Gill Racing Sensors Brochure

www.gillsensors.co.uk

Level | Flow | Quality | Speed | Position | Specialist

Contents

About Gill Sensors

Oil Flow Meter ................................................................................p.1Oil Quality Sensor ..........................................................................p.1

M-Series Custom Level SensorsFuel Level Sensors ..........................................................................p.2Oil Level Sensors ............................................................................p.3Bio-Fuel Level Sensors ...................................................................p.4Water Level Sensors ......................................................................p.5Specialist Miniature Level Sensors ...............................................p.5Pit-Lane Refuelling Tank Sensors ..................................................p.6

R-Series Liquid Level Sensors ........................................................p.7

Digital Level Display ......................................................................p.8ProbeMON Software .....................................................................p.8Sensor Service Unit ........................................................................p.8Speed Sensors ...............................................................................p.9Oil Debris Sensor ............................................................................p.9Position Sensors ..............................................................................p.10

Sensor Specifications ....................................................................p.11-13

Based in Lymington, UK, Gill Sensors supply level, flow, speed and position sensors, along with a full range of custom solutions. We have been involved with Motorsport for over ten years and now supply all leading Formula 1, LMS and ALMS teams among many others.

What sets us apart is our unique ability to produce full-custom designs rapidly- to exacting requirements. We pride ourselves on our attention to customer satisfaction and understand that our customers face individual challenges which often cannot be serviced by traditional methods.

We offer a full range of standard and custom level sensors for any fluid on the racecar, custom hall-effect wheel speed sensors, portable ultrasonic oil flow sensors and non-contact position sensors. An overview of the entire range follows in this brochure, with full specifications located at the rear. Further details, images and datasheets are available from our website: www.gillsensors.co.uk.

Gill SensorsSolent House, Cannon Street, Lymington, Hants, SO41 9BR

ý www.gillsensors.co.uk

* [email protected]

( +44 (0)1590 613400

7+44 (0)1590 613401

Principal Motorsport Engineering Contact:Neville Meech


Ultrasonic Liquid Flow Sensor

Oil Quality Sensor

The Gill Oil Quality Sensor is a solid-state, compact device that offers the user the ability to monitor the fluid quality via the dielectric constant of a chosen liquid.

The sensor is available as a configurable device allowing the customer to pre-calibrate it against fluid samples of known quality or related use.

Calibration can be conducted using our own free software, firstly qualifying the sensor in a clean sample of the medium. Subsequent exposure to further samples of decreasing quality will enable results to be collated within a database. This data can then be used as a performance indicator when the sensor is used in the racecar environment.

The sensor is designed to be used only in a fully submerged condition and is therefore IP68 rated.

FULL SPECIFICATIONSON P.12

This sensor has been developed for ‘real time’ liquid measurement with specific attention given to the mechanical packaging to allow dyno and ‘on car’ correlation of data. The sensor installs directly into a suitable existing pipeline modified to accept flexible -16 tube connector couplings.

The system uses the established ultrasonic ‘time of flight’ measurement principle. The flow tube, transducers and mounting arrangement are compatible with an installation on an engine, capable of measuring liquid flow of up to 200 litres/min and temperatures of up to 150°C.

The remote processing electronics are rated for 105°C and can be placed up to one metre away from the flow tube. These electronics provide the user with flow data over a USB or analogue interface and can be powered from an automotive supply of 5 to 24 volts.

Sensors Designed

to Your

Requirements

1

M-Series

Petroleum / Gasoline Level SensorsCustom Sensors designed to your requirements

Gill is the leading supplier of petroleum/gasoline fuel cell and collector level sensors in Formula 1, ALMS, LMS and IRL, and has a proven reputation for a quality product developed and manufactured for the world’s premier race teams.

Gill Petroleum/Gasoline level sensors are designed to be fully immersed in any petroleum/gasoline fuel and offer class-leading functions such as user configurable outputs and on-board multiple fuel grade calibration storage capabilities.

Compatible with:- Race Petroleums- Gasoline- Unleaded Petrol (95-102 RON)- Jet Fuel- AVGAS 100

Our unique approach offers the customer a sensor individually designed for their exact requirement, while benefiting from proven technology, reliability and experience we have gained over years of involvement in Motorsport.

Each sensor is designed with integrated electronics, customer specified harness or integrated connector and has no moving parts. A novel use of a capacitive measurement technique combined with compact, lightweight, robust designs ensure this sensor range is the preferred choice for fuel cell and collector installations in all premier Motorsport categories, led by F1.

Every Gill M-Series sensor is fully user configurable using our own simple software enabling the level settings to be finely adjusted to suit precise individual requirements.

Sensors Designed

to Your

Requirements


2

Gill Motorsport Oil Level Sensors are specifically designed for use in dry sump engine oil tanks and applications. We design and manufacture each sensor to match the customer’s exact requirements and with no moving parts used within the construction, this product is a genuine solid-state device.

Compatible with:- Engine Oil- Hydraulic Oil- Diesel

Our reputation for supplying individually designed oil sensors for either integrated, fabricated or carbon-fibre oil tanks is unparalleled. M-Series Oil Level Sensors are offered with the same user functionality as the petroleum/gasoline range, packaged in a format to withstand the higher operating temperatures witnessed in most oil applications.

Each sensor is designed with integrated electronics and a customer specified harness or integrated connector and custom mountings. A novel use of a capacitive measurement technique combined with compact, lightweight, robust designs ensure this sensor range is the preferred choice for many engine designers and user groups.

Most designs can be offered with integrated oil temperature monitoring and multiple on-board oil grade calibration storage functions, enabling the sensor to be instantly re-configured in up to twelve different oil types without the need to remove the sensor from the vehicle or application.


M-Series

Oil Level SensorsCustom Sensors designed to your requirements

Sensors Designed

to Your

Requirements


3

M-Series

Methanol / Ethanol Level Sensors

Gill’s Motorsport range of fuel cell and collector level sensors specifically developed for methanol and ethanol based fuels have set the standard for accuracy, reliability and quality with the increasing popularity of bio-fuels in Motorsport. Each sensor is available with full Gill M-Series specification designed to suit individual team or customer requirements.

Each sensor can be totally immersed in methanol or any blend of ethanol ensuring the maximum fuel depth of the cell or collector can be monitored.

Compatible with:- Ethanol E10, E50, E85, E100- Methanol

In addition to each sensor being factory calibrated by Gill in the fuel(s) of customer choice, the solid-state, lightweight construction results in a product with unparalleled quality and performance, the first choice in Motorsport bio-fuel collector level sensors.

Integrated electronics, customer specified mounting, sealing, cable exit locations or integrated connectors are just a sample of the list of options customers have when considering their preferred design.


Custom Sensors designed to your requirements

Sensors Designed

to Your

Requirements


4

M-Series

Water/Coolant Level SensorsCustom Sensors designed to your requirements

M-Series

Specialist Level SensorsCustom Sensors designed to your requirements

M-Series Water/Coolant level sensors benefit from constructions utilising materials such as Titanium and 316 Stainless Steel to withstand the corrosive nature of coolant, high temperature water and additives. All Gill Water/Coolant level sensors are designed to be lightweight, compact and totally reliable - key reasons why Gill remains the first choice for this type of sensor.

Compatible with:- Hot Water / Glycol- Coolant

Sensors Designed

to Your

Requirements

Specialist applications within or associated with the engine or chassis require specialist compact sensors that will operate in extreme environments. Gill has extended its M-Series liquid level sensor range and produced the specialist range to meet these requirements.

Applications such as engine catch tank, brake fluid reservoir, swirl pot and gearbox oil level installations are typical examples of the range of sensors Gill is requested to design and produce. Often the design will result in miniature, bespoke solutions for mainly oil based medium for either racecar or development use.


5

Gill Pit Lane Refuelling Rig level sensors have become essential tools for many teams in IRL, LMS and ALMS, providing valuable real-time data during pit-stop activities.

This product, combined with a Gill on-board fuel cell or collector level sensor, provides reliable, accurate data essential for race winning pit-stop strategies.

Our Pit Lane Refuelling Rig level sensors have been used in the former Champ Car World Series, as well as currently in the IRL, LMS and ALMS Series. Their suitability for use with bio-fuels makes them particularly desirable in these series as the aggressive nature of the fuel tends to be unsuitable for other types of liquid level sensor.

We can offer full-custom sensor designs in addition to our standard flange mount used on most refuelling rig applications. The sensor flange is designed to mount to a simple boss welded to the top face of the tank, or installed in a custom external sight glass tube, with the probe suspended in the deepest section of the fuel tank ensuring that a fast, accurate measurement is made in real time. Each sensor is constructed from an aluminium alloy equipped with fully encapsulated integral electronics and a Deutsch connector offering a robust design, proven in the pit lane environment.

The Refuelling Rig level sensor is available in any preferred customer length and each device is supplied factory calibrated to ensure a quality result straight from the box.

M-Series

Pit Lane Refuelling Rig Level SensorsCustom Sensors designed to your requirements

Sensors Designed

to Your

Requirements


6

R-Series

R-Series Liquid Level SensorStandard Sensor for Fuel, Oil, BioFuel & Water

The Gill R-Series level sensor is available for gasoline/petroleum, oil, bio-fuel and water medium. Each sensor is equipped as standard with an SAE 5-bolt mounting pattern, common with the aperture in FIA approved Motorsport fuel cells. The standard R-Series sensor is available in lengths of up to 500mm, with each sensor manufactured to the customer’s requirement. For lengths over 500mm we offer the Rxl variant, see below.

Compatible with:

FUEL

- Race Petroleums- Gasoline- Unleaded Petrol (95-102 RON)- Jet Fuel- AVGAS 100

OIL- Engine Oil- Diesel

BIO-FUEL- Ethanol E10, E50, E85, E100- Methanol

Water- Fresh Water- Salt Water- Coolant / Hot Water & Glycol

Rxl-Series

Extra Long Sensors

For extra-long sensor requirements (over 500mm) we offer the Rxl-Series sensor. This sensor has additional mechanical strengthening features which are necessary for the longer lengths. We recommend that Rxl-Series sensors are supported at the tip to prevent any unnecessary stress being applied to the sensor whilst in the application, however for applications where support of the tip is not possible we offer a mounting boss to give extra strength to the flange mount.

R-Series

Baff le Kit

For applications where the sensor is positioned in an open void in the tank (with no foam surrounding the sensor) we offer a baffle tube kit to combat fuel slosh and stabilise the sensor output.

This type of occurrence is common in Australian V8 Supercars, where an open void is required to maintain access to fuel pumps within the tank.

7

Digital Level Display


Suitable for use with R-Series Level Sensors

ProbeMON Calibration SoftwareQuick and Easy Sensor Re-Calibration

Portable Sensor Service UnitSimple On-Car Calibration Tool

All Gill liquid level sensors are supplied with ProbeMON Calibration software, giving the user full control over the sensor’s output characteristics. The software can be used to:

- Re-calibrate the level sensor for use with a different liquid type

- Change the measurement range limits

- Store multiple calibration files within the sensor to change between medium types.

- Monitor the output performance of the sensor

The Portable Sensor Service Unit is light, compact and useable with any Gill Liquid Level Sensor. The minimum and maximum liquid level is set using the simple user interface provided via the graphical LCD display and push buttons.

The sensor will then be calibrated to provide a highly accurate linear analogue output between these points. The liquid level voltage can also be displayed in real time enabling the user to easily check the settings are correct. Power is provided to the sensor when connected to the Service Unit, increasing the ease of calibration as no separate power supply is required. To conserve battery life, an automatic ‘power down’ feature has been incorporated into the unit.

The Liquid Level Gauge has been introduced to complement the Gill range of R-Series liquid level sensors. The gauge is available for most liquid types (fuel, oil, water...) and can be etched with other data labels if necessary.

The gauge has been designed with special features including fully configurable scaling, adjustable electronic damping and a fully adjustable low level warning indicator. Additional features include auto-dimming control and multi-coloured LEDs ensuring this device can be seen in all lighting conditions.

8

Gill Speed Sensors use a dual element hall-effect device to detect changing magnetic fields in the presence of a toothed ferrous metal target wheel. Tried and proven in F1 championship gearboxes, Gill speed sensors are suitable for either gearbox or wheel speed applications.

With robust fully encapsulated constructions and a unique internal sealing method, the sensors may be fully immersed in oil at high temperature without reduction in performance.We currently have several differential hall-effect speed sensor designs available and have the ability to rapidly produce custom products if required.

Hall-Effect Speed SensorsCustom Sensors designed to your requirements

Oil Debris Sensor KitDetection of Quantity & Type of Debris Build-up in Oil

Sensors Designed

to Your

Requirements


This sensor is designed to replace a conventional magnetic oil plug or sump plug in Motorsport transmission or engine applications.

The sensor works by attracting metallic debris to the face of the sensor just like any other conventional plug but with the added ability to measure the particle build-up remotely and subsequently provide the user with a dynamic “health check” of the engine or transmission.

The sensor uses a remotely sited electronic module connected by a screened harness to the plug. The sensor can be operated in oil temperatures of up to 180ºC for continuous periods. A function to zero the measurement start position (representing a clean plug condition) can be accessed via RS232.

9

Non-Contact Position SensorsStandard & Custom Sensors for Extreme Environments

The Blade® range of position sensors utilises our patented induction technology to accurately sense the position of a metallic ‘activator’ or target, which is mounted to the moving part of the application. There is no physical contact between the sensor and the moving part, so the sensor performance will not deteriorate through use.

Available for both linear and rotary measurement, Blade® sensors are sealed to IP67 and are ideal for use in extreme environments where moisture, grime, temperature and vibration can have an adverse effect on other types of sensor. Custom designs are also available for both low and high volume production

25mm Blade Sensor

- +/- 12.5mm Linear Measurement- +/- 45º Rotary Measurement- Configurable Measurement Range- Fully Submersible- Unlimited Mechanical Life

60mm Blade Sensor

- +/- 30mm Linear Measurement- +/- 45º Rotary Measurement- Configurable Measurement Range- Fully Submersible- Unlimited Mechanical Life

360 Blade Rotary Sensor

- Up to 360º Rotary Measurement- Configurable Measurement Range- Various Wiring Options- Fully Submersible- Unlimited Mechanical Life

Dual Cavity Sensor

- Linear Measurement- +/- 45º Rotary Measurement- Fully Submersible- Unlimited Mechanical Life

Rod Position Sensor

- +/- 4mm Precision Linear Measurement- Fully Submersible- Unlimited Mechanical Life

SENSORTM

CUTTING EDGE TECHNOLOGY

10

Supply Voltage +4.8VDC to +30VDC PWM Output Frequency 250Hz or 1KHz

Over Voltage Protection >31VDC Serial Output - Data Type Asynchronous ASCII Data

Supply Current <10mA Switch Output Type Switch to GND 32VDC Max, 8mA

Reverse Polarity Protection to -30VDC Range Accuracy ±0.1mm or equivalent

Resolution 10 bit over configured range Size 6 x 40 x 50mm (DxWxL)

Sample Rate 1KHz Weight 30g

Measuring Range Linear: ±12.5mm (Configurable)Rotary: ±45°C (Configurable)

Protection Class IP67

Analogue Voltage Output Range 0-4.2V Operational Temperature -40°C to +85°C (standard)-40°C to +125°C (optional)

25mm Blade Sensor

Supply Voltage +4.8VDC to +14VDC PWM Output Frequency 1KHz

Supply Current <25mA without comms Serial Output Data Type RS485, 19.2K 8N

Reverse Polarity Protection Up to 14V indefinitely Switch Output Type May be used as V Ref or switch from V Supply to ground

Resolution 10 bit over configured range Size 16mm x ø38mm

Sample Rate 1KHz Weight 33g without cable

Measuring Range 0-360˚ (Configurable) Protection Class IP67

Analogue Voltage Output Range 0-5.5V (Unless limited by V Supply) Operational Temperature -40°C to +125°C

Range Accuracy ±0.5˚ over temperature range

360º Blade Rotary Sensor

Supply Voltage +6VDC to +30VDC Voltage Output Range 0-4.2V

Over Voltage Protection >31VDC Range Accuracy ±3% over full temperature range

Supply Current <10mA Size 19 x 25.5 x 64mm (DxWxL)

Reverse Polarity Protection to -30VDC Weight 34g (Integral Connector Version)

Resolution 10 bit Protection Class IP67

Sample Rate 1KHz Operational Temperature -40°C to +85°C (standard)-40°C to +125°C (optional)

Measuring Range Linear: Range governed by activator shape Rotary: ±45°

Dual Cavity Sensor

Sensor Specif ications

60mm Blade SensorSupply Voltage +4.8VDC to +30VDC PWM Output Frequency 250Hz or 1KHz

Over Voltage Protection >31VDC Serial Output - Data Type Asynchronous ASCII Data

Supply Current <10mA Switch Output Type Switch to GND 32VDC Max, 8mA

Reverse Polarity Protection to -30VDC Range Accuracy ±0.1mm or equivalent

Resolution 10 bit over configured range Size 6 x 77 x 32.5mm (DxWxL)

Sample Rate 1KHz Weight 34g

Measuring Range Linear: ±30mm (Configurable)Rotary: ±45°C (Configurable)

Protection Class IP67

Analogue Voltage Output Range 0-4.5V Operational Temperature -40°C to +85°C (standard)-40°C to +125°C (optional)

Complete Product Datasheets & Specif ications Available Online:

www.gillsensors.co.uk11


Supply Voltage +5VDC to +24VDC Hose Couplings -16 Flexible Tube Connectors

Supply Current <100mA Sensor Dimensions Ø25mm x 160mm (Nominal Ø x L)

Serial Interface USB Sensor Weight 140g (excluding couplings)

Flow Rate 0-200 l/min Control Electronics Dimensions 105mm x 65mm x 25mm (L x W xH)

Sample Rate 500Hz Control Electronics Weight 200g

Voltage Output Range 0V - 5VDC (configurable) Protection Class Sensor: IP67, Electronics: IP65

Connectors Deutsch ASU Operational Temperature Sensor: -40ºC to +150ºC, Electronics: -40ºC to +105ºC

Ultrasonic Liquid Flow Sensor

Supply Voltage +6VDC to +24VDC Wiring Gauge Typically 26 AWG (options up to 20 AWG if requested)

Supply Current <10mA @12V Cable Material Compatibility Wiring sleeved with either Fluorocarbon or Raychem DR25, or customised to customer specifications

Serial Interface RS232 (+5V)


Sample Rate 80Hz Operational Temperature 0°C to 125°C

Voltage Output Range Calibrated 2.50V, ranging ±2V with medium quality Vibration 15g RMS (24-2000Hz) &SAE J1455 design guidelines used

Accuracy ± 0.5% of calibrated datum EMC Immunity Level SAE J1113/2 1996 design guideline

Wire/Connector Customer Specified - Flying lead or integrated con-nector of customer choice or combination

Dimensions 33 x 46 x 26 (LxWxH) or customer specified

Weight 85g including 1m cable

Oil Quality Sensor

Supply Voltage +6VDC to +24VDC Probe Length 0 - 1500mm (customer to specify)

Supply Current <10mA @12V Mounting SAE 5-Bolt Pattern

Serial Interface RS232 (+5V) Weight From only 180g (dependent on length)


Sample Rate 80Hz Operational Temperature -40°C to +125°C

Voltage Output Range 0.25V - 4.75V over sensing range EMC Immunity Level SAE J1113/2 1996

Range Accuracy ±2% of medium depth @20˚C Compatible Medium

Wire 0.5m Flying Lead unless specified Fuel Gasoline, Unleaded, LRP, Jet Fuel, AVGAS

Wiring Gauge Typically 26 AWG (options up to 20 AWG if requested)

Oil Engine oils, transmission oils, steering & hydraulic fluidsDiesel, Heavy Oil

Cable Material Compatibility Wiring sleeved with either Fluorocarbon or Raychem DR25, or customised to customer specifications

BioFuel Ethanol E100, E85, E50, E10Methanol

Water Salt Water, Fresh Water, Glycol

R-Series / Rxl-Series Level Sensor

M-Series Custom Level SensorsSupply Voltage +6VDC to +24VDC Probe Length 0 - 1000mm (customer to specify)

Supply Current <10mA @12V Mounting Customer Specified, various standard options available

Serial Interface RS232 (+5V) Weight From only 45g (dependent on design)


Sample Rate 80Hz Operational Temperature 0°C to 125°C

Voltage Output Range 0.25V - 4.75V over sensing range EMC Immunity Level SAE J1113/2 1996 design guideline

Range Accuracy ±0.5% of medium depth @20˚C Vibration 15g RMS (24-2000Hz) &SAE J1455 design guidelines used

Wire/Connector Customer Specified - Flying lead or integrated con-nector of customer choice or combination

Compatible Medium

Fuel Gasoline, Unleaded, LRP, AVGAS 100

Wiring Gauge Typically 26 AWG (options up to 20 AWG if re-quested)

Oil Engine oils, transmission oils, steering & hydraulic fluidsDiesel, Heavy Oil

Cable Material Compatibility Wiring sleeved with either Fluorocarbon or Raychem DR25, or customised to customer specifications

BioFuel Ethanol E100, E85, E50, E10Methanol

Water Salt Water, Fresh Water, Glycol

12

Supply Voltage Nom 12VDC ±2.8V Integral Connector Microfit III

Supply Current <140mA @12V Protection Class IP65

Serial Interface RS232 (+5V) Operational Temperature -10°C to +40°C

Resolution 10 bit EMC Immunity Level SAE J1113/2 1996 design guideline

Voltage Input Range Configurable 0V - 5V Vibration 15g RMS (24-2000Hz) &SAE J1455 design guidelines used

Dimensions 116 x 50 x 13 (mm)

Mounting Two M4 threaded holes on 106mm centres Finish Anodised to DEF STAN 025

Liquid Level Display

Screen Graphical LCD 50 x 25 mm Connector 9-Way D-Type

Power Source PP3 9V Battery Options Wiring loom with connectors

Rubber Ergonomic Grip Yes Dimensions 120 x 80 x 25 mm (DxWxL)

Power Saving Function Yes Weight 180g

Auto Power-On Yes Protection Class IP54

Compatible Sensors M-Series Liquid Level Sensors (Petroleum, Oil, BioFuel, Water)

R-Series Liquid Level Sensors (Petroleum, Oil, BioFuel, Water)

Operational Temperature 0°C to +70°C

Impact Resistance IK06

Vibration 15g RMS (24-2000Hz) &SAE J1455 design guidelines used

Sensor Service Unit

Supply Voltage +5VDC to +20VDC Size Customer Specific Designs

Supply Current <10mA Weight from only 25g

Frequency Response 0 to 20 KHz Protection Class IP68

Output Open Collector Operational Temperature -20°C to +150°C

Wiring Raychem Type 55 24AWG with Viton sleeving

EMC Immunity Level SAE J1113/2 1996 design guideline

Connector Unterminated Vibration 40g per axis (50-2500Hz)

Speed Sensors

Supply Voltage +4.5VDC to +14VDC Channel 1 Output 2.25V - 4.25V Fine Measurement (Plug F)

Over Voltage Protection >31VDC Channel 2 Output 0.5V - 4.25VCoarse Measurement (Plug I)

Supply Current <10mA Error Indication 4.5V (Channel 1 & 2)

Reverse Polarity Protection to -30VDC Size 41mm x ø22.25mm

Resolution 10 bit Mounting M14 x 1.0 Thread (or customer specified)

Sample Rate 10Hz Weight from only 25g

Zero Tare Function Accessible via RS232 Protection Class IP68

Onboard Integrity Test Function Yes Operational Temperature 0°C to +180°C

Wiring Raychem Type 55 / Screened 26 AWG or customer specified

EMC Immunity Level SAE J1113/2 1996 design guideline

Connector Deutsch ASC 1 05-06-SN or customer specified

Vibration 15g RMS (24-2000Hz) &SAE J1455 design guidelines used

Oil Debris Sensor Kit


Complete Product Datasheets & Specif ications Available Online:

www.gillsensors.co.uk13


Gill SensorsSolent House, Cannon Street, Lymington, Hants, SO41 9BR

ý www.gillsensors.co.uk* [email protected]( +44 (0)1590 6134007+44 (0)1590 613401

Principal Motorsport Engineering Contact:Neville Meech

Content Copyright © Gill Sensors 2009

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