Handling Steps
Remove safety vacuum sheets.
Unlock machine wheels.
Move carefully to foundation area.
Position and level machine on foundation.
Power: 4 kW, 10 A, 230 V ± 5%, Single Phase, 50 Hz.
Earthing: Two independent earth points (machine & control panel).
Cable: 2.5 sq.mm × 2 core copper.
Earth rod: 3 mm Cu, resistance ≤ 5 Ω.
Compressor: 6–7 bar.
In-line pressure: Maintain 5–6 bar.
Air hose: Ø 8 mm (SMC or equivalent).
Tank: 3 L reservoir.
Mount machine on 4 rubber dampers.
Check for damage, debris, or loose parts.
Ensure free shaft rotation.
Place control panel 600 mm right of machine.
Verify independent earthing.
Test motor rotation (anti-clockwise).
All work must be done by qualified personnel.
Load: 4 kW / 10 A max.
Voltage: 230 V ± 5%.
Frequency: 50 Hz.
Working temp: –20 °C to +60 °C.
Ensure all electrical work is performed by certified technicians.
Air: 7 bar input / 6 bar working.
Hose: 8 mm (10 bar rated).
Main valve: SMC ITV 1050.
Regulator: SMC IR 2000-02 BG-A.
Reservoir: 3 L.
Operating temp: –20 °C to +60 °C.
No hydraulic components. Machine runs on pure air pressure.
Safety Labels Include:
Electrical hazard (single & three-phase).
Earth connection warning.
High voltage & hot surface warnings.
Rotating/moving parts hazards.
Mandatory use of gloves, shoes, and PPE.
Reference manual before operation.
Operators must be trained by OEM.
Read full user manual before operation.
Verify air & electrical connections.
Mount injector properly before testing.
Handle control panel carefully.
Control Panel Functions:
Mains ON/OFF
Pump ON/OFF
Light control
Dummy (future use)
Always disconnect main power before opening panels.
Only authorized personnel may operate main isolator.
Emergency Stop: Provided on control panel top — immediately stops machine.
Dynamic Test: 5–50 Hz, 200–650 KPa, measures flow rate (gm/pulse, cc/sec).
Static Test: Injector fully ON, measures max output at fixed pressure.
Leak Test: Checks injector sealing at static pressure (200–650 KPa).
Software: LabVIEW 2017 on Windows 10.
Data acquisition: NI-6001 USB card.
Controlled via PC, keyboard, and GUI interface.
| Parameter | Specification |
|---|---|
| Power | 230 V ± 5%, 10 A, 1 φ |
| Air | Input 9 bar / Working 6 bar |
| Pressure | 200–650 KPa |
| Load range | 2 mg – 1000 g |
| Accuracy | ±1% ± 1 digit |
| Tank | 5 L |
| Machine weight | ≈ 100 kg |
| Rig size | 1300 × 1000 × 1400 mm |
Switch ON machine MCB & control panel.
Power ON CPU.
Open software → Main Menu → Dynamic / Static / Leak Test.
Enter login & test details.
Run test → Save report → Drain fuel after test.
Dynamic, Static, Leak, and Manual Modes.
Test Schedule creation.
Automatic report generation (Excel export).
NI-6001 pin mapping:
AI0 = Load, AI1 = Pressure
AO0 = Set Pressure
P0.0 = Fault, P0.1 = Run, P1.0 = Emergency Input
| Component | Make / Model | Description |
|---|---|---|
| PC | HP Core i3 / 4 GB RAM / 1 TB HDD | Windows 10 x64 |
| Load Cell | Senstronics 1001 | 1.5 kg / 2.99 mV/V |
| Amplifier | Syscon DRO-1168 | Load signal amp |
| Pressure Sensor | Keller PA-23-SYEI | 10 bar |
| Pump | MEYLE 0140910000 | Fuel pump |
| NI Card | National Instruments 6001 | DAQ Interface |
| SMPS | Mean Well 12 V/24 V | Power supply |
| IGBT SSR | Unison 15 A | Control relay |
| Tower Lamp | Stronger | 3 Color / 24 V |
| Component | Make / Model | Description |
|---|---|---|
| Air Regulator | SMC AW20-02B-B | 9 bar |
| Mist Separator | SMC AC200-02CGL-B | Air cleaning |
| E/P Regulator | SMC ITV 1050-312CL3 | Pressure control |
| Precision Regulator | SMC IR 2000-02 BG-A | Fine adjustment |
| Cylinder | SMC CJ2B10-15Z | Pressure control |
Note: This machine operates on air pressure only — no hydraulic system used.
Essential spares include:
Loadcell, Load Amplifier, Pressure Sensor, Fuel Pump, WEMOS D1, Relay Board, NI 6001 Card, SMPS (12 V & 24 V), SSR IGBT, Power Supply, Spike Buster.
Electrical & Pneumatic circuit diagrams included.
NI-6001 DAQ datasheet provided.
All calibration certificates supplied with the machine (Pressure, Loadcell, DAQ).
Common Checks
Voltage between Phase–Neutral = 230 V ± 5%.
Emergency button released.
SMPS ON indicator active.
Verify NI 6001 analog outputs.
Check ITV1050 valve pressure reading.
Confirm WEMOS D1 & IGBT status.
Check load amplifier & loadcell wiring.
Use EXXSOL D60 fuel, max 5 L.
Drain and refill fuel regularly.
No other maintenance required (zero-maintenance components).
No service activity allowed when powered.
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