Holykell HPT604 Troubleshooting

Despite being connected to a power source,
the fuel sensor does not receive any power

The issue will be identified during the check that the technician should perform with the electronic test tool (FLUKE).

1. Ensure that the incoming wires from the power source are properly secured at both ends. A power source can be an external source or a Galooli internal connection, such as an Elara cabinet tray/Elara metal box.

   

2. Ensure that the power supply is between 10 and 30 volts DC.

 When the fuel sensor is connected to the communication terminal block but is unable to communicate with the Elara device 

• Connect the fuel sensor cables to the terminal block properly.

• Ensure that the terminal block's power supply is 12 volts. 

• The RS485 connection cables should be connected according to the pinout diagram:
  

  • On the fuel sensor side

    

  • On the terminal block side - refer to the wiring diagram provided by Galooli
    

Despite receiving power and being properly connected, the Galooli gateways in Power Center are not connected to the fuel sensor

1. Ensure that the fuel sensor ID is configured with the correct baud rate of 19200 and the device ID by the wiring diagram.

   

2. Be sure to select the correct fuel sensor parameters when adding the fuel sensor to the Elara gateway, including: "Device", "ID", and "Device Baudrate” according to the wiring diagram provided by Galooli.

   

Fuel sensors are communicating properly, but the data they provide is incorrect.

1. Remove the fuel sensor from the fuel tank and place it straight on a flat surface. Ensure the tip of the fuel sensor is 2 cm away from the base of the fuel's sensor securing rod.
   

2. Read all configurations from the fuel sensor calibration tab on the “Services center”.

   

3. Once done perform the “Zero calibration” on the fuel sensor
   

   

What is the fault and how can it be detected?

Troubleshooting Steps

The fuel reading is stuck

Several platforms can be used to identify the problem:

• Pro application detailed report.

• Power Center.

• Galooli Mobile App.

In order to confirm that the fuel reading is indeed stuck, follow these steps:

1. Find a day when the generator was certainly in use. Generate a detailed report on that day using the Pro application, containing two fields: "Generator X Total used" and "Generator_X.Engine_Hours". In the event that the working hours of the generator change and the fuel consumption does not change accordingly, then the reading is indeed stuck and you should proceed to the next step.
   

2. Using one of the Galooli platforms, create a detailed report and determine when the fuel reading last changed . If you have determined the time and date at which the readings of the fuel stopped, proceed to the next step.
   

3. Check whether the fuel calibration table has been modified in accordance with the previous section and make sure that a calibration table has been applied properly.
   

4. Check via the Power Center if the sensor's open-air value exceeds the OA value of +7 or -7, it may indicate a fault.
   

5. Verify that the fuel sensor pores are not blocked at the diaphragm.
   

6. Make sure that there is no sludge in the fuel tank.
   

7. Make sure the fuel is of good quality.
   

8. Make sure that the fuel sensor is properly secured to the sensor securing rod.
   

9. Check for signs of wear and tear.
   

10. Recalibrate the sensor.

The fuel readings indicate a wave pattern

Use the detailed report provided by the Pro application to identify the issue.

1. Create a detailed report using Galooli Pro application in order to determine when the fuel readings begin to behave in a wave pattern. Proceed to the next step if you have determined the time and date.
   

2. Check whether the fuel calibration table has been modified in accordance with the previous section and make sure that a calibration table has been applied properly.
   

3. Check via the Power Center if the sensor's open-air value exceeds the OA value of +7 or -7, it may indicate a fault.
   

4. Verify that the fuel sensor pores are not blocked at the diaphragm.
   

5. Make sure that there is no sludge in the fuel tank.
   

6. Make sure the fuel is of good quality.
   

7. Make sure that the fuel sensor is properly secured to the sensor securing rod.
   

8. Check for signs of wear and tear.
   

9. Recalibrate the sensor.

The fuel readings contain “noise”

An example of noise would be a deviation from how the Galooli system interprets the fuel trend from a particular site.
The following factors may be contributing to this noise, either individually or in combination:

• The presence of sludge in the tank

• A large amount of water has been mixed with the fuel in the tank.

• Fuel sensor malfunction

• An improperly installed fuel sensor in which the rod of the sensor is not firmly fastened to prevent vibration.

First you need to identify the noise readings:

Step 1: Build a summary report with the following fields:

•unit id
•Refuels
•Numeric Calculated field"(IF(('Refuels'>8)||('Drops'>8);1;0).
The assumption is that a normal functioning sensor should not experience refuel or drop count of more than 8 in a day.
The count can vary depending on the client and their mode of operation.

Step 2: Under data Aggregation use "Daily"

Step 3: Run the report and under Calculated field (Named "1 equals irregular fuel")

Step 4: Filter out 1, this represents the sensors with irregular fuel/noise.

How to resolve noise issues?

Resolution approach depends on the cause of the noise. To know the exact cause of the noise, a site visit for physical inspection is recommended. Below, a list of action for different root cause is highlighted.

Presence of sludge in the tank

1. Evacuate sludge from the tank.

2. Clean the fuel sensor by removing sludge deposits from the diaphragm.

3. Wash the sensor with fuel but be careful to ensure fuel does not penetrate the cable or internal circuitry of the sensor.

4. Power up the sensor and observe for normal functionality. If sensor reading is OK, then sensor can be re-used otherwise a replacement is advised.

5. Re-install the sensor and calibrate as per standard operating procedure.

Presence of water in the tank

1. Evacuate fuel contaminated with water from the tank.

2. Inspect the sensor to be sure there is no water ingress in the cable or sensor internal circuitry.

3. Wash the sensor with fuel but be careful to ensure fuel does not penetrate the cable or internal circuitry of the sensor.

4. Power up the sensor and observe for normal functionality. If sensor reading is OK, then sensor can be re-used otherwise a replacement is advised.

5. Re-install the sensor and calibrate as per standard operating procedure.

6. Identify potential points of water ingress to the tank and seal it off.

Faulty fuel sensor

Once confirmed faulty, replacement is recommended.

Installation issue (Lack of rigidity)
When identified as the cause of the noise, re-install the sensor, and make sure the sensor rod is securely fastened to the tank to prevent excess vibration when generator is running.