DUT-E fuel sensor installation manual
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DUT-E fuel level sensor is used for accurate fuel level and volume measurement in tanks of vehicles and stationary units. DUT-E allows determining current fuel volume and change in volume (refueling or draining) of fuel in the tank.
DUT-E is used in GPS tracking and vehicle telematics systems as additional fuel sensor or as a replacement of standard built-in (factory) fuel level sensor. When used as a part of telematics system, DUT-E allows getting reliable and accurate information on current fuel volume in the tank and to reveal misuse and fuel theft from tank. DUT-E also gives a general overview on fuel usage by vehicle or stationary unit.
Before installation
DUT-E is installed in if fuel tank of vehicle, that means focus should be put on the condition of fuel tank. It is recommended to install DUT-E in a special hole, drilled in geometrical center of fuel tank. This will decrease inaccuracy of fuel volume measurement in fuel tank if Vehicle is heeling when parked or moving (see figure 1).
Figure 1 — Place of installation of DUT-E
Before drilling the hole, make sure that under the place of drilling there are no inner walls that can prevent from installing the sensor. DUT-E installation can be performed both with dismantling or without dismantling fuel tank of vehicle. Make sure that there is enough space (not less than 30 mm) to place ―head‖ of DUT-E between top of fuel tank and any elements of Vehicle above the tank.
Before drilling, fuel tank must be dried or filled with water to avoid ignition of fuel vapors. Before installation, check the tightness of fuel tank and connected fuel pipes, also check integrity of insulation of electrical wires.
It is recommended to check condition of onboard power network of the Vehicle and its compliance with power supply range of DUT-E. Pay attention to condition of battery terminal and serviceability of main switch of the battery. Resistance between any point of Vehicle’s chassis ground and ―-‖ terminal of the battery or between terminals of the chassis ground switch should not exceed 1 Ohm. If resistance exceeds 1 Ohm, DUT-E may work improperly.
Tools and accessories for installation, connection and configuration
Recommended list of tools and accessories necessary for DUT-E installation:
- Locksmith tools (wrenches, bits, pliers, knife, metal hacksaw or angle grinder, screwdrivers)
- Drill (or screw gun) with set of metal drill bits
- Circular drill bit d=38 mm
- Certified canister for fuel 10...20 liters
- If volume of a fuel tank is more than 200 liters, it is recommended to use fuel dispenser with certified counter
- Silicone car sealant
- Rag
- Diesel fuel to fill each car’s fuel tank for 100 %
- Additional empty container for fuel, where fuel from car’s fuel tank can be pumped
- SK DUT-E service adapter
Delivery set of DUT-E fuel level sensor includes (see figure 2):
| 1 | DUT-E fuel level sensor | 1 pc.; |
| 2 | specification | 1 pc.; |
| 3 | connection cable* (7.5 m) | 1 pc.; |
| 4 | bottom stop | 1 pc.; |
| 5 | screen filter | 1 pc.; |
| 6 | plastic mounting plate | 1 pc.; |
| 7 | hole placement template | 1 pc.; |
| 8 | rubber gasket | 2 pcs.; **; |
| 9 | sealing rubber ring | 2 pcs.; **; |
| 10 | bolt | 5 pcs.; |
| 11 | threaded rivet | 5pcs.; |
| 12 | self-tapping screw | 5pcs.; |
| 13 | plastic seal | 2pcs.;***; |
| 14 | sealing cord | 2pcs.; |
| 15 | fuse with holder (2 A) | 2pcs. |
* Ordered separately for DUT-E CAN. ** 1 pc. – used for DUT-E installation and 1 pc. is a spare part. Could be complemented with 4 mm thick gasket. *** Exterior of seal can be different.
Figure 2 — DUT-E delivery set
Delivery set ofSK DUT-E serviceadapter includes (see figure 3)
| 1 | universal service adapter | 1 pc.; |
| 2 | SK DUT-E specification | 1 pc.; |
| 3 | USB A-B cable | 1 pc.; |
| 4 | CAN service cable | 1 pc.; |
| 5 | RS-485 service cable | 1 pc.; |
| 6 | RS-232 service cable | 1 pc.; |
| 7 | AF service cable | 1 pc.; |
Figure 3 — SK DUT-E delivery set
Installation to fuel tank with flat top surface
A d=38 mm hole for DUT-E fastening plate is drilled with circular drilling bit (see figure 4). In steel-made and thick-wall tanks it is also necessary to drill 5 holes d=2 mm to fix DUT-E with screws.
If installing in plastic tanks or tanks with thick walls, use threaded rivets to fix DUT-E. If you use threaded rivets, drill d=7 mm holes.
Figure 4 — Drilling hole in a tank
ATTENTION: To avoid vapors ignition, a fuel tank must be dried or filled with water before drilling the hole! Strictly follow safety rules of automobile repair works as well as local safety rules of the customer company when mounting DUT-E!
Length of measurement tubes of DUT-E should be 20...30 mm shorter than tank’s height in order:
- to provide at least 10mm operation area for bottom spring stopper (if the bottom spring is fixed in full loading position the bayonet mounting plate can get damaged);
- to avoid short circuit of measuring probe tubes with conductive mud or water at bottom of tank.
Cut DUT-E probe with a metal hacksaw. Carefully clean edge and wash tubes with clean fuel (see figures 5-7).
Figure 5 — Cutting tubes , Figure 6 — Removing metal chips after cutting, Figure 7 — Metal chips are removed
When using threaded rivets, they should be mounted using riveter and according to figure 8.
Figure 8 — Threaded rivets procedure of installation
Figure 9 — Installed fastening plate view of from inside of tank
It is possible to use DUT-E instead of standard fuel level sensor. For vehicles made in CIS countries, usual fastening plate (see figure 2) is used. For other vehicles, it is necessary to use SAE 5 bolt plate (ordered separately).
ATTENTION:to provide electrical isolation between the tank and DUT-E, make sure that screw heads are not skewed and completely sunk in the fastening plate.
If a surface of tank is uneven (not smooth), apply silicone sealant under fastening plate and screw heads. This will prevent water from gathering in those places.
Figure 10 — Mounting plate screwed to the tank, rubber ring placed in a groove of the plate
Rubber ring should be placed precisely in a groove of fastening plate. To provide additional slide, the ring can be moistened with oil or fuel.
Screen filter is mounted on the measuring probe tubes of DUT-E (see figure 11) to protect measuring probe electrodes from mud and water. Using the screen-filter significantly extends faultless lifetime of the sensor.
Figure 11 — Screen-filter mounting location
Screen-filter assembly order: first, put on fixator, then put on bottom stop and fix it with two side screws. Put the screen filter over bottom stop and fasten it with a fixator locks. (see figure 12).
Figure 12 — Mounting screen-filter
ATTENTION:Screen-filter cannot be used without installed bottom spring stop.
Installation to barrel-shaped, D-shaped or other fuel tanks with inclined surface
For installing fuel level sensor into a fuel tank, which has rounded surface, it is recommended to use special fastening plate - DUT-E FP CT (see figure 13).
For installing fuel level sensor into a fuel tank, which has inclined surface, it is recommended to use wedged fastening plate - DUT-E WP-10, which has 10° angle of slope (see figure 14).
Figure 13 — DUT-E FP CT fastening plate, Figure 14 —DUT-E WP-10 wedged fastening plate
When installing on uneven surface, use two rubber gaskets and silicone sealant.
Electrical connection
Before mounting and connecting DUT-E switch off power supply of the vehicle electrical circuits. To do this, switch off the battery switch or release the terminals of the wires connected to the battery.
When connecting DUT-E to onboard electrical network of Vehicle, use fuses from DUT-E delivery set in accordance to scheme of connection (see figure 15). Nominal fuse current is not more than 2 A.
Prior to electrical connection of the sensor, pay special attention to checking Vehicle’s chassis ground. Resistance between any point of Vehicle chassis and ―-‖ terminal of the battery or between terminals of the chassis ground switch should not exceed 1 Ohm.
Quick splice connectors (ordered separately) are recommended for electrical connection of power supply wires.
Figure 15 — DUT-E to onboard electrical network scheme of connection
It is strongly recommended to fix DUT-E connection cable together with the standard vehicle wiring using tie-wrap fixing per each 50 cm of cable (see figure 16).
Figure 16 — Connection cable laying
When connecting bare wires, use special connectors (see figure 17).
Figure 17 — Using connectors to connect wires of signal cable
DUT-E-A5/A10/Felectrical connection is made according to pinout of the connector and interface cable wires description. See figure 18 and table 1 for details.
Figure 18 — DUT-E A5/A10/F interface cable connector pinout
Table 1 — DUT-E A5/A10/F interface cable wires assignment
| Pin number | Wire marking | Wire color | Assignment |
|---|---|---|---|
| 1 | T701/T034 | White | Output analog signal |
| 2 | GND/T734 | Brown | Ground |
| 3 | VBAT | Orange | Power supply "+" |
DUT-E 232/485 electrical connection is made according to pinout of the connector and interface cable wires description. See figure 19 and table 2 for details.
Figure 19 — DUT-E 232/485 interface cable connector pinout
Table 2 — DUT-E 232/485 interface cable wires assignment
| Pin number | Wire marking | Wire color | Assignment |
|---|---|---|---|
| 1 | VBAT | Orange | Power supply "+" |
| 2 | GND | Brown | Ground |
| 3 | 232R/485A | White | Received data (RS-232) Data exchange (RS-485) |
| 4 | 232T/485B | Red | Transmitted data (RS-232) Data exchange (RS-485) |
DUT-E AFelectrical connection is made according to pinout of the connector and interface cable wires description. See figure 20 and table 3 for details.
Figure 20 — DUT-E AF interface cable connector pinout
Table 3 — DUT-E AF interface cable wires assignment
| Pin number | Wire marking | Wire color | Assignment |
|---|---|---|---|
| 1 | VBAT | Orange | Power supply "+" |
| 2 | GND | Brown | Ground |
| 3 | KLIN | Black | K-Line (ISO 9141) |
| 4 | T034 | White | Output signal |
DUT-E CANelectrical connection is made according to pinout of the connector and interface cable wires description. See figure 21 and table 4 for details.
Figure 21 — DUT-E CAN interface cable connector pinout
Table 4 — DUT-E CAN interface cable wires assignment
| Pin number | Wire marking | Wire color | Assignment |
|---|---|---|---|
| 1 | VBAT | Orange | Power supply "+" |
| 2 | GND | Brown | Ground |
| 3 | CANH | Blue | CAN-High (SAE J1939) |
| 4 | CANL | White | CAN-Low (SAE J1939) |
| 5 | KLIN | Black | K-Line (ISO 9141) |
WARNING:The manufacturer reserves the right to change wire colors. Please, pay attention to wire marking.
DUT-E-CAN fuel level sensors are supplied without signal cable. To connect the sensor, use cable from S6 cabling system.
IMPORTANT:To ensure proper operation via CAN/S6 Telematics interface use 2x 120 Ohm terminating resistors.
If you have just one or two DUT-E CAN your CAN/S6 Telematics interface, you can use S6 SC- CW-700 cables for connection. This cable is equipped with one permanently switched on resistor (near connector) and one resistor (near bare wires) which is connected to pink wires. The second resistor should be used if DUT-E CAN is used as single device in CAN/S6 Telematics interface; the second resistor should not be used if there is more DUT-E CAN connected with identical cable (see figure 22).
Figure 22 — S6 SC-CW-700 Cable
DUT-E body is electrically connected to Ground ―-‖ (brown wire of the connection cable). Electrical isolation between the DUT-E body and the fuel tank is provided by the mounting plate made of dielectric plastic material.
IMPORTANT:Tracking device and DUT-E should be connected to power supply and Vehicle’s chassis ground together (i.e. in the same places)!
If using fuel level sensor with analog output signals, tick ―Sensor output values are not dependent on voltage in onboard network‖ (if available) – i.e. there is no need to adjust sensor’s output signal to changes of voltage in onboard electrical network.
After installation and configuration of DUT-E a tank calibration procedure should be carried out.
WARNING:
1) DUT-E readings will be invalid if measuring tubes are circuited by conducting mud or water! 2) Severe contact corrosion of chassis ground connection switch or its malfunction can seriously affect DUT-E output signal!
Configuration
Minimum/maximum measurement level calibration is required for correct operation of DUT-E AF/232/485/CAN as well as configuration to specific operating conditions and requirements of tracking devices/data loggers.
Calibration and configuration is carried out with SK DUT-E service adapter (ordered separately).
Before starting with service adapter, it is necessary to download software from - https://jv-technoton.com/software-firmware and install it to your PC
Drivers - https://jv-technoton.com/software-firmware/#1520418515679-e2460841-46e6
DUT-E sensors are connected to PC through service adapter according to the connection schemes (see figure 23).
Figure 23 — DUT-E to PC connection schemes while using SK DFM
* To connect power supply, it is possible to choose any designated place. ** Not obligatory to connect.
To enable connection between the sensor and PC, connect adapter to USB port of PC and tick connection checkbox in the left from COM-port parameters field.
Note — when connecting DUT-E CAN/AF, first, select network address from the drop-down list ADDR (see figure 24)
Figure 24 — Network address selection for DUT-E CAN/DUT-E AF and Service DUT-E main window with sensor connection established
Utility will automatically change the connection status to ―Connected‖. Firmware version, serial number of the DUT-E sensor, virtual COM port number will be displayed as well as baud rate for RS-232, RS-485 or K-line connection. LED indicators of the adapter will display signals according to table 5.
Table 5 – LED signal description
| Led indicator | Signal description | |||
| Marking | Status | Light color | ||
| ON | Red | Power supply is on | ||
| ON | No signal | Power supply is off (or voltage is less than minimum required) | ||
| RX | Green | DUT-E data is being received | ||
| RX | No signal | No data from DUT-E | ||
| TX | Yellow | Data is being transmitted to DUT-E | ||
| TX | No signal | No data to DUT-E |
Calibration
Calibration is required for correct operation of DUT-E. Calibration is conducted to determine minimum and maximum levels of measurement of fuel in the tank (in case of changing tubes’ length by cutting or extending).
To calibrate minimum and maximum level follow the procedure:
1. Measure the probe length L (mm) from the edge to the drain holes (see figure 26 a).
2. Enter the value into Actual length of sensor after trimming field of Settings- Calibration entry (see figure 26 b).
3. Wait for 3...5 seconds for sensor readings stabilization.
4. Click Set empty button or minimum level calibration.
ATTENTION: When calibrating sensor to minimum level, there should not be fuel residues on surface of tubes of probe.5.
5. Dip the probe’s tubes fully into the fuel. 6. Wait for 3...5 seconds for sensor readings stabilization.
7. Click Set full button for maximum level calibration.
8. Min/max calibration is finished.
Figure 26 — DUT-E min/max calibration
Operation modes
Operation modes entry contains settings to configure sensor for operation in particular conditions with compliance of tracking device requirements (see figure 27).
Figure 27 — Operation mode configuration
1. Fuel level filter time— time interval preceding the data transmission. Fuel level value is smoothed during this interval. Thus, fuel level value transmitted by sensor to the tracking device is not instantaneous and is averaged over a certain period of time. Setting this parameter is very important for DUT-E mounted on vehicles operated on hilly surfaces.
2. Message interval*— time period the sensor automatically sends output message to the tracking device.
3. Automatic transmission mode*– defines sensor output message type:
- Off- no automatic message transmission, sensor waits for tracking device request;
- HEX - automatic message transmission in binary format (used by default);
- ASCII - automatic message transmission in text format;
- ASCII EXT - automatic message transmission in extended text format.
4. Address ** - provides DUT-E with network address when several operate via single bus (network). The following addresses are set by the Manufacturer by default:
- DUT-E 485 - two last digits of the sensor serial number
- DUT-E CAN/AF - 101.
5. Summator***— sets sensors network status when working in CAN summator mode (see figure 49 e):
- Off - no need to summarize sensor values (default value);
- Master - should be selected for a sensor which has the highest decimal address in the network;
- Slave - should be selected for all the other network sensors.
* Only for DUT-E 232/485. ** Only for DUT-E AF/CAN/485. *** Only for DUT-E CAN.
Output message
One of the following output value types available for DUT-E 232/485:
- fuel level in standard (normalized) units (0...1000);
- fuel level in millimeters (mm), 0.1 mm step;
- fuel volume in liters (L), 0.1 L step;
- fuel volume in percentage (%), 0.4% step.
Calibration table
This submenu is used for storing calibration table for particular Vehicle into sensor’s internal memory. The sensor will recalculate level of fuel into volume of fuel based on this table.
IMPORTANT: When summarizing signals from several DUT-E CAN/AF/232 it is obligatory to store calibration table into each sensor.
Calibration table is based on values, received when performing tank calibration. This procedure consists of refilling fuel tank from empty to full by certain portions of fuel.
To make tank calibration properly, please, follow the instructions:
- vehicle should not be loaded and should be parked on even horizontal surface;
- fuel tank should be empty;
- vehicle’s tires should be of standard size and type for this model;
- pressure in the tires should be within allowed range for this model;
- vehicle should not move, ignition is turned on, engine not running;
- between consequent tank refilling operations, please, wait at least 60 seconds.
The data is entered as a table of correspondence between measured fuel level value (―Fuel level (mm)‖ field) and fuel volume in the tank (―Volume (L)‖ field). Recommended number of table entries is 15. Max possible is 30 entries (see figure 28).
Figure 28 — Calibration table
Click add button to insert a new entry into the table and fill out the fields. Entries are automatically sorted from low to high fuel level value. To delete an entry highlight it and click delete button. Clicking save to file button will allow saving the table as a *.ttd file. To load previously saved table from file click Read from file button.
Analog output
Analog output* menu of Service DUT-E used for configuration of sensor’s output voltage range according to the voltage range of the tracking device input.
Figure 29 — DUT-E AF output configuration
The first drop-down list is for selection of Output signal type (see figure 29 a):
- U (voltage);
- F (frequency).
The second drop-down list for configuring value type (see figure 29 b):
- Level (fuel level in the tank);
- Volume (fuel volume in the tank);
- Sum (totalizing readings of several sensors).
* Only for DUT-E AF.
To configure analog output, follow the instructions:
1. Enter value of the lower range limit into ―Minimum level (1.0...8.0 V)‖ field.
2. Enter value of the higher range limit into ―Maximum level (2.0...9.0 V)‖ field.
Diagnostics drop-down list (see figure 29 c) allows to enable/disable special output signal diagnostics values:
Installing several DUT-E on one Vehicle
If a vehicle has more than 1 fuel tank, it is recommended to equip each with DUT-E fuel level sensor. All sensors should be installed as per instructions above.
When installing several DUT-E A5, DUT-E A10, each sensor’s output signal can be processed only if tracking device has a corresponding number of inputs.
When installing several DUT-E 485, all sensors can be connected to one RS485-port of tracking device and each sensor should have unique address (set up via Service DUT-E software).
When installing several DUT-E 232, summarization device should be used – DUT-E SUM 232 (see figure 30).
Figure 30 — DUT-E SUM 232
In this case, several fuel tanks, which are equipped with fuel level sensors connected through summarization device, will be treated by tracking devices as a single fuel tank. Fuel tank calibration table should be recorded into the internal memory of each sensor. Connection scheme is described on figure 31.
Configuration of DUT-E 232 should be done according to DUT-E operation manual.
Figure 31 — DUT-E SUM 232 connection schemes
When installing several DUT-E AF, summarization device should be used – DUT-E SUM AF (see figure 32).
Figure 32 — DUT-E SUM AF
Fuel tank calibration table should be recorded into the internal memory of each sensor.
Readings can be totalized both for analog (voltage) and frequency output signal types of DUT-E AF.
If there are three or more fuel tanks to be measured with DUT-E AF sensors, cascade connection can be used according to figure 33.
Figure 33 — DUT-E SUM AF connection schemes
DUT-E CAN sensors can be used for obtaining data on total fuel volume of several tanks under CAN 2.0B interface.
To get correct result of summarizing data from several DUT-E CAN, configure sensors according to DUT-E operation manual. In this case, Fuel Volume (l) and Fuel Level (mm) parameters will still be sent separately by each sensor, At the same time, DUT-E CAN configured to ―Slave‖ will not send SPN 96 parameter (Fuel Volume 1 (in %)) and DUT-E CAN configured to ―Master‖ will send data (in %), taking in account a total of volumes in all fuel tanks.
Functioning check
Measurement accuracy check
DUT-E accuracy check test is conducted to determine the reduced and absolute error of fuel level measurement on the vehicle.
Check tests procedure
Check tests should be carried out in the following order:
- Turn ignition on.
- Drain a fixed volume of fuel.
- Determine the exact amount of fuel with the calibrated measuring container.
- Record the data into the Check test report.
- Wait for the fuel getting still in the tank (for a stable DUT-E readings).
- Refuel the tank with the previously drained fuel.
- Record the data into the Check test report.
- When analyzing accuracy errors, "Drain" and "Refill" parameters are estimated as a percentage relative to the total tank capacity.
Frequently asked questions
Q:Do I need to use any power supply stabilizers or converters when installing DUT-E? A:No. All DUT-E stabilizes power supply automatically.
Q:What does it mean when fuel level value suddenly increases from current fuel level to maximum (or almost maximum) fuel level possible for this tank? A: 1. Most frequent reason – short circuit of sensor’s tubes by water or mud from bottom of the tank.
2. Also, rapid increase can be caused by poor quality of Vehicle’s chassis ground.
Q: What are the disadvantages of installing DUT-E instead of standard fuel level sensor? A: 1. Fuel level indicator on dashboard does not work without additional devices (MasterCAN DAC15 digital-to-analogue converter) 2. DUT-E will be placed not in geometrical center of fuel tank, which may lead to increase of inaccuracy of fuel volume measurement.
Q:Why false filling/draining is depicted and values on fuel level chart are fluctuating much? A: 1. Vehicle moves on uneven ground and filling/draining is a result of fuel movement inside a tank.
2. Water or mud is getting between sensor’s tubes and periodically short circuits the tubes.
Q: How many steps (calibration points) should be done when calibrating fuel tank? A:More points you make – more accuracy you will get. If you are sure a fuel tank has regular shape and there are no inner walls – 10 points are enough. If a tank has not rectangular shape or has several compartments divided by inner walls inside – up to 30 points (maximum possible).
Q:How temperature expansion of fuel is taken in account and does it influence accuracy of measurement?
A:Yes, it does influence the accuracy. DUT-E fuel level sensors have in-built function of automatic measurement correction to environment temperature. Also, you can manually change additional correction coefficient to adapt sensor to local conditions of operation. The coefficient can be changed through Service DUT-E software (sensor should be connected to PC with SK DUT-E service adapter).