USER GUIDE FUEL LEVEL SENSOR

GPSM

PRO SENSOR

Intelli LLC

Ukraine, 03035, Kyiv, Lva Tolstogo street, 63

tel.: +38 (044) 3622956

fax: +38 (044) 2494445

E-mail: info@fuel-sensor.com

www.fuel-sensor.com www.intelli.com.ua

Revision: 5.03

Contents

1. Fuel level sensor application ......................................................................................................... 3

2. Specifications ................................................................................................................................ 3

3. General view ................................................................................................................................. 5

3.1. Dimensions ............................................................................................................................ 5

3.2. Description of connector pins ............................................................................................... 5

4. Wiring diagram to connect the power supply and control module ............................................. 6

4.1. Diagram of wiring through the battery disconnect switch ................................................... 7

4.2. Diagram of avoiding the battery disconnect switch .............................................................. 7

5. The GPSM Pro Sensor installation and calibration ....................................................................... 7

5.1. Installation procedure ........................................................................................................... 9

5.2. Tank tare .............................................................................................................................. 10

6. Operation concept ...................................................................................................................... 10

7. Operating rules ........................................................................................................................... 10

8. Component parts ........................................................................................................................ 10

9. Servicing ...................................................................................................................................... 11

10. Repair ...................................................................................................................................... 11

11. Warranty ................................................................................................................................. 11

Attachment А. The unit calibration guide

1. Fuel level sensor application

GPSM Pro Sensor is applied for measuring the level of fuel and lubrication materials (like diesel

oil, petrol, paraffin oil) and other dielectric liquids keeping its physical character at the operating

temperature range.

The given manual describes the operation and setting of GPSM Pro Sensor, hereafter referred

to as “sensor”, in conjunction with the fuel metering systems.

Observe job safety rules before installation of the fuel level sensor!

2. Specifications

Electrical specification

DC supply voltage, V 9 - 30

Input current (at 12V), mA max 50

Serial interface RS-485, RS-232 (optionally)

ADC bit capacity 12

Level gauging

Bit rate, Mbit/s 1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200

Averaging time, s 0 - 100

Automatic data output interval, s 0 - 255

Measuring period, s 1

e erat re eas r n ran e, С - 80 … + 80

Computer controlled accelerometer calibration yes

Liquids to be measured

Fuels petrol, diesel oil, paraffin oil

Oils Engine oils, transmission lubricants, power steering fluids and hydraulic oils

Bio fuel Ethanol Е100, Е85, Е50, Е20, Е10, ethanol

Range Accuracy

Rate of ambient temperature change -20 С…+80 С, %

ax ±0,7

Rate of ambient temperature change -80 …+80 С, %

ax ±0,9

Operation conditions

IP Code IP 67

erat n te erat re, С -80…+80

EMC Immunity Level SAE J1113/2 1996

Figure 1 shows the straight-line relation between the fuel level and sensing data. Figure 2 provides

data about relation between accuracy and temperature.

Figure 3 shows volume and temperature relationship of a fuel. For demonstration purposes, this

relationship showed for diesel oil with average density.

Fig. 1. Metrological characteristics of the fuel level sensor.

Fig. 2. Constancy of Pro Sensor fuel gauge unit readings at -60 °С… +80 °С temperature range.

Fig. 3. Relation between diesel fuel volume and temperature. Average density of the diesel fuel

(810kg/m3) at 20 °С.

0

500

1000

1500

2000

2500

3000

3500

4000

4500

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Un

it r

ead

ings

Fuel level

Relation between fuel level and output data

0,0%

0,1%

0,2%

0,3%

0,4%

0,5%

0,6%

0,7%

-60 -40 -20 0 20 40 60 80

Ad

dit

ion

al p

erce

nta

ge e

rro

r, %

Temperature, °С

Relation between accuracy of the fuel level sensing and temperature of the environment

1,149

1,169

1,189

1,209

1,229

1,249

1,269

1,289

-60 -40 -20 0 20 40 60 80

Spec

ific

vo

lum

e, l/

kg

Temperature, °С

Relation of fuel level and temperature

3. General view

3.1. Dimensions

33мм

67мм

25мм

L

1

2

3

4 5мм

67мм

330±100мм

5

htt

p://f

ue

l-s

en

so

r.co

m

Fig. 4. General view, mounting dimensions of the Pro Sensor.

1 - he eas r n art of the n t has a len th of 200…6000 and cons sts of two arallel aluminum

tubes having anodized coating.

2 - The case made of high-strength polymer.

3 - Flexible protection tube.

4 - Four-pin connector.

5 - Fixing holes.

Due to the commonly used location of holes, the unit can easily be mounted instead of the regular

(float sensors) fuel gauge units.

3.2. Description of connector pins

A – + 9-30 V B – B (RS-485)

C – GND (-) D – A (RS-485)

Fig. 5. The layout of the connector pins of Pro Sensor unit.

red/green

yellowblue

black/brown

Fig. 6. The layout of the pins of Pro Sensor fuel gauge unit.

А – yellow;

В – blue;

«+» – red/green;

GND («-») – black\brown.

The Pro Sensor is protected against polarity reversal; the protection against polarity reversal

will protect the electronics from incorrect connection of the voltage. RS-485 circuits are

protected from overvoltage (up to 30V) and short circuit.

The improper connection of the unit results in termination of the warranty liabilities of the unit

supplier.

Regardless the unit modification, it is prohibited to connect the unit to the in vehicle network

without installing two additional fuses for “+” and “-” that come with the unit. The fuses should

have a capacity less than 500 mA.

4. Wiring diagram to connect the power supply and control module

There are two recommended schemes to connect the power supply:

1) Connection to the power of the vehicle with the battery disconnect switch.

2) Connection to the power supply avoiding the battery disconnect switch.

Pro Sensor has a galvanic isolation (1000 V) between its electric circuits.

Besides, the unit polymeric case is isolated from the car body. That is why the Pro Sensor can be

connected directly to the car battery avoiding the battery cut off switch.

4.1. Diagram of wiring through the battery disconnect switch

Vehiclebattery

Fleet management

terminal

RS485 A

RS485 BBattery

disconnectswitch GPSM Pro sensor with

built-in galvanic isolation

F1F2

F3

Vehicle electrical system

The unit case has electric

isolation from the car

disconnect switch

Fig. 7. Connection diagram №1. Connecting the unit to the power source through the battery

disconnect switch.

4.2. Diagram of avoiding the battery disconnect switch

Vehiclebattery

Fleet management

terminal

RS485 A

RS485 BBattery

disconnectswitch GPSM Pro sensor with

built-in galvanic isolation

F1 F2

F3

Vehicle electrical system

The unit case has electric

isolation from the car

disconnect switch

Fig. 8. Connection diagram №2. Connecting the unit to the power source directly to the vehicle’s

battery.

5. The GPSM Pro Sensor installation and calibration

It is recommended to install the fuel level sensor in geometric center of the fuel tank. It helps

to reduce error in measurement when the vehicle is inclined. If it is needed to install two sensors

in one tank, they should be placed in one diagonal line. Examples of the proper sensor mounting

are given below:

Fig. 9. Tank, side view. Recommended installation place.

It is recommended to install two units in a tank to reduce the measurement uncertainty when

the vehicle is inclined or if the tank length exceed 1.2 meters.

68%

32%

50% 50%

32%

68%

32%+68%

2

50%

68%+32%

2

50% Fig. 10. Tank, side view. Installation of two sensors in one tank.

Place the fuel level sensor as closeto the tank geometric centeras possible.

If two sensors installed into one tank, they should be placed on one diagonal line. .

GPSM

GPSM

GPSM

Fig. 11. Tank, top view. Recommended positions for installation of one or two Pro Sensor units.

5.1. Installation procedure

It is required to remove the tank, fill it with water and/or evaporate residual fuel before

starting the unit installation! It also refers to all tanks containing flammable liquids.

Dealing with diesel fuel tanks, it is required to get rid of the fuel steams to avoid the explosion!

1. Having finished the steaming, drill a small hole on the unit would-be location. Take a rod

and check for the absence of blocks like bumps/dimples in a tank bottom or a baffle.

2. Make a hole in a tank (35-40mm) with a crown milling cutter or dual-cut drill.

3. Measure the tank height and cut the unit making it 10-200 mm shorter than a tank.

20 мм

L, мм

Fig. 12. Choosing the Pro Sensor unit length.

4. Remove the cutting burrs from the unit tubes.

5. Try the unit on a tank and mark the positions for drilling the holes for five self-tapping

screws.

6. Drill the holes for self-tapping screws.

7. Perform the unit calibration testing (see Attachment A)

8. Install the unit with a sealing; screw the self-tapping screws supplied as a set tightening

every next screw located opposite.

Fig.13. The sequence of tightening the self-tapping screws while installing the Pro Sensor fuel

gauge unit.

9. Enable the unit to the extending cable by connecting the pins, after putting two additional

fuses for “+” and “-” of the in vehicle network.

5.2. Tank tare

Calibration test means obtaining a table of correspondence of the unit output signal (in

nominal units) to the fuel volume.

1. Before starting calibration, put the vehicle on the level ground.

2. Drain the fuel from the tank.

3. Fuel until the unit readings start changing. Write the unit readings and the used fuel

volume into a Table.

4. Fill the tank with 10-40 liters of fuel at a blow (depending on the tank volume) and each

time write the output signal values and the corresponding amount of fuel into a Table.

6. Operation concept

The unit uses the capacity method of measuring the liquid level, which is based on the

dependence of capacity of condenser from dielectric capacitance of the medium between its

plates.

For the operational comfort, Pro Sensor unit has a built-in LED having two operation modes:

1) Flashing at the unit acceleration and tank vibration;

2) Flashing at transferring the data to an external device.

You can switch the LED off at the settings of the unit profile program.

7. Operating rules

The unit operating rules:

- it is prohibited to expose the unit to aggressive influences, magnetic fields having the

activity exceeding the one specified in SAE J1113/2 1996, mechanical stresses, sudden

alteration of temperatures differing from the natural ones, also to operate the unit under

conditions differing from conditions described in this manual;

- it is prohibited to connect the unit to devices having interface differing from the one

described in this manual;

- the installation and setting of the unit should be performed by the staff who has studied

the occupation standards, the unit operation concept, its operating features and technical

specification.

8. Component parts

The supply package includes:

- Pro Sensor fuel gauge unit;

- extension cable (up to 8 m);

- rubber pad;

- self-tapping screws (5 pcs) fastening the unit to a tank;

- a fuse for a fuel gauge unit;

- a device for setting the fuel gauge unit (optional);

9. Servicing

The unit does not require servicing.

10. Repair

The unit is maintainable if there is no mechanical damage.

11. Warranty

Warranty period is 24 months since production date. The production date can be seen in the

unit datasheet.

Removing the device number from the unit leads to the cessation of the warranty.

The manufacturer guarantees the normal operation of the unit if the customer follows the

operating rules.