STARDEX SISU 2016 USER INTERFACE

DESCRIPTION, INSTRUCTION MANUAL

As all other Stardex products, our software we create by ourselves.

We like it and we are sure - you will also like our convenient,
intuitive, easy to use and reliable interface.

All Stardex original software was and will be free for our clients.
No fees for updates or prolongation of the license.
All updates are available on our website free.

STARDEX OY LTD

HELSINKI, FINLAND 2016

www.stardex.fi
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Table of contents

Chapter Title Page

Whats new 3

Sections 4

Main Section 5

The Test Bench Management Section 8

The Regulators Control Section 10

The Injectors Control Section 11

Categories of the additional section:

FLOW 12

CODING 13

PUMP 14

VOLTAGE 15

DELAY 16

INFO 17

SETTINGS 18

REPORT 19

Pump testing 20

Injector testing 22

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Whats new
Universal user interface for simulators STARDEX 0304, 0305, 0402, DIMAS

Compatible with flow meters STARDEX 0102, 0103, 0104

Compatible with test bench STARDEX 0803 STARDEX DIMAS

Support of STARDEX 0502

Improved support of widescreen monitors

Wide range of screen resolutions from 1024x768 to Full HD

Simple operation that facilitates the work for beginners

Extensive additional functionality for advanced users

Extended tips for each component

Multi-language support

The ability to insert the test report, company logo and details

Save the report in PDF format

Improved support of color printers

A huge database of CR injectors and pumps of the world's major manufacturers

Easily create your own test plans from a template or from scratch

Ability to create and save your own current-voltage profiles

Free software with free and easy to install updates for all users of STARDEX

Delphi C2I, Bosch IMA and Denso coding

A lot of useful additional information

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Sections

1. The main section.

2. The test bench management section.
3. The high-pressure control section.
4. The injectors control section.
5. Additional section.
6. Status bar.

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Main section

Pumps Test Mode Injectors Test Mode

Filter

Manufacturers
Number of
Manufacturer or OEM

Manual test mode Selected product

Semi-automatic test
mode
Auto test mode

Coding mode

List of tests
Changing the test plan
Save the test plan

Add / Remove test

Create the test plan

Print a report
Save readings of flow
meter
Enable timing

Resetting the flow

Stabilization time
meter

Measuring time

Start/Stop

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Work on the device starts with the main section. Here, the user first determines what
will be tested - the pump or injector. Then, he chooses the manufacturer and serial
number. For a quick search in our database, you can use the filter. It is enough to
enter a part of the serial number and the list of relevant results will be displayed.

TESTING THE INJECTORS COMMON RAIL:

When choosing injectors, the system, using the number, determines itself, which,
electromagnetic or piezoelectric injector is selected by the user, and activates the
corresponding indicator (coil or piezo) in the injectors control section.

Selecting the test mode.

With manual testing MANUAL - the user sets all test parameters itself. In this
mode, there is no test plan and there is no report on the results of testing. Current-
voltage characteristics of the control signal for the injectors are installed by default
from the database. This mode is recommended for advanced users only.

In semiautomatic mode TESTPLAN - the user makes the test, following the test
plan. In each step of the test, all the set and measured parameters are preset.
Navigating the tests carried out in the list of tests. The user has the ability to modify
most of the settings on his own.

In the automatic mode AUTO - the user does not have the ability to change test
parameters, and navigate through the tests. All the tests automatically go from the
beginning to the end without any participate of the operator.

Coding mode CODING is similar to the automatic test mode, but it involves a lot
more tests and therefore takes more time. At the end of the process, in the
additional section, in the Coding section will be new repair injector codes.

The buttons New Edit Save + - are used by advanced users to create
their own test plans.

Store button saves the current value of the supply or return flow into the report.
Reset button resets the current supply or the return value of the drain and allows
to start re-flow measurement at any time. If the timer is activated by checking the

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appropriate box, then injectors performance measurement will be strictly on time.

During the stabilization the user is given the opportunity to estimate the flow, but
the final accurate measurement will be displayed and automatically saved in the
report only at the end of the measurement time. Using the timer increases the
accuracy and repeatability of test results.

Print button opens an additional window, in which you can print out the test
results, save the report to PDF, change the company logo and details on the form,
enter the customer's data.

Button Start / Stop is used to start / stop the test in Auto and Coding mode. In
Manual and Test-plan mode, the start/stop button enable / disable the motor control
section (only when working with a test bench Stardex), regulators and injectors.
Sections are turned on one by one. The injectors are activated upon reaching a
predetermined pressure.

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Test bench Management Section

The Temperature Pressure Indicator of The fuel On / Off

target sensor 1 sensor 1 the fans level in the section
speed readings readings tank

Left / Right Temperature Pressure sensor Charge pump

sensor 2 Actual speed
rotation 2 readings indicator
readings

This section is available for users of complexes on the basis of the test benches
STARDEX 0801, 0802, 0803 STARDEX DIMAS.

Here is a motor control and test bench's supply pump control, as well as control of
the temperature and pressure in the arteries of the test bench, the level of fuel in the
tank and the cooling fans control.

Before starting the work on the test bench, you must install the motor rotation
direction (left / right) in accordance with the established pump in the test bench.
And turn on the supply pump or switch it in automatic mode.

To activate the supply pump it is needed to press on supply pump indicator, pressing
it again will lead to the switching the supply pump to the automatic mode. Another
press will turn off the supply pump. In automatic mode, the supply pump turns on
simultaneously with the start of rotation of the test bench engine.

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To start test bench motor rotation, press on/off switch of the section, or START
button in the main section. The engine seamlessly picks up the target speed. To stop,
press on/off switch of the section or STOP.

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The pressure regulators control section

The target Activation of the Current On / Off

pressure Amperage regulator 2 Amperage pressure sections

Duty cycle Activation of the Duty cycle Activation of the

regulator 1 regulator 3

In this section is the management of pressure regulators. Current tire pressure is also
displayed here.

If the regulator is activated, at inclusion of the section, the signal needed to achieve
the target value will be sent. The target value may be amperage, duty cycle, the
pressure.

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The injectors management section

Pulse Injectors type On / Off

length indicators sections

Pulse Injectors work

frequency indicators

In this section the user controls the injectors.

The signal at the injector is characterized by length, frequency, and voltage-current

profile. It is important not to be mistaken with the type of tested injectors. In the
piezo-regime, the voltage is very high and can damage the injector with solenoid
valve!

It is very easy to check the type of injector. You need to measure the resistance
between the injector contacts with a tester. The resistance of the solenoid valve is no
more than several Ohms. The piezo resistance is over several hundred KOhms.

To get started, activate necessary injectors by clicking on the corresponding

numbered LEDs. When you press the power button section, the signal will be fed to
the activated injectors.

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Additional section. Measuring injectors delivery.

Units of delivery Units of backflow

measurement measurement

Upper
limit

Lower
limit

Delivery Delivery
value value

This section serves to measure delivery and backflow of injectors.

When using STARDEX 0102, 0103, 0104, 0305, DIMAS, the measurements will be
made automatically. If the e-measuring system is not present, then the measurement
should be carried out in glasses, and the results must be entered directly in the flow
value field. For the convenience of working at different measuring systems and test
benches, units can be changed from mL/min to mL/100 cycles, mL/200 cycles,
mL/1000 cycles, l / h.

If Test-plan mode or Auto mode selected, upper and lower flow limit for this test will
be displayed on the glasses.

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Additional section. Coding.

Repair injectors codes

Upon completion of the encoding process, new repair codes can be viewed in this
section.

Injectors coding function is available only with an electronic measuring system

STARDEX 0102, 0104, 0305, DIMAS!

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Additional section. Pump delivery flow meter.

Units of delivery Units of backflow

measurement measurement

Delivery Backflow value Information field

value

This section serves to measure pump delivery and backflow.

When using STARDEX 0102, 0103, 0104, 0305, DIMAS, the measurements will be
made automatically. If the e-measuring system is not present, then the measurement
should be carried out in glasses, and the results must be entered directly in the flow
value field. For the convenience of working at different measuring systems and test
benches, units can be changed from mL/min to l / h.

In the information field is the description of the procedures and test parameters.

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Additional section. The graph of amperage and voltage-current

characteristics of the signal.

Current graph Length of 1 phase Voltage

Current of first phase Current of second phase Set defaults

Injectors current graph serves as an additional tool for the analysis of injector failure.
Abnormal graph may indicate shorted turns in the electromagnet or breakdown of
injector's piezo element.

On the right are the basic parameters of the current-voltage profile. Signal voltage,
the first and second phase current value (the pushing and holding phase), and the
first phase duration in microseconds. Change of the profile settings is recommended
for advanced users only. In rare cases, incorrect values of currents and voltages can
cause failure of the injector or simulator!

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Additional section. Injection delay.

This function is active, when using our devices Stardex Dimas or Stardex 0502. By the
end of the test in these fields injection delay in microseconds (s) appears.

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Additional section. Information.

Additional information section may include information about the applicability of the
product, cross references, number of spare parts, as well as information on the
assembly moves, dimensions and clearances.
For the majority of Bosch injectors, there is a detailed description of the location and
purpose of shims. This window is opened by clicking the Show details button.

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Additional section. Settings.

Pressure sensor Regulators Injectors

type configuration configuration

Autoreset Fast coding Language of tooltips

As a rule, a user enters settings a time, when he first sets up the device.

Pressure sensor type should be selected according to the pressure transducer

mounted on the fuel rail.

The regulators configuration is necessary to establish the amount of pressure

regulators used in accordance with the simulator. Their amount may be from one to
three.

In the configuration, you must install the injectors number, in accordance with the
simulator, you use. Their number can be from one to six.

The main language in the program is English, but the tooltips for the components can
be displayed in different languages. Simply select the desired language from the
corresponding list.
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Additional section. Report.

During the injectors test in the Auto or Test-plan mode, or during the pump test, the
report on the results is formed.

The report contains the names of the tests, the permissible ranges of values and
values, obtained from tests.

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Pump test
Connection example for STARDEX 0803 + STARDEX 0304 + STARDEX 0104

Set Common Rail system pump and fuel rail as shown in the diagram above at the test
bench. Connect test bench STARDEX 0803 and STARDEX 0104 flow meter by USB cable
to the simulator STARDEX 0304. In STARDEX SISU program, select the manufacturer
and serial number of the tested pump. Install the direction of rotation of the pump in
accordance with the set pump, in the program. Switch charge pump in Auto mode or
ON mode. On an additional panel, go to the "Pump" section and follow the instructions
in the information field.

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To begin testing, you need to select a test and then click "Start" in the main section. To
save the test results to the report, click "Store" button in the main section.

Printing a report, saving to PDF, entering company data and customer data is carried
out in an additional window that appears when you press the "Print" button in the
main section.

When working on a test bench with high pressure, it is needed to use protective
cover, to prevent human injury in case of emergency situations!

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Injectors test
Connection example for STARDEX 0803 + STARDEX 0304 + STARDEX 0104

Set Common Rail system pump and fuel rail and tested injectors as shown in the
diagram above at the test bench. Connect test bench STARDEX 0803 and STARDEX
0104 flow meter by USB cable to the simulator STARDEX 0304. In STARDEX SISU
program, select the manufacturer and serial numbers of the tested injectors. Choose
the test mode. Install the direction of rotation of the pump in accordance with the set
pump, in the program. Switch supply pump in Auto mode or ON mode.

Activate the connected injectors, according to the numbered cable. Open the "Flow"
section in the additional section. Press "Start" in the main section.

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In AUTO or CODING mode, tests will be carried out from the beginning to the end,
one by one, without user intervention. At the end of the process, it will generate a
report or new injectors' codes.

In TESTPLAN mode, the user chooses tests from a list and launches them. Test results
are stored in the report by pressing the STORE button or automatically at the end of
the "Measuring time".

Manual mode is only for experienced users who know what they are doing and why.
It is used to make exotic test conditions. Saving the results in a report is not available.

Printing a report, saving to PDF, entering company data and customer data is carried
out in an additional window that appears when you press the "Print" button in the
main section.

When working on a test bench with high pressure, it is needed to use protective
cover, to prevent human injury in case of emergency situations!

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