USER MANUAL FLS "STRELA" WITH INTERFACE OUTPUT
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Content 1. Function ............................................................................................................. 4 2. Technical data .................................................................................................... 5 3. Delivery set.............. .......................................................................................... 6 4. Design and function ........................................................................................... 7 5. Operating rules ................................................................................................ 15 5.1. Sensor operation requirements ............................................................... 15 5.2. General installation data ......................................................................... 15 5.3. Connection diagrams .............................................................................. 16 5.4. Setting steps............................................................................................. 21 5.5. Isolation plug assembly .......................................................................... 23 6. Sensors setting and configuration.................................................................... 25 6.1 Sensor setting in the standard mode.............................................................. 28 6.1.1 Sensors calibration ............................................................................ 29 6.1.2 Setting of averaging interval............... ............................................... 29 6.1.3 Setting of FLS working parameters under "Omnicomm" protocol.....29 6.2 FLS setting in the extended mode .................................................................. 30 6.2.1. Sensors calibration ............................................................................ ..30 6.2.2. Thermal compensation setting ................................................ ............31 6.2.3. Level to volume conversion ............................................................... 31 6.2.4. Setting of averaging type and interval .... ........................................... 33 6.2.5. Setting of parameters of FLS work under "Omnicomm" protocol......33 6.2.6. Change of the firmware.......................................................................33 6.3. Description of Omnicomm communication protocol............................... 34 6.3.1 Command description for symbol communications protocol ................ 34 6.3.2 Command description for binary communication protocol................... .35 6.3.3 Command 0x06 (single data reading) ..................................................... 36 6.3.4 Comand 0x07 (periodical data output) .................................................... 37 6.4. Description of Modbus communication protocol...................................... 38
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6.4.1 Supported functions of MODBUS protocol ......................................... 38 6.4.2 Description of registers used in the FLS................................................ 38 6.4.3 Data transmission format ....................................................................... 40 6.5. Performance test ....................................................................................... 41 7. Maintenance...................................................................................................... 42 8. Marking............................................................................................................ 44 9. Storage and transportation ............................................................................... 46
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1. Function Fuel level sensor "Strela" with interface RS232/485 output (hereafter FLS) is designed to measure the level of fuels and lubricants (POL) and can be used on vehicles and fuel depots in the systems which measure and control the fuel amount: gasoline, diesel fuel, oil.
FLS performs the functions of determining the fuel level, recalculation of level to amount (if there are no recalculation tables the sensor output value is proportional to the fuel level), transmission of measured values via RS-232 / RS-485 using protocol Modbus / Omnicomm.
FLS can be used with display units or programmable controllers with the characteristics of the input electrical signals corresponding to specifications of FLS.
Figure 1 – FLS appearance To improve reliability and performance of FLS there are following technical solutions and functions: The electronic circuit of the sensor is filled with an elastic compound that provides maximum protection and reliability in all operating conditions. Measuring tubes are made of material that does not react chemically with the fuel components. The sensor contains a built-in voltage regulator, and its output is not affected by fluctuations of the supply voltage. The averaging algorith is integrated in the sensor that allows to average readings at a given time interval. The sensor has a built-in troubleshooting system.
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2. Technical data Name Value Power Power supply voltage, V 10…30 Consumption current , mA 20 Interfaces RS-232 (RS-485) Communications protocol Modbus, Omnicomm Data transmission rate by default, bit/sec 19200 Supported data communications rate, bit/sec 9600, 14440, 19200 38400, 57600, 115200 Parity no Stop bit 1 Level measurement Low limit value of fuel level to capacity bottom, mm from 20 High limit measuring value, mm from 200 to 4000 Basic level measurement percentage error, % of sensor length ± 1 Additional temperature percentage error %* not above ± 1 General data Dimensions, mm L x 70 x 70 Weight, kg from 0,3 to 3 Running time unlimited Operation temperature range, °С от -40 до +70 Relative humidity of ambient air at temperature not above +40 °С, % not above 95 *Additional percentage error calculates the temperature effect of ambient air from – 40°C to +70°C.
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3. Delivery set Name Quantity Fuel level sensor 1 pc. Extension Cable 1 pc. Gasket 1 pc. Screws for mounting 1 pc. * The sensors are supplied in the following length: 1400, 1000, 700, 500, 350, mm and other lengths on order.
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4. Design and operation principle The measuring principle of the sensor is capacitive. The sensing element is a cylindrical capacitor formed by two concentric tubes which capacity changes with the level of immersion in the fuel.
Figure 2 – FLS schematic diagram This capacitor is connected to the drive circuit of the measuring generator, so the period of signal generated from the measuring generator depends directly on capacitance of sensing element, and therefore on the immersion level of FLS tubes into the fuel. Microcontroller according to built in program measures the period of signal generated by the measuring generator, processes it - checks the validity of the measured values, averaging and temperature compensation. It also calculates the values of output parameters - the level of immersion, corresponding fuel amount, the values of N, F, T of Omnicomm protocol, generates diagnostic codes. According to requests (see chapter 6.3, 6.4 - "Description of Omnicomm protocol", "Description of MODBUS protocol") all the calculated and measured parameters can be read using the RS-232 / RS-485 lines.
Power module (Fig. 2) is used to form stable power supply for components of the sensor from the input voltage onboard power supply and to protect the sensor against voltage surges in the vehicle electrical system, reverse polarity on supply lines and interferences.
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Figure 3 – FLS working algoritm
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ATTENTION !!! It should be kept in mind that long-term effect on the sensor of limit values (and especially exceeding the limit values) of the parameters in the power circuit may cause irreversible consequences in the elements of safety circuits due to overheating or breakdown. This may lead to the device malfunction. Operating range of supply voltages can be found in the section "Technical Specifications". Description of FLS working algorith (fig.3): 1. First the frequency is measured (F instantaneous frequency) in the sensor, if there are no errors the value is averaged according to type of averaging set in the software. ATTENTION !!! At power on the averaging module is initialized so that for any type of averaging F average is equal to the first measured value of the instantaneous frequency. Running average Simple moving average, SMA is the arithmetic mean value of (n) values, received during the period of time (t) (fig. 4): ∑
, ( ) Fi – value of the instantaneous frequency, Hz.
Figure 4 – Running average for 3 values Below are graphs where: blue line – curve of changes of values for the instantaneous frequency; red line – curve of average using 3 last values; green line – curve of average using 5 last values; purple line – curve of average using 10 last values.
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0
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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F, Hz
t, s
Running average
F inst SMA(3) SMA(5) SMA(10)
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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F, Hz
t,s
Example of interfering by running average
F inst SMA(3) SMA(5) SMA(10)
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Exponential moving average, EMA considers that more late data are more important. Thus this type of moving average reacts more quickly to changes in readings.
The exponential moving average for the averaging interval t is calculated by the formula: : ( ), Yi – EMA in the point corresponding to the definite point of time; Yi-1 – EMA in the point before definite point of time, X – current frequency value, Hz; – smoothing factor takes values from 0 to 1; t – averaging interval (s), The minimum allowed value of t = 5 s. Below are graphs where: blue line – curve of changes of values for the instantaneous frequency; red line – curve of average if t=5 s; green line – curve of average if t=10 s; purple line – curve of average if t=15 s;;
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F, Hz
t,s
exponential average
F inst EMA(5) EMA(10) EMA(20)
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ATTENTION !!! If during measurement of the instantaneous frequency occurs an error an error code will be created, the current averaged frequency value remains unchanged and the error value is omitted.
If temperature compensation is activated in the sensor settings the temperature compensation is carried out in accordance with the measured value of the temperature of the head; if the function of temperature compensation is deactivated the averaged frequency value remains unchanged. ATTENTION!!! There is no need to use temperature compensation now because additional conventional error by temperature is less then 1%. All factory coefficients are equal to 1.
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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F,Hz
t,с
Example of interfering by exponential average
F inst EMA(5) EMA(10) EMA(20)
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Piecewise-linear approximation is a partition of complex curved correspondence of fuel volume from level for a number of sections with following substitution of these sections of the curve to segments of a straight line. Piecewise-linear approximation suits best for irregular shape tanks where the dependence of volume to the level is linear on definite sections (Fig. 6).
Figure 6 – The advantage of a piecewise linear approximation for irregular- shaped tanks Polynomial approximation is the replacement of complex function with third- degree polynomial that is approximated to the original function.
Polynomial approximation is sometimes suitable for tanks of cylindrical shape (Fig. 7).
Figure 7 - Example of polynomial approximation for tanks of cylindrical shape
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MODBUS or Omnicomm protocol using lines of RS-232/RS-485 interface. MODBUS protocol also allows to read other calculated sensors parameters (see chap. 6.4).
FLS error codes tranmitted into the "T"-field Code, T-field of Omnicomm protocol* Error description -100; 156 (-1; 255) values of sensor for empty and full tank are not calibrated -101; 155 (-2; 254) value of sensor for full tank is not calibrated -102; 154 (-3; 253) The frequency of the generator is equal to 0
-103; 153 (-4; 252)
Divide by zero, sensor is calibrated in one and the same point
-104; 152 (-5; 251) EEPROM reading error -105; 151 (-6; 250) Range excess in top point F>(Fmax+10%) -106; 150 (-7; 249) Range excess in bottom point F<(Fmin-10%) *Within the brackets are error codes for sensors with firmware up to 5112010
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5. Operating rules 5.1. Sensor operation requirements
Before sensor use it is necessary to examinate it visually. If there are signs of mechanical damage (cracks, chips, dents, etc.) introduction into service of the sensor is not allowed; After the sensor is installed in the vehicle it is recommended to seal all electrical connections; Repair of the sensor should be performed in certified service centers; Operation of the sensor must be carried out by personnel that have learnt the assembly, principle of sensor operation and all instructions in this manual;
The permittivities of meassured fuel must be close to constant. Otherwise, the measurement error can get increased.
5.2. General installation data The sensor can be installed instead of standard fuel level sensor or in special hole. It is recommended to install it as close as possible to the geometric center of the tank (Fig. 8a), in order to avoid the influence of vehicle inclination to sensor readings. For vehicles with two tanks in each tank is installed one sensor. In some cases (operating of vehicles on rough ground) it is recommended to install two sensors to one tank (Fig. 8b). In this case, they must be placed on the one diagonal at opposite side walls of the tanks and count the combined output value for both sensors.
а) closer to the geometric center of the tank ;
b) two sensors in one tank
Figure 8 - How to select sensor placement for installation
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5.3. Connection diagrams Connector pin assignments Pin of connector Assignment Color of wire 1 Power «-» brown 2 Power «+» red 3 А/Rx green 4 B/Tx yellow
Figure 9 – FLS connector To implement various schemes of connection of FLS on vehicles 2 types of sensors are manufactured: 1. Sensor with aluminum body. It is designed to connect in the vehicle electrical system after the battery switch. Wire of the power "-" is connected to the sensor head (the resistance between the negative wire and the head is less than 1 Ohm). 2. Sensor with a carbon-fiber body. Designed to connect sensors directly to the battery in any place of the vehicle electrical system.
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Legend
Variant 1 It provides work of the system ONLY BY SWITCHED ON BATTERY SWITCH (CONNECTION AFTER BATTERY SWITCH) – the simple variant.
ATTENTION !!! According to this scheme the sensors with both aluminum and carbon-fiber body can be connected.
Figure 10 - Connection diagram before battery switch
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FA fuse should be installed as close as possible to the point of connection "+ power" to protect the vehicle wiring against short-circuit of power lines of monitoring system. Point A is connected in place of the presence (+) of electrical system when the ignition is off. It is recommended to connect it to set standard fuse to prevent them from burning due to the additional load. One of the best places is input "+" wire of ignition switch. Point B is connected somewhere under the dashboard of vehicle.
ATTENTION !!! Connect the "-"of your GPS-device and of the sensor to the same points!
Advantages: Reliability Simplicity Disadvantages: Does not provide continuous monitoring
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Variant 2 It provides CONTINUOUS SYSTEM OPERATION (connect before battery swith). It is applied in the case when you need round the clock monitoring of the fuel. Sensor and GPS-device must be powered directly from the battery.
ATTENTION !!! This way can be connected sensors with carbon-fiber head only.
Figure 11 - Connection diagramm after battery switch FA fuse should be installed as close to the point of connection of "+ power" to protect the vehicle power line from short-circuit in wiring of monitoring system . Points A and B are connected to the terminals "+" and "-" of battery. ATTENTION !!! DO NOT use this scheme to the fuel tanks of gasoline- powered vehicles.
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ATTENTION !!! When connected under this variant make sure that there is no contact between the outer tube and the body of the tank or a standard fuel level sensor. ATTENTION !!! Installation of the fuse FA2 is a must. If during the operation at battery switch off the outer tube of FLS comes into contact with the body of the tank or standart level gauge, FA2 will protect wiring of your system from burning out. Advantages: Simplicity Provides continuous monitoring Disadvantages: Unreliable, if not ensured 100% protection from possible contact of outer tube of FLS with the body of the tank or standard fuel level sensor.
Can not be used for fuel tanks of petrol vehicles.
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5.4. Setting steps 1. Drill a central hole (Fig. 12) for mounting the sensor. To install the sensor you would need bimetallic boring bit with diameter of 35 mm. Insert the sensor into hole and mark the places for holes to mount the sensor in the tank. Hole layout chart is shown in Fig. 12.
Figure 12 – Hole layout chart ATTENTION!!! Before drilling a hole in the tank with diesel fuel it must be completely filled in order to avoid vapor explosion! The fuel tank with gasoline fuel must be filled with water completely, or must be dismantled and the remaining fuel must be evaporated. 2. Cut the sensor to required heigth - see. Fig. 13. Cut off aluminum tubes for required tank heigth with hacksaw and leave not less than 15-20 mm between the end of the sensor and the bottom of the tank for accumulation of water and dirt. Thoroughly clean the aluminum filings between the tubes.
3. Insert the isolation plug supplied with the sensor into the end of the tubes (see art. 5.5). ATTENTION!!! It is strictly prohibited to use sensors without the isolation plug; it may lead to the sensor failure due to loosening of tubes during operation.
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Figure 13 - Diagram of sensor cutting 4. Lay cable for connection of FLS, make all connections in accordance with the selected connection diagram (see chap. 5.3). 5. Check operation of FLS. 6. Disconnect FLS. 7. Install the sensor and mount it with screws. 8. Connect FLS.
ATTENTION !!! Do not mix up wires, incorrect connection may lead to sensor malfunction! ATTENTION !!! Do not supply power more than 30 V.
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5.5. Isolating plug assembly After sensor cutting an isolating plug (IP) must always be inserted into the end of the tubes supplied with the sensor. ATTENTION!!! It is strictly prohibited to use sensors without the isolating plugs, it may lead to the sensor failure due to loosening of tubes during operation. Isolating plug has 3 positions: Position 1 Before inserting the IP into sensor it is necessary to push the inner rod from IP body by pressing it until it stops (Fig. 14).
Figure 14 - Appearance of IP in position 1
Position 2 After inserting the IP inside the sensor, press the inner rod and insert it into IP on the same level as white part of IP for its fixation in tubes (Fig. 15).
Figure 15 - Appearance of IP in position 2
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Position 3 To remove the IP from the sensor, press the inner rod and push it deep into the IP body. Thus the IP retainer can be easily removed from the tubes (Fig. 16).
Figure 16 - Appearance of IP in position 3
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6. Sensor setting and configuration For configuration you should: 1. Download the archive with the program DUTConfig from www.chelk.by, install DUTConfig software. 2. Connect the sensor to PC according to Fig. 17.
Figure 17 – Connection of FLS to PC To connect the sensor to a PC the universal service adapter USA (Fig. 18) should be used, produced by our company (for connection / calibration sensors with RS232 / 485 cable USA - FLS 4-pins required ).
Figure 18 – Appearance of USA Connection of USA to sensor RS-485 DRB-9F FLS Strela RS-485 Connector pin Pin assignment Connector pin Pin assignment Wire colour 2 Common 1 Power «-» Brown
1 +12 V 2 Power «+» Red
9 A 3 A Green
5 B 4 B Yellow
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Connection of USA to sensor RS-232 DRB-9F FLS RS-232 Connector pin Pin purpose Connector pin Pin purpose Colour of the wire 2 Common 1 Power «-» Brown
1 +12 V 2 Power «+» Red
9 Tx 3 Rx Green
5 Rx 4 Tx Yellow
3. Select on USA the operating mode RS-232, TTL UART (first LED must light, fig. 19, а) or RS-485, TTL UART (second LED must light, fig. 19, b).
а) Mode RS-232 b) Mode RS-485 Figure 19 – USA working indication 4. Start DUTConfig software. In the appeared window (Fig. 20) select sensor type: Interface.
Figure 20 – Select the sensor type
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5. In the appeared window indicate: Connection port (fig. 21,1); you can check its number in the Windows Media Device Manager, where it is assigned to USA driver; Data rate (standard speed of sensor work – 19200) (fig. 21,2);
Fig. 21 – FLS connection 6. Click [Connect] and make sure that the connection with sensor is set (fig. 21,4). If the connection is set you will see a software version in the main window. If connection is successful in the main window you will see software version (fig. 21,5) and sensor ID (fig. 21,3). ATTENTION!!! Originally ID – 1 is set to all devices. ATTENTION!!! If connection is not set automatically, enter 0 and click [Connect] in the field «Modbus ID». ATTENTION!!! To change data rate and device ID (in any setup mode) you should:
1. Click [Connect]; 2. Click [Edit] (fig. 21,6); 3. Set desired data rate and new ID; 4. Click [ОК] in the main window.
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Fig. 22 – Change of ID and data rate 6.1 Setting of FLS in the standard mode In the standard mode the following parameters are configurated:
1. Sensor calibration; 2. Averaging interval is set; 3. Parameters of sensor work under Omnicomm protocol are set. To configure FLS in the standard mode you should: 1. Click [Edit] (fig. 21,6). 2. Set required parameters. 3. To save parameters in the sensor click [ОК].
Fig. 23 – Standard mode of FLS setting
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6.1.1 Sensor calibration To calibrate a fuel sensor you should: 1. Completely immerse sensor in fuel. 2. Click [Full tank]. 3. Take the sensor out of fuel and dry it during 2-3 minutes. 4. Click [Empty tank]. If you know the frequency of dry and of completely immersed fuel sensor you can enter it manually: 1. In the field «Frequency for full tank, Hz» enter frequency value that corresponds to full tank. 2. In the field «Frequency for empty tank, Hz» enter frequency value that corresponds to empty tank. 6.1.2 Setting of averaging interval The averaging interval is a time period during which averaging of the measured frequency values of the measuring generator is made. To set an averaging interval you should enter value of an interval in seconds in the field "Averaging Interval, sec". ATTENTION!!! The possible averaging interval : 0 0-90 sec; the recommended averaging interval: 8 – 30 sec. ATTENTION!!! The averaging method set by default is running average. You can select other averaging method in the extended mode (see chapter 6.2). 6.1.3 Setting of FLS working parameters under Omnicomm protocol To set parameters of Omnicomm protocol you should: 1. To select data sending mode from FLS to terminal you should select in the field "Check box of automatic data output": Switch off, if the terminal polls the sensor itself. FLS sends data on request of terminal. Binary, if the FLS sends data itself in the binary format after time period set in the software in the field «Data output period, sec».
Text based, if the FLS sends data itself in the symbol format during time period set in the software in the field «Data output period, sec».
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2. Set the period of data output (only in case if «Check box of automatic data output» differs from «Turn off»). To set the period you should enter time interval in seconds in the field «Data output period, sec» after which the data packets will be sent from FLS to terminal. 3. Set the network activity mode by selecting in the field "Mode of network activity": Autonomous, if one FLS with RS-232 or one FLS with RS-485 is connected to terminal. In this mode FLS responses to any ID. Network, if several sensors are connected to one terminal simultaneously (only for FLS with RS-485). In this mode FLS responses only to its own ID or ID=255. 6.2 FLS setting in the extended mode ATTENTION!!! To set and configurate the fuel sensor in the extended mode you should select menu Mode in the main window, then Mode → Extended. In the extended mode you can configurate the following parameters:
1. Sensor calibration; 2. Switch on/off thermal compensation ; 3. Level conversion to volume (FLS gauging); 4. Type and interval of averaging; 5. Parameters of the sensor work under Omnicomm protocol; To configure FLS in the extended mode you should: 1. Click [Edit] (fig. 21,6). 2. In the main window select tab Mode → Extended. 3. Set the required parameters. 4. To save parameters in the sensor click [ОК]. 6.2.1. Sensor calibration The sensor calibration in the extended mode is made similar to calibration in the standard mode.
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6.2.2. Thermal compensation setting Thermal compensation is a function that allows to remove dependence of FLS readings on the temperature changes. To set thermal compensation you should select Switch ON or OFF in the field "Thermal compensation". ATTENTION!!! At the moment there is no need to use thermal compensation because extra temperature percentage error is less then 1%. All factory coefficients are set equal to 1.
6.2.3. Level to volume conversion (FLS gauging) 1. In the field «Approximation type» select its type: Piecewise linear approximation type is used for tanks of irregular shape; Polynomial approximation type is sometimes used for tanks of cylindrical and elliptical shape (cisterns). 2. Fill in gauging table:
Fig. 24 – Piecewise linear approximation
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You should enter the following lines for piecewise linear approximation type (fig. 26): immersion level in % and the corresponding value of fuel volume in liters. The lines can be placed randomly (not necessarily in ascending or descending order). The lines entered by mistake can be removed.
Fig. 25 – Polynomial approximation
You should enter as basic data the following lines in the gauging table for polynomial approximation type (fig. 25): immersion level in % and the corresponding value of fuel volume in liters. Coefficients of polynom A,B,C,D will be automatically calculated and appear in the field "Polynom".
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6.2.4. Setting of averaging type and interval To set avering you should: 1. In the field "Averaging type" select the averaging type: Exponential, averaging interval is set starting from 5 sec. Running average, averaging interval is set within the limits from 0 to 90 sec. 2. To set averaging interval you should enter the time of average in seconds in the field «Averaging interval, sec».
ATTENTION!!! Adaptive averaging type is in the test stage and currently it is not recommended for usage. 6.2.5. Setting of parameters of FLS work under Omnicomm protocol Setting of parameters of sensor work under Omnicomm protocol is made similar to setting in the standard mode. Additionally in the Extended mode you can set the maximum value of N parameter (from 0 to 65535). To do this you should set it in the field "Maximum N value".
6.2.6. Change of the firmware To change the firmware you should: 1. In the Extended mode select menu «Change firmware» (fig. 26).
Fig. 26 – Change of the firmware 2. In the appeared window (fig. 27) click [Specify firmware file].
Fig. 27 – Open firmware file 3. Indicate file with firmware and click [Upgrade firmware].
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6.3. Description of Omnicomm protocol FLS supports commands of public part of Omnicomm protocol. The public part supports two types of the communications protocol: binary (HEX) or symbolical (passing of ASCII sequences). 6.3.1 Command description for symbol communications protocol The communication under the symbol protocol consists in reception and sending of sequence of ASCII symbols perceived as interrogation and reply commands. Command «DO» (0x44 0x4F) – data reading Reply line: F=xxxx t =xx N=xxxx.0 (CR)(LF) The command serves to read out the current data: F – current value of the immediate (not averaged) frequency of measuring generator, t – current temperature value in degrees Celsius or error code (see chapter 4), N – value of level (volume) (see chapter 4). After the command «DO» is received the program answers as the sequence of ASCII symbols, for example:
F=0AF9 t=1A N=03FF.0 <CR><LF>, All values are sent in hexadecimal form. Command «DP» (0x44 0x50) – periodical data output Reply line: F=xxxx t =xx N=xxxx.0 (CR)(LF) The command is intended for activation of periodic data output. After command processing the sensor makes periodic delivery symbolically (ASCII codes) of parmeters F, t, N (similar to the reply to the DO command).
Data are delivered periodically within interval set during FLS configuration in the software DUTConfig. ATTENTION!!! If an interval of data output is set equal to zero data won't be generated. ATTENTION!!! Temporary (upto power off) switching off of periodic data output in a symbolical format is made after any reliable command of the Omnicomm protocol is received. ATTENTION!!! Switching off periodic data output in a symbolical format is made after "DO" command is received or after change of settings in the software DUTConfig .
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6.3.2 Commands description for binary communications protocol Data between the sensor and the external device are sent as messages with format represented in table «FLS command format».
FLS command format Field Field size, byte Value Prefix 1 0x31 for interrogation,0x3E for reply Network address 1 0x00…0xFF Operation code 1 0x06, 0x07
Parameters
from 0 to 8 Depends on the operation code
see command description
Check sum
1
It is calculated for all command fields. Initialization= 0. Polynom: a^8+a^5+a^4+1.
CRC algorithm To calculate CRC polynom a^8+a^5+a^4+1 can be used the following algorithm (language С):
1.
U8 CRC8(U8 data, U8 crc) { U8 i = data ^ crc; crc = 0; if(i & 0x01) crc ^= 0x5e; if(i & 0x02) crc ^= 0xbc; if(i & 0x04) crc ^= 0x61; if(i & 0x08) crc ^= 0xc2; if(i & 0x10) crc ^= 0x9d; if(i & 0x20) crc ^= 0x23; if(i & 0x40) crc ^= 0x46; if(i & 0x80) crc ^= 0x8c; return crc; }
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2.
U8 CRC8 (U8 b, U8 crc) { U8 i = 8; do { if ( (b ^ crc) & 0x01) { crc = ( (crc ^ 0x18) >> 1 ) | 0x80; } else { crc >>= 1; } b >>= 1; } while (--i); return crc; } 6.3.3 Command 0x06 (Single data reading)
Function code Description
0x06
DATA_READ (get the current data, once) The command serves to read out the current data: F – current value of the immediate (not averaged) frequency of measuring generator, t – current temperature value in degrees Celsius or error code (see chapter 4), N – value of level (volume) (see chapter 4). Data are sent least significant byte first. For example – function code under Omnicomm – 0х06 (DATA_READ). Request Reply Field (HEX) Field (HEX) Prefix 31 Prefix 3E Network address 00…FF Network address 00…FF Operation code 06 Operation code 06 Check sum 00…FF t, °С -128…127 N 0000…FFFF F 0000…FFFF Check sum 00…FF
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6.3.4 Command 0x07 (Periodical data output)
Function code Description
0x07
DATA_CONTIN (activate continuous data output) The command serves to activate periodical data output.
After command processing the sensor will start to generate periodic data: F, t, N (similar to the command reply to command 0x06), with time interval set at FLS configuration in software DUTConfig. At zero value of an interval data aren't delivered. Periodic data output is deactivated after receiving any reliable command, processor reset or shutdown of supply voltage if the mode of automatic data output wasn't set at FLS configuration in software DUTConfig.
Data are sent least significant byte first. For example – function code under Omnicomm – 0х07 (DATA_CONTIN). Request Reply Field (HEX) Field (HEX) Prefix 31 Prefix 3E Network address 00…FF Network address 00…FF Operation code 07 Operation code 07 Check sum 00…FF Command is completed successfully 00 Command cannot be completed 01 Check sum 00…FF Format of periodically generated data: Reply Field (HEX) Prefix 3E Network address 00…FF Operation code 07 Temperature, °С -128…127 Relative level 0000…FFFF Frequency value 0000…FFFF Check sum 00…FF
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6.4. Description of Modbus protocol FLS is intended for use with display devices and programmable controlers which support connection via RS-232 interface (only one sensor on the line), via RS-485 (several sensors on the line + increase in communication range) and work under the MODBUS protocol (see www.modbus.org).
6.4.1 Supported functions of MODBUS protocol
Function code Description
0x04
Read Input Registers (reading of register values, starting from definite address)
0x06
Write Single Register (record of register value) 6.4.2 Description of registers used in the FLS. Addressing in MODBUS happens through 16-bit registers. To use float type a pair of two registers is applied. Name Address Size/mode Description
liter 0 (0x00) Float/ro
Sensor readings, l (if V is set - sensor volume) prosent_L 2 (0x02) Float/ro Sensor readings, % from length DOT_frequency 4 (0x04) Float/ro Frequency of internal generator
DOT_frequency core 6 (0x06) Float/ro
Frequency of internal generator, non-normalized DOT_period 8 (0x08) Float/ro Period of internal generator
DOT_period_core 10 (0x0A) Float/ro
Period of internal generator, non- normalized U_t 12 (0x0C) Float/ro Voltage of thermal sensor t 14 (0x0E) signed short/ro Head temperature
Fl_termo 15 (0x0F) unsigned short/ro
Tick box of temp. sensor (0–no) type_appr 16 (0x10) unsigned short/rw Approximation type
deltaU_pow 17 (0x11) unsigned short/rw
Voltage drop of sensor power – engine state interrogation ON/OFF, mV
EngineState 18 (0x12) unsigned short/rw
Engine state: 0 – shut off, not 0 – started version_po 19 (0x13) unsigned long/ro Software version
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type_average 21 (0x15) unsigned short/rw
Averaging type: 0 -exponential, 1 - running average
Time 22 (0x16) unsigned short/rw
Averaging time of running average, sec
Alfa 23 (0x17) Float/rw
Alpha coefficient of exponential averaging
fl_auto_send 25 (0x19) unsigned short/rw
Check box of auto data output under Omnicomm protocol: 0 – no; 1 – yes
period_auto 26 (0x1A) unsigned short/rw
Data output period under Omnicomm protocol in the autogeneration mode omni_net_mode 27 (0x1B) unsigned short/rw Mode of line work for Omnicomm
Omni_error 28 (0x1C) unsigned short/ro
Error code, that will be shown in the temperature field under Omnicomm protocol
max_N 29 (0x1D) unsigned short/rw
Max. value, generated under Omnicomm protocol
N_point 30 (0x1E) unsigned short/ro Number of approximation points dev_id 31 (0x1F) unsigned short/rw Modbus address Boudrate 32 (0x20) unsigned long/rw Data rate under Uart error 34 (0x22) unsigned short/ro Error code Password 35 (0x23) unsigned short/rw Password for parameters change F_min 36 (0x24) Float/rw Frequency of the full sensor F_max 38 (0x26) Float/rw Frequency of the empty sensor *U_pow 40 (0x28) unsigned short/ro Sensor power supply voltage, mV
*time_average_win dow_stop
41 (0x29) unsigned short/rw
Averging time of the running average at adaptive filtration and shut off engine, sec
*deltaFout 42 (0x2a) unsigned short/rw
Frequency generation range on the frequency output reservID 43 (0x2b) unsigned short/rw Reserved for the future
fl_termo_correct 44 (0x2c) unsigned short/ro
Tick box for thermal compensation polinom_termo_correct 45 (0x2d) Float[5]/rw Polynom thermal correction polinom_t 55 (0x37) Float[4]/rw Temperature sensor polynom * Present registers are available only in the firmware versions manufactured after 22.11.2012.
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6.4.3 Data transmission format Unsigned short (16 bit) Number 0х1234 – byte 0х12 is sent first, then 0х34. Float inverse (32 bit) Number 0х12345678 – consists of two 16 bit registers 0х1234 and 0х5678. Register 0х1234 is addressed first, then 0х5678. Registers are transmitted as unsigned short (see above). Example – reading of sensor parameters. Function code under MODBUS – 0х04 (READ_INPUT_REGISTERS). Example – percent reading of tank filling: Request Reply Field (HEX) Field (HEX) Function code 04 Function code 04 Address Hi 00 Number of bytes 02 Address Lo 02 Register 0 Hi 12 Number of registers Hi 00 Register 0 Lo 34 Number of registers Lo 02 Register 1 Hi 56 Register1 Lo 78 Example - record of sensor parameters. Function code under MODBUS – 0х06 (WRITE_SINGLE_REGISTER). Example – record of dry sensor frequency (record is done with 2 packages): Package №1 Request Reply Field (HEX) Field (HEX) Function code 06 Function code 06 Address Hi 00 Address Hi 00 Address Lo 26 Address Lo 26 Register value Hi 12 Register value Hi 12 Register value Lo 34 Register value Lo 34
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Package №2
Request Reply Field (HEX) Field (HEX) Function code 06 Function code 06 Address Hi 00 Address Hi 00 Address Lo 27 Address Lo 27 Register value Hi 56 Register value Hi 56 Register value Lo 78 Register value Lo 78
6.5. Performance test 1. Connect FLS to PC. 2. Define fuel volume in the vehicle tank. 3. In the software BridgeToolBox click [Read everything from the device]. 4. Total volume displayed in the program window has to correspond to filled in the tank fuel volume.
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7. Maintenance The device doesn't require technical maintenance. Typical failures and troubleshooting Error Failure description Troubleshooting Generator frequency is equal to 0 Code: -102; 154 (-3; 253) Description: generator is stopped –the sensor doesn’t measure fuel level . Type of error: The error is of sporadic* (water short-out when vehicle is moving) or permanent (mechanical short-circuit) nature. After troubleshooting the sensor switches into operation mode. Reason: Tubes of sensing element are short-out, there is water in the fuel, mechanical short-circuit. 1. Dry the sensor, drain water from the tank; 2. Eliminate mechanical short-circuit. Measure resistance between the tubes of the sensing element with circuit analyzer when the sensor is off. The value of the resistanc should be above 460 kOhm.
Read error EEPROM Code: -104; 152 (-5; 251)
Description: parameters set at sensor calibration are failed. Reason: possible damage by static electricity at sensor cutting.
1. You should configurage FLS again (see chapter 6). Turn on and off the power. 2. Contact the manufacturer.
Range excess on top F> Fmax +10% Code: -105; 151 (-6;
250)
Description: at low fuel level the sensor shows zero and then shows error. Type of error: the error occurs on the «dry» sensor. If you submerse sensor into fuel it works properly after it passes dead zone.
Reason: the sensor is calibrated wrong. The error can also be caused by damage of sensing element cover.
1. Calibrate the sensor, if you couldn't correct the failure you should contact the manufacturer.
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Range excess on bottom F<Fmin– 10% Код: -106; 150 (-7; 249)
Description: fuel level is higher than the real one, the sensor shows an error from time to time. Type of error: the error occures when sensor is immersed into fuel at the level close to max or at any other level at water short-circuit. If the error changes to error «Generator frequency is equal to 0», the failure is caused by the water in fuel. Reason: the sensor is calibrated wrong. short-circuit of the sensing element with water or dirt in the tank.
1. The error appears at any level and the error code changes to -102; 154 from time to time (-3; 253) (Generator frequency is equal to 0) Please follow the recommendations given to error code -102; 154 (-3; 253). 2. If the error appears at one and the same level you should calibrate the sensor. If the failure wasn't corrected please contact the manufacturer.
*Sporadic – from time to time.
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8. Marking
code thatOn every sensor there is a dot peen marking that consists of 10 symbols: Example of the code 3 3 L 3 4 1 8 5 3 2 Order number of symbol from code 1 2 3 4 5 6 7 8 9 10 Symbol value FLS type Code of length Code type* Date Decoding Digital 232 700 mm for FLS it's always «L» 17:00 09.07.2012 *«Code type» – for FLS it's always «L» Sensor type 3 Digital 232 4 Digital 485
Codes of lengths 1 350 mm 2 500 mm 3 700 mm 4 1000 mm 5 1400 mm
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«Date» — manufacturing date of FLS, coding – UNIX time, without the first and the last two symbols.
UNIX time 1 Date from marking 0 0
here — You can decode UNIX time http:// www.onlineconversion.com/unix_time.htm Example. FLS with code 42L3655169. Decoding: 4 – FLS with 485 interface; 2 – length 500 mm; L – code type; 3655169 – date in code: We get 3655169; Add 1 at the beginning and 00 at the end → 1365516900; On the website http://www.onlineconversion.com/unix_time.htm in the field «Unix timestamp» enter the received code, click [Submit] – in the field below you will see the manufacturing date – Tue, 09 Apr 2013 14:15:00 GMT.
Fig. 30 – Date decoding
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9. Transportation and storage Transportation The packed device can be transported on the following conditions:
air temperature from -40°C to +80°C; relative air humidity not above 95% at temperature 40°C; transportation is allowed by enclosed transport of any type.
Storage The packed device can be stored on the following conditions: air temperature from -40°C to +80°C; relative air humidity not above 95 % at temperature 40°С.
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Content 1. Function ............................................................................................................. 4 2. Technical data .................................................................................................... 5 3. Delivery set.............. .......................................................................................... 6 4. Design and function ........................................................................................... 7 5. Operating rules ................................................................................................ 15 5.1. Sensor operation requirements ............................................................... 15 5.2. General installation data ......................................................................... 15 5.3. Connection diagrams .............................................................................. 16 5.4. Setting steps............................................................................................. 21 5.5. Isolation plug assembly .......................................................................... 23 6. Sensors setting and configuration.................................................................... 25 6.1 Sensor setting in the standard mode.............................................................. 28 6.1.1 Sensors calibration ............................................................................ 29 6.1.2 Setting of averaging interval............... ............................................... 29 6.1.3 Setting of FLS working parameters under "Omnicomm" protocol.....29 6.2 FLS setting in the extended mode .................................................................. 30 6.2.1. Sensors calibration ............................................................................ ..30 6.2.2. Thermal compensation setting ................................................ ............31 6.2.3. Level to volume conversion ............................................................... 31 6.2.4. Setting of averaging type and interval .... ........................................... 33 6.2.5. Setting of parameters of FLS work under "Omnicomm" protocol......33 6.2.6. Change of the firmware.......................................................................33 6.3. Description of Omnicomm communication protocol............................... 34 6.3.1 Command description for symbol communications protocol ................ 34 6.3.2 Command description for binary communication protocol................... .35 6.3.3 Command 0x06 (single data reading) ..................................................... 36 6.3.4 Comand 0x07 (periodical data output) .................................................... 37 6.4. Description of Modbus communication protocol...................................... 38
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6.4.1 Supported functions of MODBUS protocol ......................................... 38 6.4.2 Description of registers used in the FLS................................................ 38 6.4.3 Data transmission format ....................................................................... 40 6.5. Performance test ....................................................................................... 41 7. Maintenance...................................................................................................... 42 8. Marking............................................................................................................ 44 9. Storage and transportation ............................................................................... 46
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1. Function Fuel level sensor "Strela" with interface RS232/485 output (hereafter FLS) is designed to measure the level of fuels and lubricants (POL) and can be used on vehicles and fuel depots in the systems which measure and control the fuel amount: gasoline, diesel fuel, oil.
FLS performs the functions of determining the fuel level, recalculation of level to amount (if there are no recalculation tables the sensor output value is proportional to the fuel level), transmission of measured values via RS-232 / RS-485 using protocol Modbus / Omnicomm.
FLS can be used with display units or programmable controllers with the characteristics of the input electrical signals corresponding to specifications of FLS.
Figure 1 – FLS appearance To improve reliability and performance of FLS there are following technical solutions and functions: The electronic circuit of the sensor is filled with an elastic compound that provides maximum protection and reliability in all operating conditions. Measuring tubes are made of material that does not react chemically with the fuel components. The sensor contains a built-in voltage regulator, and its output is not affected by fluctuations of the supply voltage. The averaging algorith is integrated in the sensor that allows to average readings at a given time interval. The sensor has a built-in troubleshooting system.
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2. Technical data Name Value Power Power supply voltage, V 10…30 Consumption current , mA 20 Interfaces RS-232 (RS-485) Communications protocol Modbus, Omnicomm Data transmission rate by default, bit/sec 19200 Supported data communications rate, bit/sec 9600, 14440, 19200 38400, 57600, 115200 Parity no Stop bit 1 Level measurement Low limit value of fuel level to capacity bottom, mm from 20 High limit measuring value, mm from 200 to 4000 Basic level measurement percentage error, % of sensor length ± 1 Additional temperature percentage error %* not above ± 1 General data Dimensions, mm L x 70 x 70 Weight, kg from 0,3 to 3 Running time unlimited Operation temperature range, °С от -40 до +70 Relative humidity of ambient air at temperature not above +40 °С, % not above 95 *Additional percentage error calculates the temperature effect of ambient air from – 40°C to +70°C.
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3. Delivery set Name Quantity Fuel level sensor 1 pc. Extension Cable 1 pc. Gasket 1 pc. Screws for mounting 1 pc. * The sensors are supplied in the following length: 1400, 1000, 700, 500, 350, mm and other lengths on order.
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4. Design and operation principle The measuring principle of the sensor is capacitive. The sensing element is a cylindrical capacitor formed by two concentric tubes which capacity changes with the level of immersion in the fuel.
Figure 2 – FLS schematic diagram This capacitor is connected to the drive circuit of the measuring generator, so the period of signal generated from the measuring generator depends directly on capacitance of sensing element, and therefore on the immersion level of FLS tubes into the fuel. Microcontroller according to built in program measures the period of signal generated by the measuring generator, processes it - checks the validity of the measured values, averaging and temperature compensation. It also calculates the values of output parameters - the level of immersion, corresponding fuel amount, the values of N, F, T of Omnicomm protocol, generates diagnostic codes. According to requests (see chapter 6.3, 6.4 - "Description of Omnicomm protocol", "Description of MODBUS protocol") all the calculated and measured parameters can be read using the RS-232 / RS-485 lines.
Power module (Fig. 2) is used to form stable power supply for components of the sensor from the input voltage onboard power supply and to protect the sensor against voltage surges in the vehicle electrical system, reverse polarity on supply lines and interferences.
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Figure 3 – FLS working algoritm
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ATTENTION !!! It should be kept in mind that long-term effect on the sensor of limit values (and especially exceeding the limit values) of the parameters in the power circuit may cause irreversible consequences in the elements of safety circuits due to overheating or breakdown. This may lead to the device malfunction. Operating range of supply voltages can be found in the section "Technical Specifications". Description of FLS working algorith (fig.3): 1. First the frequency is measured (F instantaneous frequency) in the sensor, if there are no errors the value is averaged according to type of averaging set in the software. ATTENTION !!! At power on the averaging module is initialized so that for any type of averaging F average is equal to the first measured value of the instantaneous frequency. Running average Simple moving average, SMA is the arithmetic mean value of (n) values, received during the period of time (t) (fig. 4): ∑
, ( ) Fi – value of the instantaneous frequency, Hz.
Figure 4 – Running average for 3 values Below are graphs where: blue line – curve of changes of values for the instantaneous frequency; red line – curve of average using 3 last values; green line – curve of average using 5 last values; purple line – curve of average using 10 last values.
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0
200
400
600
800
1000
1200
1400
1600
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F, Hz
t, s
Running average
F inst SMA(3) SMA(5) SMA(10)
0
200
400
600
800
1000
1200
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F, Hz
t,s
Example of interfering by running average
F inst SMA(3) SMA(5) SMA(10)
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Exponential moving average, EMA considers that more late data are more important. Thus this type of moving average reacts more quickly to changes in readings.
The exponential moving average for the averaging interval t is calculated by the formula: : ( ), Yi – EMA in the point corresponding to the definite point of time; Yi-1 – EMA in the point before definite point of time, X – current frequency value, Hz; – smoothing factor takes values from 0 to 1; t – averaging interval (s), The minimum allowed value of t = 5 s. Below are graphs where: blue line – curve of changes of values for the instantaneous frequency; red line – curve of average if t=5 s; green line – curve of average if t=10 s; purple line – curve of average if t=15 s;;
0
200
400
600
800
1000
1200
1400
1600
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F, Hz
t,s
exponential average
F inst EMA(5) EMA(10) EMA(20)
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ATTENTION !!! If during measurement of the instantaneous frequency occurs an error an error code will be created, the current averaged frequency value remains unchanged and the error value is omitted.
If temperature compensation is activated in the sensor settings the temperature compensation is carried out in accordance with the measured value of the temperature of the head; if the function of temperature compensation is deactivated the averaged frequency value remains unchanged. ATTENTION!!! There is no need to use temperature compensation now because additional conventional error by temperature is less then 1%. All factory coefficients are equal to 1.
0
200
400
600
800
1000
1200
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F,Hz
t,с
Example of interfering by exponential average
F inst EMA(5) EMA(10) EMA(20)
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Piecewise-linear approximation is a partition of complex curved correspondence of fuel volume from level for a number of sections with following substitution of these sections of the curve to segments of a straight line. Piecewise-linear approximation suits best for irregular shape tanks where the dependence of volume to the level is linear on definite sections (Fig. 6).
Figure 6 – The advantage of a piecewise linear approximation for irregular- shaped tanks Polynomial approximation is the replacement of complex function with third- degree polynomial that is approximated to the original function.
Polynomial approximation is sometimes suitable for tanks of cylindrical shape (Fig. 7).
Figure 7 - Example of polynomial approximation for tanks of cylindrical shape
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MODBUS or Omnicomm protocol using lines of RS-232/RS-485 interface. MODBUS protocol also allows to read other calculated sensors parameters (see chap. 6.4).
FLS error codes tranmitted into the "T"-field Code, T-field of Omnicomm protocol* Error description -100; 156 (-1; 255) values of sensor for empty and full tank are not calibrated -101; 155 (-2; 254) value of sensor for full tank is not calibrated -102; 154 (-3; 253) The frequency of the generator is equal to 0
-103; 153 (-4; 252)
Divide by zero, sensor is calibrated in one and the same point
-104; 152 (-5; 251) EEPROM reading error -105; 151 (-6; 250) Range excess in top point F>(Fmax+10%) -106; 150 (-7; 249) Range excess in bottom point F<(Fmin-10%) *Within the brackets are error codes for sensors with firmware up to 5112010
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5. Operating rules 5.1. Sensor operation requirements
Before sensor use it is necessary to examinate it visually. If there are signs of mechanical damage (cracks, chips, dents, etc.) introduction into service of the sensor is not allowed; After the sensor is installed in the vehicle it is recommended to seal all electrical connections; Repair of the sensor should be performed in certified service centers; Operation of the sensor must be carried out by personnel that have learnt the assembly, principle of sensor operation and all instructions in this manual;
The permittivities of meassured fuel must be close to constant. Otherwise, the measurement error can get increased.
5.2. General installation data The sensor can be installed instead of standard fuel level sensor or in special hole. It is recommended to install it as close as possible to the geometric center of the tank (Fig. 8a), in order to avoid the influence of vehicle inclination to sensor readings. For vehicles with two tanks in each tank is installed one sensor. In some cases (operating of vehicles on rough ground) it is recommended to install two sensors to one tank (Fig. 8b). In this case, they must be placed on the one diagonal at opposite side walls of the tanks and count the combined output value for both sensors.
а) closer to the geometric center of the tank ;
b) two sensors in one tank
Figure 8 - How to select sensor placement for installation
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5.3. Connection diagrams Connector pin assignments Pin of connector Assignment Color of wire 1 Power «-» brown 2 Power «+» red 3 А/Rx green 4 B/Tx yellow
Figure 9 – FLS connector To implement various schemes of connection of FLS on vehicles 2 types of sensors are manufactured: 1. Sensor with aluminum body. It is designed to connect in the vehicle electrical system after the battery switch. Wire of the power "-" is connected to the sensor head (the resistance between the negative wire and the head is less than 1 Ohm). 2. Sensor with a carbon-fiber body. Designed to connect sensors directly to the battery in any place of the vehicle electrical system.
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Legend
Variant 1 It provides work of the system ONLY BY SWITCHED ON BATTERY SWITCH (CONNECTION AFTER BATTERY SWITCH) – the simple variant.
ATTENTION !!! According to this scheme the sensors with both aluminum and carbon-fiber body can be connected.
Figure 10 - Connection diagram before battery switch
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FA fuse should be installed as close as possible to the point of connection "+ power" to protect the vehicle wiring against short-circuit of power lines of monitoring system. Point A is connected in place of the presence (+) of electrical system when the ignition is off. It is recommended to connect it to set standard fuse to prevent them from burning due to the additional load. One of the best places is input "+" wire of ignition switch. Point B is connected somewhere under the dashboard of vehicle.
ATTENTION !!! Connect the "-"of your GPS-device and of the sensor to the same points!
Advantages: Reliability Simplicity Disadvantages: Does not provide continuous monitoring
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Variant 2 It provides CONTINUOUS SYSTEM OPERATION (connect before battery swith). It is applied in the case when you need round the clock monitoring of the fuel. Sensor and GPS-device must be powered directly from the battery.
ATTENTION !!! This way can be connected sensors with carbon-fiber head only.
Figure 11 - Connection diagramm after battery switch FA fuse should be installed as close to the point of connection of "+ power" to protect the vehicle power line from short-circuit in wiring of monitoring system . Points A and B are connected to the terminals "+" and "-" of battery. ATTENTION !!! DO NOT use this scheme to the fuel tanks of gasoline- powered vehicles.
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ATTENTION !!! When connected under this variant make sure that there is no contact between the outer tube and the body of the tank or a standard fuel level sensor. ATTENTION !!! Installation of the fuse FA2 is a must. If during the operation at battery switch off the outer tube of FLS comes into contact with the body of the tank or standart level gauge, FA2 will protect wiring of your system from burning out. Advantages: Simplicity Provides continuous monitoring Disadvantages: Unreliable, if not ensured 100% protection from possible contact of outer tube of FLS with the body of the tank or standard fuel level sensor.
Can not be used for fuel tanks of petrol vehicles.
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5.4. Setting steps 1. Drill a central hole (Fig. 12) for mounting the sensor. To install the sensor you would need bimetallic boring bit with diameter of 35 mm. Insert the sensor into hole and mark the places for holes to mount the sensor in the tank. Hole layout chart is shown in Fig. 12.
Figure 12 – Hole layout chart ATTENTION!!! Before drilling a hole in the tank with diesel fuel it must be completely filled in order to avoid vapor explosion! The fuel tank with gasoline fuel must be filled with water completely, or must be dismantled and the remaining fuel must be evaporated. 2. Cut the sensor to required heigth - see. Fig. 13. Cut off aluminum tubes for required tank heigth with hacksaw and leave not less than 15-20 mm between the end of the sensor and the bottom of the tank for accumulation of water and dirt. Thoroughly clean the aluminum filings between the tubes.
3. Insert the isolation plug supplied with the sensor into the end of the tubes (see art. 5.5). ATTENTION!!! It is strictly prohibited to use sensors without the isolation plug; it may lead to the sensor failure due to loosening of tubes during operation.
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Figure 13 - Diagram of sensor cutting 4. Lay cable for connection of FLS, make all connections in accordance with the selected connection diagram (see chap. 5.3). 5. Check operation of FLS. 6. Disconnect FLS. 7. Install the sensor and mount it with screws. 8. Connect FLS.
ATTENTION !!! Do not mix up wires, incorrect connection may lead to sensor malfunction! ATTENTION !!! Do not supply power more than 30 V.
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5.5. Isolating plug assembly After sensor cutting an isolating plug (IP) must always be inserted into the end of the tubes supplied with the sensor. ATTENTION!!! It is strictly prohibited to use sensors without the isolating plugs, it may lead to the sensor failure due to loosening of tubes during operation. Isolating plug has 3 positions: Position 1 Before inserting the IP into sensor it is necessary to push the inner rod from IP body by pressing it until it stops (Fig. 14).
Figure 14 - Appearance of IP in position 1
Position 2 After inserting the IP inside the sensor, press the inner rod and insert it into IP on the same level as white part of IP for its fixation in tubes (Fig. 15).
Figure 15 - Appearance of IP in position 2
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Position 3 To remove the IP from the sensor, press the inner rod and push it deep into the IP body. Thus the IP retainer can be easily removed from the tubes (Fig. 16).
Figure 16 - Appearance of IP in position 3
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6. Sensor setting and configuration For configuration you should: 1. Download the archive with the program DUTConfig from www.chelk.by, install DUTConfig software. 2. Connect the sensor to PC according to Fig. 17.
Figure 17 – Connection of FLS to PC To connect the sensor to a PC the universal service adapter USA (Fig. 18) should be used, produced by our company (for connection / calibration sensors with RS232 / 485 cable USA - FLS 4-pins required ).
Figure 18 – Appearance of USA Connection of USA to sensor RS-485 DRB-9F FLS Strela RS-485 Connector pin Pin assignment Connector pin Pin assignment Wire colour 2 Common 1 Power «-» Brown
1 +12 V 2 Power «+» Red
9 A 3 A Green
5 B 4 B Yellow
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Connection of USA to sensor RS-232 DRB-9F FLS RS-232 Connector pin Pin purpose Connector pin Pin purpose Colour of the wire 2 Common 1 Power «-» Brown
1 +12 V 2 Power «+» Red
9 Tx 3 Rx Green
5 Rx 4 Tx Yellow
3. Select on USA the operating mode RS-232, TTL UART (first LED must light, fig. 19, а) or RS-485, TTL UART (second LED must light, fig. 19, b).
а) Mode RS-232 b) Mode RS-485 Figure 19 – USA working indication 4. Start DUTConfig software. In the appeared window (Fig. 20) select sensor type: Interface.
Figure 20 – Select the sensor type
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5. In the appeared window indicate: Connection port (fig. 21,1); you can check its number in the Windows Media Device Manager, where it is assigned to USA driver; Data rate (standard speed of sensor work – 19200) (fig. 21,2);
Fig. 21 – FLS connection 6. Click [Connect] and make sure that the connection with sensor is set (fig. 21,4). If the connection is set you will see a software version in the main window. If connection is successful in the main window you will see software version (fig. 21,5) and sensor ID (fig. 21,3). ATTENTION!!! Originally ID – 1 is set to all devices. ATTENTION!!! If connection is not set automatically, enter 0 and click [Connect] in the field «Modbus ID». ATTENTION!!! To change data rate and device ID (in any setup mode) you should:
1. Click [Connect]; 2. Click [Edit] (fig. 21,6); 3. Set desired data rate and new ID; 4. Click [ОК] in the main window.
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Fig. 22 – Change of ID and data rate 6.1 Setting of FLS in the standard mode In the standard mode the following parameters are configurated:
1. Sensor calibration; 2. Averaging interval is set; 3. Parameters of sensor work under Omnicomm protocol are set. To configure FLS in the standard mode you should: 1. Click [Edit] (fig. 21,6). 2. Set required parameters. 3. To save parameters in the sensor click [ОК].
Fig. 23 – Standard mode of FLS setting
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6.1.1 Sensor calibration To calibrate a fuel sensor you should: 1. Completely immerse sensor in fuel. 2. Click [Full tank]. 3. Take the sensor out of fuel and dry it during 2-3 minutes. 4. Click [Empty tank]. If you know the frequency of dry and of completely immersed fuel sensor you can enter it manually: 1. In the field «Frequency for full tank, Hz» enter frequency value that corresponds to full tank. 2. In the field «Frequency for empty tank, Hz» enter frequency value that corresponds to empty tank. 6.1.2 Setting of averaging interval The averaging interval is a time period during which averaging of the measured frequency values of the measuring generator is made. To set an averaging interval you should enter value of an interval in seconds in the field "Averaging Interval, sec". ATTENTION!!! The possible averaging interval : 0 0-90 sec; the recommended averaging interval: 8 – 30 sec. ATTENTION!!! The averaging method set by default is running average. You can select other averaging method in the extended mode (see chapter 6.2). 6.1.3 Setting of FLS working parameters under Omnicomm protocol To set parameters of Omnicomm protocol you should: 1. To select data sending mode from FLS to terminal you should select in the field "Check box of automatic data output": Switch off, if the terminal polls the sensor itself. FLS sends data on request of terminal. Binary, if the FLS sends data itself in the binary format after time period set in the software in the field «Data output period, sec».
Text based, if the FLS sends data itself in the symbol format during time period set in the software in the field «Data output period, sec».
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2. Set the period of data output (only in case if «Check box of automatic data output» differs from «Turn off»). To set the period you should enter time interval in seconds in the field «Data output period, sec» after which the data packets will be sent from FLS to terminal. 3. Set the network activity mode by selecting in the field "Mode of network activity": Autonomous, if one FLS with RS-232 or one FLS with RS-485 is connected to terminal. In this mode FLS responses to any ID. Network, if several sensors are connected to one terminal simultaneously (only for FLS with RS-485). In this mode FLS responses only to its own ID or ID=255. 6.2 FLS setting in the extended mode ATTENTION!!! To set and configurate the fuel sensor in the extended mode you should select menu Mode in the main window, then Mode → Extended. In the extended mode you can configurate the following parameters:
1. Sensor calibration; 2. Switch on/off thermal compensation ; 3. Level conversion to volume (FLS gauging); 4. Type and interval of averaging; 5. Parameters of the sensor work under Omnicomm protocol; To configure FLS in the extended mode you should: 1. Click [Edit] (fig. 21,6). 2. In the main window select tab Mode → Extended. 3. Set the required parameters. 4. To save parameters in the sensor click [ОК]. 6.2.1. Sensor calibration The sensor calibration in the extended mode is made similar to calibration in the standard mode.
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6.2.2. Thermal compensation setting Thermal compensation is a function that allows to remove dependence of FLS readings on the temperature changes. To set thermal compensation you should select Switch ON or OFF in the field "Thermal compensation". ATTENTION!!! At the moment there is no need to use thermal compensation because extra temperature percentage error is less then 1%. All factory coefficients are set equal to 1.
6.2.3. Level to volume conversion (FLS gauging) 1. In the field «Approximation type» select its type: Piecewise linear approximation type is used for tanks of irregular shape; Polynomial approximation type is sometimes used for tanks of cylindrical and elliptical shape (cisterns). 2. Fill in gauging table:
Fig. 24 – Piecewise linear approximation
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You should enter the following lines for piecewise linear approximation type (fig. 26): immersion level in % and the corresponding value of fuel volume in liters. The lines can be placed randomly (not necessarily in ascending or descending order). The lines entered by mistake can be removed.
Fig. 25 – Polynomial approximation
You should enter as basic data the following lines in the gauging table for polynomial approximation type (fig. 25): immersion level in % and the corresponding value of fuel volume in liters. Coefficients of polynom A,B,C,D will be automatically calculated and appear in the field "Polynom".
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6.2.4. Setting of averaging type and interval To set avering you should: 1. In the field "Averaging type" select the averaging type: Exponential, averaging interval is set starting from 5 sec. Running average, averaging interval is set within the limits from 0 to 90 sec. 2. To set averaging interval you should enter the time of average in seconds in the field «Averaging interval, sec».
ATTENTION!!! Adaptive averaging type is in the test stage and currently it is not recommended for usage. 6.2.5. Setting of parameters of FLS work under Omnicomm protocol Setting of parameters of sensor work under Omnicomm protocol is made similar to setting in the standard mode. Additionally in the Extended mode you can set the maximum value of N parameter (from 0 to 65535). To do this you should set it in the field "Maximum N value".
6.2.6. Change of the firmware To change the firmware you should: 1. In the Extended mode select menu «Change firmware» (fig. 26).
Fig. 26 – Change of the firmware 2. In the appeared window (fig. 27) click [Specify firmware file].
Fig. 27 – Open firmware file 3. Indicate file with firmware and click [Upgrade firmware].
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6.3. Description of Omnicomm protocol FLS supports commands of public part of Omnicomm protocol. The public part supports two types of the communications protocol: binary (HEX) or symbolical (passing of ASCII sequences). 6.3.1 Command description for symbol communications protocol The communication under the symbol protocol consists in reception and sending of sequence of ASCII symbols perceived as interrogation and reply commands. Command «DO» (0x44 0x4F) – data reading Reply line: F=xxxx t =xx N=xxxx.0 (CR)(LF) The command serves to read out the current data: F – current value of the immediate (not averaged) frequency of measuring generator, t – current temperature value in degrees Celsius or error code (see chapter 4), N – value of level (volume) (see chapter 4). After the command «DO» is received the program answers as the sequence of ASCII symbols, for example:
F=0AF9 t=1A N=03FF.0 <CR><LF>, All values are sent in hexadecimal form. Command «DP» (0x44 0x50) – periodical data output Reply line: F=xxxx t =xx N=xxxx.0 (CR)(LF) The command is intended for activation of periodic data output. After command processing the sensor makes periodic delivery symbolically (ASCII codes) of parmeters F, t, N (similar to the reply to the DO command).
Data are delivered periodically within interval set during FLS configuration in the software DUTConfig. ATTENTION!!! If an interval of data output is set equal to zero data won't be generated. ATTENTION!!! Temporary (upto power off) switching off of periodic data output in a symbolical format is made after any reliable command of the Omnicomm protocol is received. ATTENTION!!! Switching off periodic data output in a symbolical format is made after "DO" command is received or after change of settings in the software DUTConfig .
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6.3.2 Commands description for binary communications protocol Data between the sensor and the external device are sent as messages with format represented in table «FLS command format».
FLS command format Field Field size, byte Value Prefix 1 0x31 for interrogation,0x3E for reply Network address 1 0x00…0xFF Operation code 1 0x06, 0x07
Parameters
from 0 to 8 Depends on the operation code
see command description
Check sum
1
It is calculated for all command fields. Initialization= 0. Polynom: a^8+a^5+a^4+1.
CRC algorithm To calculate CRC polynom a^8+a^5+a^4+1 can be used the following algorithm (language С):
1.
U8 CRC8(U8 data, U8 crc) { U8 i = data ^ crc; crc = 0; if(i & 0x01) crc ^= 0x5e; if(i & 0x02) crc ^= 0xbc; if(i & 0x04) crc ^= 0x61; if(i & 0x08) crc ^= 0xc2; if(i & 0x10) crc ^= 0x9d; if(i & 0x20) crc ^= 0x23; if(i & 0x40) crc ^= 0x46; if(i & 0x80) crc ^= 0x8c; return crc; }
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2.
U8 CRC8 (U8 b, U8 crc) { U8 i = 8; do { if ( (b ^ crc) & 0x01) { crc = ( (crc ^ 0x18) >> 1 ) | 0x80; } else { crc >>= 1; } b >>= 1; } while (--i); return crc; } 6.3.3 Command 0x06 (Single data reading)
Function code Description
0x06
DATA_READ (get the current data, once) The command serves to read out the current data: F – current value of the immediate (not averaged) frequency of measuring generator, t – current temperature value in degrees Celsius or error code (see chapter 4), N – value of level (volume) (see chapter 4). Data are sent least significant byte first. For example – function code under Omnicomm – 0х06 (DATA_READ). Request Reply Field (HEX) Field (HEX) Prefix 31 Prefix 3E Network address 00…FF Network address 00…FF Operation code 06 Operation code 06 Check sum 00…FF t, °С -128…127 N 0000…FFFF F 0000…FFFF Check sum 00…FF
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6.3.4 Command 0x07 (Periodical data output)
Function code Description
0x07
DATA_CONTIN (activate continuous data output) The command serves to activate periodical data output.
After command processing the sensor will start to generate periodic data: F, t, N (similar to the command reply to command 0x06), with time interval set at FLS configuration in software DUTConfig. At zero value of an interval data aren't delivered. Periodic data output is deactivated after receiving any reliable command, processor reset or shutdown of supply voltage if the mode of automatic data output wasn't set at FLS configuration in software DUTConfig.
Data are sent least significant byte first. For example – function code under Omnicomm – 0х07 (DATA_CONTIN). Request Reply Field (HEX) Field (HEX) Prefix 31 Prefix 3E Network address 00…FF Network address 00…FF Operation code 07 Operation code 07 Check sum 00…FF Command is completed successfully 00 Command cannot be completed 01 Check sum 00…FF Format of periodically generated data: Reply Field (HEX) Prefix 3E Network address 00…FF Operation code 07 Temperature, °С -128…127 Relative level 0000…FFFF Frequency value 0000…FFFF Check sum 00…FF
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6.4. Description of Modbus protocol FLS is intended for use with display devices and programmable controlers which support connection via RS-232 interface (only one sensor on the line), via RS-485 (several sensors on the line + increase in communication range) and work under the MODBUS protocol (see www.modbus.org).
6.4.1 Supported functions of MODBUS protocol
Function code Description
0x04
Read Input Registers (reading of register values, starting from definite address)
0x06
Write Single Register (record of register value) 6.4.2 Description of registers used in the FLS. Addressing in MODBUS happens through 16-bit registers. To use float type a pair of two registers is applied. Name Address Size/mode Description
liter 0 (0x00) Float/ro
Sensor readings, l (if V is set - sensor volume) prosent_L 2 (0x02) Float/ro Sensor readings, % from length DOT_frequency 4 (0x04) Float/ro Frequency of internal generator
DOT_frequency core 6 (0x06) Float/ro
Frequency of internal generator, non-normalized DOT_period 8 (0x08) Float/ro Period of internal generator
DOT_period_core 10 (0x0A) Float/ro
Period of internal generator, non- normalized U_t 12 (0x0C) Float/ro Voltage of thermal sensor t 14 (0x0E) signed short/ro Head temperature
Fl_termo 15 (0x0F) unsigned short/ro
Tick box of temp. sensor (0–no) type_appr 16 (0x10) unsigned short/rw Approximation type
deltaU_pow 17 (0x11) unsigned short/rw
Voltage drop of sensor power – engine state interrogation ON/OFF, mV
EngineState 18 (0x12) unsigned short/rw
Engine state: 0 – shut off, not 0 – started version_po 19 (0x13) unsigned long/ro Software version
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type_average 21 (0x15) unsigned short/rw
Averaging type: 0 -exponential, 1 - running average
Time 22 (0x16) unsigned short/rw
Averaging time of running average, sec
Alfa 23 (0x17) Float/rw
Alpha coefficient of exponential averaging
fl_auto_send 25 (0x19) unsigned short/rw
Check box of auto data output under Omnicomm protocol: 0 – no; 1 – yes
period_auto 26 (0x1A) unsigned short/rw
Data output period under Omnicomm protocol in the autogeneration mode omni_net_mode 27 (0x1B) unsigned short/rw Mode of line work for Omnicomm
Omni_error 28 (0x1C) unsigned short/ro
Error code, that will be shown in the temperature field under Omnicomm protocol
max_N 29 (0x1D) unsigned short/rw
Max. value, generated under Omnicomm protocol
N_point 30 (0x1E) unsigned short/ro Number of approximation points dev_id 31 (0x1F) unsigned short/rw Modbus address Boudrate 32 (0x20) unsigned long/rw Data rate under Uart error 34 (0x22) unsigned short/ro Error code Password 35 (0x23) unsigned short/rw Password for parameters change F_min 36 (0x24) Float/rw Frequency of the full sensor F_max 38 (0x26) Float/rw Frequency of the empty sensor *U_pow 40 (0x28) unsigned short/ro Sensor power supply voltage, mV
*time_average_win dow_stop
41 (0x29) unsigned short/rw
Averging time of the running average at adaptive filtration and shut off engine, sec
*deltaFout 42 (0x2a) unsigned short/rw
Frequency generation range on the frequency output reservID 43 (0x2b) unsigned short/rw Reserved for the future
fl_termo_correct 44 (0x2c) unsigned short/ro
Tick box for thermal compensation polinom_termo_correct 45 (0x2d) Float[5]/rw Polynom thermal correction polinom_t 55 (0x37) Float[4]/rw Temperature sensor polynom * Present registers are available only in the firmware versions manufactured after 22.11.2012.
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6.4.3 Data transmission format Unsigned short (16 bit) Number 0х1234 – byte 0х12 is sent first, then 0х34. Float inverse (32 bit) Number 0х12345678 – consists of two 16 bit registers 0х1234 and 0х5678. Register 0х1234 is addressed first, then 0х5678. Registers are transmitted as unsigned short (see above). Example – reading of sensor parameters. Function code under MODBUS – 0х04 (READ_INPUT_REGISTERS). Example – percent reading of tank filling: Request Reply Field (HEX) Field (HEX) Function code 04 Function code 04 Address Hi 00 Number of bytes 02 Address Lo 02 Register 0 Hi 12 Number of registers Hi 00 Register 0 Lo 34 Number of registers Lo 02 Register 1 Hi 56 Register1 Lo 78 Example - record of sensor parameters. Function code under MODBUS – 0х06 (WRITE_SINGLE_REGISTER). Example – record of dry sensor frequency (record is done with 2 packages): Package №1 Request Reply Field (HEX) Field (HEX) Function code 06 Function code 06 Address Hi 00 Address Hi 00 Address Lo 26 Address Lo 26 Register value Hi 12 Register value Hi 12 Register value Lo 34 Register value Lo 34
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Package №2
Request Reply Field (HEX) Field (HEX) Function code 06 Function code 06 Address Hi 00 Address Hi 00 Address Lo 27 Address Lo 27 Register value Hi 56 Register value Hi 56 Register value Lo 78 Register value Lo 78
6.5. Performance test 1. Connect FLS to PC. 2. Define fuel volume in the vehicle tank. 3. In the software BridgeToolBox click [Read everything from the device]. 4. Total volume displayed in the program window has to correspond to filled in the tank fuel volume.
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7. Maintenance The device doesn't require technical maintenance. Typical failures and troubleshooting Error Failure description Troubleshooting Generator frequency is equal to 0 Code: -102; 154 (-3; 253) Description: generator is stopped –the sensor doesn’t measure fuel level . Type of error: The error is of sporadic* (water short-out when vehicle is moving) or permanent (mechanical short-circuit) nature. After troubleshooting the sensor switches into operation mode. Reason: Tubes of sensing element are short-out, there is water in the fuel, mechanical short-circuit. 1. Dry the sensor, drain water from the tank; 2. Eliminate mechanical short-circuit. Measure resistance between the tubes of the sensing element with circuit analyzer when the sensor is off. The value of the resistanc should be above 460 kOhm.
Read error EEPROM Code: -104; 152 (-5; 251)
Description: parameters set at sensor calibration are failed. Reason: possible damage by static electricity at sensor cutting.
1. You should configurage FLS again (see chapter 6). Turn on and off the power. 2. Contact the manufacturer.
Range excess on top F> Fmax +10% Code: -105; 151 (-6;
250)
Description: at low fuel level the sensor shows zero and then shows error. Type of error: the error occurs on the «dry» sensor. If you submerse sensor into fuel it works properly after it passes dead zone.
Reason: the sensor is calibrated wrong. The error can also be caused by damage of sensing element cover.
1. Calibrate the sensor, if you couldn't correct the failure you should contact the manufacturer.
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Range excess on bottom F<Fmin– 10% Код: -106; 150 (-7; 249)
Description: fuel level is higher than the real one, the sensor shows an error from time to time. Type of error: the error occures when sensor is immersed into fuel at the level close to max or at any other level at water short-circuit. If the error changes to error «Generator frequency is equal to 0», the failure is caused by the water in fuel. Reason: the sensor is calibrated wrong. short-circuit of the sensing element with water or dirt in the tank.
1. The error appears at any level and the error code changes to -102; 154 from time to time (-3; 253) (Generator frequency is equal to 0) Please follow the recommendations given to error code -102; 154 (-3; 253). 2. If the error appears at one and the same level you should calibrate the sensor. If the failure wasn't corrected please contact the manufacturer.
*Sporadic – from time to time.
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8. Marking
code thatOn every sensor there is a dot peen marking that consists of 10 symbols: Example of the code 3 3 L 3 4 1 8 5 3 2 Order number of symbol from code 1 2 3 4 5 6 7 8 9 10 Symbol value FLS type Code of length Code type* Date Decoding Digital 232 700 mm for FLS it's always «L» 17:00 09.07.2012 *«Code type» – for FLS it's always «L» Sensor type 3 Digital 232 4 Digital 485
Codes of lengths 1 350 mm 2 500 mm 3 700 mm 4 1000 mm 5 1400 mm
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«Date» — manufacturing date of FLS, coding – UNIX time, without the first and the last two symbols.
UNIX time 1 Date from marking 0 0
here — You can decode UNIX time http:// www.onlineconversion.com/unix_time.htm Example. FLS with code 42L3655169. Decoding: 4 – FLS with 485 interface; 2 – length 500 mm; L – code type; 3655169 – date in code: We get 3655169; Add 1 at the beginning and 00 at the end → 1365516900; On the website http://www.onlineconversion.com/unix_time.htm in the field «Unix timestamp» enter the received code, click [Submit] – in the field below you will see the manufacturing date – Tue, 09 Apr 2013 14:15:00 GMT.
Fig. 30 – Date decoding
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9. Transportation and storage Transportation The packed device can be transported on the following conditions:
air temperature from -40°C to +80°C; relative air humidity not above 95% at temperature 40°C; transportation is allowed by enclosed transport of any type.
Storage The packed device can be stored on the following conditions: air temperature from -40°C to +80°C; relative air humidity not above 95 % at temperature 40°С.
