FUEL FLOW METER TRD-500 USERS MANUAL FOR FUEL FLOW
Contents
1. Calibration of sensor TRD 500 Sensor TRD 500 has various coefficient values at various flow rates At present coefficient adjustment with the built in controller isn t carried out Therefore to increase the measurement accuracy it is necessary to calibrate the sensor at the car General installation sequence with system calibration 1 Choose the place for installation proceeding from the convenience of a pipeline running and general data on TRD installation See section General instructions on pipelines installation 2 Fix the sensor on the car on a bracket or integral unit of the car 3 Install a magnetic filter on a return pipe 4 Connect section of return flow measurement Both sections are identical Choose which section to install into supply line and which one into return line depending on the convenience of pipelines running 5 Temporarily connect section of supply measurement in sequence with section of return measurement on the return pipe See fig 3 6 Disconnect a return pipe from a tank and direct it into an auxiliary tank see fig 3 7 Connect both chambers of the flow meter to the impulse counter You may use the DailyScan computer of SapsanVneshTrog production to count the impulses You may also use the recorders that enable to see current values of the impulse counter for example Autograph terminal when it s connected to the AutoGRAPH control exe program If you use the DailyScan computer as the meas2. FUEL FLOW METER TRD 500 USERS MANUAL FOR FUEL FLOW METER TRD 500 03 04 2011 Sapsan Group www skontrol ru Chelyabinsk 2011 EH wy goteltos braous S v ES User manual fuel flow meter TRD 500 Content Main technical characteristics of fuel flow meter TRD 500 rrrvvvvvvvvvvvvrrvvvrvvvrvnvrrvvrrrrervrrrrrrrrrrrrreenn Deliver IN complete SUS see TRD 500 sensor installation eerrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrssssssesssssssssssssssssssessnnnnnnnnnsnesee Calibration of sensor TRD 500 ssrsrsnnnsnnnsnnnnnnnnnnrrnrnnnnsnrnssnsnnsnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnansnnnannnnnnnn General data on installation rrrrrrrrrrrrrrrrnnnnnvrrrrrrrnnnnnnnnrrrsrsrrrrrrsnnnvvvverersrennnnneesssssssssnaaavnvvvvveresseenee General instructions on pipelines installation rrrrrrrrrrorrorororororrrnrnrnrrrrrrrrrrrnrrrrnnrnrrnnnrnnnnrnrrnnnnnnnnn Connection of TRD 500 to recorder muurnnnunnnvnnverenennrenennnnrrnnnenenenenenenenennnenenennnenenenenenenenenenenenenenseee Final inspection and functional check of TRD 500 rvvvvvvvvvvvvvrvvvvvrrvernvrrvrrrrrrvrrerrrrvrrvrrrvrerrsnvrvvvvevenn PTE Manufacturer s warranty SS User manual fuel flow meter TRD 500 Main technical characteristics of fuel flow meter TRD 500 The fuel flow meter of differential type TRD 500 is designed for measurement of flowing fuel volume and delivery of electric impulses at
3. TRD 500 Final inspection and functional check of TRD 500 Wipe all new connections of fuel lines and check whether there is no fuel accumulation next to an exhaust system muffler Take all tools material rests flooring and rags away from a vehicle If it is necessary close an engine department lower a driver s cabin On engine operating indoors provide reliable removal of exhaust gases through exhaust ventilation Start the engine and set constant frequency of rotation idling Pay attention on the engine operation resistance Check whether the engine reacts on a gas pedal and comes back to idling when you release tt Instability of engine rpm points to problems in fuel line system in additionally installed filter or bad pumping of fuel system On engine operating evaluate visually hermiticity of all fuel line connections Stop the engine and check whether there is no fuel leak and air drain in all union joints of fuel system the sensor and the additional filter Fuel leaking in joining places of fuel lines isn t allowed Don t try to tight the joint places Use new copper joint washers to tight it Plugging fuel system leaks should be carried out only at dead engine In no case try to tighten the joint places at engine running If there is no fuel consumption indications the consumption is equal to zero it is recommended to check rotation of TRD mechanism through blowing it off by air If necessary replace TRD Operatio
4. eme see fig 2 Thus the fuel system undergoes no modifications except for insertion of two sections of TRD into a supply and return lines The first section is installed between the fine filter and high pressure fuel pump the second one back flow is installed into return flow line after a connection point connected high pressure fuel pump return flow and jet return flow Fuel consumption is determined as an indications difference of measurement chambers of supply and return flows TRD 500 is inappropriate for engines at which fuel flows from back flow line with some air some engines with HP THBJI a high pressure In such engines measurement accuracy of back flow can be essentially reduced because of the air To define whether there is some air at back flow you should sink back flow hose in transparent capacity to the bottom and watch whether fuel comes out with bubbles and foam while capacity filling The following things are necessary for installation TRD 500 installation kit a drill a key set a fuel resistant hose a knife to cut the hose a bracket and self tapping screws bolts to fix the device to a bracket common rail back flow from HPFM rom hl U SI high pressure fuel pump magnetic filter forward flow EITT Ife forward flow chamber i TRD 500 back flow chamber filter fuel feed pump t fe i Fig 2 Principle installation diagram for TRD 500 engine User manual fuel flow meter TRD 500
5. installation in a fuel line of cars tractors and other mobile and fixed machines and integral units vehicles according to the differential installation diagram The fuel flow meter is nonrepairable item Table 1 Basic technical data of fuel flow meter Measured fuel flow range from 30 to 500 I h Number of measurement channels 2 supply and return flow Conformity of one output pulse K1 with 150 250 fuel volume flowing through port K1 l pulse Conformity of one output pulse K2 with 150 250 fuel volume flowing through port K2 Operating supply voltage Power supply voltage range that provides normal operation Useful current no more Digital output Ambient temperature at which normal operation of fuel flow meter is provided Dimensions mm not above 67x73x100 5 Weight not above Run time of fuel flow meter Average time to failure not less 12500 hours Ingress protection rating of fuel flow IP68 meter not less UBbIX Basic percentage error of fuel metering e _ te i g a a 05 i o1 i i Fig 1 Data on flow meter impulse response Data on the precious materials content in fuel flow meter No precious materials are used User manual fuel flow meter TRD 500 Delivery in complete sets TRD 500 Wire length is agreed when ordering Tt is supplied in agreement with buyer TRD 500 sensor installation TRD 500 is installed according to the differential installation sch
6. measuring tank k22999 capacity of measuring tank load rpm impulse quantity impulse quantity Average low k1 0 25 k1xx 0 75 k12000 k2 0 25 k2xx 0 75 k22000 coefficient General data on installation 1 The content of a gaseous component in fuel lines isn t allowed 2 Ingress of particles at mstallation isn t allowed 3 It is required to install a fuel filter before the supply chamber and a magnetic trap for a metal dust before the return chamber to catch metal dust of worn out parts of fuel injection pump assembly If it is not possible to install TRD after the standard fine filter install the sensor after the additional fine filter 4 It is recommended to seal up all fuel lines and electric connections 5 It is not recommended to use it in Common Rail systems with open type fuel injectors 6 It is necessary to subtract indications of the fuel supply pipe from the return pipe indications to found out fuel consumption 7 To get the value of fuel consumption you should subtract indications of the fuel supply line from those of the return line 8 A direction of fuel movement through flow meter chambers are marked by arrows on chambers Return connection is not allowed 9 Use only steel not aluminum fittings User manual fuel flow meter TRD 500 E R Fig 4 choice of the installation plane m General instructions on pipelines installation Fuel lines should be laid on a vehicle in a reliably envi
7. n notes ATTENTION At work with a flow meter it is necessary to carry out following restrictions Do not apply power supply voltage exceeding 30 V on a flow meter Do not allow polarity violation of connected supply voltage Manufacturer s warranty The manufacturer guarantees the conformity of a flow meter to requirements of the design documentation while meeting the requirements of installation service rules transportation and storage rules by customer Guaranteed storage life is 2 years from the manufacturing date As the manufacturing date the date specified on a flow meter in the certificate shall be taken Guarantee period is 24 months from the date of introduction into service but no more than 30 months from the manufacturing date During a guarantee period the manufacturer undertakes the obligation to replace a flow meter for free in case of defects and failures occurrence The guarantee period is prolonged for the period from the claim submission to flow meter setting into operation after replacement The address of the manufacturer Sapsanvneshtorg Ltd Tel 8 351 247 75 58 454081 Russia Chelyabinsk Rossiyskaya str 194 www skontrol ru
8. ronment proofed way and at break of their hermiticity there should be no fire danger they should be laid under a collector turbine not over them Protection of fuel lines from contact with sharp edges of integral units of the car and break stones flying out from under wheels should be provided Fuel lines should be a little bit longer to make up temperature changes of length It is not allowed to reduce internal profile of fuel lines at bending Fuel lines should be mounted on the vehicle with couplers clamping devices which don t damage a tube and allow temperature changes of fuel lines length It is not recommended to mount TRD on parts of vehicle that undergo a strong vibration and heating Keep flanges and TRD connection carvings clean Don t touch their surface with dirty hands At installation don t let dust and water ingress in a flow meter User manual fuel flow meter TRD 500 bracket man ane 7 filter forward flow f chamber back flow chamber from Jets and FPHP outlet b i Fig 4 An example of sensor installation on JAMZ engine Connection of TRD 500 to recorder Fig 5 TRD 500 sensor slot Wire marking and sensor socket Contact Contact use Color of internal sensor Color of Wiring extender into split wires gt power Brown Brown en dn 3 Kl left chamber from Grey Yellow green wire 4 K2 right chamber from Violet Black wire I User manual fuel flow meter
9. uring tool you should do the following temporarily set both coefficients equal to I and choose the fuel rate display mode at calibration 8 Empty a measuring tank 10 liters in volume Direct the return pipe to the auxiliary tank Start the engine and set on idle rpm Displace a hose in a measuring tank and at the same moment notice current indications of both counters After the measuring tank is filled place a hose back and notice the indicators at this moment Enter the data in the table 1 and calculate k1 and k2 9 Empty the measuring tank and repeat the calibration on load rpm 2000 rpm Enter the data in the table and calculate k1 and x2 10 Reconnect supply section to a supply pipe see fig 2 and place a supply pipe back in the tank 11 Pump over engine fuel system start the engine and check working capacity common rail back flow t h r EST high pressure fuel pump forward flow magnetic filter TRD 500 back flow chamber fuel feed pump S forward chamber measuring tank fuel tank re auxillary tank L Fig 3 Installation diagram of TRD 500 at calibration User manual fuel flow meter TRD 500 Table 2 Findings of fuel flow meter TRD 500 calibration Section 1 liter impulse Section 2 liter impulse Flow coefficient at klxx capacity of measuring tank k2xx capacity of measuring tank idle speed impulse quantity impulse quantity Flow coefficient at klooo0 capacity of
Download Pdf Manuals
Related Search