Caterpillar 179-0710 Burn Rate Fuel Flow Measurement System Tool Operating Manual - PDF DOWNLOAD

R

NEHS0776-01 January 2002

TOOL OPERATING MANUAL Using the Caterpillar 179-0710 Burn Rate Fuel Flow Measurement System SMCS: 0782, 1000, 1250

154-8105 and 154-8106 Fuel Flow Displays . . . . . . . . . . . . . . . . . . . 22 Specifications . . . . . . . . . . . . . . . . . . . . 22 Controls and Indicators . . . . . . . . . . . . . 23 Front Panel Keys . . . . . . . . . . . . . . . . . . 24 Mounting the 154-8105 Display . . . . . . . . . 27 Multiple Display Operation . . . . . . . . . . . . . 28 Programming the Function Keys (F1, F2, F3, F4, F5) . . . . . . . . . . . . . . . . . . 29 Display Factory Reset . . . . . . . . . . . . . . . . 29 Display Data Items for the Function Keys . . . . . . . . . . . . . . . . . . . 30 Operational Modes . . . . . . . . . . . . . . . . . . 31 Main Menu . . . . . . . . . . . . . . . . . . . . . . . 31 Main Menu Items . . . . . . . . . . . . . . . . . 32 Data Logging Sub-Menu . . . . . . . . . . . 33 Tag Sub-Menu . . . . . . . . . . . . . . . . . . . 35 Arrange Sub-Menu. . . . . . . . . . . . . . . . 36 Data Logging Operation . . . . . . . . . . . . . . 37 General Codes. . . . . . . . . . . . . . . . . . . . 37 Performing a Datalog . . . . . . . . . . . . . . . 37 Downloading the Logged Data. . . . . . . 38 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . 40 Material Data Safety Sheets . . . . . . . . . . . . 41

Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Components . . . . . . . . . . . . . . . . . . . . . . . . 4 179-0710 Burn Rate Meter System with Hand-Held Display . . . . . . . . . . . . . . 4 179-0711 Burn Rate Meter System (No Display). . . . . . . . . . . . . . . . . . . . . . . 5 Optional Items . . . . . . . . . . . . . . . . . . . . . 5 Service Parts . . . . . . . . . . . . . . . . . . . . . . 5 179-0705 Hose Group . . . . . . . . . . . . . . . 6 Specifications . . . . . . . . . . . . . . . . . . . . . . . 7 Principle of Operation . . . . . . . . . . . . . . . . . 8 179-0700 Burn Rate Meter . . . . . . . . . . . . 8 179-0701 Burn Rate Computer. . . . . . . . . 8 Installation Instructions. . . . . . . . . . . . . . . . 10 Engines with Supply and Return Fuel Flow Lines . . . . . . . . . . . . . . . . . . . 10 Engines with Only Supply Fuel Flow Lines (No Return Fuel Flow Lines) . . . . . 11 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . 11 Controls and Connections . . . . . . . . . . . . . 12 Burn Rate Computer . . . . . . . . . . . . . . . 12 Burn Rate Meter. . . . . . . . . . . . . . . . . . . 13 Operating Instructions . . . . . . . . . . . . . . . . 14 Setting the Calibration Switches . . . . . . . 14 Setting the Serial Number Switches . . . . 14 Using One Burn Rate Meter with One 154-8106 Hand-Held Fuel Flow Display . . . . . . . . . . . . . . . . . . 15 Using Two Burn Rate Meters with One 154-8106 Hand-Held Fuel Flow Display . . . . . . . . . . . . . . . . . . 16 Using the 131-5050 DataView for Reading Burn Rate. . . . . . . . . . . . . . . . . 18 Using Two or Three Burn Rate Meters with One 131-5050 DataView . . . . . . . . . 18 Using the 9U-6701 Multitach II for Reading Burn Rate. . . . . . . . . . . . . . . . . 19 Using Two Burn Rate Computers with One 9U-6701 Multitach II . . . . . . . . 20 Troubleshooting . . . . . . . . . . . . . . . . . . . . . 20 Checking the Operation of the Burn Rate Meter System . . . . . . . . . . . . . . 21 Care and Maintenance. . . . . . . . . . . . . . . . 22 Checking and Adjusting the Calibration Switches . . . . . . . . . . . . . . . . . . . . . . . . . 22

Introduction

Illustration 1. 179-0710 Caterpillar Burn Rate Meter Fuel Flow Measurement System.

2

The Caterpillar 179-0710 Burn Rate Meter Fuel Flow Measurement System is a portable test system designed to measure the burn rate on small to medium Caterpillar diesel engines. It has a built-in heat exchanger and electric fuel pump to cool warm fuel from the return fuel line of the engine.

Safety

The burn rate meter uses one positive displacement flowmeter, making it more accurate than a two-meter system. Problems with air bubbles in the return fuel are eliminated because the return fuel flow is not measured by the flowmeter.

The 179-0701 Burn Rate Meter Computer connects to the 179-0700 Burn Rate Meter with a 179-0702 Cable. It provides power, automatic fuel temperature correction, and two outputs. A frequency output represents burn rate in gallons per hour and can be measured with the Caterpillar 131-5050 DataView (use a PC for monitoring) or 9U-7401 Multitach II. The RS485 output represents burn rate in gallons per hour and can be monitored with the Caterpillar 154-8106 Hand-Held Fuel Flow Display.

To avoid personal injury or death follow all warnings.

To avoid personal injury, carefully read and understand all instructions before attempting to operate this equipment.

Always follow all State and Federal health and safety laws and/or local regulations.

The burn rate computer is powered from the machine’s 11 to 32 VDC batteries. An optional 95 to 250 VAC power supply is also available.

Always consult the Material Safety Data Sheet for chemical hazards and first aid instructions. These sheets should be available from the manufacturer/ supplier of the fluid.

The Caterpillar burn rate measurement system is available in two groups. The 179-0710 Burn Rate Meter System contains a hand-held display and the 179-0711 Burn Rate Meter System is available without a display. The burn rate measurement system has an operating range of 4 to 260 Lph (1.05 to 69 gph) burn rate and is designed to work with 3116, 3126, 3176, 3208, 3304, 3306, 3406, and 3408 Engines. This system is not recommended for electronic engines larger than 3408 because of fuel line restriction, but can be used for mechanical 3412 Engines with lower fuel flow circulation.

Always wear protective clothing while operating any machinery. Keep loose clothing and fingers away from moving parts to prevent pinching and crushing.

To avoid eye injury, always wear protective glasses or face shield when using any equipment, a hammer, or similar tool. Chips or other debris can fly off objects when struck. Make sure no one can be injured by flying debris before striking any object.

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Components 179-0710 Burn Rate Meter System with Hand-Held Display

Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak.

Diesel engine exhaust contains products of combustion which may be harmful to your health. Always start and operate the engine in a wellventilated area and, if in an enclosed area, vent the exhaust to the outside.

Personal injury or death can result from fire caused by fuel sprayed on a hot engine.

Clean up any spilled fuel. An accumulation of any flammable substance can ignite. Fuel leaked or spilled onto any hot surface or electrical component can cause fire.

Illustration 2. 179-0710 Burn Rate Meter System With Hand-Held Display.

(1) 179-0700 Burn Rate Meter. (2) 179-0702 Cable.

(3) 6V-2198 Extension Cable. (4) 154-8106 Hand-Held Fuel FLow Display. (5) 154-8095 Display Cable.

(6) 5P-7366 Power Cable. (7) 179-0701 Burn Rate Computer. (8) 179-0705 Hose Group. (9) 4C-9660 Carrying Case. (10) 179-0706 Foam Insert.

Do not smoke while working on or near any fuel system.

Personal injury or death can occur as a result of a spark.

To prevent personal injury, clean up any spilled fluids immediately.

To avoid tripping, do not leave tools or components laying around in the work area.

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179-0711 Burn Rate Meter System (No Display)

Service Parts

Illustration 4. Service Parts.

(1) 081-4662 Fuel Filter. (2) 179-0703 Metric to JIC Adapter. (3) 179-0708 Temperature Sensor.

(4) 179-0704 Electronic Connector (Fuel Meter).

Not Shown: 9W-1442 10 Amp Fuse.

Illustration 3. 179-0711 Burn Rate Meter System ( No Display).

(1) 179-0700 Burn Rate Meter. (2) 179-0702 Cable.

(3) 6V-2198 Extension Cable. (4) 5P-7366 Power Cable.

(5) 179-0701 Burn Rate Computer. (6) 179-0705 Hose Group. (7) 4C-9660 Carrying Case. (8) 179-0706 Foam Insert.

Optional Items (not shown) Chart A. Optional Items (Not Shown) Part No.

Description

154-8093

Extension Cable (for hand-held display)

131-5047

AC Power Cable (110 VAC USA Plug)

1P-7408

Thermo-Hydrometer, 29 to 41 API

5P-2712

Thermo-Hydrometer, 39 to 51 API

1P-7438

Beaker (250 mL)

179-0713

AC Power Supply (95 to 250 VAC)

154-8105

Fuel Flow Panel Mount Display

137-0171

European Power Plug Adapter

133-6975

AC Power Cable, 220 VAC (European Plug)

179-0715

Y Cable (connects two burn rate computers to 154-8106 Display)

131-5050

DataView

9U-7401

Multitach II

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179-0705 Hose Group

Illustration 5. 179-0705 Hose Group (Refer To Chart B).

6

Chart B. 179-0705 Hose Group Item Part No. Qty 1

Chart C. Burn Rate Fuel Flow Measurement System Specifications

Description Carrying Case

Flowmeter Burn Rate Flow Range

4 Lph (1.05 gph) to 260 Lph (69 gph)1 154-8106 Display flashes UNDERFLOW or OVERFLOW when out of range.

Calibration Switch Range

700 to 1200 Pulses/Liter

1

4C-4730

2

NEEG2866 1

Label, Hose Group

3

148-5675

1

Accessories Case

4

NEEG2061 1

Label, Accessories

5

1U-5360

2

Hose, size 10, 0.3 m (1 ft)

6

179-0712

4

Hose, size 8, 2.44 m (8 ft)

Flowmeter Accuracy

± 1% of reading ± 0.4 Lph (.1 gph)

7

1U-5356

2

Hose, size 6, 0.3 m (1 ft)

Fuel Temp. Range

-17.7 to 85°C (0 to 185°F)

8

1U-5354

2

Hose, size 4, 0.3 m (1 ft)

9

061-8248

2

Union, size 10 male to 10 male

Fuel Temperature Accuracy

0.5°C (1°F) providing fuel flow has stabilized the reading.

10 3R-2704

4

Union, size 8 male to 8 male

Flowmeter Type

11 3J-7355

2

Union, size 4 male to 4 male

12 5P-8228

2

Reducer, size 10 female to size 8 male

Positive displacement, rotary piston.

The 179-0701 Burn Rate Computer provides automatic temperature compensation and output scaling.

13 030-8144

2

Reducer, size 8 female to size 6 male

14 1P-1441

2

Nut size 8 female

15 5P-5007

2

Reducer size 8 female to 4 male

16 5P-2909

4

Plug, size 8

17 9S-8927

1

Plug, size 6

18 9S-5518

1

Plug, size 4

19 6V-6132

8

Plastic tie strap, 203 mm (8.0 in)

20 6V-7555

6

Plastic tie strap, 1020 mm (40.0 in)

Horsepower Range 11.3 to 735 KW (15.2 to 1000 HP)

Output Signals 1. RS485 Communications for 154-8106 Fuel Flow Hand-Held Display.

2. Frequency output for 131-5050 DataView or 9U-7401 Multitach II. Output scaling

Power Requirements

O-Ring Face Seal to JIC Hose Coupling Adapters 21 8T-6701

1

Size 4 ORFS male to size 4 JIC female

22 8C-7309

1

Size 4 ORFS female to size 4 JIC male

23 107-3877

1

Size 6 ORFS male to size 6 JIC male

24 8C-7310

1

Size 6 ORFS female to size 6 JIC male

25 8C-7306

1

Size 8 ORFS male to size 8 JIC male

26 8C-7311

1

Size 8 ORFS female to size 8 JIC male

27 8C-7307

1

Size 10 ORFS male to size 10 JIC male

28 8C-7312

1

Size 10 ORFS female to size 10 JIC male

Standard

11 to 32 Volts DC @ 12 Amp max

Optional

179-0713 AC Power Supply2 Optional 179-0713 AC Power Supply2

Input Output

1

O-ring, size 4 (pkg 25)

— 6V-8397

1

O-ring, size 6 (pkg 100)

— 6V-8398

1

O-ring, size 8 (pkg 100)

— 7J-9108

1

O-ring, size 10 (pkg 50)

100 to 240 VAC, 47 to 63 Hz @ 1.6 Amps 24 VDC, 3.0 Amps Filter Response Time

Flow change

Filter, Low

Filter, High

11.4 to 121.3 Lph (3 to 32 gph)

6 seconds

4 seconds

121.3 to 11.4 Lph (32 to 3 gph)

21 seconds

6 seconds

179-0700 Burn Rate Meter

17.7 kg (39 lbs)

179-0701 Burn Rate Computer

3.2 kg (7 lbs)

Replacement O-Rings — 4J-5477

10 Hz = 3.785 Lph (1 gph)

Weight

179-0705 Hose Gp. 9.5 kg (21 lbs)

Group

Size

Specifications Notice Do not use this measurement system for 3500 Engines, because the restriction created by the burn rate meter will cause the return fuel to overheat and damage the engine.

179-0700 Burn Rate Meter

320 x 298 x 130 mm (12.6 x 11.75 x 5.1 in), includes filter

179-0701 Burn Rate Computer

260 x 160 x 90 mm (10.3 x 6.3 x 3.5 in)

179-0705 Hose Group

660.4 x 393.7 x 109.2 mm (26.0 x 15.5 x 4.3 in)

1

Not recommended for engines with supply fuel lines larger than #10 JIC because of fuel flow restriction.

2 Do not turn the burn rate computer ON until the AC power supply has been plugged into an AC wall outlet.

7

Principle of Operation

FUEL TANK COOLING FUEL LOOP 1

ENGINE

BURN RATE METER HEAT EXCHANGER

RETURN

FROM ENGINE

TO TANK

RETURN FUEL

METER

SUPPLY

FROM TANK TO ENGINE

PUMP

ENGINE FUEL PUMP

SUPPLYFUEL

ENGINE FUEL LOOP 2 BURN RATE COMPUTER

DISPLAY

0776-03

Illustration 6. Operation Of Burn Rate Meter.

As the engine operates and burns fuel, Loop 2 becomes depleted of fuel and must draw fuel from Loop 1. The positive displacement fuel meter measures fuel traveling from Loop 1 to Loop 2. This fuel measurement is converted to a calibrated signal in the burn rate computer and represents the burn rate.

179-0700 Burn Rate Meter The 179-0700 Burn Rate Meter consists of three basic parts as shown in Illustration 6: a positive displacement fuel meter, an electric fuel pump, and a heat exchanger.

The burn rate meter has two fuel loops: the cooling fuel loop (Loop 1) and the engine fuel loop (Loop 2).

179-0701 Burn Rate Computer The burn rate computer connects to the 179-0700 Burn Rate Meter using a 179-0702 Cable. The burn rate computer provides power, automatic temperature compensation, filtering, and output signal calibration.

The cooling fuel loop (Loop 1) is powered by an electric fuel pump in the burn rate meter.

This pump circulates fuel from the fuel tank, through the heat exchanger, and back to the fuel tank. This loop runs continuously and is used to cool the engine return fuel.

System calibration is obtained by setting the pulses/liter rotary switches inside the burn rate computer. Refer to the “Controls and Connections” section. The calibration number stamped on the 179-0700 Burn Rate Meter must be set on the 179-0701 Burn Rate Computer pulses/liter rotary switches. If the switches do not match the calibration number stamped on the burn rate meter the calibration will not be accurate.

The engine fuel loop (Loop 2) supplies fuel to the engine (supply fuel) and then recirculates unburned fuel. The warm, unburned fuel from the engine (return fuel) travels through the heat exchanger to be cooled. The cooled fuel is routed back to the engine and recirculated.

The fuel pump of the engine keeps fuel Loop 2 circulating continuously.

8

The converter power supply in the burn rate computer allows the system to operate using 11 to 32 Volts DC power.

Electronic circuits in the burn rate computer measure fuel pulses and temperature from the burn rate meter. A semiconductor device attached to the fuel meter measures the fuel temperature and compensates for the change in volume of diesel fuel as the fuel changes temperature.

The burn rate computer includes a high and low-filter setting. The high-filter setting is recommended for burn rates above 19 Lph (5 gph) or if faster response-to-load changes are needed, while the low-filter setting is recommended for burn rates below 19 Lph (5 gph) to improve the stability of burn rate readings.

The burn rate computer also provides two outputs. The first output is a frequency output scaled at 10 Hz equals 3.8 Lph (1 gph) of burn rate. The frequency output can be used by the Caterpillar 131-5050 Dataview or 9U-7401 Multitach II when connected to the burn rate computer using a 6V-2198 Extension Cable. The second output is for RS485 communications and can be used with the Caterpillar 154-8106 Hand-Held Fuel FLow Display when connected to the burn rate computer with a 154-8095 Cable. The display will show the fuel temperature at the fuel meter.

9

Installation Instructions Engines with Supply and Return Fuel Flow Lines

Illustration 7. Hook-Up Diagram For Engines With Supply And Return Fuel Flow Lines.

Use this procedure to connect the burn rate meter into the engine fuel system. Although every engine installation cannot be covered here, this procedure is the basic connection method for the burn rate meter.

Always connect fuel lines before applying power to the burn rate system. The built-iin electric fuel pump could spray fuel from an open hose and cause fire or personal injury.

Refer to Illustration 7 during the installation procedure. This illustration shows the burn rate meter installed in the best location. The "From Tank" connection is the most important connection. This is where fuel is supplied to the entire system and should be free from air bubbles and pressure pulses.

NOTICE Clean all dirt and contamination from the fitting areas where the fuel lines will be disconnected.

Do not allow any dirt to enter the lines. Install the appropriate hoses and fittings and tighten so fittings will not leak.

1. The “From Tank” line of the burn rate meter must be connected a) directly to the fuel tank and b) before the engine fuel pump.

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NOTE: Do not connect the “From Tank” line of the burn rate meter after the output of a gear or piston-type transfer fuel pump. The fuel pump of the engine circulates fuel through the engine and the heat exchanger of the burn rate meter. Connecting the burn rate meter after the fuel transfer pump will not allow fuel to circulate through the engine.

2. Select the required hoses and fittings from the hose adapter group to make the necessary connections.

NOTE: The hose adapter group includes standard 37 degree flare fittings and O-ring face seal adapters. Special fittings may be required for some installations.

3. Close the fuel shut-off valve at the fuel tank.

Use 6V-7555 Tie Straps through the handle and around the body to mount the burn rate meter (two mounting screws on the rear of the meter are also available). The meter should be upright, with the carrying handle on top, when being operated.

NOTE: The meter can be tipped 30 degrees from an upright position and still work properly.

Engines with Only Supply Fuel Flow Lines (No Return Fuel Flow Lines) In applications where only one fuel line exists, such as in older engines, use this procedure.

1. Install a cap on the "From Engine" fitting of the burn rate meter.

2. The "To Tank" line on the burn rate meter must return to the fuel tank. Since a “To Tank” line on the equipment probably does not exist and must be provided, run the "To Tank" line into the fuel tank fill opening of the equipment. Take steps to make sure the "To Tank" line cannot come loose and leak fuel or allow dirt into the fuel tank of the equipment.

Fuel Tank Heat from the engine fuel system is transferred to the fuel tank. To ensure the engine fuel does not overheat always keep the fuel tank at least one-third full of fuel. For best results, fill the fuel tank before testing.

11

4. Frequency Output. The frequency output range is 10 to 690 Hz with an output scaling of 10 Hz equals 3.8 Lph (1 gph).

This frequency output represents the temperature compensated burn rate and can be used with the Caterpillar 131-5050 DataView, 9U-7401 Multitach II, or other data recording instrument with frequency input that uses a 6V-2198 Extension Cable.

Controls and Connections Burn Rate Computer

1 Illustration 8. Burn Rate Computer.

(1) Power. (2) 11-32 VDC Input. (3) RS485 Output.

(4) Frequency Output. (5) Filter. (6) To Fuel Meter.

4

0776-07

Illustration 10. Frequency Output Connector Pin Identification.

(1) Ground. (2) Frequency Output. (3) N/C. (4) N/C. (5) N/C.

2. 11 to 32 VDC Input. Connects to the 5P-7366 Power Cable and provides 11 to 32 Volts DC input power for the burn rate meter system.

5. FILTER (HI/LO). This switch selects the high or low-filter setting. A high-filter setting is recommended for burn rates above 19 Lph (5 gph) and provides a faster response to engine load changes, while a low-filter setting is recommended for burn rates below 19 Lph (5 gph) to improve stability. Refer to Chart C in the “Specifications” section for additional information.

3. RS485 Output. This output transmits the temperature compensated burn rate and fuel temperature to the Caterpillar 154-8106 Hand-Held Display using a 154-8095 Display Cable.

6. To Fuel Meter. Use the 179-0702 Cable to connect the burn rate computer with the burn rate meter.

1

4

2 3

5 2

1. Power. Applies power to the burn rate computer, burn rate meter, and hand-held display. The lamp at the right of the Power switch indicates the power is ON.

5

3

0776-06

Illustration 9. RS485 Output Connector Pin Identification.

(1) +RS485. (2) +VDC. (3) Ground. (4) N/C. (5) -RS485.

12

Burn Rate Meter

Illustration 11. Burn Rate Computer (With Lid Removed).

(1) Calibration Switches (Pulses/Liter). Must match burn rate meter calibration tag. (2) Serial number switch.

The “down” position equals supply serial number 00001 and return serial number 00003, while the “up” position equals supply serial number 00002 and return serial number 00004. (3) 9W-1442 10 Amp Fuse.

Illustration 13. Burn Rate Meter.

(1) Calibration Tag (Pulses/Liter). (2) Fuel Filter.

(3) “From Tank” Connection. (4) “To Tank” Connection.

(5) “From Engine” Connection. (6) “To Engine” Connection. (7) Electronic Connector (connects to burn rate computer using 179-0702 Cable).

Illustration 12. Decal (NEEG2880) Inside Of Lid Of Burn Rate Computer (provides location for switches and connectors on circuit board).

(1) Calibration switch “X1”. (2) Calibration switch “X10”.

(3) Calibration switch “X100”. (4) Calibration switch “X1000”. (5) Serial number switch “up position” (supply 00002, return 00004). (6) Serial number switch “down position” (supply 00001, return 00003). (7) Flash program connector.

Illustration 14. Calibration Tag (1, Illustration 13) Located On Front Of Burn Rate Meter.

(1) Pulses per liter. (2) Pulse width. (3) Meter number.

13

1. To use a ONE burn rate meter system, set serial number switch (1) in the “down” position. This will identify the burn rate meter serial number as 00001 supply meter and even though a return meter is not being used, the burn rate computer will send a 00003 serial number and a zero flow rate to the display, which makes it operate properly.

Operating Instructions Setting the Calibration Switches System calibration is obtained by setting the pulses/liter rotary switches inside the burn rate computer. Refer to “Care and Maintenance” section to check or change the setting. The 179-0701 Burn Rate Computer is factory set for 800 pulses/Liter. This is the calibration setting required for all burn rate meters, unless the meter has a PPL number other than 800 on the calibration tag.

NOTE: This is the factory Serial Number Switch Setting.

2. To use a TWO burn rate meter systems with the 154-8106 Display, to monitor twin engine installation, set up the first burn rate system as described in Step 1. The second burn rate meter system is set up to identify its meter as serial number 00002.

Set the switch in the “up” position. This will identify the second burn rate meter as a supply meter having a serial number 00002 and even though a return meter is not being used, the burn rate computer will send a 00004 serial number and a zero flow rate to the display, which makes it operate properly.

Setting the Serial Number Switches NOTE: These steps are required only when using the 154-8106 Display with two burn rate meters.

NOTE: The two burn rate computers and display are connected using the optional 179-0715 “Y” Cable.

NOTE: Once the serial number switch settings are made they will not have to be changed unless different burn rate meters are used.

Illustration 15. Serial Number Switch (1).

Illustration 16. Side View Showing Location Of Serial Number Switch (1).

14

Using One Burn Rate Meter with One 154-8106 Hand-Held Fuel Flow Display

Make sure power switch is OFF because the built-iin electric fuel pump could spray fuel from an open hose and cause a fire or personal injury.

Always connect fuel lines before applying power to the burn rate system. The built-iin electric fuel pump could spray fuel from an open hose and cause a fire or personal injury.

5. Connect the 5P-7366 Power Cable to the 179-0701 Burn Rate Computer. Attach one clamp to the positive terminal of the battery and the other clamp to the frame.

6. Connect a 154-8095 Display Cable between the burn rate computer and the 154-8106 Hand-Held Fuel Flow Display.

7. Turn the burn rate computer POWER switch to ON. The electric fuel pump in the burn rate meter will start and the hoses will begin filling with fuel.

8. Check all hoses and fittings for leaks. The electric fuel pump makes leaky fittings easy to find as it pressurizes the fuel system.

9. Set the serial numbers on the 154-8106 Hand-Held Fuel Flow Display:

Illustration 17. Burn Rate Meter With 154-8106 Hand-Held Fuel Flow Display.

a. Power-up the display. For about five seconds the initialization screen will show the software version number.

1. Install the burn rate meter as described in the “Installation Instructions” of this manual.

b. Press the Menu key, then use the arrow keys to move the cursor to the TOTALIZER STARTED line and press Enter once. The display should change to TOTALIZER STOPPED.

2. Make sure the serial number switches are properly set. Refer to the “Setting the Serial Number Switches” section in this manual.

c. Use the arrow keys to move the cursor to the VOLUME line and press Enter to toggle between GALLONS or LITERS.

3. Make sure the calibration switch settings are properly set. Refer to the “Setting the Calibration Switches” section in this manual.

d. Use the arrow keys to move the cursor to the TEMP UNITS line and press Enter to toggle between DEG. F and DEG. C.

4. Connect the 179-0702 Cable between the 179-0700 Burn Rate Meter and 179-0701 Burn Rate Computer.

e. Use the arrow keys to move the cursor to the ENG 1 SUP ADR line. Press Enter, and press 00001 (supply meter address). Press Enter. f. Use the arrow keys to move the cursor to the ENG1 RET ADR line. Press Enter and press 00003 (return meter address).

Press Enter.

15

g. Use the arrow keys to move the cursor to the TOTALIZER STOPPED line.

Press Enter (the display will now read TOTALIZER STARTED). Press Menu.

Using Two Burn Rate Meters with One 154-8106 Hand-Held Fuel Flow Display

NOTE: The hand-held fuel flow display should now be indicating a burn rate (flow from the electric fuel pump in the 179-0700 Burn Rate Meter filling the system and hoses with fuel).

The 154-8106 Fuel Flow Display can be used with two burn rate meters during a two engine par test. This setup will require two burn rate meters and a 179-0715 Y Cable.

h. When the hand-held fuel flow display indicates zero burn rate, the system is filled with fuel and the engine being tested can be started.

Always connect fuel lines before applying power to the burn rate system. The built-iin electric fuel pump could spray fuel from an open hose and cause a fire or personal injury.

10. The fuel temperature at the burn rate meter is displayed at the bottom of the screen labeled S1 (supply temperature 1) and R1 (return temperature 2).

11. The burn rate computer FILTER switch should be set to HIGH for burn rates above 19 Lph (5 gph) so the display can respond faster to engine load changes and to LOW for burn rates below 19 Lph (5 gph) to provide more stable readings.

Refer to the “Specifications” section for additional information.

1. Install the burn rate meter as described in the “Installation Instructions” of this manual.

2. Make sure the serial number switches are properly set. Refer to the “Setting the Serial Number Switches” section in this manual.

NOTE: After the hand-held fuel flow display is setup, the information is stored in the unit even when the power is OFF. Refer to the “154-8105 and 154-8106 Fuel Flow Display” section for more display capabilities.

3. Make sure the calibration switch settings are properly set. Refer to the “Setting the Calibration Switches” section in this manual.

4. Connect the 179-0702 Cable between the 179-0700 Burn Rate Meter and 179-0701 Burn Rate Computer on both units.

Always remove power from the burn rate system before disconnecting fuel lines. The built-iin electric fuel pump could spray fuel from an open hose and cause a fire or personal injury.

Make sure power switch is OFF because the built-iin electric fuel pump could spray fuel from an open hose and cause a fire or personal injury.

5. Connect the 5P-7366 Power Cable to the 179-0701 Burn Rate Computer on both units. Attach one clamp to the positive terminal of the engine battery and the other clamp to the frame.

16

6. Connect the 179-0715 Y Cable to the 154-8106 Hand-Held Fuel Flow Display.

Connect the remaining ends to burn rate computer 1 and burn rate computer 2.

NOTE: The hand-held fuel flow display should now be indicating a burn rate (flow from the electric fuel pump in the 179-0700 Burn Rate Meter filling the system and hoses with fuel).

NOTE: The 154-8106 Display will only draw power from one burn rate computer.

h. When the hand-held fuel flow display indicates zero burn rate, the system is filled with fuel and the engines under test can be started.

7. Turn ON the power switches to the burn rate computers. The electric pumps inside the burn rate meters will run and fill the hoses with fuel.

10. The fuel temperature at the burn rate meter is displayed at the bottom of the screen and is labeled S1 and R1.

8. Check all hoses and fittings for leaks. The electric fuel pump makes leaky fittings easy to find as it pressurizes the fuel system.

11. The burn rate computer FILTER switch should be set to HIGH for burn rates above 19 Lph (5 gph) so the display can respond faster to engine load changes and to LOW for burn rates below 19 Lph (5 gph) to provide more stable readings.

Refer to the “Specifications” section for additional information. To see the burn rate for both engines at the same time press the BOTH key.

9. Set the serial numbers on the 154-8106 Hand-Held Fuel Flow Display. a. Power-up the display. For about five seconds the initialization screen will show the software version number. b. Press the Menu key, then use the arrow keys to move the cursor to the TOTALIZER STARTED line and press Enter once. The display should change to TOTALIZER STOPPED.

NOTE: After the hand-held fuel flow display is setup, the information is stored in the unit even when the power is OFF. Refer to the “154-8105 and 154-8106 Fuel Flow Display” section for more display capabilities.

c. Use the arrow keys to move the cursor to the VOLUME line and press Enter to toggle between GALLONS or LITERS. d. Use the arrow keys to move the cursor to the TEMP UNITS line and press Enter to toggle between DEG. F and DEG. C.

Always remove power from the burn rate system before disconnecting fuel lines. The built-iin electric fuel pump could spray fuel from an open hose and cause a fire or personal injury.

e. Use the arrow keys to move the cursor to the ENG 1 SUP ADR line. Press Enter and press 00001 (supply meter address). Press Enter. f. Use the arrow keys to move the cursor to the ENG1 RET ADR line. Press Enter and press 00003 (simulated return meter address). Press Enter. g. Use the arrow keys to move the cursor to the ENG 2 SUP ADR line. Press Enter and press 00002 (supply meter address). Press Enter. h. Use the arrow keys to move the cursor to the ENG2 RET ADR line. Press Enter and press 00004 (simulated return meter address). Press Enter. i. Use the arrow keys to move the cursor to the TOTALIZER STOPPED line. Press Enter (the display will now read TOTALIZER STARTED). Press Menu.

17

6. Using DataView PC software, set up a frequency channel (channel 7, 8, or 9).

Using the 131-5050 DataView for Reading Burn Rate

• Version 3.0 of DataView software includes

the 179-0700 Burn Rate Meter in the Sensor Type menu box.

Always connect fuel lines before applying power to the burn rate system. The built-iin electric fuel pump could spray fuel from an open hose and cause a fire or personal injury.

• At the DataView main menu,

double-click on channel 7, 8, or 9.

• From the Sensor Type menu box,

click on 179-0701 Burn Rate Meter.

• From the Units menu box,

select the desired units and press OK. 7. Turn ON the POWER switch to the burn rate computer. The electric pump inside the burn rate meter will run and fill the hoses with fuel and DataView will indicate a burn rate.

8. Check all hoses and fittings for leaks. The electric fuel pump makes leaky fittings easy to find as it pressurizes the fuel system.

9. When DataView is indicating zero burn rate, the system is filled with fuel and the engine under test can be started.

10. The burn rate computer FILTER switch should be set to HIGH for burn rates above 19 Lph (5 gph) so the display can respond faster to engine load changes and to LOW for burn rates below 19 Lph (5 gph) to provide more stable readings.

Refer to the “Specifications” section.

Illustration 18. 131-5050 DataView For Reading Burn Rate.

1. Install the burn rate meter as described in the “Installation Instructions” in this manual.

2. Make sure the calibration switch settings are properly set. Refer to “Setting the Calibration Switches” section.

3. Connect the 179-0702 Cable between the 179-0700 Burn Rate Meter and 179-0701 Burn Rate Computer.

Always remove power from the burn rate system before disconnecting fuel lines. The built-iin electric fuel pump could spray fuel from an open hose and cause a fire or personal injury.

Make sure power switch is OFF because the built-iin electric fuel pump could spray fuel from an open hose and cause a fire or personal injury.

Using Two or Three Burn Rate Meters with One 131-5050 DataView

4. Connect the 5P-7366 Power Cable to the 179-0701 Burn Rate Computer. Attach one clamp to the positive terminal of the battery and the other clamp to the frame.

The 131-5050 DataView can be used with two or three burn rate meters during a test. This setup will require additional burn rate meter systems.

5. Connect 6V-2198 Extension Cable between the burn rate computer and the DataView.

18

1. Follow the instructions in the "Using the 131-5050 DataView for Reading Burn Rate" section for setting up the system.

Make sure power switch is OFF because the built-iin electric fuel pump could spray fuel from an open hose and cause a fire or personal injury.

2. Connect the frequency output from burn rate computer 1 to DataView frequency input channel 7.

3. Connect the frequency output from burn rate computer 2 to DataView frequency input channel 8.

4. Connect the frequency output from burn rate computer 3 to DataView frequency input channel 9.

4. Connect the 5P-7366 Power Cable to the 179-0701 Burn Rate Computer. Attach one clamp to the positive terminal of the battery and the other clamp to the frame.

Using the 9U-7401 Multitach II for Reading Burn Rate

5. Connect a 6V-2198 Extension Cable between the burn rate computer and the Multitach II IN1 Input.

6. To display burn rate press ON and press IN1 (in order) followed by:

Always connect fuel lines before applying power to the burn rate system. The built-iin electric fuel pump could spray fuel from an open hose and cause a fire or personal injury.

a. Press PPR, press 60, and press RPM, to display gallons per hour x 10.

(Example: If Multitach reads 104, this represents 10.4 gallons per hour.) b. Press PPR, press 15.8, and press RPM, to display Liters per hour x 10.

(Example: If Multitach reads 394, this represents 39.4 liters per hour.)

NOTE: Liters per hour conversion has an additional 0.3 % error. To obtain a correct conversion, a PPR of 15.83 must be used.

The Multitach II can only be programmed for a PPR of 15.8.

7. Turn ON the POWER switch of the burn rate computer. The electric fuel pump inside the burn rate meter will run and fill the hoses with fuel and the Multitach II display will indicate a burn rate.

8. Check all hoses and fittings for leaks. The electric fuel pump makes leaky fittings easy to find as it pressurizes the fuel system.

Illustration 19. 9U-7401 Multitach II For Reading Burn Rate.

9. When Multitach II indicates zero burn rate, the system is filled with fuel and the engine under test can be started.

1. Install the burn rate meter as described in the “Installation Instructions” in this manual.

10. The burn rate computer FILTER switch should be set to HIGH for burn rates above 19 Lph (5 gph) so the display can respond faster to engine load changes and to LOW for burn rates below 19 Lph (5 gph) to provide more stable readings.

Refer to the “Specifications” section for additional information.

2. Make sure the calibration switch settings are properly set. Refer to the “Setting the Calibration Switches” section in this manual.

3. Connect the 179-0702 Cable between the 179-0700 Burn Rate Meter and 179-0701 Burn Rate Computer.

19

Using Two Burn Rate Meters with One 9U-7401 Multitach II

Always remove power from the burn rate system before disconnecting fuel lines. The built-iin electric fuel pump could spray fuel from an open hose and cause a fire or personal injury.

The 9U-7401 Multitach II can be used with two burn rate meters during a two engine test.

This setup will require two burn rate meter systems and a 9U-7401 Multitach II. 1. Follow the instructions in the "Using the 9U-6701 Multitach II for Reading Burn Rate" section for setting up the system.

2. Connect the frequency output from the burn rate computer 1 to the Multitach II frequency input channel 1.

3. Connect the frequency output from the burn rate computer 2 to the Multitach II frequency input channel 2.

Troubleshooting Chart D. Troubleshooting Problem Flow is restricted.

Display Flashes "warning comm lost".

Burn rate readings are inaccurate or unstable.

Display screen is black.

Possible Cause

Possible Solution

Dirty fuel filter.

Install new 081-4662 Filter.

Engine fuel circulation too high.

Do not connect to fuel lines larger than #8 JIC.

154-8095 Display Cable is faulty.

Replace display cable.

Serial numbers switches are not properly programmed.

See the “Operating Instructions” section in this manual.

Fuel entering the burn rate system from the "From Tank" connection has air bubbles or pressure pulses.

Connect the "From Tank" connection as close to the fuel tank as possible. Check the piping system for sources of air. Never connect after a piston type fuel pump.

The flow rate is under 19 Lph (5 gph).

Set the filter switch to low.

The fuel tank is low on fuel.

Add more fuel to the tank.

No power.

Burn rate computer power switch is OFF. Disconnected or faulty cables.

Fuse inside burn rate computer is blown Equipment battery needs charged.

Burn rate reads UFL or OFL. UFL=Underflow, OFL=Overflow

The burn rate is out of range.

4 to 260 Lph (1.05 to 69 gph)

If the burn rate is too low, load the engine.

If the burn rate is too high, reduce the load.

The burn rate meter is not properly installed.

Recheck the installation. Refer to the “Installation Instructions” section of this manual.

The calibration switches are not properly set.

See page 14 in this manual to properly set the calibration switches.

20

6. Connect the 5P-7366 Power Cable to the 179-0701 Burn Rate Computer. Connect the battery clamps to a battery with 11 to 32 Volts DC.

Checking the Operation of the Burn Rate Meter System Use the following procedure to check the operation of the burn rate meter, burn rate computer, and cables.

7. Connect a 154-8095 Cable between the burn rate computer and the 154-8106 Hand-Held Fuel Flow Display.

This procedure checks:

8. Turn the burn rate computer POWER switch to ON. The electric fuel pump in the burn rate meter will start and the hoses will begin filling with fuel.

• the built-in electric fuel pump.

• the positive displacement fuel meter.

• the temperature sensor.

9. Check all hoses and fittings for leaks. The electric fuel pump makes leaky fittings easy to find as it pressurizes the fuel system.

• the burn rate computer.

• all the cables.

10. Set the serial numbers on the 154-8106 Hand-Held Fuel Flow Display:

NOTE: This procedure is a functional check only and is not a calibration check.

a. Power-up the display. For about five seconds the initialization screen will show the software version number.

1. Unscrew (counterclockwise) and fill the fuel filter with diesel fuel. Reinstall the fuel filter, hand-tighten only.

b. Press the Menu key, then use the arrow keys to move the cursor to the TOTALIZER STARTED line and press Enter once. The display should change to TOTALIZER STOPPED.

2. Install and tighten a #8 JIC hose (a short hose works best) between the "From Tank" fitting and "To Engine" fitting. The "To Tank" and "From Engine" fittings must be capped.

c. Use the arrow keys to move the cursor to the VOLUME line and press Enter to toggle between GALLONS or LITERS.

3. Make sure the serial number switches are properly set. Refer to the “Setting the Calibration and Serial Number Switches” section in this manual.

d. Use the arrow keys to move the cursor to the TEMP UNITS line and press Enter to toggle between DEG. F and DEG. C.

4. Make sure the calibration switch settings are properly set. Refer to the “Setting the Calibration and Serial Number Switches” section in this manual.

e. Use the arrow keys to move the cursor to the ENG 1 SUP ADR line. Press Enter and press 00001 (supply meter address). Press Enter.

5. Connect the 179-0702 Cable between the 179-0700 Burn Rate Meter and 179-0701 Burn Rate Computer.

f. Use the arrow keys to move the cursor to the ENG1 RET ADR line. Press Enter and press 00003 (return meter address).

Press Enter.

Make sure power switch is OFF because the built-iin electric fuel pump could spray fuel from an open hose and cause a fire or personal injury.

g. Use the arrow keys to move the cursor to the TOTALIZER STOPPED line.

Press Enter (the display will now read TOTALIZER STARTED). Press Menu NOTE: The hand-held fuel flow display should now be indicating a burn rate of about 166 Lph (44 gph) as the built-in electric pump circulates fuel through the flowmeter.

21

11. The fuel temperature at the burn rate meter is displayed at the bottom of the screen labeled S1 (supply temperature 1) and R1 (return temperature 2). The fuel temperature should be close to the temperature of the fuel poured into the filter in Step 1.

Care and Maintenance The burn rate meter will require some maintenance after each use.

• Always keep fuel in the burn rate meter

and keep the end caps installed when the meter is not being used.

Illustration 20. Calibration Switches (1) X1 represents the 1's digit.

(2) X10 represents the 10's digit.

(3) X100 represents the 100's digit.

(4) X1000 represents the 1000's digit.

• Do not drop the burn rate meter or the

burn rate computer.

• Never permit dirt or contamination to

enter the burn rate meter.

• The fuel filter should be changed every

As of January 2002, all meters shipped have used 800 PPL. If other settings are required in the future, the switch settings can be changed. The label in the lid of the burn rate computer identifies which number digit is set by each switch.

year. The filter can be replaced with a 081-4662 Fuel Filter.

• Do not apply air pressure through the

burn rate meter.

Checking and Adjusting the Calibration Switches

154-8105 and 154-8106 Fuel Flow Displays

The calibration tag (1, Illustration 13, page 13) on the 179-0700 Burn Rate Meter shows the PPL (Pulses Per Liter) calibration number for the meter. It is usually 800 PPL. The calibration switches in the burn rate computer must be set to this number. Illustration 20 shows the location and settings for 800 PPL.

Specifications The following are specifications for the 154-8105 and 154-8106 Fuel Flow Display.

The power for the fuel flow display is supplied by the 179-0701 Burn Rate Computer.

22

Controls and Indicators

Chart E. Fuel Flow Display Specifications Item Display

Backlit super twist LCD, 3/16 inch high characters. 4 rows by 20 characters per row. 5 by 7 pixel character resolution.

Burn Rate Display Range

0.00 to 9999.99 Lph or gph

Average Burn Rate Display Range

0.00 to 9999.99 Lph or gph

Total Fuel Burn Quantity Display Range

0 to 9,999,999 liters or gallons

Supply Rate, Return Rate Resolution

0.0378 Lph (0.01 gph)

Burn Rate Resolution

0.0378 Lph (0.01 gph)

Burn Average Resolution

0.00 to 378.99 Lph = 0.0378 Lph (0.00 to 99.99 gph = 0.01 gph) 379.0 to 9999.9 Lph = 0.378 Lph (100.0 to 9999.9 gph = 0.1 gph)

Burn Total Resolution

Once each second

Operating Temperature Range

0 to 50°C (32 to 122°F)

Storage Temperature Range

-20 to 70°C (-4 to 158°F)

Humidity

Maximum of 90% non-condensing

154-8105 Display Size

126 x 126 x 36 mm (5.0 x 5.0 x 1.4 in) (without custom mounting bezel)

154-8105 Display Weight

370 kg (13 oz)

154-8106 Display Size

104.0 x 182.0 x 25 mm (4.09 x 7.17 x 1.0 in)

154-8106 Display Weight

226 kg (8 oz), without protective boot

Power

7.5-12 VDC, 100 mA maximum supplied by the 179-0701 Burn Rate Computer

Memory Battery Back-up Real Time Clock

NOTE: The touch keys must be pressed and held until the display changes.

®

1

154-8105 FUEL FLOW DISPLAY

4

3

5 2 ENG 1 ENG 2

7

0.00 to 37,899.99 Lph = 0.0378 Lph (0 to 9999.99 gph = 0.01 gph) 37,900.0 to 9,999,999 Lph = 0.378 Lph (10,000.0 to 9,999,999 = 0.1 gph)

Display Update Rate

Interface connector

Illustrations 21 and 22 show the location of the indicators and touch-type keys on the front of the 154-8105 and 154-8106 Fuel Flow Displays.

Description

10

TEMP

11

TIME

7

8

9

4

5

6

F4

F5

PRINT

1

2

BOTH

F1

MENU CTRL SHIFT

3

9

F2

F3

0

ENTER

12

RESET

16 13

8

14

6

AVG TOTAL

15

17

0697-05

Illustration 21. 154-8105 Display.

1

®

FUEL FLOW DISPLAY

12 F1 F2 F3 F4 F5

2 3 7 8 10 9 11 13 16

Five pin dual key-way MicroChange® connector (male)1 256 K battery-backed static RAM, 128 K flash EEPROM CR1632 (coin type 3 VDC lithium, up to 5 year life)

ENG 1 ENG 2 BOTH

TEMP

Dallas semi-conductor DS1994L-F5 [integrated lithium power cell with up to 10 year life at 25°C (77°F)]

TOTAL

TIME

7 8 9

PRINT

4 5 6

CTRL

1 2 3

MENU SHIFT RESET

14

AVG

0

4 5 6 18

17

ENTER

15

Illustration 22. 154-8106 Display (Shown Without Protective Boot).

1 MicroChange® is a registered trademark of Woodhead

Industries, Inc.

23

0697-04

4. BOTH:: Displays the burn rate and average burn rate for Engines 1 and 2 on the display simultaneously. (While in the Menu Mode, this key is disabled for the 154-8106 Display and numeric "7" for the 154-8105 Display.)

1. Digital Display:: LCD (liquid crystal display) with backlight. The display and backlight will always be ON when power is applied to the 154-8105 or 154-8106 Fuel Flow Display.

Front Panel Keys 2. ENG1:: Displays Engine 1 supply, return, burn, flow rates, and fuel temperatures on the display simultaneously. (This key is disabled while in the Menu Mode.)

Display

Definition

ENG1 BURN Burn rate of Engine 1.

ENG1 AVG

Average burn rate of Engine 1.

ENG2 BURN Burn rate of Engine 2.

Display

ENG1 AVG

Definition

ENG1 SUP

Flow rate of the Engine 1's supply line.

ENG1 RET

Flow rate of the Engine 1's return line.

GPH or LIT will appear after each fuel rate to indicate units.

R1

Temperature of fuel in the flowmeter in Engine 1's supply line.

Temperature of fuel in the flowmeter in Engine 1's return line.

Average burn rate of Engine 1.

5. AVG:: Displays the average burn rate and the time over which the average was accumulated for both Engine 1 and 2 on the display simultaneously. (While in the Menu Mode, this key is disabled for the 154-8106 Display and numeric "8" for the 154-8105 Display.)

ENG1 BURN Burn rate of Engine 1.

S1

DEG.F or DEG.C will appear after each temperature to indicate units.

Display

3. ENG2:: Displays Engine 2 supply, return, burn, flow rates and fuel temperatures on the display simultaneously. (This key is disabled while in the Menu Mode.)

Display

Definition

ENG2 SUP

Flow rate of the Engine 2's supply line.

ENG2 RET

Flow rate of the Engine 2's return line.

GPH or LIT will appear after each fuel rate to indicate units.

ENG2 BURN Burn rate of Engine 2.

S2

R2

Temperature of fuel in the flowmeter in Engine 2's supply line.

Temperature of fuel in the flowmeter in Engine 2's return line.

GPH or LIT will appear after each fuel rate to indicate units.

DEG.F or DEG.C will appear after each temperature to indicate units.

24

Definition

ENG1 AVG

Average burn rate of Engine 1.

E1A TIME

Time over which average burn rate of Engine 1 was accumulated.

ENG2 AVG

Average burn rate of Engine 2.

E2A TIME

Time over which average burn rate of Engine 2 was accumulated.

GPH or LIT will appear after average to indicate units.

—

GPH or LIT will appear after average to indicate units.

—

8. TIME:: Displays the burn rate total times for Engine 1 and 2, the stopwatch timer, and the real time clock time on the display simultaneously. (This key is disabled while in the Menu Mode.)

6. TOTAL:: Displays the total burn rate and the time over which the burn was accumulated for both Engines 1 and 2 on the display simultaneously. (While in the Menu Mode, this key is disabled for the 154-8106 Display and numeric "9" for the 154-8105 Display.)

Display ENG1 TOT

E1T TIME

ENG2 TOT

E2T TIME

Definition Total burn rate of Engine 1.

GPH or LIT will appear after average to indicate units.

Time over which total burn rate of Engine 1 was accumulated.

Total burn rate of Engine 2.

Display

Definition

E1T TIME

Time over which total burn rate of Engine 1 was accumulated.

ENG1 AVG

Time over which total burn rate of Engine 2 was accumulated.

STOPWATCH Stopwatch timer.

—

CLOCK

GPH or LIT will appear after average to indicate units.

Time over which total burn rate of Engine 2 was accumulated.

Real time clock.

9. PRINT: Pressing this key activates the log memory function, that stops all other operations, and transmits all logged data through the RS485 Port. The user will be required to confirm this selection by pressing the F1 key to continue with the transmission, or the F5 key to abort the action. (While in the Menu Mode, this key is disabled for the 154-8106 Display and numeric "6" for the 154-8105 Display.)

—

7. TEMP:: Displays the supply and return flowmeter’s fuel temperatures for both Engines 1 and 2 on the display simultaneously. (This key is disabled while in the Menu Mode.)

Display Display E1S TEMP

E1R TEMP

E2S TEMP

E2R TEMP

PRINT LOG DATA NOW?

Definition Temperature of fuel in the flowmeter in Engine 1’s supply line.

Temperature of fuel in the flowmeter in Engine 1’s return line.

Temperature of fuel in the flowmeter in Engine 2’s supply line.

Options F1-YES

F5-NO

10. Scroll Up:: Pressing this key moves the cursor up one line at a time. It can be used while in the Menu Mode and while programming the function keys in the Normal Display Mode.

DEG.F or DEG.C will appear after each temperature to indicate units.

11. Scroll Down: Pressing this key moves the cursor down one line at a time. It can be used in the Main Menu, Data Logging SubMenu, and while programming the function keys.

Temperature of fuel in the flowmeter in Engine 2’s return line.

12. Function Keys:: F1, F2, F3, F4, and F5 function keys are programmable keys.

When a programmable function key is pressed while in Normal Display Mode, that function key will change the display to show parameters selected by the user from a predefined list of choices.

NOTE: These keys are disabled while in the Menu Mode for the 154-8106 Display and are the numerical value shown on each key for the 154-8105 Display.

25

16. MENU:: Pressing this key while in the normal display mode will cause the display to enter the Menu Mode and vice-versa. This key is also pressed to exit the DATA LOGGING TAG Sub-Menus.

13. CTRL:: This key is pressed and held, and then the RESET is pressed to perform a factory reset.

14. SHIFT:: This key is pressed and held, and then the RESET key is pressed to perform a reset (i.e. reset the average burn rate, total burn rate, or stopwatch). The cursor must be positioned on the correct display line before the keys are pressed.

17. ENTER:: While in the Normal Display Mode, this key scrolls forward through the list of available display data items when one of the F1 through F5 function keys has been pressed. This is used for selecting display items to save one of the F1 through F5 keys. In the Menu Mode, the ENTER key selects a menu item, confirms changes to menu options, or tags items for data-logging.

15. RESET:: This key is pressed after the SHIFT key has been pressed and held to perform a reset (i.e. reset the average burn rate, total burn rate, or stopwatch).

The cursor must be positioned on the correct display line before the keys are pressed. This key is also pressed after the CTRL key has been pressed and held to perform a factory reset.

18. Numeric Keys:: These keys are used to enter numeric values while in the Menu Mode. They are disabled while in the Normal Display Mode.

26

Mounting the 154-8105 Display

Illustration 23. Mounting Options For The 154-8105 Display.

27

Bezel Mount:: An optional bezel is supplied to allow simple installation through the front of the panel. With the use of the bezel gasket, this method allows the display's housing to create a seal with the front panel.

Multiple Display Operation If two displays, 154-8105 and/or 154-8106, are connected to the junction box using 154-8095 Cables, only one can be allowed to communicate with the 179-0701 Burn Rate Computer or the two displays will interfere with each other trying to communicate. The display allowed to communicate with the flowmeters to acquire fuel data is called the "Master" and the other display must be setup to receive fuel data from the "Master" display, so it is referred to as the "Slave". To setup a display as "Master" or "Slave", go to the Main Menu from the Normal Display Mode by pressing MENU. Use the arrow keys until the cursor is on the line showing COMM MODE:, followed by MASTER or SLAVE. Use the ENTER key to toggle from MASTER to SLAVE or vice versa. If the ENTER key is pressed and ERR: LOGGING ACTIVE momentarily is shown on this line, then Logging is ON and must be turned OFF. Refer to “Data Logging Sub-Menu” section.

Surface Mount:: The display has mounting slots that allow it to be snapped onto fasteners which are partially unscrewed from the panel.

NOTE: This arrangement does not provide sealing for the display's housing to front panel interface.

Sandwich Mount:: The display may be separated into two halves and reassembled with the panel sandwiched between the two halves. The display's front housing can be sealed to the panel using the enclosure gasket. The internal connector must be separated to install unit.

NOTICE Note the orientation of the connector before removing the connector from the front half. The display may be damaged if connector is reversed when reassembled to the front half.

Now the displays may be programmed with the flowmeter address(es) to display that particular flowmeter(s) fuel parameters. Refer to the "Measuring Fuel Flow" section.

NOTE: The "Master" and "Slave" displays can be programmed with different flowmeter address(es).

The “Master” and “Slave” arrangement allows the user to have remote displays, multiple data loggers to simultaneously log different data at different logging rates, or to perform the same log with both displays so there is a "backup".

NOTE: If the “Master” display fails to communicate with the “Slave” display, the “Slave” display will “promote” itself to “Master” and communicate directly with only the flowmeters that have their flowmeter addresses programmed in the “Slave” display.

28

Programming the Function Keys (F1, F2, F3, F4, F5)

Display Factory Reset While in the normal display mode (the mode the display is in after power-up) press and hold the CTRL key and then press the RESET key until the screen changes to:

When one of the five function keys is pressed and the key was not previously programmed, the display will go blank.

To program a function key:

Display

1. Use the arrow keys to scroll to the line to be programmed or reprogrammed (line 1 through line 4).

PRINT RESET ARE YOU SURE?

2. Press the ENTER key to scroll forward through the list of available data display items. Holding the SHIFT key in the pressed position and pushing the ENTER key will allow scrolling backwards.

Options F1-YES

F5-NO

The user is given a chance to abort the reset at this point. If the factory reset is continued, then the display is changed to its factory default condition:

3. Stop scrolling when the line the cursor is on shows the desired data display item.

1. Flowmeter's addresses are changed to 00000.

4. Repeat Steps 1 through 3 until data display items are changed or added on each display line(s).

2. Units of measure reset to Non-SI (English).

3. Function keys (F1, F2, F3, F4, and F5) functions are blanked.

5. To save the new display setup, first enter the Menu Mode by pushing the MENU key.

Stop the TOTALIZER if it shows it is started, and scroll to the line showing the function key to be programmed. Then push the ENTER key to save. If the display setup is being changed, then USED will continue to be shown on the right side of the line. If the function key was not already programmed, then USED will be shown only after the ENTER key is pressed.

4. Data Logging Default Settings: a. Data logging setups and logging memory will be cleared. b. Logging interval = 10 minutes. c. Logging interval units = minutes. d. Logging parameters: NONE. e. Dump format = tab separated variable (TSV).

NOTE: Pressing any key other than what is described in Steps 1 through 5, before the function setup is saved in the display, will result in that temporary setup being lost.

f. Logging = OFF. 5. All other setups are reset.

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Display Data Items for the Function Keys

Chart F. (Cont’d) Display Data Items for the Function Keys

Most of the data display items are the same as pressing the specific front panel key on the 154-8105 or 154-8106 Fuel Flow Display, but the function keys allow selecting what may be displayed on the screen line-by-line. Refer to Chart F for a list of available data display items (shown in the viewable scrolling order as seen while programming): Chart F. Display Data Items for the Function Keys Display ENG1 SUP

Display

Definition

S1

R1

Shows both supply (S1) and return (R1) temperatures for Engine 1 on a single display line for convenience.

S2

R2

Shows both supply (S2) and return (R2) temperatures for Engine 2 on a single display line for convenience.

E1S TEMP

Engine 1 supply temperature.

E1R TEMP

Engine 1 return temperature.

E2S TEMP

Engine 2 supply temperature.

E2R TEMP

Engine 2 return temperature.

STOPWATCH

Count-up timer in hours/minutes/seconds up to 999 hours. Can be reset by placing the cursor on its display line in normal display mode and then pressing the SHIFT and RESET switches at the same time. This item cannot be tagged for logging.

CLOCK

24 hour real-time clock. The real-time clock/calendar is powered by a lithium battery and continues to operate whether the display is powered or not. This item cannot be tagged for logging. The date and time are automatically saved with each log entry.

LOG END

This item is not actually a data item, but an indicator of logging progress. This item displays the number of hours remaining until the end of logging memory is reached. When logging is active (on), this display item will alternate between showing "LOG END XXXXX.XXHRS" and "LOG EVERY XXXX.XXMIN".

The "LOG EVERY..." shows how often data is logged to memory and only appears when logging is active. This item cannot be tagged for logging. Blank for the display line.

Definition Engine 1 supply flow rate.

ENG1 RET

Engine 1 return flow rate.

ENG1 BURN

Engine 1 burn flow rate.

ENG2 SUP

Engine 2 supply flow rate.

ENG2 RET

Engine 2 return flow rate.

ENG2 BURN

Engine 2 burn flow rate.

ENG1 AVG

Engine 1 average burn rate since last reset.

(See note).

E1A TIME

Engine 1 average time. This is the amount of time over which the average burn rate was accumulated.

ENG2 AVG

Engine 2 average burn rate since last reset.

(See note).

E2A TIME

Engine 2 average time. This is the amount of time over which the average burn rate was accumulated.

ENG1 TOT

Engine 1 totalizer. Accumulates the burn rate since last reset. (See note).

E1T TIME

Engine 1 total time. The time over which the burn total was accumulated.

ENG2 TOT

Engine 2 totalizer. Accumulates the burn rate since last reset.

E2T TIME

Engine 2 total time. The time over which the burn total was accumulated.

G.TOT ENG1

Grand total burn rate for Engine 1. This is another totalizer for Engine 1. It has no associated timer and must be cleared from within the main menu.

G.TOT ENG2

Grand total burn rate for Engine 2. This is another totalizer for Engine 2. It has no associated timer and must be cleared from within the main menu.

Blank for the display line.

NOTE: If there is not a return side flowmeter, as indicated by an all zero address field, then this data item will only reflect the supply side flowmeter.

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Operational Modes

Main Menu

There are two general modes of operation for the fuel flow display. They are referred to as “Normal Mode” and “Menu Mode”. Normal Mode is the display mode the unit starts in after power-up. This mode is used for viewing different engine (Engine 1/Engine 2) flowmeter parameters, such as temperature and burn rate. Changing which data is visible is done using the keys on the front side of the display.

This menu is entered while in the Normal Display Mode by pressing the ENTER key.

Press the ENTER key again to exit the Main Menu and return to the Normal Display Mode.

The Main Menu allows the user to view and make changes to the parameters viewed in the Normal Display Mode. Use the arrow keys to scroll the flashing block-shaped cursor to the line of interest, then press the ENTER key to initiate the action with the particular menu item (line).

The Menu Mode is entered while in the Normal Mode by pressing the MENU key. Press the MENU key again to exit the MENU Mode and return to the Normal Mode. The Menu Mode has several Menus:

Pressing and holding the SHIFT key and then pressing the scroll up key while in Menu Mode will cause the menu display to shift “up” by 4 lines in the display order, leaving the cursor positioned 4 lines “higher” than before.

Main Menu Data Logging Sub-Menu

Pressing and holding the SHIFT key and then pressing the scroll down key while in Menu Mode will cause the display to shift “down” by 4 lines in the display order leaving the cursor positioner 4 lines “lower” than before.

Tag Sub-Menu Arrange Sub-Menu The menus are arranged one beneath the other. The Menu Mode's Main Menu is the menu first entered when the MENU key is pressed while in the Normal Mode. The Data Logging Sub-Menu is then entered by using the arrow keys to scroll the cursor to the line showing DATA LOGGING MENU>: and pressing the ENTER key. The Data Logging Sub-Menu is exited to the Main Menu by pressing the MENU key. The Data Logging Sub-Menu and its two Sub-Menus (Tag and Arrange) are used for setting up, performing, and down loading a datalog.

NOTE: You will not be allowed to change some menu items when either logging is active, or the totalizer is active. The display will warn you when this is the case by flashing a short message such as: ERR: TOTALIZER ACTIVE or something similar for a second or two.

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NOTE: The two digit year designators '98', and '99' are interpreted as meaning 1998 and 1999, respectively. '00' through '96' are interpreted as meaning the years 2000 through 2096, respectively.

Main Menu Items 1. TOTALIZER STARTED:: Starts and stops all totalizing functions which include ENG1 TOTAL, ENG2 TOTAL, G.TOT ENG1, and G.TOT ENG2. Average burn calculations are not affected. When the cursor is on this line, press ENTER to toggle between TOTALIZER STARTED and TOTALIZER STOPPED. When power is first applied to the display, the totalizer is automatically started. Some functions, such as changing the addresses of the flowmeters is not allowed while the totalizer is running.

5. VOLUME UNITS:: Sets volumetric units of measure to gallons or liters. After moving the cursor to this line, press ENTER to toggle between GAL or LIT. The factory default is GAL. 6. TEMP UNITS:: Sets temperature units of measure to degrees F or degrees C. When the cursor is located on this line, press ENTER to toggle between DEG.F or DEG.C. The factory default is DEG.F.

2. CLEAR GRAND TOTALS:: When the cursor is on this line, press the ENTER key to clear the grand totals. You will be prompted to confirm that you wish to clear the grand totals. Press F1 to confirm, or F5 to abort the action. The values of the grand totals (G.TOT ENG1 and/or G.TOT ENG2) can be viewed by programming one of the function keys ( F1, F2, F3, F4, or F5).

7. ENG1 SUP ADR:: Engine 1 supply flowmeter address (serial #). To set the serial number, see the "Setting the Serial Number Switch" section of this manual (page 14).

8. ENG1 RET ADR:: Engine 1 return flowmeter address (serial #). To set the serial number, see the "Setting the Serial Number Switch" section of this manual (page 14).

3. SET TIME:: To set the current time of the clock, move the cursor to this line and press the ENTER key. The cursor will move to the hours position. This is a 24 hour clock (no AM/PM). Enter a 2 digit number between 00 and 23 and press the ENTER key. This will move the cursor to the minutes location.

Enter a two digit number between 00 and 59 and press the ENTER key. This will move the cursor to the seconds location.

Enter a two digit number between 00 and 59 and press the ENTER key. Pressing the ENTER key after entering a two digit number for the seconds causes the time to be set. To avoid changing a field (hours/minutes/seconds), press the ENTER key without entering a new number. The time display in menu mode does not change (update) as the seconds pass, such as occurs when in normal display mode.

The display in menu mode is only updated after a key has been pressed.

9. ENG2 SUP ADR:: Engine 2 supply flowmeter address (serial #). To set the serial number, see the "Setting the Serial Number Switch" section of this manual (page 14).

10. ENG2 RET ADR:: Engine 2 return flowmeter address (serial #). To set the serial number, see the "Setting the Serial Number Switch" section of this manual (page 14).

11. SAVE F1:: Used for saving a programmed F1 key. Refer to the “Programming the Function Keys (F1, F2, F3, F4, F5)” section for a more detailed explanation.

12. SAVE F2:: Refer to “SAVE F1“.

13. SAVE F2:: Refer to “SAVE F1“.

14. SAVE F4:: Refer to “SAVE F1“.

4. SET DATE mm/dd/yy:: Displays the current date in MONTH/DAY/YEAR format. To change the date press the ENTER key.

Enter a two digit number for the month and press ENTER. Enter a two digit number for the day and press ENTER. Enter a two digit number for the year and press ENTER.

15. SAVE F5:: Refer to “SAVE F1“.

16. COMM MODE: MASTER:: For single display systems, this should be left in the MASTER position. The SLAVE position is used to allow more than one display to be connected to the 154-8107 Junction Box. Refer to the “Multiple Display Operation” section for a more detailed explanation.

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3. LOG SPAN:: This value displays the time (in hours) remaining in logging memory, given the current logging interval selected and the number of items currently tagged for logging. The LOG SPAN can be viewed at anytime and decreases as a datalog is performed until it reaches 0.0 hours. At this point, the display will turn off the logger and LOGGING OFF will be shown on the logging line. If you choose to enter a value here (in hours), the display will calculate the minimum logging interval required to fill logging memory in that selected time, and will change the logging interval to the calculated minimum interval. Only an integral number of hours can be entered.

For example: If the log memory is empty, two items are tagged to be logged (ENG 1 NET and ENG 1 TOTAL), and the selected log interval is 60 seconds, this value will be displayed as over 270 hours. This means logging will stop with memory completely filled up approximately 11 days after being started (providing uninterrupted power is provided). If the number 168 were entered here, the logging interval would change to about 36 seconds. Then, logging would stop with memory full 168 hours (7 days) after being started.

17. UPPER SPAN:: UNUSED. 18. LOWER SPAN:: UNUSED. 19. DATA LOGGING MENU:: Selecting this item by pressing the ENTER key will activate the Data Logging Sub-Menu.

Data Logging Sub-Menu This sub-menu is used for setting up and doing a Datalog. Select this sub-menu by going to the DATA LOGGING MENU>: in the Main Menu and pressing the ENTER key. Go from the Data Logging Sub-Menu back to the Main Menu by pressing the MENU key.

1. TAG ITEMS TO LOG >:: Selecting this menu entry causes the display to enter and display the TAG sub-menu. The TAG sub-menu is used to select and de-select (tag/untag) the data items to be logged.

Tagging/Untagging of data items is not allowed while datalogging is active. The error message ERR: LOGGING ACTIVE will appear momentarily if the cursor is on the TAG ITEMS TO LOG> line and ENTER is pressed while logging is active (ON).

2. LOGGING IS:: This value toggles between ON and OFF, which turns the logging on and off. If logging is turned ON (active), and power is removed from the display, then logging will resume as soon as power is reapplied to the display. The display will automatically turn logging off when the memory is full. If logging is turned ON, then OFF, and then back ON at a later time, the data logging continues from the point that it was when it was last turned off. The data from the previous logging session is NOT lost.

4. LOG INTRVL:: This value represents the time period between successive “logs” of data to memory. The minimum value for this item is 1 second. The maximum value is 65535 seconds (1092 minutes, 18.2 hours).

The default is 10 minutes.

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7. MEMORY OVERWRITE:: If memory overwrite is OFF, logging will stop when the memory is full. If memory overwrite is ON when the logging data fills up all of the available memory, the unit will “wrap” back around to the beginning of log memory, overwriting the oldest data with new data.

This will continue indefinitely, or until terminated by external means, such as turning logging OFF. Memory must be clear before turning memory overwrite ON. If logging is ON (active), memory overwrite cannot be turned ON or OFF. Once logging is turned OFF, then memory overwrite can also be turned OFF. At this point, the tag definitions can be changed and logging continued, but not with memory overwrite. The log memory must be clear in order to engage memory overwrite. When memory overwrite is ON, the indicators of remaining log memory only indicate the amount of time before the next “wrap” back to the beginning of memory.

5. LOG INTRVL UNIT:: This value toggles between SEC and MIN. The corresponding value in LOG INTRVL will change when this selection is changed. Note that when displaying minutes, the actual value is still in seconds, and the minute value displayed is actually a rounded value. For example, if 110 seconds was initially entered for a log interval, then the logging interval units was changed from seconds to minutes, the logging interval would then display as 1 minute, however, the actual interval for logging would still be 110 seconds. To enter an integral number of minutes (for example, 10 minutes), first change the units to minutes, then enter 0010. To double check, toggle back to seconds, and the logging interval should display 600SEC. 6. CLEAR LOG MEMORY/LOG MEMORY IS EMPTY: This function is used to clear log memory. If log memory is already cleared, the menu entry will appear as: LOG MEMORY IS EMPTY. If the log memory contains data, the entry will appear as: CLEAR LOG MEMORY. If the ENTER key is pressed, the screen will change to prompt the user with: CLEAR LOG MEMORY? and ARE YOU SURE? with F1-YES and F5-NO. If the user wishes to clear log memory, the F1 key should be pressed. If the F1 key is pressed, the message LOG MEMORY CLEARED will appear momentarily, and the menu entry will change to LOG MEMORY IS EMPTY. If the user does NOT wish to clear memory, then press the F5 key to abort the operation, and the message CLEAR ABORTED will appear. If the menu entry appears as CLEAR LOG MEMORY, then the log memory contains data. If the menu entry appears as LOG MEMORY IS EMPTY, then, of course, the log memory is empty.

8. DUMP FORMAT IS:: This item appears as TSV (tab separated variable) or CSV (comma separated variable) and is changed by pressing the ENTER key with the cursor on this line. It changes the format of data retrieved from log memory and dumped to a personal computer. It separates the variables by tabs (TSV) or commas (CSV). The default is TSV, which is compatible with most spreadsheets.

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Tag Sub-Menu

The items available for logging are:

The tag menu lists all of the data items available for logging. It is only accessible from the Data Logging Sub-Menu. Enter the Tag Sub-Menu by scrolling to TAG ITEMS TO LOG > and pressing the ENTER key.

1. ENG 1 SUPPLY

Items to be logged are “tagged” by moving the cursor to the line to the desired data item using the scroll up or down key and then pressing the ENTER key. This action will tag an item if it was untagged, or untag a previously tagged item. Tagged items are shown by an asterisk (*) to the right of the item.

5. ENG 2 RETURN

2. ENG 1 RETURN 3. ENG 1 BURN 4. ENG 2 SUPPLY 6. ENG 2 BURN 7. ENG 1 AVG. BURN 8. ENG 1 AVG. TIME 9. ENG 2 AVG. BURN 10. ENG 2 AVG. TIME

When you have finished tagging/untagging items to be included/excluded as data items to be logged, press the MENU key. This will place the display in the ARRANGE Sub-Menu.

Refer to the “ARRANGE Sub-Menu” section.

11. ENG 1 TOTAL 12. ENG 1 TOTAL TIME 13. ENG 2 TOTAL 14. ENG 2 TOTAL TIME 15. ENG 1 GRAND TOTAL 16. ENG 2 GRAND TOTAL 17. ENG 1 SUPPLY TEMP 18. ENG 1 RETURN TEMP 19. ENG 2 SUPPLY TEMP 20. ENG 2 RETURN TEMP

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Unlike the other menus, the Arrange Menu is not “circular”, in that, if you are at the bottom (last) menu item and attempt to move “down”, the display does not move back to the top of the list of menu items. When you are at the top (bottom), the “up” (“down”) arrow keys will be ignored. The Arrange Sub-Menu can be exited by pressing the Menu key, which changes the display to the Data Logging Sub-Menu.

Arrange Sub-Menu The Arrange Sub-Menu is entered by pressing the MENU key while in the tag sub-menu.

The Arrange Sub-Menu is used to allow the user to view and change the ordering in which the data items are stored while logging. The data will be in this order when “dumped” to a computer at a later time. Initially, the ordering of the data items is the order in which they were tagged, in the Tag Sub-Menu. The Arrange Menu shows only those items that have been tagged.

The ordering of the data items in the Arrange Sub-Menu determines in which “column” the data item appears. For example, tag Engine 2 Return, Engine 2 Supply, Engine 1 Supply, and Engine 1 Return (in order), then when the MENU key is pressed to enter the Arrange Sub-Menu, it will appear as shown in Illustration 24.

To change the ordering of the data items, place the cursor on the data item you wish to move “up” in the list, and press the ENTER key. The data item will swap places with the data item which was above it, and the cursor will remain on the data item that was moved, allowing for multiple moves of the same data item by pressing the ENTER key multiple times.

ENG 2 RETURN ENG 2 SUPPLY ENG 1 SUPPLY ENG 1 RETURN

CATERPILLAR 154-8106 FUEL FLOW DISPLAY v3 - 2.09 LOG DATA REPORT 06/18/1998 06:53:37 DATE/TIME ENG2 RETURN GPH 06/17/1998 16:54:09 06/17/1998 16:54:10 06/17/1998 16:54:11 06/17/1998 16:54:12 06/17/1998 16:54:13 06/17/1998 16:54:14

226.16 226.16 226.16 226.16 226.33 226.31

ENG2 SUPPLY GPH

ENG1 SUPPY GPH

ENG1 RETURN GPH

287.76 287.78 287.80 287.80 287.94 288.01

288.20 288.29 288.38 288.38 288.40 288.37

227.13 227.18 227.25 227.25 227.32 227.34 0697-10

Illustration 24. Example Of Results From 154-8106 Fuel Flow Display Entries.

Example of items tagged in the Arrange Menu in the following order: Engine 2 Return, Engine 2 Supply, Engine 1 Supply, and Engine 1 Return.

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3. Clear the log memory, if desired, by going to the Data Logging Sub-Menu, scrolling up or down to the CLEAR LOG MEMORY line and pressing the ENTER key and when prompted pressing the F1 key. If the line shows LOG MEMORY IS EMPTY, then the log memory is already cleared. If the log memory is not cleared and a log is performed, then the logged data will be stored in memory just after the data of the last logged data.

Data Logging Operation The 154-8105 and 154-8106 Fuel Flow Displays have the ability to record (log) information at user specified intervals into its memory. This information can be later retrieved using a personal computer. The information is pre-formatted into row/column type of format suitable for importation into a spreadsheet or database program.

NOTE: Contact CSTG for more information and the components necessary to download the datalog from a fuel flow display to a personal computer.

4. Select the Logging Interval (LOG INTRVL), which is how often the user desires the “tagged” data items to be recorded in memory. Changing the value of the LOG SPAN, LOG INTRVL, or LOG INTRVL UNIT (logging interval unit) will change the value of the other two if the memory of the display would fill before completing the requested datalog (depends on if Loggers Memory was filled, the number of “tagged” data items, the sampling rate (LOG INTRVL and LOG INTRVL UNIT), and the length of logging (LOG SPAN).

General Codes ERR: LOGGING ACTIVE

This message appears when the user tries to change items that are disallowed during logging (LOGGING ON), such as attempting to clear log memory, or trying to change which items are tagged for logging. This message will appear on the display's bottom line.

ERR: This message appears if the user attempts to OVERWRITE change the logging tag definitions when ON overwrite is on, and there is existing data in the log memory. This message will appear on the display's bottom line.

-9999.99

5. To clear the Grand Total(s) enter the Main Menu. Scroll up or down to the CLEAR GRAND TOTALS line. Press the ENTER key and when prompted press the F1 key.

The display's line will still show CLEAR GRAND TOTALS even after clearing the grand totals. The value(s) of the grand total(s) can only be viewed by “tagging” the grand total(s), performing a datalog, and then downloading the datalog.

This number will be logged in place of a number to indicate that the entry is invalid. The invalid data may be the result of the display not communicating with flowmeter, which can be caused by an incorrect flowmeter "ADDRESS NO." keyed into the display or a defective cable.

6. While still in the Data Logging Sub-Menu, scroll up or down to the display line showing MEMORY OVERWRITE. Toggle between memory overwrite OFF or ON by pressing the ENTER key. If it is OFF, then the datalogger will automatically stop logging when memory is full. The logger may be stopped manually at any time by pressing the ENTER key on the display line showing LOGGING OFF. If the MEMORY OVERWRITE is ON, when the LOG SPAN reaches 0.00 (log memory is full) the datalogging will continue and the LOG SPAN will be reset back to its initial state when it started the log. This will continue indefinitely and the logging is terminated manually.

Performing a Datalog 1. Refer to “Measuring Fuel Flow” in the “Operating Instructions” section to setup the display and system connection.

2. Data logging functions are done while in the Data Logging Sub-Menu. Refer to the Operational Modes section. Next “tag” the data items desired to be logged in memory.

Enter the Tag Sub-Menu through the Data Logging Sub-Menu.

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NOTE: Memory must be cleared before MEMORY OVERWRITE can be turned ON.

Downloading the Logged Data A personal computer with an available RS232 or RS485 port is necessary to download the logged data. An RS485 to RS232 converter will be required if only an RS232 port is available on the personal computer). Any device used to capture the data must be capable of accepting continuous data at 19,200 baud to a total of approximately one megabyte. Contact CSTG for information on how to interface the fuel flow display and personal computer in order to download the datalogged information. The data logged, which is stored inside of the display is not cleared after a download and will be retained even if power is removed to the display.

7. Scroll up or down to the DUMP FORMAT IS line. Toggle between TSV (tab separated variable) and CSV (comma separated variable) using the ENTER key. DUMP FORMAT IS changes the format of the data retrieved from log memory and dumped to a personal computer. It is either separating the variables by tabs (TSV) or commas (CSV). The default is TSV, which is compatible with most spreadsheets.

NOTE: The dump format can be changed after logging has been turned ON or when it is finished and the logging is turned OFF. 8. The fuel flow display is now set up for Data Logging. Turn on the logger by going to the LOGGING OFF line in the Data Logging Sub-Menu and pushing the ENTER key.

Logging with start and the displays line will change to show LOGGING ON (note).

1. Set up the fuel flow display to download the data. Press the PRINT key on the display keypad and the display will show PRINT LOG DATA NOW? and prompts F1-YES and F5NO. Do not push any other key pads and setup the personal computer to accept the logged file.

9. Press the MENU key to go to the Main Menu. Scroll up or down to the display line showing TOTALIZER STOPPED and press the ENTER key to restart the totalizer (line will now show TOTALIZER STARTED).

NOTE: The fuel flow display's data logger does not have to be turned off (LOGGING OFF) while downloading to a personal computer. Logging will be suspended automatically while the fuel flow display downloads data to the personal computer and then resumes when the download is complete.

10. Reset the Average(s) and Total(s) now, if desired.

11. Power to the fuel flow display may be removed and the logged data in memory will be preserved (memory is battery backed). The datalogging setup will remain the same until a new setup is programmed into the display and is retained even if power is removed from the display.

2. Set up the personal computer to accept the data to be downloaded from the fuel flow display. For a personal computer running Windows95, the “HyperTerminal” program will be utilized to capture the data file from the fuel flow display and then store it.

3. When using the “HyperTerminal” program in Windows95, open the “HyperTerminal” program by using the “Windows95... Start...

Programs... Accessories... HyperTerminal...

HyperTerminal” menu sequence.

NOTE: If logging is turned ON, but no data items have been “tagged”, then the logging will be turned OFF (display line will change from LOGGING ON to LOGGING OFF when the cursor is moved from this line, the display is turned off and then turned back on, or the MENU key is pressed).

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4. Set up the HyperTerminal by selecting whether the COM1 or COM2 port will be used to capture data on the personal computer.

8. Watch the transfer of the logged data scroll by on the personal computer's display. The transfer is complete when END-OF-DATA is seen on the display in real time. Select Transfer on the HyperTerminal menu bar, select sub menu item Capture, and then select sub-menu item Stop to stop the data capture (delaying the manual termination of the download will increase the amount of extraneous characters stored at the end of the data file).

a. Type in COM1 Direct for using COM1 port or COM2 Direct for using COM2 port for the name of the new connection.

Click on OK. b. Click on the down arrow to the right of Connect Using and choose Direct to Com1 or Direct to Com2 depending on whether using the COM1 or COM2 port.

9. Information stored inside the display is not cleared after a download. The information is also stored in the personal computer in an ASCII text file and ready for importation into a spreadsheet or it can be sent directly to a printer.

c. Choose 19200 for “Bits per Second”, 8 for “Data Bits”, None for "Parity", 1 for "Stop bits", and None for "Flow Control".

Click on OK to save this setup.

5. Select the “Call” pull down window and then select Disconnect to reset capture before transferring the data file.

NOTE: Tab settings may cause the column headers to be slightly misplaced if the file is sent directly to a printer. Column headings will be in the proper position if imported into a spreadsheet. Tab settings may be adjusted inside a word processor and many text editors.

Any extraneous characters at the end of the data file may be deleted while in a spreadsheet or word processor.

6. Select Transfer on the menu bar of the HyperTerminal and then select sub-menu item “Capture Text...”. The HyperTerminal will respond by offering the default file name of CAPTURE.TEXT. Accept this default or choose another file name and directory location. Click on OK when ready to capture the data file. The HyperTerminal program is now waiting for the data file from the fuel flow display.

NOTE: If the format of the data is changed using a word processor or text editor, the data may not import into a spreadsheet correctly and will require adjustment there. If the user wants to print out the data, it is recommended the data file be imported to a spreadsheet and then print it out.

7. Press the F1 key on the fuel flow display, which will start the transmission of the formatted ASCII data to the personal computer.

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Service

Calibration

If the burn rate meter system does not operate correctly, refer to Chart D in the “Troubleshooting” section. If the problem still cannot be located, disconnect the system from the engine and refer to “Checking the Operation of the Burn Rate Meter System” section.

The burn rate meter comes with a calibration certificate. A label on the burn rate meter indicates the calibration in pulses/Liter. The calibration number must be transferred to the burn rate computer calibration switches Refer to the “Controls” section.

NOTE: The burn rate meter should have its calibration checked annually.

For additional information on the fuel flow displays, refer to NEHS0697, “Using the Caterpillar FuelCom Fuel Flow Measurement System”.

If the system does not work correctly, contact the Caterpillar Service Technology Group for information on how to obtain service.

Caterpillar Service Technology Group provides the user of this instrument with a one year warranty from the date of purchase. If abuse is determined to be the reason for failure, the warranty will be void. Any out-of-warranty repairs will be charged to the owner. For any product support questions about your instrument contact your Caterpillar dealer or CSTG at: (800) 541-8665 (inside Illinois) (800) 542-8665 (outside illinois) (800) 523-8665 (Canada) Hotline E-mail “CSTG” 022 849 4036 (Geneva Phone) 022 849 4929(Geneva Fax) 36 CSTG (Cosa E-mail) If the instrument, or any part of it needs repair, contact and send to: ATS (Advanced Technology Services) 8201 North University Avenue Peoria, Illinois USA 61615 (800) 328-7287 (inside USA) (309) 693-4000 (309) 693-4170 (fax) E-mail “repair@advancedtech.com”

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NOTES

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For information on service tools or shop supplies, contact Caterpillar Service Technology Group on: Caterpillar Service Technology 501 S.W. Jefferson Ave. Peoria, Illinois 61630-2184 1-800-542-8665 (USA) 1-800-541-8665 (Illinois) 1-800-523-8665 (Canada) 404435 (Telex) 1-309-675-6618 (Fax) CSTG_Hotline@cat.com (E-mail) or Caterpillar Service Technology Caterpillar Overseas S.A. P. O. Box 6000 1211 Geneva 6 Switzerland +41 (79) 217 27 45 (Geneva Phone) +41 (22) 849 49 29 (Geneva Fax) 36CSTG (COSA E-Mail Address)

©2002 Caterpillar Inc. All Rights Reserved

NEHS0776-01 Printed in U.S.A.