J.P.Instruments Fuel Flow Installation Manual
Contents
1. indicator STC SA 2586NM If this instrument is to replace an existing unit in the aircraft it is the installer s responsibility to move or replace any existing instruments or components in accordance with FAA approved methods and procedures The following Installation Instructions do not cover moving or the removal of any existing instruments or components Before connecting any hoses to the transducer thoroughly clean them and insure they are free of any loose material Never pass high pressure air through or blow through the transducer damage will occur Remove the transducer cap plugs when ready to install hoses Do not use aluminum fittings with the fuel flow transducer or Gauling may occur Note the direction of fuel flow marked on the transducer Fuel must flow in this direction Mount the transducer with the three wires pointing up Note and record the K factor engraved in the side of the transducer Do not use teflon tape or thread sealent compound of any kind J P Instruments Fuel Flow Installation Manual for EGT 701 with Fuel Flow Option 3 Installing the Fuel Flow Transducer Mount the Fuel Flow Transducer using the appropriate drawing at the back of this manual Report 503 Page 4of 14 Rev B Date 03 14 97 Aircraft Configuration Drawing Location 1 All gravity Flow installations without fuel pump Must use 700923 Between Fueltank and Carburetor FXT 231 2 All Fuel injected engines with vapor return lines t2. per Continental Service Bulletin M89 10 7 Cessna 182 T aircraft with an IO 540 engine must use the gravity 700900 2 Transducer if connecting between the Throttle Body and the Flow Divider J P INSTRUMENTS PO Box 7033 Huntington Beach CA 92646 Title Installation of the Fuel Flow Transducer in the fuel line between the Throttle Body and the Flow Divider Only applicable for Continental Fuel Injected Engines Drawing No 700922 Date Approved R J P Instruments Fuel Flow Installation Manual Report 503 for EGT 701 with Fuel Flow Option Page 10 of 14 Rev B Date 03 14 97 Fuel injector e ne TRANSDUCER Existing Fitting MS21919 Clamp SDUC To Engine Driven ius as required ump Existing 8 max from SS support Aeroquip oe i Pa 900591B Clamp Aeroquip Fire Sleeve 2 AN816 Pipe to New 303Aeroquip hose AE102 624 24 Flare fitting Do not use aluminum fittings Mounting Procedure 1 Find a convenient location within 8 of a hose support or fitting and away from any hot exhaust pipes to suspend the Fuel Flow Transducer The hose support or fitting may be on the input or output line of the Flow Transducer 2 Remove the fuel hose which goes from the Fuel Pump to the Carburetor or Fuel Servo 3 Purchase two new hoses one from the fuel pump or the Fuel Filter to the Fuel Flow Transducer and the other from the Fuel Flow Transducer to the carburetor or fuel servo There must be flexible hose in and out of the Transducer Th
3. DWGS A VIA OrIO O lt lt SALON WdaANAD 335 E 2 HILIAS AU3 1304 7 Id OSe O 28 Lie jlDH VIG ele N lOd Viva NOIL 307 YNDI LaO 36 6 38991398 NOILJNGOJd Report 503 J P Instruments Fuel Flow Installation Manual for EGT 701 with Fuel Flow Option Date 03 14 97 Page 12 of 14 Rev B 40 t LAHHS ulvd ON Ada ON LUVd ONI AL LL HO MJOndS 8 814 8 v14 Nc JjNISN3 JAI Z ys r4Kdoo Q Sjuaunij3su dq f jo uo 1 8U 10 jut Aare ye tidodd suleyuoo SUMeIP SWL S 13ON YJDNASNYHL AN IN SINANA Q NO ILY T IVLSN Ac IH JM NVOSMO 14 SONA ANY NO ILVZ SALON 3HL ae LIONE ANY OL nnau y Udd dal 3M 11 39 IASC Q3 TIVISN O3NNOO 38 A ISnO Nanlad SO ILOn aoc 5 OL 1nO Ze 2 S GEG 5d e i0 n oo sF wy J P Instruments Fuel Flow Installation Manual Report 503 for EGT 701 with Fuel Flow Option Page 13 of 14 Rev B Date 03 14 97 Fuel Flow differential Module FFDM 1 2 Used with carbureted engines with a Fuel Connect to 15 pin D Sub Return line pressure carburetors M T on the EDM 3 Power Lead connects to 12 or 24 Volt Bus Via amp fuse Power not requir
4. J P Instruments Fuel Flow Installation Manual for EGT 701 with Fuel Flow Option Table of Contents 1 General 2 Initial Check Out 3 Installing the Fuel Flow Transducer 4 Route the Optional warning control line 5 Install the instrument in the panel 6 Route the Fuel Flow Transducer Wires 7 System Checkout 8 Specifications and Limitations 9 Pilot Programmable Modes 10 Drawing 700923 11 Drawing 700922 12 Drawing 700921 13 Drawing 700124 excerpt from report 103 STC 2586NM 14 Drawing 700744 excerpt from report 103 STC 2586NM 15 Drawing 700920 Installing the Fuel Flow Differential Module FFDM 1 or FFDM 2 J P INSTRUMENTS PO BOX 7033 HUNTINGTON BEACH CA 92704 Last printed 8 7 2008 1 58 00 PM Report 503 Page 1 of 14 Rev B Date 03 14 97 oO OND C1 O1 01 Ci B W PO J P Instruments Fuel Flow Installation Manual Report 503 for EGT 701 with Fuel Flow Option Page 2 of 14 Rev B Date 03 14 97 EGT 701 with Fuel Flow Option Installation Instructions 1 General A complete thorough familiarization and understanding of the system and this manual is necessary before commencing the installation All work must conform with A C 43 13 1A ch 11 sec 2 3 7 The accuracy of this instrument depends entirely upon the accuracy of the data entered A periodical checking of the actual fuel onboard will eliminate the accumulation of errors due to evaporation leaks etc Do not use the FXT 201 Flow Transduce
5. ad with the cylinder number All wires must be routed away from high temperature areas exhaust stacks turbochargers etc Secure Probe leads to a convenient location on the engine approximately 8 to 12 inches from the probe being sure there is sufficient slack to absorb engine torque It is essential in routing the probe and fuel flow transducer wires not be allowed to touch metal parts of the air frame or engine since abrasion will destroy this wire Connect wires in accordance with dwg 700744 page 12 7 System Checkout Check instrument operation as follows 1 Turn the aircraft master switch on engine off and set the toggle switch to Fuel Flow Tap the step switch until 0 GPH is displayed Turn the boost pump on for a few seconds The display should indicate 3 to 8 GPH A problem at this step could be caused by poor connections on the red or black power and ground leads 2 Set the instrument toggle switch to Fuel Flow and check for a digital fuel flow reading of 00 GPH indicates the fuel flow is too low to register A reading of GPH dashes indicate no fuel flow transducer signals A problem at this step could be caused by a poor connection or crossed flow transducer wires 3 With the engine running check the FLOW Display Mode to read properly If there is a problem at this point Refer to EDM 700 Fuel Flow Option Supplement Rev C Section 4 for troubleshooting information 4 After running the engine check the fuel hos
6. ation Manual For EGT 701 No 103 Page 8 for more information RS232 422 Input Ports EGT 701 with Fuel Flow option Only Single Line Receive Method RS 232C RS423 or 5 Volt Serial Dual Line Receive Method RS 422 or RS 485 Protocol Start bit 8 Data bits 1 Stop bit Baud Rate L129600 L 2 1200 Format Moving Map Output L 1 King KIN 88 L 2 Northstar RS232 Output Port Transmit Method RS 232 Single Line Protocol Start bit 8 Data bits 1 Stop bit Baud Rate 9600 Transmit Format King KIN 88 Fuel Flow Transducer Standard FXT 201 Fuel Flow Transducer Gravity Only FXT 231 Range 0 6 to 60 GPH Range 3 to 90 GPH Linearity 961 8 to 60 GPH Linearity 961 8 to 60 GPH K Factor Approx 29 000 K Factor Approx 19500 Pressure Drop 1 2 PSI at 30 GPH Pressure Drop 31 PSI at 30 GPH 4 8 PSI at 60 GPH 2 8 PSI at 90 GPH Working Press 200 PSI Working Press 200 PSI Min Burst Press 2000 PSI Temp Range 65 C to 125 C Fuel Ports 1 4 Female NPT Min Burst Press 2000 PSI Temp Range 65 C to 125 C Fuel Ports 1 4 Female NPT J P Instruments Fuel Flow Installation Manual Report 503 for EGT 701 with Fuel Flow Option Page 8 of 14 Rev B Date 03 14 97 Fuel line from the Carburetor ee To the Fuel Tank aximum trom support TRANSDUCER ip Fi To the Fuel Tank i Aeroquip Fire Agodan eats 900591B AE102 62 24 Mount to Firewall or Fittings 14 NPT to Fuel Engine Aero
7. e hoses must meet TSO C53a Type C or D FAA specification The new hoses must be the same size as the current hose in the aircraft 4 Mount the Fuel Flow Transducer in the fuel line You must use the FXT 231 Fuel Flow Transducer on a gravity feed system The FXT 201 Transducer is marked Model 231 on the top of the transducer The Flow Transducer must be wrapped with Fire Sleeving Place a small hole in the fire sleeve and pass the transducer wires through it Seal with High temperature Silicone RTV sealant 5 Before connecting fuel hose to the carburetor verify that the boost pump delivers at least 125 of takeoff fuel consumption at minimum fuel pressure as marked on fuel pressure gage J P INSTRUMENTS PO Box 7033 Huntington Beach CA 92646 Title Installation of a Fuel Flow Transducer in the fuel line from the fuel pump to the carburetor or fuel servo Drawing No 700921 Date Drawn Approved Rev NC 02 14 97 Report 503 J P Instruments Fuel Flow Installation Manual for EGT 701 with Fuel Flow Option Page 11 of 14 Date 03 14 97 Rev B t661 1u8raKdoo syuoun2i amp u d fy 4g 1 914 uo yeusoyuy Aseya adol sure1u o Suraeup SIUL OM EIO0L oy sya SZ 2 3iVIdW3l 0226 V2 VNV BAD JAIS 4337 ND LNAWASLSNI YVAN Ladd Viva 31v30 Ce SINJW OHISNI d f NADHS SV iHOIS 83AU NI INGWOSISNI 40 1H9Is 3Hl OL 38019 HOLIAS LNNOW 1 SALON 1V33N39 Ovi Sadia NOLLAG 3A
8. ed 3 Ground Lead connects to same ground as FP 5 on the FFDM 2 taken from EDM 700 Wire bundle marked Wire bundle marked Return J P INSTRUMENTS PO Box 7033 Huntington Beach CA 92646 Title FFDM 1 Interconnect Wiring Diagram Drawing No 700920 Date 02 14 97 Drawn Approved Sheet Rev NC 1 of 2 J P Instruments Fuel Flow Installation Manual Report 503 for EGT 701 with Fuel Flow Option Page 14 of 14 Rev B Date 03 14 97 10 Installing the Fuel Flow Differential Module FFDM I and the FFDM 2 If your engine is equipped with a fuel return line from the carburetor back to the fuel tank install the FFDM 1 or FFDM 2 in the aircraft as outlined below see sheet one Otherwise omit this step a b c d e f Connect the connector to the FFDM I 2 Install the FFDM 1 2 under the instrument panel using two tie wraps on each end of the module to support it to a wire bundle or bracket Only required on the FFDM 1 Route and connect the 3 red power lead to the 12 or 24 volt bus via a 1 amp fuse Route and connect the 3 black ground lead to the same ground used for the EGT 701 with Fuel Flow option Route and connect the 6 red black and white leads marked Feed to the flow transducer installed in the fuel line from the fuel pump to the carburetor Route and connect the 6 red black and white leads marked Return to the flow transducer installed in the return fu
9. el line from the carburetor to the fuel tank Connect the red black and white leads to the same color 6 leads from the EGT 701 with Fuel Flow option Any excess wires can be rolled up and tie wrapped under the instrument panel Tie wrap these wires so they do not obstruct the freedom of travel of any controls J P INSTRUMENTS PO Box 7033 Huntington Beach CA 92646 Title FFDM 1 Interconnect Wiring Diagram Drawing No 700920 Date Approved 02 14 97 Sheet Rev NC 2 of 2
10. es transducers and fittings for leaks J P Instruments Fuel Flow Installation Manual for EGT 701 with Fuel Flow Option s Specifications and Limitations Model EGT 7010 with Fuel Flow option Case Dimensions 2 5 x 2 5 x 7 5 depth 2 1 4 Bezel Weight Unit Only 16 oz Flow Transducer 3oz Environmental Passed TSO C43c and DO 178a software level 3 Power Requirements 10 to 35 Volts 2 Amp Low Fuel Warning Display Report 503 Page 6 of 14 Rev B Date 03 14 97 The display message will blink anytime the programmed Low Fuel Reminder Low Fuel Warning or the Time to Empty Limit are violated External Warning Control Line Grounds when any Warning display is on or blinking Current should be limited to 2 10 amp Accuracy Flow 2 or better in accordance with TSO C44a Resolution Fuel Flow 0 1 Gal or 1 Lb or 1 Ltr Fuel Remaining 0 1 Gal or 1 Lb or 1 Ltr Fuel Used 0 1 Gal or 1 Lb or 1 Ltr Time to Empty 10 minute Max Displayed Range Unit Only Fuel Flow 199 9 Gals or 162 0 or Gal Hr or 1199 Lbs Hr or 749 Ltr Hr Fuel Remaining 999 Gals or 811 or Gals or 1999 Lbs or 1999 Ltrs Fuel Used 999 Gals or 811 or Gals or 1999 Lbs or 1999 Ltrs Time to Empty 19 hours 59 minutes J P Instruments Fuel Flow Installation Manual Report 503 for EGT 701 with Fuel Flow Option Page 7 of 14 Rev B Date 03 14 97 9 Pilot Programmable Modes excerpt from STC 2586NM See JPI Install
11. fuel SIDE VIEW Mount the transducer SEVO with the Carburetor or Servo wires up t7 The direction of the fuel flow through the transducer is marked on top 14 NPT END VIEW UP J P Instruments Fuel Flow Installation Manual Report 503 for EGT 701 with Fuel Flow Option Page 5 of 14 Rev B Date 03 14 97 The flow transducer must be mounted so the wires exiting the transducer are pointing up Before connecting any hoses thoroughly clean them and insure they are free of any loose material High air pressure my be used However do not allow high air pressure to pass through the flow transducer 4 Route the Optional External Warning Control Line The wire from pin 12 on the J 1 D SUB 25 Connector can be connected to an external warning light or buzzer This wire grounds when the display flashing a warning is on The current in this line must be limited to 2 10 of an amp maximum Exceeding this limit will damage the unit If this feature is not used leave this line open Tie wrap this wire so it does not obstruct the freedom of travel controls 5 Install the Instrument in the Panel The following section is an excerpt from report 103 Installation Manual STC 2586NM Locate a 2 25 diameter hole in the instrument panel where you would like to mount the indicator per drawing 700124 A steel template supplied with the installation kit is used as a guide for drilling two button holes in the instrument panel Alig
12. n 02 14 97 J P Instruments Fuel Flow Installation Manual Report 503 for EGT 701 with Fuel Flow Option Page 9 of 14 Rev B Date 03 14 97 To the Flow Divider Aeroquip Mounting Procedure 900591B Clamp Ye s is 1 Find a convenient location between the Throttle Body and the Flow Divider and M Fittings 4 NPT to away from any hot exhaust pipes to suspend the Fuel Flow Transducer Fuel Hose do not use aluminum 2 Remove the fuel hose which goes from the Throttle Body to the Flow Divider panes 3 Purchase two new hoses one from the Fuel Servo to the Fuel Flow Transducer and the other from the Fuel Flow Transducer to the Flow Divider There must be flexible hose in and out of the Fuel Transducer The hoses must meet TSO C53a Type C or D FAA specification The new hoses must be the same size as the current hose in the aircraft A source of fittings and fabricated Aeroquip Fire Sleeve AE102 62 24 hoses is ee 4 Mount the Fuel Flow Transducer in the fuel line The Flow Transducer must be wrapped with Fire Sleeving Place a small hole in the fire sleeve and See notes E pass the transducer wires through it Seal with High temperature Silicone From the Throttle Body RTV sealant 5 Secure at either end of the transducer to any convenient point on the engine with MS21919 clamps or equivalent 6 For Continental fuel injected engines adjust the fuel pressure to account for the pressure drop across the transducer
13. n and Mount the Template into the instrument panel hole First drilling a 0 125 hole Remove the template and check the instrument alignment if OK redrill with a 0 147 drill The EGT 701 with Fuel Flow option mounts in a standard 2 25 instrument hole The instrument configures itself automatically for 4 to 9 cylinder 14 28 volt aircraft The instrument is 7 5 deep less connectors and is 2 6 square behind the panel To prevent display damage it is essential that the mounting screws not penetrate the bezel more than 12 inches The indicator is FAA TSO approved as a temperature indicator under TSO C43b and must be installed in accordance with STC SA2586NM Mount the placard Do Not Rely on Fuel Flow Instrument to Determine Fuel Levels in Tanks on the aircraft instrument panel near the EGT 701 with fuel flow option If the aircraft is equipped with a primary fuel flow instrument the following placard must be mounted on the aircraft instrument panel near the EGT 701 with Fuel Flow option Refer to Original Fuel Flow Instrumentation for Primary Information 6 Route the Fuel Flow Transducer Wires The following section is an excerpt from report 103 Installation Manual STC 2586NM Route the thermocouple and fuel flow wires from the probes through the firewall using fireproof rubber grommets and flame retarding silicone Use an existing hole if possible Following the existing wiring harness and connect to the indicator marking each le
14. o fuel tank all 700922 Between throttle body A and fuel flow divider Continental and certain Lycoming engines 3 All pump fed carbureted and Fuel injected engines without 700921 Doveen engine driven R pump and servo throttle vapor return lines body or carburetot 4 Pressure Carbureted engines with vapor return lines 700923 One transducer in Carb inlet line and one 700920 transducer in out let line The instructions listed below must be followed when installing a Fuel Flow Transducer Note If your engine is equipped with a fuel return line from the carburetor back to the fuel tank you will need to install two flow transducers one in the feed line from the fuel pump to the carburetor and one in the return line from the carburetor back to the fuel tank Also a Fuel Flow Differential Module Dwg 700920 will need to be installed The transducer output port should be mounted lower or even with the carburetor inlet port or fuel servo on a fuel injected engine If this is not possible a loop should be put in the fuel line between the Fuel Flow Transducer and the carburetor or fuel servo see diagram below Do not remove the caps on the flow transducer until the fuel hoses are ready to be installed The flow of fuel through the transducer must follow the direction marked on the transducer If the transducer is higher than the carburetor or fuel servo put a loop in the fuel line between the transducer and the carburetor or
15. quip Fire sleeve Hose do not use AE102 62 24 aluminum fittings MS 21919 Clamp as required Mounting Procedure 1 Find a convenient location within 8 of a hose support or fitting and away from any hot exhaust pipes to suspend the Fuel Flow Transducer The hose support or fitting may be on the input or output line of the Flow Transducer 2 Remove the fuel hose which goes from the Carburetor to the Fuel Tank 3 Purchase two new hoses one from the Carburetor to the Fuel Flow Transducer and the other from the Fuel Flow Transducer to the Fuel Tank There must be flexible hose in and out of the Transducer The hoses must meet TSO C53a Type C or D FAA specification The new hoses must be the same diameter as the current hose in the aircraft 4 Mount the Fuel Flow Transducer in the fuel supply line and in the return line for pressure carburetors The Flow Transducer must be wrapped with Fire Sleeving Place a small hole in the fire sleeve and pass the transducer wires through it Seal with High temperature Silicone RTV sealant 5 Before connecting fuel hose to the carburetor verify that the boost pump delivers at least 125 of takeoff fuel consumption at minimum fuel pressure as marked on fuel pressure gage J P INSTRUMENTS PO Box 7033 Huntington Beach CA 92646 Title Installation of a Fuel Flow Transducer in the fuel supply or return line from the carburetor to the fuel tank Drawing No 700923 Approved Rev NC Date Draw
16. r on aircraft with a gravity feed system The standard Fuel Transducer FXT 201 shipped with the EGT 701 with Fuel Flow option Fuel Flow instrument is intended to be used on aircraft equipped with fuel pumps A gravity feed system requires the FXT 231 flow transducer Transducer Identification Markings FXT 201 Marked 201 on the top of the unit FXT 231 Marked 231 on the top of the unit Installation of the EGT 701 with Fuel Flow option on an aircraft with a fuel return line from the Carburetor requires a FFDM 1 2 Differential Module manufactured by from EI or JPI The placard Do Not Rely on Fuel Flow Instrument to Determine Fuel Levels in Tanks must be mounted on the aircraft instrument panel near the EGT 701 with fuel flow option If the aircraft is equipped with a primary fuel flow the following placard must be mounted on the aircraft instrument panel near the EGT 701 WITH FUEL FLOW OPTION Refer to Original Fuel Flow Instrumentation for Primary Information do not obstruct the freedom of travel of arty controls J P Instruments Fuel Flow Installation Manual Report 503 for EGT 701 with Fuel Flow Option Page 3 of 14 2 10 11 12 13 14 Rev B Date 03 14 97 Initial Check Out The aircraft owner must read the Warranty before starting the installation There is information in the Warranty that may alter your decision to install this instrument If you do not accept the terms of the War
17. ranty JPI offers a 30 day money back guarantee If you are not an FAA Certified Aircraft Mechanic familiar with the issues of installing aircraft fuel flow Do Not attempt to install this instrument The installer should use current aircraft standards and practices to install this instrument refer to AC 43 13 Check that any necessary FAA Approvals STC s etc are available for your aircraft before starting the installation The FAA Approved Model List AML is located at the back of this manual Read the entire Installation Instructions and resolve any issues you may have before starting the installation THIS INSTALLATION WILL REQUIRE SOME PARTS UNIQUE TO YOUR AIRCRAFT THAT ARE NOT SUPPLIED IN THE KIT including but not limited to hoses and fittings Acquire all the parts necessary to install this instrument before starting the installation Do not use aluminum fittings with the FXT 201 or FXT 231 transducer Check that the instrument make and model are correct before starting the installation check the markings on the side of the instrument A gravity feed system requires an FXT 231 flow transducer marked 231 on top A carbureted engine with a fuel return line requires an FFDM I 2 which can be purchased from Electronics International or J P Instruments Before starting the installation make sure the unit will fit in the location you intend using Refer to J P Instruments installation report 103 for the EGT 701 temperature
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