Open System Mega Tester V4

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Summary

Introduction, Purpose, and General Provisions

Introduction

Certifies main parameters and technical characteristics of the device.

Purpose of the Device

Checks electrical parameters of piezoelectric diesel injectors.

General Provisions

Details the hardware/software system for measuring injector parameters.

Technical Characteristics, Equipment, and Safety

Main Technical Characteristics

Lists key electrical and environmental specifications of the Mega Tester.

Equipment of the Device

Lists the included items: device, cables, and passport.

Safety Precautions

Advises on safe operation, handling, and warnings for dangerous voltage.

Device Description and Operation Modes

Brief Description of the Device

Explains testing integrity, capacitance, resistance, and operation modes.

Operating Modes

Details 'Settings', 'Resistance', 'Isolation', 'Stroke', and 'Span' modes.

Transport, Warranty, and Appendices

Transport and Storage

Specifies conditions for storing and transporting the device.

Limitation of Liability

Details manufacturer's liability limitations for product use and damage.

Manufacturers Warranty

Outlines the warranty period, terms, and exclusions for the device.

Appendix A: Nozzle Polarity

Illustrates polarity of common nozzle types for Continental, Bosch, and Denso.

Annex B: Installing Batteries

Provides instructions and warnings for installing the device batteries.

Documentation Forms

Warranty Card and Repair Tickets

Includes templates for warranty details and recording repair history.

Fault and Malfunction Reporting

Provides forms for reporting detected faults and malfunctions.

The "Mega Tester V4" (OS.110 V4) is a sophisticated hardware and software system designed for testing the electrical parameters of piezoelectric diesel injectors used in Common Rail systems. This device is crucial for diagnosing and assessing the condition of piezo nozzles, ensuring their correct operation and facilitating their assembly.

Function Description

The primary function of the Mega Tester V4 is to evaluate the integrity and performance of piezoelectric diesel injectors. It offers five distinct operating modes: "Parameters," "Resistance," "Isolation," "Stroke," and "Span," each tailored to specific diagnostic tasks.

In the "Parameters" mode, the device measures the resistance and capacitance of the piezoelectric element. This mode helps in quickly assessing the basic electrical properties of the injector.

The "Resistance" mode cyclically measures the resistance of the piezoelectric element, displaying current, minimum, and maximum values. This allows for dynamic observation of resistance under varying test voltages, which can be adjusted during the test.

The "Isolation" mode is designed to measure the insulation resistance of the piezoelectric element under high voltage. This is a critical test for identifying insulation breakdowns or weaknesses that could lead to injector failure.

The "Stroke" mode measures the stroke of the piezoelectric element and the gap between the piezo actuator and the pusher of the injector hydraulic valve. This mode gradually raises the voltage to a set level, allowing observation of the piezoelectric element's operation. When connected to a computer, this mode's capabilities are significantly expanded, enabling automated measurement of piezo actuator stroke and the generation of tables and graphs showing the dependence of lift on applied voltage. Additionally, the nozzle can be mounted on a test bench to measure flow and return flow, helping to assess the piezoelectric element's condition and the correct tightening torque by observing changes in backflow with increasing nozzle voltage.

The "Span" mode sends a test signal to the nozzle to measure the gap, which is useful for determining the correct tightening torque during assembly.

The device can be controlled either from a computer using a keyboard and mouse, or manually via buttons on its front panel. For computer control, it can be connected via a USB cable or Bluetooth. Bluetooth connection requires pairing the device with the computer using a password.

Important Technical Specifications

The Mega Tester V4 boasts several key technical specifications that highlight its precision and capabilities:

Insulation resistance range: 1 MΩ to 10 MΩ
Resistance of the piezoelectric element range: 100 kΩ to 1 MΩ
Capacitance of the piezoelectric element range: 0.5 μF to 10 μF
Gap measurement range: 1 μm to 15 μm
Piezoelectric element voltage setting range: 20 V to 160 V
Voltage setting range for insulation test: 50 V to 1000 V (Note: at test voltages below 300V, resistance measurement accuracy is not standardized)
Accuracy of resistance measurement: ±2% + 3ppm
Accuracy of voltage measurement: ±1% + 2ppm
Capacitance measurement accuracy: ±0.3 µF
Nominal supply voltage: 220 V
Network frequency: 50 Hz
Maximum power consumption: 10 W
Maximum current consumption: 0.25 A
Operating temperature range: 0 to +35 °C
Storage temperature: -10 to +50 °C
Relative humidity (non-condensing): 0-85%

The device comes with a universal cable for measuring electrical parameters and testing piezoelectric element operation, a power cable, and a passport.

Usage Features

Operating the Mega Tester V4 requires careful adherence to safety guidelines and proper connection procedures.

Connection: For all modes, the universal cable must be connected to the nozzle connector, observing polarity. In "Isolation" mode, an additional alligator clip connects to the metal part of the nozzle body. The device can be connected to a computer via USB or Bluetooth for enhanced control and data visualization.

Mode Selection and Control: Modes can be selected from the instrument menu using arrow keys. The encoder knob allows adjustment of test voltage values. The "Start" button initiates tests, and the "Stop" button terminates them. For "Span" mode, a long press of the encoder button selects the injector type.

Safety Precautions: The device operates with dangerous voltages (up to 1000V). Only persons aged 18 or older, who have received appropriate training and studied the technical documentation, should operate it.

Never operate the device with parts of the housing removed or missing.
Ensure the device body, cables, and connectors are free from mechanical damage, moisture, dust, and contaminants before use.
Do not touch conductors or live parts during electrical tests.
Individual elements can retain voltage for up to two minutes after power-off.
In case of malfunction (e.g., burnt smell), immediately disconnect power and do not restart until the cause is resolved.
Disconnect the device from power during long breaks in operation.
Never expose internal parts to dripping or splashing.
Do not leave the device running unattended.
Do not store flammable or explosive substances near the operating device.
It is not recommended to keep the piezo actuator under constant voltage for a long time.

Battery Installation (Annex B): The device can be powered by two 3.7-volt 18650 lithium-ion batteries with built-in protection (BMS).

Remove the top cover by unscrewing six screws on the side walls.
Install batteries observing polarity: positive pole of the battery to the positive terminal on the board (marked with "+"). The positive pole of 18650 batteries is typically convex.
Warning: Incorrect battery connection can damage the device.
After installation, switch on the device, enter the "Settings" menu (long press "X" button), change "Power" option from "External" to "Battery," then exit settings (short press "X" button).
Close the lid and tighten screws.

Maintenance Features

The manufacturer provides a warranty and outlines conditions for repair and liability.

Manufacturer's Warranty (Section 10):

The warranty period is 12 months from the date of purchase.
Free repairs are provided during the warranty period upon presentation of the passport and warranty card.
The warranty card will include the date of sale, legal address, and telephone number of the repair company, and a list of troubleshooting activities after repair.
Warranty repair requires presentation of the passport and warranty card.
Repairs due to non-compliance with the operating manual are at the owner's expense.

Warranty Exclusions: The warranty does not cover malfunctions resulting from:

Misuse, negligent use, or use for other purposes.
Inept/erroneous actions of personnel during operation, maintenance, or storage.
Failure to comply with storage and operation rules.
Use of a power supply network with parameters differing from specifications.
Unauthorized changes to the product design or repairs performed by anyone other than the manufacturer.
Independent software changes/upgrades or installation of third-party software.
Normal wear and tear, unauthorized repairs, or damage to fragile components.
Other mechanical damage (chips, cracks, missing screws, parts, electrical disconnections).
Damage caused by liquids, dust, animals, insects, aggressive environments, overload, power supply failure, inappropriate voltage/frequency, force majeure (accident, fire, flood, lightning), or intentional damage.

The manufacturer reserves the right to make design changes that do not impair performance without prior notice. The manufacturer is not liable for lost profits, lost savings, accidental damage, or other consequential economic damage, nor for damage or loss of information, programs, or data. Further repairs after the warranty period may be carried out under a separate agreement.