ultrasonic level sensor sigma · 2017-07-06 · 7.4.2 to achieve the optimal sensor operation,...
TRANSCRIPT
1
Ultrasonic level sensor
"SIGMA"
ULSx-yy models
Installation Manual
ULS.0000-EN IM
_v.170515_
2
CONTENTS
Page
1 GENERAL INSTRUCTIONS ................................................................................... 2
2 BASIC DEVICE INFORMATION ........................................................................... 3
3 BASIC TECHNICAL CHARACTERISTICS ........................................................... 4
4 DEVICE MARKINGS ................................................................................................ 5
5 GENERAL VIEW AND CONTENTS OF DELIVERY ........................................... 5
6 SAFETY REQUIREMENTS ..................................................................................... 8
7 PREPARATION FOR INSTALLATION AND MOUNTING PLACE
PRESELECTION ............................................................................................................ 8
8 SENSOR ELECTRICAL CONNECTION .............................................................. 11
9 FINAL SELECTION OF MEASURING PART MOUNTING PLACE ................ 13
10 SENSOR INSTALLATION AND SETTING ....................................................... 14
11 SENSOR PARAMETERS SETTING ................................................................... 19
12 SENSOR SETTING AND ADJUSTMENT WITH "uS_Install" PROGRAM ..... 21
13 TRANSPORTATION AND STORAGE ............................................................... 23
APPENDIX A SENSOR OPERATION MODES ...................................................... 24
APPENDIX B "uS_Install" APPLICATION PROGRAM......................................... 28
APPENDIX C LAYOUTS FOR SENSOR CONNECTION TO PC ......................... 35
APPENDIX D FIRMWARE UPDAITING, CONFIGURATION DATA SAVING
AND RESTORING ....................................................................................................... 36
APPENDIX E DATA EXCHANGE PROTOCOL .................................................... 39
APPENDIX F CALIBRATION TABLE CALCULATION ...................................... 45
APPENDIX G QUICK GUIDE FOR “US20 Install Service” PROGRAM .............. 47
The present manual is intended to provide information necessary for users to
install and maintain ultrasonic level sensor "SIGMA" ULS-20, ULS2-20 and ULS4-20
models (hereinafter – Sensor or Product).
1 GENERAL INSTRUCTIONS
Only personnel that acknowledged the present manual is allowed to install the
sensor.
During the fuel level sensor installation, organizational and technical actions
that ensure the occupational safety with autogas systems, control and measuring
equipment, ancillary equipment and consumable materials have to be carried out (see
Section 6).
3
2 BASIC DEVICE INFORMATION
Ultrasonic level sensor “SIGMA” is purposed for noninvasive liquified petroleum
(propane/butane) gas (LPG) level measurement in horizontally positioned gas tanks of
vehicles.
a b
Fig. 2.1 – Typical LPG fuel containers layout and recommended position for
sensor measuring part installation in passenger cars
(a – toroidal container, b – cylindrical container)
It is also possible to use sensor for gasoline, diesel and other fluids level
measuring.
Sensor consists of two parts – measuring part and transducer with indicator
(hereinafter – Transducer).
Transducer calculates fuel level by processing data from the measuring part and
outputs result to the indicator. Calibration procedure is performed to indicate fuel
volume instead of fuel level. After the calibration, fuel level (in centimeters) is
recalculated into volume (liters). Measuring results are demonstrated on the indicator;
they can be also transferred to the GPS tracking device for further processing.
See Appendix A for indicator use description with different operation modes and
settings.
Measuring part is installed on the container bottom from outside by using fixing
mechanism – cable with traction device.
Sensor can transfer data to vehicle information system.
There are 3 modifications of SIGMA ULS sensors, which have different data
transfer interface:
SIGMA ULS - no data transfer interface;
SIGMA ULS2 - RS-232 digital interface;
SIGMA ULS4 - RS-485 digital interface.
To protect the sensor from mechanical influences and unauthorized access to the
sensor and its mounting system, a ULM.4000 protection device can be used
(optionally) on horizontally located fuel gas ballons up to 450 mm in diameter
mounted outside the vehicle.
Sensor installation does not interfere with the tank structure or influence autogas
equipment operation.
Sensor can be used with equipment that supports unified communication
protocol Epsilon Data Exchange (see Appendix E).
4
3 BASIC TECHNICAL CHARACTERISTICS
Table 3.1 – Basic technical data
Parameter or characteristic name Unit Value Note
General
Type of measured fuel LPG
Allowed tilt angle of vehicle when measuring
level, max degrees 12
Container wall thickness mm 1,5…4,0
Operational temperature range С – 40 … + 70
Measuring part ingress protection rating IP67
Transducer ingress protection rating IP50
Mode of operation Continuous
Measurement
Indicator resolution capability liters 1*
Measurement range mm 20…600**
Averaging period sec. 30
Code length of presentation of measurement
results bit
10/12/16 level
8 temperature
Exchange rate through the serial port bps
2400, 4800,
9600, 19200,
38400,
57600,
115200
Programmed,
default setting -
19200
Power supply
Power supply voltage, operational range V +9 …+36 Nominal value
Current consumption, max mA 70
Interface
Digital RS-232 ULS2 model
RS-485 ULS4 model
Dimensions
- transducer, max mm 62х38х16
- measuring part, max mm Ø26х11
* - Indicator readings are considered adequate in 30 seconds after the filling-in if the vehicle
stays in horizontal position.
** - When level of fuel in tank is lower than the minimal measuring range of sensor, readings can
be incorrect. It is recommended to fill in before fuel reaches lower measuring range of sensor.
5
4 DEVICE MARKINGS
Fig. 4.1 – Device markings legend
5 GENERAL VIEW AND CONTENTS OF DELIVERY
Fig. 5.1 – Measuring part components
Fig. 5.2 – General view of transducer with indicator
(Button 1- to change the operation mode, Button 2 – to browse the menu entries; see
Appendix A)
ULS 4 - GW - xxxx
Model
Interface type
4 - RS-485
2 - RS-232 - no interface
Additional modifications (blank field for standard devices)
blank
Indicator color
B - black
- dark-grey
- grey
T
G
Y
Display glow color
W - white
G - green-yellow
- beige
Button 1
Button 2
6
Table 5.1 – Basic delivery kit
Name q. Note
Measuring part 1 Assembled with 7 m cable
Transducer with indicator 1
Assembled with cables: power supply
(~1 m), interface and signal (~0,2 m
each), fuse holder with fuse SI 0,1 А,
two heat shrinkable cambrics (Ø3 and
Ø6 mm).
Measuring part fixing kit 1 See fig. 5.3
Transducer mounting holder 1 With mounting kit
Passport 1
1 – Half-bushing ( 5)
2 – Half-bushing (М5)
3 – Clamp cover – to press
measuring part
4 – Bushing (cable protection)
5 – Measuring part gasket (attached
to the measuring part)
6 – Cable. 2 m long
7 – Container vibration isolator
8 – Sensor vibration isolator
9 – Cable double clamp
10 – Screw М5 х 35
11 – Grower washer
12 – U-washer (inner 5)
13, 14 – Polyethylene bag
15 – TSIATIM-221 lubricant - 5 g
Fig. 5.3 – Measuring part mounting kit
7
Table 5.2 – Optional items, documentation and software
Name Note
Indicator tilting holder ULS.4200 For comfortable angle-wise indicator mounting
Protection device for sensor
ULM.4000 (Optionally)
For mechanical protection and restriction of
access to the sensor (See Fig. 5.4)
Installation manual ULS.0000 IM. -
User Software CD ULS.0000 CD3.
CD contains:
- "US20_Install" and "US20 Install Service"
programs for sensor installation and calibration;
- "US20_AppLoader" loader program for firmware
updating, configuration data saving and restoring.
- "US20 Calibration table calculation for automotive
LPG containers" program for calibration table
generation according to LPG container dimensions.
Fig 5.4 – ULM.4000 - Measuring part protective cover with traction device
8
6 SAFETY REQUIREMENTS
Requirements of fire safety regulations, according to ГOCT (GOST) 12.1.004-
91 "Occupational safety standards system. Fire safety. General requirements," and
electrical safety, according to ГOСT (GOST) 12.1.019-91 "Occupational safety
standards system. Electrical safety. General requirements" or other requirements in
force within the territory of the consumer have to be observed on the working site.
Requirements of occupational health and safety rules have to be observed on
road transport at the working sites according to НПАОП (NPAOP) 0.00-1.62-12
"Occupational safety and health rules on road transport", autogas occupational safety
requirements or other requirements in force within the territory of the consumer.
The responsibility for the implementation of security measures lies with the
technical staff involved in the installation of the fuel level sensor, as well as the
employees responsible for the equipment at the working site.
7 PREPARATION FOR INSTALLATION AND MOUNTING PLACE
PRESELECTION
7.1 Unpack and check the specification according to Table 5.1
7.2 Prepare equipment, instruments and consumables according to Table 7.1:
Table 7.1
Name
Wrench with mouth size of 10 mm.
Electric drill with 6,5 mm drill
Gasket lubricant (included in delivery kit) – 5 gram
Automotive sealant (recommended: ABRO RTV Silicone Gasket Maker, part
No.12AB or analogue) – 2 - 3 grams
Highlighter to mark possible place of measuring part installation
Measuring tape to measure fuel container before calibration
Rubber roller to press the vibration isolator
Note – to install sensor, rubber spacers with 20 mm thickness may be necessary
to use. Spacers can be from any nonmetal elastic material with enough rigidity to
withstand the weight of fuel container. Spacers should be inserted under the fuel
container to insure the required space for measuring part installation.
7.3 Fill the container not less than 2/3 of its volume.
9
7.4 Select the installation place for measuring part beforehand. To do this:
7.4.1. Place the vehicle on flat horizontal surface, fuel container must be in
horizontal position too.
7.4.2 To achieve the optimal sensor operation, measuring part must be installed
in the lower point underneath the container, right in the middle, as demonstrated
on fig. 2.1, 7.1, 7.2.
Fig. 7.1 – Correct and incorrect installation positions for cylindrical container
7.4.3 The best places for measuring part installation are cavities and hollow
spaces in the vehicle trunk bottom. Distance between the bottom, trunk walls
and measuring part must be no less than 5 mm (see fig. 7.2). To achieve this,
rubber spacers may be used. Spacers must be positioned in a way that container
remains in horizontal position.
Fig. 7.2 – Measuring part position in the vehicle trunk hollow space
Another solution for installation can be cutting Ø 40 – 50 mm hole in the trunk
bottom, where the measuring part can be placed. Hole can be hermetically
sealed afterwards with a slab of rubber sheet or with matching blanking plug
(user-supplied).
10
!
There must be no division walls or other container construction
elements (float gauge, nozzles, etc.) inside, under the measuring
part installation place. Measuring part installation on welded
seams or other surface irregularities is forbidden.
Measuring part working surface should be parallel to fuel surface, in other
words – horizontally.
Fig .7.2 – Potential installation place of measuring part on a toroidal container
7.4.4 Considering information above, chose two, three potential installation
places of measuring part, clean them from dirt and rust, degrease and mark
them.
11
8 SENSOR ELECTRICAL CONNECTION
8.1 Sensor electrical connection involves connecting cable wires of the measuring part
and transducer, connecting power supply cables to vehicle electrical system and, if
needed, connecting RS-232/RS-485 interface cables to GPS tracking device
(according to color markings, demonstrated on fig. 8.1).
Fig. 8.1 – Sensor electrical connection layout
8.2 Sensor wires electrical connection is performed as follows:
8.2.1 Connect shielded cables from the measuring part to transducer by twisting
them (step by step instruction is in table 8.1).
8.2.2 Connect power supply wires to vehicle electrical system.
Red power supply wire must be connected after the ignition switch for
sensor to operate only when ignition is ON.
0,1 A fuse with holder (in the delivery kit) must be installed in place of sensor
connection to "+" vehicle electrical system (fig. 8.1).
8.3 If it is necessary to remove the sensor, perform wire disconnection in reverse
order.
12
Table 8.1 – Cable wires connection method
Step 1. Pull heat-shrinkable tubing 6 x 30 mm on
one of cables for connection.
Step 2. Perform (check) cable stripping according to
figure on the right.
Step 3. Twist corresponding (same color)
conductors and shields of two cables to each other.
Step 4. Lay down twisted conductors of red and
white wires alongside the isolation. Contact between
signal conductors and shield conductors is
forbidden.
Step 5. Pull on the heat-shrinkable tubing 2 х 8 mm
on red and white conductors and heat them.
Step 6. Coil twisted shield conductors on the heat-
shrinkable tubing of signal (red) wire. Lay down
cables in line.
Step 7. Additionally, make sure that there is no short circuits between signal
conductors and shield conductors.
Step 8. Move (put on) heat-shrinkable tubing 6 х 30
mm onto the connection place and heat it.
13
9 FINAL SELECTION OF MEASURING PART MOUNTING PLACE
The following sensor installation actions can be performed both by using
indicator and with personal computer or laptop (hereinafter – PC) with preinstalled
"uS_Install" program (see Appendix B). The latter variant is recommended for
installation at autogas vehicle service stations.
Prior to sensor installation with nondefault settings, make sure
that container height settings in sensor are correct. Container
height value in sensor shouldn’t be lower than the actual
container height. Container height settings in sensor can be
changed in menu n6 (Appendix A) or by using "uS_Install"
program (Appendix B). Container height value is 99 cm by the
default.
Required actions according to first variant (with indicator) are described
below.
To determine final place of measuring part installation it is necessary to select
one of previously marked places according to maximum echo signal power, which is
controlled by indicator.
To do this:
9.2 Lubricate (lubricant in table 7.1) the measuring part clamp surface, which is
constrained by a gasket.
Lubricant is purposed to create an acoustic contact between the measuring part
and container.
9.3 Apply the voltage to sensor.
9.4 Enter the transducer service mode (see appendix A) and select section n1 of
service menu.
9.5 Press measuring part to previously marked places one by one and select the most
suitable installation place according to the maximum values on indicator. Slightly vary
the measuring part position to achieve the maximum signal value.
!
Make sure there is enough lubricant on the measuring
part before each pressing (measuring part won’t work
without lubricant)!
Foreign objects or sand grains must not enter the region
of acoustic contact!
!
14
9.6 The best place for measuring part installation is the place with the highest signal
value.
9.7 Turn the sensor power supply OFF.
10 SENSOR INSTALLATION AND SETTING
10.1 Select installation variant. Depending on gas container type, several installation
variants are used (fig. 10.1):
in case of cylindrical container, cable with traction device wraps container in the
selected installation place;
in case of toroidal container, cable with traction device can contact container
from one side and pass through container construction elements from the other
side.
10.2 Installation is performed as follows:
10.2.1 Attach the vibration isolator in place of measuring part installation. Clean
the container surface from dirt, rust and degrease it beforehand. Remove a
protection cover from the isolator and attach it to the container, then press it
with the rubber roller.
10.2.2 Extend cable through the measuring part clamp cover.
a b
Fig.10.1 – Measuring part installation variants (a –toroidal container, b – cylindrical container)
15
10.2.3 Drill a hole Ø 6,5 mm if necessary (in case of measuring part installation
on the toroidal container), to allow cable passing through container mounting
hardware. Insert bushing from the delivery kit into the hole and clamp it with U-
washer. Pass the cable through bushing as demonstrated on fig. 10.2:
Fig. 10.2 – Cable passes through the container mounting hardware
10.2.4 Pass cable ends through holes in half bushings of traction device.
Unscrew the traction device screw to the maximum possible length. Insert cable
into clamps and slightly screw clamp nuts.
Fig. 8.3 – Traction device
10.2.5 Holding the whole construction, pull cable ends to the extent, that the
distance between clamp cover and container surface was approximately 20 mm.
Screw up tightly one of the clamps.
10.2.6 Fill the measuring part cavity (restricted by gasket) with lubricant from
Table. 7.1:
Fig. 10.3 – Filling the measuring part cavity with lubricant
ø6,5
16
There must be no air bubbles or foreign particles, such as dust
or sand inside the lubricant.
10.2.7 Insert the measuring part inside the clamp cover and press it to the
container surface in the selected place (it is allowed to press measuring part with
lubricant only once).
While pressing measuring part to the container, pull cable end through
loosened clamp and taunt the cable. Screw tight the second cable clamp.
Tighten the cable under container by spinning the traction device screw. While
tightening the cable, lubricant surplus will squeeze from under the gasket.
Gasket is purposed to seal hermetically the operating region. Cable should be
tightened until the surplus lubricant stops squeezing through the gasket, which
indicates that measuring part is fastened tightly.
Paste sensor vibration isolator from the delivery kit (fig. 5.2) around the
measuring part and clamp cover.
10.2.8 If measuring part installation is performed outside vehicle body, it is
necessary to seal hermetically the outer diameter of measuring part and
container contact zone with an automotive sealant (indicated in table 7.1).
Before sealing, it is necessary to remove the lubricant surplus and degrease the
surface.
10.2.9 Energize the sensor. Make sure that the signal level had not decreased
or decreased slightly by using service menu (see Appendix A). Otherwise, it is
necessary to repeat place selection and sensor installation, starting from section
9.
10.2.10 Perform transducer automatic parameters setup (see section 11.1) and
confirm its successful completion by using service menu.
Otherwise, it is necessary to repeat place selection and sensor installation,
starting from section 9 (or consult the technical support).
10.2.11 Turn OFF sensor power supply and perform electrical disconnection
according to section 8.
Upon successful measuring part installation, disconnect sensor
from power supply!
!
!
17
10.3 Install transducer in a convenient place for driver. For example, on the
vehicle dashboard, as demonstrated on fig. 10.4, or on the suitable horizontal
surface by using mounting holder from the delivery kit or with tilting holder
which can be ordered optionally (see table 5.3 and fig. 10.5).
Fig. 10.4 –Usual placement for transducer with indicator
Fig. 10.5 – Transducer with indicator mounting options
10.4 Lay cable from the measuring part to the transducer through service openings of a
vehicle, attach it with zip ties to the stationary parts every 50-60 cm.
Transducer with
indicator
18
If cable is laid outside the vehicle interior, this section should be fitted with
split corrugated tube to protect cable from mechanical damage. In case of damaging
wire ends, isolation or conductors, while laying shielded cable, damaged section must
be removed and a new connection established according to section 8.2.
10.5 Shielded cable can be reduced in length if the following connection is performed
according to section 8.2.
10.6 Perform sensor electrical connection according to fig. 8.1.
10.7 Energize the sensor by turning an ignition key and check its operational status
(see Appendix A).
19
11 SENSOR PARAMETERS SETTING
Sensor setting consists of several steps:
- Transducer parameters setting;
- Fuel type selection;
- Container type selection;
- Container calibration;
- Container height setting.
11.1. Transducer parameters setting.
Container must be filled not less than 2/3 of its volume for automatic transducer
parameters setting.
Select n2 entry in the service menu. Results storage menu will appear on
indicator after parameter setting. It is necessary to select “YE” to save the automatic
setting results or “no” to cancel.
Error code will be demonstrated on the display if error occurred. Error E1
indicates that there is not enough fuel to perform automatic parameter setting. If E2-E5
errors occur, it is necessary to repeat setting procedure several times. In case of
permanent error, consult the service center.
11.2. Fuel type selection
Fuel type selection is performed in n3 entry of the menu. It is necessary to select
fuel type according to table (see Appendix A). If user-defined fuel type is selected,
setting can be performed by using end-user software only (see Appendix B).
11.3. Container type selection
User-defined fuel container selection is performed in n4 entry of the menu. It is
necessary to select container type according to table (see Appendix A).
11.4. User-defined container calibration
When selecting user-defined container, it is necessary to calibrate it. User-
defined container calibration is performed in n5 entry of the menu.
Container must be drained of fuel before calibration start.
Select a calibration unit in t1 entry of the menu, then select t2. Total fuel
amount will be demonstrated on the display (0 liters, since the container is empty).
Press Button 1 30 - 40 seconds after fuel is filled into container to record the
fuel unit. Doing this, indicator readings will increase by the unit value.
20
If after shutdown valve activation the last filled unit is smaller than the required,
it is necessary to select new unit in t1 menu entry and continue calibration in t2 entry.
If there is an error, indicator will enter a flickering mode. In that case, it is
necessary to wait 1 minute and, if flickering continues, add unit by pressing Button 1,
but this last unit will not be added to calibration table.
Calibration results saving menu will appear on the indicator after closing t3
entry.
11.5. Container height setting
Container height setting is performed in n6 entry of the menu. It is necessary to
enter previously measured container height in range of 10-99 cm.
21
12 SENSOR SETTING AND ADJUSTMENT WITH "uS_Install" PROGRAM
It is possible to use PC with installed "uS_Install" program (delivered
optionally) for sensor setting apart from using indicator. This setting variant is
recommended to use for installation at autogas vehicle service stations, if using sensor
for fuels and liquids different from LPG, diesel or gasoline (e.g. water) and also for
more convenient sensor installation.
"uS_Install" program is used as following:
12.1 Prepare equipment, instruments and consumables according to tables 7.1 and 12.1
Table 12.1
Name q.
Laptop (PC), minimum requirements: Pentium 500 MHz, 64 MB
RAM, MS Windows XP / 7 / 8 / 10, MS Office, at least 20MB of
free hard disk space, "mouse" manipulator and free USB-port.
1 pc.
USB/RS-485 converter (for ULS4 model setting) or USB/RS-232
(for ULS2 model setting) according to the sensor model. It is
recommended to use MOXA UPort 1130 model or MOXA UPort
1110 respectively.
1 pc.
12.2 Connect interface cables to PC and install software according to Appendix B,
where program interface and operation is described.
12.3 Execute all steps from sections 7 – 10, but using PC readings instead of indicator
according to Appendix B.
12.4. Further sensor setting is performed by using "uS_Install" program.
Setting consists of following steps:
- Transducer parameters setting;
- Fuel type selection;
- Container type selection;
- Container calibration (only for user-defined container);
- Container height setting.
12.4.1 Transducer parameters setting
Container must be filled not less than 2/3 of its volume for automatic
transducer parameters setting.
Find «Autotuning» field in «Oscilloscope» property page and press “Step
2” button:
22
Fig. 12.1
Installation progress will be demonstrated on the screen. Upon setting
completion, successful Autotuning finishing message or error message will
appear on the screen. Error E1 indicates that there is not enough fuel to perform
automatic parameters setting. If E2-E5 errors occur, it is necessary to repeat
procedure in manual mode according to Appendix G.
12.4.2. Fuel type selection
Fuel type selection is performed in “Fuel” field at «Oscilloscope»
property page. It is necessary to select fuel type according to table (see
Appendix B). If user-defined fuel type is selected, it is necessary to set
following parameters:
“Speed of sound” – sound speed in fuel at a temperature 25 °C, m/sec.;
“Temperature coefficient” – change of sound speed if the temperature
fluctuates by 1 °C, m/sec./ °C.
Fig. 12.2
12.4.3. Container type selection
Selection of user-defined or pre-defined fuel container is performed in
“Container type” field at «Calibration» property page. It is necessary to select
container type according to table (see Appendix B).
12.4.4. User-defined container calibration
When selecting user-defined container, it is necessary to calibrate it. User-
defined container calibration is performed by pressing “Table” button on
“Calibration” property page. Calibration procedure is described in Appendix B.
12.4.5. Container height setting
Container height setting is performed in “Container height” field on
“Calibration” property page.
12. 5 Disconnect sensor from power supply and PC, perform electrical connection
according to Section 8.
23
13 TRANSPORTATION AND STORAGE
Transportation of the sensor in avenue packing of the manufacturer is allowed
by all types of covered land and sea transport (in railway cars, containers, closed-top
cars, holds, etc.). Transportation in the pressurized compartments of planes is allowed.
When transporting products in an original packaging by uncovered transport,
they must be protected from dust, dirt and influence of an atmospheric precipitation.
During transportation and storage, requirements of the markings, indicated on
avenue packing must be applied.
24
APPENDDIX A
SENSOR OPERATION MODES
Fig. А.1 – n1 operation mode as demonstrated on the display
(Button 1- changes operation modes, Button 2 – shifts the menu entries)
Sensor operation modes:
Basic operation mode
When using basic operation mode, indicator demonstrates current fuel
volume in liters or fuel level in centimeters, depending on fuel container
selection.
Refueling/drain mode
When using refueling/drain mode, indicator demonstrates fuel level change
compared to reference value. In that case, indicator operates in flickering
mode.
To switch between basic operation mode and refueling/drain mode, press
Button 1. To set the reference fuel value, press Button 2.
Service menu mode
To enter service menu mode, press and hold both Buttons simultaneously
during ~ 5 seconds.
To switch menu entries, press Button 2, to enter – Button 1.
Кнопка 1
Кнопка 2Button 2
Button 1
25
n1
Automatic
setting
step 1
n2
Automatic
setting
step 2
n3
Fuel
type
n4 Contai-
ner ID
n5 Cali-
bration
n6 Container
height
Fig. А.2 – Service menu
3.1. n1 entry of service menu. Automatic setting, step 1.
This menu entry is used to determine the most suitable location for measuring
part installation. Indicator demonstrates signal level of the measuring part (see
table below).
Signal level Signal level evaluation
None There is no signal or insufficient level, it is necessary to find
another location for measuring part installation.
| Insufficient signal level, it is necessary to find another
location for measuring part installation.
|| The minimal sufficient signal level. It is recommended to
find more suitable location for measuring part installation.
||| Sufficient signal level, suitable location for measuring part
installation.
|||| Good signal level, suitable location for measuring part
installation.
||||| Good signal level, suitable location for measuring part
installation.
E1 Not enough fuel in container for measuring part installation.
E2 Place is not suitable for measuring part installation.
3.2. n2 menu entry. Automatic setting, step 2.
This menu entry is used to perform transducer automatic parameters setting.
Indicator demonstrates setting process.
Results saving menu will be displayed on the indicator in case of successful
automatic setting completion. In case of failure – error code.
26
YE
Save and exit
no
Exit without
saving
Fig. А.3 – Saving menu
Error codes:
Error code Error description
E1 Not enough fuel in container for measuring part installation
E2
Place is not suitable for measuring part installation, consult
the service center or technical support.
E3
E4
E5
3.3. n3 menu entry. Fuel Type
This menu entry is used to determine fuel type according to table:
№ Fuel type
0 User-defined type. Sound speed and temperature coefficient
values are specified by user software.
1 LPG
2 Gasoline
3 Diesel
3.4. n4 menu entry. Container ID.
This menu entry is used to determine user fuel container.
№ Container ID
0 Container is not selected. When using basic operation mode,
indicator demonstrates current fuel level in centimeters.
1 User-defined fuel container. Calibration is performed buy
user.
27
3.5. n5 menu entry. Calibration.
This menu entry is used for user-defined fuel container calibration. This
menu entry is available only if user-defined container (ID 1) was selected in
previous menu entry.
t1
Unit, liters
t2
Add unit
t3
Exit
Fig. А.4 – n5 menu
Press Button 2 for 30 - 40 seconds after fuel is filled into container to record the
fuel unit. Doing this, indicator readings will increase by the unit value. If the last filled
unit is smaller than the required after shutdown valve activation, it is necessary to
select new unit in t1 menu entry and continue calibration in t2 entry.
If there is an error, indicator will enter a flickering mode. In that case, it is
necessary to wait 1 minute and, if flickering continues, add unit by pressing Button 1,
but this last unit will not be added to calibration table. Calibration results saving menu
will appear (fig. A3) on the indicator after closing t3 entry.
3.6. n6 menu entry. Container height.
This menu entry is used for fuel container height setting. Height is set in
centimeters, possible height range is 10 – 99 centimeters.
28
APPENDIX B
"uS_Install" APPLICATION PROGRAM
«uS Install» application program (hereinafter – Program) is purposed for fuel
level sensor Sigma ULSx-20 setting.
Program is included in user software package on CD, which is present in
delivery kit. To install program on PC it should be copied into required directory file.
Moreover, PC should be equipped with RS-232 or RS-485 port.
Use USB/Serial adapters MOXA UPort 1110 for RS-232 and MOXA UPort
1130 for RS-485 interface if there are no such ports on PC.
Before launching the program it is necessary to perform sensor electrical
connection in accordance with sensor to PC connection scheme in Appendix C.
Software has an adaptive user interface. Depending on model or/and firmware
version, software interface can change (only options for the current model and
firmware version are displayed).
After starting the program, it is necessary to select the port number, baud rate
and device address in the “Port settings” field (fig. B 1). Default sensor setting are
19200 bps for baud rate and device address – 1.
Fig. B.1 - «Program» property page
Press “Open” button to start working. If baud rate parameters and device
address are unknown, “Device search” button can be used. When “Device search”
button is pressed, software sends an enquiry with a broadcast address into the port.
29
ATTENTION! “Device search” option is not recommended if several sensors
are connected to the network.
Port status is indicated in the lower part of the window.
- Port closed – means that COM port is closed; press “Open” or “Device
search” button to start working with device;
- Port open – means that COM port is open and operates properly;
- Open error – means that COM port is opening with error; also, error
message will be displayed (fig. B 2). In this case, it is necessary to check if
port is blocked with other application programs and diagnose port operability
on the software and hardware levels.
Fig. B.2 - Port opening error
If program settings and sensor connection are correct, “Oscilloscope” property
page (fig. B.3) will appear in working window. Parameters are read automatically
when property page is selected.
30
Fig. B.3 - «Oscilloscope» property page
Fuel type selection, measuring part installation place and transducer automatic
parameters setting are performed on this property page.
Signal transformation error code is demonstrated in “Autotuning” field. See the
error code legend in Table B.1:
Table B.1 Code Description Recommendation
0 Correct signal
transformation Suitable place for measuring part installation
1 No return signal Check measuring part acoustic contact. Try
another place for measuring part installation
2,3,5,11 Insufficient return signal
range
Check measuring part acoustic contact. Try
another place for measuring part installation
4,6-10,16-19 Distorted return signal Try another place for measuring part
installation
12,13,15 Incorrect measuring
result Wait several seconds until error resets
31
20
Measured fuel level
exceeds preset container
height
Check container height settings.
Check the vibration isolator and its proper
installation at the measuring part region.
Level icon demonstrates fuel level in millimeters, T, °C icon – measuring part
temperature in degrees Celsius.
To enter mode for measuring part installation place, press “Step 1” button in
“Autotuning” field. To initiate measuring part automatic parameters setting, press
“Step 2” button.
Fuel type selection and user-defined fuel parameters setting are performed in
“Fuel” field. To save fuel and fuel parameters, press “Write” button.
“Calibration” property page is purposed for container type selection, user-
defined container calibration, calibration tables uploading and container height setting
(fig. B.4).
Fig. B.4 - «Calibration» property page
Container type selection is performed in “Tank ID” icon;
If container type 0 is selected (container not selected), container calibration
table is unavailable.
Manual calibration is available if container type 1 is selected.
32
Container calibration table is available for reading only if container types 2-99
(pre-defined types) are selected.
Container height setting is performed in “Tank height” icon.
“Data output in liters” parameter sets scale division of low bit data, which is
transferred by the sensor. If container type 0 is selected, data outputs in millimeters.
Press “Set” button to save container type and calibration tables.
To export calibration tables into Excel file format (*.xls, *.xlsx), press “Export
of tables”, to import – press “Import of tables” in “Import/Export of tables” field.
!
Calibration tables’ import and export can be
performed only with the pre-defined containers. User-
defined calibration table import/export can be
performed in “Calibration table” work window.
To open calibration table work window, press “Calibration table” button.
Calibration table work window will appear after pressing (fig. B.5).
Fig. B.5 - «Calibration table» work window
(Entered records will be confirmed after pressing “OK” button)
33
Manual calibration:
To add calibration table manually, press button or by using right-click
menu. Calibration table record adding window will appear on the screen (fig. B.6). To
delete record from the calibration table, press button or by using right-click menu.
Fig. B.6 - «Add record» window
Automatic calibration:
To add record into calibration table in automatic mode, press “Add” button.
Portion of fuel to add is defined by “Portion” parameter. When performing calibration
by adding, “Portion” parameter must have positive value, when performing calibration
by draining – negative value.
“Sensitivity” parameter defines minimal change in code value when fuel
portion is added. If value is lower than defined, record will not be added in calibration
table. The following message will be displayed:
Fig. B.7
To perform calibration table import of Microsoft Excel (*.xls, *.xlsx) format
files, press button, to perform export - button or by using right-click menu.
Calibration table generation for cylindrical container described in Appendix E.
34
“Settings” property page is purposed for manufacturing data viewing and data
parameters setting, which are displayed by the sensor (fig. B.8). Manufacturing data
and displayed data parameters reading are performed automatically when opening
property page. To write parameters, press “Set” button.
Fig. B.8 - «Settings» property page
Manufacturing data:
Date – sensor production date;
S/N – sensor serial number;
Model – sensor model;
SW version – firmware version;
HW revision – sensor board revision number.
Output data parameters:
Data resolution – data resolution for reading from sensor;
Response to the 255 address – Sensor response on broadcast query:
With 255 address – Sensor answers with a broadcast address;
With own address – Sensor answers with the defined address.
Address – Sensor network address;
Baud rate – Baud rate speed
«US20_AppLoader» program is purposed for firmware updating,
configuration data saving and restoring (see Appendix D).
35
APPENDIX C
LAYOUTS FOR SENSOR CONNECTION TO PC
Fig. C.1 ULS2 model connection to PC layout
Fig. C.2 ULS4 model connection to PC layout
36
APPENDIX D
FIRMWARE UPDAITING, CONFIGURATION DATA SAVING AND
RESTORING
D.1 To update firmware, save and restore configuration data, «US20_AppLoader»
software is used. For this purpose, it is necessary to perform the following steps:
D.1.1 Turn OFF transducer power supply. Connect sensor transducer to RS-
232 (RS-485) port of PC. Launch «US20_AppLoader» program (fig. D.1):
Fig. D.1
D.1.2 Select COM port. During network connection of two or more sensors -
specify device network address in “485 N” field.
D.1.3 Press button in «US20_AppLoader» program.
D.1.4 Power the sensor. After ~1 second technological parameters will be
acquired from sensor:
,
37
After that, button becomes active again.
D.1.5 Then, select the firmware file by pressing button (fig. D.2):
Fig. D.2
D.1.6 Upload firmware into device by pressing
button.
Uploading process is indicated in percent:
.
Message will appear after uploading.
D.2 Configuration data saving and restoring.
D.2.1 Press button to save configuration data into file.
D.2.2 Select folder for saving and file name in appeared window, then press
button (fig. D.3):
38
Fig. D.3
D.2.3 Calibration data saving is performed similar to configuration saving, but
instead of “Save configuration” button it is necessary to press “Save calibration”.
D.2.4 Configuration (calibration) data restoring is performed similar to firmware
uploading, but instead of firmware file it is necessary to select configuration
(calibration) file.
D.3 Firmware activation.
D.3.1 To activate new firmware, press
button or turn OFF and resupply indicator power.
D.3.2 To exit application loader program, press button or close program
work window.
D.4 Note.
D.4.1 «US20_AppLoader» works with COM1 … COM9 communication ports.
D.4.2 Availability and number of ports can be checked here:
«My computer\Properties\Device Manager\Ports (COM and LPT)».
D.4.3 To assign the necessary number to the COM port among available, go to:
«My computer\Properties\Device Manager\Ports (COM and LPT)\
Communications port (COMx)\Utilities\Port parameters\Advanced\COMport
number».
39
APPENDIX E
DATA EXCHANGE PROTOCOL
E.1 General
This section describes data exchange protocol of the ultrasonic fuel level sensor
SIGMA with external devices.
E.2 Physical level
Exchange with external device is carried out by RS-232 or RS-485 interfaces.
Baud rate can be chosen from following values: 2400, 4800, 9600, 19200 (by
the default), 38400, 57600, 115200 bps;
Data width – 8 bps;
Evenness – disabled;
Stopping bit – 1;
Flow control – disabled.
E.3 Logical level
Data exchange is carried out by data packets according to “Request/Response”
principle. External device is a Master (exchange initiator).
Network address is assigned to each sensor. Range of valid addresses is 0x00 –
0xFE, 0xFE address is used for broadcast requests, to which sensor replies
independently of established address. Default address – 0x01.
Following data packets are used in the protocol:
- “Request” data packet – contains command and transferred by the external device
- “Response” data packet – contains command response and transferred by the
identifier.
"Request" packet format
Prefix
Reader
network
address
Command
code
Parameters
CRC
0x31 0х00..0xFF
See
command
description
see. E4 Calculated according to
Application note 27 from Dallas
40
"Response" packet format
Prefix
Reader
network
address
Command
code
Device
response CRC
0x3E 0х00..0xFЕ
See
command
description
See command
description
Calculated according to
Application note 27 from Dallas
Multibyte parameters are transferred in order of precedence from lowest byte to
high byte ("Little endian").
Following intervals are used in the protocol:
- Timeout between bytes – the maximum interval between transferred bytes inside the
data packet.
- Response transmission delay – minimal interval between the end of “Request” data
packet receipt and start of “Response” data packet transfer.
- Response timeout – the maximum interval between “Request” data packet receipt
and start of “Response” data packet transfer.
- Delay before the transmission start of “Request” data packet after “Response” data
packet receipt (or unidentified data packet) – minimal interval between end of
“Response” data packet receipt (or unidentified data packet) and start of “Request”
data packet transmission.
The parameters of above-mentioned values listed in table 3.
Sequence of bytes, which don’t have data packet format or which exceed the
maximum allowed interval between bytes or packet with data field that exceeds 150
bytes or data packet with incorrect CRC is considered unidentified and is ignored by
the sensor.
Time intervals Parameter Value for different baud rates, ms
2400 4800 9600 19200 38400 57600 115200
Timeout between bytes 15 8 4 2
Response transmission delay 15 8 4 2
Response timeout 100
Delay before the transmission
start of “Request” data packet
after “Response” data packet
receipt
15 8 4 2
41
E.4 Commands description
E.4.1 Single data readout (command 06h)
Command is used for current data reading: user value of fuel level (10 or 12
bits), technological value of fuel level (16 bits) and temperature (8 bits).
Command format
Offset,
byte Field size, byte Value Description
0 1 31h Prefix
+1 1 00h…FFh Recipient network address
+2 1 06h Command code
+3 1 00h…FFh CRC8
Response format
Offset,
byte Field size, byte Value Description
0 1 3Eh Prefix
+1 1 00h…FFh Sender network address
+2 1 06h Command code
+3 1 -128…127 Temperature, °C
+4 2 0000h…03FFh
or 0000h…0FFFh
User value of fuel level
+6 2 0000h…FFFFh Technological value of fuel
level
+8 1 00h…FFh CRC8
E 4.2 Technological parameters reading (command 41h)
This command is used to read the technological parameters of the sensor: issue
date, serial number, model code, firmware version, data output mode.
Command format
Offset,
byte Field size, byte Value Description
0 1 31h Prefix
+1 1 00h…FFh Recipient network address
+2 1 41h Command code
+3 1 00h…FFh CRC8
42
Response format
Offset,
byte Field size, byte Value Description
0 1 3Eh Prefix
+1 1 00h…FFh Sender network address
+2 1 41h Command code
+3 1 00h…FFh Year of issue:
00h corresponds to 2000
year
+4 1 00h…0Bh Month of issue:
00h – January, 0Bh -
December
+5 1 01h…1Fh Day of issue: 1 … 31
+6 3 000001h…FFFFFFh Serial number
(1 … 16777215)
+9 1 01h…02h Model code
(see the following table)
+10 1 01h…FFh Firmware version
+11 6 - Reserved
+17 1 00h…FFh Network address
+18 2 - Reserved
+20 1 00h…FFh Data output mode
(see command 55h)
+21 1 00h…FFh CRC8
Sensor model code
Model code (HEX) Model name
01 ULS4-уу
02 ULS2-уу
E.4.3 Serial number and date of issue reading (command 42h).
Command is used for reading the following FLS parameters: date of issue, serial
number, model code and firmware version.
Command format
Offset,
byte Field size, byte Value Description
0 1 31h Prefix
+1 1 00h…FFh Recipient network address
+2 1 42h Command code
+3 1 00h…FFh CRC8
43
Response format
Offset,
byte Field size, byte Value Description
0 1 3Eh Prefix
+1 1 00h…FFh Sender network address
+2 1 42h Command code
+3 1 00h…FFh Year of issue:
00h corresponds to 2000 year
+4 1 00h…0Bh Month of issue:
00h – January, 0Bh -
December
+5 1 01h…1Fh Day of issue: 1 … 31
+6 3 000001h…FFFFFFh Serial number
(1 … 16777215)
+9 1 01h…02h Model code
+10 1 01h…FFh Firmware version
+11 1 00h…FFh CRC8
E.4.4 Setting the data output mode (command 55h).
This command is intended to set the following parameters: output data width
(10 or 12 bit), baud rate through serial port (2400...115200 bps) and response
parameters on broadcast request.
Command format
Offset,
byte Field size, byte Value Description
0 1 31h Prefix
+1 1 00h…FFh Recipient network address
+2 1 55h Command code
+3 1 00h…FFh See the table of transcripts
below
+4 1 00h…FFh CRC8
Response format
Offset,
byte Field size, byte Value Description
0 1 3Eh Prefix
+1 1 00h…FFh Sender network address
+2 1 55h Command code
+3 1 00h Return code
+4 1 00h…FFh CRC8
44
Code identification of data output mode
Bits Use Description Default
value
7 Output data width 0: 10 bit
1: 12 bit 1
6 Reserved - 0
5 Response to the
broadcast request
0: respond with own
address
1: Respond with 255
address
0
4,3,2 Baud rate through the
serial port, bps
000 – Rate is constant;
001 – 2400;
010 – 4800;
011 – 9600;
100 – 19200
(default setting);
101 – 38400;
110 – 57600;
111 – 115200
100 (19200 bps)
1 Reserved - 0
0 Reserved - 0
E.4.5 Setting the network address (command 56h)
This command is intended to set sensor network address for simultaneous
operation of several sensors.
Command format
Offset,
byte Field size, byte Value Description
0 1 31h Prefix
+1 1 00h…FFh Recipient network address
+2 1 56h Command code
+3 1 00h…FFh Sensor new network address
+4 1 00h…FFh CRC8
Response format
Offset,
byte Field size, byte Value Description
0 1 3Eh Prefix
+1 1 00h…FFh Sender network address
+2 1 56h Command code
+3 1 00h Return code
+4 1 00h…FFh CRC8
45
APPENDIX F
CALIBRATION TABLE CALCULATION
Calibration procedure is applied to transform current sensor readings into fuel
volume values if using external device.
Container calibration is performed by using “US20 Calibration table
calculation for vehicle autogas containers.xls” program, which opens in MS Excel
(Macros feature must be allowed to work with file):
Fig. F.1
46
It is necessary to perform below mentioned measurements for cylindrical autogas
container (see fig. F.2):
Fig. F.2
where L1 – Container length, mm;
L2 – Container girth (perimeter), mm;
L3 – Length of bulge part semi-ellipse, mm;
T – Container wall thickness, mm.
This data is entered in corresponding boxes I4-I7.
The necessary number of records in calibration table is entered in N field (I9
box). Recommended number of records is no less than10 records. More records means
higher accuracy. Maximum records number – 50.
Calibration table calculation is performed after pressing “Calculate” button.
Result is stored in A-B columns:
Column A – Fuel level, l;
Column B – Fuel level height, mm;
Т
L1
L3
L2
47
APPENDIX G
QUICK GUIDE FOR “US20 Install Service” PROGRAM
Sigma ULS4-20 setting is performed using US20_Install_Sevice v.2.0.0.x
program or later version.
After launching the program, select required port, baud rate and device address
in “Port settings” field.
Default sensor setting are 19200 bps for baud rate and device address – 1.
Press “Open” button to start working.
If baud rate parameters and device address are unknown, “Device search” button can
be used. When “Device search” button is pressed, software sends an enquiry with a
broadcast address into the port.
Mounting place preselection
Perform the mounting place preselection on Oscilloscope/Autotuning property
page.
To start search it is necessary to press Step 1 button and to monitor signal level
according to Signal level scale. The best place for installation is the place with
maximum Signal level value. When search is concluded, press Step 1 button again.
48
.
Sensor setting
Further sensor setting is performed after vibration isolation fitting and final
measuring part mounting.
To determine operation signal frequency it is necessary to build sensor-tank
AFC system. Before building AFC, set Frequency– 2000 kHz and Pulse – 20 periods
on Oscilloscope/Pulse property page. Atten parameter set as “On”; adjust
amplification factor so that first echoed signal amplitude will be in 5000-20000 range.
After that, select WideBand on Filtr property page.
49
AFC generation is performed on AFC property page. It is necessary to determine first
echoed signal range and enter initial echoed signal value in Pulse begin field; enter
echoed signal width value in Pulse width field. Enter echoed signal width and initial
value with margin of 100-300 points from the signal threshold.
To build AFC, press AFC button, selecting AFC displaying on the oscillogram
beforehand.
50
AFC build completion is signaled by «AFC Plot complete» message.
If diagram exceeds 20000 mark, it is necessary to lessen amplification factor
(each Ku step alters amplification factor approximately by 1,5) and generate another
AFC.
Chose frequency with the maximum signal amplitude according to AFC
diagram.
If there are several AFC “peaks” with similar amplitude (in 30% range), specific
peak is selected according to minimal after-ring (see next step).
If there is the same after-ring level on different “peaks”, frequency closest to
2000 kHz should be selected.
51
Enter selected frequency in Freq field on Pulse property page. Also, switch
oscillogram into Oscill mode.
To minimize after-ring, select “Source” mode, set Ku parameter to “24” and
Atten in “Off”.
52
It is necessary to achieve after-ring minimization by changing Pulse parameter in
range of 10-20 periods.
Dead zone adjustment is performed on Integrator property page. It is necessary
to set Atten parameter in “On” position before dead zone adjustment.
DeadZone parameter is defined by after-ring width on X-direction.
Minimum permissible value of DeadZone parameter is 400 points. Acceptable
value is 500-700 points.
If after-ring exceeds 700 points, lower Ku parameter (but no less than 18 points)
until after-ring value becomes 500-700 points.
If after-ring parameter exceeds 700 points, when Ku parameter is 18, such value
is entered in DeadZone parameter. To record DeadZone value, press Set button.
53
After that, it is necessary to limit maximum amplification factor MaxKu.
To do that, enter current Ku or Unlim (if current Ku equal to 24) value in
MaxKu field
Then, perform filter adjustment on Filtr property page. Filtr parameter value is
selected as close as possible to Freq parameter value on Pulse property page.
Then, it is necessary to set Ku parameter in Auto and visually estimate
oscillogram in Envelope mode.
Oscillogram should look like the figure (periodical sequence of fading echoed
signals).
54
Go to Calibration property page.
Calibration is performed separately according to installation manual.
Tank ID - “0”, if calibration table wasn’t uploaded into Sigma ULSx sensor.
Tank ID - “1” if calibration table was uploaded into Sigma ULSx sensor.
Tank height is measured by measuring tape.
ATTENTION! Do not forget to press “Set” button!
55
Go to Settings property page.
It is necessary to select Fuel type; adjust other settings if required.
Press Write button.