Level Measuring Sensor for Diesel Fuel Tanks

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1 Installation and Operating Manual Level Measuring Sensor for Diesel Fuel Tanks Executions with switchable output voltage signal: V and industrial standard signal 0-10 V: Tank Sensor Diesel Tank Height cm, 12 V/24 V, V and 0-10 V No Tank Sensor Diesel Tank Height cm, 12 V/24 V, V and 0-10 V No Tank Sensor Diesel Tank Height cm, 12 V/24 V, V and 0-10 V No Executions with current standard signal 4-20 ma: Tank Sensor Diesel Tank Height cm, 12 V/24 V, 4-20 ma No Tank Sensor Diesel Tank Height cm, 12 V/24 V, 4-20 ma No Tank Sensor Diesel Tank Height cm, 12 V/24 V, 4-20 ma No Operation and Safety Instructions: The VOTRONIC Tank Sensor Diesel had been designed exclusively for operation with Diesel fuel! Operation with other combustible or explosive liquids or water and hydrous liquids is not admissible! The VOTRONIC Tank Sensor Diesel has been particularly designed for tank control of auxiliary tanks, extension tanks and special tanks in intervention vehicles, high-quality campers, as well as in the marine field. It allows exact electric remote measurement of the tank levels. Suitable for Plastic and Metal Tanks Free installation, even subsequently, at the upper side of the tank No mechanically moved parts, fully electronic capacitive measuring method Linear, continuous signal of the level The electronic system is sealed waterproof and vibration-proof Independent of pressure, no falsification of measured values in case of pressure filling etc. Protection against reverse battery, overvoltage, short-circuit and overload Safety through internal test procedures being executed continuously. Type: Tank Sensor Diesel 010: Voltage output (3-wire) switchable: Standard signal 0-10 V or V for connection of different display and evaluation units: Setting 0-10 V: VOTRONIC LED Tank Display HE10 VOTRONIC Multiswitch FW External units, such as pointer indicators, board computers, measuring transmitters etc. Setting V: VOTRONIC Tank Display Diesel VOTRONIC LCD Tank Monitor 4 The powerful output of the sensor allows simultaneous connection of several display and evaluation units, such as: 4 Pieces VOTRONIC LED Tank Displays HE10 and additionally 1 Piece Switching Unit VOTRONIC Multiswitch FW Type: Tank Sensor Diesel 420: Current output (2-wire) with industrial standard signal 4-20 ma for connection of different display and evaluation units: VOTRONIC LED Tank Display HE420 External units, such as pointer indicators, board computers, 4-20 ma measuring transmitters etc.

2 Installation at the Tank: The sensor is designed for vertical installation viewed from the tank top. The sensor should be placed at the topmost location and in the tank centre. Use a conventional circular cutter to drill a hole of a diameter of 63 ± 0.5 mm at this location. Adaptation of the probe to the existing tank height: Shorten the probe with a commercially available metal cutting saw to the required length. The exterior protective tube as well as the inside electrode are separated at the same height. Eventually produced chips or burrs must be removed carefully (sharp blade or the like)! It is important that a clearance of at least mm is left between tank bottom and probe (formation of sludge, condensate water, tank movement during driving etc.)!

3 --3-- Connection Tank Sensor Diesel 010 (Voltage Output Three-wire Conductor): After the installation at the tank, the sensor is connected to the tank display and the power supply (battery+, fused!) according to the following drawing. Load resistor (burden) at the signal output: From minimum 1,000 Ohms to max. infinite. a. Tank Display with Voltage Input 0-10 V (Rotary Encoder to Output 0-10 V): b. VOTRONIC Tank Displays (Set Rotary Encoder to Output V ): The connections to the VOTRONIC Tank Displays are marked with the figures 1, 4 and 5, and their assignment is the following: 1 = black Battery 4 = grey Signal Out V 5 = brown Battery + (switched +12 V / 24 V)

4 Level Adjustment and Start-up: The operating mode and the setting (calibration, adjustment) of the sensor to tank empty and full is effected by adjusting the built-in rotary encoder with a small screw-driver. Full and empty adjustment must be effected once for adaptation of the sensor to the tank. This is the prerequisite for full measuring accuracy of the sensor. This can be executed in any sequence, i. e. first empty and after that full, or vice-versa, first full and after that empty. If necessary, full and empty adjustment can be repeated at any time individually and independently of each other. There is no mutual influence of the values. Empty Adjustment: 1. Evacuate the tank to the desired minimum level. 2. Set the rotary encoder to the left limit stop EMTY-Cal. (Empty adjustment). The red LED starts lighting. During this time (approx. 5 seconds), the sensor measures the empty value, which will be stored automatically. After that the LED will be flashing, the empty adjustment is finished, and the rotary encoder can be reset to working position V or 0-10 V. The red LED will extinguish. Full Adjustment: 1. Fill the tank until the desired maximum level is reached. 2. Set the rotary encoder to the right limit stop FULL-Cal. (Full adjustment). The green LED starts lighting. During this time (approx. 5 seconds), the sensor measures the full value, which will be stored automatically. After that the green LED will be flashing, the full adjustment is finished, and the rotary encoder can be reset to working position V or 0-10 V. The green LED will extinguish. Start-up: Set the rotary encoder to the position of the desired output signal using a small screw-driver: V: This signal is used for VOTRONIC Tank Displays, such as Tank Display Diesel, LCD Tank Monitor 4 etc. Tank empty = 0 V, linear increase up to tank full = 2.3 V V: This signal is a standard signal for industrial applications of any kind. Among other things, it is used for the VOTRONIC Tank Display LED Tank Display HE 010 and the universal Switching Unit Multiswitch FW. Tank empty = 0 V, linear increase up to tank full = 10 V. The sensor is also able to control several displays in parallel. This function allows simultaneous display of the tank at several locations of the vehicle. Failure Corrective Action: No reaction of display: a) Battery connection or fuse defective b) Cable grey Signal out interrupted - check c) Cable grey Signal out has short-circuit or to ground - check. d) Cable brown Battery +12 V to 24 V DC interrupted - check. Constant display of 100 % on the display unit: a) Cable black Battery -, Common, GND is interrupted - check b) Cable grey Signal out has short-circuit or to +12 V / +24 V - check. c) Short-circuit between inside probe and exterior protective tube due to burr or sawdust - remove d) Short-circuit between inside probe and exterior protective tube due to water penetration - check e) Erroneous operation of display unit V with 0-10 V - Set sensor to position V. Indication Errors: a) Bad contact of cable black Battery -, Common, GND - check b) Operating mode of the sensor V or 0-10 V is inappropriate for the display unit - correct setting c) Probe is clogged by rough dirt - remove d) Formation of sludge in the tank hinders Diesel fuel from flowing into the protective tube of the probe.

5 --5-- Technical Data Tank Sensor Diesel 010 (with Voltage Output): Nominal Operating Voltage: 12 V and 24 V Operating Voltage Range: 10.3 V 32 V Current Consumption: 7 ma Output Signal adjustable: V (for VOTRONIC Tank Displays) or 0-10 V (Industrial Standard Signal) Load Resistor at the Output: Minimum 1,000 Ohms to max. infinite Built-in Diameter: 63 mm Flange Diameter: 89 mm Tank Heights according to Type: 15 cm - 25 cm 15 cm - 35 cm 15 cm - 50 cm Temperature Range: -20 C C System of Protection: IP 67 Weight: 200 g Notes:

6 --6-- Connection Tank Sensor Diesel 420 (Current Output 4-20 ma Two-Wire Conductor): After the installation at the tank, the sensor is connected to the tank display and the power supply (battery+, fused!) according to the following drawing. Depending on the default of the display unit (ground or plus-side switching), the sensor will be placed accordingly into the measuring cable (see a. or b.). Load resistor of the display 0 Ohm to max. (operating voltage -7 V) / 20 ma such as for 11.0 V operating voltage: (11,0 V 7 V) / 20 ma = max. 250 Ohms a. Display Ground Side: such as for VOTRONIC Tank Display LED Tank Display HE 420 b. Tank Sensor Ground Side:

7 Level Adjustment and Start-up: The operating mode and the setting (calibration, adjustment) of the sensor to tank empty and full is effected by adjusting the built-in rotary encoder with a small screw-driver. Full and empty adjustment must be effected once for adaptation of the sensor to the tank. This is the prerequisite for the full measuring accuracy of the sensor. This can be executed in any sequence, i. e. first empty and after that full, or vice-versa, first full and after that empty. If necessary, full and empty adjustment can be repeated at any time individually and independently of each other. There is no mutual influence of the values. Empty Adjustment: 1. Evacuate the tank to the desired minimum level. 2. Set the rotary encoder to the left limit stop EMTY-Cal. (Empty adjustment). The red LED starts lighting. During this time (approx. 5 seconds), the sensor measures the empty value, which will be stored automatically. After that the red LED will be flashing, the empty adjustment is finished, and the rotary encoder can be reset to working position work 4-20 ma. The red LED will extinguish. Full Adjustment: 1. Fill the tank until the desired maximum level is reached. 2. Set the rotary encoder to the right limit stop FULL-Cal. (Full adjustment). The green LED starts lighting. During this time (approx. 5 seconds), the sensor measures the full value, which will be stored automatically. After that the green LED will be flashing, the full adjustment is finished, and the rotary encoder can be reset to working position work 4-20 ma. The green LED will extinguish. Start-up: Set the rotary encoder to position work 4-20 ma using a small screw-driver ma: This signal is a standard signal for industrial applications of any kind. Among other things, it is used for the VOTRONIC Tank Display LED Tank Display HE 420. Tank empty = 4 ma, linear increase up to tank full = 20 ma. Failure Corrective Action: No reaction of display: a) Battery connection or fuse defective b) Cable brown Battery +12 V to 24 V DC interrupted - check. c) Cable blue Signal out interrupted - check Constant display of 100 % on the display unit: a) Cables brown or blue have short-circuit or to ground or +12 V / check b) Reverse battery of tank sensor - check c) Short-circuit between inside probe and protective tube due to burr or sawdust - remove d) Short-circuit between inside probe and exterior protective tube through water penetration - check Indication Errors: a) Probe is clogged by rough dirt - remove b) Formation of sludge in the tank hinders Diesel fuel from flowing into the protective tube of the probe. c) Load resistor too high or operating voltage too low Technical Data Tank Sensor Diesel 420 (with Current Output): Nominal Operating Voltage: 12 V and 24 V Operating Voltage Range: max. 32 V Current Consumption / Output Signal: ma Load Resistor: 0 Ohm to max. (Operating Voltage -7 V) / 20 ma such as for 11.0 V Operating Voltage: (11.0 V 7 V) / 20 ma = max. 250 Ohms Built-in Diameter: 63 mm Flange Diameter: 89 mm Tank Heights according to Type: 15 cm - 25 cm 15 cm - 35 cm 15 cm - 50 cm Temperature Range: -20 C C System of Protection: IP 67 Weight: 200 g

8 Safety Regulations: Appropriate Application: The VOTRONIC Tank Sensor Diesel has been designed according to the valid safety regulations. Appropriate application is restricted to: 1. Level measuring of commercially available Diesel fuels. 2. In fixed installed 12 V / 24 V DC (direct current) systems / on-board power supply systems. 3. In consideration of the indicated cable cross sections. 4. Observing the indicated fuse rates for the supplied operating voltage. 5. Technically faultless condition. 6. Never use the unit with other combustible or explosive liquids, but always with Diesel fuel! NEVER use the unit as limit value indicator for release of an automatic overflow protection, The used measuring method does NOT work with water or hydrous media! Never use the unit at locations where the risk of gas or dust explosion exists! Cables are always to be laid in such a way that damage is excluded. Observe to fasten them tightly. Never lay 12 V (24 V) cables and 230 V mains supply cables into the same cable conduit (empty conduit). Check live cables or leads periodically for insulation faults, points of break or loosened connections. Occurring defects must be remedied immediately. The unit is to be disconnected from any connection prior to execution of electrically welding or work on the electric system. If the non-commercial end-user is not able to recognize the characteristic values being valid for a unit or the regulations to be observed, a specialist is always to be consulted. The user/buyer is obliged to observe any construction and safety regulations. The unit is not equipped with parts, which can be replaced by the user. Keep children away from the tank probe and measuring sensor. Non-observance may result in injury or material damage. The warranty period is 24 months from the purchase date (against presentation of the sales slip or invoice). The warranty will be void in case of any inappropriate utilisation of the unit, if it is used beyond the technical specification, in case of improper operation or external intervention. We do not assume any liability for any damage resulting hereof. The liability exclusion is extended to any service being executed by third, which has not been ordered by us in writing. Service is to be effected exclusively by VOTRONIC Lauterbach/Germany. Declaration of Conformity: According to the stipulations of the regulations 2006/95/EG, 2004/108/EG, 95/54/EG this product corresponds to the following standards or standardized documents: EN55014; EN55022 B; DIN14685; DIN ; EN ; EN ; EN Disposal of the product in the normal household waste is not allowed. The product conforms to RoHS. Thus, it complies with the directives for Reduction of Hazardous Substances in Electrical and Electronic Equipment. Delivery Scope: 1 Pc. Tank Sensor Diesel 1 Pc. Operating Manual 8 Pc. Fastening Screws 1 Pc. Mounting Instructions and Operating Manual Subject to misprints, errors and technical modification without notice. All rights reserved, particularly the right of reproduction. Copyright VOTRONIC 11/12. Made in Germany by VOTRONIC Electronic-Systeme GmbH & Co. KG, Johann-Friedrich-Diehm-Str. 10, LAUTERBACH/GERMANY Phone: +49 (0)6641 / Fax: +49 (0)6641 / Internet:

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