RCS EPSILON EZ User manual

RCS
Brand
RCS
Model
EPSILON EZ
Type
User manual

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The fuel level sensor
"EPSILON"
Models EN and EZ
Instruction manual
EN.000 RE (EN)
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Content
Page
Introduction
3
1. Description and operation
3
1.1. Description of the sensor operation
3
1.2. Description of the components operation
18
2. Operations
20
2.1. Operation limits
20
2.2. Explosion-proofness
2.3. Preparation for use
21
2.4. Usage
22
3. Technical maintenance
23
3.1. Technical maintenance of the sensor
23
4. Current maintenance
26
4.1. Current maintenance of the sensor
26
4.2. Current maintenance of the components
26
5. Transportation and storing of the sensor
29
This instruction manual is designed to inform users about operation and maintenance
of the fuel level sensor "EPSILON" models EN and EZ, hereafter referred to as the
sensor or FLS.
The staff, which operates this sensor, must read this instruction manual carefully.
This instruction manual is referred to all the modifications of "EPSILON" models EN
and EZ.
This sensor doesn’t generate any hazardous emissions and doesn’t produce any other
negative effects on humans and the environment.
1. Description and operation
1.1. Description of the sensor operation
1.1.1. Product designation.
This sensor is designed to measure fuel level inside fuel tanks of vehicles and stationary
fuel storages. The sensor could be applied for measurement of any non-conductive
FLSids.
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The sensor should be applied with equipment that supports a unified protocol of
Epsilon Data Exchange (hereafter referred to as EDE).
The sensor is compatible with various kinds of control units, concentrators and GPS
monitoring devices, such as:
- "Autograph";
- "Scout";
- "Locarus";
- "Intellitrac";
- "Patriot";
- "Teletrack";
- "Teltonika";
- "M2M – Cyber GLX";
- "Ruptela FM";
- "FM blue" and others.
1.1.2. Specifications.
Table 1.1.
Characteristic or parameter
Unit
of
meas
ure
ment
Value
Remark
1
2
3
4
General
Working temperature range
С
– 40 … + 75
Measuring head dust and moisture
protection level
IP67
Operating regime
Continuous
Measurement
Upper limit of the level measuring range,
depending on modification
mm
from 150 to
3000
(1)
The limits of reduced error level
measurement
%
±1.0
(2)
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Relative electric permittivity range of values
for operating FLSid (ε)
1.5…3.3
Models
EXXxх-XXXX
1.5…5
Models
EXХRxх-
XXXX (3)
Averaging period of measurement results
с
0…32
Measurement information width
bit
10;12;16
(4)
Data rate of COM port
bits
per
seco
nd
2400, 4800,
9600, 19200,
38400,
57600,
115200
Selected by
program
Estimation of vehicle inclination
The range of vehicle inclination estimation
degre
e
±75
(5)
Resolving ability of vehicle inclination
estimation
degre
e
0.1
(5)
Data interpretative code width
bit
16
(5)
Estimation of measuring head
temperature
The range of measuring head temperature
estimation
°С
- 40…+ 85
The width of measuring head data
interpretative code
bit
8
Built-in data concentrator
Maximum number of connected external
FLS
pcs
7
(6)
Maximum number of calibration chart
records for all FLS
pcs
960
(7)
Maximum number of calibration chart
records for random FLS
pcs
960
(7)
Measurement information width
bit
10;12;16
Power
Supply voltage, operational range
V
from 9 till
36
Nominal
Useful current, no more than
m
50
Model EN
250
Model EZ
(8)
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Permissible impact of impulse voltage
through power circuits
V
+160, 1 s
-1000,
continuous.
(8, 9)
Permissible short-time impact of electric
potential between signal ground and
measuring head cabinet
V
1500
(10)
Interface
Digital
RS-232
Model EN2
RS-485
Model EN4
RS-232 and
RS-485
(independent
)
Model EN6
RS-232 or
RS-485
(dependent)
Model EZ6 (11)
Connection dimensions, weight
Modification of flange
5 holes
diameter 4.5
mm
(12)
Type of fuel probe connecting thread
М36×1.5
Height of measuring head over tank surface,
including flange, no more than
mm
30
(13)
Sensor weight, no more than
kg
3.2
(14)
Notes
1 The level measuring range is the distance Ly between the cap claw (where there is)
or the cap bottom surface (without cap claw) of the fuel probe and drain port bottom
edge, which are minimum and maximum scale values respectively (see fig 1.1).
2 For fuel control with the same dielectric permittivity for the fuel, which used for
calibration. For other kinds of fuel, the personal should use calibration chart
(according to fuel dielectric permittivity table).
3 For level measurement of other dielectric liquids, it is necessary to use other
special fuel probe types, depending on the liquid parameters and operation
conditions.
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4 There are two formats of data representation: 16 and 10; 12 bits. Capacity 10 or 12
bits is defined by programming controller. Default value is12 bit.
5 For both of two axes (lateral and transversal).
6 External FLS connections are possible for model EN6 only. For other models it is
possible to use internal calibration chart only. Quantity of external connected FLS
depends on ports functionality. If port RS-232 is mapped, maximal possible quantity
of connected external FLS is 1, otherwise (port RS-485) – 7.
7 Total amounts of calibration chart records could be distributed randomly between
any FLS. Calibration chart of any FLS could be absent (no records) or all records
could be belonged to single FLS.
Total amount of all FLS calibration chart records couldn't be more than 960.
If FLS doesn’t contain calibration chart for actual volume estimation, actual level
and volume of the tank are applied.
8 For the model EZ the parameter is shown for simultaneous usage of the FGU and
electrical protection unit BIZ-EZ.
9 Impulse parameters comply with requirements of State Standard 28751-90 (ГОСТ
28751-90) (unit class А, degree of fixity 3 for 24 V of supply-line voltage).
10 Exposure time is up to 1 second. For EZ model unit– voltage difference between
signal ground of spark protection block and measuring head cabinet.
11 For EZ model unit concurrent operating is possible by single interface only.
12 Other modifications of flange are possible by agreement with the customer.
13 Except packing washer.
14 Total weight of the sensor depends on the length and modification of its fuel prob.
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Fig.1.1
1.1.3. Contained parts.
1.1.3.1. Main contained parts.
The main contained parts are the probing device and attached detecting head, which
is fixed to FS tank surface with flange (Fig 1.2).
Fig.1.2. General view of FLS with string central contact (left) and pluggable central
contact (right).
1.1.3.2. Product designation and brief summary of the model range
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There are different identification marks of sensor, depending on the interface type,
measuring liquid dielectric permittivity, presence of tilt meter, probing device type
and length.
Fig. 1.3.
Epsilon EN2" – provides data exchange by RS-232 interface. "Epsilon EN4" -
provides data exchange by RS-485 interface.
"Epsilon EN6" – has two independent interfaces: RS-232 and RS-485. This sensor
is able to be a data concentrator for other FLS.
"Epsilon EZ6" – is operated only together with spark protection unit BIZ-EZ. Spark
protection unit BIZ-EZ - provides explosion protection of sensor model "EZ" and
data exchange by RS-232 and RS-485 interfaces.
1.1.3.3 Sensor identification to order.
1.1.3.3.1 Sensor identification contains of:
Designation;
space
- absent
i
- presence of tilt meter
m
- data processing considering
tank models
E Х 6 R i m - H 075
Identification of
measuring head
Identification
of fuel probe
Model
Interface type
2
- RS-232
4
- RS-485
6
- RS-232+RS-485
8
- CAN
For measurement
of liquids
dielectric
permittivity
space
- from 1.5 to 3.3
R
- from 1.5 to 5
operational characteristics
and combinations
Fuel probe design
space
- string
H
- pluggable
Fuel probe length (cm)
EN
EZ
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Sensor type - "Epsilon"
Model designation;
Interface type;
Relative electric permittivity range of values for operating fluids;
Operational characteristics
Modification of fuel probe;
Fuel probe length (cm);
Identification of these specifications.
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1.1.3.3.2 Example of "Epsilon" sensors’ identification recording when
ordering and in documentation of other products, where it can be applied:
Fuel level sensor
"Epsilon" EN6Ri-H075 TOR U30466754-07:2013,
where:
- " Fuel level sensor"– item;
- "Epsilon" – name;
- "EN" – model;
- "6" – RS-232 and RS-485 interfaces;
- "R" – for measuring in a liquid with dielectric permittivity between 1.5
and 5;
- "i" – presence of an inclinometer;
- "-" – separator character in an identification;
- "H" – plug-in probe;
- "075" – probe length is 75 cm;
1.1.3.3.3 Probe length determination when ordering (see fig. 1.4)
Required length of the probe is determined by formula
L of probe = extern. L of tank – ∆, where:
L of probe – length of probe upon ordering (see fig. 1.5, 1.6);
extern. L of tank – external height of tank in the place of sensor
installation;
∆ – size of gap between the probe and the bottom of the tank.
Recommended values of the gap:
- ∆ = 10…20 mm – for hard metallic tanks (higher elevation of the tank must
comply with higher value of gap);
- ∆ = 30 mm – for hard tanks having insufficient rigidity (such as plastic
tanks of considerable height).
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Fig. 1.4 Probe length determination when ordering
Fig. 1.5 Probe with a string
Fig. 1.6 Probe with plug contact
It is recommended to use the probes having lengths, standardized by
manufacturer (see table 1.1) – this will eliminate additional works during
sensor installing or replacing.
22
L зонда
22
L зонда
Flange
Ext. L of tank
L of probe
L of probe
L of probe
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Thus, for example, overall height of the tank semi-trailer tractors of such
widespread brands as DAF, MAN, Renault, Scania is 620 mm – it is necessary to
apply the sensor with 600 mm long probe for them.
Sensor manufacturer provides the following set of standardized lengths of
probes (Table 1.1)
Table 1.1
Recommended length
of the probe
Typical vehicle models
800
Special vehicles
600
Semitrailer tractors DAF, IVECO, MAN,
Mercedes-Benz, Renault, Scania etc., technique
on their platform.
510
KAMAZ, KrAZ trucks, technique on their
platform
420
MAZ trucks, technique on their platform
340
ZIL trucks
250
Light commercial vehicle, minibuses
In case if data on the length in the record is absent, measuring probe is
typically supplied 750 mm long.
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1.1.3.4 Delivery package
1.1.3.4.1 Basic delivery package
Table 1.2
Name
Models
Quantity,
pcs.
Notes
1
2
3
4
Measuring head
EN, EZ
1
Probe
EN, EZ
1
Flange
EN, EZ
1
Rubber seal ring
EN, EZ
1
Support of the probe
EN, EZ
1
Socket plug cap
EN
1
Self-drilling helical screw
EN, EZ
4
Ø 4.2х19 mm
Self-drilling helical screw
EZ
2
Ø 3.9х16 mm
Self-drilling helical screw for
sealing
EN, EZ
1
Ø 4.2х19, stainless, with an
aperture for sealing
Tamper-evident seal
EN
2
With wire for sealing
EZ
4
Interface cable EN2
EN2,
EN4
1
Length 7.5 m
Interface cable EN6
EN6
1
Length 7.5 m
Interface cable EZ
EZ
1
Length up to 300 m
manufactured upon request
Interface cable BIZ
EZ
1
Length 1.0 m
Cable tightening
EN, EZ
15
200х3.6 mm
Spark protection module BIZ-
EZ
EZ
1
Grounding wire
EZ
1
Length 1 m
String
EN, EZ
with
string
1
SPTA
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end of Table 1.2
1
2
3
4
Fuse strip 0.1 А 250V
EN
1
Ø 5х20 mm, quick-action
Fuse strip 0.5 А 250V
EZ
1
Ø 5х20 mm, quick-action
Insertion label
EN, EZ
with
string
1
Scheme of string fixing
Vehicular safety appliance 1А
EZ
1
1.1.3.4.2 Additional accessories
Table 1.3
Name
Indication
Quantity
Notes
Socket plug
IEC EN C.100
1
Installed on the tank after
complete dismantling of the
sensor
Socket plug-cover
IEC EN. 002.0
1
Installed on the tank after
removal of the measuring
head
EX2 cable for
connecting a
sensor to PC
IEC ES С.100
1
For models EN2
Supplied upon additional
request
EX4 cable for
connecting a
sensor to PC
IEC ES С.100-
01
1
For models EN4
Supplied upon additional
request
EX6 cable for
connecting a
sensor to PC
IEC EN СА.100
1
For models EN6, EZ6
Supplied upon additional
request
CD-ROM with
software
EN.000 CD1
1
Supplied upon additional
request
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1.1.3.4.2 Operation documentation
Table 1.4
Name
Identification
Q-ty
Notes
Passport
EN.000 ПС
1
For model EN
Passport
EZ.000 ПС
1
For model EZ
Passport
BIZ-EZ.000 ПС
1
For spark protection module
Operation manual
EN.000 РЕ
1
1 copy per batch on a single
address
Installation
manual
EN.000 ИМ
1
Supplied upon additional request
1.1.4 Structure and Functioning
Measuring of fuel level is carried out by measuring head together with
probe immersed into the fuel.
When immersed into the fuel, probe of sensor performs the function of a
variable capacitor whose capacitance is linearly dependent on the filling level of
fuel.
Sensor’s measuring head performs a linear transformation of probe's
capacitance into a digital code of the fuel level, processing of obtained digital data
with averaging the measurement results, measurement of head’s temperature
and data output in unified EDE Protocol via RS-485 or RS-232 interface. Fuel level
data is outputted in form of 16-bit value, and optionally as 10- or 12-bit value
selectable, data about the temperature – in the form of 8-bit value. In order to
estimate acceleration and angle of vehicle's inclination, for purpose of estimation
of reliability of level value and its further compensation depending on the angle,
there is the inclinometer built in the head.
In order to define volume of controlled fuel, the procedure of the fuel tank
calibration should be performed, at which dependence between the volume of
fuel and level code is determined.
Calibration procedure control and establishing data exchange parameters
by means of "eS Install" software are described in Appendix А to the document
"EN.000 ИМ. Installation manual ".
EDE data exchange protocol is given in Appendix B of that document.
The embedded software update process, as well as saving and restoration
process of configuration data is described in Appendix C of that document.
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1.1.5 Labeling and Sealing
1.1.5.1 Labeling
1.1.5.1.1 Labeling of measuring head:
- name and label for goods and services of the enterprise-
manufacturer;
- name and conventional identification;
- explosion-proofing labeling;
- operational temperature range;
- serial (factory) number according to the system of enterprise-
manufacturer.
1.1.5.1.2 Labeling of spark protection module (for "EZ" models):
- name and label for goods and services of the enterprise-
manufacturer;
- name and conventional identification;
- explosion-proofing labeling;
- operational temperature range;
- lettering "Intrinsically safe circuits";
- serial (factory) number according to the system of enterprise-
manufacturer.
1.1.5.1.3 Labeling on sensor packaging:
- name and label for goods and services of the enterprise-
manufacturer;
- name and conventional identification;
- production date (month, year);
- explosion-proofing labeling (for "EZ" model);
- type and length of the probe;
- operational temperature range;
- TOR number, according to which sensor is manufactured;
- lettering "Made in Ukraine";
- serial (factory) number in Arabic numerals;
- serial (factory) number in the form of barcode.
1.1.5.2 Sealing
In order to protect sensor and spark protection module against
unauthorized tampering, tamper-evident seals are installed.
One seal protects the measuring head from unscrewing, and the rest are installed
on separable interface cable connections.
Sealing procedure is described in section 4 of the document "EN.000 ИМ.
Installation manual".
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1.1.6 Packing
Measuring head with attached probe is packed in polyethylene "sleeve" and
building kit from basic delivery package (see table 1.2) and spark protection
module (for models "EZ"), are packed in sealed polyethylene packages.
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1.2 Description of product components
1.2.1 Measuring heads
Sensor’s measuring head (fig. 1.2) contains:
- capacitometer;
- inclinometer (in certain models);
- data concentrator with calibration tables;
- digital data processing circuit;
- data exchange device;
- galvanic barrier (for model EN);
- power stabilizer and scheme providing necessary protection of input
and output circuits.
Connection with external devices is provided through interface cable.
Capacitometer performs the conversion of current capacity of the probe
into digital code. Conversion is a linear function with variable parameters.
Inclinometer is present in the models of EXХXiх-XXXX version. Inclinometer
is executed on the basis of accelerometer with high resolution, and designed for
evaluation of acceleration and inclination angle of the vehicle, in order to estimate
reliability of the fuel level value and for possibility of its consequent compensation
depending on inclination angle.
Built-in data concentrator features in all listed models, however, using it
together with other sensors is possible only with EN6 model due to the presence
of two independent interfaces RS-232 and RS-485. Designation of master and
slave ports is set programmatically. Other models may only use embedded
calibration tables on the eigenvalues.
Digital data processing circuit performs control of capacitance meter (range,
zero offset, etc.) as well as temperature compensation, filtering and scaling the
obtained data. Data exchange device allows data exchange with the monitoring
device, saving / loading of calibration and configuration data of fuel level sensor,
remote upgrade of built-in software via serial interface.
Built-in galvanic isolation is an additional instrument fuel level sensor safety
system, and it is designed for isolation of measuring element’s and probe’s circuits
from the rest of electronics of the head.
This solution eliminates the possibility of passage interference currents on
circuits "case – signal ground”, increases interference immunity of measuring
element, enhances stability and reliability of the entire device.
For EZ model galvanic barrier is realized in spark protection module BIZ-EZ.
The measuring head is attached to the probe by means of a threaded
connection. Tightness of measuring head's attachment is provided by sealing ring
located in the end groove.
1.2.2 Probe
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The probe is a coaxial capacitor formed by a pipe made of aluminum alloy
(outer electrode) and an insulated copper string or aluminum alloy pin (inner
electrode). Required string tension is supported by a spring that is located in
contact of the probe’s connector. Concentricity of a pin and an outer pipe is
provided by internal plastic inserts.
1.2.3 Spark protection module BIZ-EZ (for model "Epsilon EZ")
Intrinsic Safety Requirements for sensor of "EZ" model is provided by
connecting them via spark protection module, which is included in delivery
package.
Spark protection module is designed for power supply of the sensor with
type of explosion protection "intrinsically safe electrical circuit" of "ia" level, and
for exchange of information signals with a sensor via RS-485 interface. Spark
protection module has galvanic insulation both between inputs and outputs of
power supply, and between inputs and outputs of RS-485 interface.
Spark safety of electrical circuits of a unit, associated with equipment in
potentially explosive area, is provided by current and voltage limiting in electrical
circuits down to intrinsically safe values.
Spark protection module is designed for installation beyond the potentially
explosive areas. It relates to an apparatus of active type and is designed for the
protection of intrinsically safe circuits under the influence of a voltage up to
250 V.
Power supply of spark protection module is carried out from the source of
direct current with voltage of 9...36 V. Parameter values of intrinsically safe
circuits of spark protection module are given in Table 2.2.
1.2.4 Flange
Flange serves for hermetic fixing of the probe to the tank of vehicle. Fixation
of flange to the tank is realized by means of self-drilling screws. Tight seal
between tank and flange is provided by a rubber gasket.
1.2.5 Interface cable
Interface cable is designed for connecting measuring head to external
devices. Interface cable is protected against mechanical impacts with flexible
metal hose or corrugated pipe.
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2 INTENDED USAGE
2.1 Operating restrictions
2.1.1 During operation of the sensor it is prohibited:
– to use the device inappropriately;
– to connect the sensors to devices, whose interface does not meet the
specifications indicated in this manual;
– to expose device to the impact of aggressive media;
– to supply power, exceeding the limit value of 36 V;
– to allow exposure to pulsed voltage on power circuits with values greater
than the values listed in the Table 1.1.
2.1.2 Using an item with fluids, preserving their aggregate state in the
operating temperature range, is allowed.
2.1.3 Dielectric permeability measured liquid should correspond to liquid
permeability, applied when calibrating. Failure to observe this results in an
increase in measuring errors.
2.2. Explosive safety
2.2.1 EN model sensors are explosion proof, have "1ExsiaIICT6 Х" explosion
proof mark and can be used in Class 1 and 2 explosion-hazardous areas – head,
and 0, 1, 2 – probe. Sign "Х" in explosion proofing labeling indicates specific
conditions of sensors’ safe application, lies in the following:
- sensors should be included in the electrical circuits of equipment, powered
only from the vehicle battery with a voltage not exceeding 36 V, and having
no electrical connections with electrical equipment which has other sources
of power;
- connection of sensors to the mains must be carried out via a fuse with a
nominal value of not more than 0.1 A.
EZ model sensors are explosion proof, have explosion proofing labeling "0
Ex ia IIВ T6" and can be used in Class 0, 1 and 2 explosion-hazardous areas.
Explosion proofing of EZ model sensor is provided by its connection via
spark protection module BIZ-EZ.
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RCS EPSILON EZ User manual

RCS
Brand
RCS
Model
EPSILON EZ
Type
User manual
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