RUPTELA FLS Pro User manual

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Fuel Level Sensor
FLS Pro
FLS Eco
QUICK
START GUIDE

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Table of contents
Device overview ............................................................................................................................3
Preparation...................................................................................................................................4
Assembly and configuration............................................................................................................5
Installation ...................................................................................................................................9
Further reading ........................................................................................................................... 13
Legal information ........................................................................................................................ 13
Appendix A: Required tools ..........................................................................................................14
Appendix B: Connection schematic................................................................................................ 15
Notes .........................................................................................................................................16

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Make sure that you have:
•Computer with Windows 7/8/10
•FM device with a predownloaded configurator pack
•USB A to USB mini cable
•The required tools (see Appendix A)
Device overview
Probe
12 Measurement head
Signal cable
Device pinout (FLS Pro)
Wire color
Description
Red
Power supply (10 –32 V DC)
Black
Ground connection
Orange
RS-232 RX
Pink
RS-232 TX
Grey/Red
RS-485 A
Yellow
RS-485 B
Grey/White
Voltage output
Device pinout (FLS Eco)
Wire color
Description
Red
Power supply (10 –32 V DC)
Black
Ground connection
Orange
RS-232 RX
Pink
RS-232 TX
Grey/White
Voltage output

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Preparation
Go to the FLS section in doc.ruptela.lt. (1)
Download the FLS configurator. (2)
Download and install the RS232 drivers. (3)
Connect the FM device to your computer using a
USB cable.
Start the FM device configurator.
Select the port you connected your FM device to.
Click Connect in the configurator.
Click Options in IO events.
In Interfaces, tick the interface you will connect
the FLS to (PortA is recommended).
Select DFS RS232 from the drop-down list.
Enable the v1.1 protocol on the top right side of
IO settings.
Click the Enable IO button.
Enable the Digital Fuel Sensor parameter in the
Configured IO window.
Click the Save button.
Click Send CFG to upload the config to the FM
device.

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Assembly and configuration
Drill a hole in the center of the tank.
Use a 38 mm hole saw arbor.
Insert a gasket into the measurement head.
Screw in the flange.
Insert the assembled probe into the fuel tank.
Measure the distance from the flange to the fuel
tank (MD).
Add an additional 4.5 cm to get the cutting
distance (CD).
Drill
Insert
Screw
MD
CD = MD + 4.5 cm

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Mark the cutting distance on the probe.
Cut the probe at the marked length, using a wire
cutting tool.
Do not cut the chord!
Polish the probe edges with a file.
Insert the cap onto the end of the probe.
Pull on the chord while pressing on the cap.
Make sure the chord is tense.
Tie the chord around the cap.
Tap on the probe with a finger.
If you feel a vibration, it means the chord is tense
and tied correctly.
Cut probe
File
Pull
Press

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Cut the remaining chord as close to the cap as
possible.
Insert the cap end onto the cap.
Put the measurement head on the probe.
Insert the probe into the tank and orientate the
signal cable towards where it will be going out.
Note the position of the signal cable on the flange.
Make a marking 45 degrees counter-clockwise
from the cable.
Route the 7 m extension cable to the cabin.
Connect the cable to the power supply and to the
FM device (see Appendix B).
Insert
Cut
Cable direction
45°
Mark position
Mark stripe on flange
Route 7 m cable

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Connect the measurement head to your
computer.
Use an external power supply to power the
measurement head.
Open the FLS configurator.
Select your FLS type. (1)
Select the COM port. (2)
Click Connect. (3)
Check FLS connection status (should be Connected). (1)
Set Output data width to 12 bit . (2)
Before starting installation, set Data averaging to 8 samples. (3)
Click Send CFG to upload the config to the FLS. (4)
Connect
External power supply (10-32 V DC)

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Installation
Fill a vessel with enough fuel to submerge the probe in.
Submerge the probe fully into the vessel.
Take out the probe, holding the FLS as shown in the picture below.
Let fuel drip out for 15 seconds.
Go to the Calibration section. (1)
Go to the Dry calibration section. (2)
While holding the probe, click the Calibrate button. (3)
Make sure the probe is not touching anything!
Once calibration is complete, the sensor can be installed.
Hold for 15 s

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Remove the measurement head.
Add a thin layer of silicone on both sides of the flange gasket.
Insert the flange gasket onto the flange.
Insert the probe into the tank.
Position the flange according to the previously
made markings.
Screw in the flange bolts using a cordless drill.
Finish screwing in the bolts by hand to avoid
screwing the bolts too much.
Run a security seal wire through the small holes
on the flange.
Screw in
Marked position
Cable direction
Add silicone
Add silicone
Insert

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Perform fuel tank calibration, starting with an empty tank.
Go to the Real time data section. (1)
Check the N value of the sensor (should be less than 50), assign it to 0 liters. (2)
Add a known amount of fuel and check the N value again.
For accurate results, add fuel 10-20 times.
The maximum N value should be around 3600.
Enter the calibration table into your tracking software.
Example:
N Liters
17 0
49 50
154 100
251 150
507 200
752 250
981 300
1011 350

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Fill the fuel tank completely.
Before finishing installation, set Data averaging to 64 samples. (1)
Click Send CFG to upload the config to the FLS. (2)
Disconnect the measurement head from the computer. (3)
Twist the measurement head onto the probe.
Do not use force on the cable when tightening the
head.
Make a loop around the signal cable with the seal
wire.
Run the seal wire through the holes on the seal
and tighten the seal.
Twist
Seal

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Guide a security seal wire through an opening on the cable connector.
Make several loops around the signal cable connector with the seal.
Guide the seal wire through the holes on the seal and tighten the seal.
Connect the FLS to the 7 m extension cable (see Appendix B).
Turn on the ignition.
Check that the required data is received before finishing the installation.
Further reading
•Documentation website: http://doc.ruptela.com
•Datasheet: https://doc.ruptela.lt/pages/viewpage.action?pageId=1442787
•User manual: https://doc.ruptela.lt/pages/viewpage.action?pageId=1442787
•RS232 converter drivers: https://doc.ruptela.lt/display/AB/Drivers+for+the+RS232-USB+Converter
•FLS configurator tool: https://doc.ruptela.lt/pages/viewpage.action?pageId=1442785
We highly recommend you read the user manual before using the device.
Legal information
Copyright © 2019 Ruptela. All rights reserved. Reproduction, transfer, distribution or storage of parts or all of the
contents in this document in any form without the prior written permission of Ruptela is prohibited. Other products
and company names mentioned in this document are trademarks or trade names of their respective owners.
Seal

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Appendix A: Required tools
Make sure that you have the following tools BEFORE starting the installation:
1. Measuring tape
2. Sealant with pistol (i.e. Makroflex SX101 sanitary silicone from Henkel Makroflex AS or equivalent)
3. Plastic straps (290 x 3.5 mm, might vary in size)
4. 1 A fuse
5. 7 mm hexagon drill head. It must fit into the cordless drill!
Example:
6. Cordless drill (recommended at least 40 Nm torque). Check if the hole saw arbor (12) fits it!
7. File tool
8. Pipe cutting tool. Mandatory for FLS installation! Example: Rothenberger tube cutter 35 or similar, that
allows cutting a 22 mm aluminum tube.
9. RS232-USB converter cable
10. FLS to RS232 cable
11. Wire cutting pliers
12. 38 mm hole saw and hole saw arbor. It must fit the cordless drill! Mandatory for FLS installation!
13. External power supply (not in photo)
14. Fuel pump and vessel to drain fuel for calibration (not in photo)

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Appendix B: Connection schematic
•Power input: 12/24 V DC
•Recommended fuse: 1 A

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Notes