TKLS Fuel Level Sensor User Guide
Contents
1. Fi Technokom VEHICLE TRACKING SYSTEM FUEL LEVEL SENSOR USER MANUAL EI Table of Contents Introduction EEE ea ee meters ater 4 Software Copyright Nottce sir 5 Safe Operation and Installation s eeseeeeeeeeeeseeeeeeeetsetettnstneetnntinetnntttntnnttnstnnstnneenneennee nnt 6 Ereegnes H Technical Specifications 8 SCOPE Ol SUPP UE 9 Components ITT 10 SENSO LA EE TE LU EE 12 Connection of the Sensor see 14 Power Supply Connection sise 16 RS 485 TIA EIA 485 A Bus Connection eccececeeeeeeeeeeeeeeeeteaeeeeeeeseaeeeeaeeteaeessaeeseaeeeaaes 17 Frequency Output Connection iii 18 Seele dns id ne A ml a 19 Sensor Configuration sens 20 Modbus Register Mapping sise 22 PPD GIIGIX icio ssr ona eegen Eder eege re een ein 24 Introduction This User Manual applies to the TKLS fuel level sensor hereafter TKLS sensor produced by TechnoKom Lid It contains installation and connection procedures of the TKLS as well as its function and control This Manual is intended for specialists who are aware of the maintenance and installation principles typical for motor vehicles and are proficient in using the electronic and electrical equipment of various vehicles To ensure the best performance of the TKLS it should be installed and set up only by qualified specialists The TKLS sensor can operate both as a part of a fuel monitoring system and as a part of a fleet manage2. LSConf can be downloaded for free from the manufacturer s official web site www tk chel ru Note For more information about sensor configuration using the TKLSConf Software see the Sensor Configuration section General Diagram of Connection of External Devices to RS 485 Bus The connection diagram of the TKLS to the AutoGRAPH GSM on board vehicle tracking controller is depicted in the figure below This diagram is also true for other devices which are connected to the sensor via the RS 485 bus RS 485 A 2 ORANGE with WHITE STRIPE AutoGRAPH GSM controller BROWN with WHITE STRIPE Connector 2 TO VEHICLE SYSTEM VOLTAGE TO VEHICLE SYSTEM VOLTAGE Warning Be careful not to cross the A and B wires otherwise the sensor may operate incorrectly Warning All connections should be performed when the sensor and all external devices to be connected to the RS 485 bus are disconnected from the power supply 17 Frequency Output Connection TKLS sensor is equipped with one frequency output which is open collector The frequency of the output signal is proportional to the fuel level in the tank The output frequency range varies from 100Hz to 3000Hz Maximum load current should not exceed 200 mA The frequency output is intended to be connected to the digital input of the AutoGRAPH GSM on board vehicle tracking device which can acquire the reading in fr
3. an error has occurred this will be shown in the program window 19 Sensor Configuration The TKLS can be set up in the following ways e Using the TKLSConf Configuration Software e remotely via Bluetooth e remotely via RS 485 To set up the sensor using the TKLSConf program it is necessary to connect the device to a PC or a laptop For correct operation the sensor drivers should be installed before connection H the device drivers have not been installed follow the steps in the Installing the Drivers section To connect the sensor to a PC use the special adaptor and USB data cable supplied with the sensor see fig 1 TO CONNECTOR 1 D of TKLS TO PERSONAL COMPUTER Fig 1 Connection to a PC To connect the sensor to a PC follow these steps e turn off the sensor power supply e connect the 4 pin connector of the USB cable to the 4 pin connector of the adaptor see fig 2 step 1 e connect the USB cable to the PC fig 2 step 2 e connect the free end of the adaptor Molex connector to Connector 1 of the sensor fig 2 step 3 e turn on the sensor power supply e if the sensor drivers were previously installed the PC will automatically detect the connected device 20 Note For more information on the TKLSConf Software see TKLS Configuration Software help file The TKLSConf Software provides configuration of the sensor via the RS 485 bus The customer can specify t
4. average or exponential Resolution bit 12 Temperature Measuring Range C 40 85 Temperature Measuring Accuracy C 1 Operational Conditions Operational Voltage V 7 60 Power Consumption at 12 VDC mA lt 30 Operational Temperature C 40 85 Protection Class IP69K Probe Length mm 750 1500 2000 Mounting SAE 5 bolt pattern Average Life Time years 10 Averaging Methods Scope of Supply Description TKLS Fuel Level Sensor with Plastic Cover Mounting Kit Signal Cable in Corrugated Pipe Registration Certificate Warranty Certificate The mounting kit includes following tools Seal gasket 1 pc Self tapping screws with mounted washer and sealing M5 size 5 pc Rivet nut knurled M5 size 5 pc Machine screw M5 size 5 pc Plastic seal 1 pc Meter seal for connector 1 pc End cap 1 pc Fuse with holder 1 pc Components of sensor Gelle Product identification 5 Mounting hole x5 6 Interface Connector 1 male 7 Sensor cover 8 1 2 O O T 6 Seal gasket Measuring probe End cap Sealing hole x4 Device designation contains trademark and contact details of the manufacturer device description serial number and release date of the device The sensor is supplied with a transport plug whi
5. ch should be removed and replaced with the end cap before sensor installation 10 Interface Connectors D 0 0 Dr 0 D Interface Connector 1 male Connector 2 female View from side of pins View from side of sockets Vin RS 485 A Frequency output OK Vin RS 485 B Digital input active low Both connectors are keyed to prevent wrong orientation Sensor Installation Before installation it is highly recommended to check the sensor for any mechanical damage Sensor location e The sensor location depends on the geometric form of the tank and should be chosen in such a way as to provide accurate readings regardless of fuel movement in the tank during vehicle motion e Normally the sensor should be located at the center of the top of the tank See figures below e If it is impossible to install the sensor as shown above it should be located as close as possible to the recommended area e If due to the geometric features of the tank one fuel level sensor does not provide the required accuracy of readings it is recommended that several sensors are installed into the tank A set of two sensors is commonly used in this way In this case the fuel level in the tank amounts to the average readings of the two sensors Preparation of the fuel tank All preparation work mu
6. equency form Before connecting to the TKLS the input of the AutoGRAPH GSM must be switched to Frequency Mode Internal Diagram of Frequency Output FREQUENCY OUTPUT DIGITAL ISOLATOR General Connection Diagram for Frequency Output FREQUENCY OUTPUT 3 ORANGE with WHITE STRIPE AutoGRAPH GSM controller KE A No TO VEHICLE SYSTEM TO VEHICLE SYSTEM VOLTAGE VOLTAGE Important All connections should be performed when the sensor and all external devices to be connected to the frequency output are disconnected from the power supply 18 Error Codes The TKLS sensor has an embedded self diagnostic procedure that provides detection of errors during sensor operation When connected to the AutoGRAPH GSM controller via RS 485 bus the TKLS sends error codes if any to the controller The code will be recorded in the controller as a temperature record Error Code Description Error Code Error failure description short circuit capacitance probe break frequency out of calibration range built in accelerometer fault Important The TKLS sensor transfers the error code via RS 485 only when it is connected to the AutoGRAPH GSM or AutoGRAPH WiFi onboard vehicle tracking controllers When connecting to other external device the error code won t be transferred Diagnostic operation can be performed using the TKLSConf configuration program If
7. es transfer of fuel level values in the form of pulses at a variable frequency The sensor is also capable of measuring ambient temperature 15 Power Supply Connection When making the power connection pay careful attention to the safety rules stipulated by the regulations for motor vehicle repair procedures The sensor is supplied with a fuse intended to provide short circuit protection of the power supply The fuse holder is installed on a wire ring which should be cut before operation The power supply input of the sensor is rated for a voltage of 7 60 V Connector 2 To connect the power to the sensor you should follow these steps e Connect Vin wire of the signal cable to Vin line of vehicle power system and connect Vin wire to Vin line of the vehicle power system e Connect the fuse supplied with the sensor to the Vin line The fuse should be placed as close as possible to the point where the TKLS is connected to vehicle power system e Connect Connector 2 of the signal cable to the male Connector 1 16 RS 485 TIA EIA 485 A Bus Connection The TKLS sensor is equipped with an RS 485 TIA EIA 485 A bus which allows the sensor to transfer collected data to an external unit equipped with RS 485 The TKLS supports the following commonly used data transmission protocols LLS and ModBus The data transfer protocol can be selected using the configuration program The configuration program TK
8. he settings in the TKLSConf program and send them to the data server These settings will be transferred to the AutoGRAPH onboard controller which is connected to the sensor and after that will be transferred to the sensor via the RS 485 bus The sensor supports remote configuration via Bluetooth using a mobile device To do this the Bluetooth option must be enabled in the sensor s settings and an access password must be known by the customer 21 Modbus Register Mapping The TKLS is capable of communication via the RS 485 serial bus in the Modbus RTU protocol The TKLS supports the Modbus function 03 Read Holding Registers TKLS address RS 485 baud rate high bit RS 485 baud rate low bit Full calibration high bit Full calibration low bit Zero calibration high bit Zero calibration low bit Averaging time weighting coefficient Temperature Raw fuel level data high bit Raw fuel level data low bit Fuel level Serial number high bit Serial number low bit Averaging method Output frequency when tank is full Output frequency when tank is empty Raw fuel level data before temperature compensation high bit Raw fuel level data before temperature compensation low bit Averaged raw fuel level data high bit Averaged raw fuel level data low bit Error code high bit Error code low bit Number of
9. hich is granted in virtue of law upon each sale of the product When a TKLS is connected to an AutoGRAPH GSM Series on board vehicle tracking controller the data is transferred to a data server using a communication protocol which is considered to be confidential information and intellectual property of TechnoKom The communication protocol between the AutoGRAPH GSM Series on board vehicle tracking controllers and a communication data server shall be transferred by TechnoKom to integrators and software manufacturers only upon signing a Confidentiality Undertaking Unauthorized distribution of the protocol used for communication between the AutoGRAPH GSM Series on board vehicle tracking controllers and communication data server is strictly prohibited Safe Operation and Installation This section contains important information for effective and safe operation of TKLS fuel level sensors Please read the information below before using the sensor e Sensors with damaged insulation of conductive parts testing probe and body must not be used e Operational conditions of the TKLS such as electrical and environmental characteristics and condition of measured liquid should fit the requirements contained in this User Manual Otherwise the manufacturer will not be responsible for sensor safety and functional efficiency e All connections should be made when the sensor and external devices to be connected to the sensor are disconnected from the power su
10. input pulses high bit Number of input pulses low bit Roll angle Pitch angle 22 Note Reading Modbus Holding Registers is supported by the firmware of revision TKLS 1 27 23 TKLS User Manual Appendix APPENDIX 1 SAE 5 MOUNTING 24 IN WD AutoGRAPH USER MANUAL V 1 4 0 TechnoKom Ltd www tk chel ru Copyright Chelaybinsk 2014 All Rights Reserved mail tk chel ru
11. lied with and install the supplied end cap in its place Note The effective length of the sensor must be at least 150 mm after cutting 13 Sensor Installation e Install the seal gasket on the sensor with the wide side of the seal s outer ring facing the tank see figure below When installing the seal also be sure that the mounting holes of the sensor matches the mounting holes of the seal TO FUEL TANK TO SENSOR e Install the sensor into the tank and tighten five fastening screws supplied with the sensor 14 Connection of the Sensor This section covers connection procedures of the TKLS fuel level sensor e Power supply connection e RS 485 bus connection e Frequency output connection The sensor is supplied with a 7 5m signal cable in a corrugated pipe The cable is equipped with a female connector Connector 2 for connecting to the sensor to Connector 1 Both connectors are keyed which prevents incorrect orientation When making connections pay careful attention to the safety rules stipulated by the regulations for motor vehicle repair procedures All connections should be properly isolated and securely connected If the wire is too short it can be spliced with a wire of at least 0 5 mm cross section 20 AWG or thicker The TKLS sensor can be connected to any external unit that supports ModBus or LLS protocols to transfer fuel level readings The TKLS sensor is equipped with a frequency output that provid
12. ment system For proper operation of the TKLS sensor the customer should be aware of the operating principles of these systems as a whole as well as understanding the functions of its individual components Important All information on functions functional capabilities and other specifications related to TKLS fuel level sensors as well as all information contained in this User Manual is based on current data at time of writing and is deemed to be valid as of the date of publication TechnoKom reserves the right to modify the information or specifications without prior notice or commitment Software Copyright Notice Products of TechnoKom referred to in this Manual may incorporate software stored in semiconductor memory or other media copyrights to which belong to TechnoKom or third parties Laws of the Russian Federation and other countries secure certain exclusive rights of TechnoKom and third parties to the software which is subjected to copyright for example exclusive rights for distribution or reproduction Therefore any alteration reverse engineering distribution or reproduction of any software incorporated in TechnoKom products is prohibited to the extent provided by law Furthermore purchase of TechnoKom products does not imply direct indirect or other granting of any licenses related to copyrights patents and patent applications of TechnoKom or any third party except for an ordinary nonexclusive free license for use w
13. pply Product Overview The TKLS fuel level sensor is designed to measure fuel level in a vehicle fuel tank and transfer this information to external devices via one of the supported interfaces The TKLS can be used as a replacement of the factory fitted standard fuel level sensor or as an additional sensor for fuel level monitoring The TKLS supports data transfer via RS 485 bus in LLS and Modbus protocols and via frequency output as pulses proportional to measured fuel level In addition to fuel level the sensor measures ambient temperature and sends the readings to an external device Any device equipped with RS 485 which supports data exchange in LLS or Modbus protocols can operate as an external device for example a level indicator or an onboard vehicle tracking device Technical Specification Output Interface RS 485 TIA EIA 485 A Frequency output Protocols for RS 485 LLS ModBus Bluetooth BLE Yes Built in Accelerometer Yes Self diagnostic Yes Error Report Yes Remote Configuration via Bluetooth Yes Remote Configuration via RS 485 Yes Remote Firmware Update Yes Logging Yes Temperature Measuring Yes Automatic Calibration Yes Digital Input numbers 1 Frequency Output Output Frequency Range Hz 100 3000 Output Type Open collector Maximum Load Current mA 200 Measuring Features Operational liquids Gasoline Fuel oil Level Measuring Accuracy lt 1 Moving
14. st be performed in accordance with the safety requirements specified for the tank e Before installation on a diesel tank it must be filled with diesel e Before installation on a petrol tank it must be completely emptied of petrol and filled with water 12 e Before drilling ensure that there aren t any baffle plates inside in the tank in the proposed sensor installation area within a radius of 20 mm This can be checked by drilling a small hole about 3 mm in the installation area e Drill a central hole 35 37 mm diameter using a bimetal boring bit e Drill five holes for SAE 5 bolts e Install the seal gasket on the sensor then mount the sensor into the tank Sensor Cutting The sensor length can be cut to match the specific fuel tank To do this you should follow these steps e Measure the tank depth by inserting a ruler in the tank through the central hole that has been prepared for installing the sensor e Measure the tank depth on the effective length of the sensor L It is recommended that the sensor is shorter than the tank depth by 10 30 mm to prevent false reading due to impurities including water in the bottom of the tank The effective length of the sensor should be adjusted depending on the amount of the impurities e When cutting the sensor be sure that the cut is straight and perpendicular to the roll axis of the sensor e Remove the transport plug which the sensor is supp
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