Gas tank Level instrument: Unit 2 (M J RHOADES)

For this assignment, I chose the gas tank level instrument on my Ford Ranger truck.
Not very exotic, I know, but if you knew where I lived you would understand. I can
however, demonstrate that a current loop does exist, and that calculations can be made for
current flow.

For the theory of operation, current calculations, and demonstration of the loop, please
refer to the drawing and figures as referenced in the following discussion.

Inside the gas tank there is a "sender," which is really a fuel level detector using a
float, and resistive potentiometer. As the level in the gas tank raises the buoyant float
stays on top of the gas, and as the position changes, the arm, attached to the float,
positions a potentiometer to the new position. (See figure1)

Look at the drawing 1 page. When the ignition switch is turned to the start or run
position, current flows through wires, from the positive terminal of the battery through
the ignition switch. It then flows through the meter causing the position of the needle to
move to the level of gas in the tank. It then continues to the gas tank, and flows through
the potentiometer which determines the amount of current that is allowed to flow. The
current then returns to chassis ground through a wire from the negative side of the
potentiometer. The current then continues through the trucks body, back to the batteries
negative terminal, which is also grounded to chassis. This is the current loop for the level
gauge.

The amount of current flowing through this loop is determined by the total resistance
of the circuit with the variable portion being the potentiometer controlled by the float.
The level gauge is calibrated to the current variations caused by the resistance of the
potentiometer on the sending unit. The resistance values for the potentiometer are as
follows, with the current calculated at each calibration point. (Wire resistance is not
considered)

Full tank reading of meter = Full current = 10 Ω on the potentiometer.

𝑣𝑜𝑙𝑡𝑎𝑔𝑒 12𝑣𝑜𝑙𝑡𝑠
By ohms law Current = = = 1.2 amps
𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 10 𝑜ℎ𝑚𝑠

Empty tank reading of meter = 50Ω on the potentiometer

12 𝑣𝑜𝑙𝑡𝑠
Current = = 0.24 amps
50 𝑜ℎ𝑚𝑠

Pointer width below empty = minimum Current = 73 Ω on the potentiometer

 12 𝑣𝑜𝑙𝑡𝑠
Below empty = Current = = 0.164 amps
73 𝑜ℎ𝑚𝑠
This data has been tabulated below:

Level gauge reading Level gauge current Potentiometer resistance (ohms)

Full 1.2 amps 10 ohms

Empty 0.24 amps 50 ohms

Pointer below empty 0.164 amps 73 ohms

By this table, it can be seen that the range of the meter (Fuel gauge) is from truly
empty (One pointer width below empty) to full, with current changing from 0.164 amps
to 1.2 amps respectively. See figure 2 for an example of a fuel gauge with the different
reading points indicated.

Note: At times, some vehicles have a fuel gauge that reads full for a long time while
driving, then rapidly decreases to empty. In other words, the current flow is too high. If
you want to correct this, without replacing the sender or the gauge, you can add a small
value resister in the wiring to increase the resistance by a few ohms. Do the work with
your tank full, so you can find the correct resistance to just meet the full mark.
 Drawing 1

- + Ignition switch

Run
12v Battery
Start

Fuse: 15 amp

Fuel gauge

Potentiometer (73Ω to 10Ω)

Float
Figure one. Gas tank sending element: (After market replacement)

The float is made of buoyant material that will

float on top of the gasoline and position the
arm to a different angle that is proportional to
the level in the tank. This will intern, position
the potentiometer to a new resistance.

Float arm.

Potentiometer and housing

 Figure 2: example fuel gauge: (Aftermarket)

Max current
Empty reading reading at 10 Ω
at 50 Ω
Gauge de-
energized One pointer width
below empty at 73 Ω