Galooli uses the Omnicomm capacitive fuel sensor to read fuel data directly from the fuel tank. Any other fuel sensor utilized by the customer will not be supported by Galooli.
Fuel sensor installation requires direct access to the fuel tank. Therefore installation of fuel sensors can be attempted only with large vehicles that provide direct and secure access.
Preparation
Installation Preparation
Fuel hand pump
RS485 To USB Converter & two 0.5mm thick communication cables. The length of the cables is determined by the distance between the RS485 to the USB converter and the computer
Assorted pair of screwdrivers
¾ inch hollow copper rod.
Measuring tape
Zip-ties
35mm (1.4”) Bi-metal hole saw
Power drill
Fuel (Diesel, Gasoline)
Junction box – we recommend at least IP 65
Configuration Preparation
Compute with an internet connection.
Configuration Center installed - Click here to download.
Login credentials for Galooli Solution
RS485 to USB converter - Refer here for driver installation instructions
Project’s Wiring diagram - Provided by Galooli
Physical Installation
Step 1 - Mount Hole Location
The correct mounting location for LLS on the tank is the mechanical center of the tank's upper part.
Note! The wrong locations for LLS are the edges of the tank's or reservoir's upper part. Wrong LLS location might result in spurious draining and fueling.
In some cases of vehicle's configuration, it’s impossible to get to the mechanical center of the tank's (or reservoir's) upper part. In such cases the tank should be dismounted off the vehicle for the correct (and easy) LLS installation
Step 2 - Drilling Holes in Fuel Tank
The main hole is drilled with Hole Saw 35 mm diameter, using an electric drill.
The sensor’s tube should be cut accordingly with the adjusted depth of fuel tank (exact depth of the fuel tank, minus 8 – 10 mm).
Four small holes for LLS fixing screws are drilled with 4.0 mm diameter drill bit
Step 3 - Fuel Depth Measuring and Sensor Cutting
Prior to drilling, take proper measurements of the fuel tank:
Measure the depth of the tank with the help of a measuring rod by plunging the rod into the central hole intended for the sensor.
Along the working length (L) of the product, measure off the length (L1) that is equal to the depth of the tank minus 20 mm
Measure the internal height of the tank up to the sensor cover. Cut the sensor based on the measurements and remove 2cm from the bottom of the sensor.
Pay attention the middle rod inside the sensor doesn’t touch the tank walls.
After the sensor tube was cut for proper length, the insulation cap should be filled with sealant (silicon compound) for ¼ volume and fit on core rod.
Step 4 - Sealing
Seal the sensor with the insulating cap. The cap should be placed directly above the pipe located in the sensor. Make sure to use sealant resistant to oil and diesel. Fixate sensor to tank. Always cover the sensor with a box to prevent humidity, dirt or dust.
Fuel Sensor Range Calibration
Open the Omnicomm fuel sensor range configurator platform, the following screen will appear
Submerge the LLS tube completely into the fuel (slowly and carefully). Add the fuel to the measuring tank so as to cover the fuel level sensor along its full L1 length. Wait at least 1 minute until the «The level is stabilized” message appears.
In the program window, click on the “Full” button.
Take the fuel level sensor out from the calibration tank and let the fuel drip off from the sensor for 1 minute. In the program window, click on the “Empty” button and click “Save in the sensor”.
Fuel tank calibration involves the process of filling the fuel tank beginning with the empty tank until it becomes full and is characterized by a defined interval for calibration points, with the product readings subsequently recorded into a calibration table. To begin the calibration process, drain the fuel tank and connect the sensor to a PC.
From the Omnicomm configurator platform, open the “Calibration” tab and click “Add Sensor”
Select the network address and click ok. For one sensor, the “Sensor Network Address” should be set to “1”.
In the first row of the “Liters” column, specify the initial fuel volume in the tank.
Define the “Filling step, Liters” according to the volume of the measuring tank, and click “Start calibration”. When adding fuel into the tank, use a measuring tank or a flow-meter with the preset scale interval. Fill out the table as follows:
In the “Liters” column, specify the number of liters corresponding to the amount of fuel added.
The “Sensor readings” column will display the value corresponding to the amount of fuel added.
Record the sensor’s reading corresponding to the amount of fuel added by clicking on one of the following: “Enter” or “Add a row”. In the latter case, a new row will be added to the table. To delete the entered row, click “Del”.
When adding the fuel to the tank, the values of the relative level must increase monotonically. The first and last lines are the most important for a correct calibration table (and further correct readings of the tank’s fuel volume).
Each of the liter's values for the next steps is inserted in the table according to real fueling (how many liters of the fuel are in the tank for this exact moment). It can be seen at fuel counter display or arithmetically adding fueling step to the former liters value.
Each N value could be added after a portion of the fuel is added into the fuel tank and 30 seconds have passed to obtain the stable, correct N value.
To finish tank calibration, click “Finish the calibration”. To save the calibration table as an XML-file, click “Export”.
IO Configuration
IO Configuration in the Galooli solution is conducted per unit. To configure the IO’s, perform the following steps:
Right-click the selected unit -> Edit Unit -> IOs -> Analog Inputs -> Click to add…
Input: Choose Analog 5
Check ‘V’ in “Main Fuel Tank” checkbox
Click on the Magnification Icon to open the calibration table
Calibration with engine computer requires 2 parameters: Liters when the tank is empty and Liters when the tank is full. Enter bother parameters to calibrate the fuel.
Click Save to finalize the process.