How to install a digital fuel level sensor on a vehicle? Let's look at the entire installation process in stages using the Siensor D107 as an example.
Necessary
- - a computer with the installed program for configuring the fuel level sensors Siensor Monitor
- - device for adjusting fuel level sensors Siensor UNIC
- - navigation terminal configured to work with fuel level sensors
- - Siensor D107 fuel level sensor in full delivery set
- - container for draining fuel from the tank
Instructions
Step 1
Fuel tank preparation.
The fuel from the tank must be drained into a prepared container. If the tank was previously used for gasoline of any brand, it must be steamed.
Step 2
Laying the connecting cable.
To connect the FLS to the navigation terminal, it is necessary to lay the connecting cable in the corrugated sleeve supplied with the sensor. The cable is routed along the vehicle frame past the engine compartment and into the cab. There should be no moving parts of the car or heated mechanisms in the path of the cable in order to avoid its melting. The purpose of the connector pins and the colors of the cable wires for connection to the navigation terminal are given in the user manual for the Siensor D107 sensor, which can be found on the official website irzonline.ru in the section "Help and Support" - "Documentation" - "Fuel Level Sensors" - "SIENSOR D107 "-" User's Guide ", section" Requirements for the installation of connecting cables ".
Step 3
Installing Siensor Monitor.
To configure the sensor, you will need the Siensor Monitor software. The program is available for download on the official website irzonline.ru in the section "Help and support" - "Documentation" - "Fuel level sensors" - SIENSOR D107 - "Program for configuring fuel level sensors". The programs are different for digital and analog sensors.
Step 4
Preparation of the navigation terminal.
To read the sensor readings, you need a configured navigation terminal. An example of setting up and installing iON series terminals from iRZ Online is described in the video located on the official website irzonline.ru in the section "Help and support" - "Video" - "Instructions" - "Working with the configurator program, setting up the iON Pro terminal".
Step 5
Preliminary work with the tank.
Particular attention should be paid to the selection of the sensor installation site. The sensor must not touch the tank walls, tank bulkheads, and other standard equipment. The place for installing the FLS is chosen depending on the geometric shape of the tank. In our case, the car has a tank of the correct shape, so we choose the geometric center of the tank to install the sensor. This will reduce the measurement error of the FLS during tilting, braking and acceleration of the vehicle. You can learn more about choosing a place for installation from the user's manual for the sensor, section “Preparing for installation”.
Using a drill and a bimetallic bit, a hole with a diameter of 35 mm is drilled in the tank. Then this part must be carefully removed. It is not allowed to get into the tank of shavings, cut-out element and other foreign bodies.
The sensor is supplied with two plates: metal and plastic. The choice depends on the hardness of the tank surface. If the tank is curved, it is recommended to choose a plastic plate. A mounting plate is attached to the tank and the five locations of the mounting holes in the center are marked. The center hole is sealed with tape to prevent chips from entering the tank while drilling the targeted holes.
For a metal tank with a thickness of more than 3 mm, it is recommended to make a hole with a diameter of 3.5 mm and use the countersunk screws supplied with the sensor. For a metal tank with a thickness of less than 3 mm or a plastic tank, it is recommended to make a hole with a diameter of 7 mm and use the threaded rivets supplied with the sensor.
In our case, threaded rivets are used. Pre-marked holes are drilled with a thin drill with a diameter of 3 to 5 mm. Then a drill with a diameter of 7 mm is used. Rivets are installed in the prepared holes using a riveter. The rivet is screwed over the entire length of the stud. When installed in a hole, it must be strictly perpendicular to the sensor plate and the tank wall. Then you need to rivet the rivet and unscrew the pin.
Next, a sealant is applied to the tank around the center hole. The sealant layer should be 5 mm thick and 10 mm wide. Fitted with a rubber gasket and a mounting plate on top.
Step 6
Cutting the sensor for the depth of the fuel tank.
To determine the depth of the tank, a sensor is lowered into the center hole. On the sensor, you need to measure the trim length and add another 20 mm to this length. Cut off the excess length with a hacksaw so that the cut plane is strictly perpendicular to the longitudinal axis of the sensor. Carefully clean the sawn-off spot from burrs and metal shavings with a file.
Step 7
Sensor configuration.
To adjust the FLS, you will need a Siensor UNIC adjusting device. The FLS is connected to the Siensor UNIC device using a special adapter cable, while the Siensor UNIC is connected to a free USB port on the computer. Sensor cables are included in the Siensor UNIC delivery set.
Siensor UNIC has the ability to work both via RS-485 and RS-232 interfaces. Since the Siensor D107 digital sensor can operate on both interfaces, the position of the RS-232 and RS-485 switch on the Siensor UNIC front panel does not matter.
Configurator connection is described in the Siensor UNIC user manual, which can be found on the official website irzonline.ru in the section "Help and support" - "Documentation" - "Fuel level sensors" - "Siensor UNIC" - "UNIC user manual".
In the main window of the program, select the "Settings" tab, in the window that opens, select the COM port that appeared when the Siensor UNIC device was connected. The COM port number assigned to the system when Siensor UNIC is connected can be viewed in the Device Manager in the Ports (COM and LPT) tab. Change the baud rate if necessary. The default password is 00000000, here you can set a new one. The password must be a numerical combination of 8 digits from 0 to 9. Press "Save".
When the connection to the sensor is established, the connection indicator in the main program window will turn green and the status "Connected" will be displayed.
Step 8
Calibration of the sensor.
Next, you need to calibrate the sensor using the Siensor Monitor program. Calibration is performed with exactly the fuel with which the sensor will be used in the future.
To calibrate the sensor, you must first place it in a full tank, or in a calibration pipe filled with fuel, and record the measured value. Then you need to pull the sensor out of the tank and fix the value again.
Another way to get sensor readings that correspond to a full tank is to pour fuel directly into the sensor probe and take the readings. To do this, you must first screw the bolt that comes with the delivery into the drain hole. The fuel is then poured into the probe.
When “Level stabilized” appears in the main window of Siensor Monitor, press “Calibrate sensor”. In the window that opens, you need to click "Full". The value is fixed. Then the fuel is completely drained from the probe, the drain holes are opened. When the message “Level stabilized” appears in the main window, press the “Empty” button in the “Sensor calibration” window. Calibration complete.
Step 9
Sensor installation.
The final installation of the sensor is carried out. In place of the saw is put on the spring for the nozzle from the delivery set. Using the hexagon wrench H 2, 5, the bolts are tightened on the sides of the nozzle. The O-ring is installed. The sensor must be inserted into the hole and turned until it is fully fixed.
Step 10
Calibration of the sensor.
Calibration is necessary to improve the accuracy of measuring the fuel level in irregularly shaped tanks, in which the fuel level changes disproportionately.
Fuel must be poured into an empty tank in portions and the sensor readings must be recorded. Thus, a calibration table is compiled. It is recommended to make at least 20 control points. The filling step is selected independently. The more complex the tank shape, the smaller the filling step and the more control points.
The table of the recommended refueling step and the process of tank calibration is described in detail in the sensor user manual, section "Fuel tank calibration".
Before calibration, it is recommended to check the fuel meter using a measuring device. A certain amount of fuel is discharged from the container into the measuring vessel. If the readings of the dispenser and the scale of the test measure coincide, then you can proceed to calibration.
After adding each portion of fuel to the tank and the inscription “Level stabilized” appears in the Siensor Monitor, press the “Enter” button to add a new line in the table with the same step. The program provides a synchronization function. The synchronization mode is turned on with the "F4" button, turned off with the "F5" button. In synchronization mode, the fuel level readings from the sensor are displayed in the program table automatically. If at the end of calibration the maximum sensor reading does not match its setting, you need to manually add one line and enter a value 1 liter more than the previous one, and in the "Sensor readings" line enter the maximum reading given by the sensor.
Step 11
Installation of a protective seal on the sensor and connector.
The last stage of installation is sealing. The Siensor D107 sensor provides for the installation of a seal on the measuring part of the sensor itself and on the connecting cable. A locking screw is installed on the measuring part of the sensor. The sealing wire must be passed through the hole in the locking screw, tightened and the ends secured with a seal. There should be no sagging of the wire, the excess wire is removed. The process of installing a seal on the connector is similar. The wire is threaded through the holes, pulled together, the ends are secured with a seal.
This completes the installation of the Siensor D107 digital fuel level sensor.
