Flo-tech FT204P User manual

FloTech
FT204P
Programmable
Retain / Overfill
Onboard Monitor
Dixon Bayco
4740T Interstate Dr.
Cincinnati, OH 45246
513 874 8499 office
513 874 8399 fax
Dixon Bayco LTD.
2315 Bowman St.
Innisfil, ON L9S 3V6
705 436 1125 office
705 436 6251 fax

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NOTES:

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Table of Contents
Introduction .....................................................................................4
Monitor Features .............................................................................4
Monitor Indicators...........................................................................5
Monitor Connections.......................................................................5
Mounting Instructions .....................................................................6
Monitor Housing .........................................................................6
Cable Installation Instructions.........................................................7
Monitor Housing .........................................................................7
Wiring Instructions..........................................................................8
Proper Wire Connections ............................................................8
Monitor Wiring Connections.......................................................9
TB1 POWER Connections....................................................10
TB2 TOP and BOTTOM SENSOR Connections .................10
TB3 FLOAT, THERMISTOR and OPTIC Socket
Connections...........................................................................11
TB4 AUX PERMIT Connections..........................................13
TB5 PROGRAM Connections..............................................14
Programming.................................................................................15
Overview ...................................................................................15
Procedure...................................................................................15
Operation.......................................................................................15
Normal Operation......................................................................16
Troubleshooting.............................................................................17
Technical Support Hotline.............................................................21

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Introduction
This Manual describes the features, installation, programming,
operation and troubleshooting techniques for the FloTech
FT203P Programmable Retain / Overfill Onboard Monitor.
Monitor Features
The FloTech FT203P Retain / Overfill Monitor have the
following features:
-Operates on 12 VDC or 24 VDC systems.
-Monitors up to six overfill sensors.
-Monitors up to six retain sensors.
-Connects to Float, Thermistor or Optic style rack
connections.
-The monitor is field programmable for the number of
sensors.
-Simple Wiring –no jumpers, terminators or dummies
required
Fig. 1
FT203P Monitor

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Monitor Indicators
Refer to Fig. 1.
PWR LED
Yellow LED that indicates power is connected to the monitor.
AUX LED
Green LED indicates the Auxiliary input is permissive.
PERMIT LED
Green LED indicates to the rack the sensors are permissive.
TOP LEDs
Overfill Sensor Indicators, ON indicates a wet sensor.
BOTTOM LEDs
Retain Sensor Indicators, ON indicates a wet sensor.
Monitor Connections
TB1 –12/24 VDC Power Connections
TB2 –Overfill and Retain Sensor Connections
TB3 –Float, Thermistor and Optic Rack Connections
TB4 –AUX Input Connections
TB5 –Timer/Reset Pushbutton and Programming jumper
Connections

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Mounting Instructions
Fig. 2
Mounting Hole Pattern Detail
Monitor Housing
The FloTech model FT204 Retain / Overfill Monitor Housing is
typically mounted on the trailer main frame rail, fitting storage
box, or any flat surface within easy view of the bottom loading
connections. Leave the top cover on the monitor housing and
hold it in the position you wish to mount it. Using a black
marker, transfer the pattern of the four mounting holes to the
mounting surface. BEFORE drilling, check to make sure you
will not drill through or damage any existing trailer wiring or
piping. Drill the holes through and mount the monitor using
four 3/8 inch nuts and bolts.

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Cable Installation Instructions
FloTech recommends you use FT401 jacketed 7-conductor
cable when wiring a new system. This cable is specially
designed to be oil, UV, and abrasion resistant. It incorporates a
noble tin-plated stranded copper wire which resists corrosion.
When installed properly, this cable will provide years of reliable
service.
See the Proper Wire Connections section for more detailed
directions about stripping and terminating the cables.
Monitor Housing
After the monitor housing is mounted, install FloTech FT402
cable glands in the openings where needed. These are, as
illustrated in Fig 3. : Power, Overfill Sensors, Retain Sensors (if
equipped) and Socket. Route the lengths of FloTech FT401
cable through the conduit openings. Cut the cables to length
leaving approximately 8 inches of extra length inside the
monitor housing.
Unused conduit openings in the sensor housings must have a ½
inch NPT pipe plug installed. Note that when using the
FloTech FT390 Dual Socket Assembly, you only need to install
one cable gland for the socket wiring.
Fig. 3
Monitor Housing Cable Routing Diagram

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Wiring Instructions
Proper Wire Connections
Please read this section of the manual before attempting to wire
the FloTech FT203P Monitor. This section recommends some
„guidelines‟ for installing the system wiring that, when done
properly, will insure a long, trouble free service life for your
equipment.
CABLE STRIPPING
FloTech recommends using FT401 seven conductor cable to
wire the Onboard Monitor System. When stripping the rubber
jacket from the cable, FloTech recommends using the FT9023
or equivalent Cable Stripper. This stripper has an adjustable
cutting blade depth setting. The depth should be set to only cut
through one-half to two-thirds of the outer jacket thickness.
This will insure that the insulation on the inner conductors is
not nicked. Any nicks or cuts in the wire insulation can, over
time, degrade the quality of the wire and lead to intermittent or
total failure.
BUTT SPLICE CONNECTIONS
FloTech recommends using the FT9022 or equivalent Crimp
Tool for securing the Butt Splice connections. Follow this
process to secure each connection:
1. Follow the Cable Stripping instructions in the previous
paragraph to expose the individual conductors of the
wire.
2. Strip the insulation back on each conductor
approximately ½ inch. Take care not to cut off any
strands of wire. If too many strands were accidentally
cut off, cut the wires flush with the insulation and strip
again.
3. Hold the two wires to be connected together by the
insulation. Tightly twist the bare wires together. This
insures a good electrical connection.

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4. Fill a FloTech Butt Splice with Silicone RTV
compound. Insert the twisted wires into the filled splice.
Check to see that the bare wires are fully inserted into
the splice and RTV. Make certain that NO bare wire is
protruding from the splice.
5. Securely crimp the wires into the butt splice.
6. Give the splice and the wires a „tug‟ to make sure you
have a good mechanical connection.
TERMINAL BLOCK CONNECTIONS
Follow this process to secure each connection:
1. Strip approximately 3/8 inch of insulation back from the
end of the wires.
2. Tightly twist the strands of wire together.
3. Rotate the terminal block screws counter-clockwise a
few turns to relieve pressure on the wire retainer.
4. Insert the bare wire end into the terminal block.
5. While holding the wire in place, rotate the terminal
screw clockwise to tighten the wire retainer.
6. Once fully tightened, give the wire a slight „tug‟ to
insure that a proper connection has been made.
Monitor Wiring Connections
Before attaching wires to the FT203P Monitor, please read the
following:
CAUTION: Turn off or disconnect power to the trailer before
wiring the monitor.
CAUTION: Only use the conduit opening marked “POWER
INPUT” as shown in Fig. to wire power to the monitor.
CAUTION: The FloTech FT203P Monitor will NOT work on
POSTIVE GROUND electrical systems. Any attempt to wire
the monitor to a positive ground system will damage the
monitor and void the warranty.

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TB1 POWER Connections
Refer to Fig. 4. FloTech recommends routing the trailer power
through a weatherproof inline fuse holder containing a 1/2 amp
fast blow fuse to the monitor. Optionally, a switch can be
added in series with the fuse to the TB1 input. Connect the
positive power supply wire to the TB1 terminal marked “12/24
VDC”. This is the upper screw on TB1. Be careful that no
stray wires are touching the metal barrier or ground terminal.
The Power Ground wire connects to the TB1 terminal marked
GND.
Fig. 4
Monitor Power Connections
TB2 TOP and BOTTOM SENSOR Connections
FloTech recommends wiring the sensors to the FT203P Monitor
using FT401 seven wire cable using color code shown in Fig.5.
Complete wiring schematic is shown in back of this booklet.
Fig. 5
TOP and BOTTOM Sensor Connections

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TB3 Float, Thermistor, and Optic Socket
Connections
These connections and are wired to the appropriate socket(s) as
dictated by the Loading Terminals in your area. At this time,
FloTech offers the following sockets:
FT300 API Optic Socket
FT301 API Thermistor Socket
FT302 API Float Socket
FT303 Optic Contact Pattern with Thermistor J slot
FT304 Canadian / Euro Thermistor Socket
FT305 J560 Type Thermistor Socket
FT306 J560 Type Optic Socket
FT390 API Dual Thermistor and Optic Sockets
Refer to Figs. 6 through 9 for socket wiring.
Fig 6.
Float Socket Connections

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U.S. Sockets do not use pins 1&2
Fig. 7
Thermistor Socket Connections
Fig. 8
Optic Socket Connections
Another Socket Option is to install the FloTech FT390 Dual
Socket Assembly. This unit comes with the sockets pre-wired
to a length of FloTech eleven conductor cable. Refer to Fig. 9
for wiring connections.

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Fig. 9
FloTech FT390 Socket Connections
TB4 AUX PERMIT Connections
Refer to Fig. 6. In order for the FT203P Monitor to work
properly, the AUX terminals must be connected together. This
can be done either by placing a shorting jumper across the AUX
terminals (factory installed) or by connecting the AUX
terminals to a dry relay contact. Examples of this would be a
Hobbs switch or a Vapor Recovery interlock switch. When the
AUX connection is made, the FT203P Monitor issues a
PERMIT signal. Refer to the Control Drawing in the back of
this booklet for the switch specifications.
Fig. 6
AUX Terminal Connections

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TB5 RESET Connections
Refer to Fig. 7 . The Reset/Timer terminals connect to a
Normally Open push button switch. The primary function of
this switch is to override wet Retain Sensors for „Splash
Blending‟ product. When this button is pressed, the FT203P
Monitor will issue a Permit signal to the Rack without regard to
the Retain Sensors for up to 90 minutes. The Permit signal will
be disabled if any of the Overfill Sensors become wet or there is
signal activity on any Retain Sensors that have been
programmed as inactive.
Fig. 7
Timer/Reset and Program Connections
TB5 PROGRAM Connections
Refer to Fig. 7. The FT203P Monitor must have a jumper
installed in the PGM terminals ONLY during programming of
the monitor. This connection must be left open for normal
operation. See the Programming Section of this manual for
detailed instructions about programming this unit.

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Programming
Overview
Before the FloTech FT203P Monitor can be put into service, it
must be programmed. This procedure informs the monitor
which inputs have sensors attached. These inputs are then
labeled as ACTIVE sensors. The remaining inputs that do NOT
have sensors attached are labeled as INACTIVE inputs. This
insures that a PERMIT signal will be issued only if ALL of the
following conditions are met:
All active overfill sensors are dry.
All inactive overfill sensors are not connected.
All active retain sensors are dry or the Timer/Reset
button has been pressed.
All inactive retain sensors are disconnected.
The AUX input has a jumper or made through an
external switch contact.
If ANY of the above conditions are not met, the PERMIT signal
will not be generated.
Procedure
1) Turn the power off to the monitor.
2) Remove the reset switch wires from TB5.
3) Connect the programming module per Fig. 8.
Fig. 8
Program Module Position

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4) Move SW1 to “PRGM” on Program Module.
5) Turn on the power. The sensor LEDs will sequentially
flash through the power up test pattern.
6) The sensor LEDs will light up the last valid
configuration.
7) Each time SW2 is pressed on the Program Module, the
sensor LEDs will shift to the next valid configuration.
This sequence is Top #1 to Top #8 and then Top and
bottom #1 to Top and Bottom #8. This sequence will
repeat every time the pushbutton is pressed.
8) Press SW2 until the pattern representing the number of
connected sensors on the trailer is correct. Move SW1
to the “RUN” position. The monitor will flash the
sensor LEDs sequentially through the test pattern.
9) If all connected sensors are dry there shouldn‟t be any
RED compartment lights on. At this point, if the AUX
LED is on the PERMIT LED should also be on.
10)Remove power from the monitor. Remove the
programming module, reconnect the timer reset switch
and turn power back on to the monitor.
Operation
Normal Operation
When power is applied to the FT203P monitor, the unit will
sequentially flash the sensor LEDs through the power up test
pattern. This sequence is from the TOP #1 LED to the TOP #6
LED then from the BOT #1 LED to the BOT #6 LED. Once
this sequence is completed, the unit tests all the sensor inputs.
A PERMIT signal will be issued if:
All the sensor inputs that have been programmed as see
active “dry”sensor signals.
Any of the Retain sensors are wet and the Timer/Reset
pushbutton has been pressed.

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All the sensor inputs that have been programmed as
inactive “no sensors” see no signals.
The AUX input has a jumper or made through an
external set of contacts.
A PERMIT signal will NOT be issued if:
Any of the sensors that have been programmed as active
are wet or are not connected.
Any of the sensors that have been programmed as
inactive see a sensor signal.
The AUX input does not have a jumper or made through
an external set of contacts.
At this time if only the active BOTTOM sensors are wet, the
TIMER/RESET pushbutton can be pressed to get a PERMIT
signal. This action will keep the PERMIT signal active for
approximately 90 minutes.
Troubleshooting
Look up symptom below and follow step by step instructions.
The PWR LED is not lit.
Measure the voltage on TB1. The input voltage must be
between 11and 24 VDC.
If the voltage is zero or low, work your way up the wiring to
the trailer nose plug. Check the inline fuse holder for
bad connections and for a blown fuse. Check the wiring
and trailer nose plug connections. Fuse housings my
have corrosion that causes the voltage to read low.
If the input voltage to TB1 is correct then replace the
monitor.
NOTE: Do NOT use a battery charger to power the trailer.
A battery charger does not output a pure DC voltage and
will damage the onboard monitor.

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System powers up and runs through power on
test sequence OK, then flashes all sensor
LEDs in an alternating pattern:
This means that the monitor is not programmed.
1. Go to the PROGRAMMING section of this manual and
program the monitor.
2. If the monitor fails to program, call FloTech for
Technical Service.
System will not load and one or more RED
sensor LEDs are lit on inactive sensor inputs:
Follow these instructions for top or bottom sensors.
1. Remove onboard monitor cover.
2. Check the sensor inputs on TB2 that are not being used
(inactive sensor inputs). Make sure there are no wires
connected.
3. Go to the PROGRAMMING section of this manual and
repeat this procedure, making certain to accurately
program the unit.
4. If the monitor still does not function properly, contact
FloTech Technical Service for further instructions.
System will not load and one or more RED
sensor LEDs are lit on active sensor inputs:
Follow these instructions for top or bottom sensors.
1. Remove onboard monitor cover.
2. Go to TB2. Remove sensor wire from the terminal
block that corresponds with the lit LED. Example: If
LED TOP #3 is lit, remove the sensor wire to terminal
T3 (yellow).
3. Select a compartment where the LED is NOT lit and
exchange that wire with the suspect wire. Example:

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exchange failed sensor wire TOP #3 (yellow) with the
working TOP #2 wire (orange).
4. If the lit sensor LED does not move to the new position,
the monitor is defective. Example: LED TOP #3 top
stays lit after the sensor wires are switched. Replace the
onboard monitor chassis with a FloTech model FT203P.
5. If the lit sensor LED moves to the new switched
compartment, the problem is with the sensor or wiring.
Example LED TOP #3 go out and LED TOP #2 lights,
return the wires to the original positions.
6. Open all the sensor caps and check each wiring
connection. Look for pinched wires that may short the
sensor signal to ground. Also, look for defective crimp
connections.
7. Measure voltage across the failed sensor wires (Black to
Red). Voltage should measure 8-10 VDC.
8. If steps 6 and 7 check OK, replace the sensor with a
FloTech FT201.
NOTE: A quick test of the sensor can be accomplished by
connecting the sensor directly to the onboard monitor.
Example: Remove sensors wires from ground (black) and the
TOP sensor 1 (red) and connect the sensor to be tested. If the
sensor is good the RED TOP #1 LED with NOT light. If the
sensor is defective the Diagnostic LED WILL light.
System will not load, has no green AUX LED
and no green PERMIT LED, power LED is lit
and no red sensor LEDs are lit.
1. Check the TB4 AUX input. This input must have a
closed switch or jumper connected to allow the monitor
to load. The AUX input has it‟s own green LED. This
LED must be lit to send a permissive signal to the load
rack.
2. Check to see if a jumper is connected to TB4. If TB4
has no connections, add a jumper.

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3. If TB4 has a wire connection, follow the cable to the
switch. This switch is typically connected to a vapor
recovery interlock or to a brake air lines interlock.
Activate the switch and see if the AUX green LED is lit.
If not repair the air switch. If the air switch appears OK
then check the monitor by installing a jumper wire to
force the AUX LED on. If the Aux LED can‟t be forced
on then replace the monitor.
Monitor’s PERMIT and AUX LEDs are ON, all
sensor LEDs are OFF, but the rack will not
load.
This condition usually indicates:
the sensors and sensor wiring are functioning.
the monitor has the proper power.
the AUX connections are OK.
Bad ground bolt (if equipped).
Socket output failed.
The problem usually lies in the monitor output, socket wiring or
the socket itself. To troubleshoot this condition, use the
FloTech FT520 Optic System Tester or a Scully Universal
Tester
1. Check the system by connecting a FloTech FT520 Optic
System Tester or a Scully Universal Tester to the Socket
output. Check for a good light on all compartments.
2. If not permissive then check all wiring connections, poor
crimp connections, or worn J slots on socket faceplate.
NOTE: The ground hog bolt can fail or have a bad
ground connection and not allow the tank to load. This
is an independent system not part of the overfill system
and is prone to problems.
3. If wiring connections check OK, test TB3 on the
monitor using the FT520 Optic System Tester. The
FT520 Optic System Tester is the only positive way to