obel vpud-1100-sv

VPUD 1100 SV An electronically controlled pneumatic/hydraulic test rig for 2- and 4-stroke fuel injectors featuring six programs to choose from, an electronic data collection system & IOP SafeTest Technology (patented).

- Technical specifications - Operation - Maintenance (Patented Worldwide) IOP Marine A/S • Engager 7 • DK-2605 Brondby, Denmark, Tel: +45 4498 3833 • Fax: +45 4498 1125 • E-mail: contact@iopmarine.dk • Homepage: www.iopmarine.dk

IOP Marine A/S • Engager 7 • DK-2605 Brondby, Denmark, Tel: +45 4498 3833 • Fax: +45 4498 1125 • E-mail: contact@iopmarine.dk • Homepage: www.iopmarine.dk

1. Introduction This instruction has been made to facilitate the understanding of the working principles of the pump unit.

The various control instruments and manoeuvring handles are fitted with a number. These numbers are mentioned in this instruction and are also referring to the numbers found on the drawing showing the complete pump unit and on the control panel of the pump unit.

Please read this instruction of use carefully before using the pump unit and follow the instructions given very carefully. Read also the section: “Overhaul of Fuel Valves” in the valve vendors instruction manual.

The test rig type VPUD 1100 SV for diesel engine fuel injectors consists of the following main components: TEST UNIT: VPUD 1100 SV

Length: Depth: Height: Weight:

TABLE:

Length: Depth: Depth: Height: Weight:

880 mm 520 mm excl. valve holder 730 mm excl. valve holder 850 mm ≈ 40 kg

Length: Width: Height: Weight:

200 275 750 ≈7

VPU 602

Valve holder VPU 603-series* For 1 to 3 fuel injectors (incl. thrust piece(s))

690 480 650 MK I ≈ 70 MK II ≈ 90

mm mm mm kg (on-board unit) kg (land-based unit)

mm mm mm kg

* The VPU 603 valve holder design is depending on engine type. Measures for all valve holders are approx as above. Most valve holders can be adapted for multiple fuel injectors so test rig can be used for main / aux / emergency engine injectors and engine safety valves. Ask for more information.

Special operating instructions apply for valve holders with built-in pneumatic/hydraulic tools – please check separate sheets.

Flexible high-pressure hose Type VPU 604-1:

Diameter: Length: Weight:

0.5

Ø12 mm 1000 mm excl. couplings kg

IOP Marine A/S • Engager 7 • DK-2605 Brondby, Denmark, Tel: +45 4498 3833 • Fax: +45 4498 1125 • E-mail: contact@iopmarine.dk • Homepage: www.iopmarine.dk

IOP Marine A/S • Engager 7 • DK-2605 Brondby, Denmark, Tel: +45 4498 3833 • Fax: +45 4498 1125 • E-mail: contact@iopmarine.dk • Homepage: www.iopmarine.dk

2. Technical Specification  6 programs to choose from: - Injector Prefill - Opening Pressure Test - Nozzle Leakage Test - Venting / Non-return valve test - O-Ring Sealing Test - Manual Operation (4-stroke only)  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  One unit tests all fuel-injection & most engine safety valves aboard a vessel  Two different discharge capacities available - makes it suitable for onboard and workshop use

Specifications VPUD 1100 SV Hydraulic output pressure:

0 - 1100 bar 0 - 800 bar

@ 10 bar air input @ 7 bar air input

Air consumption:

60,5 l/cycle 44 l/cycle

@ 10 bar air input. @ 7 bar and no output pressure

Max. flow at no pressure:

1,2 l/min

@ > 7 bar air input

Cycle frequency:

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

Discharge pr. cycle, Mk I: Discharge pr. cycle, Mk II:

20 cm3 40 cm3

Tank capacity:

6l

Gauges:

Gauge: Display:

Weight Mk I (on-board): Weight Mk II (workshop):

70 kg empty, excl. table & valve holder 85 kg empty, excl. table & valve holder

Dimensions:

560 x 950 x 1525 mm

Power supply

110/230 V AC (Single Phase)

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, Tel: +45 4498 3833 • Fax: +45 4498 1125 • E-mail: contact@iopmarine.dk • Homepage: www.iopmarine.dk

Unit Layout

11 8 6 9

7 4

5

10

(1) (2) (3) (4) (5) (6) (7) (8)

1 2

3

FULL STROKE push button Pressure relief valve Pressure control valve High-pressure valve (4A = closed, 4B = open) Program Selection Switch (6 positions) Gauge: Primary Air Pressure 0-10 bar Digital instrument: Current Output Pressure + Measured Pressure Gauge: Current System Pressure

IOP Marine A/S • Engager 7 • DK-2605 Brondby, Denmark, Tel: +45 4498 3833 • Fax: +45 4498 1125 • E-mail: contact@iopmarine.dk • Homepage: www.iopmarine.dk

3. Before using the unit (information and setup) 3.1 Introducing IOP SafeTest Technology and the Program Switch The VPUD 1100 SV was in 2009 upgraded with a new generation of 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.

In Manual Operation (4-stroke engine injectors only) mode, nothing is interrupted or logged.

Note that this mode is NOT TO BE USED for MAN Diesel 2-stroke engine slide-valve injectors.

3.2 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, Tel: +45 4498 3833 • Fax: +45 4498 1125 • E-mail: contact@iopmarine.dk • Homepage: www.iopmarine.dk

Unit Layout

11 8 6 9

7 4

5

10

(1) (2) (3) (4) (5) (6) (7) (8)

1 2

3

FULL STROKE push button Pressure relief valve Pressure control valve High-pressure valve (4A = closed, 4B = open) Program Selection Switch (6 positions) Gauge: Primary Air Pressure 0-10 bar Digital instrument: Current Output Pressure + Measured Pressure Gauge: Current System Pressure

IOP Marine A/S • Engager 7 • DK-2605 Brondby, Denmark, Tel: +45 4498 3833 • Fax: +45 4498 1125 • E-mail: contact@iopmarine.dk • Homepage: www.iopmarine.dk

4. Operation Instructions Connection of the fuel injector to the VPUD test unit: Fit fuel injector into the valve holder. Block injector holes not in use, using the supplied covers. Note that MAN Diesel injectors must have leak hole facing forward and some 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 high-pressure-hose. The test unit is now ready for use.

Before executing Program A-E, move the high-pressure valve (4) to position OPEN (4B) and leave it here. This valve is only operated in the program “Manual Operation” (Program F).

Program A: Prefill (MAN Diesel 2-stroke injectors only) Before performing any tests, all MAN Diesel slide-valve fuel injector must be completely filled with test-oil: • • • •

Before executing Program A-E, move the high-pressure valve (4) to position OPEN (4B) Switch knob (5) to “PREFILL” – position A. Close Pressure Relief Valve (2) Turn Pressure Control Valve (3) clockwise, until the CURENT OUTPUT PRESSURE display (7) shows a pressure between 1 and 10 bar. If a higher pressure is reached, wait while the pressure slowly drops back below 10 bar.

The valve is now filled with oil and the pressure is fluctuating while doing so. When clear oil without airbubbles 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) – turn it counter-clockwise

In case air-supply is blocked during pre-fill (program stops), make sure that you keep pressure low as described above. To re-execute the program, press the RESET button.

Program B: Opening Pressure Test • Switch knob (5) to “OPENING PRESSURE TEST” – position B. • Close Pressure Relief Valve (2) • Adjust pressure by means of Pressure Control Valve (3) until fuel injector opens* • The opening pressure is locked as the “Measured Pressure” on display (7) The pump stops automatically* • Close Pressure Control Valve (3) – turn it counter-clockwise • Open Pressure Relief Valve (2) – turn it counter-clockwise To re-execute the test, press the RESET button. * Note: If the IOP SafeTest Technology is activated before opening takes place, this may be due to high leakage through injector leak hole. Repeat the test (press the RESET button), and then press the Full Stroke Button (1) before reaching

200 bar and continue immediately after to increase the pressure until an opening takes place.

IOP Marine A/S • Engager 7 • DK-2605 Brondby, Denmark, Tel: +45 4498 3833 • Fax: +45 4498 1125 • E-mail: contact@iopmarine.dk • Homepage: www.iopmarine.dk

Unit Layout

11 8 6 9

7 4

5

10

(1) (2) (3) (4) (5) (6) (7) (8)

1 2

3

FULL STROKE push button Pressure relief valve Pressure control valve High-pressure valve (4A = closed, 4B = open) Program Selection Switch (6 positions) Gauge: Primary Air Pressure 0-10 bar Digital instrument: Current Output Pressure + Measured Pressure Gauge: Current System Pressure

IOP Marine A/S • Engager 7 • DK-2605 Brondby, Denmark, Tel: +45 4498 3833 • Fax: +45 4498 1125 • E-mail: contact@iopmarine.dk • Homepage: www.iopmarine.dk

Program C: Nozzle Sealing Test • Close Pressure Relief Valve (2) • Switch knob (5) to “NOZZLE SEALING TEST”– position C. The lower part of the display will continue to display the result of the OPENING PRESSURE TEST • Adjust pressure using the Pressure Control Valve (3) until displayed CURRENT OUTPUT PRESSURE (8) is 10-20 bar below the value displayed in MEASURED PRESSURE • Check that there is no leak at nozzle tip* • Close Pressure Control Valve (3) – turn it counter-clockwise • Open Pressure Relief Valve (2) – turn it counter-clockwise To re-execute the test, press the RESET button. * Note: If the IOP SafeTest Technology is activated while inspecting nozzle leakage this may be due to high leakage through injector leak hole. Repeat the test (press the RESET button), and then press the Full Stroke Button (1) before reaching

200 bar and continue immediately after to increase the pressure until an opening takes place. The value displayed at MEASURED PRESSURE will in this test not be affected by pressing the RESET button.

Program D: Venting / Non-return Valve Test (MAN Diesel 2-stroke injectors only) • Close Pressure Relief Valve (2) • Switch knob (5) to VENTING / NON-RETURN VALVE TEST – position B • Adjust Pressure Control Valve (3) until unit switches off automatically around 160 bar.

The pressure will slowly decrease on the CURRENT OUTPUT PRESSURE display (8). When the injector leak valve opens, the venting pressure is locked as MEASURED PRESSURE (7).

• •

Close Pressure Control Valve (3) – turn it counter-clockwise Open Pressure Relief Valve (2) – turn it counter-clockwise

To re-execute the test, press the RESET button.

Program E: O-ring Sealing test (MAN Diesel 2-stroke injectors only) • Dismantle breathing pipe from the venting hole in the fuel-injection valve head/fixture • Plug venting hole in fuel injector head.

• Close Pressure Relief Valve (2) • Switch knob (5) to O-RING SEALING TEST - position E •

Adjust Pressure Control Valve (3) until the system stops automatically with a CURRENT OUTPUT PRESSURE (8) ≈ 100 bar

•

Read pressure at CURRENT OUTPUT PRESSURE (8). The displayed pressure should remain stable after a few moments.

Close Pressure Control Valve (3) – turn it counter-clockwise Open Pressure Relief Valve (2) – turn it counter-clockwise

• •

To re-execute the test, press the RESET button.

IOP Marine A/S • Engager 7 • DK-2605 Brondby, Denmark, Tel: +45 4498 3833 • Fax: +45 4498 1125 • E-mail: contact@iopmarine.dk • Homepage: www.iopmarine.dk

Unit Layout

11 8 6 9

7 4

5

10

(1) (2) (3) (4) (5) (6) (7) (8)

1 2

3

FULL STROKE push button Pressure relief valve Pressure control valve High-pressure valve (4A = closed, 4B = open) Program Selection Switch (6 positions) Gauge: Primary Air Pressure 0-10 bar Digital instrument: Current Output Pressure + Measured Pressure Gauge: Current System Pressure

IOP Marine A/S • Engager 7 • DK-2605 Brondby, Denmark, Tel: +45 4498 3833 • Fax: +45 4498 1125 • E-mail: contact@iopmarine.dk • Homepage: www.iopmarine.dk

Program F: Manual Operation (NOT for MAN Diesel 2-stroke Slide-Valve fuel injectors) Note that in manual mode, the unit will NOT stop operating by itself no matter what happens.

• •

Switch knob (5) to “MANUAL OPERATION” - position F Close Pressure Relief Valve (2)

Injector Opening Pressure Calibration • Leave High-pressure valve (4) in position OPEN (4B) • Build up pressure until continuous openings take place • Adjust Injector Opening pressure and increase pressure again until desired opening pressure is reached.

• Verify exact Opening Pressure by executing Program B. Injector Spray Test / Atomising Test • Move high-pressure valve (4) to CLOSED position (4A) • Build up pressure by means of Pressure Control Valve (3) until gauge 8 indicates approx. 600 bar • Move high-pressure valve 4 to position OPEN (4B) with a quick movement Atomising test is performed – the fuel injector opens continuously when working correctly, and the spray pattern can be studied. Note, this test ONLY is to be carried out for the 4 stroke fuel injectors.

The text “4-stroke engine injectors only” is written on the unit itself in order to REMIND operators NOT to perform atomising on the MAN Diesel 2-stroke engine slide-valve fuel injectors.

• • • • •

Move high-pressure valve (4) to position CLOSED (4A) to end test.

Repeat opening of high-pressure valve (4) to perform atomising again After end testing, leave high-pressure valve (4) in position OPEN (4B) Close Pressure Control Valve (3) – turn it counter-clockwise Open Pressure Relief Valve (2) – turn it counter-clockwise

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 Move high-pressure valve (4) to the OPEN position (4B)

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, Tel: +45 4498 3833 • Fax: +45 4498 1125 • E-mail: contact@iopmarine.dk • Homepage: www.iopmarine.dk

5. Troubleshooting the VPUD 1100 SV Test Rig Problem: Possible solution: Explanation:

No tests can be performed. Inlet pressure reads 0 bar at all times (Gauge 6) although air supply is working Press “RESET” button and start test over When the electronic blocking system in the VPUD 1100 SV 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 (clear oil is tickling from venting hole when PRESSURE CONTROL VALVE (3) is turned a few times clockwise) using the PREFILL program before attempting to run a test. Also, during testing, make sure that you press the Full Stroke Pushbutton (1) before reaching 200 bar.

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 when the pump is initiating a new pump cycle, if the injector has a very high leakage. This can be avoided by pressing the full-stroke push-button as described above.

Explanation A Explanation B:

Problem: Solution:

Air supply is turned off when full stroke button is pressed Reset the unit, and start the test again. Press the “FULL STROKE” button (1) before CURRENT OUTPUT PRESSURE reaches 200 bar.

Problem:

The VPUD 1100 SV is plugged in and turned on, but air supply is never blocked during testing.

If switch (5) is pointing at “MANUAL OPERATION” (Program F) no blocking will take place.

If the switch (5) is pointing at Program A-E, and a sudden oil pressure drop does not result in a blocking of the air inlet, the unit needs further troubleshooting. Contact IOP Marine for advice.

Possible explanation Solution:

Problem: CURRENT OUTPUT PRESSURE (7) does not zero at no pressure Possible explanation: Extreme temperature changes may impact the setting of the pressure transducer Solution: Contact IOP Marine for step-by-step re-zero guide.

Problem:

The display on the VPUD 1100 SV is not working.

Possible explanation: Unlike standard VPU units, the VPUD 1100 SV requires 110V/220V power-supply.

Solution: Check power supply. If unit is supplied with power from known-good source, contact IOP Marine for advice.

For general maintenance instructions, please consult section 6.

IOP Marine A/S • Engager 7 • DK-2605 Brondby, Denmark, Tel: +45 4498 3833 • Fax: +45 4498 1125 • E-mail: contact@iopmarine.dk • Homepage: www.iopmarine.dk

6. Maintenance 6.1 Cleaning of oil filters: The mesh filter, which is found in the filter cap (11) is removed and cleaned when the fuel oil has a tendency of slow flow.

The oil filter (12), which is found in the outlet from the oil vessel, is of the “throw-away” type, which should be removed and substituted by a new filter, when the old one has clogged, and the filter should under all circumstances be changed whenever main pump is maintained.

Please note that before removing this filter the oil vessel should be emptied completely, which is easily done by operating the pump unit without a fuel injector.

6.2 Gauge calibration: IOP Marine use only high-quality gauges.There is no class requirement for calibration of these gauges.

However, current accuracy of oil & display gauges can easily be verified by measuring against external, calibrated, gauge 6.3 Lubrication instructions: WARNING: AVOID AIRLINE LUBRICATION. The pump B1100-2 has been pre-lubricated and a lubro unit will decrease the efficiency of the pump.

Air valves of the B1100-2 pump should be lubricated periodically. Remove exhaust fittings and valve spool and apply a thin coat of Obel-P grease 8601-07-030 (IOP item 3000010).

If primary air drive section is dismantled, always apply a thin coat of IOP grease to entire inner surface of cylinder tube and plunger O-rings..

6.4 Spare Parts: Although the test unit is a robust and reliable piece of equipment it might be necessary to change certain parts, which are particularly exposed to wear such as O-rings, springs etc. in the pump itself, and when such worn components are changed, it will also be necessary to install new seals.

The pump itself is shown in a skeleton drawing and to facilitate the ordering of spare parts, these are found with ordering numbers on the following pages. Ordering can happen directly from IOP Marine A/S or through a handling agent of your choice. Visit http://www.iopmarine.dk for more information.

6.5 Maintenance at IOP Marine A/S authorised repair shop A range of repair-shops have proved skill full in maintenance of these products – please visit our homepage, for a complete listing of these repair-shops. http://www.iopmarine.dk

IOP Marine A/S • Engager 7 • DK-2605 Brondby, Denmark, Tel: +45 4498 3833 • Fax: +45 4498 1125 • E-mail: contact@iopmarine.dk • Homepage: www.iopmarine.dk

6.6 Unit Layout & Spare Part Numbers

11 8 6 9

7 4

5

10

1 2

3

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

Full stroke valve (push button) Pressure relief valve Pressure Control Valve / pneumatic reducing valve High pressure valve Program Selection Switch (6 positions) Manometer for “Inlet air pressure” (0-10 bar) Digital instrument with two displays Gauge for CURRENT OUTPUT PRESSURE 0-1600 bar Stud “air inlet” / air inlet w/ claw coupling or M42x2 Stud “fuel outlet” / high pressure outlet Filler cap with strainer Oil filter (inside oil tank)

(IOP no. 31904-46/-47/-48) (IOP no. 1111032) (IOP no. 3788003) (IOP no. 1112087) (IOP no. 3133070) (IOP no. 3805003) (IOP no. 3133071) (IOP no. 3805004 (as ordered) (IOP no. 2112005) (IOP no. 3787001) (IOP no. 3332002)

Inside:

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

(IOP no. 1113021)

IOP Marine A/S • Engager 7 • DK-2605 Brondby, Denmark, Tel: +45 4498 3833 • Fax: +45 4498 1125 • E-mail: contact@iopmarine.dk • Homepage: www.iopmarine.dk

6.7 Main pump, cross section (IOP 1113021)

IOP Marine A/S • Engager 7 • DK-2605 Brondby, Denmark, Tel: +45 4498 3833 • Fax: +45 4498 1125 • E-mail: contact@iopmarine.dk • Homepage: www.iopmarine.dk

6.8 Main Pump, Spare Parts List

IOP Marine A/S • Engager 7 • DK-2605 Brondby, Denmark, Tel: +45 4498 3833 • Fax: +45 4498 1125 • E-mail: contact@iopmarine.dk • Homepage: www.iopmarine.dk