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FUEL-VIEW installation manual

1. TECHNOTON 2007 2014 Version 2 0 6 hole 28 5 4 be 1 Dimensions for reference 2 Serial number xxxx 52 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 Appendix A continued DFM 250C and DFM 500C I MMLYY p 2 c p 3 6 hole 8 5 H p etr 45 60 1 Dimensions for reference 2 Serial number xxxx TECHNOTON 2007 2014 53 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 Appendix A continued TECHNOTON 2007 2014 54 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 Appendix A continued TECHNOTON 2007 2014 55 of 63 Version 2 0 DFM Fuel Flow Meters Operation Manual Appendix A continued AA WIN 91ep uononpoud Xxxxx 1equunu jeues Z 69u9J9J91 JO SUDISUBWIG L a E u S Lj H 4 vy I eee HIDE G Oe m mq 4 f ug 1 I o_u l 1 1 to cy to og 4200L WAG 51205 WAG S 8 eru 9 EM E 1no jnouid 10 28uu0 XV00L WAG AYOS WAG 0S9 cd JTN 56 of 63 TECHNOTON 2007 2014 Version 2 0 DFM Fuel Flow Meters Operation Manual Appendix A continued AA WW 9jep uononpoud E xxxx 1equunu eues z 82U919J81 104 SUOISUBWIG 441 ee u m i j
2. L u B a o acy l CD acy ED ay Ln acy asies o co FD cy pn cq i LE RN 4900S WA i20S2 WA o E i A hx WT 4 f pans ll I Eee oe Seen t ALL q i J i M 1 dy 1 1 i i Ln cq Cn cj Cn cj DO cj En drj r OND 5 7 SK 1V8A 2 EIN ct ino U jnouid 10j28uuo0 Xvoos WAC ivvosz WAG SOL D 06 j Lo 05 j i V1 T WN Hr 1 o9 sr 1199 4 SR 4pp e 1 H i Cn ay D ag Da 059 rj Fn cy l 1 x t J mani i Ir XXXX in SS SL 57 of 63 TECHNOTON 2007 2014 DFM Fuel Flow Meters Operation Manual Version 2 0 Appendix A continued DFM 100D Connector pinout OUT VBAT A GND 1 Dimensions for reference 2 Fuel flow direction F feeding R return 3 Serial number xxxx TECHNOTON 2007 2014 58 of 63 DFM Fuel Flow Meters Operation Manual Appendix A continued 162 DFM 250D 6 hole 8 5 144 J 112 T i ja I i a e L H T i hr i i 4n 1 4 IT fh f i 4 i j Ti 4T is A 4 Hie ee a a if T NEU RENE RON US UM re 1 l 2 CLI Connector pinout LL OUT TECHNOTON 2007 201
3. ATTENTION If the measurement value of the average fuel consumption of the vehicle is close to the upper limit of a certain DFM model it is recommended to choose a DFM model with higher rating values That will ensure absence of a fuel flow meter s influence on the fuel system as well as longer DFM operating life TECHNOTON 2007 2014 11 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 1 5 Unit structure and operation principle DFM consists of a ring type measurement chamber 1 a top cover 2 with a microprocessor board inside a bracket 3 and an interface cable with plug connection 4 Figure 8 DFM components DFMs refer to devices of direct volumetric measurement of the fuel consumption with ring type measurement chambers The principle of DFM operation is based on measuring fuel volume that passes through a measurement chamber Under pressure of the fluid flowing through the fuel flow meter inlet nozzle to the inlet of the measuring chamber the ring slides along the inner surface of the chamber and it also slides along the web The ring pushes the fluid inside and outside the chamber out through the outlet into the outlet nozzle see Figure 9 One turn of the ring pushes out the volume of fluid equal to the volume of the chamber At the same time the electronic board of the DFM makes one outlet pulse Figure 9 The scheme of DFM measuring chamber work The structure is presented by the example of
4. DFM 50C DFM 100C DFM 250C DFM 500C FUEL VIEW Fuel Flow Meters DFM 50AK DFM 50CK DFM 100AK DFM 100CK DFM 250AK DFM 250CK DFM 500AK DFM 500CK DFM 100D DFM 250D DFM 500D TECHNOTON DFM Fuel Flow Meters Operation Manual Version 2 0 Contents EACEOGUCU Oy REP RODEO 4 1 Basic information and technical SPECIFICATIONS sssseeeeeeeee nennen nennen 6 Pod cPURDOS S Ol WSS yah T D TU AT 6 1 2 Extertor view and delivery S CU sesiiateseterceabixtiz de pud NE d d rate Ex atr d Cade b E riu Nba 7 UMS DEM WATICHCS NETTE II LIT 8 1 3 L DEM B zangd DEM C models rreran raa OUR a E Sa ata senna dva SPA Rai S Emus 8 moe DRM CK MOJE En 9 153 5 DFM AP and DFM AKR IMOGElS seihict2 teianunaride tiie nian T ME Date 9 1 3 4 DEMJD fulodelssssaseevssiavtatevs dor paese rede et eoa vare d ovr voor pad evuw dod dard a vvpebor roro ier edet un 1 0 1 4 Measurement range and precision ccccccccceeeeee eee E PEE HEHE nnnm EERE SEES EERE nnn 11 1 5 Unit struct ure and operation DFINCI DIG sa ssuinsieiininersancaianeete ined Poe eoim dnt qur Pad e OR ed turi 12 LO bechinieal SpecifIcablofis disbiazesh raodo sidan Lis qx Pa tav anc Data aa Reid tta ban imis tutem Of 13 12651 WVOPKIDO TIUS cedo cR tratados E Pape aua tasa diit E teo qni dcn 13 126 2 Mat speci Necat ON ENE awew IV DoaM Eo esas rU UN M PO ES SUN Li rrr DO PO EIE 14 1 6 3 Specifications of measurement chambers ccssseeeeeeeen eene nnns 15 1 64
5. Representative of the CUSTOMER fo Representative of the CONTRACTOR _ 63
6. 28 2 4 3 DFM installation after the pump sssesexesspeebissass taut ep vin xurcwerida ker Pix ned uber br vr erae 31 2 4 4 Differential DEM installatlon Schelme zi xsive veu Er ERR en wees E RAO TRP PUAUADUUE 32 TECHNOTON 2007 2014 2 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 25 Electrical CONNECLION sous p pEERARYEEEUR Es UE MUR T EXER MEnEM e cau sanenaboense teens KEROS 34 2 6 DFEM a dJUS NEN rr C E 3 5 2 7 Measurement accuracy CHECK eu tcm vs taxe utb UE Vh EE xDD EXPE PUEDE ev eee RE MM REP aw 35 2 FL VES CONGIUIOMNS au deep aee exten oben reda ger ires lareo itn ered A bd Fa t ebbe Avus 3 5 2c Preparation for the LOSES raaire qug iur UE MERE AX X RR CR VENTURE CER ME E 36 PERS CONUN GNO MEET LT anne one nae eae 3 6 2 9 ACCSSSOFIGS irria cuneo vi RN EO FARO IURI en NECI Po Ud Da NC MM COPI R DEPXI LAUDE 3 8 2 90 1 MOUFICITIGKIUS acus e oed adeb T ad RM he hoards 3 8 2 02 CONMNCCEING CAD CS aiscevrssausainiavnvauasaescennaasor iain PI daa vr DRIN UE PTRER EE eae V a 4 1 2 9 29 DFM fuel CONSUMPTION IndICalor iuri eur eure E UT EYE ER DF EE DDR EF UEN REF Ik Rx E RR EE ERR eis 42 3 Diagnostics and troubleshooting icis uwix ves EX PEREEAKVRERVEUE ER EUER VEA ERRARE Y ase MERKEN RENT 4 8 Zval dtlolie deste etae ut ossi im Maui ule LE EIL Rb LL MM LI Ua ELE te 4 9 S Malntelalleessbsor ed No een ea End PIDE LUE Sven M VN VERO Pri EoI ME 4 9 6 SOJ Oneone LU LIU II IIMTLTTUUTLSMM 50 7 TEANSD OMCING
7. PoWeI SUBDIV HTIOGBS xu Rod ESQ Ra or Be ane vd Om R GN OD KO ee 1 5 1 6 5 Operation MOGES iss o Odor Morte deca istum e pa rei e obtu eva e i En 1 6 136 0 DISDla VCC Cala REESE TT TII IIT aeeavacs eres sen aan ynaieee 1 7 1 6 7 DFM protection from tampering and INterVentiONn cccccceceeeeeeeeeeteteeeeeeneneenes 19 1 6 8 Specifications of output pulse signal of the DFM with interface output 20 1 7 DFM compatibility WIth tekmilblals sss tux dust eap ra a cet winner tea e reda doni c cete 22 BODEM SCIGCUION civani m 23 1 8 1 Selection depending on the engine power boiler output eese 23 1 8 2 Selection depending on the fuel flow in the supply and return lines of the engine 24 2 Installatior and setis ia dx ov amid d vind er EE Md ene Ma uate to ns tea I PIE 25 2 A Ext emal examination before Start isissse ei eves dedu qup 43 EE2XARaRIUOUMORIZARNE E TUDUNDETDA a Au dod 25 2 2 AS5sessimmentof the vehicle Condition ses ecsdea quee Rs vbt rennan Orr P tubi PVP ux Sa FE EP EI DES 25 2 3 General Thstalldtor INStrUCUONS caesos ele npMERRARE AT InUQE dU MIU CIR UD RAS EH ATE MM IMPERA MISES 26 2 4 Fuel flow meters mounting schemes cccccccssssensccecueueueueuuueeecesensueeeueeenaugugeueuennes 28 2 4 1 Typical diesel engine fuel system scheme seseeeeeeennnnn nemen 28 2 4 2 DFM installation before the pump ccssen mmm meme nennen
8. a single chamber DFM with display and interface output TECHNOTON 2007 2014 12 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 Distinctive design features of DFM fuel flow meters DFM structure allows the fluid flow even if the ring is fixed for example due to chamber clogging Special coating of the ring ensures its durability and wear resistance The measuring chamber is made of durable and lightweight zinc aluminium ZA alloy A mud filter effectively protects the working chamber from fouling The filter can be removed and cleaned without disassembling the DFM body M14x1 5 and M16x1 5 nozzles allow mounting the DFM on any automotive vehicles without adapters A large flow passage minimizes hydraulic resistance to the fuel flow An improved magnetic circuit reduces sensitivity to hydraulic shocks in the fuel system of an engine 1 6 Technical specifications 1 6 1 Working fluids DFM can measure consumption of the following kinds of fluids Diesel fuel GOST 305 STB 1658 Furnace oil GOST 10585 Fuel oil GOST 10585 STB 1906 Motor fuel GOST 1667 Admiralty and furnace fuel oil GOST 10585 Biofuel GOST R 52808 STB 1658 Other liquid fuels and mineral oil with kinematic viscosity of 1 5 to 6 mm s TECHNOTON 2007 2014 13 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 1 6 2 Main specifications Main DFM characteristics are shown in Table 2 Table 2 DFM
9. are supplied with electrical power from onboard vehicle power source DFM pilot cable Figure 22 Laying the DFM pilot cable DFM electrical connection is made in accordance with the purpose of the interface cable see Table 10 To connect DFM power supply wires it is recommended to use terminals see Figure 23a and to connect pilot cable wires it is recommended to use connectors see Figure 23b ALI a terminals b connectors Figure 23 Terminals and connectors to connect DFM TECHNOTON 2007 2014 34 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 Table 10 Wire assignment in the plug of the DFM interface cable Wire marking Wire assignment Pulse signal see 1 6 8 Ww 7 Chassis Feed 2 6 DFM adjustment DFM fuel flow meters are supplied ready to use and require no configuration The manufacturer calibrated all DFMs for diesel fuel In the DFM registration certificate is specified the number of pulses of the output signal that corresponds to 1 liter of fuel flowing through the flow meter When DFM is used in GPS GLONASS vehicle tracking and fuel monitoring system interface cable of the fuel flow meter is connected to the pulse input of the tracking device terminal Certified value of the number of pulses per 1 liter is entered into the software configuration at the server of a vehicle tracking system 2 7 Measurement accuracy check To determine accuracy of measure
10. in accordance to Table 8 Table 8 DFM selection depending on the engine power boiler output Engine power kW Boiler output kW Recommended models DFM 50C DFM 50AK up to 80 up to 400 DEM 50CK DFM 100C DFM 100AK from 80 to 150 from 400 to 800 DFM 100CK DFM 250C DFM 250AK from 150 to 300 from 800 to 1500 DFM 250CK DFM 500C from 300 to 600 from 1500 to 3500 DFM 500AK DFM 500CK TECHNOTON 2007 2014 23 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 1 8 2 Selection depending on the fuel flow in the supply and return lines of the engine Selection of the differential DFM depends on fuel consumption values in the supply and return lines of the engine according to Table 9 Table 9 Selection of the differential DFM depending on fuel consumption values in supply and return lines Minimum consumption Maximum consumption Recommended differential l h I h fuel flow meters DFM 100D DFM 500D ATTENTION 1 Maximum and minimum fuel consumption values in supply and return lines of the engine can be found in the performance specification of the booster pump of the engine mounted on the vehicle 2 Installation of a differential DFM on the fuel system with high performance pump and engine with small fuel consumption is not recommended For example the booster pump performance is 300 l h fuel consumption in idle run mode is 5 6 l h and relative fuel measurement error in supply and return lines is 1 9o a
11. repair and installation rules on vehicles and who are experts in the field of electrical and electronic equipment of various vehicles In order to ensure proper functioning of the DFMs their installation and adjustment has to be carried out by certified professionals Models DFM AK DFM C DFM CK and DFM D TECHNOTON 2007 2014 4 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 Order identity code is being formed in accordance with Figure 1 DFM NNN A A Capacity Wired output 50 50l h no wired output 100 100 l h K normalised pulse 250 250 l h 500 500 l h Functionality blind cover C cover with LCD screen D blind cover differential fuel flow meter Figure 1 DFM identification code for an order DFM fuel flow meter 50C Max consumption 50 l h model with LCD display DFM fuel flow meter 100AK Max consumption 100 l h model without display electronic interface normalized pulse ATTENTION The manufacturer reserves the right to change DFM specifications that do not deteriorate consumer qualities without customer consent TECHNOTON 2007 2014 5 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 1 Basic information and technical specifications 1 1 Purpose of use amp OFM are designed to measure fuel consumption of vehicle and stationary installations Figure 2 DFM use Use of DFM provides vehicle owners with the following e
12. to 18 V Onboard 24 V power system must have voltage in the range from 18 to 32 V 4 Check the amount of excess fuel removed from injectors through the return line With a significant amount of excess fuel measurement error increases as the excess fuel gets back into the tank and DFM fuel flow meter counts it again 5 Check pressure in the fuel line with a pressure gauge Hydraulic resistance of a selected DFM at nominal consumption must not lower the pressure by more than 5 in the fuel system 6 Check the quality of the chassis of the vehicle Resistance between any point of the chassis and the negative clamp of the battery should not exceed 1 Ohm According to the results of the check a Vehicle Inspection Report must be filled in and Signed see Appendix B Before DFM installation the owner of the vehicle has to eliminate any malfunctions filled in the Inspection Report TECHNOTON 2007 2014 25 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 2 3 General installation instructions ATTENTION This chapter provides particular cases of the engine operation scheme Read carefully the technical documentation of the vehicle where you want to install a fuel flow meter in order to make a decision on applicability of the meter on this particular vehicle In order to install the fuel flow meter you will need the following e a DFM e a mounting kit sold separately e a bracket sold separately In some cases D
13. 2 4 3 DFM installation after the pump DFM installation after the pump involves installation of flow meter in the line after the low pressure pump where fuel flows under pressure Particular case of DFM installation according to After the Pump scheme In order to install DFM according to pressure scheme in the fuel system with LPFP see Figure 20 it is necessary to use the line between fine filter and high pressure fuel pump input Return line Injectors return line Bypass valve Injectors Fine filter Low pressure fuel pump n Rough filter Figure 20 DFM installation according to After the Pump scheme Return flow from the high pressure fuel pump has to be modified to fuel circulation in a small circle without fuel tank involvement i e the return line needs to be moved from high pressure fuel pump output to fine filter input and high pressure fuel pump output needs to be plugged For correct operation of modified fuel system a bypass valve has to be installed at the fine filter input which will support necessary constant fuel pressure at 1 1 5 atmosphere in the TECHNOTON 2007 2014 31 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 line between the fine filter and high pressure fuel pump input Install a 0 35 0 5 atmosphere non return valve at the DFM output to prevent fuel flow through the DFM in the opposite direction This will decrease fuel system hydraulic shocks at the DFM Thus excess
14. 4 Version 2 0 i i q ee i n j a _ H 4 oitE a ae SE LI Lj 1 Dimensions for reference 700 2 Fuel flow direction F feeding R return 3 Serial number xxxx 59 of 63 DFM Fuel Flow Meters Operation Manual Appendix A continued 6 hole 8 5 DFM 500D Connector pinout TECHNOTON 2007 2014 a 1 Dimensions for reference 2 Fuel flow direction F feeding R return 3 Serial number xxxx Version 2 0 700 60 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 Table A 1 DFM weight DFM 50AK DFM 50C DFM 50CK DFM 100AK DFM 100C DFM 100CK DFM 100D DFM 250AK DFM 250C DFM 250CK DFM 250D DFM 500AK DFM 500C DFM 500CK DFM 500D TECHNOTON 2007 2014 61 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 Appendix B Vehicle inspection report ood 4520 Date Month Year We the undersigned representatives of the Customer and representatives of the Contractor have conducted vehicle installation inspection Vehicle type Brand model Registration number for conformity to DFM installation requirements and have concluded the following Requirement Conforms q Does not conform If there is leakage in fuel system measurement accuracy and DFM performance is not guaranteed Fuel system repair to eliminate leaks is re
15. Actual fuel consumption records e Time tracking of the machinery work e Fuel rationing e Fuel theft detection and prevention e Real time monitoring and fuel consumption optimization e Engine tests for fuel consumption TECHNOTON 2007 2014 6 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 1 2 Exterior view and delivery set DFM delivery set is shown in Figure 3 and includes the following Zavod Flometr 3asoan Dnomerp Laboratory 2 CERTIFICATE OF Garinen wait CBVAETENECTEO iced oun COMM 13 08 2014 4 1 Fuel flow meter PacxortoMep TOnnuBa 3 i 5 1 Assembled fuel flow meter 1 pc 2 iButton key 1 DC 3 Pilot cable 7 5 m 1 pc 4 Verification certificate 1pc 5 Registration certificate 1 pc Figure 3 DFM delivery set for fuel flow meters with display for DFM with interface output TECHNOTON 2007 2014 7 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 1 3 DFM varieties The following types of DFM fuel flow meters exist 1 Single chamber fuel flow meters measure the volume of fuel that flows in the line The following models of single chamber fuel flow meters are being produced e DFM C fuel flow meters with display e DFM CK fuel flow meters with display and interface output e DFM AK fuel flow meters with interface output 2 Dual chamber fuel flow meters measure fuel consumption as the difference in volume of
16. FM 100D and DFM 250D DFM Kit10D l l using 10 mm pipes DFM Kit20D To install DFM 500D differential fuel flow meters using 10 mm pipe TECHNOTON 2007 2014 38 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 DFM Kit composition see Table 12 has been selected on the basis of many years of experience of installing fuel flow meters on various types of machinery There are differences in compositions of DFM Kit for differential and single chamber flow meters depending on an installation scheme and engine features of a vehicle Table 12 DFM Kit composition External Label appearance Description Banjo bolt BB 14 To couple the fuel line and the fuel flow meter to the units of the fuel system the high Bani pressure fuel pump or AAO PODE e the fine filter To couple 2 branches of the fuel system to Banjo bolt double the units of the fuel BB 14 2 system the high pressure fuel pump or the fine filter To connect 8 mm pipe to mounting elements Banjo fitting BF 14 8 Banjo fitting BF 14 10 To connect 10 mm pipe to mounting elements Banjo fitting BF 16 10 Non return valve To remove the K10 hydraulic shocks influence on the measurement accuracy Non return valve Of the flow meter K15 white valve TECHNOTON 2007 2014 39 of 63 DFM Fuel Flow Meters Operation Ma
17. FM installation can be carried out without a bracket e automobile hand tool kit cap key drive socket and screw driver sets A DFM can be mounted in any position vertical horizontal or tilted Sharp bends of cable and fuel pipes must be avoided when mounting ATTENTION When fitting the mounting plate of the DFM vehicle frame drilling is prohibited If fitting of the mounting plate is impossible with bolts spot welding is allowed The following rules must be observed when mounting 1 Vehicle fuel lines must be protected from any external damage 2 It is prohibited to reduce internal dimension of the fuel pipes on bends 3 Mounting of the fuel pipes of the vehicle should be made with buckles every 0 5 m 4 Fuel pipes need to have some spare length in order to compensate length changes due to the temperature 5 DFM installation on the elements of the vehicle subject to heating or vibration in not recommended 6 When connecting fuel pipes flanges and threaded connections must be clean When installing only new copper sealing washers from a mounting kit have to be used 8 Rubber fuel pipes must be connected to the elements of the fuel system using drive type nipples or direct flow fittings and secured with hose clamps or with crimping coupling of necessary diameter 9 After DFM installation it is necessary to remove air from the fuel system TECHNOTON 2007 2014 26 of 63 DFM Fuel Flow Meters Operation Manual
18. ION The manufacturer reserves the right to make changes to the DFM kits and replace components with similar ones without notifying the customer 2 8 2 Connecting cable For electrical connection the fuel flow meters to the interface output connection cables are used in accordance with Table 13 Table 13 DFM connecting cable External appearance Indication label Purpose and description Flow meter cable Designed to connect a flow meter to recording and display devices and to external power supply Supplied with all interface fuel flow meters TECHNOTON 2007 2014 41 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 2 8 3 DFM fuel consumption readout unit When using fuel flow meters with interface cable DFM AK DFM CK DFM D device that registers and indicates information on fuel consumption engine operation time or any other fuel consumer may be needed To implement those functions a fuel counter DFM I hereinafter referred to as indicator was designed by Technoton JV see Figure 25 Figure 25 DFM fuel consumption indicator The indicator can be installed in a cab or in any other location convenient for reading The indicator displays an extended set of information according to 1 6 6 Model specifications of indicators are shown in Table 14 Table 14 DFM fuel flow meters indicators model specifications Rinput Dimensions Flow mod ts Operating i excluding measuring kOhm inedia harnes
19. MERC 5 0 G DiISDOSa lt aupsrasc recat setae pence N Ma essai E ups AUI Le Up LM o M REESE 50 Contact informal TRE IR T 0 oO DE 51 ADpendbeA Dimensions ana Welgdbib ss ssbexixa vera Ed tpa E Dee lbi ee ep Dn dtd Eater Puta wees 52 Appendix B Vehicle inspection repOTIt eii vesti or en LR n ER Rar EE e d a GR YE CX HEX VR CE WERE n ca 62 Appendix C GaglbratioriJPFOEOGOL equiti Gases PR OQ Idae Denon edu ined ted ca n dc REDDE 6 3 TECHNOTON 2007 2014 3 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 Introduction Recommendations and regulations given in the Operational Manual are related to DFM fuel flow meters hereinafter referred to as DFM marketed by Mass Flow ONLINE BV and developed by Technoton JV Minsk Belarus This document contains information about design principle of operation DFM data and recommendations on the operation and installation is a precision tool to measure fuel consumption DEM features e conformity to domestic and European automotive standards e protected from unauthorized tampering and cheating e fuel consumption time tracking general consumption and in various modes e integrated filter e minimum resistance to fluid flow e 100 9o of manufactured DFMs are being verified at a certified metrological installation e great operating experience e high quality technical support e affordable price The operation manual is intended for professionals who are familiar with
20. Version 2 0 Figure 16 Deaerator TECHNOTON 2007 2014 27 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 2 4 Fuel flow meters mounting schemes 2 4 1 Typical diesel engine fuel system scheme The most common scheme of the fuel system of diesel engine is shown in Figure 17 Injectors return line Injectors Fine filter Low pressure fuel pump Rouah filter Figure 17 Typical fuel system scheme The low pressure fuel pump pumps significantly more fuel to the input of the high pressure fuel pump than the engine needs in any operation mode Excess fuel from the high pressure fuel pump and injectors flows back to the fuel tank One peculiarity of automobile operation is uneven fuel consumption Besides that hydraulic shocks can cause errors in DFM work In order to compensate hydraulic shocks at the fuel flow meter it is recommended to install a non return valve after the DFM 2 4 2 DFM installation before the pump DFM installation according to Before the Pump scheme involves installation of a fuel flow meter in the part of the fuel system where the flow of fuel is carried out due to depression created by a low pressure fuel pump ATTENTION DFM installation before the pump requires compulsory use of additional fine filter on the line from the tank to the DFM Particular case of DFM installation according to Before the Pump scheme In order to install a DFM in the fuel system with a low pressure
21. acy of fuel consumption measurement of DFM and CKPT 45 CKPT 25 CKPT 21 and CKPT 31 terminals F lm mm Additional information on DFM use in vehicle tracking and fuel monitoring system as well as the range of CKPT terminals and their specifications are presented at www jv technoton com Technoton regularly conducts tests for compatibility and joint accuracy of DFM with different models of terminals of popular brands Table 7 shows the models of terminals compatible with DFM providing accuracy of joint measurement of fuel consumption not more than 1 Table 7 Vehicle tracking terminals compatible with DFM Analytical software Mode LocarusInformer 702S MT 530 SCOUT Scout Explorer MT 600 GP PRO Gis GT 10 GPS Trace Orange BASb a rnocaB GLOSAV BK11 02 GLOSAV Ruptela Ruptela FM Pro3 Trust Track web server Relevant information about the compatibility of specific terminal and DFM models and recommendations for their connections and setups can be found at www jv technoton com TECHNOTON 2007 2014 22 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 1 8 DFM selection IMPORTANT Final decision on applicability of a particular model of a fuel flow meter for a particular vehicle must be made by an installation specialist after inspection of a vehicle 1 8 1 Selection depending on the engine power boiler output DFM selection depending on engine power boiler output is performed
22. ainst malicious acts by third parties 1 Tampering Mode is to protect from tampering with the purpose to increase fuel consumption metering for example by blowing air Tampering usually causes sharp increase in fuel consumption exceeding maximum DFM electronic board registers increased fuel consumption while the fuel meter work suspends and tampering meter activates which registers the volume of fuel flown through the fuel meter at higher speed Tampering Mode the screen displays dashes see Figure 12 Figure 12 Display view in Tampering Mode Exiting the Tampering Mode is automatic in a few seconds after the conditions of the fuel meter work return to normal TECHNOTON 2007 2014 19 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 2 Interference Mode is made to protect DFM from magnetic field impact with the purpose to stop fuel counting or to tamper readings of fuel consumed When exposed to external magnetic field DFM registers an attempt of interference and as the result increment of all the counters stops and the time of exposure counts in a special counter as Interference Time In the Interference Mode the display reads vertical strokes see Figure 13 pi Figure 13 Display view in Interference Mode Exiting the Interference Mode is automatic in a few seconds after the conditions of the fuel meter work return to normal 3 Independent Power Supply Mode for DFM AK and DFM CK models when extern
23. al power supply is off models vehicle onboard power supply the integrated battery provides autonomous independent work of the fuel meter 4 Junction Sealing original DFM accessories fuel connectors valves etc have openings for sealing which allow to detect the facts of tampering with the fuel system after installation of the meter 1 6 8 Specifications of output pulse signal of the DFM with interface output Fuel flow meters with normalized pulse DFM AK DFM CK and DFM D models generate certain number of pulses indicated in registration certificates for 1 liter fuel Npuses see Table 6 Normalized pulse signal view is shown in Figure 15 TECHNOTON 2007 2014 20 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 Unich Uwatt Uiow 0 7 V tiow and T use see Table 6 Figure 15 Normalized pulse signal view of DFM AK DFM CK and DFM D models Table 6 Parameters of normalized pulse of DEM AK DFM CK and DFM D models om vom ud m i DFM 50AK DFM 50CK from 360 to 18000 DFM 100AK DFM 100CK from 180 to 9000 DFM 100D from 200 to 36000 from 100 to 500 DFM 250D from 200 to 90000 from 100 to 500 DFM 500AK DEM 500CK from 144 to 7200 DFM 500D from 180 to 144000 from 54 to 500 DFM 250AK DFM 250D s Oo TECHNOTON 2007 2014 21 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 1 7 DFM compatibility with terminals Technoton guarantees full compatibility and joint accur
24. bsolute error value of differential measurement is up to 6 l h That is comparable with the amount of fuel consumed by the engine 3 Counter indication to install a differential fuel flow meter is the fact of air presence in the supply or return fuel lines TECHNOTON 2007 2014 24 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 2 Installation and setup This chapter contains main DFM installation recommendations 2 1 External examination before start Before the work starts external inspection of a DFM must be done for possible defects detection that could arise during transportation storage or careless handling visible damage of the body connecting elements the mounting plate the display pilot cable and the socket backlash of components relative to one another and gaps between them If defects are found please contact your supplier 2 2 Assessment of the vehicle condition Before DFM installation the vehicle condition must be assessed and conclusion made on possibility to install DFM Assessment of the vehicle includes the following sequence 1 Start the engine and check its operation for 5 10 minutes at idle and 5 10 minutes in movement under load The engine must run evenly not stall under load loss of power must not be felt 2 Inspect all fuel pipes of the vehicle for damage and fuel leakage 3 Check system voltage with a voltmeter Onboard 12 V power system must have voltage in the range from 10
25. commended If the fuel pressure is insufficient DFM performance is not guaranteed It is recommended to repair or do maintenance of the booster pump Increased fuel consumption of injectors return flow can seriously affect Condition of the ww measurement error injectors return flow Maintenance work or replacement of the injectors is recommended Leakage resistance of the fuel system Fuel pressure in the system Insufficient voltage does not guarantee DFM performance Onboard circuit and or of power generator repair is recommended Significant resistance oxidation does not guarantee DFM performance Replacement of the chassis switch is recommended Onboard voltage Condition of the chassis switch Representative of the CUSTOMER Representative of the CONTRACTOR Name signature Name signature TECHNOTON 2007 2014 62 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 Appendix C Calibration Protocol BEEN Date Month Year Actual fuel consumption According to measurement tank Vm Fuel consumption Fuel consumption measured According to DFM reading Vmeasured Relative measurement error of fuel consumption Actual fuel amount from injectors return line Proportion of the return V flow from the injectors in oLretum 100 overall fuel consumption Vm Conclusions The fuel consumption measurement corresponds does not correspond to the technical specification Comments
26. e recording and display devices Fuel filter plugging Remove and clean the fuel filter Fuel doesn t flow Fuel filter plugging Remove and clean the through the fuel fuel filter flow meter Overrated fuel Wrong fuel flow Study the technical consumption meter selection or documentation of the error in the engine and check the installation scheme connection scheme Hydraulic shocks in Install a return valve the fuel system after the flow meter or check its operability if the return valve is installed TECHNOTON 2007 2014 48 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 4 Evaluation At product release each DFM flow meter passes departmental metrological evaluation on metrological certified automatic test installations Any DFM delivery package contains a verification certificate that serves as a confirmation of its departmental metrological evaluation 5 Maintenance It is recommended to perform visual inspection and DFM operation check at least once a year In order to provide DFM operability it is recommended to remove and clean the mud filter from time to time see Figure 28 Figure 28 Mud filter ATTENTION When you remount DFM replace used copper washers with new ones TECHNOTON 2007 2014 49 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 6 Storage It is recommended to store DFM in enclosed dry rooms DFM storage is allowed only in original packaging at temperatur
27. e from 50 to 40 C and relative humidity up to 100 at 25 C It is prohibited to store DFM in the same room with chemicals that cause metal corrosion and or contain corrosive agents DFM storage period must not exceed 24 months 7 Transporting DFM can be transported in any kind of enclosed vehicle which can provide protection from physical damage and package from precipitations Air quality in vehicles must not contain acid alkaline and other corrosive contaminants Shipping containers with DFMs packed should be sealed 8 Disposal DFM doesn t contain harmful agents and components that are hazardous to human health and the environment during its lifetime and after disposal DFM does not contain precious metals in amounts required for accounting TECHNOTON 2007 2014 51 of 63 DFM Fuel Flow Meters Operation Manual Contact information Distribution and first line of support Mass Flow ONLINE BV Support massflow online com Distribution technical support service Technoton JV Phone fax 375 17 223 78 20 marketing technoton by Support technoton by Manufacturer Zavod Flometr office flometr by quality 9001 2008 certified quality 9001 2008 certified TECHNOTON 2007 2014 Version 2 0 Gp 51 of 63 DFM Fuel Flow Meters Operation Manual Appendix A Dimensions and weight DFM 50C and DFM 100C i 65 80 j LIE
28. el pump to pump through the fuel system in order to remove all air 8 Start the engine and let it warm up to operating temperature At the same time make sure there is no air coming out from return fuel pipe 2 9 Simultaneously close inlets of fuel pipes 1 and 2 and stop the engine 10 NY Move fuel pipes 1 and 2 from tank 1 into tank 2 the air must not get into the hoses 11 Close inlet of injectors return fuel pipe 3 and move it from tank 1 into empty tank 3 12 Record the initial readings of the DFM according to the readings of a tracking device or the DFM display 13 Record the time when the test was started 14 Start the engine and set medium run 15 Let the engine run until tank 2 is empty At the same time air cannot be let into fuel pipe 1 16 Stop the engine 17 Measure the fuel left in tank 2 Viemain 18 Use measuring tank to measure actual fuel consumption from tank 2 Vn 10 Vremain 19 By difference of initial and final DFM readings determine measured fuel consumption V measured TECHNOTON 2007 2014 36 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 20 Calculate the relative measurement error of fuel consumption by the formula 5 Vmeasured Vm Vm where Vmeasured measured fuel consumption l 100 Vm actual fuel consumption l 21 Use measuring tank to determine actual fuel amount from injectors return line Vinj return 22 Determine the proport
29. fuel flowing through the supply and return fuel lines The following dual chamber fuel flow meters are being produced e DFM D differential fuel flow meters with interface output 1 3 1 DFM C models DFM C fuel flow meters with display see Figure 4 serve to build the fuel monitoring system in a vehicle company without additional hardware and software Figure 4 DFM C exterior Fuel consumption and vehicle operating time is displayed on the LCD of the DFM hereinafter referred to as display Monitoring and recording is to be performed visually copying out the data into a fuel timesheet by a responsible person TECHNOTON 2007 2014 8 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 1 3 2 DFM CK model DFM CK Model fuel flow meter with display and interface output see Figure 5 can work both independently and as a part of automated fuel consumption control and vehicle monitoring system Figure 5 DFM CK exterior Fuel consumption and vehicle running time is displayed In addition fuel consumption information is given to the pulse output 1 3 3 DFM AK models DFM AK models fuel flow meter with interface output see Figure 6 serve to measure fuel consumption as a part of automated fuel consumption control and vehicle monitoring system Figure 6 DFM AP and DFM AK exterior DFM AK models do not have displays but they have LED indicator on their covers Flashing light signal indicates
30. fuel pump see Figure 18 according to this scheme it is necessary to use the line between the rough filter and the low pressure fuel pump input TECHNOTON 2007 2014 28 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 Injectors return line Injectors High pressure fuel pump 4 Fine filter 7 Fuel tank Return line Rough filter Non return valve Additional fine filter Figure 18 DFM installation according to Before the Pump scheme with a low pressure pump When injectors operate correctly their return flow is less than 0 1 9o of fuel consumption and therefore this can be negligible In order to prevent measuring of the fuel returns back to the tank it is necessary to make changes in the return line In this particular case the return line from the high pressure fuel pump has to be modified in such way that fuel could circulate in a small circle without fuel tank participation It can be done by connecting return line of the high pressure fuel pump with low pressure fuel pump input Thus fuel from two lines flows to the low pressure fuel pump input 1 from the fuel tank through DFM flow meter 2 from high pressure fuel pump return line For proper operation of the modified fuel system install a bypass valve at the high pressure fuel pump output which will support necessary constant pressure of 1 1 5 atmosphere At DFM output a 0 35 0 5 atmosphere non return valve has to be instal
31. fuel pumped by low pressure fuel pump will be dropped back to the fuel tank from fine filter s side and only amount of fuel consumed by the engine will flow through the flow meter Advantages of After the Pump scheme e DFM is installed after a regular fine filter e Fuel flows under pressure and doesn t overload the low pressure fuel pump e Return fuel flow can heat fuel in the tank Disadvantages of After the Pump scheme e High pressure fuel pump is slightly deteriorated e Return flow fuel temperature is lower than with a regular fuel system 2 4 4 Differential DFM installation scheme ATTENTION Differential fuel flow meters installation in fuel systems with high performance low pressure fuel pump and small fuel consumption is not recommended due to increase of measurement errors higher than allowed see Table 1 Fuel circulation in the fuel system doesn t change with differential measurement Straight flow chamber of differential DFM is to be installed in the gap of supply fuel line of the engine Return flow chamber is to be installed in the gap of the return line Fuel consumption is calculated as a difference of measured values of fuel flows in straight flow and return flow chambers Particular cases of differential DFM installation scheme 1 Installation of the feed chamber is made after the low pressure fuel pump After the Pump scheme see Figure 21a 2 Installation of the feed chamber is made before the low
32. ion of the return flow from the injectors in overall fuel V consumption for a tested vehicle by the formula E 100 23 Document test result into the protocol Protocol form is in Appendix C Fuel line 3 ONY Fuel line 1 Tank 3 Figure 24 Fuel system scheme during test TECHNOTON 2007 2014 37 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 2 8 Accessories To install connect and operate DFM fuel flow meters Technoton offers high quality accessories 2 8 1 Mounting kits DFM mounting kits hereinafter referred to as MK DFM are designed to connect fuel flow meters to the engine fuel system using pipes with diameters of 8 mm and 10 mm MK DFM use only high quality components designed for use in the fuel system of vehicles Distinctive feat t MK DEM e manufacturing material steel e manufacturing technology hot stamping e coating zinc e enlarged orifice e no burrs or shavings e connecting pipes valves bolts of the drive type nipples have holes for sealing Selection of a MK DFM is carried out in accordance with Table 11 Table 11 MK DFM application Kit Indication Application DFM Kit2 Universal to install single chamber flow meters using 8 mm pipe DFM Kit4 Universal to install single chamber flow meters using 10 mm pipe Universal to install DFM 500 single chamber flow meters using DFM Kit5 10mm pipe l To install differential fuel flow meters D
33. le 5 DFM AK and DFM CK fuel flow meters have the function of recording the data on fuel consumption when onboard power is off When onboard power is on the electronic board of the fuel meter sends a higher frequency pulse the frequency is approximately 2 times higher than an output pulse during maximum fuel consumption That signal contains all pulses counted when external power supply was off 1 6 5 Operation modes Table 4 Operation modes of the fuel flow meters Engine operation Interference Normal consumption The impact of 0 lt QSQmax constant magnetic Tampering field more than O05 5 seconds Idle run Optimal run Overload 0 lt Q lt 2 5Qnin 2 SQminS Q lt 9 75Qmax 0 75QmaxS QS Qmax Q instantaneous fuel consumption Qmin the lower limit of the measuring range Qmax the upper limit of the measuring range TECHNOTON 2007 2014 16 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 1 6 6 Displayed data DFM models with display are marked with letters C and CK see Introduction Figure 1 Display information switching is performed by 1 2 seconds light touch to the top cover of the fuel flow meter by iButton key see Figure 10 Figure 10 ching information screens In order to save the charge of the built in battery the DFM display goes to sleep mode one minute after the last touch of the cover by the iButton At the same time dots are shown on the display see Figure 11 Fig
34. led which will prevent fuel flow in the opposite direction and will reduce fuel system s hydraulic shocks at the DFM After the fuel system is modified according to depression scheme all excess fuel pumped by the low pressure fuel pump will be directed from the high pressure fuel pump output to low pressure fuel pump input Thus only the fuel that is consumed by the engine flows through the DFM DFM Fuel Flow Meters Operation Manual Version 2 0 In order to install DFM according to Before the Pump scheme without low pressure pump see Figure 19 it is necessary to use the line between a rough filter and a bypass valve of the high pressure fuel pump At the same time installation of additional fine filter between the rough filter and DFM is necessary Injectors return line Injectors Non return valve Rough filter Additional fine filter Figure 19 DFM installation according to depression scheme without a low pressure pump TECHNOTON 2007 2014 30 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 Advantages of Before the Pump scheme e Minimal interference into the fuel system e Simple installation e Applicable for most engines Disadvantages of the scheme e requires installation of an additional fine filter and causes additional costs e additional load on the low pressure fuel pump e fuel is not heated in the tank by return flow line it sometimes requires fuel heater installation
35. main characteristics Max pressure MPa Nominal pressure MPa 2 5 eren 08 Nominal filtering degree of measured fluid mm not less than Connecting thread M14x1 5 M16x1 5 Pressure drop at maximum fuel consumption 0 02 nominal pressure diesel fuel at 20 C MPa not more than Voltage range of the power supply V from 10 to 50 Current consumption at 12 V mA not more than Current consumption at 24 V mA not more than Environment operating temperature range C from 40 to 80 Environment relative humidity at t 40 C not 95 more than Vibration resistance Max acceleration to 100 m s in the frequency range from 5 to 250 Hz GOST 3940 GOST R 50607 Resistance to aggressive environments Oil and gasoline resistance GOST 3940 GOST R 52230 Electromagnetic compatibility ESD protection degree of fixity II GOST 30378 GOST R 50607 protection against conducted interference degree of fixity IV STB ISO 7637 2 GOST 28751 Boundary dimensions See Appendix A Weight In the standard series of DFM 500 fuel flow meters The data is displayed in a range of environment temperature from 20 to 60 C TECHNOTON 2007 2014 14 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 1 6 3 Specifications of measurement chambers Table 3 Specifications of measurement chambers Nominal volume of the Operational life of measuring chamber the measuring mi chamber Nominal dia
36. ments of DFM flow fuel meter installed in the vehicle it is necessary to carry out tests 2 7 1 Test conditions Representatives of interested parties should attend the test Persons who have studied DFM electronic terminals operational documentation and who have experience with testing equipment are allowed to conduct these tests Tests are conducted on operable vehicle Conditions for test flow 1 Engine run time not less than 1 hour 2 The engine must run at medium speed 3 During the test engine shutdown is not allowed 4 To check the amount of fuel it is necessary to use only proven measuring tanks TECHNOTON 2007 2014 35 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 2 7 2 Preparation for the tests Install the fuel flow meter and connect it to recording and display devices Conduct all works in accordance with the installation manuals for fuel flow meters and recording and display devices 2 7 3 Conducting the tests 1 Pour fuel into tank 1 The amount of fuel must be enough to eliminate air from the fuel system and warm up the engine see Figure 24 2 Use a measuring tank to fill tank 2 with testing fuel in the amount of 10 liters 3 Connect low pressure fuel pump input with fuel pipe 1 4 Put into tank 1 the free end of fuel pipe 1 5 Return flow fuel pipe 2 put into tank 1 6 Disconnect the injectors return line from the fuel tank and put it into tank 1 7 Use manual pump of the fu
37. meter Dy mm DFM 50AK DFM 50C DFM 50CK DFM 100AK DFM 100C DFM 100CK DFM 100D DFM 250AK DFM 250C DFM 250CK 175000 DFM 250D DFM 500AK DFM 500C DFM 500CK DFM 500D 350000 When the operational life of the measuring chamber is finished contact the service center to check the fuel flow meter 1 6 4 Power supply modes DFM fuel flow meters can operate in the following power supply modes External power supply DFM D models DFM operation is provided by external power supply e g onboard power supply of the vehicle Self contained power supply DFM C models DFM operation is provided by an integrated lithium silicon battery Estimated duration of the DFM operation until full battery discharge is not less than 24 months Combined power supply DFM AK and DFM CK models DFM operation is provided by external power supply or by an integrated battery if onboard power Supply is switched off In addition self contained power supply switches on in case of low onboard voltage less than 10 V Estimated duration of DFM operation with onboard power off until full battery discharge is not less than 24 months TECHNOTON 2007 2014 15 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 ATTENTION When DFM AK and DFM CK are supplied by integrated battery pulse signal is not sent to the interface output For DFM CK model it is possible to copy data from display in the amount in accordance with Tab
38. nual Version 2 0 Table 12 continued 1 2 3 245 10 20 DD a rmm To release excessive B ams Bypass valve K20 Pressure in the fuel line 4 4 4 MN YP at the output of the booster pump To plug the high Bolt plug BP14 pressure fuel pump 1 1 1 hole to the return line To connect the fuel line Nipple adapter with a return fuel line 01 1 1 ME NA 14 4 through the bypass valve To reverse the return Nipple adapter fuel line from the fine 01 1 1 MEE NA 14 20 filter via the bypass valve Nipple adapter To connect the fuel line 01 1 1 MEE NA 10 14 and heater tube NPP E QM apEe For joining two fuel Bonne lines with heater line 1 1 1 mE NA 10 14 2 Copper washer CW 14 19 To seal connections 16 16 12 16 8 PAET To seal connections 4 8 CW 16 21 Copper washer To seal connections on Wide the fine filter of YaMZ 1 1 1 E engines T To fix 8 mm fuel p hose onto the angle 8l HC 10 16 ia joint or filter a EM To fix 10 mm fuel H P hose onto the angle 8 8 8 8 C 12 22 a joint or filter TECHNOTON 2007 2014 40 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 Table 12 continued TO mount the flow Bolt B8x16 meter to the bracket 4 4 4 ue Nut N8 meter to the bracket ms TS To mount the flow Q To mount the flow Oo Washer W8 meter to the bracket me te mi Lock washer TO mount the flow A ala AlA WL8 65 meter to the bracket ATTENT
39. of this counter indicates the incorrect installation of the fuel flow meter or possible facts of fuel theft TECHNOTON 2007 2014 18 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 Screen 8 displays the counter reading Interference Time accumulated by DFM as the total time of exposure to external factors strong magnetic field Increase of the values of this counter may indicate an installation of the fuel flow meter near a source of strong electromagnetic radiation or deliberate attempts to lock the fuel meter see 1 6 7 Screen 9 Instantaneous Fuel Consumption displays current value of fuel consumption It can serve for a visual check of device operability and its correct installation Screen 10 Battery Charge in Percentage of the Maximum displays the value of remaining charge of integrated battery Note When the environment temperature is below 10 C displayed value of remaining charge can decrease by 10 30 Screen 11 Temperature in the Measuring Chamber displays current temperature value in the measuring chamber of the fuel flow meter Screen 12 Firmware Version and the Chamber Volume displays the firmware version installed on the fuel meter as well as the exact volume of the measuring chamber 1 6 7 DFM protection from tampering and intervention In order to prevent false readings of the fuel flow meter its damage or locking DFM models with display DFM C and DFM CK have the following protection modes ag
40. pressure fuel pump Before the Pump scheme In this case additional fine filter installation is required see Figure 21b Return flow chamber of differential DFM in both cases is to be installed in return line between high pressure fuel pump output and the fuel tank TECHNOTON 2007 2014 32 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 Return line Injectors return line Injectors Bypass valve High pressure fuel pump Er Fuel tank Non return valve Low pressure fuel pump Rough filter a The feed chamber installation after the pump Injectors return line Injectors Fuel tank Fine filter k A A z c 20 im nam n A a 1 li Non return valve Low pressure fuel pump h fil Rough filter Additional fine filter b Feed chamber installation before the pump Figure 21 Differential DFM installation scheme Advantages of differential installation scheme e no changes in the fuel system e installation possible for engine during warranty period Disadvantages of differential installation scheme e higher cost e higher fuel consumption measurement error e additional fine filter and DFM increase load on the low pressure fuel pump TECHNOTON 2007 2014 33 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 2 5 Electrical connection Fuel flow meters with interface cable DFM AK DFM CK and DFM D
41. s range l h not less range mm not than more than Pulse rate ml pulse from 20 12 5 from 5 to 250 5 to 250 500 Input resistance of the measuring input of the indicator More detailed information about DFM fuel consumption indicator is in DFM fuel consumption indicator User Manual document The latest version of this document can be downloaded at www massflow online com TECHNOTON 2007 2014 42 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 TECHNOTON 2007 2014 43 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 TECHNOTON 2007 2014 44 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 TECHNOTON 2007 2014 45 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 TECHNOTON 2007 2014 46 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 TECHNOTON 2007 2014 47 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 3 Diagnostics and troubleshooting In case of DFM fuel flow meters malfunction please contact your supplier DFM repair works can be carried out only by certified regional service centers Full list of service centers can be found at www jv technoton com Some self help troubleshooting is allowed see Table 18 Table 18 DFM flow meters malfunctions when self help troubleshooting is allowed Troubleshooting Possible reason method No output signal Incorrect connection Check if the flow meter is connected to th
42. that there is given an output pulse signal containing information on vehicle fuel consumption In combination with fuel consumption indicators DFMs can be used independently see 2 8 3 TECHNOTON 2007 2014 9 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 1 3 4 DFM D model DFM D model differential fuel flow meter see Figure 7 is used in vehicle fuel consumption monitoring systems installed in automotive and tractor machinery with modern EURO TIER 3 4 5 diesel engines Figure 7 DFM D exterior A differential fuel flow meter calculates fuel consumption as the difference of the fuel flows of the supply and return fuel lines Vehicle fuel consumption information is sent to the pulse output In combination with fuel consumption indicators DFMs can be used independently see 2 8 3 TECHNOTON 2007 2014 10 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 1 4 Measurement range and precision Table 1 Measurement range and precision i O0 Starting Min Max Relative error zia aid consumption consumption no more than DFM 50AK DFM 50C DFM 50CK DFM 100AK DFM 100C DFM 100CK DFM 250AK DFM 250C DFM 250CK DFM 500AK DFM 500C DFM 500CK DFM 100D DFM 500D Consumption in each chamber Minimum consumption threshold value when the fuel flow meter begins to work indicated for reference fuel consumption measurement error at the startup is not standardized
43. ure 11 Display view in sleep mode When next time the display is touched it wakes up and shows information again TECHNOTON 2007 2014 17 of 63 DFM Fuel Flow Meters Operation Manual Version 2 0 Table 5 DFM display information screens counter Total Fuel Consumption counter Engine Operation Time Engine Operation Time counter Engine Operation Time in Optimal Run Mode counter Engine Operation Time counter Fuel Consumption in counter 9 jue fot counter Consumption EN Battery Charge in 10 Percentage of the Maximum Temperature in the Measuring Chamber EN Firmware Version X X 12 and Chamber Volume Y Screen 1 displays the counter reading Total Fuel Consumption the accuracy to within 0 1 1 accumulated since the DFM release Screen 2 displays the counter reading Total Fuel Consumption High Accuracy Data the accuracy to within 0 001 accumulated since the DFM release Screen 3 displays the counter reading Engine Operation Time accumulated as the total time of engine operation in all modes including idle run Screens 4 5 and 6 display the counter readings of Engine Operation Time In Idle Optimal and in Overload Modes accumulated by DFM as a total engine operation time in corresponding modes see 1 6 5 Screen 7 displays the counter readings of Fuel Consumption In Tampering Mode accumulated by DFM measured as the amount of fuel higher than maximum consumption see 1 6 7 Value increase

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