Eurosens fuel flow meters installation

Installation of the Fuel flow meters

eurosens Direct & eurosens Delta

• current fuel consumption records• registration of machinery operation time• normalizing of fuel consumption limits• fuel theft detection and prevention• real-time monitoring and fuel consumption

optimization;• fuel consumption tests for engines

Application

• 3 Hall-effect detectors• No need in check valves• Built-in temperature sensors in each chamber• Wear-resistant coating of measuring chamber• No hidden defects in material structure• 3 Year warranty

Unique features

Some more Advantages

• Modifications with built-in display• Electric disturbance protection• Smart calibration possibilities• Automotive-type built-in connector• Built-in temperature compensation• LED and LCD status indication• Reversing and adding of flow

The flow sensor measures the amount of fuel flowing through the measuring chamber. Pressurized fluid coming through the inlet nozzle flow sensor in the inlet of the measuring chamber, the piston slides along the inner surface of the chamber and simultaneously slides along the jumper. The piston displaces fluid enclosed in it inside and outside of the piston chamber through its outlet to the outlet port

Operation principle

SpecificationConnecting thread M14x1, 5

Max pressure 2.5 MPaPower voltage, V 10 – 50Reverse polarity protection Yes

Measuring accuracy* ±1%

Temperature range,°C -40 – +85Maximum flow rate in l/h * 500

Output interface pulses, RS232, RS485, K-Line, CAN

Seal rating IP 66

EUROSENS flow meters can measure:

• Diesel fuel• Heating oil• Motor fuel• Biofuels

Other liquids :

fuels and mineral oil with a kinematic viscosity of 1.5 to 6 mm2 / s.

Product lines

Single chamber - Direct Differential- Delta

ModificationsDirect P - Not normalized pulse outputРH - Not normalized pulse output, external magnetic field protectionPN - Normalized pulse outputI – bult-in LCD 05 – enhanced precisionА – autonomous counter (built-in battery) RS – interfaces RS232 and RS485

ModificationsDelta РH - Not normalized pulse output, external magnetic field protectionPN - Normalized pulse outputI – bult-in LCD 05 – enhanced precisionА – autonomous counter (built-in battery) RS – interfaces RS232 and RS485CAN – J1939 or NMEA2000 interface

Порядок установки

1. Assessment of the engine condition2. Flowmeter mounting3. Connection of hoses4. Electric connection5. Testing operation6. Precision test

Connection of the hoses

Use fuel connectors from Eurosens mounting kit or compatible.

Fuel hoses must be resistant to oils and fuels

Use only high-quality mounting kits!

Flow meter installation

• Flanges and threaded connections must be clean during connection.

• When installing, use only new copper sealing from the mounting kit.

• Fuel lines must be protected from external destructive effects. • It is not allowed to reduce the internal cross section of the fuel

lines on the bends. • Fuel hoses on the vehicle must be fixed every 0.5 m.


• Fuel hoses in length should have a small length margin to compensate temperature changes.

• Do not install a flow sensor on the elements of the vehicle, subject to strong vibrations and heat.

• After flow sensor is installed it is necessary to remove air from the fuel system.

• It is recommended to install extra fine fuel (or filters) filter before the flowmeter chambers and let engine run for 30 minutes to collect all possible dirt after installation. Then filters can be removed.


Installation schemes:

1. “at pressure side”(after fuel supply pump)

2. “at suction side”(before fuel supply pump)

3. Differential scheme

Installation of the Direct flow meter(fuel system before installation)

Installation of the Direct flow meter(at pressure side)

Check valve is required only for “P” modifications

At pressure sideAdvantages1. Flow meter is installed after fine fuel filter .2. Fuel is under pressure that make system more tolerable for dirt

particles. 3. Return line still back in tank.

Disadvantages4. High-pressure pump has less cooling.5. Temperature of fuel in the return line is lower – less heating of fuel in

the tank6. Engine warranty will be ended.

Installation of the Direct flow meter(fuel system before installation)

Installation of the Direct flow meter(at pressure side)

Check valve is required only for “P” modifications

Check if the air bubbles in the return line are present

Check air bubbles at hot engine, at idle, middle and max RPMs

Check the fuel temperature at high-pressure pump entrance

Installation at suction side

Install if needed:• Radiator• Deaerator

If it is difficult – just try Eurosens Delta!

Check:• ∆t C of fuel• Air in return line

Installation at Suction side

Advantages1. Minimal changes of the fuel system

Недостатки 2. You may need extra fuel filter to be installed.3. Increased load at fuel supply pump.4. Fuel in the tank is not heated anymore by fuel from return line.5. Troublesome diagnostics of fuel system operation.6. Air in the return line problem requires deaerator installation

Installation of the differential flow meter(supply chamber at pressure side)

Differential scheme Differential method of measurement does high demands to flow meter precision. It is because flow rates in supply and return line usually are much bigger than engine fuel consumption.

For example, for John Deere tractor , at idling in fuel supply line – 200 liters/hour, in return line – 197 liters/hour. Engine consumption – 3 liters/hour. That means, that for adequate result at idling we need to measure both fuel flows with precision no more than 0.3%. Moreover, temperature expansion of fuel (0.7% per every 10 Celsius degrees) add extra error to differential measurement, because temperature of fuel coming to engine and returning to tank is differ.

That means, you can’t use idea of 2 separate flow meters without good precision and temperature correction.

Fuel flow meters Delta are made from hard aluminium alloy, measuring chambers have antifriction coating, in both measuring chambers fuel temperature sensor is installed. Each manufactured flow meter is pre-calibrated for differential application. Thereby Delta flow meters can provide accurate results in any mode of engine operation.

Differential schemeAdvantages1. No changes in the fuel system. 2. Can be installed at engines during warranty.

Disadvantages3. More costly flow meter model. 4. Precision is a bit lower. 5. Air in the return line will require deaerator

installation

Inline plunger high-pressure pump

For such old-schooled engines you can use Direct installation at pressure side

Mercedes, MAN,…

Common Rail fuel system

Common Rail

VOLVO

Fuel injectors

DAF

PLD fuel system

Differential scheme is suggested (Unipump UP DAF)

Electric connection of P и PN modifications

Green

Black

Blue

Electric connection of RS modifications

Red

Brown

Blue

Black

Wight

Yellow

Green

Connection of «Ground»Ground wire must be connected to the same point with Ground wire of GPS tracker

Power wire must be connected to the same point with Power wire of GPS tracker. Use 1.5A fuse for flow meter circuit protection.

Connection of power«+»

You may use electric clamps

Sometimes incorrect results from flow meter may be caused by electric disturbances in the wiring

Very good if your software can show instant fuel consumption based at flow meter data. You may easy check if flow meter works correctly

How to check precision of flow meter

"Refueling" method

1. Refill fuel tank for max, till visible level of fuel.2. Leave vehicle to perform its usual operations to consume at least 1/2 of tank.3. After it make refueling till max and visible level of fuel in tank again and measure volume of refueling.4. Compare volume of refueling with consumed fuel volume by flow meter.

"Measuring tank" method

What do you need for this method:

1. Calibrated standard measuring tank of the 2nd precision class, 10 liters 2. Clean capacities, >10 liters3. 500-1000 ml capacity measuring flask of the 2nd class with a continuous

scale4. Transparent fuel hoses - 2 pieces.


1. Connect fuel system like shown at this picture


1. Supply and return lines will come from tank capacity with some fuel volume inside.

2. Start engine and let it run until both fuel hoses will be fulfilled by fuel. No air bubbles is allowed.

3. Prepare second tank with exactly 10 liters. Attach it to the vehicle tightly.4. Connect second tank instead of first one. Fuel inside fuel hoses must be

saved.


5. Let vehicle perform its usual duties. No pure idling is allowed. Vehicle must spend some fuel in idle, normal and hard load more (preferably). So you can test flow meter in all operation conditions. Be sure that supply hose fully immersed in fuel and air can't get into fuel system.

6. Stop engine. Remove fuel hoses from measuring tank. Fuel from the hoses must not drop in measuring tank.

7. Measure rest of fuel from measuring tank and calculate fuel consumption. Compare it with fuel meter data.

Measuring tank with simulated fuel comsumption method

Same with previous method. •

But you must have much bigger tank capacities - at least 50 liters.

• Make extra fuel hose connection between relief valve and connect it with extra fuel capacity with 50 liters.

• Install an usual crane in this hose.

• Connect PC with configuration software or Eurosens Display to see instant fuel rates during experiment.

• See picture


You can now simulate engine consumption by opening crane. Fuel will pass fuel secondary tank before return chamber of flow meter.

As flow rates in supply/return line is much bigger than fuel consumption - 10 liters is not enough.

Thats why we need least 50 liters for an experiment. Fuel in supply tank will finish fast.

Measure rest of fuel in supply tank and compare with fuel flow meter data.

Intervention to the sensor operationFuel theft after sensorWhat you can see:

Fuel consumption is always higher than normal

Fuel theft after Direct flow meter

What you can see:Sometimes fuel consumption is

abnormal

Intervention to the sensor operation

Fuel theft example

For fuel flow meter installation you will need USB Destination 01 adapter

Configuration

Спасибо за внимание


Приглашаемк партнерству



Приглашаемк партнерству

Thank you for attention

JSC «Mechatronics»

222417 Vilejka, 1St May, 80BelarusPhone: +375 (1771) 71300Fax: +375 (1771) 24190E-mail: [email protected] www.mechatronics.by

Eurosens fuel flow meters installation

Automotive

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