fuel rail, install pump regulator in the fuel rail and install at its place a special plug from the delivery kit of six injector fuel rail. 17. Delivery Kit STARDEX 0202 1 piece Power cable 1 piece Power supply with the connector to the device 1 piece Cable to connect to the car battery 1 piece Cable to connect to Bosch solenoid 3 piece Cable to connect to Bosch Mercedes solenoid 1 piece Cable to connect to Delphi/Siemens solenoid 2 piece Cable to connect to Denso solenoid 1 piece Cable to connect to Bosch pressure sensor 1 piece Cable for the probe with a connector to the device 1 piece Solenoid emulator 2 piece One injector fuel rail 1 piece Plug for fuel rail 1 piece Bosch pressure sensor 1 piece High pressure tube 14x1.5 12x1.5 1 piece High pressure tube 14x1.5 14x1.5 1 piece Probe to connect to pressure sensor signal wire 1 piece Technical Description 1 piece CD with test-plans 1 piece 18. 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. 19. Shipping details The product is packed into bubble wrap and carton box. Weight 4,5 kg. Length 450 mm. Width 300 mm. Height 160 mm. MANUFACTURED BY: OY STARDEX LTD PULTTITIE 2 00880 HELSINKI FINLAND +358 (0)44 5523130 www.stardex.fi