OPERATION MANUAL - Fuel monitoring solutions. Fuel...

FUEL LEVEL SENSORS

OPERATION MANUAL

Version 2.0

DUT-E А5 DUT-E А10 DUT-E I DUT-E F

DUT-E CAN DUT-E 232 DUT-E 485

Fuel level sensor DUT-E. Operation manual Ver. 2.0

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Content

Introduction .............................................................................................................. 4 1 Main data and technical characteristics ...................................................................... 6

1.1 Purpose of use ..................................................................................................................................... 6

1.2 Exterior view and delivery set ............................................................................................................. 6

1.3 Unit structure and principle of operation ........................................................................................... 7

1.4 Technical characteristics ..................................................................................................................... 8

1.4.1 Main characteristics ..................................................................................................................... 8

1.4.2 Characteristics of output signal for DUT-E А5, DUT-E А10 and DUT-E I ....................................... 9

1.4.3 Characteristics of output signal for DUT-E F .............................................................................. 10

1.4.4 Characteristics of output signal for DUT-E 232 and DUT-E 485 ................................................. 10

1.4.5 Characteristics of output signal for DUT-E CAN ......................................................................... 11

1.4.6 Compatibility of DUT-E with GPS/GLONASS tracking systems .................................................. 12

1.4.7 Explosion-proof version of DUT-E .............................................................................................. 13

1.5 Dimensions ........................................................................................................................................ 14

1.6 Packing .............................................................................................................................................. 14

2 Installation and set-up .......................................................................................... 15 2.1 Exterior examination before starting of works ................................................................................. 15

2.2 Installation on the place of a standard fuel sensor ........................................................................... 15

2.3 Installation into a special opening .................................................................................................... 16

2.4 Cutting of the measuring part for the necessary tank depth ............................................................ 19

2.5 Length increasing .............................................................................................................................. 20

2.6 Mounting ........................................................................................................................................... 20

2.7 Electrical connection ......................................................................................................................... 21

2.7.1 Electrical connection of DUT-E A5, DUT-E A10, DUT-E I and DUT-E F ....................................... 22

2.7.2 Electrical connection DUT-E 232 and DUT-E 485 ....................................................................... 23

2.7.3 Electrical connection of DUT-E CAN ........................................................................................... 23

2.8 Set-up of analog or frequency DUT-E sensors .................................................................................. 25

2.9 Set-up of serial DUT-E sensors .......................................................................................................... 25

2.10 Connection of DUT-E to the indicator of fuel level ......................................................................... 26

2.11 DUT-E 232 data summarizing .......................................................................................................... 27

2.11 Sealing ............................................................................................................................................. 30


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2.12 Measurement precision check ........................................................................................................ 30

2.12.1 Basic issues ............................................................................................................................... 30

2.12.2 Control test steps ..................................................................................................................... 31

3 Diagnosis and troubleshooting ................................................................................ 31 3.1 Diagnosis and troubleshooting of analog DUT-E............................................................................... 32

3.2 Diagnosis and troubleshooting of frequency DUT-E ......................................................................... 33

3.3 Diagnosis and troubleshooting of serial DUT-E ................................................................................. 33

4 Maintenance ......................................................................................................... 34 4.1 General recommendations ............................................................................................................... 34

4.2 De-mounting ..................................................................................................................................... 34

4.3 Examination ....................................................................................................................................... 34

4.4 Cleaning ............................................................................................................................................. 35

5 Storage ............................................................................................................... 36 6 Transportation ...................................................................................................... 36 7 Utilization/re-cycling ............................................................................................. 36 Contact information ................................................................................................. 37 Appendix A Check-out test protocol ........................................................................... 38 Appendix B Variants of DUT-E CAN connection ............................................................ 39


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Introduction Recommendations and regulations given in the operation manual are referred to fuel level sensors DUT-E (hereinafter DUT-E), developed by JV Technoton, Minsk, Belarus. This document gives information about DUT-E unit structure, principle of operation (functioning) and characteristics, as well as provides guidance/recommendations on the installation & op-eration. DUT-E is used for measurement of fuel level in any vehicle tanks and in fixed/immovable tanks. DUT-E is used as part of fuel consumption monitoring and vehicle tracking systems, but also, it is possible to use it as a standard sensor of the fuel-level indicator. Distinctive features of DUT-E:

• possibility to reduce the length up to 30% without calibration *;

• possibility to increase the length by using the additional sections;

• easy bayonet fastening;

• unique bottom spring stop serves to give extra stiffness for sensor mounting;

• complete set of mounting materials, and the cable;

• thermo-correction with adjustable coefficient allows to make automatic updat-ing of measurements based on the ambient temperature **;

• possibility to integrate the sensor into on-board information bus of the vehi-cles ***.

By using DUT-E it is necessary strictly to follow the manufacturer's recommendations men-tioned in this manual. The manual is for the professional users who are familiar with the rules for repair and instal-lation works on vehicles and who have professional knowledge in the field of electrical and electronic equipment of various transport vehicles. To ensure the proper functioning of DUT-E, its installation and set-up should be carried out by certified professionals trained by the company. For detailed information please follow the link http://www.jv-technoton.com/

* DUT-E A5, DUT-E A10, DUT-E I and DUT-E F. ** DUT-E 232, DUT-E 485 and DUT-E CAN. *** DUT-E CAN.

http://www.technoton.by/


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Reference marking of the sensors is formed as follows:

Fuel level sensor DUT-E Х Y L=Z

* On request, it is possible to make the DUT-E measuring part of any length up to 1400 mm. Minimal order of the sensors needed for 3 months shall be as follows:

• analog from 500 pcs.; • frequency and serial from 100 pcs.

** sectional (measuring part consists of several sections).

*** delivered in versions DUT-E 232 and DUT-E 485 without standard measuring part. Used with DUT-E additional sections.

To set up DUT-E 232, DUT-E 485 and DUT-E CAN versions, Service kit SK DUT-E is used. (not in delivery set and should be purchased separately).

Manufacturer guarantees that DUT-E sensors correspond to the requirements of technical regulations provided that conditions of storage, transportation and maintenance as well as recommendations on use given in the present manual are followed.

Type of sensor output signal: А5 – analog signal, voltage from 1.5 to 4.5V;

А10 – analog signal, voltage from 2.5 to 9.0 V;

I – analog signal, current from 6.7 to 20.0 mА

F – frequency signal, frequency from 500

to 1500Hz;

232 – interface RS-232;

485 – interface RS-485

CAN – interface CAN 2.0B

Nominal length of the measuring part (in mm) *:

- analog: 180; 250; 350; 500; 700; 1000; 1400; 2000**; 2500**

- frequency: 180; 250; 350; 500; 700; 1000; 1400

- serial: 700; 1000; 1400

Reference marking for special versions of DUT-E: Ex - explosion-proof

Base - sensing head of the fuel level sensor ***


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1 Main data and technical characteristics

1.1 Purpose of use Fuel sensor DUT-E is designed to measure the level of liquid fuel and other non-electroconductive liquids in tanks of vehicles and fixed/immovable tanks.

1.2 Exterior view and delivery set

DUT-E delivery set is shown on Fig. 1 and includes:

1 sensor DUT-E in set – 1 pc.; 2 specification – 1 pc.; 3 cable* (7.5 m) – 1 pc.; 4 DUT-E bottom stop – 1 pc.; 5 mounting plastic plate – 1 pc.; 6 rubber gasket for the mounting plate – 2 pcs. **; 7 sealing O-ring – 2 pcs. **; 8 screw – 5 pcs.; 9 self-drilling screw – 5 pcs.; 10 plastic seal – 2 pcs.; 11 sealing cord – 2 pcs.

* for DUT-E CAN it shall be purchased separately. ** 1 pc. – used by installation of DUT-E and 1 pc. – as a spare part.

Fig. 1 —DUT-E delivery set

1

2

3

11

10

4

8

9

5

7

6


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1.3 Unit structure and principle of operation

Fuel sensor DUT-E (see Fig. 2) consists of measuring part 1, sensing head 2 with inside electronic board and cable 3 with the connector 4.

Fig. 2 —DUT-E components

DUT-E CAN

DUT-E A5 DUT-E A10 DUT-E I DUT-E F

1

4

3

2

4

4

1 1

3 3 2

2

DUT-E 232 DUT-E 485

DUT-E 232 Base DUT-E 485 Base

2

3

4


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The principle of the DUT-E operation is based on measurement of electric capacity of the condenser. Tubes of the sensor measuring part are used as a condenser armature. The electric capacity varies depending on the depth of its immersion into dielectric fluid (fuel). The electronic board of the sensor analyzes the current electric capacity value and generates a corresponding output signal.

Recalculation of the fuel level into the volume is carried out according to the calibration table. In order to make the calibration table it is necessary to calibrate the tank. Detailed description of the tank calibration procedure during installation is given in the document “Fuel level sensor DUT-E. Installation manual”.

DUT-E can be used together with the recording and displaying devices (incl. GPS/GLONASS vehicle trackers) which have characteristics of input signals that correspond to output sig-nals of DUT-E (See item 1.4).

By using the analog and frequency DUT-E sensors as a part of vehicle tracking system, the fuel volume calculation can be performed in the recording device (e.g., in tracker), or in the software of the system.

Serial DUT-E sensors are able to make calculation of the current fuel volume in the tank in-dependently according to calibration table which is put into the DUT-E memory by means of Service kit SK DUT-E.

1.4 Technical characteristics Power supply of DUT-E is carried out via on-board vehicle power system, on which it is installed.

DUT-E can be used in moderate and cold climates.

As for the mechanical stability, sensors DUT-E are vibration-shockproof and vibration-crashworthy.

1.4.1 Main characteristics

Main DUT-E characteristics are given in the table 1.


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Table 1. DUT-E main characteristics

Factor name, m. u. Value

Principle of operation capacitative

The relative measurement inaccuracy (to the length of the measuring part),%, not more

± 1

Supply voltage range, V from 10 to 50

Current consumption at power voltage 12 V, mА, not more 50

Current consumption at power voltage 24 V, mА, not more 25

Readiness time after power-up, s, not more 10

Temperature range, °C from — 40 to + 85

Protection level of housing IP54

Nominal length of DUT-E measuring part See Introduction

1.4.2 Characteristics of output signal for DUT-E А5, DUT-E А10 and DUT-E I

The voltage value of the DUT-E output signal (for DUT-E А5 and DUT-E А10) and current value of output signal (for DUT-E I) have a linear dependence on the measured fuel level in the tank.

The output signal of the sensor doesn’t depend on supply voltage value.

Input resistance of the device to which sensors DUT-E A5 and DUT-E A10 are connected shall not be less than 10 kOhm.

Characteristics of output signal DUT-E A5, DUT-E A10 and DUT-E (I) are given in table 2.


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Table 2. Characteristics of output signal for DUT-E A5, DUT-E A10 and DUT-E I

Model DUT-E Tank status Voltage, V Current, mА

At nominal length

After cutting by 30%

At nominal length

After cutting by 30%

DUT-E A5 Empty tank 1.5 0.9 — —

Full tank 4.5 3.7 — —

DUT-E A10

Empty tank 2.5 1.0 — —

Full tank 9.0 5.6 — —

DUT-E I Empty tank — — 6.7 4.0

Full tank — — 20.0 16.4

1.4.3 Characteristics of output signal for DUT-E F The frequency value of the DUT-E output signal has a linear dependence on the measured fuel level in the tank. The output signal doesn’t depend on supply voltage value. Output cascade – open collector with load resistor of 10 kOhm. Characteristics of output signal DUT-E F are given in table 2.

Table 3. Characteristics of output signal for DUT-E F

Tank status

Frequency, Hz

At nominal length After cutting by 30%

Empty tank 500 262

Full tank 1500 941

1.4.4 Characteristics of output signal for DUT-E 232 and DUT-E 485 Characteristics of DUT-E 232 and DUT-E 485 output signal correspond to the specification of RS-232 and RS-485 interfaces accordingly.

The results of DUT-E 232 and DUT-E 485 measurements can be transferred via serial interface as:

a) Standard units, from 0 to 1000 (0 — empty tank, 1000 — full tank); b) Fuel level in the tank, mm; c) Fuel volume, l; d) Fuel volume in relation to the full tank, %.


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Besides the data on fuel amount in the tank, DUT-E passes information about current temperature (measured by the sensor located on the electronic board). Information transfer of DUT-E 232 and DUT-E 485 is carried out according to DUT-E COM Protocol. You can download the updated version of the document from http://www.jv-technoton.com/.

1.4.5 Characteristics of output signal for DUT-E CAN Characteristics of DUT-E CAN output signal meet the specification of S6 bus that was developed by JV Technoton in order to integrate elements of the vehicle on-board equipment into the GPS/GLONASS tracking system. S6 bus represented by cables, inter-faces and protocols.

S6 bus is based on:

- interface CAN 2.0В (ISO 11898-1:2003) used to transfer the useful information;

- interface K-Line (ISO 9141) used to set up of DUT-E CAN.

The protocol of data exchange via S6 meets the standard SAE J1939-73.

DUT-E CAN data can be sent both on request and automatically (main mode).

S6 bus allows connecting up to 8 DUT-E CAN sensors. To identify them, the bus uses the decimal addresses from 101 to 108.

DUT-E CAN generates and transmits messages in accordance with table 4.

Table 4 — messages of the DUT-E CAN data exchange protocol

Message mark sign Short message description

PGN 62982 DUT-E CAN fuel sensor

PGN 62994 DUT-E CAN operation counters

PGN 62995 DUT-E CAN specification

PGN 65276 Dashboard

DM1 DUT-E CAN active failures (DTC’s)

DM2 DUT-E CAN saved failures (DTC’s)

DM4 Revealed events: - “Fueling”; - “Fuel discharge”

You can ask the detailed data exchange protocol DUT-E CAN by e-mail from [email protected] .


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1.4.6 Compatibility of DUT-E with GPS/GLONASS tracking systems

Technoton guarantees complete compatibility and combined measurement accuracy of DUT-E A5 with terminals CКРТ 45, CКРТ 25 and CКРТ 31.

Additional information on the application of DUT-E in vehicle tracking and fuel consumption monitoring system, as well as a full range of СКРТ trackers and their technical characteristics are given at the website http://www.ckpt.ru/.

Technoton regularly makes tests on compatibility and combined accuracy of DUT-E with different tracker models of popular brands. Table 5 shows the compatible tracker models which ensure the combined fuel consumption measurement accuracy error of not more than 1%.

Table 5 — Compatible vehicle trackers

№ Tracker

Software DUT-E Model

Manufacturer Brand Model

1 Helios Adv+ AMP10353 eInstall DUT-E A5/A10

2

Autograph GSM+ software AutoGRAPH DUT-E A5/A10

DUT-E 485 3

Teltonika FM1100 TAVL.NET DUT-E А5/А10

4 Teltonika FM4200 TAVL.NET DUT-Е 232

5 Teltonika FM5300 TAVL.NET DUT-Е 232

6 MapOn GBOX web server mapOn DUT-E A5/A10

7 NaviFleet ET100 NaviFleet DUT-E A5, DUT-E 232, DUT-E 485

8 Locarus 702R LocarusInformer DUT-E A5/A10

9

SKAUT MT-530 Scout Explorer v3.0 DUT-E A5/A10

10 SKAUT MT-600 GP PRO Scout Explorer v3.1 DUT-E A5/A10

11

Signal S-2117 http://cybermonitor.ru/ DUT-E 485

12 Atrack AT5 ATrack Server Tool DUT-E 232

Update information about compatibility of specific tracker models and fuel level sensors DUT-E, as well as recommendations on their connection and set-up can be found at http://www.jv-technoton.com/.

http://www.ckpt.ru/



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1.4.7 Explosion-proof version of DUT-E

DUT-E in a special explosion-proof version Ex is designed for use in hazardous areas.

Such version of the sensor is marked as Ex (explosion-proof), and marking contains the following information:

• Class of Ex protection — 1ExibIIBT6;

• Type of Ex protection — intrinsically safe electrical circuit “i”.

In order to meet the requirements of intrinsically circuit , the electrical connection of explo-sion-proof DUT-E shall be carried out via the I.S. unit (sold separately) that provides gal-vanic isolation between the explosive and safe zones. Parameters of intrinsically electric circuit are given in table 6. Table 6 — Parameters of intrinsically electric circuit

Parameter name, m.u. Value

Minimum input voltage Umin, V 8.75

Maximum input voltage Umax, V 15

Maximum input current Ii, mА 200

Max internal capacity Ci, mfd 15.0

Maximum internal inductance Li, mH 1.188


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1.5 Dimensions

DUT-E dimensions are shown on Fig. 3.

* Nominal length of the measuring part.

Fig. 3 — dimensions of DUT-E

1.6 Packing DUT-E set is delivered in the carton box. Please see Fig. 5. below.

Fig. 5 — Packing DUT-E

*


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2 Installation and set-up This chapter provides basic recommendations for the DUT-E installation. More detailed information on DUT-E installation is given in the document “Fuel level sensor DUT-E. Installation manual”.

2.1 Exterior examination before starting of works Before you start, you should make external check of DUT-E for any possible defects that oc-curred during transportation, storage or careless handling. By discovering any defects, please, contact the product supplier. DUT-E can be installed as on the place of a standard fuel sensor* as into a special opening in the tank. * Study carefully the scheme of the mounting openings for the standard fuel sensor and compare with the scheme of the openings of DUT-E mounting plate.

ATTENTION! By installing the sensor, you should follow safety rules when carrying out the repair works on automotive vehicles as well as safety requirements prescribed by the enter-prise.

2.2 Installation on the place of a standard fuel sensor

ATTENTION! It is not recommended to install DUT-E on a place of standard fuel sensor if it

is located far from the geometric centre of the tank, otherwise inaccuracy in the fuel level measurement may occur.

Before the DUT- E installation it is necessary to remove the standard fuel sensor and clean the installation place.

Align the holes of the mounting plate and rubber gasket with the holes in the tank.

For the installation you can use screws M5x16, that come together with the DUT-E set (Fig. 6). Screw heads must be deeply put into the mounting plate.


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Fig. 6 — Mounting plate on the place of standard fuel sensor

DUT-E delivery set includes the mounting plate. Its installation dimensions are given in Fig. 8.

If you need to install DUT-E instead of a standard sensor with SAE 5 bolt mounting dimen-sions, then you should order the corresponding mounting plate.

2.3 Installation into a special opening

ATTENTION! 1 Before drilling the holes in the tank you should dismantle it, evaporate or add water.

2 Before you start drilling the hole, please, make sure that there are no partitions inside the tank under the selected location, what can prevent DUT-E installation. Avoid that DUT-E measuring part touches the floater rod of standard fuel level sensor.

Installation steps:

a) Identify the place where it is supposed to install the sensor. It is recommended to choose a place in the geometric centre of the tank (Fig. 7) as it will reduce the error of fuel volume measurement by its vibration during the movement;

Fig. 7 — Recommended place for DUT-E installation

b) Mark the place and drill the holes according to the scheme of the openings for DUT-E mounting plate (Fig. 8).

DUT-E Standard fuel sensor


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BE ATTENTIVE! Mounting plate can be installed on the pre-drilled holes only in one posi-tion! Prior to marking and drilling, please, study the place where it is supposed to install the plate so that holes for sealing were located in an accessible position.

Fig. 8 —Scheme of the holes for the DUT-E mounting plate

Put the rubber gasket and mounting plate on the prepared hole, fix with screws M5х16 or self-drilling screws 3,9х25 that come in the delivery set (Fig. 9).

ATTENTION! While attaching the plate to the tank, make sure, that the screw heads or self-drilling screw heads are not warped and deeply put into the mounting plate so that to provide electrical insulation of the vehicle tank casing from the DUT-E!


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Fig. 9 — Installation scheme of the mounting plate

ATTENTION! For the further sealing of the sensor it is recommended to put a sealing cord through the holes prior to installation on the fuel tank!

A sealing cord

Screw M5x16 or self-drilling

Mounting plate

Rubber gasket

Fuel tank


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2.4 Cutting of the measuring part for the necessary tank depth

ATTENTION! For DUT-E A5, DUT-E A10, DUT-E I and DUT-E F: allowed to make cutting up to 30% of measuring part length without further sensor calibration; For DUT-E 232, DUT-E 485, DUT-E CAN: allowed to make cutting up to 70% with further sensor calibration.

In order to avoid the short circuit of the measuring part tubes caused by water or electroconductive residues that are gathered on the bottom of the tank, there should be at least 25-30 mm gap between the tube end of the DUT-E measuring part and the bottom of the fuel tank.

Steps by DUT-E cutting:

a) measure the depth from the mounting plate till the tank bottom;

b) cut the DUT-E measuring part based on the location of the tube end at a distance of 25-30 mm from the tank bottom;

ATTENTION! DUT-E cutting shall be done by means of hacksaw or with a pipe cutter of a suitable diameter. After that, cutting edges should be thoroughly cleaned up and washed up with the fuel (Fig. 10).

Fig. 10 — Cutting of DUT-E measuring part

c) In case of DUT-E 232, DUT-E 485 and DUT-E CAN cutting, you should calibrate the sensor using the Service kit SK DUT-E (See item 2.9).


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2.5 Length increasing Length increasing is carried out by attaching the DUT-E additional sections to the measuring part (Fig. 11). Model range of DUT-E additional sections include: KDC 250, KDC 500 and KDC 1000 with lengths of 250, 500 and 1000 mm correspondingly.

Fig. 11 — Additional section of DUT-E

Length increasing of analog and frequency DUT-E sensors is possible only for restoring the length after cutting and only within limits of the DUT-E nominal length. Length increasing for serial DUT-E sensor is allowed to a length of 6000 mm. Additional sections of DUT-E can be cut to the desired length. When cutting, you should fol-low the recommendations given in item 2.4 of this guide.

2.6 Mounting In order to fix the DUT-E it is necessary to put an O-ring right on the dap of the mounting plate, and then put the sensor into the hole, press it with force and lock by turning clockwise (Fig. 12).

ATTENTION! During installation it is recommended to apply a small amount of oil or fuel on the O-ring of the mounting plate to prevent its deformation when you fix the DUT-E.

Installation should be done in such a way that after the DUT-E has been mounted, the sealing openings on the mounting plate and DUT-E housing were located above each other.


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Fig. 12 — Installation scheme of DUT-E

2.7 Electrical connection

ATTENTION! 1 When you connect the DUT-E to the on-board power system, you shall connect power “+” and ground “—” to the same places where the recording and display device is con-nected. 2 Before you start electrical connection of the sensor, you should check the quality of the ground of the vehicle. Resistance between any point of the ground of the vehicle and the terminal “—” of the accumulator battery shall not exceed 1 Ohm.

The DUT-E housing is electrically connected with the power “minus” (brown wire harness).

The mounting plate made of dielectric plastic material provides electrical insulation of the DUT-E body from the vehicle body (of the tank).

ATTENTION! DUT-E cable is strongly recommended to stack together with the standard wiring of the vehicle and mandatory to fix its position by means of hose clamps every 50 cm. (Fig. 13)

Sealing O-ring

Fuel tank


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Fig. 13 — DUT-E cable laying

2.7.1 Electrical connection of DUT-E A5, DUT-E A10, DUT-E I and DUT-E F Electrical connection of DUT-E A5, DUT-E A10, DUT-E I and DUT-E F is carried out in accordance with the following pin assignment (Figure 14, Table 7):

Fig. 14 — Pins of wire for DUT-E A5, DUT-E A10, DUT-E I and DUT-E F

Table 7 — Pin assignment of wire for DUT-E A5, DUT-E A10, DUT-E I and DUT-E F

Pin No Wire name Wire colour Remark

1 Т701/Т034 white Analog or frequency output

2 GND/Т734 brown Ground “—”

3 VBATT orange Power “+”

Cable DUT-E


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2.7.2 Electrical connection DUT-E 232 and DUT-E 485

Electrical connection of DUT-E 232 and DUT-E 485 is carried out in accordance with the following pin assignment (Figure 15, Table 8):

Fig. 15 — Pins of wire for DUT-E 232 and DUT-E 485

Table 8 — Pin assignment of wire for DUT-E 232 and DUT-E 485


1 VBAT orange Power “+”

2 GND brown Ground “—”

3 232R/485A white Received data (RS232) Data exchange (RS485)

4 232T/485B red Transferred data (RS 232) Data exchange (RS485)

2.7.3 Electrical connection of DUT-E CAN

DUT-E CAN electrical connection to the on-board equipment is carried out in accordance with the following pin assignment (Figure 16, Table 9):

Options for DUT-E connection to trackers and instruction of what cables are neces-sary for the order are given in Appendix B (fig. B1 — B4).


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Fig. 16 — Pins of wire for DUT-E CAN

Table 9 — Pin assignment of wire for DUT-E CAN



2 GND brown Ground “—”

3 CANH blue CAN-High

4 CANL white CAN-Low

5 KLIN black K-Line

ATTENTION! The manufacturer keeps the right to change the colors of the wires. Study thoroughly the textual wire tagging before you make DUT-E connection.


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2.8 Set-up of analog or frequency DUT-E sensors

Setup and calibration of analog and frequency DUT-E is not required.

2.9 Set-up of serial DUT-E sensors

This chapter provides basic recommendations on set-up of serial DUT-E. More detailed information on set-up of serial DUT-E sensors is given in the document “Operation manual of Service Kit SK DUT-E”.

For the proper operation of serial DUT-E, they shall be calibrated in order to define maximal and minimal levels of fuel measurement range in the tank.

Recalibration of DUT-E is carried out by means of “Service kit SK DUT-E” (not in the delivery set and should be purchased separately).

By means of the “Service DUT-E” software, you can also set up the sensor in order to adjust it for specific operating conditions and requirements of registration and display devices. You can change the following settings of DUT-E modes:

1) Fuel level filtration time is the time interval that precede the data transmission and which is used to calculate the average fuel level in the tank. Thus, information about the fuel level in the tank which is transmitted by the sensor to the recording and display device is not the instant value, but the averaged value over the set period of time. The setting value varies from 0 to 125 s (pitch is 5 s). The default value is 10 s. Setting this function is important when you use the DUT-E sensor on the vehicle which is applied in rough areas (lack of roads). 2) Interval of automatic data output is the time period which is used by the DUT-E to transmit the data about the fuel level in the tank to the connected recording and display device. The values for the interval vary from 1 to 60 s (pitch is 1 s). The default value is 1 s.


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3) Automatic transmission mode defines the data transmission to DUT-E:

• OFF – no automatic data output. Data transmission works only on-request of the recording device);

• HEX - binary format of automatic data output (used on default); • ASCII - text format of automatic data output; • ASCII EXT – extended text format of automatic data output. When you use it, the

following additional parameters are available: Prefix and Postfix that set accordingly the beginning and end of the transmitted text data.

4) Network address specifies the DUT-E address in case it works in RS-485 network or in CAN-bus. Default address DUT-E is set by the manufacturer that corresponds to:

• for DUT-E 485 — the last two digits of sensor serial number; • for DUT-E CAN — 101.

2.10 Connection of DUT-E to the indicator of fuel level By installing the DUT-E on the place of standard fuel level sensor you may need to control the needle indicator of remaining fuel in the tank. In order to implement this function you shall use an interface device UС-1 (Fig. 17) developed by JV Technoton.

ATTENTION! Interface device complies only with DUT-E A5!

Table 10 — Interface device models

Article order No

Remark

UС-1-90 Emulation of the level sensor with low resistance: 0-90 Ohm Resistance increases with increasing of the fuel level

UС-1-800 Emulation of the level sensor with high resistance: 800-185 Ohm Resistance decreases with increasing of the fuel level

Fig. 17 — Exterior view of the interface device UС-1

Electrical connection of UC-1 is carried out in accordance with the wire assignment given in Table 11.


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Table 11 — Wire assignment for UС-1

Wire No Wire name Wire colour* Remark

1 T034 white

Signal from the fuel level sensor (input)

2 GND brown

Ground “—”

3 T734 pink

Fuel level indicator (output)

4 T733 pink

Control lamp of the fuel level (output)


* The manufacturer reserves the right to change the wire colours.

2.11 DUT-E 232 data summarizing Sensors DUT-E 232 with SUMMATOR DUT-E SUM are used to measure the total volume of fuel on vehicles that have two or more fuel tanks.

Attention!

1 Summator works only with DUT-E 232 firmware version not older than 3.0.

2 Calibration table for the measured fuel tank shall be recorded into the internal memory of each sensor (see 1.4).

Fig. 18 — exterior view of SUMMATOR DUT-E SUM

Summator is used to connect two DUT-E 232 and one tracker (Fig. 19а).


© Technoton, 2007 - 2012 28 of 42

Output signal of the summator contains the summarized fuel volume (in litres) measured by sensors that are connected to its inputs IN and IN/OUT. If you need to measure the fuel volume in three or more tanks with installed DUT-E 232, you shall use the cascade summator connection (Fig. 19b). Electrical connection is carried out in accordance with the wire assignment (table 12).

Table 12 — wire assignment for SUMMATOR DUT-E SUM

Wire No Wire name Wire colour* Remark

1 VBAT orange power “+”

2 GND brown ground “—”

3 232R white Received data (RS-232)

4 232T red Transmitted data (RS-232)

* The manufacturer reserves the right to change the wire colours.

To obtain the correct data, DUT-E 232 shall be set up using the software “Service DUT-E”. Installation process is the following: 1) For data transmission on request, please, set the following status for all sensors:

• set the parameter “Automatic transmission mode” into status “Off” (tab “Operation mode”);

• set the parameter “Output message” into status “Fuel volume (l)” (tab “ Output message “).

2) For data transmission in automatic mode, please, set the following status and parame-ter values of the sensors:

• for all sensors — set the parameter “Output message” into status “Fuel volume (l)” (tab “ Output message”);

• for sensor N1 — set the parameter “Automatic transmission mode” into status “HEX”; set the value “1” for the parameter “Interval of automatic data output (s)” (tab “Operation mode”);

• for sensors from N2 to N(n-1) — set the parameter “Automatic transmission mode” into status “Off” (tab “Operation mode”);

• for sensor Nn (the last one) — set the parameter “Automatic transmission mode” into status “HEX\ASCII\ASCII EXT”; parameter “Interval of automatic data output (s)” shall be set to any value required for the terminal operation (tab “Operation mode”).


© Technoton, 2007 - 2012 29 of 42

Fig. 19 — Summator connection schemes


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2.11 Sealing To prevent the fuel theft or unauthorized tampering into DUT-E operation, you shall seal up the sensor and its electrical connection as well as connection of its harness using the supplied sealing cords and disposable plastic seals. In order to seal the sensor you need to put the cord through the special holes of the mounting plate and DUT-E housing, after that, put the free cord ends through two openings in the centre of the seal. The cord will be fixed after the seal has been locked. If necessary, you can use seals of other models and manufacturers. Separation of the seal without its breaking is not possible. ATTENTION! The sealing cord shouldn’t touch the tank!

2.12 Measurement precision check

2.12.1 Basic issues Measurement precision check is needed to detect the relative and absolute measurement error of DUT-E on the vehicle. In order to check the measurement accuracy of DUT-E you should make control tests, i.e. to fill in and empty the fuel tank, compare DUT-E readings with the actual filled-in/drained fuel. Fuel discharging is done by manual or mechanical pomp. When you make tests, you should use the verified/tested containers (batch meters) to determine the volume capacity of the drained or filled-in fuel. ATTENTION! While testing, the volume of the filled-in/drained fuel should take at least 20% of the tank.


© Technoton, 2007 - 2012 31 of 42

2.12.2 Control test steps

Control tests shall be done according to the following steps:

1) Start up the ignition.

2) Discharge the fuel of a certain volume.

3) Determine the discharged fuel volume with the help of the verified batch meter.

4) Record the data into the check-out test protocol.

5) Make a pause in order to stabilize the fuel in the tank (prior to stabilizing of DUT-E readings).

6) Refuel the tank on the amount of the earlier discharged fuel.

7) Record the amount of the re-fuelling into the protocol.

8) By analyzing the inaccuracy, the parameters “Discharge” and “Refuel” are estimated in percentage relatively to the tank volume.

Sample of the check-out test protocol and formulas for error calculation are given in Appen-dix A.

3 Diagnosis and troubleshooting If there are any failures during DUT-E operation, first of all, pay attention to electric wiring of the vehicle, cleanness and condition of power socket pins.

ATTENTION! 1. Strong oxidation of the ground switch contacts or its failure can lead to a distortion of the DUT-E output signal. 2. DUT-E indications will be incorrect if DUT-E tubes are stuck with current-conductive dirt or water!


© Technoton, 2007 - 2012 32 of 42

3.1 Diagnosis and troubleshooting of analog DUT-E The efficiency of the analog DUT-E can be checked with a multimeter by means of measuring the output voltage or current (for DUT-E I) and then verifying the obtained data with the data from Table 13.

Table 13 — Malfunction of analog DUT-E

Output voltage, V Malfunction reason Troubleshooting

Voltage: From 0.4 to 5.0 V (for DUT-E А5); From 0.4 to 10.0 V (for DUT-E А10) Current : from 2 to 22 mА (for DUT-E I)

No failures, normal operation

Check the recording and displaying device

Voltage: More than 5 V (for DUT-E А5); More than 10 V (for DUT-E А10) Current: More than 22 mА (for DUT-E I)

Short circuit of tubes of the measuring part because of metal burrs and chips; dirt or water in the tank bottom

Eliminate the short circuit, clean the sensor tubes clean the fuel tank of the vehicle

Voltage: Less than 0.4 V (for DUT-E А5 and DUT-E А10) Current: Less than 2 mА (for DUT-E I)

Failures in the electronic board of the sensor

Contact the closest regional service center


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3.2 Diagnosis and troubleshooting of frequency DUT-E Efficiency of the frequency DUT-E can be checked with a frequency meter by means of measuring the output frequency of the sensor and verifying the obtained data with the one from Table 14. Table 14 — Malfunction of frequency DUT-E

Output frequency, Hz Malfunction reason Troubleshooting

From 100 to 1600 No failures, normal operation Check the recording and display devices

More than 1600

Short circuit of tubes of the measuring part because of metal burrs and chips; dirt or water in the tank bottom

Eliminate the short circuit, clean the DUT-E tubes clean the fuel tank of the ve-hicle

Less than 100 Failures in the electronic board of the sensor

Contact the closest regional service center

3.3 Diagnosis and troubleshooting of serial DUT-E Efficiency of serial DUT-E is checked by connecting it to the PC with DUT-E Service kit. When any malfunction of the serial DUT-E occurs, a message appears in the bottom part of Service DUT-E window. The message contains the following information:

• error code; • code definition of the malfunction; • possible malfunction reason.


© Technoton, 2007 - 2012 34 of 42

4 Maintenance

4.1 General recommendations External inspection and functional test of DUT-E are recommended to do at least 1 time per year.

ATTENTION! When remounting the DUT-E, you should replace the O-ring of the mounting plate. DUT-E repair is carried out only by certified Regional Service Centers. You can find the full list of centres at http://www.jv-technoton.com/ .

4.2 De-mounting Before de-mounting the DUT-E, you should clean the surface of the tank near and around the place of the DUT-E installation. Prepare a clean rag to remove any remaining fuel from the sensor, as well as provide pro-tection with a cap (should be purchased separately) from falling any rubbish or any debris into the tank through the mounting opening of the DUT-E. Cut the sealing cord without damaging the signal wire. Disconnect the DUT-E signal cable. Undock DUT-E by turning the housing counter-clockwise by 1/6 turn.

ATTENTION! When de-mounting the DUT-E, do not make any efforts to the signal cable. Otherwise, it is possible to damage the cable and/or an electronic board.

4.3 Examination After the DUT-E has been de-mounted, it should be examined for possible defects:

a) Visible damage to the electronic board, measuring part, mounting plate, signal cable or connector/pin;

b) Tube play of the measuring part relatively to each other and/or housing; c) Presence of residues, incrustation, wax or any other debris between the tubes of the

measuring part; d) Any leakages of fuel through the rubber gasket of the mounting plate.

If any defects discovered, please, contact the Service Center (see 4.1) or the manufacturer.



© Technoton, 2007 - 2012 35 of 42

4.4 Cleaning During the operation there can be incrustation, any deposits, residues or debris on the tube walls of the DUT-E measuring part. Contamination of the cavity between the tubes of the DUT-E measuring part by any types of deposits leads to significant inaccuracy increase of DUT-E.

ATTENTION! Incrustation or sediments inside the central tube of the measuring part does not influence the efficiency and accuracy of DUT-E! You should control only the cleanness of the cavity between the two tubes of the measuring part. Tubes of the DUT-E measuring part should be washed in the fuel that is measured with the given DUT-E.

ATTENTION! During washing the tubes of the measuring part do not spill fuel on the DUT-E housing, signal cable and/or its socket.


© Technoton, 2007 - 2012 36 of 42

5 Storage DUT-E is recommended to be stored in dry areas. DUT-E storage is allowed only in original packaging at temperature range from —50 °C to +40 °C and relative humidity up to 100% at 25 °C. Do not store DUT-E in the same room with substances that cause metal corrosion and/or contain aggressive impurities. Storage life for DUT-E should not exceed 24 months.

6 Transportation Transportation of DUT-E is recommended in closed transport that provides protection for DUT-E from mechanical damage and no access of precipitation. During transportation by air the DUT-E must be placed in heated sealed compartments. Air environment in vehicles should not contain acid, alkaline and other aggressive impurities. Shipping containers with packed DUT-E sensors should be sealed.

7 Utilization/re-cycling DUT-E does not contain harmful substances and ingredients that are dangerous to human health and environment during and after the end of life and recycling. DUT-E does not contain precious metals in amount that should be recorded.


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Contact information

Distribution, technical support, service

Technoton

Tel/fax: +375 17 223-78-20

[email protected]

[email protected]

Manufacturing plant

Zavod Flometr

Tel/fax: +375 1771 3-99-89

[email protected]

mailto:[email protected]


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Appendix A

check-out test protocol

Protocol

Dated “___”____________ 20___

Model and serial number of DUT-E

Vehicle make, model, registration plate

Model, factory number of the recording and displaying device

Discharge volume from the tank

Acc. to the batcher readings BV , l

Acc. to the terminal readings termV , l

Inaccuracy of discharge

measurement

absolute Bterm VV −=∆ , l

relative to the tank volume of the vehicle

%100fueltank

×−

=V

VV Btermδ , %

Volume of fuel filling into the tank

Acc. to the batcher readings BV , l

Acc. to the terminal readings termV , l

Inaccuracy of fuel filling

measurement

absolute Bterm VV −=∆ , l

relative to the tank volume of the vehicle

%100fueltank

×−

=V

VV Btermδ , %

Conclusions:

Result of the fuel filling measurement corresponds (doesn’t correspond) to the technical requirements.

Result of the discharge measurement corresponds (doesn’t correspond) to the technical requirements.

Remarks: ___________________________________________________

Customer representative __________________ /____________________/

Contractor representative __________________ /____________________/


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Appendix B

variants of DUT-E CAN connection

Fig. B.1 — Connection of one DUT-E CAN to tracker that is not compatible with S6 cable system

GLONASS/GPS GSM

Vehicle tracker

Cable S6 SC-CW-700

Outside the driver's cabin

Inside the driver's cabin

DUT-E CAN


© Technoton, 2007 - 2012 40 of 42

Fig. B.2 — Connection of several DUT-E CAN to the tracker that is not compatible

with S6 cable system

DU

T-E C

AN

DU

T-E C

AN

DU

T-E C

AN

Outs

ide

the

dri

ver'

s ca

bin

12

8

Cable

blin

dco

ver

S6 S

CT-

connect

or

S6 3

SC

Cabl

e ex

tender

SC S

6 1

000

S6 S

C-M

ol-700

Ext

ensi

on c

abl e

/Adap t

er

S6 S

C- M

ol-3

00

SC S

6 3

000

SC S

6 7

000

SC S

6 1

2000

GLO

NA

SS

/GPS

GS

M

Vehic

le

trac

ker

T-co

nnec

tor

wit

h p

ow

er

S6 3

Mol pow

er

Insi

de

the

driv

er's

cabi

n

...

Cable

bli n

dc o

ver

S6 M

ol

GN

D

VBA T


© Technoton, 2007 - 2012 41 of 42

Fig. B.3 — Connection of one DUT-E CAN to the tracker that is compatible with S6 cable system

GLONASS/GPS GSM

Vehicle tracker



Cable blindcover S6 Mol

T-connector with power S6 3Mol power

DUT-E CAN

Cable blindcover S6 SC

T-connector S6 3SC

S6 SC-Mol-700Extension cable/Adapter S6 SC-Mol-300

GND

VBAT


© Technoton, 2007 - 2012 42 of 42

Fig. B.4 — Connection of several DUT-E CAN to the tracker that is compatible

with S6 cable system

DU

T-E C

AN

DU

T-E C

AN

DU

T-E C

AN

Outs

ide

the d

rive

r's

cabin

12

8

Ca b

le b

li nd

cov e

r S6 S

CT-

connect

or

S6 3

SC

Exte

nsi

on c

ord

SC S

6 1

000

S6 S

C-M

ol-700

Exte

nsi

on c

able

/Ada

pte

r S6 S

C- M

ol-3

00

SC S

6 3

000

SC S

6 7

000

SC S

6 1

2000

Insi

de

the

d riv

er 's

cab i

n

...

GND

VBAT

GL O

NAS

S/G

PS

GS

M

Vehic

le

trac

ker

T-co

nnect

or

with

pow

er

S6 3

Mol

pow

er

Cabl e

bl i n

dco

v er

S6 M

ol

OPERATION MANUAL - Fuel monitoring solutions. Fuel...

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