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Common Rail System Driver STARDEX® 0202
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 250-190-75mm
AC power supply 220V 50Hz or 110V 60Hz
Power from vehicle battery 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
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.
Real
pressure
Target
pressure
Mode
Power
supply
Info
window
Duty cycle Current Control
buttons
Start\Stop
button
Frequency Status indicator
Indicator of the
controlled
parameter
Menu
Stop
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
