081 - Fuel - Mass - Flow - Meter - 735S - User Manual

AVL FUEL MASS FLOW METER
Product Guide
Model 7351 and later
August 2009
AT1442E, Rev. 06
Copyright 2009 by AVL List GmbH, Graz - Austria
The contents of this document may not be reproduced in any form or communicated to any third party without the
prior written consent of AVL. While every effort is made to ensure its correctness, AVL assumes no responsibility
neither for errors and omissions which may occur in this document nor for damage caused by them.
All mentioned trademarks or registered trademarks are owned by their respective owners.
Printed in Austria at AVL

All rights reserved
Warnings and Safety Instructions 3
Warnings and Safety Instructions

This guide contains many important warning and safety instructions, which
have to be followed by the user.
The product described is intended only for the type of application which is
described in the instructions. The manual also explains the essential prerequi-
sites for the application and operation of the product as well as the safety
measures to ensure smooth operation. AVL can offer no warranty nor accept any
liability if the product is used in applications other than those described or if the
necessary prerequisites and safety measures are not met.
The product may only be used and operated by personnel, which, due to its qual-
ification, is capable of observing the necessary safety measures during use and
operation. All accessories and equipment used with the product must be
supplied or approved by AVL. The operating principle of this product is such that
the accuracy of the measurement results depends not only on the correct opera-
tion and functioning of the product, but also on a variety of peripheral conditions
beyond the control of the manufacturer. The results obtained from this product
therefore must be examined by an expert (e. g. for plausibility) before any action
is taken based on those results.
All adjustment and maintenance work necessary on instruments when open and
under voltage must be carried out by a professional technician who is aware of
the dangers.
Repairs to the product may be carried out by the manufacturer or qualified
service personnel only.
When the product is in use, an expert must ensure that neither the test object nor
the testing equipment is operated under conditions that may lead to damage or
injury.
AVL List GmbH
Product Guide
4 Warnings and Safety Instructions
Fuel Mass Flow Meter

Grouped Safety Messages 5
Grouped Safety Messages
WARNING
Danger of explosion and chemical burns

The device must not be operated in an environment where there is the risk of an
explosion. To prevent fire and explosion of volatile fuels please follow the instruc-
tions in the section Measures to Prevent Fire and Explosion on page 26.
Work on media circuits (fuel) may only be carried out with cooled-down and pres-
sureless media.
Fuels like gasoline and alcohol can cause skin burns. Therefore wear appro-
priate protection equipment during work with fuels.
Note the relevant safety data sheets of the employed fuels.
Note that the fuel circuit must not be vented if the vapor pressure of the fuel
exceeds the atmospheric pressure in the tank. Even at only slightly increased
fuel temperatures, highly volatile fuels can produce gas resulting in a tank over-
flow.
The device must always be vented and filled up with fuel!
The device must not be drained after it has been operated with Otto fuels or
alcoholic mixtures (e.g. for a longer standstill period).
If draining is necessary, (e.g. for transportation or storage) make sure to observe
the following instructions:
1. Drain the device completely.
2. Fill up the device with inert-gas.
3. Seal the five hydraulic connectors (except connector K, compressed air)
hermetically.
These steps must only be followed if the device was filled up with Otto fuels or
alcoholic mixtures!
WARNING
Danger of death from electrical voltage

Any connected equipment that uses higher voltages than 50 V AC or
75 V DC must satisfy the requirements of the 73/23/EEC Low Voltage
Directive.
If a foreign body or liquid gets inside the device, disconnect the device from the
power supply and have it checked by an expert before using it again.
Make sure that the device is supplied with the correct supply voltage.
Product Guide
6 Grouped Safety Messages
NOTICE
Only shielded cables may be used with appropriately shielded connectors in

order to comply with the 89/336/EEC Electromagnetic Compatibility Directive.
Power supply connections with standardized connectors and the exceptions
mentioned do not need to be shielded.
NOTICE
Bear in mind that during mounting there is a risk of injury due to the heavy
weight, the center of gravity and the sharp edges of the case.
If the AVL Fuel Mass Flow Meter has been rigged for a short-term period without
any fastening, the device cover may not be opened under any circumstances –
the device would tip over.
During transportation of the device the transport lock of the sensor has to be
inserted, otherwise there is a risk of damage to the fuel lines!
Cables and hoses have to be professionally laid to the correct connections.
Make sure that they are not exposed to mechanical stress and nobody is
obstructed (e.g. use cable pits).
NOTICE
Thermal expansion or contraction of fuel causes excess differential pressures in

stiff lines that are closed on either side, which in turn may lead to leaks or the
destruction of installed components. Use pressure surge tanks or relief valves to
prevent such pressure rises.
NOTICE
There absolutely must be an appliance that interrupts the fuel supply in case of
errors. If there is no corresponding mechanism available at the test bed, the
option shutoff valve has to be used.

Grouped Safety Messages 7
Information
The device is not suitable for monitoring the fuel circuit for line breaks.
During work at any part of the fuel circuit / device, switch off the device and
disconnect all communication lines (digital I/O, COM1 and COM2).
Please note that the compressed air supply must be maintained for a short
period in case of emergency during switching off the power supply (delayed
switching-off).
The device must not be exposed to rain or permanent humidity.
Check the functioning of the float switch and the entire safety circuit (shutoff
valve) on a regular basis.
After the warning "Tank overflow", the overflow tank must be completely drained!
Information
Changes from device type 7350 to 7351 (see type plate)

If wiring the outputs without potential separation (switch S1 at position 1),
pins 2/6/7/8 have +24 V DC at the digital I/O connection (X5).
Draining the device via the drain cock as used in device type 7350 causes only a
draining of the overflow tank with device type 7351.
Information
There are two types of the device AVL 735S, which differ in terms of fuel resis-
tance.
See Scope of Delivery on page 15.
Please absolutely make sure that only the appropriate spare parts are used for
the type 7351CME:
Type "alcohol-resistant" (M100).
Information
Please follow the instructions given in the section Scope of Application and
Intended Use on page 65.
Information
When disposing of the product or of parts of it, make sure that the legal regula-
tions in force in the country in which the device is operated are observed (e.g.
regulations for the disposal of electronic scrap). The device must always be
completely emptied of any fuel which might be present.
Please contact AVL for further information on the substances that are contained
in the device.
Product Guide
8 Grouped Safety Messages

Table of Contents 9
Table of Contents
Warnings and Safety Instructions................................................................................................................ 3
Grouped Safety Messages ............................................................................................................................ 5
1 What You Should Know.................................................................................................. 13

1.1 Safety Instructions .................................................................................................................. 13
1.2 Intended Application ............................................................................................................... 13

1.2.1 Typographic Conventions ................................................................................................. 13
1.2.2 We Want to Hear from You............................................................................................... 14
2 Installation Instructions.................................................................................................. 15
2.1 General................................................................................................................................... 15
2.2 Scope of Delivery ................................................................................................................... 15

2.2.1 Basic Device ..................................................................................................................... 15
2.2.2 Options ............................................................................................................................. 17
2.3 Installation at the Test Bed ..................................................................................................... 22

2.3.1 Design of the Measurement Circuit................................................................................... 26
2.3.2 Measures to Prevent Fire and Explosion .......................................................................... 26
2.3.3 Combination of AVL Fuel Mass Flow Meter and AVL Fuel Temperature Control............. 27
2.3.4 Single Mounting of the AVL Fuel Mass Flow Meter .......................................................... 28
2.3.5 Mounting on the Trolley .................................................................................................... 28
2.3.6 Fixing the Device to the Mounting Bracket ....................................................................... 29
2.3.7 Leveling the AVL Fuel Mass Flow Meter .......................................................................... 29
2.4 Hydraulic / Pneumatic Integration........................................................................................... 30

2.4.1 General Installation Guidelines ......................................................................................... 30
2.4.2 Hydraulic Connectors........................................................................................................ 33
2.4.3 Connecting Compressed Air ............................................................................................. 40
2.5 Electrical Connection.............................................................................................................. 40

2.5.1 Power Supply.................................................................................................................... 40
2.5.2 Emergency Stop (X7)........................................................................................................ 41
2.5.3 Device Integration with AVL Fuel Temperature Control (X2)............................................ 44
2.5.4 Interfaces .......................................................................................................................... 44
2.5.5 Digital Control Lines.......................................................................................................... 45
2.5.6 Integration via AK Protocol ............................................................................................... 46
2.5.7 Hybrid Integration.............................................................................................................. 46
2.5.8 Connecting the Shutoff Valve (X1).................................................................................... 47
2.5.9 Serial Interfaces (X3/X4)................................................................................................... 48
2.5.10 Digital I/O (X5) .................................................................................................................. 50
2.5.11 Analog Interface (Analog Output of the Measurement Value) .......................................... 53
2.5.12 Overview Pin Assignment ................................................................................................. 54
2.5.13 Device Configuration......................................................................................................... 54
Product Guide
Table of Contents 10
2.6 Connecting the Options .......................................................................................................... 57

2.6.1 Shutoff Valve .................................................................................................................... 57
2.6.2 Calibration Unit ................................................................................................................. 59
2.6.3 Option Venting Valve ........................................................................................................ 61
2.7 First-Time Start-up.................................................................................................................. 62

2.7.1 Drain / Rinse ..................................................................................................................... 64
3 User's Guide .................................................................................................................... 65

3.1 Scope of Application and Intended Use ................................................................................. 65
3.2 System Description................................................................................................................. 66

3.2.1 General ............................................................................................................................. 66
3.2.2 Operating States ............................................................................................................... 68
3.2.3 Data Acquisition ................................................................................................................ 75
3.2.4 Calibration – Adjustment................................................................................................... 75
3.2.5 Consumption Totalizers .................................................................................................... 81
3.2.6 Operating-hour Counter, Maintenance Limit..................................................................... 82
3.3 Test Bed Integration ............................................................................................................... 82

3.3.1 Application ........................................................................................................................ 82
3.3.2 Operation .......................................................................................................................... 85
3.4 Remote Control ...................................................................................................................... 85

3.4.1 General ............................................................................................................................. 85
3.4.2 Operation .......................................................................................................................... 86
3.4.3 Configuration .................................................................................................................... 87
3.4.4 Measurements .................................................................................................................. 90
3.4.5 Accuracy Check ................................................................................................................ 92
3.4.6 Calibration......................................................................................................................... 92
3.4.7 Adjustment ........................................................................................................................ 93
3.4.8 Parameter ......................................................................................................................... 94
3.4.9 Analog Output ................................................................................................................... 94
3.4.10 Information ........................................................................................................................ 95
3.4.11 Maintenance ..................................................................................................................... 95
3.4.12 Service .............................................................................................................................. 96
3.4.13 Warnings and Errors ......................................................................................................... 97
3.5 Interface Protocol (AK Protocol) ............................................................................................. 97

3.5.1 General ............................................................................................................................. 97
3.5.2 Basic Communication ..................................................................................................... 101
3.5.3 Data Acquisition .............................................................................................................. 107
3.5.4 Maintenance ................................................................................................................... 113
3.5.5 Measurement of the Total Consumption......................................................................... 115
3.5.6 Calibration and Adjustment............................................................................................. 119
3.5.7 Service ............................................................................................................................ 127
3.6 Terminal Mode...................................................................................................................... 135
Product Guide
4 Maintenance and Troubleshooting.............................................................................. 137

4.1 Maintenance Schedule ......................................................................................................... 137
4.1.1 Weekly Maintenance....................................................................................................... 137
4.1.2 Maintenance Tasks by Maintenance Indication .............................................................. 137
4.2 General Maintenance and Operation Tasks......................................................................... 138

4.2.1 Drain Device ................................................................................................................... 138
4.2.2 Fill Device ....................................................................................................................... 138
4.2.3 Zero Consumption Measurement ................................................................................... 139
4.2.4 Check Emergency Stop Relay ........................................................................................ 140
4.2.5 Check Pressure Regulator.............................................................................................. 140
4.3 Replace Components ........................................................................................................... 140

4.3.1 Fuel Pump Standard M20 ............................................................................................... 141
4.3.2 Fuel Pump Alcohol-Resistant M100................................................................................ 142
4.3.3 Pressure Regulator ......................................................................................................... 143
4.3.4 Float Switch Standard M20............................................................................................. 144
4.3.5 Float Switch Alcohol-Resistant M100 ............................................................................. 144
4.3.6 Flow Sensor .................................................................................................................... 144
4.3.7 Tank Level Sensor .......................................................................................................... 145
4.3.8 Fill Valve ......................................................................................................................... 146
4.3.9 Controller Board.............................................................................................................. 147
4.3.10 Filter Mat ......................................................................................................................... 147
4.4 Check of Safety Equipment .................................................................................................. 148

4.4.1 Check Compressed Air Switch ....................................................................................... 148
4.4.2 Check Overflow Float Switch .......................................................................................... 148
4.5 Overview of Errors................................................................................................................ 149

4.5.1 Error Messages............................................................................................................... 149
4.6 Error Diagnosis..................................................................................................................... 152

4.6.1 Valve Positions and Pump States................................................................................... 152
4.6.2 Defective Function .......................................................................................................... 152
4.7 Wear and Spare Parts .......................................................................................................... 154
4.8 Controller Board ................................................................................................................... 158

4.8.1 Circuit Diagrams ............................................................................................................. 161
4.9 Wiring Diagrams ................................................................................................................... 164
5 Technical Data ............................................................................................................... 167

5.1 CE-Compliance .................................................................................................................... 170
6 Appendix ........................................................................................................................ 171

Index............................................................................................................................................................ 175
Product Guide
Product Guide
What You Should Know 13
1 What You Should Know

The present documentation describes the AVL Fuel Mass Flow Meter.
1.1 Safety Instructions

This documentation contains a number of important warnings and safety
instructions which must be observed by the user. Smooth operation is only
ensured if the necessary prerequisites and safety measures are kept.
1.2 Intended Application

The product is only intended for the area of application which is described in the
documentation. If used contrary to its intended purpose or if the requirements
and safety measures mentioned are not observed, no guarantee and/or liability
shall be assumed.
1.2.1 Typographic Conventions

Safety messages:
WARNING
WARNING indicates a hazardous situation which – if not avoided – could result

in death or serious injury.
CAUTION
CAUTION indicates a hazardous situation which – if not avoided – could result in

minor or moderate injury.
Additional safety symbols:
Voltage hazard warning
Additional messages:
NOTICE
This text indicates situations or operation errors which could result in property
damage or data loss.
Product Guide
14 What You Should Know
Information
This text indicates important information or operating instructions. Not observing

these instructions could inhibit or impede you from succesfully completing the
tasks described in this documentation.
Standard text styles:

Bold Parameters; control elements in windows and
dialog boxes; important text
Italics Cross-references; foreign-language or new
terms; wild-card for elements that need to be
entered by the user, i.e. characters or text. If you
read, for example, macro name, you are required
to type the name of a macro.
UPPERCASE LETTERS Operating modes
Courier Programming examples; source code
Times New Roman Formulas
Menu | Option Description of how to select a menu item from a
given menu
Lists:
1. Step-by-step procedures with a given sequence
2.
• One-step instructions
Unordered series of concepts, items or options
–
–
1.2.2 We Want to Hear from You

Your comments and suggestions help us to improve the quality and practical
relevance of our manuals.
If you have any suggestions for improvement, please send them to:
docu@avl.com
We look forward to hearing from you!

Installation Instructions 15
2 Installation Instructions
This section covers the following topics:
General on page 15
Scope of Delivery on page 15
Installation at the Test Bed on page 22
Hydraulic / Pneumatic Integration on page 30
Electrical Connection on page 40
Connecting the Options on page 57
First-Time Start-up on page 62
2.1 General
These installation instructions describe the prerequisite conditions as well as
each individual steps for a successful installation and commissioning of the AVL
Fuel Mass Flow Meter.
This documentation also relates to the fuel conditioning device AVL Fuel
Temperature Control – for further information refer to the corresponding Product
Guide.
2.2 Scope of Delivery
Information
There are two types of the device AVL 735S:

Type Standard = Type 7351CST (ST = Standard)
(Otto and diesel fuels, alcoholic mixtures up to 20 %)
Type FlexFuel = Type 7351CME (ME=methanol/ethanol)
(Otto and diesel fuels, alcoholic mixtures up to 100 % and biomass fuels)
The type can be identified at the type plate of the device (see Fig. 1).
Please absolutely make sure that only the appropriate spare parts may be used
for the type 7351CME: Type "alcohol-resistant" (M100).
Fig. 1
2.2.1 Basic Device

The following accessory is contained in the scope of delivery of all device varia-
tions, whereby the number of accessory parts differs depending on the device
variation. See also Wear and Spare Parts on page 154.
Product Guide
Description Number
(min. 2 ×) Serial cable RS232 BV2431
(interface cable, 15 m)
(min. 1 ×) Analog cable BV2432
(BBY signal cable, 15 m)
(min. 1 ×) Digital I/O cable (15 m) BV2266
(min. 1 ×) Emergency stop cable (15 m) BV2573
(min. 2 ×) 25-pin panel jack EU0033
(min. 2 ×) 9-pin panel jack EU0930
(min. 2 ×) 9-pin panel plug EU1511
(min. 2 ×) 25-pin cap EU1145
(min. 2 ×) 9-pin cap EU1228
1 × 8-pin cable plug EU1458
1 × Product guide AT1442E
1 × Test protocol —
1 × Test Certificate —
1 × Checklist AT1670
1 × CD-ROM PC software XF0163
1 × CD-ROM documentation and software PA0713
Tab. 1

2.2.2 Options
This section contains a listing of the optional equipment for the operation with
AVL 735S.
Example 735S
9 3
1
4
7 6
1 .....Fuel supply line of type "standard" BH 0338, type "alcohol-resistant" BH 0340

2 .....Calibration unit TM0735CALA.02
3 .....AVL 735S Fuel Mass Flow Meter TM0735SA.01
4 .....Fuel supply and return line of type "standard" BH0336, type "alcohol-resistant" BH0341
5 .....Trolley TM0735TROA.01
6 .....Fuel venting valve BH0317
7 .....NPT connection set of type "standard" BH0339
8 .....Shutoff valve of type "standard" T 0735AVA.01, type "alcohol-resistant" TM0735AVM.01
9 .....Flame filter FF1 TM0730FF1A.01
Fig. 2
Product Guide
Example
735S + 753C
15 2
12
17
4
13
8
16 9
14
5
18 10
11 6
1 .... Calibration unit TM0735CALA.02

2 .... AVL 735S Fuel Mass Flow Meter TM0735SA.01
3 .... Flame filter FF1 TM0730FF1A.01
4 .... Engine return line pressure control TM0735PR3A.01
5 .... Engine supply and return line pressure control TM0735PR2A.01
6 .... Engine supply line pressure control TM0735PR1A.01
7 .... Fuel supply and return line of type "standard" BH0336, type "alcohol-resistant" BH0341
8 .... Metal return line filter of type "alcohol-resistant" TM0735CRFMA.01
9 .... AVL 753C Fuel Temperature Control TM0735CA.01
10 .. Water supply and drain line BH0335
11 .. Trolley TM0735TROA.01
12 .. Shutoff valve of type "standard" TM0735AVA.01, type "alcohol-resistant" TM0735AVM.01
13 .. System flow 150 liters/hour
14 .. System flow 500 liters/hour
15 .. Fill pump module TMFILLPUMP.01
16 .. NPT connection set of type "standard" BH0339
17 .. Fuel supply line of type "standard" BH0338, type "alcohol-resistant" BH0340
18 .. Chiller Unit TMWIL3200W.01
Fig. 3

2.2.2.1 Calibration Unit

This option is used for the calibration of the AVL Fuel Mass Flow Meter.
Description Number
Calibration Unit TM0735CALA.02
Tab. 2
2.2.2.2 Power Supply

This external option serves as supply of the AVL Fuel Mass Flow Meter and has
to be mounted in an appropriate switch cabinet. If an AVL Fuel Temperature
Control (AVL 753C) is available, this option is not required.
Description Number
Power supply 24 V/10 A, 115/230 V AC TM0735P2A.01
Tab. 3
2.2.2.3 Shutoff Valve

This option interrupts the fuel supply of the AVL Fuel Mass Flow Meter. It is
controlled by the AVL Fuel Mass Flow Meter.
Description Number
Shutoff valve (including valve, plug, 2 screw
fittings, cable, hose pipe)
for standard fuels TM0735AVA.01
alcohol-resistant TM0735AVM.01
Tab. 4
2.2.2.4 Flame Filter

The flame filter is an attachment at the end of the venting line, which in case of
fire prevents the ignition of the fuel-air mixture in the venting line and the AVL
Description Number
Flame Filter TM0730FF1A.01
Tab. 5
2.2.2.5 Fine Filter

Fuel filter in the inlet with a cross-sectional area of c. 590 cm².
Description Number
Fine filter 25 µ for standard fuels TM0730FE1A.01
alcohol-resistant TM0733F1MA.01
Tab. 6
Product Guide
2.2.2.6 Coarse Filter

Fuel filter in the return line with a cross-sectional area of approximately 590 cm²
Description Number
Coarse filter 60 µ for standard fuels TM0730FE2A.01
alcohol-resistant TM0733F2MA.01
Tab. 7
2.2.2.7 Remote Control
Description Number
Remote control AVL Fuel Mass Flow Meter / TM0735FA.02
AVL Fuel Temperature Control
Tab. 8
The following component is included in the scope of supply of the remote control
option:
Description Number
1 × Connecting cable (15 m) BV2191
Tab. 9
2.2.2.8 Trolley
This option allows one to mount the AVL Fuel Mass Flow Meter and AVL Fuel
Temperature Control on a movable trolley.
Description Number
Trolley TM0735TROA.01
Tab. 10
2.2.2.9 Fuel Filling Pump Module

This option serves as a fuel supply of the AVL Fuel Mass Flow Meter, if the
existing filling rate is too low.
Description Number
Fuel filling pump module TMFILLPUMP.01
Tab. 11
2.2.2.10 Venting Valve

This option is utilized, if the AVL Fuel Temperature Control is not used and the
fuel return of the engine has to be integrated. It can be used both for standard
fuels and alcohols.

Description Number
Venting valve BH0317
Tab. 12
2.2.2.11 Application Notes "Fuel Consumption Measurement"

This guide provides in-depth information on the installation and operation of the
AVL Fuel Mass Flow Meter on the test bed. An electronically readable version is
also available on the CD-ROM "Documentation and Software".
Description Number
Application Notes AT0802E
"Fuel Consumption Measurement"
Tab. 13
2.2.2.12 Fuel Supply Line

The fuel supply line option consists of a coarse filter (60 µm) and a fine filter
(25 µm). This option is installed into the fuel supply line and has a filter
cross-section of 590 cm2.
Description Number
Fuel supply line for standard fuels BH0338
Fuel supply line alcohol-resistant BH0340
Tab. 14
2.2.2.13 Fuel Supply and Return Line

The fuel supply and return line consists of two drain valves, a return line manom-
eter (0 - 2.5 bar) and a return line filter (60 µm).
Fuel supply and return line of type "standard" BH0336, type "alcohol-resistant"
BH0341
Coarse filter (60 µm) and fine filter (25 µm). This option is installed into the fuel
supply line and has a filter cross-section of 590 cm2.
Description Number
Fuel supply and return line for standard fuels BH0336
Fuel supply and return line alcohol-resistant BH0341
Tab. 15
2.2.2.14 NPT Connection Set

The NPT connection set option consists of connection nipples for the connection
of NPT threads of 3/8" and 1/2" diameter.
Product Guide
Description Number
NPT connection set for standard fuels BH0339
Tab. 16
2.3 Installation at the Test Bed
CAUTION
Danger of injury due to heavy weight and sharp edges

Bear in mind that during mounting there is a risk of injury due to the heavy
weight, the center of gravity and the sharp edges of the case.
CAUTION
Danger of injury from device due to risk of toppling over

If the AVL Fuel Mass Flow Meter has been rigged for a short-term period without
any fastening, the device cover may not be opened in any case – the device
would tip over.
Information
Please note also the following sections:

Measures to Prevent Fire and Explosion on page 26
Design of the Measurement Circuit on page 26
General Installation Guidelines on page 30
In addition, follow the instructions in the Application Notes "Fuel Consumption
Measurement" (Material No. AT0802E).

Total dimensions of the AVL Fuel Mass Flow Meter
770
667
324
683 342
530
770
Fig. 4
Transport The AVL Fuel Mass Flow Meter and the corresponding accessories will be deliv-
ered in an appropriate packing.
Information
Although the device has been drained, remainders of the test fuel can be in fuel
lines and containers.
1. Remove all sealing stoppers with which all connections are sealed.
2. Remove the transport lock of the flow sensor (see the figure below).
3. Position the transport safety guard at the output pressure gage correctly,
see Fig. 33 on page 59.
If the device has been stored below room temperature, let it be warmed up
to room temperature for several hours before commissioning the device.
The AVL Fuel Mass Flow Meter can be rigged at the test bed in various ways:
fixed wall mounting (preferred)
mobile on a movable trolley
In any case it can be used standalone as well as in combination with the AVL
Fuel Temperature Control.
Regardless of the mounting method the AVL Fuel Mass Flow Meter must be
installed free of vibrations – therefore it is recommended to mount it at a fixed
wall of the test bed.
Product Guide
NOTICE
Make sure that the bearing capacity of the wall is sufficient to allow for mounting
the device. The wall must be solid, fixed, even and totally perpendicular.
Allow 360 mm of free space above the mounting bracket for a fixed mounting at
a test bed (wall mounting).
After the AVL Fuel Mass Flow Meter is mounted, it has to be leveled with the
built-in box level. Thus, make sure that the mounting bracket is mounted as hori-
zontally as possible.
The AVL Fuel Mass Flow Meter may only be mounted and installed indoors.
In order to mount the device the mounting bracket has to be screwed off the
device.
1. Remove the upper fastening screw (1).
2. Loosen the securing screws (2) at the bottom of the device by positioning
the knurled lock nuts fully into the direction of the housing and by slightly
turning the hexagonal bolt outwards.
The following figure shows the fastening screws on the mounting bracket.
1 3
2 2
1 .... Upper fitting screws
2 .... Lower fastening screws (left and right)
3 .... Transport lock
Fig. 5
3. Lift the device off the mounting bracket.

To facilitate the mounting there are two lifting eyelets at the AVL Fuel Mass Flow
Meter on the top surface of the device.
NOTICE
Components, hoses or lines of the AVL Fuel Mass Flow Meter must not be used
for lifting the device because of the risk of damage.

View from below:
216,5
175,5
140,5
121,5
85
66,5
75
45
96
113 71,5
138 101,5
163,53
189,25 215
321,5
430
Fig. 6
Side view:
1
79,5
53,5
2
1 .....Assembly Drilling of the Mounting Bracket
2 .....Fuel Connections
Fig. 7
Product Guide
2.3.1 Design of the Measurement Circuit

It is preferable to utilize stainless steel pipes (with an inside diameter of 10 mm).
Information
Utilize armored hoses for flexible connections. If you apply teflon hoses, you
should only use technically conducting PTFE hoses with metal coating.
There are adaptor kits available for the connection of the systems AVL Fuel
Mass Flow Meter and AVL Fuel Temperature Control.
2.3.2 Measures to Prevent Fire and Explosion

The AVL Fuel Mass Flow Meter is suitable for operation with diesel or gasoline
and, in case of the alcohol-resistant version, with methanol, ethanol, biofuels and
mixtures of these fuels.
In the event of faults (leakages), these fuels can form an ignitable fuel-air
mixture.
WARNING
Danger of explosion
hermetically.
alcoholic mixtures!
A typical combustion engine achieves during normal operation an exhaust

temperature which is higher than the ignition temperature of these mixtures
(e.g. ignition temperature of gasoline: ≥260 °C).
Therefore these test beds require provisions against explosions.
Among other safety devices, test beds contain a suction unit with an air
exchange capacity of 30 to 150 times of the room volume per hour and a
negative pressure of 30 to 50 Pa. A lock circuit allows to switch on the
power supply of the test bed only after a certain lead time of the fan;
at least one gas sensor attached at the lowest point of the test bed.
This sensor will be adjusted with standard gas in order to issue a warning at
20 % of the inflammable concentration of the used fuel and to shut down the
fuel supply at 40 % via a safety valve (closing without electricity/without
compressed air).

The AVL Fuel Mass Flow Meter is also involved in the provisions:
The fuel circuit in the AVL Fuel Mass Flow Meter has to be leak-tight due to
functionality reasons. The leak-tightness is checked during assembly.
Normally a surface temperature of 260 °C cannot be reached inside the device,
the isolation of the built-in electrical components would be destroyed much
earlier.
2.3.3 Combination of AVL Fuel Mass Flow Meter and AVL Fuel Temperature Control
Space requirement of the mounting brackets for the installation of AVL Fuel
Mass Flow Meter with AVL Fuel Temperature Control
360
~400 50 430 50 >350
50
494
150 250
Ø12
A B
165
1566,5
811
E
45,5
C 215 D
430
>345
530
Fig. 8
1 Bracket AVL Fuel Mass Flow Meter

2 Bracket AVL Fuel Temperature Control
3 Floor
A…E Mounting borings of the bracket AVL Fuel Temperature
Control
(A, B, and D for wall mounting, A, B, C, and E for mounting
on the trolley)
All mounting borings for screws Ø 10 mm
Product Guide
Information
The devices AVL Fuel Mass Flow Meter and AVL Fuel Temperature Control must
be installed in the specified vertical distance.
2.3.4 Single Mounting of the AVL Fuel Mass Flow Meter

Space requirement of the mounting bracket of the AVL Fuel Mass Flow Meter
360
110 ~150 50 430 50 ~250
50
494
Ø12
120
430
530
Fig. 9
All mounting borings for screws Ø 10 mm
2.3.5 Mounting on the Trolley

If the AVL Fuel Mass Flow Meter (also in combination with the AVL Fuel Temper-
ature Control) is not to be mounted fixed, but has to be mounted on the trolley,
note that:
Trolley and device require a base of at least 850 × 770 mm, the height is
1978 mm.
CAUTION
Danger of injury from device due to risk of toppling over

Bear in mind that a device on the optional trolley might tip over during transport!
The AVL Fuel Mass Flow Meter must not be mounted standalone on a trolley
because of a high risk of tipping over. Thus, use only the combination with the
AVL Fuel Temperature Control.
Information
The trolley has to be placed free of vibrations! Make sure that the trolley is
placed on an even base.
Fit the mounting bracket with the enclosed mounting material to the borings of
the trolley.

2.3.6 Fixing the Device to the Mounting Bracket
NOTICE
Components, hoses or lines of the AVL Fuel Mass Flow Meter must not be used
for lifting the device because of the risk of damage.
1. Lift the device into the mounting bracket.

2. Fix the device using the fitting screws that have been unscrewed in
advance.
Information
A leveling of the device is only required if the option calibration unit is integrated.
Nevertheless it is recommended to level the device after mounting; see section
Leveling the AVL Fuel Mass Flow Meter on page 29.
2.3.7 Leveling the AVL Fuel Mass Flow Meter

A proper calibration of the AVL Fuel Mass Flow Meter requires a leveling of the
device with the box level at the tank foot. An incorrectly leveled device can result
in wrong measurements during the calibration or accuracy check.
2 3 4 2
1 .....Upper fitting screws
2 .....Lower fastening screws (left and right)
3 .....Tank foot
4 .....Box level
Fig. 10
Utilize the adjustment and fitting screws to level the system.
Product Guide
1 .... Tank foot

2 .... Box level
Fig. 11
1. Start leveling of the AVL Fuel Mass Flow Meter with the upper fitting screws
(x-axis).
2. Then align the device with the lower fitting screws (y-axis).
2.4 Hydraulic / Pneumatic Integration
2.4.1 General Installation Guidelines
NOTICE
Thermal expansion or contraction of fuel causes excess differential pressures in

stiff lines that are closed on either side, which in turn may lead to leaks or the
destruction of installed components. Use pressure surge tanks or relief valves to
prevent such pressure rises.
Information
Adhere to the local safety regulations (e.g. grounding of fuel lines …)!
Make sure that the fuel pipework and the system elements (filter,
pumps, heat exchanger) are abolutely leak-tight and sufficiently resis-
tant against the used fuels and pressures (recommended: 25 bar).
Keep the fuel volume in the measurement as small as possible.
Utilize absolutely pressure-proof pipes and system components in
order to keep the geometric volume constant.
Recommended pipe material:
– stainless steel
– metal-braided, electrically conducting teflon hoses for flexible connec-
tions

Ensure the following items to prevent leakages, venting problems and

local negative pressure (risk of the formation of vapor bubbles):
– fuel lines with the lowest possible flow resistance
– pipe bends instead of elbows
– changes of cross-sections are avoided
– screw fittings are avoided
– in case of contaminated fuels a fuel filter with sufficient filter area is
used: with a consumption of 100 kg/h approximately 300 cm²
– Prior to the assembly of the system, rinse the fuel lines and the system
elements with clean fuel
– Use the system elements (filter, heat exchanger) in correct assembly
position: they must be passed from top to bottom to ensure a safe
venting. Do not use any elements, at which a complete venting cannot
be ensured.
– Aim at a flow rate of the fuel in the range between 0.5 and 1 m/s.
the fuel constantly circulates in the measurement circuit in order to
ensure a good ventilation and/or transport of steam bubbles in the
venting vessel (bubble condenser). The specified values are good
compromise between sufficient bubble transport and low flow resis-
tance.
– Avoid line sections, which are not permanently passed (e.g. branch
lines to manometers or drain cocks …), or different arrangements of
the elements, which allow for a spontaneous escaping of bubbles into
the permanently passed lines.
Avoid fluctuations of the fuel temperature in the measurement circuit.
– Do not install the fuel pipes in parallel to heaters (e.g. exhaust pipes).
– Provide a thermal isolation of the fuel pipes.
– If required, attach a cooler: Electrically operated valves and pumps
heat up the fuel; especially at diesel engines, the fuel return line tem-
perature is very high and therefore a cooler must be attached in every
case.
– Ensure a constant fuel temperature: The fuel in the measurement cir-
cuit and in the supply line should have the same temperature to avoid
temperature changes due to the refilling of the measurement vessel.
Select the fuel temperature and the fuel pressure that the vapor pres-
sure is not reached at any location.
Install stop cocks at suitable positions to avoid the drainage of too
much fuel, e.g. during replacement of a fuel filter.
At least provide the following:
– Stop cock in the supply line
– Drain cock in the measurement circuit (supply)
– In order to check bubble-free operation, an area for a visual inspection
in the return line is very useful.
Product Guide
R>
Fig. 12
2.4.1.1 Frequent Causes for Apparent Measurement Errors

Mean fuel temperature change during measurement in the measurement
circuit
Formation of vapor bubbles in the measurement circuit present, particularly
at fuel with high vapor pressure. Possible Causes:
– Contaminated filters cause excessively low pressure
– Pumps in the measurement circuit cause excessively pressure on the
induction side
– Fuel temperature too high
Insufficient circulation of the fuel in the measurement circuit, thus no ventila-
tion or bubble condensation in the venting vessel.
System elements or pipe design allows for the accumulation of air or vapor
bubbles in the measurement circuit
Vibrations

2.4.2 Hydraulic Connectors
NOTICE
There must always be an appliance that interrupts the fuel supply in case of
errors.
If there is no corresponding mechanism available at the test bed, the shutoff
valve option has to be used.
The fuel line in has to have a fuel filter.
Draining the device via the drain cock as used in device type 7350 (see type
label) causes only a draining of the overflow tank with device type 7351.
Please follow the related instructions in section General Installation Guidelines

on page 30.
A C D B
K E
Fig. 13
A Fuel in Female thread G 3/8"

B Fuel to engine ARGUS conical nipple connector
R ½" for swivel nut with 60° cone
C Fuel return line ARGUS conical nipple connector
R ½" for swivel nut with 60° cone
D Venting Female thread G 3/8"
E Drain overflow tank (only after tank overflow)
ball valve with inside thread G 3/8"
K Compressed air Hose nozzle 9 mm
2.4.2.1 Fuel Supply

Make sure that the fill pressure is sufficiently high at the fuel supply line. For
standard values of the required fill pressure refer to the following table. The fill
rate should exceed the maximum consumption by at least 25 l/h.
Product Guide
NOTICE
The maximum pressure may not exceed 80 kPa in the fuel supply line. Espe-
cially pay attention to the pressure if you are using a fill pump.
If the existing fill pressure is too low, please utilize the "option fuel fill pump". If a
different fill pump is utilized, the flow rate of the pump has to be within the range
of 150 … 250 l/h.
A currentless shutoff valve must be installed in the fuel supply line between the
supply tank and the AVL Fuel Mass Flow Meter (see section Connecting the
Shutoff Valve (X1) on page 47).
The fuel fill pressures of the following table refer to an open fill valve in front of
the shutoff valve at ~25 °C and diesel fuel.
Pressure at Fill rate Maximum Maximum

opened fill valve [l/h] consumption consumption
[kPa] diesel [kg/h] gasoline [kg/h]
5,0 90 53 49
7,5 155 105 97
10,0 180 125 116
12,5 200 125 125
15,0 210 125 125
17,5 218 125 125
20,0 225 125 125
Tab. 17
2.4.2.2 Assembly of the Shutoff Valve Option

1. Connect the shutoff valve in the fuel supply line with a hollander or bulkhead
stuffing box (1/2" female thread) rigid to the pipework of the test bed.
Pay attention to the direction of flow and the length of the connected fuel
hose.
2. Screw on the fuel hose at the fuel supply connector with the pre-assembled
connector nipple.
3. Connect the compressed air supply with the shutoff valve.
– Cut the internal compressed air supply directly after the connection
nipple (see Shutoff Valve on page 57).
– Fit the supplied T-piece at that location.
– Insert the compressed air line (6 mm) from the T-piece to the pilot
valve. For this there is a bearing in the case bottom to lead in the com-
pressed air hose.
– Connect the plug of the shutoff valve in the fuel supply line to socket
X1.
2.4.2.3 Fuel Drain

If there is a fuel drain line at the location of the installation, connect this line to
the manual ball valve, which is fitted to the connector marked "Drain Overflow".

If there is still some fuel in the overflow tank after the error "Tank Overflow", you
have to drain the overflow tank with this valve (see Venting, Overflow on
page 35).
2.4.2.4 Venting, Overflow

In case of errors There can be an inadvertent leaking of fuel from the tank inside
the device. The leaked fuel will then be captured in an overflow tank inside the
device. In every case the venting line has to be connected to the venting line of
the test bed.
In case of a tank overflow, drain the overflow tank with the related drain
cock.
WARNING
Danger of explosion from explosive mixtures

The device may not be operated without connection to the venting line. For
safety reasons and if there is no fill pump in use, we recommend leading the
venting line above the level of the daily tank.
If the venting line ends in the test cell, we recommend providing a flame filter.
The flame filter is an attachment at the end of the venting line, which in case of
fire prevents the ignition of the fuel-air mixture in the venting line and the AVL
To prevent leaking of fuel at the location of the installation make sure that you
drain the overflow tank after each warning "Tank overflow".
Product Guide
AVL
Fuel Mass 2
Flow Meter
3 4
1 .... Roof venting to area free of danger

(ejection of fuel vapor)
2 .... Venting line
3 .... Drain line of the overflow tank
4 .... Venting line
5 .... Floor of test bed
6 .... Collection vessel
Fig. 14
Sizing of the For the sizing of the venting line, the following guidelines can be used:
venting line
Length of line Clear pipe diameter
up to 5 m 10 mm
up to 10 m 12 mm
up to 20 m 14 mm
Tab. 18
NOTICE
The maximum pressure drop in the venting line may not exceed 0.5 mbar at 400
l
/h air throughput.
The pressure at the venting connector affects the measurement circuit and thus
influences possibly also the mixture former.
An excess pressure of more than 0.2 bar can cause damage to the AVL Fuel
Mass Flow Meter.
Pressure changes due to venting of more than 0.5 mbar affect the venting of the
device negatively.

WARNING
Danger of explosion from explosive mixtures

An explosive mixture can be formed in the venting line and in the collection
vessel.
As, in case of fault, the venting line is also used as overflow line, it must be sized
appropriately.
At vertically arranged test beds the pipework must be provided such that the
overflow of a higher system does not inadvertently fill the lower venting lines!
The venting line must be implemented in every case technically leak-tight.
2.4.2.5 Combination of AVL Fuel Mass Flow Meter and AVL Fuel Temperature Control
If the AVL Fuel Mass Flow Meter is used in conjunction with the AVL Fuel
Temperature Control, a separate adaptor kit is available.
Product Guide
45
43
41
58
e b c a d 57
46 G
44
J A B
42
F E D C
H P
51
52 54
P P
60
53
48
F
E
49
50
Fig. 15
41 AVL Fuel Mass Flow Meter

42 AVL Fuel Temperature Control
43 Shutoff valve
44 Shutoff valve (optional)
45 Fuel tank
46 Ball valve (optional)
48 Bypass near engine
49 Engine (consumer)

50 Drain cock of the measurement circuit

51 Drain cock of the cooling-water circuit
52 Manometer cooling-water line in (0 … 6 bar) (optional)
53 Manometer cooling-water return line (0 … 6 bar) (optional)
54 Manometer fuel return line pressure (0 … 2 bar) (optional)
57 Fine filter 25 µm
58 Coarse filter 60 µm
60 Fuel filter 60 µm (optional)
A Fuel in
B Fuel return line (venting)
C Fuel from engine
D Fuel to engine
E Cooling-water inlet
F Cooling-water outlet
G Fuel feed-line (e.g. from a tank)
H Fuel collector drain
J Rest fuel drain
Hydraulic Connections at the AVL Fuel Mass Flow Meter:

a Fuel return line
b Fuel to engine
c Venting, overflow
d Fuel in (fuel inlet)
e Drain overflow tank
Fuel to Engine
Connect this outlet via the supplied hose with the connector fuel inlet at the
AVL Fuel Temperature Control.
Fuel Return Line
Connect this outlet via the supplied hose with the connector fuel return line
(venting) at the AVL Fuel Temperature Control.
2.4.2.6 Single Mounting of the AVL Fuel Mass Flow Meter

Fuel to Engine
Connect this outlet with the supply line of the engine.
Fuel Return Line
Connect this outlet with the return line of the engine.
If there is no return from the engine available, seal the return line with the
locking part (DN0524) and the swivel nut (DN0529) (not in the scope of
supply).
Product Guide
2.4.3 Connecting Compressed Air

Hose nozzle diameter 9 mm brass
Compressed Air 350 … 1000 kPa

Supply:
filtered
For the connection to the system refer to Hydraulic Connectors on page 33
NOTICE
Make sure that the device is permanently supplied with compressed air.
period in case of emergency during switching off the power supply (delayed
switching-off).
2.5 Electrical Connection
2.5.1 Power Supply
Operating voltage: 24 V DC ± 5 %
Current consumption: max. 10 A
If the AVL Fuel Mass Flow Meter is used in conjunction with the AVL Fuel
Temperature Control, the power supply has to be provided by the AVL Fuel
Temperature Control. An appropriate cable is part of the related adaptor kit.
If there is no AVL Fuel Temperature Control available, either the option power
supply or another power pack with secure power separating, which conforms to
the aforementioned specifications, can be used as power supply.
WARNING

Make sure that the device is supplied with the correct voltage. Connect
the device only if properly grounded!
It must be ensured that the device is connected to the test bed's ground. The
central location for grounding is right on the bottom outside of the device.
Utilize only power supplies with secure separation of the power pursuant DIN
VDE 0551!
A "secure separation of power" is provided, if in case of internal errors the output
voltage can be securely limited to 50 V~ by appropriate circuit provision.
Transformer must conform to VDE 0551, clocked power supplies must conform
to VDE 0160.
period in case of emergency while switching off the power supply (delayed
switching-off).

2.5.1.1 Connecting the AVL Fuel Mass Flow Meter With the Option Power Supply
2
AVL
3
Fuel Mass
Flow Meter 4
1
1 .....Included supply line (15 m)

2 .....+ Wire (red)
3 .....- Wire (black)
4 .....Ground (yellow/green)
5 .....Power supply
Fig. 16
2.5.2 Emergency Stop (X7)
WARNING

The emergency stop switching device must fulfill the requirements
pursuant to the implementation of safety circuits (EN 60204-1).
The AVL Fuel Mass Flow Meter can be integrated in two different ways:
Wiring without potential separation
(state of supplied device, jumper J17 in position 2-3)
Wiring with potential separation
(jumper J17 in position 1-2)
Product Guide
Wiring without potential separation (state of supplied device)

(Jumper J17: 2-3)
+24 V
F5
0.5 A X7
1
2
1
2
3
J17
1 .... Emergency stop

Fig. 17

(Jumper J17: 1-2)
X7 0.5 A
1
2
1
2
J17 3
3
1 .... Emergency stop

Fig. 18

Main board, position of jumper J17
1 2
1 .....Jumper J17
2 .....Device front side
Fig. 19
Information
The supplied cable (emergency stop cable, Material No. BV2573) is designed for
the wiring without potential separation. For an integration with potential separa-
tion the pin assignment has to be changed.
The figure below shows the emergency stop cable,
the view 1 shows the solder side of the socket.
S
+24 V
Sig.
1
22 1
33 3 1
1 .....Connection to AVL Fuel Mass Flow Meter (X7)

2 .....Emergency stop cable, Material No. BV2573
3 .....Connect the screen throughout with the connector housing
Fig. 20
Pin Color Description

1 White +24 V
2 Brown Signal
3 Not used
Tab. 19
Product Guide
2.5.3 Device Integration with AVL Fuel Temperature Control (X2)

1. Connect both devices (AVL Fuel Mass Flow Meter socket X2 and AVL Fuel
Temperature Control socket X3) with the supplied Sync cable (Material No.
BV2434).
2. If the supply of the AVL Fuel Mass Flow Meter is provided by the AVL Fuel
Temperature Control, connect both devices (AVL Fuel Mass Flow Meter
socket X8 and the AVL Fuel Temperature Control socket X8) with the sup-
plied power cable 753C-735 (Material No. BV2436), which is included in the
adaptor kit.
3. In order to ensure certain functioning of the fuel system in conjunction with
the AVL Fuel Temperature Control, the trigger mode of venting has to be set
to "during signal 'venting request + …'" at the AVL Fuel Temperature Con-
trol (see Product Guide of AVL Fuel Temperature Control).
Information
The option venting valve cannot be used in conjunction with the AVL Fuel
Temperature Control.
2.5.4 Interfaces
10
11
Fig. 21
1 Mains Switch POWER

2 Type plate (serial no., revision,
CE-Logo)
3 Connection of shutoff valve in EXT. VALVE (X1)
fuel supply line

4 Synchronization interface fuel SYNC (X2)

meter appliance
5 Serial interface COM1 (X3)
6 Serial interface COM2 (X4)
7 Digital inputs and outputs DIGITAL I/O (X5)
8 Analog output ANALOG OUT (X6)
9 Emergency stop input E-STOP (X7)
10 24 V direct voltage power supply SUPPLY 24 V DC (X8)
11 Connection for external
grounding cable (bottom)
2.5.5 Digital Control Lines

Output DEVICE OK (X5)
This output is active if the AVL Fuel Mass Flow Meter is able to convey fuel, i.e.
there was no critical error and the device is in state STBY. The output can be
connected at the input for sum errors of the test bed's engine monitoring.
Information
Changes from device type 7350 to 7351 (see type plate)

At the wiring of the outputs without potential separation (switch S1 on position 1)
pins 2/6/7/8 have +24 V DC on the digital I/O connection (X5).
Input SET DEVICE OK (X5)

This edge-triggered input sets the AVL Fuel Mass Flow Meter during serial and
hybrid control with active edge into the state STBY.
If this warning is active (and the device is in state Pause), the fault can be
acknowledged by reapplying an active edge, thus switching the device into the
state STBY.
Here it has to be ensured that the media (fuel, compressed air) have to be avail-
able while an active edge is sent to input SET DEVICE OK (X5), because other-
wise the measurement device could be damaged (dry running of fuel pumps).
Input SET VENTING (n-min) (X5)

An active edge triggers the time-controlled venting operation mode provided that
the device is in state STBY (otherwise, this signal will be ignored).
This input can be connected to the "n-min" signal of the test bed if the AVL Fuel
Mass Flow Meter is used without AVL Fuel Temperature Control – this ensures
that after each start of the engine a venting is performed.
Information
If the AVL Fuel Mass Flow Meter is combined with the AVL Fuel Temperature
Control, the system venting is controlled by the AVL Fuel Temperature Control –
therefore this input may not be used in this case.
Product Guide
2.5.6 Integration via AK Protocol

Device control and parameter configuration is accomplished via the serial inter-
face (AK protocol).
Recommended connections for control via the AK protocol:
Ext. Valve (X1): Shutoff valve

COM1 (X3): Test Bed Computer / PC / Remote
Control
Digital I/O (X5):
– Input SET DEVICE OK

If required, the input SET DEVICE OK (X5) can be used to switch to
the state STBY in a simple way. An active edge at this input transfers
the device from state Pause or Drain into the state STBY.
– Output DEVICE OK
– Input VENTING (possibly n-Min signal), only if the AVL Fuel Mass Flow
Meter is operated without AVL Fuel Temperature Control.
E-STOP (X7) Emergency stop switch device
NOTICE
Make sure that the media (fuel, compressed air) are available while an active
edge is sent at the input SET DEVICE OK (X5), because otherwise the measure-
ment device could be damaged (dry running of the fuel pump).
2.5.7 Hybrid Integration

The integration of the AVL Fuel Mass Flow Meter via hybrid control allows for a
control of the most important functions of the device with digital inputs. The data
sampling is done via the analog output of the device. But only the instantaneous
value of the flow rate is available.
Information
The assigning of the device parameters (measurement parameter, venting time

…) can only be achieved via the serial interfaces.
Analog Output
The measurement value (depending on the selected domain mass, volume or
volume API) is available as analog voltage:
0 … 10 V correspond to 0 … 125 kg/h or 0 … 125 l/h
(default values; can be parameterized)
The permissible value range for 0 V is –50 … 200 kg/h or l/h,
the parameterized value for 10 V must be at least 10 kg/h or l/h higher than the
parameterized value for 0 V.
The data rate of the analog output is 20 Hz.
During connecting, note that the integration of the data sampling may only be
accomplished without grounding (differential), otherwise the measurement signal
can be disrupted.

Recommended connections with hybrid control:
Ext. Valve (X1): Shutoff valve

Digital I/O (X5):
– Input SET DEVICE OK

– Output DEVICE OK
– Input VENTING (n-min), only if the AVL Fuel Mass Flow Meter is oper-
ated without AVL Fuel Temperature Control.
ANALOG OUT (X6): Analog output

E-STOP (X7): Emergency stop switch device
Information
If there is no valid measurement value available, the analog output shows a

voltage of 10.5 V.
2.5.8 Connecting the Shutoff Valve (X1)
NOTICE
If there is a failure of the compressed air supply or an overflow of the tank inside
the device, it has to be ensured that the fuel supply is interrupted. Therefore a
shutoff valve has to be provided.
The activation is electrically triggered via the output EXT. VALVE (X1).
This output is switched with a currentless open relay. The internal activation of
the relay is done by a float switch.
This connection can be actuated with max. 60 VA (at max. 60 V).
For third party valves, an additional power supply has to be provided, as shown
in the following figure. If necessary, provide a free-wheeling diode to keep
voltage spikes away from the device board.
Socket EXT. VALVE (X1),
the socket is shown viewed from the plug.
7 8 6
3 1
5 2 4
Fig. 22
Product Guide
Connection Pin Color Description

(material no. cable)
Ext. Valve X1 (8-pin 1 — Isolated relay connection
cable plug EU1458)
2 — Isolated relay connection
3 — Wiring without potential
separation (+24 V DC,
max. 10 W)
separation (ground)
Tab. 20
The shutdown valve option (TM0735AVA.01 / TM0735AVM.01, see section

Shutoff Valve on page 57) can be connected directly with this connector without
external voltage supply.
If an existing shutoff valve has to be controlled with the output EXT. VALVE (X1),
there is an isolated relay connection at pin 1/2 at connection EXT. VALVE (X1)
available.
At pin 3/4 there is a wiring without potential separation (24 V DC), the switching
capacity is c. 10 W.
Use the supplied 8-pin cable plug (Material No. EU1458) for the connection at
output EXT. VALVE (X1).
2.5.9 Serial Interfaces (X3/X4)

Depending on the integration type, the following control systems can be
connected via the serial interfaces COM1 and COM2 of the AVL Fuel Mass Flow
Meter:
Test bed automation system
(preferably at COM1 of the AVL Fuel Mass Flow Meter)
PC
Remote Control

Connection via serial interface:
AVL Fuel Mass Flow Meter
DIGITAL
ANALOG COM2 COM1
I/O
1
2 3
X1 X2 X3 X4 X5
POWER COM 2 COM 1 EXTERN COM 0
! GRAZ
AUSTRIA
FOLLOW THE DIRECTIONS! DON´T
OPERATE THIS INSTRUMENT IN
Type S/No
EXPLOSIVE HAZARDOUS LOCATIONS!
THE OPENING OF THIS DEVICE IS Rev
PERMITTED ONLY BY AUTHORIZED
TRAINED PERSONNEL!
1 .....Connecting cable remote control

(15 m, Material No. BV2191)
2 .....Cable (15 m, material number BV2431)
3 .....Test Bed Automation System or PC
Fig. 23
Interface Parameter
Baudrate 9600
Databits 8
Stopbits 1
Parity none
Handshake: none
Tab. 21
Pin Assignment
Pin 1 RxD
Pin 2 TxD
Pin 3 Ground
Pin 4 Ground Supply for remote control
Pin 8 +24 V
Tab. 22
Product Guide
Pin configuration of the RS232 Interface, the socket is shown viewed from the
plug.
7 8 6
3 1
5 2 4
Fig. 24
Pin Connection:
8-Pin Plug 9-Pin 25-Pin 9-Pin Plug

Serial Cable RS232 Socket Socket
1 (RxD) brown 3 (TxD) 2 (TxD) 2 (TxD)
2 (TxD) green 2 (RxD) 3 (RxD) 3 (RxD)
3 (GND) white 5 (GND) 7 (GND) 5 (GND)
AVL Fuel Mass Flow PC PC Remote Control
Meter
Tab. 23
2.5.10 Digital I/O (X5)

Depending on the planned type of integration of the AVL Fuel Mass Flow Meter
some of the herein quoted digital control lines are required to operate the device.
If necessary, the input SET DEVICE OK can be connected.
The digital interface "Digital I/O" consists of 3 digital inputs and 3 digital outputs,
which are led by an opto-coupler and therefore totally indirect-coupled and sepa-
rated from the remaining electronics (but not among each other). If a potential
separation is not required, e.g. by using relays or opto-coupler, the internal
power supply can be utilized allowing for a simpler wiring. The switching is done
on the board with the switches S1 and S2.
NOTICE
Ensure the correct position of the switches S1/S2 according to your application
before wiring the digital inputs and outputs.
If the outputs are wired without potential separation (switch S1 in position), pin
2/7/8 of the connection digital I/O (X5) can have +24 V DC.

2.5.10.1 Digital Inputs

(Switch S2: position 2)
S2 / Pos 2
1; 4; 5
(+)
6
(-)
5 4 3 2
Fig. 25
"0" U < 0.5 V

"1" U = 4.5 … 30 V
(Imax = 3 mA)

(Control with potential-free contacts)
S2 / Pos 1
1; 4; 5
6
+24 V
6 5 2 1
Fig. 26
"0" Switch open

"1" Switch closed
permissible voltage drop: 0.5 V
(Imax = 3 mA)
2.5.10.2 Digital Outputs
C_OUT/+24 V (Pin 3) Common reference potential for each of

the 3 outputs.
On wiring without potential separation:
+24 V
Maximum permissible current: 25 mA
Product Guide

S1 / Pos 2
2; 7; 8
....
3
5 4 3 2
Fig. 27

S1 / Pos 1
2; 7; 8
....
3
+24V
+24 V
6 5 2 1
Fig. 28
Logic assignment
"0" Normally open relay contact

"1" Normally closed relay contact
A suitable cable (digital I/O cable, Material No. BV2266) is available for the
connection to the digital I/O socket.
Pin / color assignment of the digital I/O cable:

1 White Input SET DEVICE OK
2 Brown Output "reserved"
3 Green Common connection for outputs
4 Yellow Input "reserved"
5 Gray Input SET VENTING
6 Pink Common connection for inputs
7 Blue Output DEVICE OK
8 Red Output "reserved"
Tab. 24

The socket is shown viewed from the plug:
7 8 6
3 1
5 2 4
Fig. 29
2.5.11 Analog Interface (Analog Output of the Measurement Value)

The measurement value is indicated as analog voltage (0 … 10 V):
In state STBY, the continuous measurement values are available at the analog
measurement output, the data rate is 20 Hz.
The response time (measurement damping) depends on the setting of the
internal damping. The shortest response time can be obtained with a damping of
0.0 s.

1 Brown Output measurement signal 0 …10 V
2 White Ground
Tab. 25
For pin assignment, see Digital I/O (X5) on page 50.
Information
Make sure that none of the poles of the analog output is grounded, because this
could cause interference at the analog output.
Integrate the analog output differentially into your data aquisition.
Product Guide
2.5.12 Overview Pin Assignment

(Material No. Cable)
Power supply X8 1 Red +24 V DC line
(complete cable set: BK0350) 2 Black – line
4 Yellow/green Ground
Ext. Valve X1 1 — Isolated relay connection
(8-pin cable plug EU1458) 2 — Isolated relay connection
3 — Wiring without potential sepa-
ration (+24 V DC, max. 10 W)
4 — Wiring without potential sepa-
ration (ground)
COM1/2 X3/X4 1 Brown RxD
(BV2431) 2 Green TxD
3 White Ground
4 — Ground for remote control
8 — +24 V for remote control
Digital I/O X5 1 White Input SET DEVICE OK
(BV2266) 2 Brown Output "reserved"
3 Green Common connection for all
outputs
4 Yellow Input "reserved"
5 Gray Input "SET VENTING"
6 Pink Common connection for all
inputs
7 Blue Output "DEVICE OK"
8 Red Output "reserved"
Analog X6 1 Brown Signal 0…10 V
(BV2432) 2 White Ground
E-STOP X7 1 White Potential-free contact
(BV2573) 2 Brown Potential-free contact
3 — Not used
Tab. 26
2.5.13 Device Configuration

The following settings have to be carried out at the device (by means of a DIL
switch).
Both DIL switch blocks S3 and S4 are located on the main board.
Information
Changes of the DIL switch settings only take effect after a reset of the devices.

1 .....DIL switch block S3

2 .....DIL switch block S4
3 .....Device front side
Fig. 30
Information
In the shipment configuration the DIL switches DIL2 through DIL8 of the DIL
switch block S3 are in the OFF position.
The DIL switches DIL1 through DIL8 of the DIL switch block S4 are in the OFF
position.
With the DIL switch block S3, the following device parameters can be set:
Device Type DIL1

Device for standard fuels (CST) Off
Device alcohol-resistant (CME) On
Tab. 27
The AVL Fuel Mass Flow Meter offers a simple method for achieving measure-
ment readiness / state STBY. Immediately after switching on the device tries to
get into the state STBY. The automatic procedure is called Auto-STBY.
Product Guide
Operation with Auto-STBY DIL5

Device function standard (Power On → Pause) Off
(default)
Device function with Auto-STBY On
(Power On → Pause → STBY)
Tab. 28
WARNING
Leaking of fuel
When utilizing the AVL Fuel Mass Flow Meter with the Auto-STBY function,
please ensure that the device gets into the state STBY via the Pause state after
the device is supplied with voltage. With that a fuel pressure is built up and the
fuel is conveyed.
Do not use this device function if it gives rise to safety risks (e.g. because of
leaking fuel).
Function Bypass
Device Function Bypass DIL8

Device function standard Off
(default)
Device function Bypass (no consumption measurement, On
fuel supply is unpressurized)
Tab. 29
Information
The device function Bypass can only be set from the state Pause and the corre-
sponding DIL switch setting. Compressed air must be available and the emer-
gency stop circuit must be closed.
The DIL switches DIL2/3/4/6/7 of the DIL switch block S3 have no documented
function, they must be set to position Off. All DIL switches of the DIL switch block
S4 also have to be set to position Off.
The filter at the analog output (X6) can be varied with the jumper J19.
Filter Analog Output Jumper J19 J19

Filter slow Slow
1/2
(default)
Filter fast Fast
2/3
Tab. 30
The jumpers J16 and CONT1 have no documented function and must be set to
position 1/2.

Jumper J16 J16

Standard setting 1/2
(default)
Inadmissible setting 2/3
Tab. 31
Jumper CONT1 CONT1

Standard setting 1/2
(default)
Inadmissible setting 2/3
Tab. 32
2.6 Connecting the Options
2.6.1 Shutoff Valve
NOTICE
There must always be an appliance that interrupts the fuel supply in case of
errors.
If there is no corresponding mechanism available at the test bed, the shutoff
valve option has to be used.
If the test bed is equipped with a corresponding mechanism for interrupting the
fuel supply in case of failure, the output EXT. VALVE (X1) has to be connected
there.
Product Guide
2
8
7 6
3 1
4
1 .... Fuel inlet of the AVL Fuel Mass Flow Meter

2 .... Attach connection cable of shutoff valve to EXT. VALVE (X1)
3 .... Shutoff valve
4 .... Test bed pipework
5 .... T-piece
6 .... Rubber grommet (through the lead-in of the pneumatic line)
7 .... Compressed air line
8 .... Pilot valve
Fig. 31
1. Use the 8-pin cable plug EU1458 for the connection to EXT. VALVE (X1).
2. Wire the plug according to the following table.

(Material No. Cable)
Ext. Valve X1 (8-pin 1 — Isolated relay connection
cable plug EU1458)
2 — Isolated relay connection
separation (+24 V DC,
max. 10 W)
separation (ground)
Tab. 33

Pin configuration connector EXT. VALVE (X1),

the socket is shown viewed from the plug.
7 8 6
3 1
5 2 4
Fig. 32
2.6.2 Calibration Unit
2
1
1 .....Plug of the connecting cable (connected to calibration unit)

2 .....Calibration Unit
3 .....Venting screw
4 .....Quick releases
5 .....Transport lock
Fig. 33
Information
After a period of 18 months the calibration unit has to be sent to the relevant AVL
subsidiary in order to check the calibration.
Product Guide
1. The option calibration unit ("automatic accuracy check") has to be plugged

onto the related quick releases of the device.
If it is difficult to plug on the sensor due to manufacturing tolerances, adjust
the distance between the two connections exactly with the two eccentric
screws, as shown in the figure above.
2. The connecting cable to the AVL Fuel Mass Flow Meter is already provided
with the basic device – it has to be connected to the calibration unit.
3. After connecting the connection cable the device has to be set into the state
Pause. In this state the device automatically detects the existence of the
calibration unit.
Calibration unit with eccentric screws
1
1 .... Eccentric screws
Fig. 34
Information
To ensure a proper calibration procedure, the AVL Fuel Mass Flow Meter has to
be leveled (see Leveling the AVL Fuel Mass Flow Meter on page 29).
If the device is to be moved, the calibration unit has to be removed.
2.6.2.1 Venting of the Option Calibration Unit

Ensure sufficient venting of the calibration sensor before using the calibration
unit.
1. Open the front venting screw with a wrench (size 10); see Calibration Unit
on page 59).
2. Make sure that the escaping fuel is collected.
3. Wait until only fuel and no more air is escaping from the venting opening of
the calibration sensor.
4. Then lock the front venting screw.
5. Control the backside venting screw by opening and closing it shortly; no fuel
may be ejected here.

Information
Due to the exhalation of fuels it is also from time to time necessary, even after
the first-time installation, to ensure a sufficient venting of the calibration sensor
for a proper functioning of the calibration option.
With gasoline, the calibration unit has to be vented before each calibration
procedure (-point).
Before any transportation, the calibration unit has to be removed. We recom-
mend that the calibration unit is even removed before transportation with the
optional trolley. Make sure that the quick release couplers are centered when
plugging on the calibration unit.
2.6.3 Option Venting Valve

The 3/2-way venting valve has to be attached outside the AVL Fuel Mass Flow
Meter.
Information
For consumers without return flow, this option may be omitted. In that case, the
connection "fuel return (C)" has to be closed.
Mounting:
1. Connect the venting valve option to the connections "fuel to engine" and
"fuel return" of the AVL Fuel Mass Flow Meters an (see the figure below).
2. Connect the pneumatic outlet of the pilot valve with the air pressure supply
by the means of a T-piece.
3. Lead the air pressure conductor through the rubber bushing in the bottom of
the device.
4. Lead the cable through the secong rubber bushing into the device and con-
nect it with the circuit board on the upper left side.
5. Check that installation is successful:
– Switch the AVL Fuel Mass Flow Meter to operating state PAUSE.
– Drain the AVL Fuel Mass Flow Meter.
– The connections 2 and 4 in the figure below must be connected when
the pilot valve is not supplied with power.
When the pilot valve is supplied with power (bypass), connections 3
and 4 have to be connected.
Information
Allow 120 mm of free space above the mounting bracket for a fixed mounting at
a test bed (wall mounting).
Product Guide
3 6
5
4
1 .... Connect with the connection "fuel to engine" at the AVL Fuel Mass
Flow Meter
2 .... Connect with the connection "fuel return" at the AVL Fuel Mass
Flow Meter
3 .... Fuel supply of the engine
4 .... Fuel return from the engine
5 .... Servo control valve (pre-assembled)
6 .... Electrical connection cable of the servo control valve
7 .... T-piece
Fig. 35
2.7 First-Time Start-up
Information
Before each start-up, check whether all fuel lines which are required for oper-
ating are properly connected.
Make sure that the drain cock of the overflow tank is connected.
Check, whether the transport locks have been removed and are properly
aligned, see Installation at the Test Bed on page 22.
If the outputs are wired without potential separation (switch S1 in position), pins
2/6/7/8 of the connection digital I/O (X5) can have +24 V DC.
Information
The operation of the AVL Fuel Mass Flow Meter can be accomplished with a test
bed computer, the PC software, the remote control or a terminal program. In the
following comments these special circumstances will not be dealt with, but rather
the corresponding AK commands will be specified.

1. Make sure that the requirements of the section Installation at the Test Bed
on page 22 and Hydraulic / Pneumatic Integration on page 30 as well as the
related subsections are fulfilled.
2. If the AVL Fuel Mass Flow Meter is integrated with a hybrid interface, it is
recommended to temporarily connect the serial interface during the
first-time start-up and parameterization of the system.
3. If fuel and compressed air supplies are available, switch on the system.
It takes a maximum of 50 s until the device has completed the initialization
and the interfaces are ready for operation. After the initialization, the device
switches into the state Pause and performs an internal error check.
Now, you can check the communication with the device across the serial
interface (9600 Baud, 1 stopbit, no parity, 8 databits).
4. Enter the gravitational acceleration (g) for your location (can usually be
requested at the national calibration laboratories for force-measuring). (AK
command EKGP)
Warnings are indicated by slow flashing of the device. At the first-time
start-up (the device has not yet been filled) the error "Density too low"
should be indicated.
5. Start the first filling of the AVL Fuel Mass Flow Meter (AK command SFIL). If
the device has been parameterized to Auto-STBY, the device automatically
starts the first filling.
The device fills the internal tank completely with fuel. If due to excessively
filling pressure, the filling takes longer than 80 s, the error "Filling rate too
low" is set. In this case, recheck the pressure of the fuel inlet line and restart
the first filling.
After complete filling of the internal device tank, the device performs an
internal venting and remains in the state SFIL (permanent venting), until it is
transferred into another state.
Now, all warnings should have been reset.
Information
Ensure proper fuel supply when sending the command for the first filling.
The first filling can also be accomplished in the state STBY (AK command
STBY), but the venting has to be made manually. The state STBY may have to
be activated several times, because the device might be set into the state Pause
due to the warning "Density too low".
6. The filling of other fuel devices (e.g. fuel conditioning or engine circuit)
should be done during the internal venting in state SFIL. Always ensure a
good venting of all fuel lines before you switch the device into the state
STBY!
7. Now, you can switch the device into the state Pause (AK command SPAU).
Product Guide
8. If you want to adjust the output pressure regulator, switch the device into the
state STBY. Now, adjust the output pressure regulator of the AVL Fuel Mass
Flow Meter to the desired output pressure:
– Return line pressure in combination with a conditioning system
– Supply pressure in systems without return lines
If there is no calibration available for the used fuel, the warning "Adjustment
error" is shown, after the system switches into the state STBY for the first
time.
Make sure that the required minimum pressure of >0.05 bar is maintained!
The first-time start-up is now complete.
NOTICE
The device was subjected to a leak check prior to delivery. Caused by transpor-
tation or thermal stress, however, leakages may occur during the first operating
hours which could not be detected in a cooled-down system condition.
2.7.1 Drain / Rinse

Due to the device end tests before shipment, it can happen that residual test fuel
is still in the device. If the device is to be used with fuels other than diesel, it is
recommended to rinse the device with the respective fuel.
"Rinse" corresponds to repeated filling and draining of the device.
2.7.1.1 Drain
1. Switch the device into the state Pause or STBY.
2. Switch off the fuel supply (takes place automatically, if the option "shutoff
valve" is integrated).
3. Start the draining procedure (AK command SDRN) and ensure fuel con-
sumption (possibly by opening the drain lines in the AVL Fuel Temperature
Control).
After several minutes the device is drained and the device remains in this
operating state.
4. Now, drain any other devices (e.g. AVL Fuel Temperature Control).
Not all internal lines can be drained with this draining procedure:
return line inside device (~75 ml)
Drain these lines as well as the other fuel lines to and from the engine
through suitably positioned valves.
Information
The AVL Fuel Mass Flow Meter can also be drained by manually closing the fuel
inlet line in state STBY. The device will be drained, until the warning "Density too
low" appears.

User's Guide 65
3 User's Guide
3.1 Scope of Application and Intended Use

The AVL Fuel Mass Flow Meter and the thereby enabled continuous measure-
ment are applied in areas in which a permanent readiness for measurements is
very important: especially for cycle measurements on transient, dynamic test
beds or roller and oil test beds with long test runtimes, but also for the reduction
of the measurement times on steady-state test beds.
Due to the large measurement range (0 … 125 kg/h) all types of engines ranging
from one-cylinder engines to 500 kW engines can be supported without
changing the sensor.
The AVL Fuel Mass Flow Meter is prepared for the installation of a calibration
system – this allows a regular check of the measurement device according to
ISO 9001.
The standard version of the AVL Fuel Mass Flow Meter is suitable for operation
with gasoline and diesel fuels with up to 20 volume per cent of methanol and/or
ethanol. For pure methanol/ethanol fuels an alcohol-resistant version is avail-
able.
NOTICE
Fuel resistance:
Standard: Otto and diesel fuels, alcoholic mixtures up to 20 %
(corresponds to the short term M20 and E20)
FlexFuel: Otto and diesel fuels, alcoholic mixtures up to 100 %
(corresponds to the short term M100 and E100)
Intended Use According to the intended use, the AVL Fuel Mass Flow Meter 735S is suitable
for the highly precise measurement of fuel consumptions according to the tech-
nical specifications, particularly in areas with the demand of a permanent
measurement capability.
In particular, the device is suitable for the continuous measurement of flows of
liquid fuels (diesel fuel, Otto fuel, in the special version also for methanol and
ethanol as well as mixtures of them) to an emission location (consumer like
combustion engines, injection pumps and jets).
WARNING
Danger of explosion
According to the intended use, the AVL Fuel Mass Flow Meter 735S is not suit-
able for the measurement of flows of mixtures of two or more phases, such as
boiling fuels, immiscible liquids or precipitating particles or solids, even if these
are only formed by the physical conditions within the measurement circuit.
able to measure flows of gaseous media. Such a use represents a high safety
risk.
According to the intended use, the AVL Fuel Mass Flow Meter 735S may not be
operated in an explosion-endangered environment. The minimum requirements
of monitoring of these indoor rooms must be fulfilled, see Measures to Prevent
Fire and Explosion on page 26.
Product Guide
66 User's Guide
According to the intended use, the AVL Fuel Mass Flow Meter 735S has to be
mounted stationary or on a mobile trolley indoors and is usually used at
steady-state engine and vehicle test beds.
Information
An "on-board measurement" in moving vehicles is not provided!

The installation, commissioning, operation, maintenance and adjustment of the
AVL Fuel Mass Flow Meter 735S may only be performed by trained specialists,
who are aware of the associated risks.
able to monitor the connected measurement circuit (pipework) for leak-tightness
or line break.
3.2 System Description

This section covers the following topics:
General on page 66
Operating States on page 68
Data Acquisition on page 75
Calibration – Adjustment on page 75
Consumption Totalizers on page 81
Operating-hour Counter, Maintenance Limit on page 82
3.2.1 General
The AVL Fuel Mass Flow Meter is based on a Coriolis mass flow sensor –
allowing continuous measurements. The high sensitivity and precision is accom-
plished with a very small inside diameter of the sensor pipe, a pump in front of
the sensor produces the required pressure.
A pressure regulator in front of the sensor always adjusts the required pressure
for the corresponding fuel consumption, so that behind the sensor a constant
adjustable output pressure is available.
The following figure shows the AVL Fuel Mass Flow Meter in the state current-
less, compressed air available.

User's Guide 67
7
1 10
B
5 12
9 4
2
C
E 11 6
H
G
A
8
F
Fig. 36
Standard M 100
1 Tank level sensor
2 Fill valve
3 Float switch (overflow)
4 Fuel Pump
5 Stop valve
6 Pressure regulator
7 Flow sensor
8 Bypass venting valve
9 Drain cock overflow tank
10 Outlet pressure sensor
11 Inlet pressure sensor
12 Outlet pressure manometer
A Fuel in
B Fuel to engine
C Fuel return line
D Venting
E Drain overflow tank
F Shutoff Valve option TM0735AVA.01 TM0735AVM.01
G Venting valve option BH0317
H Calibration TM0375CALA.02
unit option
Product Guide
68 User's Guide
The following measured quantities can be provided by the AVL Fuel Mass Flow
Meter:
Mass domain
– Mass flow [kg/h]
Instantaneous value (10 Hz), time-averaged value during the set mea-
surement time, moving average on the number of measurements,
standard deviation of the mean time values of the set number of mea-
surements
– Accumulated mass flow per period = mass [kg]
Volume domain
– Volume flow [l/h]
Instantaneous value (10 Hz), time-averaged value during the set mea-
surements
– Accumulated volume flow per period = volume [l]
Volume domain/API
– Volume flow API (standard volume according to API-2540, standard-
ized at 15 °C) [l/h]
– Instantaneous value (10 Hz), time-averaged value during the set mea-
surements
– Accumulated volume flow API per period = volume [l]
In all domains
– Density [kg/m³]
– Fuel temperature in the AVL Fuel Mass Flow Meter
3.2.2 Operating States

The AVL Fuel Mass Flow Meter shows the following static operating states
("static" means that the device remains in this state, until it is switched to another
state):
Pause
STBY (and Auto-STBY)
Bypass
Service
Draining
Filling
The following operating states are called procedural. After completion of the
executed procedure the device returns to its original state.
Venting
Accuracy Check
Adjustment
In addition, there are initialization operating states. They are always called auto-
matically and shift as soon as possible to another operating state.
Init Pause
Init STBY

User's Guide 69
The following diagram shows the various operating states and their transitions.
In order to change from the state Pause to another state, the emergency stop
circuit must be closed. (You can only change to the state Service if the emer-
gency stop circuit is not closed.)
Power on
- AK: SRES
- Emergency stop
- No compressed air AK: SRES
Init Pause
From all states:
- AK: SPAU AK: SSRV
Pause Service
- System error
AK: SDRN
Pause AK: SRES
Draining
System Error
"Density too low"
- AK: STBY
- Emergency stop not interrupted + Reset
AK: SDRN
Setting On
S3 / DIL8
Bypass
AK: SFIL / SVNT

Off
Init STBY
Init STBY
AK: SVNT
STBY Venting
AK: STBY
AK: SATK
AK: SKCH
AK: STBY
AK: STBY
Accuracy
Adjusting
check
Fig. 37
Product Guide
70 User's Guide
3.2.2.1 Init Pause

After switching on or after a software reset (e.g. AK command SRES) the AVL
Fuel Mass Flow Meter takes up the state Init Pause for a maximum of 50 s.
Information
An active edge at the digital input SET DEVICE OK does not switch the AVL Fuel
Mass Flow Meter to the state Init Pause.
A communication via the serial RS232 interface (COM1 or COM2) is possible

within the specified time-out (COM1: 0.5 s, COM2: 2 s).
The following actions are carried out automatically by the AVL Fuel Mass Flow
Meter:
Initialization of the interfaces
Initialization of all device data
Preparation of the related valve settings
The following error conditions are checked during the state Init Pause:
15 Tank overflow
23 Error NV-RAM
26 Error flow sensor
27 Communication calibration sensor (if available)
28 Error EEPROM
29 General device error
30 Communication error flow sensor
31 Fan blocked
After completing the state Init Pause the AVL Fuel Mass Flow Meter changes to
the state Pause.
3.2.2.2 Pause
In the state Pause, the automatic fuel refill as well as the fuel pump is switched
off, therefore there is no outlet pressure available. The device does not generate
any measurement values.
The state Pause is always taken up statically. After switching on and exiting the
state Init Pause the device takes on at least temporarily the state Pause.
If DIL5 of switch block S3 is set to position "Off" (see also Auto-STBY on
page 72) or the emergency stop circuit is open, this state is static, i.e. the state
can only be changed by sending a related request to the device (e.g. AK
command STBY, closing the emergency stop circuit or an edge at input "Set
Device OK" at a statically closed emergency stop input).
If compressed air is available, an external venting is possible in this state, if not,
the related inputs are switched passive. The error "No compressed air" is not
activated in this state. The error is only activated when the change of state is
requested (e.g. AK command STBY via emergency stop).
Due to safety reasons the valves are in a state which allows a venting with an
external conditioning unit, but this is not recommended, because the internal
venting cannot be ensured.

User's Guide 71
In the state Pause the fuel circuit is switched pressureless via the internal tank.
Depending on the tank level, only the pressure of the column of the fuel is avail-
able.
The following errors are checked in the state Pause:
At entering the state Pause:
1 Maintenance limit pump
3 Maintenance limit fill valve
Every second:
9 No compressed air (set only at the attempt to change the
state)
11 Density too low
10 Hz cycle:
At occurrence:
15 Tank overflow
3.2.2.3 STBY
In the state STBY the AVL Fuel Mass Flow Meter provides all measurement
values that are available in the selected domain. The filling of the internal tank is
carried out automatically. The state is static and can only be left by transition to
another state.
A constant outlet pressure can be adjusted with the pressure regulator.
The state STBY can be called in the following ways (provided that: S3/DIL8 is in
position "Off"):
AK command STBY
Positive edge at input SET DEVICE OK, if the emergency stop circuit is
statically closed (from state Pause and Drain)
The following error conditions are checked during the state STBY:
In the transition phase after STBY:
7 Error adjustment
23 Error NV-RAM
28 Error EEPROM
Every second:
9 No compressed air
11 Density too low (will be reset 30 s after the start of the internal
venting)
13 Pump overload
14 Filling rate too low
10 Hz cycle:
Product Guide
72 User's Guide
Every hour:
At occurrence:
15 Tank overflow
3.2.2.4 Auto-STBY
If the Auto-STBY is activated (switch S3/DIL5 in position "On"), the AVL Fuel
Mass Flow Meter immediately after switching on attempts to change to the state
STBY.
Auto-STBY deactivated:
After switching on, the device changes to the state Pause.
STBY activated:
After switching on, the device changes to the state Pause and then to the
state STBY.
WARNING
leaking fuel
If the AVL Fuel Mass Flow Meter is used with the function Auto-STBY, please
make sure that the device changes to the state STBY via the state Pause as
soon as the device is supplied with voltage. This builds up a fuel pressure and
fuel is conveyed.
Do not use this device function if safety risks (e.g. from discharged fuel) could
arise.
3.2.2.5 Venting
In this state an internal venting of the device is carried out.
The state Venting can be reached from the states Pause and STBY.
Venting is a default procedural operating state, i.e. the device returns into
the original state after the set venting time. Here, only the AVL Fuel Mass
Flow Meter is vented internally.
In the state Venting the external fuel circuit (motor circle) is also vented with
the option venting valve.
If the venting is controlled via the AVL Fuel Temperature Control, the
external fuel circuit (motor circle) and the AVL Fuel Temperatur Control are
also vented.
Information
In the state Venting the AVL Fuel Mass Flow Meter is not able to provide the set
outlet pressure. The adjusted pressure at the outlet pressure regulator cannot be
maintained.
Make sure that no venting of the fuel circuit is carried out, if the vapor pressure of
the fuel is higher than the pressure in the overflow tank of the AVL Fuel Mass
Flow Meter (environment pressure). With highly volatile fuels it can result in an
overflow of the tank by an exhalation of the fuel even at only slightly increased
fuel temperatures.

User's Guide 73
The following errors are checked for in the state Venting:

Every second:
9 No compressed air
11 Density too low (will be reset 30 s after the start of the internal
venting)
13 Pump overload
10 Hz cycle:
At occurrence:
15 Tank overflow
3.2.2.6 Accuracy Check

The state Accuracy Check can only by reached from the state STBY and it is a
procedural state, i.e. after completion of the accuracy check the device resets
itself to the state STBY.
Information
Due to the exhalation of fuels it is also from time to time necessary, even after
the first-time installation, to ensure a sufficient venting of the calibration sensor
for proper functioning of the option calibration unit.
The following conditions have to be met for taking up this state and proper func-
tioning:
The calibration option must be properly installed in the device.
The flow sensor must be fully rested in the relevant quick-release couplings
and must seal completely.
The connection cable to the calibration sensor must be fitted.
After the installation of the option calibration unit the device must have been
switched at least once to the state Pause.
The local gravitational acceleration (g) must have been entered at least
once.
A flow of >3 l/h must be available.
A sufficient venting of the calibration sensor must be ensured (see section
Calibration Unit on page 59).
The valve settings and the maintenance of the pressure in the measurement
circuit by controlled pumping corresponds to the state STBY during the accuracy
check.
The accuracy of the flow sensor will be checked in this state by means of an
additional measurement system consisting of the internal tank and a pressure
sensor.
The determined deviations between the flow sensor and the calibration unit are
used to calculate a mean deviation, which will be output as well as the mean
flow.
Product Guide
74 User's Guide
Mathematical Formula
Descriptions:
ρ Media density
g Local gravitational acceleration
A Cross-sectional area of the tank
hi Distance tank level membrane of the pressure sensor
ΔM K Mass determined by calibration
ΔM S Mass determined by flow sensor
m· ( t ) Instantaneous mass flow of the flow sensor
R Deviation in %
Calculation of the tank level change during the measurement:

Δp = ρgΔh
Calculation of the consumed mass at calibration:
A
ΔM K = ρΔV = ρAΔh = ---- Δp
g
Calculation of the consumed mass via flow sensor:
ΔM S = ∫ m· ( t ) dt
Calculation of the deviation between calibration and flow sensor:
ΔM S – ΔM K
R [ % ] = ------------------------------- 100
ΔM K
3.2.2.7 Adjustment
The state Adjusting is a temporary state (3 … 5 s), during which a fitted curve is
calculated by a completely performed multi-point calibration (see section Cali-
bration – Adjustment on page 75) in order to compensate the flow sensor.
In terms of valve position and system pressure (i.e. pump mode) and error
checks the state Adjusting is identical with the state STBY, but no measurement
points are output.
3.2.2.8 Bypass
The static state Bypass allows a pressureless fuel supply without operating the
fuel pump. A consumption measurement is not possible.
The state Bypass (signalized as STBY) can only be taken on from the state
Pause and when the DIL-switch is in the respective position (S3/DIL8 "On"). If
system errors 26, 27, 28 or 30 are active, the state Bypass can be selected to
still supply the engine with fuel.
Conditions Compressed air must be available.
The emergency stop circuit must be closed.
3.2.2.9 Draining
The state Draining corresponds to the state STBY, but without automatic fuel
refilling.
The error "Density too low" completes the state Draining – the device switches to
the state Pause.

User's Guide 75
3.2.2.10 Filling
The state Filling corresponds to the state Venting, but with prior fuel filling. The
filling of further fuel devices (e.g. fuel conditioning or engine circuit) should only
be carried out during the internal venting in the state SFIL.
3.2.3 Data Acquisition

The AVL Fuel Mass Flow Meter acquires the instantaneous values of the flow
(depending on the domain as volume or mass flow) with a rate of 10 Hz. These
instantaneous values are subject to an internal damping of the measurements
(filter of the 1st order) with a related damping constant (rise time in seconds to
~6 % of the measurement value).
These instantaneous values will be summarized to a mean value during an
adjustable period (measurement time). By using a configurable number of mean
time values a moving average is also calculated. The standard deviation of the
mean time values (the current mean value of each moment is used for the calcu-
lation of the standard deviation) is an indicator of the quality of the measurement
(calculation in 1/n-1).
The measurement uncertainty of the device is not calculated, because this value
reflects only a small fraction of the measurement uncertainty of the whole device
and therefore is not representative for the measurement of the whole system
consisting of measurement device, conditioning equipment and engine.
When parameterizing the system, note that the mean time value is only available
after the elapse of measurement time. Both moving average and standard devia-
tion are updated after a new mean time value has been calculated. Depending
on the request command, they are available either during the averaging or only
after all measurements have been taken into account.
A parameterization of damping constant, measurement time or number of
measurements and/or domains causes an initialization of the statistical calcula-
tions.
Flow measurement values and statistical calculation are only active in the state
STBY and during the Accuracy Check. If these states are left, the statistical
calculation will be reinitialized on entering the state STBY. The measurement
values for density and temperatures are always available with the exception of
the state Reset.
3.2.4 Calibration – Adjustment
3.2.4.1 Definitions
Calibration
Calibration is a comparative check with a reference device. The accuracy of the
reference device should be three times higher than the accuracy of the checked
system.
Single-point calibration
A single-point calibration is the calibration of one point within the measurement
range of the measurement device to be calibrated.
Multi-point calibration
A multi-point calibration is the calibration of several points within the measure-
ment range of the measurement device to be calibrated.
Product Guide
76 User's Guide
Adjustment
If a measurement device shows a systematic error, e.g. a systematic nonlin-
earity, this error can be reproduced by multiple calibration runs. Systematic
errors can be compensated with an error correction (compensation). This allows
to compensate for offset, gain or linearity errors of the measurement device.
3.2.4.2 Implementation of the Calibration in the AVL Fuel Mass Flow Meter
The AVL Fuel Mass Flow Meter offers two different methods of calibration:
An accuracy check at a special measurement point within the measurement
range.
A comprehensive multi-point calibration in the range between 0 kg/h and
125 kg/h.
After a multi-point calibration the sensor can be adjusted, if required. Usually it is
sufficient to check the sensor by carrying out a multi-point calibration. However,
the linearity error might be increased or the sensor might be maladjusted during
the adjustment. If you perform an adjustment, make sure that multi-point calibra-
tion is carried out very carefully.
Accuracy check (single-point calibration)

At an accuracy check or at a single-point calibration the measurement deviation
between the calibration unit and the flow sensor is determined (see section
Operating States on page 68). In every case, the result of an accuracy check
(the measurement deviation) consists of a systematic component and a random
component of the measurement uncertainty (e.g. AK command AKAL).
Besides the measurement deviation and the mean flow the accuracy check
results in an evaluation of the executed procedure, thereby checking whether the
measurement deviation complies with the device specification. The evaluation is
performed by means of the maximum measurement deviation Rmax, which
consists of a systematic component C1 [%] and a random component C2 [kg/h]
with the mean flow m· as follows:
C2
R max [ % ] = C1 + 100 ⋅ -------
m·
The resulting output of a single-point calibration or an accuracy check always

depends on the currently set sensor adjustment.
Multi-point calibration – Adjustment

Prior to an adjustment, a multi-point calibration must always be carried out. An
adjustment can be carried out on the basis of the calibration.
To start a multi-point calibration the following parameters have to be entered
(e.g. AK command EMKP):
Current Date
ID (user-defined)
Minimum flow of the calibration range
Maximum flow of the calibration range
After the input of the parameters a multi-point calibration list is initialized, whose
content consists of the above information and the set flows derived form the cali-
bration range (AK command AMKS).

User's Guide 77
1. After the initialization of the multi-point calibration list, single-point calibra-

tions (accuracy checks) can be performed on the reference flows in any
order.
Now, the results of the individual single-point calibrations are entered into
the multi-point calibration list according to the flow. Please note that the
herein recorded deviations are not corrected, i.e. they have been deter-
mined on the basis of an unadjusted sensor. The individual list entries can
be queried in any order (e.g. AK command ASEK n or AMKS). If the result
of the accuracy check is requested (e.g. AK command AKAL), the values
are output with the current adjustment, however.
2. Perform an adjustment (e.g. AK command SATK) as soon as all nominals
flows have been measured with single-point calibrations, i.e. the multi-point
calibration list is completely filled out.
In this procedure the multi-point calibration list is used to calculate a fitted
curve, which is used to adjust the sensor. In addition, the recorded mea-
surement deviations in the multi-point calibration list are corrected by the
recalculated sensor adjustment. These deviations are therefore the
remaining error of the sensor adjustment.
If the adjustment has been successful, all relevant data are stored in non-volatile
memory. In total, eight adjustments can be stored.
Density Ranges – Media Classes

The flow sensor utilized in the AVL Fuel Mass Flow Meter shows, depending on
the measurement method, a slight media dependancy due to different media
densities. The resulting deviations of the measurement values are smaller than
0.2%, but due to the high reproducibility can be compensated for specifically
both per sensor and per density. Due to the density dependancy of the arising
nonlinearities every accomplished compensation is only valid in a limited range
of densities. Corresponding to the usual fuels, three classes of media have been
defined: gasoline, alcohol and diesel. As gasoline or diesel is used in the
majority of these applications, both of these classes are automatically detected
according to a density limit of 795 kg/m³.
If the device is used for alcohols (methanol or ethanol), the corresponding media
class (alcohol) must be selected manually (e.g. AK command EALC).
In each of these media classes an adjustment can be accomplished, stored and
retrieved.
Current Adjustment – Adjustment Retrieval – Storage

A current adjustment (fitted curve) exists for all of the aforementioned media
classes. At every transition of the operating state from Pause to STBY the
current adjustment is selected according to the current density from the corre-
sponding density range and used to adjust the sensor. If no adjustment exists for
the corresponding density range, the error 7 "Error Adjustment" is set. In this
case, the sensor applies a general media-independent factory adjustment.
If several adjustments have been made in the corresponding density range, it is
possible to retrieve an existing adjustment to adjust the sensor. In this case, the
multi-point calibration list is initialized with the stored data. The adjustment is
accomplished analogously to the compensation of a new multi-point calibration.
Product Guide
78 User's Guide
3.2.4.3 Basics of Calibration

Calibration means comparing sensor measurements with reference measure-
ments. The calibration result is determined by the extent to which the sensor
deviates from the result of the reference measurement.
The AVL Fuel Mass Flow Meter 735S measures the mass flow by means of a
Coriolis sensor. A precision tank level measurement for which a tank with a
defined cross-sectional area and a pressure sensor is used serves as a refer-
ence measurement.
Geometric conditions
Fig. 38
Fuel is sampled continuously from a tank at a constant flow rate. At a given time
t1, the tank has a defined cross-sectional area A and a fill height h1. At a later
time t2, the level has fallen to a fill height h2. A pressure sensor that is connected
to the lowest point of the tank determines the pressures p1 and p2 at the times t1
and t2. From these values, the following information is derived for the pressures
p1 and p2 with the fill heights h1 and h2, under consideration of the gravitational
acceleration g and the fuel density ρ:
(1)
(2)
(3)
If equation (3) is multiplied by the cross-sectional area A and if then the result is
divided by the gravitational acceleration g, the following is obtained for the mass
ΔM sampled in the time period Δt = (t2 - t1):
(4)
If equation (4) is divided by the time difference Δt, the mass flow of the reference
measurement at the time t2 is obtained:

User's Guide 79
(5)
For an arbitrary moment i, the mass flow of the calibration unit is as follows:
(6)
Calibration procedure
In the calibration procedure, the deviation of the mass flow of the Coriolis sensor
from the reference system (calibration unit) is determined at regular intervals
(~300 ms):
(7)
In addition, the mean value and the standard deviation of these deviations since
calibration start are calculated:
(8)
(9)
By dividing the result by k , the measurement uncertainty of the mean devia-

tion at the time k is determined with a confidence level of 63 %:
(10)
This quantity therefore represents the uncertainty of calibration result determina-

tion. It is referred to as the "measurement uncertainty, mean sensor deviation"
(AK command AKMW). Thus, in every case, the result of a calibration consists
of two components – of the absolute deviation between sensor and reference
measurement as well as of this measurement uncertainty.
Due to the fact that all values are averaged from calibration start, the number of
values used for the determination increases. This also increases the accuracy of
difference determination until a system-immanent limit is reached.
If the device-internal tank has to be refilled during the calibration, the calculation
is halted until refilling has been completed and is then continued.
To enable the customer to determine the calibration result more quickly, a defin-
able limit for the measurement uncertainty to be achieved was introduced for the
735S. This limit is referred to as the "calibration uncertainty" (AK command
AKUG/EKUG) and can be set between 0.03 % and 0.5 %.
Product Guide
80 User's Guide
If the limit is not reached within seven cycles of emptying the device-internal
tank, the calibration will be terminated and the determined uncertainty will be
output.
The figure below shows the single deviation values, the mean value and the
measurement uncertainty interval. As can be seen, the measurement uncer-
tainty interval decreases with time while the number of measured values
increases.
Single deviations, mean deviation and measurement uncertainty of mean devia-
tion over time
Fig. 39
Evaluation of the calibration procedure (for accuracy checks only)

The purpose of every calibration procedure is to determine the mean deviation of
the sensor from the reference system. In an accuracy check, i.e. if no multi-point
calibration takes place, the measurement deviation is evaluated by means of an
evaluation curve whether it complies with the device specification. The following
evaluation curve is used to this end:
(11)
·
Here, M K is used for the mean flow of the calibration unit during the calibration
procedure. The parameters C1 and C2 can be adjusted with the AK command
ASFP/ESFP, whereby C1 = 0.16 % and C2 = 0.004 kg/h are selected as the
base settings.
If the percental deviation of the calibration procedure is smaller than the relevant
value from the evaluation curve, successful calibration is reported (query using
AK command AKAL).

User's Guide 81
Accuracy check in the PC software

"Accuracy Check" window as called up from the "Measurement Settings" menu
Fig. 40
3.2.5 Consumption Totalizers

The AVL Fuel Mass Flow Meter is equipped with two kinds of totalizers:
Working totalizer
Background totalizer
Working totalizer The working totalizer is used for the measurement of the fuel consumption in
dynamic processes. This kind of measurement is called integral measurement
and provides consumption and time within a certain period (start – stop). This
measurement should be used for short-term dynamic processes.
The integral measurement always works in the currently set domain (mass,
volume, volume API).
The integral measurement is only available in state STBY. If the state STBY is
left, the working totalizer is stopped automatically.
Information
The measurement values of the integral measurement are lost upon switching
off the device or changing the domain (stop + reset).
The working totalizer can be started with two different resolutions.

Gram (g) or ml with two digits after the decimal point
kg or liters (l) with three digits after the decimal point
When the reading of 42,949.67296 kg is exceeded (overflow), the reading
restarts at 0. In the same way the time measurement has an overflow after
429,496,729.6 s resulting in a reading of 0.
Background Two background totalizers (1 and 2) implement the summation of the consump-
totalizer tion reading for long-term consumption measurements. This measurement is
used for test bed or test run consumption measurements.
The working domain (mass or volume) is independent from the current domain,
which is used by the AVL Fuel Mass Flow Meter. If the volume API is selected as
current domain, a background totalizer, which runs in the volume domain, is
updated with the API standard volume (standardized to 15 °C) beginning with
the current reading.
The values of these background totalizers do not get lost upon switching off the
device, as they are stored in non-volatile memory. The values are stored every
hour or in the state Pause.
Product Guide
82 User's Guide
Information
The device has to be switched to the state Pause to avoid errors in the long-term
metering of the consumption.
The values of the background totalizers can only be retrieved or changed (start,
stop, domain) during the state Pause. A change of the totalizer domain stops and
deletes the corresponding totalizer.
The values are output with one digit after the decimal point. The significance of
this digit after the decimal point is to be seen in connection with the specification.
3.2.6 Operating-hour Counter, Maintenance Limit

The AVL Fuel Mass Flow Meter supports three non-volatile stored oper-
ating-hour counters:
Fuel Pump
Fill valve
While the counter of the pump measures the time during the runtime, the fill
valve counts the switchings.
The operating hours are calculated internally with a precision of a minute to
avoid the distortion of the display of the operating hours for operating times
shorter than an hour.
The values are stored every hour or in the state Pause. At this moment, a
comparison is also carried out between the operating hours of the pump and the
stored maintenance limit.
If the operating-hour counter exceeds the maintenance limit, an error condition is
set (category: notification). The error condition can be deleted by a reset of the
operating-hour counter or by an increase of the maintenance limit.
Default values for the maintenance limit:
Component Maintenance Limit

Fuel Pump 5000 h
Fill valve 500,000 switchings
Tab. 34
3.3 Test Bed Integration
3.3.1 Application
Information
The AVL Fuel Mass Flow Meter has to be at the highest point of the fuel circuit to
avoid an overflow of the system.
The following applications are examples, which have to be adapted to the indi-
vidual requirements.
Pay attention to the instructions in the Application Notes "Fuel Consumption
Measurement" (Material No. AT0802E).

User's Guide 83
Fit drain cocks at the lowest positions of the lines to and from the engine to
simplify and facilitate the draining of the fuel lines.
3.3.1.1 Application With Conditioning System
3
4 11 5 6
7 8
10
1 .....AVL Fuel Mass Flow Meter

2 .....Conditioning System, e.g. AVL Fuel Temperature Control
3 .....Drain line of the overflow tank
4 .....Fuel to engine
5 .....Fuel return line (venting)
6 .....Fuel in line (e.g. from a tank)
7 .....Fuel to engine
8 .....Fuel from engine
9 .....Bypass near engine
10 ...Engine (consumer)
11 ...Ball valve (optional)
Fig. 41
Product Guide
84 User's Guide
3.3.1.2 Application Without Conditioning System, No Return Line
3
4
5
2
6
1 .... AVL Fuel Mass Flow Meter

2 .... Fuel to engine
3 .... Fuel in line (e.g. from a tank)
4 .... Locking part on fuel return line
5 .... Ball valve (optional)
6 .... Engine (consumer)
Fig. 42
3.3.1.3 Application Without Conditioning System, With Return Line
7 5
8
3
2 6
1 .... AVL Fuel Mass Flow Meter

2 .... Fuel to engine
3 .... Fuel return
4 .... Fuel in line (e.g. from a tank)
5 .... Engine pump
6 .... Engine (consumer)
7 .... Venting valve option
8 .... Ball valve (optional)
Fig. 43

User's Guide 85
3.3.2 Operation
For the various ways of integration of the AVL Fuel Mass Flow Meter please refer
to the section Electrical Connection on page 40.
The AVL Fuel Mass Flow Meter can be controlled in different ways:
Serial RS232 interfaces with AK-compliant protocols allow easy integration
of the most common test bed automation systems. In addition, for safety
reasons, digital control lines are required for proper operation.
The hybrid test bed integration is used in test bed automation systems
which do not allow integration via RS232 interfaces.
Then the system is operated via digital control lines and the data is output
via an analog interface.
PC software (included in the scope of delivery)
Remote Control (optional)
The operation of the AVL Fuel Mass Flow Meter should preferably be accom-
plished via serial communication with an automation system, the PC software or
the remote control.
3.4 Remote Control
3.4.1 General
The remote control is a universal control device for various AVL measurement
devices, including the AVL Fuel Mass Flow Meter, AVL Fuel Temperature Control
and AVL Fuel Balance. Depending on the firmware version, two of these devices
can be controlled with one remote control.
This section describes the basic operation of the AVL Fuel Mass Flow Meter by
means of the remote control. For detailed information about the various oper-
ating states and parameters of the AVL Fuel Mass Flow Meter please refer to the
related sections of this manual.
Fig. 44
The inverted field shows the device ID of the device and/or devices, for which
the remote control is configured. If the remote control has not been used, hori-
zontal dashes are shown instead and the remote control must be configured first
(see section Configuration on page 87).
For instructions about the connection of the remote control, please refer to
the section Serial Interfaces (X3/X4) on page 48.
The operation of the remote control is described in the section Operation on
page 86.
Product Guide
86 User's Guide
The setting options of the remote control are shown in the section Configu-
ration on page 87.
The sections Measurements on page 90 through Warnings and Errors on
page 97 illustrate the individual displays of the remote control.
Information
The shown display screens of the remote control are examples, which can differ
from the actually displayed information.
The firmware version of the remote control must be MT 1.25 or later.
Device IDs AVL devices can be identified with the internal device IDs in the menu of the
remote control:
Device Device ID
AVL Fuel Mass Flow Meter 735S
AVL Fuel Temperature Control 753C
AVL Smoke Meter 415S
AVL Opacimeter 439
Tab. 35
3.4.2 Operation
The upper left shows the title of the screen, the device ID and the software
version of the device is displayed to the right of this.
Fig. 45
In the second line, the operating mode and the device state is shown. The oper-
ating mode indicates where the device is controlled from:
REMOTE Control via remote control

MANUAL Control via the second serial interface of the device
(test bed computer or PC)
EXTERNAL Hybrid control
----- Device is not controlled at the moment
You can only communicate with the device (e.g. set parameters), if the operating
mode is set to REMOTE.
In order to control a connected device with the remote control, the remote control
must take over control. This is accomplished by pressing the key READY.

User's Guide 87
It depends on the device state as to which functions are available.

The line above the key function is reserved for messages.
The remote control is operated with six function keys (F1 to F6) and two cursor
keys ( and ). The currently selected function of the function keys is shown
on the display directly above.
1. Select the desired function by pressing the corresponding function key or
select the desired item with the cursor keys in a menu (e.g. main menu) -
the current selection is shown reversed - and activate the selection by
pressing RUN.
The key at the very left (MENU) always leads you back to the higher menu.
In setup screens you can also make changes – select the desired param-
eter with the cursor keys (the current selection is shown reversed) and
press SET – the field is now shown within a frame.
2. Select using the cursor keys either a list of options or set a numeric value.
For numeric values, select the decimal point with the keys  and .
3. Press SET to complete the entry.
4. If the key STORE is shown on the screen, it has to be pressed in order to
transmit the changed settings to the device and to store them in the device.
Information
Settings which have not been stored are lost after leaving the screen.
To prevent unauthorized changes at the the set device parameters, a password

can be used. The corresponding screens then show the key PASSW instead of
the key SET.
3.4.3 Configuration
Fig. 46
If the remote control has not been configured, dashes appear in the black field
after switching on.
Product Guide
88 User's Guide
1. Select MENU to go to the main menu and use the cursor keys ( and )
to select the menu item Configuration.
Fig. 47
2. Select RUN and then SERIAL LINE RUN
Fig. 48
3. Press SET, select the combination of connected devices with the cursor
keys ( and ), confirm your selection with ENTER.
4. Select an interface with the cursor keys, press SET and select the con-
nected device, confirm your selection with ENTER.
5. If necessary, use the cursor keys to go to the display of the baud rate, press
SET and select the desired value.
Information
Make sure that the setting corresponds to the setting of the respective device.

User's Guide 89
Fig. 49
6. Finally store the changes by pressing STORE and leave the screen with
MENU.
In the main menu of a configured remote control, the left side shows the
available devices, which can be selected, and on the right side the options
CONTRAST, LANGUAGE, PASSWORD NEW and CONFIGURATION are
shown.
Fig. 50
7. At the beginning, use the cursor keys to select the menu item CONTRAST
and press the key RUN.
8. Use the cursor keys to adjust the contrast for good readability.
9. Complete the setting with ENTER.
10. In the same way you can select the language.
At the menu option PASSWORD, a valid password can be entered to bypass the
password protection of the parameterization of the AVL Fuel Mass Flow Meter. A
bypassed password protection is indicated by the menu PASSWORD NEW. This
menu is used to view the current password or to enter a new password.
The password protection will only be activated after a restart (switching off
and switching on of the remote control).
If password protection is not desired, select the figure 0 as password.
Product Guide
90 User's Guide
3.4.4 Measurements
If the remote control is configured and only the AVL Fuel Mass Flow Meter is
connected, the title screen is shown for a few seconds after switching on and
then the main screen is shown (Measurement, see below).
1. If the remote control is configured for more than one device, you first have
to select the device in the main menu and go to the respective menu with
RUN.
Fig. 51
2. Press the key RUN in the 735 menu to activate the main screen (Measure-
ment).
Fig. 52
You can set the following parameters on this screen:

Measurement time
Averaging number
Scaling of the bar display (a change of this value is accepted immediately
and does not need to be explicitly stored)

User's Guide 91
3.4.4.1 Integral Measurement

The integral measurement is selected by pressing the key INT.M in the screen
Measurement (see Measurements on page 90).
Fig. 53
START Fine Starts the integral measurement with fine resolu-

tion
(g/ml)
START Starts the integral measurement with coarse reso-
Coarse lution
(g/ml)
STOP Stops the integral measurement
DEL Resets the displayed values.
GO ON Jumps back to the screen Measurement.
3.4.4.2 Measurement of the Total Consumption
Fig. 54
Changes can only be made in the device state Pause.

Use START (or STOP, each on function key F4) to start or stop the counter.
The counter can only be reset with the key DEL if it has been stopped.
You can set the domain of the summation meters of consumption by
changing the unit to kg or l.
Product Guide
92 User's Guide
3.4.5 Accuracy Check
Fig. 55
Information
A start of the accuracy check is only possible, if the device is in the state STBY
(conditions see section Operating States on page 68.
The remaining time for the calibration is always set to zero.
The message "Accuracy check successful" is not shown on the remote control,
even if the check has been successful. Instead of this message, it always
displays "Accuracy check not passed".
The accuracy check is carried out automatically.
3.4.6 Calibration
The following figure shows the initialization of a multi-point calibration.
Fig. 56
The following values can be set:

Date
ID (user name)
Minimum flow
Maximum flow

User's Guide 93
After editing the values and pressing SET, the device initializes the multi-point
calibration list. You can fill this list now by performing an accuracy check repeat-
edly. The results of the individual accuracy checks can be retrieved as summary
on this screen. With a filled multi-point calibration list the adjustment can be
started by pressing ADJST.
Now, the multi-point calibration is ready for the adjustment.
Fig. 57
3.4.7 Adjustment
Fig. 58
On this screen you can revise the adjustments of the current density range which
are already stored in the device and, if necessary, retrieve an adjustment and set
it on the screen Calibration. The currently active adjustment is checked.
Product Guide
94 User's Guide
3.4.8 Parameter
Fig. 59
On this screen the following parameters can be set:

Domain
Sensor time constant (= damping constant)
Venting time
Gravity constant
Coefficients C1 and C2 for the assessment of the accuracy check (see sec-
tion Calibration – Adjustment on page 75)
As all of the above parameters are sent to the device at the same time, it can
happen that the feedback message "Device not ready" is displayed. If the
changed parameters are correctly displayed the set value has been correctly
accepted.
3.4.9 Analog Output

The following screen is activated by pressing the key DAC on the screen Param-
eter.
Fig. 60
On this screen the following parameters can be set:

Domain of the analog output (the analog output returns valid values only if
the domain of the device and the domain of the analog output are identical).
Scaling of the analog output with the two values for 0 and 10 V in units of
the respective domain
Compensation of the Analog Output

User's Guide 95
3.4.9.1 Compensation of the Analog Output

As soon as the fields for 0 or 10 V [digit] are changed, the analog output of the
AVL Fuel Mass Flow Meters provides the nominal value for 0 or 10 V. Change
the digits in a way, so that your reference device shows the desired voltage of 0
or 10 V.
3.4.10 Information
Fig. 61
3.4.11 Maintenance
Fig. 62
Information
The fill valve switchings (cycles) are displayed in steps of 100 cycles.
Product Guide
96 User's Guide
3.4.12 Service
Fig. 63
Press VENT., in order to control the valve settings, or TEST, in order to test the
Overflow Float Switch.
Controlling the valve settings:
Fig. 64
Check Overflow Float Switch
Fig. 65

User's Guide 97
3.4.13 Warnings and Errors

If warnings are available, they are automatically displayed – with WARN. you
can always manually display the warnings available at present.
If system errors occurred the respective error screen is displayed.
Fig. 66
For further information refer to section Overview of Errors on page 149.

Press CONT. to close the screen and return to the previous screen.
3.5 Interface Protocol (AK Protocol)
3.5.1 General
This section refers mainly to programmers, who have to integrate the AVL Fuel
Mass Flow Meter into a test bed automation system.
The communication via the RS232 interface follows the AK protocol, which is
very common in test bed technology. The protocol frame is defined in the AK
paper "V24/RS232-Schnittstelle – Grundsätzliches". The communication is
based on a master-slave principle.
For instructions on the interface parameters, please refer to section Serial Inter-
faces (X3/X4) on page 48.
Product Guide
98 User's Guide
3.5.1.1 Protocol Frame – Command Telegram
Byte Function
1 <STX>
2 Don’t care byte
3…6 Function code
Sxxx … Control command
Exxx … Setting command
Axxx … Request command
Rxxx … Request command (repeated query)
7 Space (20 hex) The channel number (bytes 7 to 9) can be
8 K … ID for channel number omitted.
9 0 … Channel number
Space (only if there is a subsequent data block)
data block (depending on the function code)
The individual data are separated by spaces.
n. Byte <ETX> … Command level
Tab. 36
3.5.1.2 Protocol Frame – Acknowledgment Telegram
Byte Function
1 <STX>
2 Don’t care byte (identical with the sent command)
3…6 Function code (identical with the sent command)
7 Space (20 hex)
8 Error status
0 No error
1…9 One or more errors
(counts up cyclically, if the error screen changes)
Space (only if there is a subsequent data block)
data block (depending on the function code)
The individual data are separated by spaces.
n. Byte <ETX> … Command level
Tab. 37
All commands and data are transmitted in ASCII.

The first character of the command must be <STX> in order to interpret it as
an AK command.
If the device is directly controlled via a terminal program from a PC, a sim-
plified protocol mode is available (see section Terminal Mode on page 135).
The commands are defined as four-digit function code. They are divided
into four groups:
– Control commands (prefixed with "S", e.g. SREM)
– Request commands (prefixed with "A", e.g. ASTZ)
– Setting commands (prefixed with "E", e.g. EMSP)
– Request commands/repeated query (prefixed with "R", e.g. RSRV)

User's Guide 99
As response to a command the system always sends an acknowledgment

telegram.
In addition the following special definitions apply:
The channel specification can be omitted in the command telegram, other-
wise the channel number 0 must always be used (K0).
The don't care byte (the second byte after <STX>) is not evaluated, but is
only copied into the acknowledgment telegram.
CTRL-Y resets the device.
If the transmission of a value cannot be accomplished in a request com-
mand, it is replaced by #.
If, upon a request command being given, a value is only valid conditionally,
it is prefixed by #.
3.5.1.3 General Definitions and Possible Acknowledgments in Case of Errors

If the device is directly controlled via a terminal program from a PC, a simplified
protocol mode is available (see section Terminal Mode on page 135).
The command telegram must start with <STX> and end with <ETX>.
Acknowledgment of unknown function codes:
<STX> ???? n<ETX>
n … Error status
Spaces are used as delimiters.
The variable long floating point format is used to display numeric values.
With integers the decimal point is omitted. The sign is only used for negative
values. Physically meaningless digits are dropped.
If a control or setting command is sent in the operation state SMAN (which
allows only request commands), the acknowledgment is as follows:
<STX> xxxx n K0 OF<ETX>
xxxx … Function code
n … Error status
OF …
If a command is sent, which cannot be executed in the current state or due
to an error status, the acknowledgment is as follows:
<STX> xxxx n K0 BS<ETX>
n … Error status
BS … Busy
If the command telegram contains a syntactic error (e.g. missing or surplus
parameters), the acknowledgment is as follows:
<STX> xxxx n K0 SE<ETX>
n … Error status
SE … Syntax error
Product Guide
100 User's Guide
If the value of a parameter is out of the valid range, the acknowledgment is

as follows:
<STX> xxxx n K0 DF<ETX>
n … Error status
DF … Data error
3.5.1.4 Definition of the Error Handling

The AVL Fuel Mass Flow Meter signals the errors according to the AK protocol in
the form of error codes with a maximum of 32 errors. The error codes are
arranged in three categories:
Notification (No. 1 … 4)
Warning (No. 7 … 23)
Error (No. 26 … 31)
The meaning of the individual categories is defined as follows (see section Over-
view of Errors on page 149):
Notification Notifications do not influence the normal functioning of the device.
The user is notified that a certain action is necessary in the near future or that a
certain event has happened (e.g. maintenance limit exceeded, service required).
An immediate action by the user is not necessary.
Warning Warnings influence the normal functioning of the device.
The device cannot be switched to the desired state (e.g. STBY) or the normal
functionality is not available. But the device is not faulty!
The user must take certain actions to resolve the faulty state (e.g. switch on
media supply etc.).
Error If there is an error, the user is usually not able to remedy this. The device has a
(temporary) internal defect. The user must contact the service organization. The
device may possibly function normally after a RESET (power-on or AK
command).

User's Guide 101
3.5.2 Basic Communication
3.5.2.1 AKEN
Device ID
Field Description Format Value Range

1 Device ID string 735
2 Firmware version string Sx.xx
Tab. 38
Note The device ID of the AVL Fuel Mass Flow Meter ("735S") consists of the field 1
(device ID) and the first character of field 2 ("S").
The firmware version is in field 2 (without the prefix "S").
3.5.2.2 SREM
Control mode – switches the interface to control mode, i.e. setting and control
commands are available via this interface.
Condition None, command is allows permitted.
3.5.2.3 SMAN
Monitoring mode – switches the interface to monitoring mode and sets user to
"none", i.e. this interface allows only request commands.
3.5.2.4 ASTF
Provides the number of the active errors (ascending); if there is no error the data
block is omitted.
The third table below shows the assignment of the errors displayed by PUMA 5.x
and PUMA Open (with version earlier than 1.2) to the error messages of the AVL
Notifications
Error Number Description
2 No tank data
4 State Bypass
Tab. 39
Product Guide
102 User's Guide
Warnings
Error Number Description
7 Error adjustment
8 Gravity not entered
9 No compressed air
11 Density too low
13 Pump overload
15 Tank overflow
17 Emergency stop
18 Error fill valve
23 Error NV-RAM
Tab. 40
System errors Assignment of the errors that are displayed by PUMA 5.x and PUMA Open (with
version number below 1.2) to the error messages of the AVL Fuel Mass Flow
Meter.
Error number Description

26 Communication error flow sensor
27 Communication error calibration sensor
28 Error EEPROM
29 General device error
31 Fan blocked
Tab. 41
Error number Error message PUMA Error message

5.x and PUMA Open AVL Fuel Mass Flow
(<1.2) Meter
1 Maintenance limit main Maintenance limit pump
pump
2 Maintenance Limit No tank data
Bypass Pump
3 Maintenance limit fill Maintenance limit fill
valve valve
4 Calibration error State Bypass
7 Adjustment error Error adjustment
9 No compressed air No compressed air
11 Density too low Density too low
13 Pump overload Pump overload
14 Filling rate too low Filling rate too low
15 Tank overflow Tank overflow
23 EEPROM checksum Error NV-RAM
error
26 Flow sensor Communication error
flow sensor
Tab. 42

User's Guide 103
Error number Error message PUMA Error message

5.x and PUMA Open AVL Fuel Mass Flow
(<1.2) Meter
27 Calibration sensor Communication error
calibration sensor
28 EEPROM read / write Error EEPROM
29 DAC error General device error
Tab. 42
3.5.2.5 ASTZ
Device state

1 Interface mode string SREM … Control mode
SMAN … Monitoring mode
2 Device status string SRES … Reset
SPAU … Pause
STBY … STBY
SVNT … Venting
SATK … Adjustment
SKCH … Accuracy Check
SFIL … Filling
SDRN … Draining
SSRV … Service mode
Tab. 43
3.5.2.6 SPAU
Stops running procedures (SFIL, SDRN, SSRV); switches the device to state
Pause.
3.5.2.7 STBY
Stops running procedures (calibration, adjustment, venting, etc.), switches the
device to state STBY (measurement running, engine can be supplied with fuel).
Condition Not allowed in SSRV and SDRN.
Product Guide
104 User's Guide
3.5.2.8 AVNP, EVNP

Venting parameter

1 Venting time integer 0 … Permanent venting
5 … 300 s
Default: 30 s
Tab. 44
3.5.2.9 ASTX
Error causes
ASTX n
n … Error number
If the existing error n can have more than one cause, the response contains a
binary number, the bits of which are assigned to the error causes according to
the following table, otherwise 0 is returned .
Error Number Bit Error Cause

23 0 Measurement settings
1 Summation meter
2 Operating-hour Counter
3 DAC adjustment
4 Device calibration data
5 Calibration directory
6 Calibration data
7 Calibration parameter (g, tank area)
26 See next table.
27 0 Error telegram frame
1 Data error
2 LRC error
3 Unknown command
4 Bus
5 Software
6 Time-out
29 0 Failure filling level sensor
1 Reserved
2 Reserved
3 Reserved
30 0 Overrun
1 XCOM Overflow
2 Time-out
3 CRC Error
Tab. 45
The AK command ASTX 26 returns a series of digits (0 or 1) in 16 blocks of four
bits, enumerated from left to right.

User's Guide 105
Block Position Description

1 1 Real-time interrupt failure
2 Transmitter not configured
3 0
4 Input overrange
2 1 Temperature sensor failure
2 Sensor not vibrating
3 RAM diagnostic failure, core processor
4 (E)EPROM checksum failure, core processor
3 1 0
2 0
3 Drive overrange
4 Density overrange
4 1…4 0000
5 1 Slug flow
2 0
3 Data loss possible
4 Transmitter electronics failure
6 1 Zero too noisy
2 Zero value too high
3 Zero value too low
4 Calibration failure
7 1 Sensor/transmitter communication failure
2 0
3 0
4 0
8 1…4 0000
9 1 (E)EPROM program corrupt, core processor
2 (E)EPROM powerdown totals corrupt, core
processor
3 (E)EPROM database corrupt, core processor
4 0
10 1…4 0000
11 1…4 0000
12 1 Case temperature sensor out of range
2 Line temperature sensor out of range
3 0
4 0
13 1…4 0000
14 1…4 0000
15 1…4 0000
Tab. 46
Product Guide
106 User's Guide
Block Position Description

16 1 0
2 0
3 0
4 Boot sector fault, core processor
Tab. 46
3.5.2.10 ASIN
Cause for non-execution of a control command.
If the last control command could not be executed and therefore has been
acknowledged with BS or NA, ASIN returns a 12-bit binary number, the bits of
which are assigned to the causes according to the following table.
Bit Cause
0 Error status
1 Not in standby
2 Not in the necessary state
3 Venting AVL Fuel Temperature Control 753C is running
4 —
5 —
6 No calibration sensor installed
7 Wrong domain
8 Fuel alcohol
9 No acceleration due to gravity entered
10 Flow too low
11 No tank data entered
Tab. 47

User's Guide 107
3.5.2.11 Communication Example

The communication is based on a master-slave principle. A value >0,5 s is
recommended as time-out for the acknowledgment telegram.
Example
Initialization, error and request of a measurement value.
Command Acknowledgment
Initialization
Correct device connected?
<STX> AKEN<ETX> <STX> AKEN 3 735 S1.00<ETX>
3 … Error status
735S … AVL Fuel Mass Flow Meter
1.00 … Firmware version
Error status not equal 0 → request
current error numbers
<STX> ASTF<ETX> <STX> ASTF 3 1 9<ETX>
3 … Error status
1 … Error number (Maintenance limit main pump)
9… Error number (No compressed air)
Periodical requesting of the
measurement value (e.g. 1 Hz)
<STX> ASEM<ETX> <STX> ASEM 3 5 M M S 13.672 13.221 1.735 765.23 21.39<ETX>
If the error status changes, the error 3 … Error status
numbers have to be updated with 5 … Parameter status
the request command ASTF. M … User (the second serial RS232 interface is in control mode)
M … Device status: mass domain
S … Device function: standby
13.672 … Mean over measurement time
13.221 … Moving average
1.735 … Standard deviation
765.23 … Density
21.39 … Sensor temperature
Tab. 48
3.5.3 Data Acquisition
3.5.3.1 AMSP, EMSP, RMSP

Measurement parameter

1 Measurement time real 0.1 … 60.0 s
Default: 0.5 s
2 Number of values for integer 1 … 100
the moving average Default: 10
Tab. 49
Note The request command RMSP can also be repeated.
Product Guide
108 User's Guide
3.5.3.2 ADMP, EDMP

Domain setting

1 Domain integer 0 … Mass
1 … Volume
2 … Volume API
Default: 0
Tab. 50
Note A change of the domain stops the working totalizer and resets it.
3.5.3.3 AMEM, RMEM

Instantaneous value mass flow
Field Description Format

1 Instantaneous value mass flow [kg/h] real
Tab. 51
Conditions Available only in mass domain.

Available only in STBY or SKCH.
3.5.3.4 AMEV, RMEV

Instantaneous value volume flow

1 Instantaneous value volume flow [l/h] real
Tab. 52
The volume flow is derived in the sensor from the mass flow based on the fuel
density.
Conditions Available only in volume domain.
Instantaneous value volume flow/API

l
1 Instantaneous value volume flow [ /h] real
Tab. 53
The volume flow is derived in the sensor from the mass flow based on the fuel
density at 15 °C (60 °F).
Conditions Available only in volume domain API.

User's Guide 109
3.5.3.5 ASEM, RSEM, ASEV, RSEV, ASEP, RSEP

ASEM, RSEM: Measurement value mass flow
ASEV, RSEV: Measurement value volume flow
ASEP, ASEP: Measurement value volume flow API

1 Parameter status integer 1 … 9 (cyclically)
This byte is incremented at each change of
a parameter.
2 User char R … This serial RS232 interface is in
control mode (SREM)
M … The second serial RS232 interface is
in control mode (SMAN)
E … Hybrid interface (external)
N … None
3 Status char E … System error
I … Initialization
M … Mass domain
V … Volume domain
P … Volume domain/API
4 Function char L … Pause
S…
T … Standby / working totalizer active
V … Venting
U … Calibration
K … Adjustment
R … Service mode
F … Filling
E … Draining
kg l
5 Mean over measurement time [ /h] or [ /h] real
6 Moving average [kg/h] or [l/h] real
7 Standard deviation [kg/h] or [l/h] real
8 Density [kg/m³] real
9 Temperature of medium at sensor [°C] real
Tab. 54
Conditions Available only in mass domain.

Product Guide
110 User's Guide
3.5.3.6 ASEX, RSEX

Extended output of measurement values regardless of domain

1 Parameter status integer 1 … 9 (cyclically)
This byte is incremented at each change of
a parameter.
2 User char R … This serial RS232 interface is in
control mode (SREM)
M … The second serial RS232 interface is
in control mode (SMAN)
E … Hybrid interface (external)
N … None
3 Status char E … System error
I … Initialization
M … Mass domain
V … Volume domain
P … Volume domain/API
4 Function char L … Pause
S…
T … Standby / working totalizer active
V … Venting
U … Calibration
K … Adjustment
R … Service mode
F … Filling
E … Draining
kg l
5 Instantaneous value [ /h] or [ /h] real
6 Mean over measurement time [kg/h] or [l/ h] real
kg l
7 Moving average [ /h] or [ /h] real
8 Number of measurement values for aver- integer 0 … 100
aging
9 Relative standard deviation [%] real
kg
10 Density [ /m³] real
11 Temperature of medium at sensor [°C] real
12 Measurement number integer 0 … 100
Tab. 55
Condition Available only in STBY or SKCH.

User's Guide 111
3.5.3.7 AFIP, EFIP

Sensor filter time constant

1 Sensor filter time real 0, 0.04, 0.08, 0.16,
constant 0.32, 0.64, 1.28, 2.56 s
Default: 0.32S
Tab. 56
Condition EFIP is only available in STBY and SPAU.

Note When setting values, which are not contained in the field "Value Range", the
value is rounded to the next smaller value.
3.5.3.8 ADSP, EDSP

Scaling analog output

1 Mode integer 0 … Adjustment output
(raw data)
1 … Mass flow [kg/h]
2 … Volume flow [l/h]
3 … Volume flow API
[l/h]
4 … Density [kg/m³]
5 … Temperature [°C]
Default: 1
2 Mode 0: integer 0 … 65535
raw data
Mode 1 … 3: real –50.000 … 200.000
0 V physical value
Default: 0
Mode 4: real 0.000 … 1500.000
0 V physical value
Mode 5: real 0.000 … 100.000
0 V physical value
3 Mode 1 … 5: real 10.000 above physical
10 V physical value value at 0 V
Default: 125
Tab. 57
Product Guide
112 User's Guide
3.5.3.9 Communication Example
Example
Setting of measurement parameters, domain, scaling the analog output and peri-
odical requesting of the measurement value.
Data acquisition
Control mode
<STX> SREM<ETX> <STX> SREM 0<ETX>
0 … Error status
Set measurement parameters:
1 s measurement time, averaging of
15 measurement values
<STX> EMSP 1 15<ETX> <STX> EMSP 0<ETX>
0 … Error status
Analog output:
scaling on volume
(0 … 60 l/h to 0 … 10 V)
<STX> EDSP 2 0 60<ETX> <STX> EDSP 0<ETX>
0 … Error status
Periodical requesting of the
measurement value (e.g. 1 Hz)
<STX> ASEV<ETX> <STX> ASEV 0 5 R V S 13.672 13.221 1.735 765.23 21.39<ETX>
the request command ASTF.
R … User (this serial RS232 interface is in control mode)
V … Device status: volume domain
S … Device function: standby
13.672 … Mean during measurement period
765.23 … Density
Alternative: fast data acquisition for dynamic measurements, e.g. 10 Hz
(optional: change filter setting for the fast data acquisition: EFIP)
<STX> AMEV<ETX> <STX> AMEV 0 13.570<ETX>
numbers have to be updated with 13.570 … Instantaneous value
Tab. 58

User's Guide 113
3.5.4 Maintenance
3.5.4.1 SVNT
Activates venting.
Conditions Permissible only in the state STBY.
Warning 15 must not be active.
3.5.4.2 SFIL
Starts first-time filling and remains in the state permanent venting after filling.
The first-time filling is completed after the init state is left.
Conditions Permissible only in SPAU.
Only the warning 11 (density too low) may be active.
3.5.4.3 SDRN
Starts draining procedure and remains in that state after the draining has been
completed. The draining is completed after the init state is left.
Condition Only permissible in STBY or SPAU.
3.5.4.4 EALC, AALC

Fuel type

1 Fuel type integer 0 … Automatic selec-
tion (gasoline / diesel)
1… Methanol
2 … Ethanol
Default: 0
Tab. 59
Condition EALC is only permissible in SPAU.

Note The setting is stored permanently. At setting 0 (no alcohol) the appropriate cali-
bration curve is loaded due to the fuel density (gasoline or diesel).
3.5.4.5 ACFG
Device Configuration

1 (no function) integer Always 0
3 Calibration sensor integer 0 … Not available
1 … Available
Tab. 60
Product Guide
114 User's Guide
3.5.4.6 ADJP, EDJP

Adjustment parameter analog output

1 Digits for 0 V integer 0 … 4,000
2 Digits for 10 V integer 50,000 … 64,000
Tab. 61
Note No default values, adjusted in factory.
3.5.4.7 ABSZ, EBSZ

Operating counter

1 Operating time of fuel integer 0 … 30,000 h
pump [h]
3 Switchings fill valve integer 0 … 1,000,000 switch-
ings
Tab. 62
3.5.4.8 AWGP, EWGP

Maintenance limit
Field Description Format Value Range EWGP

1 Operating time of fuel integer 0 … 30,000 h
pump [h]
Default: 5,000
3 Switchings fill valve integer 0 … 1,000,000 switch-
ings
Default: 200,000
Tab. 63
Note If the limits of maintenance are exceeded, the corresponding notification (notifi-
cation 1 … 3) is output.
3.5.4.9 APMW, RPMW

Pump measurement values

1 Pressure [mbar] integer 100 … 5,500
2 Duty cycle [%] integer 0 … 120
3 Pump current [mA] integer 0 … 9,999
Tab. 64

User's Guide 115
3.5.4.10 AADC
ADC- channels (raw data)

1 Channel 0 (inlet pres- integer 0 … 1024
sure)
2 Channel 1 (outlet pres- integer 0 … 1024
sure)
3 Channel 2 (hydrostatic integer 0 … 1024
tank pressure)
4 Channel 3 (pump integer 0 … 1024
current)
Tab. 65
3.5.5 Measurement of the Total Consumption
3.5.5.1 AATS, EATS

Status of working totalizer

1 Status of working total- integer 0 … Stopped
izer
1 … Started in coarse
mode
2 … Reset (only with
setting command
EATS)
3 … Started in fine
mode
Tab. 66
Condition EATS is only possible in state STBY.
Product Guide
116 User's Guide
3.5.5.2 AATW
Working totalizer

1 Current domain integer 0 … Mass
1 … Volume
2 Status integer 0 … Stopped in coarse
mode
1 … Started in coarse
mode
3 … Started in fine
mode
4 … Stopped in fine
mode
3 Integral value (mass or real 0.000 …
volume) +42,949.673 kg or
0.000 … +42,949.673 l
at rough setting or
0.00 …
+42,949,672.96 g or
0.00 …
+42,949,672.96 ml at
fine setting
4 Integration time real
5 Mean Flow (Mass or real
Volume) [kg/h] or [l]
Tab. 67
Note The measurement values of the integral measurement are lost at switching off
the device or change of domain (stop + reset). If the STBY is left, the working
totalizer is automatically stopped.
3.5.5.3 AHTP, EHTP

Domain setting of the main totalizers

1 n … Totalizer number integer 1, 2
2 Domain setting integer 0 … Mass
1 … Volume
Default: 0
Tab. 68
Note EHTP stops and clears the respective totalizer.

User's Guide 117
3.5.5.4 AHTS, EHTS

Status of main totalizer

1 n … Totalizer number integer 1, 2
2 Status of main totalizer integer 0 … Stopped
1 … Started
Default: 0
Tab. 69
3.5.5.5 AHTW
Main totalizers

1 Domain main totalizer 1 integer 0 … Mass
1 … Volume
2 Status main totalizer 1 integer 0 … Stopped
1 … Started
3 Value of main totalizer 1 real
[kg] or [l]
4 Domain main totalizer 2 integer 0 … Mass
1 … Volume
5 Status main totalizer 2 integer 0 … Stopped
1 … Started
6 Value of main totalizer 2 real
[kg] or [l]
Tab. 70
Note These are only available in the states SPAU and SSRV.
If the system is switched off in state SPAU, no measurement errors arise.
Product Guide
118 User's Guide
3.5.5.6 Communication Examples
Data acquisition
Control mode
0 … Error status
Switch device to state STBY:
<STX> STBY<ETX> <STX> STBY 0<ETX>
numbers have to be updated with
Measurement domain: select mass
<STX> EDMP 0<ETX> <STX> EDMP 0<ETX>
0 … Error status
Start working totalizer
<STX> EATS 1<ETX> <STX> EATS 0<ETX>
0 … Error status
Request general measurement
values or the summation values of
the consumption periodically (e.g. at
1 Hz)
<STX> ASEM<ETX> <STX> ASEM 0 5 R M T 13.672 13.221 1.735 765.23 21.39<ETX>
T … Device function: standby / working totalizer active
765.23 … Density
Tab. 71
Query working totalizer
<STX> AATW<ETX> <STX> AATW 0 0 1 1.230 147.6 30.412<ETX>
numbers have to be updated with 0 … Mass domain
1 … Totalizer started
1.230 … Integral value
147.6 … Integration time
13.570 … Mean flow
Stop working totalizer
Tab. 72

User's Guide 119
<STX> EATS 0<ETX> <STX> EATS 0<ETX>
0 … Error status
After the working totalizer has been
stopped the final value can be read
with AATW.
Tab. 72
3.5.6 Calibration and Adjustment
3.5.6.1 SKCH
Starts a single-point calibration as an accuracy check or during a multi-point cali-
bration.
Mass domain
Calibration unit must be available
Gravitational acceleration must have been entered
(AK commands EGTD, EKGP)
Tank area must have been entered
(AK command EGTD)
Volume flow must be >3 l/h.
3.5.6.2 SATK
Start of the adjustment procedure
A complete multi-point calibration must be available.
3.5.6.3 AKAL
Result of the last single-point calibration carried out

1 Deviation from the cali- real
bration unit [‰], [%/10]
2 Mean mass flow during real
the calibration [kg/h]
3 Status integer 0 … Accuracy check
out of specification
limits
1 … Accuracy check
successful
Tab. 73
Product Guide
120 User's Guide
Information
The status of the accuracy check is compared to the systematic error curve of
the sensor.
C2
R [ % ] = C1 + 100 ⋅ -------
m·
During a multi-point calibration, the evaluation is deactivated and always sends

"Accuracy check successful".
3.5.6.4 ASFP, ESFP

Evaluation curve parameter

1 Coefficient C1 [‰], real 0.0 … 9.9
[%/10] Default: 1.6
kg
2 Coefficient C2 [ /h] real 0.000 … 9.999
Default: 0.004
Tab. 74
3.5.6.5 AKAS
Status calibration procedure

1 Phase of calibration integer 1 … 99
procedure
2 (no function) integer Always #
3 Pressure of the calibra- real
tion sensor [Pa]
4 Instantaneous value real
mass flow [kg/h]
Tab. 75
Condition Only available in SKCH.
3.5.6.6 AKGP, EKGP

Gravitational acceleration

1 Gravitational accelera- real 9.70 … 9.90
tion [m/s2]
Tab. 76
Note In event of transportation to another location, this value has to be entered once –
there is no default value.

User's Guide 121
3.5.6.7 AGTD
Gravitational acceleration and tank data
Due to compatibility reasons, the AGTD provides four parameters, of which the
second and third have no function.

1 Gravitational accelera- real
tion [m/s²]
2 (no function) real Always #
3 (no function) real Always #
4 Tank area [mm²] real
Tab. 77
Note Gravitational acceleration and tank data are requirements for carrying out a cali-
bration.
3.5.6.8 EGTD
Gravitational acceleration and tank data

1 Gravitational accelera- real 9.7 … 9.9
tion [m/s²]
2 Tank area [mm²] real 5000 … 5100
Tab. 78
Note Gravitational acceleration and tank data are requirements for carrying out a cali-
bration.
3.5.6.9 AKLE
Result of adjustment

1 Number of valid partial integer 1…8
calibrations
2 Date of current adjust- string YYMMDD
ment
3 ID of current adjust- string Max. 10 characters
ment
4 Maximum deviation [‰] real 0.00 … 9.99‰ ()
[%/10]
Tab. 79
Product Guide
122 User's Guide
3.5.6.10 ASGJ
Valid adjustments
In ASGJ the optional parameter n selects the desired adjustment – a call without
this parameter returns the current adjustment.

1 Active (selected) integer 0 … Plant
adjustment
1…8
2 Number of valid integer 1…9
adjustments
3 Date of adjustment string YYMMDD
4 ID of adjustment string Max. 10 characters
5 Maximum deviation of real 0.000 … 9.999‰ (%/10)
the adjustment
6 Density range ID integer 0: <795 kg/m³ …gasoline
1: alcohols
(EALC = 1 or 2)
2: > 795 kg/m³ … diesel
7 Manufacturer code of integer
the calibration sensor
8 Device code of the integer Refer to the manual of
calibration sensor the calibration sensor
9 Identifier of the cali- integer

bration sensor
Tab. 80
3.5.6.11 ESGJ
Initialization of the current multi-point calibration with the data of an existing
adjustment.

1 Calibration data of the integer 0 … Plant
desired adjustment
1…8
Tab. 81
Condition Only available in the state STBY.

Note This setting initializes the current multi-point calibration with the calibration
results of the selected adjustment. The next SATK command causes an adjust-
ment with this values.

User's Guide 123
3.5.6.12 AMKS
Status multi-point calibration

1 Deviation of partial cali- real 0.0 … 9.9 kg/h or
bration 1 or set-point 1 … 125 kg/h
flow 1
A # as a prefix marks
an uncorrected devia-
tion.
… … … …
8 Deviation of partial cali- real 0.0 … 9.9 kg/h or
bration 8 or set-point 1 … 125 kg/h
flow 8
A # as a prefix marks
an uncorrected devia-
tion.
Tab. 82
Note Provides values, if a multi-point calibration has been initialized (EMKP, ESGJ).
The command provides uncorrected deviations [kg/h] to the calibration unit or
set-point of the flow [kg/h] of still missing calibration points.
3.5.6.13 AMKP, EMKP

Multi-point calibration parameters

1 Date of adjustment string YYMMDD
2 ID string Max. 10 characters
3 Minimum flow of the real Output always 0 kg/h,
multi-point calibration input ignored
4 Maximum flow of the real 0.00 … 125.00
multi-point calibration Values <16 are set to
[kg/h]
16, values >125 are set
to 125.
Tab. 83
Conditions EMKP is only available in the state STBY.

These values are used to calculate the required flow set-points for the
multi-point calibration. A setting of these parameters clears the contents of
the current multi-point calibration.
EMKP has to be executed before every multi-point calibration to initialize
the internal multi-point calibration of the device.
Note No default values.
Product Guide
124 User's Guide
3.5.6.14 ASEK
Status single-point calibration
ASEK n
n=1…8

1 Set-point flow [kg/h] real
kg
2 Deviation from calibration unit [ /h] real
A # as prefix marks an uncorrected deviation
(before the adjustment carried out).
3 Mean mass flow during the calibration [kg/h] real
Tab. 84
3.5.6.15 AKMW
Calibration measurement values

1 Time since start of the single measurement real
2 Pressure Calibration unit [Pa] real
3 Flow of the sensor real
4 Flow calibration unit real
5 Mean flow calibration unit real
6 Mean deviation calibration unit real
7 Mean deviation sensor real
8 Measurement uncertainty, mean sensor deviation real
Tab. 85
3.5.6.16 AKUG, EKUG

Calibration uncertainty

1 Calibration Uncertainty real 0.03 … 0.5
[%]
Tab. 86

User's Guide 125
3.5.6.17 Communication Examples
Accuracy Check
(only available in mass domain)
Control mode
0 … Error status
Start accuracy check
<STX> SKCH<ETX> <STX> SKCH 0<ETX>
0 … Error status
Periodically acquire measurement
values or calibration (e.g. with a rate
of 1 Hz)
<STX> ASEM<ETX> <STX> ASEM 0 5 R M U 13.672 13.221 1.735 765.23 21.39<ETX>
U … Device function: calibrate. After completion of the calibration: S
765.23 … Density
<STX> AKAS<ETX> <STX> AKAS 0 6 # 5637.5 15.241<ETX>
6 … Calibration phase
5637.5 … Pressure of the calibration sensor
15.241 … Instantaneous mass flow
Querying of the results after the
automatic completion of the accu-
racy check:
<STX> AKAL<ETX> <STX> AKAL 0 0.81 15.361 1<ETX>
0 … Error status
0.81 … Deviation from the calibration unit
15.361 … Mean mass flow during calibration
1 … Accuracy check successful
Tab. 87
Product Guide
126 User's Guide
Multi-point calibration with subse-
quent adjustment
(only available in mass domain)
control mode
0 … Error status
Initialize multi-point calibration
<STX> EMKP 030130 WIESEL 3 <STX> EMKP 0<ETX>
17<ETX>
0 … Error status
Start accuracy check several times
(in this case twice)
<STX> SKCH<ETX> <STX> SKCH 0<ETX>
0 … Error status
Retrieve multi-point calibration state
(provides a rough overview of the
calibration points for the following
eight single-point calibrations)
<STX> AMKS<ETX> <STX> AMKS 0 0.7 0.5 #7 #9 #11 #13 #15 #17<ETX>
numbers have to be updated with 0.7 0.5 … Deviation from the calibration unit
#7 … #17 … Flow set-points, which still must be calibrated. Detailed
information can be requested with the request command ASEK n (n
= 1 … 8).
Tab. 88
The respective flow set-points are used to determine the deviations with the
accuracy check procedure. These deviations are automatically stored by the
AVL Fuel Mass Flow Meter. After completing the multi-point calibration, an
adjustment can be started.
<STX> SATK<ETX> <STX> SATK 0<ETX>
0 … Error status
A few seconds later you can request
the results of the adjustment:
Tab. 89

User's Guide 127
<STX> AKLE<ETX> <STX> AKLE 0 # 030130 DIESEL1 0.09<ETX>
numbers have to be updated with # … Number of existing partial calibrations (invalid after an adjust-
the request command ASTF. ment)
020130 … Date of current adjustment
DIESEL1 … Id of the current adjustment
0.09 … Maximum deviation
Tab. 89
Detailed results can be requested with the request commands ASEK n (n = 1 …

8) or ASGJ.
3.5.7 Service
3.5.7.1 SRES
Reset – stops all running procedures, switches the device to power-on state.
3.5.7.2 SSRV
Service mode – switches the device into the service mode.
Condition State SPAU
NOTICE
All error monitoring and safety appliances are deactivated.

The careless activation of the outputs can lead to damage to the components.
There is no longer response to control signals or control commands (except:
SRES, SDAE and SDAA).
Product Guide
128 User's Guide
3.5.7.3 SDAE, SDAA

SDAE: Switches the internal digital output into the active state.
SDAA: Switches the internal digital output into the passive state.

1 Number of output as shown in the table below
Tab. 90
Note "Active state" and "passive state" refer to the name of the output, rather than the
logic level.
Number Output
1 Pump
2 (no function)
3 Fill valve
4 Stop valve
5 (no function)
6 External venting valve
7 Shutoff valve
8 Venting disable
9 Venting request
10 Status LED
11 DIO out 0: Device OK
12 DIO out 1
13 DIO out 2
Tab. 91
3.5.7.4 EGSZ, AGSZ

Set internal device state.

1 Device state integer 1... Pause
2 ... STBY
3 ... Venting
# … Except in state
Service
Tab. 92
Condition Can only be set in the state Service.

User's Guide 129
3.5.7.5 AIDA, EIDA

Internal digital outputs
0: off / closed
1: on / open
Field Position Description

1 1 Pump
2 (no function)
2 1 Fill valve
2 Stop valve
3 Venting bypass
4 (no function)
5 Option venting valve
0: No venting (on)
1: Venting (off)
6 Shutoff valve
3 1 Venting disable
2 Venting request
4 1 Status LED
5 1 DIO out 0: Device OK
2 DIO out 1
3 DIO out 2
Tab. 93
3.5.7.6 AIDE
Internal digital inputs

1 DIL switch string 0, 1
(8 characters)
2 Sync AVL 753 / AVL char 1st character: venting
Fuel Temperature
Control (1 character)
3 Internal switch string 1st character: tank level
(3 characters) 2nd character: Tank
overflow
3rd character:
compressed air
4 Digital inputs string 1st character: DI(0)
(3 characters) user external (hybrid)
2nd character: DI(1)
emergency stop
3rd character: DI(2)
start venting
Tab. 94
Meaning of the 0 … passive state

character states 1 … active state
Product Guide
130 User's Guide
Note "Active state" and "passive state" refer to the name of the output, rather than the
logic level.
3.5.7.7 APMP
Pump parameter

1 Mode integer 0 … Normal (pressure
control)
1 … Manual (control)
2 … Off (control)
Default: 0
2 Mode 0: integer –200 … 1200
device outlet pressure
[mbar]
Mode 1, 2: integer 0 … 120
duty cycle [&]
Tab. 95
3.5.7.8 EPMP
Pump parameter

1 Mode integer 0 … Normal (pressure
control)
1 … Manual (control)
2 … Off (control)
Default: 0
2 Mode 0, 2:
date can be omitted
Mode 1: integer 0 … 120
Duty cycle [%]
Tab. 96

User's Guide 131
3.5.7.9 AIMW, RIMW

Internal measurement values

1 Flow raw data [kg/h] or real
[l/h]
2 Density [kg/m³] integer 0 … 1000
3 Inlet pressure [mbar] integer –200 … 5000
4 Outlet pressure [mbar] integer –200 … 500
5 Fill height tank [mm] integer –50 … 500
kg
6 Fill rate [ /h] integer 0 … 500
7 Duty cycle pump integer 0.0 … 120.0
control [%]
8 Pump current [mA] integer 0 … 5000
1
9 R.p.m. fan [ /min] integer 0 … 5000
10 Hydrostatic calibration integer 0.000 … 250.000
pressure [mbar]
Tab. 97
3.5.7.10 ARMW, RIMW

Measurement values pump control

1 Flow raw data [kg/h] or real
[l/h]
2 Inlet pressure [mbar] integer 0 … 5000
3 Outlet pressure [mbar] integer 0 … 500
4 Duty cycle pump integer 0 … 120
control [%]
Tab. 98
3.5.7.11 SREE
Read the permanently stored variables out of the EEPROM.
Condition SPAU and error 23 (NV-RAM).
Product Guide
132 User's Guide
3.5.7.12 AAKN, EAKN

Automatic fuel refill

1 State automatic fuel integer 0…1
refill
Tab. 99
3.5.7.13 ESCK
Start the test procedure for the float switch

1 Parameter integer 0 … Stop
1 … Start
Tab. 100
Condition Available only in SPAU.
3.5.7.14 ASCK
Test float switch

1 Float switch test status integer 0 … inactive
1 … active
2 Fill height tank [mm] integer –50 … 500
3 Fill rate [kg/h] integer 0 … 500
4 State float switch integer 0…1
5 Test result integer 0…1
Tab. 101

User's Guide 133
3.5.7.15 ASRV, RSRV

Measurement value, service information

1 Inlet pressure [mbar] integer –200 … 5000
2 Duty cycle pump integer 0 … 120
control [%]
3 Pump current [mA] integer 0 … 5000
4 (no function) 0
5 (no function) 0
6 Pump off (0) / on (1) integer 0/1
7 Valve positions open (1) / closed (0)
7.1 Fill valve
7.2 Shutoff valve in fuel
supply line
7.3 Venting bypass
(1 = venting)
7.4 (no function)
7.5 External option venting
valve
7.6 External option shutoff integer
valve
9 Venting 753C off / on integer 0/1
Tab. 102
3.5.7.16 ARDR, ERDR

Parameter for repeated measurement value transmission

1 Mode integer 0 … Time interval
1 … Measurement time
2 … Calibration
2 Time interval [s] real ≤10
Tab. 103
Product Guide
134 User's Guide
3.5.7.17 AMOD
Register contents of the flow sensor
(The detailed assignment of the addresses and the permitted value ranges are
described in the Micro-Motion Modbus-Manual.)
Query
1 Data format ASCII character
A … ASCII string
C … Coil
F … Float register
H … Holding register
I … Input register
2 Address integer
Tab. 104
Response
1 Value According to field 1 of the query
Tab. 105
3.5.7.18 EMOD
Set the registers of the flow sensor
(The detailed assignment of the addresses is described in the Micro-Motion
Modbus-Manual.)

1 Data format ASCII character
A … ASCII string
C … Coil
F … Float register
H … Holding register
I … Input register
2 Address integer
3 Value According to field 1
Tab. 106

User's Guide 135
3.6 Terminal Mode

In terminal mode, the AVL Fuel Mass Flow Meter is controlled by means of AK
commands. The handling (compared to the standard AK protocol) has been
simplified and adapted to keyboard operation.
1. Connect a PC to the AVL Fuel Mass Flow Meter and start the terminal pro-
gram.
2. Make sure that the correct interface parameters are set in the terminal pro-
gram (for detailed information refer to the documentation of your terminal
program).
For instructions about the interface parameters of the AVL Fuel Mass Flow
Meter please refer to the section Serial Interfaces (X3/X4) on page 48.
3. Activate the terminal mode with <ESC> (Escape).
The system prompts you with the following message:
735S>
4. Enter the AK commands without <STX> as a prefix and complete the input
with <Enter>.
Example
Query of the device ID
If the terminal program prompts you with 735S>, enter the following command:
AKEN <Enter>
The device responds with the following output:
735 Sx.xx
735S>
The device is ready again and waits for the next input.
The terminal mode is automatically terminated if a standard AK command is sent

(e.g. via remote control).
Product Guide
136 User's Guide

Maintenance and Troubleshooting 137
4 Maintenance and Troubleshooting
Information
Before any maintenance work, switch the device to the state Pause. Read the
manometer to check that the fuel pressure is dropped completely and disconnect
all communication lines which could change the operating state (digital I/O,
COM1 and COM2).
Check the safety devices regularly (according to the maintenance plan):
compressed air switch and overflow float switch.
At suitable intervals (weekly), perform an eyeball check of the leak tightness of
the internal and external fuel lines.
Manual switching of the pilot valve is not permitted.
4.1 Maintenance Schedule
4.1.1 Weekly Maintenance

Zero consumption measurement (see section Zero Consumption Measure-
ment on page 139)
Check:
Compressed air switch (see section Check Compressed Air Switch on
page 148)
Float switch (see section Check Overflow Float Switch on page 148)
Emergency stop relay (see section Check Emergency Stop Relay on
page 140)
Check filter mat (and replace it, in case of contamination, see Abschnitt
Filter Mat on page 147)
4.1.2 Maintenance Tasks by Maintenance Indication

Fuel pump, after exceeding the maintenance limit
Fill valve, after exceeding the maintenance limit
Product Guide
4.2 General Maintenance and Operation Tasks
4.2.1 Drain Device
WARNING
Danger of explosion
hermetically.
alcoholic mixtures!
1. Switch device into the state Pause or STBY.

2. Switch off the fuel supply (takes place automatically, if the option "shutoff
valve" is integrated).
3. Start draining (AK command SDRN) and ensure fuel consumption (possibly
by opening the drain lines in the AVL Fuel Temperature Control).
After a few minutes, the device is drained and the device remains in this
operating state.
4. Now, drain any other devices (e.g. AVL Fuel Temperature Control).
Not all internal lines can be drained with this draining procedure:
Return line inside device (~75 ml)
Drain these lines as well as the other fuel lines to and form the engine by
suitably positioned valves.
Information
The AVL Fuel Mass Flow Meter can also be drained by manually closing the fuel
inlet line in state STBY. The device will be drained until the warning "Density too
low" appears.
4.2.2 Fill Device

1. Start the first filling of the AVL Fuel Mass Flow Meter (AK command SFIL). If
the device has been parameterized to Auto-STBY, the device automatically
starts the first filling.
The device fills the internal tank completely with fuel. If due to excessively
low filling pressure, the filling takes longer than 80s, the error "Filling rate
too low" is set. In this case, recheck the pressure of the fuel inlet line and
restart the first filling.

After the complete filling of the internal device tank, the device performs an
internal venting and remains in the state SFIL (permanent venting), until it is
transferred into another state.
Now, all warnings should have been reset.
Information
Ensure proper fuel supply when sending the command for the first filling.
The first filling can also be accomplished in the state STBY (AK command
STBY), but the venting has to be done manually. The state STBY may have to
be activated several times, because the device the device might be set into the
state Pause due to the warning "Density too low".
2. The filling of other fuel devices (e.g. fuel conditioning or engine circuit)
should be done during the internal venting in state SFIL. Always ensure a
good venting of all fuel lines before you switch the device into the state
STBY!
3. Now, you can switch the device into the state Pause (AK command SPAU).
4. If you want to adjust the outlet pressure regulator, switch the device into the
state STBY. Now, adjust the output pressure regulator of the AVL Fuel Mass
Flow Meter to the desired output pressure:
– Return line pressure in combination with a conditioning system
– Supply pressure in systems without return lines
If there is no calibration available for the used fuel, the warning "Adjustment
error" is shown, after the system switches into the state STBY for the first
time.
Make sure that the required minimum pressure of >0.05 bar is maintained!
4.2.3 Zero Consumption Measurement

This test checks the leak-tightness and setting of the valves as well as the
proper operation of the pressure regulator.
1. Make sure that there is no consumption of fuel.
For this, apply a ball valve which you should attach to the fuel line to the
engine right at the outlet of the AVL Fuel Mass Flow Meter.
2. Reset the device to the state STBY and read the consumption measured by
the AVL Fuel Mass Flow Meter.
If the consumption is greater than zero, check the following items:
Fuel line to engine closed?
Bypass venting valve closed?
Visible leaks in the system (visual check)
If the consumption remains, check the following components:
Bypass venting valve leaky
– Remove the valve and check the valve with compressed air whether it
is leak tight.
Membrane in pressure regulator leaky
– This check may be only carried out by the AVL service organization.
Flow sensor defect
– This check may be only carried out by the AVL service organization.
Product Guide
Option venting valve

– Check valve position (setting 0 "external circuit")
– Check leak tightness of the valve seat
Venting valve in AVL Fuel Temperature Control
– Leak Tightness
For detailed information about this subject refer to the Product Guide of AVL
Fuel Temperature Control.
4.2.4 Check Emergency Stop Relay

1. Press the test button on the emergency stop relay (REL1).
2. If the contacts are sticky, the emergency stop relay has to be replaced.
4.2.5 Check Pressure Regulator

1. Close the line "Fuel to engine" right after the device.
2. Reset the device to STBY mode.
3. Vary the setting of the pressure regulator between minimum and maximum
limits.
During this procedure, the flow rate must be zero.
4.3 Replace Components
NOTICE
There are two types of the device AVL 735S, which differ in terms of fuel resis-
tance. See Scope of Delivery on page 15.
Please absolutely make sure that only the appropriate spare parts may be used
for the type 7351CME:
Type "alcohol-resistant" (M100).
The following section contains instructions for the replacement of the following
.
components:
Fuel Pump Standard M20 on page 141
Fuel Pump Alcohol-Resistant M100 on page 142
Pressure Regulator on page 143
Flow Sensor on page 144
Tank Level Sensor on page 145
Fill Valve on page 146
Controller Board on page 147
Filter Mat on page 147

4.3.1 Fuel Pump Standard M20

The following instructions refer to the type "Standard" (Bosch), which corre-
sponds to the mnemonics M20 and E20:
Resistant against diesel and gasoline with a maximum methanol / ethanol
content of up to 20 volume per cent.
You need the following tools:
Wrench/box wrench 7 mm, 8 mm
Wrench 15 mm, 16 mm, 19 mm
1. Drain the AVL Fuel Mass Flow Meter and switch it off.
2. Disconnect the device from power supply
(socket SUPPLY 24 V).
3. Unscrew the pump cable.
4. Remove the pump pressure line.
At works at the line fittings, always counter with a second wrench at the fit-
ting bodies!
– Open the swivel nut of the pressure line.
– Pull out the line upwards.
5. Loosen the swivel nut of the pump suction line.
6. Pull out the pump upwards.
Information
There are fuel residuals in the pump!
7. Unscrew the FC sealing ring and the swivel nut from the pump suction
thread and loosen the screw fitting on the pump pressure side.
The screw fitting of the pump pressure side has to be mounted again on the
replacement pump, the gasket of fluor rubber has to be replaced with the
supplied gasket.
8. Clean the screw fitting at the thread.
9. Seal the screw fitting with a liquid, fuel-resistant sealant (e.g. Loctite 572).
NOTICE
The must never be clamped in its circumference – this would cause deforma-
tions of the pump housing, thus destroying the pump.
10. Assemble the new pump in reverse order of the above steps.
11. Reattach the pressure line.
12. Put the device into operation again.
13. Carry out an eyeball check for leak-tightness.
14. Reset the operating counter to 0.
Product Guide
4.3.2 Fuel Pump Alcohol-Resistant M100

The following instructions refer to the type "alcohol-resistant", which corresponds
to the mnemonics M100 and E100:
Resistant against diesel, gasoline, methanol and ethanol.
Hexagon wrench 5 mm
Wrench 15 mm, 16 mm
3. Unplug the pump cable.
4. Loosen the angle bracket at the mounting plate: Screws with hexagon
5 mm.
5. Remove the pump pressure line.
At works at the line fittings, always counter with a second wrench at the fit-
ting bodies!
– Open the swivel nut of the pressure line.
– Pull out the line upwards.
6. Loosen the swivel nut of the pump suction line.
7. Pull out the pump upwards.
Information
There are fuel residuals in the pump!
8. Clean the screw fitting at the thread.

9. Seal the screw fitting with a liquid, fuel-resistant sealant (e.g. Loctite 572).
NOTICE
The pump must never be clamped in its circumference – this would cause defor-
mations of the pump housing, thus destroying the pump.
10. Assemble the new pump in reverse order of the above steps.
11. Reattach the pressure line.
12. Put the device into operation again.
13. Carry out an eyeball check for leak-tightness.
14. Reset the operating counter to 0.

4.3.3 Pressure Regulator
HINWEIS
There are two types of pressure regulators:

Type "Standard" M20 = BO5329
Type "alcohol-resistant" M100 = BO5940
The pressure regulator may only be removed or maintained by AVL. At problems
with the pressure regulator, only the whole unit can be replaced.

Hexagon wrench 5 mm
Wrench 15 mm, 16 mm, 18 mm, 19 mm, 27 mm
4
A
1 .....Pressure sensor ML025PG1PC 1.7 bar

2 .....T-screw fitting
3 .....Pressure sensor ML100P52PC 6.9 bar
4 .....Line diameter 10 mm
Fig. 67
2. Disconnect the device (A) from power supply
3. Unplug the plugs of both pressure sensors from the pressure regulator and
note the position for the later assembly.
4. Loosen the swivel nuts of all pipe lines with diameter of 8 mm (wrench
15/16 mm) and disconnect the pipe lines carefully from their screw fittings.
5. Loosen the swivel nuts of the pipe line with diameter of 10 mm (wrench
19/18 mm) and disconnect the pipe line carefully from their screw fittings.
6. Loosen the pressure regulator form the angle bracket at the mounting plate:
Screws with hexagon 5 mm.
7. Remove the pressure regulator. At the same time push the tank return line
slightly away.
Information
Be careful at the removal, because the regulator contains fuel!
Product Guide
8. Disassemble both pressure sensors and the manometer

9. Disassemble the T-screw fitting
10. Remove sealant residuals at the threads, if required
11. Install the pressure sensors and teh T-screw fitting with the apropriate
fuel-resistant teflon sealing band at the replacement regulator.
12. The installation of a new pressure regulator is made in the reverse order of
the above steps.
13. Finally carry out an eyeball check for leak-tightness.
4.3.4 Float Switch Standard M20
WARNUNG
Fuel overflow
The float switch must only be replaced by specially trained staff (e.g. AVL service
engineer).
Handling the float switch without special training may lead to personal injury and
physical damage.
4.3.5 Float Switch Alcohol-Resistant M100
WARNING
Fuel overflow
The float switch must only be replaced by specially trained staff (e.g. AVL service
engineer).
Handling the float switch without special training may lead to personal injury and
physical damage.
4.3.6 Flow Sensor

Screw driver for slotted screws
Wrench 18 mm and 19 mm
Hexagon wrench 5 mm
Box wrench 10 mm
3. Remove the cover from the electronic housing.
4. Loosen the connectors of the sensor cable.
Refer to the table below for the pin configuration.
5. Loosen the die PG screw fitting and pull out the sensor cable.
6. Turn around the electronic housing and remove the ground cable with a
slotted-screw driver.
7. Loosen the connector pieces with the wrenches 18 mm and 19 mm.

8. Loosen the sensor mounting screws and replace the sensor (hexagon
wrench 5 mm and box wrench 10 mm).
9. The assembly is made in reverse order.
Clamp Color sensor cable

A Yellow
B Green
+ White
- Brown
Tab. 107
4.3.7 Tank Level Sensor

Angled screw driver for cross-recessed screws
Wrench 22 mm
Hexagon wrench 5 mm
1 .....Valve
2 .....Calibration block
3 .....Sensor
Fig. 68
3. Loosen the screw fitting of the calibration block (hexagon wrench 5 mm)
and disassemble the calibration block.
Information
There is residual fuel in the sensor, which cannot be drained!
Product Guide
4. Remove the plug of the tank level sensor after loosening the screw fitting
(cross-recessed).
5. Disassemble the tank level sensor with wrench 22 mm.
6. Install a new sensor. Do not tighten the screw fitting too strongly, low hand
power is sufficient!
7. The remaining assembly is carried out in reverse order.
4.3.8 Fill Valve

Angled screw-driver for cross-recessed screws or short ratchet with
cross-recessed insert
Wrench 19 mm and 22 mm
Hexagon wrench 5 mm
1 .... Valve
2 .... Calibration block
3 .... Sensor
Fig. 69
3. Loosen the screw fitting of the calibration block (hexagon wrench 5 mm)
and disassemble the calibration block.
Information
There is residual fuel in the sensor, which cannot be drained!
4. Remove the plug of the tank level sensor after loosening the screw fitting
(cross-recessed).
5. Disassemble the tank level sensor with wrench 22 mm.
6. Loosen the plug of the fill valve cable from the valve (with a screw driver).
7. Disassemble the solenoid spool after removing the nut (SW 19 mm).

8. Replace the fill valve.

9. The remaining assembly is carried out in reverse order.
Information
Do not tighten the screw fitting of the fill level sensor too strongly, low hand
power is sufficient!
4.3.9 Controller Board

Angled screw-driver for cross-recessed screws or short ratchet with
cross-recessed insert
Special box wrench EU2508
(assembly wrench for C091)
Hexagon wrench 3 mm
Small screw driver for slotted screws
1. Switch off the AVL Fuel Mass Flow Meter.

3. Disassemble all plugged cables from the outside of the device: Unscrew the
plugs and unplug them.
4. Disassemble the cover of the circuit board (cross-recessed).
5. Unplug all cables from the controller board.
6. Loosen the fitting from the frame of the controller board at the outside of the
device (3 mm hexagon).
7. Loosen the ring nut of the sockets at the controller board by means of the
aforementioned special wrench (outside of the device).
8. Remove the controller board including the frame.
9. Loosen the cross-recessed screws and disconnect the controller board from
the frame.
10. Carefully loosen the NV-RAM at socket I20 (with the small screw driver for
slotted screws). Install the RAM of the old board into the new replacement
board. That way, all configuration data are transferred to the new board.
11. Assemble the controller board in reverse order.
4.3.10 Filter Mat

The filter mat is located in the upper left of the device in front of the fan.
1. Withdraw the old filter mat.
2. Insert the new filter mat.
Product Guide
4.4 Check of Safety Equipment
4.4.1 Check Compressed Air Switch

Does the output signal of the compressed air switch conform to the status of the
compressed air supply?
1. Reset the device into the operation state STBY.
2. Disconnect the compressed air supply and make sure that the pressure at
the device inlet drops under 3.5 bar.
3. Check whether the error 9 "No compressed air" has been set.
4.4.2 Check Overflow Float Switch

This test is carried out completely automatically.
Activate the corresponding function in your user interface (PC program, remote
control …).
See item "Warning No. 15: Tank Overflow" in section "Help for Troubleshooting"
of the Online Help.

4.5 Overview of Errors
4.5.1 Error Messages

The AVL Fuel Mass Flow Meter signals the errors according to the AK protocol in
the form of error codes signaling a maximum of 32 errors. The error codes are
arranged in three categories:
Notification (No. 1 … 4)
Warning (No. 7 … 23)
Error (No. 26 … 31)
Warnings and critical errors cause the device to switch into the state Init Pause.
After notifications the device remains in the current operating state.
Notifications Notifications inform the user about the corresponding device state (e.g. "Mainte-
nance limit exceeded").
Warnings Warnings require an action of the user (e.g. the error "Filling rate too low"
requires opening the fuel supply).
Information
In case of critical errors:

Contact the AVL service organization!
4.5.1.1 Notifications
This section is only used as a short overview.
For a detailed description with instructions for the correction and spare part
numbers refer to section "Help for Troubleshooting" in the Online Help.
No. Error Checked in Device response Reset error Measure

device state
735s / (PUMA)
1 Maintenance limit Exceeded main- — After replacing a Replace pump
pump tenance limit component and and reset counter
(Maintenance (5,000 h) resetting the error to zero
Limit Main Pump)
2 No tank data Start accuracy Remains in state Transition to Enter tank data
entered check STBY STBY or entering (see test protocol)
tank data
(Maintenance
Limit Bypass
Data)
3 Maintenance limit Exceeded main- — After replacing a Replace fill valve
fill-valve tenance limit component and and reset counter
(500,000 resetting the error to zero
switching opera-
tions)
4 State Bypass Setting switch No display of Reset switch —
(Calibration Error) DIL8 (switch measured value, DIL8 and Reset
block S3) and AK only fuel supply
command STBY
Tab. 108
Product Guide
4.5.1.2 Warnings

device state
7 Adjustment error During the calcu- Default adjust- After successful If necessary
(Adjustment lation of the fit- ment is used calculation repeat the cali-
Error) ting polynomial in bration point
Init STBY and
start of the adjust-
ment (SATK)
8 No gravitational Accuracy check Remains in STBY Transition to Enter the gravita-
acceleration STBY or enter the tional accelera-
entered gravitational tion
acceleration
9 No compressed Always, except State Pause As soon as com- Ensure supply of
air during state pressed air is compressed air
Pause available again
11 Density too low Init STBY, STBY, State Pause Init STBY Ensure fuel
Accuracy Check, supply and acti-
Venting, if specific vate state STBY
gravity for 5s < or Filling
500 kg/m³
13 Pump overload Init STBY, STBY, State Pause Init STBY Check valve set-
Accuracy Check, tings
Venting Check pump cir-
cuit on blockage
Check pump
function
14 Filling rate too low Init STBY, STBY, — If problem is Ensure fuel
Accuracy Check, resolved supply or a higher
Venting fill pressure might
be necessary
15 Tank overflow Always Closes fill valve If problem is Drain overflow
and shutoff valve resolved
Check fill valve
17 Emergency-stop Init STBY, STBY, State Pause If problem is Close emer-
Accuracy Check, resolved gency stop circuit
Venting
18 Error fill-valve Init STBY, STBY, Automatic filling is Init STBY Ensure fuel
Accuracy Check, stopped supply and acti-
Venting vate state STBY
Check fill valve
If necessary, let
the device cool
down
23 Error NV-RAM Init Pause Non-volatile data If problem is Replace NV-RAM
(EEPROM Check of the EEPROM resolved and restore the
are not perma- data of the
sum error)
nently stored EEPROM with
the AK command
SREE
Tab. 109

4.5.1.3 Errors

device state
26 Error flow sensor All states except State Init Pause Reset Replace sensor
(Error flow Init Pause (only by an AVL
sensor) Service on error service organiza-
tion)
of sensor elec-
tronics
27 Communication Accuracy check State Init Pause Reset Replace sensor
error calibration (only by an AVL
sensor service organiza-
(Calibration tion)
sensor)
28 Error EEPROM During the access State Init Pause Reset Replace board
to the EEPROM (only by an AVL
(EEPROM read /
write) service organiza-
tion)
29 General device Always State Init Pause Reset Check pressure
error sensor, board and
(DAC error) cable (only by an
AVL service orga-
nization)
30 Communication All states except State Init Pause Reset Check cabling,
error flow sensor Init Pause board and sensor
Service on error (only by an AVL
of sensor elec- service organiza-
tion)
tronics
31 Fan blocked Always State Init Pause Reset Replace fan
Tab. 110
Product Guide
4.6 Error Diagnosis
4.6.1 Valve Positions and Pump States
Component State
Init Pause Pause Function STBY Venting

Bypass
(STBY)
Fill valve Closed Closed Automatic Automatic Automatic
kg
Stop valve Closed: density >700 /m³ Closed Open Open
Open: <700 kg/m³
Bypass venting valve Open Open Open Closed Open
Pump Off Off Off Regulated Statically on
Shutoff valve (option) Closed Closed Open Open Open
Venting valve (option) Venting Venting External cir- External cir- Venting
cuit cuit
Tab. 111
4.6.2 Defective Function
4.6.2.1 Outlet Pressure Fluctuations

Check the manometer value for the specified range (10 … 50 kPa).
Venting the device (Venting)
4.6.2.2 Outlet Pressure Not Adjustable

Check the following:
Valve settings
Compressed air supply

4.6.2.3 Venting with AVL Fuel Temperature Control

If the pressure drops relatively below 50 kPa, control the following points:
Valve settings
Compressed air supply
Sync line (pin connection)
Product Guide
4.7 Wear and Spare Parts

Component overview
Fig. 70

Pos Description Standard 7351CST Alcohol-resistant

7351CME
1 Screw connector (male) DN1564
2 Screw plug DN1823
3 Fuel pump 24 V DC MV0209SP BV2727SP
(including FC sealing ring YM4042)
– FC sealing ring YM4042
4 Tank complete BO5330
5 NPT male elbow DN1013
6 Hose line 280P DR0439
7 Male elbow DN1566
8 Pneumatic ball valve MM0676SP
9 Protection cover YM4015
10 Level sensor EZ0284
11 Fill valve MM0840SP
12 Pressure switch EZ0222SP
13 Silencer MY0100
14 Valve block connection module left MM0666
15 Solenoid valve 4/2-way MM0665SP
17 Hose line 200P DR0440
18 Mass flow and density sensor EZ0276
19 Pressure gauge outlet pressure MA0070 MA0074
20 Pressure regulator BO5329SP BO5940SP
21 Inlet pressure sensor EZ0278
22 Outlet pressure sensor EZ0277
23 Pneumatic ball valve MM0676SP MM0677
24 Pump sealing YM4042
25 Connecting piece DN0408 DN0622
26 Ball valve MM0843 MM0501
27 Double nipple DN0673 DN0539
28 Valve block connection module right MM0667
29 Straight union piece DN1479
30 Protection bow ZG3628
31 Adapter YM3525
32 T-screw fitting DN1499
33 Screw connector (male) DN1564
Tab. 112
Product Guide
Wearing parts
Description Standard Alcohol-resistant Number Spare or wear

7351CST 7351CME part
Fine Filter Mat IP54 x x EI0278SP V
Fill valve - x MM0389SP V
Fill valve x - MM0840SP V
Fuel pump including pump x - MV0209SP V

sealing YM4042
Fuel pump - x BV2727SP V
(use existing connections, no
additional sealing required)
Solenoid valve 4/2-way, 2 … 10 x x MM0665SP V
bar, 6 mm, 24 V
Tab. 113

Spare parts
Description Standard Alcohol-resi Number Spare or wear

7351CST stant part
7351CME
Solenoid spool for fill valve type 0801 x x ME0109SP E
Outlet pressure sensor: x x EZ0277 E

pressure sensor ML025PG1PC, 1.7 bar,
1/8 NPT
Controller Board Fuel Meter x x BB1120SP E
Compressed Air Switch x x EZ0222SP E
Pressure regulator complete - x BO5940SP E
Pressure regulator complete x - BO5329SP E
Inlet pressure sensor: x x EZ0278 E

pressure sensor ML100PG2PC, 6.9 bar,
1/4 NPT
Tank level sensor: x x EZ0284 E
pressure sensor PR23S, 0 … 200 mbar,
G1/4"
Ball valve for the drain cock Overflow - x MM0501 E
tank and ball valve Fuel to engine
Ball valve for the drain cock Overflow x - MM0843SP E
tank and ball valve Fuel to engine
Fan x x BV2690 E
Manometer 0 … 1 bar, 63 mm, G1/4" at x x MA0070 E

the backside
Emergency stop relay (REL1) x x ER0207 E
Pneumatic ball valve for shutoff valve x - MM0676SP E

and for venting bypass valve
Pneumatic ball valve for shutoff valve - x MM0677SP E
and for venting bypass valve
Tank cap sealing O-ring 70 × 4 Viton x x DA0381SP E
Tank foot sealing radial O-ring 84 × 2 x x DA0445 E

Viton
Tank foot sealing O-ring axial 80 × 3 x x DA0389 E
Viton
Valve block connection module left x x MM0666 E
Valve block connection module right x x MM0667 E
Locking nipple at the device for the x x MZ0018 E

connection of the calibration unit AG 1/4"
Loctite 542 HD0010 E
TEFLON sealing band DN1200 E
NV-RAM x x EE0669 E
Tab. 114
Product Guide
4.8 Controller Board

Assembly diagram
5 4 1 2 3
7
8
9
10
11
12
13
14
15
16
17
ST
Fig. 71

LED functions on The descriptions in the column Plan refer to the numbering in the figure above.
the controller
The position designations refer to the figure in section General on page 66.
board .
LED Plan Color ON = illuminated Off Interface

LED 1 1 Red Fill valve (Pos. Desc. 2) Fill valve closed -
open
LED 2 2 Red Shutoff valve (Pos. Desc. Shutoff valve closed -
5) open
LED 3 3 Red Venting/bypass valve (Pos. Venting/bypass valve open -
Desc. 8) closed
LED 4 4 Red Option venting valve (Pos. Option venting valve - -
Desc. G) - no venting Venting
LED 5 5 Red Option shutoff valve (Pos. Option shutoff valve closed EXT.VALVE (X1)
Desc. F) open
LED 6 6 Green RUN = Slowly flashing
DOWNLOAD = Rapidly
flashing
LED 7 7 Green Emergency closed Emergency off E-STOP (X7)
LED 8 8 Red No compressed air Compressed air available -
LED 9 9 Red Tank overflow (Pos. Desc. No tank overflow -
3)
LED 10 10 Yellow SYNC IN VENTING No venting SYNC (X2)
LED 11 11 Red SYNC OUT Venting Dis- Not locked SYNC (X2)
able
LED 12 12 Yellow IN: SET DEVICE OK - Digital I/O (X5)
LED 13 13 Yellow IN: TRIGGER - Digital I/O (X5)
LED 14 14 Yellow IN: venting - Digital I/O (X5)
LED 15 15 Green OUT: Device OK - Digital I/O (X5)
LED 16 16 Green OUT: TRIGGER - Digital I/O (X5)
LED 17 17 Green Reserved - -
Status ST Green Function see Error Display - -
at the Status LED on
page 160
Tab. 115
Product Guide
4.8.0.4 Error Display at the Status LED

During a notification or an error, the status LED flashes at the front side of the
AVL Fuel Mass Flow Meter with different frequencies.
The following table shows the possible signals and their meaning.
Status LED Possible causes Correction Device state

No power supply Check power supply
Device switched off Switch on the device at the
Not illuminated mains switch Device not operating
Fuse blown out Check fuses and replace, if
required
Cable to status LED defect Replace cable and plug in
or unplugged
Flashes fast Error occurred Check error message, cor- Errors
(~ 9,6 Hz) rect error and reset device
Flashes Function booting acitve Reset Device at start-up
(~ 3,2 Hz) (permissible software
update)
Flashes slowly Notification or warning Check error message, cor- Normal operation with
(~ 1,4 Hz) occurred rect error, if required notification or warning
Permanently illumi- Device o.k. No notifications, warnings Normal operation
nated or errors occurred
Tab. 116

1 2 3 4 5 6 7 8
+2.5V_1 IOK1
+5V +5V_2 +2.5V_1 + 24V_1 +24V_ 1 +5V nicht bestueckt PORT0(7)
470K
R66 0.3A
4.8.1
X3 / 1
EU1080
J8 / 5
J8 /7
J8 / 8
J8 / 2
J8 /3
J8 / 9
J8 /1
J8 / 4
J8 /6
2R2 10NF 8
+5V +5V +5V +5 V
Fig. 72
R75
R91
R93
R74 L7
68R
TL16C452 TL16C452
150R
22K C81 LT1180
BAS21 BAS21 0.3A X3 / 2
17
18
6 28 24 0 1 2 3 28 24
CTS0 RTS0 CTS0 RTS0 0.1uF
A c 7 25 25 VCC ON_OFF* 2
C83
C71
D43 D42 T19 TLC3702CD 31 DSR0 31 DSR0 0.1uF C1_P
DTR0 DTR0 L9
MMBT3904 5 29 26 29 26 3 4 C9
RLSD0 RLSD0 C1_N
33uF
33uF
BAS21 BAS21 SOUT0 SOUT0 VPOS
22K
b ACE1 ACE1 X3 / 3
R67
30 45 LT1180 30 45 C8 5
0.1uF
C82
C70
I31 RI0 INT0 RI0 INT0 C2_P
D39 D38 e 41 +5V +5V 41 7 6
0.1uF
0.1uF
+5V_2 e SIN0 SIN0 VNEG C2_N
17
18
4 32 HSI(0) 1 0.1uF 10 32 C1 C2 0.1uF
T18 12 CS0 VCC ON_OFF* CS0 uP RS232 X3 / 4
8 MMBT3906 0.1uF
2
C1_P
R92
68R
b 13 12 2 3 4 C114 13 12 11 TR2_ IN TR2_OUT 8
CTS1 RTS1 VPOS C1_N CTS1 RTS1
2 c 5 11 C102 5 5 11
1K2 DSR1 0.1uF C2_P DSR1
RS232(3:0)
J9 / 1 1R 10uF 10K 82K DTR1 0 DTR1 REC2 _OUT REC2_IN X3 / 5
1 LT1366 8 10 7 6 8 10 10 9
COM 1
R96 R85 R78 R72 RLSD1 SOUT1 VNEG C2_N RLSD1 SOUT1
C85 3 6 ACE2 60 C91 C103 0.1uF 6 ACE2 60
RI1 INT1 uP RS232 RI1 INT1 PORT2(2)
+5V TR1_ IN TR1_OUT
C92
12 15
MONITOR(2:0)
I32 62 SIN1 62 SIN1
TR2_IN TR2_OUT
0 X3 / 6
20 0 11 8
10uF
3 CS1 11 3 CS1
R77
4
2K7
+5V 13 REC1 _OUT REC1_IN 14
4N7
J9 / 2 + 2. 5V _1 REC2_OUT REC2_IN
1
0 14 53 0 1 10 9 0 14 53 0
C89
330R DB0 PD0 DB0 PD0 0.3A X3 / 7
EU1218
10K
R63
1 15 52 1 1 15 52 1 GND
R79 DB1 PD1 2 DB1 PD1
+ 5V 2 16 51 2 2 12 TR1_IN TR1_OUT 15 2 16 51 2 I3
PRESSURE TRANSDUCER
DB2 PD2 DB2 PD2 L8
16
10K
R14
0.1uF + 5V 3 17 50 3 3 17 50 3
DB3 PD3 3 DB3 PD3 X3 / 8
+5V_2 C80 HT2012 4 18 49 4 13 REC1_OUT REC1_IN 14 4 18 49 4
EINPRESSBOLZEN M3 DB4 PD4 DB4 PD4
+5V EU2187
+ 2. 5V _1 +2.5V_1 1 27 5 48 5 5 48 5
FPROG
VCC ITXD 19 DB5 PD5 19 DB5 PD5
DIL1(7:0)
8
B 14 6 20 47 6 GND 6 20 47 6
4K7 ORXD DB6 PD6 DB6 PD6
R94
R84
220K
150K
8 16 17 7 21 46 7 I39 7 21 46 7
SCHIRM R73 OTXA INRTS DB7 PD7 DB7 PD7
16
2 4 3
IRXA OCD PARALLEL PORT PARALLEL PORT 0.3A
DATA_BUS(7:0)
1 X4 / 1
AR1
AR1
AR1
AR1
AR1
AR1
AR1
AR1
10K
5 TLC3702CD 2 28 63 63
7 2K7 O19K2 CLOCK ERROR ERROR DIL8POL
4.7NF LT1366 3 26 65 59 65 59
J15 / 1 J15 / 2
R80 TEST0 SLCT INT2 SLCT INT2 0 L11
CONTROL SIGNALS 6 I31 13 15 66 58 2N7002 66 58 1 16 S1 1
TEST1 GND BUSY SLIN BUSY SLIN 0.3A X4 / 2
C84 5% 67 57 D 67 57 15 S2 2
I32 I35 PE INIT RES1 / 1 RES1 / 2 PE INIT 2
0 RESET 68 56 68 56 14 S3 3
4 ACK AFD RESET_IN ACK AFD 3 L10
4 S
1 RD 1 55 G 1 55 4 13 S4 4
LPTOE STB LPTOE STB X4 / 3
38 13 38 12 S5 5
Circuit Diagrams
2 WR 21 CS2 T20 CS2 5

82K 74HC4060D 11 6
S6
3 ALE R81 6
0 35 0 35 10 S7 7
4 READY 2M2 A0 PORT1(7:0) A0 7 X4 / 4
7 1 34 SELECT 1 34 SELECT 9 S8 8
R83 820K Q3 A1 A1
5 BUSWIDTH 11 5 2 33 CONTROL 44 +5V 2 33 CONTROL 44
R64 RS Q4 A2 BDO A2 BDO S3
6 BOOTROM 390K LOCIG LOCIG
10 4 2 36 2 36
44 0
43 1
42 2
40 19
39 18
38 17
37 16
36 15
41 3
R82 7.372MHZ 820R CTC Q5 IOW IOW X4 / 5
7 FLASH 9 6 1 37 26 1 37 +5V
R65 RTC Q6 IOR IOR
COM 2
33PF 12 14 0 39 39
IO28
IO27
IO26
IO25
IO24
IO23
8 RAM RES Q7 RESET CONTROL_BUS(3) 0 RESET
VDD_VCC
C90 Q2 4 I34 14 4 I33
13
C55
C56
1 34
IO_GCK2
IO_GCK1
IO_GTS1
DIL2(7:0)
C 9 NV-RAM Q8 CLK IO_GCK3 IO_GTS2 CLK X4 / 6
15 5 2 IO1 IO_GSR 33 13
33PF
33PF
10 UART1 Q9
AR2
AR2
AR2
AR2
AR2
AR2
AR2
AR2
10K
1 6 3 IO2 IO22 32 12
nicht Q11 CLOCK CLOCK DIL8POL
2M2
+5 V I28
R95
R97
120K
11 UART2 2 7 5 IO3 IO21 31 11
bestueckt Q12 J14 / 1 DIL2(7:0) 0 X4 / 7
12 UART3 3 8 6 IO4 XC9536 IO20 30 10 16 S1 1
Q13 1
+5 V
CONTROL_BUS(21:0)
9 9 15 S2 2
ADDRESS_BUS(15:0)
13 PARPORT1 7 IO5 IO19
29
I30 J14 / 2 2
10 8 28 8 14 S3 3
14 PARPORT2/UART4 IO6 IO18 3
+5V + 5V +5V 74HC74 7 13 4 X4 / 8
+5V 9 TDI IO17 27 S4
15 ADDR_15 CLK1 J14 / 7 4 EU2187
4 S 10 24 12 S5 5
TMS TDO 5
16 ADDR_16 3 5 + 5V 74HC74 6 11 S6 6
22PF
22PF
C1 11 TCK IO16 23 6
10K
10K
J14 / 9
RESET_IN
2 6 10 10 S7 7
R110
R111
17 MMO 1D S CLOCK 7
4K7
8K2
4K7
CONTROL_BUS(0)
1 Q1 11 9 9 S8 8
R112
R113
R101
ADDRESS_BUS(15:0)
C51
C52
J18 / 2
18 DAC R C1
IO10
IO11
IO12
IO13
IO14
IO15
IO7
IO8
IO9
TL7702 nicht 12 8 J14 / 4 CONT1 /1
19 LOAD DAC 1D S4
2 5 bestueckt I26
+5V 13
12
13
14
16
18
19
20
22
21
RESIN RESMIN 20MHZ R J14 / 6 CONT1 / 2
20 UART4 10uF/35V
21 PARPORT2 7 6 I26 +24V_1 EI0288
11 12 13 14 15 1 2 4 5
J18 / 1
SENIN RES 4K7 CONT1 /3 0.5A 25V/6A /VAR 50 V
C50 20 14 21 1 3
CT VREV R62
CONTROL_BUS(21:0) F1
3 1 I38
PORT0(7:0)
D
0.1uF
7 6 2 0 1 3 5 3 1
10K
RESET1
R114
L6
10uF
DATA_BUS(15:0) 2
0.1uF
+24V_1
9
8
7
6
5
4
3
2
1
68
67
66
65
64
63
62
61
C101
C113
C111
+5V
Vpp
1 VPP 1 VPP
Product Guide
I11 MMO(7:0)
st1
6 22 7 22 74HCT273
I19 CE CE
I13
I14
I18 1 1 0
+5VANA 74HCT573 24 24 1
OE OE R
F11
+5V +5V +5V +5V 1 31 2 31 17 11
0.5A
10uF/35V
ACH7_PO.7
ACH6_PO.6
ACH2_PO.2
ACH0_PO.0
ACH1_PO.1
ACH3_PO.3
NMI
EA*
VCC
VSS1
XTAL1
XTAL2
CLKOUT
BUSWIDTH
INST
ALE_ADV*
RD*
EN WE WE C1
5 10 60 0 3 11
J11 / 1 ACH5_PO.5 AD0_P3.0 C1
C40 4 11 59 1 0 12 0 12 628128 0 3 2 0
ACH4_PO.4 AD1_P3.1 A0 0 A0 0 1D
28F010_smd
28F010_smd
0.1uF 12 58 2 0 2 19 0 1 11 13 1 11 13 0 12 1 4 5 1
J11 / 2 C43
ANGND AD2_P3.2 3 A1 DQ0 A1 DQ0 A0
10K
10K
R21
R20
13 57 1 3 18 1 2 10 2 10 1 11 13 0 2 7 6 2
MAX487E VREF AD3_P3.3 A2 1 A2 1 A1 I_O0
4
4K7
R23
14 56 2 4 17 2 3 9 14 3 9 14 2 10 14 1 3 8 9 3
J11 / 3 VSS2 AD4_P3.4 5 A3 DQ1 A3 DQ1 A2 I_O1
8 VCC 1 15 55 3 5 16 3 4 8 4 8 3 9 15 2 4 13 12 4
R EXTINT_P2.2 AD5_P3.5 A4 2 A4 2 A3 I_O2
7 B 2 16 54 6 4 6 15 4 5 7 15 5 7 15 4 8 17 3 5 14 15 5
J11 / 4 B RESET* AD6_P3.6 7 A5 DQ2 A5 DQ2 A4 I_O3
6 A 3 17 80C196KC 53 5 7 14 5 6 6 6 6 5 7 18 4 6 17 16 6
RXD_P2.1 AD7_P3.7 A6 3 A6 3 A5 I_O4
EU1219 6 5 7 7
FLOW SENSOR
5 4 +5V + 5V 18 52 8 8 13 6 7 5 17 7 5 17 6 6 19 18 19
D TXD_P2.0 AD8_P4.0 A7 DQ3 A7 DQ3 A6 I_O5
A GND 7 6
2 0 19 51 9 9 12 7 8 27 4 8 27 4 7 5 20
P1.0 AD9_P4.1 A8 A8 A7 I_O6
E EINPRESSBOLZEN M3 I9 1 20 50 10 9 26 18 9 26 18 8 27 21 7
D9
P1.1 AD10_P4.2 A9 DQ4 A9 DQ4 A8 I_O7
FPROG
4K7
R22
2 21 49 11 74HCT573 10 23 5 10 23 5 9 26
P1.2 AD11_P4.3 A10 A10 A9
R9
10K
+5V +5V 3 22 48 12 1 11 25 19 11 25 19 10 23 +5V 12 2 19 7
BAS86
PWM1_P1.3 AD12_P4.4 EN A11 DQ5 A11 DQ5 A10 23 A12 D7
4 23 47 13 11 12 4 6 12 4 6 11 25 11
SCHIRM PMW2_P1.4 AD13_P4.5 C1 A12 A12 A11 A11
0 24 46 14 13 28 20 13 28 20 12 4 22 8 10 21 18 6
HSI0 AD14_P4.6 A13 DQ6 A13 DQ6 A12 CS1* 24 A10 D6
+5V 1 25 45 15 8 2 19 8 14 29 14 29 13 28 30 9
HSI1 AD15_P4.7 A14 7 A14 7 A13 CS2 A9
10K 25 17
10K
10K
9 1 5
R31
R30
X24C08 3 2 26 44 3 18 9 3 21 15 3 21 14 3 24 8
R8 HSI2_HSO4 T2CLK_P2.3 A15 DQ7 A15 DQ7 A14 OE* 3 A8 D5
1 8 10 4 17 10 2 16 2 31 29 2 7
A0 VCC A16 A16 15 A15 WE* A7
2 7 11 5 16 11 30 30 2 1 6 4 16 4
A1 TEST 6 7 NC NC A16 NC A6 D4
3 6 6 12 6 15 12 5 5
A2 SCL 16 A5
4 13 7 14 I27 4 6 15 3
10NF
5 7 13
D8
GND SDA A4 D3
14 7
HSI3_HSO5
HSO0
HSO1
P1.5_BREQ*
P1.6_HLDA*
P1.7_HOLD
P2.6_T2UP-DN
HSO2
HSO3
VSS
VPP
P2.7_T2_CAPT
PWM_P2.5
WRL*_WR*
WRH*_BHE*
T2RST_P2.4
READY
8 13 3
1NF
1NF
14 A3
I10
PROG
15 9 12 8 13 2
C7
15 2
BAS86
A2 D2
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
3 1 9
C16
C15
I16 10 A1 12
0 1
ADDRESS_BUS(15:0) A0 D1
0 1
2 27 11 0
HSO(3:0) +5V 22 WE D0
2 1
3 20 OE
F 9
HSI(3:0) 4 CE
4 5 6 7 1
NC1
I20
2 26 PM1
PORT1(7:0) NC2
BQ4010
28 14 PM2
6 7 5 4 3 VCC1 GND PM3
+5V
PORT2(7:0)
SZT-0654 1 3 12.02 W.M. Datum 4.2002 Benennung =
Bearb
ZM1105
SZT-0481 1 2 10.02 W.M. H.E.S./S.H. CIRCUIT DIAGRAM
DIGITAL CAD Z.Nr.
SZT-0481 1 1 07.02 LIE Gepr K.GRUBER ID.NR. Blatt 1
Aenderung Rev Datum Name Norm Urspr Ers f Ers d

FUEL METER 735S BB1120 7350L05./C00D1 3 Bl
REPRODUCED IN ANY FORM, EITHER IN WHOLE OR IN PART, OR MADE

AVAILABLE TO ANY THIRD PARTY OR USED FOR MANUFACTURING OR ANY
OTHER PURPOSE WITHOUT THE PRIOR WRITTEN PREMISSION OF AVL LIST GMBH.
COPYRIGHT c 2002 AVL LIST GMBH, ALL RIGHTS RESERVED

THIS DRAWING IS THE PROPERTY OF AVL LIST GMBH AND MAY NOT BE
Maintenance and Troubleshooting
161
162
1 2 3 4 5 6 7 8
+5V +5 V +5V
+24V_ 1 V5_POS1
0.47uF 0.47uF 0.05A 0.3A
+5VANA +5V_1 +15V X2 / 1
SPR3 +5V OUT
Fig. 73
+5V C58 C46
78L05 MMO(7:0) BSP78 F6 L3
470R
470R
1 8
R119
R120
OUT IN
100K 100K 5 1 IN X2 / 3
D 2
R58 R41 GND1-4 +1 5V VENT. REQUEST
+5VANA
F13
A
0.05A
L5
8K2
+15V
R42
7
6
3
2
D34
J10 / 1 8
ROT
+ 5VANA
GELB
3
10uF
0.1uF
ULN2003
LY_T670
LS_T670
8 82K S
9 COMMON
BAS21
T5
C28
SEN1
C18
LED10
LED11
R43 PORT0_2 3 4
4 14 3
J10 / 2 47K 6 47R 1 BSP78
8
R54 R33 AD706 GND 0.3A
7 33K 2 4 X2 / 4
AD706 2 ULN2003 1 IN D 2
I8
SYNC
R57 VENT. DISABLE

5 OP491 1 9 COMMON +5V
D32
J10 / 3 PORT0(2) I17 L2
3 13 4
I22
R53
220R
4 8 3
BAS21
I21 GND
10NF
S
4 +5VANA I37 T4
C30
11
10K
-1 2V
R99
-12V 74HC14
PC357 J507 0.3A X2 / 5
4 10 11 4 1 K A
22N 22N HSI(2) +24V IN
+5VANA D3
I40 L1
C47 C26 3 2 BAS86 X2 / 6
12
47N 820K 47N EU2187 STATUS VENT.
14 D4
R36 OP491 I2 L4
+5V C57 C31 13 +5 V +5V
+5V_1 +5V +5V
I21
47K 1M 47K
B 0.3A
R52 R35 R37 11 0.05A X5 / 7
+15V REL5 OUT1:DEVICE OK
R16
470R
470R
1
R115
F4
14
L19
D33
J10 / 5 + 5VANA
470R
R124
8 39K 6
BAS21
SEN2 R51 PORT0_1
4
47K
15005B
J10 / 6 2 +2 4V _1
GRUEN
GRUEN
ULN2003
STATUS
R48 1 2M2 13
AD706 6 COMMON 9
GRUEN
LED6
LED15
R40
LG_T670
9
8
7
3 OP491 7 5 12
D31
J10 / 7 PORT0(1) HSO(1)
I22 5 8 GND
+5V +5V
BAS21
I21 I8 0.3A
0.05A X5 / 2
F10
0.05A
4 OUT2:TRIGGER
11
J12 / 1 F2 L14
-12V REL3
1
14
2N7002
470R
22N 22N R125
+5VANA D 6
C37 C35 T21
47N 47N
820K
15005B
6 G S
C R45 STATUS ULN2003
+5V C38 C36 COMMON 9 13
GRUEN
LED16
PORT1(7:0)
LG_T670
+5V_1
9
8
7
7 10
47K 1M 47K HSO(2)
ULN2003 8 GND
R38 R47 R46 74HC14
COMMON 9 +5V +5V
J12 / 2 I8 0.05A 0.3A X5 / 8
+15V 7 9 8 2 15
D28
J10 / 9 + 5VANA EU1770 OUT3
I40 8 GND
8 39K F3 L18
REL4
1
BAS21
SEN3
14
R44 PORT0_0 I8
470R
R126
4
J10 / 10 47K 6 6 +24V_1
R34 7 2M2
AD706 9
R39
15005B
5 OP491 8 6 1 1
ULN2003 0.3A
D27
J10 / 11 PORT0(0) +5V +5V +5V 13 5 2 X5 / 3
10 COMMON 9
GRUEN
LED17
I17 COMMON OUT

LG_T670
EU1907
9
8
7
4 13 4 3
BAS21
I21 HSO(3) 2 L12
4 8 GND
11 S1
DIGITAL I/O
I8
-12V
470R
470R
470R
R123
R122
R121
+ 24 V_ 2 +24V_1
J3 / 1 3K3 0.05A
+5V +5V +5V
R17
6 1 1
GELB
GELB
GELB
D MV1 ULN2003 F7
LY_T670
LY_T670
LY_T670
9 COMMON 5 2
MMO(7:0) 0.3A
LED14
LED13
LED12
BSP78 X5 / 6
D18
ROT
12 5 4 3
LED1
BAS21
FILL VALVE J3 /2 0 2 COMMON IN
10K
10K
10K
2 D IN 1 8
R104
R102
R103
GND L17
74HC14 S2
I37 PC357 J507 0.3A X5 / 1
4 3 4 1 K A
+ 24 V_ 1 PORT0(5) IN1:RESET
3 +5V ANA ULN2003 I40 D14
J3 / 3 3K3 S BAS86 L16
9 COMMON 3 2
R25 10uF
MV2 T8 11 6 D15
C13 74HC14 I6
GND
8
BSP78 PC357 J507 0.3A X5 / 4
D20
ROT
TURN OFF 4 1
LED2
0.1uF 6 5 K A
BAS21
J3 /4 1 I37 IN2:TRIGGER
2 D IN 1 I40 D12
PORT0(6) BAS86 L15
C12 3 2
ULN2003
DATA_BUS(15:0)
CONTROL_BUS(21:0)
21 32 26 9 COMMON D13
+ 24 V_ 1 74HC14 I5
3 +2.5V 10 7

RSTSEL VDD VCC PC357 J507 0.3A
J3 / 5 3K3 S 4 1 X5 / 5
20 GND
8 2 1 K A
MV3 R24 RST EU2187 IN3:VENTING
T7 18 17 28 D10
CS REFH I37 I40 L13
3 2
BAS86
E 18
BSP78 R_W PORT2(4)
D23
ROT
19 19 27
LED3
D11
BAS21
VENT.BYPASS J3 /6 2 LDAC SREFH J19 / 1 J19 / 2 0.1uF I4
2 D IN 1
EU2061
C17
0 16 29 C11 A_OUT
D0 SREFL
1 15
D1 220K 22NF 0.3A
0.1uF
+ 24 V_ 1 3 2 14 30 X6 / 1
J2 / 1 3K3 D2 REFL R11
S 3 13 C3
MV4 R7 D3 L20 X6 / 2
T9 4 12 DAC7641YB
D4 10K 22K 22K
5 11
RETFLOW D5 R12 R3 R2
D7
BSP78 X6 / 3
ROT
6 10 I12
LED4
BAS21
J2 /2 3 D6 47PF
2 D IN 1 7 9 +15V +5V
(EXT) D7 0.1uF X6 / 4
8 8 C4
D8 10K
9 7 22 C5 +1 5V
D9 OUT R13 8 X6 / 5
+ 24 V_ 2 3 10 6
J1 /2 3K3 D10 8 FREQ
4K7
S 11
R15
5 23
R1 D11 SOUT X6 / 7
MV5 12 4 2
T3 D12 10K J16 / 1 J16 / 2
ANALOG OUT
13 3 1 6
SEC.VALVE D13 AD706
D1
BSP78 R10 7 47R X6 / 8
ROT
14 3
LED5
2 AD706
BAS21
(EXT) J1 / 3 6 D14 R4
F 2 D IN 1 15 1 5 2N7002
EU2058
D15 I1 0.05A 0.3A X6 / 6
D
AGND VSS DGND I1 EU2187
T6
4 0.1uF F8 L21
3 25 24 31 4 G S
S HSO(0)
C6
-12V -1 2V
T1
SZT-0654 1 3 12.02. W.M. Datum 4.2002 Benennung =

ZM1105
SZT-0481 1 2 10.02. W.M. Bearb H.E.S./S.H. +
SYNC/DIGITAL I/O /DAC CIRCUIT DIAGRAM
Gepr K.GRUBER CAD ID.NR. Z.Nr. Blatt 2
SZT-0481 1 1 07.02. LIE
Datum Name Norm Ers d
FUEL METER 735S
Aenderung Rev Urspr Ers f BB1120 7350L05./C00D1 3 Bl


1 2 3 4 5 6 7 8
SUPPLY_15V
+24V_1 BAS86 +15 V BAS86
+5V
+15V +15V
D47 D41
0.1uF
Fig. 74
MBR745 EI0288 7815CT 7805CT +15V
J6 / 1 3.15A/T 1A/T 25V/6A/VAR50V 10R 22R
1 3 KK-EM014 8 C77
R98 IN KK-EM0148 OUT R86 IN OUT SUPPLY_5V
R71
1W
82R
+24V D46 5W 5W
A F15 F16 GND1 GND1 8
LT1027ECS8
0.1uF
SPR1 SPR2 8
47uF
C94
33uF
C86
33uF
C61
33uF
C75
D45
D37
IN 3
2 L31 C63 4 T16 3
OUT 4K7
F14
1
R68
SUPPLY 1 1 BC817-40
30VAC
0.1uF
C95
C73
C74
6.3A/T
C93
NR AD706 R69
TVS328
MPTE-5
2
MPTE-15
0.1uF
0.1uF
0.1uF
D48
2
1000uF/40V
C104
2 3
J6 / 3 GND TRIM I29
C76
I25
0V 4
REF2
10K
R56
+5V
47PF
EI0288
J6 / 2 25V/6A/VAR50V
1 3
EU0235
+5VANA
470R
+5V
10uF
R116
GRUEN ULN2003
MBR745
9 COMMON +15V
LG_T670
D44
2 L29 5533_ER0207 16 1
C62
8
1 LED7 GND
8
1N4007 TEST REF1
10K
4
R105
74HC14 I37
D40 7 5
BAS21 J507 PC356 7 47R
TVS328 EI0210 EI0288 A1 A K 1 4 13 12
B 25V/6A/VAR50V HSI(1) AD706 R70 +2.5V
4 1 1 3 2 D16
6
D17 I40
D30
CB B 2 3
D36 5
I29
24V
3 CG PSG 2 8
C64
BAS21
I7
10K
R61
B1 4
L27 +24V_1 3
SOCKEL=ER0208=
2 L28
47PF
6
+15V 9
0.1uF
BEFESTIGUNG
C59 +5V +5V REL2
5
TEST_PUMP
8
+24V_1
PORT0(3)
4
0.3A
D35
0.5A X7 / 1
2
BAS86
4K7 F5 L24
1
LT1366 0.3A
10K R50 X7 / 2
1 3 +5V
INA168NA OUT R60
C42
I24 L22
+5V
I23 J17 / 1 0.3A X7 / 3
0.47uF
C 4
J17 / 2 EU21 86
R59
330K
470R
3
R117
0.1uF
ULN2003 ROT J17 / 3 L23
GND
COMMON 9 LS_T670 +5V
C60
2 15
BAS21
2
D25
8 GND LED8
KK-EM0148 0.5A J4 / 1
I37
10K
R106 F12
74HC14 74HC14
10K PC356 J507 J4 / 2
c 12 13 2 1 4 1 K A
T14 T10 PORT1(5) R107 EU2057
S G
PRESSED AIR
MMBT3904 I41 I41 D26
R27
1K
10K
b
R18
3 2
D e +24V_1 ER0116
T15 I15
680NF
10R
S G 1
DJA-5001 DJA-5001 IRF4905 R26 +24V_2
C109
5
J5 / 1 0.01R 204uH/5A e
5 1 5 204uH/5A 1 D 9
R49
2W 6 2 6 2 b 2 13
IRF4905 MMBT3906
1K2
R19
7 3 7 3 +5V 6
T11
D19
8 4 8 4 c 10
R55
24V
3K3
204uH/5A 204uH/5A 3
BAS21
D
L25 L26 7 14
PUMP
470R
SOCKEL=ER0192=
11
Product Guide
D29
R118
ULN2003 ROT
MBR745
c +5V
COMMON 9 LS_T670 4
KK-EM0148
T12
BAS21
10K 3 14 8
GELB
MMBT3904
C39
C72
R28
LY_T670
PORT2(5)
1000uF/40V
1000uF/40V
BAS21
b
D21
D22
8 GND LED9 12 2c
ERDE
LED18
J5 / 3
e I37
EU205 8
10K
REL1
R109
74HC14 74HC14
+5V +5V
BAS21
10K 10K BAS86 J7 / 1

D24
10 11 8 9
+24V_1
PORT0(4) R100 R108
I41 I41 D50
D6
+12V
D49
0.5A 10K
R5
J13 / 1 J7 / 2
5K6
+15V
BAS21
74HC14 R32
680NF
680NF
EU1682
BAS86
F9 ULN2003
C99
J13 / 2 5K6
C110
3 4 78M12AC 9 COMMON
TANK OVERFLOW
R6 HSI(3)
I41 1 3 16 1
J13 / 3 IN OUT MMO(7) X1 / 1
S G 8
GN D
D5
EU1223 GND1 T13
I8 X1 / 2
2 SPR4 D
BAS21
E VPP
VP0808M
1uF/16V
C20
+24V_2 BSP452
2N2 Vpp X1 / 3
+5V 4 VBB OUT 1
C105
8 X1 / 4
D2
V12_NEG
R29
10K
22K 120K 120K
ULN2003 3 IN 2
R87 R88 R89 6
MMO(6) X1 / 5
GND
9 COMMON
1uF/16V
BAS21
C19
ANA_GND1 7
0.1uF +15V 11 6 LT1366
0.3A 2R2 T2 X1 / 6
SEC. VALVE
8 5
R76 GN D
ANA_GND2 DIG_GND1
C106
L30 I8 I24 X1 / 7
-12V ANA_GND3 DIG_GND2
LT1054 c
T17 4
3 VPOS 14
X1 / 8
MMBT3904
FB_SD b EU2187
33uF 4
CPOS
C96 6 +5VANA +15V -12V
VOUT 11 e
CNEG
12 +5V
C88
VREF
13 5
OSC GND
R90
0.1uF
3K3
33uF
F
33uF
I36
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
C27
C32
C49
C34
C48
C33
C87
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
0.1uF
C97
C98
C66
C65
C10
C68
C23
C25
C67
C54
C53
C24
C29
C79
C78
C41
C45
C69
C44
C14
C21
C22
C100
C112
C107
C108
SZT-0654 1 3 12.02. W.M. Datum 4.2002 Benennung =
Bearb
ZM1105 +
SZT-0481 1 2 10.02. W.M. H.E.S./S.H. CIRCUIT DIAGRAM
POWER
SZT-0481 1 1 07.02. LIE Gepr K.GRUBER CAD ID.NR. Z.Nr. Blatt 3
Aenderung Rev Datum Name Norm Urspr Ers f Ers d

FUEL METER 735S BB1120 7350L05./C00D1 3 Bl


163
4.9 Wiring Diagrams
Fig. 75

Fig. 76
Product Guide

Technical Data 167
5 Technical Data
Installation location
Only for indoor use
Rel. air humidity
max. 80 % up to 30 °C, above this range linearly decreasing until a rel. air
humidity of 50 % at 40 °C is reached
Protection class by housing
IP24
Transportation and storage conditions
Temperature: -25 ... +55 °C
Relative air humidity: max. 80 %, no rain fall
Recommended measurement range
0 … 125 kg/h
Negative flows can be measured.
Measurement uncertainty of mass flow
AVL fuel consumption meter devices are tested before shipment in a compre-
hensive manufacturing test on a special test bed. Thereby, all systematic and
random components of the measurement uncertainty are determined with a
confidence level of 95 %.
The values of the measurement uncertainty stated herein are limits for the manu-
facturing test, which in practice are significantly lower most of the time.
Systematic measurement uncertainty (linearization error):
us ≤ 0.12 %
Stochastic measurement uncertainty uZ = 2σ (scattering) with a damping
constant of 0.1 s without flow:
Measurement Limit Standard Deviation σ [kg/h]

Time [s]
0.1 0.0100
1 0.0040
5 0.0025
10 0.0020
Tab. 117
The total measurement uncertainty pursuant to DIN 1319 comprises the compo-
nents uS, uZ and the measurement value (MV) as follows:
⎛ kg 2
u z ------ ⎞
2 ⎜ h ⎟
u ges [ % ] ≤ u s [ % ] + ⎜ 100 ⋅ -----------------------⎟
⎜ MW ------ ⎟⎠
kg
⎝ h
Product Guide
168 Technical Data
Measurement uncertainty of the integral measurement (working totalizer)
Measurement ≤ ±(0.05 s + 0.01 % of the MV)

time
Mass 100 ⋅ Um max ------
kg
0, 00055 [ h ] ⋅ m ss ------
kg
h h
≤ ± 0, 001% + -------------------------------------------- + -------------------------------------------------------
kg kg
m ------ m ------
h h
Um max
… measurement uncertainty at max. measured consumption [kg/h]
m … average consumption [kg/h]
m ss … average of consumption at Start and Stop [kg/h]
m … consumed mass [kg]
Measurement uncertainty of total consumption (background totalizers)
Mass ≤ ±(0.05 kg + 0.0001 % of MV)

Volume ≤ ±(0.05 l + 0.0001 % of MV)
Measurement uncertainty density (domain mass / volume / volume API)

≤ ±0.5 kg/m³
Measurement uncertainty temperature
≤ ±(1 °C + 0.5 % of the MV)
Measurement uncertainty volume / volume flow (domain: volume/volume
API)
The measurement uncertainties of the volume flow and the working totalizers in
the volume domains are determined by error propagation from the specification
for the mass domain and the specification of the density measurement.
Measurement uncertainty of the calibration unit according to DIN 1319
(confidence level 95 %)
uges ≤ 0.04 %
Maximum dynamics
t90 = 230 ms
t10-90 = 125 ms
Damping constant
Adjustable: 0 … 1.6 s
Measurement time
Adjustable: 0.1 … 60 s
Number of measurement points (moving average)
Adjustable: 1 … 99
Temperature drift (fuel supply temperature)
0.000205 kg/h ° C
An offset error of the AVL Fuel Mass Flow Meters due to a temperature drift is
corrected during the transition of state Pause to STBY.
Ambient temperature
5 °C … 50 °C
Fuel supply temperature
–10 … 40 °C (not coagulating or boiling, bubble-free)
short-time: up to 70 °C (one-time venting up to 30 s)

Technical Data 169
Fuels
Standard implementation = Type 7351CST (ST=Standard)
(Otto and diesel fuels, alcoholic mixtures up to 20 %)
– Otto fuels, complying to the minimum requirements as described in
EN228
– Diesel fuels, complying to the minimum requirements as described in
EN590
– Alcoholic additives up to a maximum of 20 % volume (methyl and ethyl
alcohol)
– Biofuel/biodiesel additives up to a maximum of 20 % volume according
to the minimum requirements as decribed in EN14214
The model "Standard" M20 = Type 7351CST is conditionally perma-
nent for biofuel additives specified according to EN14214. For standstill
times that last longer than 24 hours, the device needs to be emptied
completely, rinsed with customary Otto or diesel fuel and left in a filled
up state.
Model FlexFuel = Typ 7351CME (ME=methyl/ethyl alcohol)
(Otto and diesel fuels, alcoholic mixtures up to 100 % and biofuels)
– Otto fuels, complying to the minimum requirements as decribed in
EN228
– Diesel fuels, complying to the minimum requirements as decribed in
EN590
– Alcoholic additives of up to 100 % volume (methyl, ethyl alcohol)
– Biofuel/biodiesel additives of up to 100 % volume complying to the
minimum requirements as decribed in EN14214
Output pressure
Adjustable, depending on media and flow
10 … 50 kPa (typical at zero consumption)
Maximum 100 kPa
Filling pressure
Depending on the maximum flow
max. 80 kPa
The following table shows reference values for the required filling pressures. In
every case, the filling rate should be 25 l/h higher than the maximum consump-
tion.
The fuel filling pressures of the following table refer to an open fill valve in front of
the shutoff valve at ~25 °C and diesel fuel as medium.
Pressure with Filling rate Maximum con- Maximum con-

open fill valve [l/h] sumption sumption
[kPa] diesel gasoline
[kg/h] [kg/h]
5.0 90 53 49
7.5 155 105 97
10.0 180 < 125 116
12.5 200 < 125 < 125
15.0 210 < 125 < 125
17.5 218 < 125 < 125
20.0 225 < 125 < 125
Tab. 118
Product Guide
170 Technical Data
Compressed air
550 ... 800 kPa (filtered)
Air consumption: Only when changing an operating state to switch a pneu-
matic valve (e.g. when switching from PAUSE to STBY), otherwise no air is
consumed.
Electrical connections
Operating voltage 24 V DC ± 5 %
Current consump- Max. 10 A
tion
Interfaces Shutoff valve
Two RS232 interfaces with AK compliant
protocols
Synchronization interface for the connection of
Digital I/O (with jumper setting w/ or w/o
potential separation)
Analog interface 0 … 10 V with digital I/Os
Analog output Data rate: 20 Hz
Resolution: 16 bit
Linearization error: < 6 mV
Max. output current (short circuit-proof):
15 mA
Dimensions
Basic device: c. 770 × 667 × 34 mm (W × H × D)
Weight
62 kg (including wall bracket, without options, not filled)
5.1 CE-Compliance
Compliant to the 89/336/EEC Directive of electromagnetic compatibility by
fulfilling the requirements of the following standard:
– EN 61326:97/A1:98/A2:01 Electrical equipment for measurement, con-
trol and laboratory use EMC requirements
The conformity of the pressure equipment to Directive 97/23/EC is ensured,
because an evaluation of the product / component did not result in any
exceeding of the ranges pursuant to "Article 3 / paragraph (3)".

Appendix 171
6 Appendix
The figures below illustrate the design of the internal fuel tank.
A B
H
1 Overflow tank
4 Tank block
A Fuel in
B Fuel to engine
H Calibration unit option
Fig. 77
Product Guide
172 Appendix
6
5
4 Tank block
5 Fill valve
6 Tank level sensor
A Fuel in
Fig. 78

Appendix 173
H
4
D
A
C
1 Overflow tank
2 Tank cover
3 Tank
4 Tank block
A Fuel in
B Fuel to engine
C Fuel return line
D Venting
Fig. 79
Product Guide
174 Appendix

175
Index
A B
AADC … 115 Bypass … 74
AAKN … 132
AALC … 113 C
AATS … 115 Calibration – Adjustment … 75
AATW … 116 Calibration Unit … 19, 59
ABSZ … 114 Venting … 60
Accessories … 15
Calibration
Accuracy Check … 73 unit option … 59
ACFG … 113 CE-Compliance … 170
ADJP … 114 Circuit Diagrams … 161
Adjusting … 74 Coarse Filter … 20
ADMP … 108 Connecting Compressed Air … 40
ADSP … 111 Connector … 57
AFIP … 111 Consumption Counter … 81
AGSZ … 128 Consumption Totalizers … 81
AGTD … 121 Control Lines
AHTP … 116 Digital … 45
AHTS … 117 Controller Board
AHTW … 117
Assembly Diagram … 158
AIDA … 129
Cooler
AIDE … 129
in the fuel return line … 31
AIMW … 131
AK Protocol … 46 Counter … 81
AKAL … 119
AKAS … 120 D
AKEN … 101 Delivery rate … 33
AKGP … 120 Device configuration … 54
AKLE … 121 Device dimensions … 23
AKMW … 124 Device Integration … 44
AKUG … 124 Device Variation … 15
AMEM … 108 Dimensions … 23
AMEV … 108 Drain … 64
AMKP … 123 Drain Overflow … 34
AMKS … 123 Drainage … 34
AMOD … 134 Draining … 74
AMSP … 107
Analog Interface … 53 E
APMP … 130 EAKN … 132
APMW … 114 EALC … 113
Application Notes … 21 EATS … 115
ARDR … 133 EBSZ … 114
ARMW … 131 EDJP … 114
ASCK … 132 EDMP … 108
ASEK … 124 EDSP … 111
ASEM … 109 EFIP … 111
ASEP … 109 EGSZ … 128
ASEV … 109 EGTD … 121
ASEX … 110 EHTP … 116
ASFP … 120 EHTS … 117
ASGJ … 122 EIDA … 129
ASIN … 106 EKUG … 124
ASRV … 133 Emergency Stop (X7) … 41
Assembly … 23 Emergency Stop Relay … 140
ASTF … 101 EMKP … 123
ASTX … 104 EMOD … 134
ASTZ … 103 EMSP … 107
Auto-STBY … 72 EPMP … 130
AVL Fuel Temperature Control … 27 ERDR … 133
AVNP, EVNP … 104 ESCK … 132
AWGP, EWGP … 114 ESFP … 120
Product Guide
176
ESGJ … 122 P
Explosion … 26 Pause … 70
Pin Assignment … 54
F Pipe Material … 30
Filling … 75, 138 Potential Isolation … 41
Filling pressure … 33 Power Supply … 19
Filling pump … 33 Power supply … 40
Fine Filter … 19 Pressure Regulator … 140
Fire … 26 Pump states … 152
First-Time Start-up … 62
Flame Filter … 19 R
Fuel Direction … 31 Remote Control … 20
Fuel Drain … 34 Replace Components … 140
Fuel filling pump module … 20 Replacement of Components … 140
Fuel Filter … 31 Rinse … 64
Fuel Lines … 39
S
G
SATK … 119
Gas Sensor … 26 Scope of Supply … 15
SDAA … 128
H SDAE … 128
Hydraulic Connections … 39 SDRN … 113
Serial Interfaces … 48
I SFIL … 113
Init Pause … 70 Shutoff Valve … 19
Inputs Shutoff valve … 34, 47, 57
Digital … 51 Shutoff Valve option … 34, 57
Installation … 15 SKCH … 119
Installation Guidelines … 30 SMAN … 101
Spare Parts … 154
Installation Instructions … 15
Interfaces … 44 SPAU … 103
Serial … 48
SREE … 131
SREM … 101
SRES … 127
L SSRV … 127
Leak-tightness of the system STBY … 71, 103
Test pressure … 30 SVNT … 113
LED Functions … 159
Level … 52 T
Levelling … 29 Tank overflow … 34-35
Technical Data … 167, 171
M Terminal mode … 135
Maintenance limit … 82 Transport … 23
Maintenance Schedule … 137 Trolley … 20, 28
Measured Quantities
Overview … 68 V
Measurement Error Valve settings … 152
Frequent Causes … 32 Venting … 35
Mounting Bracket … 23, 28-29 Flow Rate … 31
System … 31
O venting … 72
Operating States Venting valve … 20, 61
Overview … 68
Operating-hour Counter … 82 W
Option Power Supply … 40 Wearing Parts … 154
Option Venting Valve … 61
Options … 15, 57
Optocoupler … 52
Z
Outputs Zero Consumption Measurement … 139
Digital … 51
Overflow … 35
Product Guide
AVL List GmbH
Hans-List-Platz 1, A-8020 Graz, Austria
Phone: +43 316 787-0, Fax: +43 316 787-400
http://www.avl.com

081 - Fuel - Mass - Flow - Meter - 735S - User Manual

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081 - Fuel - Mass - Flow - Meter - 735S - User Manual

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AVL FUEL MASS FLOW METER

Model 7351 and later

Printed in Austria at AVL

Warnings and Safety Instructions

AVL List GmbH

Fuel Mass Flow Meter

Grouped Safety Messages

Danger of explosion and chemical burns

Danger of death from electrical voltage

Only shielded cables may be used with appropriately shielded connectors in

Thermal expansion or contraction of fuel causes excess differential pressures in

Fuel Mass Flow Meter

Changes from device type 7350 to 7351 (see type plate)

Fuel Mass Flow Meter

Grouped Safety Messages ............................................................................................................................ 5

1 What You Should Know.................................................................................................. 13

1.2 Intended Application ............................................................................................................... 13

2.2 Scope of Delivery ................................................................................................................... 15

2.3 Installation at the Test Bed ..................................................................................................... 22

2.4 Hydraulic / Pneumatic Integration........................................................................................... 30

2.5 Electrical Connection.............................................................................................................. 40

2.6 Connecting the Options .......................................................................................................... 57

2.7 First-Time Start-up.................................................................................................................. 62

3 User's Guide .................................................................................................................... 65

3.2 System Description................................................................................................................. 66

3.3 Test Bed Integration ............................................................................................................... 82

3.4 Remote Control ...................................................................................................................... 85

3.5 Interface Protocol (AK Protocol) ............................................................................................. 97

3.6 Terminal Mode...................................................................................................................... 135

4 Maintenance and Troubleshooting.............................................................................. 137

4.2 General Maintenance and Operation Tasks......................................................................... 138

4.3 Replace Components ........................................................................................................... 140

4.4 Check of Safety Equipment .................................................................................................. 148

4.5 Overview of Errors................................................................................................................ 149

4.6 Error Diagnosis..................................................................................................................... 152

4.7 Wear and Spare Parts .......................................................................................................... 154

4.8 Controller Board ................................................................................................................... 158

4.9 Wiring Diagrams ................................................................................................................... 164

5 Technical Data ............................................................................................................... 167

6 Appendix ........................................................................................................................ 171

1 What You Should Know

1.1 Safety Instructions

1.2 Intended Application

1.2.1 Typographic Conventions

WARNING indicates a hazardous situation which – if not avoided – could result

CAUTION indicates a hazardous situation which – if not avoided – could result in

Additional safety symbols:

Voltage hazard warning

This text indicates important information or operating instructions. Not observing

Standard text styles:

1.2.2 We Want to Hear from You

Fuel Mass Flow Meter

2.2 Scope of Delivery

There are two types of the device AVL 735S:

2.2.1 Basic Device

Fuel Mass Flow Meter

1 .....Fuel supply line of type "standard" BH 0338, type "alcohol-resistant" BH 0340

1 .... Calibration unit TM0735CALA.02

Fuel Mass Flow Meter

2.2.2.1 Calibration Unit

2.2.2.2 Power Supply

2.2.2.3 Shutoff Valve

2.2.2.4 Flame Filter