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TRD-500 user manual v1.4 ENG _2011-11-07_

1. a flow meter ag 7 ri bracket a rom fine filter forward flow f chamber back flow chamber from jets and FPHP outlet ey Fig 5 An example of sensor installation on J AMZ engine User manual V1 4 fuel flow meter TRD 500 Connection of TRD 500 to terminal Fig 6 TRD 500 slot Tab 2 Marking of wire and sensor socket Contact Contact use Color of internal sensor Color of wiring extender into split wires 1 8 power Brown Brown 2 power Red Blue 3 K1 left chamber from Grey Yellow green wire 4 K2 right chamber from Violet Black wire Calibration of sensor TRD 500 Sensor TRD 500 has various coefficient values at various flow rates viscosity and working temperatures of flowing fuel 2 variants of flow meters are produced at present one with coefficient adjustment through the built in controller streamwise and one without it At the same time real flow coefficients on the vehicles can differ from that of the factory ones because of different viscosity and temperature If you have a flowmeter with engraved serial number with engraved underlining it is a flowmeter of the first type with flow factor modification by the built in controller Such flowmeters were calibrated at normal temperature and viscosity in the manufacture and they give out exactly 200 impulses per liter in operating modes from 80 to 500 liters per hour Basically such flowm
2. of installation of such stabilizer is shown on fig 4 In this case it is not recommended to displace bypass valve 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 User manual V1 4 fuel flow meter TRD 500 common rail romer sd back flow from HPFM I high prdssure fuel pump back flow from jets magnetic filter forward flow o mm mm e d forward flow chamber TRD 500 back flow chamber filter fuel feed pump B remove bypass valve to this point RAT Fig 3 a sample of back fuel flow stabilizer User manual V1 4 fuel flow meter TRD 500 General data on installation 1 The content of a gaseous component in fuel lines isn t allowed 2 Ingress of particles at installation 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 subtra
3. FUEL FLOW METER TRD 500 USERS MANUAL version 1 4 FOR FUEL FLOW METER TRD 500 07 11 2011 Sapsan Group www skontrol ru Chelyabinsk 2011 User manual V1 4 fuel flow meter TRD 500 Content Main technical characteristics of fuel flow meter TRD 500 r nssrrvnrsvrenssrrrnssrvrnrsrvrnssrrnsssrrnserressrnrn 3 DSIVery AF COM PIGESS CES eee ES 4 TRD 500 sensor INStallAtiOliss 25s 5ssecs dasacsessacsusactawatgoasasacteadsvadgecsanaesectasadevasebvaceceawsdasiuasiasseladesesaurncens 4 Calibration of sensor TRD 500 Lane jat 5 General data on installation ds icc ccsttin cea ueteent st casun Seas enl 5 General instructions on pipelines installation srronrronrronrrnvrrnrronrronrrnnrrnvrnnvrenrrenrrnnrnnvrnnvrensrenssennnnn 7 Connection of TRD 500 TO lt PAC ORC se 8 Final inspection and functional check of TRD 500 r rsrrsnrrevrrnvrenvrrnrrrvrrevrrnvrenvrsnrrsvrrevsrsvrsnsennnsennrnn 10 Operation NE Aer Sk en 10 Manufacturer s warranty uret apene en 10 User manual V1 4 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 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 fue
4. ct 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 Fig 4 Choice of the installation place User manual V1 4 fuel flow meter TRD 500 General instructions on pipelines installation 1 Fuel lines should be laid on a vehicle in a reliably environment 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 2 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 6 It is not recommended to mount TRD on parts of vehicle that undergo a strong vibration and heating 7 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
5. e 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 10 User manual V1 4 fuel flow meter TRD 500 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 11
6. eive coefficients for both chambers on several modes 3 5 times and then bring a curve into internal memory of flow meter tab 4 9 Return system back in a working condition ul S fuel feed pump forward flow common rail back flow if high pressure fuel pump magnetic filter TRD 500 back flow chamber forward chamber N measuring tank fy EN auxillary tank uE fuel tank Fig 7 Installation diagram of TRD 500 at calibration User manual V1 4 fuel flow meter TRD 500 Table 3 Findings of fuel flow meter TRD 500 calibration fuel flow meter WITHOUT correction card Supply chamber Return chamber Flow coefficient Flow rate Q1 Flow coefficient Flow rate Q2 volume k1 volume of spent volume of spent k2 volume of of spent fuel sampling fuel quantity of fuel sampling spent fuel quantity time pulses time of pulses I h ml pulse l h ml pulse at idle speed k1xx k2xx at load rom k1load k2load Avarage flow k1 0 25 k1xx 0 75 k2 0 25 k2xx 0 75 coefficient k1 load k2 loadp 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 pr
7. eters can be installed without additional calibration The calibration should be done only in case of discrepancy of the received data If you have a flowmeter with engraved serial number but without underlining it is a flowmeter of the second old type without flow factor modification by the built in controller Such flowmeters should be calibrated extra To increase the accuracy of measurement you need to calibrate the sensor on 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 Prepare supply and drain capacities 10 liters in volume Capacities should be calibrated and give a possibility to define fuel quantity with 100 ml accuracy That will make possible system calibration with 1 accuracy User manual V1 4 fuel flow meter TRD 500 6 Disconnect supply and return pipes from a tank and direct them into supply and drain capacities See fig 6 Do not let the air into supply hose at hoses displaceme
8. l flow meter Measured fuel flow range from 30 to 500 I h Number of measurement channels 2 supply and return flow WITHOUT WITH correction card correction card Conformity of one output pulse K1 with 1 150 250 1 200 fuel volume flowing through port K1 re liters pulse Conformity of one output pulse K2 with 1 150 250 1 200 fuel volume flowing through port K2 liters pulse eee ew ece Basic percentage error of fuel metering 1 Operating supply voltage 12 24V Power supply voltage range that provides 10 30 V normal operation Useful current no more 50 mA Digital output impulse open collector Ambient temperature at which normal operation of fuel flow meter is provided From 40 to 65 OC Dimensions mm not above 67x73x100 5 Weight not above 0 5 kg Run time of fuel flow meter twenty four hour Average time to failure not less 12500 hours Ingress protection rating of fuel flow IP68 meter not less UBbIx Fig 1 Data on flow meter impulse response User manual V1 4 fuel flow meter TRD 500 Data on the precious materials content in fuel flow meter No precious materials are used Delivery in complete sets Name Quantity TRD 500 1 piece Wiring extender with interconnect plug I piece Hose adapters 4 pieces Joint washers 4 pieces Certificate 1 piece Wi
9. nt If necessary pump over the fuel supply system 7 Fill supply capacity and empty drain capacity 8 Connect both chambers of the flow meter to the impulse counter You may use the Daily Scan computer of SapsanVneshTrog production to count the impulses You may also use the terminals 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 Daily Scan computer as the measuring tool you should do the following temporarily set both coefficients equal to 1 and choose the fuel rate display mode at calibration a Start the engine and set idle rpm Note quantity of the spent fuel of supply capacity 1 2 glasses and power on the terminal at this moment that is start impulses counting Note the time with 1 2 seconds accuracy b Let the vehicle to spend fuel from supply capacity c At fuel use practically to the bottom stop the engine Stop calculation of impulses and time d Define quantity of the spent fuel from supply and drain capacities to within 100 ml e Bring the data in the table f Repeat procedure for other turns For a flow meter without correction card it is enough to receive coefficients for both chambers on two modes idle rpm and at usual load then calculate coefficient by formula from table 3 Enter the received coefficients into the monitoring program For a flow meter with correction card you should better rec
10. ovide 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 it 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 Operation 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 whil
11. re 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 scheme 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 of 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 fuel injection pump assembly of 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 If there is a bypass valve on fuel injection pump output we recommend to unscrew it and to displace it to the output of the return flow chamber see fig 2 It will allow to increase pressure in the return flow chamber If there are air or foam bubbles installation of additional fuel stabilizer deaerator in a return line between fuel injection pump and the return flow chamber is required The example

TRD-500 user manual v1.4 ENG _2011-11-07_

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