obel vpud 1000-4

Fuel Injector Test Unit Type: VPUD 1000-4 (Patented Worldwide) Manual Revision 1.1, Dec. 2009

IOP Marine A/S Obel-P-Products Engager 7 • DK-2605 Brondby • Denmark IOP44 Marine 7, DK-2605 Brondby, Denmark, Tel: +45 44 98 38 33 • Fax: +45 98 11A/S, 25 •Engager www.iopmarine.dk Phone: +45 4498 3833, Fax: +45 4498 1125, e-mail: contact@iopmarine.dk, web: www.iopmarine.dk

IOP Marine A/S, Engager 7, DK-2605 Brondby, Denmark, Phone: +45 4498 3833, Fax: +45 4498 1125, e-mail: contact@iopmarine.dk, web: www.iopmarine.dk

1. Technical specifications:  5 programs to choose from: - Injector Prefill - Opening Pressure Test - Nozzle Leakage Test - Venting / Non-return valve test - O-Ring Sealing Test  IOP SafeTest system (Patented) – a protection system for correct testing of MAN Diesel Slide Fuel Valve injectors  Precise digital read-out (± 1 bar)  Separate display for data collection – stores data for easy evaluation and further use.

Specifications VPUD 1000-4 Hydraulic output pressure:

Max. 1100 bar Max. 800 bar

@ 10 bar air @ 7 bar air

Air consumption:

50 l/cycle 36 l/cucle

@ 10 bar air @ 7 bar air

Max flow at no pressure:

1,2 l/min

@ 7 bar air

Cycle frequency:

60 cycles/min @ > 7 bar air input and no output pressure

Discharge pr. cycle:

20 cm3

Tank capacity:

6l

Gauges:

Gauge: Display:

Weight:

100 kg

Dimensions:

560x950x1525 mm

Power consumption:

200 mA 100 mA

Included adapters

Pneumatic: Hydraulic:

Class 1.0 (10% error margin) Class 0.2 (2% error margin)

@ 110V @ 220V MAN Diesel Standard Claw Coupling or M42x2 CEJN 116 series male coupling

IOP Marine A/S, Engager 7, DK-2605 Brondby, Denmark, Phone: +45 4498 3833, Fax: +45 4498 1125, e-mail: contact@iopmarine.dk, web: www.iopmarine.dk

Unit Layout

8 6 7

5

1

(1) (2) (3) (5) (6) (7) (8)

2

3

FULL STROKE push button Pressure relief valve Pressure control valve Program Selection Switch (5 programs + reset button) Gauge for primary air pressure 0-10 bar Digital instrument: CURRENT OUTPUT PRESSURE Digital instrument: MEASURED PRESSURE

IOP Marine A/S, Engager 7, DK-2605 Brondby, Denmark, Phone: +45 4498 3833, Fax: +45 4498 1125, e-mail: contact@iopmarine.dk, web: www.iopmarine.dk

2. Before using the unit (information and setup) 2.1 Introducing IOP SafeTest Technology and the Program Switch The VPUD 1000-4 was introduced in 2009 and features a new generation of the electronic control system. The new system features an enhanced version of the IOP SafeTest Technology (Patented) and data collection system introduced in 2004, with 10+ updates to the digital display per second as well as a new program selector.

The program selector controls the operation of the unit, and with a specific program selected, the unit will behave in a specific way, in order to make it even easier     

In Prefill mode, it is ensured that pressure cannot exceed 200 bar. No value will be logged.

In the Opening Pressure mode, it is ensured that the unit will stop when an opening of the fuel injector nozzle takes place and the measured pressure is logged on the lower display.

In the Nozzle Leakage Test mode, it is ensured that the unit will stop if an opening of the fuel injector takes place. In addition data from the Opening Pressure Test are available during Nozzle Leakage test, so it is easy to see which value one should stay below.

In Venting / Non-return Valve Test mode, pressure build-up will be terminated before 200 bar and then the sudden pressure drop happening when the non-return valve inside the injector opens, will be detected.

In O-Ring Sealing Test mode, pressure build-up will be terminated automatically around 100 bar. No data will be logged.

2.2 Start-up preparations (new units / units where oil tank has run empty): Fill tank with hydraulic oil (viscosity 7-10 cSt at 50ºC) through the filler cap (11) in the right side of the top panel. The tank will hold 6 litres.

Connect compressed air is to the stud marked “AIR INLET” (9) on the right side of the cabinet.

To avoid contamination of the pump, it is essential that an effective air filter and water separator are inserted in the air line. A lubro unit should however be avoided - see lubrication instruction in section 6 Open the Pressure Relief Valve (2) by turning anti-clockwise The Pressure Control Valve (3) is opened by turning the handle clockwise until the gauge indicates approx. 2 bar Pumping of fuel oil through the whole system is now done for about one minute to make sure that no entrapped air is found in the unit. This pumping is only necessary to repeat, if the oil tank runs empty.

Turn Pressure Control Valve (3) counter-clockwise to switch off air supply Open Pressure Relief Valve (2) by turning counter-clockwise

IOP Marine A/S, Engager 7, DK-2605 Brondby, Denmark, Phone: +45 4498 3833, Fax: +45 4498 1125, e-mail: contact@iopmarine.dk, web: www.iopmarine.dk

Unit Layout

8 6 7

5

1

(1) (2) (3) (5) (6) (7) (8)

2

3

FULL STROKE push button Pressure relief valve Pressure control valve Program Selection Switch (5 programs + reset button) Gauge for primary air pressure 0-10 bar Digital instrument: CURRENT OUTPUT PRESSURE Digital instrument: MEASURED PRESSURE

IOP Marine A/S, Engager 7, DK-2605 Brondby, Denmark, Phone: +45 4498 3833, Fax: +45 4498 1125, e-mail: contact@iopmarine.dk, web: www.iopmarine.dk

3. Operation instructions The VPUD 1000 (patented worldwide) ensures correct testing of MAN Diesel slide fuel valves.

The below procedure for fuel-valve testing is in compliance with the MAN Diesel A/S’ guidelines for testing of fuel-injection valves. Please refer to the engine manufacturers manual for general fuel valve maintenance as well as possible derivations from the below procedure. All numbers in the text refers to numbers found on the VPUD 1000 front panel. If the test unit runs out of hydraulic oil during testing, please consult section 2 of this manual.

Connection of the fuel injector to the VPUD test unit: Make sure that section 2.2 has been completed before testing first injector. Then fit the MAN Diesel 2-stroke engine fuel injector into the valve holder. Note that MAN Diesel injectors must have leak hole facing forward and many are to be tightened with MAN Diesel spring-houses fitted. The fuel injector is connected to the pump unit through the stud marked “FUEL OUTLET” (10) found on the left side of the cabinet. The fuel injector is connected to the test unit by means of a flexible highpressure-hose. The test unit is now ready for use.

Program A: Prefill injector Before testing, the slide-valve fuel injector must be completely filled with test-oil:      

Switch knob (5) to position PREFILL Close pressure relief valve (2) by turning clockwise Turn pressure control valve (3) clockwise, until the CURRENT OUTPUT PRESSURE display (7) shows a pressure above zero* The valve is now filled with oil. When clear oil without air-bubbles tickles from the venting hole through the breathing-pipe, the valve is full Turn pressure control valve (3) counter-clockwise to switch off air supply Open pressure relief valve (2) by turning counter-clockwise

* Note: The unit will not be able to pass 200 bar in position PREFILL. The IOP SafeTest Technology may be activated during this process if pressure increases too much. If activated, the pump will stop operating. Complete the described procedure and press RESET to restart the PREFILL program.

Program B: Opening Pressure Test Switch knob (5) to OPENING PRESSURE position.

Close pressure relief valve (2) Adjust pressure control valve (3) until until opening pressure is reached and the injector sprays once in the test chamber. The measured opening pressure is shown on the lower part of the digital display (7). The pump stops automatically Close pressure control valve (3) – turn it counter-clockwise Open pressure relief valve (2) – turn it counter-clockwise Evaluate measured pressure – it should be lie within the range 320 and 380 bar (350 bar +/30 bar).

IOP Marine A/S, Engager 7, DK-2605 Brondby, Denmark, Phone: +45 4498 3833, Fax: +45 4498 1125, e-mail: contact@iopmarine.dk, web: www.iopmarine.dk

Repeat the Opening Pressure Test a few times, until two similar results (+/- 10 bar) have been obtained one after the other. To repeat the test, press “RESET”. Do NOT press RESET after last test!

Note that the first result measured after valve dis-/reassembly may differ from the following results.

Program C: Nozzle Leakage Test Switch knob (5) to NOZZLE LEAKAGE TEST position Close pressure relief valve (2) Adjust pressure using the regulator valve (3) until displayed CURRENT OUTPUT PRESSURE is approx. 50 bar below the result of the opening pressure test, which is shown in MEASURED PRESSURE (7).

Maintain pressure and inspect visually that there is no leak at the valve nozzle Close pressure control valve (3) – turn it counter-clockwise Open pressure relief valve (2) – turn it counter-clockwise If no drops are forming at the nozzle tip, the nozzle is tight. In case pressure by accident is increased above the opening pressure, the unit will stop operating. Complete above procedure and then press RESET to re-do the test. If by accident opening pressure is passed, the unit will stop automatically. Press RESET to re-do the test.

Program D: Non-return Valve Test (Venting Function) Switch knob (5) to Non-return Valve Test position Close pressure relief valve (2) Increase pressure using the pressure control valve (3) until the system automatic turns off the VPU pump ≈ 150 bar The pressure will slowly decrease on the WORKING PRESSURE display (8). When the internal leak slide valve opens, the venting pressure is frozen on the MEASURED PRESSURE display (7).

Close pressure control valve (3) – turn it counter-clockwise Open pressure relief valve (2) – turn it counter-clockwise If mesured valve is within the range specified by MAN Diesel (e.g. 30 bar), the non-return valve is working correctly. The test can be repeated by pressing the RESET button.

IOP Marine A/S, Engager 7, DK-2605 Brondby, Denmark, Phone: +45 4498 3833, Fax: +45 4498 1125, e-mail: contact@iopmarine.dk, web: www.iopmarine.dk

Unit Layout

8 6 7

5

1

(1) (2) (3) (5) (6) (7) (8)

2

3

FULL STROKE push button Pressure relief valve Pressure control valve Program Selection Switch (5 programs + reset button) Gauge for primary air pressure 0-10 bar Digital instrument: CURRENT OUTPUT PRESSURE Digital instrument: MEASURED PRESSURE

IOP Marine A/S, Engager 7, DK-2605 Brondby, Denmark, Phone: +45 4498 3833, Fax: +45 4498 1125, e-mail: contact@iopmarine.dk, web: www.iopmarine.dk

Program E: O-ring Sealing Test

    

Switch knob (5) to O-ring Sealing Test position Close pressure relief valve (2) Dismantle breathing pipe from the leak hole in the fuel-injection valve head Plug leak hole with plug supplied with the valve holder Increase pressure using the pressure control valve (3) until the system automatic turns off the VPU pump ≈ 100 bar The pressure in both parts of the digital display (7) should after a few seconds remain stable, close to 100 bar.

Open pressure relief valve (2) – turn it counter-clockwise

If pressure remained stable , the test is completed correctly.

Removal of Fuel Injector: Before attempting to remove the fuel injector, remember to relieve pressure: Turn Pressure Control Valve (3) counter-clockwise to switch off air supply Open Pressure Relief Valve (2) – turn it counter-clockwise The oil pressure has now been completely removed from the pump system and the fuel injector may be removed, if desired.

The test procedures provided in this chapter are an example test procedure for fuel injectors.

Please refer to fuel injector supplier’s test instructions for vendors recommended test procedure.

IOP Marine A/S, Engager 7, DK-2605 Brondby, Denmark, Phone: +45 4498 3833, Fax: +45 4498 1125, e-mail: contact@iopmarine.dk, web: www.iopmarine.dk

4. Troubleshooting the VPUD 1000 Test Rig Problem: Possible solution: Explanation:

No tests can be performed. Inlet pressure reads 0 bar at all times (manometer 6) although air supply is working Press “RESET” and start test over.

When the electronic blocking system in the VPUD 1000 is activated, air supply to the unit is blocked. The magnet valve is “released” by resetting the unit.

Problem:

Air supply is turned off almost immediately after test is initiated

Possible solution:

Make sure that the injector is filled with oil by running the PREFILL program (clear oil is tickling from venting hole when PRESSURE CONTROL VALVE (3) is turned a few times clockwise) before attempting to run any test.

Air inside the fuel valve results in malfunction of the electronic pressure transmitter. In special cases early shutdown can be a result Shutdown may also occur if pump is ending a cycle in the early stage of the venting function testing. In this case – start test over, follow instructions carefully.

Explanation A Explanation B:

Problem: Solution:

Problem:

During execution of OPENING PRESSURE TEST / NOZZLE LEAKING TEST air supply is turned off before test is completed Reset the unit, and start the test again. Press the “FULL STROKE” push button (1) while working pressure is between 100 and 140 bar.

Solution:

The VPUD 1000 is plugged in and turned on, but air supply is never blocked during testing.

Consult IOP Marine for maintenance advice.

Problem:

The display on the VPUD 1000 is not working

Possible solution: Explanation:

Check power supply.

Unlike standard VPU units, the VPUD 1000 requires 110V/230V power-supply.

For a more detailed trouble-shooting guide, please contact IOP Marine A/S For general maintenance instructions, please consult section 2.

IOP Marine A/S, Engager 7, DK-2605 Brondby, Denmark, Phone: +45 4498 3833, Fax: +45 4498 1125, e-mail: contact@iopmarine.dk, web: www.iopmarine.dk

5. Spare Parts

11

7+8 6 5

10 9 1 3 2

Pos. 1 Pos. 2 Pos. 3 Pos. 4 Pos. 5 Pos. 6 Pos. 7+8 Pos. 9 Pos. 10 Pos. 11 Pos. 12 Pos. 13

Full stroke valve (push button) Pressure relief valve Pressure control valve / pneumatic reducing valve Transducer (inside VPU unit) Switch (5 programs + reset) Manometer for “Inlet air pressure” (0-10 bar) Digital instrument with two displays Stud “air inlet” / air inlet with claw coupling or M42x2 Stud “fuel outlet” / high pressure outlet Filler cap with strainer Oil filter (inside oil tank) 2-Way pneumatic valve

(IOP no. 31904-46/-47/-48) (IOP no. 1111032) (IOP no. 3788003) (IOP no. 3865030) (IOP no. 3133070) (IOP no. 3805003) (IOP no. 3133071) (as ordered) (IOP no. 2112005) (IOP no. 3787001) (IOP no. 3332002) (IOP no. 3190629)

Pos. 14

Pump B1100-2 (inside VPU unit)

(IOP no. 1113021)

For spares for the main pump, please check the cross-section diagram and the B1100-2 spare part list on the following pages

IOP Marine A/S, Engager 7, DK-2605 Brondby, Denmark, Phone: +45 4498 3833, Fax: +45 4498 1125, e-mail: contact@iopmarine.dk, web: www.iopmarine.dk

Main pump, cross section (IOP 1113021)

IOP Marine A/S, Engager 7, DK-2605 Brondby, Denmark, Phone: +45 4498 3833, Fax: +45 4498 1125, e-mail: contact@iopmarine.dk, web: www.iopmarine.dk

Main Pump, Spare Parts List

IOP Marine A/S, Engager 7, DK-2605 Brondby, Denmark, Phone: +45 4498 3833, Fax: +45 4498 1125, e-mail: contact@iopmarine.dk, web: www.iopmarine.dk

VPUD 1000 – Mechanic/Electric Diagram

IOP Marine A/S, Engager 7, DK-2605 Brondby, Denmark, Phone: +45 4498 3833, Fax: +45 4498 1125, e-mail: contact@iopmarine.dk, web: www.iopmarine.dk