Technical description of the fuel tank sensor "Escort TD-500"

Technical description of the fuel tank sensor "Escort TD-500" Kazan, 2016 1

Table of contents 1. General info..3 2. Technical characteristic.. 3 3. Operating mode. 3 3.1. Mode RS-485 3 3.2. Frequency mode 3 3.3. Analog mode 3 3.4. Periodic mode.3 3.5. Periodic RS-485..4 4. Software settings..4 5. How to configure the sensor.5 5.1. Connection for setting.. 5 5.2. Setting the upper and lower levels 5 5.3. Final setting 6 6. How to install the sensor.7 6.1. Location of the sensor.. 7 6.2. Preparing of the tank to install the sensor. 9 6.3. Preparation of the sensor to a present fuel tank. 9 6.4. Specialty of the connection.. 9 Power connection 10 Connection of the information output.10 Connecting regular level indication and emergency remaining fuel lamp 13 6.5. Collaboration with digital display 13 6.6. Collaboration with the frequency summer..13 7. Calibrating details..13 8. Error codes..14 9. Gauge voltage card 14 2

1. General info. The sensor converts a level in digital code. Depending on the mode of operation sensor translates value trough the interface RS-485, as a frequency or analog signal, as well as a periodic signal. The sensor has an analog signal output for the connection to a petrol sensor and output for indicating emergency remaining fuel. 2. Technical characteristic. 1. Measurement error in the effective range is not more than 1% 2. Resolution of the output 0.1% 3. Measured petrol and diesel 4. Minutes of digital output RS485, 19200 bps 5. Frequency range of the output signal 300... 1323Gts 6. Range of the output voltage 0.1... 4.9 7. Output resistance of the level indicator * 0... 110 Ohm +_ 10% 8. The level of emergency fuel remaining 10% _ +2% 9. Power supply + (10... 36)V 10. Taken current is no more than 30mA 11. Sensor weight is not more than 0.5 kg * Defined by an external resistor 3. Modes of operation. The sensor can operate in one of five modes: 3.1. RS-485 mode. The sensor waits for a request from an external device in this mode. After 2... 3 ms. after receiving the request sends the sensor a response that has information about the level and temperature. Only those requests can be serviced whose network address agree the address recorded in the sensor. 3.2. Frequency mode. The sensor standing generates a frequency similar to the measured level menu in this mode. Zero level has a frequency of 300 Hz. Maximum level conforms to the frequency of 1323 Hz. Incorrect installation maximum frequency can be higher or lower 1323Hz. Frequency begins to form in 60... 90 seconds after power sensor. 3.3. Analog mode. The sensor generates an analog voltage conformed to the measured fuel level in this mode. Zero level has a voltage level of 0.1 V. The maximum voltage level conforms to 4.9 V. By incorrect installed maximum level voltage can be limited at grade of 4.9 V. Analog output voltage begins to form in 60... 90 seconds after power sensor. 3.4. Periodic mode The sensor generates a pulse packet with the frequency of 50 Hz in this mode. The number of pulses in a packet matches the measured level. Zero level conforms to a pack of 2 pulses, the maximum level conforms to a pack of 1025 pulses. One packet forms in 62 seconds. The first pulse packet forms in 60... 90 seconds after power sensor. 3

3.5. Periodic RS-485 The sensor sends a message which has information about the level and temperature without a request from external devices in this mode. Cycle of the sending messages is 2 seconds. 4. Software settings Use to configure the program "Escort sensor tuning 2.6.3". The program window is shown in Figure 1. Figure 1. Settings window o Open port - activates communication sensor port (transmitter USB-RS485) o Close port - closes communication sensor port o Serial number - indicates the serial number of the active sensor. o IP address - activate the necessary sensors, if there are connected several sensors on one line. o Empty - shows the set value of the minimum level. o Full - displays the set value of the maximum level. o Level - the calculated level (0... 4096). o Temperature - the measured temperature. o Frequency - raw value level. o Devices in network - displays a list of network numbers of connected sensors. Modes section The new mode will be installed after you click Install o Mode RS485 - switch for the sensor output to RS-485 mode. o Analog mode - switch for the sensor output to analog mode. o Frequency mode - switch for the sensor output to frequency mode. o Periodic mode - switch for the sensor output to periodic mode. o Periodic RS-485 - switch for the sensor output mode to periodic RS-485 o Indicator inversion presence of the mark inverts output of dial indicator (purple line). This is 4

necessary for the correct operation of the level indicator for cars GAS, etc. o Averaging presence of the mark switches averaging measurements inside with time constant of about 2 minutes. o Range of 4096 - the presence of the mark switches a measuring range of 0 to 4096 units. Without mark the measuring range is from 0 to 1023 units. Control buttons o Set empty - set actual value as minimum. o Set full - the actual value as maximum. o Change net address - set the network number for the active sensor. o Ask net sets up connected sensors and their net numbers. o Set - sets the introduction mode. o Change password - sets the password to change the sensor settings. o Generate - generates an order to change the present settings for following data transmission according controllers "Autograph" means. o Shift - adds the specified offset to previously exposed levels. 5. How to configure the sensor ATTENTION! After the sensor power its output founds in mode RS-485 for 30 sec. This allows you to connect for setting the sensor which founds in a mode other than the mode of RS-485. 5.1. Connecting the sensor to setting Figure 2. Connect your computer, converter USB-RS485, sensor according to figure 2. Run the setup program. Select the port conforming to converter USB-RS485 in the window. You can see it in the device manager of the computer (Figure 2). Note. If the port number is greater than the 9, then open the "Manager devices." Locate the "COM and LPT» ports and transmitter device. Open the properties of the port, and click "Advanced", change the number to the right one. Activate port (Open Port). Switch on the power of sensor. Click "Ask network" - should appear a list of detected sensors. If nothing does appear, try turning off and on the power sensor and start from the preceding paragraph. Select the appropriate sensor in the drop-down list "Network address", then you can see the setting values, in 10... 30 seconds the temperature value and the value of "Current". 5.2. Setting the upper and lower levels. The sensors are supplied with the levels. Levels can be installed if necessary, if the sensor has been sawed off. o Seal the drain hole with harness tape. 5

o Turn the sensor and the fuel fill pipes. Make sure that the pipes are clean from the water and mud. o Turn off averaging. o Wait for 1 minute. To "Current" should not be changed in the 3rd symbol. o Click the "Install Full" - the value of "Current" should appear in the section "Settings" o Drain the fuel and let it to drain for 2 minutes. o Click the "Install empty" - value "Current" should appear in the section "Settings" Note. The value Full should be about twice the value Empty, depending on the length - about the value of Empty = 1200 * (length in cm). When you set the sensor you can move fixed empty and full levels. This is useful by absence or poor access to previously installed sensor. To shift set in the window number to which you want to shift the fixed level, and press Shift. For example: Full till shift is 209060, Full after shift by 100 units is 2109060. 5.3 The final setting. o If necessary install the needful network address. Numbers are set in the range 1... 255.In order to the sensor with a new number was available press Ask net. o Set the needful mode of the sensor output. o If necessary set the measuring range of 4096 (the default of 0 to 1023). o Set Smoothing - in most cases it is useful for exploitation. o Set a password - if there is a need to save the sensor from outside interference. o Check the need to install an inversion. Usually it is wanted for GAS. Set it if necessary. If the sensor does not connect to the indicator - you can not change anything. The program Escort sensor tuning 2.6.3 has a possibility to generate orders for remote change of the configuration of the terminal on the sensor trough the GPS / GLONASS monitoring. Line will be generated in form of SMS orders to the terminal "Autograph" (Figure 4). 6

To generate the order for level shift set the desired shift in the section level shift of. Click Create request and in the pop-up window enter the number of the address of the sensor. Copy the order and send it via SMS to the terminal "Autograph". You can also turn on or off the "averaging". Select or clear mark in the section averaging if it is necessary. Click Create request, the order will appear in the same window. Passing orders to the sensor is only possible in RS-485 mode. Sensor should be connected to the terminal via the RS-485. 6. How to install the sensor. 6.1 Location of the sensor. 1) Install sensor in the center of the tank as shown. It lets the sensor to give correct responses free from the grade of the vehicle. 2) In cases where it is impossible to locate the sensor in the center of the fuel tank install as close to these on (Fig. 5, 6, 7). Figure 5 7

Figure 6 Figure 7 3) The fixing system sizes of the sensor allows you to set it in place over the existing regular "float" and continue using indicator and lamp remaining fuel. This setup is suitable for vehicles that are operated on a highway in the plains. 4) To perfection the registrations and reduce the vibration level it is allowed to install two sensors in a single tank. It is commonly used in tanks with a capacity of more than 600 l and longer than 1500 mm. Sensors can be installed on the center line on the length of third tank and 2/3 tank. Shown in Figure 8, 9 Figure 8 8

Figure 9 6.2 Preparing of the tank to install the sensor 1) Prepare the fuel tank for the installation work in accordance with the requirements of the manufacturer and other standard documentation for safety prevention for the type of work. 2) As a general rule there are barriers in the tanks, because of that first of all drill hole diameter of 3 mm. in the installation place. Make sure that within a radius of 20 mm are no barriers. 3) Drill the opening with diameter 27... 32 mm in the tank. 6.3 Preparation of the sensor to a present fuel tank 1) Measure with the scale the deepness of the tank. 2) On the working length of the sensor L measure the length L1 with the scale even deepness of the tank minus 10-15 mm. Fig.10. Figure 10 3) Cut a length L1 hacksaw sensor so that the interval between the sensor pipes could be free from chip. After that put in and out the sensor till the middle of the pipe in fuel a few times and let it drain every time. After that set the upper and lower levels. Without this you can get what is called silence areas. 6.4 Specialty of the connection The sensors are supplied with a standard cable length of 70 cm. Cable can be stretched with the PVA-wire 4x0, 75, laid in the channel. If you use the output pointer and lamp of emergency 9

remaining fuel, they can be connected directly to a regular wire. But remove the connecter from the sensor and seal it. Wire connections outside the cabin must be securely sealed, excluding contact of copper with water. For example, seal the cable connections, put the thermal shrinkage with the right size and fire it down pressing out excessive sealant. Power connection Connection must be powered in the cabin. It is strongly recommended to switch series the 620 Ohm resistor (Supplied) in rail. This resistor lets except arcing of the power cable on the sensor, if its isolation is defaced. If one power wire connected to two sensors, connect two resistors dual. Data output connection - In RS-485 mode Correctly connect lines A and B If necessary, check the voltage on the lines. On the A line voltage is 1.2 V, on the B line voltage is 1.3 V. WARNING! Do not let the long standing of voltage on the lines A and B. Fig. 11 Connection in the RS-485 mode and by programming. - In the frequency mode Connect according to the diagram shown in Figure 12 and Figure 13 and 14 Fig. 12 Connection Diagram in the frequency mode 10

Attention! For use in hazardous areas it is needful to fix extra protection circuits: Fig. 13 Connection Diagram in frequency mode with a ground failure. 11

Fig. 14 Connection Diagram in the frequency mode with the closure to the positive side. Place the optocouple near the terminal in far from water place. Compare with documents of the terminal and check the behavior of the frequency input of the terminal. Connect the output of the optocouple as a " ground failure " or "the closure of the on +." If the input impedance of the frequency input of the terminal is more than 100 kohm, use the extra load resistor par 10-20 kohm. There is a galvanic separation, so minus of the sensor and the minus of the terminal could not connect each other. For example, - of the sensor is connected to the ground of the car and - of the terminal is connected to - of the accumulator. If necessary, check the voltage on the orange wire of the sensor. In this mode voltage is constant - 2.5 V and is independent of the fuel level. - In analog mode Fig. 15 Connection for the analog mode 12

Supplied filter and optocouple must be fixed in a far from the water place. It is recommended to reduce the effect of interference to connect - cables of the terminal and sensor. If the input impedance of the analog input in terminal is less than 100 kohm, than the maximum output analog voltage from the sensor can be less than 4.9 V. Check with the tester and compare with the level in the tank. - In periodic mode. The diagram and recommendations for connecting similar to connection in the frequency mode. Desirable to check if there is at least 1/3 of fuel in tank. The voltage on the orange wire is 0V. Once a minute for a few seconds the voltage is equal to 2.5 V. Connecting regular level indication and lamp emergency remaining fuel If the TD-500 is used to control the dial pointer: Connect ballast resistance for 110 Ohm 1W (Supplied) between "ground" and the wire pointer for proper operation of the dial pointer. In this time regular sensor should be deactivated. Resistor allows the position of the dial "Full tank". TD-500 resistor being connected in parallel reduces the resistance in accordance with the level of the fuel, thus ensuring the position of the dial from empty to full. For GAS resistace is 280... 300 Ohms. 6.5 Collaboration with digital display Digital display allows you to connect up to 4 sensors simultaneously. It is an intermediate link between the terminal and the sensor. Indicator removes level information from sensors in RS- 485 mode and displays the volume in liters. For level conversion to liters is used calibration table of the indicator. The indicator has a frequency or analog output. For details see the description of the indicator. 6.6 Collaboration with frequency summer Summer allows you to connect 4 sensors, which can be in different tanks. With inbuilt summer calibration table, tanks can be of different sizes and shapes. Sensors and summer connected via RS-485. Frequency output of the summer - 300...2348 Hz. For details see the description of the summer. 7. Features tare The sensor has a linear characteristic. If you use a tank in the shape of the box sometimes can be installed in the calibration table of the software only the upper and lower value (at the discretion of building organization). Installed averaging mode greatly increases the time of the calibration. It must be remembered that at a constant average time of 2 minutes you must wait for 15 minutes between batches of fuel. If it is possible deactivate averaging during calibration using the setup program. If you can not deactivate averaging, you can reduce the time of calibration as follows. After power sensor averaging isn t in operation for the first 2 minutes. Using this property is necessary after pouring each batch of fuel momentarily turn off the power of the sensor. In cars with switchable ground it is rational to do it trough the short cutting off of the ground. Then wait 1.. 2 minutes and fix the get level. 13

8. Error codes The sensor has a built-in self-test system. If there is an error in level measurement which springs from closure or broken measuring pipes, on the output of the sensor will be coded error signal. -In RS-485 mode the closure of the pipes - 6500 units. the break of the measuring pipes 7500 units. -In frequency mode the closure of the pipes - 6500 Hz the break of the measuring pipes - 7500 Hz -In the periodic counter the closure of the pipes - 6500 imp. the break of the measuring pipes - 7500 imp 9. Sensor voltage card Parameters Unit Norm Resistance between ground and the negative cable of the sensor Ohm not more than 10 Power supply red-black wires Volt 12... 24 Supply current from an external source ma 8... 15 AC voltage between the ends of the pipes Volt 0.35... 0.5 The voltage between the black wire and ground Volt not more than 0,1 In RS485 mode Voltage on the line A (orange wire) - ground (black) Volt 1,2 Voltage on the line B (white wire) ground (black) Volt 1,3 In Analog Mode Voltage on the line A (orange wire) - ground (black) Volt 0... 5 Voltage on the line B (white wire) ground (black) Volt 5-Line A Frequency Hz 2000 In frequency mode Voltage on the line A (orange wire) - ground (black) Volt 2,5 Voltage on the line B (white wire) ground (black) Volt 2,5 Frequency Hz 300... 1500 In periodic mode Voltage on the line A (orange wire) - ground (black) Volt 0V; 2,5V once per minute for 5 15 sec Voltage on the line B (white wire) ground (black) Volt 5V; 2,5V once per minute for 5 15 sec 14