Installation / Troubleshooting Manual
Contents
1. Primary Forward Sensor Filter And Pulsation C Damper Assembly FloSca B i Ba i L Enoi Return Fuel oO aaa MA 2 4 Ae me tenente ee ane ee i l beat Q J ngine Cooler i THE RETURN FLOW SENSOR MUST i i REMAIN FLOODED AT ALL TIMES i AE PLEASE REFER TO STEPS 9 12 BELOW a l E Return Sensor 1 AQ la And Pulsation eae 2 as cag a N Damper Assembly Tank ae E pr Dal Ly ses ee Fuel Flow Direction FloScan Sensor amp Pulsation Damper Plumbing Guidelines Caution Diesel System Components are not designed for use on Gasoline Fuel Systems 1 Before installing the assembled Flow Sensor amp Pulsation Damper assembly s into the fuel system verify that their orientation arrows are pointing UP 2 The Forward Flow Sensor Pulsation Damper assembly must be protected by and installed downstream of a 10 to 30 Micron Primary Filter The forward assembly can be installed at any convenient location from the bottom of the bilge to the top of the overhead 3 NOTE Always use the primary filter micron rating Specified by the Engine Manufacturer usually 10 20 or 30 Do not follow advice given by local experts mechanics or magazines There are several reasons for avoiding 2 and 5 micron filters 4 Filtered fuel must enter into the Forward Sensor through its Hex Flow Straightener on the port marked IN Fuel must exit through the Pulsation Damper port with an outward pointing arr2. 9 Determine which type of fitting is required for the Pulsation Damper s outlet port 10 If the Pulsation Damper s base is clamped in a vise a counter torque wrench is not required for the outlet fitting assembly 11 Straight 45 or single 90 elbow fittings are each acceptable at the forward Pulsation Damper s outlet port 12 The Pulsation Damper s outlet port has 1 2 FMPT threads If a 90 elbow fitting is required use a 1 2 elbow with 2 MNPT threads e CAUTION When tightening the forward fuel line fitting into the Forward Sensor s Hex Flow Straightener always place a counter torque wrench on the Sensor s Hex Flow Straightener e Never place a wrench on the Forward Sensor s body while assembling the fuel line fitting into the Forward Sensor s Hex Flow Straightener The Hex Flow Straightener is locked into place with a very strong retaining compound It must remain in position and must not be tightened or loosened Moving the Hex Flow Straightener in relation to the Sensor body will destroy the Sensors accuracy Turned Hex Flow Straighteners are not considered warranty items CAUTION DO NOT OVER TIGHTEN FLOW SENSOR FITTINGS Over tightening may crack the sensor s body Cracks cause leaks and fuel leaks sometimes cause catastrophic explosions and fire Assemble fittings with a Lubricating Fuel Proof Non or Semi Hardening pipe thread sealant designed for aluminum and stainless steel t
3. 91 5 gallon 346 3 liter assumed burn 2 7 gallon 10 2 liter difference e Determine percentage difference between readings 2 7 gallon 10 2 liter difference 94 2 gallon 356 5 liter totalizer reading 028 x 100 2 8 Higher difference e To calibrate rotate the Port FloNET s Black Switch counter clockwise to position F reducing the totalizer reading by 2 Starboard System Calibration e Find the difference between the totalizer and fuel pump readings 91 5 gallon 346 3 liter assumed burn 87 9 gallon 332 7 liter totalizer reading 3 6 gallon 13 6 liter difference e Determine percentage difference between readings 3 6 gallon 13 6 liter difference 87 9 gallon 332 7 liter totalizer reading 041 x 100 4 1 Lower difference e To calibrate rotate the Starboard FlONET s Black Switch clockwise to position 2 increasing the totalizer reading by 4 This completes system calibration The FIONET readings should be within 5 of actual consumption Calibrating a second time should bring it to within 3 especially on twin engine single tank vessels Larger fuel burns increase calibration accuracy Drastically changing operating habits i e changing from mostly cruising to mostly trolling may affect totalizer accuracy If this occurs re calibration may be necessary 04 09 2008 2000 086 00 FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley
4. 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 email service floscan com http www floscan com Twin Engine FIONET Interface Module amp Fuel Tron Installation using T Connectors Terminating Resistor Tap T Connector g 16 5 H 16 8 s Fuel Tron NMEA 2000 SPST Momentary ON Switch Drop Cable Tap T Connector Network Power Connect Cable Shield Drain Wire to Vessel Bonding System or Engine Block 04 09 2008 Supply Connection Shield 12VDC Electronic Distribution Panel In Accordance With ABYC E I1 12VDC Terminating Tap T Connector Resistor Cable Shield Connect Cable Shield Drain Wire to Vessel Bonding System or Engine Block Backbone j Tap T Connector Cable PORT STBD FIONET Interface Module FIONET Interface Module Drop Cable 16 5 GPH R 16 8 GPH 293 7 GAL TOT I 305 4 GAL TOT O O O 0000 Z gt Cable Shield Cable Shield Cable Shield Forward Return Forward Return Flow Flow Flow Flow Sensor Sensor Sensor Sensor Connect Cable Shield Connect Cable Shield Connect Cable Shield Drain Wire to Drain Wire to Drain Wire to Ves
5. Rotate the FloNET s Green Switch to Position 0 to display consumption in US Gallons FIONET Interface Module WE i a 16 5 GPH BOW 5 293 7 GAL TOT Lo a COVERED BLUE ORANGE VIOLET 4 Ser COMPUTER c P 1 6 s 5 INTERFACE B 5 H sro A 6 O 6 Se 5 1 l dun v Fuel Tron Fuel Tron GREEN BLACK RED RECESSED GREEN Switch NMEA 2000 Screen Selection Switch e For Metric Liters Rotate the FloNET s Green Switch to Position 8 to display consumption in Liters FIONET Interface Module a LPH F01 A 47283 LIT TOT LE COVERED BLUE ORANGE VIOLET c 4 COMPUTER 5 6 INTERFACE B dI cen el i T gt 7 BY Di v Fuel Tron Fuel Tron GREEN BLACK RED ARROW GREEN Switch NMEA 2000 Screen Selection Switch NOTE All switch adjustments are made on the FIONET 04 09 2008 2000 083 00 FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 Email service floscancom Http www floscan com Flow Consumption GPH or LPH The FIONET display s upper line shows the rate at which your engine is consuming fuel Depending on the Green Switch setting the upper line will show consumption in Gallons per Hour or Liters per Hour Total Consumption Gallons or Liters The FIONET displays lower line is the totalizer It shows the amount of fuel in either Gallons or Liters that your engine has consumed since the last time the totalizer was reset FIONET Interface Module FIONET Interface
6. 04 09 2008 2000 082 00 FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 email service floscan com http www floscan com Terminating Resistor Twin Engine FIONET Interface Module Installation using T Connectors Tap T Connector NMEA 2000 Display Device Drop Cable m Network Power Supply Connection Shield 12VDC Electronic Distribution Panel In Accordance With ABYC E 11 12VDC Connect Cable Shield Drain Wire to Vessel Bonding System or Engine Block 04 09 2008 Tap T Connector Cable Shield Ta Terminating T Connector Resistor Backbone ti Tap T Connector Cable PORT STBD FIONET Interface Module FIONET Interface Module Drop Cable Drop Cable 165 GPH il 16 8 GPH 293 7 GAL TOT iH 3054 GAL TOT CVO oc t 6 0 0S OS Forward Flow Sensor Retum Flow Sensor Connect Cable Shield Drain Wire to Vessel Bonding System or Engine Block Cable Shield Connect Cable Shield Drain Wire to Vessel Bonding System or Eng
7. 12 VDC and a low of 0 to 4 VDC as the sensors turbine slows to a stop VDC NOTE This may not be seen on digital voltmeters 4 With engine s idling measure and record voltage between the RED power and BLACK wires on the butt connector side on the Return Sensor If used Voltage should be 12 to 14 VDC VDC 5 Move the voltmeters negative lead to the White Signal wire With engine idling measure and record the voltage Readings between 4 and 10 VDC usually indicate a good sensor VDC 6 Stop the engine and observe the voltmeter Voltage readings should fluctuate between a high of 9 to 12 VDC and a low of 0 to 4 VDC as the Sensors turbine slows to a stop VDC NOTE This may not be seen on digital voltmeters 7 The Sensor s may be defective if voltage readings in steps 3 amp 5 remain constant VDC IV PULSATION PROBLEMS A stiff anti siphon valve s or miss plumbed Pulsation Damper s can cause fluctuating GPH readings These are most pronounced at low Rpm s and tend to disappear around mid throttle They are annoying and can affect totalizer accuracy To eliminate repair or replace any defective valves or re plumb dampers according to the Fuel Flow Schematic Instructions V FINDING FUEL SYSTEM VACUUM LEAKS Fluctuating GPH and High Totalizer Readings are usually caused by a small vacuum leak between the fuel tank and fuel pump inlet Fluctuations tend to be between 2 and 4 GPH These vacuum leaks also affect totalizer
8. Avg MPG 1 28 Fuel Tron NMEA 2000 Single or Twin Engine Combined Trip Average Miles per Gallon 09 08 08 FloScan Instrument Company Inc Tel 206 524 6625 498 7 Fuel Tron Screen Selection Switch Single Engine Gallons or Liters Consumed Combined GPHI 32 9 Fuel Tron Screen Selection Switch Fuel Tron NMEA 2000 Fuel Tron NMEA 2000 Twin Engine Combined Gallons or Liters per Hour 1 34 Fuel Tron Screen Selection Switch Fuel Tron NMEA 2000 Single or Twin Engine Combined MPG or LPG Total Non Reset 70584 Gallons x100 Fuel Tron NMEA 2000 Fuel Tron Screen Selection Switch Single or Twin Engine Combined Total Non Resettable Gallons or Liters Consumed 2000 084 00A Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 Email service floscan com Http www floscan com 09 08 08 498 7 Port Trip A Fuel Tron Screen Selection Switch Fuel Tron NMEA 2000 Single or Port Engine Trip A Total Gallons Used 157 6 Port Trip B Fuel Tron Screen Selection Switch Fuel Tron NMEA 2000 Single or Port Engine Trip B Total FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 Gallons Used 523 1 Stbd Trip A Fuel Tron NMEA 2000 Fuel Tron Screen Selection Switch Starboard Engine Trip A Total 162 8 Fuel Tron NMEA 2000 Gallons Used Stbd TripB Fuel Tro
9. Hex Reducer Nipple s 4 MNPT threads with sealant 3 Place the 4 MNPT Hex Reducer Nipple threads into the Pulsation Damper s base end with the Inward Pointing Arrow gt m Sensor 4 Tighten hand tight Body FloScan Pulsation Damper 5 Coat the Hex Reducer Nipple s 14 MNPT threads with Hex Flow Ny Base sealant Straightener ye 6 Place the Forward Sensor s OUT port onto the 4 MNPT Hex Reducer Nipple end 7 Tighten hand tight 8 Use an adjustable wrench to tighten the Hex Reducer Nipple into the Pulsation Damper base Hex Reducer ii Nipple 9 Use an adjustable wrench to tighten the sensor body onto the Hex Reducer Nipple DO NOT put a wrench on the Forward Sensor s Hex Flow Straightener at the Sensor s inlet port 10 When tightened the Sensor s base and the Pulsation Damper base must be even e CAUTION When tightening the Forward Sensor onto the Hex Reducer always place the wrench onto the Sensor s body e Never place a wrench on the Forward Sensor s Hex Flow Straightener while assembling the Sensor onto the Forward Pulsation Damper The Flow Straightener is locked into place with a very strong retaining compound and must remain in position It must not be tightened or loosened Moving the Flow Straightener in relation to the Sensor body will destroy the Sensors accuracy Turned Flow Straighteners are not considered warranty items CAUTION DO NOT OVE
10. Module 56 LPH 47283 COVERED BLUE ORANGE VIOLET C SWITCH e O COMPUTER 16 5 GPH 293 7 GAL TOT COVERED BLUE ORANGE VIOLET SWITCH e COMPUTER INTERFACE roy E 2 D 3 e i B s Ne RED RECESSED ARROW INTERFACE p i a RECESSED GREEN BLACK Totalizer Reset The totalizer is reset or zeroed by pushing the Blue Switch and holding it down for 10 to 15 seconds When the Blue Totalizer Reset Switch is pushed down the GALLONS or LITERS display will flash for 10 seconds then reset to zero Flashing indicates the instrument is in reset mode If the Blue Totalizer Reset Switch is turned OFF opened or released before the totalizer reads 0 0 the instrument will NOT reset If you neglect to turn OFF open or release the Blue Totalizer Reset Switch 0 0 continues to flash Additional FIONET Switches e Software Reset The Orange Switch is the FloNET s Software Reset or Interrupt Service Routine switch To reset the software hold the Orange Switch in for 10 to 15 seconds After 10 seconds the Interface Hub Display s upper line will read HELLO and the Totalizer will be reset to 0 0 e Hardware Reset The Covered Switch is the FIONET s Hardware Reset or Microcontroller Restart switch To reset the hardware insert a piece of stiff wire such as a paper clip into the hole marked S4 Push down on the wire to close the switch and hold for 10 to 15 seconds A
11. There must be some vertical rise to the return fuel flow upon exiting the Return Sensor There should be a minimum Up Hill climb of 1 or 2 inches Higher rises up to 3 feet or a little more are ok 11 If installing the Return Sensor Pulsation Damper as outlined in step 9 is not practical please refer to steps 12 and 13 below 12 If the return line is fairly horizontal but with a small Down Hill drop after exiting the sensor install an upward pointing 45 elbow into the return sensors outlet port Install the fuel line with a downward radius bend Do not pinch the hose 13 If there is a steep vertical drop in the return fuel line a tube with a 180 radius bend may be the best option This option requires e One 90 male elbow with one male JIC 37 3 8 or Dash 6 6 end and one 1 4 male NPT end e Two Dash 6 6 3 8 FlareTite fitting seals www flaretite com to be installed onto the male JIC fitting ends e One Dash 6 6 3 8 JIC tube assembly The tube assembly P N 231 058 00 can be purchased directly from FloScan Technical Support The 90 NMPT x JIC elbow fitting and the FlareTite fitting seals can be purchased at most hydraulic shops 14 Flow sensor model numbers are molded into the colored plastic wire cap Sensors are shipped in matched pairs They must not be mixed on twin engine installations Match codes are identified by a single stand alone letter stamped into the sensor body or from a colo
12. a wide range of Hose Barb to Male NPT JIC SAE amp NPTF sizes and combinations Example 12 HB X 16 MNPT 3 4 Hose Barb by 1 Male NPT Steel Braid Aeroquip type A 1 fuel hose have reusable hose end fittings Aeroquip type hose ends come in a wide variety of types and sizes JIC SAE NPT amp NPTF Review the electrical installation instructions II Mechanical Installation Install or mount the Sensor Pulsation Damper assemblies or Sensors NMEA 2000 Interface Hub Fuel Tron and Switch HI Plumbing Fabric Braid A 1 Fuel Hose Install the correct HB X MNPT fitting into each fuel system component Tank Manifolds Filter Sensor s Damper s and Engine Assemble fittings using a fuel proof pipe thread sealant Never use Teflon Tape Referring to the Fuel Flow Schematic run the fuel hose between system components Cut to correct length with a pocket or razor knife Hoses should not be twisted have adequate slack an ample radius at all bends and be supported at reasonable distances approximately 2 4 feet When clamping hose onto the barbs use 2 narrow or wide stainless hose clamp on each hose end Wire Braid A 1 Aeroquip Type Fuel Hose Install the correct fitting into each fuel system component Tank Manifolds Filter Sensor s Damper s and Engine Assemble fittings using a fuel proof pipe thread sealant Never use Teflon Tape Referring to the Fuel Flow Schematic run the fuel hose between system components Cut to
13. and type of fittings needed for each plumbing connection JIC SAE NPT NPTF or Hose Barb FloScan Series K High Flow Diesel system components have 1 and 1 2 Female NPT ports FloScan Series K Standard Flow Diesel system components have 4 Female NPT ports FloScan Gasoline High Flow system components have 2 Female NPT ports FloScan Gasoline Standard Flow system components have 4 Female NPT ports Gasoline Fuel Systems USCG requires Type A 1 Fuel Hose to be installed between the fuel tank and the engines fuel inlet connection Type B 1 may be used if certain safety requirements are met 33 CFR Subpart J 183 558 33 CFR Subpart J 183 532 require hose clamps to be made from a corrosion resistant material To meet American Boat amp Yacht Council ABYC standards the clamps must be made from a corrosion resistant metal ABYC H 24 11 1 Diesel Fuel Systems Fuel hose and fittings can comprise a significant portion of the total installation cost Costs for A 1 Fabric Braid hose amp hose barb fittings are approximately 1 3 the cost of Steel Braid hose amp JIC fittings Both Type A 1 fabric braided hose and wire braided hose meet exactly the same regulatory requirements USCG amp ABYC but fabric braid installation costs are far less For more information contact Ed Sanford FloScan s Technical Service Manager at extension 302 Fabric Braid A 1 fuel hose generally uses hose barb fittings These come in
14. clamp all hose barb fittings Minimize the use of 90 elbow fittings Install Sensors as far from the engine as practical Fuel must travel Up hill at least 1 or 2 inches Avoid bolting or mounting after leaving the Diesel Return Sensor and all sensor s directly onto the engine Gasoline Sensors Verify correct orientation and fuel flow direction Always install Diesel Forward Sensor Pulsation i Limit Sensor Pulsation Damper assembly Damper assemblies and Gasoline Sensors in the i i Operating Pressure to 20 PSI or Less Fuel Pump s Inlet or Vacuum line Try to use A 1 Fabric Braid Fuel Hose If possibi avoid suie Seta Aeroquip type hose hard pipe or metal tube Always use 30 micron primary filters on Diesel systems 20 and 10 micron filters are also Avoid 2 or 5 micron primary filters acceptable if required by the engine manufacturer Wire with Shielded Cable on Diesel installations o If possible use a dedicated shielded wire pair for Never use unshielded wires on Magnetic Pickup Tachometer Senders Magnetic Pickup Tachometer Senders Connect all Negative wires to a Battery Minus Buss or directly to the Battery s Negative Terminal Never connect Negative Batter eane A A at i i to the Vessel s Hull Engine Block Connect or Ground wire shields shield drains i or other machinery to the engine block or vessel bonding system Always use non illuminated swi
15. decreases you ve found the leak area Repair or replace as needed If this occurs one time you probably dislodged some trapped air If the leak hasn t been found the last step is to inspect each pipe joint Thread sealant should be visible around each joint If not that joint is suspect and must be resealed After resealing run the engine for a few minutes to purge any remaining air There should now be bubble free fuel running through the clear hose If bubbles are still present a leak was missed Recheck your work After all the leaks are stopped remove the clear hose VI FUEL FILTERS A dirty Primary fuel filter or one that is too fine 2 or 5 micron tends to draw vapor bubbles out of the fuel causing fluctuations and high readings Replace it with a new Engine Manufacturer Recommended Filter usually 10 or 30 microns Vil FLOW SENSOR ORIENTATION Sensor orientation is critical for proper operation All Sensors have their inlet and outlet ports clearly marked IN OUT or gt This identifies fuel flow direction The Sensor must be Plumbed correctly for it to operate properly If there is an additional single arrow on the Sensor body it is crucial that this single arrow points up Vill LOW RPM OPERATION At idle under a No Load condition it is common for GPH readings to fluctuate slightly These fluctuations are caused by the engine governor regulating fuel flow to maintain a steady engine RPM This concludes system
16. g i 7 220 igg 18 BLACK Switch 2000 086 00 Fax 206 523 4961 Http www floscan com PART II Propulsion Engine Systems Idle Consumption Adjustment for Forward and Return Two Sensor Propulsion Engine Systems e Start and run engine s until it is at operating temperature e Referring to the switch diagram rotate the Red and Black switches to position 0 e Increase engine speed to 1800 RPM for one minute This purges any trapped air from the system e Return engine speed to low idle and determine its consumption from Table 1 below Table 1 No Load Idle Consumption 2 9 42 4 _ E 0 n 4 100 400 0 1 0 5 GPH 1 2 LPH 0 3 0 7 GPH 2 3 LPH a E i da or 1 6 400 750 0 8 GPH 3 LPH 1 0 GPH 3 4 LPH DO ee See da 750 1000 1 0 GPH 4 LPH 1 5 GPH 5 6 LPH iaia Se 1000 1250 2 0 GPH 7 8 LPH 2 5 GPH 9 10 LPH 10 i 5 10 1250 1500 3 0 GPH 11 12 LPH 3 5 GPH 13 14 LPH 12 gt lt 9 8 7_ 412 14 Izz 18 1500 2000 3 5 GPH 13 14 LPH 4 0 GPH 15 16 LPH Be e 2000 3000 4 5 GPH 17 LPH 5 0 GPH 18 19 LPH RED Switch e Rotate the Red Switch until the idle GPH or LPH reading matches engine HP from Table 1 NOTE At this point idle consumption is approximate It establishes operating parameters for final calibration Part III Determining Optimum Tank Configuration amp Cruise RPM e Determine the optimum fuel tank configuration for your vess
17. the angle and flat brackets into the Pulsation Damper base Tighten the bolts a little past hand tight compressing the lock washers slightly Install the two long spacers between the Sensor body and flat bracket Slide the two 244 bolts through the Sensor body spacers and flat bracket Grasp the Pulsation Damper and hold the flat bracket against the Pulsation Damper s base Verify that the Sensor s base is perpendicular to the flat bracket If the Sensor and spacers are flush with the flat bracket install flat washers and ESNA nuts onto the 2 4 bolt ends and tighten until snug The Pulsation Damper and Sensor bolts should be tightened evenly If a small air gap is present between Sensor and spacers place one flat washer between each spacer and the flat bracket Install flat washers and ESNA nuts onto the bolt ends and tighten until snug The Pulsation Damper and Sensor bolts should be tightened evenly Continued on next page FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 MECHANICAL INSTALLATION 4001 43 00 Tel 206 524 6625 Fax 206 523 4961 Email service floscan com Http www floscan com Fuel Flow Schematic Standard Flow Diesel Systems BOS 201 231 amp 235 2K
18. totalizer and fuel pump readings 94 2 gallon 356 5 liter totalizer reading 89 7 gallon 339 5 liter pump reading 4 5 gallon 170 3 liter difference e Determine percentage difference between readings 4 5 gallon 17 0 liter difference 94 2 gallon 356 5 liter totalizer reading 047 x 100 4 7 Higher difference e To calibrate rotate the Port FloNET s Black Switch counter clockwise to position E reducing the totalizer reading by 4 Starboard System Calibration e Find the difference between the totalizer and fuel pump readings 93 2 gallon 24 4 liter fuel pump reading 87 9 gallon 332 7 liter totalizer reading 5 3 gallon 20 1 liter difference e Determine percentage difference between readings 5 3 gallon 20 1 liter difference 87 9 gallon 332 7 liter totalizer reading 060 x 100 6 Lower difference e To calibrate rotate the Starboard FloNET s Black Switch clockwise to position 3 increasing the totalizer reading by 6 Example 2 Twin engine vessel with a single fuel tank Port System Calibration After refueling the tank took 182 9 gallons 692 liters The Port Totalizer reads 94 2 gallons 356 6 liters and the Starboard reads 87 9 gallons 332 7 liters With a single tank you must assume that each engine burned 91 5 gallons 346 3 liters e Find the difference between the totalizer and fuel pump readings 94 2 gallon 356 5 liter totalizer reading
19. 33 236 1K amp 2K 233 236 2K Forward Sensor Return Sensor And Pulsation And Pulsation Damper Assembly FloScan Damper Assembly Fjoscan Inlet TT J Outlet ys seg et f TI Inlet 201 231 1K amp 2K 235 2K 201 231 235 2K Caution Diesel System Components are not designed for use on Gasoline Fuel Systems Determine fitting type amp size Minimize the number of elbows and fittings If swivel fittings are used JIC or SAE their mating surfaces must be sealed with Copper Conical Sealing Washer Connie Seals or fitting seals Fitting seals may be purchased through Fittings Inc in Seattle WA 206 767 4670 1 800 552 0632 or a local hydraulic supply house 04 09 2008 FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 Tel 206 524 6625 Email service floscan com Http www floscan com 2000 081 00 Fax 206 523 4961 e Select Fuel Tron Mounting Location If Used The instruments face is waterproof and a gasket is provided to seal its bezel to the control panel Choose a shaded location since direct sunlight may cause the LCD display to temporarily turn dark This does not damage the LCD but makes it impossible to read until cooling down Make a cutout in the instrument panel for the Fuel Tron Instrument It has a 2 diameter and its maximum depth is approximately 1 7 8 minus the thickness of the console panel Mounting bracket studs extend down another 2 e Pre S
20. H R 1962 LPH 3 Using the chart below record Forward and Return sensor readings at IDLE 1000 RPM 1500 RPM and 1800 RPM Circle S or F to indicate steady or fluctuating readings If fluctuating show fluctuation range High amp Low Forward Return S F IDLE S F S F 1000 S F S F 1500 S F S F 1800 S F 4 Rotate the Green Switch through Positions 2 3 4 amp 5 for US Gallon models or A B C amp D for Metric Models Record the various readings in the chart below the example boxes EXAMPLES POSITION 1 287 1 NET GPH F amp R DIFFERENTIAL POSITION 3 F 75 F FUEL TMP R 90 F FUEL TMP POSITION 4 1086 POSITION 9 NET LPH F amp R DIFFERENTIAL POSITION B F 24 C FUEL TEMP R 32 C FUEL TEMP POSITION C F 19373 PROGRAM R 47932 K FACTOR F 19373 PROGRAM R 47932 K FACTOR Display K Factor Sensor K Factor Differential Flow Rate 5 Measure fuel line length between system components and draw a system sketch 09 017 08 FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 2000 085 00A Fax 206 523 4961 Http www floscan com Tel 206 524 6625 Email service floscan com II SUPPLY VOLTAGE VERIFICATION NMEA 2000 Backbone Cable with T Connectors 1 Referring to the connector pin out drawing and the table below disconnect the first connector nearest the Network Power Connection and measure voltage acro
21. Installation Troubleshooting Manual FIONET NMEA 2000 Diesel Standard Flow K Series U S amp Metric This manual part 2000 077 00 applies to the following product part numbers 1 N20D 201 2K 2 N20D BOS 2K 3 N20RBBOS 2K 4 N20D0 2012K 5 N20D 231 2K 6 N20D0 BOS2K 7 N20D0 2312K 8 N20RB201 2K 07 10 08 2000 078 00 FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 Email service floscan com Http www floscan com 07 10 08 2000 078 00 FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 Email service floscan com Http www floscan com INSTALLATION PLANNING READ ME FIRST Detailed Mechanical amp Electrical Planning Saves Installation Hours FloScan systems are not difficult to install Installing one requires only basic electrical amp mechanical skills With forethought and planning your system will be installed with few problems I Installation Preparation Review the pre installation booklet and mechanical installation instructions then survey your vessel Determine where the Sensor s Pulsation Damper s NMEA 2000 Interface Hub Fuel Tron amp Fuel Tron Screen Selection Switch are to be mounted Place them at their approximate locations Measure fuel line lengths between system components Primary Filter Sensor s Damper s Engine and Fuel Tank Determine fitting sizes
22. R TIGHTEN FLOW SENSOR FITTINGS Over tightening may crack the sensor s body Cracks cause leaks and fuel leaks sometimes cause catastrophic explosions and fire Assemble fittings with a Lubricating Fuel Proof Non or Semi Hardening pipe thread sealant designed for aluminum and stainless steel threads Loctite 567 or equivalent DO NOT USE TEFLON TAPE Continued on next page Forward Fuel Line Fitting to Forward Sensor Assembly 07 24 08 4001 443 00 FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 Email service floscan com Http www floscan com 1 Leave the Pulsation Damper s base clamped in the vise a 2 Coat the fuel line fitting s 4 MNPT threads with sealant 3 Place the fitting into the Sensor s Hex Flow Straightener a 4 Tighten hand tight Sensor i Body FloScan Pulsation 5 Place an adjustable wrench on the Sensor s Hex Flow Damper Straightener to act as a counter torque Hex Flow Base TA Aena Straightener td 6 Use an adjustable wrench to tighten the fuel line fitting into Ny Xx the Hex Flow Straightener i_ Hy 7 Whenever possible use a straight fitting on the Forward sh Sensor s inlet port If required a 45 elbow fitting can be d Fuel Line oe Fitting 8 90 elbow fittings on the Forward Sensor s inlet port should be avoided
23. Street Seattle WA 98105 Email service floscan com Http www floscan com 04 09 2008 2000 086 00 FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 Email service floscan com Http www floscan com FIONET NMEA 2000 Fuel Tron Instrument FUEL TRON DISPLAY OPERATION There are a variety of screens that the Fuel Tron Instrument will display The different display screens are accessed by pushing the Fuel Tron Screen Selection Switch Each time the selection switch is pushed a different screen is displayed NOTE U S Gallons GPH or Liters LPH readings are determined by the NMEA 2000 Interface Hub s Green Switch setting The Fuel Tron Screen Selection Switch is also used for resetting fuel consumption totals on the Fuel Tron Instrument Toggle to the desired fuel consumption total screen then push amp hold the Fuel Tron Selection Switch for 10 20 seconds until the fuel consumption total resets back to 0 0 FloScan e 16 5 Fuel Tron NMEA 2000 Fuel Tron Screen Selection Switch Single Engine Gallons or Liters per Hour Fuel Tron Screen Selection Switch Fuel Tron NMEA 2000 Twin Engine Gallons or Liters per Hour Combined Total 1021 8 Gallons Fuel Tron Screen Selection Switch Fuel Tron NMEA 2000 Twin Engine Combined Gallons or Liters Consumed Fuel Tron Screen Selection Switch Trip
24. accuracy causing it to read 15 to 100 high Larger leaks produce greater fluctuations and higher readings They generally do not affect engine performance Finding suction leaks can be time consuming When approached properly they can usually be found and repaired quickly Two common places for suction leaks to occur are at the primary fuel filter water separator and or a loose valve stem packing nut Remove the filter housing and coat all o rings gaskets and sealing surfaces with a medium to heavy grease Do not use oil and reassemble Grease all valve stem packing s and gently tighten gland nuts Don t over tighten valve handles should turn freely Tighten all hose clamps and compression fittings Don t over tighten Run the engine for 5 to 10 minutes observing GPH readings If you ve found the problem fluctuations should be reduced to less than Ya GPH If the problem persists temporarily install a clear piece of fuel resistant hose downstream of the forward flow sensor Run the engine and watch for a stream of small bubbles in the clear hose or an occasional larger bubble Sometimes shining a light through the hose makes bubbles easier to see 09 017 08 2000 085 00A FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 Email service floscan com Http www floscan com Observe the clear hose while shaking the fuel lines If the bubble stream continually increases or
25. ain Wire to rain Wire to rain Wire to Drain Wire to rain Wire to Vessel Bonding System Vessel Bonding System Vessel Bonding System Vessel Bonding System Vessel Bonding System or or r or Engine Block Engine Block Engine Block Engine Block Engine Block 04 09 2008 2000 082 00 FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 Tel 206 524 6625 email service flo Fax 206 523 4961 scan com http www floscan com Single Engine FIONET Interface Module amp Fuel Tron Installation using Barrier Terminal Strip Connectors Fuel Tron NMEA 2000 Drop Cable TERMINATION RESISTOR D 120 Ohm 5 5 Ox 1 4 Watt 12VDC 12VDC crea SHIELD Network Power Supply Connection Cable Shield 12VDC Electronic Distribution Panel In Accordance 12VDC Connect Cable Shield Drain Wire to Vessel Bonding System or Engine Block 04 09 2008 FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 ie SPST Momentary ON Switch 22 TERMINATION ae D RESISTOR NET L 120 Ohm 5 rara SA TI BLUE NMEA 2000 NET C 1 4 Watt Backbone Cable i P i SHIELD ON FIONET Interface Module Drop Cable 165 GPH 293 7 GAL TOT bi O bce Cable Shie
26. correct length and install hose ends If you choose to do this yourself rent a hose cutting tool and purchase a tube of assembly lubricant Most dealers will cut and assemble both hose ends for 10 per hose Some charge as much as 40 04 09 2008 2000 080 00 FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 Email service floscan com Http www floscan com Hoses should not be twisted have adequate slack an ample radius at all bends and be adequately supported at reasonable distances approximately 2 4 feet AP 50 copper sealing washers or Flaretite fitting seals may be required to seal JIC amp SAE fittings IV Electrical Installation If the NMEA 2000 backbone has not been run into the engine room open and survey your vessel s wire ways and determine how and where it should be run Measure the cable length distance from each sensor Wire each Sensor to the NMEA 2000 Interface Hub with 18 AWG 3 conductor shielded cable Always connect the cable shield drain to the vessels bonding system or engine block Wire Terminations referring to the wiring diagram connect the Sensor s to the NMEA 2000 Interface Hub and the Fuel Tron to its display cycling switch with crimp type butt or ring connectors Always cover connectors and wire ends with heat shrink tubing Isolated Ground Electrical Systems FloScan manufactures 12 VDC to 12 VDC PN 7000 097 00 and 24 VDC t
27. d in the vise 2 Determine which fuel line fitting type is most appropriate for your application please refer to steps 8 12 on pages 7 and 8 in the Mechanical Installation section of this mi document Any type of fitting straight 45 or 90 elbow is acceptable on the Return Sensor s outlet port Sp 3 Coat the fuel line fitting s 4 MNPT threads with sealant Straight 4 Tighten hand tight Fitting 5 Place an adjustable wrench on the Sensors body to act as a counter torque 6 Use an adjustable wrench to tighten the fuel line fitting into the Sensors outlet port Hex Flow 45 Degree Straightener Elbow Fitting Sensor Zt I CA 90 Degree Fitting Pulsation a Damper Straight and 45 elbow fittings are each acceptable at the Base Return Pulsation Dampers inlet port FloSca 8 The return Pulsation Damper s inlet port has Ya FMPT threads If a 90 elbow fitting is required use a 1 2 elbow with 4 MNPT threads 9 If the pulsation damper base is clamped in the vise a counter torque wrench is not required for installing the inlet in fitting Fuel Line Fittings e CAUTION When tightening the fuel line fitting into Return Sensor always place a counter torque wrench on the Return Sensor s Body e Never put a wrench on the Return Sensors Hex Flow Straightener while assembling the fuel line fitting into Return Sensor If the Retu
28. el If possible single engine vessels should draw and return fuel to a single tank On twin engine vessels try to configure the fuel system so that each engine draws and returns fuel to its own dedicated tank If your twin engine vessel has only a single tank equal consumption rates for both engines must be assumed e Close any cross connect or limber line valves between tanks during calibration e Take your vessel for a short cruise Using the GPH or LPH reading as a guide determine the best cruising RPM for the way you normally operate Don t be concerned that the readings are slightly off Calibration is most accurate when done at a single cruising RPM Part IV Final Calibration e Return to the fuel dock and top off the fuel tank s e Reset the totalizer so that the Interface Hub totalizer reading is zero e Operate the generator under load or take the vessel for a cruise Once underway steam at your optimal cruising RPM Determined in Part III Consume a minimum of 20 to 30 gallons 75 to 115 liters of fuel per engine Higher consumption gives better accuracy After consuming some fuel return to the fuel dock and top off the fuel tank s Compare the FIONET totalizer reading to the fuel pump reading Calculate the percentage difference between the fuel pump amp FIONET totalizer readings Refer to Examples I amp II below Determine if the FloNET totalizer is reading High or Low Rotate the Black Switch until the Interface H
29. fter 10 seconds the Interface Hub Display s upper line will read HELLO and the Totalizer will be reset to 0 0 e System Data Switch The Violet Switch is the FloONET s data display switch When the Violet switch is pushed the display s upper line will show the system kit number or system model number The display s lower line s left side will show the system serial number The date of manufacture will be shown the right side NOTE If the FloScan FIONET unit is operating properly but the NMEA 2000 monitoring display operates intermittently is in error or has no reading check the following 1 Verify that the NMEA 2000 display is programmed to both receive and display fuel consumption data 2 Depending on the number of engines on your vessel verify that the NMEA display can be programmed for Instance 0 1 2 3 If this does not resolve the issue review the display s instruction manual or contact the manufacturer 04 09 2008 2000 083 00 FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 Email service floscan com Http www floscan com IDLE CONSUMPTION ADJUSTMENT amp TOTALIZER CALIBRATION FIONET Interface Module FIONET Interface Module 16 5 GPH 293 7 GAL TOT a ORANGE VIOLET COVERED SWITCH COMPUTER INTERFACE 222 GREEN BLACK RED RECESSED PART I Generators amp Diesel Electric Propulsion Engine Systems Contact t
30. he engine dealer or refer to the engine manual data sheet and determine the engines e No load fuel consumption e The 10 or 25 load fuel consumption Idle Consumption Adjustment for Forward and Return Two Sensor Generator Systems Start and run the engine until it is at operating temperature Rotate the Red and Black switches to position 0 With no load verify that the engine is running at the correct RPM usually 1200 1500 or 1800 Rotate the Red Switch until the FloNET GPH or LPH reading matches the manufacturer s No Load fuel consumption specification Totalizer Calibration for Forward and Return Two Sensor Generator Systems e Put a 10 or 25 load on the generator e Rotate the Black Switch until the GPH reading matches the manufacturer s 10 or 25 load fuel consumption listing NOTE Generators turning at 1200 1500 or 1800 RPM will consume much more fuel at No Load than propulsion engines If you are unable to obtain the engine manufacturer s consumption data proceed to Part s II and IV below You should triple the readings in Part II Table 1 04 09 2008 FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 Tel 206 524 6625 Email service floscan com 0 42 Ce aa 4 _ gt 44 n i 0 I ENN i 1 n 6 E i 6 D F lr See aN evita zaia 8 1 8 Oats Sette 410 B 5 410 x z N 12 9 g 1 7412 14 igy 18 RED Switch t 5 410
31. heads or engine parts To verify that a suction leak is present temporarily insert a clear piece of fuel resistant tubing downstream of the Forward Sensors outlet Observe the clear hose for at least two minutes looking for bubbles Bubbles can appear as a constant stream of small bubbles or as an occasional larger bubble Tighten all possible leak sources grease primary filter seals and install fitting seals on JIC SAE fittings Continue to observe the clear tubing until it runs clear without any bubbles Flex or wiggle rubber hose sections while observing the clear tubing If bubble volume increases inspect the hose and check its fittings Repair as necessary e When idling in neutral No Load GPH fluctuations can also be caused by the governor trying to maintain a steady engine RPM e Calibration When the system is running properly refer to the calibration instructions and calibrate your system If installed properly initial calibration takes much less than 1 hour After consuming some fuel final calibration should only take a few minutes 04 09 2008 2000 08 1 00 FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 Email service floscan com Http www floscan com MECHANICAL ASSEMBLY Standard Flow Diesel Systems BOS 201 231 amp 235 2K Forward Sensor to Forward Pulsation Damper Assembly 1 Clamp the Pulsation Damper s aluminum base into a vise 2 Coat the
32. heet to determine the correct Instance setting When known place the White Recessed Arrow Switch at the correct setting VII Operation Selection Refer to the Instance Selection amp Operation sheet to determine the correct Operation setting When known place the Green Rotary Switch at the correct setting VIII System Start Up Start and run your engines Look for leaks and other installation problems If system is not operating properly refer to the Troubleshooting Instructions and correct any deficiencies IX Calibration When system is running properly refer to the calibration instructions and calibrate your system If installed properly initial calibration takes less than one hour After consuming some fuel final calibration should only take a few minutes 04 09 2008 2000 080 00 FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 Email service floscan com Http www floscan com e The US Code of Federal Regulations CFR s contain no requirement for using Type A 1 A 2 B 1 or B 2 USCG approved fuel hose on diesel powered pleasure vessels To meet ABYC standards fuel hose shall comply with the requirements of UL 1114 Marine USCG Type A Flexible Fuel Line Hoses or SAE J1527 Marine ABYC H 33 6 1 Fuel Line Hoses USCG approved fuel hose with either fabric or wire reinforcing braid meet the following standards Hose Marking Permeation Rating 212 Min
33. hreads Loctite 567 or equivalent DO NOT USE TEFLON TAPE Continued on next page 07 24 08 4001 443 00 FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 Email service floscan com Http www floscan com ET TER Short Spacers dl sE a Additional Flat Washers If Needed Flat Washers ESNA Nuts 10 Place the Forward Sensor Pulsation Damper assembly with inlet and outlet fittings installed onto the flat bracket Orient the Sensor body over the slots and the Pulsation Damper base over the bolt holes Slide a lock washer onto two 114 bolts Chose your 90 mounting bracket option Assemble the 14 bolts through the angle and flat brackets into the Pulsation Damper base Tighten the bolts a little past hand tight compressing the lock washers slightly Install the two short spacers between the Sensor body and flat bracket Slide the two 2 bolts through the Sensor body and spacers Grasp the Pulsation Damper and hold the flat bracket against the Pulsation Damper s base Verify that the Sensor s base is perpendicular to the flat bracket If the Sensor and spacers are flush with the flat bracket install flat washers and ESNA nuts onto the 2 bolt ends and tighten until snug The Pulsation Damper and sensor bolts should be tightened even
34. ine Block Cable Shield Forward Flow Flow Sensor Retum Sensor Connect Cable Shield Drain Wire to Vessel Bonding System or Engine Block Cable Shield Connect Cable Shield Drain Wire to Vessel Bonding or System Engine Block 2000 082 00 FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 Tel 206 524 6625 Fax 206 523 4961 email service floscan com http www floscan com Single Engine FIONET Interface Module amp Fuel Tron Installation using T Connectors e 16 5 x P H i o REIA SPST Momentary ON Switch Drop Cable Terminating Terminating Resistor Tap T Connector Tap T Connector Resistor OC dh UC UO Backbone Tap T Connector Cable A FIONET Interface Module Network Power Drop Cable Supply C ti upply Connection sn 293 7 GAL TOT IK 12VDC Electronic Distribution Panel In Accordance With ABYC E 11 12VDC Cable Shield b Cable Shield Return Flow Sensor Connect Cable Shield Connect Cable Shield Connect Cable Shield Drain Wire to Drain Wire to Drain Wire to Vessel Bonding System Vessel Bonding System Vessel Bonding System Engine Block Engine Block Engine Block 04 09 2008 2000 082 00 FloScan Instrument Company Inc Tel 206 524 6625 Fax
35. kwards Wiring Diagram Incorrect switch settings Calibration sheet Vacuum leak Section V Fine Primary Filter Section VII Dirty Primary Filter Section II Wiring Diagram Fluctuating GPH Readings Vacuum leak Pulsations Sections IV V Wiring Wiring Diagram No GPH or Totalizer Readings Installation sheet Section Sensor orientation VII No Forward or Return Sensor Readings Wiring A failure SecHOns I I I VII Sensor Failure Sections I II III Vacuum Leak Section V High Forward or Return Sensor Readings Incorrect switch settings Calibration sheet Sensor orientation Section VII 09 017 08 2000 085 00A FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 Tel 206 524 6625 Email service floscan com Fax 206 523 4961 Http www floscan com I DIAGNOSTIC TEST 1 Start the engine s and allow them to warm up for 5 to 10 minutes 2 With engine s running place the FloNET Module into Diagnostic Test mode To do so rotate the Green Switch to Position 1 for US Gallons models or Position 9 for Metric models This places the instrument into Diagnostic Test mode The displays upper line shows raw un calibrated fuel flow through the Forward Sensor The displays lower line shows raw un calibrated fuel flow through the Return Sensor NOTE Calibration settings do not affect diagnostic mode readings EXAMPLES US STANDARD METRIC POSITION 2 POSITION A F 4976 GPH F 1883 LPH R 518 3 GP
36. ld Cable Shield Z Forward Return Flow Flow Sensor Sensor Connect Cable Shield Connect Cable Shield Drain Wire to Drain Wire to Vessel Bonding System Vessel Bonding System Engine Block Engine Block 2000 082 00 Tel 206 524 6625 Fax 206 523 4961 email service floscan com http www floscan com Twin Engine FIONET Interface Module amp Fuel Tron Installation using Barrier Terminal Strip Connectors FloScan c 16 5 P H 16 8 s Fuel Tron A gt amea 2000 SPST Momentary ON Switch Drop Cable TERMINATION RESISTOR a ee acco NMEA 2000 4 di QD Da NET H Backbone Cable a E WHITE i T NETL BLUE NET C S BLACK voe NETS RED vo a ao PORT Network FIONET Interface Module Power Supply Connection 165 GPH 293 7 GAL TOT s4 en 40 Q 0 Cable Shield 12VDC nm m Lal a ig lectronic bel E Distribution 3 Panel In Accordance With ABYC E I1 7 i Cable Shield a I2VDC able Shield _ Cable Shield E E 3 4 3 8 8 Forward Return Flow Flow Sensor Sensor Connect Cable Shield Connect Cable Shield Connect Cable Shield Drain Wire to Drain Wire to Drain Wire to Vessel Bonding System Vessel Bonding System Vessel Bonding System Or or or Engine Block Engine Block Engine Block 04 09 2008 FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 TERMINATION RESISTOR y 120 Ohm 5 on
37. ly If a small air gap is present between the Sensor and both spacers place one flat washer between each spacer and the flat bracket Install flat washers and ESNA nuts onto the bolt ends and tighten until snug The Pulsation Damper and Sensor bolts should be tightened evenly Continued on next page Return Sensor to Return Pulsation Damper Assembly 07 24 08 FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 4001 443 00 Tel 206 524 6625 Fax 206 523 4961 Email service floscan com Http www floscan com 1 Clamp the Pulsation Damper s aluminum base in a vise a 2 Coat the Hex Reducer Nipple s 4 MNPT threads with sealant 3 Place the 4 MNPT Hex Reducer Nipple threads into the Pulsation Damper s base end with the Outward Pointing Arrow a 4 Tighten hand tight Hex Flow ii Y Straightener FloScan Pulsation 5 Coat the Hex Reducer Nipple s 14 MNPT threads with Damper sealant Sensor uF Base Body Pa 6 Place the Return Sensor s Hex Flow Straightener onto the Ng i DE 4 MNPT Hex Reducer Nipple threads 7 Tighten hand tight 8 Use an adjustable wrench to tighten the Hex Reducer Nipple into the Pulsation Damper base Hex Reducer ii Nipple 9 Use an adjustable wrench to tighten the Sensor s Hex Straightener onto the Hex Reducer Nipple s 4 MNPT threads DO NOT put a wrench on the Return Sens
38. n Screen Selection Switch Starboard Engine Trip B Total Tel 206 524 6625 Email service floscan com 2000 084 00A Fax 206 523 4961 Http www floscan com TROUBLESHOOTING FIONET Interface Module Fuel Tron Instrument BEFORE CALLING FOR ASSISTANCE COMPLETE THESE TROUBLESHOOTING CHECKS AND RECORD YOUR FINDINGS TECHNICAL SUPPORT REQUIRES THIS INFORMATION BEFORE A RETURN AUTHORIZATION WILL BE ISSUED IT TAKES ABOUT 20 MINUTES AND IS VERY IMPORTANT IN ANALYZING SYSTEM PROBLEMS FIONET Interface Module 16 5 GPH 293 7 GAL TOT COVERED BLUE ORANGE VIQLET C e O C COMPUTER SWITCH INTERFACE Dori E 2 c i n s RECESSED ARROW GREEN BLACK RED r 16 5 Fuel Tron NMEA 2000 Before starting please record the FIoNET Module and Fuel Tron Instrument if applicable model number serial number and switch settings MODEL SERIAL GREEN BLACK RED RECESSED ARROW FAULT PROBABLE CAUSE SEE SECTION Network Power Reversed Section II Blank FloNET Module Display Defective NMEA Cable Section II Network Power OFF Section II Network Power Reversed Section II Blank Fuel Tron Display No Backlighting Defective NMEA Cable Section II Network Power OFF Section II Calibration Calibration sheet Incorrect flow sensor s Sensors Installed backwards Section VII High or Low Totalizer reading Over 10 Sendis Wired bac
39. nnect Cable Shield Connect Cable Shield Drain Wire to Drain Wire to Vessel Bonding System Vessel Bonding System or Engine Block Engine Block 2000 082 00 Tel 206 524 6625 Fax 206 523 4961 email service floscan com http www floscan com Twin Engine FIONET Interface Module Installation using Barrier Terminal Strip Connectors NMEA 2000 Display Device Drop Cable TERMINATION TERMINATION RESISTOR RESISTOR 120 Ohm 5 120 Ohm 5 DO 1 4 Watt De al A OD MA NMEA 2000 OD 1 4 Watt VETTA See cae AE D _ T Backbone Cable D tia sa oa DG a So NET C I 5 NET C i TR NET S D NET S 4 _ RED H2VDC D RED FI2VDC re Cp n A e o Ott ex PORT STBD Network FIONET Interface Module na FIONET Interface Module Power Drop Cable Drop Cable Supply Connection 165 GPH ll 168 GPH 293 7 GAL TOT H 3054 GAL TOT TO 0 Ore Se LC OLO Cable Shield 12VDC Electronic Distribution Panel In Accordance With ABYC E 11 l2vpc _ Cable Shield b Cable Shield Cable Shield Cable Shield Forward Return Forward Return Row cow Flow Flow Sensor Sensor Sensor Sensor Connect Cable Shield Connect Cable Shield Connect Cable Shield Connect Cable Shield Connect Cable Shield r
40. o 12 VDC PN 7000 096 00 Isolated Ground Power Supplies Voltage Reducers These power supplies electrically isolate the FloScan system from ship s power and are used by the Washington State Ferry System and other large steel and aluminum vessel operators Additionally mounting sensors onto a non conductive surface and using short lengths of non metallic fabric braid fuel hose to connect them further isolates the system Diesel Fuel is non conductive but does contain a Static Electricity Dissipater additive to minimize the risk of fuel tank fires and explosions Even with this additive the electrical resistance of Diesel Fuel is extremely high and can be considered non conductive Installing the FloScan system with Isolated Ground power Supplies Non Conductive Sensor Mounting Surfaces and Fabric Braid Fuel Hose will electrically isolate it from the vessel s hull V Pre Startup e Always Prime the fuel system before Engine Start Up This prevents your engine from becoming air bound If you have an electric priming or boost pump circulate fuel for 10 minutes while checking for leaks If the fuel system does not have an electric priming pump use the engine s manual pump Before starting slightly open or crack the lift pumps outlet fitting Pump until all air is purged at the lift pumps outlet Before start up verify that all fuel system fittings are tight VI Instance Selection Refer to the Instance Selection amp Operation s
41. on Wires at the Power Feed Terminal Strip The reading should be approximately 12 to 14 VDC but not lower than 9 VDC 09 017 08 2000 085 00A FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 Email service floscan com Http www floscan com 6 If 12 VDC is not present measure between the Red power wire and a known good battery minus point There may be a loose battery minus connection or other wiring problem Check wiring switches fuse and the 12 VDC power source 7 If 12 to 14 VDC is present between the Red wire and battery minus there may be a loose battery minus connection broken wire open termination or other wiring problem 8 If voltage is present across the Red amp Black Network Power Feed and the FloNET Module or Fuel Tron Instrument does not Light Up supply voltage on every terminal strip must be checked for voltage until the problem connector or cable section is found II SENSOR S TEST 1 With engine s idling measure and record voltage between the RED power and BLACK wires on the butt connector side of the Forward Sensor Voltage readings should be 12 to 14 VDC VDC 2 Move the voltmeters negative lead to the WHITE signal wire With engine idling measure and record the voltage Readings between 4 and 10 VDC usually indicate a good sensor VDC 3 Stop the engine while observing your voltmeter Readings should fluctuate between a high of 9 to
42. or s body 10 When tightened the Return Sensor s body and the Pulsation Damper base must be even e CAUTION When tightening the Return Sensor onto the Hex Reducer Nipple always place the wrench on the Sensor s Hex Flow Straighterer e Never place a wrench on the Return Sensors body while assembling the Sensor onto the Return Pulsation Damper If the Return Sensor is tightened at its body the Sensors Hex Flow Straightener may be moved The Flow Straightener is locked into place with a very strong retaining compound and must remain in position It must not be tightened or loosened Moving the Flow Straightener in relation to the sensor body will destroy the Sensors accuracy Turned Flow Straighteners are not considered warranty items CAUTION DO NOT OVER TIGHTEN FLOW SENSOR FITTINGS Over tightening may crack the sensor s body Cracks cause leaks and fuel leaks sometimes cause catastrophic explosions and fire Assemble fittings with a Lubricating Fuel Proof Non or Semi Hardening pipe thread sealant designed for aluminum and stainless steel threads Loctite 567 or equivalent DO NOT USE TEFLON TAPE Continued on next page Return Fuel Line Fitting to Return Sensor Assembly 03 11 2008 4001 443 00 FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 Email service floscan com Http www floscan com 1 Leave the Pulsation Damper s base clampe
43. ow gt 5 Return fuel from the engine must enter into the Return Pulsation Damper s inlet port This is the port marked with an inward pointing arrow and exit through the port marked OUT on the Return Sensor 6 Install the Forward amp Return Sensor Pulsation Damper assemblies as far from the engine as practical Maximizing fuel line length between the engine and Sensor Pulsation Damper assembly improves instrument accuracy 7 Use the smallest approved fuel line diameter for your engine especially on the return line Higher fuel flow velocities increase overall system accuracy Refer to the engine owners or shop manual for more information 8 IMPORTANT NOTE THE RETURN FLOW SENSOR MUST REMAIN FLOODED AT ALL TIMES 9 If possible install the Return Sensor Pulsation Damper assembly at a low point in the fuel system Continued on next page Return Sensor Return Sensor And Pulsation And Pulsation Damper Assembly Damper Assembly Return Sensor 07 24 08 3 8 JIC And Pulsation 4001 443 00 FloScan Instrument Te1 206 52446162523 1 058 00 PS BAK 2 FilqSca 3016 NE Biiieley St mail service floscan c Com pany Inc 45 Degree f EE WA 981 wa Fitting N ed 4 AID J li ui j l i ia 1 10
44. red sticker on the sensors body 15 Model 235 sensors are temperature compensated and stamped with their instruments serial number xxxxF Forward xxxxR Return 235 2K Temp Comp sensor kits are precisely calibrated and matched to each instrument Sensors are labeled FORWARD and RETURN and must be installed in these positions for proper operation The instrument head serial number must match the flow sensor s serial number 16 If there s a shut off valve in the return line do not operate the engine with it closed Fuel system pressure could exceed the maximum system working pressure of 40 PSI and may cause a catastrophic system failure You should either tag the valve so the engine will not run when it is closed for maintenance or bypass it with a relief valve NOTE Minimize the number of 90 elbows and pipe fittings on the sensor or pulsation dampers inlet port Excessive use may create a high vacuum fuel restricting pressure drop across the forward part of the fuel system Refer to the engine owners manual for maximum fuel pump inlet vacuum A vacuum gauge can be used to confirm that the system is within limits CAUTION DO NOT OVER TIGHTEN FITTINGS Over tightening may crack the sensor s body or pulsation damper s base Cracks cause leaks and fuel leaks sometimes cause catastrophic explosions and fire Assemble fittings with a Lubricating Fuel Proof Non or Semi Hardening pipe thread sealant designed for aluminum and stainles
45. rn Sensor is held at the Hex Flow Straightener it may be moved The Hex Flow Straightener is locked into place with a very strong retaining compound It must remain in position and must not be tightened or loosened Moving the Hex Flow Straightener in relation to the Sensor body will destroy its accuracy Turned Flow Straighteners are not considered warranty items CAUTION DO NOT OVER TIGHTEN FLOW SENSOR FITTINGS Over tightening may crack the sensor s body Cracks cause leaks and fuel leaks sometimes cause catastrophic explosions and fire Assemble fittings with a Lubricating Fuel Proof Non or Semi Hardening pipe thread sealant designed for aluminum and stainless steel threads Loctite 567 or equivalent DO NOT USE TEFLON TAPE Continued on next page 1 Place the Return Sensor Pulsation Damper assembly with inlet and outlet fittings installed onto the flat bracket Orient the Sensor body over the slots and the Pulsation Damper base over the bolt holes 07 24 08 4001 443 00 FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 Email service floscan com Http www floscan com ZIA Flosca Long Spacers Additional Flat Washers If Needed 07 24 08 Flat Washers ESNA Nuts 10 Slide a lock washer onto two 114 bolts Chose your 90 mounting bracket option Assemble the 144 bolts through
46. s NMEA 2000 1 4 Watt WHITES Backbone Cable P NET L h D BLUE p NET C T BLACK ype NETS RED 2vDe SHIELD SET P Toy STBD FIONET Interface Module Drop Cable Drop Cable 16 8 GPH 3054 GAL TOT s4 O a a Rl B w le Bw n m E 8 S 8 Cable Shield _ Cable Shield E Ei E 5 3 a i a gt Forward Return Flow Flow Sensor Sensor Connect Cable Shield Connect Cable Shield Drain Wire to Drain Wire to Vessel Bonding System Vessel Bonding System or Engine Block Engine Block 2000 082 00 Tel 206 524 6625 Fax 206 523 4961 email service floscan com http www floscan com INSTANCE SELECTION amp OPERATION FIONET FIloNET Engine Measurement Instance Selection White Recessed Arrow Switch Settings The Recessed Arrow Switch is used for setting engine instances Mechanical amp Diesel Electric Propulsion Engines F0 1 e Fora Single Main Engine or Port Main Engine Rotate the Recessed Arrow Switch to Position 0 D Y a e Fora Starboard Main Engine Rotate the Recessed Arrow Switch to Position 1 c 4 Generators and Auxiliary Engines BY LIS e Fora Single Auxiliary Engine or Port Auxiliary Engine Rotate the Recessed Arrow Switch to Position 2 9 g 7 e Fora Starboard Auxiliary Engine Rotate the Recessed Arrow Switch to Position 3 Recessed Arrow gt Switch US or Metric Operation Selection Green Switch Settings e For US Gallons
47. s steel threads Loctite 567 or equivalent DO NOT USE TEFLON TAPE 07 24 08 4001 443 00 FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 Email service floscan com Http www floscan com WIRING FIONET NMEA 2000 Diesel Fuel Monitoring System Single Engine FIONET Interface Module Installation using T Connectors NMEA 2000 Display Device Drop Cable Terminating Terminating Resistor Tap T Connector Tap T Connector Resistor Backbone 1 Tap T Connector Cable FIONET Interface Module Network Power Drop Cable Supply Connection N PPY 16 5 GPH Tl 293 7 GAL TOT UF IT a FQ e Shield R B W R B par I 12VDC m Electronic lt a Distribution U oO Panel In Accordance With ABYC E 11 12VDC Cable Shield 1 IT Cable Shield 2 5 s Ss 4 al al Forward Return Flow Flow Sensor Sensor Connect Cable Shield Connect Cable Shield Connect Cable Shield Drain Wire to Drain Wire to Drain Wire to Vessel Bonding System Vessel Bonding System Vessel Bonding System Engine Block Engine Block Engine Block
48. sel Bonding System Vessel Bonding System Vessel Bonding System or or or Engine Block Engine Block Engine Block LI Drop Cable FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 Tel 206 524 6625 2000 082 00 Fax 206 523 4961 email service floscan com http www floscan com Single Engine FIONET Interface Module Installation using Barrier Terminal Strip Connectors NMEA 2000 Display Device Drop Cable TERMINATION RESISTOR 120 Ohm 5 ae 1 4 Watt 7 SHIELD Network Power Supply Connection Cable Shield L_ 412vDC 4 Electronic Distribution Panel In Accordance With 12VDC Connect Cable Shield Drain Wire to Vessel Bonding System or Engine Block 04 09 2008 FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 NMEA 2000 NET H TERMINATION So D oS RESISTOR NETL H 120 Ohm 5 BLUE ae 1 4 Watt Backbone Cable FRS NET S RED SHIELD FIONET Interface Module Drop Cable 16 5 GPH 293 7 GAL TOT a OD na gt Cable Shield Cable Shield a Forward Return Flow Flow Sensor Sensor Co
49. ss the RED and Black Network Power Supply Connection Wires NET S and NET C pins or holes The reading should be approximately 12 to 14 VDC but not lower than 9 VDC NMEA 2000 Connector Pinout NET C 3 Shield 1 NET S 2 era venda NET L 5 Shield 1 AC 7 NET L 5 NET H 4 NET C 3 Micro C Female Mini C Female NAME PAIR PIN COLOR Shield Drain 1 Bare NET S Power 2 Red NET C Power 3 Black NET H Signal 4 White NET L Signal 5 Blue NOTE Micro Cable Pin Out is on the left side of diagram Mini Cable Pin Out is on the right 2 If 12 VDC is not present measure between the Red power wire and a known good battery minus point There may be a loose battery minus connection or other wiring problem Check wiring switches fuse and the 12 VDC power source 3 12 to 14 VDC is present between the Red wire and battery minus there may be a loose battery minus connection broken wire open termination or other wiring problem 4 If voltage is present across the Red amp Black Network Power Feed and the FloNET or Fuel Tron does not Light Up Every connector junction between the Network Power Feed connection and the FloNET Module or Fuel Tron Instrument must be disconnected and checked for voltage until the problem connector or cable section is found NMEA 2000 Backbone Cable with Barrier Terminal Strip Connectors 5 Measure voltage across the RED and Black Network Power Supply Connecti
50. tartup amp Installation Check Always Prime the FloScan Fuel Monitoring System This is an important step in preventing your engine from becoming air bound If you have an electric priming or boost pump circulate fuel for 10 minutes while checking for leaks If the fuel system does not have an electric priming pump use the engines manual pump Before starting open or crack the lift pumps outlet fitting slightly Continue pumping all air is purged and fuel flow from the lift pumps outlet Before start up verify that all fuel system fittings are tight e System Start Up Start and run your engines Survey the installation for leaks and other problems If the system is not operating properly refer to the Troubleshooting Instructions and correct any deficiencies When the engine reaches operating temperature increase engine speed to about 1500 2000 RPM Letting it run for five or ten minute s helps purge residual air from the system e Any vacuum leaks between the fuel tank and lift pump will allow air to be drawn into the system These leaks cause high and or fluctuating GPH readings Only severe leaks affect engine performance but all leaks affect sensor performance and instrument readings Vacuum or suction leaks occur at improperly sealed primary filters loose packing nuts on cross over amp shut off valves and improperly sealed fittings Vacuum leaks can also occur from corroded copper fuel lines and chaffed fuel hose where it rubs against bulk
51. tches for Totalizer Reset Port Starboard Select Hours Synch and Never use illuminated or back lit switches GPH MPG 04 09 2008 2000 080 00 Fax 206 523 4961 Http www floscan com FloScan Instrument Company Inc Tel 206 524 6625 3016 NE Blakeley Street Seattle WA 98105 Email service floscan com INSTALLATION MECHANICAL OVERVIEW NMEA 2000 K Series Systems To Ensure System Accuracy Follow All Installation Instructions e Sensor Placement Determine where the Flow Sensor or Flow Sensor Pulsation Damper assembly is to be installed Install the sensor or sensor pulsation damper assembly so that the two fuel flow arrows gt or the IN and OUT markings are on a horizontal plane All orientation arrows 48 must be pointing up The forward sensor or forward sensor pulsation damper assembly must be installed downstream of the primary filter Do not install the sensor or either sensor assembly at a high point in the fuel system This could negatively impact system accuracy by trapping air The fuel return line between the return sensors outlet port and fuel tank should be at least 12 long and have a 1 to 2 upward rise This keeps the return sensor flooded improving accuracy Place sensor assemblies in a protected location away from water spray Return Sensor amp Pulsation Damper Assembly Forward Sensor amp Pulsation Damper Assembly FloScan 2
52. testing If problems with your system persist contact FloScan Technical Support with test results 09 017 08 2000 085 00A FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 Email service floscan com Http www floscan com 09 017 08 2000 085 00A FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 Email service floscan com Http www floscan com
53. ub totalizer reading matches the fuel pump reading Starting at 0 rotating the BLACK Switch in a clockwise direction increases the totalizer readings by 2 for each click Rotating the switch in a counter clockwise direction decreases totalizer readings by 2 Totalizer readings can be increased by 10 or reduced by 20 Single Engine Vessels Please refer to Example 1 Port system on the following page 04 09 2008 2000 086 00 FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 Email service floscan com Http www floscan com Example 1 Twin engine vessel with two dedicated fuel tanks For single engine vessels with a gi 0 nih L70 2 single tank use either the Port or Starboard system calibration procedure in Example 1 ee xe 4 _ F 0 no 4 2 1 Si I After steaming and returning to refuel The Port tank took 89 7 gallons 339 5 liters It s totalizer 6 E i Vaia reads 94 2 gallons 356 5 liters The Starboard tank took 93 2 gallons 352 8 liters and its D vl 3 N totalizer reads 87 9 gallons 332 7 liters sa Fa See eg OO ER 4 148 e Using the formula calculate the percentage difference between the totalizer reading and kB 5 actual fuel consumption j E 110 I 12 9 1 20 Difference in Gallons Liters x 100 su Panty Port System Calibration Totalizer Reading 16 BLACK Switch e Find the difference between the
54. ute Fire Test USCG Type A 1 100g m 24hrs USCG Type A 2 300g m 24hrs USCG Type B 1 100g m 24hrs Not Required USCG Type B 2 300g m 24hrs Not Required Table I Cost comparison between steel amp fabric braid A 1 fuel hose on a 50 Diesel pleasure vessel with Stand up engine room e Aeroquip A 1 Steel Braid Hose A 1 Fabric Braid Hose with with JIC x MNPT Fittings HB x MNPT Fittings Hose End Fittings 28 Ends 11 50 per End x 28 322 Hose End Assembly Fee 10 Hose x 14 140 Fittings 12 x 12 20ea x 11 90 238 20ea x 4 20 84 Fittings 8 x 12 4ea x 10 75 43 4ea x 3 59 14 36 le a TT it e cir eee ty 1732 28 641 64 Table II bd 2 Stainless Hose Clamps 28ea x 1 49 41 72 9 Fittings 16 x 12 4ea x 13 80 55 20 4ea x 5 39 21 56 04 09 2008 2000 080 00 FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 Email service floscan com Http www floscan com Installation Do s amp Don ts Do Don t Always use a Fuel Proof Pipe Thread Sealant when assembling fittings into fuel system components Never use Teflon Tape Locktite PST Rector Seal or equivalent If possible avoid using Push Lok Barb Tite Use thin wall low pressure full flow type IC orSak dira aed always NPT or NPTF hose barb fittings Copper AP 50 sealing washers or Flaretite fitting seals onto JIC and SAE swivel fittings Double
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