DIESEL FUEL FLOW SENSORS Installation and Operation Manual English .................... 3 Español ................. 38 Português ............. 73 www.navman.com NAVMAN FCC Statement Note: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a normal installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: Reorient or relocate the receiving antenna. Increase the separation between the equipment and receiver. Connect the equipment into an output on a circuit different from that to which the receiver is connected. Consult the dealer or an experienced technician for help. A shielded cable must be used when connecting a peripheral to the serial ports. 2 Diesel fuel flow sensor kit Installation and Operation Manual Contents Contents ................................................................................................. 3 Important ................................................................................................ 5 1 Introduction .................................................................................. 6 1-1 Diesel fuel flow sensor features ................................................. 6 1-2 A typical system ........................................................................... 7 A diesel flow sensor .....................................................................................7 1-3 2 The bypass valve .......................................................................... 7 Understanding boat performance data ...................................... 8 Boats ............................................................................................................8 Fuel Consumption ........................................................................................8 Engine RPM .................................................................................................8 Boat Speed ..................................................................................................8 3 3-1 3-2 Plotting a fuel consumption curve ............................................. 9 Fuel consumption table ............................................................. 12 Notes on filling out this table ......................................................................12 Understanding the fuel consumption curve ............................ 14 A typical fuel consumption curve ................................................................14 Understanding your fuel consumption curve ..............................................14 Note on fuel usage .....................................................................................14 4 Measuring your propeller's performance ................................ 15 Propeller size .............................................................................................15 Slip factor ...................................................................................................15 Calculating the slip factor ...........................................................................15 Understanding your slip factor ...................................................................16 5 5-1 5-2 6 6-1 6-2 6-3 Measuring engine performance ................................................ 17 Engine power and propeller curves ......................................... 17 The theoretical propeller load curve ...........................................................18 Specific fuel consumption curve .............................................. 19 Diesel fuel flow sensor hardware ............................................. 20 What comes with your diesel fuel flow sensor kit .................. 20 Options and accessories ........................................................... 20 Filtering the fuel ..........................................................................................20 Sensor fittings ............................................................................ 21 Diesel fuel flow sensor kit Installation and Operation Manual NAVMAN 3 7 7-1 7-2 Installing the diesel flow sensor kit .......................................... 22 Installation sequence .................................................................................22 Twin engine installations ........................................................... 22 Notes on pipes, fittings and installation .................................. 23 7-2-1 Pipe ..........................................................................................................23 7-2-2 Flare Nuts ..................................................................................................23 7-2-3 Flexible Hoses. ..........................................................................................23 7-2-5 Threadseal tape or paste ............................................................................23 7-3 Planning where the parts of the kit will be fitted ..................... 25 7-3-1 Overview ....................................................................................................25 7-3-2 Mounting a sensor ......................................................................................25 7-3-3 Locating the sensors in the fuel lines .........................................................26 Locating the supply sensor ........................................................................26 Locating the return sensor .........................................................................26 Sensor mounting positions .........................................................................26 7-4 7-5 7-6 Installing the temporary straight through pipes ..................... 28 Test running and installing the sensors ................................. 31 Installing the tachometer pickup .............................................. 33 Locating the tachometer pickup .................................................................33 Installing the tachometer pickup .................................................................34 7-4-1 Installing a through pipe with flare joints into a copper pipe run ................29 7-7 Installing the cables ................................................................... 35 7-7-1 Link and tachometer cables .......................................................................35 7-7-2 Connecting to a DIESEL 3200 ...................................................................35 Appendix A Specifications ................................................................. 37 4 NAVMAN Diesel fuel flow sensor kit Installation and Operation Manual Important It is the owner's sole responsibility to install and use the instrument and its sensor(s) in a manner that will not cause accidents, personal injury or property damage. The user of this product is solely responsible for observing safe boating practices. Fuel type: Navman diesel flow sensors (metal) and DIESEL 3200 instruments have been specifically developed for use in marine applications with diesel engines and are not warranted for any other type of application. These sensors and instruments must NOT be used with petrol (gasoline) engines. Fuel formulation: Every effort has been made by the manufacturer to ensure that the materials used in the Navman fuel flow sensor(s) will operate reliably with different fuel mixtures. The manufacturer or its distributors can not be held responsible for fuel formulation or any affect this may have on the performance and durability of the fuel flow sensor(s). Back pressure: A diesel fuel flow sensor will create additional back pressure in a fuel system of an estimated 0.3" of mercury at 25 US gallons /hour (100 litres/hour) and 1.5" of mercury at 80 US gallons per hour (300 litres/hour). It is the owners responsibility to ensure that fitting the fuel flow sensor(s) does not cause fuel starvation which may lead to poor engine performance. Fuel Computer: Fuel economy can alter drastically depending on the boat loading and sea conditions. The fuel computer should not be the sole source of information concerning available fuel onboard and the electronic information should be supplemented by visual or other checks of the fuel load. This is necessary due to possible operator induced errors such as forgetting to reset the fuel used when filling the tank, running the engine with the fuel computer not switched on or other operator controlled actions that may render the device inaccurate. Always ensure that adequate fuel is carried onboard for the intended trip plus a reserve to allow for unforeseen circumstances. Specific requirements: Your boat's fuel installation boat might be subject to specific requirements (such as USCG, NMMA and ABYC guidelines or local laws), particularly if the boat is licensed, surveyed, charted or inspected. It is the owner's sole responsibility to install and use the instrument and its sensor(s) in compliance with these requirements. NAVMAN NZ LIMITED DISCLAIMS ALL LIABILITY FOR ANY USE OF THIS PRODUCT IN A WAY THAT MAY CAUSE ACCIDENTS, DAMAGE OR THAT MAY VIOLATE THE LAW. Governing Language: This statement, any instruction manuals, user guides and other information relating to the product (Documentation) may be translated to, or has been translated from, another language (Translation). In the event of any conflict between any Translation of the Documentation, the English language version of the Documentation will be the official version of the Documentation. This manual represents Navman's Diesel fuel flow sensor kit as at the time of printing. Navman NZ Limited reserves the right to make changes to specifications without notice. Copyright © 2004 Navman NZ Limited, New Zealand. All rights reserved. Navman is a registered trademark of Navman NZ Limited. Diesel fuel flow sensor kit Installation and Operation Manual NAVMAN 5 1 Introduction The Navman diesel fuel flow sensor kit measures the fuel consumption and RPM of your diesel engined boat. But that is a gross understatement of the capabilities of this powerful diagnostic tool. This manual is written to help you understand the many functions the system can perform, and to help you interpret the numbers it can provide. We also give some basic information on some of the factors which can influence boat performance, and what the various readings from the sensors can reveal about your boat. Hopefully, by understanding more, you will no longer think of the engine as just a noisy and expensive mystery. In the end we should be able to help you make your boating experience more relaxing, safer, more economical and better informed. This manual describes: How to install a diesel fuel flow sensor kit onto a diesel engine (sections 6 and 7). How to understand and interpret the fuel sensor readings (sections 2 and 3). How to use the fuel flow readings to understand and optimise your propeller and engine performance (sections 4 and 5). Note that this fuel flow sensor kit does not have a display. The kit must be installed with a Navman marine instrument to display the fuel readings, such as the DIESEL 3200. A second sensor kit can be fitted for twin engine boats. It is vital to read this document and the Navman display instrument's installation and operation manual before installing or using this kit. 1-1 Diesel fuel flow sensor features A positive displacement flowmeter, with one moving internal part - there are no fine pointed shafts and jewelled bearings to get worn or hammered by diesel pulsing. Diecast aluminium housing. A direct flow bypass valve, to take the sensor out of the fuel line if required. Low pressure drop across the sensor. Simple, in-line installation, much like a primary fuel filter. The inlet and outlet ports have a commonly-available thread: a ¼ NPT parallel female thread on sensor is used with a ¼ NPT taper male thread on the fitting. No restrictions on pipe geometry on entry or exit from sensor. Supplied with temporary straight through pipes to make installation safer. Factory tested and calibrated - sensors do not normally require calibrating again. Each engine is fitted with two fuel flow sensors. One sensor, in the the fuel supply line measures flow from tank to engine. The other sensor, in the fuel return line measures flow from the engine back to the tank. The flow sensor sy ...