Technoton DUT-E A5 User manual

FUELLEVELSENSORS

DUT-E 5

DUT-E 10

DUT-E F

DUT-E 232

DUT-E 485

INSTALLATIONMANUAL

Version 5.0

Version 5.0DUT-EInstallationManual

Content

Introduction.............................................................................................................. 3

1. Maindataandtechnicalcharacteristics..................................................................... 5

1.1Purposeof use.................................................................................................. 5

1.2Exterior viewanddeliveryset............................................................................. 5

1.3Technicalcharacteristics .................................................................................... 6

1.3.1Maincharacteristics..................................................................................... 6

1.3.2Characteristics of output signalforDUT-E 5andDUT-E 10 ........................... 6

1.3.3Characteristics of output signalforDUT-EF.................................................... 6

1.3.4Characteristics of output signalforDUT-E232 andDUT-E485.......................... 7

2.Installationandset-up ........................................................................................... 8

2.1Exterior examinationbeforestartingof works....................................................... 8

2.2Installationontheplaceof astandardfuelsensor................................................. 8

2.3Installationinto aspecialopening ..................................................................... 10

2.4 Cuttingof themeasuringpartforthenecessarytankdepth ................................. 13

2.5Lengthincreasing............................................................................................ 15

2.6Mounting ....................................................................................................... 15

2.7Electricalconnection........................................................................................ 17

2.8Set-upof theanalogorfrequencyDUT-Esensor ................................................ 19

2.9Set-upof thedigitalDUT-Esensor .................................................................... 19

2.10 Connectionof DUT-Etotheindicator of fuellevel.............................................. 20

2.11 Sealing ........................................................................................................ 21

2.12 Measurement precisioncheck ......................................................................... 22

2.12.1 Basic issues............................................................................................ 22

2.12.2 Controlteststeps.................................................................................... 22

3. Diagnosis and troubleshooting............................................................................... 23

3.1Diagnosis andtroubleshootingof analogDUT-E .................................................. 23

3.2Diagnosis andtroubleshootingof frequencyDUT-E.............................................. 24

3.3Diagnosis andtroubleshootingof digitalDUT-E................................................... 24

Appendix1. Actof thevehicleinspection.................................................................... 26

Appendix2. Tankcalibration..................................................................................... 27

Appendix3. Check-out testprotocol .......................................................................... 29

Appendix4. DUT-Efactorysettings............................................................................ 30

Version 5.0DUT-EInstallationManual

Introduction

Recommendationsandregulations given inthe installationmanual are referredto fuel level

sensorsDUT-E (hereinafter DUT-E),developedbyJV Technoton CJSC,Minsk,Belarus. This

document definestheprocedureforinstallationandconnectionof DUT-E,aswell as

providesguidance/recommendations ontheoperation.

DUT-E are used foraccurate measurement ofliquidfuellevelinthevehicle tanksand in

fixed/immovabletanks.

DUT-Ecanbeusedasa standardsensorofthefuel-levelindicator,aswellas apartof the

fuelconsumptioncontrolandvehiclemonitoring systems.

Distinctivefeaturesof DUT-E:

−deliveryset includesallnecessaryitemsforthe properinstallation and

connection, incl. mountingplate, connectingcable, rubbergaskets, screws andseals;

−supply voltage range is from 10 to 50 V;

−possibility toreduce the length upto 30% without calibration*;

−possibility toincrease thelength byusing the additionalsectionsofDUT-E;

−thermo-correction with adjustable coefficient allows tomake automatic updating of

measurements basedontheambient temperature **;

−easy bayonetfastening allows youto installandremovethesensorwithout any tools;

−bottomspringstop serves to give extra stiffness for sensormounting;

−openingsforsealing will help to prevent theunauthorized demounting or operating

troubles of DUT-E;

−self-diagnostic check of DUT-Eallows to controlthe sensor operation.**

*DUT-EA5, DUT-EA10, DUT-EF

** DUT-E 232, DUT-E 485

Themanualisfor the professional users whoarefamiliarwith therules for repairand

installation works onvehicles and whohave professionalknowledgeinthefieldof electrical

andelectronicequipment of various transport vehicles. Toensuretheproper functioningof

theDUT-E, itsinstallationand set-up shouldbecarriedout bycertifiedprofessionalstrained

by the manufacturer.

Version 5.0DUT-EInstallationManual

DUT-Ecanbeusedin moderate andcoldclimates.

As for the mechanical stability sensors arevibration-shockproofandvibration-crashworthy.

Marking of sensors is formedasfollows:

Fuellevelsensor DUT-E ХL=Y

To setup DUT-E232 andDUT-E485,Service kitSKDUT-Eis applied. (shouldbepurchased

separately).

Typeofsensor output signal:

5 – analogsignal, voltageupto 4.5V;

10 – analogsignal, voltageupto 9V;

F – frequencysignal, frequency upto

1500Hz;

232 – digitalsignal, interface RS-232;

485 – digitalsignal, interface RS-485.

Nominal length of themeasuring

part (inmm):

- analog: 180, 250, 350, 500,

700, 1000, 1400,2000;

- frequency: 180, 250, 350, 500,

700, 1000, 1400;

- digital: 700, 1000, 1400.

Commercialname

Version 5.0DUT-EInstallationManual

1. Maindata andtechnicalcharacteristics

1.1 Purposeof use

FuellevelsensorDUT-Eisdesignedtomeasure thelevelof liquidfuel andother non-

electroconductive liquidsintanks of mobile vehicles and fixed/immovable tanks.

1.2 Exterior viewanddeliveryset

DUT-E deliverysetincludes:

a) sensorDUT-Einset – 1 pce;

b) thebottomstop(forthesensorswith ameasuringpartlengthof 500 mm or more) –

1pce;

c) signalcable7m - 1 pce;

d) mountingplastic plate - 1pce;

e) rubbergasketforthemountingplate - 2pcs;

f) sealingO-ringplate - 2pcs;

g) self-drillingscrew - 5pcs;

h) screwM5x16 - 5 pcs;

i) seal - 2pcs;

j) sealingcord - 2 pcs;

k) specification - 1pce.

Fig.1. Delivery setof DUT-E

f i

Version 5.0DUT-EInstallationManual

1.3 Technical characteristics

Power supply of DUT-E is carried out via on-boardvehiclepower system, onwhichitis

installed.

1.3.1 Main characteristics

Table 1. DUT-E maincharacteristics

Therelativemeasurement inaccuracy (tothelength of

themeasuring part),% ±1

Supplyvoltagerange,V

10 - 50

Current

consumption

, mA

≤50 at 12 V

≤25 at 24 V

Protection from pulseinterferences, V

100

Readiness

timeafterpower

up,

≤10

Temperaturerange, °C

-40 …+85

Protection

levelof housing

IP54

1.3.2 Characteristics of outputsignal for DUT-E 5 and DUT-E 10

Thevoltage valueof the DUT-Eoutput signal hasalineardependence onthemeasuredfuel

level inthetank.

Theoutput signaldoesn’tdependon supplyvoltage.

Table2. Characteristicsof output signalfor DUT-E A5 and DUT-E A10

Voltage, V

Nominallength Aftercutting by 30%

DUT-EA5 Emptytank 1.5 0.65

Fulltank 4.5 2.65

DUT-EA10 Emptytank 2.5 0.65

Fulltank 9.0 5.30

1.3.3 Characteristics of outputsignal for DUT-E F

The frequency valueof the DUT-Eoutput signal hasalineardependence onthemeasured

fuel level inthetank.

Theoutput signaldoesn’tdependon supplyvoltage.

Output cascade – opencollector with loadresistor 10 kOhm.

Table3.Characteristicsofoutput signalfor DUT-EF

Frequency, Hz

Nominallength Aftercutting by 30%

Emptytank 500 270

Fulltank 1500 970

Version 5.0DUT-EInstallationManual

1.3.4 Characteristics of outputsignal for DUT-E 232 and DUT-E 485

Characteristicsof output signalof DUT-E232 andDUT-E485 correspond tothespecification

of interfacesof RS-232 andRS-485 accordingly.

Factory interface settings: 19200 bit/s, 8bit, 1stopbit.

Otherfactorysettings aregiveninAppendix4of this manual.

Speedof data exchange via digitalinterfacecanbechosenfrom thefollowing values:4800,

9600, 19200 bit/s.

Theresults of DUT-E measurements canbetransferred via digitalinterface as:

a) standardunits, from0to 1000 (0-emptytank,1000 - fulltank);

b) fuellevelinthetank, mm;

c) fuelvolume, l;

d) fuelvolumeinrelationto thefulltank, %.

Besidesthe remaining fuel amount in the tank,DUT-Epassesinformationabout current

temperature(measuredbythesensorlocatedon the electronic board).

Information transfer is carriedout accordingto DUT-ECOMprotocol.

Version 5.0DUT-EInstallationManual

2. Installationand set-up

This chapter provides basic recommendations for the DUT-E installation.

Beforeyou start,youshouldmake external check of thevehicle for any possible failures

andmakeInspectionActof thevehicle (seeAppendix 1)

2.1 Exterior examination before startingof works

Beforeyou start,youshouldmake external check of DUT-Efor any possibledefectsthat

occurredduringtransportation, storageorcarelesshandling:

a) visible damage ofthehousing,measuringpart,mountingplate,rubber gaskets,signal

cableorconnector;

b) tubeplay of themeasuringpart in relation to eachotherand/or to the housing.

By discoveringanydefects, please,contact theproduct supplier.

DUT-Ecanbeinstalled as intotheopeningof the standardfuelsensor* as intoa special

opening inthetank.

*Studycarefullytheschemeof the mountingopeningsforthestandardfuelsensorand

comparewiththeDUT-Einstallationscheme(SeeFigure 9).

ATTENTION! By installingthesensor youshouldfollow safetyrules of the repairworks on

automotive vehicles aswell as safetyrequirements prescribedbytheenterprise.

2.2 Installation on theplaceofa standard fuel sensor

ATTENTION! It is not recommended toinstallthe DUT-E on the place of a standard fuel

sensor because ofitsfarlocation from the geometric center of the tank, and as a result,

inaccuracy in the fuel levelmeasurement may occur. Thereasonforthatissignal

fluctuationof DUT-E thathappens becauseof fuelflowinginsidethetank.

BeforetheDUT- Einstallationit isnecessaryto remove the standard fuelsensorandclean

the installationplace (seeFigure 2)

Version 5.0DUT-EInstallationManual

Fig.2. Standardfuelsensorremoval

Aligntheholesof themountingplateandrubber gasketwith theholesinthetank,thenfix

withthe screws thatcometogether with theDUT-E set (seeFigure 3).Screwheadsmustbe

deeplyput into themountingplate.

Fig.3. Mounting plateontheplaceof astandardfuelsensor

Installationof the DUT-E sensor inthemountingplateis given in chapter 2.6of this

manual.

Version 5.0DUT-EInstallationManual

2.3 Installation into a specialopening

ATTENTION! Beforedrilling the holesinthetank youshould dismantleit, evaporate oradd

water.

ATTENTION! Beforeyoustartdrillingthehole,please,makesurethatthere are no

partitions insidethetankundertheselectedlocation, whatcanpreventDUT-Einstallation.

Installationsteps:

a) Identify the place where it is supposed to install the sensor. Itisrecommendedtochoose

aplaceinthegeometriccenter ofthetankasit will reducetheerror of fuelvolume

measurement byits vibration duringthemovement;

Fig.4. Recommendedplacefor DUT-E installation

DUT

Regular/stand

ardfuellevelsensor

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