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Installation / Troubleshooting Manual This manual

1. Table 1 No Load Idle Consumption 0 is the HP Non Turbo w Turbo pets 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 0GPH 3 4LPH a0 1 eh g switch Turning switch 750 1000 1 0 GPH 4 LPH 1 5 GPH 5 6 LPH counter clockwise elodlewis from 1000 1250 2 0 GPH 7 8 LPH 2 5 GPH 9 10 LPH S will increase 0 5 will 1250 1500 3 0 GPH 11 12 LPH 3 5 GPH 13 14 LPH reading OSH TEED 1500 2000 3 5 GPH 13 14 LPH 4 0 GPH 15 16 LPH reading 2000 3000 4 5 GPH 17 LPH 5 0 GPH 18 19 LPH TI Lower BLACK Switch e Rotate Lower Black Switch until the idle GPH LPH reading matches engine HP from Table 1 NOTE At this point idle consumption is approximate It establishes operating parameters for final calibration On G model instruments the Green Switch replaces the Lower Black Switch G Instruments were discontinued in 1999 Part II Determining Optimum Tank Configuration amp Cruise RPM e Determine the optimum fuel tank configuration for your vessel If possible single engine vessels should draw and return fuel to a single tank On twin engine vessels try to configure the fuel system so that each engine draws and returns fuel to its own dedicated tank If your twin engine vessel has only a single tank equal consumption rates for both engines must be assumed e Close any cross connect or limber line valves between tanks during calib
2. STBD Wiring harness 15 Double Pole Double Throw DPDT Center OFF Momentary ON J 10 13 PORT Wiring harness 2 x a w w he Lee Do not use Back lit or Illuminated switches BACK OF INSTRUMENT xk Switch option 9500 9600 NMEA Input Multifunction Instrument wiring harness Instrument Connection Harness FUNCTION PIN ORANGE Illumination 12VDC BLACK Instrument Ground BLACK switches ground 7 GREEN BLACK DATA NMEA B Connect to GPS Signal Ground or Battery Connect to GPS Signal Output See NMEA 0183 Input Installation Sheet 12 18 2003 9000 016 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 CALIBRATION Series 7500 7600 8500 8600 9500 9600 Multifunction Instrument Magnetic Pick Up INTEGER This instrument MUST BE calibrated to your specific engine in the following manner 1 Determine the number of pulses generated by the Magnetic Pulse Source Magnetic Pick Up Pulses are generated as a gear tooth passes the face of the Pick Up Pulses the number of teeth of the gear usually the flywheel multiplied by the number of gear revolutions per crankshaft revolution Contact your local engine dealer if you need help with finding this
3. 5 Er2 indicates that GPRMC or LCRMA is missing from the GPS NMEA 0183 speed signal message Verify the GPS sending a NMEA 0183 version 1 5 or newer signal This concludes system testing If problems with your system persist contact FloScan Technical Support with test results 1 17 2002 7000 074 00C 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 Flow Homogenizer Can Replacement ATTENTION Thisis NOT aFILTER FloScan MOUNT WITH ARROWS UP 5 14 2003 FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 Aluminum Base Tube Assembly P N 4001 250 00 Rubber Sealing Washer Flow Homogenizer Can P N 4001 199 03 Remove the old Flow Homogenizer can A Claw type oil filter wrench or pipe wrench may be needed Remove the Brass Tube Subassembly and Debris Screen If used from the old can Install them in new can Put a coating of grease on the new Flow Homogenizer s rubber sealing washer Clean the Aluminum base and put a coating of grease on the seal s mating surface Place new Flow Homogenizer can on its Aluminum base Turn until Finger tight Using a band type oil filter wrench carefully rotate the can until tight approximately of a turn past finger tight
4. Position a strip of rubber Bicycle tube or rubber glove between the wrench and can The rubber both increases friction and protects the can Use caution as over tightening will buckle or collapse the can 7000 144 01 Tel 206 524 6625 Fax 206 523 4961 email service floscan com http www floscan com 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 have 1 Female NPT ports FloScan K Series Hi Cap Diesel Return Sensor Assemblies have 1 inlet and 1 2 outlet Female NPT ports FloScan Hi Flo 10 Diesel and Gasoline Sensors have 1 2 Female NPT ports Fl
5. 5 21 2003 233 056 00B 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 Series 9500 9600 Multifunction Instrument Diesel NMEA 0183 Input This unit conforms to NMEA 183 Version 1 5 and 2 0 interface standards and requires a message that includes GPRMC or LCRMA Check your owners manual to verify your GPS LORAN C includes this information To insure an easy trouble free installation read all instructions before starting Wiring NMEA 0183 Connections 1 Refer to the electrical wiring section of the GPS LORAN C Owner s Manual for the proper procedure to connect your GPS LORAN C to NMEA 183 devices Use shielded wire between instruments and ground the shield ONLY at the GPS LORAN C sender end not at the FloScan instrument end receiver end The shield is not to be used as a ground path 2 Connect the WHITE ORANGE wire terminal 15 FloScan instrument to the NMEA A BNC center terminal terminal coming from your GPS LORAN C instrument 3 Connect the GREEN BLACK wire terminal 7 FloScan instrument to the NMEA B BNC shield terminal coming from your GPS LORAN C instrument 4 Connect the GRAY wire terminal 2 FloScan instrument to one terminal of a single pole single throw switch Connect the BLACK wire terminal 13 FloScan instrument to the other terminal 5
6. For single engine installations the RED wire terminal 1 is not used and should be taped off Calibration 1 See your GPS LORAN C owners manual and set output for NMEA 0183 Speed is always sent as speed over ground in knots no matter what units your GPS LORAN C displays 2 Fuel flow rate used in the MPG calculation is automatically done when the totalizer s are calibrated To calibrate see the Totalizer calibration instruction page MPG GPH Operation With the MPG GPH switch in the OFF position your instrument displays engine fuel flow in twin engine installations each instrument displays fuel rate and total consumption only for the engine on which it is installed In the ON position fuel mileage speed over ground in Knots all fuel being consumed is shown as 0 00 to 9 99 then 10 0 to 99 9 You must have valid NMEA 0183 speed and a total flow rate of at least 0 1 GPH LPH to display fuel mileage or you receive an error code Error Codes No signal activity present on NMEA 0183 terminals for four GPS LORAN C OFF seconds NMEA OUTPUT not selected Leads not connected A amp B leads reversed Receiving valid NMEA 0183 Version 1 5 or 2 0 message GPS satellite reception is poor speed message invalid GPS LORAN C in startup mode Fuel flow reading below 0 1 GPH LPH twin both Engine s not running engines Valid NMEA 0183 speed message present Fuel flow reading problem Some pulsi
7. You will need your engine serial number and configuration codes 2 From the table below determine the number of pulses per crank shaft revolution Example Pulses per crank shaft revolution 212 3 Follow the row across and find the position to set the RED switch For the 212 example in step 2 set the RED switch at D 4 Follow the column up to find the position to set the GREEN switch For the 212 example in step 2 set the GREEN switch at 3 GREEN SWITCH RED SWITCH i O Z gt p oo al A Q t Q tS OS NOTE You can check to ensure the correct number was properly set by putting the gauge into show switches mode To do this turn the power to the gauge OFF and then back ON While the display is showing all 8 s cycle the totalizer reset switch from the reset position to the run position at least twice The calibration will be displayed in the RPM window for about twenty seconds The gauge will then go into diagnostic mode To put the gauge back into normal operating mode cycle the power OFF and back ON Do not touch the reset switch while the display is showing all 8 s 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 AC Signal Generator Input Switch Settings Drive Ratio Green Switch Red Switch Q I 1 3 7 3 7 F E D B Altern
8. appear as a constant stream of small bubbles or as an occasional larger bubble Tighten all possible leak sources grease primary filter seals and install fitting seals on JIC SAE fittings Continue to observe the clear tubing until it runs clear without any bubbles Flex or wiggle rubber hose sections while observing the clear tubing If bubble volume increases inspect the hose and check its fittings Repair as necessary e When idling in neutral No Load GPH fluctuations can also be caused by the governor trying to maintain a steady engine RPM e Calibration When the system is running properly refer to the calibration instructions and calibrate your system If installed properly initial calibration takes much less than 1 hour After consuming some fuel final calibration should only take a few minutes 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 High Capacity Diesel Systems 233 amp 236 2K Primary Filter FloScan s s Detura push n m as we Engine Cooler a l oe Tas sas s MT
9. 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 Twin HOURS GPH MPG Systems SYNCH MPG SYNCH 2500 SPST or Momentary ON _ SPST 5500 SPST or Momentary OFF SPST NA 5800 SPST or Momentary OFF A A N SPST NA NA SPST w both GPH amp Tach NA Not Applicable A 6500 6600 SPST or Momentary OFF SPST Twin N Cummins PT only A 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 the equipment 24 amp 32 VDC systems must be reduced to 12 VDC Two different types of voltage reducers are available through FloScan CONNECT THE WIRES Installation Connect wires one at a time and Install heat shrink before proceeding to i x the next wire refer to wiring diagram Connect ground wires first BLACK eee instrument ground wire to the BLACK sensor wires Connect this junction to the 1 Slide heat shrink tubing battery s negative terminal or the ground buss Connect all other wires leaving the 2 asan onde inin bale splice Red power wires for last to prevent short circuits during the installation 3 Crimp bu
10. 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 1 17 2002 7000 074 00C 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 VIII 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 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
11. 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 VII 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 2 Minute Fire Test USCG Type A 1 100g m 24hrs Required USCG Type A 2 300 m 24hrs Required USCG Type B 1 100g m 24hrs Not Required USCG Type B 2 300 m 24hrs Not Required Table I 5 14 2004 4001 386 02B 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 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
12. of switches needed always use good quality marine 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 sig
13. 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 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 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 remaini
14. 2 0 GPS satellite reception is poor message speed message invalid GPS LORAN C in startup mode Fuel flow reading below 0 1 GPH LPH twin both Engine s not running ines Valid NMEA 0183 speed message present Fuel flow reading problem Some pulsing activity present No valid NMEA 0183 Leads connected to wrong source message received in last four seconds GPS LORAN C set to NMEA 0180 or 0182 A amp B leads reversed NMEA message detected Missing GPRMC or GPS LORAN C incompatible with NMEA 0183 ver LCRMA sentence 1 5 or newer 1 An OFF display in the GPH MPG window indicates the FloScan Instrument isn t receiving a NMEA 0183 speed signal from the GPS Check wiring connections to the GPS and verify that it is turned on 2 A Dash Dash Dash display indicates the GPS is in startup mode or satellite reception is poor 3 A Dash 0 Dash 0 display indicates a valid NMEA 0183 speed message is present but that fuel flow readings are so low the FloScan Instrument is unable to compute a meaningful MPG figure Dash 0 Dash 0 may be displayed when motoring at low speeds or when slowing down When slowing down the FloScan Instrument may display ever increasing MPG readings go to Dash 0 Dash 0 and start redisplaying ever increasing readings again 4 Erl indicates that the FloScan Instrument isn t receiving a valid NMEA 0183 message from the GPS Check wiring connections to the GPS
15. Installation Troubleshooting Manual MFI Diesel NMEA PULSE 9800 K Series Combination HI CAP with Magnetic Pick up AC Signal Generator or Alternator Pick up Tachometer This manual part 9000 020 02 applies to the following product part numbers 1 940M 3BB 2K 2 940M 3CB 2K 3 940M 3DC 2K 4 940M 3ED 2K 5 940M0 3ED2K 6 94TM 6DD 2K 7 980M 3BB 2K 8 980M 3CB 2K 9 980M 3CC 2K 10 980M 3DB 2K l 980M 3DC 2K 12 980M 3DD 2K 13 980M 3ED 2K 14 980M 3EE 2K 15 980M0 3BB2K 16 980M0 3CB2K 17 980M0 3DB2K 18 980M0 3DC2K 19 980M0 3DD2K 20 980M0 3ED2K 21 98TM 6BB 2K 22 98TM 6CB 2K 23 98TM 6CC 2K 24 98TM 6DB 2K 25 98TM 6DC 2K 26 98TM 6DD 2K 27 98TM 6ED 2K 28 98TM 6FD 2K 29 98TM 6FE 2K 30 98TM0 6CC2K 31 98TM0 6DC2K 32 98TM0 6DD2K 33 98TM0 6ED2K 1 14 2004 9000 018 42 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 ELECTRICAL Wiring Connections Twin Diesel One Series 95 96 NMEA 0183 Input Multifunction Meter One Series 85 86 Pulse Output Multifunction Meter To insure years of trouble free operation please read all of these instructions carefully before beginning your installation Your twin diesel kit contains one NMEA kit and one Pulse kit The Pulse kit provides fuel flow information from the engine It is installed on to the NMEA head on the other engine The twin
16. 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 Install Forward Sensors on the Fuel Pumps Inlet or Vacuum side and not on the pressure side If on the Pressure Side Limit Sensor System Operating Pressure to 20 PSI or Less Always use 30 micron primary filters Avoid 2 or 5 micron primary filters Wire with Shielded Cable Use a dedicated shielded pair for Magnetic Pickup Tachometer Senders Never use unshielded wires on Magnetic Pickup Tachometer Senders 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 Dat
17. O O _ I wor l FloScan n I i Forward i i Russ flow sensor i OA Tank Te SS FloScan w A ey hie Asal Se HL a Fuel Flow Direction LL Return flow sensor 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 with an inward pointing arrow gt and exit through the port marked 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 2 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 3 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 4 23 2003 4001 291 04 FloScan Instrume
18. VOJAYVLS JOSU MOJA IOSUIS MOJA pemo avo P hN mv F premiog u u Luod quyoguvis s uoyejesur g1 VAIN 298 Vu V NN YLVA yndur 19W00 LYOd us uonel elsut 81 VHINN 998 wu WAN VLVG or Hs mdu 1299002 CYVOMUVLS lt 9I EL E HE m P f F r ja m B TI T T oI CH Aoqg 3J0U 99S ssnq Aoyeg O oL NO Areyuourou yms OdW HdD asny dwe z asny dwe z L YMS 4989Y IZVO L TUVOEUVLS i QdAZI NO 40x puno3 moto OGAZI mono OdAZI NO fom Nam A OVIS Yous uous TONETTE TOPPUNT OL YOUMs uonrusr N Lad OL ssnq Aroyeq PIS CUVOTUV LS IP ol u umnsur TAVOAVLS OL 3 sql Nd No Areuowou CAVO8SWV LS IP 1o uuoO ssnq A1aneQ opis LAOd PY 0 YAMS PHA va W N Ju ummsur L2IOd Op 193uuo2 suraysAs uonnqrnsiIp 12m0d p lejosr UT Guvogdavls sk PTPIOL LOd LYOd ne i SIYIPMS p euruuniii 10 r N3eq sn Jou od x y u uinnsul uonoSunjninIi ndul VINN 0096 00S6 s li S j u uinn3sul uonounjninN nd no asind 0098 00S8 s u sS IWWV 4SVIG 9NI XIM 8500 8600 Pulse Output Multifunction Instrument wiring harness Instrument Connection Harness FUNCTION PIN FUNCTION ED 12VDC x RED WHITE pulse out REEN Totalizer Reset WHITE YELLOW pulse in Twin applications O RANGE Illumination 12VDC BLACK Instrument Ground GREEN BLACK pulse out YELLOW tachometer pick up 10
19. a 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 14 2004 FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 4001 386 02B Tel 206 524 6625 Fax 206 523 4961 email service floscan com http www floscan com OPERATION Series 7500 0 7600 0 8500 0 8600 0 9500 0 9600 0 Temperature Compensated amp Non Temperature Compensated Magnetic Pickup amp AC Signal Generator Type Tachometer Sender Instruments Series 7500 0 7600 0 8500 0 8600 0 9500 0 9600 0 Diesel Multifunction Instruments use a microprocessor based non volatile Random Access Memory RAM to store engine hours and gallons of fuel consumed Non volatile RAM requires no power for memory retention All 8 s are displayed for 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 con
20. ator Input The signal from the alternator input comes from one alternator winding before it s rectified You may notice fluctuations in the tachometer due to belt slippage and varying alternator load No Tachometer reading at lower RPMs Until engine RPM reaches a certain point the alternators output voltage will be too low for the tach to read Installing a 12 VDC light across a DC power source 12 VDC to ground will increase the alternator load slightly and cause its output voltage to increase to a usable level Calibration The tachometer can be calibrated by two methods Calibrate to an existing tachometer Rotate the RED and GREEN knobs on the back of the instrument until the two tachometers agree with each other The accuracy of this method depends on the accuracy of the existing tachometer at the RPM to which you calibrate Most analog tachometers are accurate to either 50 RPM or 100 RPM with the center of the scale being the most accurate If you set the calibration here and find a difference toward the minimum or maximum ends of the analog tachometer scale it is probably due to the nonlinearity of the analog meter movement This method may not be as accurate as 2 below II 1 Calculate the number of pulses per crank shaft revolution To find the number of crank shaft pulses per revolution divide the diameter of the engines crank shaft pulley by the diameter of the alternator pulley and multiply by the number of altern
21. ator pulses Diameter of Crank Shaft Pulley x Number of Alternator Pulses Pulses per Revolution Diameter of Alternator Pulley 2 Locate the number of pulses per crank shaft revolution from the table select the number closest to the actual pulses per crank shaft revolution Set the RED and GREEN switches on the back of the instrument accordingly Example A Motorola alternator has 12 pulses 12 pulses per revolution Crank shaft pulley 10 diameter Alternator pulley 4 diameter 12 x 10 4 number of pulses per revolution 12x 2 5 30 pulses per revolution 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 Series 75 7600 0 85 8600 0 95 0600 0 M amp I Multifunction Instrument Totalizer Calibration This is a three part calibration procedure Part one adjusts idle consumption Part two determines optimum cruising RPM and fuel tank configuration Part three calibrates for overall accuracy PART I Idle Consumption Adjustment Start and run engine s until they re at operating temperature Referring to the switch diagram rotate the Upper and Lower Black Switches to 0 Increase engine speed to 1800 RPM for one minute This purges any trapped air from the system Return engine speed to low idle and determine its consumption from Table below
22. ds 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 4 11 2001 7000 065 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 AC Signal Generator G Type Only 750G 760G 75TG 76TG 750G0 760G0 75TG0 76TG0 850G 860G 85TG 86TG 850G0 860G0 8STG0 86TG0O 950G 960G 95TG 96TG 950G0 960G0 9STG0 96TGO Type G Diesel Multifunction Instruments are preset for the correct flow sensor combination Before installing the instrument verify that the switch settings are correct for your application Flow Sensor types are coded as part of your kit model number Recessed Arrow Rotary Switch Settings Switch Position A All 235 236 amp 233 B C C D D E E F and combinations 7 233A 233A Cummins 233D Cummins 231 Cummins 233C 201 201 33F 233F Cummins Engines with PT pump injection system using one flow sensor in the feed line to the engine 4 11 2001 7000 065 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 INSTALLATION MECHANICAL amp WIRING OVERVIEW K Series am
23. e for 20 seconds Record these readings below HOURS RPM GPH GALLONS After 20 seconds the Instrument automatically goes into diagnostic mode A minus sign in the GALLONS window indicates when this occurs The Instrument remains in diagnostic mode until power is secured 1 17 2002 7000 074 00C 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 With engine s running and the Instrument in diagnostic mode the GPH window shows raw un calibrated fuel flow through the Forward Sensor The GALLONS window shows raw fuel flow through the Return Sensor Calibration adjustments do not affect diagnostic mode readings Example 60 Z S2 3 GPH GALLONS 3 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 E 1800 S F 4 With engine s idling record Engine Hour Window 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 5 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 res
24. e 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 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 gall
25. et switch with all 8s showing IL SUPPLY VOLTAGE and GROUND TEST 1 Measure voltage between the RED power wire on pin 9 and the BLACK Instrument ground wire on pin 5 It should read approximately 12 to 14 VDC but not lower than 10 VDC VDC 2 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 If12 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 Measure voltage between the ORANGE wire on pin 4 and the BLACK wire on pin 5 for 75 7600 0 and 85 8600 0 series Instruments On 95 9600 0 series Instruments measure between pin 4 and the BLACK ORANGE wire on Pin 12 VDC 2 If12 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 1 17 2002 7000 074 00C 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 ie With engine s idling measure and record voltage between the RED po
26. gs 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 TEMPERATURE COMPENSATED Forward Sensor Return Sensor Kit 236F 236E 6FE 2K 236E 236D 6ED 2K 236D 236D 6DD 2K 236C 236C 6CC 2K 236C 236B 6CB 2K 236B 236B 6BB 2K 4 23 2003 FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 Tel 206 524 6625 NON TEMPERATURE COMPENSATED Forward Sensor Return Sensor Kit 233F 233E 3FE 2K 233E 233D 3ED 2K 233D 233D 3DD 2K 233C 233C 3CC 2K 233C 233B 3CB 2K 233B 233B 3BB 2K 4001 291 04 Fax 206 523 4961 email service floscan com http www floscan com BRACKET ASSEMBLY 1K amp 2K Hi Cap Forward Sensor Bracket Assembly D e 90 angle bracket part number 4001 357 00 and mounting hardware available upon request Please see reverse for Return Sensor Bracket Assembly 5 21 2003 233 056 00B 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 BRACKET ASSEMBLY 2K Hi Cap Return Sensor Bracket Assembly e 90 angle bracket part number 4001 357 00 and mounting hardware available upon request
27. 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 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
28. in the UP position This puts the meter in the reset mode when the switch is up 8 See the NMEA 0183 wiring sheet 9000 01 1 00 for connection of the white orange wire terminal 15 and the green black wire terminal 7 9 Connect the red wire terminal 1 to the engine ON side of the engine key switch 9 3 1998 4001 369 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 10 Connect the orange wire terminal 4 to the instrument light power 12 VDC and the black orange wire terminal 12 to the instrument light ground Installing the PULSE instrument 85 86 Series 1 If you have an existing tachometer on this side label the signal lead s and remove the power and ground leads and the tachometer Install the meter labeled on the back Pulse Plug in the white connector labeled Pulse to the meter labeled Pulse and separate out the wires coming from this connector 2 See the tachometer section of the Diesel Installation sheet 4001 325 00B for connection of the yellow wire terminal 8 and the violet wire terminal 16 3 The black wire terminal 5 system ground connects to the junction of the black wires from the feed and return flow sensors and goes to battery ground This instrument uses a single point ground system to reduce noise interference and must have only one connection to batter
29. it locks onto a satellite If this occurs changing to a different screen then back should update the original screen e The WHITE RED and GREEN BLACK wires are twisted to prevent noise interference If they are not long enough to reach the GPS cut them back to 3 Use a shielded wire to connect the GPS and MFI Connect the shield to the GPS REF terminal 5 15 2002 7000 105 00D 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 ELECTRICAL Series 5500 0 56100 5800 0 6500 0 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 wire shield or shield drain wire in the engine room by connecting it to the bonding system or engine block The double wiring harness for twin engine Pulse NMEA Diesel installations is included in all 97 9800 0 kits FloScan suggests using J Boxes Terminal Blocks and three conductor cables between the 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 in kit To determine which switch types
30. k gt Ld we gt 233 236 1K amp 2K Return Sensor amp Pulsation Damper Assembly 233 236 2K Return Sensor And Pulsation Damper Assembly FloScan Outlet 201 231 235 2K Outlet Inlet 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 4 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
31. kit comes with a special cable harness with all the cross connections required between the two meters already made for you Follow the electrical connection steps listed below after you have completed the mechanical part of the installation The twin install kit includes a wiring connection schematic showing the NMEA unit on the PORT side and the Pulse unit on the Starboard side The meters are shown looking aft from the connector side of the meter If you want the NMEA head on the Starboard side wherever you find Port write Starboard and vice versa All 95T 96T 85T 86T kits come with the flow sensors labeled with the same serial number as the meter in the kit and are labeled as Feed or Return flow The serial numbers must stay with the meter they came with and must be installed in the fuel system as labeled Follow the steps below and make all the wiring connections to the instrument and engine on one side before proceeding to the instrument and engine on the other side This greatly reduces confusion and wiring problems Turn OFF the power to your instrument panel before beginning the electrical installation Installing the NMEA instrument 95 96 Series 1 Decide whether you want the MPG reading on the Port or the Starboard side of your instrument panel If you have an existing tachometer label the signal lead s and remove the power ground leads and the tachometer Install the meter labeled on the back NMEA The lower left hand window dis
32. lakeley Street Seattle WA 98105 7000 087 00F Tel 206 524 6625 Fax 206 523 4961 email service floscan com http www floscan com 2 0 2 Example 1 Twin engine vessel with two dedicated fuel tanks For single engine vessels with a E F 0 4 single tank use either the Port or Starboard system calibration procedure in Example 1 6 E 6 D 3 After steaming and returning to refuel The Port tank took 89 7 gallons 339 5 liters Its totalizer go C 4 8 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 B 5 10 e Using the formula calculate the percentage difference between the Totalizer reading and I 12 9 g 7 20 actual fuel consumption 14 iey 18 Difference in Gallons Liters x 100 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 gallon 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 th
33. nal wire to the ungrounded lead or terminal Connect 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
34. ng activity present No valid NMEA 0183 Leads connected to wrong source message received in last four seconds GPS LORAN C set to NMEA 0180 or 0182 A amp B leads reversed NMEA message detected Missing GPRMC or LCRMA GPS LORAN C incompatible with NMEA 0183 ver 1 5 or sentence newer 7 23 1998 9000 011 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 PULSE OUTPUT INSTRUCTIONS Series 8500 8600 Diesel Multifunction Instrument kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk NOT FOR 9500 9600 OR TWINSCAN COMBINATION INSTALLATIONS kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk The 85 8600 series Pulse Output Multifunction Instrument MFI produces a 1000 pulse per liter or 3785 pulse per gallon output signal 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 WIRING Single Engine Installation 1 Connect the WHITE RED wire from pin 2 to the GPS fuel SIGNAL input 2 Connect the GREEN BLACK wire from pin 7 to the GPS REFFERENCE input WHITE RED Signal ae 2 Twin Engine Installation Fuel Reference 7 Select the MFI that is physically close
35. ng 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 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 fluctuations are caused by the engine governor regulating fuel flow to maintain a steady engine RPM 1 17 2002 7000 074 00C 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 XII NMEA 0183 Input MPG Nautical Miles per Gallon Problems Error Codes No signal activity present on NMEA 0183 terminals OFF for four seconds NMEA OUTPUT not selected Leads not connected A amp B leads reversed Receiving valid NMEA 0183 Version 1 5 or
36. nt 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 4 Flow sensor model numbers are molded into the colored plastic wire cap Sensors are labeled FORWARD and RETURN and must be installed in these positions for proper operation A single stand alone letter stamped into the sensors body identifies its match code 5 Model 236 sensors are temperature compensated and marked with their Instruments serial number xxxxF Forward xxxxR Return 236 Temp comp sensor kits are precisely calibrated and matched to each instrument 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 systems 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 CAUTION DO NOT OVER TIGHTEN FITTINGS Torque sensor and pulsation damper pipe thread fittin
37. oScan K Series Lo Flo Diesel and Gasoline System Components Sensors and Pulsation Dampers have 1 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 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
38. on 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 10 30 2002 7000 087 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 TROUBLESHOOTING Series 7500 7600 8500 8600 9500 9600 Multifunction 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 Instrument model number and
39. p 10 Systems To Ensure System Accuracy Follow All Installation Instructions e Sensor Placement Determine where the Flow Sensor or Flow Sensor Pulsation Damper assembly is to be installed Install the sensor or sensor pulsation damper assembly so that the two fuel flow arrows gt or the IN and OUT markings are on a horizontal plane All orientation arrows 48 must be pointing up The forward sensor or forward sensor pulsation damper assembly must be installed downstream of the primary filter Do not install the sensor or either sensor assembly at a high point in the fuel system This could negatively impact system accuracy by trapping air The fuel return line between the return sensors outlet port and fuel tank should be at least 12 long and have a 1 to 2 upward rise This keeps the return sensor flooded improving accuracy Place sensor assemblies in a protected location away from water spray Forward Sensor amp Pulsation Damper Assembly FloScan Diet Forward Sensor And Pulsation Damper Assembly FloScan Inlet g Se Sa 201 231 1K amp 2K 235 2K Inlet gt O i y Outlet L 233C 10 amp 233D 10 Cummins PT Systems 8 5 2003 FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 Outlet
40. plays either GPH for this engine or total MPG 2 Plug in the white connector labeled NMEA 0183 to the meter labeled NMEA and separate out the wires coming from this connector 3 See the tachometer section of the Diesel Installation sheet 4001 325 00B for connection of the yellow wire terminal 8 and the violet wire terminal 16 4 The black wire 12 terminal 5 system ground connects to the junction of the black wires from the feed and return flow sensors and goes to battery ground This instrument uses a single point ground system to reduce noise interference and must have only one connection to battery ground 5 The white wire terminal 6 signal connects to the white wire of the feed flow sensor 6 The brown wire terminal 14 signal connects to the white wire of the return flow sensor 7 The NMEA meter requires two switches one for GPH MPG and one for the Gallon reset Connected the black wire terminal 13 to one of the terminals of the GPH MPG switch and one of the terminals of the Gallons reset switch Connect the gray wire terminal 2 to the other side of GPH MPG switch Mount the switch with ON in the UP position This puts the meter in MPG mode when the switch is up and GPH mode when the switch is down Connect the green wire terminal 10 to the other side of the Gallons reset switch This switch can be either a normally open momentary push button or a spring loaded toggle switch Mount the switch with ON
41. ration e Take your vessel for a short cruise Using the GPH LPH reading as a guide determine the best cruising RPM for the way you normally operate Don t be concerned that the readings are slightly off Calibration is most accurate when done at a single cruising RPM Part III Final Calibration e Return to the fuel dock and top off the fuel tank s e Reset the totalizer so that the GALLONS LITERS window reading is zero Take the vessel for a cruise Once underway steam at your optimal cruising RPM Determined in Part II Consume a minimum of 20 to 30 gallons 75 to 115 liters of fuel per engine Higher consumption gives better accuracy After consuming some fuel return to the fuel dock and top off the fuel tank s Compare the 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 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 Continued on reverse side 10 30 2002 FloScan Instrument Company Inc 3016 NE B
42. rts A B amp C below A NO READING 1 Check continuity of the YELLOW and VIOLET Tachometer signal wires Section VI Verify that the tachometer signal wires are connected at the correct signal output point Disconnect either the YELLOW or VIOLET Tachometer signal wire from the Tachometer Sender Connect an Ohmmeter to the two sender wires and measure its resistance AC Signal Generators should measure approximately 180 Q 10 Magnetic Pick ups can measure between 100 to 800 depending on manufacturer Next connect an AC Voltmeter to the sender wires Both AC Signal Generator and Magnetic Pick up senders should produce at least several volts at idle If the voltmeter reads 0 on an AC Signal Generator it may not be properly attached to its drive port Verify that its drive shaft and tang are installed correctly If the voltmeter reads 0 on a Magnetic Pick up sender it may not be installed correctly With engine stopped loosen its lock nut Turn the sender clockwise until it bottoms out Back the sender out 1 8 to 1 4 turn Turn the engine over by hand or slowly jog it to verify adequate clearance Engine alternators tend to be an inaccurate Tachometer signal source especially at low Rpm s The engine may have to be revved up before the Tachometer will read HIGH OR LOW READINGS 1 Verify that the Tachometer is calibrated correctly C FLUCTUATING READINGS 1 Listen to your engine s If
43. should read approximately 0 1 to 3 Q Ohm Reading 1 17 2002 7000 074 00C 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 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 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 Disconnect the YELLOW wire harness conductor from the Port Tachometer Sender Connect a jumper from the YELLOW wiring harness conductor to a known good ground At the Molex connector connect an Ohmmeter lead to its YELLOW wire Connect the other Ohmmeter lead to a known good ground The Ohmmeter should read approximately 0 1 to 3Q Ohm Reading Disconnect the VIOLET wire harness conductor from the Starboard Tachometer Sender Connect a jumper from the VIOLET wiring harness conductor to a known good ground At the Molex connector connect an Ohmmeter lead to its VIOLET wire Connect the other Ohmmeter lead to a known good ground The Ohmmeter should read approximately 0 1 to 3Q Ohm Reading VII TACHOMETER PROBLEMS Note Refer to the engine owners manual wiring diagram installation and calibration instructions for pa
44. st to the GPS GREEN BLACK Connect its WHITE RED wire from pin 2 to the GPS fuel SIGNAL input Connect its GREEN BLACK wire from pin 7 to the GPS fuel REFFERENCE input Connect the WHITE RED wire from pin 2 of the second MFI to the WHITE YELLOW wire from pin 3 of the first MFI Connect he GREEN BLACK wire from pin 7 of the second MFI to the BLACK wire from pin 5 of the first MFI A eh 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 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 GPS Output Calibration The GPS output requires no special calibration Calibration of the MFI totalizer automatically calibrates the GPS output signal GPS SETUP AND OPERATION GPS setup and operation information is located in the GPS user manual Select a Presentation screen from the setup menu and program in the fuel volume unit desired Go to the Sensor Control screen and set the fuel flow sensor to Pulse Set conversion to 1000p Liter 3785p Gallon 4546p UK or Imperial Gallon When not locked onto a satellite the GPS goes into Hunt Mode Screen readings may freeze until
45. 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 5 14 2004 4001 386 02B 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 V Pre Startup Prime the fuel system If you have an electric priming or boost pump circulate fuel for 10 minutes while checking
46. switch settings Pi s Gee m OD amp MODEL oes i SERIAL 16 15 J14 13 12 11 f0 9 N z gt z 2 gt 8 7 6 5 4 3 2 Ji UPPER BLACK RED GREEN BACK OF INSTRUMENT BACK OF INSTRUMENT LOWER BLACK or RECESSED ARROW FAULT PROBABLE CAUSE Blank LCD Display Sections II II No Back Lighting High or Low Totalizer reading Over 10 Sections III Calibration sheet Wiring Calibration Incorrect flow sensor Operations sheet Incorrect switch settings Calibration sheet Vacuum leak Pulsations Sections VII IX X Wiring Sections II V VI Installation sheet Section IV Fluctuating GPH Readings No GPH or Totalizer Readings High Low or No Tachometer Reading Wiring Installation sheet Section II Calibration Calibration sheet Continuity Section VI In synch with engine or Glen Denning cable whip Section VII Wiring Instrument failure Sections I IL IV V VI Sensor Failure Section I IV Incorrect switch settings Calibration sheet Sensor orientation Section XI No Forward or Return Sensor Readings High Forward or Return Sensor Readings L 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 Mod
47. trast 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 acceptable Optimum viewing angle Engine Hours ae The engine hours meter is shipped at or near zero hours It accurately tracks the number of hours your engine has run Unlike most hour meters it only accumulates time when the engine is actually running If the meter is turned ON but the engine is NOT running NO time is added to the engine hour display The engine hour meter cannot be reset Tachometer RPM The Tachometer window shows engine speed in RPM and is accurate to within 1 belt driven alternator tachometer signals are only accurate to 50 RPM Flow Consumption GPH LPH The GPH LPH window shows the rate at which your engine is consuming fuel The GPH LPH and Gallons Liters readings will both change if the flow calibration switch UPPER BLACK SWITCH on the back of the instrument is turned Totalizer Gallons Liters The Gallons Liters window shows total fuel consumed The GPH LPH and 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 GALLONS LITERS display will flash for ten secon
48. tt splice Splicing Splice or join individual wires per the diagram Slide heat shrink tubing over See Se the splices to prevent shorts Do not seal splices until the installation is finished and 4 Slide heat shrink tubing has been tested over butt splice Eh 5 Apply 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 9 19 2003 4001 100 00H 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
49. uld 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 13 or similar non plated bolt to the Black wire Run the WHITE 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
50. wer 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 It should be approximately 5 to 7 VDC about 1 2 of the reading in step 1 VDC Stop the engine while observing your 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 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 It should be approximately 5 to 7 VDC about of the reading in step 1 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 sho
51. y ground 4 The white wire terminal 6 signal connects to the white wire of the feed flow sensor 5 The brown wire terminal 14 signal connects to the white wire of the return flow sensor 6 The PULSE meter requires one switch for the Gallons reset Connect the black wire terminal 15 to one of the terminals of the Gallons reset switch Connect the green wire terminal 10 to the other side of the Gallons reset switch This switch can be either a normally open momentary push button or a spring loaded toggle switch Mount the switch with ON in the UP position This puts the meter in the reset mode when the switch is up 7 Connect the red wire terminal 9 to the engine ON side of the engine key switch This completes the wiring section of your installation Read the Checking the Installation and Checking the Calibration section on the back side of the Diesel Installation sheet 4001 325 00B to complete your installation 9 3 1998 4001 369 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 WOULO F AAA d11u WOUL gAs preu S0186 VM NLs 4S Ao oye g AN 910E 196b 7S 907 Xeq 799 b7S 907 TOL suy Auedwop Ju um nsul Ugs 400 910 0006 SUIPOD 10709 Joquunu urd pue 0 81 Z1 Josuag MOTI suondo YOUAMS 10 IPIS SI9A91 99S ek 10SU9S moja umo 2 HTIgVO a a z ummy dA

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