Fuel Alert FA-KRS-P21. Mounting instruction

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1 Fuel Alert Mounting instruction

2 1- General Points : Alarm Mode and Measure Mode 2- Connections 3- Notice, warnings 4- Compatibility check up with the vehicle s level sensor 5- Wire connections with the level sensor 6- Installation and settings with the software VEGAZOLE 7- Functional Test 8- References and specificities 2

3 1- General Points : Alarm Mode and Measure Mode Fuel Alert s function is to supervise the tank level and the activation of an alarm After the ignition key 12 Vor 24 V, ground or speed signal deactivation, Fuel Alert is triggered and takes over the fuel level sensor. The reading of the fuel level is made via RS232. The fuel level is stored. If it gets lower than the present level, the alarm is triggered When the ignition key is switched to ON, the level sensor is connected back to its instrument in the power supply, and the monitor makes measures in a cyclic and adjustable way via the RS232 bus and the software. So Fuel Alert is designed to not interfere with fuel level information displayed on your dash board. The product works with a 12V or 24V power supply. The monitor has to be installed in the driver s cabin, because it is not water proof designed 3

4 2- Pin assignment Front view X RS-P21 J1 J2 J3 (Front view) Connector Micro-Fit 3.0: Connector J1 (14 pins) general connections Connector J2 (2 pin) for the additional battery (optional) Connector (4 pin) for USB interface to perform GIGA-CONCEPTFA configuration 4

5 Connection Table: Table 1. Pinning J1 Pin Function Limit Wire Color Connection 1 NC (not connected) - Not used 2 NC - Not used 3 NC - Not used 4 NC - Not used 5 Output sensor Hi (to Green Mandatory level sensor) 6 Input sensor Hi (to tank) Blue Mandatory 7 RS232- Tx Brown Mandatory 8 Input +12/24V 9 to 32V Red Mandatory 9 Ground Black Mandatory 10 + Ignition (vehicle) 9 to 32V Purple Mandatory 11 NC - Not used 12 Output sensor Lo (level Yellow Mandatory sensor) 13 Input sensor Lo (to tank) White Mandatory 14 RS232- Rx Grey Mandatory Table 2. Pinning J2 Pin Function Limit Connection 1 Ground Optional 2 Battery input +12V 9 to 15V Optional Table 3. Pinning J3 Pin Function Limit 1 Ground - 2 Serial bus- Tx 0 to 5V 3 Serial bus- Rx 0 to 5V 4 Input 5V (USB) 0 to 5V 5

6 3- Notice, warnings Correspondingly to the actual system, this product has been designed, manufactured and controlled in the respect of the security regulations Caution an inappropriate manipulation by a non-qualified person can seriously damage the monitor. Every employee none qualified for this job can be responsible of the following damages after the intervention. Do not install the product in the rain or wet weather. The infiltration humidity can damage the circuit and the electronic parts and cancel the waranty. A basic knowledge electricity and car mechanic are necessary during the assembly to avoid every material, environmental and bodily damage. Modifying the GIGA-CONCEPT product cancels the warranty Please do not damage the cables or loosen the connectors during the assembly; Notice: - Read attentivily all the porcedures in the mounting instruction before beginning the assambly. 4- Compatibility check up with the vehicle s level sensor Before mounting, verify the electrical impedance and the connections to the level sensor Remove the level sensor and measure its impedance with an empty and a full tank. Put the floater on high position (until it stops) and measure with an ohmmeter the value for a full tank. Put the floater on low position (until it stops) and measure with an ohmmeter the value for an empty tank Write these 2 values These 2 values must be between 0 and 1500 ohm Verify the tank volume on the dash board level indication to verify that the mounting is well done 6

7 5- Wire connections with the level sensor You will have to find the Hi and Lo signal (1) with vehicle contact turned ON and with using a voltmeter to detect the (+) wire which will be the high (Hi) signal, and the (-) wire which will be the low (Lo) signal. (During this measure, the level sensor will have to be connected to the vehicle) 7

8 Connect the Pin N.10 of the J1 connector (purple wire) on the (+) after turning ON the vehicle (+12V/+24V) or on a command ground cable. Connect the Pin N.8 of the J1 connector (red wire) on the permanent (+) (12V or 24V) Connect the Pin N.9 of the J1 connector (black wire) on the ground, must be connected on a screw fixed on the vehicle s chassis Connect the Pin N.7 of the J1 connector (brown wire/ RS232-TX) on the fleet management system. Connect the Pin N.14 of the J1 connector (grey wire/ RS232-RX) on the fleet management system. It will be necessary to configure the fleet management system to obtain the wanted information on the control monitor. It will be for instance possible to make appear the tank volume of all the vehicles. The connection wire is equipped with Micro Mate-N lock 4 channels Connector Micro Mate-N lock 4 Channels Wire Color Pin 1 Grey Wire / RS232-RX Pin 2 Brown Wire / RS232-TX Pin 3 Not used Pin 4 Not used Optional connections: Connect the pin N.2 of the connector J2 directly on the 12V battery via the optional battery kit GIGA-CONCEPT references FAX A11 Connect the pin N.1 of the connector J2 directly on the ground-battery via the optional battery kit GIGA-CONCEPT references FAX A11 8

9 9

10 6- Installation and settings with the software VEGAZOLE The alarm configuration is made with the interface X USB-P20 and the software Vegazole available on: The last Firmware is avaible on : The cable USB/mini USB is not supplied. (The software is compatible with Windows XP,Vista and 7). - Launch the program Fr\setup(.exe) to install Vegazole (Fuel Alarm configuration programmable X P10) - Launch then the program CDM20802_Setup(.exe) to install the needed driver to dialog with the Fuel alarm Launch the program FTDI(.reg) to complete the installation Administrator rights can be necessary to begin the installation. To set the alarm X RS-P21, Launch the program Vegazole 10

11 Then follow the different steps: - With the menu Command/ Serial Port, select a serial port and set its specificities, (38400 bauds, 8 data bits, 1 stop bit no parity). - Connect the unpowered alarm via the interface with the PC s USB port - Click on the Connect button, which become store/ disconnect 11

12 Power-On must be displayed in the toolbar, otherwise disconnect and reconnect the USB connector and start again. In case of none connection, try again on a other USB plug or check the port com number of your USB plug in the Device Manager panel on the computer. - Click on the USB serial port to obtain the actual configuration of the alarm 12

13 In the right window (Tank profil), put the demanded values o To read and modify the actual tank s profile, click on Change o To edit and send a new tank profile, click on New In the right window (new parameters), put the demanded values o Resistance with empty tank = level sensor s resistance when the tank is empty o Resistance with full tank= level sensor s resistance when the tank is full o The values are adjustable between 0 and 1500Ohm - Alarm level (%): the release sensibility can be adjusted according to the table. It is said in percentage of level sensor value corresponding to a full tank. It can be set between 1 and 20 %. To avoid invalid alarm triggers, and get a fairly sensitive detection, a setting of 5% is recommended. - IIC/RS232 Address: 357 (default); another address will be used and set, if 2 monitors are used for 2 different tanks unlinked. - Advanced engine computer: On some vehicles the gauge is connected directly to an electronic device (engine computer), this system works with software more or less evolved. You will need to activate this mode in case there appear to malfunction of display fuel level after the Ignition key is On. Be careful if this setting is enabled and used with an analog instrument, the fuel level rise or descend regularly every 30 seconds. Default setting is ''OFF'' - Ignition key signal type: the (+) ignition key signal can be activated by a (+) 12V/24V, by the speed signal form tachograph (connector B pin7), or can be driven by the fleet management system RS232. Be careful of the wrong settings which can involve a wrong running of the alarm function and a 0 indication of the tank level. By default setting is "Plus". - Permanent Alarm: alarm activation after ignition key signal. - Profile (New / Change) By default the product is set with a linear tank profile, you can change it manually - Click on send to memorize les product settings - Click on store / Disconnect - Disconnect the USB port; the product is ready to be use - To measure the level sensor s resistance: (Value with empty and full tank) Do NOT supply GIGA-CONCEPTFA Connect the USB Wire between GIGA-CONCEPTFA and the computer Launch the program and click on Connect Supply the interface (+ battery or + permanent) Measure with empty tank: click on Measure, then Empty. The value is copied in the new settings. Measure with a full tank: click on Measure, then Full. The value is copied in the new settings Verify the other settings and click on Send to memorize the settings in the interface s memory. Deactivate the supply (+ Battery 12V or + Permanent) Click on Disconnect Plug off the USB cable between the interface and the computer. 13

14 7- Functional Test Verify that when the tension is OFF, there is really 2.5V on the Pin N.10 of the connector J1 (purple cable) of the alarm monitor Switch the ignition key signal to ON and verify that the fuel level indicator on the dash board shows the real value of the tank volume. Verify this before and after connecting VDO FuelMonitor If the value is 0, verify the settings of the ignition key signal in the software, or the wire connection coming from level sensor. Use the tool VDOFM-TEST to check the settings stored, read if the ohm value from the FA-0RS-P21 is identical to the value measured directly on the sensor level via an ohmmeter. Default Root causes Cures The gauge always indicates empty or full Ignition key signal type inverted, Type APC inversé = Ground Check settings Ignition key signal type with Vegazole software. level or the level is not correct. instead of Plus Bad ground connection Connect the ground wire directly on a screw Input and output wires are inverted (sensors + and -) No ignition key signal Temporised ignition key signal fixed on the vehicle s chassis. Plug directly the sensor level and check the polarity Check the connection Check if ignition key signal appears or disappears immediately when switching of the ignition key The fuel level on the dashboard moves every 30 seconds Advanced engine computer is activated while the vehicle is equipped with an analog level gauge Disable the Advanced engine computer mode with the Vegasoil software. Alarm occurs intermittently Sensitivity adjustment too low Incorrect setting of sensor ohm values Wrong profile setting The sensitivity must be set to a value close to 5% or higher. Check the low and high ohm values of the sensor in Vegazole software. Put the default values by clicking on "New" profile in the Vegazole software. Or adjust values based on measurements during a filling of the tank, with different measurement points. 14

15 Paste the sticker on the tank (option none supplied with the product referenced FA-100-A10) 15

16 8- References and specificities Boitier Fuel Alert Désignation - Sortie Analogique - Sortie RS232 - Sortie I2C FA-100-PF20 ou P10 FA-0RS-P21 FA-I2C- P21 Kit chargeur batterie (charger + batterie) câble Autocollant Fuel Alart Boitier de configuration FA-000-A11 FA-002-PF20 FA-001-A10 FA-USB-P20 Technical specificities Alimentation 9 V à 30 V Consumption 6 ma max temperature functional -40 C à 85 C This alarm must not be installed on a vehicle carrying dangerous material under the ADR regulation Compatibility : The measure is made with the vehicle s original gauge. It must be resistive between 0 and 1500 Ohm. 16

17 To help us to develop a database about the alarm connections on the different vehicles, thank you too fill this table, and to send it via gilbert@giga-concept.fr Broche n Functions Position on the vehicle 1 + ignition key signal (+24V) 2 0 V (ground) Ohm value with empty tank Ohm value with full tank Level sensor reference and ohm value measured Vehicle s brand Type of vehicle Year Notes: 17

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