Omnicomm LLS 5 User manual

Omnicomm LLS 5 Fuel Level
Sensor
User Manual
02.10.2020

Contents
General information
3
Technical Specifications
4
Preparation
6
Fuel Tank Preparation
6
Sensor Preparation
8
Setting
9
“Full/Empty” Calibration
11
Omnicomm LLS 5 Sensor Setting
12
Installation and Connection
13
Calibration
15
Sealing
18
Recommendations for the Assembly of the Fuel Sensors from 3 to 6 meters in
length
20
Fuel Level Sensor Installation Recommendations for Cylindrical Fuel Tanks
21
Appendix. List of equipment for Omnicomm LLS fuel level sensors installation
24

Omnicomm LLS 5 Fuel Level Sensor
General information
This User Manual is designed for Omnicomm LLS 5 fuel level sensors.
Omnicomm LLS 5 is a fuel level sensor with RS-232 and RS-485 interfaces.
While carrying out installation, observe the safety rules and regulatory requirements for
this type of work.
Minimum allowable length of the measuring probe is 150 mm.
3
General information

Technical Specifications
Parameters Value
Measurement range, mm 0…700, 1000, 1500, 2000, 2500, 3000
REF-channel length, mm
- for sensors of 700, 1000 mm length
- for sensors longer than 1500 mm
200
700
Limit of the allowed basic level
measurement error, %
± 0,5 (when working with fuel for which the
calibration was carried out or after filling the tank to
the full when changing the type of fuel)
Output interface for measured values RS-232, RS-485
Programmable interface transmission
rate, bit/s
1200, 2400, 4800, 7200, 9600, 14 400, 19 200, 38 400,
57 600, 115 200
Power supply voltage, V 7 – 75
Power consumption, W 0,4
Current consumption, mA 40
Electric strength of galvanic isolation,
not less than, V
1500
Working temperature range, °С From -40 to +80
Relative humidity at 25 °C (without
moisture condensation), %
From 5 to 95
4
Technical Specifications

Atmospheric pressure, kPa From 84 to 107
Maximum relative humidity at 25 °С
(without moisture condensation), %
100
Ingress protection rating IP69k
Operating mode Continuous
Internal filter size From 0 to 30
Measurement time period, s 1
Overall dimensions, mm 87.3 x 83.5 x (21 + length of the measuring probe)
Weight, kg Not more than 2
Average service life, years 8
Digital reading range corresponding to
the maximum value of the measured
level
1…4095
Digital reading range corresponding to
the minimum value of the measured
level
0…1023
Temperature measuring range, °C From -40 to +80
Absolute temperature measurement
error throughout the whole range of
working temperature, °C
± 5
Parameters Value
5
Technical Specifications

Preparation
Fuel Tank Preparation
1. Select the location for Omnicomm LLS sensor installation, taking into account the
following requirements:
The installation location should be as close to the geometric center as possible and be
placed at the deepest level of the tank:
When installed, the sensor should not be in contact with reinforcement ribs and
existing equipment inside the tank
Installing two sensors in one fuel tank allows to significantly reduce the influence of
the vehicle inclination angle on the fuel level:
2. Steam out the tank to comply with safety regulations
3. Drill out the central bore using a bimetal hole saw ø35 mm
4. Drill out four mounting holes according to the diagram:
6
Preparation

The mounting hole diameter depends on the material of the tank:
ø 4 mm – for metal tanks with wall thickness over 3 mm (cut M5 thread)
ø 7 mm – for plastic and metal tanks with wall thickness up to 3 mm (for rivets)
ø 4 mm – for plastic tanks with wall thickness over 3 mm
7
Preparation

Sensor Preparation
1. Cut the sensor measuring part according to the following recommendations:
The length of the sensor measuring probe should be 20mm less than the depth of the
tank.
The REF channel must be at least 100 mm shorter that the measuring part of the
sensor. If the difference is less than 100 mm, trim the REF channel according to the
figure:
2. Install the central partition into the sensor measuring part at the depth of 1 cm.
Cut the REF channel (only if the length of the REF channel and the measuring part is
less than 100 mm):
1. Install the central partition in the REF channel in close proximity to the cut point.
2. Cut with a cutting wheel (max. 125 mm in diameter)
3. Remove a section of the REF channel rod
The REF channel rod is shorter than the main measuring rod and is located on the right
when looking at the sensor body on the connector side.
8
Preparation

Setting
Firmware update is only done via RS-485 interface connection.
Connect the sensor to a PC.
Connect the Omnicomm LLS 5 sensors according to the diagram:
Run the Omnicomm Configurator program on your PC.
9
Setting

Omnicomm Configurator (PC):
The fuel level value is displayed without filtering.
10
Setting

“Full/Empty” Calibration
1. Fill the measuring container with fuel
2. Immerse the Omnicomm LLS sensor in the fuel to the full length of the measuring
piece
3. Wait for the green indicator “Stabilized” to appear.
Press the button “Full” to record the value corresponding to a full tank
4. Remove the Omnicomm LLS sensor from the container and allow the fuel to drain
from the measuring probe for 1 minute. Press the button “Empty” to record the value
corresponding to an empty tank
5. Press the “Write to Device” button
11
Setting

Omnicomm LLS 5 Sensor Setting
“Automatic ajustment” - turn on for automatic adjustment of measurements in case of a
change in the permittivity of the fuel. Upon activation of auto-tuning, changes of level
caused by thermal expansion of fuel will be displayed, i.e. the level will be shown
considering the current temperature. The setting is only available after sensor calibration.
To adjust automatically Omnicomm LLS 5 sensor calibration values, full fuelling of the
tank is required when operating the vehicle. When the tank is to be fully fueled, the max
length of the measuring part that is not emerged into the fuel shall not exceed 10 cm
from the sensor's flange. When operaеing a vehicle with insufficient fuel level in the tank,
auto-tuning cannot be performed.
“Network address” (1 to 254) – set the network address for the Omnicomm LLS fuel level
sensor. When several sensors are connected to one external device, they should have
unique network addresses.
“Min Level” (0 to 4095) – select the minimum reading for the LLS fuel level sensor.
Default value – 0.
“Max Level” (1 to 4095) – select the maximum reading for the LLS fuel level sensor.
Default value – 4095.
“Filtering” – set the output signal filtration parameters as follows:
“None”– no filtration is performed. This option is used when the filtration is carried out
by an external device.
“Minimum”– this filtration is used in stationary fuel storages and non-mobile
machinery
“Medium”– this filtration is used when the vehicle operates under normal conditions
“Maximum”– this filtration is used when the vehicle operates in severe conditions
“Baud rate” – select the rate of data exchange with external devices. Default value –
19,200 bit/s.
“Automatic data output” – select:
“Off” – no automatic data output (without request) is performed
“On” – automatic binary data output
12
Setting

“Data output interval” (1 to 255 seconds) – set the automatic data output interval
The automatic data output mode may be used with no more than one Omnicomm LLS 5
sensor connected to one interface.
“Heavy exploitation conditions” - turn on for additional filtering of measurement
values that takes into account severe operating conditions.
“Parameters initialization” - displays the correctness of calibration results. Options:
“Yes” - the calibration results are correct
“No” - a recalibration of the sensor is required
Installation and Connection
When installing the fuel level sensor onto the plastic fuel tank it is important to provide a
secure electrical connection between the sensor's body and the frame of the vehicle. If
this condition isn't met, it can lead to sensor malfunction caused by static electricity.
For installation onto cylindrical fuel tanks with the diameter 420...710 mm follow the
instructions in the section Fuel level sensor installation recommendations for cylindrical
fuel tanks.
1. Put the mounting point gasket (included in the kit) on the measuring probe of the
Omnicomm LLS sensor
2. Put the Omnicomm LLS sensor into the tank and secure it:
when securing with rivets, use a riveter
when securing with bolts, first put a seal (one on each bolt), a spacer and a spring
washer
when securing onto a plastic tank with wall thickness of more than 3 mm, use the self-
tapping screws and a seal (one on each self-tapping screw), included in the kit
3. Connect the Omnicomm LLS sensors to an external device as shown in the diagram:
13
Installation and Connection

Functions of the mounting cable wires
Name of signal Wire Color
RS-485 A Orange-white
RS-485 B White-blue
RS-232 Tx Pink
RS-232 Rx Gray
+V Power Brown
Ground White
4. Connect the fuse holder to the LLS sensor power cable (brown wire) in close vicinity to
the vehicle power supply circuit
14
Installation and Connection

5. Install the fuse in the fuse holder
6. If necessary, seal the bolt (self-tapping screw) and the connection. Multiple
Omnicomm LLS 5 sensors must be connected side-by-side via the RS-485 interface.
Calibration
Calibration of the fuel tank is necessary to verify the conformity of the digital code issued
by the Omnicomm LLS 5 sensor to the fuel volume in a particular fuel tank.
Calibration of the fuel tank is performed by refueling up the tank – from empty to full,
with a certain refueling interval, and recording the Omnicomm LLS 5 sensor readings in
the cali-bration table.
A container may be calibrated by draining.
The calibration of a container with multiple Omnicomm LLS 5 sensors is performed simi-
larly to the calibration with one sensor. Before the calibration process, add the necessary
quantity of sensors and specify the network addresses.
The calibration is performed for all sensors simultaneously. Connecting multiple sen-sors
to a PC using a KTZ splitter.
Calibration of the tank with one Omnicomm LLS 5 sensor:
1. Empty the fuel tank
2. Connect the sensor to a PC according to the diagram in the Setting section
3. Run the Omnicomm Configurator program. Select “Calibration”.
Omnicomm Configurator (PC):
15
Calibration

If the sensor reading column is not displayed, press the “Add sensor” button. Select the
type of sensor. Specify the network address set for the sensor during the setup.
16
Calibration

4. Set the flow interval in liters
If the tank has irregular shape, and/or there are wider or narrower parts, it is
recommended to perform calibration on such tanks with higher amounts of calibration
steps to improve accuracy.
5. Press the “Start/continue calibration” button
6. Fill with an amount of fuel equal to the flow interval
7. Press “Add line”
The “Liters” column will display the refueling volume equal to the predefined flow
interval.
The “Sensor” column will display the value equal to the refueling volume.
8. Press “Add line”
9. Repeat items 6, 7 and 8 according to the number of control points. Minimum
recommended number of control points: 20
10. Press the “Finish calibration” button
11. Save the calibration table in a calibration file (.ctb), Omnicomm Online (.xml) file, in
the Terminal or in the Indicator, by pressing the “Export” button
When performing the calibration table export to the Omnicomm Online (.xml) file, the
“Export” window will open. Specify the Omnicomm LLS sensor number to display in
Omnicomm Online.
17
Calibration

Sealing
For Omnicomm LLS sensors, the sensor housing is sealed with a casing-seal and a
connector:
1. Install the casing-seal on the sensor housing
2. Place the pins in the grooves of the casing-seals, making sure that they are positioned
with the smaller diameter towards the jut of the casing, and push them all the way in
Once the pins are in place, the sensor cannot be removed without destroying the casing
of the seal.
Install the seal-tie on Omnicomm LLS 5 connector:
18
Sealing

1. Join Omnicomm LLS 5 connector to the mounting cable until it clicks
2. Run the flexible part of the seal through the connectors
3. Run the flexible part of the seal through the hole in the seal body
4. Tighten up the connection
5. Cut off the protruding section of the flexible part of the seal
Additional casing-seals can be purchased separately.
19
Sealing

Recommendations for the Assembly of the
Fuel Sensors from 3 to 6 meters in length
1. Take the fuel level sensor and the extension of the measuring part from the package
2. Determine the appropriate length of the fuel and cut the excess of the measuring part
The measuring probe extension must be cut only from the threadless side.
3. Connect them by screwing completely the central rod of the fuel sensor and the
extension of the measuring part
4. Move the profile (tube) of the extension of the measuring part until it is levels with the
profile of the sensor
20
Recommendations for the Assembly of the Fuel Sensors from 3 to 6 meters in length