Piezo injector current (using a low-current

clamp)
You will require a PicoScope to perform this test. A list of suitable accessories can be found at
the bottom of this page.

Figure 1

How to perform the test

Plug the current clamp into Channel A of the scope. Set the clamp to the 20 amp setting if
required and auto-zero it. Place the clamp around one of the injector's multi-plug wires. It may be
necessary to carefully remove some of the loom tape to allow adequate space for the clamp's
jaws.

The connection is illustrated in Figure 1.

Note: If the waveform does not start with a positive pulse, the current clamp has been connected
around the wrong way. Remove it and replace facing the opposite direction.

Example waveforms
Example 1: Engine at idle

Example 2: Increased engine speed

Example 3: Engine over-run

Waveform notes
These example waveforms show the injector current during different operating conditions. The
positive signals are the injector 'open' commands and the negative signals are the injector 'close'
commands.

Example 1: The first two injector phases are pre-injection and the third is the main injector
phase.
Example 2: As the engine speed is raised, the control module increases the duration of the main
injector phase.

Example 3: On over-run, only the first pilot injection phase remains.

Figure 2

Figure 3

Technical information
Figure 2 shows a Bosch piezo injector, as used in most Bosch systems since 2007. Similar
injectors are made by Siemens.

Piezo injectors have the advantage over conventional electromagnetic injectors of a very quick
reaction time - some five times faster.

Piezo injectors operate by means of a stack of about 300 wafer-thin ceramic plates. When the
switching voltage is applied, the plates expand and push upon the injector nozzle, opening the
needle and injecting the fuel into the cylinder.

As with all common-rail systems, there may be various injection phases:

Pre-injection (or pilot) phases are to combat 'diesel knock' by gently starting combustion

Main injection phase is for the power and torque characteristics

Post-injection is to increase combustion temperature during diesel particulate

regeneration

Figure 3 shows a piezo element in its two different states. Illustration 1 shows the stack with no
supply voltage and illustration 2 shows the increase in height of the stack when the supply
voltage is switched on.

Important note: Once the stack is in the injector open position, it does not need to have a
continuous supply voltage and will remain in the open state until the close command. Hence the
positive and negative current spikes in the waveform. For this reason, never disconnect the
injector's multi-plug with the engine running. If the injector is in the open state it could
hydraulic-lock the engine with the diesel fuel. The engine will cut out if the control module
detects any faults with the injectors or driver circuit.

AT098-2

Disclaimer
This help topic is subject to changes without notification. The information within is carefully
checked and considered to be correct. This information is an example of our investigations and
findings and is not a definitive procedure. Pico Technology accepts no responsibility for
inaccuracies. Each vehicle may be different and require unique test settings.