Maretron FFM100 User manual

Revision 1.2 Page i
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FFM100
Fuel Flow Monitor
User’s Manual
Revision 1.2
Copyright © 2012 Maretron, LLP All Rights Reserved
Maretron, LLP
9014 N. 23rd Ave #10
Phoenix, AZ 85021
http://www.maretron.com
Maretron Manual Part #: M003010

FFM100 User’s Manual
Page ii Revision 1.2
Revision History
Revision Description
1.0 Release for Review
1.1 Public Release
1.2 Corrected formatting problems in certain figures
Added notes about tamper-proof silicone seals on sensor screws
Added information about location of sensors

Revision 1.2 Page iii
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Table of Contents
1General ................................................................................................................................1
1.1Introduction....................................................................................................................1
1.2Firmware Revision.........................................................................................................1
1.3Features ........................................................................................................................1
1.4FFM100 Accessories.....................................................................................................1
1.5Quick Install...................................................................................................................1
1.6Theory of Operation.......................................................................................................2
1.6.1Operating Modes ................................................................................................2
1.6.2Sensor Accuracy.................................................................................................2
1.6.3Diesel Fuel Flow Measurement...........................................................................4
1.6.4Temperature Compensation ...............................................................................5
1.6.5Fuel Flow Sensor Selection ................................................................................6
1.6.6Accuracy of Diesel Fuel Flow Measurement.......................................................7
1.6.7Choosing a Fluid Flow Sensor Mounting Location..............................................8
2Installation............................................................................................................................8
2.1Unpacking the Box.........................................................................................................8
2.2Choosing a Mounting Location ......................................................................................8
2.3Mounting the FFM100....................................................................................................9
2.4Mounting the Fluid Flow Sensor ....................................................................................9
2.5Connecting the FFM100................................................................................................9
2.5.1Fluid flow sensor Connections............................................................................9
2.5.2NMEA 2000®Connection..................................................................................10
3Configuring the FFM100 ....................................................................................................11
3.1Advanced Configuration ..............................................................................................12
3.1.1Configuring Device Instance.............................................................................12
3.1.2Configuring Channel #0 Installation Orientation................................................12
3.1.3Configuring Channel #1 Installation Orientation................................................12
3.1.4Configuring Channel #0 Allow Negative Flow...................................................12
3.1.5Configuring Channel #1 Allow Negative Flow...................................................13
3.1.6Configuring Differential Mode Allow Negative Flow ..........................................13
3.1.7Configuring Installation Description...................................................................13
3.1.8Configuring NMEA 2000 PGN Enable/Disable..................................................13
3.1.9Restoring Factory Default Settings ...................................................................13
3.2Configuring the Device Label.......................................................................................13
3.3Configuring the Operating Mode..................................................................................13
3.4Configuring Channel #0...............................................................................................14
3.4.1Enabling/Disabling Channel #0.........................................................................14
3.4.2Configuring Channel #0 Engine Instance..........................................................14
3.4.3Configuring Channel #0 Engine Label...............................................................14
3.4.4Configuring Channel #0 K-factor.......................................................................14
3.4.5Configuring Channel #0 Data Damping Period.................................................14
3.4.6Resetting the Total Volume Recorded for Channel #0......................................14
3.4.7Configuring Channel #0 Temperature Instance ................................................14
3.4.8Configuring Channel #0 Temperature Source...................................................14
3.4.9Configuring Channel #0 Temperature Label.....................................................15

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3.5Configuring Channel #1...............................................................................................15
3.5.1Enabling/Disabling Channel #1.........................................................................15
3.5.2Configuring Channel #1 Engine Instance..........................................................15
3.5.3Configuring Channel #1 Engine Label...............................................................15
3.5.4Configuring Channel #1 K-factor.......................................................................15
3.5.5Configuring Channel #1 Temperature Coefficient.............................................15
3.5.6Configuring Channel #1 Data Damping Period.................................................16
3.5.7Resetting the Total Volume Recorded for Channel #1......................................16
3.5.8Configuring Channel #1 Temperature Instance ................................................16
3.5.9Configuring Channel #1 Temperature Source...................................................16
3.5.10Configuring Channel #1 Temperature Label.....................................................16
4Maintenance.......................................................................................................................16
5Troubleshooting .................................................................................................................18
6Technical Specifications.....................................................................................................19
7Technical Support..............................................................................................................20
8Installation Template..........................................................................................................21
9Maretron (2 Year) Limited Warranty...................................................................................22
Table of Figures
Figure 1 - M1RSP-2R-E8 and M2RSP-2R-E8 Accuracy and Pressure Loss............................. 3
Figure 2 - M4ARP-2-E8 Typical Accuracy and Pressure Loss .................................................. 4
Figure 3 - Diesel Fuel Rate Measurement Fluid Flow Sensor Locations................................... 5
Figure 4 – Fluid Flow Sensor Selection Chart for Diesel Engine Applications........................... 6
Figure 5 – Mounting the FFM100 .............................................................................................. 9
Figure 6 – Fluid flow sensor Connection Diagram................................................................... 10
Figure 7 – NMEA 2000®Connector Face Views ..................................................................... 11
Figure 8 – Troubleshooting Guide........................................................................................... 18
Figure 9 – Mounting Surface Template ................................................................................... 21
Table of Appendices
Appendix A – NMEA 2000®Interfacing....................................................................................A1

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1 General
1.1 Introduction
Congratulations on your purchase of the Maretron Fuel Flow Monitor (FFM100). Maretron has
designed and built your monitor to the highest standards for years of reliable, dependable, and
accurate service.
Maretron’s Fuel Flow Monitor (FFM100) is used to adapt up to two positive displacement fluid
flow sensors to the NMEA 2000®network (Fluid Flow sensors sold separately). This allows you
to observe engine fuel usage on a vessel where there are NMEA 2000®compatible displays.
With the appropriate sensor, the FFM100 reports flow rate for diesel engines or gasoline
engines.
The FFM100 can be used with the positive displacement sensors to detect flow rates of many
other types of fluid as well, including water, hydraulic oil, or other fluids.
The Maretron FFM100 is designed to operate within the harsh demands of the marine
environment. However, no piece of marine electronic equipment can function properly unless
installed, calibrated, and maintained in the correct manner. Please read carefully and follow
these instructions for installation, calibration, and usage of the Maretron FFM100 in order to
ensure optimal performance.
1.2 Firmware Revision
This manual corresponds to FFM100 firmware revision 1.0.1.
1.3 Features
The Maretron FFM100 has the following features:
•NMEA 2000®interface
•Adapts up to two fluid flow sensors to the NMEA 2000 network
•Each channel independently programmable to match fluid flow sensor characteristics
•The FFM100 can be programmed to measure a differential flow rate using two fluid flow
sensors (supply and return flow for diesel engines) or two completely independent flow
rates.
1.4 FFM100 Accessories
Maretron offers the following accessories for the FFM100:
•M1RSP-2R-E8 Fuel Flow Sensor 20 to 200 HP (0.53 to 26.4 GPH, 2 to 100 LPH)
•M2RSP-2R-E8 Fuel Flow Sensor 200 to 1000 HP (4 to 132 GPH, 15 To 500 LPH)
•M4ARP-2-E8 Fuel Flow Sensor 1000 to 3000 HP (48 to 396 GPH, 180 To 1500
LPH)
1.5 Quick Install
Installing the Maretron FFM100 involves the following steps. Please refer to the individual
sections for additional details.

FFM100 User’s Manual
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1. Unpack the Box (Section 2.1)
2. Choose a Mounting Location (Section 2.2)
3. Mount the FFM100 (Section 2.3)
4. Mount the Flow Sensors and Connect Fluid Lines (Section 2.4)
5. Connect the Flow Sensors to the FFM100 (Section 2.5.1)
6. Connect the FFM100 to the NMEA 2000®network (Section 2.5.1)
7. Configure the FFM100 (Section 3)
1.6 Theory of Operation
The FFM100 operates by using positive displacement fluid flow sensors. These sensors are
volumetric (they measure the volume of fluid passing through them as opposed to the mass of
the fluid).
1.6.1 Operating Modes
The FFM100 can operate in one of two user-selectable operating modes:
1) Differential Flow Rate – this mode is used for diesel engines that recirculate unused fuel
back into the fuel tank. These engines will have separate supply and return fuel lines.
2) Two Independent Flow Rates – the FFM100 can measure flow rates from two
independent sources; for example, a water flow rate on one channel and a gasoline fuel
flow rate on another channel.
1.6.2 Sensor Accuracy
The M1RSP-2R-E8, M2RSP-2R-E8, and M4ARP-2-E8 fuel flow sensors use positive
displacement technology. These sensors are extremely accuracy over a wide flow range.
Please refer to Figure 1 below for a chart detailing typical accuracy and pressure loss versus
flow rate for the M1RSP-2R-E8 and M2RSP-2R-E8 fuel flow sensors.

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Figure 1 - M1RSP-2R-E8 and M2RSP-2R-E8 Accuracy and Pressure Loss
Please refer to Figure 2 below for a chart detailing typical accuracy and pressure loss versus
flow rate for the M4ARP-2-E8 fuel flow sensor.
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FFM100 User’s Manual
Figure 2 - M4ARP-2-E8 Typical Accuracy and Pressure Loss
1.6.3 Diesel Fuel Flow Measurement
Most diesel engines do not use all of the fuel that is supplied to them by the fuel pump via the
supply line. A portion of the fuel is consumed by the engine, but the majority of the fuel is used
for cooling the injection system and returned to the fuel tank via the return line.
For diesel engines, the FFM100 will operate in its differential mode, and will measure the net
fuel consumption of these engines by separately measuring the fuel sent to the engine via the
supply line and the fuel returned to the fuel tank from the engine via the return line. The
difference between these two readings is the fuel consumption of the engine. Please refer to
Figure 3 below for a system diagram demonstrating the location of the supply and return fuel
flow sensors in a diesel fuel system.
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Return Fuel
Flow Sensor
Fuel Tank
Supply Fuel
Flow Sensor
Engine
Dis
p
la
y
/MFD
Fuel Filter
Figure 3 - Diesel Fuel Rate Measurement Fluid Flow Sensor Locations
1.6.4 Temperature Compensation
The task of computing fuel consumption for a diesel engine is further complicated by the
following two factors:
1) Diesel fuel expands when heated
2) Diesel fuel is heated as it passes through the engine
When using volumetric sensors such as positive displacement sensors or turbine flow sensors,
simply subtracting the return flow rate from the supply flow rate without taking these factors
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FFM100 User’s Manual
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into account will result in the fuel consumption being underestimated. In fact, without
compensating for temperature, if the engine were consuming no fuel, the return fuel flow rate is
greater than the supply fuel rate, since the fuel is expanded by the engine’s heat as it passes
through the injection system.
The M1RSP-2R-E8, M2RSP-2R-E8, and M4ARP-2-E8 fuel flow sensors feature embedded
temperature sensors, so that the temperature of both the supply and return fuel is sensed and
used in real time by the FFM100 to compensate for the expansion of the fuel due to the
increase in temperature, for the most accurate possible fuel flow measurement.
1.6.5 Fuel Flow Sensor Selection
The fluid flow sensors must likewise be sized to accommodate the flow rate of fluid flowing
through the supply and return lines, as opposed to the net fuel consumption used by the
engine. If too small a fuel flow sensor is used, excessive back pressure will occur through the
sensors and the sensor may wear prematurely.
For example, consider the M1RSP-2R-E8 fluid flow sensor, which is rated at a maximum flow
rate of 26.4 GPH (100 LPH). A typical diesel engine will consume 20% of the fuel sent to the
engine, so under this assumption, this fuel sensor will be able to support a diesel engine which
consumes 5.28 GPH (20 LPH).
The fluid flow sensor you select must have sufficient range to measure the supply flow rate of
the engine whose fuel consumption you are monitoring. The table in Figure 4 below shows the
maximum fuel supply flow rates that can be sensed by each fuel flow sensor, and approximate
engine power ranges for each fuel flow sensor type. Please consult your engine’s
documentation or contact your engine manufacturer for the maximum supply fuel flow rate
(sometimes called fuel feed rate) for the specific engine whose fuel consumption you wish to
monitor.
Fluid Flow Sensor Flow Rate Range Approximate Engine Power
Range
M1RSP-2R-E8 0.53 to 26.4 GPH
2 to 100 LPH 20 to 200 HP 14.9 to 149 kW
M2ESP-2R-E8 4 to 132 GPH
15 to 500 LPH 200 to 1000 HP 149 to 746 kW
M4ARP-2-E8 48 to 396 GPH
180 to 1500 LPH 1000 to 3000 HP 746 to 2237 kW
Figure 4 – Fluid Flow Sensor Selection Chart for Diesel Engine Applications
If you are unable to obtain maximum supply fuel flow rates from the engine manufacturer,
another way to get a good estimate of the engine’s fuel feed rate is to disconnect the fuel
return line from the tank and direct it into a five gallon bucket. Run the engine at maximum
RPM until the bucket is filled, and calculate the return fuel flow rate by dividing the amount of
fuel in the bucket by the amount of time it took to fill the bucket. For instance, if it took 15
minutes (0.25 hour) to fill the five gallon bucket, the return flow rate is: