Hartridge IFT-c Owner's manual

HL048 (EN) Issue 4, H1852, August 2011
World Leaders in Diesel Fuel Injection Test Equipment.
IFT-c
Injector Function Tester Controller
Operating and Servicing Manual
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HARTRIDGE LIMITED IFT-c Operating and Servicing Manual
HL048 (EN) Issue 4, H1852, August 2011 1
Hartridge IFT-c
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IFT-c Operating and Servicing Manual HARTRIDGE LIMITED
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HARTRIDGE LIMITED IFT-c Operating and Servicing Manual
HL048 (EN) Issue 4, H1852, August 2011 3
CONTENTS
FOREWORD.........................................................................................................................................................5
1. INTRODUCTION.........................................................................................................................................7
1.1 SPECIFICATION &SITE REQUIREMENTS...................................................................................................7
1.2 DEFINITION OF TERMS AND ABBREVIATIONS...........................................................................................7
2. IFT-C OVERVIEW ......................................................................................................................................8
3. INSTALLATION..............................................................................................................................................9
4. OPERATION - SETTING A TEST PLAN.....................................................................................................9
5. OPERATION –DRIVING AN INJECTOR.................................................................................................11
6. NOZZLE OPENING PRESSURE DETECTION (IFT-70N ONLY).........................................................11
7. OPERATING NOTES....................................................................................................................................12
8. TROUBLESHOOTING .................................................................................................................................12
9. WIRING DIAGRAM......................................................................................................................................13
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HARTRIDGE LIMITED IFT-c Operating and Servicing Manual
HL048 (EN) Issue 4, H1852, August 2011 5
Foreword
Copyright
Hartridge™ Ltd. reserves the copyright of all information and illustrations in this publication which is
supplied in confidence and which may not be used for any other purpose other than that for which it
was originally supplied. The publication may not be reproduced in part or in whole without the
consent in writing of this company.
© Hartridge Ltd.
Safety Information
Warnings, Cautions and Notes
The precautionary notes in this publication, indicated by the words WARNING, CAUTION, or NOTE
provide information about potential hazards to personnel or equipment. Ignoring these notes may
lead to serious injury to personnel and/or damage to equipment. These notes appear as follows:
WARNING! INDICATES THAT A SITUATION MAY BE HAZARDOUS TO PERSONNEL.
INSTRUCTIONS ARE PROVIDED FOR AVOIDING PERSONAL INJURY.
CAUTION! Indicates that conditions exist that could result in damage to equipment.
Instructions are provided to prevent equipment damage.
NOTE Indicates additional information for clarification where there may be confusion.
Operational & General Warnings
Do not open the guard while the system is running.
Wait for the test bench to stop before opening the
guard.
Do not attempt to remove the rear cover of the
machine while the system is running. Wait for the
test bench to stop, the pressures to decay to zero
before opening and to be isolated from the services.
Safety glasses conforming to standard BS EN
166:1996 must be worn when working on this
equipment for the following reasons:
The test equipment is capable of producing high
pressures which can cause severe eye injury in
the event of a malfunction.
The test stand uses fluid which may be harmful to
the eyes.
WARNING! HIGH PRESSURE FLUID SPRAYS
CAN CAUSE SERIOUS INJURY OR DEATH.
COMMON RAIL SYSTEMS OPERATE AT
EXTREMELY HIGH PRESSURES. IF USED AS
INSTRUCTED THE TEST KIT WILL RELIEVE ANY
HIGH PRESSURE WHENEVER THE GUARD
DOOR IS OPENED.
DO NOT ATTEMPT TO BYPASS THE PRESSURE
DUMP VALVE OR THE SAFETY INTERLOCK.
Gloves conforming to standard BS EN 407:1994
must be worn when handling parts after testing
which may be hot.
Ensure good levels of lighting for safe, efficient
equipment operation.
Accidents can occur to unauthorised personnel
during testing. Untrained person(s) must not be
present in the test area when the equipment is
operating. Only qualified personnel are to operate
this equipment.
This equipment contains electrostatic sensitive
devices. Observe the necessary precautions for
handling electrostatic discharge sensitive devices. Do
not touch printed circuit boards and associated
electronic connections and components.
Safety footwear must be worn in the test area at
all times. Injury to the feet may be sustained in
the event that equipment under test (during
loading or unloading).
Severe injury can be caused by slipping on spilt oils
or fluids. All spillage of fluids in the test area must be
dealt with immediately.
There must be no naked flames. Smoking in the
vicinity of the equipment is strictly forbidden.
Potentially flammable vapours are present in the
test stand and ignition is possible although
unlikely.
Arc welding equipment must not be operated within 5
metres of the test stand. The electrical supply to
welding equipment must be provided from a remote
isolating transformer. Arc welding can disturb the
electronics.
Ensure that the servicing requirements and
intervals as set out in the Maintenance section
are adhered to. Operate and service this
equipment only if competent to do so. Carry out
regular inspections to make sure all high pressure
connections are tight and safe.
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IFT-c Operating and Servicing Manual HARTRIDGE LIMITED
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Use fluid of the correct specification only. Obtain the
manufacturers Health & Safety Data Sheets and
follow the advice given therein. Prolonged and
repeated contact with oil products, ingestion or
excessive and prolonged inhalation of oil mists can
be detrimental to health. Use an appropriate barrier
cream.
High Voltage!
Isolate and lock the electrical supply off before
performing any maintenance operations. Do not
work on electrical equipment while voltage is
supplied.
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HARTRIDGE LIMITED IFT-c Operating and Servicing Manual
HL048 (EN) Issue 4, H1852, August 2011 7
1. Introduction
The IFT-c is designed to be used in conjunction with a Hartridge IFT-70, Testmaster 2 HH700
or a Testmaster 3 HH701 to provide an electrical signal to drive common rail injectors. When
used in conjunction with an IFT-70N it gives the ability to measure nozzle opening pressures
on traditional single stage injectors.
The IFT-c is of a steel fabricated construction with a 2 line LCD display of 20 characters. It
has a green start button, red escape button, a rotary control and 7 individual injector driver
leads.
1.1 Specification & Site Requirements
Dimensions
Height 405mm
Width 200mm
Depth 250mm
Injector type
connectivity
Delphi Solenoid
Denso Solenoid
Bosch Solenoid
Siemens Piezo
Bosch Piezo
Weight
11kg
Injection Frequency
Range
0 –3000 IPM for 0-2.0 mS
(100 IPM increments)
0 –2000 IPM for 2.0-3.0 mS
(100 IPM increments)
Electrical
supply
Single phase, 100 –120Vac, 50 / 60 Hz
Single phase, 200 –240Vac, 50 / 60 Hz
Pulse width Range
0 –3.0 mS for 0-2000 IPM
(0.1mS increments)
0 –2.0 mS for 2000-3000 IPM
(0.1mS increments)
Electrical
output
Single phase, 230Vac 60Hz
(Rated 1 amp)
Timer
10 –120
(10 second increments)
IFT-70
Integration
16 pin automotive type connector
Shot Count
10 –1000
(20, 50, 100, 200, 500 increments)
9999 (continuous running)
NOP hold time
(IFT-70n only)
0 - 1.0 sec in 0.5 sec increments, 1.0 to
5.0 in 1 sec increments.
1.2 Definition of Terms and Abbreviations
IFT-70
Injector Functional Tester
IFT-c
Injector Functional Tester - controller
NOP
Nozzle Opening Pressure (NOP)
IPM
Injections Per Minute
HH700
Hartridge Testmaster 2
HH701
Hartridge Testmaster 3
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IFT-c Operating and Servicing Manual HARTRIDGE LIMITED
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2. IFT-c overview
`
1
IFT-c
9
Electrical inlet fuse
2
-
10
Voltage selector
3
LCD display
11
240Vac 60Hz outlet fuse
4
Rotary control knob
12
IFT-70 loom connection
5
Escape button
13
240Vac 60Hz Outlet (1A)
6
Start button
14
Serial plate
7
On / Off switch
15
Overload protection
8
Electrical inlet
16
Injector driver loom outlets
Fig 1
Fig 2
1
3
4
5
6
9
11
7
8
10
12
15
16
14
13
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HARTRIDGE LIMITED IFT-c Operating and Servicing Manual
HL048 (EN) Issue 4, H1852, August 2011 9
3. Installation
Note: When installing an IFT-c to an IFT-70 follow the instructions as detailed in Hartridge manual
HL047. This section should only be followed if the IFT-c is being used in conjunction with a HH700 /
701.
1. Unpack the IFT-c.
2. Set the voltage selector to the appropriate voltage on the inlet IEC connector using a flat
bladed screwdriver (fig 3).
Fig 3
3. Connect the mains power using the supplied power cable (fig 4).
Fig 4
4. Switch on the IFT-c (1, fig 5).
Fig 5
4. Operation - setting a test plan
When the unit is switched on the display shows the current injector type and stored values for that
test. There are 50 selections of injector tests; 10 for each of the 5 pre-defined injector types (10 x
Delphi solenoid, 10 x Denso solenoid, 10 x Siemens piezo, 10 x Bosch solenoid, 10 x Bosch piezo)
100-120Vac
200-240Vac
50/60Hz
1
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IFT-c Operating and Servicing Manual HARTRIDGE LIMITED
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There are 6 ‘fields’ to the display, 4 of which are for holding stored values for the test:
D
E
L
P
H
m
S
I
P
M
N
S
O
L
0
0
.
0
0
0
0
0
9
9
9
9
Field 1 Field 2 Field 3 Field 4 Field 5 Field 6
Rotating the rotary control knob will scan through the 50 test selections in field 1, displaying in the
other fields the stored values for that test.
Noting that fields 2 and 3 are not immediately visible the six fields are:
Field 1: Injector type and test. Injector type automatically selects the correct voltage and
current drive for the injector.
Field 2: Status/storage field (described later)
Field 3: Spray pattern illumination lamp on/off selection (only available when connected to an
IFT-70)
Field 4: Pulse width selection from 0 to 3.0 mS in 0.1 mS steps
Field 5: Injection frequency range from 0 to 3000 IPM in steps of 100 (equating to 0 to 50
pulses per second in steps of 1 pulse)
Field 6: Run time / count. Time range (S) between 10 and 120 seconds. This field can also
display count range (N) between 10 to 1000, and continuous (9999).
To scan through fields 3 to 6 to make a change to the stored test values hold the red escape button
while rotating the rotary knob –the flashing cursor will move through the fields. To adjust a field
release the red button and rotate the rotary knob.
As soon as fields 3 to 6 are changed field 2 shows ‘?’ and ‘◄’. This is a prompt to store the values (if
required) before exit. To save modified values hold down the red button and scroll over to field 2,
release the red button and rotate the rotary knob one click anticlockwise. The ‘?’ and ‘◄’ will
disappear indicating the settings have been stored. Note that a test can be run saved or un-saved.
When connected to an IFT only field 3 can be switched between:
‘o’ – light off
‘*’ – light on
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HARTRIDGE LIMITED IFT-c Operating and Servicing Manual
HL048 (EN) Issue 4, H1852, August 2011 11
5. Operation –driving an injector
Switch on the IFT-c.
Select a stored test or create one as described in the previous section.
Connect an injector of the correct type for the test plan to the correct injector lead.
Press the green start button to start firing the injector. The injector stops firing as dictated by
the time or count settings in the test plan, or when the red button is pressed.
When the start button has been pressed the top line in field 2 displays a solid square block
when in run mode. The bottom line in field 2 also displays a solid square block if there are no
problems. If an error is present a status indication will be displayed as follows:
d –door open (IFT-70 only)
i –incorrect injector type plugged in or no injector connected
g –injector fault (short to ground) or wrong type
v –low injector voltage. (Requires reset of overload protection button)
To clear an error resolve the problem and press the red escape button.
NOTE: Piezo and Bosch solenoid test plans can be started without connecting an injector and
without getting an incorrect injector indication; this is normal as these injectors have a specific
way of working and the IFT-c does not interrogate the injector on these test plans.
6. Nozzle Opening Pressure detection (IFT-70n only)
When the unit is connected to an IFT-70n the IFT-c gives capability to measure NOP on mechanical
injectors. In this instance testplan 51 is enabled and the display will be as follows:
N
O
P
b
a
r
?
o
S
b
a
r
↑
0
0
0
◄
4
►
0
↓
Field 1 Field 2 Field 3 Field 4 Field 5
The five fields are:
Field 1: Nozzle opening pressure
Field 2: Status/storage field (see previous section)
Field 3: Spray pattern illumination lamp on/off selection
Field 4: NOP hold time from 0 to 1.0 sec in 0.5 sec increments, 1.0 to 5.0 in 1 sec increments.
Field 5: Pressure transducer calibration
To scan through fields 2 to 5 to make a change to the stored test values hold the red escape button
while rotating the rotary knob –the flashing cursor will move through the fields. To adjust a field
release the red button and rotate the rotary knob.
As soon as fields 3 to 6 are changed field 2 shows ‘?’ and ‘◄’. This is a prompt to store the values (if
required) before exit. To save modified values hold down the red button and scroll over to field 2,
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IFT-c Operating and Servicing Manual HARTRIDGE LIMITED
12 HL048 (EN) Issue 4, H1852, August 2011
release the red escape button and rotate the rotary knob one click anticlockwise. The ‘?’ and ‘◄’ will
disappear indicating the settings have been stored. Note that a test can be run saved or un-saved.
Before testing NOP it is important to ensure the pressure transducer is calibrated. This should be
carried out with nothing connected to the high pressure outlet on the IFT-70. Set field 4 to 0 seconds,
then scroll to field 5 and release the red escape button. Rotating the rotary knob in either direction will
adjust the transducer offset; adjust field 1 to read 0 bar ± 1 bar. Save the results; the unit is now
calibrated.
7. Operating notes
The unit should not be run with more than one injector connected.
Bosch and Siemens piezo injectors have the same connector but polarity is reversed. Take
care to insert the correct piezo lead. Piezo injectors click with reversed polarity but do not
inject.
8. Troubleshooting
If ‘!’ and ‘t’ is displayed in field 2 then the unit has tripped through a high current pulse.
Resolve the problem and switch the unit off and back on again to clear this fault.
If the injector will not fire, check that the overload button on the rear panel is pushed in.
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HARTRIDGE LIMITED IFT-c Operating and Servicing Manual
HL048 (EN) Issue 4, H1852, August 2011 13
9. Wiring diagram
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World Leaders in Diesel Fuel Injection Test Equipment.
The Hartridge Building, Network 421, Radclive Road,
Buckingham, MK18 4FD, United Kingdom
Tel: [phone] Fax: + 44 (0)1280 825 601
Email: [e-mail] www.hartridge.com
© Hartridge Ltd., 2009
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