DIESEL FUEL F L O W S E N S O R S Installation and Operation Manual www.navman.com English .................... 3 Español ................. 38 Português .............
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.
Contents Contents ................................................................................................. 3 Important ................................................................................................ 5 1 Introduction .................................................................................. 6 1-1 Diesel fuel flow sensor features ................................................. 6 1-2 A typical system ...........................................................................
7 Installing the diesel flow sensor kit .......................................... 22 Installation sequence .................................................................................22 7-1 7-2 Twin engine installations ........................................................... 22 Notes on pipes, fittings and installation .................................. 23 7-2-1 Pipe ..........................................................................................................23 7-2-2 Flare Nuts ..
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.
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.
1-2 A typical system Display unit, such as a DIESEL 3200 Other wiring and connection to sensors on a second engine (optional) Other connector(s) Sensor cable Supply flow sensor Primary filter Supply fuel line Diesel tank Diesel engine Return flow sensor Return fuel line Tachometer pickup Link cable Tachometer cable These parts are included in a diesel flow sensor kit A diesel flow sensor Bypass valve (see below) Mounting bracket Fuel inlet / outlet port Fuel inlet / outlet port Two electrical conn
2 Understanding boat performance data As with all measurements, you will get no meaningful data if you do not have accurate instruments. Once you have accurate fuel consumption, boat speed and engine speed figures, then the true power of the diesel flow sensors can be used. Boats All boats are different - even consecutive boats off a production line can be quite different in performance. So there is no real ‘generic’ data that can be applied to your particular boat/engine/propeller combination.
3 Plotting a fuel consumption curve A fuel consumption curve gives a picture of how fuel consumption varies with engine RPM, and allows you to select an economical cruising speed for the given conditions. By plotting fuel consumption curves for different boat and weather conditions, you can understand how fuel consumption, economy and range vary with different conditions. When you first get your Navman diesel flow system installed on your boat, perform a test run and plot a fuel consumption curve.
NAVMAN Diesel fuel flow sensor kit Installation and Operation Manual 0 500 1000 1500 2000 2500 3000 0.8 12 0.2 0 3 0 Displacement Craft 0.4 6 0.6 1.0 15 9 1.
1 0 5 0 Planing Craft 0 500 1000 1500 2000 2500 3000 2 10 4 20 3 5 25 15 6 30 Economy - L / nautical mile Speed - knots Diesel fuel flow sensor kit Installation and Operation Manual NAVMAN 11
3-1 Fuel consumption table Photocopy this page or download a copy from www.navman.com Date Vessel Displacement Gearbox ratio Engines Weather Conditions Sea State Load aboard Passengers aboard Water Tanks Fuel Tanks Propeller Max. Fuel Capacity Working fuel capacity (max x 0.9) Notes on filling out this table Start at a slow speed. Allow a minute or two for the boat to settle to its speed and trim and for the display readings to stabilise.
1 Column 2 Reading 3 Reading 4 Calculate 5 Reading 6 Calculate 7 Calculate Engine RPM Fuel Flow Fuel Flow L/hr or Gal./hr Starboard Total flow L/hr or Gal./hr Both 2+3 Speed Naut. m/hr (Knots) Economy L/Naut. mile or Gal per Naut mile Range L/hr or Gal./hr Single or port On full tank Naut.
3-2 Understanding the fuel consumption curve A typical fuel consumption curve Note: If the boat does not plane, there will be no dip in economy as illustrated. 24 12 20 10 16 8 Speed 12 6 Economy 8 4 4 0 2 600 800 1000 1200 Engine RPM Understanding your fuel consumption curve Notice that while the speed is constantly increasing as the engine RPMs increase, the economy figure usually has a dip in its curve, as shown above.
4 Measuring your propeller’s performance The propeller is the final link in the chain that decides if your vessel is a peak performer or just another boat. The best hull and the strongest engine will be wasted unless your propeller is the right size and shape. From the fuel consumption curve, you can very simply work out how well your propellers are working. The performance of a propeller is measured by its slip factor, and this section describes how to calculate the slip factor of your propeller.
Understanding your slip factor Now, some slip is always to be expected. This slip factor varies with different types of hull, and typical slip factors are A propeller encased in an aperture behind a keel, as in a yacht: 40%. A hard chine planing hull with a full keel, or deadwood: 30% to 35%. · A hard chine planing hull with little or no keel: 25% to 30%. Twin engined planing hulls: 18% to 25%.
5 Measuring engine performance 5-1 Engine power and propeller curves Engine curves are published by the manufacturer of every engine. If you do not have the curve for your engine, ask your marine dealer for the curve. Usually there will be several curves showing the different characteristics of your engine - horsepower, fuel consumption etc, each plotted against engine revs. The curve we want to discuss is the power (horsepower or kW) versus engine RPM.
and ahead of the propeller, the degree of fouling of the hull, and the amount of weight aboard. You will probably not be able to find the exact propeller load curve for your boat, but knowing the general shape of the curve will help you understand how your boat performs. The important thing to notice is that, for a correctly sized propeller, the engine is loaded to the maximum only at the maximum RPM.
5-2 Specific fuel consumption curve Most engine manufacturers publish graphs of the specific fuel consumption for their engines. Specific fuel consumption is a graph showing how much fuel the engine burns to produce one horsepower (or kW) for one hour. Each engine has a particular RPM range where it burns the least amount of fuel to produce one unit of power. Some engines are designed to work most efficiently at high RPM, others at low RPM.
6 Diesel fuel flow sensor hardware 6-1 What comes with your diesel fuel flow sensor kit Diesel flow sensor for supply line Diesel flow sensor for return line The two sensors are distinguished by a different coloured band around the body. The supply line sensor has a blue band (think cooler fuel) and the return line sensor has a red band (think warmer fuel, after it has been through the engine).
6-3 Sensor fittings Each sensor inlet or outlet requires one or more fittings to connect it to the fuel line. The fuel sensor connections are all ¼ NPT taper thread, fixed female. The fittings required will vary with where in the fuel lines the sensors are installed. For a discussion of the issues involved, see section 7-3-3. You will need threaded barrel adaptors to suit the piping on your boat.
7 Installing the diesel flow sensor kit Installation sequence Warnings Correct installation is critical to the performance of the unit. Before starting installation, it is vital to read this manual and the documentation that comes with the other parts. The fuel lines are modified and temporary straight through pipes fitted where the sensors will be fitted. The engine is run, then the real sensors are fitted. This procedure ensures that debris from the installation does not enter the sensors.
7-2 Notes on pipes, fittings and installation Push the flare nut along the pipe before flaring the pipe!! Then flare the end of the pipe using the flaring tool. Inspect the inside face of the flared pipe - it must be smooth and scratch-free. If it is not, cut it off and try again. This section discusses fuel pipes terminology and the fittings and tape used to join the pipes. 7-2-1 Pipe Diesel fuel lines are often solid copper pipe.
If you do use tape, then to prevent pieces of tape from breaking off: Make sure you wind the tape on to the male thread so that the first couple of threads remain uncovered; do not cover all of the threads. Be careful when snapping off the tape that threads of tape do not fall back over the end of the fitting. If removing fittings from previous installs make sure the male threads are cleaned of any remnants of the thread sealer used.
7-3 Planning where the parts of the kit will be fitted Plan where all the parts will be located before starting to install the parts. 7-3-1 Overview Other wiring and connection to sensors on a second engine (optional) Locate the two sensors and the tachometer reasonably close together to allow for neat and tidy cable routing. Supplied with the sensors are the sensor cable (20 m (65 ft)); the link cable (2 m (6 ft)) and the tachometer cable (4 m (13 ft)).
7-3-3 Locating the sensors in the fuel lines The supply sensor will be installed in the fuel supply line between the the primary fuel filter and the engine fuel intake. The return sensor will be installed in the fuel return line between the engine fuel return and the fuel tank. There are several options where to locate each sensor, discussed below, and the best option will depend on the layout of your engine’s fuel system and what fittings are used.
This is often more difficult than the other options, because the lift pump is usually mounted on the engine and the fuel line from the lift pump to the injector body is steel tube. However, being after the lift pump does get rid of any of the problems of pressure drop across the sensor. The fuel line to the engine needs to be connected to the outlet of the sensor. If the fuel line is solid copper, a flare joint is probably easiest to install (see section 6-3).
7-4 Installing the temporary straight through pipes However, when fitting the through pipe in the supply line, tighten the inlet connection but leave the outflow connection loose temporarily. Before fitting the straight through pipes, plan where the sensors will be fitted (see section 7-3). This section describes how to fit the temporary through pipes where the flow sensors will be fitted. The actual sensors are not fitted until later, after the engine has been checked (see section 7-5).
7-4-1 Installing a through pipe with flare joints into a copper pipe run This describes how to install a through pipe with a flare joint. For the full procedure, follow the steps of section 7-4. Top view 3 Fitting a flare joint requires the use of a pipe cutting tool, a flaring tool, possibly pipe bending tools and flare nuts. To take the example of a 3/8 OD inch pipe, you will need to find from a fitting supplier, for each flare joint: Hold sensor in place 65 mm (2.
4 6 Install the required fittings to the straight through pipe (for flare joints use a barrel union fitting): Put flare nut on first Flare end of tube 1 Put the flare nut on the pipe first!! Then flare the end of the pipe using the flaring tool. Inspect the inside face of the flared pipe - it must be smooth and scratch-free. If it is not, cut the end of the tube off and try again. Apply thread sealer to the fitting’s ¼ NPT threads.
7-5 Test running and installing the sensors This section describes how to test run the engine and then install the flow sensors in place of the straight through installation pipes: 1 the gap where the sensor came from, and no re-work of the pipework is necessary. 7 When you have both supply and return lines connected up and all fittings tightened, bleed the fuel lines. This is the same procedure you use after changing a fuel filter - consult your engine manual. 2 Turn on the fuel tap at the tank.
tight to prevent leakage. 12 Carefully open the fuel tap at the fuel tank until fuel drips from the joint at the outlet of the sensor in the supply line. This should have filled the pipe and first joint with fuel - meaning there will be less air in the system that has to be bled out to start the engine. Turn the tap off. 13 Tighten the fitting on the outflow side of the supply sensor with the correct tool.
7-6 Installing the tachometer pickup This section describes how to install the tachometer pickup. The tachometer is optional and need not be installed, however the tachometer gives a precise measurement of engine RPM, essential for measuring engine fuel consumption at different speeds. Piece of reflective tape Rotating flywheel or pulley Infra-red light from tachometer The pickup operates by sending a beam of pulses of infrared light towards the crankshaft pulley.
Installing the tachometer pickup Warning: The pickup is fitted near a rotating part of the engine. Make sure you do not touch any rotating part. Mount the pickup firmly so it will not break off and fall into the engine. When working near the engine, do not wear loose loose clothing; tie back long hair. 1 Clean any grease or dirt off the area where you are going to stick the reflective tape. Wipe the area with a cloth or tissue, then use the alcohol wipe provided to degrease the surface.
7-7 Installing the cables Once the flow sensors and tachometer pickup have been installed, install the cables. 7-7-2 Connecting to a DIESEL 3200 When installing a cable: The sensor cable from the supply sensor up to the DIESEL 3200 display is 20 metres long. It has a connector with a white collar on one end and bared tinned wires on the other: Keep the cable away from sources of electrical signals or electrical noise. Route the cable neatly and out of harms way.
Black Fuse Red 12 VDC Ignition Switch External alarm (optional) Green Yellow NMEA in (GPS, optional) White NMEA out (optional) Orange NavBus (optional) Blue Fuel transducer (white plug) Speed transducer (blue plug) } Display unit, DIESEL 3200 Note: The diesel sensors can be used in 12 or 24 V DC systems. Some display units, such as the DIESEL 3200 require 12 V DC. Before connecting any power greater than 12 V DC to the display unit, check that the unit can tolerate the intended voltage.
Appendix A Specifications General: Size: 60mmHx129mmWx93mmD Weight: 300g Per sensor Supply Voltage: 12-24v DC Current Consumption: 25mA @ 12 VDC Recommended Operating ambient temperature: 5 degrees C to 70 degrees C Maximum Operating ambient temperature: -29 degrees C to 80 degrees C Flow Rates: Max 400L/h and Min of 25L/h Standards and Compliance: EMC USA: FCC Part 15 Class B. Europe: (CE) EN64000-6-1 and EN64000-6-3. New Zealand and Australia: (C-Tick) AS-NZS 3548.
Anexo B - Como contactar-nos NORTH AMERICA BNT - Marine Electronics 30 Sudbury Rd, Acton, MA 01720. Toll Free: +1 866 628 6261 Fax: +1 978 897 8264 e-mail: sales@navmanusa.com web: www.navman.com OCEANIA Australia Navman Australia Pty. Limited Suite 2, 408 Victoria Road Gladesville NSW 2111, Australia. Ph: +61 2 9879 9000 Fax: +61 2 9879 9001 e-mail: sales@navman.com.au web: www.navman.com New Zealand Absolute Marine Ltd. Unit B, 138 Harris Road, East Tamaki, Auckland.
FUEL 3100 and DIESEL 3200 Diesel fuel flow sensor kit Made in New Zealand MN000235C Lon 174° 44.535`E LF000100A English LF000102A Spanish LF000103A Portuguese NAVMAN Lat 36° 48.
