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IOP Marine products are
developed and continously
improved
in cooperation
IOP Marine
products arewith:
MAN Diesel
era stcudorp eniraM POI
developed and continously
ylsuonitnoc dna depoleved
improved in cooperation
tiw noitarepooc ni devorpmi
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iD NAM MAN:hDiesel
Hydraulic
Power Units
Fuel Injector
Test Equipment
Propulsion
Gen-set
Powerplant
Offshore
Workshop
QUICK GUIDE
Minimum HPU/VPU requirements for common engine types
Wärtsilä 2-stroke with electronic injectors
RT-flex Common Rail ≤ 72 VPUD 1000 CR
RT-flex Common Rail ≥ 84 VPUD 1000 CR
HPU 2250 S
HPU 2250-2 S
All 2-stroke engine test rigs can also be used for test of auxiliary
engine fuel injectors with optional adapter.
VPU 1500-2
VPA 1100
PPMI 1000
PPMI 2000
Wärtsilä 2-stroke engines with tradtional injectors
RND Series
VPUD 1100
HPU 1500
72
VPUD 1100
HPU 2250 S
RTA Series
84
VPUD 1100
HPU 2250-2 S
RTA Series
72
VPU 500
HPU 2250 S
RT-flex Series
84
VPU 500
HPU 2250-2 S
RT-flex Series
VPUd 1100 SV
HPU 1500
VPUd 1100
VPUD 1100
VPU 1100
Mitsubishi
UEC
VPUd 1000 Cr
MAN Diesel 2-stroke engines with slide-valve injectors
MC Series
60MC
VPUD 1000
HPU 1500
70MC
VPUD 1000
HPU 1500-2
MC Series
VPUD 1000
HPU 2250
MC-C Series 50 MC-C
VPUD 1000
HPU 2250
MC-C Series 60 MC-C
ME Series
VPUD 1000
HPU 3500
VPUd 1000
MAN Diesel 2-stroke engines with traditional injectors
GF Series
VPU 1100 MKI
HPU 1500
MC Series
60MC
VPU 1100 MKI
HPU 1500
70MC
VPU 1100 MKII
HPU 1500-2
MC Series
VPU 1100 MKI
HPU 2250
MC-C Series 50 MC-C
VPU 1100 MKII
HPU 2250
MC-C Series 60 MC-C
Recommended Fuel Injector Test Unit
for main and auxiliary diesel engines
VPU 900-2
2-STROKE ENGINES
Fuel Injector Test rigs – type VPU, VPUd & VPA
VPU 700-2
Note that recommended equipment will also be suitable for all
conventional auxiliary engines equipped with mechanical injectors.
Originally developed for the MAN Diesel
slide-valve fuel injectors, the IOP SafeTest technology (patented worldwide)
has been adapted for many injector
types. It simplifies correct execution of
all required test-steps, provides precise &
consistent data collection and eliminates
the risk of unnecessary injector damage
VPU 500
IOP Marine A/S is an approved and recommended supplier for MAN
Diesel & Turbo, Wärtsilä, Rolls Royce & Caterpillar MAK 2- and 4-stroke
engines, and supplies equipment to MAK, Deutz, Rolls Royce and
HiMSEN by appointment.
500
700
900
1000
1000
1100
1100
1100
1500
1100
n/a *
n/a *
6
✔
0,6
✔
0,45
✔
1,2
1,2
1,2
✔
1,2
1,2
0,55
✔
1,2
✔
n/a *
n/a *
✔
✔
✔
✔
Air
Air
Air
Air
Air
Air*
Air*
✔
✔
✔
✔
✔
✔
✔
PrOdUCT SPECIFICATIOnS
Max. output pressure (bar)
Max. flow (l/min)
Analogue gauge
Digital gauge
Drive medium
VPU series – Flexible fuel injector test
solutions for 2- and 4-stroke engines
IOP Marine’s air-powered Valve Pressure-test Units (VPU’s) ensure optimal
fuel injector performance and help avoiding unnecessary fuel consumption
and particle emissions. Our solutions are approved & recommended by
leading engine designers including MAN Diesel, Wärtsilä, Rolls Royce and
Caterpillar MAK for their 2- and 4-stroke engines.
Air
Air/Hand Air/Hand
Step-by-stepSafeTestTechnology
(Patented worldwide)
Target engine
MAN Diesel 4-stroke engine
Genset
VPU 700-2
Propulsion
VPU 700-2
HPU 1500
HPU 1500
Wärtsilä 4-stroke engines
Propulsion
VPU 900-2
Genset
VPU 900-2
Electronic Injectors
VPU 900-2
HPU 1500
HPU 1500
HPU 1500
w/trigger box
Caterpillar / MAK
MAK Traditional Injectors
MAK Electronic Injectors
Caterpillar 3xxx series
VPU 1500-2
VPU 1500-2
VPU 1500-2
Rolls Royce
Bergen Series
VPU 1500-2
HPU 1500
See page 3
See page 5
w/trigger box
HPU 1500
HPU 1500
HPU 1500
Approved and
recommended
MAN Diesel
✔
✔
✔ PLC
1) & 2)
✔
PrIMAry EngInE, lOW SPEEd
MAn diesel 2-stroke
Conventional injector design
✔
SlideValveinjectordesign
✔
✔
✔
✔
✔
1)
1)
Wärtsilä 2-stroke
RND
✔
RTA
W-X / RT-flex
✔
✔
✔
2)
✔
✔
2)
2)
✔
W-X / RT-flex w. electronic injectors
2)
✔
Mitsubishi 2-stroke
✔
✔
PrIMAry EngInE, MEdIUM/HIgH SPEEd
Changing the way fuel injectors are tested
Cooperation with acknowledged engine designers has resulted in unique
solutions like:
• IOPSafeTesttechnologyforMANDiesel2-strokeslide-valvefuelinjectors
• ScalablepumptechnologyforWärtsilä2-strokefuelinjectors
• Air-poweredtestrigsfor4-strokeengineinjectors,allowingfast
and precise adjustment of opening pressure second to none
• Activatorsforelectronicallycontrolledinjectors&pilotvalves
• Adaptersforinjectorswithintegratedfuelpump
• Systemsfortestofcombinedgas-dieselinjectors
MAn diesel 4-stroke
Mechanical injection control
✔
✔
(✔)
✔
✔
1)
Electronic injection control
Wärsilä 4-stroke
Conventional injector design
✔
✔
(✔)
✔
✔
5)
✔
(✔)
✔
✔
2)
✔
✔
✔
✔
2) & 5)
✔
(✔)
✔
✔
3)
(✔)
✔
✔
MAK / Caterpillar
MAK / CAT Conventional
CAT Combined pump / injector
MAK Electronic injection control
(✔)
✔
✔
3) & 5)
CAT Electronic injection control
rolls royce / Bergen diesel
Ask
✔
Ask
✔
Ask
✔
4)
S.E.M.T. Pielstick
(✔)
✔
✔
yanmar
✔
(✔
✔
✔
daihatsu
✔
(✔)
✔
✔
HiMSEn
✔
(✔)
✔
✔
✔
SECOndAry (AUxIlAry) EngInES
The VPU’s are compatible with fuel injectors and safety valves from
hundreds of different engine models and are continuously adapted for new
models according to customers’ needs.
Medium-speed, mechanical injectors
Medium-speed, electronic injection control
High-speed & Common Rail Injectors
✔
✔
✔
✔
✔
✔
✔
✔
Limited
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
5)
5)
✔
1) Approved by MAN Diesel & Turbo
2) Approved by Wartsila, choice of equipment for W-X/RT-flex depends on actual injector design
3) Approved by MAK Caterpillar
4) Approved by Rolls Royce
5)Mayrequireanadditionalinjectortriggerbox.Seeaccessoriespage.
*PPMI1000-IOPSafeTestadapterfortraditionaltestrigs(IOP/3rdParty),forsafetestofMANDieselslide-valveinjectors
PPMI2000-IOPSafeTestadapterforusetogetherwithHPUunitforsafetestofMANDieselslide-valveinjectors
Other
Main / aux diesel engine
✔
Air
HPU functionality
Electronic (DWI / DF / Common Rail)
4-STROKE ENGINES
✔
Air
2
3
HPU Series
MPU 1800
MPU 2500
HPU 1500
Compact
HPU 1500
HPU 1500-2
HPU 2250
HPU 2250 S
HPU 2250-2
HPU 2250-2 S
HPU 2800-2
HPU 2800-2 S
HPU 3500-2
Twin Power HPU’s reduces pumping
time with up to 80% for large engines
MPU 1500
Recommended Hydraulic Power
Units for different purposes
1500
1800
2500
1500
1500
1500
2250
2250
2250
2250
2800
2800
3500
PErFOrMAnCE SPECIFICATIOnS
Max. output pressure (bar)
Max. output flow (l/min)
Variable Variable Variable
0,25
0,33
0,55
0,45
0,45
1,85
1,85
1,7
1,7
1,6
16
20
20
23
28
28
28
28
28
Air
Air
Air
Air
Air
Air
Air
Single
Single
Twin
Twin
Twin
Twin
Twin
✔
✔
✔
Weight (kg)
6/8
8
8
6
Drive medium
Hand
Hand
Hand
Air
Pump technology
2-step 2-step
2-step
Single
Air/Hand Air/Hand
Single
Single
Low-pressure mode
✔
POWErIng HydrAUlIC TOOlS
MAn diesel 2-/4-stroke engines
HPU units – fast, powerful
and reliable powerpacks
Powerful hydraulic tools require reliable power sources. Together
with MAN Diesel, Wärtsilä and 2-stroke engine owners worldwide,
IOP Marine has developed a range of mobile Hydraulic Power Units
delivering up to 5 times the normal speed when needed, while
fulfilling the requirement for pressures above 3000 bar - in other
words, a HPU unit from IOP Marine can loosen a cylinder cover for
the world’s largest diesel engines in less than five minutes.
The HPUs are not only suitable for closed-circuit tools, but can also
beusedforthefloatingofcamshafts,openingofSKFcouplingsand
soon.Specialoperationmodesmakeitpossibletooperateseveral
types of tool series safely with one unit.
900 bar tool series, small-bore 2-stroke
✔
900 bar tool series, large-bore 2-stroke
✔
✔
(✔)
1)
1)
✔
1500 bar tool series, small-bore 2-stroke
✔
✔
1500 bar tool series, large-bore 2-stroke
✔
✔
2200 bar tool series
All 4-stroke engine tool series
1)
✔
✔
✔
✔
✔
✔
2000 bar tool series, small-bore 2-stroke, RTA/RT-flex/W-X
✔
2000 bar tool series, large-bore 2-stroke, RTA/RT-flex/W-X
✔
2200 bar tool series 2-stroke, RTflex/W-X
✔
850 bar standard tool series, 4-stroke
✔
2)
✔
2)
✔
✔
2500 bar high-pressure tools, 4-stroke
2)
✔
✔
✔
✔
Other engine maker
1000 bar tools or less
✔
1500 bar tools or less
✔
✔
2000 bar tools or less
✔
2500 bar tools or less
✔
✔
✔
✔
✔
✔
✔
✔
Frequent maintenance (high-duty equipment)
Workshop, 4-stroke engine tools
✔
Workshop, 2-/4-stroke engine tools
PowerPlant & Off-shore
✔
✔
✔
3)
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
3)
3)
✔
SPECIAl PUrPOSE FUnCTIOnAlITy
Floating of camshaft
Test of safety valves (opening pressure > 1000 bar)
(✔)
(✔)
✔
Operation of injector dis-/reassembly tool
Other Use
Ask
Ask
Ask
Ask
✔
✔
✔
✔
✔
4)
✔
✔
✔
✔
✔
4)
✔
✔
✔
✔
✔
5)
Ask
Ask
Ask
✔
✔
Ask
Ask
2)
1) Approved and recommended by MAN Diesel
2) Approved and recommended by Wärtsilä (HPU units)
3) Choice depends on max. pressure and flow to be supplied by HPU/MPU
4) Depends on actual leakage
5) Approved and recommended for certain MAN Diesel & Wärtsilä safety valves
4
1)
Wärtsila 2-/4-stroke engines
OpeningofSKFcouplings
At the other end of the spectrum advanced new 2-step hand pumps
and ultra-compact HPU’s for 4-stroke engines are available.
1)
✔
5
2
1
Accessories and spares
A large range of accessories is available to extend the functionalities of IOP Marine
units. These include:
Multi-injector holders & electronic injector trigger-boxes
Test all injector types and safety valves with one test rig. For electronic injector
testing a separate trigger-box enables verification of functionality and spray pattern
for 24V & 110V electronic injectors. Large range of valve adapters and trigger-boxes
available.
Hydraulic tools for dis- and re-assembly of fuel injectors
Replacing clumsy manually powered spanners, our easy-to-use hydraulic tool can be
used for easy and precise tensioning/loosening of the Injector Nozzle. Hydraulic tools
can be integrated in the injector holder, or work as a stand-alone unit. These tools
are approved & recommended by Wärtsilä for their 2- and 4-stroke engine injectors.
1
VPU Oil Mist Separator
for a better working
environment
2
High pressure hoses &
couplings for various
applications
Workshop Equipment
IOP offers a full range of 2- and 4-stroke engine fuel injector test rigs and injector
valve-holders designed for workshops, as well as fuel-pump testers for 4-stroke
engine fuel pumps.
The top-of-the-line VPA series for fuel injector testing is PLC controlled and the
built-in test programs are easily customised. Combining it with a rotating multi
valve-holder provides any workshop with a powerful and space-efficient tool to
provide full service to all diesel engine customers.
The FPT series for fuel-pump testing features PC-integration and possibilities for
thorough testing, logging and comparison of fuel pump and plunger/barrel wear
& tightness.
In cooperation with Chris-Marine AB, IOP Marine can also supply grinders and
other tools for injector maintenance, as well as hydraulic jacks for engine alignment
and HPU units for use during general on-board engine maintenance.
References include MAN Diesel, Wärtsilä, Caterpillar/MAK & Daihatsu production
facilities as well as major fuel injector & pump repair-shops worldwide.
Test Chamber Air Purifiers
This small yet very effective filter technology separates the oil mist from the air in the
VPU spray chamber, resulting in improved chamber visibility. And working conditions
in the area. The solution is approved by the Danish Maritime Authority and eliminates
the need for dedicated air purification / ventilation around the VPU unit.
The VPA – a stateof-the-art, semiautomatic fuel
injector test bench
for demanding
workshops.Features
built-in PLC, printer
and PC-connectivity
High pressure hoses and couplings (0-4000 bar)
When working with hydraulics at several thousands bars no compromise can be
made regarding safety and reliability. IOP Marine supplies MAN / Wärtsilä approved
hoses and couplings for all of your engine needs.
digital reference gauges
High-precision battery powered hand-held gauges ensures correct pressure readout
from 0 to 2500 bar - useful for verification of analog gauge readout and for continuous
pressure measurement.
FPT fuel pump test rig with
integrated PC and compressor
6
7
svaneK.dk
IOP Marine A/S
Obel-P Products
Engager 7
DK-2605 Brøndby
Denmark
Phone +45 44 98 38 33
Fax
+45 44 98 11 25
Email [email protected]
www.iopmarine.dk
www.iopmarine.dk