obel vpud 1000-4

IOP Marine A/S, Engager 7, DK-2605 Brondby, Denmark,

Phone: +45 4498 3833, Fax: +45 4498 1125, e-mail: [email protected], web: www.iopmarine.dk

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 Tel: +45 44 98 38 33 • Fax: +45 44 98 11 25 • 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 @ 10 bar air Max. 800 bar @ 7 bar air

Air consumption: 50 l/cycle @ 10 bar air 36 l/cucle @ 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: 6 l

Gauges: Gauge: Class 1.0 (10% error margin) Display: Class 0.2 (2% error margin)

Weight: 100 kg

Dimensions: 560x950x1525 mm

Power consumption: 200 mA @ 110V 100 mA @ 220V

Included adapters Pneumatic: MAN Diesel Standard Claw Coupling or M42x2 Hydraulic: CEJN 116 series male coupling



Unit Layout

2 3

1

6

5

7

8

(1) FULL STROKE push button

(2) Pressure relief valve

(3) Pressure control valve

(5) Program Selection Switch (5 programs + reset button)

(6) Gauge for primary air pressure 0-10 bar

(7) Digital instrument: CURRENT OUTPUT PRESSURE

(8) Digital instrument: MEASURED PRESSURE



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



Unit Layout








2 3

1

6

5

7

8



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 high-

pressure-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).



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


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



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


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).



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.



Unit Layout








2 3

1

6

5

7

8



Program E: O-ring Sealing Test

Switch knob (5) to O-ring Sealing Test position


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.


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.



4. Troubleshooting the VPUD 1000 Test Rig

Problem: No tests can be performed. Inlet pressure reads 0 bar at all times

(manometer 6) although air supply is working

Possible solution: Press “RESET” and start test over.

Explanation: 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.

Explanation A Air inside the fuel valve results in malfunction of the electronic

pressure transmitter. In special cases early shutdown can be a result

Explanation B: 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.

Problem: During execution of OPENING PRESSURE TEST / NOZZLE

LEAKING TEST air supply is turned off before test is completed

Solution: Reset the unit, and start the test again. Press the “FULL STROKE”

push button (1) while working pressure is between 100 and 140 bar.

Problem: The VPUD 1000 is plugged in and turned on, but air supply is never

blocked during testing.

Solution: Consult IOP Marine for maintenance advice.

Problem: The display on the VPUD 1000 is not working

Possible solution: Check power supply.

Explanation: 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.



5. Spare Parts

Pos. 1 Full stroke valve (push button) (IOP no. 31904-46/-47/-48)

Pos. 2 Pressure relief valve (IOP no. 1111032)

Pos. 3 Pressure control valve / pneumatic reducing valve (IOP no. 3788003)

Pos. 4 Transducer (inside VPU unit) (IOP no. 3865030)

Pos. 5 Switch (5 programs + reset) (IOP no. 3133070)

Pos. 6 Manometer for “Inlet air pressure” (0-10 bar) (IOP no. 3805003)

Pos. 7+8 Digital instrument with two displays (IOP no. 3133071)

Pos. 9 Stud “air inlet” / air inlet with claw coupling or M42x2 (as ordered)

Pos. 10 Stud “fuel outlet” / high pressure outlet (IOP no. 2112005)

Pos. 11 Filler cap with strainer (IOP no. 3787001)

Pos. 12 Oil filter (inside oil tank) (IOP no. 3332002)

Pos. 13 2-Way pneumatic valve (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

1

2 3

5

9

11

10

7+8

6



Main pump, cross section (IOP 1113021)



Main Pump, Spare Parts List



VPUD 1000 – Mechanic/Electric Diagram

Documents

obel vpud 1000-4