Fuel Level FL1 ® - Flybox Innovative Avionics
Contents
1. FLYEOX gm be FUEL LEVEL LEFT RIGHT pe 20 04 ne FLYBOX gt 3 Fuel Level FL1 Revision 2 0 28 11 2014 For firmware version 1 2 Page intentionally left blank SECTIONS Introduction F LYE OX Thank you for purchasing a Flybox product We hope it fully satisfy you and makes your flights pleasant and secure Developing FL1 our intent was to create a compact and lightweight fuel levels indicator easy to install and use SYMBOLS USED IN THE MANUAL A NOTE Used to highlight important informations A CAUTION Used to vvarn the user and indicate a potentially hazardous situation or improper use of the product A WARNING Used to indicate a dangerous situation that can cause personal injury or death if the instruction is disregarded FL1 User s manual Rev 2 0 F LYEOXS Important notices amp warnings NOTE Keep this manual in the aircraft This document must accompany the instrument in the event of change of ownership A NOTE This device is intended for installation onto non type certified aircraft only because it has no aviation certifications Refer to your local aviation authorities to check if this device may be installed in your aircraft A CAUTION Read entirely this manual before installing the instrument in your aircraft and follow the installation and operating instructions described here A CAUTION The pilot must understand the operation of this instrument prio2. LYEOXS INDEX SECTION 1 Mechanical installation 1 1 Mechanical installation 1 2 Fuel level sensors installation SECTION 2 Electrical installation 2 1 Electrical installation o o e SECTION 3 Operating instructions 3 1 Minimum settings before first use 3 2 Panel indicators amp commands 3 3 Use of the instrument eese SECTION 4 Instrument settings 4 1 Low fuel warnings menu esses 42 Sep MENU ss aoa Dones SE UE m s 4 3 Fuel level sensors calibration Calibration tables sese ete ner nena n ten 4 4 Fuel level sensors checking SECTION 5 Technical specifications Warranty sali FL1 User s manual Rev 2 0 Index Mechanical installation F LYE OX SECTION 1 1 1 MECHANICAL INSTALLATION The FL1 fits in a standard 2 4 57 mm panel cutout it s recommended to choose a position that permits optimal display visibility It s furnished with four M4 screws to install it to the panel if you use other screws consider that the maximum thread length inside the FL1 panel is 15mm see following picture 8 FL1 User s manual Rev 2 0 F LYEOX Mechanical installation All dimensions are in millimeters FL1 User s manual 9
3. the Calib step is set to 5 and the tank choosed for calibration is the LEFT D Left t calibration Step 01 empty D 0263 mV 00 DONE END CAL G On this screen the following indications are displayed e The tank currently calibrating 1 e The calibration step that need to be executed 2 e The electrical output ot the fuel level sensor 3 e DONE select it and press the knob to go to the next calibration step 4 e The fuel quantity already added to the tank at this point of calibration 5 e END CAL select it and press the knob to end the calibration 6 FL1 User s manual Rev 2 0 F LYEOX Fuel level sensors calibration NOTE Before executing the following procedure prepare the aircraft with a normal angle of attack and mantain it for all the calibration duration Use the tables at the bottom of this chapter to annotate the value of each calibration steps e Step 1 Drain the tank such that only the fuel unusable remain in the tank e Step 2 Wait until the indication 3 is stable and click on DONE e Step 3 Add to the tank the indicated fuel quantity it s the same quantity choosed with the Calib step parameter on this example it s required to add 5 liters of fuel Left t calibration Step 02 Add 5 L 0484 mV Tk OOL DONE END CAL NOTE It s important that the fuel quantity is exactly measured to reach the maximum
4. NO to go back to previous calibration step FL1 User s manual 29 Rev 2 0 Calibration tables F LYE OX CALIBRATION TABLE FOR LEFT TANK STEP mV of value 3 STEP mV of value 3 1 26 2 27 3 28 4 29 5 30 6 31 7 32 8 33 9 34 10 35 11 36 12 37 13 38 14 39 15 40 16 41 17 42 18 43 19 44 20 45 21 46 22 47 23 48 24 49 25 50 30 FL1 User s manual Rev 2 0 FLYEOXS Calibration tables CALIBRATION TABLE FOR RIGHT TANK STEP mV of value 3 STEP mV of value 3 1 26 2 27 3 28 4 29 5 30 6 31 7 32 8 33 9 34 10 35 11 36 12 37 13 38 14 39 15 40 16 41 17 42 18 43 19 44 20 45 21 46 22 47 23 48 24 49 25 50 FL1 User s manual Rev 2 0 31 Calibration tables F LYE OX CALIBRATION TABLE FOR MAIN TANK STEP mV of value 3 STEP mV of value 3 1 26 2 27 3 28 4 29 5 30 6 31 7 32 8 33 9 34 10 35 11 36 12 37 13 38 14 39 15 40 16 41 17 42 18 43 19
5. Rev 2 0 Fuel level sensors installation F LYE OX 1 2 FUEL LEVEL SENSORS INSTALLATION FL1 has 4 fuel level inputs that can be connected to both resistive sensors with max resistance of 300 ohm and capacitive sensors with output voltage from 0 5 Volt Resistive sensors can be of two types both supported by FL1 resistive sensors that increase resistance as you add fuel and resistive sensors that decrease resistance as you add fuel If you don t know what type of sensors are installed please see chapter 4 4 Fuel level sensors checkings It s also possible to install a mixed type of sensors i e 2 resistive 2 capacitive A All fuel level sensors connected to FL1 must not be connected to any other instrument Disconnect any previously used instrument 10 FL1 User s manual Rev 2 0 F LYEOX Fuel level sensors installation A NOTE Make sure that the fuel level sensors are mounted so that all the fuel in the tank can be measured If the fuel sensor cannot measure completely the fuel in the tank the FL1 will display inaccurate readings For example pic 1 if a fuel sensor cannot measure the lowest part of the tank that contains 7 liters the FL1 will display O zero for fuel level of 7 liters and below Another example pic 2 is if a tank can holds 40 liters of fuel but at 25 liters the fuel is at the top of the sensor the maximum that FL1 will display is 25 liters Not measurable Not measura
6. accuracy in the calibration FL1 User s manual 27 Rev 2 0 Fuel level sensors calibration F LYBOX e Step 4 Verify that the indication 3 is changed wait until it is stable if necessary annotate that value on the table and click on DONE e Next steps repeat step 3 and step 4 until tank is completely filled e When the tank is filled click on DONE to confirm the last calibration step and then click on END CAL to end the calibration If you wish to know the tank capacity read the indication 5 before clicking on END CAL A NOTE A common problem for many fuel level sensors is that they can t completely measure the tank capacity so one or both of this conditions can occur see also chapter 1 2 Fuel level sensors installation As you add fuel to an empty tank it takes a certain amount of fuel before the fuel sensor start to move from the bottom As you drain fuel to a filled tank it takes a certain amount of fuel before the fuel sensor start to move from the top 28 FL1 User s manual Rev 2 0 F LYEOX Fuel level sensors calibration If one of this conditions occur during calibration the FL1 notice that the fuel sensor doesn t produce an electrical change and ask the user if fuel was already added for that calibration step small change Confirm fuel already added YES NO If you are sure to have already added the fuel click on YES otherwise click on
7. 44 20 45 21 46 22 47 23 48 24 49 25 50 32 FL1 User s manual Rev 2 0 FLYEOXS CALIBRATION TABLE FOR AUX TANK Calibration tables STEP mV of value 3 STEP mV of value 3 1 26 2 27 3 28 4 29 5 30 6 31 7 32 8 33 9 34 10 35 11 36 12 37 13 38 14 39 15 40 16 41 17 42 18 43 19 44 20 45 21 46 22 47 23 48 24 49 25 50 FL1 User s manual Rev 2 0 33 Fuel level sensors chechings F LYBOX 4 4 FUEL LEVEL SENSORS CHECKINGS To setup correctly the FL1 you need to know what type of fuel level sensors are installed in your aicraft The resistive sensors can be of two types e Sensors that increase resistance as the fuel level increase e Sensors that decrease resistance as the fuel level increase If you don t know what type of resistive sensors are installed in your aircraft follow this procedure e Empty the tank that you want to check e On the FL1 enter in the calibration for that tank from the setup menu press the knob for 3 seconds on Left t calibration Right t calibration Main t calibration or Aux t calibration e From the screen that appear annotate the numerical value indicated in picture Left t calibration e 34 FL1 User s manual Rev 2 0 F LYEOXS Fuel level
8. at decrease resistance as you add fuel If you don t know what type of sensors are installed please see chapter 4 4 Fuel level sensors checkings e CAP for capacitive fuel sensors 29 FL1 User s manual Rev 2 0 FLYE Oe Setup menu Right t sensor Set the fuel level sensor type installed in the RIGHT tank Main t sensor Set the fuel level sensor type installed in the MAIN tank Aux t sensor Set the fuel level sensor type installed in the AUX tank Setup menu page 3 Left tank Set YES if the LEFT tank fuel level sensor are installed and connected to FL1 set NO if not installed or not used Right tank Set YES if the RIGHT tank fuel level sensor are installed and connected to FL 1 set NO if not installed or not used Main tank Set YES if the MAIN tank fuel level sensor are installed and connected to FL 1 set NO if not installed or not used Aux tank Set YES if the AUX tank fuel level sensor are installed and connected to FL1 set NO if not installed or not used FL1 User s manual 23 Rev 2 0 Setup menu F LY EOXS Setup menu page 4 Setup menu page 5 Left Right Main Aux t calibration Calibrate the fuel tanks see next chapter Calib step Set the fuel quantity to add at each calibration step see next chapter Range in liters 1 5 Range in Gallons 0 1 1 3 Fuel unit Set the unit of measure in liters Lt or US Gallons UsG Min mV step Mi
9. ble PIC 1 PIC 2 FL1 User s manual 11 Rev 2 0 Fuel level sensors installation F LYE OX FUEL LEVEL SENSORS CONNECTION 12 Vbatt TO FLi FUEL SENSOR INPUTS 3 RESISTIVE CAPACITIVE SENSOR SENSOR 12 FL1 User s manual Rev 2 0 F LYEOX Electrical installation SECTION 2 2 1 ELECTRICAL INSTALLATION On the back of the FL1 there is a 9 pole D SUB male connector it is also furnished with the corresponding 9 pole female connector to be wired as follows 12V MAIN SUPPLY 12V AUXILIARY BACKUP BATTERY GND MAIN SUPPLY INTERCOM AUDIO OUT ALARM OUT LEFT TANK FUEL LEVEL SENSOR INPUT RIGHT TANK FUEL LEVEL SENSOR INPUT MAIN TANK FUEL LEVEL SENSOR INPUT AUX TANK FUEL LEVEL SENSOR INPUT 9 pole female connector view from wiring side A CAUTION Fuel level sensors must be connected only to the FL1 It s not possible to connect other instruments to the fuel level sensors FL1 User s manual 13 Rev 2 0 Electrical installation F LYE OR Connector pinout 1 12V Main supply 2 GND Main supply 3 Alarm out 300mA max Connect the load for example a lamp indicator between out and 12V 4 RIGHT tank fuel level sensor input 5 AUX tank fuel level sensor input 6 12V auxiliary backup battery if present 7 Audio out for intercom it s recommended to use shielded cable 8 LEFT tank fuel level sensor input 9 MAIN tank fuel level sensor input A NOTE Insert a 1A circuit breaker or fus
10. e to the power lead 12V A Take care to properly insulate any exposed wire to avoid short circuit between any of the wires WARNING Voltage peaks on the supply line that exceeds the operating limits can damage the device 14 FL1 User s manual Rev 2 0 F LYEOX Minimum settings before first use SECTION 3 3 1 MINIMUM SETTINGS BEFORE FIRST USE A CAUTION Before using the FL1 in flight for the first time you must set at least the following parameters reading the operating instructions in the following pages e Set the unit of measure USgallons or liters set this before all the other parameters e Enable the tanks installed in your aircraft and let disabled all the other tanks e Set the fuel sensor type for every tanks resistivet resistive capacitive e Execute the calibration procedure for all the tanks FL1 User s manual 15 Rev 2 0 Panel indicators amp commands F LYEOX 3 2 PANEL INDICATORS amp COMMANDS Reserve LED Knob with pushbutton The knob can be rotated or used as a pushbutton for example it must be rotated to increment or decrement a value and pushed to confirm 16 FL1 User s manual Rev 2 0 F LYEOX Use of the instrument 3 3 USE OF THE INSTRUMENT At startup the display briefly shows the software version then it appear the fuel level readings to see all the available indications rotate the knob A NOTE The first time you turn on the instrumen
11. et the fuel quantity for the MAIN tank fuel warning when the fuel remaining reaches this setpoint the FL1 activate an alarm Range 0 50 to disable this function set the value to zero Aux t reserve Set the fuel quantity for the AUX tank fuel warning when the fuel remaining reaches this setpoint the FL1 activate an alarm Range 0 50 to disable this function set the value to zero Tot reserve Set the fuel quantity for the reserve fuel warning when the total fuel remaining reaches this setpoint the FL1 activate an alarm The total quantity is intended as the sum of all the fuel available in the single tanks Range 0 200 to disable this function set the value to zero A NOTE In case of only one tank installed this function is not enabled Setup enter the setup menu see next chapter FL1 User s manual 21 Rev 2 0 Setup menu F LY EOXS 4 2 SETUP MENU Setup menu page 1 Setup menu page 2 Done exit from the setup menu Contrast adjust the LCD contrast Audio volume Adjust the volume for the audio out min 0 max 7 Sensor filter To remove fluctuation or jump in the fuel level readings increase this value viceversa decrease the value if the fuel level display update is too slow Range 1 200 default 50 Left t sensor Set the fuel level sensor type installed in the LEFT tank e RES for resistive fuel sensors that increase resistance as you add fuel e RES for resistive fuel sensors th
12. ion 05 2009 10 First release 09 2010 11 Updated installation notes 11 2014 20 Layout update WARNING All photos data drawings instruments layouts technical solutions and data representation you find in this document or watching at FLYBOX instruments working and or you can access by means of any other media including web sites are sole property of MICROEL s r l cannot be copied or imitate without a written permission of MICROEL s r l itself and are protected by law even by means of extended international copyright and or specific patents deposited Any infringement of this statement and of MICROEL s r l intellectual property will be prosecuted 2014 Microel s r l all rights reserved FL1 User s manual 37 Rev 2 0 Page intentionally left blank Page intentionally left blank MIC ROEL s r l Via Mortara 192 194 27038 Robbio PV ITALY Tel 39 0384 670602 Fax 39 0384 671830 www flyboxavionics it
13. n the same way explained for the single tank and will also activate the yellow led for reserve indication 18 FL1 User s manual Rev 2 0 F LYEOX Use of the instrument If only one tank is installed the total indication is not present and the yellow led will activate when the fuel level drops below the setpoint for that single tank FL1 User s manual 19 Rev 2 0 Lovv fuel vvarnings Main menu F LYEOX SEZIONE 4 4 1 LOW FUEL WARNINGS MAIN MENU To enter in the low fuel warnings menu press the knob for at least one second the menu is divided in two pages Rotate the knob to scroll from first to second page To modify a menu item select it and click the knob then rotate the knob to change the value click again to confirm and store the new value Done Right t reserve 003 Main t reserve 003 Main menu page 1 Main menu page 2 Done exit from the main menu and return to the fuel readings screen Left t reserve Set the fuel quantity for the LEFT tank fuel warning when the fuel remaining reaches this setpoint the FL1 activate an alarm Range 0 50 to disable this function set the value to zero Right t reserve Set the fuel quantity for the RIGHT tank fuel warning when the fuel remaining reaches this setpoint the FL1 activate an alarm Range 0 50 to disable this function set the value to zero 20 FL1 User s manual Rev 2 0 F LYEOX Low fuel warnings Main menu Main t reserve S
14. nimum thresold to detect fuel sensors movement default 20 don t modify this value 24 FL1 User s manual Rev 2 0 F LYEOX Fuel level sensors calibration 4 3 FUEL LEVEL SENSORS CALIBRATION Before using the FL1 it s necessary to calibrate all the aircraft fuel tanks following the procedure explained in this chapter The calibration is divided in more calibration steps in each step you will fill the tanks with predetermined fuel quantity The calibration end when the tank is completely filled It s possible to choose the fuel quantity to add at each calibration step see Calib step parameter in the setup menu choose a proper value considering the tank Capacity and how many calibration step you want to execute For example with a 40 liters tank and Calib step set to 2 it s required 40 2 20 calibration steps The maximum number of calibration steps is 50 The Calib step parameter is used for all the 4 tanks calibrations dont t modify it once you have choosed a value Begin calibration choose the tank to calibrate and select the relative item in the setup menu Left t calibration Right t calibration Main t calibration Aux t calibration FL1 User s manual 25 Rev 2 0 26 Fuel level sensors calibration F LYBOX To enter in the calibration press the knob for at least 3 seconds until the display shows this screen in the example that follow the unit of measure are set to liters
15. r to flight and must not allow anyone to use it without knowing the operation Don t use this instrument in flight until you are sure of the correct operating of the same A CAUTION When the installation is finished you must do a test prior to flight switching on all the possible source of electric noise and checking the properly operation of this instrument A CAUTION The software of this instrument can be subject to change update addition or removal of functions so also the operating mode of the instrument can be subject to change Always refer to the installation and operating manual updated with the software version used in your instrument To obtain updated manuals please visit www flyboxavionics it FL1 User s manual Rev 2 0 Important notices amp warnings F LY EOX A WARNING Do not solely rely on the FL1 to determine the fuel available in the tanks A WARNING Responsibility for installation lies entirely with the installer Responsibility for operations lies entirely with the operator Responsibility for any calibration settings or any other customization lies with the person performing these operations IMPORTANT If you do not agree with the notices above do not install this instrument in your aircraft but return the product for a refund Microel s r l reserves the right to change or improve its products Information in this document is subject to changes without notice FL1 User s manual Rev 2 0
16. sensors checkings e Add a certain amount of fuel to the tank and check if the numerical indication increase or decrease if increase then the sensors installed increase the resistance as you add fuel RES if decrease the sensors decrease the resistance as you add fuel RES To exit from the calibration screen turn off the FL1 or click on END CAL Repeat the procedure for any other unknown sensors installed FL1 User s manual 35 Rev 2 0 Technical specifications F LYEOX SECTION 5 5 1 TECHNICAL SPECIFICATIONS e Graphic LCD with backlight and coated glass dimensions 29x18mm e Standard mounting 2 1 4 57mm e Anodized aluminium case e Dimensions 60 x 60 x 40 mm e Weight 140g e 4 fuel level sensors input for resistive 300 ohm max or capacitive 0 5 Volt sensors e Supply voltage 12 20 V e Supply current 60mA e Intercom audio output 2Vpp 10Kohm e Open collector alarm output max 300mA active low e Operating temperature range 10 70 C e Humidity 9096 max without condensation 36 FL1 User s manual Rev 2 0 FLYEOXS WARRANTY This product is warranted to be free from defects for a period of 12 months from the user invoice date The warranty only cover the manufacture s defects shall not apply to product that has been improper installed misused or incorrect maintenance repaired or altered by non qualified person Date Revision Descript
17. t the display will shows NO TANK ENABLED to indicate that you need to enable and calibrate the tanks as explained in chap 4 2 The examples below is related to a complete installation with 4 tanks if your aircraft doesn t have some tanks the indications may differ LEFT RIGHT 2 2 4 Left and Right tanks indications MAIN AUX 4 0 Main and Aux tanks indications FL1 User s manual 17 Rev 2 0 Use of the instrument F LYBOX T 0 T AL Total fuel quantity available it s the sum of all the fuel available in the single tank L If only one tank is installed this indication is not present When the fuel level of a single tank drops below the relative reserve setpoint see chapter 4 1 Low Fuel warnings gt Left Right Main Aux t reserve the FL1 activate an alarm warning in this way e The FL1 automatically switch to the page of the tank that went into reserve e The number that indicate the remaining quantity of the tank will blink e The red led will blink e The audio out and the alarm out will activate To reset the alarm condition press the knob Note that the tank indication will continue to blink as far as the reserve condition remain while all the other alarm indications will be reset the led stop blinking and the audio out is muted When the total fuel quantity drops below the reserve setpoint see chapter 4 1 Tot reserve the FL1 activate an alarm warning i
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