Page 1: Table Of Contents
TD-150 and TD-500 Installation and Conﬁguration User Manual Contents TD-150 and TD-500 Installation and Conﬁguration User Manual Deﬁnition and purpose of the sensor Basic terms and concepts Tank preparation Sensor preparation Sensor conﬁguration and ﬁne-tuning Sensor calibration 1. Open the “Sensor calibration” menu and click the slider “Calibration without fuel” and after filling the sensor with fuel press “Full”...
Page 2: Definition And Purpose Of The Sensor
Escort brand are designed to determine the ﬁlling level of petroleum products in fuel tanks, reservoirs and storage tanks. Sensors TD-150 and TD-500 are used in transport equipment as a fuel level meter, in industry - as a level meter for any light oil products.
Page 3 Analog - is a mode in which the corresponding voltage is formed on the basis of CNT in the approximate range of 0.2-5V (TD-500) or 0.2-9V (TD-150). Frequency- the mode in which the corresponding frequency in Hz is formed on the basis of CNT (301-1323 Hz with a range of values 1-1023;...
Page 4: Td-150 And Td-500 Installation And Configuration
Analog Pulse Periodic RS-485 LLS Periodic RS-485 LLS TD-150 and TD-500 fuel level sensors installation and conﬁguration procedure includes the following steps: Preparation of the tank (selecting installation spot, removing fuel vapors and fumes, drilling a whole) 2. Preparation of the sensor (cutting or extending the tubes of the sensor) 3.
Page 5 4. Installing the sensor in the tank 5. Tank calibration (to create a tank calibration table; NB: be sure to have enough fuel to be able to ﬁll the tank completely) 6. Connecting the sensor to a GPS tracker ATTENTION! The one above is the only right order of steps.
Page 7: Tank Preparation
Tank preparation To prepare the tank, you need to: ● Empty the tank and clean it from any dirt if necessary ● Remove any fuel vapors and fumes (especially if it is a gasoline/petrol tank); to do so you can boil some water in a separate recipient and administer the vapor from that recipient into the tank so it could “push”...
Page 8 Fig. 2 Selecting the spot Fig. 3 Drilling a hole to later probe for any obstacles inside with a piece of wire ● If the space around the selected spot is clear, drill a bigger hole with a ø 30-35 mm bimetallic hole saw; be sure to tilt the saw a little bit to prevent the cut piece from falling into the tank (Fig.
Page 9 Fig. 4 Drilling a hole at an angle Fig. 5 Removing the cut piece If the sensor cannot be installed in the geometric center of the tank, try to pick a spot as close to the geometric center as possible; that spot also must coincide with the point where the tank’s height is at its maximum.
Page 10: Sensor Preparation
Sensor preparation Before calibrating the sensor, you need to adjust the length of its measuring tubes according to the height of the tank by either cutting or extending them. The length of the tubes should be calculated based on the following formula: L = H - 15 mm, where L is the length of the tubes after they were cut or extended and H is the height of the tank at the installation spot.
Page 11 Fig. 7 Establishing the length of the tubes To cut the tubes, use a metal hacksaw. Be careful while cutting them and avoid damaging the connection between the tubes and the sensor’s circuit inside its head. Fig. 8 Cutting the tubes Do not let any metal shavings end up stuck inside the tubes: that could provoke a short circuit in the sensor and then you would need to blow the tubes with compressed air through the drainage holes under the sensor’s ﬂange.
Page 12 To extend the tubes of the sensor, use a collet coupling and an extra piece of tubes. Fig. 9 Collet coupling The yellow nuts go into the inner Screwing in the inner coupling Fixing the outer coupling tubes Fig. 10 Collet coupling ﬁxed The collet nuts (the gold-yellow ones shown on the Fig.
Page 13: Sensor Configuration And Fine-Tuning
Be sure to check out this video on our YouTube channel to see the coupling assembled in real time. Sensor conﬁguration and ﬁne-tuning The sensor can be conﬁgured by means of a conﬁguration tool for PC (hereinafter – “conﬁgurator”) or by means of a mobile application installed on an Android OS device. This instruction will be focused on the PC conﬁgurator.
Page 14 Download and install the Escort Conﬁgurator for PC from the Downloads section of the fmeter.ru website (Fig. 12). Additionally, download and install the components and libraries for Windows from the same Downloads section, Additional ﬁles tab (Fig 16 and 17). While installing them be sure to wait until the message informing of the installation being complete appears on your screen (Fig.
Page 15 Fig. 13 Additional ﬁles Fig. 14 Windows components and libraries Fig. 15 RuntimePack is installed...
Page 16 Download and install the drivers for the C200M. Be sure to check if you have Windows x64 or x32 (indicated as x86 sometimes too) and choose the right installation .exe ﬁle. (Fig. 16) Fig. 16 Drivers’ version If the drivers were installed properly, after you connect the C200M to your PC/laptop a STMicroelectronics Virtual COM Port (COM X) must appear on the COM and LPT ports list in the Windows Device Manager (Fig.
Page 17 Select the COM port with the right number in the conﬁgurator. Fig. 18 Opening the COM port Connect the sensor to a USB-RS485 converter via the 6 pin MOLEX connector (Fig. 19) or via the clamps and wires (if the extension cable is already connected to the sensor).
Page 18 Fig. 20 Sensor connected via the extension (shortened) cable and the clamps Then click on the “FLS” button or you can click this button before powering on the sensor (Fig. 21). You need to do that within the 15 seconds after the sensor was powered up if you changed its operating mode from the RS485 to any other before.
Page 19: Sensor Calibration
When the sensor is connected, you should be able to see the following data: Fig. 22 Main menu of sensor conﬁgurator Sensor’s serial number 2) FW version 3) Network address of the sensor (its ID used for the RS485 connection) 4) Status message with the sensor’s current status 5) Current readings of the sensor 6) Current mode of the sensor, range of the output data (1-1023 or 1-4095) and...
Page 20 Fig. 23 Entering sensor calibration menu Make sure the sensor is physically not in the fuel and dry and click “Calibrate” Fig. 24 Sensor calibration menu After that you can close this menu by pressing “OK”.
Page 21 Also you can do calibration with fuel to do so, be sure to follow the next steps: Open the “Sensor calibration” menu and click the slider “Calibration without fuel” and after filling the sensor with fuel press “Full” It is possible to set the Full calibration value in two ways. way: you can turn the sensor upside down cover its drainage holes with an insulation tape or something similar,...
Page 22: Setting The "Empty" Calibration Value
Setting the “Empty” calibration value Empty the tubes or take the sensor out of fuel completely, wait for 2-3 minutes until the last drops of fuel trickle down the tubes and then click on the “EMPTY” button. Fig. 26 Calibration with fuel...
Page 23 Fig. 27 CNT, level and physical fuel level ATTENTION! If you covered the drainage holes of the sensor before, make sure to unblock the drainage holes after the calibration is over!!! Otherwise, when you put the sensor into the tank, the fuel will not be able to go up the tubes because of the air trapped inside and the level reading will not change no matter how much fuel you put into the tank Fig.
Page 24: Setting Operating Mode
LLS communication protocol - Analog mode is used to connect the sensor's analog output to the analog input (AIN) of the tracker capable of registering the voltage readings of TD-150 within the ≈0.2V … ≈9.0 V range and TD-500 0.2V …...
Page 25 - Periodic/Active RS485 mode should be used if the tracker has the RS485 interface but cannot poll the sensor, i.e. request the data from it; the sensor will be transmitting its data by itself every 2 seconds...
Page 26: Measurement Ranges
Measurement ranges If you set the sensor to the RS-485, Periodic/Active RS-485 or Frequency mode, you can change the Range of output. In the Frequency mode, 4095 range will be the range from 300 Hz to 4395 Hz. Fig. 30 Selecting range After you choose the range click Save the parameters to device.
Page 27 ø3mm bit in order to screw the self-tapping screws into them. This is an obligatory step in case of a plastic tank. The centralizer from the sensor’s installation kit must be already inserted into the tubes (even before the sensor FULL and EMPTY calibration) to securely separate them from touching each other and provoking a short circuit in the sensor.
Page 28 Mount the sensor into the tank driving its tubes through the ø 30-35 mm hole you drilled previously. Make sure that the gasket is still there, between the sensor’s ﬂange and the tank’s top surface. Then screw in the self-tapping screws from the sensor’s installation kit into the ø...
Page 29 20 lines in total. Normally, the platform’s capacity is a lot higher. TD-150 don’t have this feature. Besides, it is easier to adjust or correct any mistakes in the table if it is uploaded onto the platform rather than if it is saved in the sensor’s memory.
Page 30 Let’s imagine that you need to do a tank calibration with portions equal to 10 liters. You create an Excel table. Use the .csv format. The ﬁrst line of the table must read the following: Fig. 35 Fuel level 1, Volume 0 (liters/gallons) If you cannot empty the tank completely, you need to somehow ﬁnd out how many liters or gallons are already there in the tank.
Page 31 You add the ﬁrst portion into the tank. The level must change from 115 to a different value. If the level value doesn’t change, check the drainage holes of the sensor. They could be blocked by an insulation tape you left there after the calibration at full and empty or some surplus of the sealer got stuck in them.
Page 32 the tank. Once past that shape’s peculiarity, switch back to the previous volume of portions. Let’s imagine that you do the tank calibration with portions of 10 liters just like before. The level gets to some peculiarity of the tank’s shape. Fig.
Page 33 When the level is above the problematic part, you can switch back to ﬁlling the tank with portions of 10 liters. When the tank is full, you should have a tank calibration table that looks like the following example. Fig. 41 Tank is full and table is ready If in your case the level cannot reach the 1023 or 4095 because you cannot ﬁll the tank completely, don’t worry about that.
Page 34 Fig. 42 Table for tank that cannot be ﬁlled 100% The total number of the portions depends on the tank’s total capacity. See the table with our recommendations below. Table 1 The general rule is: the more portions – the more precise will be the data in the reports on the platform.
Page 35: Filtration
Filtration After the tank calibration is over, select the level of Filtration and click Save the parameters to device. Fig. 44 Smoothing/Filtration The following are our recommendations on what level of Filtration to choose for a particular type of vehicle: Table 2 These are some general recommendations.
Page 36: Connecting Sensor To Gps Tracker
The ﬁltration reduces the magnitude of level ﬂuctuations that happen because of the fuel’s sloshing during trips. Connecting sensor to GPS tracker To connect the sensor to a GPS tracker and a power supply, use the following wiring diagrams. Fig. 45.1 TD-500/TD-150 RS-485 Mode...
Page 37 Fig. 45.1.2 TD-500/TD-150 RS-485 Mode For explosion proof For Explosion proof connection in any mode of the wired sensors you need to connect with a resistor, not a fuse. INSTEAD OF THE FUSE NOT WITH THE FUSE Fig. 45.2 TD-500/TD-150 Frequency Mode...
Page 38: Sensor Fw Update
Fig. 45.3 TD-500 Analog Mode Fig. 45.4 TD-150 Analog Mode TD-150 have Analog mode always ON, you dont need to change to that mode in the conﬁgurator. Sensor FW update TD-150 and TD-600 sensors’ FW update manual: https://docs.google.com/document/d/16KhS0ZV5Hrb44J66LmGOy7Gy2TKcuEqU TD-100 and TD-500 sensors’ FW update manual:...
Page 39: Changing Com Port Number
Changing COM port number The bootloader requires the COM port to have any number from 1 to 10. If in your case the COM port has the number 11 or higher, you need to change it to any number between 1 and 10. To do so, open the Windows Device Manager and right click on the COM port you need to modify.
Page 40 Fig. 47 Port Settings. Advanced Next, select a new COM port number from 1 to 10. It could be marked as ‘in use’, you still can select that option as long as there are no real COM ports connected at the moment and listed in the Ports (COM &...
Page 41: Checking Connection Between Sensor And Tracker Via Rs485
After that, disconnect and reconnect the converter to your PC one more time. Then you will be able to select the COM port in the bootloader program. Checking connection between sensor and tracker via Rs485. If, for some reason, the sensor’s data is not transmitted onto the tracker properly after you have properly conﬁgured everything, you need to check if there’s any data exchange between the devices.
Page 42 Once the converter is properly connected, select the COM port and click ‘Connect’. If the tracker polls the sensor and the sensor responds, then everything is ﬁne. Fig. 50 Sensor responding to tracker via Rs485 If the tracker polls the sensor and the sensor responds, then everything is ﬁne.
Page 43 Fig. 51 Sending requests to sensor The requests structure depends on the address of the sensor. If you change the address of the sensor to 255 for example, then the request will look like this: 31$FF$06$29 ● where FF stands for 255 converted from DEC into HEX ●...
Page 44: Common Issues And How To Resolve Them
Fig. 52 CRC calculated for 255 network address If the sensor doesn’t respond to the tracker but does respond to a request you send to it manually then you need to check the Rs485 or Rs232 port of the tracker. If the sensor doesn’t respond at all, you need to run some basic diagnostics on it.
Page 45 the empty calibration value. Try and recalibrate the sensor. If it doesn’t help, take a screenshot of the conﬁgurator and send it to us. Current and Full and Empty calibration values must be clearly visible!!! 7000 is a code for short circuit. It means that there’s some dirt, water or admixtures between the tubes of the sensor that affect its readings.
Page 46 listed in your Windows Device Manager as a STMicroelectronics Virtual COM Port) if possible, connect another sensor that is in perfect working condition; if it connects, then there’s nothing wrong neither with the COM port nor with the C200M (or other converter you are using); Fig.
Page 47 if everything mentioned above fails, try to update the sensor’s FW if the update fails too, take a multimeter and measure the sensor’s power consumption and the voltage readings on the orange and white wires of the sensor, make a short video of that check and send it to us; ⎓...
Page 48 connected ﬁrst to the line A (orange wire of the sensor) and then to the line B (white wire of the sensor). Power the sensor up. Fig. 59 Line A voltage check (relative to GND) Fig. 60 Line B voltage check (relative to GND) Compare the readings you get on both A and B lines with the normal values indicated in the table below.
Page 49: Setting Full And Empty Calibration Manually
Setting Full and Empty calibration manually We do not recommend it but you can set the Full and Empty calibration values manually to save time if you always cut/extend the sensor equal to the same length and install them in ‘similar’ tanks. ATTENTION!!! Setting calibration values manually will likely increase the margin of error of the sensor! We do not recommend using this option!
Page 50 Fig. 61.2 Setting Full and Empty values manually Fig. 61.3 Setting Full and Empty values manually...
Page 51: Using The Same Tank Calibration Table For Different Sensors
Using the same tank calibration table for different sensors To save time, you could use the same tank calibration table for the sensors of the equal length installed in the ‘identical’ tanks. ATTENTION!!! We strongly recommend you not to use the same table for different sensors as doing so will likely increase the margin of error of the sensors.
Page 52 Sealing the sensor To seal the sensor and prevent anyone from taking it out of the tank without you or your customer being aware of that, put the sensor’s protecting cap over its head and then drive the plastic dowel (Fig. 63, 1) through the sealing oriﬁce (Fig. 64, 2). Fig.
Page 53 Fig. 64 Push the dowel into the oriﬁce To seal the connection of the extension cable, drive the plastic seal through the special oriﬁces and fasten the seal.
Page 54 Fig. 65 Sealing cable connection point Fig. 66 Sealing sensor (old design)
Page 55 Wiring with fuse (FU1) or resistance (R1) The sensors are shipped with kits that contain 2 ballasts/resistances. Each of them can be installed instead of the fuse from kit (not along with it) in case it is necessary to comply with special anti-explosion safety requirements.

This manual is also suitable for:

Td-500