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Installation / Troubleshooting Manual

1. 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 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 pS TOR Po Mgsimsy sven wo synen SPST or Momentary ON N NA A 5800 SPST or Momentary OFF NA_ N hal a A 6500 6600 SPST or Momentary OFF SPST Twin N Cummins PT only PST TwinScan GPH SPST orMomentaryON NA NANA TwinScanTach Na NAT NANA GPH amp Tach NA Not Applicable NA NA NA NA NA 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 Pow
2. Finding suction leaks can be a time consuming chore When approached properly they can be found and repaired quickly Two common places for suction leaks to occur are the primary fuel filter water separator and or from a loose valve stem packing nut 4 17 2003 4001 103 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 Remove the filter housing and coat all o rings gaskets and sealing surfaces with a medium to heavy grease Not oil and reassemble Grease all valve stem packings and gently tighten gland nuts Do not over tighten valve handles should be able to turn freely Tighten all hose clamps and compression fittings Do not over tighten Run the engine for 5 to 10 minutes and observe GPH readings If you ve found the problem fluctuations should be reduced to less than GPH If this does not cure the problem temporarily insert a clear piece of fuel resistant tubing in the fuel line On diesel engines install it downstream of the forward flow sensor Run the engine and watch for a constant stream of small bubbles in the clear tube or an occasional larger bubble Sometimes shining a light through the tube makes bubbles easier to see Have someone observe the clear tube while you shake any flexible fuel hose s If the bubble stream continually increases or decreases as you do this you ve found the leak area Repair or
3. makes no difference which one gets power TO RESET THE TOTALIZER Select the OFF position of the Totalizer reset switch for approximately 15 seconds Once the totalizer has been reset to zero select the ON position of the Totalizer reset switch for normal operation LOCATION OF INSTRUMENT The series 6500 dial meter requires a 3 1 16 diameter cutout The instrument contains a magnet which may affect your compass so some care is required in choosing its mounting location 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 5800 58000 6500 65000 6600 66000 Gas Diesel Cruisemaster GPH Instrument with LCD Totalizer WIRING LEGEND WIRE COLOR FUNCTION Ignition 12VDC GREEN Totalizer Memory Constant 12VDC Diesel engines using only one sensor Totalizer 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 ica A BLACK gn Ss BLUE not connected diagnostic wire To Illuminatio Circuit 12VDC BROWN not connected in single sensor installations Me ae To Ignition Switch key ON 12VDC RED 3 WHITE Flow CABLE Ooa e Sensor BLACK Battery buss 4 17 2003 4001 372 00D FloScan Instrument Company Inc Tel 206
4. RPM operation Section VIII No Forward or Return Sensor readings High Forward or Return Sensor readings 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 if not a Check for voltage between the RED wire and another ground point b If voltage 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 4 17 2003 4001 103 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 In Diagnostic Mode the totalizer will
5. about 1 2 of the reading in step 3 VDC 7 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 flow sensors turbine slows to a stop VDC NOTE This may not be seen with a digital voltmeter 8 The flow sensor may be defective if voltage readings in steps 5 amp 7 remain constant when the engine is stopping With this guide in hand contact FloScan Technical Support HI 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 back side 2 Measure between the RED Power wire and the BLACK Instrument ground wire This reading should be approximately 12 VDC but not lower than 10 VDC 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 an Instrument ground problem VDC 4 If 12 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 ground another wire or to power Before starting secure all power 2 Disconnect the WHITE and BLACK wire harness conductors from the WHI
6. 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 2 outlet Female NPT ports FloScan Hi Flo 10 Diesel and Gasoline Sensors have 1 2 Female NPT ports FloScan K Series Lo Flo Diesel and Gasoline System Components Sensors and Pulsation Dampers have 4 Female NPT ports Review the electrical installation instructions Open and survey your vessels wire ways Determine if it would be easier to run a 3 conductor cable from each sensor to the instrument or install a junction box J Box with terminal strip in the engine room The J Box requires a 4 conductor cable from it to the instrument and a 3 conductor cable from each sensor Measure cable lengths from sensor s to J Box If used to Instrument Tachometers require a separate 2 conductor cable If there s an existing tachometer its signal wires can be used II Mechanical Installation Install or mount the Sensor s or Sensor Assemblies Instruments and Switches Reset MPG HI Plumbing Most K Series and 10 installations do not require additional fuel hose Mount the sensor s or sensor assem
7. count at 1 gallon or 1 liter per second If it does not the instrument is defective With the BLUE wire floating Disconnected the pointer should read approximately 10 GPH models 9 40 LPH models 20 GPH models 80 LPH models 32 GPH models 160 LPH models 50 GPH models 500 LPH models 450 100 GPH models 90 With the BLUE wire connected to the Instruments BLACK wire the pointer should read approximately 10 GPH models 40 LPH models 20 GPH models 80 LPH models 5 32 GPH models 160 LPH models 50 GPH models 500 LPH models 100 GPH models 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 2 13 or similar non plated bolt to the BLACK wire With the BLUE wire disconnected 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 12 VDC lightly run the BROWN 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 If the Instrument passes steps 10 amp 11 returns switches 1 9 to thei
8. problems If the system is not operating properly refer to the Troubleshooting Instructions and correct any deficiencies When the engine reaches operating temperature increase engine speed to about 1500 2000 RPM Letting it run for five or ten minute s helps purge residual air from the system e Any vacuum leaks between the fuel tank and lift pump will allow air to be drawn into the system These leaks cause high and or fluctuating GPH readings Only severe leaks affect engine performance but all leaks affect sensor performance and instrument readings Vacuum or suction leaks occur at improperly sealed primary filters loose packing nuts on cross over amp shut off valves and improperly sealed fittings Vacuum leaks can also occur from corroded copper fuel lines and chaffed fuel hose where it rubs against bulkheads or engine parts To verify that a suction leak is present temporarily insert a clear piece of fuel resistant tubing downstream of the Forward Sensors outlet Observe the clear hose for at least two minutes looking for bubbles Bubbles can appear as a constant stream of small bubbles or 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
9. replace as needed If it is a one time occurrence you probably dislodged air trapped in the fuel line If you haven t found it yet the last step is to inspect each pipe joint in the system You should be able to see joint compound all around the joint If you do not that joint is suspect and needs to be resealed After re sealing you may need to run the engine for a few minutes to purge any remaining air You should now see bubble free solid fuel running through the clear tube If you still see bubbles you missed a leak somewhere recheck your work Remove the tube and restore the fuel system to its normal condition Fuel Filters A dirty fuel filter or one that is too fine 1 25 micron will draw vapor bubbles out of the fuel Replace it with a new 30 micron filter VII 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 point up VII 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 problems persist contact FloScan Tec
10. 0g 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 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 Magnet
11. 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 email service floscan com http www floscan com Forward and Return Sensor Gasoline EFI amp Diesel Engine Installations Totalizer Memory Constantt 12 VDC Source Negligible battery draw GREEN Q i O Totalizer 1 2 amp fuse Reset Switch momentary OFF Do not use Back lit or Illuminated switches To Ignition Key ON 12VDC 1 2 amp fuse To Illumination Circuit 12VDC BLACK Battery buss BLACK yf o BLUE not connected diagnostic wire r Forward BLACK SADIE vee CABLE 7 r Return z m v soni Sensor NOTE For twin engine installations you will repeat the wiring shown above for each engine 4 17 2003 4001 372 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 CALIBRATION Series 6600 Analog Instrument Return Flow Calibration Totalizer Calibration Return Flow Calibration ON There are nine Dip switches located on the back of your 6500 Series Instrument These switches are used to calibrate the instrument prior to use a a a a a a L Switches 1 through 9 are shipped in the OFF position Before proceeding with the calibration verify that switch 8 is ON and that the rest are OFF 1 R Se S Instrument calibration is accomplished in two s
12. 61 email service floscan com http www floscan com Lo Flo Pulsation Damper Can Replacement FloScan FloScan f 233 041 00 frost l Rubber Sealing Rubber Sealing Washer gt Washer Aluminum Base a Aluminum Base Forward Sensor Return Sensor 1 Remove the old Pulsation Damper can A Claw type oil filter wrench or pipe wrench may be needed 2 Put a coating of grease on both sides of the new Pulsation Dampers rubber sealing washer 3 Clean the Aluminum base and put a coating of grease on the seal s mating surface 4 Place the new Pulsation Damper can on its Aluminum base Turn until Finger tight 5 Using a band type oil filter wrench carefully rotate the can until tight approximately of a turn past finger tight e Position a strip of rubber Bicycle tube or rubber glove between the wrench and can Rubber increases friction and protects the can Use caution as over tightening will buckle or collapse the can White Replacement K Series Pulsation Damper Can P N 233 041 00 4 23 2003 7000 145 01 FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 email service floscan com_ http www floscan com Hi Cap Pulsation Damper Can Replacement Rubber Sealing Rubber Sealing Washer Washer Forward Sensor 1 Remove the old Pulsation Damper can A Claw type oil filter wrench or pipe wrench may b
13. B 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 S Dh lt 3 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 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 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
14. Installation Troubleshooting Manual Marine Cruisemaster Diesel K Series HI CAP U S This manual part 4001 406 02 applies to the following product part numbers 1 6320 3CB 2K 2 6332 3BB 2K 3 66100 3CB2K 4 66100 3CC2K 5 66100 3DB2K 6 66100 3DC2K 7 66100 3DD2K 8 66100 3EC2K 9 66100 3ED2K 10 66100 3EE2K 11 66100 3FE2K 12 6620 3BB 2K 13 6620 3CB 2K 14 66200 3EE2K 15 66200 3FD2K 16 66200 3FF2K 17 6632 3BA 2K 18 6632 3BB 2K 19 6632 3CB 2K 20 6632 6DB 2K 21 6632 3DD 2K 22 6650 3BB 2K 23 6650 3CB 2K 24 6650 3CC 2K 25 6650 3DB 2K 26 6650 3DC 2K 27 6650 3DD 2K 28 6650 3ED 2K 5 13 2004 4001 391 23 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 5800 58000 6500 65000 6600 66000 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 FAULT PROBABLE CAUSE SEE SECTION Low Totalizer Reading more than 10 Sensor orientation failure High Totalizer Readings more than 10 Suction leak Section VI Fluctuating GPH readings Low
15. 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 Hea d FloScan LL i Forward i EZ flow sensor aa Tank C _ _ Fuel Flow Direction Return Fuel aa Engine Cooler fp OS FloScan aj 5 7 gt agp ag a nus lee PLS Return flow sensor U 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 arr
16. TE 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 to a known good ground The Ohmmeter should read approximately 0 1 to 3 Q Ohm Reading 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 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 Ohm Reading VI FINDING FUEL SYSTEM SUCTION LEAKS Two common complaints are Fluctuating GPH readings and High Totalizer Readings These are generally caused by small vacuum leaks between the fuel tank and fuel pump inlet Generally fluctuations tend to be between 2 and 4 GPH Vacuum leaks also affect totalizer accuracy and usually cause it to read about 15 to 100 high Vacuum leaks can occur in both gasoline and diesel systems Larger leaks produce greater fluctuations and higher readings Except in severe cases they do not affect engine performance A stiff anti siphon valve or sticking carburetor float valve also cause fluctuating GPH readings but do not affect totalizer accuracy If the totalizer reading is within 6 you should repair or replace defective valve
17. blies 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 wide stainless hose clamp on each hose end Wire Braid A 1 Aeroquip Type Fuel Hose or Hydraulic Hose Mount the sensor s or sensor assemblies where they re to be installed Mark the hose where it is to be cut Remove hose and bring it to a hydraulic shop Have them cut the hose and install hose ends Reinstall the hoses and install the correct fitting into each sensor or sensor assembly Always assemble fittings using a fuel proof pipe thread sealant Never use Teflon Tape Hoses should not be twisted have adequate slack an ample radius at all bends and be adequately supported at reasonable distances approximately 2 4 feet AP 50 copper sealing washers Connie Seals or Flaretite seals may be required to seal JIC amp SAE fittings IV Electrical Installation Run cables between Sensor s J Box If used and Instrument s Cables must be adequately supported at reasonable distances approximately 2 4 feet Wir
18. 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 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 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 Minute Fire Test USCG Type A 1 100g m 24hrs Required USCG Type A 2 300g m 24hrs Required USCG Type B 1 10
19. e needed 2 Put a coating of grease on both sides of the new Pulsation Dampers rubber sealing washer 3 Clean the Aluminum base and put a coating of grease on the seal s mating surface 4 Place the new Pulsation Damper can on its Aluminum base Turn until Finger tight 5 Using a band type oil filter wrench carefully rotate the can until tight approximately of a turn past finger tight e Position a strip of rubber Bicycle tube or rubber glove between the wrench and can Rubber increases friction and protects the can Use caution as over tightening will buckle or collapse the can White Replacement K Series Pulsation Damper Can P N 233 041 00 4 23 2003 7000 145 01 FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 3016 NE Blakeley Street Seattle WA 98105 email service floscan com_ http www floscan com 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
20. e totalizer reading is less than the fuel used Switch Positions Amount of compensation 2 4 8 16 5 OFF Totalizer reading higher ON Totalizer reading lower 8 14 1998 4001 376 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
21. er 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 the next wire refer to wiring diagram Connect ground wires first BLACK gt Se 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 ee Vice nokii splice Red power wires for last to prevent short circuits during the installation 3 Crimp butt splice Splicing Splice or join individual wires per the diagram Slide heat shrink tubing over z a 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 HEAT 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
22. hnical Support 4 17 2003 4001 103 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 Flow Homogenizer Can Replacement ATTENTION This is 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 4 of a turn past finger tight 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 49
23. ic 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 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 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 INSTALLATION MECHANICAL amp WIRING OVERVIEW K Series amp 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 mus
24. inal or to the ground buss For the system to operate properly the Ground wires must be connected in this manner Connect other wires per the wiring diagram Leave the RED power wire for last Tachometer Installation Options 75 7600 85 8600 and 95 9600 series tachometers require one or two additional wires If your engine isn t equipped with a tachometer sender determine which type it requires AC Signal Generator or Magnetic Pickup and install one Some engine alternators produce a tachometer signal and can be used as the tachometer sender Mechanically driven AC signal generators and magnetic pickups are available from FloScan and most marine dealers Hewitt Motorola VDO and Stewart Warner are some of the more common brands 1 Keep Existing Tachometer s Connect the FloScan tachometers Yellow and Violet signal wires to the existing tachometer If the tachometer sender wire s are not marked trace them from the tachometer sender up to the existing tachometer If one sender lead is grounded connect the FloScan tachometers Yellow signal wire to the ungrounded lead or terminal 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 commo
25. ize Minimize the number of elbows and fittings If swivel fittings are used JIC or SAE their mating surfaces must be sealed with Copper Conical Sealing Washer Connie Seals or fitting seals Fitting seals may be purchased through Fittings Inc in Seattle WA 206 767 4670 1 800 552 0632 or a local hydraulic supply house Select Instrument Mounting Location The instruments face is waterproof and a gasket is provided to seal its bezel to the control panel Choose a location away from the compass Install 65 6600 series instruments 12 away from compass Choose a shaded location since direct sunlight may cause the LCD display to temporarily turn This does not damage the LCD but makes it impossible to read until cooling down Make a cutout in the instrument panel for the instrument The instruments maximum depth is 3 1 2 minus the thickness of the console panel Instrument Series Cutout Size 6500 6600 3 1 16 7500 7600 8500 8600 9500 9600 TwinScan 3 3 8 Wiring Determine wiring run length and the number of switches needed always use good quality 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 term
26. le 2 add 2 to the GPH reading Turn switch 6 ON If the instrument continues to read low increase the GPH reading another 2 Turn switches 6 OFF and 7 ON Continue to increase the GPH reading in 0 5 increments until the desired GPH reading is achieved Fuel flow fluctuations of 1 to 2 GPH are fairly common on Marine Diesels when idling Some governors tend to hunt as they try to maintain a steady low engine speed This completes the return flow calibration procedure If you re unable to obtain the correct idle setting refer to the Troubleshooting guide for guidance in locating the problem If you have any questions or have a problem you can t solve call the FloScan Technical Service Department for assistance Totalizer Calibration Fill the fuel tank s and reset the totalizer Operate the boat as you normally would Do at least two fill ups and determine the difference between the fuel consumed and your totalizer reading Calculate the percentage difference using this formula S al eee Difference in Gallons Totalizer Reading 100 5 Turn ON the combination of switches 1 2 3 and or 4 which equal that difference Example You determine the totalizer reading is 6 5 lower than what actually was actually used The combined percentage total of switches 1 2 and 2 4 is 6 Turn switches 1 and 2 and 5 ON Switch 5 remains OFF if the totalizer reads higher than the actual fuel used and is turned ON if th
27. n size and fits into most instrument mounting holes Identify the engines tachometer sender wires Connect the FloScan tachometers Yellow and Violet signal wires to the sender wires If one sender lead is grounded connect the FloScan tachometers Yellow signal wire to the ungrounded lead or terminal Connect the VIOLET wire to a Ground Buss or Battery Minus 3 New Tachometer s Run a dedicated shielded pair of wires between the instrument and tachometer sender This is especially important with Magnetic Pickup senders Ground the shield only in the engine room e Magnetic Pickup amp AC Signal Generator Tachometer Senders Connect the FloScan tachometers Yellow signal wire to one sender terminal Connect the Violet wire to the other terminal e Engine Alternators Connect the FloScan tachometers Yellow signal wire to the alternators tachometer output terminal This terminal is usually marked as TACH or SIG Connect the VIOLET wire to a Ground Buss or Battery Minus e Pre Startup amp Installation Check Prime the fuel system If you have an electric priming or boost pump circulate 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
28. ows pointing UP 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 FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 Tel 206 524 6625 4001 291 04 Fax 206 523 4961 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 ma
29. r original position and proceed with Part II If not contact FloScan Technical Support Il TEST FLOW SENSOR S 3016 NE Blakeley Street Seattle WA 98105 1 With the engine idling connect the BLUE diagnostic wire to Ground The instrument needle will display fuel flowing through the Forward Sensor GPH When testing the scale and readings on 0 10 GPH amp 0 40 LPH Instruments increase by a factor of 3 2 Connect the BLUE wire to 12 VDC The instrument will display fuel flowing through the Return Sensor VDC 3 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 4 Move the voltmeters negative lead to the WHITE Signal wire With engine idling measure and record the voltage reading It should be approximately 5 7 VDC about of the reading in step 3 VDC 5 Stop the engine while observing the voltmeter Voltage readings should fluctuate between a high of 9 to 12 VDC and a low of 0 to 4 VDC as the flow sensors turbine slows to a stop VDC NOTE This may not be seen on a digital voltmeter 4 17 2003 4001 103 00F FloScan Instrument Company Inc Tel 206 524 6625 Fax 206 523 4961 email service floscan com http www floscan com 6 Move the voltmeters negative lead to the BROWN signal wire With engine idling measure and record the voltage reading It should be approximately 5 7 VDC
30. 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 ELECTRICAL Series 6500 6600 65000 66000 GPH Cruisemaster To ensure years of trouble free operation please read these instructions carefully before beginning your installation Your Cruisemaster is supplied with a sufficient number of crimp on and heat shrink tubing to make a typical installation The heat shrink tubing is a special type that gt will bond with the wire insulation to make a water tight connection See the diagram T 1 Slide heat shrink tubing to right for proper application of the tubing The crimp on connectors work best e Sae nlia with 18 gauge stranded wire wire not included 2 Insert wire ends into butt splice 3 Crimp butt splice Connect the wires one at a time see wiring diagram for your particular installation and install heat shrink before proceeding to the next wire saving the RED wire to 12V until last to prevent short circuits during the installation Slide heat shrink tubing over butt splice Apply heat HEAT NOTE On installations with two flow sensors the WHITE wire MUST go to the Forward Flow Sensor and the BROWN wire MUST go to the Return Flow Sensor Reversing these wires will cause the instrument to show O flow The RED
31. t be installed downstream of the primary filter Do not install the sensor or either sensor assembly at a high point in the fuel system This could negatively impact system accuracy by trapping air The fuel return line between the return sensors outlet port and fuel tank should be at least 12 long and have a 1 to 2 upward rise This keeps the return sensor flooded improving accuracy Place sensor assemblies in a protected location away from water spray Forward Sensor amp Pulsation Damper Assembly FloScan Inlet a Ol d Outlet gt gt oo L gt baal Wat aa Forward Sensor And Pulsation Damper Assembly FloSean Inlet ha a ae 201 231 1K amp 2K 235 2K Inlet gt 2 A 0 5 Outlet L 233C 10 amp 233D 10 Cummins PT Systems 8 5 2003 FloScan Instrument Company Inc 3016 NE Blakeley Street Seattle WA 98105 233 236 1K amp 2K Return Sensor amp Pulsation Damper Assembly 233 236 2K Return Sensor And Pulsation Damper Assembly FloScan Outlet nM Inlet 201 231 235 2K Outlet Ouieta Inlet ARROW UP 231 10 Cummins PT Systems 4001 325 00F Tel 206 524 6625 Fax 206 523 4961 email service floscan com http www floscan com Determine fitting type amp s
32. tch 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 fittings to a maximum of 15 ft lb 180 inch lb or 2 full turns past hand tight whichever comes first Leak Lock pipe thread sealant is provided with your system Use it on all pipe thread fittings DO NOT USE TEFLON TAPE TEMPERATURE COMPENSATED Forward Sensor Return Sensor Kit 236F 236E 6FE 2K 236E 236D 6ED 2K 236D 236D 6DD 2K 236C 236C 6CC 2K 236C 236
33. teps First the Return Flow is calibrated Then after operating the vessel and consuming one or two tanks of fuel the totalizer is adjusted Return Flow Calibration Referring to Tables 1 and 2 do the following to calibrate the return flow sensor 1 Start your engine and let it idle until it reaches its normal operating temperature 2 Increase engine speed to 1800 RPM Unloaded for 1 or 2 minutes This purges any air trapped in the fuel lines 3 Return the engine to low idle Referring to table 1 determine its no load fuel consumption No Load Idle Setting Naturally Aspirated Turbo Charged Table 1 4 Referring to Table 2 turn switches 6 7 8 and 9 ON or OFF as necessary to get the instrument to read the amount selected from Table 1 If the instrument reads lower than the value selected use the percentages to increase its reading If the instrument reads higher than the value selected use the percentages to decrease its reading Begin by adding or subtracting 2 from the reading Continue in 2 steps until the desired reading is obtained Switches Switches Change factor 6 7 8 9 Table 2 Off Initial gt Position 8 14 1998 4001 376 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 Example The instrument reads 0 GPH after the engine warms up Referring to Tab
34. wire to 12V Supply should be connected to the keyed side of the ignition switch If power is not being supplied through a fuse panel a 1 amp fuse should be installed at the source of power 12VDC SYSTEM MUST BE PROPERLY GROUNDED FOR CORRECT OPERATION Run a stranded ground wire from the negative terminal of the battery and splice it into the black wire common between the flow sensor s and the instrument head The Cruisemaster internal circuitry is isolated from the can at the instrument head to prevent ground loop interference Connect to ground only at the black wire junction to the flow sensor s The BLUE wire is used for troubleshooting only Leave disconnected for normal operation For the Cruisemaster installation a single pole single throw SPST switch is required not supplied to reset the totalizer A good selection is a SPST momentary OFF Connect the GREEN wire through the reset switch to a constant 12VDC The display only uses 70 microamps 0007 amps of power so it will not appreciably drain your batteries even for an extended period of time If your boat is equipped with a MASTER BATTERY SWITCH and you do not want to lose the totalizer memory you will need to run a power wire through a 1 4 amp fuse to the battery The fuse is to protect the wiring and should be as close to the battery as possible Connect one BLACK wire from the illumination bulb to the illumination circuit and the other BLACK wire to instrument ground It

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