Fuel level sensor STRELA

Transcription

1 Fuel level sensor STRELA CALIBRATION MANUAL For analog and frequency sensors САМФ РК (version 1.02) Chelyabinsk 2012 Page 1 of 12

2 Contents Introduction...3 Calibration through the universal service unit...5 Calibration through the specialized calibration module...9 Isolating plug...11 Page 2 of 12

3 Introduction New fuel level sensors (FLS) Strela A and Strela F produced since September, 2011, may be cut to any length (up to 150 mm). These FLSs are supplied only with an isolating plug at the end face of tubes. If you use sensors without a plug it can lead to its failure through the loosening of tubes in operation. FLS produced before September, 2011 FLS Strela A Previously analog sensors could be cut up to 30% and had the following working range: Strela AО (analog cuttable) 0-10 (10-Volt) Strela АО(analog cuttable) 0-7 (7- Volt) Strela АО(analog cuttable) 1-7 (7- Volt) Strela АО (analog cuttable) 0-5 (5- Volt) (2,03 10) V (1,42 7) V (2,22 7) V (1,31 4,5) V At cutting the range was shifted down (the more we cut up from the sensor the more the range was shifted) up to 0 Volt for an empty tank. Thus the working range of the sensor was decreased. FLS Strela F Previously frequency sensors were manufactured in 2 versions - cutable for 30 % (frequency cuttable) and 50 % (frequency cuttable short) from the sensor length. Strela F (ЧО) (frequency cuttable) 702 Hz (empty tank) ( ) Hz (full tank) Strela F (ЧОК) (frequency cuttable short) 797 Hz (empty tank) ( ) Hz (full tank) When cutting the range was shifted down (the more we cut up from the sensor the more the range was shifted) up to 500 Hz - ( ) Hz. Thus the working range of the sensor was decreased. FLS produced since September, 2011 FLS Strela A New fuel level sensors Strela A as well as previous sensors have the same initial voltage range from 1.42 to 10 volt, depending on the sensor version. LESS THAN 30% CUTTING If you cut less than 30 % of sensor length recalibration of the sensor is not required, that is you may use the sensor as before. Thus the working voltage will be above 0 volt but maximal value of the working range will be be proportionally less from the initial one (it will depend on the cut length). If you recalibrate the sensor you will extend the working range to the initial values 1.42V to 10 V (depending on the sensor version). MORE THAN 30% CUTTING If you cut more than 30 % from the sensor the range is shifted down even more. To restore the initial working range from 1.42 to 10V volt (depending on the sensor version) you need to recalibrate the sensor with the calibration module. Page 3 of 12

4 FLS Strela F New fuel level sensors Strela F as well as previous sensors of version FLS frequency cuttable short, have the same initial frequency range from 797 Hz to ( ) Hz. LESS THAN 50% CUTTING If you cut less than 50 % of the sensor recalibration is not required, that is you may use the sensor as before. The working frequencies will be in a range from ( ) to ( ) Hz. If you recalibrate the sensor you will extend the working range to its best from 500 Hz to ( ) Hz that also a norm. MORE THAN 50% CUTTING If you cut more than 50 % from the sensor the range is shifted down even more. To extand the working to its best from 500 Hz to ( ) you need to recalibrate the sensor with the calibration module. Options of fuel level sensor calibration: - Calibration through the specialized calibration module; - Calibration through the universal service unit and specialized cable. Page 4 of 12

5 Calibration through the universal service unit You will need the following tools: Universal service unit (USU) (see fig. 1) ( Specialized cable to connect FLS Strela A and F (see fig. 2); PC (labtop) with installed drivers for USU; DUT Calibrator program. Fig. 1. Universal service unit. Calibration gauge Fig. 2. Specialized cable for FLS A and F connection. You can make the specialized cable yourself. Wire map is shown in fig.3. Page 5 of 12

6 Fig. 3. Wire map of specialized cable for universal service unit. Fig. 4. Socket RJ-45. Calibration procedure Make sure that the sensor model supports calibration (consult your dealer for the information). If the fuel level sensor was immersed into fuel let the fuel rests flow down for at least 20 minutes so that it becomes dry. 1. Cut the sensor to the required length. 2. Insert the isolating plug into the face end of the tubes. Page 6 of 12

7 3. Connect the sensor to PC according to the figure Switch the relay of USU to work with FLS Strela A/F. Fig. 5. Connection diagram of the sensor to PC, where 1 - FLS Strela A (F); 2 - Specialized cable for FLS Strela A and F connection; 3 - USU; 4 - USB-cable; 5 PC 6 Calibration gauge of the cable. 5. Set up the driver ( 6. Start the program DUT Calibrator on your PC. 7. Press Connect in the program DUT Calibrator. Page 7 of 12

8 Fig. 6. Connection diagram of fuel level sensor to PC. 8. Select the sensor type: frequency or analog. 9. Take out the plug from the face end of the tubes. 10. Connect the gauge to sensor center electrode. Attention, do not touch the electrode with fingers! 11. Press Calibration. Fig. 7. Connection of gauge to sensor center electrode. 12. Wait for program message Disconnect the gauge from the center electrode. 13. Disconnect the gauge from the center electrode and wait for program message calibration is done. 14. Insert the isolating plug into the face end of the tubes. 15. The calibration is done. If the mistakes arise during the calibration process please retry the process. Calibration results: For analog sensor: The output voltage of the dry sensor is 1,42 Volt and the frequency of the sensor completely immersed into fuel is close to maximum value for this type of sensor. For frequency sensor: The frequency of the dry sensor is 500 Hz and the frequency of the sensor completely immersed into fuel is about 1500 Hz. Page 8 of 12

9 Calibration through the specialized calibration module To calibrate a sensor a calibrator module is required only. No laptop is required. The calibration module has a plastic body. It has two sockets for its connection in the chain splitting Terminal - FLS. It also has a long wire (further the gauge) for connection to the center electrode of the calibrated sensor. There are three light-emitting diodes of different colors on the calibration module body: red, yellow and green. They signal about an operating mode of the calibration module. Fig. 8. Calibration module. You need to choose the calibration module type A for FLS Strela A. There is a RED mark at the end of the body. Calibration module type A restores the working range of the analog sensors: Strela AО (analog cuttable) 0-10 (10- Volt) (0 10) V Strela АО (analog cuttable) 0-7 (7-Volt) (0 7) V Strela АО (analog cuttable) 1-7 (7- Volt) this sensor type cannot be restored Strela АО (analog cuttable) 0-5 (5- Volt) (0 4,5) V You need to choose the calibration module type F for FLS Strela F. There is a BLUE mark at the end of the body. Page 9 of 12

10 Calibration module type F restores the working range of the frequency sensors from 500 Hz (sensor not in the fuel) to ( ) Hz (the sensor is completely immersed into fuel). Calibration procedure Make sure that the sensor model supports calibration (consult your dealer for the information). If the fuel level sensor was immersed into fuel let the fuel rests flow down for at least 20 minutes so that it becomes dry. 1. Cut the sensor to the length required. 2. Insert the isolating plug into the face end of the tubes. 3. Without inserting into the tank connect the sensor through cable to vehicle wiring and terminal (you may also connect the sensor through the service unit of the labtop). 4. Pull out the isolating plug from the face end of the tubes. 5. Disconnect the sensor from wiring and connect the calibrator module in the developed chain splitting. If frequency differ from 500 Hz for STRELA F (output voltage is not equal to 0 Volt for STRELA A) the red light-emitting diode should light up, if frequency is equal to 500 Hz (output voltage is 0 Volt for STRELA A) the green one should light up. 6. Connect the gauge to the sensor center electrode. Attention, do not touch the electrodes with fingers! Fig. 9. Connection of the gauge to the sensor center electrode.. 7. When the red light-emitting diode will stop blinking and the yellow light-emitting diode will light up you should disconnect the gauge from the center electrode. The green light-emitting diode should light up. Transition time between light-emitting diodes states is about 5-10 seconds. 8. Insert the isolating plug into the face end of the tubes. 9. The calibration is done. Calibration results: For analog sensor: Output voltage of the dry sensor is 1,42 Volt and the frequency of the sensor completely immersed into fuel is close to maximum value for this type of sensor. For frequency sensor: Frequency of the dry sensor is 500 Hz and the frequency of the sensor completely filled with fuel is about 1500 Hz. Page 10 of 12

11 Isolating plug FLSs Strela A and Strela F that support calibration and have isolating plugs are manufactured since September, After you have cut the sensor you must insert an isolating plug in the face end of the tubes (Position 2). Sensor usage without a plug is strongly prohibited because it can lead to its failure through the loosening of tubes in operation. The isolating plug can be in 3 positions: Position 1 Before you insert a plug into the sensor you need to pull forward an internal rod out of the sensor through pressing the internal blocking rod up to the stop (Fig.10): Press up to the stop Position 2 Fig. 10. Isolating plug in position 1. After you have inserted a plug into the sensor you need to press an internal blocking rod and to insert it even with a plug. Thus the plug is wedged and hence is fixed in a sensor tube. (Fig.11) Press up to the stop Fig. 11. Isolating plug in position 2. Page 11 of 12

12 Position 3 Fuel level sensor Strela Calibration manual To pull a plug out of the sensor you need to press the blocking rod once again and move it deeper into the plug. Thus wedging is gone and the plug can be easily pulled out of the sensor. (Fig.12) Press up to the stop Fig. 12. Isolating plug in position 3. Limited liability company Group of companies «SAPSAN» Rossiyskaya str., 194, Chelyabinsk, Tel. +7 (351) office@skontrol.ru Page 12 of 12