Operation Manual Diesel Tech DS2
Contents
1. This symbol is used to denote the Air Input connection Please consult Appendix A for specifications Beneath it is a Water Trap Filter Regulator Figure 2 iii d Fumes This symbol is used to denote the Fumes Output Spray Chamber Extractor Connection DO NOT connect the compressed air line here Beneath it is a Fumes liquid Trap collector Separator Figure 2 iii c Clean Test Fluid Fluid These symbols denote that in the left part of the machine the hydraulics are used for the Cleaning MACC and in the right part of the machine the hydraulics are used for Testing Calibration Oil The filters and drain valves are considered hydraulics in this case Operating Manual 2 9 DS2 Series These symbols x 1 and x 2 provide relative positions for further connectors 100 240 VAC 50 60 Hz This symbol denotes the Mains Power Supply of the unit Beneath it are the ON OFF switch Fuse Holder and Mains Power Connector Figure 2 iii k For further specifications please consult Appendix A Serial Tag DIESEL TECH OS Diesel Injector Service Unit model DS2 xx s n 9999999 date dd MM YY t a m a Seem zee The Serial Tag of the machine provides information on the Machine Model Serial Number Date of Manufacturing and also basic specifications 2 10 Operating Manual Getting Started Getting St arted This chapter provides basic information to start using2. Figure 3 iv Operating Manual 3 9 DS2 Series Starting up for the first time 1 Switch to the ON position the rear power Switch a Figure 3 v 0 OFF 1 ON Figure 3 v 2 Wait a few seconds until the DS2 Software Boots up If more than 1 minute pass and the Software has not loaded Blank screen look at Chapter 7 Troubleshooting 3 Once the Software loads the initial Screen will show the S W and H W version of the machine 3 10 Operating Manual Getting Started DIESEL TECH DSZ SW Im HW 20 ENCER es lesa F for Settings Menu Figure 3 vi 4 By Pressing the ENTER button once the unit is ready to operate 5 Look in Chapter 4 Menu Tour for further information on software navigation important Always wait at least 15 seconds when switching on the unit again after a power down Operating Manual 3 11 DS2 Series Powering down the system 1 Press the CANCEL button for more than 3 seconds until the Home screen is revealed 2 Once this operation is complete you can switch off the machine using rear ON OFF Power 3 12 Operating Manual HMI Menu Tour Menu To ur This chapter provides useful information on the DS2 Menu It covers the following topics Control Panel Basic Screens O Start up Screen Settings Screen Injector selection Screens Test MACC Screens O O 0 Operating Manual 4 1 DS2 Series A new user should pre
3. Max System Build Up Pressure Bar Psi Operating Manual A 3 Adapters and Connectors Appendix B Adapters and Conne ctors Operating Manual B 1 DS2 Series DESCRIPTION Generic_1 Electrical connector for connector ih Generic_2 Electrical connector for connector ih Delphi Electrical connector for connector ih High Pressure Hose Extension converter from M12 to M14 HP T Connection B 2 Operating Manual Adapters and Connectors Bosch Siemens etc R Adapt for Returned Testing Calibration Oil Denso CRIN etc R adapt for Returned Testing Calibration Oil Delphi R Adapt for Returned Testing Calibration Oil Spare o ring for RA 1 Adapter Spare o ring for D ADAPT 7 2 DA 7 Adapter Operating Manual B 3 DS2 Series Spare o rings for D ADAPT 7 DA 7 Adapter Spare Screen Filter for D amp R Adapters R Adapt Hose for Returned Testing Calibration Oil for quick coupler R Bosch Piezo R Adapt for Returned Testing Calibration Oil for quick coupler R 7mm D Adapt for Discharged Testing Calibration Oil for quick coupler D 9mm D Adapt for Discharged Testing Calibration Oil for quick coupler D B 4 Operating Manual Adapters and Connectors Calibration Oil Fluid Funnel Large 7mm Discharge Adapter for Cleaning MACC for quick coupler C DS2 X1 only 9mm Discharge Adapter for Clean
4. Operation Manual Diesel Tech DS2 ver 2010 2 DS2 Series Contents Chapter 1 Introduction 1 1 Equipment checklist 1 2 Options 8 Chapter 2 Product Tour 2 1 Front View 2 3 Side View 2 5 Rear View 2 7 Rear Panel symbols 2 9 Serial Tag 2 10 Chapter 3 Getting Started 3 1 Unpacking and setting up 3 3 Connecting the AC power 3 4 DS2 Unit 3 4 Injector Ultrasonic Device optional DS2 X1 3 5 Connecting the Pneumatics 3 6 Starting up for the first time 3 10 Powering down the system 8 12 Chapter 4 Menu Tour 4 1 Control Panel 4 3 Startup Screen 4 5 Settings Screen 4 6 Injector Selection Screens 4 8 Test MACC Screens 4 12 Chapter 5 Prepare the DS2 5 1 Fluids and Filters 5 2 Operating Manual DS2 Series Testing Fluid amp Filter 5 3 Cleaning Fluid amp Filter DS2 X1 only 5 5 Chapter 6 Operation Basics 6 1 Injector Ultrasonic Cleaner 6 3 Injector Mounting 6 5 Injector Clamp 6 5 Injector Spray Chamber Clamping Position and connections 6 8 Injector iVM Clamping Position and connections 6 9 Sample Procedure on Testing Injectors 6 10 1 Select the injector 6 10 2 OHM Test 6 10 3 Spray Test 6 11 4 iVM Injector Volume Metering 6 11 5 CANCEL STOP button in each test screen 6 12 Injector MACC Clamping Position and connections 6 13 MACC Cleaning Injectors internally DS2 X1 only 6 14 Chapter 7 Troubleshooting 7 1 Appendix A Specifications A 1 Appendix B Adapt
5. H W versions are shown here The DS2 is now ready for operation Press the ACCEPT button to continue info Ifthe Startup Screen loads and after pressing Accept Button there is no H W or S W version displayed consult Chapter 7 Troubleshooting DIESEL TECH DSZ SS il oo Eine KENE O Be e atra F for Settings Menu Figure 4 ii Operating Manual 4 5 DS2 Series Settings Screen There are several options in the settings menu that can further customize the DS2 software Scroll up down using the Arrow keys to navigate in the setting menu and press the Enter button to select an option SETTINGS MENU OWNER S NAME DEA LIN Sii LING EEE E ES Ueda PROGE AMMING Macul SIMI TEES Figure 4 iii OWNER S NAME Change the company name on the screen saver DRAIN SETTINGS Change the drain time settings PUMP PRESSURE Change the maximum time the pump will remain active PROGRAMMING Edit the Default Test Plans for Spray Volume metering and MACC for the different types of injectors 1 Common Rail Diesel Injector CRDI 2 UI EUI Unit Injector 3 Conventional Diesel Injector For each injector type there is an option to change the test plans for 1 Spray Testing 2 Volume Testing 3 MACC Cleaning 4 6 Operating Manual HMI Menu Tour For each option there are 4 different test plans composed of STRK milliseconds time of test and Single or Multi injection operation Each test plan can
6. DB9 adapter from the local computer market and install the required software on that computer Save the FLIP program and the HEX file on that PC Unzip and Install the FLIP program on the PC to be used FLIP Device gt Select gt AT89C51ED2 FLIP File gt Load HEX file FLIP Settings gt Preferences gt ISP Conditions controlled by Flip this option should always be checked Operating Manual DS2 Series Reveal the DS2 PCB board 9PIN SERIAL connector by removing the side panel Connect the PC to the Boards COM port using the 9 pin COM SERIAL cable IMPORTANT Disconnect any injectors 10 Power up the machine 11 FLIP Settings gt Communication gt RS232 gt Port COM1 or COMxx gt Baud lt 19200 gt Connect 12 If the PC already has a 9 pin Serial Port the COM number is usually COM1 otherwise open the Device Manager from Windows System Properties and look for the USB TO SERIAL Device 13 FLIP Make sure ERASE BLACK CHECK PROGRAM VERIFY are checked and click on Run 14 FLIP When step 12 is done check the option Level 2 and then click on START APPLICATION 15 Power Off the machine 16 Disconnect the COM cable and power ON the machine 17 From the machines settings MENU scroll down to Option LOAD DEFAULTS and press ENTER Below are some sample picture of the FLIP utility C 12 Operating Manual Connectivity Illustrations R
7. are in accordance with industry standard practices Carbon Zapp warrants that the equipment it manufactures will be free of defects in materials and workmanship The warranty terms are 2 years beginning on the date of the Carbon Zapp invoice in accordance with the following described This warranty does not cover damage due to external causes including accident abuse misuse scratches on external components or surfaces problems with electrical power supply servicing not authorized by Carbon Zapp usage not in accordance with machine s Operating manual failure to perform required preventative maintenance failure to change the testing calibration oil fluid and cleaning detergent when indicated by machine failure to change the testing and cleaning fluid filter when indicated by machine to permit machines fluid pump to sit or operate without fluid in it usage of improper testing or cleaning fluid in the machine usage of improper ultrasonic cleaning fluid in the ultrasonic bath usage of ultrasonic fluid instead of testing fluid or the opposite usage of cleaning solvents and chemicals not provided or indicated approved by Carbon Zapp use of parts and components not supplied or approved by Carbon Zapp Note Failure to clean injectors with Carbon Zapp s ultrasonic device Optional before any test is performed on the DS2 test bench will void the warranty of the machine If the iVM hydraulic system operation and graduated tube indica
8. be edited by pressing the Flunction key and using the arrow keys HEATING SETTINGS Not used on this version VACUUM SETTINGS Change the vacuum time settings LIGHT SETTINGS Change the LED time settings FILTERS FLUID Reset In these options the Filter and Fluid life span can be viewed in hours for the Cleaning MACC Filter and fluid When the Life ofthe filter fluid is over eguals to zero a pop up message will appear every time in the Home Screen informing that the filter fluid needs to be changed To RESET the TIME press the F unction key for more than 3 seconds More information regarding fluid and filter specification can be found Appendix A INJECTOR TYPE NAME Change the names of the customized Injector brands LANGUAGE Select one of the available operation languages LOAD DEFAULTS Reset the Test plans Injectors and all other parameterized data on the board to factory defaults MULTI SHOT SETTINGS Edit the multi shot settings Pilot and Post Pulse and Dwell time in milliseconds INSTRUCTIONS Show or hide instructions before each test important Every time the Testing filter is replaced it is mandatory also to replace the screen filters 30 88 in the D and R adapters a shown in Appendix C Operating Manual 4 7 DS2 Series Injector Selection Screens The DS2 unit can operate all types of diesel injectors depending on the options installed Before a test or a cleaning procedure in start
9. exiting the MACC procedure the DS2 will perform a Flush program that will flush the injector and lines with Testing fluid and it will drain the mixed fluid in the MACC Cleaning tank Operating Manual Operation Basics IMPORTANT The MACC hydraulic system is considered separate from the Testing system please use all adapters hoses and connectors marked with a C Itis important to follow the Flushing procedure after the MACC cleaning If the Flushing procedure is not performed for any reason please redo the MACC procedure in order to perform the Flushing of the injector and lines Operating Manual 6 15 Troubleshooting Troubles hooting Carbon Zapp designed the DS2 unit for durability However should problems occur following the procedures in this chapter can help to determine the cause All DS2 operators should become familiar with this chapter Knowing what might go wrong can help prevent problems from occurring Operating Manual 7 1 DS2 Series Symptom Detailed Cause Solution Repair Problem Description CONTROL PANEL No Boot Start BASED up PROBLEMS LCD screen Software Update procedure e File System is corrupt e Perform a Full System Restore reprogram PCB board via RS232 with latest version software e or contact support carbonzapp com e LCD Screen was scratched vandalized Needs replacement e or Contact support carbonzapp com e Fol
10. 2 Series Mains Voltage VAc 100 250 V Mains Frequency Hz 50 60 Mains Fuse Ampere 5 0 A Mains Power Cord CE Approved 250 10 V A mm Voltage Amperage Length 200 Power Consumption at Idle Operation Power Com umpion at Average Watt 100 0 Operation Power Consumption at Max Watt 250 0 605 702 Outer dimensions W D H SL 702 Outer Max dimensions W D H 605 702 Watt 15 0 m mm Clear Protection Cover Open 1015 Weight of DS2 X0 Testing Unit only Kg Lbs 41 0 90 du of DS2 X1 Testing amp Cleaning Kg Lbs 44 0 97 Weight of DS2 X0 Complete in Box Kg Lbs 56 0 123 Weight of DS2 X1 Complete in Box Kg Lbs 67 0 148 Max Filling Volume for It l 2 92 0 771 Testing Calibration Oil Tank GE Filtering for Testing Calibration Oil i 20 MANN 5 WK712 2 or Equivalent P i Testing Filter Life Hours 60 Testing Fluid Life Hours 20 Max Filling Volume for Cleaning Detergent Tank It gal 2 30 0 607 Filtering for Cleaning Detergent FLEETGUARD 7 FF 5074 or Equivalent A 2 Operating Manual Specifications Cleaning Filter Life Hours 30 Cleaning Fluid Life Hours 10 Input System Pressure Bar Psi a EE Recommended Min Operating Pressure for iVM Min Inner Diameter of Input Supply Hose Min inner Diameter Exhaust Hose if used to replace the Exhaust muffler mm as shown in Figure 3 iii Bar Psi 08 115 mm 10 1850 26 830 Injector Clamping diameters mm 9 45
11. Before each test plan is performed an automatic Draining of the tubes will also be performed The operator can cancel the draining procedure at any time by pressing the CANCEL button 5 CANCEL STOP button in each test screen a If the CANCEL STOP button is pressed once during a test the current test will stop By pressing the CANCEL button twice or for more than 3 seconds the software will initialize to the home screen Operating Manual Operation Basics Injector MACC Clamping Position and connections Figure 6 vii Operating Manual 6 13 DS2 Series MACC Cleaning Injectors internally DS2 X1 only The DS2 provides a separate function for cleaning injectors with the MACC Molecule Activated Chemical Cleaning method Navigate to the Tests Screen and press the F button The Cleaning Screen will appear Follow the steps below to effectively service the injectors 1 Mount the injector on the DS2 in the MACC clamping position Use the C adapt and ih electrical harness and connect the injector with the DS2 Figure 6 iv Press the START button and the MACC process will begin Four predefined test plans will activate the injector in different frequencies for the full period of the time for more effective servicing As soon as this process has terminated the program will remain in idle mode and the operator can either repeat the process or Return to the Home Screen While
12. ange SOOD FEAR Oht sai FPO nua hee 4 Amp G00 FRPP sea Rep OD ER Dansa FROG Die ID Operating Manual C 13 DS2 Series ions isting Piip REA Amar Flew FA nn ame Sim lien a lt Baca Ba ide or Cect PEDO a he boiada ve Raisi Baias Limin 7 sd A Ox r bw Drm 158 Wad Level Leal I Bu kl dual li U ve Mi 0 251 mn Im ji C 14 Operating Manual NOTES
13. b for SIEMENS Piezo Injectors If you accidentally connect the Polarity wrong the injector will sound like it is operating but it will not spray or discharge volume correctly u Figure 4 vi a b Figure 4 vii 4 10 Operating Manual HMI Menu Tour Choose the brand of the injector SELECT MANUFACTURER 1 BOSCH E TEMEN PELERIN 4 DENSO DPOC E ell Ge OM 2 Figure 4 viii Choose a profile of the injector The GENERIC profile should be used for new users BOSCH COIL D PETB ZIE MIE Aes O EF for properties Figure 4 ix Operating Manual 4 11 DS2 Series Test MACC Screens Once the Injector has been selected the TESTING CYCLE ACTIVE screen will appear giving the option to the operator to select either Spray or Volume testing In addition for units equipped with MACC by pressing the F unction button the unit will switch to Cleaning Cycle Active MACC providing the user with the option to MACC clean the injectors Before a Spray or Volume test is performed an OHM test is also performed for COIL INJECTORS TESTING CYLCE ACTIVE 1 SPRAY TESTING 21 LOID JUUT TECO EING jee e declaren S Figure 4 x CLEANING CYLCE ACTIVE Clodio eno ees 4 12 Operating Manual HMI Menu Tour Figure 4 xi Operating Manual 4 13 Prepare the DS2 Prepare t he DS2 This chapter provides useful information on preparing the DS2 uni
14. e live wall outlet depending on the Ultrasonic device specifications info Please consult the accompanying Ultrasonic device Operating Manual Operating Manual 3 5 DS2 Series Connecting the Pneumatics info Always use a Water Trap Filter Regulator to connect the Air Supply to the machine even if the Shop Air Compressor has a dehumidifier installed Always use the nearest route to the Shop Air Compressor and avoid Air Hose bottlenecks in order to achieve maximum Air Pressure and Air Flow Follow the specifications in Appendix A The DS2 units are equipped with a standard Water Trap Always regulate the compressed air input according to the specifications in Appendix A or on the Serial Tag of the machine 1 Use a hose fitting a not provided to connect the Water Trap Regulator to the hose that leads to the Shop Air Compressor Figure 3 ii 3 6 Operating Manual Getting Started Figure 3 ii 2 Optional Disconnect the Fumes Extractor Exhaust Port muffler filter b Figure 3 iii and connect a large diameter hose in order to reduce fumes and noise info Vacuum performance issues may occur by installing a hose instead of the muffler Operating Manual 3 7 DS2 Series Figure 3 iii 3 8 Operating Manual Getting Started important A periodic emptying of the vacuum collector is needed Figure 3 iv DIDO TT IVATO PROD IO IT IT A IR TTTTE IE ON
15. e altered from the SETTINGS menu d Use the HP Pressure Control Regulator to increase or decrease the system pressure info Ifthe F unction button is pressed while a single injection program is running using the arrow keys the operator can dynamically change the Strokes and milliseconds of the test plan 4 iVM Injector Volume Metering a Important Please clean injectors in the ultrasonic device for at least 15 minutes prior to mounting on the DS2 unit Injector Ultrasonic Cleaning is Mandatory Please review the Warranty Failure to clean injectors with the use of Carbon Zapp s ultrasonic device provided before any test is completed on the test bench will void the warranty of the machine If the sensor reading is out of specification or accuracy due to dirt verified the machine s warranty will be voided Operating Manual 6 11 DS2 Series b The Injector should be in the iVM clamping position c Use the D adapt R adapt and ih electrical harness and connect the injector with the DS2 d Each Test Plan will perform for a predefined time measuring both D ischarge and R eturn volume per Test plan e Once each test plan is performed the unit will provide some time for the operator to record the volume values from the R AND D tubes f The operator can either perform the next test plan by pressing ENTER CANCEL button or use the arrow keys to select a specific test plan info
16. eaning Detergent start up consumable for MACC Cleaning of injectors DS2 X1 only Calibration Oil Fluid Funnel Large Cleaning detergent Funnel MACC Small with extension for quick coupler C DS2 X1 only Adapters and Accessories Kit for Testing Injectors look at Appendix B Adapters and Accessories Kit for Cleaning Injectors look at Appendix B DS2 X1 only Piezo Injector Back Leak Regulator Kit PIR Optional Operating Manual and Quality Control Certificate 1 2 Operating Manual Options Introduction There are a number of options to make the DS2 unit even more powerful and universal in diagnosing and servicing the Diesel Injectors The following options are available CRIN ADAPTERS Description Upgrade Kit Industrial Common Rail Injector Adapters Request availability list from your local dealer Portable stand DS2 Piezo Injector Back Leak Regulator Kit PIR Hardware M Needed AE YES DS2 X0 MES YES Operating Manual 1 3 Product Tour Product T our This chapter provides an overview of the DS2 exterior views and connections It covers the following topics Front View Side View Rear View Rear View Symbols Serial Tag Operating Manual 2 1 DS2 Series A new user should be familiar with all the views and connections in this chapter 2 2 Operating Manual Product Tour Front View Injector Clamp Injector Spray Chamber fumes extractor Inj
17. ector Spray Chamber Unit adjustable support pads PIR Pressure Regulator PIR Pressure Gauge Control Panel High Pressure Regulator LCD SCREEN Front Connections a ih Injector Harness connector b iVM i PI R Testing Return Connector for PIR use ii R Testing Return Connector iii D iVM Testing Discharge Connector c MACC i C Cleaning MACC Discharge and Return Port k iVM lit Volumetric Tubes High Pressure clear protective cover opening switch m Clear Protective cover Tm Toa Pe a Tv Operating Manual 2 3 DS2 Series bi a Figure 2 i 2 4 Operating Manual Side View a Left Side Panel b Right Side Panel c Testing Calibration OIL level indicator d Cleaning MACC detergent level indicators Product Tour Operating Manual 2 5 DS2 Series Figure 2 ii 2 6 Operating Manual Product Tour Rear View Rear Top Panel Serial Tag Spray Chamber fumes extractor output Regulated and filtered compressed air input HP Pump air exhaust port Testing Calibration OIL drain valve Testing Calibration OIL Filter Cleaning MACC Filter Cleaning MACC drain valve Rear Bottom Panel Mains Rear ON OFF switch m UIS Attachment unit connections x 1 x 2 ATT Tora Perm a Om w Operating Manual 2 7 DS2 Series IN IN TN ILLITLKIVIATEKKTKKKKKKHKKKKKVKKKKKKVIKKKKKKKKKK Figure 2 iii Operating Manual Product Tour Rear Panel symbols
18. ed the injector selection process must be completed Below is the basic screen to define the injector selection process Choose between CRDI UIS or Mechanical injectors SELECT INJECTOR TYPE 2 UI eUT ats ieee Cors Comte meena tl Diesel Injector Mechanical Figure 4 iv 4 8 Operating Manual HMI Menu Tour Choose between COIL Solenoid older PIEZO Newer actuation An easy way to distinguish if an injector is coil or piezo is to perform an OHM TEST if the injector has OHM most likely it is a coil injector SELECT COMM RAIL TYPE 1 COIL Common Rail STANDARD 2 PIEZO Common Rail NEWER Figure 4 v The Injector Harness is used to provide the injector with power while operating Electrical Diesel Injectors Some Injectors have a PLUS sign engraved on the connection fitting in order to denote how to correctly apply voltage The machine harness connectors also denote the PLUS sign with a RED Dot The user should always connect the Plus side of the connector to the Plus side of the injector see Figure 4 vi info The PIEZO Diesel Injectors must at all times use the correct polarity Often the PLUS is not denoted therefore the user should always consult the manufacture s or the automobile s service manual For example look at Figure 4 vii a to see the Operating Manual 4 9 DS2 Series most common PLUS polarity for BOSCH 115 116 and 117 and Figure 4 vii
19. edure on Testing Injectors important Always expect pressure in fluid lines and wear protective goggles and gloves For DS 1X models were the clear protective cover is not a standard option extra care is advised when dealing with high pressures It is recommended to observe the condition of the screen filters 30 88 before each operation a shown in Appendix C Every time the Testing filter is replaced it is mandatory also to replace the screen filters 30 88 a shown in Appendix C info If the Test is performed for a Piezo injector please consult the Appendix C for PIR Piezo Injector Return connectivity instructions and procedure When Switching injectors it may be needed to perform a de aeration in the high pressure lines a shown in Appendix C 1 Select the injector a Consult the screens in Chapter 4 on how to select the correct injector 2 OHM Test a This test is only performed for Coil Injectors because Piezo Injectors don not have measurable resistance b When this test is performed 1 of 3 values will be displayed Operating Manual Operation Basics i OHM value of the injector ii OPEN Open Coil Circuit iii SHORT Short Coil Circuit 3 Spray Test a The Injector should be in the Spray Chamber clamping position b Use the R Adapt and ih electrical harness c The will begin after the OHM test and the vacuum and light will be automatically activated The time and test plans can b
20. er you must first empty the tank completely using the drain valve next to the filter and then use a Filter tool to unscrew it Counterclockwise In order to install a new filter after taking out the old one close the drain valve and screw the new one in Clockwise using the Filter tool After that you can fill again the tank info Operating Manual 5 5 DS2 Series After replacing the filter and filling the tank drain some fluid in order to eliminate some are pockets in the lines Fluid level is acceptable when it is visible through the bottom level indicator Always check fluid level when the DS2 is idle Never let the fluid level fall below the lowest visible point in the tank level indicator Always consult Appendix A for Tank and Filter capacity and specifications Excess Fluid can always be drained using the specified drain valve The DS2 Software will provide a visual prompt on when to change the Filter 5 6 Operating Manual Prepare the DS2 Figure 5 iii Operating Manual 5 7 Operation Basics Operatio n Basics In this chapter instructions with figures will be shown on how to perform a basic operation with the DS2 unit The following topics are covered Cleaning Injectors with ultrasonic device Injector Mounting Injector Clamp Injector Soray Chamber Clamping Position and connections Injector iVM Clamping Position and connections Sample Procedure on testing injec
21. ers and Connectors B 1 Appendix C Connectivity Illustrations C 1 Operating Manual Figures Figure 2 i Figure 2 ii Figure 2 iii Figure 3 i Figure 3 ii Figure 3 iii Figure 3 iv Figure 3 v Figure 3 vi Figure 4 i Figure 4 ii Figure 4 iii Figure 4 iv Figure 4 v Figure 4 vi Figure 4 vii Figure 4 viii Figure 4 ix Figure 4 x Figure 4 xi Figure 5 i Figure 5 ii Figure 5 iii Figure 6 i Figure 6 ii Figure 6 iii Figure 6 iv Figure 6 v Figure 6 vi Figure 6 vii DS2 Series 2 4 2 6 2 8 3 4 3 7 3 8 3 9 3 10 3 11 4 3 4 5 4 6 4 8 4 9 4 10 4 10 4 11 4 11 4 12 4 13 5 2 5 5 5 7 6 3 6 4 6 7 6 8 6 9 6 13 Operating Manual DS2 Series Copyright The distribution and sales of the product are intended for use by the original purchaser This document may not in whole or part be copied photocopied reproduced translated or reduced to any electronic medium of machine readable form without prior consent in writing from Carbon Zapp The information in this document is subject to change without notice Company Information CARBON ZAPP 8 Alimou Ave Alimos 17455 Athens GREECE Tel 30 210 99 28 304 Fax 30 210 99 28 655 E mail info carbonzapp com support carbonzapp com URL www CarbonZapp com Laa Operating Manual DS2 Series Warranty 2 YEAR DS2 LIMITED WARRANTY Carbon Zapp company manufactures its equipment from new parts and components that
22. est and adjust pressure at 200Bar e Visually inspect for leaks while Possible HIGH PRESSURE Leaks Inside the machine operating unit If there is no visual leak then increase gradually the operating pressure in increments of 50Bar until leak is visible e When leak is located focus on the origin of the problem elf there is a damaged loose or worn HP hose or connector part ONLY replace with new from your 7 4 Operating Manual Troubleshooting closest Carbon Zapp dealer eRe test unit after repairing to verify the problem is solved MACHINE HP hose D LEAKS FLUIDS squirting fluid EXTERNALLY fromthe WHILE connectors or OPERATING the hose itself eReplace complete HP hose with new one supplied from your closest Carbon Zapp dealer BACK LEAK R hose leaking fluid from the connectors or the hose itself eReplace complete Back Leak hose with new one supplied from your closest Carbon Zapp dealer D or R QUICK CONNECT COUPLER AT FRONT PANEL OF eReplace Quick connect coupler MACHINE Is with New one supplied from your leaking while closest Carbon Zapp dealer operating D or R hose connected EXHAUST in e Check Air supply circuit and water back side of trap dehumidifier of the shop for machine is water and dirt spraying water eEmpty the water trap which is mist along with located at the rear side of the Operating Manualr instead of dry machine 5 air e After this has been do
23. evice will be screened by these filters Please note that this filter does not replace the ultrasonic cleaning operation Operating Manual Operation Basics Injector Mounting All the Common Rail injectors can be mounted on the DS2 using the Injector clamp Figure 6 iii Some injectors e g Side Feed Injectors e g BOSCH INDUSTRIAL CRIN may need additional adapters For further specifications on Clamping diameters please consult the Appendix A For further guidance in Side Feed Injector CRIN adapter mounting please consult Appendix C Injector Clamp The injector Clamp has two horizontal and many vertical positions Using the a side handle you can securely clamp the injector or loosen to free the injector Figure 6 iii Using the b rear handle you can adjust the height vertical position of the clamp Figure 6 iv Using just force Figure 6 iv c the clamp rotates horizontally between two preset positions o Left Position Spray Chamber o Right Position iVM Volume metering amp MACC Operating Manual 6 5 DS2 Series a Figure 6 iii 6 6 Operating Manual Figure 6 iv Operation Basics Operating Manual DS2 Series Injector Spray Chamber Clamping Position and connections Figure 6 v 6 8 Operating Manual Operation Basics Injector iVM Clamping Position and connections Figure 6 vi Operating Manual 6 9 DS2 Series Sample Proc
24. heck if OHM test gives valid nn Me an ce ac ne ei ae Operating Manual DS2 Series Piezo injector ONLY Not operating No injector operation driver circuit on the pcb board has failed e Contact you closest Carbon Zapp dealer for spare part and instructions e Verify that injector is good and operating e Check and replace if needed with spare provided the injector wire protection circuit located at the beginning of the injector driving wire connecting to the pcb board e Test with a good known injector e If Piezo does not work test the machine with a coil injector and verify normal operation e If test fails then the high voltage circuit on the PCB board has failed e Contact you closest Carbon Zapp dealer for spare part and instructions e Verify that injector is good and operating e Check and replace if needed with spare provided the injector wire protection circuit located at the beginning of the injector driving al wire connecting to the pcb board e Test with a good known injector e Check if OHM test gives valid OHM test results are inaccurate CLEAR PROTECTION COVER CRACKED OR BROKEN EXHAUST VACUUM AND FUMES EXTRACTOR NOT WORKING SEPARATOR ISSUES Operating Manual Troubleshooting e If the OHM test passes than the driver circuit on the pcb board has failed e Contact you closest Carbon Zapp dealer for spare part and instructions e Verify that injector is good and o
25. ing MACC C Adapt DS2 X1 only Bosch Piezo Return Adapter for Returned Cleaning MACC C Adapt DS2 X1 only Operating Manual B 5 DS2 Series T Piece C Adapt Hose for quick coupler 1 C DS2 X1 only Cleaning detergent Funnel MACC Small with extension for quick coupler C DS2 X1 only 100 240 VAC Mains Power Cable Hose Clamp DS2 X1 1 QTY B 6 Operating Manual Adapters and Connectors Vacuum Muffler for connecting to the rear Spray Chamber fumes extractor Figure 2 iii c Piezo Injector Back Leak Regulator Kit a Input Piezo Injector Return from injector b Regulator Increase Important Pressure To be used ONLY in Testing Mode Clockwise Optional c Gauge Piezo Return Indicator Operating Manual B 7 Connectivity Illustrations Appendix C Connectiv ity Illustra tions Operating Manual DS2 Series Description Illustration C 2 Operating Manual Electrical Wire Connection ih gt Injector Connectivity Illustrations Operating Manual C 3 DS2 Series Return Adapter R Adapt Connection for Testing Calibration Oil R iVM C 4 Operating Manual Discharge Adapter D Adapt Connection for Testing Calibration Oil D iVM Operating Manual discharge Connectivity Illustrations O WM C5 DS2 Series Discharge and Return T Piece Adapter C Adap
26. k important When completely replacing the testing fluid filter air elimination process should be followed after filling the tank o Connect the air input if not yet done o Place the High Pressure hose directly into the large Spray Chamber without connecting anything to the hose end o Slowly increase the system pressure pressing the HP ON OFF button from the Control Panel and turning pressure regulator clockwise o Some fluid will run through the hose into the o After a period of 20 seconds press the HP ON OFF button and turn off the pressure o Now the DS2 Testing Tank Filter and Lines are free of air Operating Manual 5 3 DS2 Series info After replacing the filter and filling the tank drain some fluid in order to eliminate some are pockets in the lines Fluid level is acceptable when it is visible through the level indicator Always check fluid level when the DS2 is idle Never let the fluid level fall below the lowest visible point in the tank level indicator Always consult Appendix A for Tank and Filter capacity and specifications Excess Fluid can always be drained using the specified drain valve 5 4 Operating Manual Prepare the DS2 Figure 5 ii Cleaning Fluid amp Filter DS2 X1 only In order to fill the Cleaning tank up to acceptable level you must use the accompanied funnel and pour liquid through the C Cleaning port Figure 5 iii Inorder to change the filt
27. low instructions shown in Appendix C 7 2 Operating Manual Troubleshooting e Good Injector not working correctly Spray Ohm Check the FFA fast fuse adapter connected on the PCB board and the injector wiring for continuity while INJECTOR DRIVER the unit is switched off If PCB board issues there is no continuity on either pins replace the FFA with one provided e Injector Driver is defective contact support carbonzapp com MACHINE LEAKS FLUIDS INTERNALLY WHILE OPERATING e Open both side panels of machine Possible LOW e Operate unit in Manual mode at PRESSURE Leaks both spray test and iVM test from e Visually inspect for leaks while 1 Low Pressure Operating unit Supply Hoses eWhen leak is located focus on the filter assembly origin of the problem and HP pump elf a hose clamp is loose tighten it 2 D and R to solve the problem elf there is a damaged or worn hose dani an or part replace with equivalen 3 connecting to from the local market or contact vu system your closest Carbon Zapp dealer 3 IM system for spare part DS2 Series hose connecting to machine Cleaning tank DS2 X1 only Spray Chamber drain Hose Fumes Extractor fluid hose from Spray Chamber to rear side of machine 8 Testing tank gaskets or level indicator Cleaning tank gaskets or level indicator DS2 X1 only e Open both side panels of machine e Operate unit in Manual mode at spray t
28. low your closest Carbon Zapp dealer pressure for spare part pump filtering system and HP pump e Open rear side panel of machine e Visually inspect for wiring of the valves disconnected wire e Manually activate the drain valves and hear or feel that both valves are activating listen for a strong clicking noise elf neither valve is working check for wiring circuit from PCB to the valves Check for 12Volts between red and blue wire of the valves while activated Assure there is no correlation to another part failing on the machine e f the valve clicks and operates but still does not drain that means there is dirt that has clogged the valve and needs to be opened and cleaned Disassemble the valve by first removing the solenoid holding Specific Draining valve not Draining GLASS Both Draining VOLUMETRIC valves not TUBES NOT Draining DRAINING Volumetric tube draining slowly Operating Manual 7 7 DS2 Series nut than unscrewing the valve assembly screws and pulling outwards all together Wash off all parts and reassemble elf there is a damaged drain electro valve or part replace with equivalent from the local market or contact your closest Carbon Zapp dealer for spare part Cracked or e Replace with new one Contact broken Glass your closest Carbon Zapp dealer tube for spare part e Remove Glass Tube by turning GLASS SPRAY counterclockwise and applying an CHAMBER upward force e Replace bo
29. ne operate Soaking wet again the machine for at least 5 behind the minutes for the system to free the DS2 Series MACHINE EXHAUST in back side of machine after long operation and humid environment is spraying a small amount of water mist along with air instead of dry air NOT soaking wet behind the machine EXHAUST in back side of machine is spraying calibration oil mist along with air instead of dry air Possible Leaks LEAKS FLUIDS from AT STAND BY 1 Testing tank of water you need to contact your hydraulic air network provider to check your system for humidity and dehumidifier for possible problem e This is Normal operation of the machine and pump does not present a problem Pump will need to be replaced or serviced from authorized personnel only Please contact you nearest Carbon Zapp dealer to report the problem or email to support carbonzapp com to be send the service guide for replacing or repairing the pump s e Open both side panels of machine e Visually inspect for leaks around 7 6 Operating Manual Troubleshooting gaskets or level the body of the unit indicator e When leak is located focus on the Cleaning tank origin of the problem gaskets or level elf a hose clamp is loose tighten it indicator DS2 to solve the problem X1 only elf there is a damaged or worn hose Low Pressure or part replace with equivalent Supply Hoses from the local market or contact to
30. onomy and performance through accurate injection of fuel The Electronically Controlled Diesel Fuel Injectors although accurate produce chronicle defects Through time numerous faults may occur such as fuel residue built up at nozzle and back leak valve pressure relief valve electrical coil or Piezo crystal failure and injector pathway blockage These faults in turn produce an undesired effect which causes increase in emissions and fuel consumption unstable engine operation and loss of engine performance Carbon Zapp a leading manufacturer in Automotive Injection Service Solutions offers the DS2 Unit for the treatment of all Common Rail Injectors presently used and provides upgradeability of the machine for Future Injectors Operating Manual 1 1 DS2 Series Equipment checklist Carefully unpack the machine and its components Save the box and packaging materials for future use Check if you have all the following items DS2 Series Common Rail Testing and Servicing Unit Injector Ultrasonic Device 100 240 VAC with DS2 X1 o Operating Manual o AC Power Cord 100 240 VAC o Injector Holder AC 100 240 VAC Power Cord for DS2 Series Unit Calibrating Oil Shell V OEL 1404 or equivalent prefilled 32 tank start up consumable for Testing injectors 4 liter Calibration Oil start up consumable for DS2 Testing injectors 4 liter Ultrasonic Cleaning Solvent start up consumable for Ultrasonic Cleaning injectors 2 liter Cl
31. perating e Test with a good known injector e Check if OHM test gives valid numbers and not values out of specification verify with a calibrated multimeter e If the OHM test passes than the low power resistance metering circuit on the pcb board has failed e Contact you closest Carbon Zapp dealer for spare part and instructions e Replace the clear protection cover with a new one e Contact you closest carbon Zapp dealer for spare part and instructions e Verify that there is air input at the machine of at least 4 Bars e Manually activate the vacuum button at the Control panel and DS2 Series LEAKING AT BACK SIDE OF MACHINE POOR SPRAY CHAMBER CLEARING EFFICIENCY check if vacuum is operating e If not replacement of the vacuum electrical valve controller is needed to be replaced Contact you closest Carbon Zapp dealer for Spare part and instructions e Remove the glass bottom of the device and empty the fluid e Visually check o ring seal at upper position of glass bottle and replace if needed e Replace into original position e Remove the silencer filter Figure 2 iii c from the exhaust of extractor collector at rear side of machine and verify the problem still exists or not e If it still exists then remove the glass bottom of the device and empty the fluid e Replace into original position Operating Manual Specifications Appendix A Specificat ions Operating Manual A 1 DS
32. t Connections for Cleaning MACC C DS2 X1 only C 6 Operating Manual Connectivity Illustrations DIR Piezo Injector Back Leak Pressure Regulator Operating Manual C 7 DS2 Series Piezo Injector Back Leak Pressure Regulation Operation Instructions For correct operation of the Piezo injectors Testing Mode ONLY use the optional Carbon Zapp Piezo Back leak Pressure Controller PIR Connect using the proper back leak adapter from the injector to the PIR and then connect the PIR to the DS2 unit at the front side at connector R as shown in above figure Unwind completely the pressure regulator to drop pressure Close clear protection cover Choose Piezo injector type and select Spray Test from Manual Tests at the menu to start Let injector operate for at least 30sec at 1000STRK 700us and at least 750bar HP T pressure and read the pressure indicated on the PIR gauge Adjust pressure according to the following values Bosch Piezo 8 bars Siemens Piezo 1 5 bars Note All injectors to be tested should be tested at the exact same Back Leak pressure D amp R Adapter Screen Filter 30 88 o es Replacement e 0 ua y J C 8 Operating Manual CRIN Side Feed Injector Adapter connection Connectivity Illustrations Operating Manual DS2 Series High Pressure lines De aeration Air pockets in the High Pressure lines restrict pressure build up and
33. t for the initial operation It covers the following topics Fluids and Filters o Testing Fluid amp Filter o Cleaning Fluid amp Filter Operating Manual 5 1 DS2 Series Fluids and Filters The DS2 comes with half a tank of Testing fluid Diesel Calibration oil and an empty tank of Cleaning fluid The machine filters and drain valves are divided into two parts left right and are shown on the rear panel of the machine Figure 5 i Clean Test Fluid Fluid Figure 5 i info Always check if you have acceptable levels of fluids important Every time the Testing filter is replaced it is mandatory also to replace the screen filters 30 88 a shown in Appendix C 5 2 Operating Manual Prepare the DS2 Testing Fluid amp Filter In order to fill the Testing tank up to acceptable level you must use the accompanied funnel and pour liquid through the Large Spray Chamber Figure 5 ii Inorder to change the filter you must first empty the tank completely using the drain valve next to the filter and then use a Filter tool to unscrew it Counterclockwise In order to install a new filter after taking out the old one close the drain valve and screw the new one in Clockwise using the Filter tool After that you can fill again the tank In order to fill with Testing fluid use the accompanied funnel through the large Spray Chamber Figure 5 ii The fluid will drain directly into the testing tan
34. th Viton o rings at the Leaky Glass tube base with equivalent from the local market or contact your closest Carbon Zapp dealer for spare part e Replace the Glass tube in its position and test FLUID PRESSURE ISSUES NO or LOW Pressure built up e Check Air Supply and verify that the input specifications are according to the ones listed at Annann N 4 e Injector to be tested has a very high back leak value and injector cannot built the required pressure 7 8 al Troubleshooting e Clear Protection cover Switch has failed Use contact spray at the switch Figure 2 i j to solve the problem If problem is not solved this way replace switch with new one Contact your closest Carbon Zapp dealer for spare part and Pump is instructions continuously Pressure Regulator located inside pumping but NO the machine at the center bottom Pressure is built compartment has been in the system disconnected from the control wire Re connect wire to pressure regulator to solve the problem If this does not solve the problem then replace the regulator with a new one Contact you closest Carbon Zapp dealer for spare part and instructions INJECTOR DRIVING PROBLEMS Coil Injector e Verify that injector is good and ONLY Not operating operating e Check and replace if needed with spare provided the injector wire protection circuit located at the wire connecting to the pcb board e Test with a good known injector e C
35. the DS2 unit and covers the following topics info All users should be familiar with diesel systems and should always wear protective goggles and gloves Unpacking and setting up Connecting the AC power Connecting the Pneumatics Starting up for the first time Powering down the system Operating Manual 3 1 DS2 Series A new user should follow the steps in each section of this chapter in order to operate the machine 3 2 Operating Manual Getting Started Unpacking and setting up Verify that all the items in the equipment check list in Chapter 1 are present Place the DS2 Unit and Ultrasonic Device optional in a clean and well ventilated space Usea leveled steady bench that can support the weight and vibrations of the machine or use the PS80 Portable Stand optional Operating Manual 3 3 DS2 Series Connecting the AC power DS2 Unit Verify that the rear ON OFF Power Switch is in the OFF position 1 Connect one end of the AC power cord a to the rear power socket of the machine b Figure 3 i 2 Connect the other end of the AC Power cord to any grounded 100 240 VAC 50 60 Hz power source live wall outlet Figure 3 i 3 4 Operating Manual Getting Started Injector Ultrasonic Device optional DS2 X1 1 Connect one end of the AC power cord to the rear power socket of the device 2 Connect the other end of the AC Power cord to any grounded 100 240 VAC 50 60 Hz power sourc
36. therefore the HP pumps will pulsate in a high frequency with almost very low or no pressure build up To bleed the system from air DE Connect the HP hose to the injector and tighten by hand Release the HP pressure by unwinding the HP regulator Press the leak PUMP button to activate the HP Pump Slowly increase the HP Pressure by winding the HP regulator Clockwise Remember the High Pressure Safety Switch it must be pressed for the HP pressure to build up While the HP pump is pulsating in low frequency and some liquid is flowing of the HP hose tighten the HP hose to the injector with an appropriate wrench Close the Clear Protective Cover and increase more pressure Confirm that there is no leak in the lines Operating Manual Software Update Procedure Connectivity Illustrations IMPORTANT Disconnect any injectors from the machine NOTE Read all the instruction once and then proceed step by step Please visit the www atmel com web site search and download the latest FLIP utility in order to update the software search in AVR Solutions Tools amp Software Direct Link http www atmel com dyn products tools car d asp tool id 3886 Upon contact you will be sent a HEX file which is the software file for the PCB boards Please follow the instructions below in order to program the boards Acquire a PC or laptop that has a 9 pin Serial COM port or buy a USB TO SERIAL
37. tions are is out of specification or accuracy due to dirt verified the machine s warranty will not be liable Carbon Zapp will repair or replace parts and components returned to manufacturer s facility To request warranty service contact Carbon Operating Manual v DS2 Series Zapp within the warranty period If warranty service is required you must ship the defective part or component in their original or equivalent packaging prepay shipping charges and insure or accept the risk of loss or damage during shipment Carbon Zapp will return the repaired or replacement part or component freight prepaid If Carbon Zapp repairs or replaces a part or component its warranty term is Not Extended Carbon Zapp does not accept liability beyond the remedies set forth in this warranty statement or liability for incidental or consequential damages Machine serial number Signed by Technical Department vi Operating Manual DS2 Series Date Operating Manual vii Introduction Introducti on Through the years there has been an excess demand in Pollution Reduction Fuel Economy and Enhanced Performance for Consumer Engines Engine Manufacturers have gone a long way since conventional Diesel systems to reach today at the revolutionary approach of Electronically Controlled Injection systems thereafter called Common Rail CRDI With this approach they have successfully reduced emissions and gained fuel ec
38. tors o Select the injector o OHM test o Spray test o Volume test Injector MACC Clamping Position and connections Sample Procedure on MACC cleaning injectors A new user should fully understand this chapter prior to operating the DS2 unit Operating Manual 6 1 DS2 Series 6 2 Operating Manual Operation Basics Injector Ultrasonic Cleaner Before mounting any injector on the DS2 it is obligatory to clean the Injectors Nozzles Figure 6 i in the ultrasonic device Figure 6 ii Figure 6 i Injector Ultrasonic Cleaning is Mandatory Failure to clean injectors with the use of Carbon Zapp s ultrasonic device optional DS2 X0 before any test is completed on the test bench will void the warranty of the machine if dirt particles enter the system lines If the iVM drain valves are inoperable due to dirt verified the machine s warranty will be voided This step is needed first to clean the micro meter nozzle openings as part of servicing the injector and second to avoid any dirt particles to enter the DS2 hydraulics of the system The Ultrasonic Cleaning operation should be performed for at least 15 minutes although 30 minutes is recommended Operating Manual 6 3 DS2 Series Figure 6 ii important Every time the Testing filter is replaced it is mandatory also to replace the screen filters 30 88 a shown in Appendix C Any dirt left after cleaning with the ultrasonic d
39. view all the screens in this chapter prior to operating the DS2 unit 4 2 Operating Manual HMI Menu Tour Control Panel In this section the Control Panel buttons and features are previewed and explained The Menu is designed for easy and simple operation B The ENTER button is used to Confirm and action move forward in the menu or select an option y stop AA cancel The STOP button This button is used to Stop Cancel an action or move backward in the menu Operating Manual 4 3 DS2 Series 6 AO the Leak PUMP button is used to toggle the High Pressure HP On and OFF A red LED next to it denotes the state lit when ON ua the Drain Tubes button is used to toggle the Volumetric tube drain valves ON and OFF draining the tubes from any remaining liquid A red LED next to it denotes the state lit when ON a the Fumes Vacuum button is used to toggle the Fumes extractor ON and OFF clearing the Spray tube gt the Light button is used to toggle the LEDs ON and OFF OFF Lighting the Spray and Volumetric tubes 2 OMO O the Arrow Keys are used to navigate through the menu select another option or change a value CD y the F unction button is used to edit or reset a value 4 4 Operating Manual HMI Menu Tour Startup Screen This screen is shown once the DS2 software loads Information such as Software S W and Hardware
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