Fuel level sensors Strela - Users manual

Fuel level sensors

Strela

Users manual

10.09.2011

Sapsan Control Co Ltd

www.skontrol.ru
Russia, Chelyabinsk
2011
 Fuel level sensors Strela - Users manual

Content
Brief description .......................................................................................................................................3
Technical data...........................................................................................................................................4
The short description of sensor product range ...........................................................................................5
Delivery set ..............................................................................................................................................7
Installation of fuel level sensor..................................................................................................................7
Calibration of tank ..................................................................................................................................10
Sensor Strela performance test ................................................................................................................11
Service and application note ...............................................................................................................14
Transportation and storage .................................................................................................................15
Manufacturer’s warranty......................................................................................................................15
Appendix 1. Dimensions.........................................................................................................................16
 Fuel level sensors Strela - Users manual

Brief description
Fuel level sensors STRELA are used for petroleum, oil and lubricants. They enjoy
wide application in automotive telematic systems for fuel level recording such as Intellitrac,
GoSafe, Enfora, Teltonika. Various interfaces provide a suitable solution for all telematic
systems.
FLS Strela is a capacitive fuel level sensor without movable parts. Two aluminum tubes
create a capacitor plate; its capacity depends from level inside tubes. FLS Strela is not
intended for measuring water: with water inside tubes the output signal coincides with that
of a full tank.
There are different kinds of output signal. You can choose among:
• Analog output (0.5-4.5 V, 0.5-3V,0.5-10V,0.5-12V) – Strela A
• Frequency output (500-1500 Hz) – Strela F
• Digital output (serial RS232 of 485 interface with 1024 or 4096 points resolution) –
Strela D232, Strela D485
• Custom interfaces by demand: current 4-20 mA, MODBUS, CAN

Electronic components of sensor are immersed into elastic compound that provides
maximum protection (IP66) and safety under any operation conditions.
Measuring tubes are made of the material that doesn’t react with fuel components.
Sensors are adjustable for desired tank height – you may cut them according to the height
of your tank. But from fuel lever sensors (FLS for short) Strela A and Strela F you may not
cut more than 50% of initial length.
There is a list of available initial length of sensors: 180, 250, 350, 400, 500, 600, 700,
1000, 1400, 2000 mm. You should choose from this list the most suitable length for your
need; however take the longer one to provide the most accurate length.
Strela D232 and Strela D485 can be cut for any height.
Sensors have built-in supply voltage stabilizer and sensor output doesn’t depend from
onboard voltage.
Sensors have built-in algorhythm of data filtration and averaging that allows us to receive
smooth fuel data. You can change averaging settings in Strela D232 and Strela D485
sensors. Data averaging in Strela A and Strela F must be defined while making an order
before production.
Sensors have self-diagnostic capabilities.
There are some series of the sensors. For sensors with label PM a body of sensor is
electrically not connected with ground.
 Fuel level sensors Strela - Users manual (version 1.1 10-09-2010)

Technical data
Table 1
Sensor model Strela A1 StrelaА3 Strela D232, Strela F Strela PP
Strela D485
-type of output Analog, Analog, Serial Frequency, Pulse-packet,
signal voltage resistive(Ohm) interface Hz pulses, per
RS232 or minute
RS 485
Data
protocol:
Omnicomm,
Modbus
Fuel level 0% 2.5 800 Ohm, - 500 Hz 500
350 Ohm, 90 Pulses/min
Fuel level 100% 5,7,10* Ohm - 1500 Hz 1500
Pulses/min
Fuel alarm output - 0,5 Ohm - - -
Supply voltage, V 10...30
Maximum current, 100 100 50 100 100
mA
Distance from 1... 20
lower end from
tank after
installation, mm
Length of 180…2000 and up to 10000 for composite sensors
sensor,mm
Measurement ± 0.1 ± 0.3 ± 0.1... ± ± 0.1 ± 0.1
error, % of sensor 0.025 and
length less
Max value of ± 1,0 %.
error**
Self-diagnostic + - + + +
feature
An allowed cutting 30 30 50 30 30
value, %
* On vehicles with 12V onboard circuit voltage can sometimes drop below 10V. In this
case sensor will not able to form a signal being that of a full tank – signal will be limited
by onboard voltage. We recommend for 12V vehicles to use sensors with 0.5-7V output.
** Error caused by external temperature in range – 400C + 55 0С

Table 2
Working temperature,°С -40 +65
Average time before malfunction Тav* 12500 hours
Protection class IP66
Power consumption, W < 0.2
Dimensions, mm L x 70 x 70
Mass, kg 0.3...3
Operation time Not limited
 Fuel level sensors Strela - Users manual (version 1.1 10-09-2010)

The short description of sensor product

range
FLS Strela А is a widely used fuel level sensor with analog voltage output.
Advantages:
1) Voltage output range is extended up to 12 V - it is a MUST for AVL trackers with
analog input of 0-24V (Teltonika, and 90% others)
2) No signal pulses above 1-3 mV
3) Self-diagnostic codes
4) Output circuit protection
5) Isolation of sensor body from "ground" power supply - you can connect fuel level
sensor directly to car battery.

Note: The voltage drop below 10 V is possible on the vehicles with 12 V board electric
mains. In that case the sensor is not able to produce signal equal to that of full tank
level. The signal will be limited by supply voltage. We recommend to order sensors with
maximal output signal up to 7V for vehicle with 12 V board electric mains.

FLS Strela A3 should be used in combination with standard fuel level indicators.
Sensor Strela A3 can:
• Determinate fuel level and produce signal equal to the quantity of fuel in the
tank.
• Produce signal of minimal balance of the fuel.

The sensor may be used in combination with standard fuel level indicators. Equivalent
of sensor resistance corresponds to the range 800 Ohm, 350 Ohm, 90 Ohm.

As a part of GPS-monitoring system sensor has one fail - the voltage across analog
input depends not only on sensor output, but also on standard indicator resistance and
board electric mains voltage.

Strela F

The fuel level sensors Strela F have greater accuracy and indication stability in
comparison with Strela A. The tank fuel level is coded by frequency that linearly varies
by changing of fuel level. The signal format is meander 50%, pulse height is equal to
half of supply voltage. Currently such terminals as GOSAFE support these sensors.

Main advantages:
ü High resistance to external pickups, poor ground and other interfering signals due
to great pulse height
ü No loss of data quality on terminal analog to digital converter in compartment with
analog output

The disadvantage of FLS with pulse output:

• As a rule there is a lack of terminal software support
 Fuel level sensors Strela - Users manual (version 1.1 10-09-2010)

Strela PP

The fuel level sensors Strela PP have same advantages over Strela A as Strela F. The
output signal extends with pulse packet. Packet communication frequency is 1 minute
for work mode and 15 seconds for test mode. Pulse count in work mode codes
measurable value (from 500 to 1500 pulses). Pulse count in test mode codes error type.
Pulse count in packet is over 380 Hz. The signal format is meander 50%; pulse height is
equal to the half of supply voltage.

Fig. 1.. Format of output signal of FLS Strela PP

FLS Strela D232 (D485)

The fuel level sensors Strela D 232 (D485) with digital interface RS232 (RS48) are used
with record or monitoring systems that have input interface. There are some
compatible AVL devices – Intellitrac, Teltonika, DaisyTrack.
Digital interface can work with MODBUS protocols or with Omnicomm–compatible
protocol. Protocol parameters: 19200 bit per second, 8 bit, 1 stop bit. Resolution - up
to 63535 points per length.

Main advantages:
ü High resistance to external pickups, poor ground and other interfering signals due
to great pulse height
ü No loss of data quality on terminal analog to digital converter in compartment with
analog output
 Fuel level sensors Strela - Users manual (version 1.1 10-09-2010)

Delivery set
In the set there are sensor, 4-m cable, gasket, screws, passport

Fig. 2 delivery set

Installation of fuel level sensor

It is recommended to install FLS Strela in the center of tank, in addition to vehicle level
sensor.
In some cases (when vehicles are used on rugged terrain and tank shape is symmetric)
the installation of TWO FLS is recommended.
Sometimes FLS Strela can be installed instead of truck level sensor. But in this case you
should take into account that:
1. For better measurement the best place for FLS installation is geometric center of the
tank (see Fig. 3). Truck level sensor is usually mounted not in the center.
2. FLS Strela have no output on vehicle fuel indicator, you will need FLS gauge unit to
connect it to gauge.

Fig. 3. Recommended installation scheme

Sequence of installation:
 Fuel level sensors Strela - Users manual (version 1.1 10-09-2010)
1) Drill holes for FLS flange (see fig. 4). Usually bi-metall drill head with 35mm
diameter is used.

Fig. 4. Bi-metall bore HAWERA

Before drilling a hole in a tank with diesel fuel you should refuel it until
full. In this case explosive vapor will not produced. If you drill a hole in
tank with petrol fuel you should load it with water instead of petrol fuel!

It is better to start from central hole, after that insert sensor in hole and mark
places for outside 5 holes. They are not symmetric! We use standart hole SAE-5 PIN –
see dimensions in Appendix 1).

2) Cut a FLS for desired length with saw – see fig. 5. You should leave about 5-10 mm
for water on a bottom of the tank. For Strela A, Strela F: Length of sensor after cutting
should be not less than 30 and 50% of initial length accordingly! If your tank needs a
shorter sensor – you need Strela with shorter initial length!

Fig. 5 Cutting a sensor

3) For Strela D232 or D485 –make a sensor calibration (see instruction of

Calibration).
 Fuel level sensors Strela - Users manual (version 1.1 10-09-2010)

4) According to wiring diagram from passport connect supply voltage, ground and
output signal to telematic system. Be aware of incorrect connection – FLS may be
burned out!

Please follow sensor connection circuit into vehicle electrical

system!

Don’t mix up cables. Wrong connection may bring sensor out of

operation.
Don’t apply supply voltage over +30V!

Fig. 6 Strela A, Strela F, Strela PP connector and wiring

Fig. 7 Strela D232. Strela D485 connector and wiring

Table. 1
Strela D232 Strela D485 Colour
1 “-” “-” brown
2 “+” “+” blue
3 Rx RS-A Yellow-green
4 Tx RS-B Black
 Fuel level sensors Strela - Users manual (version 1.1 10-09-2010)

Calibration of tank
Sensor output
Table 3- an example of tank calibration table
Liters value, Hz
20 300 The tank calibration consists in recording in the ROM of terminal
70 370 or AVL software the conversion table of sensor output signal
130 460 (voltage, frequency, pulses and others) to fuel volume value.
180 530
230 600
280 665
330 730
380 795
440 870

Tank calibration technique:

1) Stop vehicle on the flat part of the road (road angularity must minimized).
2) Discharge tank completely.
3) Add fuel till sensor will begin to change indication. Write into table added fuel
value.
4) Add in tank by 10-50 liters (lowest value by min and max tank volume, greatest
value by half empty tank). Get new proper values of sensor output signal and
write down them into the table.
 Fuel level sensors Strela - Users manual (version 1.1 10-09-2010)

Sensor Strela performance test

Resistance between pipes works out about 500 kOhm. If value is a sequence less you
should check whether there is a contamination between pipes.

Strela A1. Without fuel immersion voltage on the working sensor at the output in
reference to ground must range from 0.1 to 2.5 V (depending on cutting). Full tank
output voltage may be 8 - 10 V (depending on cutting). When sensor touches water
diagnostic code is 1.4 V. It is possible to produce versions with decreased output
voltage (under order).

Table 4. Errors diagnostic codes

No Code, V Error description
1 1,0 Sensor is not calibrated at lowest and upper point
2 1,2 Sensor is not calibrated at upper point
Oscillator frequency is equal to 0 (pipe closing against each other particularly
3 1,4
because of water)
4 1,6 Divide by zero, sensor was calibrated at the same point
5 1,8 Reading error EEPROM
Break through upper range F> (Fmax+10%) (possible reason is change of fuel
6 2,0
type or significant water rate in the fuel)
7 2,2 Break through lowest range F < (Fmin – 10%)
8 2,4 Calibrating contact point is short-out

Strela F. Without fuel immersion signal frequency on working sensor at the output in
reference to ground must range from 600 to 700 Hz (depending on cutting). Full tank
frequency may be equal to 1300 – 1600 Hz (depending on cutting). When sensor
touches water the diagnostic code is 340 Hz.

Table 5. Errors diagnostic code

Code, sensor output
No Error description
signal, Hz
1 300 Sensor is not calibrated at lowest and upper point
2 320 Sensor is not calibrated at upper point
Oscillator frequency equal to 0 (pipe closing against each other
3 340
particularly because of water)
4 360 Divide by zero, sensor was calibrated at the same point
5 380 Reading error EEPROM
Break through upper range F> (Fmax+10%) (possible reason is
6 400
change of fuel type or significant water rate in the fuel)
7 420 Break through lowest range F < (Fmin – 10%)
8 440 Calibrating contact point is short-out

Strela PP. Without fuel immersion pulse packet on working sensor at the output in
reference to ground must be 600 – 750 pulses (depending on cutting). Full tank pulse
packet must be equal to 4300 – 4600 pulses (depending on cutting). When sensor
touches water the diagnostic code is 340 pulses packet. Packet communication
frequency is one minute for work mode and 15 seconds for test mode (see fig.1)
 Fuel level sensors Strela - Users manual (version 1.1 10-09-2010)
Table 6. Errors diagnostic code
Code, sensor output
No Error description
signal, pulse count
1 300 Sensor is not calibrated at lowest and upper point
2 320 Sensor is not calibrated at upper point
Oscillator frequency equal to 0 (pipe closing against each
3 340
other particularly because of water)
4 360 Divide by zero, sensor was calibrated at the same point
5 380 Reading error EEPROM
Breakthrough upper range F> (Fmax+10%) (possible reason
6 400
is change of fuel type or significant water rate in the fuel)
7 420 Breakthrough lowest range F < (Fmin – 10%)
8 440 Calibrating contact point is short-out

Strela D232 and D485. The error codes transfer with protocol (see appendix 2)

Table 7. Errors diagnostic code

No Code Error description
Oscillator frequency equal to 0 (pipe closing against each
3 003
other particularly because of water)
5 005 Reading error EEPROM
Breakthrough upper range F> (Fmax+10%) (possible reason
6 006
is change of fuel type or significant water rate in the fuel)
7 007 Breakthrough lowest range F < (Fmin – 10%)
 Fuel level sensors Strela - Users manual (version 1.1 10-09-2010)
Table.8 Causes of error appearance
Working
Error Failure description Repair
ability
Oscillator Description: oscillator is stopped Works 1. Dry sensor, drain
frequency – sensor doesn’t measure fuel water from the
equal to 0 level Type of failure: error is of tank;
sporadic* (water short-out when 2. Eliminate
vehicle is in motion) or mechanical short-
permanent (when mechanical circuit.
short-circuit occur) nature. After Check resistance
cause is eliminated the sensor between sensing
passes into work mode. element pipes when
Cause: Sensing element pipes sensor is off by
are short-out – water in the fuel, circuit analyzer.
mechanical short-circuit. Resistance value
must range from 460
to 500 k Ohm.
Reading error Description: set sensor doesn’t work Replacement
EEPROM calibration parameters failed.
Type: error appears at once Check: close
when you switch sensor on and sensing element
has permanent nature, i.e. fuel electrodes by
immersion, wire short-circuits metallic object, if
doesn’t effect on sensor output sensor output signal
signal. didn’t change then
Cause: possible static electricity sensor is out of
impact by static electricity while work.
sensor cutting.

Breakthrough Description: sensor stands by Dead zone Replacement

at upper zero if fuel level is low than gives below
range F> an error. Check: Submerse
(Fmax+10%) Type: error occurs on dry sensor. sensor into fuel it
If you submerse sensor into fuel works properly after
it works properly after it passes it passes dead zone.
dead zone.
Cause: more then 10% of non-
cutting sensor or more than 40%
of cutting sensor was cut. The
problem may also be caused by
damage of sensing element
coating.
 Fuel level sensors Strela - Users manual (version 1.1 10-09-2010)
Breakthrough Description: fuel level is over Works Check: by
lowest range real value, sensor gives error submersion of
F < (Fmin – from time to time. sensor into the fuel
10%) Type: error occurs at sensor the output signal is
immersion on the level that is proportional to
close to maximal one or on any sinkage.
other level by water short-out. If
error changes to error «Oscillator
frequency equal to 0», then the
problem is caused by water in the
fuel.
Cause: measurement fluid is
different from diesel fuel or
gasoline. Circuit shot of
measuring element by water in
tank.
*Sporadic – from time to time.

Service and application note

ü Sensor operation requirements are stated in sensors certificate.
ü To avoid sensor breakdown do not expose sensors to aggressive
environments, electromagnetic fields as well as mechanical and weather loads,
that exceed determined parameters in the present guide;
ü Do not connect sensor to devices which have interface that fails to meet
the specification, indicated in present performance specification and detailed
engineering drawings;
ü After sensor installation on vehicle or equipment it is recommended to
seal all electrical connections;
ü Sensors repair must be done by qualified staff that has repair right
certificate
ü An exterior check is essential before introduction sensors into service. If
there are mechanical damages (cracks, shears, dents and etc) at sensor than
sensors introduction into service is not allowed;
ü Sensors service must be done by staff that studied the device, its mode of
functioning and all instruction indicated in sensor certificate;
ü It is recommended to use proper grade diesel fuel that answer to range of
temperature (summer, winter, arctic) to All-Union standard 305.

Maintenance support
Product does not need maintenance support

Maintenance repair
Product is nonrepairable.
 Fuel level sensors Strela - Users manual (version 1.1 10-09-2010)

Transportation and storage

Transportation

The sensors transportation must be done in enclosed transport of any type that can
provide protection for sensor against mechanic damage and exclude impact of
atmospheric fallout onto pack.
By air transport sensors are places in heated pressurized module.
The air in vehicles should not contain acid, alkaline and others aggressive addictive
agents.
Transport package with packed sensor must be sealed. Sealing method should exclude
access to packed sensor without removal of the seal.

Storage

Storage of sensors in the same facility with metal corrosive materials or materials
containing aggressive addictive agents is not allowed.

Manufacturer’s warranty
1. Guarantee period is 18 month from manufacture data, which is indicated in
product certificate.
2. Manufacturer guarantees product working ability under keeping of service rules,
transportation and storage rules by customer.
3. Products that have been installed by experts that have received training in
Sapsan Export Trade and have personal certification are covered under warranty.
4. Sensors with damage (cracks and shears, dents, impact marks, chamber choking
etc) that occured through customer’s fault due to violation of service, storing and
transportation terms are not covered under warranty.
 Fuel level sensors Strela - Users manual

Appendix 1. Dimensions