Installation / Troubleshooting Manual
Contents
1. ET Flow Sensop ENGINE FILTER l N J 12 Minimum Distance A 1 Fabric Braid Flexible Fuel Line Preferred Outboard Motor Diaphragm Fuel Pump to 2 Mini Primi mami AMT iur FUEL an E v 7 ENGINE FILTER Se 4 12 Minimum Distance A 1 Fabric Braid Flexible Fuel Line Preferred Engine Driven Diaphragm Fuel Pump Carbureted Inboards and I O s Pulsation Damper 1 to 2 Minimum Ji N 20A 20B 231 ertical Rise L FUEL Flow Sensor v i ENGINE FILTER l FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 81 12 Minimum Distance A 1 Fabric Braid Flexible Fuel Line Preferred 7000 036 00J Tel 206 524 6625 Fax 206 523 4961 email service floscan com http www floscan com FUEL TANK High Flow Gasoline Fuel Flow Schematics Vane Gear Gear Rotor FUEL TANK nes ENGINE Diaphragm Fuel Pump Carbureted Inboards and I O s 5 19 2004 FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 Electric Fuel Pump EFI amp Carburetor Engi 1 to 2 Minimum k X 233 Vertical Rise j i FUEL Flow Sensor gt FILTER OESE N l B 5 12 Minimum Distance A 1 Fabric Braid Flexible Fuel Line Preferred Engine Driven Pulsation Damper 1 to 2 Minimum 4 gt 233 Vertical Rise E FUEL Flow Se2. of the reading in step 1 VDC 5 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 NOTE This may not be seen with a digital voltmeter 6 The Sensor may be defective if voltage readings in steps 3 amp 5 remain constant while the engine is stopping 7 Ontwin engine systems try swapping the Brown amp White signal wires Observe the Instrument and see if the problem shifts sides or remains on the same side With this guide in hand contact FloScan Technical Support III BACKLIGHTING 1 Referring to the wiring diagram check back lighting bulb and Instrument illumination circuit IV CHECK 12 VDC and GROUND 1 Turn Instrument power ON and go to the Instruments backside 2 Measure between the RED Power wire and the BLACK Instrument ground wire VDC This reading should be approximately 12 VDC but not lower than 10 VDC 3 If12 VDC is not present measure between the RED power wire and a known good ground in the instrument panel If you measure 12 to 14 VDC between the Red wire and ground you may have VDC an instrument ground problem 4 If12 to 14 VDC is not present in steps 2 or 3 check wiring switches fuse and the 12 VDC power source V CONTINUITY TESTING 1 Continuity testing requires access to the back of the Instrument and an Ohmmeter It verifies that wires are not broken shorted to
3. defective With the BLUE wire floating Disconnected on single engine systems or the Port Starboard select switch set to Port on twin engine systems the pointer should read approximately 5 GPH models 4 5 20 LPH models 10 GPH models 9 40 LPH models 20 GPH models 80 LPH models 32 GPH models 160 LPH models 50 GPH models 45 500 LPH models 100 GPH models 90 With the BLUE wire connected to the Instruments BLACK wire on single engine systems or the Port Starboard select switch set to Starboard on twin engine systems the pointer should read approximately 20 LPH models 10 GPH models 0 5 40 LPH models 80 LPH models 160 LPH models 500 LPH models 20 yb NOTE If readings are significantly Higher or Lower the Instrument may be defective 8 9 10 11 12 Turn switches 1 2 3 4 5 8 and 9 OFF leave 6 and 7 ON Disconnect the WHITE and BROWN wires at the Instrument Connect a course thread 13 or similar non plated bolt to the BLACK wire With the BLUE wire floating Disconnected or Port Starboard select switch set to Port lightly run the WHITE wire up and down the bolt threads This generates a pulse and should lift the needle off zero The totalizer should also eventually start counting Faster movements give higher readings With the BLUE wire connected to ground or the Port Starboard select switch set to Starboard lightly run th
4. ground another wire or to power Before starting secure all power 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 back of the Instrument connect an Ohmmeter lead to its WHITE wire Connect the other Ohmmeter lead Ohm Reading to a known good ground The Ohmmeter should read approximately 0 1 to 3 Q 3 Disconnect the BROWN and BLACK wire harness conductors from the WHITE and BLACK Starboard Sensor wires Connect a jumper from the BROWN wiring harness conductor to a known good ground At the back of the Ohm Reading Instrument 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 VI PULSATION PROBLEMS A stiff anti siphon valve sticking carburetor float 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 parts or re plumb dampers according to the Fuel Flow Schematic Instructions 5 19 2004 4001 102 00H FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 email service g floscan com http www floscan com VII FINDING FUEL SYSTEM VAC
5. have a Carburetor Inboard or I O engine Pulsation Dampers can be purchased factory direct Standard Flow Dampers are 30 00 each and High Flow Dampers are 45 each Damper orders ship via UPS 3 day on purchase date Prices include shipping and handling To order please contact FloScan Sales or Service 206 524 6625 X 306 316 309 or 302 E mail sales floscan com or service floscan com The following engine types DO NOT require Pulsation Dampers Outboard Gasoline Engines Including Ficht Optimax 2 amp 4 Cycle Closed Loop EFI Gasoline Outboard Inboard and I O Engines Open Return EFI Gasoline Inboard and I O Engines e Sensors are marked with orientation and fuel flow arrows They must be installed with these arrows pointing in the right direction Standard Flow Pulsation Damper 20A 20B 231 SENSOR if Outlet Inlet Fuel Flow Direction 5 19 2004 7000 036 00J 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 High Flow Pulsation Damper 233C SENSOR Inlet c 2 Outlet inlet ie A Q TU e Install sensor s with orientation arrows pointing UP Fuel must enter through the port marked IN or with an inward pointing gt fuel flow arrow and exit through the port marked OUT or with an outward
6. 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 5 21 2004 4001 100 001 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 Tachometer Wiring Information applies only to MFI amp TwinScan Instrument Tachometers Tachometer signal wires on MFI amp TwinScan Tachometers should be shielded For proper tachometer operation on gasoline EFI engines especially outboards the engine Ground wire must be physically connected to the MFI or TwinScan instrument ground wire Note FloScan recommends using dedicated 18 AWG shielded cable for tachometer signal wire connections Always Ground wire shields or the shield drain wire in the engine room by connecting to the bonding system or engine block MULTI FUNCTION amp TWINSCAN INSTRUMENT TACHOMETERS for CARBURETOR amp CLOSED LOOP EFI GASOLINE ENGINES with POINTS or STANDARD ELECTRONIC IGNITIONS Inboard amp I O Engines Connect the YELLOW wire from pin 8 to the distributor coil s negative terminal On twin engine systems the Yellow wire from pin 8 connects to the port engine the VIOLET wire from pin 16 to starboard Outboard Engines Outboard tachometers are connected to either the engine alternator or tachometer signal wire Conn
7. 24 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 Mechanical amp Electrical Installation Planning Saves Time 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 mechanical installation instructions then survey your vessel Determine where the Sensor s Pulsation Damper s 1f used Switches and Instruments 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 and type of fittings needed for each plumbing connection JIC SAE NPT NPTF or Hose Barb FloScan Gasoline Hi Flo system components have 2 Female NPT ports FloScan Gasoline Lo Flo system components have 4 Female NPT ports Review the electrical installation instructions Open and survey your vessels wire ways and run 3 conductor cables from each sensor to the instrument Tachometers require 1 or 2 additional conductors If there s an existing tachometer its signal wires can be used II Mechanical Installation Install or mount the Sensor s Pulsation Damper s If required Instruments and Switches Reset MPG Port Starb
8. I SPST or Momentary ON 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 ox the next wire refer to diagram Connect ground wires first BLACK instrument ground m wire 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 overone wire 7 Ff 7 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
9. Installation Troubleshooting Manual Marine AccuTroll amp CruiseMaster Gasoline Inboard amp I O to 1000 HP All Outboards This manual part 4001 010 00 applies to the following product part numbers 1 5232 231 1 2 5232 231 1M 3 53080 231 1 4 53080 231 2 5 53100 231 1 6 53100 33C 1 7 53100 33C11 8 5320 20B 1 9 5320 20B 2 10 5332 20B 1 11 5332 231 1 12 5332 231 2 13 5350 231 11 14 54020 20A 1 15 54020 20A 2 16 54040 20A 1 17 54040 20A 2 18 5405 20A 1 19 5405 20A 2 20 54080 20A 1 21 54080 20A 2 22 5410 20A 1 23 5410 20A 2 24 5420 20A 1 25 5420 20A 2 26 55040 20B 1 27 55040 231 1 28 55040 231 2 29 55080 20B 1 30 55080 20B 2 31 55080 231 1 32 55080 231 2 33 5510 20B 1 34 5510 20B 2 35 5510 231 1 36 55100 231 1 37 55100 231 2 38 55160 231 1 39 55160 231 2 40 55160 23121 41 55161 231 1 42 55161 231 2 5 20 2004 4001 391 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 43 5520 20B 1 44 5520 20B 2 45 5520 231 1 46 5520 231 2 47 5532 20B 1 48 5532 20B 2 49 5532 231 1 50 5532 231 1M 51 5532 2312 52 5532 231 2M 53 5532 231 11 54 5532 231 21 55 5550 231 1 56 5550 231 2 57 5550 231 11 58 5550 231 21 59 56100 33C 1 60 56100 33C 2 61 56100 33C11 62 56100 33C21 3 29 2004 4001 391 00 FloScan Instrument Company Inc Tel 206 5
10. N FLOW SENSOR FITTINGS Over tightening may crack the sensor s body Cracks cause leaks and fuel leaks sometimes cause catastrophic explosions and fire Torque pipe thread fittings to a maximum of 15 ft LB 180 inch LB or two full turns beyond hand tight Whichever comes first Use a fuel proof pipe thread sealant be used when installing fittings into the flow sensors LockTite PST Rector Seal Jomar etc INSTRUMENT INSTALLATION e Before cutting holes in your Instrument Panel verify that the instrument will be installed approximately 12 away from the compass and in a shaded location out of direct sunlight Mounting it within 12 of a compass may interfere with compass operation Direct sunlight may cause the LCD display to temporarily turn black due to heat Instrument Series Cutout Size Instrument Depth 5400 0 5500 0 3 1 16 3 Console Panel Thickness 7000 0 8000 0 9000 0 TwinScan 3 3 8 2 Console Panel Thickness Table 1 5 19 2004 7000 036 00J 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 FUEL TANK Standard Flow Gasoline System Schematics Vane Gear Gear Rotor Electric Fuel Pump EFI amp Carburetor Engines 1 to 2 Minimum 20A 20B 231 Vertical Rise FUEL TANK FUEL TANK 5 19 2004
11. UUM 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 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 5 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 c
12. ation 10 What do I do if I have a problem Most problems are related to improper installation Step 1 is to review the installation and verify that system components are installed and wired correctly Next follow the troubleshooting guide and record your results This will most likely lead you to the problem If not please call FloScan Technical Support at 800 522 3610 with your test findings If you did not complete the troubleshooting steps you will be asked to do so before calling back 5 19 2004 4001 213 00C FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 email service g floscan com http www floscan com TROUBLESHOOTING Series 5400 0 5500 0 56100 AccuTroll amp CruiseMaster GPH LPH 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 Before starting record the Instrument MODEL and all Switch settings Switch Settings Blank LCD Display No Back Lighting Wiring bulb failure Section III Low Totalizer Reading more than 10 Calibration sheet Sensor orientation failure Installation Sheet High Totalizer Readings more than 10 Incorrect defective sensor Fluctuating GPH readings High sensor readings Wrong switch settings Calibra
13. e BROWN wire up and down the threaded bolt as described above This generates a pulse and should lift the needle off zero The totalizer should also eventually start counting Faster movements give higher readings If the Instrument passes steps 10 amp 11 returns switches 1 9 to their original position and proceed with Part II If not contact FloScan Technical Support NOTE Occasionally a good Instrument will fail the Bolt scratch test II TEST FLOW SENSOR S 1 With your voltmeter set to a DC scale greater than 14 volts measure between the RED 12VDC and BLACK Instrument ground wires With engine idling measure and record the voltage reading VDC 2 Move the voltmeters negative lead to the WHITE Signal wire With engine idling measure and record the voltage reading It should be approximately 5 to 7 VDC about of the reading in step 1 VDC 3 Stop the engine while observing the voltmeter 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 a digital voltmeter 5 19 2004 4001 102 00H FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 email service g floscan com http www floscan com 4 Move the voltmeters negative lead to the BROWN Signal wire With engine idling measure and record the voltage reading It should be approximately 5 to 7 VDC about
14. e 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 V System Start Up Prime the fuel system and check for leaks 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 5 25 2004 4001 386 01D FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 email service g floscan com http www floscan com VI Calibration When system is running properly refer to the calibration instructions and calibrate your system 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 300g m 24hrs Not Required Table I Installation Do s amp Don ts Do Don t Use a Fuel Proof Pipe Thread Sealant when assembling fittings into fuel system components Locktite PST Leak Lock or equivalent Never use Teflon Tape Use thin wall low pressure full flow type NPT or NPTF hose barb fittings Don t use Push Lok or Barb Tite fitti
15. e flow sensor s are mounted YES There is only one way to install the sensors Flow sensor s must be installed with the fuel flow and orientation arrows pointed in the right direction for the system to work properly 7 Will the flow sensor cause fuel starvation No the flow sensors will not cause fuel starvation Anything put into a fuel line does however have a certain pressure drop across it Everything in the fuel line combines to form the systems total pressure drop If this is more than the fuel pump can tolerate you must find a way to reduce the total pressure drop or fuel starvation will occur at higher engine RPM 8 Will the flow sensor shut off fuel to the engine if it stops working FloScan flow sensors are of a FAIL SAFE design A failure will not restrict fuel flow to the engine nor will the sensors pressure drop increase even if the rotor stops turning 5 19 2004 4001 213 00C FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 email service g floscan com http www floscan com 9 Why isn t my totalizer as accurate as it could be The major causes of inaccurate totalizer readings are Air bubbles in the fuel line caused by vacuum leaks around fuel filter gaskets and or improperly sealed plumbing joints Incorrect flow sensor installation Installing sensor within 12 14 of the fuel pump Faulty wiring Improper sensor selection and instrument calibr
16. ect the YELLOW wire from pin 8 to the engine alternator or tachometer signal wire On twin engine systems the Yellow wire from pin 8 connects to the port engine the VIOLET wire from pin 16 to starboard MULTI FUNCTION amp TWINSCAN INSTRUMENT TACHOMETERS for CLOSED LOOP EFI GASOLINE ENGINES with CPU IGNITION SYSTEMS Inboard I O amp Outboard Engines Connect the YELLOW wire from pin 8 to the engines tachometer signal wire On twin engine systems the Yellow wire from pin 8 connects to the port engine the VIOLET wire from pin 16 to starboard Outboard Engines Connect the YELLOW wire from pin 8 to the engines tachometer signal wire On twin engine systems the Yellow wire from pin 8 connects to the port engine the VIOLET wire from pin 16 to starboard MULTI FUNCTION INSTRUMENT TACHOMETERS for OPEN RETURN EFI GASOLINE ENGINES with CPU IGNITION SYSTEMS Inboard amp I O Engines Connect the YELLOW wire pin 8 to the engines tachometer signal wire Connect the VIOLET wire pin 16 to ground MULTI FUNCITON INSTRUMENT TACHOMETERS DIESEL ENGINES e Keep existing tachometer Connect the YELLOW and VIOLET wires to the existing tachometer signal wires If one lead is grounded at the pickup or alternator connect the YELLOW wire to the tachometer signal wire Connect the VIOLET wire to a ground buss e Replace existing tachometer Connect the YELLOW and VIOLET wires to the existing magnetic pickup or signal ge
17. ed percentage total of switches 1 296 and 2 4 is 6 Turn switches 1 and 2 and 4 ON Switch 4 remains OFF if the totalizer reads higher than the actual fuel used and is turned ON if the totalizer reading is less than the fuel used Switch position results when turned on Tete ID 4 OFF Totalizer reading higher ON Totalizer reading lower OFF Normal meter damping 1 2 3 4 5 6 7 8 9 Table I Sensor Switches Example Totalizer reading 696 higher with sensor 8 9 F F OFF O Instruments programmed for the 20A sensor cannot be used with 20B 231 or 233C sensors NOTE 1 Adjusting instrument calibration affects both Totalizer and GPH readings 2 Drastically changing operating habits from mostly cruising to mostly trolling may slightly effect totalizer accuracy 3 On custom calibration instruments at least one of the switches from 1 5 must be OFF If switches 1 9 are all turned ON the instrument automatically goes into diagnostic mode 5 19 2004 4001 009 05I FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 email service g floscan com http www floscan com COMMON ACCUTROLL amp CRUISEMASTER SYSTEM QUESTIONS 1 How is the 5400 0 5500 0 56100 twin engine system wired so that either engine will power the meter Use two diodes 1N4005 and wire as per the sketch below gt PORT flow sensor RED wire t
18. lems persist contact FloScan Technical Support 5 19 2004 4001 102 00H FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 email service g floscan com http www floscan com
19. nerator If one lead is grounded at the pickup or alternator connect the YELLOW wire to the existing signal wire terminal at the tachometer and connect the VIOLET wire to a ground buss e Install as a new tachometer On engine alternator installations connect the YELLOW wire to the tachometer output terminal usually marked tach or sig and connect the VIOLET wire to a ground buss For mechanically driven A C signal generators and magnetic pickups connect the YELLOW wire to one terminal and the VIOLET wire to the other TWINSCAN INSTRUMENT TACHOMETERS DIESEL ENGINES e Connect the YELLOW wire to one terminal the Port tachometer sender AC signal generator Magnetic pickup or the engines alternators tach or sig terminal Connect the VIOLET wire to the Starboard sender The tachometer senders second terminal must be grounded FINAL ACTIONS Check Electrical Installation Test all connections Support and secure all dangling wires Start engine and calibrate system 5 21 2004 4001 100 001 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 DIAGRAM Series 5400 0 5500 0 56100 AccuTroll amp CruiseMaster GPH Instrument with LCD Totalizer WIRING LEGEND WIRE COLOR FUNCTION Ignition 12VDC GREEN Totalizer Memory Constant 12VDC Instrument Ground Single Sensor Installation Totalize
20. ngines Inboard I O Outboard FLOW SENSOR INSTALLATION Flow Sensors must be placed in a horizontal section of fuel line at a low point in the fuel system Fuel should travel Up hill when exiting the sensor Its outlet should be at least 1 or 2 inches lower than the fuel pump inlet priming bulb or pulsation damper if used Pulsation Dampers and Priming Bulbs must also be mounted horizontally Installing sensor s 12 upstream of the fuel pump priming bulb or pulsation damper improves system accuracy Install sensors in a protected location away from water spray Model 20A 20B 231 amp 233C gasoline sensors must be installed downstream of a fuel filter or water separator On vessels not equipped with off engine filters we suggest installing a Flow Ezy model ILA 02 filter with 238 micron screen directly to the 20A 20B or 231 Low Flow Sensors inlet Use model 4ILA 04 with 595 micron screens with High Flow 233C Sensors Flow Ezy can be reached at 800 237 1165 Caution NEVER install sensor s downstream of an engine mounted fuel filter NEVER use Teflon Tape when installing sensors Teflon Tape can jam a sensor s rotor Instead always use a fuel proof pipe thread sealant For proper system operation Carburetor Inboard amp I O Engines having diaphragm fuel pumps require Gasoline Pulsation Dampers FloScan Systems are not shipped with Pulsation Dampers as carburetor Inboard and I O engines are no longer in production If you
21. ngs 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 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 On Instruments with a GPS interface connect FloScan s Data to the GPS signal output Connect Data to the GPS signal ground Do not connect FloScan s Data to the GPS Data Always use non illuminated switches for Totalizer Reset Port Starboard Select Hours Synch and GPH MPG Never use illuminated or back lit switches 5 25 2004 FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 4001 386 01D Tel 206 524 6625 Fax 206 523 4961 email service floscan com http www floscan com Mechanical Installation Series 5400 0 5500 0 56100 7000 0 8000 0 9000 0 TwinScan GPH Instrument Gasoline E
22. nsor FILTER iit 3 7 12 Minimum Distance A 1 Fabric Braid Flexible Fuel Line Preferred Tel 206 524 6625 ENGINE 7000 036 00J Fax 206 523 4961 email service floscan com http www floscan com ELECTRICAL Series 5400 0 5500 0 56100 5800 0 6500 0 6600 0 AccuTroll amp CruiseMaster All Multi Function Instruments amp TwinScan 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 The double wiring harness for twin engine Pulse NMEA Diesel installations 1s included in all 97 9800 0 kits 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 Totalizer Reset Port Starboard Select Engine Hours Synchronizer and GPH MPG switches are not included with kit To determine which switch types are required for your system refer to the table below All instruments except TwinScan Tachometers require a totalizer reset switch SYSTEM TOTALIZER RESET PORT STBD HOURS GPH MPG P OTT Teniegeetpsen sync Med synen SPST NA SPST NA NA Not Applicable 7000 8000 Gasoline MF
23. o 1N4005 lt PORT key switch Cruisemast ruisemaster f 45 lt STBD key switch STBD flow sensor 2 What type of switch is used for the PORT STBD select switch A single pole single throw SPST On Off switch When the switch is turned OFF the needle shows the Port engine consumption When turned on the needle shows Starboard engine consumption 3 How do I reset the totalizer Totalizer memory is powered through the Green wire If Green wire power is interrupted for 10 15 seconds the totalizer resets to zero Memory is retained as long as 9 15 VDC is maintained between the GREEN and BLACK meter wires 4 Will Pegging the GPH meter needle hurt the instrument Will the totalizer record accurately with the needle pegged When Pegged the needle rests harmlessly against a mechanical stop while the totalizer continues to accurately record consumption 5 What causes needle fluctuations Fluctuating readings are usually caused by one of the following Air bubbles passing through the flow sensor Fuel pump pulsations Do not install the flow sensor closer than 12 to the fuel pump A Sticky or misadjusted carburetor float valve A 4 sided square float valve installing and properly adjusting a three 3 sided triangular float valve corrects this problem A sticking or chattering anti siphon valve NOTE Sticking float and anti siphon valves do not effect system accuracy 6 Does it make any difference which way th
24. o power the Port Stbd side independently of each other using it s own ignition switch Option 2 is used to power the FloScan syste using one ignition switch BLACK BLACK 5 20 2004 FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 Tel 206 524 6625 email service floscan com STARBOARD Flow Sensor 4001 167 00G Fax 206 523 4961 http www floscan com CALIBRATION Series 5400 0 5500 0 56100 AccuTroll amp CruiseMaster There are nine Dip switches on the back of your 5400 0 5500 0 56100 Series Instrument Switches 1 4 are used for instrument calibration Refer to Table I Switches 6 9 select the flow sensor required by your engine Refer to Table II Switch 5 is used to dampen the instrument needle in heavy seas When turned on switch 5 slows the needles response rate Totalizer Calibration Top off the fuel tank s and reset the totalizer to 0 Operate the boat the way that you normally would consuming at least 20 gallons of fuel Return to the fuel dock and top off your fuel tank s Compare the totalizer reading to the fuel pump reading Calculate the percentage difference using the following formula mp EE Difference in Gallons 1 Totalizer Reading i 6 Tum ON the combination of switches 1 2 and or 3 which equal that difference Example You determine the totalizer reading is 6 5 lower than what actually was actually used The combin
25. oard Synch III Plumbing Mount sensor s 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 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 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 1 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 and Instrument s Cables must be adequately supported at reasonable distances approximately 2 4 feet Wir
26. ontinually increases or 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 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 VIII FUEL FILTERS A dirty 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 or coarser filter IX 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 X 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 Instrument and Sensor testing If prob
27. pointing gt arrow e The sensor must be installed horizontally at a low point in the fuel system When fuel exits the sensor it must travel up hill slightly One or two inches of vertical rise is adequate more is ok e The sensor must be installed downstream of and protected by a screen filter or water separator Sensors are tolerant of fine debris A coarse screen up to 800 microns or water separator is all that is required e tis recommended that the sensor be installed between the fuel filter and fuel pump inlet There should be at least twelve inches of fuel hose more is ok between the sensor and fuel pump inlet e If required the pulsation damper must be installed horizontally with its orientation arrow pointing up refer to fuel flow schematics below e Minimize the number of 90 elbows and pipe fittings Excessive use may create a high vacuum fuel restricting pressure drop across the fuel system Whenever possible use a large radius hose bend instead of elbows Refer to the engine owner s manual for maximum fuel pump vacuum A vacuum gauge can be used to confirm that the system is within limits e If swivel fittings are used JIC or SAE their mating surfaces should be sealed with AP 50 Copper Conical Sealing Washers or Flaretite Fitting Seals Seals and sealing washers can be purchased through Fittings Inc in Seattle WA 206 767 4670 1 800 552 0632 or a local hydraulic supply house CAUTION DO NOT OVER TIGHTE
28. r Memory Constantt 12 VDC Source Negligible battery draw 1 2 amp fuse Totalizer Reset Switch momentary OFF Do not use Back lit or Illuminated switches BLUE not connected diagnostic wire BROWN _ not connected in single sensor installations 1 2 amp fuse To Ignition Switch key ON 7 12VDC R Battery buss D To Illumination Circuit 12VDC for twin installations please see reverse side 5 20 2004 4001 167 00G 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 Twin Engine Installations 1 2 amp fuse GREEN O i O N Totalizer C3 Reset Switch momentary OFF Td v Do not use Back lit or z Illuminated switches m Totalizer Memo 3 e Battery buss on Ty 2 MI E mem Constant x E z 12 VDC To 3 B Source n m Negligible battery draw Illumination Circuit A 12VDC ON BLUE STARBOARD CABLE Do not use Back lit o1 Illuminated switches Option 1 Port Engine Starboard Engine key switch 1 2 amp fuse 2 places key switch To Port sensor To Starboard sensor IN4005 DIODES Option 2 To PORT or STARBOARD ignition switch key ON 12VDC 1 2 amp fuse To Port sensor To Instrument RED To Starboard sensor See option 1 and 2 diagram for instructions Option is used t
29. tion sheet Sensor orientation Section VII I INSTRUMENT HEAD DIAGNOSTIC TEST 1 Referring to the wiring diagram verify that Instrument amp Sensor s are wired correctly 2 Verify that all wiring connections are tight and not corroded Check continuity with an ohmmeter 3 With power switched ON measure voltage between the RED and BLACK wires Take readings on the Instrument side of the butt splice connections VDC The voltage reading should be between 12 and 14 5 VDC Proceed to step 4 if it is 1f not a Check for voltage between the RED wire and another ground point b Ifvoltage is present trace along the BLACK wire until its open connection is found c Ifno voltage is present trace the RED wire until its open connection is found 4 With switched power ON slide Dip switches 1 9 to the ON or UP position This places the Instrument into diagnostic mode NOTE If the LCD display is blank verify that the totalizer reset switch Connected between the GREEN wire and 12 volts is in the ON position Verify that 12 VDC is present between both switch terminals and the Black wire Next check the Green wire fuse 5 19 2004 4001 102 00H FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 email service g floscan com http www floscan com In Diagnostic Mode the totalizer will count at 1 gallon or 1 liter per second If it does not the Instrument is
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