1. No category

FUEL LEVEL SENSORS
DUT-E
DUT-E
DUT-E
DUT-E
А5
А10
I
F
DUT-E CAN
OPERATION MANUAL
Version 2.0
DUT-E 232
DUT-E 485
Fuel level sensor DUT-E. Operation manual
Ver. 2.0
Content
Introduction .............................................................................................................. 4
1 Main data and technical characteristics ...................................................................... 6
1.1 Purpose of use ..................................................................................................................................... 6
1.2 Exterior view and delivery set ............................................................................................................. 6
1.3 Unit structure and principle of operation ........................................................................................... 7
1.4 Technical characteristics ..................................................................................................................... 8
1.4.1 Main characteristics ..................................................................................................................... 8
1.4.2 Characteristics of output signal for DUT-E А5, DUT-E А10 and DUT-E I....................................... 9
1.4.3 Characteristics of output signal for DUT-E F ..............................................................................10
1.4.4 Characteristics of output signal for DUT-E 232 and DUT-E 485 .................................................10
1.4.5 Characteristics of output signal for DUT-E CAN .........................................................................11
1.4.6 Compatibility of DUT-E with GPS/GLONASS tracking systems ..................................................12
1.4.7 Explosion-proof version of DUT-E ..............................................................................................13
1.5 Dimensions ........................................................................................................................................14
1.6 Packing ..............................................................................................................................................14
2 Installation and set-up .......................................................................................... 15
2.1 Exterior examination before starting of works .................................................................................15
2.2 Installation on the place of a standard fuel sensor ...........................................................................15
2.3 Installation into a special opening ....................................................................................................16
2.4 Cutting of the measuring part for the necessary tank depth............................................................19
2.5 Length increasing ..............................................................................................................................20
2.6 Mounting ...........................................................................................................................................20
2.7 Electrical connection .........................................................................................................................21
2.7.1 Electrical connection of DUT-E A5, DUT-E A10, DUT-E I and DUT-E F .......................................22
2.7.2 Electrical connection DUT-E 232 and DUT-E 485 .......................................................................23
2.7.3 Electrical connection of DUT-E CAN ...........................................................................................23
2.8 Set-up of analog or frequency DUT-E sensors ..................................................................................25
2.9 Set-up of serial DUT-E sensors ..........................................................................................................25
2.10 Connection of DUT-E to the indicator of fuel level .........................................................................26
2.11 DUT-E 232 data summarizing ..........................................................................................................27
2.11 Sealing .............................................................................................................................................30
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2.12 Measurement precision check ........................................................................................................30
2.12.1 Basic issues ...............................................................................................................................30
2.12.2 Control test steps .....................................................................................................................31
3 Diagnosis and troubleshooting ................................................................................ 31
3.1 Diagnosis and troubleshooting of analog DUT-E...............................................................................32
3.2 Diagnosis and troubleshooting of frequency DUT-E .........................................................................33
3.3 Diagnosis and troubleshooting of serial DUT-E.................................................................................33
4 Maintenance......................................................................................................... 34
4.1 General recommendations ...............................................................................................................34
4.2 De-mounting .....................................................................................................................................34
4.3 Examination.......................................................................................................................................34
4.4 Cleaning .............................................................................................................................................35
5 Storage ............................................................................................................... 36
6 Transportation ...................................................................................................... 36
7 Utilization/re-cycling ............................................................................................. 36
Contact information ................................................................................................. 37
Appendix A Check-out test protocol ........................................................................... 38
Appendix B Variants of DUT-E CAN connection ............................................................ 39
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Introduction
Recommendations and regulations given in the operation manual are referred to fuel level
sensors DUT-E (hereinafter DUT-E), developed by JV Technoton, Minsk, Belarus. This
document gives information about DUT-E unit structure, principle of operation (functioning)
and characteristics, as well as provides guidance/recommendations on the installation & operation.
DUT-E is used for measurement of fuel level in any vehicle tanks and in
fixed/immovable tanks.
DUT-E is used as part of fuel consumption monitoring and vehicle tracking systems, but
also, it is possible to use it as a standard sensor of the fuel-level indicator.
Distinctive features of DUT-E:
•
possibility to reduce the length up to 30% without calibration *;
•
possibility to increase the length by using the additional sections;
•
easy bayonet fastening;
•
unique bottom spring stop serves to give extra stiffness for sensor mounting;
•
complete set of mounting materials, and the cable;
•
thermo-correction with adjustable coefficient allows to make automatic updating of measurements based on the ambient temperature **;
•
possibility to integrate the sensor into on-board information bus of the vehicles ***.
By using DUT-E it is necessary strictly to follow the manufacturer's recommendations mentioned in this manual.
The manual is for the professional users who are familiar with the rules for repair and installation works on vehicles and who have professional knowledge in the field of electrical and
electronic equipment of various transport vehicles.
To ensure the proper functioning of DUT-E, its installation and set-up should be carried out
by certified professionals trained by the company. For detailed information please follow
the link http://www.jv-technoton.com/
*
DUT-E A5, DUT-E A10, DUT-E I and DUT-E F.
** DUT-E 232, DUT-E 485 and DUT-E CAN.
*** DUT-E CAN.
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Reference marking of the sensors is formed as follows:
Fuel level sensor
DUT-E Х Y L=Z
Type of sensor output signal:
Nominal length of the measuring
part (in mm) *:
А5 – analog signal, voltage from 1.5 to 4.5V;
- analog: 180; 250; 350; 500;
700; 1000; 1400; 2000**;
2500**
А10 – analog signal, voltage from 2.5 to 9.0 V;
I
– analog signal, current from 6.7 to 20.0 mА
F
–
frequency
signal,
frequency
from
500
to 1500Hz;
- frequency: 180; 250; 350;
500; 700; 1000; 1400
- serial: 700; 1000; 1400
232 – interface RS-232;
485 – interface RS-485
CAN – interface CAN 2.0B
Reference marking for special
versions of DUT-E:
Ex
- explosion-proof
Base
- sensing head of the fuel
level sensor ***
*
On request, it is possible to make the DUT-E measuring part of any length
up to 1400 mm. Minimal order of the sensors needed for 3 months shall be as follows:
•
•
**
analog
frequency and serial
from 500 pcs.;
from 100 pcs.
sectional (measuring part consists of several sections).
*** delivered in versions DUT-E 232 and DUT-E 485 without standard measuring part.
Used with DUT-E additional sections.
To set up DUT-E 232, DUT-E 485 and DUT-E CAN versions,
SK DUT-E is used. (not in delivery set and should be purchased separately).
Service
kit
Manufacturer guarantees that DUT-E sensors correspond to the requirements of
technical regulations provided that conditions of storage, transportation and maintenance as
well as recommendations on use given in the present manual are followed.
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1 Main data and technical characteristics
1.1 Purpose of use
Fuel sensor DUT-E is designed to measure the level of liquid fuel and
non-electroconductive liquids in tanks of vehicles and fixed/immovable tanks.
other
1.2 Exterior view and delivery set
DUT-E delivery set is shown on Fig. 1 and includes:
1
2
3
4
5
6
7
8
9
10
11
sensor DUT-E in set
specification
cable* (7.5 m)
DUT-E bottom stop
mounting plastic plate
rubber gasket for the mounting plate
sealing O-ring
screw
self-drilling screw
plastic seal
sealing cord
–
–
–
–
–
–
–
–
–
–
–
1
1
1
1
1
2
2
5
5
2
2
pc.;
pc.;
pc.;
pc.;
pc.;
pcs. **;
pcs. **;
pcs.;
pcs.;
pcs.;
pcs.
* for DUT-E CAN it shall be purchased separately.
** 1 pc. – used by installation of DUT-E and 1 pc. – as a spare part.
2
1
3
8
9
10
7
5
11
6
4
Fig. 1 —DUT-E delivery set
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1.3 Unit structure and principle of operation
Fuel sensor DUT-E (see Fig. 2) consists of measuring part 1, sensing head 2 with inside
electronic board and cable 3 with the connector 4.
2
3
4
DUT-E 232 Base
DUT-E 485 Base
2
2
3
3
2
4
3
4
4
1
1
1
DUT-E
DUT-E
DUT-E
DUT-E
A5
A10
I
F
DUT-E 232
DUT-E 485
DUT-E CAN
Fig. 2 —DUT-E components
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The principle of the DUT-E operation is based on measurement of electric capacity of the
condenser. Tubes of the sensor measuring part are used as a condenser armature. The
electric capacity varies depending on the depth of its immersion into dielectric fluid (fuel).
The electronic board of the sensor analyzes the current electric capacity value and
generates a corresponding output signal.
Recalculation of the fuel level into the volume is carried out according to the calibration
table. In order to make the calibration table it is necessary to calibrate the tank. Detailed
description of the tank calibration procedure during installation is given in the document
“Fuel level sensor DUT-E. Installation manual”.
DUT-E can be used together with the recording and displaying devices (incl. GPS/GLONASS
vehicle trackers) which have characteristics of input signals that correspond to output signals of DUT-E (See item 1.4).
By using the analog and frequency DUT-E sensors as a part of vehicle tracking system, the
fuel volume calculation can be performed in the recording device (e.g., in tracker), or in the
software of the system.
Serial DUT-E sensors are able to make calculation of the current fuel volume in the tank independently according to calibration table which is put into the DUT-E memory by means of
Service kit SK DUT-E.
1.4 Technical characteristics
Power supply of DUT-E is carried out via on-board vehicle power system, on which it is
installed.
DUT-E can be used in moderate and cold climates.
As for the mechanical
vibration-crashworthy.
stability,
sensors
DUT-E
are
vibration-shockproof
and
1.4.1 Main characteristics
Main DUT-E characteristics are given in the table 1.
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Table 1. DUT-E main characteristics
Factor name, m. u.
Value
Principle of operation
capacitative
The relative measurement inaccuracy (to the length of the
measuring part),%, not more
Supply voltage range, V
±1
from 10 to 50
Current consumption at power voltage 12 V, mА, not more
50
Current consumption at power voltage 24 V, mА, not more
25
Readiness time after power-up, s, not more
10
Temperature range, °C
from — 40 to + 85
Protection level of housing
IP54
Nominal length of DUT-E measuring part
See Introduction
1.4.2 Characteristics of output signal for DUT-E А5, DUT-E А10
and DUT-E I
The voltage value of the DUT-E output signal (for DUT-E А5 and DUT-E А10) and current
value of output signal (for DUT-E I) have a linear dependence on the measured fuel level in
the tank.
The output signal of the sensor doesn’t depend on supply voltage value.
Input resistance of the device to which sensors DUT-E A5 and DUT-E A10 are connected
shall not be less than 10 kOhm.
Characteristics of output signal DUT-E A5, DUT-E A10 and DUT-E (I) are given in table 2.
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Table 2. Characteristics of output signal for DUT-E A5, DUT-E A10 and DUT-E I
Voltage, V
Model DUT-E
DUT-E A5
DUT-E A10
DUT-E I
Tank status
Current, mА
At nominal After cutting At nominal After cutting
length
by 30%
length
by 30%
Empty tank
1.5
0.9
—
—
Full tank
4.5
3.7
—
—
Empty tank
2.5
1.0
—
—
Full tank
9.0
5.6
—
—
Empty tank
—
—
6.7
4.0
Full tank
—
—
20.0
16.4
1.4.3 Characteristics of output signal for DUT-E F
The frequency value of the DUT-E output signal has a linear dependence on the measured
fuel level in the tank.
The output signal doesn’t depend on supply voltage value.
Output cascade – open collector with load resistor of 10 kOhm.
Characteristics of output signal DUT-E F are given in table 2.
Table 3. Characteristics of output signal for DUT-E F
Frequency, Hz
Tank status
At nominal length
After cutting by 30%
Empty tank
500
262
Full tank
1500
941
1.4.4 Characteristics of output signal for DUT-E 232 and DUT-E 485
Characteristics of DUT-E 232 and DUT-E 485 output signal correspond to the specification of
RS-232 and RS-485 interfaces accordingly.
The results of DUT-E 232 and DUT-E 485 measurements can be transferred via serial
interface as:
a)
b)
c)
d)
Standard units, from 0 to 1000 (0 — empty tank, 1000 — full tank);
Fuel level in the tank, mm;
Fuel volume, l;
Fuel volume in relation to the full tank, %.
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Besides the data on fuel amount in the tank, DUT-E passes information about current
temperature (measured by the sensor located on the electronic board).
Information transfer of DUT-E 232 and DUT-E 485 is carried out according to DUT-E COM
Protocol. You can download the updated version of the document from
http://www.jv-technoton.com/.
1.4.5 Characteristics of output signal for DUT-E CAN
Characteristics of DUT-E CAN output signal meet the specification of S6 bus that was
developed by JV Technoton in order to integrate elements of the vehicle on-board
equipment into the GPS/GLONASS tracking system. S6 bus represented by cables, interfaces and protocols.
S6 bus is based on:
- interface CAN 2.0В (ISO 11898-1:2003) used to transfer the useful information;
- interface K-Line (ISO 9141) used to set up of DUT-E CAN.
The protocol of data exchange via S6 meets the standard SAE J1939-73.
DUT-E CAN data can be sent both on request and automatically (main mode).
S6 bus allows connecting up to 8 DUT-E CAN sensors. To identify them, the bus uses the
decimal addresses from 101 to 108.
DUT-E CAN generates and transmits messages in accordance with table 4.
Table 4 — messages of the DUT-E CAN data exchange protocol
Message mark sign
Short message description
PGN 62982
DUT-E CAN fuel sensor
PGN 62994
DUT-E CAN operation counters
PGN 62995
DUT-E CAN specification
PGN 65276
Dashboard
DUT-E CAN active failures (DTC’s)
DM1
DM2
DUT-E CAN saved failures (DTC’s)
DM4
Revealed events:
- “Fueling”;
- “Fuel discharge”
You can ask the detailed
[email protected] .
data
exchange
protocol
© Technoton, 2007 - 2012
DUT-E
CAN
by
e-mail
from
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1.4.6 Compatibility of DUT-E with GPS/GLONASS tracking systems
Technoton guarantees complete compatibility and combined measurement
accuracy of DUT-E A5 with terminals CКРТ 45, CКРТ 25 and CКРТ 31.
Additional information on the application of DUT-E in
vehicle tracking and fuel
consumption monitoring system, as well as a full range of СКРТ trackers and their technical
characteristics are given at the website http://www.ckpt.ru/.
Technoton regularly makes tests on compatibility and combined accuracy of DUT-E with
different tracker models of popular brands. Table 5 shows the compatible tracker models
which ensure the combined fuel consumption measurement accuracy error of not
more than 1%.
Table 5 — Compatible vehicle trackers
№
Tracker
Manufacturer
Software
DUT-E
Model
DUT-E A5/A10
Brand
Model
1
Helios Adv+
AMP10353
eInstall
2
Autograph
GSM+
software AutoGRAPH
3
Teltonika
FM1100
TAVL.NET
DUT-E 485
DUT-E А5/А10
4
Teltonika
FM4200
TAVL.NET
DUT-Е 232
5
Teltonika
FM5300
TAVL.NET
DUT-Е 232
6
MapOn
GBOX
web server mapOn
DUT-E A5/A10
7
NaviFleet
ET100
NaviFleet
DUT-E A5,
DUT-E 232,
DUT-E 485
8
Locarus
702R
LocarusInformer
DUT-E A5/A10
9
SKAUT
MT-530
Scout Explorer v3.0
DUT-E A5/A10
10
SKAUT
MT-600 GP PRO
Scout Explorer v3.1
DUT-E A5/A10
11
Signal
S-2117
http://cybermonitor.ru/
DUT-E 485
12
Atrack
AT5
ATrack Server Tool
DUT-E 232
DUT-E A5/A10
Update information about compatibility of specific tracker models and fuel level sensors
DUT-E, as well as recommendations on their connection and set-up can be found at
http://www.jv-technoton.com/.
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1.4.7 Explosion-proof version of DUT-E
DUT-E in a special explosion-proof version Ex is designed for use in hazardous areas.
Such version of the sensor is marked as Ex (explosion-proof), and marking contains the
following information:
•
Class of Ex protection — 1ExibIIBT6;
•
Type of Ex protection — intrinsically safe electrical circuit “i”.
In order to meet the requirements of intrinsically circuit , the electrical connection of explosion-proof DUT-E shall be carried out via the I.S. unit (sold separately) that provides galvanic isolation between the explosive and safe zones.
Parameters of intrinsically electric circuit are given in table 6.
Table 6 — Parameters of intrinsically electric circuit
Parameter name,
m.u.
Value
Minimum input voltage U min , V
8.75
Maximum input voltage U max , V
15
Maximum input current Ii, mА
200
Max internal capacity Ci, mfd
15.0
Maximum internal inductance Li, mH
1.188
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1.5 Dimensions
DUT-E dimensions are shown on Fig. 3.
*
* Nominal length of the measuring part.
Fig. 3 — dimensions of DUT-E
1.6 Packing
DUT-E set is delivered in the carton box. Please see Fig. 5. below.
Fig. 5 — Packing DUT-E
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2 Installation and set-up
This chapter provides basic recommendations for the DUT-E installation. More detailed
information on DUT-E installation is given in the document “Fuel level sensor DUTE. Installation manual”.
2.1 Exterior examination before starting of works
Before you start, you should make external check of DUT-E for any possible defects that occurred during transportation, storage or careless handling.
By discovering any defects, please, contact the product supplier.
DUT-E can be installed as on the place of a standard fuel sensor* as into a special opening
in the tank.
* Study carefully the scheme of the mounting openings for the standard fuel sensor and
compare with the scheme of the openings of DUT-E mounting plate.
ATTENTION! By installing the sensor, you should follow safety rules when carrying out the
repair works on automotive vehicles as well as safety requirements prescribed by the enterprise.
2.2 Installation on the place of a standard fuel sensor
ATTENTION! It is not recommended to install DUT-E on a place of standard fuel sensor if it
is located far from the geometric centre of the tank, otherwise inaccuracy in the fuel level
measurement may occur.
Before the DUT- E installation it is necessary to remove the standard fuel sensor and clean
the installation place.
Align the holes of the mounting plate and rubber gasket with the holes in the tank.
For the installation you can use screws M5x16, that come together with the DUT-E set
(Fig. 6). Screw heads must be deeply put into the mounting plate.
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Fig. 6 — Mounting plate on the place of standard fuel sensor
DUT-E delivery set includes the mounting plate. Its installation dimensions are given
in Fig. 8.
If you need to install DUT-E instead of a standard sensor with SAE 5 bolt mounting dimensions, then you should order the corresponding mounting plate.
2.3 Installation into a special opening
ATTENTION!
1 Before drilling the holes in the tank you should dismantle it, evaporate or add water.
2 Before you start drilling the hole, please, make sure that there are no partitions inside the
tank under the selected location, what can prevent DUT-E installation. Avoid that DUT-E
measuring part touches the floater rod of standard fuel level sensor.
Installation steps:
a)
Identify the place where it is supposed to install the sensor. It is recommended to
choose a place in the geometric centre of the tank (Fig. 7) as it will reduce the
error of fuel volume measurement by its vibration during the movement;
Standard fuel sensor
DUT-E
Fig. 7 — Recommended place for DUT-E installation
b) Mark the place and drill the holes according to the scheme of the openings for DUT-E
mounting plate (Fig. 8).
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BE ATTENTIVE! Mounting plate can be installed on the pre-drilled holes only in one position! Prior to marking and drilling, please, study the place where it is supposed to install the
plate so that holes for sealing were located in an accessible position.
Fig. 8 —Scheme of the holes for the DUT-E mounting plate
Put the rubber gasket and mounting plate on the prepared hole, fix with screws M5х16 or
self-drilling screws 3,9х25 that come in the delivery set (Fig. 9).
ATTENTION! While attaching the plate to the tank, make sure, that the screw heads or
self-drilling screw heads are not warped and deeply put into the mounting plate so that to
provide electrical insulation of the vehicle tank casing from the DUT-E!
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Screw M5x16 or self-drilling
Mounting plate
A sealing cord
Rubber gasket
Fuel tank
Fig. 9 — Installation scheme of the mounting plate
ATTENTION! For the further sealing of the sensor it is recommended to put a sealing cord
through the holes prior to installation on the fuel tank!
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2.4 Cutting of the measuring part for the necessary tank
depth
ATTENTION!
For DUT-E A5, DUT-E A10, DUT-E I and DUT-E F: allowed to make cutting up to 30% of
measuring part length without further sensor calibration;
For DUT-E 232, DUT-E 485, DUT-E CAN: allowed to make cutting up to 70% with further
sensor calibration.
In order to avoid the short circuit of the measuring part tubes caused by water or
electroconductive residues that are gathered on the bottom of the tank, there should be at
least 25-30 mm gap between the tube end of the DUT-E measuring part and the bottom of
the fuel tank.
Steps by DUT-E cutting:
a) measure the depth from the mounting plate till the tank bottom;
b) cut the DUT-E measuring part based on the location of the tube end at a distance of
25-30 mm from the tank bottom;
ATTENTION! DUT-E cutting shall be done by means of hacksaw or with a pipe cutter of a
suitable diameter. After that, cutting edges should be thoroughly cleaned up and washed up
with the fuel (Fig. 10).
Fig. 10 — Cutting of DUT-E measuring part
c) In case of DUT-E 232, DUT-E 485 and DUT-E CAN cutting, you should calibrate
the sensor using the Service kit SK DUT-E (See item 2.9).
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2.5 Length increasing
Length increasing is carried out by attaching the DUT-E additional sections to the measuring
part (Fig. 11).
Model range of DUT-E additional sections include: KDC 250, KDC 500 and KDC 1000 with
lengths of 250, 500 and 1000 mm correspondingly.
Fig. 11 — Additional section of DUT-E
Length increasing of analog and frequency DUT-E sensors is possible only for
restoring the length after cutting and only within limits of the DUT-E nominal
length.
Length increasing for serial DUT-E sensor is allowed to a length of 6000 mm.
Additional sections of DUT-E can be cut to the desired length. When cutting, you should follow the recommendations given in item 2.4 of this guide.
2.6 Mounting
In order to fix the DUT-E it is necessary to put an O-ring right on the dap of the mounting
plate, and then put the sensor into the hole, press it with force and lock by turning
clockwise (Fig. 12).
ATTENTION! During installation it is recommended to apply a small amount of oil or fuel
on the O-ring of the mounting plate to prevent its deformation when you fix the DUT-E.
Installation should be done in such a way that after the DUT-E has been mounted, the sealing
openings on the mounting plate and DUT-E housing were located above each other.
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Sealing O-ring
Fuel tank
Fig. 12 — Installation scheme of DUT-E
2.7 Electrical connection
ATTENTION!
1 When you connect the DUT-E to the on-board power system, you shall connect power
“+” and ground “—” to the same places where the recording and display device is connected.
2 Before you start electrical connection of the sensor, you should check the quality of the
ground of the vehicle. Resistance between any point of the ground of the vehicle and the
terminal “—” of the accumulator battery shall not exceed 1 Ohm.
The DUT-E housing is electrically connected with the power “minus” (brown wire harness).
The mounting plate made of dielectric plastic material provides electrical insulation of the
DUT-E body from the vehicle body (of the tank).
ATTENTION! DUT-E cable is strongly recommended to stack together with the standard
wiring of the vehicle and mandatory to fix its position by means of hose clamps every 50 cm.
(Fig. 13)
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Cable DUT-E
Fig. 13 — DUT-E cable laying
2.7.1 Electrical connection of DUT-E A5, DUT-E A10,
DUT-E I and DUT-E F
Electrical connection of DUT-E A5, DUT-E A10, DUT-E I and DUT-E F is carried out in
accordance with the following pin assignment (Figure 14, Table 7):
Fig. 14 — Pins of wire for DUT-E A5, DUT-E A10, DUT-E I and DUT-E F
Table 7 — Pin assignment of wire for DUT-E A5, DUT-E A10, DUT-E I and DUT-E F
Pin No
Wire name
1
Т701/Т034
2
GND/Т734
3
VBATT
Wire colour
white
Remark
Analog or frequency
output
brown
Ground “—”
orange
Power “+”
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2.7.2 Electrical connection DUT-E 232 and DUT-E 485
Electrical connection of DUT-E 232 and DUT-E 485 is carried out in accordance with the
following pin assignment (Figure 15, Table 8):
Fig. 15 — Pins of wire for DUT-E 232 and DUT-E 485
Table 8 — Pin assignment of wire for DUT-E 232 and DUT-E 485
Pin No
Wire name
1
VBAT
2
GND
3
232R/485A
4
232T/485B
Wire colour
Remark
orange
Power “+”
brown
Ground “—”
white
Received data (RS232)
Data exchange (RS485)
red
Transferred data (RS 232)
Data exchange (RS485)
2.7.3 Electrical connection of DUT-E CAN
DUT-E CAN electrical connection to the on-board equipment is carried out in accordance
with the following pin assignment (Figure 16, Table 9):
Options for DUT-E connection to trackers and instruction of what cables are necessary for the order are given in Appendix B (fig. B1 — B4).
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Fig. 16 — Pins of wire for DUT-E CAN
Table 9 — Pin assignment of wire for DUT-E CAN
Pin No
Wire name
Wire colour
Remark
1
VBAT
orange
Power “+”
2
GND
brown
Ground “—”
3
CANH
blue
CAN-High
4
CANL
white
CAN-Low
5
KLIN
black
K-Line
ATTENTION! The manufacturer keeps the right to change the colors of the wires. Study
thoroughly the textual wire tagging before you make DUT-E connection.
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2.8 Set-up of analog or frequency DUT-E sensors
Setup and calibration of analog and frequency DUT-E is not required.
2.9 Set-up of serial DUT-E sensors
This chapter provides basic recommendations on set-up of serial DUT-E.
More detailed information on set-up of serial DUT-E sensors is given in the
document “Operation manual of Service Kit SK DUT-E”.
For the proper operation of serial DUT-E, they shall be calibrated in order to define maximal
and minimal levels of fuel measurement range in the tank.
Recalibration of DUT-E is carried out by means of “Service kit SK DUT-E” (not in the delivery
set and should be purchased separately).
By means of the “Service DUT-E” software, you can also set up the sensor in order to adjust
it for specific operating conditions and requirements of registration and display devices. You
can change the following settings of DUT-E modes:
1) Fuel level filtration time is the time interval that precede the data transmission and
which is used to calculate the average fuel level in the tank. Thus, information about the
fuel level in the tank which is transmitted by the sensor to the recording and display device
is not the instant value, but the averaged value over the set period of time.
The setting value varies from 0 to 125 s (pitch is 5 s). The default value is 10 s.
Setting this function is important when you use the DUT-E sensor on the vehicle which is
applied in rough areas (lack of roads).
2) Interval of automatic data output is the time period which is used by the DUT-E to
transmit the data about the fuel level in the tank to the connected recording and
display device.
The values for the interval vary from 1 to 60 s (pitch is 1 s). The default value is 1 s.
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3) Automatic transmission mode defines the data transmission to DUT-E:
•
•
•
•
OFF – no automatic data output. Data transmission works only on-request of the
recording device);
HEX - binary format of automatic data output (used on default);
ASCII - text format of automatic data output;
ASCII EXT – extended text format of automatic data output. When you use it, the
following additional parameters are available: Prefix and Postfix that set
accordingly the beginning and end of the transmitted text data.
4) Network address specifies the DUT-E address in case it works in RS-485 network or in
CAN-bus. Default address DUT-E is set by the manufacturer that corresponds to:
•
•
for DUT-E 485 — the last two digits of sensor serial number;
for DUT-E CAN — 101.
2.10 Connection of DUT-E to the indicator of fuel level
By installing the DUT-E on the place of standard fuel level sensor you may need to control
the needle indicator of remaining fuel in the tank. In order to implement this function you
shall use an interface device UС-1 (Fig. 17) developed by JV Technoton.
ATTENTION! Interface device complies only with DUT-E A5!
Table 10 — Interface device models
Article
order No
Remark
UС-1-90
Emulation of the level sensor with low resistance: 0-90 Ohm
Resistance increases with increasing of the fuel level
UС-1-800
Emulation of the level sensor with high resistance: 800-185 Ohm
Resistance decreases with increasing of the fuel level
Fig. 17 — Exterior view of the interface device UС-1
Electrical connection of UC-1 is carried out in accordance with the wire assignment given in
Table 11.
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Table 11 — Wire assignment for UС-1
Wire No
Wire name
1
T034
2
GND
3
T734
4
T733
5
VBAT
Wire colour*
white
brown
Remark
Signal from the fuel
level sensor (input)
Ground “—”
pink
Fuel level indicator
(output)
pink
Control lamp of the fuel
level (output)
orange
Power “+”
* The manufacturer reserves the right to change the wire colours.
2.11 DUT-E 232 data summarizing
Sensors DUT-E 232 with SUMMATOR DUT-E SUM are used to measure the total volume of
fuel on vehicles that have two or more fuel tanks.
Attention!
1 Summator works only with DUT-E 232 firmware version not older than 3.0.
2 Calibration table for the measured fuel tank shall be recorded into the internal memory of
each sensor (see 1.4).
Fig. 18 — exterior view of SUMMATOR DUT-E SUM
Summator is used to connect two DUT-E 232 and one tracker (Fig. 19а).
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Output signal of the summator contains the summarized fuel volume (in litres) measured by
sensors that are connected to its inputs IN and IN/OUT.
If you need to measure the fuel volume in three or more tanks with installed DUT-E 232,
you shall use the cascade summator connection (Fig. 19b).
Electrical connection is carried out in accordance with the wire assignment (table 12).
Table 12 — wire assignment for SUMMATOR DUT-E SUM
Wire No
Wire name
1
VBAT
2
GND
3
232R
4
232T
Wire colour*
Remark
orange
power “+”
brown
ground “—”
Received data
(RS-232)
Transmitted data
(RS-232)
white
red
* The manufacturer reserves the right to change the wire colours.
To obtain the correct data, DUT-E 232 shall be set up using the software “Service DUT-E”.
Installation process is the following:
1) For data transmission on request, please, set the following status for all sensors:
•
•
set
(tab
set
(tab
the
parameter
“Automatic
transmission
“Operation mode”);
the parameter “Output message” into
“ Output message “).
mode”
into
status
“Fuel
status
volume
“Off”
(l)”
2) For data transmission in automatic mode, please, set the following status and parameter values of the sensors:
•
•
•
•
for all sensors — set the parameter “Output message” into status
“Fuel volume (l)” (tab “ Output message”);
for sensor N 1 — set the parameter “Automatic transmission mode” into status
“HEX”; set the value “1” for the parameter “Interval of automatic data output (s)”
(tab “Operation mode”);
for sensors from N 2 to N (n-1) — set the parameter “Automatic transmission mode”
into status “Off” (tab “Operation mode”);
for sensor N n (the last one) — set the parameter “Automatic transmission mode”
into
status
“HEX\ASCII\ASCII
EXT”;
parameter
“Interval
of
automatic
data output (s)” shall be set to any value required for the terminal operation
(tab “Operation mode”).
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Fig. 19 — Summator connection schemes
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2.11 Sealing
To prevent the fuel theft or unauthorized tampering into DUT-E operation, you shall seal up
the sensor and its electrical connection as well as connection of its harness using the
supplied sealing cords and disposable plastic seals.
In order to seal the sensor you need to put the cord through the special holes of the
mounting plate and DUT-E housing, after that, put the free cord ends through two openings
in the centre of the seal. The cord will be fixed after the seal has been locked.
If necessary, you can use seals of other models and manufacturers.
Separation of the seal without its breaking is not possible.
ATTENTION! The sealing cord shouldn’t touch the tank!
2.12 Measurement precision check
2.12.1 Basic issues
Measurement precision check is needed to detect the relative and absolute measurement
error of DUT-E on the vehicle.
In order to check the measurement accuracy of DUT-E you should make control tests, i.e. to
fill in and empty the fuel tank, compare DUT-E readings with the actual filled-in/drained
fuel.
Fuel discharging is done by manual or mechanical pomp.
When you make tests, you should use the verified/tested containers (batch meters) to
determine the volume capacity of the drained or filled-in fuel.
ATTENTION! While testing, the volume of the filled-in/drained fuel should take at least
20% of the tank.
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2.12.2 Control test steps
Control tests shall be done according to the following steps:
1)
Start up the ignition.
2)
Discharge the fuel of a certain volume.
3)
Determine the discharged fuel volume with the help of the verified batch meter.
4)
Record the data into the check-out test protocol.
5)
Make a pause in order to stabilize the fuel in the tank (prior to stabilizing of DUT-E
readings).
6)
Refuel the tank on the amount of the earlier discharged fuel.
7)
Record the amount of the re-fuelling into the protocol.
8)
By analyzing the inaccuracy, the parameters “Discharge” and “Refuel” are
estimated in percentage relatively to the tank volume.
Sample of the check-out test protocol and formulas for error calculation are given in Appendix A.
3 Diagnosis and troubleshooting
If there are any failures during DUT-E operation, first of all, pay attention to electric wiring
of the vehicle, cleanness and condition of power socket pins.
ATTENTION!
1. Strong oxidation of the ground switch contacts or its failure can lead to a distortion of the
DUT-E output signal.
2. DUT-E indications will be incorrect if DUT-E tubes are stuck with current-conductive dirt
or water!
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3.1 Diagnosis and troubleshooting of analog DUT-E
The efficiency of the analog DUT-E can be checked with a multimeter by means of
measuring the output voltage or current (for DUT-E I) and then verifying the obtained data
with the data from Table 13.
Table 13 — Malfunction of analog DUT-E
Output voltage, V
Malfunction reason
Voltage:
From 0.4 to 5.0 V (for DUT-E А5);
From 0.4 to 10.0 V
(for DUT-E А10)
Troubleshooting
No failures,
normal operation
Check the recording
and displaying device
Short circuit of tubes of
the measuring part
because of metal burrs
and chips; dirt or water
in the tank bottom
Eliminate the short circuit,
clean the sensor tubes
clean the fuel tank
of the vehicle
Failures in the electronic
board of the sensor
Contact the closest
regional service center
Current :
from 2 to 22 mА (for DUT-E I)
Voltage:
More than 5 V (for DUT-E А5);
More than 10 V (for DUT-E А10)
Current:
More than 22 mА (for DUT-E I)
Voltage:
Less than 0.4 V (for DUT-E А5
and DUT-E А10)
Current:
Less than 2 mА (for DUT-E I)
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3.2 Diagnosis and troubleshooting of frequency DUT-E
Efficiency of the frequency DUT-E can be checked with a frequency meter by means of
measuring the output frequency of the sensor and verifying the obtained data with the one
from Table 14.
Table 14 — Malfunction of frequency DUT-E
Output frequency, Hz
Malfunction reason
Troubleshooting
From 100 to 1600
No failures, normal operation
Check the recording and
display devices
More than 1600
Short circuit of tubes of the
measuring part because of
metal burrs and chips; dirt or
water in the tank bottom
Eliminate the short circuit,
clean the DUT-E tubes
clean the fuel tank of the vehicle
Less than 100
Failures in the electronic
board of the sensor
Contact the closest regional
service center
3.3 Diagnosis and troubleshooting of serial DUT-E
Efficiency of serial DUT-E is checked by connecting it to the PC with DUT-E Service kit.
When any malfunction of the serial DUT-E occurs, a message appears in the bottom part
of Service DUT-E window. The message contains the following information:
•
•
•
error code;
code definition of the malfunction;
possible malfunction reason.
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4 Maintenance
4.1 General recommendations
External inspection and functional test of DUT-E are recommended to do at least 1 time
per year.
ATTENTION! When remounting the DUT-E, you should replace the O-ring of the mounting
plate.
DUT-E repair is carried out only by certified Regional Service Centers.
You can find the full list of centres at http://www.jv-technoton.com/ .
4.2 De-mounting
Before de-mounting the DUT-E, you should clean the surface of the tank near and around
the place of the DUT-E installation.
Prepare a clean rag to remove any remaining fuel from the sensor, as well as provide protection with a cap (should be purchased separately) from falling any rubbish or any debris
into the tank through the mounting opening of the DUT-E.
Cut the sealing cord without damaging the signal wire.
Disconnect the DUT-E signal cable.
Undock DUT-E by turning the housing counter-clockwise by 1/6 turn.
ATTENTION! When de-mounting the DUT-E, do not make any efforts to the signal cable.
Otherwise, it is possible to damage the cable and/or an electronic board.
4.3 Examination
After the DUT-E has been de-mounted, it should be examined for possible defects:
a) Visible damage to the electronic board, measuring part, mounting plate, signal cable
or connector/pin;
b) Tube play of the measuring part relatively to each other and/or housing;
c) Presence of residues, incrustation, wax or any other debris between the tubes of the
measuring part;
d) Any leakages of fuel through the rubber gasket of the mounting plate.
If any defects discovered, please, contact the Service Center (see 4.1) or the manufacturer.
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4.4 Cleaning
During the operation there can be incrustation, any deposits, residues or debris on the tube
walls of the DUT-E measuring part.
Contamination of the cavity between the tubes of the DUT-E measuring part by any types of
deposits leads to significant inaccuracy increase of DUT-E.
ATTENTION! Incrustation or sediments inside the central tube of the measuring part does
not influence the efficiency and accuracy of DUT-E! You should control only the cleanness of
the cavity between the two tubes of the measuring part.
Tubes of the DUT-E measuring part should be washed in the fuel that is measured with the
given DUT-E.
ATTENTION! During washing the tubes of the measuring part do not spill fuel on the DUTE housing, signal cable and/or its socket.
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5 Storage
DUT-E is recommended to be stored in dry areas.
DUT-E storage is allowed only in original packaging at temperature range from —50 °C
to +40 °C and relative humidity up to 100% at 25 °C.
Do not store DUT-E in the same room with substances that cause metal corrosion and/or
contain aggressive impurities.
Storage life for DUT-E should not exceed 24 months.
6 Transportation
Transportation of DUT-E is recommended in closed transport that provides protection for DUT-E
from mechanical damage and no access of precipitation.
During transportation by air the DUT-E must be placed in heated sealed compartments.
Air environment in vehicles should not contain acid, alkaline and other aggressive impurities.
Shipping containers with packed DUT-E sensors should be sealed.
7 Utilization/re-cycling
DUT-E does not contain harmful substances and ingredients that are dangerous to human
health and environment during and after the end of life and recycling.
DUT-E does not contain precious metals in amount that should be recorded.
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Contact information
Distribution, technical support, service
Technoton
Tel/fax: +375 17 223-78-20
[email protected]
[email protected]
Manufacturing plant
Zavod Flometr
Tel/fax: +375 1771 3-99-89
[email protected]
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Appendix A
check-out test protocol
Protocol
Dated “___”____________ 20___
Model and serial number of DUT-E
Vehicle make, model,
registration plate
Model, factory number of
the recording and displaying device
Discharge volume
from the tank
Inaccuracy
of discharge
measurement
Volume of fuel
filling into
the tank
Acc. to the batcher readings
Acc. to the terminal readings
VB , l
Vterm , l
absolute ∆ = Vterm − VB , l
relative to the tank volume of the vehicle
V −V
δ = term B × 100% , %
Vfueltank
Acc. to the batcher readings
Acc. to the terminal readings
VB , l
Vterm , l
absolute ∆ = Vterm − VB , l
Inaccuracy of
fuel filling
measurement
relative to the tank volume of the vehicle
V −V
δ = term B ×100% , %
Vfueltank
Conclusions:
Result of the fuel filling measurement corresponds (doesn’t correspond) to the technical
requirements.
Result of the discharge measurement corresponds (doesn’t correspond) to the technical
requirements.
Remarks: ___________________________________________________
Customer representative __________________ /____________________/
Contractor representative __________________ /____________________/
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Appendix B
variants of DUT-E CAN connection
Outside the driver's cabin
DUT-E CAN
Cable S6 SC-CW-700
Inside the driver's cabin
Vehicle
tracker
GLONASS/GPS
GSM
Fig. B.1 — Connection of one DUT-E CAN to tracker that is not compatible
with S6 cable system
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T-connector S6 3SC
Cable extender SC S6 1000
SC S6 3000
SC S6 7000
SC S6 12000
DUT-E CAN
Inside the driver's cabin
Cable blind
cover S6 SC
1
Outside the driver's cabin
2
...
DUT-E CAN
Vehicle
tracker
GLONASS/GPS
VBAT
GND
S6 3Mol power
GSM
S6 SC-Mol-700
Extension cable/Adapter S6 SC-Mol-300
DUT-E CAN
T-connector with power
Cable blind
cover S6 Mol
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Fig. B.2 — Connection of several DUT-E CAN to the tracker that is not compatible
with S6 cable system
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Outside the driver's cabin
DUT-E CAN
Extension cable/Adapter S6 SC-Mol-300
S6 SC-Mol-700
Cable blind
cover S6 SC
T-connector S6 3SC
Outside the driver's cabin
T-connector with power
S6 3Mol power
Cable blind
cover S6 Mol
GND
VBAT
Vehicle
tracker
GLONASS/GPS
GSM
Fig. B.3 — Connection of one DUT-E CAN to the tracker that is compatible
with S6 cable system
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T-connector S6 3SC
Extension cord SC S6 1000
SC S6 3000
SC S6 7000
SC S6 12000
DUT-E CAN
Inside the driver's cabin
Cable blind
cover S6 SC
1
Outside the driver's cabin
2
...
DUT-E CAN
Vehicle
tracker
GLONASS/GPS
VBAT
GND
S6 3Mol power
GSM
S6 SC-Mol-700
Extension cable/Adapter S6 SC-Mol-300
DUT-E CAN
T-connector with power
Cable blind
cover S6 Mol
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Fig. B.4 — Connection of several DUT-E CAN to the tracker that is compatible
with S6 cable system
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