Aerospace Logic FL-100-5 Specification sheet

FL-100-5 Dual Fuel Level Indicator Page 1 of 23
Aerospace Logic Inc.
3150 Ridgeway Drive, Unit #43, Mississauga, Ontario, L5L 5R5, CANADA
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FL-100-5 Operations & Installation Manual – Ver. 2.0 – October 24, 2004
All specification subject to change
© 2002-2004 Aerospace Logic Inc.
FL-100-5
Operations and Installation Manual
Congratulations on the purchase of your FL-100 Dual Fuel Level Indicator. This
instrument is a complex precision instrument manufactured to exceed Airborne
Equipment Standards DO-160D, DO-178B and TSO C55 standards. In order for your
instrument to function correctly you will need to review the instructions in this brief
manual.
This manual is certified for use with
instrument serial number
ASL000000
Use of this manual with any other
instrument voids all warranties and may
result in damage to the instrument

FL-100-5 Dual Fuel Level Indicator Page 2 of 23
Aerospace Logic Inc.
3150 Ridgeway Drive, Unit #43, Mississauga, Ontario, L5L 5R5, CANADA
Tel. [phone] | Fax. [phone] | [e-mail]
www.aerospacelogic.com
FL-100-5 Operations & Installation Manual – Ver. 2.0 – October 24, 2004
SECTION 1
Introduction
Your FL-100 Dual Fuel Level Indicator will provide you with years of reliable service and
generally outlast the life of your aircraft. The instrument is constructed from the highest
quality components and will provide a design life in excess of 100,000 hours.
It is the most reliable instrument of its kind. Gone are the days of questioning the
accuracy or operation of the instrument. No stuck needles, erroneous readings or
instruments that keep you guessing as to their operational status.
Every reading you will see displayed on your instrument has been validated 256 times
before you see it. This all happens in less than a second. When you see the result you
know the instrument is functioning correctly as it is monitored by an independent
microprocessor just to insure that it is functioning correctly. In turn the main processor
validates the independent monitoring processor. A failure detected in either processor
will cause the instrument display to be turned off or an error message to be displayed,
depending on the failure status.
Display
Under normal operations the main display of the instrument shows the status of both left
and right tanks on the bar display, irrespective of the switch setting.
The lower four-digit seven-segment
display provides a mathematically
computed display of the selected
parameters. The switch setting
controls this display. When the switch
is placed in the Lposition the LEFT
LED indicator will be lit and the fuel
quantity will be computed and
displayed for the left tank. Likewise,
when the switch is placed in the Rposition the RIGHT LED indicator will be lit and the
fuel quantity will be computed and displayed for the right tank.
Moving the switch momentarily to the Sposition will change the display option if
applicable (See SECTION 4 – Operation).
.

FL-100-5 Dual Fuel Level Indicator Page 3 of 23
Aerospace Logic Inc.
3150 Ridgeway Drive, Unit #43, Mississauga, Ontario, L5L 5R5, CANADA
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FL-100-5 Operations & Installation Manual – Ver. 2.0 – October 24, 2004
SECTION 2
Installation
The FL-100 will fit any standard 2 ¼” aircraft mounting hole. Place the instrument in the
hole from the rear of the panel and then attach it with the four screws provided. If you
need to replace the screws, ensure that the threads do not penetrate the instrument
more than ½”. Screws that penetrate the instrument further will cause severe damage to
the instrument.
DISCONNECT ANY EXISITING FUEL INSTRUMENTS FROM THE
FUEL SENDERS
This instrument will not work in conjunction with any other fuel indicating
instruments.
Now connect the wiring as follows (See Page 4 for the Installation Schematic):
BLACK Aircraft supply ground
RED Master switched 14/28V bus (Instrument is internally fused)
ORANGE Left tank sensor output
YELLOW Right tank sensor output
BLUE 28V dimmer control (if required)
WHITE 14V dimmer control (if required)
THIS IS THE MOST IMPORTANT STEP OF THE INSTALLATION
OMISSION OF THIS STEP VOIDS ANY AND ALL PRODUCT CERTIFICATIONS!
Place the following placards within view of the pilot:
“Do not rely on indications from ANY fuel level instrument for flight safety”
AND
If the aircraft manufacturer has ANY limits or conditions associated with the original fuel
gauge, they MUST be placed under this fuel gauge as well. Items such as minimum
take-off capacities MUST be placarded.
Once installed your instrument will require setup and calibration before it may be
commissioned for service.

FL-100-5 Dual Fuel Level Indicator Page 4 of 23
Aerospace Logic Inc.
3150 Ridgeway Drive, Unit #43, Mississauga, Ontario, L5L 5R5, CANADA
Tel. [phone] | Fax. [phone] | [e-mail]
www.aerospacelogic.com
FL-100-5 Operations & Installation Manual – Ver. 2.0 – October 24, 2004

FL-100-5 Dual Fuel Level Indicator Page 5 of 23
Aerospace Logic Inc.
3150 Ridgeway Drive, Unit #43, Mississauga, Ontario, L5L 5R5, CANADA
Tel. [phone] | Fax. [phone] | [e-mail]
www.aerospacelogic.com
FL-100-5 Operations & Installation Manual – Ver. 2.0 – October 24, 2004
SECTION 3
Setup and Calibration
Instrument setup is only required when a parameter or display configuration is to be
changed. With proper planning you should only have to perform this function once in the
life of the instrument. All information is stored in the instruments lifetime memory which
will be retained without power for up to 100 years.
NOTE: When in the setup mode the two left most characters will have decimal
points displayed with the specific characters. The display bars as well as LEFT
and RIGHT LED indicators will be off at all times during the setup process.
STEP 1
To enter the Setup mode turn off the power to the instrument.
Then press and hold the switch in the Sposition and turn on
the power.
Do not release the Sswitch during this process.
STEP 2
When the “Set-” message is displayed release the Sswitch.
The display will now show one of the two displays as follows
depending on the instrument brightness control source.

FL-100-5 Dual Fuel Level Indicator Page 6 of 23
Aerospace Logic Inc.
3150 Ridgeway Drive, Unit #43, Mississauga, Ontario, L5L 5R5, CANADA
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FL-100-5 Operations & Installation Manual – Ver. 2.0 – October 24, 2004
STEP 3
The display will show either the
Internal or the External setting
depending on the previous selection.
By moving the switch between the L
and Rpositions you can select the
brightness source for the control of
the LED display.
An Internal setting allows the intensity of the instrument display to be controlled using
the switch on the front of the instrument while an External setting allows the intensity of
the instrument to be controlled using the panel rheostat.
Once the correct value is displayed move the switch to the Sposition and then back to
the Rposition.
STEP 4
The instrument will now display the following two screens with a pause of about 3
seconds between the first and the last.
First the CAL- message is displayed
and the display will then wait for user
input at the SurE message point.

FL-100-5 Dual Fuel Level Indicator Page 7 of 23
Aerospace Logic Inc.
3150 Ridgeway Drive, Unit #43, Mississauga, Ontario, L5L 5R5, CANADA
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FL-100-5 Operations & Installation Manual – Ver. 2.0 – October 24, 2004
STEP 5
? Do you want to perform the tank calibration at this point?
•NOI just want to return the instrument to normal operations after changing or
viewing the intensity setting for the instrument
oThen press the switch to the Sposition and release it. Now proceed to
SECTION 4 – Operation.
•YESI want to perform the tank calibration for this instrument. I have completed
the installation preparation as outlined in the FL-100-5 Installation Checklist
and Guide as well as any applicable manufacturer guidelines.
oThen move the switch to the Lposition and return it to the Rposition.
STEP 6 The instrument will display either of
these two options depending on the
previous setting.
Now set the sender orientation
From the FL-100-5 Installation
Checklist select either nor r
depending on the value in box #3
OR
If the output voltage from the fuel sending device INCREACES in voltage with fuel
volume select r
If the output voltage from the fuel sending device DECREACES in voltage with fuel
volume select n
You can change the setting from nto rand rto nby moving the switch to the L
position and then back to the Rposition. Once the correct value is displayed move the
switch to the Sposition and then back to the Rposition.

FL-100-5 Dual Fuel Level Indicator Page 8 of 23
Aerospace Logic Inc.
3150 Ridgeway Drive, Unit #43, Mississauga, Ontario, L5L 5R5, CANADA
Tel. [phone] | Fax. [phone] | [e-mail]
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FL-100-5 Operations & Installation Manual – Ver. 2.0 – October 24, 2004
STEP 7
?Do you want to calibrate the LEFT tank at this time?
•NOI want to either calibrate the RIGHT tank or exit the calibration process.
oThen move the switch to the Sposition and back to the Rposition. Now
proceed to the STEP 16 on Page 12 of this document
•YESI want to calibrate the LEFT tank now. I have completed the installation
preparation as outlined in the FL-100-5 Installation Checklist and Guide as
well as any applicable manufacturer guidelines.
oThen move the switch to the Lposition and then back to the Rposition.
STEP 8
Now read BOTH STEP 8 and STEP 9 before performing them. Then
perform STEP 8 and STEP 9.
YOU MUST HAVE YOUR CALIBRATION FORMS READY BEFORE
CONTINUING (SECTION 5).
At this point you will allow the instrument to obtain the reference
point where there is no usable fuel in the tank.
Ensure that only the unusable amount of fuel is in the tank.
Wait 20 seconds for the fuel to settle and then move the switch
to the Sposition and back to the Rposition. Once the switch is
in the Rposition the instrument will display one of the following:

FL-100-5 Dual Fuel Level Indicator Page 9 of 23
Aerospace Logic Inc.
3150 Ridgeway Drive, Unit #43, Mississauga, Ontario, L5L 5R5, CANADA
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FL-100-5 Operations & Installation Manual – Ver. 2.0 – October 24, 2004
STEP 9
A number preceded by the letter Lthat will be displayed for
three seconds and then the L..1 display as in STEP 11.
If you received this display then note this number on the
calibration sheet for this tank. See SECTION 5 (Page 16 or 17)
or the enclosed copy of the calibration sheet and proceed to
STEP 11.
If you did not receive this display proceed to STEP 10
STEP 10
You received either an error message
#3 or #5.
See SECTION 6 to determine the
cause of this error message. The
instrument will return to the L..0
display until you resolve the error
condition.
If you have not completed the installation preparation as outlined in the FL-100-5
Installation Checklist and Guide as well as any applicable manufacturer guidelines
perform it before continuing with the calibration procedure. Do not continue this process
until this has been done.
STEP 11
Now add one gallon of fuel to the tank.
Wait 20 seconds for the fuel to settle and move the switch to
the Sposition and back to the Rposition.
Once the switch is in the Rposition the instrument will display
one of the following:

FL-100-5 Dual Fuel Level Indicator Page 10 of 23
Aerospace Logic Inc.
3150 Ridgeway Drive, Unit #43, Mississauga, Ontario, L5L 5R5, CANADA
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FL-100-5 Operations & Installation Manual – Ver. 2.0 – October 24, 2004
STEP 12
A number preceded by the letter Lthat will be displayed for
three seconds and then the L..2 display as in STEP 14.
If you received this display then note this number on the
calibration sheet from this tank. See SECTION 5 (Page 16 or
17) or the enclosed copy of the calibration sheet and proceed to
STEP 14.
If you did not receive this display then proceed to STEP 13.
STEP 13
Error #6, #7 or #8.
If you received this display then see SECTION 6 to determine
the cause of this error message. The instrument will return to
the L..1 display until you resolve the error condition.
If you have not completed the installation preparation as
outlined in the FL-100-5 Installation Checklist and Guide as
well as any applicable manufacturer guidelines perform it
before continuing with the calibration procedure.
STEP 14
Now add one gallon of fuel to the tank.
Wait 20 seconds for the fuel to settle and move the switch to
the Sposition and back to the Rposition.
Once the switch is in the Rposition the instrument will display
the next fuel quantity level to calibrate after displaying the
calibration value that you need to record, as in STEP 12.

FL-100-5 Dual Fuel Level Indicator Page 11 of 23
Aerospace Logic Inc.
3150 Ridgeway Drive, Unit #43, Mississauga, Ontario, L5L 5R5, CANADA
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FL-100-5 Operations & Installation Manual – Ver. 2.0 – October 24, 2004
STEP 15
Repeat STEP 12 to STEP 15 until the first of the following occurs:
1. The tank is full; OR
2. The sender reaches the maximum quantity of fuel it will indicate.
When either of the above conditions is met AND an error #6, #7 or #8 is displayed
perform the following:
Move the switch to the Lposition and then back to the Rposition. The display should
now look like this:
If all the conditions of this step have been met and you have
completed the calibration of this tank then move the switch to
the Lposition and then back to the Rposition.
If you completed this step for the LEFT tank then continue with
STEP 16 of this process.
If you completed this step for the RIGHT tank then continue
with STEP 18 of this process.
If all the conditions of this step have NOT been met and you wish to continue with the
calibration of this tank then move the switch to the Sposition and then back to the R
position. The instrument calibration will continue at the last step that was not completed.

FL-100-5 Dual Fuel Level Indicator Page 12 of 23
Aerospace Logic Inc.
3150 Ridgeway Drive, Unit #43, Mississauga, Ontario, L5L 5R5, CANADA
Tel. [phone] | Fax. [phone] | [e-mail]
www.aerospacelogic.com
FL-100-5 Operations & Installation Manual – Ver. 2.0 – October 24, 2004
STEP 16
?Do you want to calibrate the RIGHT tank at this time?
•NOI want to exit the calibration process.
oThen move the switch to the Sposition and back to the Rposition. Now
proceed to the STEP 18 of the Setup and Calibration process
•YESI want to calibrate the RIGHT tank now. I have completed the installation
preparation as outlined in the FL-100-5 Installation Checklist and Guide as
well as any applicable manufacturer guidelines.
oThen move the switch to the Lposition and then back to the Rposition.
STEP 17
Now perform STEP 8 through STEP 15 for the right tank. The entire process is exactly
the same except that the instrument will display the rcharacter instead of the L
character in the leftmost position of the digital display for all steps.
Once STEP 15 has been completed for the RIGHT tank proceed to STEP 18.

FL-100-5 Dual Fuel Level Indicator Page 13 of 23
Aerospace Logic Inc.
3150 Ridgeway Drive, Unit #43, Mississauga, Ontario, L5L 5R5, CANADA
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FL-100-5 Operations & Installation Manual – Ver. 2.0 – October 24, 2004
STEP 18
The text donE will be briefly displayed on the instrument and
it will then restart in the normal operation mode.
One of the following three conditions will be met at this point:
1. You have reviewed the calibration process without calibrating the instrument.
The instrument may not be commissioned for use at this point.
2. You have calibrated either the LEFT or RIGHT tanks and may return to the
calibration process at a later point to complete the calibration process for the
remaining tank.
The instrument may not be commissioned for use at this point.
3. You have completed calibration of both tanks.
Once the necessary documentation has been completed the instrument
may be placed in service.
WARNING: This instrument may only be commissioned for legal
use once the calibration procedure has been completed on
BOTH LEFT AND RIGHT tanks.

FL-100-5 Dual Fuel Level Indicator Page 14 of 23
Aerospace Logic Inc.
3150 Ridgeway Drive, Unit #43, Mississauga, Ontario, L5L 5R5, CANADA
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FL-100-5 Operations & Installation Manual – Ver. 2.0 – October 24, 2004
SECTION 4
Operation
STEP 1: Power Up
Once power is applied to the instrument it will scroll the text
FL-100 through on the digital display.
Then a tESt message will be displayed with all LED elements
of the display lit.
Next the software version will be
displayed. For this instrument it must
be v205.
Finally the instrument will display four
dash characters on the digital display.
This display will remain on the
instrument while it initializes the first
fuel level measurement. This may take
up to 20 seconds to complete. Once the initial fuel level is displayed the instrument is
ready for use.
STEP 2: General Operation – Fuel Level Display
Move the switch to the Lposition to
display the fuel quantity in the LEFT
tank. At the same time the LEFT LED
will light up indicating that the digital
display contains the fuel quantity in the
LEFT tank.
By moving the switch to the Rposition
the display will show the fuel quantity
in the RIGHT tank. At the same time the RIGHT LED will light up indicating that the fuel
quantity indicated in the digital display is for that of the RIGHT tank.

FL-100-5 Dual Fuel Level Indicator Page 15 of 23
Aerospace Logic Inc.
3150 Ridgeway Drive, Unit #43, Mississauga, Ontario, L5L 5R5, CANADA
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FL-100-5 Operations & Installation Manual – Ver. 2.0 – October 24, 2004
STEP 3: General Operation – Display Intensity Control - External
If you set the intensity control to E (see SECTION 3) then the intensity of the instrument
will be controlled by your panel rheostat.
Furthermore, moving the switch to the Sposition in normal operations more will have no
effect on the operation of the instrument.
STEP 4: General Operation – Display Intensity Control – Internal
By moving the switch to the Sposition while the instrument is
displaying the fuel quantity the display will change as shown.
The ncharacter indicates that the increase intensity
operation has been selected. The instrument will default to
intensity level 32 and will retain the last set intensity level as
long as power is applied to the instrument. Intensity level
ranges are from 0 to 255 where 0 is the lowest level of intensity
and 255 the highest.
To increase the intensity of the instrument move the switch to the Lposition. When the
desired intensity level has been reached move the switch back to the Rposition. If you
do not wish to increase the instrument intensity or have reached the desired intensity
level, move the switch to the Sposition and then back to the Rposition. If you do not
press the switch, the display will return to the fuel quantity display after a few seconds.
If you moved the switch to the Sposition from the increase
intensity mode the display will now be as shown.
The ucharacter indicates that the decrease intensity
operation has been selected. The instrument will default to
intensity level 32 after power up and will retain the last set
intensity level as long as power is applied to the instrument.
Intensity level ranges are from 0 to 255 where 0 is the lowest
level of intensity and 255 the highest.
To decrease the intensity of the instrument move the switch to the Lposition. When the
desired intensity level has been reached move the switch back to the Rposition. If you
do not wish to decrease the instrument intensity or have reached the desired intensity
level, move the switch to the Sposition and then back to the Rposition. If you do not
press the switch, the display will return to the fuel quantity display after a few seconds.

FL-100-5 Dual Fuel Level Indicator Page 16 of 23
Aerospace Logic Inc.
3150 Ridgeway Drive, Unit #43, Mississauga, Ontario, L5L 5R5, CANADA
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FL-100-5 Operations & Installation Manual – Ver. 2.0 – October 24, 2004
SECTION 5
FL-100 Calibration Form (Left Tank)
Instrument Serial # __________________________________
0 25 50 75
1 26 51 76
2 27 52 77
3 28 53 78
4 29 54 79
5 30 55 80
6 31 56 81
7 32 57 82
8 33 58 83
9 34 59 84
10 35 60 85
11 36 61 86
12 37 62 87
13 38 63 88
14 39 64 89
15 40 65 90
16 41 66 91
17 42 67 92
18 43 68 93
19 44 69 94
20 45 70 95
21 46 71 96
22 47 72 97
23 48 73 98
24 49 74 99
Calibrated By: _________________________________________
Date: _________________________________________
Aircraft Registration: _________________________________________

FL-100-5 Dual Fuel Level Indicator Page 17 of 23
Aerospace Logic Inc.
3150 Ridgeway Drive, Unit #43, Mississauga, Ontario, L5L 5R5, CANADA
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FL-100-5 Operations & Installation Manual – Ver. 2.0 – October 24, 2004
SECTION 5
FL-100 Calibration Form (Right Tank)
Instrument Serial # __________________________________
0 25 50 75
1 26 51 76
2 27 52 77
3 28 53 78
4 29 54 79
5 30 55 80
6 31 56 81
7 32 57 82
8 33 58 83
9 34 59 84
10 35 60 85
11 36 61 86
12 37 62 87
13 38 63 88
14 39 64 89
15 40 65 90
16 41 66 91
17 42 67 92
18 43 68 93
19 44 69 94
20 45 70 95
21 46 71 96
22 47 72 97
23 48 73 98
24 49 74 99
Calibrated By: _________________________________________
Date: _________________________________________
Aircraft Registration: _________________________________________

FL-100-5 Dual Fuel Level Indicator Page 18 of 23
Aerospace Logic Inc.
3150 Ridgeway Drive, Unit #43, Mississauga, Ontario, L5L 5R5, CANADA
Tel. [phone] | Fax. [phone] | [e-mail]
www.aerospacelogic.com
FL-100-5 Operations & Installation Manual – Ver. 2.0 – October 24, 2004
SECTION 6
Error Messages and Fault Resolution
During normal operations and the calibration process the
instrument continually monitors operations to ensure that it
operates in accordance with the necessary specifications.
While calibrating the instrument a number of parameters must
be met in order for the instrument to be commissioned in an
aircraft. This section will provide you with an identification of the
error messages as well as possible problem resolutions. In all
cases error messages are displayed as indicated to the left.
Error Point of Occurrence Resolution
1 Reserved Contact our Technical Support department. You should
never see this message.
2 Reserved Contact our Technical Support department. You should
never see this message.
3 L..0 or r..0 of the
calibration process Cause:
The fuel sender is not providing a valid indication of fuel
for the zero fuel level. To qualify for installation into a
certified aircraft the fuel sender must provide a valid
zero fuel level indication to the instrument.
Resolution (in order of probability):
1. If you have not added the unusable fuel to the
tank, do so now and return to the calibration
process.
2. The fuel sender system zero level is not
correctly set. Refer to the manufacturer
documentation and correct the problem.
3. The fuel sender system is defective. Replace it
with a new or rebuilt unit.
4. If the sender orientation is set in the rmode
check:
a. for an open circuit condition between the
instrument and the sender;
b. that the sender system output is not
shorted to ground.

FL-100-5 Dual Fuel Level Indicator Page 19 of 23
Aerospace Logic Inc.
3150 Ridgeway Drive, Unit #43, Mississauga, Ontario, L5L 5R5, CANADA
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FL-100-5 Operations & Installation Manual – Ver. 2.0 – October 24, 2004
SECTION 6
Error Messages and Fault Resolution (Continued)
Error Point of Occurrence Resolution
4 Any time during
normal operations or
calibration
The instrument has detected an internal failure. Contact
our Technical Support department for an RMA and
shipment of a new instrument.
5 L..0 or r..0 of the
calibration process Cause:
The fuel sender is not providing a valid indication of fuel
for the zero fuel level. To qualify for installation into a
certified aircraft the fuel sender must provide a valid
zero fuel level indication to the instrument.
Resolution (in order of probability):
1. If you have not added the unusable fuel to the
tank, do so now and return to the calibration
process.
2. The fuel sender system zero level is not
correctly set. Refer to the manufacturer
documentation and correct the problem.
3. The fuel sender system is defective. Replace it
with a new or rebuilt unit.
4. If the sender orientation is set in the nmode
check:
c. for an open circuit condition between the
instrument and the sender;
a. that the sender system output is not
shorted to ground.

FL-100-5 Dual Fuel Level Indicator Page 20 of 23
Aerospace Logic Inc.
3150 Ridgeway Drive, Unit #43, Mississauga, Ontario, L5L 5R5, CANADA
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FL-100-5 Operations & Installation Manual – Ver. 2.0 – October 24, 2004
SECTION 6
Error Messages and Fault Resolution (Continued)
Error Point of Occurrence Resolution
6 Any time AFTER
L..0 or r..0 Cause:
The fuel sender system output has not changed
sufficiently since the last calibration reading.
Resolution (in order of probability):
1. Did you add one gallon of fuel since the last
calibration point?
If not, do so now and continue with the process.
2. The fuel sender system did not sense the
addition of fuel:
a. Is the fuel tank full? Go to SECTION 3
STEP 15
b. Has the fuel sender system reached the
maximum point of indication?
i. If this point of indication is in
agreement with the
manufacturers stated indication
then go to SECTION 3 STEP 15
ii. If this point of indication is not in
agreement with the
manufacturers stated indication
then either adjust the sender
system output or have it repaired.
3. If the fuel tank is not full, the sender system has
not reached the full point of indication and the
fuel has changed with the addition of fuel then
the sender system may be defective. Add up to
two gallons of fuel in ¼ gallon increments
checking to see if the error is cleared at each
point. If the instrument allows progress to the
next calibration step proceed with ¾ gallon
increments until the additional fuel quantity has
been compensated for.
If the error cannot be resolved within two
gallons the sender must be repaired before
continuing.