Aquametro CONTOIL DFM Service manual

VD 4-605 e 09.2011
Mounting and operating instructions
CONTOIL
®
DFM
Table of contents
Safety instructions 2
- Designed use
- Installation, commissioning and operation
- Operational safety
- Return of the instruments
- Notes on safety conventions and icons
Configuration overview 3
- Schematic of a configuration
- Installation Advices
- For your Security...
How to connect the... 4
- Double Flow-Sensor to the Board Computer
(DFM 8D to the DFM-BC)
- Single Flow-Sensors to the Board Computer 5
(DFM 8S / 20S /25S to the DFM-BC)
- Single Flow-Sensors to the Board Computer for 7
direct fuel consumption
- Board Computer (DFM-BC) to a Fleet Manager or 8
GPS Tracking System
- Flow-Sensors to other Fuel Counter than the DFM 9
Board Computer (DFM 8D / 8S / 20S / 25S)
Startup (commissioning) 10
Operating Instruction for the Board Computer (DFM-BC) 11
- For User ... daily information (User Mode)
- Total Consumption
- TRIP
- Reset the TRIP
- Consumption
- Display Test
- For Managers … more and deeper information (Manager Mode)
- Entering the Info Mode
- Configuration
(Information about Sensor Type, RL Sensor, User Reset)
- Supply Line
(information about Total, TRIP, Current l/h, Op. Hours)
- Return Line
(information about Total, TRIP, Current l/h, Op. Hours)
- Consumption Overview
(results from Supply Line minus Return Line)
- Supply Configuration
- Return Configuration
- Error Log Entry
- Error Log
- Config Log Entry
- Config Log
- Clock
- Factory Data
For Service Peoples … parameter setting (Service Mode)
- Entering the Service Mode
- Entry Code
- Configuration (Sensor Type, Return Line Sensor, User Reset, AUX)
- Supply Line (Total, TRIP, Current)
- Return Line (Total, TRIP, Current)
- Consumption Overview (Total, TRIP, Consumption)
- Supply Configuration (SL KF, SL app, Qmax)
- Return Configuration (SL KF, SL app, Qmax)
- Error Log Entry
- Read the stored Error Messages (Error Log)
- Config Log Entry
- Read the stored Config Messages (Config Log Entry)
- Clock
- Factory Data
Error condition 18
- Error Messages
- Description of the Error Messages.
Higher Performance Results (with application optimization) 20
What do if it is not functioning? 20
- No Display on the Board Computer (DFM-BC).
- The Board Computer (DFM-BC) is running, but no value from
the Sensors.
- After Installation, an <Error> is displayed.
Electrical Connections and Specifications 21
- For the DFM-8D
- For the DFM 8S / 20S / 25S
- For the DFM-BC
Electrical scheme of the DFM Systems 23
Specification and Technical Data 25
Dimensions 26
- DFM-8S
- DFM-8D
- Flow-Sensors DFM 20S and DFM 25S
- DFM-BC
Ordering Information 28
Warranty Information 28

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Safety instructions
Designed use
This unit is designed for acquisition, calculation, displaying and sending datas. Resulting from incorrect use or from use other than that de-
signated, can suspend the operational safety of the devices. The manufacturer accepts no liability for damages being produced from this.
Installation, commissioning and operation
Installation, connection to the electricity supply, commissioning and maintenance of the device must be carried out by trained,qualified spe-
cialists authorised to perform such works. The specialist must have read and understood these Operating Instructions and must follow the
instructions they contain. The installer must ensure that the measuring system is correctly wired in accordance with the wiring diagrams.
Before working on electrical installation, make sure to disconnect the power supply and ensure that nobody can reconnect it without your
permission.
Pay attention to the following points:
• Voltage, operation data
• Maximum transmission length
• Cable cross section, length
• Ambient temperature and mounting position
Operational safety
The manufacturer reserves the right to modify technical data without prior notice. Your local distributor will supply you with current infor-
mation and updates to these Operating Instructions.
Return of the instruments
The following procedures must be carried out before a device requiring repair or calibration, for example, is returned to Aquametro:
• Always enclose a fully completed “Repair Form” with the device. Only then Aquametro can transport, examine and repair a returned
device.
Notes on safety conventions and icons
The devices are designed to meet state-of-the-art safety requirements. They have been tested and left the factory in a condition in which
they are safe to operate. They can, however, be a source of danger if used incorrectly or for use other than the designated use. Conse-
quently, always pay particular attention to the safety instructions indicated in these instructions by the following symbols:
Warning!
“Warning” indicates an action or procedure which, if not performed correctly, can result in injury or a safety hazard.
Comply strictly with the instructions and proceed with care.
Caution!
“Caution” indicates an action or procedure which, if not performed correctly, can result in incorrect operation or de-
struction of the device. Comply strictly with the instructions.
Note!
“Note” indicates an action or procedure which, if not performed correctly, can have an indirect effect on operation or
trigger an unexpected response on the part of the device.

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Configuration overview
Schematic of a configuration
The 2 sensor meter are just an example. They can be changed with a compact one.
Installation Advices
• The sensors have to be always protected by a fuel filter.The max. mesh size depends on the sensor size. The original truck filter is ide-
al for all sensor sizes.
• Be aware, that all the fuel which is passing through the supply line sensor AND is not consumed by the engine, MUST return through
the return line sensor to the tank.
• A leak line of the injector MUST be returned on the return line and before the return flow meter
• If the sensors are marked with S and R, install the S-sensor in the SUPPLY and the R-sensor in the RETURN pipe.
• The arrow on the sensors must be show in the flow direction.
• The sensors must be absolutely free of gas inclusions.
• High pressure hammers from injection pump have to be avoided on flow sensors (for example, with a min. 2 meter wounded hose
between sensor meter on the supply line and the injection pump).
• Install the DFM-BC on the cabin floor, on the car dashboard or on the cabin top; but always in good readable and accessible position.
• For a good and professional installation of the Board Computer (DFM-BC) we recommend the Mounting Bracket Kit (part no. 80485)
For your Security...
• DO NOT program or change parameters while you drive. This is / may be dangerous for you and the other traffic
participants.
• During the electrical installation disconnect the vehicle battery.
• Be careful when disconnecting the pipes (exit of fuel will occur).
• After installation check all pipes for leaks.
Preliminary
filter Pump
Fine filter
Mechanical
injection
pump
EngineTank
Battery
Fleet
Manager

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How connect the...
Before you start with the electrical connection of the system, you must have done a correct installation of the delive-
red components. This installation must be done by an authorized and certified company/person.
Please be aware: an incorrect installation may destroy the DFM-System and damage your vehicle. In this case, Aqua-
metro will deny all responsibilities.
Double Flow-Sensor to the Board Computer
(DFM 8D to the DFM-BC)
Please read the Installation Tips before you start.
1. With the DFM-BC in front of you, open the side-wings of the box and unscrew the 4 screws. Put the upper part of
the DFM-System careful by side. The upper part is connected to the base part with a flat cable.
2. Look at the print on the base. You will see a connector with 14 positions.
3. Take the cable from the DFM-8D and pass it through one of the gland of the DFM-BC. Tight very well by hand the
gland-nut, until the cable is fixed.
4. Now connect the wires from the DFM-8D according to the table below to the connector on the DFM-BC print:
DFM-8D - cable colors DFM-BC - positions on the connector
Black to 1
Brown to 2
Yellow to 3
Green to 4
Red to 5
White to 6
To ensure a proper function, the cable, described in the procedure below, must be connected direct to the vehicle
battery. Do not connect it over the start-key of the vehicle.That means, also with the vehicle key in your pocket the
DFM-BC must be electrical powered. The consumption of the electrical power is far below 1mA.
5. Connect a two wire cable (0.75 mm
2
) from the vehicle battery, through one of the gland of the DFM-BC, to the con-
nector position 13 (batt. plus) and position 14 (batt. minus). Tight very well by hand the gland-nut, until the cable is
fixed.
6. After all cables are connected and well in place, put the upper part of the DFM-BC on the base part and screw it
down.
7. Look at the type plate of the DFM-8D Sensor Meter. Read the value for the SL-KF and the RL-KF (it must be a va-
lue like SL KF +0.12 or SL KF -0.13). Keep this value in mind or write it down to paper.
These values are needed to reach optimal performance.
8. Take the DFM-BC. If it is off, press one of the 4 Keys on the front to reactivate it.
Go to the menu point <Service>.
Press <OK> and enter the Service-Code. Standard service code is: 1111.
9. Input Value and Output Value:
Change the “Input Value” by doing the following:
a. Press the down-arrow
b. On the “Input” line press <OK>
c. The field “Input xxxx.x ml” will by highlighted.
d. ”Move the cursor to the right with the <OK> key, move the cursor to the left with the <ESC> key.
e. Press the down-arrow or the up-arrow to adjust the “Input Value” to 12.5 ml/pulse.
f. Press <OK> to confirm the modification.
g. The “Output Value” can be chosen from the “Sensor Type” table or set a value of your choice.
Sensor Type Input Value
DFM-8S 12.5 ml
DFM-20S 36 ml
DFM-25S 100 ml
10. Set the Return Line Sensor
a. Press the down-arrow to move to the <RL Sensor> line.
b. The value must be <Yes> (standard). If not, press the <OK> key and change the value with the arrows key.

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11. Set the <SL KF> and the <SL app>.
a. Starting from the previous position, press many time the down-arrow, until you reach the menu point “Supply
configuration”.
b. Press <OK> at the menu point “SL KF”. Enter the value for the <SL KF> using the arrow keys.This value is prin-
ted on the type plate of the flow meter. Confirm with <OK>.
c. Move with <OK> to the menu point <SL app>. Normaly you do not need to change this value. For more infor-
mation go to the section <Higher Performance Results>
d. Press many times the down-arrow key until you reach the menu point “Return configuration”.
e. Press <OK> at the menu point “RL KF”. Enter the value for the <RL KF> using the arrow keys.This value is prin-
ted on the type plate of the flow meter. Confirm with <OK>.
f. Move with <OK> to the menu point <SL app>. Normaly you do not need to change this value. For more infor-
mation go to the section <Higher Performance Results>
12. Set the date
a. Starting from the previous position, press many time the down-arrow, until you reach the menu point “Clock”.
b. On the line “Date”, press <OK>. Modify the date by using the down-arrow or the up-arrow. Move from
left to right with the <OK> key.
c. When the date is set, confirm it with the <OK> key.
13. Set the time
a. Move with the down-arrow key to the line “Time”.
b. On the line “Time”, press <OK>. Modify the time by using the down-arrow or the up-arrow. Move from
left to right with the <OK> key
c. When the time is set, confirm it with the <OK> key.
14. Set the Service code.
This procedure is optional. We recommend to change it for more security.
Store the new service code in a save place. Loosing of the service code leads to a “factory reset”, which means
sending the DFM-BC to the factory with loosing of all setting parameters. So, be careful.
a. Move with the down-arrow key to the line “Service code”.
b. On the line “Service code”, press <OK>. Modify the service code by using the down-arrow or the
up-arrow. Move from left to right with the <OK> key and from right to left with the <ESC> key.
c. When the new service code is set, confirm it with the <OK> key.
15. End of installation
a. Exit with <ESC>.
b. After the installation is done and before you start the engine, go to the section “Startup (commissioning)” for the
initial checks and startup.
Single Flow-Sensors to the Board Computer
(DFM 8S / 20S / 25S to the DFM-BC)
This installation consists always in pair installation of the Sensor Meters.
For an easier reading during this section the DFM 8S / 20S / 25S are called DFM Sensor.
Please read the Installation Advices before you start.
1. With the DFM-BC in front of you, open the side-wings of the box and unscrew the 4 screws. Put the upper part of
the DFM-System careful by side. The upper part is connected to the base part with a flat cable.
2. Look at the print on the base. You will see a connector with 14 positions.
3. Take the cable from the first DFM-Sensor and pass it through one of the gland of the DFM-BC. Do the same with
the second one. Tight very well by hand the gland-nut, until the cable is fixed.
4. Now connect the wires from the DFM-Sensor according to the table below to the connector on the DFM-BC print:
Supply-Line Sensor
DFM-Sensor - cable colors DFM-BC - positions on the connector
Black to 1
Brown to 2
Yellow to 3
Green to 4
Red to Not used
White to Not used

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Return-Line Sensor
DFM-Sensor - cable colors DFM-BC - positions on the connector
Black to 7
Brown to 8
Yellow to 9
Green to 10
Red to Not used
White to Not used
5. To ensure a proper function, the cable, described in the procedure below, must be connected direct to the vehicle
battery. That means, also with the vehicle key in your pocket the DFM-BC must be electrical powered. The con-
sumption of the electrical power is far below 1mA.
Connect a two wire cable (0.75 mm
2
) from the vehicle battery, through one of the gland of the DFM-BC, to the con-
nector position 13 (Batt. plus) and position 14 (Batt. minus). Tight very well by hand the gland-nut, until the cable
is fixed.
6. After al cables are connected and well in place, put the upper part of the DFM-BC on the base part and screw it
down.
7. Look at the type plate of the DFM-Sensor Meter. Read the value for the SL-KF and the RL-KF (example: it must be
a value like <SL KF +0.12> or <SL KF -0.13>). Keep this value in mind or write it down to a paper.
These values are needed to reach optimal performance.
8. Take the DFM-BC. If it is off, press one of the 4 Keys on the front to reactivate it.
Go to the menu point <Service>. Press <OK> and enter the Service-Code.
Standard service code is: 1111.
9. Input Value and Output Value
Change the “Input Value” by doing the following:
a. Press the down-arrow
b. On the “Input” line press <OK>
c. The field “Input xxxx.x ml” will by highlighted.
d. Press the down-arrow or the up-arrow to adjust the “Input Value” according to the table “Sensor Type”
e. Press <OK> to confirm the modification.
f. The “Output Value” can be chosen from the “Sensor Type” table or set a value of your choice.
Sensor Type Input Value
DFM-8S 12.5 ml
DFM-20S 36 ml
DFM-25S 100 ml
10. Set the Return Line Sensor
a. Press the down-arrow to move to the <RL Sensor> line.
b. The value must be <Yes> (standard). If not, press the <OK> key and change the value with the arrows key.
11. Set the <SL KF> and the <SL app>.
a. Starting from the previous position, press many time the down-arrow, until you reach the menu point “Supply
configuration”.
b. Press <OK> at the menu point “SL KF”. Enter the value for the <SL KF> using the arrow keys.This value is prin-
ted on the type plate of the flow meter. Confirm with <OK>.
c. Move with <OK> to the menu point <SL app>. Normaly you do not need to change this value. For more infor-
mation go to the section <Higher Performance Results>.
d. Press many times the down-arrow key until you reach the menu point “Return configuration”.
e. Press <OK> at the menu point “RL KF”. Enter the value for the <RL KF> using the arrow keys. This value is prin-
ted on the type plate of the flow meter. Confirm with <OK>.
f. Move with <OK> to the menu point <SL app>. Normaly you do not need to change this value. For more infor-
mation go to the section <Higher Performance Results>
12. Set the date
a. Starting from the previous position, press many time the down-arrow, until you reach the menu point “Clock”.
b. On the line “Date”, press <OK>. Modify the date by using the down-arrow or the up-arrow. Move from
left to right with the <OK> key and from right to left with the <ESC> key.
c. When the date is set, confirm it with the <OK> key.

13. Set the time
a. Move with the down-arrow key to the line “Time”.
b. On the line “Time”, press <OK>. Modify the time by using the down-arrow or the up-arrow. Move from
left to right with the <OK> key and from right to left with the <ESC> key.
c. When the time is set, confirm it with the <OK> key.
14. Set the Service code
This procedure is optional. We recommend changing for more security.
Store the new service code in a save place. Loosing of the service code leads to a “factory reset”, which means
sending the DFM-BC to the factory with loosing of all setting parameters. So, be careful.
a. Move with the down-arrow key to the line “Service code”.
b. On the line “Service code”, press <OK>. Modify the service code by using the down-arrow or the
up-arrow. Move from left to right with the <OK> key and from right to left with the <ESC> key.
c. When the new service code is set, confirm it with the <OK> key.
15. End of installation
a. Exit with <ESC>.
b. After the installation is done and before you start the engine, go to the section “Startup (commissioning)” for
the initial checks and startup.
Single Flow-Sensors to the Board Computer for direct fuel
consumption (DFM 8S / 20S / 25S to the DFM-BC)
This installation is done with a single installation of the Sensor Meters. For an easier reading during this section the
DFM-8S / 20S / 25S are called DFM Sensor.
Please read the Installation Advices before you start.
1. With the DFM-BC in front of you, open the side-wings of the box and unscrew the 4 screws. Put the upper part of
the DFM-System gently by side. Be CAREFULL. The upper part is connected to the base part with a flat cable.
2. Look at the print on the base. You will see a connector with 14 positions.
3. Take the cable from the DFM-Sensor and pass it through one of the gland of the DFM-BC. Tight very well by hand
the gland-nut, until the cable is fixed.
4. Now connect the wires from the DFM-Sensor according to the table below to the connector on the DFM-BC print:
DFM-Sensor - cable colors DFM-BC - positions on the connector
Black to 1
Brown to 2
Yellow to 3
Green to 4
Red to Not used
White to Not used
5. To ensure a proper function, the cable, described in the procedure below, must be connected direct to the vehicle
battery. That means, also with the vehicle key in your pocket the DFM-BC must be electrical powered. The con-
sumption of the electrical power is far below 1mA.
Connect a two wire cable (0.75 mm
2
) from the vehicle battery, through one of the gland of the DFM-BC, to the con-
nector position 13 (Batt. plus) and position 14 (Batt. minus). Tight very well by hand the gland-nut, until the cable
is fixed.
6. After all cables are connected and well in place, put the upper part of the DFM-BC on the base part and screw it
down.
7. Look at the type plate of the DFM-Sensor Meter. Read the value for the SL-KF (example: it must be a value like
<SL KF +0.12> or <SL KF -0.13>). Keep this value in mind or write it down to a paper.
These values are needed to reach optimal performance.
8. Take the DFM-BC. If it is off, press one of the 4 Keys on the front to reactivate it.
Go to the menu point <Service>. Press <OK> and enter the Service-Code.
Standard service code is: 1111.
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9. Input Value and Output Value
Change the “Input Value” by doing the following:
a. Press the down-arrow
b. On the “Input” line press <OK>
c. The field “Input xxxx.x ml” will by highlighted.
d. Press the down-arrow or the up-arrow to adjust the “Input Value” according to the table “Sensor Type”
e. Press <OK> to confirm the modification.
f. The “Output Value” can be chosen from the “Sensor Type” table or set a value of your choice.
Sensor Type Input Value
DFM-8S 12.5 ml
DFM-20S 36 ml
DFM-25S 100 ml
10. Set the Return Line Sensor
a. Press the down-arrow to move to the <RL Sensor> line.
b. This value must be <No>. If it is not, press the <OK> key and change the value with the arrows key.
11. Set the <SL KF> and the <SL app>.
a. Starting from the previous position, press many time the down-arrow, until you reach the menu point “Supply
configuration”.
b. Press <OK> at the menu point “SL KF”. Enter the value for the <SL KF> using the arrow keys.This value is prin-
ted on the type plate of the flow meter. Confirm with <OK>.
c. Move with <OK> to the menu point <SL app>. Normaly you do not need to change this value. For more infor-
mation go to the section <Higher Performance Results>
d. Press many times the down-arrow key until you reach the menu point “Return configuration”.
e. Press <OK> at the menu point “RL KF”. Enter the value for the <RL KF> using the arrow keys. This value is prin-
ted on the type plate of the flow meter. Confirm with <OK>.
f. Move with <OK> to the menu point <SL app>. Normaly you do not need to change this value. For more infor-
mation go to the section <Higher Performance Results>
12. Set the date
a. Starting from the previous position, press many time the down-arrow, until you reach the menu point “Clock”.
b. On the line “Date”, press <OK>. Modify the date by using the down-arrow or the up-arrow. Move from
left to right with the <OK> key and from right to left with the <ESC> key.
c. When the date is set, confirm it with the <OK> key.
13. Set the time
a. Move with the down-arrow key to the line “Time”.
b. On the line “Time”, press <OK>. Modify the time by using the down-arrow or the up-arrow. Move from
left to right with the <OK> key and from right to left with the <ESC> key.
c. When the time is set, confirm it with the <OK> key.
14. Set the Service code
This procedure is optional. We recommend changing for more security.
Store the new service code in a save place. Loosing of the service code leads to a “factory reset”, which means
sending the DFM-BC to the factory with loosing of all setting parameters. So, be careful.
a. Move with the down-arrow key to the line “Service code”.
b. On the line “Service code”, press <OK>. Modify the service code by using the down-arrow or the
up-arrow. Move from left to right with the <OK> key and from right to left with the <ESC> key.
c. When the new service code is set, confirm it with the <OK> key.
15. End of installation
a. Exit with <ESC>.
b. After the installation is done and before you start the engine, go to the section “Startup (commissioning)” for
the initial checks and startup.
Board Computer (DFM-BC) to a Fleet Manager or GPS Tracking System
For an easier reading during this section the Fleet Manager or the GPS Tracking-System
are called Auxiliary.
This configuration allows you to send the exactly calculated consumption amount to an external device (e.g., Fleet Ma-
nager or GPS Tracking System). In order to work, a flow meter with the correct “Output Value” must be installed on the
DFM-BC

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1. With the DFM-BC in front of you, open the side-wings of the box and unscrew the 4 screws. Put the upper part of
the DFM-System gently by side. Be CAREFULL. The upper part is connected to the base part with a flat cable.
2. Look at the print on the base. You will see a connector with 14 positions.
To ensure a proper function, this cable must be connected direct to the vehicle battery. Do not connect it over the
start-key of the vehicle. That means, also with the vehicle key in your pocket the DFM-BC must be electrical powe-
red. The consumption of the electrical power is far below 1mA.
3. Connect a two wire cable (0.75 mm
2
) from the vehicle battery, through one of the gland, to the position 13 (Batt.
plus) and position 14 (Batt. minus). Tight very well by hand the gland-nut, until the cable is fixed.
To ensure a proper function, this cable must have a direct connection to the battery. Do not connect it over the
start-key of the vehicle.
4. Take the cable from the Auxiliary and pass it through one of the gland of the DFM-BC. Tight very well by hand the
gland-nut, until the cable is fixed.
5. Connect the cable according to the table below:
DFM-BC Fleet-Manager or
positions on the connector GPS Tracking-System
11 (Signal Output) to Signal or Digital/Analog Input
12 (Ground) to Ground
For more information see section “Electrical connections and Specifications”
6. After all cables are connected and well in place, put the upper part of the DFM-BC on the base part and screw it
down.
7. Take the DFM-BC. If it is off, press one of the 4 Keys on the front to reactivate it. Go to the menu point <Service>.
Press <OK> and enter the Service-Code. Standard service code is: 1111.
8. Set the Auxiliary (AUX) active.
a. Press the down-arrow to move to the <AUX> line.
b. On the line “AUX”, press <OK>. Modify the value by using the down-arrow or the up-arrow.
c. Change the value to <Yes>
d. Press <OK> to confirm the modification.
e. Exit with <ESC>.
9. From this point the signal will be send to the auxiliary port of the DFM-BC and the word AUX will be displayed on
the DFM-BC Display in big letters. No more information on the DFM-BC screen will be available until you
deactivate the <AUX>.
10. Set the Fleet-Manager or the GPS-System input according to the “Output Value” set during the installation of the
flow meters.
Flow-Sensors to other Fuel Counter than the DFM Board Computer (DFM 8D / 8S / 20S / 25S)
1. Go to section <Electrical Connections and Specifications> and install the DFM Sensors according to the specifica-
tion of the used Fuel Counter.
2. Go to the section “Startup (commissioning)”
DFM-BC connection to other flow meter(s) than the DFM flow meter(s).
For differential measurement
Supply Line flow meter
1.Connect the “Signal” cable from the flow meter 1 to the pin 3 of the DFM-BC
2.Connect the “Ground” cable from the flow meter 1 to the pin 2 of the DFM-BC
Return Line flow meter
3.Connect the “Signal” cable from the flow meter 2 to the pin 9 of the DFM-BC
4.Connect the “Ground” cable from the flow meter 2 to the pin 8 of the DFM-BC
For direct measurement
1.Connect the “Signal” cable from the flow meter to the pin 3 of the DFM-BC
2.Connect the “Ground” cable from the flow meter 1 to the pin 2 of the DFM-BC

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Setting of the DFM-BC
Start with the settings of the DFM-BC by doing the following:
1.Take the DFM-BC. If it is off, press one of the 4 Keys on the front to reactivate it.
Go to the menu point <Service>. Press <OK> and enter the Service-Code
Standard service code is: 1111
2.On the “Input Value” line press <OK>
3.The field “xxx ml/p” will by highlighted.
4.Move the curse to the right with the <OK> key, move the cursor to the left with the <ESC> key
5.Press the down-arrow or the up-arrow to adjust the “Input Value” according to the flow meter signal value.
6.Press <OK> to confirm the modification.
7.Repeat the above procedure for the “Output Value” (set the “Output Value” requested by your external device
(GPS or Fleet Manager)
8.Set the Return Line Sensor
a. Press the down-arrow to move to the <RL Sensor> line.
b. Differential measurement: this value must be set to <Yes>. If it is not, press the <OK> key and change the
value with the arrows key.
c. Direct measurement: this value must be set to <No>. If it is not, press the <OK> key and change the value with
the arrows key
9.Go to the section “Startup (Commissioning)”.
Startup (commissioning)
In this section we assume that the installation of all needed instruments has been done in a correct and professional
way, that means,
The fuel system is purged according the engine manufacture advices, leak and bubble free.
If this is not the case, please set the system in proper operating condition.
1. Start the engine and let it run at min. load until it reached its operating conditions (heat exchange water between
70 °C - 90 °C)
2. Check all connections for leak proof.
The next steps are only for user which has a DFM Board Computer (DFM-BC). If you have not a DFM Board
Computer you can skip this section
3. Switch on the Board Computer (DFM-BC) by touching a key.
4. Go to the Info mode, by using the down-arrow or the up-arrow, and press <OK>.
5. Check on the <Configuration> display for the correct values.
a. Check the <Input / Output Value> > and the <RL Sensor>. Are these settings correct?
b. If not, got back to the section <How to connect …> and take the appropriate corrections.
6. Go to the <Supply Line>
a. The values for Total, TRIP and Current must shows values higher than zero.
7. Go to the <Return Line> (ONLY for differential measurement)
a. The values for Total, TRIP and Current must shows values higher than zero.
8. Go to the <Consumption Overview>
a. The values for Total and TRIP must shows values higher than zero and must change during the run, that
means, the value have to rise up.
b. The value for Consumption depends on the engine size and his fuel consumption, but must still be higher than
zero. As long as the engine runs in low load mode, this value must always show the same amount (small varia-
tions behind the comma are normal)

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9. Go to the <Supply Configuration>
a. Check the <SL KF>. Is it the right one?
b. If not, go back to the section <How to connect …> and take the appropriate corrections.
10. Go to the <Return Configuration>
a. Check the <RL KF>. Is it the right one?
b. If not, go back to the section <How to connect …> and take the appropriate corrections.
Operating Instruction for the
Board Computer (DFM-BC)
The Board Computer (DFM-BC) has no ON/OFF switch. It has a sleep mode.
What does it mean?
When no activities are recognized on the connected lines (Supply line and Return Line) the Board Computer (DFM-BC) will switch OFF
itself. It will be waked up when about 2 pulses are coming in over the connected lines.
The consumed voltage is very slow (less than 1 mA), so that no discharge of the battery can occur during a very long period.
The Menu structure has 3 branches:
•User-Mode
Is intended for the daily user. It informs him about the daily needed information.
•Manager-Mode
Is intended for the advanced user. It shows you deeper information about the DFM-System. No parameter changes are possible.
•Service-Mode.
Service-Mode is only for the Service-Engineer and is password protected. Because it give you complete access to all parameters, it is
absolutely important to be a trained and qualified person. Inaccurate changes in this section can result in fault calculations and mista-
kes.
For User ... daily information (User Mode)
Total Consumption
This picture shows the total consumption of the Engine since commissioning.
Last screen Next screen
TRIP
This picture shows the consumption of the Engine since the last reset.
Previous screen Next screen
Reset the TRIP
Press OK to Press OK to
enter reset again to reset
mode the TRIP
After this, the TRIP will show 0 l/h

12 CONTOIL
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DFM
Consumption
This picture shows the current consumption of the Engine in l/h.
Previous screen Next screen
The next two screens (Info Mode and Service Mode) are explained in the section For Managers and For Service
People.
Display Test
Press OK to start the Display test.
Previous screen Next screen
This will start the Display test. The screen will switch from a black screen to a blank screen and back. At the end of the test it will go to the
“Total screen”.
During the switching from black to blank, have a look at the surface for missing pixels (points). If you saw missing pixel, then the display
must be changed (use the Repair Form). If you do not have one, contact your local dealer.
For Managers ... more and deeper information (Manager Mode)
Take a few minutes to read first the section User Mode. It is the base for the next section.
In the manager mode you have all the relevant DFM-System information at a glance.
1. 1.From the User Mode go with the arrows or arrows to the Info screen and press OK. After you entered the Info
bran ches, the
2.ESC key has always the same function: it brings you back one step (to the Info Mode).
3.arrow brings you to the previous screen or to the line above
4.arrow brings you to the next screen or to the next line
In the following sections, the ESC key, arrow and the arrow will be no more described.
Entering the Info Mode
Press OK to enter the Info mode
Be aware: NO changes are possible in the Info Mode. This is just intended for Information.
Configuration (Information about Input / Output Value, RL Sensor, User Reset)
Input: value of the incoming signal in ml/pulse
Output: value of the outgoing signal. This value should not be lower than the “Input Value”
RL sensor: is a Return Line Sensor installed? (Yes / No)
User reset: it is allowed for the user to do a reset? (Yes / No)
Aux: communication line to an external device (e.g, Fleet Manager, GPS-Tracking system)
Be aware: the Return Line flow meter must be always the same like the Supply Line sensor

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Supply Line (information about Total, TRIP, Current l/h, Op. Hours)
Total: amount of liter that has flew through this sensor since the commissioning
TRIP: amount of liter since the last reset (it functions like a daily counter)
Current: actually flow rate in l/h
Op. hours: operation hours of the sensor since commissioning
Return Line (information about Total, TRIP, Current l/h, Op. Hours)
Total: amount of liter that has flew through this sensor since the commissioning
TRIP: amount of liter since the last reset (it functions like a daily counter)
Current: actually flow rate in l/h
Op. hours: operation hours of the sensor since commissioning
Consumption Overview (results from Supply Line minus Return Line)
Total: Engine consumption since the commission.
TRIP: Engine consumption since the last reset.
Current: Current engine consumption.
Supply Configuration
SL K’F: Optimization value for best sensor performance.
SL app: Optimization value for best application performance.
Qmax: this value shows you how high was the flow rate peak you ever had in the supply line since the
commissioning.
Return Configuration
RL cal: Optimization value for best sensor performance.
RL app: correction value for the consumption calculation (typical: fuel temp, etc.)
Qmax: this value shows you how high was the flow peak you ever had in the return line since the
commissioning.
Error Log Entry
The DFM-BC is able to catch different sensor conditions, to compare it with stored value and to decide if an error occurs or not. If an error
occurs, it will be showed on the display and stored in an Error Log for later reviewing. This information will help you in resolving complex
situation. If the allowed Error Log entries are exceeded, the oldest one will be deleted.
This screen shows you, when the last error messages was recorded.
Press OK to enter the Error Log
Error Log
This screen shows you, with data and time stamp, the last stored Error Messages in a readable form.
Press the arrows to go through the messages.
If you press the arrow by the first message you will be leaded to the last message.
If you press the arrow by the last message you will be leaded to the first message.
For more explanations see section “Description of the Error Messages”.

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DFM
Config Log Entry
The DFM-BC has the ability to store all configuration changes which happened. If the allowed entries are exceeded, the oldest one will be
deleted.
This screen shows you, when the last configuration change was recorded.
Press OK to enter the Config Log.
Config Log
This screen shows you, with data and time stamp, the last stored configuration change in a readable way.
Press the arrows to go through the messages.
If you press the arrow by the first message you will be leaded to the last message.
If you press the arrow by the last message you will be leaded to the first message.
The messages are user readable, so there are no need for more explanations.
Clock
This screen shows you the date and the time.
Factory Data
This screen shows you the firmware version and the serial number of the DFM-BC
For Service Peoples ... parameter setting (Service Mode)
In this section we assume that the service engineer is familiarly with the differential measurement technique and also knows the precedent
sections. In the Service Engineer mode you have unrestricted access to all vital parameter. Please be careful in changing parameter.
Inadequate parameter settings can lead to incorrect functions and calculations.
A good way to avoid mistakes is to write down the parameters before you change it.
1. From the User Mode go with the arrow or arrow to the Service screen and press OK. After you entered
the Service branches, the
2. ESC key
a. brings you back one step or
b. brings you back one digit (one position).
3. OK key
a. Means Modify,Show,Store,Reset,Yes,Next. All this are described on the display of the Board Computer
(DFM-BC)
4. arrow key
a. brings you to the previews screen or to the line above or
b. it is used to change values (increment).
5. arrow key
a. brings you to the next screen or to the line below or
b. it is used to change values (decrement).

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DFM
Entering the Service Mode
Press OK to enter the Service mode
Entry Code
After entering the Service Mode, a code is requested
Enter the 4 digit code and press OK
Use the arrow key to change values.
• The standard service code is: 1111.
• If you enter the wrong code, you will be redirected back to the first digit.
• If you change the Entry Code store it in a safe place. Without Entry Code you have no access to the service mode.
• If you loose your Entry Code you MUST send the DFM-BC to the factory for resetting it to its default value
(see Return of Instruments).
Configuration (Sensor Type, Return Line Sensor, User Reset, AUX)
Move the bar over the line you would like to change parameters. Press OK.The changeable field will be highlighted for changing. Make your
changes and press OK to accept the changes. If there are security questions, answer it with YES or NO.
Input value: enter the value of the signal (ml/pulse) which is coming from the flow meter used (see
table). This value is used also for the second flow meter (if any installed).
Sensor Type Input Value
DFM-8S 12.5 ml
DFM-20S 36 ml
DFM-25S 100 ml
Output Value: enter the value of the outgoing pulse (value between 1-9’999 ml/pulse.
Remember: the “Output Value” should not be lower than the “Input Value”.
RL sensor: Is a Return sensor installed? Answer this question according to the measurement method
you do use (difference measurement or direct measurement) Attention: incorrect setting of this para-
meter will result in wrong consumption calculation.
User Reset: Is the user allowed to reset the TRIP? Choose between YES or NO.
AUX: If you answer with YES, the calculating consumption will be send to the auxiliary port (for Fleet
Manager or GPS Tracking Systems)
and the screen of the DFM-BC
will only show the word AUX

Supply Line (Total, TRIP, Current)
Move the bar over the line you would like to change parameters. Press OK. The changeable field will be highlighted for changing. This
action will be followed by security questions. Answer the question with YES or NO until the value will be changed.
Total: Reset of the total amount of the fuel which is passed through the supply line since commissio-
ning. This value must be reset in case the sensor is changed.
TRIP: Reset of the total amount of the fuel which is passed through the supply line since the last
reset.
Current: No function will be activated.
Op. hours: Reset of the total amount of working hours of the supply line sensor since commissioning.
This value must be reset in case the sensor is changed.
Return Line (Total, TRIP, Current)
Move the bar over the line you would like to change parameters. Press OK. The changeable field will be highlighted for changing. This
action will be followed by security questions. Answer the question with YES or NO until the value will be changed.
Total: Reset the total amount of the fuel which is passed through the return line since commissioning.
This value must be reset in case the sensor is changed.
TRIP: Reset the total amount of the fuel which is passed through the return line since the last reset.
Current: No function will be activated.
Op. hours: Reset of the total amount of working hours of the return line sensor since commissioning.
This value must be reset in case the sensor is changed.
Consumption Overview (Total, TRIP, Consumption)
The only thing you can change is the TRIP. Press OK to reset this value.This action will be followed by
security questions. Answer the question with YES or NO until the value will be changed.
The rest is only to show you the calculated difference between the supply line and the return line
Supply Configuration (SL KF, SL app, Qmax)
Move the bar over the line you would like to change parameters. Press OK.The changeable field will be highlighted for changing. Make your
changes and press OK to accept the changes. If there are security questions, answer it with YES or NO.
SL KF: Enter the SL K’F-value (or K’F-value) which you will found on the type plate of the sensor. This
value is to optimize the sensor performance.
SL app: Put in a % value for a possible application correction. For more information go to the section
“High Performance Results”
Qmax: This value shows you how high was the flow rate peak you ever had at the supply line.
No changes are possible.
Return Configuration (SL KF, SL app, Qmax)
Move the bar over the line you would like to change parameters and press OK. The changeable field will be highlighted for changing.
With the arrow and the arrow you can change the selected value
RL cal: Enter the RL K’F-value (or K’F-value) which you will found on the type plate of the sensor. This
value is to optimize the sensor performance.
RL app: Put in a %value for a possible application correction. For more information go to the section
“High Performance Results”
Qmax: This value shows you how high was the flow rate peak you ever had at the return line. No
changes are possible
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DFM

Error Log Entry
Press OK to enter the error log
Read the stored Error Messages (Error Log)
With the arrow and the arrow you can scroll through the messages
Each message has a data and time stamp. After the last message is reached the first message will be
showed.
The messages consist in a short words-explanation about what error has happened
For more information about Error Messages see section Description of the Error Messages
Reset: To reset the Error Log press the OK key. This will lead you to the next 2 security questions.
This two security questions avoid an accidentally deleting of the log
Be aware: after the reset action is done, the error log is empty. No recovery is
possible
Config Log Entry
Press OK to enter the Config log
Read the stored Config Messages (Config Log Entry)
With the arrow and the arrow you can scroll through the messages
Each message has a data and time stamp. After the last message is reached the first message will be
showed.
The messages consist in a short words-explanation about what changes has made
Reset: To reset the Config Log press the OK key. This will lead you to the next 2 security questions.
This two security questions avoid an accidentally deleting of the log
Be aware: after the reset action is done, the error log is empty. No recovery is
possible
Clock
Move the bar over the line you would like to change parameters. Press OK.The changeable field will be highlighted for changing. Make your
changes and press OK to accept the changes. If there are security questions, answer it with YES or NO.
Move the bar over the line you would like to change parameters and press OK. The changeable field
will be highlighted for changing.
With thearrow and the arrow you can change the selected value
With the <OK> key and the <ESC> key you can move from right to left to right.
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Factory data
No changes are possible. The displayed information is needed for updates or internal use.
Error condition
Error Messages
If an error has occurred and it has consequence for the following digital readouts
Total or TRIP or the Consumption
than the Board Computer (DFM-BC) will show the following on the display:
...and after 5 seconds...
The DFM-BC will show an empty display until the correct results are available. There is no need for actions.

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Description of the Error Messages
In any case, if an error occurs look at the Error Log to define what exactly happened and at what time.
To check the installation is also a recommended approach for founding faults.
The following messages will be displayed if an error occurs:
S>0 &R=0
Supply line Sensor has a flow rate. Return line Sensor has no flow rate.
Possible causes:
• Leak on the return line before it enter the sensor.
• Was the connection on the return line unscrewed? Why? Set it tight.
• Check for loose joint of the wires.
• Return Line Sensor defect.
S=0 & R>0
Supply line Sensor has no flow rate. Return line Sensor has a flow rate.
Possible causes:
• Leak on the supply line before it enter the sensor.
• Was the connection on the supply line unscrewed? Why? Set it tight.
• Check for loose joint of the wires
• Supply Line Sensor defect.
S>0 & R>0 & S<R
Supply line Sensor has a flow rate. Return line Sensor has a flow rate. But the Supply line Sensor flow rate is smaller than Return
Line Sensor flow rate.
Possible causes:
• Leak on the supply line before it enter the sensor.
• Was the connection on the supply line unscrewed? Why? Set it tight.
• Check the temperature difference between the 2 lines. Remember: 10 °C of temperature difference mean an volume increase of 0.8 %.
• Check for loose joint of the wires.
• Supply Line Sensor defect.
S<0
Supply line Sensor has no flow rate.
Possible causes:
• Leak on the supply line before it enter the sensor.
• Was the connection on the supply line unscrewed? Why? Set it tight.
• Check for loose joint of the wires.
• Supply Line Sensor defect.
R<0
Return line Sensor has no flow rate.
Possible causes:
• Leak on the return line before it enter the sensor.
• Was the connection on the return line unscrewed? Why? Set it tight.
• Check for loose joint of the wires.
• Return Line Sensor defect.
If you have no success in finding out the reason of the fault, please call your local supplier.

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Higher Performance Results
(with application optimization)
High Performance Results means, to adapt the system to the different condition you can face during your daily work.
This can be:
1.High ambient temperatures.
2.Low ambient temperatures.
3.Different temperatures between supply line and return line of the fuel system.
4. Something else...
To avoid the influence of all the mentioned conditions listed above, the Board Computer get you the unique possibility to optimize your ap-
plication. It is an application optimization because the CONTOIL
®
DFM System it-self works perfect but the condition around it chan-
ges. To take care of this situation you can adjust the calculation according to your experience on the field.
Let’s look at an example:
The temperature of the return line fuel is 10 °C higher than the temperature of the supply line fuel. This temperature difference cause a
volume increase of about 0.8 % on the return line.
Note: all 10 °C the volume of the fuel will increase for approximately 0.8 %.This statement is based on a large experience of the developer
of the CONTOIL
®
DFM.
To compensate this fact, enter on the RL app parameter the value -0.8 %. From now on the calculated flow on the return line will be
-0.8 % reduced. This reduced flow will be used for the consumption calculation. The same you can do with the SL app.
How to enter this parameter?
Go to the section “For Service Peoples … parameter settings” enter the sub-section “Return Configuration” and change the “PL app”
value.
What is to do if it is not functioning?
No Display on the Board Computer (DFM-BC)
1. The Board Computer (DFM-BC) has a sleep mode. Press any key the wake it up. It is ok? If not go to the check list below.
2. Check the following:
a. Has the vehicle battery min. 12 VDC?
b. Power connections from the vehicle battery to the Board Computer (DFM-BC). Do you have min.12 VDC? If not the check the
connection for wire interrupts.
c. Are the wires from the vehicle battery connected to the Board Computer (DFM-BC)
(pin 13 (battery plus) and pin 14 (battery minus) of the connector inside the case)?
d. If the display is still not working, disconnect all wires except the ones from pin 13 (battery plus) and pin 14 (battery minus).
i. It works!
The problem may be by an incorrect connection of the wires from the sensor or from the auxiliary device.
ii. It still did not work!
Contact your local dealer for more information.
The Board Computer (DFM-BC) is running, but no value from the Sensors
1. Check the following:
a. Are the Sensors connected to the Board Computer?
b. Check the voltage on the Board Computer for the Sensors (pin 1 and/or 7). It must be at least 12 VDC.
See also section “Electrical connections and specifications”.
After Installation, an <Error> is displayed.
1. Check the following:
a. Are the DFM Sensor mounted the right way (look for the direction arrows on the sensors).
b. Look at the Error Log and try to found out the solution with the description of the Error Messages