Installation / Troubleshooting Manual
Contents
1. Use a Fuel Proof Pipe Thread Sealant when assembling fittings into fuel system components Locktite PST Leak Lock or equivalent Never use Teflon Tape or Permatex Thread Sealant Use thin wall low pressure full flow type NPT or NPTF hose barb fittings Don t use Push Lok or Barb Tite fittings Avoid using JIC or SAE swivel fittings If used always install copper conical sealing washers Connie seals or fitting seals on fittings Double clamp all hose barb fittings Avoid using 90 elbow fittings Install Sensor s at a low point in the fuel system as far from the engine as practical Fuel must travel Up hill slightly after leaving the sensor Verify correct orientation and fuel flow direction If possible avoid bolting or mounting sensor s directly onto the engine Always install Forward Sensors on the Fuel Pumps Inlet or Vacuum side Never install on the Pressure Side Always use 30 micron primary filters Avoid 2 or 5 micron primary filters Connect all Ground wires to a Ground Buss or directly to the Battery s Negative Terminal Connect or Ground wire shields to the engine block Never connect Instrument or Sensor Ground wires to the hull engine block or other machinery Always use non illuminated switches for Totalizer Reset Never use illuminated or back lit switches 12 8 2004 FloScan Instrument Company Inc 30162. wMM Fuel Flow Direction Caution Diesel System Components are not designed for use on Gasoline Fuel Systems FloScan Sensor amp Pulsation Damper Plumbing Guidelines 1 Install flow sensor amp pulsation damper assemblies with their orientation arrows pointing UP 4s Fuel must enter through the port marked IN or with an inward pointing arrow gt and exit through the port marked OUT or with an outward pointing arrow gt Install the sensor pulsation damper assembly as far from the engine as practical Maximizing fuel line length between engine and sensor pulsation damper assembly improves instrument accuracy Pipe plugs are provided to block unused ports Refer to Pulsation Damper Bottom View Maintaining high flow velocities through the fuel lines minimizes sensor oscillations Use the smallest approved fuel line diameter for your engine especially on the return line Consult the engine owners manual for more information To insure that the return sensor remains flooded install the return sensor pulsation damper assembly at a low point in the system Fuel should travel Up Hill upon exiting the return sensor Flow sensors must always be installed downstream of a filter or debris screen no finer than 30 micron Particles larger than 1200 microns may jam the sensors rotor and cause it to fail Continued on reverse side 2 22 2005 4001 309 02A FloScan Instrument Company Inc Tel 2
3. CAUTION DO NOT OVER TIGHTEN FITTINGS Torque sensor and pulsation damper pipe thread fittings to a maximum of 15 ft lb 180 inch lb or 2 full turns past hand tight whichever comes first Leak Lock pipe thread sealant is provided with your system Use it on all pipe thread fittings DO NOT USE TEFLON TAPE 2 22 2005 4001 309 02A 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 Pulse Output Gallons Liters Adjustment Series 850K 0 85TK 0 850L 0 85TL 0 860K 0 86TK 0 860L 0 86TL 0 Diesel Fuel Log with Pulse Output The 85 8600 series Pulse Output Multifunction Instrument MFI produces a square wave pulse output signal The Pulse Output signal is set using the Green Rotary switch Refer to table During normal operation this signal equals the engines fuel consumption In diagnostic mode zero fuel flow is transmitted The signal output is optically isolated which helps to minimize noise interference GROUNDING The Fuel Log uses a signal point ground system to prevent ground loop interference Connect the BLACK wire from each flow sensor together and connect to the BLACK wire of pin 5 at the instrument head only WIRING PC or other Equipment Setup and Operation Connect Pin 2 WHITE RED wire to the computer or equipment s signal input If the input does not supply pull up current Pin 2
4. must also be connected to 12 VDC through a 10K 47KQ pull up resistor Connect Pin 7 GREEN BLACK wire to the PC or other equipment s Ground If the FloScan MFI is used as the pull up power supply Pin 7 must also be connected to the BLACK wire on Pin 5 Instrument Ground CALIBRATION The Pulse Output MFI can be easily calibrated to read one of eight pulses per gallon values or one of eight pulses per liter values This is accomplished by rotating the Green switch on the back of the meter head GREEN Switch Switch Position Pulses per Gallon Switch Position Pulses per Liter 4 10 C 10 5 30 D 30 6 100 E 100 7 300 F 300 8 1000 0 1000 9 3000 1 3000 A 10000 2 10000 B Custom Gallons 3 Custom Liters 12 08 2004 7000 337 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 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 OPERATION All 75 76 85 86 95 96 Series Diesel Fuel Log Diesel Fuel Log Instruments use a microprocessor based non volatile Random Access Memory RAM to store gallons or liters of fuel consumed and cumulative gallons or liters of fuel consumed Non volatile RAM requires no power for memory retention All 8 s are displayed f
5. 12 to 14 VDC but not lower than 10 VDC VDC If 12 VDC is not present measure between the RED power wire on pin 9 and a known good ground in the instrument panel If 12 to 14 VDC is present between the Red wire and ground there may be a loose instrument ground connection or other wiring problem VDC NOTE Some applications use both pins 1 and 9 for Instrument power 3 If 12 to 14 VDC is not present in steps 1 or 2 check wiring switches fuse and the 12 VDC power source HI LED BACK LIGHTING WIRING TEST 1 2 Measure voltage between the ORANGE wire on pin 4 and the BLACK wire on pin 5 VDC If 12 VDC is not present measure between the ORANGE wire on pin 4 and a known good ground in the instrument panel If you measure 12 14 VDC there is a power supply problem to pin 4 or a ground connection problem to pins 5 or 12 12 8 2004 7000 336 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 IV SENSOR S TEST 1 With engine s idling measure and record voltage between the RED power and BLACK ground wires on the Forward Sensor Voltage should be 12 to 14 VDC VDC 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 Stop the engine while observing your voltmeter Readings shoul
6. 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 8 5 2003 4001 325 00F 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 Fuel Flow Schematic Low Flow Diesel Systems BOS 201 231 amp 235 2K SS BES And Pulsation l i ae Damper Assembly FioS 1 E oea Aa aaa i oScan Tank pee Tei f E e OUT a OUT lt fee a PT aca Primary Forward Sensor Toe ee oN Filter ee 3K Bottom view of Pulsation Damper FloSca ey les cena y En k Return Fuel pe ok ea aa e Engine oole he e xk EO O AS ae Return Sensor KK
7. barb fittings Hose 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 or Hydraulic Hose Mount the sensor s or sensor assemblies where they re to be installed Mark the hose where it is to be cut Remove hose and bring it to a hydraulic shop Have them cut the hose and install hose ends Reinstall the hoses and install the correct fitting into each sensor or sensor assembly Always assemble fittings using a fuel proof pipe thread sealant Never use Teflon Tape 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 Connie Seals or Flaretite seals may be required to seal JIC amp SAE fittings IV Electrical Installation Run cables between Sensor s J Box If used and Instrument s Cables must be adequately supported at reasonable distances approximately 2 4 feet Wire Terminations Referring to the wiring diagram Connect Sensor Instrument and Switches to their respective wires with crimp type butt or ring connectors Always cover connectors and wire ends with heat shrink tubing 12 8 2004 7000 339 00 FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Bla
8. fuel for 10 minutes while checking for leaks If not use the engines manual pump Before starting Crack the lift pumps outlet fitting slightly Continue pumping until system is fully primed 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 bulkheads 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
9. jumper from the BROWN wiring harness conductor to a known good ground At the Molex connector connect an Ohmmeter lead to its BROWN wire Connect the other Ohmmeter lead to a known good ground The Ohmmeter should read approximately 0 1 to 3 Q Ohm Reading VII TACHOMETER PROBLEMS Note Refer to the engine owners manual wiring diagram installation and calibration instructions for parts A amp B below A HIGH OR LOW READINGS 1 Verify that the Tachometer is calibrated correctly B FLUCTUATING READINGS 1 Listen to your engine s If engine speed cycles up and down when idling or underway the tachometer reading will follow This does not indicate a problem with the Tachometer but may indicate engine problems 2 Verify that wiring connections are tight clean and dry Check continuity while shaking the wires Ohm readings should be near zero and remain steady while shaking 3 Verify that the tachometer signal wires are connected at the correct signal output point VII 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 but won t affect totalizer accuracy To eliminate repair or replace any defective valves or re plumb dampers according to the Fuel Flow Schematic Instructions IX FINDING FUEL SYSTEM VACUUM LEAKS Fluctuating GPH and High Totalizer Re
10. 06 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 email service floscan com http www floscan com 4 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 colored sticker 5 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 6 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 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 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
11. AGRAM Series 8500 8600 Pulse Output Diesel Fuel Log Instrument Connection Harness PI PIN FUNCTION ED Not Connected twin applications see note below ED 12VDC ED WHITE pulse out EEN Totalizer Reset cen HITE YELLOW pulse in Twin applications ot Connected lack 7 RANGE Illumination 12VDC eo LACK _ Instrument Ground es eee HITE Forward Flow Sensor signal A EEEE REEN BLACK pulse out ELLOW Not Connected eiaa w lt lo 4 0 Pe I E Single Sensor Installations 4 1 2 amp fuse m 9 To Ignition Switch GREEN BLACK 1 RED Key ON 12VDC 10 _ 5 Totalizer TEE Reset Switch WHITE 6 4 ORANGE To Bae ee momentary ON aa a sd BLACK 5 lt O Battery buss R x Flow Bf BS 2 B BLACK a eae CABIE Sensor WHITE RED 7 GREEN BLACK Pulse Out To External Computer if applicable RED WHITE 2 Pulse Out NOTE This diagram is used for Diesel systems requiring only one 1 sensor in the fuel system 12 8 2004 7000 338 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 Instrument Connection Harness FUNCTION PIN FUNCTION N 1 2 3 5 7 1 RED NorComesed SO 2 REDAVHITE poisson GREEN Totalizer Reset Ca 5 WHITE
12. Diesel Fuel Log K Series Standard Flow U S Installation Troubleshooting Manual Metric Temp Comp Non Temp Comp Pulse Output This manual 7000 316 14 applies to the following product part numbers 1 2 3 4 5 6 7 6 22 2005 FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 850L 201 2K 850L 231 2K 850L BOS 2K 850L0 2012K 850L0 BOS2K 85TL 235 2K 85TK 235 2K Tel 206 524 6625 email service floscan com 7000 138 80 Fax 206 523 4961 http www floscan com FUEL LOG INSTALLATION PLANNING READ ME FIRST Detailed Mechanical amp Electrical Planning Saves Installation Hours FloScan K Series systems are not difficult to install Installation requires only basic electrical amp mechanical skills With forethought and planning your system will be installed with few problems Todd Walker Yacht Electric Co 954 325 9091 regularly installs FloScan K Series Twin Diesel Systems in about 10 hours Difficult installations may take several hours longer I Installation Preparation Review the pre installation booklet mechanical installation instructions and survey your vessel Determine where the Sensor s Sensor Assemblies Switches and Instruments are to be mounted Place them at their approximate locations Determine fitting size and types required for each plumbing connection JIC SAE NPT NPTF or Hose Barb FloScan K Series Hi Cap Diesel Forward Sensor Assemblies
13. NE Blakeley Street Seattle WA 98105 7000 339 00 Tel 206 524 6625 Fax 206 523 4961 email service floscan com http www floscan com ELECTRICAL Series 75 76 85 86 95 96 Series Diesel Fuel Log SET UP Wire amp Switches Use 18 AWG stranded wire on runs under 50 For runs over 50 use 16 AWG Shielded wire is recommended for all Diesel systems and suggested for Inboard amp I O gasoline systems Always Ground the wire shield or shield drain wires in the engine room by connecting them to the bonding system or engine block FloScan suggests using J Boxes Terminal Blocks and three conductor cables between diesel sensors and instrument to make wiring easier Install Single Pole Single Throw SPST switches for Hours amp Gallons Reset switches are not included with kit Grounding Each Black sensor wire must be connected directly to the Black Instrument Ground wire Use a single wire to connect the Black wire junction to the battery s negative terminal or a ground buss Power FloScan Instruments amp sensors operate on 9 to 12 VDC Voltages exceeding 16 VDC will damage equipment 24 amp 32 VDC systems must be reduced to 12 VDC Two different types of voltage reducers are available through FloScan WIRE CONNECTIONS Installation Connect wires one at a time and install heat shrink tubing before proceeding to the next wire refer to diagram Connect ground wires first BLACK instrument ground wire
14. RN AUTHORIZATION WILL BE ISSUED IT TAKES ABOUT 20 MINUTES AND IS VERY IMPORTANT IN ANALYZING SYSTEM PROBLEMS Before starting record Instrument a N model number and switch settings A An AEN A GD T MODEL m SERIAL T yee UPPER BLACK RED GREEN BACK OF INSTRUMENT BACK OF INSTRUMENT LOWER BLACK or RECESSED ARROW No Back Lighting Wiring Sections III High or Low Totalizer reading Over 10 Calibration Calibration sheet Incorrect flow sensor Operations sheet Incorrect switch settings Calibration sheet Fluctuating GPH Readings No GPH or Totalizer Readings Wiring Sections II V VI Installation sheet Section IV No Forward or Return Sensor Readings Wiring Instrument failure Sections I II IV V VI Section I IV High Forward or Return Sensor Readings Section IX Incorrect switch settings Calibration sheet Section XI I DIAGNOSTIC TEST 1 Start engine s For 2 seconds after powering up the Instrument will show all 8s During this time quickly cycle the Totalizer Reset Switch from its run position to reset and back at least twice This puts the Instrument into Show Switches Mode for 20 seconds Record these readings below HOURS i RPM GPH GALLONS After 20 seconds the Instrument automatically goes into diagnostic mode A minus sign in the Reset Gallons window indicates when this occu
15. YELLOW pulse in Twin applications Not Connected a BLACK Jumper to pin 13 5 BLACK Instrument Ground BLACK Jumper to pin 12 EA ia Ea 15 ae 16 RED 12VDC WHITE Forward Flow Sensor BROWN Return Flow Sensor anos GREEN BLACK pulse out 15 BLACK Reset Ground A EEEEEEER YELLOW Not Connected 16 VIOLET Not Connected BACK OF INSTRUMENT Forward and Return Sensor Installations ae 14 4 2 amp fuse 7 GREEN BLACK Grini To Ignition Switch U Key ON 12VDC To External Computer if applicable 9 or refer to Wiring Diagram sheet 9000 016 00 C RED RED WHITE ech 2 Pulse Out WHITE 6 S 5 4 To Panel Illumination a BLACK ORANGE 12VDC lt O Battery buss Forward R O R BO BS sB lt BLACK Be CABLE Flow o _ Sensor WHITE RED e R l Return BROWN WHITE w CABLE Flow o Sensor GREEN BLACK 10 S o 15 Totalizer Reset Switch momentary ON 12 8 2004 7000 338 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 MECHANICAL amp WIRING OVERVIEW K Series amp 10 Systems To Ensure System Accuracy Follow All Installation Instructions e Sensor Placement Determi
16. adings 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 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 packings 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 1 2 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 Observe the clear hose while shaking the fuel lines If the bubble stream continually increases or decreases you v
17. ct the VIOLET wire to a Ground Buss or Battery Minus 8 5 2003 4001 325 00F 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 2 Replace Existing Tachometer s FloScan MFI instruments have a 3 3 8 outside diameter This is a common size and fits into most instrument mounting holes Identify the engines tachometer sender wires Connect the FloScan tachometers Yellow and Violet signal wires to the sender wires If one sender lead is grounded connect the FloScan tachometers Yellow signal wire to the ungrounded lead or terminal Connect the VIOLET wire to a Ground Buss or Battery Minus 3 New Tachometer s Run a dedicated shielded pair of wires between the instrument and tachometer sender This is especially important with Magnetic Pickup senders Ground the shield only in the engine room e Magnetic Pickup amp AC Signal Generator Tachometer Senders Connect the FloScan tachometers Yellow signal wire to one sender terminal Connect the Violet wire to the other terminal e Engine Alternators Connect the FloScan tachometers Yellow signal wire to the alternators tachometer output terminal This terminal is usually marked as TACH or SIG Connect the VIOLET wire to a Ground Buss or Battery Minus e Pre Startup amp Installation Check Prime the fuel system If you have an electric priming or boost pump circulate
18. ctuations are caused by the engine governor regulating fuel flow to maintain a steady engine RPM This concludes system testing If problems with your system persist contact FloScan Technical Support with test results 12 8 2004 7000 336 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 12 8 2004 7000 336 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 Lo Flo Pulsation Damper Can Replacement FloScan FloScan f 233 041 00 frost l Rubber Sealing Rubber Sealing Washer gt Washer Aluminum Base a Aluminum Base Forward Sensor Return Sensor 1 Remove the old Pulsation Damper can A Claw type oil filter wrench or pipe wrench may be needed 2 Put a coating of grease on both sides of the new Pulsation Dampers rubber sealing washer 3 Clean the Aluminum base and put a coating of grease on the seal s mating surface 4 Place the new Pulsation Damper can on its Aluminum base Turn until Finger tight 5 Using a band type oil filter wrench carefully rotate the can until tight approximately of a turn past finger tight e Position a strip of rubber Bicycle tube or rubber glove between the wrench and can Rubber increases friction and
19. d 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 4 With engine s idling measure and record voltage between the RED power and BLACK ground wires on the Return Sensor If used Voltage should be 12 to 14 VDC VDC 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 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 8 The Sensor s may be defective if voltage readings in steps 3 amp 5 remain constant VDC If signal voltages in steps 3 amp 5 are ok go to the backside of the MFI Instrument With engine s running measure and record voltage across the Red amp White Forward Sensor and Red amp Brown Return Sensor signal wires The MFI voltage readings should match the Sensor readings This verifies that the Sensors signal is reaching the MFI If voltage is not present there is a wiring problem VDC V MFI SENSOR INPUT TEST 1 Disconnect the WHITE and BROWN signal wires at the MFI Instrument harness Connect a course thread 2 13 or similar non plated bolt to the Black wire Run the WHITE
20. e Part one adjusts idle consumption Part two determines optimum cruising RPM Propulsion Engines and fuel tank configuration Part three calibrates for overall accuracy PART I Idle Consumption Adjustment e Start and run engine s until they re at operating temperature e Referring to the switch diagram rotate the Upper Black and Red Switches to 0 e Increase engine speed to 1800 RPM for several minutes 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 0 is the HP Non Turbo w Turbo En 100 400 0 1 0 5 GPH 1 2 LPH 0 3 0 7 GPH 2 3 LPH 400 750 0 8 GPH 3 LPH 1 0 GPH 3 4 LPH PON H0 f urning switch Turning switch 750 1000 1 0 GPH 4 LPH 1 5 GPH 5 6 LPH counter clockwise E Pit eae he 1000 1250 _ 2 0 GPH 7 8 LPH 2 5 GPH 9 10 LPH Oqbyinspase P 35 0 5 will 1250 1500 3 0 GPH 11 12 LPH 3 5 GPH 13 14 LPH reading 4 Sten 1500 2000 3 5 GPH 13 14 LPH 4 0 GPH 15 16 LPH B 5 reading 2000 3000 4 5 GPH 17 LPH 5 0 GPH 18 19 LPH A R 7 6 8 a RED Switch e Rotate the RED Switch until the idle GPH LPH reading matches engine Horsepower from Table 1 NOTE At this point idle consumption is approximate It establishes operating parameters for final calibration Part II Determining Optimum Tank Configuration for Genera
21. e 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 visiable 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 12 8 2004 7000 336 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 X FUEL FILTERS A dirty Primary fuel filter or one that is too fine 1 25 micron will draw vapor bubbles out of the fuel causing fluctuations and high readings Replace it with a new 30 micron filter XI FLOW SENSOR ORIENTATION Sensor orientation is critical for proper operation All Sensors have their inlet and outlet ports clearly marked IN OUT or gt gt This identifies fuel flow direction The Sensor must be Plumbed correctly for it to operate properly There is an additional single arrow on the Sensor body It is crucial that this single arrow points up XII LOW RPM OPERATION At idle under a no load condition it is common for GPH readings to fluctuate slightly These flu
22. e instrument is turned Totalizer Gallons Liters The Reset Gallons Liters or Trip Reset Gallons Liters window shows fuel consumed since it was last reset The Cumulative Gallons Liters window shows the total fuel consumed and cannot be reset The GPH LPH and Trip or Reset Gallons Liters readings will both change if the flow calibration switch UPPER BLACK SWITCH on the back of the instrument is turned Totalizer Reset When the totalizer reset switch is turned ON Closed the Trip or Reset GALLONS LITERS display will flash for ten seconds then reset to zero Flashing indicates the instrument is in reset mode If the RESET switch is turned OFF Opened before the totalizer reads 0 0 the instrument will NOT reset If you neglect to turn OFF the RESET switch 0 0 continues to flash Sensor Selection Diesel Fuel Log Instruments are preset for the correct flow sensor combination Before installing the instrument verify that the Lower Black or Recessed Arrow switch is set to position number 6 Lower Black or Recessed Arrow Switch Setting Switch Position Flow Sensors 6 Custom for All Sensor Pairs 1 25 2005 7000 334 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 CALIBRATION All 75 76 85 86 95 96 Series Diesel Fuel Log Totalizer Calibration This is a three part calibration procedur
23. er Assembly 233 236 2K Return Sensor And Pulsation Damper Assembly FloScan Outlet nM Inlet 201 231 235 2K Outlet Ouieta Inlet ARROW UP 231 10 Cummins PT Systems 4001 325 00F Tel 206 524 6625 Fax 206 523 4961 email service floscan com http www floscan com 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 Select Instrument Mounting Location The instruments face is waterproof and a gasket is provided to seal its bezel to the control panel Choose a location away from the compass Install 65 6600 series instruments 12 away from compass Choose a shaded location since direct sunlight may cause the LCD display to temporarily turn This does not damage the LCD but makes it impossible to read until cooling down Make a cutout in the instrument panel for the instrument The instruments maximum depth is 3 1 2 minus the thickness of the console panel Instrument Series Cutout Size 6500 6600 3 1 16 7500 7600 8500 8600 9500 9600 TwinScan 3 3 8 Wiring Determine wiring run length and the number of switches needed always use good quality mari
24. have 1 Female NPT ports FloScan K Series Hi Cap Diesel Return Sensor Assemblies have 1 inlet and 2 outlet Female NPT ports FloScan Hi Flo 10 Diesel and Gasoline Sensors have 1 2 Female NPT ports FloScan K Series Lo Flo Diesel and Gasoline System Components Sensors and Pulsation Dampers have 4 Female NPT ports Review the electrical installation instructions Open and survey your vessels wire ways Determine if it would be easier to run a 3 conductor cable from each sensor to the instrument or install a junction box J Box with terminal strip in the engine room The J Box requires a 4 conductor cable from it to the instrument and a 3 conductor cable from each sensor Measure cable lengths from sensor s to J Box If used to Instrument Tachometers require a separate 2 conductor cable If there s an existing tachometer its signal wires can be used II Mechanical Installation Install or mount the Sensor s or Sensor Assemblies Instruments and Switches Reset MPG HI Plumbing Most K Series and 10 installations do not require additional fuel hose Mount the sensor s or sensor assemblies where they re to be installed On installations using Fabric Braid A 1 Fuel Hose install the correct HB X MNPT fitting into each sensor or sensor assembly Always assemble fittings using a fuel proof pipe thread sealant Never use Teflon Tape Use a hose cutter or knife to cut the fuel hose Next install the hose onto the
25. keley Street Seattle WA 98105 email service floscan com http www floscan com V Pre Startup Prime the fuel system If you have an electric priming or boost pump circulate fuel for 10 minutes while checking for leaks If not use the engines manual pump Before starting open the lift pumps outlet fitting slightly Before start up verify that all fuel system fittings are tight VI 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 VIL Calibration When system is running properly refer to the calibration instructions and calibrate your system If installed properly initial calibration takes less than 1 hour After consuming some fuel final calibration should only take a few minutes USCG approved fuel hose with either fabric or wire reinforcing braid meet the following standards Hose Marking Permeation Rating 2 Minute Fire Test USCG Type A 1 100g m 24hrs Required USCG Type A 2 300g m 24hrs Required USCG Type B 1 100g m 24hrs Not Required USCG Type B 2 300 m 24hrs Not Required Table I 12 8 2004 7000 339 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
26. n 356 5 liter totalizer reading 047 x 100 4 7 Higher difference e To calibrate rotate the Port MFI s Upper Black Switch Counter Clockwise to position E reducing 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 MFI s Upper Black Switch Clockwise to position 3 increasing 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 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
27. ne grade switches Use 18 AWG conductors on runs under 50 16 AWG for runs over 50 Run amp Connect Wires Wire one system at a time Always begin with the Black Ground wires Each Black sensor wire must be connected to the Black Instrument Ground wire Use a single wire to connect these Black wires to the battery s negative terminal or to the ground buss For the system to operate properly the Ground wires must be connected in this manner Connect other wires per the wiring diagram Leave the RED power wire for last Tachometer Installation Options 75 7600 85 8600 and 95 9600 series tachometers require one or two additional wires If your engine isn t equipped with a tachometer sender determine which type it requires AC Signal Generator or Magnetic Pickup and install one Some engine alternators produce a tachometer signal and can be used as the tachometer sender Mechanically driven AC signal generators and magnetic pickups are available from FloScan and most marine dealers Hewitt Motorola VDO and Stewart Warner are some of the more common brands 1 Keep Existing Tachometer s Connect the FloScan tachometers Yellow and Violet signal wires to the existing tachometer If the tachometer sender wire s are not marked trace them from the tachometer sender up to the existing tachometer If one sender lead is grounded connect the FloScan tachometers Yellow signal wire to the ungrounded lead or terminal Conne
28. ne 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 Forward Sensor amp Pulsation Damper Assembly FloScan Inlet a Ol d Outlet gt gt oo L gt baal Wat aa Forward Sensor And Pulsation Damper Assembly FloSean Inlet ha a ae 201 231 1K amp 2K 235 2K Inlet gt 2 A 0 5 Outlet L 233C 10 amp 233D 10 Cummins PT Systems 8 5 2003 FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 233 236 1K amp 2K Return Sensor amp Pulsation Damp
29. or the first 3 seconds when the instrument is powered up For 1 second after that the instrument shows switch positions and software version After completing its start up sequence the instrument goes into normal operating mode If supply voltage drops below 10V DC for any reason the instrument displays a row of decimals across the bottom of the RPM window This does not affect instrument accuracy Stored engine hours and fuel consumption data will not be lost Liquid crystal displays have an OPTIMUM VIEWING ANGLE If your viewing angle is outside this range contrast will decrease and numbers may flicker Before drilling any holes in your dash it s a good idea to temporarily power up the instrument 12V DC to the RED wire on plug 9 12V DC to the BLACK wire on plug 5 before installing it and see if the intended viewing angle is ye A acceptable Optimum Trip Hours Reset Hours Be viewing The Hours meter accurately tracks the number of hours your engine has run from ye the last time it was reset It only accumulates time when the engine is actually _ angle running If the Fuel Log is turned on and the engine is not running no time is added to the trip or reset hour display Flow Consumption GPH LPH The GPH LPH window shows the rate at which your engine is consuming fuel The GPH LPH and Reset Gallons Liters reading and Cumulative Gallons Liters readings will all change if the Red flow Calibration switch on the back of th
30. protects the can Use caution as over tightening will buckle or collapse the can White Replacement K Series Pulsation Damper Can P N 233 041 00 4 23 2003 7000 145 01 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 Hi Cap Pulsation Damper Can Replacement Rubber Sealing Rubber Sealing Washer Washer Forward Sensor 1 Remove the old Pulsation Damper can A Claw type oil filter wrench or pipe wrench may be needed 2 Put a coating of grease on both sides of the new Pulsation Dampers rubber sealing washer 3 Clean the Aluminum base and put a coating of grease on the seal s mating surface 4 Place the new Pulsation Damper can on its Aluminum base Turn until Finger tight 5 Using a band type oil filter wrench carefully rotate the can until tight approximately of a turn past finger tight e Position a strip of rubber Bicycle tube or rubber glove between the wrench and can Rubber increases friction and protects the can Use caution as over tightening will buckle or collapse the can White Replacement K Series Pulsation Damper Can P N 233 041 00 4 23 2003 7000 145 01 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
31. rs The Instrument remains in diagnostic mode until power is secured 2 With engine s running and the Instrument in diagnostic mode the GPH window shows raw non calibrated fuel flow through the Forward Sensor The Reset or Trip Gallons window shows raw fuel flow through the Return Sensor Calibration adjustments do not affect diagnostic mode readings 12 8 2004 7000 336 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 5 Example 60 a 59 3 GPH GALLONS Using the chart below record GPH and Gallon readings at IDLE 1000 RPM 1500 RPM and 1800 RPM Circle S or F to indicate steady or fluctuating readings GPH GALLONS S F IDLE S F S F 1000 S F S F 1500 S F S F 1800 S F With engine s idling record Cumulative Gallons readings at these upper BLACK switch positions Upper BLACK switch position 0 Differential flow 2 Feed K Factor 1 Temperature C 3 Return K Factor Temp Comp units only Measure fuel line length between system components and draw a system sketch Turn Instrument power OFF then ON to return system to normal operation Do not touch the reset switch with all 8s showing I SUPPLY VOLTAGE and GROUND TEST 1 Measure voltage between the RED power wire on pin 9 and the BLACK Instrument ground wire on pin S It should read approximately
32. the Port MFI s Upper Black Switch Counter Clockwise to position F reducing its 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 MFI s Upper Black Switch Clockwise to position 2 increasing its totalizer reading by 4 This completes system calibration The Instrument 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 Changing from mostly cruising to mostly trolling may affect totalizer accuracy If this occurs re calibration may be necessary 12 8 2004 7000 335 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 TROUBLESHOOTING All 75 76 85 86 95 96 Series Diesel Fuel Log BEFORE CALLING FOR ASSISTANCE COMPLETE THESE TROUBLESHOOTING CHECKS AND RECORD YOUR FINDINGS TECHNICAL SUPPORT REQUIRES THIS INFORMATION BEFORE A RETU
33. the Upper 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 12 8 2004 FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 7000 335 00 Tel 206 524 6625 Fax 206 523 4961 email service floscan com http www floscan com GENERATORS and Single Engine Vessels Please refer to Example 1 Port system is 0 2 4 F 0 1 a Example 1 Twin engine vessel with two dedicated fuel tanks 6 E N e D After steaming and returning to refuel The Port tank took 89 7 gallons 339 5 liters Its E C 4 8 totalizer reads 94 2 gallons 356 5 liters The Starboard tank took 93 2 gallons 352 8 liters and its totalizer reads 87 9 gallons 332 7 liters 10 B 5 10 e Using the formula calculate the percentage difference between the Totalizer reading and 2 9 g 7 20 actual fuel consumption ae sete Difference in Gallons Liters x 100 16 s Totalizer Reading Upper BLACK switch Port System Calibration e Find the difference between the 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 gallo
34. to the BLACK sensor wires Connect this junction to the battery s negative terminal Slide heat shrink tubing or the ground buss Connect all other wires leaving the Red power wires for last to prevent over one Wires 3 n s i E E Insert wire ends into butt splice short circuits during installation Crimp butt splice Splicing Splice or join individual wires per the diagram Slide heat shrink tubing over the splices to prevent shorts Do not seal splices until the installation is finished and has been Slide heat shrink tubing tested over butt splice Apply heat HEAT An adequate number of crimp on connectors and heat shrink tubing are included with system The heat shrink is a special type that will bond to wire insulation and make a watertight connection See diagram for proper tubing application Crimp on connectors are sized for 18 or 20 gauge stranded wire FINAL ACTIONS Check Electrical Installation Test all connections Support and secure all dangling wires Start engine and calibrate system 12 8 2004 7000 33 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 12 8 2004 7000 33 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 WIRING DI
35. tors amp Marine Propulsion Engines e Determine the optimum fuel tank configuration for your vessel If possible generators and 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 Part III Final Calibration e Fill or top off the fuel tank s e Reset the totalizer so that the Reset or Trip GALLONS LITERS window reading is zero e Operate the generator under load or take the vessel for a cruise Once underway steam at your optimal cruising RPM Consume a minimum of 20 to 30 gallons 75 to 115 liters of fuel per engine Higher consumption gives better accuracy Calibration is most accurate when done at a single cruising RPM After consuming some fuel return to the fuel dock and refill the fuel tank s to the same point Compare the Reset or Trip Gallons Liters window reading to the fuel pump reading Calculate the percentage difference between the fuel pump amp Gallons Liters readings Refer to Examples I amp II on page 2 Determine if the totalizer is reading High or LOW Rotate the Upper Black Switch until the GALLONS Liters window matches the fuel pump reading Starting at 0 rotating
36. wire up and down the bolt threads This generates a pulse which should make numbers in the GPH window start counting up The totalizer should also eventually start counting Faster movements give higher readings Run the BROWN wire up and down the bolt threads This generates a pulse which should make numbers in the GPH window start counting up The totalizer should also eventually start counting Faster movements give higher readings VI CONTINUITY TEST 1 Continuity testing requires access to the back of the Instrument and an Ohmmeter It verifies that wires are not broken shorted to ground another wire or to power Before starting secure all power and disconnect the Molex connector from the Instrument This test checks the WHITE BROWN YELLOW VIOLET and BLACK wires 2 Disconnect the WHITE and BLACK wire harness conductors from the WHITE and BLACK Port Sensor wires Connect a jumper from the WHITE wiring harness conductor to a known good ground At the Molex connector connect an Ohmmeter lead to its WHITE wire Connect the other Ohmmeter lead to a known good ground The Ohmmeter should read approximately 0 1 to 3 Q Ohm Reading 12 8 2004 7000 336 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 3 Disconnect the BROWN and BLACK wire harness conductors from the WHITE and BLACK Starboard Sensor wires Connect a
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