MGL Avionics Stratomaster Maxi Single FF-3 User manual

Stratomaster Maxi Single
FF-3
Dual sender fuel management system
Fuel flow, fuel range, fuel endurance, fuel level, accumulated
fuel burn, differential flow measurement. 13 modes of operation.
The FF-3 fuel management computer is a 3.5” instrument intended for efficient monitoring of fuel
related information onboard small aircraft and related applications.
The FF-3 unit can connect to one or two fuel flow senders, one or two fuel level senders or both.
Full functionality is available with both senders or only with a fuel flow sender using calculated
fuel levels based on fuel usage. Differential fuel flow calculations are also supported for fuel
return systems.
Standard automotive fuel level senders can be used, even with odd shaped tanks thanks to a
comprehensive, multi point calibration system.
Most fuel flow senders can be used and the K-factor of the sender can be entered into the system
for simple calibration. MGL Avionics supplies a lightweight dual range fuel flow sender that is
ideally suited for the FF-3 unit.

The main display
Mode F+CT (Single Fuel flow, single Tank, calculated level)
Mode F+PT (Single Fuel flow, single Tank, level sender)
Mode DF+CT (Differential Fuel flow, single Tank, calculated level)
Mode DF+PT (Differential Fuel flow, single Tank, level sender)
Alternate main display for the above modes only – select between the two displays by using the
“+” screen whenever you are not in the menu
Mode FF+CTT (Dual fuel flow, dual Tank,
calculated levels)
Mode FF+PTT (Dual fuel flow, dual Tank, level
senders)
Mode F+PTT (Single fuel flow, dual Tank, level
senders)
Mode DF+PTT (Single fuel flow, dual Tank, level
senders)
Remaining
fuel
Fuel endurance
hours:minutes
Fuel range
Fuel flow
Fuel level
Fuel low
alarm level

Mode F (Single Fuel flow)
Mode FF (Dual Fuel flow)
Mode PT (Single Tank, level sender)
Mode PTT (Dual Tank, level senders)
Mode DF (Differential Fuel flow)
Note: This mode is used to show the flow of both
forward flow and return flow senders. The
calculation at the bottom of the screen shows how
the fuel flow is derived.

Setting up the FF-3
Press the Menu key to enter the menu. You can move forward and backwards in the menu by
using the + and – keys. To change or select a menu item, move the highlight to the desired item
and then press the Select (Enter) key. To end an edit or function, press the Menu key again.
To exit the menu press the Menu key.
All changes you have done will only be saved if you exit the menu back to the main display.
Should you remove power before doing this, your changes will not be saved.
The menu varies depending on the mode you have selected. The following pictures and
descriptions show all the modes. Some items may not be visible if your selected mode does not
require them. This shows all possible menu items
<- Enter your cruising speed for range and
endurance calculations
<- Enter your fuel starting level for calculated fuel
levels
<-Your fuel accumulator. Total amount of fuel
used since you reset the accumulators to zero
<- Your display contrast setting. A value around
30 is most often used.
<- Switch the display backlight of or on
<- The mode selection for the instrument
<- Enter the setup menu for your selected mode
Depending on your selected mode, you may have two fuel level entry functions and two
accumulators. The above list only shows one of each as would be the case if you are using the
instrument with a single fuel flow sender.
The following chapter describes each of these functions in detail.

Speed
Enter your aircrafts cruising speed. This value will be used to calculate the fuel range, i.e. how far
you can fly with remaining fuel at zero wind speed. For this calculation, your current remaining
fuel, your current fuel flow and the speed entered here are taken into account.
You can easily change the speed during flight to reflect changes in ground speed or cruising
speed.
Use this function with care and do not use it to extend your range. You must at all times have a
secondary indication of available fuel. Note that flow senders and level senders may be subject to
malfunction that may result in incorrect fuel levels being displayed or calculated.
Level 1, Level 2
This function is used to manually enter your current fuel level after fueling or defueling your
aircraft. This function is only available if you do not have a mode selected where fuel level is
calculated from fuel flow.
Note that it is good airmanship to take into account a “silent” fuel reserve. For example, if you
have a 50 liter tank and you fill it, enter 40 or 45 liters as your available fuel. Also view the text on
“fuel tank size” below.
Accu 1, Accu 2
These entries show the amount of fuel used since the accumulator was last reset to zero. To
reset the accumulator simply move the highlight over the accumulator and press the center menu
key (Select key in menu mode).
Contrast …
This function allows you to change the display contrast to your liking. You can select values from
about 20 to 45. (can vary depending on display type).
Backlight …
This function allows you to switch the display backlight on or off.
Mode …
Select the operating mode of your instrument, for example FF+CTT.
Each “F” stands for a fuel flow sender.
Each “T” stands for a fuel tank level display.
“C” means “calculated fuel level”.
“P” means “physical fuel level” (tank level sender).

Setup
Select the “Setup” function to enter the setup menu for your selected mode. The pictures and
descriptions here show all available functions. Depending on your mode selection some of these
items may not be visible if they are not required.
<- Set the size of your tank(s)
<- Enter the K-factor of your flow senders
The sender supplied by MGL needs 7000 if
the jet is fitted, 1330 with the jet not fitted.
K-Factor = pulses per liter of liquid.
<- Enter the fuel tank level sender multi point
calibration system
<- Enter the “low fuel level” alarm for your fuel
tanks
<- Select the units of measure for your application
T1, T2 size
Enter the size of the fuel tanks in your system. It is recommended to choose a size that is slightly
less than actual size so you can compensate for sender inaccuracies and give you a measure of
reserve fuel.
K-Factor 1, K-Factor 2
The K-Factor is the number of pulses generated by the fuel flow sender for one liter of fuel. The
dual range fuel flow sender supplied by MGL Avionics has a K-Factor of 7000 in the low flow
mode (jet installed) and 1330 for the high flow mode (no jet installed).
You can use the K-Factor to calibrate your fuel flow sender.
The recommended procedure would be:
Fill your tank to an approximate known level (perhaps marked using a felt pen). Set the FF-3 to
calculate fuel level from fuel flow (disable the fuel level sender using the menu function
“LevelSend”).
Set the fuel level to read 40 liters – the exact value is not important.
Now fly of a quantity of fuel, perhaps 25 liters as example (very roughly – it does not need to be
exact). Note the reading of the fuel level after you switch off the engine. Assume we are reading
28 liters now (we used 22 liters according to the instrument).
Now fill the tank again, exactly to the previous level. Measure how much fuel you need to get to
this previous level using a measuring jug.

For example, assume we need 26 liters to get back to the previously marked fuel level. This
means the the fuel level should have been at 24 liters as we started with a value of 40 liters.
This example would mean that our fuel flow sender is under reading by four liters as it has not
measured the correct quantity of fuel.
Now start adjusting the K-Factor so your tank level changes from 28 liters to 24 liters. You would
adjust the K-factor down in this case (fewer pulses per liter of fuel).
Using this calibration method you can get to very accurate fuel flow readings. The initial accuracy
of fuel flow readings is dependant on the viscosity or type of fuel you use, added oils, installation
and finally the temperature of the fuel.
A good installation can achieve about a +/- 3% accuracy with as little as 1% error after calibration.
Alarm …
Enter your desired minimum fuel value that you would like to trigger the fuel low alarm. The fuel
low alarm will result in flashing of the fuel level display and remaining fuel readout. You can also
connect a warning lamp to the external alarm output (see installation diagram).
Note that the fuel low level will be displayed as a vertical line on your fuel level display. This level
is over and above your “silent” fuel reserve.
Each tank has its own alarm level.
Units …
Select your required units for distance and fuel quantity. The following options are available:
L/M: Liters and statute miles
G/M: U.S. Gallons and statute miles
L/Nm: Liters and nautical miles
G/Nm: U.S. Gallons and nautical miles
L/Km: Liters and kilometers
G/Km: U.S. Gallons and kilometers

Calibrate 1, Calibrate 2
This function enters the fuel level sender calibration menu. The fuel level sender needs to be
calibrated before it can be used with this system. The calibration allows the system to learn the
shape of your tank as well as any errors your fuel level sender or installation has.
Note: You only need this function if you are using your FF-3 with physical fuel level
senders, there is no need for this function if you are using calculated fuel levels using the
fuel flow senders.
Performing the calibration procedure. Note: You start with an empty tank, you need a measuring
jug or fueling device that has calibration marks and you need enough fuel to fully fill the tank.
Regardless of your use of a fuel flow sender, you can install a fuel level sender into your fuel
tank. These level senders are inexpensive and are available as after market replacement fittings
from a car spares outlet. We recommend the senders available from VDO. Be aware that some
makes of cheap level senders can prove troublesome, as the lever arms tend to be sticky.
This prevents the floats from floating on the surface of the fuel at all times. As a
consequence, this will lead to incorrect fuel level indication.
Once you have installed a fuel level sender into your tank, make sure the float can travel all the
way from empty to full position without hindrance of any kind.
The calibration procedure should be carried out with your aircraft in flight attitude. This means you
need to lift the tail if you have a tail-dragger or lift the nose wheel if you have a weightshift trike.
You start the calibration procedure with an empty tank.
We now start with the empty tank. Add five liters of fuel (our reserve quantity) using a suitable
measure. Make sure the measure is suitably accurate.
This is now the “level sender reading at 0 Lt” position. Move the highlight to this position and wait
until the sender reading has stabilized (You will see the sender reading at the top line). This could
take up to a minute so have patience.
ENSURE THAT THE FLOAT IS NOT SUBMERGED AND IS FLOATING ON TOP OF THE FUEL
LEVEL.
Should this number not react to changes of your level sender position, then you have a problem.
Please check your wiring according to the installation section of this manual.
You should expect the number to change in the region of at least 20 to 60 counts per calibration
position. If the number does not change with fuel level or only changes a very small amount –
check your installation. Something is not right !!!
The current level
sender reading
Level sender
readings at the
calibration
points
The six
calibration
points from
zero fuel level
to full tank

If you see the number changing then everything is well. Once it has stabilized and the highlight is
on the 0 Lt position, press the “Menu” key to transfer the reading from the sender to the
calibration point.
Now you are ready for the next step. Add the required amount of fuel to get to the next level (In
our case 9 Lt – this is 20% tank capacity). Once done, wait for the reading to stabilize and press
“Menu” again after you have moved the highlight to the “9 Lt” position.
Proceed in a similar manner until you have reached the last calibration position at 100% tank
capacity.
You are done !
To finish your calibration, exit the calibration function by pressing the “Menu” key.
The instrument uses the 6 calibration points to work out a correction curve that takes into account
the tolerances of your fuel level sender and the shape of your fuel tank. This results in an
incredibly accurate and usable fuel level display that far exceeds that available from ordinary dial
type gauges.
Note:
The calibration positions may be edited by using the + and – keys. This allows you, in theory, to
copy calibration settings from one instrument to another. We however recommend that you do go
though the calibration procedure even if the two aircraft are identical in all respects. Tolerances
do exist and the calibration cancels these out.
Accurate fuel level displays are a vital safety factor for an aircraft and a very useful feature for
peace of mind during cross county flights.
Notes on Slope error
Sender value is a value determined by the FF-3. It is used to calculate e.g. fuel level, fuel
endurance estimate and current range estimate. The fuel tank setup sender value can either
increase in value as fuel is added on decrease in value if fuel is added. This is dependant on the
type of fuel level sender used. However should the second reading be larger than the first
reading all readings will have to be larger than the previous reading. Likewise should the second
reading be smaller than the first reading all readings will have to be smaller than the previous
reading. If this is not the case the wording "Slope error" will be displayed. This could happen
when fuel was removed instead of added between steps, no fuel was added between steps or
when the fuel level sender was moved in the wrong direction e.g. moving the fuel level sender
manually when it is not inserted in to the fuel tank.
Should you get a slope error message determine the cause of the error. If you do not know the
cause of your error it is best to start from scratch. It should be remembered that accuracy is the
fuel tank calibration is extremely important to enable your FF-3 to display the correct data.
Adjusting calibration points manually
You may want to set individual calibration points manually. For example you may find that your
fuel level is over reading at a specific fuel level. Correcting the tank level reading for this area can
be simply done by adjusting the calibration point. You can do this by moving the float level with
your hands to the desired position and then performing the calibration as outlined above, or you
can use the manual option.
To activate manual change of the calibration points use the “+” and “-“ keys to highlight the
“Sender: ….” Entry (top line of screen). Now press the “Select” key. You get:

When you are in manual mode, use the “+” and “-“
keys as before to select the point you want to
calibrate. Then press the “Select” key. This allows
you to change the value at the calibration point
using the “+” and ‘-‘ keys. When you are done,
press the Menu key again. To end the calibration,
move the highlight past the last calibration point as
before.
When you select any of the above points for manual editing, the display on
the left shows and you can use the “+” and “-“ keys to adjust the value.
Press “Menu” or “Select” when you are finished.
Technical specifications:
Display temperature range (operational): -20 to +80 degrees C
Supply voltage: +8 to +18V. +24/28V with optional pre regulator.
Supply current: 35mA/60mA (backlight off/on)
Fuel level input: Maximum voltage: 5V, 5mA maximum current.
Fuel level senders supported: Any resistive type with common ground and capacitate probes with
active voltage outputs up to 5V level (push pull or pullup).
Fuel flow senders: Supply 5V, 20mA maximum current. TTL level input with noise filter and
schmidt trigger hysteresis. Required input voltage swing: less than 1.5V to more than 3.5V.
Maximum input voltage range -5V to +18V.
Weight: 180 grams.
Warranty:
MGL avionics warrants their products for a period of one year from date of purchase against
faulty workmanship. Warranty is limited to the replacement of faulty components and includes the
cost of labor. Shipping costs are for the account of the purchaser.
Note for operation on supplies with inductive loads:
Any operation of electronic instrumentation on power supplies that are subject to high voltages
caused by operation of inductive loads (starter motors, solenoids, relays) are required to be fitted
with suitable protection.
All Smart Singles are guaranteed to withstand temporary over voltage up to 40V without
additional protection. We recommend that measures are taken to prevent voltage transients in
excess of this limit.
MGL Avionics recommends the fitment of a fuse in line with a 33V transorb (available from MGL
Avionics at low cost) to protect electronic instruments, radios and intercom systems. Only one
such arrangement is required for a cluster of instruments.
Please note that product warranty excludes damages caused by unprotected, unsuitable or
incorrectly wired electrical supplies.
This instrument is not certified by the FAA. Fitting of this instrument to certified aircraft is subject
to the rules and conditions pertaining to such in your country. Please check with your local
aviation authorities if in doubt.
This instrument is intended for ultralight, microlight, homebuilt and experimental aircraft.

Operation of this instrument is the sole responsibility of the pilot in command (PIC) of the aircraft.
This person must be proficient and carry a valid and relevant pilots license. This person has to
make him/herself familiar with the operation of this instrument and the effect of any possible
failure or malfunction. Under no circumstances does the manufacturer condone usage of this
instrument for IFR flights.

Connecting the senders
Red
Black Fuse
Power
switch
Positive supply
(+12V from battery)
Negative supply
(airframe ground)
Suggested fuse rating:
1.0 A slow blow
To other instruments
Cannon D-9
connector
Fuel level
sender 2
Fuel level
sender 1
Fuel flow sender 1
Fuel flow sender 2
Red wire
from senders
Blue wire
from senders
Braid from senders
Brown
Yellow
Blue
Orange
Green
Cannon D-9 connector
pin mapping can cable colors
1 - ground - Black
2 - fuel level one - Orange
3 - fuel level two - Green
4 - not used
5 - fuel flow one signal - Blue
6 - power (+12V) - Red
7 - power out for fuel flow - Brown
8 - fuel flow two signal - Yellow
9 - alarm output -White
White
Pin 1 Pin 5
Pin 6 Pin 9
Terminal strip (not supplied)

If required the FF-3 can interface to standard automotive fuel level sender(s) as indicated. Most of
these senders are resistive types.
Capacitive types can be used provided they have a voltage output not exceeding 5V. The level
terminal has an internal 1K resistor pull-up to 5V.
Please note that capacitive senders may exhibit large errors as they are very sensitive to the
composition of the fuel used. We do not recommend using capacitive senders with automotive
fuels for this reason.
Please ensure that the float of the level sender moves freely at all times and that the float is large
enough not to remain submerged in case the mechanism becomes sticky. This will result in an
incorrect indication of fuel level.
Note that you need to perform the calibration routine as outlined in the respective section of this
manual.
Please observe the installation notes supplied with the fuel flow sender. Should you install a
different fuel flow sender to that supplied by MGL Avionics, ensure that you enter the K-factor
relevant for your sender.
Some senders require a pull-up resistor to the 12V supply line. We find most installations of these
senders require a 4K7 pull-up resistor.
In all cases ensure that fuel flow through the sender is continues and smooth. Nearly all flow
sender related problems are due to choosing a bad position in the fuel supply line. Any fuel flow
sender will be negatively effected by having to measure pulsed fuel supply such as is created by
most mechanical or pneumatic fuel pumps or by carburetor float valves that open and close
continuously. Nearly every installation would require a suitable fuel reservoir to help create a
smooth fuel flow for the sender. This can be easily created by installing a fuel filter before AND
after the flow sender.
IN ALL CASES OBSERVE THE FUEL FLOW MANUFACTURERS INSTALLATION
REQUIREMENTS
Be aware of possible problems with fuel tanks made from fiberglass. Some of the resins
used may leach chemicals into the fuel when the fiberglass is new. These chemicals may
interfere with the operation of your fuel flow sender, even causing it to stop producing an
output signal. The only remedy is to open and clean out your fuel flow sender.