Instruction Manual: Fuel Consumption Sensor Systems Type CDFL1A..., CDFL3A..

Instruction
Manual
Fuel consumption sensor
systems Type CDFL1A...,
CDFL3A...
User Manual | Contents DFL
It is essential that you read and understand the manual

and the accompanying safety and warning instructions
before initial operation.
Contents
1. General Information_____________________ 7
2. Quick Start_____________________________11
3. General Introduction__________________ 12
3.1. Introduction...................................... 12
3.1.1. System Overview
DFL1x‑5bar............................... 13
3.1.2. System Overview
DFL3x-5bar............................... 13
3.2. Features.......................................... 14
3.2.1. DFL1x‑5bar................................ 14
3.2.2. DFL3x-5bar............................... 14
3.3. Applications....................................16
3.3.1. Permitted Media for Fuel
Consumption Measurement......16
3.3.2. Not permitted Media for Fuel
Consumption Measurement...... 17
3.3.3. Alternative Media...................... 17
3.4. Sensor.............................................18
3.4.1. Single Device – Sensor
DFL1x‑5bar...............................18
3.4.2. DFL3x-5bar with Integrated
Sensor.......................................18
3.5. Heat Exchanger..............................19

3.5.1. External device – DFL-WTx-5bar
for DFL1x‑5bar..........................19
Heat Exchanger........................19
CDFLA_e-10.13 2
3.6. Pressure Regulator.........................20

3.6.1. External Device for the
DFL1x‑5bar...............................20
Pressure Regulator...................20
3.7. Signal Processor............................. 21

3.8. Optional Fuel Temperature
Measurement.................................22
3.9. Optional Fuel Pressure
Measurement.................................23
3.9.1. Optional Fuel Pressure
Measurement with the
DFL‑WTx‑5bar for
DFL1x‑5bar...............................23
3.9.2. Optional Fuel Pressure
Measurement with the
DFL3x‑5bar...............................23
4. System Description____________________ 24
4.1. Sensor DFL1x‑5bar with Heat
Exchange Unit DFL‑WTx‑5bar and
External Pressure Regulator........24
4.1.1. Sensor DFL1x‑5bar.......................24
4.1.2. Connection to Signal Processor
at DFL1x‑5bar ..........................25
4.1.3. Optional Fuel Temperature
Measurement at Sensor
DFL1x‑5bar...............................25
4.2. External Heat Exchanger

DFL‑WTx‑5bar...............................26
4.2.1. Optional Pressure Transducer

for DFL‑WTx‑5bar..................... 27
4.2.2. External Pressure Regulator
for DFL‑WTx‑5bar..................... 27
4.3. Sensor System DFL3x-5bar...........28

4.3.1. Integrated Sensor......................28
Measurement At Integrated
Sensor.......................................29
CDFLA_e-10.13 3
4.3.3. Integrated Heat Exchanger.......29

4.3.4. Optional Pressure
Transducer................................ 31
4.3.5. Connection to Signal
Processor..................................32
4.4. Signal Processor............................33

4.5. Tubes...............................................35
4.6. Quick Lock Connectors.................. 37
5. System Overview______________________ 38
5.1. Main Component System
DFL1x‑5bar with
DFL‑WTx‑5bar...............................38
DFL3x‑5bar....................................39
5.3. System Components......................39
5.4. Accessories....................................43
6. Operating Instructions_______________ 44
6.1. Safety Instructions..........................44
6.2. Signal Processor Setup................. 47
6.3. Initial Operation after Supply to
Customer....................................... 47
6.4. Preinstallation - Vehicles with
Feed Tube only,
no Return Tube..............................49
6.4.1. Installation of the Quick Lock
Couplings..................................49
6.4.2. Measuring the Pressure in the
Feed Tube.................................52
6.5. Preinstallation - Vehicles with Feed

and Return Tube............................53
6.5.1. Installation of the Quick Lock
Couplings..................................53
Feed Tube.................................55
Return Tube.............................. 57
6.6. System Mounting............................58
CDFLA_e-10.13 4
6.7. Sensor Only.................................... 61

6.7.1. Installation of Sensor Only
Setup......................................... 61
6.7.2. Operation of Sensor Only
Setup.........................................64
6.8. Pump@Tank Setup........................65

6.8.1. Theory......................................65
6.8.2. Installation of Pump@Tank
Setup.........................................68
6.8.3. Operation of Pump@Tank
Setup......................................... 71
6.9. Pump@Engine Setup.....................73

6.9.1. Theory......................................73
6.9.2. Installation of Pump@Engine
Setup.........................................76
6.9.3. Operation of Pump@Engine
Setup.........................................80
6.10. Demounting...................................82
6.11. Storage..........................................82
6.12. Maintenance..................................83
6.13. Sensor Calibration and
Calibration Certificate....................83
6.14. Transport and Shipment................83
7. Technical Data_________________________ 84
7.1. DFL1x‑5bar.......................................84
7.2. DFL‑WTx‑5bar.................................85
7.3. DFL3x‑5bar.....................................86
7.4 Mounting of the DFL3x-5bar...........88
7.5. Signal Processor.............................88
7.6. Housing............................................89
7.7. DFL ON/OFF Switch.......................90
7.8. Power Supply..................................90
7.9. The Fuse and the Fuel Pump......... 91
7.10. The Ground Connector.................92
7.11. Electrical Circuit.............................93
CDFLA_e-10.13 5
7.12. Signal Output.................................94

Measurement............................94
7.12.2.Optional Fuel Pressure
Measurement............................95
7.13. Fuel Tubes.....................................96
8. Trouble Shooting_______________________97
8.1. Sensor............................................. 97
8.1.1. Interfering Signals after
Cold Start..................................98
8.1.2. Checking the Sensor................98
8.1.3. Flushing the Sensor..................99
8.1.4. Flushing in Case of a
Blocked Sensor.........................99
8.1.5. Sensor Warm Up.....................100
8.1.6. Flushing before Refill with
other Type of Fuel...................100
8.2. Heat Exchanger............................ 102

8.2.1. Checking the Internal Heat
Exchanger...............................103
8.2.2. Checking the First Path
of the Heat Exchanger............103
8.2.3. Checking the Second Path
of the Heat Exchanger............105
8.2.4. Filling the Heat Exchanger
with Fuel..................................108
8.2.5. Pump power............................111
CDFLA_e-10.13 6
User Manual | 1. General Information DFL
1. General Information
Thank you for choosing a Kistler quality product cha-

racterized by technical innovation, precision and long
life.
Information in this document is subject to change wit-

hout notice. Kistler reserves the right to change or im-
prove its products and make changes in the content
without obligation to notify any person or organization
of such changes or improvements.
©2012 Kistler Group. All rights reserved. Except as ex-

pressly provided herein, no part of this manual may be
reproduced for any purpose without the express prior
written consent of Kistler Group.
Kistler Group
Eulachstrasse 22
8408 Winterthur
Switzerland
Tel. +41 52 224 11 11
Fax +41 52 224 14 14
info@kistler.com
www.kistler.com
Kistler Automotive GmbH

Competence Center Wetzlar
Charlotte-Bamberg-Str. 12
35578 Wetzlar
Germany
Tel. +49 64 41 92 82 0
Fax +49 64 41 92 82 17
info.kar@kistler.com
CDFLA_e-10.13 7
Introduction
Please take the time to thoroughly read this instruction

manual. It will help you with the installation, mainte-
nance, and use of this product.
To the extent permitted by law Kistler does not accept

any liability if this instruction manual is not followed or
products other than those listed under Accessories are
used.
Kistler offers a wide range of products for use in measu-

ring technology:
▪▪ Piezoelectric sensors for measuring force, torque,
strain, pressure, acceleration, shock, vibration and
acoustic-emission
▪▪ Strain gage sensor systems for measuring force and
torque
▪▪ Piezoresistive pressure sensors and transmitters
▪▪ Signal conditioners, indicators and calibrators
▪▪ Electronic control and monitoring systems as well as
software for specific measurement applications
▪▪ Data transmission modules (telemetry)
Kistler also develops and produces measuring solutions

for the application fields engines, vehicles, manufactu-
ring, plastics and biomechanics sectors.
Our product and application brochures will provide you

with an overview of our product range. Detailed data
sheets are available for almost all products.
If you need additional help beyond what can be found

either online or in this manual, please contact Kistler‘s
extensive support organization.
CDFLA_e-10.13 8
Important Notes
For your Safety

Please read carefully before operating the equipment.
Kistler is not responsible for damage that may occur
when this system is used in any way other than that for
which it is intended.
To assure safe and proper operation, all supplied

equipment, components and/or accessories must be
carefully transported and stored, as well as professio-
nally installed and operated. Careful maintenance and
usage in full accordance with operating instructions is
imperative.
The equipment should be installed and operated only

by qualified persons who are familiar with devices of
this type.
Local regulations may not permit the operation of mo-

tor vehicles on public highways while the equipment is
mounted on the exterior of the vehicle.
Leaking fuel can cause explosion or fire hazard.
Defective pumps can be hazardous.
Do only use original Kistler cables! Otherwise there

may be explosion or fire hazard.
Risk of injury from moving engine parts.
Do not use defective or damaged equipment, compon-

ents and/or accessories.
Do not modify or change the equipment or its accesso-

ries in any way.
Equipment must be mounted firmly and securely. Im-

proper use or mounting of the equipment may affect the
safety of the vehicle and/or occupants. The equipment
must not be mounted and/or operated in any way that
may compromise vehicle or and/or occupant safety.
Do not operate DFL systems without fuel filter(s) instal-

led. Failure to install proper fuel filter(s) can result in
damage to the system
Do not mount equipment, components and/or accesso-

ries near heat sources (e.g. exhaust).
CDFLA_e-10.13 9
The sensor and/or sensor components may be dama-

ged if power is applied for extended periods, especially
in hot environmental condition.
Use only original equipment, components and/or

accessories included in the scope of delivery.
Always note correct pin assignments and operating vol-

tages when connecting equipment, otherwise it may be
damaged if not properly connected and/or operated.
Kistler assumes no liability for damages caused due to

the use of cables other than delivered by Kistler.
Disconnect power from the sensor if the vehicle is stati-
onary or extended periods.
For additional information, please call our Hotline: +49
6441 9282 82 or mail to hotline.kcd@kistler.com.
Disposal Instructions for Electrical and Electronic Equipment

Do not discard old electronic instruments in municipal
trash. For disposal at end of life, please return this pro-
duct to an authorized local electronic waste disposal
service or contact the nearest Kistler Instrument sales
office for return instructions.
Software Upgrades and Updates

Kistler may from time to time supply upgrades or up-
dates for embedded software. Such upgrades or up-
dates must always be installed.
Kistler declines any liability whatsoever for any direct or

consequential damage caused by products running on
embedded software which has not been upgraded or
updated with the latest software supplied.
CDFLA_e-10.13 10
User Manual | 2. Quick Start DFL
2. Quick Start
Before working with fuel supply systems consider all available safety
regulations and technical documentation.
Before working with DFL fuel consumption test systems consider all
available safety regulations and the complete DFL technical documen-
tation.
Always consider the risk of severe injuries, damages and/or fire due
to:
▪▪ Fuel or any other component temperature

▪▪ Fuel pressure
▪▪ Fuel leaks
▪▪ Others
Kistler always recommends to have an appropriate fire extinguisher

ready for operation close to/within the test car or test bench.
1. Check for the type of the complete fuel supply system, for
example common rail diesel.
2. Check for expected fuel flow rate.
3. Check for the maximum fuel pressure within the fuel supply
system.
4. Get a complete overview about the fuel circuit with fuel supply to
the engine and fuel return back to the tank.
5. Select the required DFL system and components fitting to the
fuel supply system according to steps 1, 2 and 3.
6. Install the sensor, heat exchanger and all other components (if
required) according to the DFL manuals.
7. Check your complete installation for any (possible) fuel leakage.
Please consider high risk of leakage due to increasing fuel
pressure at higher engine rpm.
Do NOT start the engine before having carried out a safe instal-
lation!
8. Set the system in operation and start the engine.
9. Double check your installation according to step 7.
10. Now, the system is ready for measurement.
CDFLA_e-10.13 11
User Manual | 3. General Introduction DFL
3. General Introduction
3.1. Introduction
The DFL sensors are developed for fuel consumption measurement

of internal combustion engines. Today’s DFL devices suit all kinds of
consumption measurement with gasoline, diesel, alcohol based and
bio fuels due to easy handling, robust and durable construction and
also due to unique quality.
The field of applications covers fuel consumption testing with engines
of passenger cars, trucks, heavy duty and specialized vehicles, mo-
tor-bicycles and ships. The devices can be used mobile in vehicles as
also stationary at the test bench. The DFL systems fit to almost all fuel
systems.
Image 1 | External An external signal processor is required for this device and provides
signal processor
different outputs.
CDFLA_e-10.13 12
3.1.1. System Overview DFL1x‑5bar
Image 2 | DFL1x‑5bar sensor overview
3.1.2. System Overview DFL3x-5bar
Image 3 | DFL3x-5bar sensor overview
CDFLA_e-10.13 13
3.2. Features
3.2.1. DFL1x‑5bar
Image 4 | Sensor The DFL1X-5bar complete with external signal processor offers the fol-
DFL1x‑5bar
lowing functionalities:
▪▪ Further development of the proven and worldwide introduced

DFL sensor
▪▪ Reduced size
▪▪ Suitable for gasoline, diesel, alcohol based and bio fuel
▪▪ Designed for fuel supply systems with feed line only
Image 5 | Heat Exchanger ▪▪ External heat exchange unit DFL‑WTx‑5bar as option to improve
DFL-WTx-5bar
application range
▪▪ External pressure regulator as option to improve application
range
▪▪ Optional built-in fuel temperature and/or pressure sensors
▪▪ Suitable for almost all current engines
▪▪ Suitable for mobile applications in test vehicles (on-board road
tests) as well as for test-bench applications
▪▪ Easy to use DFL unit installs directly into the vehicle fuel system
via quick-lock couplings
▪▪ Negligible service and maintenance requirements as a result of
durable technology
▪▪ Tested and used under extreme environmental conditions
3.2.2. DFL3x-5bar
Image 6 | DFL3x-5bar The DFL3x‑5bar complete with external signal processor offers the fol-
lowing functionalities:
▪▪ Further development of the proven and worldwide introduced

DFL sensor
▪▪ Reduced size
▪▪ Suitable for gasoline, diesel, alcohol based and bio fuel
▪▪ Integrated heat exchange unit
▪▪ Integrated pressure regulator
▪▪ Optional built-in fuel temperature and/or pressure sensors
▪▪ Suitable for almost all current engines
▪▪ Suitable for mobile applications in test vehicles (on-board road
tests) as well as for test-bench applications
CDFLA_e-10.13 14
▪▪ Easy to use DFL unit installs directly into the vehicle fuel system
via quick-lock couplings
▪▪ Negligible service and maintenance requirements as a result of
durable technology
▪▪ Tested and used under extreme environmental conditions
▪▪ Manual ventilation before measurement
▪▪ Fuel temperature is held almost constant by the integrated heat
exchanger
CDFLA_e-10.13 15
3.3. Applications
The DFL fuel consumption sensor is designed for quick and easy fuel
consumption measurement.
The DFL fuel consumption sensor units are designed for quick and easy
installation and measurement. The sensor unit with its accessories in-
stalls easily and therefore saves time during installation and operation.
Small dimensions and little weight enables the device to be installed in
almost any vehicle for mobile testing.
Image 7 | Self closing The device is also designed for test bench applications, like the use on
quick lock coupling
power analysers or engine dynamometers.
It can be used with liquid fuels like gasoline and diesel as well as bio
and alcohol based fuel types.
A much cleaner handling of the complete DFL system is given by the
new quick lock coupling version which is now self closing on both con-
nectors, male and female (image 7).
Optional thermocouples measure the fuel temperature within the de-
vice at inlet and outlet position (image 8).
Image 8 | Optional Fuel pressure measurement is available with optional, built-in pressure
thermocouples
sensor.
3.3.1. Permitted Media for Fuel Consumption Measurement
▪▪ Gasoline
▪▪ Diesel
▪▪ Bio-diesel
▪▪ Alcohol based fuel types
▪▪ Others (upon request only)
CDFLA_e-10.13 16
3.3.2. Not permitted Media for Fuel Consumption Measurement
▪▪ Air, gas
▪▪ Air type fuel
▪▪ Water
▪▪ Watery fluids
3.3.3. Alternative Media
Replacement fuel for petrol or diesel (please clarify by sending in a

technical data sheet and a probe for verification).
CDFLA_e-10.13 17
3.4. Sensor
The devices DFL1x‑5bar and DFL3x-5bar use the well-known DFL

transducer for fuel consumption measurement.
The new product generation DFL introduces technically updated sen-
sors in combination with a new developed signal conditioning unit. The
new sensors are suitable for gasoline, diesel, alcohol based and bio
fuels.
The sensor version has the measuring range of up to max. 250 l/h. The
measuring range depends on the signal processor.
3.4.1. Single Device – Sensor DFL1x‑5bar
Image 9 | Sensor The device DFL1x‑5bar has the DFL transducer in its housing. The
DFL1x‑5bar
small device suits installation in vehicles with only one feed line to the
engine with no return line to the tank.
3.4.2. DFL3x-5bar with Integrated Sensor
Image 10 | DFL3x-5bar The device DFL3x-5bar incorporates the DFL transducer, the heat
exchange unit and the pressure regulator. Thus the DFL3x-5bar suits
installation in vehicles with feed line to the engine and return line to the
tank.
CDFLA_e-10.13 18
3.5. Heat Exchanger
3.5.1. External device – DFL-WTx-5bar for DFL1x‑5bar
Image 11 | Heat Exchanger The external device DFL‑WTx‑5bar is the heat exchanger unit to be
DFL-WTx-5bar
used together with the sensor DFL1x‑5bar. In combination both devices
support the range of applications, for which the DFL3x-5bar has been
designed for.
3.5.2. DFL3x-5bar with Integrated Heat Exchanger
Image 12 | DFL3x-5bar The integrated heat exchange unit extends the range of applications of
the new DFL3x‑5bar.
Fuel consumption measurement needs to meet the requirement that
surplus fuel cannot return from the engine back to the tank. Otherwise
this volume could pass the flow sensor again which would distort the
measurement.
To solve this requirement, the fuel circuit has to be modified to an
engine-related fuel circuit that supplies the engine with fuel and avoids
the fuel return flow to the tank at the same time. Only the volume of
consumed fuel will be supplied from the fuel tank into the engine-rela-
ted fuel circuit and measured by the flow sensor.
To avoid an overheating and gas bubbles within the engine-related fuel
circuit this circuit is cooled down by a second fuel circuit (tank related)
via the integrated heat exchanger.
CDFLA_e-10.13 19
3.6. Pressure Regulator
Image 13 | Pressure The pressure regulator is a mechanical device, which keeps the pres-
Regulator
sure constant around the set point. The user sets the pressure regula-
tor to match the original fuel supply conditions.
3.6.1. External Device for the DFL1x‑5bar
The user needs to install the external device into his fuel circuit to con-
trol the fuel pressure. The pressure regulator as external device incre-
ases the range of applications for the DFL1x‑5bar.
3.6.2. DFL3x-5bar with Integrated Pressure Regulator
The DFL3x-5bar has the pressure regulator integrated. The user sets
the pressure regulator to match the original fuel supply conditions.
CDFLA_e-10.13 20
3.7. Signal Processor
Image 14 | External The external signal processor reads the information from the DFL1x‑5bar
signal processor
or from the DFL3x-5bar and outputs the different signal forms for the
user‘s data acquisition.
The signal processor supports:
▪▪ TTL pulse output proportional to fuel volume

▪▪ Analogue output proportional to fuel flow rate
▪▪ CAN output for fuel volume and flow rate
In addition to the inputs for speed measurement and trigger functiona-

lity (light barrier or brake switch) will be supported by next generation
signal processor software.
CDFLA_e-10.13 21
3.8. Optional Fuel Temperature Measurement
For advanced fuel consumption measurement the DFL1X-5bar can be

supplied with two optional thermocouples (K-type or PT100) mounted
into the fuel in- and outlet of the flow sensing element.
Image 15 | Optional For advanced fuel consumption measurement the DFL3x‑5bar can be
thermocouples
supplied with two optional thermocouples (K-type or PT100) mounted
into the fuel in- and outlet of the flow sensing element.
An amplifier for the thermocouple or PT100 signal is required separate-

ly (not included in delivery).
CDFLA_e-10.13 22
3.9. Optional Fuel Pressure Measurement
Fuel pressure measurement is available as a further option. The pres-

sure sensor mounted into the fuel supply between sensor and engi-
ne generates an analogue output of 0 … 5 V for a pressure range of
0 … 6 bar.
Please consider the operational system pressure of max. 5 bar.
The sensing element is a relative pressure transducer which is alter-

natively available with 0,25 % or 0,15 % accuracy (only to be selected
when ordering). It includes an integrated signal amplifier.
It is placed directly into the fuel output of the integrated DFL3x‑5bar
sensor.
The 6 pin Lemosa connector provides pressure signal output and pres-
sure sensor power supply input.
3.9.1. Optional Fuel Pressure Measurement with

the DFL‑WTx‑5bar for DFL1x‑5bar
Image 16 | DFL‑WTx‑5bar The pressure transducer of the DFL‑WTx‑5bar is placed directly into
with optional 6 pin
round socket pressu‑
the fuel output of the heat exchange unit.
re sensor connector
3.9.2. Optional Fuel Pressure Measurement with the DFL3x-5bar
Image 17 | DFL3x-5bar The pressure transducer of the DFL3x-5bar is placed directly into the
with optional 6 pin
round socket pressu‑
fuel output of the integrated DFL3x‑5bar heat exchange unit.
re sensor connector
CDFLA_e-10.13 23
User Manual | 4. System Description DFL
4. System Description
The systems DFL1x‑5bar with DFL‑WTx‑5bar and external pressure re-

gulator and DFL3x-5bar are very similar. The user may see the DFL3x-
5bar to be a full system integrated into one housing consisting of the
sensor DFL1x‑5bar with heat exchanger unit DFL‑WTx‑5bar and exter-
nal pressure regulator.
Accessories available can be used for both systems.
4.1. Sensor DFL1x‑5bar with Heat

Exchanger Unit DFL‑WTx‑5bar and
External Pressure Regulator
4.1.1. Sensor DFL1x‑5bar
Image 18 | Sensor DFL1x‑5bar
Quick lock coupling (self-closing) (1) sensor in (chapter 4.6.)

Quick lock coupling (self-closing) (2)sensor out (chapter 4.6.)
Signal output to the external signal processor (chapter „4.3.6. Connection
to Signal Processor“ page 32)
CDFLA_e-10.13 24
4.1.2. Connection to Signal Processor at DFL1x‑5bar
Image 19 | Connection to Signal Processor at DFL1x‑5bar
E. DFL processor connector, 8 pin plug, M12x1 screw fixing
The provided cable connects the signal processor to this connector.

Furthermore the sensor is powered by the same cable.
For information about signal outputs please refer to the separate docu-
ment about the signal processor.
4.1.3. Optional Fuel Temperature Measurement at Sensor DFL1x‑5bar
The optional fuel temperature measurement uses as standard k-type

thermocouples. The k-type thermocouple voltage is accessed via the
yellow 2 pin k-type sockets.
CDFLA_e-10.13 25
4.2. External Heat Exchanger DFL‑WTx‑5bar
Image 20 | External Heat Exchanger DFL‑WTx‑5bar
3 4 5 6 8 C
7
D
F
3. Quick lock plug nipple NW 5.8

4. Quick lock plug nipple NW 5.8 3 4 5 6 7 8
5. Quick lock plug nipple NW 5.8 Purge
Measure
Pump
6. Quick lock plug nipple NW 5.8
7. Quick lock plug nipple NW 5.0 non
return
8. Quick lock plug nipple NW 5.8 valve
A. Valve
C. DFL ON/OFF switch Pressure
Sensor
D. Power connector
F. Ground connector Heat
Exchanger
CDFLA_e-10.13 26
4.2.1. Optional Pressure Transducer for DFL‑WTx‑5bar
Image 21 | DFL‑WTx‑5bar with optional 6 pin round socket pressure sensor connector
The optional fuel pressure measurement uses the six pin lemosa
connector for analogue signal output. The connector is existing, when
the pressure transducer is equipped. If equipped, the pressure signal
represents the fuel pressure close to the quick lock plug nipple 3. The
pressure measurement requieres that the fuel pump is running.
4.2.2. External Pressure Regulator for DFL‑WTx‑5bar
Image 22 | Pressure Regulator
The user installs the external pressure regulator in the fuel circuit
according to his needs.
Pressure regulator for the fuel feed pressure.
CDFLA_e-10.13 27
4.3. Sensor System DFL3x-5bar
4.3.1. Integrated Sensor
Image 23 | Integrated Sensor
1
2 EE
1. Quick lock coupling (self-closing) Ê sensor in (chapter 4.6.)

2. Quick lock coupling (self-closing) Ë sensor out (chapter 4.6.)
E. Signal output to the external signal processor (chapter „4.3.6.

Connection to Signal Processor“ page 32)
CDFLA_e-10.13 28
4.3.2. Optional Fuel Temperature Measurement

At Integrated Sensor
Image 24 | Optional The optional fuel temperature measurement uses as standard k-type
thermocouples
thermocouples. The k-type thermocouple voltage is accessed via the
yellow 2 pin k-type sockets.
4.3.3. Integrated Heat Exchanger
Image 25 | Integrated heat exchanger
C
3 4 5 6 7 8
F D
3. Quick lock plug nipple NW 5,8 A. Valve

4. Quick lock plug nipple NW 5,8 C. DFL ON/OFF switch
5. Quick lock plug nipple NW 5,8 D. Power connector
6. Quick lock plug nipple NW 5,8 F. Ground connector
7. Quick lock plug nipple NW 5,0
8. Quick lock plug nipple NW 5,8
CDFLA_e-10.13 29
Image 26 | Integrated pressure regulator
3 4 5 6 7 8
Measure Purge
Pump
A
non
return
valve
Pressure
Sensor
G
Heat
Exchanger
CDFLA_e-10.13 30
4.3.4. Optional Pressure Transducer
Image 27 | Optional pressure transducer
The optional fuel pressure measurement uses the six pin lemos con-
nector for analogue signal output. The connector is existing, when the
pressure transducer is equipped. If equipped, the pressure signal re-
presents the fuel pressure close to the quick lock plug nipple 3.
CDFLA_e-10.13 31
4.3.5. Connection to Signal Processor
Image 28 | Connector to Signal processor
E. DFL processor connector, 8 pin plug, M12x1 screw fixing
The provided cable connects the signal processor to this connector.

Furthermore the sensor is powered by the same cable.
For information about the setup of the signal outputs please refer to
the separate user manuals „CeCalWinPro“ and „CeCalWinPro & DFL“.
CDFLA_e-10.13 32
Image 29 | Signal processor
Pin DSUB 9 DFL HDSUB 15Ana.Out HDSUB 15 Dig.Out

1 SigA Analog 1 Digital 1
2 SigB Analog 2 Digital 2
3 SDA+ Analog 3 Digital 3
4 SDA– n.c. n.c.
5 SCL+ n.c. n.c.
6 +12V Analog 4 Digital 4
7 GND n.c. n.c.
8 SCL-1 Analog 5 Digital 5
9 n.c. n.c. n.c.
10 ----- Analog GND n.c.
11 ----- n.c. n.c.
12 ----- n.c. Digital GND
13 ----- n.c. n.c.
14 ----- n.c. n.c.
15 ----- n.c. n.c.
CDFLA_e-10.13 33
After connecting to power supply:
▪▪ RS-232C and Power LED will light and CYC. LED flashes with
1 Hz.
▪▪ In case of fuel flow measurement the CYC. LED will flash with
3 Hz.
▪▪ In case of having mounted the sensor against main fuel supply
direction the red DIR. LED will light.
CDFLA_e-10.13 34
4.5. Tubes
Image 30 | Fuel tube 1 ▪▪ Fuel tube

▪▪ Female coupling NW 5.0,
male plug nipple NW 5.8,
both self closing, with filter
▪▪ 1 m, Viton
▪▪ Inner tube diameter
7.3 mm
▪▪ Order no. 16032

▪▪ Both sides female cou-
plings, both NW 5.8, self
closing
▪▪ 0.2 m, Viton
11.5 mm
▪▪ Order no. 16005

closing
▪▪ 2.5 m, Viton
11.5 mm
▪▪ Order no. 16000

▪▪ Female coupling, male
plug nipple, both NW 5.8,
self closing
▪▪ 2.5 m, Viton
11.5 mm
▪▪ Order no. 16001
CDFLA_e-10.13 35

▪▪ Female coupling NW 5.0,
male plug nipple NW 5.8,
both self closing, with filter
▪▪ 2.5 m, Viton
11.5 mm
▪▪ Order no. 16002

closing
▪▪ 2.5 m, Viton
11.5 mm
▪▪ Order no. 16003
CDFLA_e-10.13 36
4.6. Quick Lock Connectors
The new system DFL includes a self-closing quick lock coupling type
with NW nominal width 5.8.
Image 36 | Quick lock nipple (left) and quick lock coupling (right)
The quick lock plug nipple fits into the quick lock coupling. The outer
grip ring of the quick lock coupling is pulled back and the plug nipple
is pushed into the connector. The grip ring jumps back into the original
position, if the plug is inserted correctly and deep enough.
Warning
Any component of older DFL system versions (without
self-closing plug nipples and couplings) does not fit to
the new coupling type.
WARNING
The quick lock couplings have to be without additional
force. Axial or radial forces may lead to destruction or
malfunction of the quick lock connectors.
The user has to take care during installation of the fuel tubes or during
installation of accessories, that there will be no load on the quick lock
connectors.
CDFLA_e-10.13 37
User Manual | 5. System Overview DFL
5. System Overview
The DFL system components are equipped with self closing quick lock
couplings NW5.8. The user works either with system DFL1x‑5bar with
DFL‑WTx‑5bar or with the compact system DFL3x-5bar.

DFL1x‑5bar with DFL‑WTx‑5bar
DFL1x‑5bar
(order no. KCD15636)
DFL‑WTx‑5bar
Pressure regulator
CDFLA_e-10.13 38
User Manual | DFL
5.2. Main Component System DFL3x-5bar
DFL3x‑5bar
5.3. System Components
The main system component is completed with the following system

components for installation.
Calibration of the DFL system
Distributor cable 1 m,

HD-SUB/5 x BNC
Distributor cable 1 m,

HD-SUB/5 x BNC
Fuel tube
female coupling NW 5.0
male plug nipple NW 5.8
both self closing, with
filter, 1 m, inner tube di-
ameter 7.3 mm
CDFLA_e-10.13 39
User Manual | DFL
Fuel tube
both sides female couplings
both NW 5.8, self clo-
sing, 0.2 m, , inner tube
diameter 7.3 mm
Two power cables for signal

electronic and DFL3x‑5bar
Banana connector/
4 Pin Binder connec-
tor, B-coded, 2 m
Banana connector/
4 Pin Binder connec-
tor, B-coded, 5 m
Pressure gauge with quick

lock couplings NW 5.8,
self closing, 0 … 6 bar,
blue rubber protector
Pressure gauge with

quick lock couplings
NW 5.8, self closing
pressure range -1 … +1.5 bar,
red rubber protector
CDFLA_e-10.13 40
User Manual | DFL
Signal cable CAN

2 m, 3 Pin Binder connector
Signal cable for

sensor connection to
signal processor, 5 m
Signal cable RS-232C

2 m, 3 pin Binder connector
Signal cable USB, 2 m,

4 pin Binder connec-
tor/USB connector
Signal processor
CDFLA_e-10.13 41
User Manual | DFL
Y-adapter, NW 5,8,
self closing, max. 5 bar
Software KiCenter
Operation manual
for DFL3x‑5bar
CDFLA_e-10.13 42
User Manual | 5. System Overview DFL
5.4. Accessories
Pressure sensor, built

into DFL‑WTx‑5bar
Available in
0,25 % accuracy or
0,15 % accuracy
(order no. KCD12923

–0,25 % accuracy)
Adapter set NW 5.8 for

11.5 mm inner tube diame-
ter, , Viton, consisting of:
▪▪ 4 × Coupling NW 5.8 with
thread nipple for fuel tube
▪▪ 4 × Plug nipple NW5.8 with
thread nipple for fuel tube
▪▪ 4 × Tube adapter NW5.8,
self closing, max 5 bar,
coupling/open end
▪▪ 4 × Tube adapter NW5.8,
self closing, max 5 bar,
plug nipple/open end
(order no. KCD15612 -

others on request)
Fuel filter max 5 bar with

connecting threads
(order no.: on request)
Fuel tube set with fuel

tubes with inner diameter
11.5 mm, 2.5 m, Viton.
Consisting of fuel tubes

, , , .
(order no.: on request)
CDFLA_e-10.13 43
User Manual | 6. Operating Instructions DFL
6. Operating Instructions
6.1. Safety Instructions
Before working with fuel supply systems always consider all available
regulations according to general safety, safety at work, environmen-
tal protection and any country and/or company specific regulations.
Please also refer to technical documentation etc. for example of the
vehicle, engine and/or components manufacturer.
WARNING!
The user needs to read and understand carefully the
safety instructions before operating the DFL.
The user must be aware of:

▪▪ Dangers caused by the engine
▪▪ Dangers caused by the measured medium
▪▪ Explosion or fire hazard by leaking and/or spraying
fuel and/or electrical short cuts
▪▪ Dangers due to defects of the pump
▪▪ Risk of injury by rotating engine parts
▪▪ Risk of personal injury
The user avoids:

▪▪ Skin contact with fuel
▪▪ To inhale fuel vapors
▪▪ To swallow up fuel
CDFLA_e-10.13 44
WARNING!
The user has to care for:
▪▪ The safety and accident prevention procedures
▪▪ Regular checks and that all precautionary measures
are followed
Do not modify the DFL configuration by yourself.
Any inconsiderated modification may cause severe

injuries or damages.
The device may only be serviced by Kistler Automotive

GmbH
WARNING!
If only one component of the system does not seem
to work properly the user is not allowed to operate the
system.
WARNING!
You have to stop the engine before installing, removing
or modifying the DFL or the measurement setup.
WARNING!
Local regulations may not permit the operation of motor
vehicles on public roads while the device is mounted to
the vehicle.
CDFLA_e-10.13 45
Should the information provided by this manual not be suffi-

WARNING!
cient, call the Kistler hotline +49 (6441) 9282-82 or e-mail to
sales@corrsys-datron.com for help with further details.
First the DFL is to be mounted to the vehicle, then all
tubes are to be connected accordingly to the following
instructions.
Tubes may not be constrained mechanically in their
diameter (e.g. tube clamps or bending).
It is strictly forbidden to switch on the DFL, when there
are no tubes orderly connected to the device and to the
engine to be tested.
WARNING!
The DFL must not only consider as a fuel consumption
measurement system but additionally as a fuel supply
system for the engine.
To avoid problems with the fuel supply to the engine, the
complete DFL installation must be properly carried out
and regularly checked for any problem.
In case, that the fuel supply to the engine does not
work properly, the engine / the vehicle may stop
unexpectedly.
CDFLA_e-10.13 46
6.2. Signal Processor Setup
Please to the separate user manual „CeCalWin Pro“ for general infor-
mation about software CeCalWinPro to setup the signal processor.
For specific information about the signal processor Setup for DFL sen-
sors please refer to the separate user manual „CeCalWin Pro & DFL“.
6.3. Initial Operation after

Supply to Customer
The sensor has been drained for shipment only. Please refill the sensor
immediately after having received the unit. Kistler recommends diesel
fuel for this purpose.
Note:
Reduce the fuel flow rate for the first filling of the
system.
Note:
Reduce the fuel flow rate for a short term of a maximum
of 10 minutes. Usually 30 seconds will be sufficient to
fill the device. The duration is dependent on the fuel
flow rate, e.g. for a higher fuel flow rate the time span
will be shorter.
Note:
Please use and refer to the set-up as described in
chapter „8.1.2. Checking the sensor” (page 98).
Image 37 The heat exchanger has been drained for shipment only. Please refill
the system immediately after having received the unit.
Kistler recommends diesel fuel for this purpose.
Note:
Please use and refer to the setup as described in
chapter „8.2.4. Filling the Heat Exchanger with Fuel“
(page 108).
CDFLA_e-10.13 47
Image 38
Note:
The DFL is delivered with protection caps on quick lock
plug nipples NW 5.0 1 and 7. Remove the protection
caps and keep them for further transportation or
shipment (please see images 37 and 38).
CDFLA_e-10.13 48

Feed Tube only, no Return Tube
If the vehicle has only a feed tube, you will need the sensor only.
For the correct installation of the system you need to know the location
of the feed tube.
6.4.1. Installation of the Quick Lock Couplings
1. Cut the feed tube (1.).
Image 39 | Fuel circuit
Engine
1. feed tube
Tank
CDFLA_e-10.13 49
2. According to the following chart mount plug nipple and couplings

at the ends of the tubes.
Image 40 | Tube adapter Please use components of the tube adapter set 15612.
set 15612
Image 41 | Fuel circuit with quick lock couplings
Engine
Tank
3. In the feed tube a coupling is mounted to the tube coming from

the tank .
4. A plug nipple is set to the tube going to the engine .
Note:
In order to use your vehicle under normal condition
without Kistler equipment just reconnect the couplings
and plug nipples. goes with .
Attention:
When using only the sensor DFL1x‑5bar you need to
mount the plug nipple to the tube that comes from
the tank (see image 42).
CDFLA_e-10.13 50
Image 42 | Fuel circuit with quick lock couplings - Sensor only
Engine
Tank
CDFLA_e-10.13 51
6.4.2. Measuring the Pressure in the Feed Tube
Image 43 | Measuring the In the next step measure the pressure in the feed tube with the pressu-
pressure in the feed tube
re gauge 15614 (pressure range 0 … 6 bar).
Engine 1. Connect the coupling of the tube coming from the tank with
the plug nipple of the pressure gauge 15614.
2. Then connect the coupling of the pressure gauge 15614 with the
plug nipple of the tube going to the engine.
3. Start the engine and read the value of the pressure gauge.
4. If the value is above 5 bar you can not use the DFL for measure-
ment.
Tank
It is important that you write down the exact value of the pressure in the
feed flow. For the following steps of installation please continue reading
chapter „6.6. System Mounting“ (page 58) and chapter „6.7. Sensor
only“ on page 61.
Attention:
When using only the sensor DFL1x‑5bar you can‘t
measure the pressure in the feed tube. You will need
tube in order to connect the pressure gauge to the
plug nipple coming from the tank.
CDFLA_e-10.13 52

Feed and Return Tube
If the vehicle has a feed and return tube the heat exchanger and the
pressure regulator are required.
For the correct installation of the system you need to know the location
of both the feed tube and the return tube.
Note:
The majority of engines have one fuel supply tube from
the tank to the engine and one feed return tube from
the engine to the tank.
However, there are also vehicles with more than one
tube returning to the tank.
6.5.1. Installation of the Quick Lock Couplings
1. Cut the feed tube (1.) as well as the return tube (2.).
Engine
1. feed tube 2. return tube
Tank
CDFLA_e-10.13 53
2. According to the following chart mount plug nipples and coup-

lings at the ends of the tubes.
Image 45 | Tube adapter Please use components of the tube adapter set 15612.
set 15612
Image 46 | Fuel circuit with quick lock couplings
Engine
Tank
3. In the feed tube a coupling is mounted to the tube coming from

the tank .
4. A plug nipple is set to the tube going to the engine .
5. In the return tube a coupling is connected to the tube coming
from the engine .
6. A plug nipple is mounted to the tube going to the tank .
Note:
In order to use your vehicle under normal condition
without DFL equipment just reconnect the couplings
and plug nipples. goes with and with
.
CDFLA_e-10.13 54
6.5.2. Measuring the Pressure in the Feed Tube
Image 47 | Pump@tank There are the two main different setups „pump@tank” and „pump@
engine” for the fuel circuitry for the measurement.
Engine The pump@tank setup is for systems with the original vehicle main fuel
pump placed close to the vehicle fuel tank. These systems may also
have a high pressure fuel pump at the engine.
Pump Tank
Image 48 | Pump@engine The pump@engine setup is for systems with the original vehicle main
fuel pump placed close to the engine.
Pump Engine
You need to choose the correct setup matching your vehicle fuel sys-
tem.
Tank
Image 49 | Measuring the In the next step measure the pressure in the feed tube with the pressu-
pressure in the feed tube
re gauge 15614 (pressure range 0 … 6 bar).
Engine 1. Connect the coupling of the tube coming from the tank with
plug nipple of the tube going to the engine.
3. Connect the coupling that comes from the engine with the
plug nipple that goes to the tank.
4. Start the engine and read the value of the pressure gauge.
Tank 5. If the value is above 5bar, you can not use the DFL for measure-
ment.
CDFLA_e-10.13 55
Engine
approx. 2 - 5 bar =
pump@tank setup with
Pressure integrated pressure regulator
Gauge
15614
(0 … 6 bar)
approx. 0 bar = repeat
measurement with pressure
gauge 15910
(pressure range -1 … +1.5 bar)
Tank
2 - 5 bar
If you get a value of approx. 2 - 5 bar the vehicle‘s fuel circuit is „pump@
tank“. It is important that you write down the exact value of the pressure
in the feed flow. For the following steps of installation please continue
reading chapter „6.5.3. Measuring the Pressure in the Return Tube“ on
the next page, chapter „6.6. System Mounting“ (page 58) and chapter
„6.8. Pump@Tank Setup“ on page 65.
0 bar
If you get a value of 0 bar you need to conduct a further measurement
with the pressure gauge 15910 (pressure range -1 … +1.5 bar). If the re-
sult of this measurement is a negative value the vehicle‘s fuel circuit is
„pump@engine“. For the following steps of installation please continue
reading chapter „6.5.3. Measuring the Pressure in the Return Tube“ on
the next page, chapter „6.6. System Mounting“ (page 58) and chapter
„6.9. Pump@Engine Setup“ on page 73.
If the result of the measurement with the pressure gauge 15910 (pres-
sure range -1 … +1.5 bar) is a positive value you had confused feed and
return tube. The mounting of the quick lock plug nipples and couplings
( , , and ) is wrong. The feed tube is the actual return
tube. Please mount the plug nipples and couplings to the right ends of
the tubes and start over at chapter „6.5. Preinstallation - Vehicles with
Feed and Return Tube“ on page 53.
CDFLA_e-10.13 56
6.5.3. Measuring the Pressure in the Return Tube
Image 51 | Measuring the Subsequently measure the pressure at the return tube with the pressu-
pressure in the return tube
re gauge 15910 (pressure range -1 … +5 bar).
Engine 1. Connect coupling of the tube coming from the engine with
plug nipple of the tube going to the tank.
3. Start the engine. At engine idle mode measure the pressure in
the return tube.
4. Then measure the pressure in the return tube at full engine
Tank rpm.
You need to write down the results of the measurements.

The values are needed as soon as the system is
installed.
Engine
Pressure
Pressure Gauge
Gauge
15910
15614
(-1 … +5 bar)
(0 … 6 bar)
Tank
CDFLA_e-10.13 57
6.6. System Mounting
Before working with fuel supply systems always consider all available
regulations according to general safety, safety at work, environmen-
tal protection and any country and/or company specific regulations.
Please also refer to technical documentation etc. for example of the
vehicle, engine and/or components manufacturer.
Before working with the DFL fuel consumption test systems consider
all available safety regulations and the complete DFL technical docu-
mentation.
Always consider the risk of severe injuries, damages and/or fire due
to:
▪▪ Possibly high fuel temperature or any other component tempe-

rature
▪▪ Possibly high fuel pressure
▪▪ Fuel leaks
▪▪ High risk of fire and/or explosion
Warning!
Always check all single components of the DFL system
to be used for its maximum permitted operating
pressure. The maximum operating pressure is limited
by the component with the smallest permitted operating
pressure range!
Kistler always recommends an appropriate fire extinguisher ready for

operation within the test car or respectively close to the test bench.
Note:
The user needs to care for the right pressure range,
to which he installs DFL. The unit is specified for a
nominal operational pressure of a maximum of 5 bar
and with a maximum of 120 l/h or a maximum of 1 bar
and with a maximum of 190 l/h.
CDFLA_e-10.13 58
Note:
Both circuitries pump@tank and pump@engine use the
return fuel flow to the vehicle tank. The heat exchanger
can not be used under the condition, that the engine
has no return fuel flow to the vehicle tank.
Note:
Check for expected fuel flow rate in the feed tube to the
engine. The fuel flow rate depends on the fuel supply
system.
At modern fuel supply systems the maximum flow rate
within the fuel supply systems is important to know.
Check for the expected maximum fuel consumption.
If any fluel flow rate is too high you might not get any
results.
Note:
Check for the expected maximum operating
temperatures within the fuel supply, especially within
the fuel supply to the engine and the fuel return back
to tank.
Image 53 | Mounting holes ▪▪ Use the M6 threads to hold the device in place and to prevent the
device from slipping or falling, especially during the test drive.
The maximum depth of the M6 threads is 10 mm.
▪▪ The DFL can be mounted in any direction. Hold the device in
place and prevent the device from slipping or falling, especially
during the test drive.
▪▪ Please take care that DFL is mounted in the vehicle in a way that
does prevent passengers and vehicle from any danger.
Image 54 | Mounting ▪▪ When installing fuel tubes, always take care that the fuel carrying
threads
tubes
▫▫ do not scrub at sharp edges or rough surfaces
▫▫ can not be damaged by moving or rotating parts
(e.g. V-belt, fan wheel, etc.) during operation.
▫▫ are not subjected to additional loads, which may introduce
axial or radial forces on the tubes themselves or on the
coupling systems to prevent damage or malfunction.
▪▪ When installing power and signal cables always take care of not
bending and damaging the cables. Damaged cables may lead to
short cuts and the risk of fire and/or explosion.
CDFLA_e-10.13 59
▪▪ Do not install the signal cable between the DFL and the signal
processor near an ignition coil or a Xenon lamp power supply.
▪▪ Fuel filters have to be installed into the measurement set up to
prevent the DFL from being destroyed due to dirt or solid obstac-
les in the fuel.
▪▪ Always work according to the technical information for the fuel
filters and fuel tubes.
CDFLA_e-10.13 60
6.7. Sensor Only
6.7.1. Installation of Sensor Only Setup
Image 55 | DFL 1. Stop the vehicle engine.

ON/OFF switch
2. Make sure that the DFL is turned off (image 55).
3. Let the engine cool down to prevent the risk of fire etc. in case of
leaking fuel during installation.
4. Connect the feed tubes according to the following chart (image
56 & 57)
Image 56 | Fuel circuit sensor only with DFL1X-5bar
CDFLA_e-10.13 61
Image 57 | Fuel circuit sensor only with DFL3x‑5bar
5. If you have followed the instructions in chapter „6.4.2. Measuring

the Pressure in the Feed Tube“ on page 52 - vehicles with feed
tube only)
▫▫ the plug nipple of the pressure gauge KCD15614 is con-
nected to coupling of the fuel tube coming from the
tank and the coupling of the same pressure gauge is con-
nected to plug nipple of the tube going to the engine.
6. Now disconnect
▫▫ the plug nipple of the pressure gauge KCD15614 from
coupling on the fuel tube coming from the tank.
7. In case of the DFL1x‑5bar connect
▫▫ the coupling of the fuel tube to plug nipple adapter to
coupling of the tube coming from the tank.
▫▫ the coupling of the fuel tube to the plug nipple of the
pressure gauge KCD15614.
8. In case of a DFL3x-5bar system connect
▫▫ the coupling of fuel tube to plug nipple Ê on the
DFL3x‑5bar.
▫▫ the coupling of fuel tube to plug nipple Ë on the
DFL3x‑5bar.
CDFLA_e-10.13 62
▫▫ plug nipple of fuel tube to coupling of the tube

coming from the tank.
▫▫ the coupling of fuel tube to the plug nipple of the pres-
sure gauge KCD15614.
9. Fix the device securely.
10. Connect the signal cable from the DFL to the signal processor.
CDFLA_e-10.13 63
6.7.2. Operation of Sensor Only Setup
1. Ventilate the vehicle fuel system according to the car

manufacturer‘s specification.
2. Turn on the ignition and start the engine.
3. At engine idle mode and at full engine rpm check the value of the
pressure gauge 15614 (pressure range 0 … 6 bar). If the results
of the measurements are different to the ones performed before
installing the system (see chapter „6.4.2. Measuring the Pressure
in the Feed Tube“ on page 52 - vehicles with feed tube only) you
can not perform a measurement with this system. Please contact
the kistler hotline +49 (6441) 9282-82 or e-mail to hotline.kcd@
kistler.com for further required accessories.
4. If the result of the measurement is similiar to the one performed
before installing the system, stop the engine.
5. Demount the pressure gauge from the feed tube to prevent it
from thermal destruction.
6. Under the condition, that the measurement setup is executed
properly, you may now execute the measurement.
7. Start the engine.
8. Execute the measurement.
Note:
For security reasons the user has to check the complete
installation daily before starting measurements and
also short after turning on the engine.
CDFLA_e-10.13 64
6.8. Pump@Tank Setup
6.8.1. Theory
With the help of the pressure gauge you found out that the pressure in
the feed tube is approx. 2 ... 5 bar. One can deduct from this value that
the car fuel supply pump is located at the tank.
The fuel pump of the DFL equipment provides a nominal pressure of
5 bar. Therefore the pressure needs to be reduced via the pressure
regulator. The pressure regulator reduces the feed flow pressure and
the feed flow volume for the engine.
Typical setups are single-point and multi-point injection systems.
Image 58 | Fuel circuit pump@tank setup, reduced pressure
Engine
Pressure 2 ... 5 bar Pressure Gauge

Gauge
15910
15614
(-1 … +5 bar)
(0 … 6 bar)
Pump Tank
CDFLA_e-10.13 65
In the following chart heat exchanger and sensor are included in the
fuel circuit.
Fuel circuit pump@tank setup with sensor DFL1x‑5bar, heat exchanger

DFL‑WTx‑5bar and external pressure regulator.
Image 59 | Fuel circuit pump@tank setup with sensor DFL1x‑5bar and heat exchanger
DFL‑WTx‑5bar
Engine
Manometer
Pressure
Regulator
Heat Exchanger
Pump
Sensor
Y-Adapter
Pump Tank
CDFLA_e-10.13 66
Fuel circuit pump@tank setup with DFL3x‑5bar and internal pressure

regulator.
Image 60 | Fuel circuit pump@tank setup with DFL3x‑5bar
Engine
DFL3x‑5bar
Pump
Internal
Pressure Sensor
Regulator
Pump Tank
CDFLA_e-10.13 67
6.8.2. Installation of Pump@Tank Setup

ON/OFF switch
4. Connect the feed and return tubes according to the following
chart (image 62 & 63).
Image 62 | Fuel circuit pump@tank setup with sensor DFL1x‑5bar and heat exchanger DFL‑WTx‑5bar
CDFLA_e-10.13 68
Image 63 | Fuel circuit pump@tank with DFL3x-5bar system

the Pressure in the Feed Tube“ on page 55
nected to coupling of the fuel tube coming from the
tank and the coupling of the same pressure gauge is con-
nected to plug nipple of the tube going to the engine.
▫▫ the plug nipple of the pressure gauge KCD15910 (pressu-
re range -1 … +1,5 bar) is connected to coupling of
the tube coming from the engine and the coupling of the
same pressure gauge is connected to plug nipple .
6. Now disconnect
▫▫ the coupling of the pressure gauge KCD15614 from plug
nipple .
CDFLA_e-10.13 69
7. In case of a system with sensor DFL1x‑5bar and heat exchanger

DFL‑WTx‑5bar connect
▫▫ the coupling of fuel tube to plug nipple of the heat
exchanger DFL‑WTx‑5bar.
▫▫ the coupling of the sensor DFL1x‑5bar to plug nipple
of the heat exchanger DFL‑WTx‑5bar.
▫▫ the plug nipple of fuel tube to coupling of the tube
▫▫ the plug nipple of fuel tube to the coupling of the pres-
sure gauge KCD15910 (pressure range –1 … +5 bar)
▫▫ the coupling of fuel tube to plug nipple of the tube
going to the tank.
▫▫ the coupling of fuel tube to plug nipple on the
DFL3x‑5bar.
▫▫ the other coupling of fuel tube to plug nipple on
the DFL3x‑5bar.
▫▫ the coupling of fuel tube to plug nipple on the
DFL3x‑5bar.
▫▫ the other coupling of fuel tube to plug nipple on
the DFL3x‑5bar.
exchanger.
exchanger.
exchanger.
exchanger.
CDFLA_e-10.13 70

sure gauge KCD15910 (pressure range –1 … +1.5 bar)
▫▫ the coupling of fuel tube to plug nipple of the tube
going to the tank.
11. Connect the power cable to the battery.
Note:
The DFL‑WTx‑5bar and the DFL3x‑5bar have to
be connected to max. 12 VDC (10 V ... 15 VDC, not
24 VDC) power supply only to prevent damage.
6.8.3. Operation of Pump@Tank Setup
Image 64 | Purge 1. Set the valve into position „purge”.

2. If possible, the sub pressure connection of the integrated pres-
sure regulator is connected to the sub pressure tube of the engi-
ne (e.g. multi point injection systems).
3. Turn on the DFL heat exchanger fuel pump with the ON/OFF
switch.
¨
¨The fuel pump starts running. Fuel is sucked from
the vehicle’s engine into the DFL and flows back to
the vehicle’s fuel tank.
4. Turn on the ignition.
¨
¨The whole system is ventilated after approximately
60 seconds.

Image 65 | Measure 6. Set the valve into position „Measure“.
If the fuel system of the vehicle does not match the measuring
system the engine may not work flawlessly.
Check the reading of the pressure gauge KCD15614 in the feed
flow of the engine. By turning the setup screw of the integrated
pressure regulator change the pressure to the previous measured
CDFLA_e-10.13 71
Image 66 | Setup screw of value (see chapter „6.5.2. Measuring the Pressure in the Feed
the pressure regulator
Tube“ page 55). If it is not possible to set the pressure to the pre-
vious measured value, you cannot perform a measurement with
this system. Please contact the Kistler hotline +49 (6441) 9282-
82 or e-mail to hotline.kcd@kistler.com for further required ac-
cessories.
7. At engine idle mode and at full engine rpm check the reading of
the pressure gauge KCD15910 (pressure range –1 … +1,5 bar). If
the results of the measurements are different to the ones perfor-
med before installing the system (see chapter „6.5.3. Measuring
the Pressure in the Return Tube“ page 57) you cannot perform a
measurement with this system. Please contact the Kistler hotline
+49 (6441) 9282-82 or e-mail to hotline.kcd@kistler.com for fur-
ther required accessories.
Image 67 | Setup screw 8. If the result of the measurement is similiar to the one performed
of the integrated pres‑
sure regulator
before installing the system, stop the engine and switch off the
heat exchanger fuel pump.
9. Demount the pressure gauges from the feed and return tubes to
prevent them from thermal destruction.
properly, you can now execute the measurement.
11. Switch on the heat exchanger fuel pump.
Image 68 | Setup screw 13. Execute the measurement.
of the integrated pres‑
sure regulator
Note:
CDFLA_e-10.13 72
6.9. Pump@Engine Setup
6.9.1. Theory
With the help of the pressure gauge you found out that the pressure in
the feed tube has a negative value. One can deduct that the pump is
therefore located at the engine.
Image 69 | Fuel circuit pump@engine setup
Pump Engine
Pressure Gauge approx. –0,5 bar Pressure Gauge

15910 15910
(–1 … +1,5 bar) (–1 … +1,5 bar)
Tank
CDFLA_e-10.13 73
In the following chart heat exchanger and sensor are included in the
fuel circuit.
Fuel circuit pump@engine setup with sensor DFL1x‑5bar and heat ex-
changer DFL‑WTx‑5bar.
Image 70 | Fuel circuit pump@engine setup with sen‑

sor DFL1x‑5bar and heat exchanger DFL‑WTx‑5bar
Pump Engine
DFL1x‑5bar
DFL1x‑5bar
Pump
Y-Adapter
Tank
CDFLA_e-10.13 74
Fuel circuit pump@engine setup with DFL3x-5bar.
Image 71 | Fuel circuit pump@engine setup with DFL3x-5bar
Pump Engine
DFL3x-5bar
Sensor
Pump
Y-Adapter
Tank
CDFLA_e-10.13 75
6.9.2. Installation of Pump@Engine Setup

ON/OFF switch
4. Connect the feed and return tubes according to the following
chart (image 73 & 74).
Image 73 | Fuel circuit pump@engine setup with sensor DFL1x‑5bar and heat exchanger DFL‑WTx‑5bar
CDFLA_e-10.13 76
Image 74 | Fuel circuit pump@engine setup with DFL3x-5bar

the Pressure in the Feed Tube“ on page 55
▫▫ the plug nipple of the pressure gauge KCD15910 (pressu-
re range –1 … +1,5 bar) is connected to coupling of
the fuel tube coming from the tank and the coupling of the
same pressure gauge is connected to plug nipple of
the tube going to the engine.
nected to coupling of the tube coming from the engi-
ne and the coupling of the same pressure gauge is con-
nected to plug nipple .
6. Now disconnect
CDFLA_e-10.13 77
▫▫ the coupling of the pressure gauge KCD15910 from plug

nipple .
7. In case of a system with sensor DFL1x‑5bar and heat exchanger
DFL‑WTx‑5bar connect
▫▫ the coupling of the Y-adapter to plug nipple of the heat
▫▫ the coupling of the sensor DFL1x‑5bar to one of the
plug nipples of the Y-adapter.
▫▫ the coupling of fuel tube to the other plug nipple of the
Y-adapter.
sure gauge KCD15910 (pressure range –1 … +1,5 bar)
that is connected to the tube going to the engine.
that is connected to the tube coming from the engine.
▫▫ the coupling of fuel tube to plug nipple of the fuel
tube going to the tank.
▫▫ the coupling of the Y-adapter to plug nipple of the
DFL3x‑5bar.
▫▫ the coupling of fuel tube to one of the plug nipples of
the Y-adapter.
▫▫ the coupling of fuel tube to the other plug nipple of the
Y-adapter.
▫▫ the other coupling of fuel tube to plug nipple of the
DFL3x‑5bar.
▫▫ the coupling of fuel tube to plug nipple of the
DFL3x‑5bar.
▫▫ the other coupling of fuel tube to plug nipple of the
DFL3x‑5bar.
CDFLA_e-10.13 78

DFL3x‑5bar.
DFL3x‑5bar.
DFL3x‑5bar.
that is connected to the tube going to the engine.
sure gauge 15910 (pressure range –1 … +1,5 bar) that is
connected to the tube coming from the engine.
▫▫ the coupling of fuel tube to plug nipple of the fuel
tube going to the tank.
11. Connect the power cable to the battery.
Note:
The DFL has to be connected to max. 12 VDC
(10 V ... 15 VDC, not 24 VDC) power supply only to
prevent damage.
CDFLA_e-10.13 79
6.9.3. Operation of Pump@Engine Setup
WARNING!
The DFL has to stay switched off while purging the
device (step 1 & 2).
1. Set the pressure regulator adjustment screw to maximum pres-

sure („+“ direction). This operates the integrated fuel pump at
maximum flow rate to provide maximum cooling power.
Image 75 | Purge 2. Set the valve always in the position measure.
3. Turn on the ignition and start the engine.
¨
¨The whole system is ventilated after approximately
30 seconds.
4. Stop the engine.

5. Switch the heat exchanger on with the ON/OFF switch.
6. Turn on the ignition.
¨¨The internal fuel pump starts running. Fuel is sucked

from the vehicle’s engine into the DFL and flows
back to the vehicle’s fuel tank.

If the fuel system of the vehicle does not match the measuring
system the engine may not work flawlessly.
8. At engine idle mode and at full engine rpm check the reading of
the pressure gauge KCD15910 (pressure range –1 … +1,5 bar)
in the feed flow and the return flow. If the results of the measure-
ments are different to the ones performed before installing the
system (see chapter 6.5.2. and 6.5.3. pages 55-57) you cannot
perform a measurement with this system. Please contact the
Kistler hotline +49 (6441) 9282-82 or e-mail to hotline.kcd@kist-
ler.com for further required accessories.
9. If the result of the measurement is similiar to the one performed
before installing the system, stop the engine and switch off the
heat exchanger fuel pump.
10. Demount the pressure gauges from the feed and return tubes to
prevent them from thermal destruction.
CDFLA_e-10.13 80
properly, you may now execute the measurement.

12. Switch on the heat exchanger fuel pump.
14. Execute the measurement.
Note:
CDFLA_e-10.13 81
6.10. Demounting
1. Stop the vehicle engine

2. Let the engine cool down to prevent from the risk of fire etc. in
case of any leaking fuel during installation and also of the risk
of injuries caused by any hot component within the engine com-
partment.
3. Disconnect all power supply cables and signal cables.
4. Set the valve into „purge“ position.
5. Disconnect the feed and return tubes. Take care of leaking fuel
that may be hot and/or pressurized to prevent from fire and in-
juries.
6. Connect the original fuel tubes to set the complete fuel circuit
into the former, original condition.
7. Remove all measurement equipment from the vehicle.
8. Check all tube connections and couplings for proper mounting.
Please consider that possibly increasing fuel pressure at higher
engine rpm may cause leaks. In case of any leak or in case of
any suspicion of a possible leak do not start the engine again
before having securely fixed the error! Prevent from any risk of
fire and/or injuries!
9. Please consider and follow all documentation provided by the
car and/or engine manufacturer regarding refilling and ventilati-
on of the fuel supply system after having opened the fuel supply
tubing. Carry out the requested procedures carefully.
6.11. Storage
The system is always to be stored in filled condition, i.e., fuel should

remain in the system at any time. If the system is to be stored for more
than 3 months, it is necessary to make a regular function test each two
months to prevent the sensitive sensing device from blocking.
The user always has to store the system without pressure inside. This
condition is achieved, if the flow tubes are demounted after powering
down the DFL and setting the valve into „purge“ position.
CDFLA_e-10.13 82
The DFL should be filled with diesel for storage.
WARNING!
For initial shipment to the customer the DFL has been
drained by the manufacturer (Kistler). Please refill the
sensor immediately after having received the unit. We
recommend diesel fuel for this purpose.
6.12. Maintenance
The DFL should be cleaned with a soft cloth, which may be damp, but
not wet. The power cable and signal cable should be cleaned in the
same way.
Image 77 | Fuel filter The fuel filters may block fuel flow due to contamination. This will lead
to insufficient engine power. Therefore it is suggested to change the
fuel filters frequently. Due to dirt particles in the used fuel the fuel filters
may contaminate faster.
6.13. Sensor Calibration and

Calibration Certificate
The calibration factor is determined individually for each sensor by a

special calibration procedure at the manufacturer (Kistler) only.
6.14. Transport and Shipment
For transport and storage the DFL system should be kept within the
optional robust carrying case.
In case of shipment an additional packing into an appropriate robust
and fitting cardboard box is a must. Otherwise damages during ship-
ment caused by unprofessional packing may occur and cause severe
repair costs.
CDFLA_e-10.13 83
User Manual | 7. Technical Data DFL
7. Technical Data
7.1. DFL1x‑5bar
Measurement Parameters Fuel volume,

Fuel temperature (option),
Fuel pressure (option)
To be used with gasoline , diesel, alcohol based and bio fuel
Quick lock Connectors NW 5,8
Measuring Flow Rate 0,5 … 250 l/h

Ranges
Fuel Temperature –20 … +75 °C (option)
Fuel Pressure 0 … 6 bar relative (option)
Measuring Fuel Volume ±0,5 % of reading (in the range 1 … 50 l/h)

Accuracy
Fuel Temperature K-Type DIN IEC 584. Class 1
PT 100
(others on request) (option)
Fuel Pressure ±0,25 % or ±0.15 % full scale (option)
Resolution Fuel Volume 330x10 -3 ml
Fuel Temperature depending on the user’s data acquisition
Fuel Pressure depending on the user’s data acquisition
Drop of Pressure 30 kPa at 50 l/h , 80 kPa at 120 l/h

usually compensated by internal pump
Operation Pressure sub pressure approx. –0,5 bar up to 5 bar

in error condition max. 6 bar
Shock and vibrati‑ 3G

on resistance
Media Temperature short term 120 °C

at approx. 70 °C and above, gas bubbles
can develop in the fuel. Presence of gas
bubbles can result in diminished accuracy!
Ambient Temperature –20 … +70 °C

Range (Operation)
Fuel Filter one filter on each side
CDFLA_e-10.13 84
Operating Mounting any
Relative humidity 80 %
Operating voltage provided by signal processor
Degree of ingress protection IP 44
Favourite mounting / not defined

operating direction
Dimension 183x106x94 mm
Weight 2,0 kg
7.2. DFL‑WTx‑5bar
Measurement Parameters Fuel pressure (option)
Quick lock Connectors NW 5,8 and NW 5,0
Measuring Fuel Pressure 0 … 6 bar relative (option)

Ranges
Measuring Fuel Pressure ±0,25 % or ±0.15 % full scale (option)

Accuracy
Resolution Fuel Pressure In cause of the signal processor1,46 mbar

otherwise depending on the user’s data
acquisition
Operation Pressure sub pressure approx. -0.5 bar up to 5 bar

Shock and vibrati‑ 3 G

on resistance


Range (Operation)
CDFLA_e-10.13 85
Fuel Filter one at inlet to pump
Operating voltage 12 VDC (10 V ... 15 V DC)
Power input fuel pump 12 VDCx8 A
Supply rate fuel pump nominal 5 bar at 12 V DC, not adjustable
max. 190 l/h at 1 bar
Degree of ingress protection IP 34

operating direction
Weight 6,0 kg
External pumps or pressure reduction devices may be required. Please

see the next chapters for description of circuit setups.
7.3. DFL3x‑5bar
Measurement Parameters Fuel volume,

Fuel temperature (option),
Fuel pressure (option)
Quick lock Connectors NW 5,8 and NW 5,0
Measuring Flow Rate 0,5 … 250 l/h

Ranges
Fuel Temperature –20 … +75 °C (option)
Fuel Pressure 0 … 6 bar relative (option)
Measuring Fuel Volume ±0,5 % of reading (in the range 1 … 50 l/h)

Accuracy
Fuel Temperature K-Type DIN IEC 584. Class 1
(others on request) (option)
Fuel Pressure ±0,25 % or ±0.15 % full scale (option)
CDFLA_e-10.13 86
Resolution Fuel Volume 330x10 -3 ml
Fuel Temperature depending on the user’s data acquisition
Fuel Pressure depending on the user’s data acquisition
Drop of Pressure 30 kPa at 50 l/h , 80 kPa at 120 l/h

(without filter) usually compensated by internal pump
Operation Pressure sub pressure approx. –0,5 bar up to 5 bar

Shock and vibrati‑ 3G

on resistance


Range (Operation)
Fuel Filter one filter each within DFL3x-5bar inlet
Operating voltage 12 VDC (10 V ... 15 VDC)
Power input fuel pump 12 VDCx8 A
Supply rate fuel pump nominal 5 bar at 12 VDC

fuel supply rate regulated via
internal pressure regulator
Degree of ingress protection IP34

operating direction
Weight approx. 9 kg
External pumps or pressure reduction devices may be required. Please

see the next chapters for description of circuit setups.
CDFLA_e-10.13 87
7.4. Mounting of the DFL3x-5bar
Image 78
Image 79
To be used with DFL1x‑5bar, DFL3x-5bar
Shock and 10 G
vibration resistance

Range (Operation)
Operating Mounting any
Operating voltage 10 … 24 VDC
Power consumption 0,2 A
Degree of ingress protection IP20
CDFLA_e-10.13 88

operating direction
Weight 1075 g
Outputs Digital 1 500 … 10 000 pulses/cm³

(consumpt.
Actual)
Digital 2 1 … 10 000 Hz/l/h

(flow rate)
Digital for connection proportional to Digital 1

Stand-Alone Display
Analog (flow rate) 0 … 10 V (10 … 1 000 mV/l/h)
CAN actual consumption in liter

flow rate in liter/hour
For USA: All channels with conversion in gallons.
7.6. Housing
All housings are made from aluminum but the DFL3x-5bar bottom shell
is of galvanized steel. The bootom shells are powdered and the upper
shells anodized.
CDFLA_e-10.13 89
7.7. DFL ON/OFF Switch
Image 80 | Image The fuel pump ON/OFF switch opens and closes the current path for
shows ON/OFF switch
in position ON
the power to the fuel pump.
The switch will light and will connect the fuel pump with power under
the conditions,
▪▪ that the power supply is connected to the power supply connec-

tor and
▪▪ that the switch is in position ON.
The switch will not light and will disconnect the fuel pump from power
under the conditions,
▪▪ that the power supply is connected to the power supply connec-

tor and
▪▪ that the switch is in position OFF.
7.8. Power Supply
Image 81 The supply cable connects the DFL power supply connector to
the vehicles electrical system (12 VDC – 10 V – 15 VDC).
Pin 1 Pin 2
Pin Signal
Notch 1 + UB (usually + 12 V DC)
2 + UB (usually + 12 V DC)
3 –UB (ground of power supply)
4 –UB (ground of power supply)
CDFLA_e-10.13 90
7.9. The Fuse and the Fuel Pump
The automatic fuse is only for the purpose of protecting the fuel pump.
The fuse is active under the condition that the fuel pump ON/OFF
switch is in the ON position.
The fuse is of automatic type. The current capacity is 8 A. The fuse
cannot be exchanged.
The fuse switches the power off the fuel pump under the condition that
the fuel pump tries to draw too much current for a too long period of
time.
The standard current drawn by the fuel pump is a maximum of 5 am-
pere at 12 VDC.
The current drawn by the fuel pump is low as 2 ampere at 12 VDC un-
der the condition, that the fuel pump needs to fill the fuel tubes with fuel
after mounting the measurement equipment correctly to the vehicle.
The procedure of filling the tubes with fuel is usually completed after
two minutes.
Under the error condition, that the flow tube at quick lock connector 3 to
the vehicle is blocked and that the flow at quick lock connector 7 from
the vehicle is connected, the fuel pump will try to pump fuel. The maxi-
mum pressure will be reached with the maximum current drawn by the
fuel pump. The pump tries to keep this condition. The fuse blows and
disconnects the fuel pump from the power supply.
ATTENTION:
If the fuse has blown you have to switch off the system
and verify the system setup.
ATTENTION:
It‘s a function of the automatic fuse that it is resetting
after a short time period. Therefore the system may be
activated automatically and without user action.
ATTENTION:
If the fuse has blown, it may be possible, that the DFL is
under pressure. Disconnecting fuel tubes or connecting
fuel tubes may lead to dangerous fuel spray.
CDFLA_e-10.13 91
7.10. The Ground Connector
Image 82 | Ground The ground connector is a one pin 4 mm socket (for a banana plug).
connector
The ground connector is connected electrically to the housing and to
the negative supply pin of the fuel pump.
The housing of the fuel pump is electrically connected to the housing
of the heat exchanger.
Note:
It is not usual to connect the ground connector to the
vehicle’s negative electrical potential (mass of the
vehicle, e.g. chassis).
WARNING!
It is not allowed to use the ground connector as negative
supply core.
Under the condition that the measurement setup requires the housing
of the DFL‑WTx‑5bar or of the DFL3x-5bar to be grounded, the ground
connector is connected to the vehicle’s negative electrical potential
with a resistance of 47 Ohm.
CDFLA_e-10.13 92
7.11. Electrical Circuit
Image 83 | Electrical circuit DFL‑WTx‑5bar and DFL3x-5bar
Fuel pump
ON/OFF
Fuse 5 A switch
fast blown
Power Fuel pump

connector
Diode
Ground
connector
CDFLA_e-10.13 93
7.12. Signal Output
The signal outputs refer to optional sensors, which can be integrated

into the DFL.
The temperature measurement can be executed with using one optio-
nal K-type thermocouple element sensor.
The pressure measurement can be executed with using one optional
pressure transducer.
Each sensor requires a special data acquisition unit for signal amplifi-
cation and data acquisition and data storage.
7.12.1. Optional Fuel Temperature Measurement
Image 84 | DFL3x-5bar The yellow 2 pin socket is optionally available for temperature measure-
with two thermocouples
ment of the fuel temperature.
The sensing element is a K-type thermocouple. It is placed directly into
the fuel flow of the sensor.
In case of two thermocouples:
▪▪ The first thermocouple is placed into the fuel input (feed) and
▪▪ The second thermocouple is placed into the fuel output (return)
In case of one thermocouple:
▪▪ The thermocouple is placed into the fuel output (return)
CDFLA_e-10.13 94
7.12.2. Optional Fuel Pressure Measurement
Image 85 | Optional 6 pin round socket Pin 1
Pin 6
Image 86 | Optional 6 The 6 pin Lemo socket is optionally available for pressure measure-
pin round socket pres‑
sure sensor connector
ment.
The 6 pin Lemosa connector provides pressure signal output and pres-
sure sensor power supply input.
The sensing element is a relative pressure transducer. This pressure
transducer is placed directly into the fuel flow outlet close to the quick
lock coupling no. 3.
The sensing element is a pressure transducer which is alternatively
available with 0,25 % or 0,15 % accuracy (only to be selected when
ordering).
Pin Signal
1 not connected
2 power supply positive (nominal +12 VDC)
3 AGND (signal GND)
4 not connected
5 signal out
6 power supply GND
CDFLA_e-10.13 95
7.13. Fuel Tubes
Bio-Diesel-resistant tubes are the best choice for applications, which

have fuel temperatures above +70 °C or which will use alcohol fuel.
Material Viton, Bio-Diesel-resistant
Fuel resistance Implementation DIN 73379-3E (version 11/97):

standard fuel and Bio-Diesel
(RME-fuel / alcohol fuel)
Temperature range –40 ... 125 °C
Pressure range 10 bar
Bending radius >60 mm
Connection techniques The tube fits on hose nipples or on pipe

connections and must be fixed with a clamp.
Inner diameter 7,3 mm

9,3 mm
11,5 mm
13,0mm
CDFLA_e-10.13 96
User Manual | 8. Trouble Shooting DFL
8. Trouble Shooting
8.1. Sensor
This applies to the DFL1x‑5bar and to the integrated sensor of the

DFL3x-5bar.
Description Cause Instruction
Engine power The pump in the Replace the

below standard cooling circuit fuel filters.
does not supply
The engine does sufficient fuel.
not reach full power
or misfires during
high performance.
The engine does The entire measu- Execute a

not start. ring system needs sensor check
to be checked
for the undeter-
mined error.
There is no signal The signal ca- Change the

from the sensor. ble is defect. signal cable.
There is no DFL si- The DFL out- Send the

gnal and the signal puts no signal. DFL system
cable is correct. for repair.
CDFLA_e-10.13 97
8.1.1. Interfering Signals after Cold Start
Such periodic faults result when a pair of pistons becomes sticky.

This effect may occur when the system was not used for quite a time.
This is caused by sediments or a light sticking of the measuring pistons
within the cylinder.
More severe faults or even damage may occur if the system is not sto-
red in filled condition.
Note:
If after flushing the sensor the periodic faults are still
appearing, it is recommended to send the DFL for
repair and calibration.
8.1.2. Checking the Sensor
The test measurement set up requires the DFL, a fuel tank, a measu-
ring glass, hoses and a valve to control the fuel flow.
The fuel tank will be installed at a height of 1,5 m. The measuring glass
will be placed on the floor (at a height of 0 m). The DFL is placed in
between with the additional hoses. The valve is used to open and close
the pipeline. The fuel will flow due to earth gravity from the tank through
the sensor into the measuring glass.
Set up the system for the test measurement.

▫▫ Connect the quick lock coupling of the DFL with a tube
to the fuel tank.
▫▫ Connect the quick lock coupling of the DFL with a tube
to the measuring glass.
Start the measuring system (signal processor or other additional

data aquisition system).
Open the valve to enable the fuel flow.
¨¨Fuel flows through the sensor into the measuring

glass.
Verify the measured quantity with the fuel volume in the measu-
ring glass.
CDFLA_e-10.13 98
If there is only sporadic fuel flow, no continuous fuel flow or no fuel

flow at all, the sensor needs to be flushed. Please see chapter „8.1.3.
Flushing the Sensor” on page 99.
If there is no fuel flow at all, although the sensor has been flushed, the
DFL needs to be sent back for repair.
If the volume measured does not match the fuel volume in the measu-
ring glass within the limits of accuracy, the DFL needs to be sent back
for repair and calibration.
8.1.3. Flushing the Sensor
Flushing the sensor is a procedure, which is used for two reasons:
▪▪ To eliminate a blocking of the sensor.

▪▪ Filling the sensor with a different medium.
8.1.4. Flushing in Case of a Blocked Sensor
The sensor may block, if there
▪▪ is dirt inside the sensor due to bad filters.

▪▪ is bad fuel due to a long storage period (e.g. more than three
months).
Flushing the sensor requires hoses, a tank and a fuel pump.
Set up the flushing system.

▫▫ The fuel pump sucks the fuel from the tank and presses
the fuel through the filter to the DFL sensor.
▫▫ The sensor will be flushed and the fuel flows back into the
tank.
¨
¨The fuel flowing to the sensor is without gas
bubbles.
Keep this procedure running for a minimum of ten minutes. You

may conduct this procedure for 72 hours (and even longer).
CDFLA_e-10.13 99
1 2
DFL Sensor
3 4 5 6 7 8
Measure Purge
Pump
A
non
return
valve
Heat
Exchanger
Pressure
Sensor
Tank
Note:
The fuel tank needs to have sufficient fuel, so that the
fuel pump does not suck fuel with gas bubbles.
The fuel tank should be that big, that it can take the
double quantity of the fuel inside the circuit.
The fuel tank should be filled with sufficient fuel to fill all
hoses, all filters, the fuel pump and the sensor.
Any safety regulations have to be considered carefully!
CDFLA_e-10.13 100
8.1.5. Sensor Warm Up
Warm-up the system before starting the test.
¨
¨The accuracy of the sensor depends on the warm-
up period, as the four-piston counter may indicate
incorrect values due to the presence of sediments
or gas bubbles. A long lead-time ensures a sufficient
purge of the measuring chamber. Should the
following irregularity occur periodically, it may be the
result of an insufficient purge time. In this case try to
flush the sensor for a longer period of time.
8.1.6. Flushing before Refill with other Type of Fuel
Flushing the sensor requires hoses, two different tanks and a fuel
pump.
Set up the flushing system.

▫▫ The fuel pump sucks the fuel from the feed tank and pres-
ses the fuel through the filter to the sensor.
▫▫ The sensor will be flushed and the fuel flows back into the
return tank.
¨
¨The fuel flowing to the sensor is without gas
bubbles.
Conduct the procedure for a minimum of five minutes.
Note:
The fuel feed tank needs to have sufficient fuel, so that
the fuel pump does not suck fuel with gas bubbles.
The feed tank should be filled with sufficient fuel to fill
all hoses, all filters, the fuel pump and the sensor.
The return fuel tank should be that big, that it can take
the double quantity of the fuel from the feed tank.
Any safety regulations have to be considered carefully!
CDFLA_e-10.13 101
8.2. Heat Exchanger
This applies to the DFL‑WTx‑5bar and to the integrated heat exchanger

of the DFL3x-5bar.
Engine power The pump does Check the fuel

below standard not supply suf- filters on the
ficient fuel. DFL system
The engine does
not reach full power
or misfires during
high performance.
No reaction is The fuel pump

audible when is not running. ATTENTION:
switching on the
fuel pump with the Check, that
ON/OFF switch. the tubes are
not blocked. A
blocked flow
tube may force
the fuse to blow
and will create
overpressure
inside the DFL.
ATTENTION:
If the fuse has
blown due to a
blocked tube, the
heat exchanger
is under pressure.
Connecting and
disconnecting
fuel tubes may
lead to fuel spray.
Execute a heat
exchanger
check.
CDFLA_e-10.13 102
The engine does The entire measu- Execute a heat

not start. ring system needs exchanger
to be checked check.
for the undeter-
mined error.
No reaction is The fuel pump Send the

audible when is not running. DFL system
switching on the for repair.
internal pump with
the ON/OFF switch.
8.2.1. Checking the Internal Heat Exchanger
The two circuits of the heat exchanger need to be checked indepen-

dently.
8.2.2. Checking the First Path of the Heat Exchanger
Checking the path through the fuel pump and the first path of the heat
exchanger.
Image 87 | Checking the first path of the DFL‑WTx‑5bar
CDFLA_e-10.13 103
Image 88 | Checking the first path of the integrated heat exchanger of the DFL3x-5bar
1. Using fuel tube Ð

connect the tank to quick lock connector
of the heat exchanger as feed flow tube.
2. Using fuel tube connect quick lock connector of the heat
exchanger to the tank as return flow tube.
3. Connect the power connector to the 12 VDC power supply of the
of the DFL.
4. Set the valve into position „Measure“.
5. Turn the DFL on with the ON/OFF switch.
¨
¨The fuel pump starts sucking the fuel from the tank.
The fuel is pressed back into the tank.
6. Check the return fuel flow volume. Check the current of the fuel
pump.
¨¨If the return fuel flow is strong (e.g. 120 l/h) and if the
electric current drawn by the fuel pump is in the range
beyond 5 ampere, you can continue with checking the
heat exchanger.
CDFLA_e-10.13 104
7. Switch the power OFF.
¨
¨The fuel pump stops working. No further fuel flow is
visible.
8.2.3. Checking the Second Path of the Heat Exchanger
Checking the path through the second path of the heat exchanger.
Image 89 | Checking the second path of the DFL‑WTx‑5bar
CDFLA_e-10.13 105
Image 90 | Checking the Second Path of the Integrated Heat Exchanger of the DFL3x-5bar.
1. Using fuel tube connect the tank to quick lock connector

of the heat exchanger as feed flow tube.
2. Using fuel tube connect the heat exchanger‘s quick lock
connector with the quick lock connector .
3. Using fuel tube connect the heat exchanger‘s quick lock
connector to the tank as return flow tube.
4. Connect the power connector to the 12 VDC power supply of the
of the DFL.
6. Switch the power ON.
¨
¨The fuel pump starts sucking the fuel from the tank.
The fuel is pressed back into the tank.
7. Check the return fuel flow volume. Check the current of the fuel
pump.
¨¨If the return fuel flow is strong (e.g. 120 l/h) and if
the electric current drawn by the fuel pump is in
the range beyond 5 ampere, you can use the heat
exchanger of the DFL for this measurement setup.
CDFLA_e-10.13 106
8. Switch the power OFF.
¨
¨The fuel pump stops working. No further fuel flow is
visible.
9. The heat exchanger of the DFL is ready to be used in a measure-

ment setup. For demounting instructions please read chapter
„6.10. Demounting“ on page 82.
CDFLA_e-10.13 107
8.2.4. Filling the Heat Exchanger with Fuel
It may be that the DFL‑WTx‑5bar or that the integrated heat exchanger

of the DFL3x‑5bar have been emptied or that they need to be filled with
diesel for storage.
Image 91 | Filling the integrated heat exchanger of the DFL3x-5bar with fuel
CDFLA_e-10.13 108
Image 92 | Filling the integrated heat exchanger of the DFL3x-5bar with fuel
1. The use of two separate tanks is recommended in order to avoid

mixing new fuel with previously used fuel (perhaps of different
qualities).
2. Connect the tubes according to the diagram (image 92).
3. Connect the power connector to the 12 VDC power supply.
Please note:
It is suggested to have two tanks, if the heat exchanger
is to be filled with diesel for storage. The feed fuel tank
(Tank1) has to be filled with diesel. The return fuel tank
(Tank 2) has to be empty.
Please note:
As the fuel pump will give a fuel flow rate of up to 120 l/h
and as the procedure of filling the heat exchanger with
fuel may last for ten minutes, it is required to have two
tanks for a volume of more than 20 litres.
CDFLA_e-10.13 109
5. Switch the DFL ON with the ON/OFF switch and operate the
pump for approx. 10 minutes.
¨¨The flow rate should be 120 ... 150 l/h.
Note:
A through-flow rate of 120 l/h produces a volume of 20
litres in ten minutes. The tanks should be bigger to avoid
a run over.
CDFLA_e-10.13 110
8.2.5. Pump power
Image 93 | Test setup
Fuel
Filter
Valve
1 2
DFL Sensor
3 4 5 6 7 8
Measure Purge
Pump
A Fuel
non Filter
return
valve
Heat
Exchanger
Pressure
Sensor
closing
valve
Tank
Inner diameter: 7,5 mm

Power supply: 12 VDC at 12,0 VDC
Suction height: 0,5 m
Pressure (bar) Flow rate (l/h) Current (A)
0,2 150 6
1 145 6
2 140 7
3 135 8
4 125 8
5 115 8
6 100 9
CDFLA_e-10.13 111
Sensor-specific Software Description
9. Sensor-specific Software Description
9.1 Device Tree Settings

The device tree displays a node comprising the sensor
identification and the serial number and three menu items:
Sensor Configuration
Analog and Digital Output
CAN Bus
The following pages describe the options for system
configuration, operation and data display.
9.1.1 Sensor Node DCA System

The DFL sensor node (serial number) displays the most
important information about the connected sensor and its
actual settings.
Fig. 1: Screen view of the status display
CDFL1A_002-xxxe-11.13 KorrEx Page

Page112
11
DFL Sensors For Fuel Flow Measurement
9.1.2 Sensor Configuration

In menu "Sensor Configuration" you can set sensor
distance, stand-off, working range, and the mean value
filter for one or two sensors.
Fig. 2: Screen view "Sensor Configuration"
Digital Input: Speed In

Set the resolution of the pulses per m. Values can be
entered manually within the specified range (shown in the
brackets below the input boxes).
Filter activate
If the checkbox is activated, you can set the values for the
average filter time within the range of 2 ... 1 024 ms (in
steps of 4 ms).
113
Page 12 CDFL1A_002-xxxe-11.13 KorrEx
9.1.3 Analog and Digital Output

In menu "Analog Outputs" you can can configure the
output of the analog and digital channels. You can set the
desired resolution and the offset of the analog channels.
Fig. 3: Screen view "Analog Output"
Digital Outputs
Digital Channel 1: Volume
Set the resolution of the
pulses per ccm
Digital Channel 2: Flow
frequency per l/h
Values can be entered manually within the specified

range (shown in the brackets below the input boxes).

Page114
13
Analog Outputs
Analog Channel 1: Flow
pulses per ccm
Analog Channel 2: Temperature Input
Set the resolution of millivolt
per °C
Analog Channel 3: Temperature Output
per °C
Analog Channel 4: Pressure
per bar
For all analog channels: Set the offset in millivolt
Values can be entered manually within the specified

range (shown in the brackets below the input boxes).
115
9.1.4 CAN Bus

In menu "CAN Bus" you can configure the CAN Bus
according to your requirements. Also see Chapter 6.2
CAN Protocol, for further information.
Fig. 4: Screen view "CAN Bus"
Baud Rate
Determines the communication baud rate for the CAN
protocol.
Data Format
You can choose between Intel or Motorola data format.
Terminating Resistor
The internal CAN terminating resistor can be activated or
deactivated here.
Send Modes
Continuous Send Mode: Sets sensor to send the
CAN message at regular intervals, selectable in 4 ms
increments.
Trigger Frame Mode: Sets sensor to respond to a
CAN trigger frame. Select either Standard (STD) or
Extended (XTD); sets the sensor message identifier.
Remote Frame Mode: Sets sensor to respond to
remote frame requests.

Page116
15
Data Frames
ID Data Frame: Sets the sensor message identifier.
Select either Standard (STD) or Extended (XTD)
Identifier mode.
ID Data Frame 2: Sets the sensor message identifier.
Select either Standard (STD) or Extended (XTD)
Identifier mode.
117
9.2 CAN Protocol

Version 1.0
(valid from sensor software version 047-01-00-02)
03.11.2008
There are 3 modes of data transmission on the CAN bus.

The transmission mode can be selected using KiCenter.
The CAN messages sent by the sensors for all three
modes consist of one or more frames (a frame is defined
in the CAN bus specifications).
The sensor sends two data frames. The data format is
the same for each send mode. It is possible to choose
between Intel data format and Motorola data format.
Continuous Send Mode

The messages are sent continuously and cyclically with
a period set in KiCenter (by default 4 ms). Cycle times
between 4 ms and 512 ms (in 4 ms steps) can be selected.
Trigger Frame Mode

Sending the data frames, the sensor responds to a trigger
frame from a master controller (for synchronization). The
trigger frame ID must be entered in the sensor using
KiCenter.
Remote Frame mode

The sensor responds to a remote-frame request from
a master controller. The sensor sends the data frame
(response to the remote frame request).
The identifier numbers of all data frames can be set

separately in KiCenter. The settings of baud rate and data
format are settable with KiCenter as well.
CAN bus type: CAN V2.0B

Baud rate: 1 MBaud (default), 500 kBaud,
250 kBaud, 125 kBaud
Data format: Intel (default), Motorola backward

Page118
17
9.2.1 Definition of the Frames

The following definitions present how the data bytes within
a CAN message frame are allocated in order to decipher
the data transmitted.
9.2.1.1 Definitions for Intel Format

Data Frame 1 (Sensor 1)
Format: 8 Data bytes
Default ID (Standard): 0x7FA
Default ID (Extended): 0x1FFFFFFA
Data byte Description Units Data Type

0 Timestamp 4 ms unsigned
1 Status byte see table "Statusbyte"
2 Total consumption (Bit 0 ... 7)
10-1 ml unsigned
6 Flow rate (Bit 0 ... 7)
10-2 l/h unsigned
Data Frame 2
Default ID (Standard): 0x7FB
Default ID (Extended): 0x1FFFFFFB

0 Liter per 100 km (Bit 0 ... 7)
10-2 l/100 km unsigned
1 Liter per 100 km (Bit 8 ... 15)
2 Km per liter (Bit 0 ... 7)
10-1 km/l unsigned
4 Temperature In (Bit 0 ... 7)
5 Temperature In (Bit 8 ... 11), Temp. Out (Bit 0 ... 3) 10-1 °C signed
6 Temperature Out (Bit 4 ... 11)
7 Pressure 10-1 bar unsigned
119
9.2.1.2 Definitions for Motorola Format

Data Frame 1 (Sensor 1)
Default ID (Standard): 0x7FA
Default ID (Extended): 0x1FFFFFFA

0 Timestamp 4 ms unsigned
1 Status byte see table "Statusbyte"
10-1 ml unsigned
10-2 l/h unsigned
Data Frame 2
Default ID (Standard): 0x7FB
Default ID (Extended): 0x1FFFFFFB

0 Liter per 100 km (Bit 8 ... 15)
10-2 l/100 km unsigned
1 Liter per 100 km (Bit 0 ... 7)
10-1 km/l unsigned
4 Temperature In (Bit 4 ... 11)
5 Temperature In (Bit 0 ... 3), Temp. Out (Bit 4 ... 11) 10-1 °C signed
6 Temperature Out (Bit 0 ... 7)
7 Pressure 10-1 bar unsigned

Page120
19
9.2.1.3 Statusbyte
Data byte Description Status

0 Power supply OK 0: Error in power supply
1: Power supply OK
1 Flow direction OK 0: Flow direction is wrong
1: Flow direction is OK
2 Calc flow rate OK 0: Flow rate calculation is not active
1: Flow rate calculation is active
3 Currently not used
4 Trigger brake switch 0: No trigger

1: Trigger from brake switch
5 Trigger light barrier 0: No trigger
1: Trigger from light barrier
6 Sensor connected 0: Sensor is not connected
1: Sensor is connected
7 Sensor parameter copied 0: Sensor parameter not copied to RAM
1: Sensor parameter copied to RAM
9.2.1.4 Control Frame

The control frame is generated by the host controller and has two functions. The first is for synchroni-
zation whereby the sensor responds to a trigger frame from a master controller. The other is to accept
control messages from the host controller and react upon them.
Data byte zero of the control frame is read out and the function described below is performed. All other
data bytes (Data byte 1 to data byte 7) of the trigger frame are ignored.
Data byte 0 value Status

0x00 0: Error in power supply
1: Power supply OK
0xAA 0: Flow direction is wrong
1: Flow direction is OK
Other 0: Flow rate calculation is not active
1: Flow rate calculation is active
Page 121
20 CDFL1A_002-xxxe-11.13 KorrEx
9.3 Creation of CAN Database Files (CAN DB)

KiCenter provides the option to create CAN database
files. To start the creation of CAN database files, please
click on the "Create CAN DB" button in the symbol bar.
Fig. 5: Screen view "Create CAN DB", 1
After selecting this menu item, you will be prompted to

choose a location for storing the CAN database file.
Select a suitable location and file name, and store the file
by clicking the "Save" button.

Page122
21

Instruction Manual: Fuel Consumption Sensor Systems Type CDFL1A..., CDFL3A..

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Instruction

It is essential that you read and understand the manual

3.5. Heat Exchanger..............................19

3.6. Pressure Regulator.........................20

3.7. Signal Processor............................. 21

4.2. External Heat Exchanger

4.2.1. Optional Pressure Transducer

4.3. Sensor System DFL3x-5bar...........28

4.3.3. Integrated Heat Exchanger.......29

4.4. Signal Processor............................33

6.5. Preinstallation - Vehicles with Feed

6.6. System Mounting............................58

6.7. Sensor Only.................................... 61

6.8. Pump@Tank Setup........................65

6.9. Pump@Engine Setup.....................73

7.12. Signal Output.................................94

7.13. Fuel Tubes.....................................96

8.2. Heat Exchanger............................ 102

Thank you for choosing a Kistler quality product cha-

Information in this document is subject to change wit-

©2012 Kistler Group. All rights reserved. Except as ex-

Kistler Automotive GmbH

Please take the time to thoroughly read this instruction

To the extent permitted by law Kistler does not accept

Kistler offers a wide range of products for use in measu-

Kistler also develops and produces measuring solutions

Our product and application brochures will provide you

If you need additional help beyond what can be found

For your Safety

To assure safe and proper operation, all supplied

The equipment should be installed and operated only

Local regulations may not permit the operation of mo-

Leaking fuel can cause explosion or fire hazard.

Defective pumps can be hazardous.

Do only use original Kistler cables! Otherwise there

Risk of injury from moving engine parts.

Do not use defective or damaged equipment, compon-

Do not modify or change the equipment or its accesso-

Equipment must be mounted firmly and securely. Im-

Do not operate DFL systems without fuel filter(s) instal-

Do not mount equipment, components and/or accesso-

The sensor and/or sensor components may be dama-

Use only original equipment, components and/or

Always note correct pin assignments and operating vol-

Kistler assumes no liability for damages caused due to

Disposal Instructions for Electrical and Electronic Equipment

Software Upgrades and Updates

Kistler declines any liability whatsoever for any direct or

▪▪ Fuel or any other component temperature

Kistler always recommends to have an appropriate fire extinguisher

The DFL sensors are developed for fuel consumption measurement

3.1.1. System Overview DFL1x‑5bar

Image 2 | DFL1x‑5bar sensor overview

3.1.2. System Overview DFL3x-5bar

Image 3 | DFL3x-5bar sensor overview

▪▪ Further development of the proven and worldwide introduced

▪▪ Further development of the proven and worldwide introduced

3.3.1. Permitted Media for Fuel Consumption Measurement

3.3.2. Not permitted Media for Fuel Consumption Measurement

3.3.3. Alternative Media

Replacement fuel for petrol or diesel (please clarify by sending in a

The devices DFL1x‑5bar and DFL3x-5bar use the well-known DFL

3.4.1. Single Device – Sensor DFL1x‑5bar