Technical Manual: Fuel Consumption Monitor For Use With "Ecovaf"

Technical Manual
Instructions for installation,

operation and maintenance
140
FCM
Fuel Consumption Monitor for use with ”EcoVAF”
fuel consumption measuring system with 3 flowmeters
Publication nr TIB-140-GB-0711
Supersedes TIB-140-GB-0409
CONTENTS
1. PREFACE ....................................................................................... 3
1.1 General ........................................................................................................ 3
1.2 Symbols ....................................................................................................... 3
1.3 Copyright ..................................................................................................... 3
2. SYSTEM DESCRIPTION................................................................ 4
3. TECHNICAL SPECIFICATIONS..................................................... 4
3.1 Fuel Consumption Monitor ........................................................................... 4
3.1.1 General ............................................................................................... 4
3.1.2 Inputs .................................................................................................. 4
3.1.3 Outputs ............................................................................................... 5
4. INSTALLATION INSTRUCTIONS .................................................. 5
4.1 Safety instructions........................................................................................ 5
5. UNPACKING .................................................................................. 5
6. INSTALLATION AND FIRST USE .................................................. 6
6.1 Connection sensors ..................................................................................... 7
6.2 Cable shield connection ............................................................................... 7
6.3 Cable Specification ...................................................................................... 8
6.4 Configuration of the system ......................................................................... 9
6.4.1 Measurement values ........................................................................... 9
6.4.2 Fuel flow.............................................................................................. 9
6.4.3 Fuel temperature................................................................................. 9
6.4.4 Ship speed input options ..................................................................... 9
6.4.5 Output signals ................................................................................... 10
6.4.6 Alarms ............................................................................................... 10
7. OPERATING INSTRUCTIONS ..................................................... 11
7.1 General ...................................................................................................... 11
7.1.1 Important settings ............................................................................. 11
7.1.2 Formulas ........................................................................................... 11
7.1.3 Example calculation .......................................................................... 12
7.1.4 Temperature compensation and accuracy of results ........................ 12
7.2 Display ....................................................................................................... 13
7.3 Main Screen 1 ............................................................................................ 14
7.4 Main Screen 2 ............................................................................................ 15
7.5 Main Screen 3 ............................................................................................ 17
7.6 Alarms screen ............................................................................................ 19
7.7 History screen (same for ME en totals) ...................................................... 20
7.8 Setup ......................................................................................................... 20
7.9 Actual flows and temperatures ................................................................... 21
7.10 General settings ...................................................................................... 22
7.11 Configuration Flowmeters ....................................................................... 24
7.12 Flow meter A, B en C .............................................................................. 25
7.13 Configuration ship speed ........................................................................ 26
7.14 Configuration output range ..................................................................... 27
7.15 Time and date ......................................................................................... 28
7.16 LCD ......................................................................................................... 29
7.17 Formulas ................................................................................................. 30
8. MAINTENANCE ............................................................................ 31
9. REPAIR ........................................................................................ 31
10. TAKE OUT OF SERVICE............................................................ 31
11. REMOVAL AND STORAGE OF EQUIPMENT ........................... 31
12. MALFUNCTION AND SEND FOR REPAIR ................................ 31
13. ENVIRONMENT .......................................................................... 31
14. DISPOSAL .................................................................................. 31
15. TROUBLE SHOOTING ............................................................... 32
16. CERTIFICATES .......................................................................... 32
17. DRAWINGS................................................................................. 33
18. ABBREVIATIONS ....................................................................... 36
19. SPARE PARTS ........................................................................... 36
19.1 Part numbers .......................................................................................... 36
20. WARRANTY CONDITIONS ........................................................ 37
2
1. PREFACE
1.1 GENERAL
This manual contains instructions for the installation, operation and maintenance (IOM) of the VAF
Fuel Consumption Monitor.
For IOM information of associated equipment supplied by VAF instruments, refer to the separate
manuals supplied with those products.
This manual contains important information for the installer, the operator and for your maintenance
department.
To ensure safe and correct installation and operation, read this manual completely
before installing the equipment and starting operations.
For any additional information contact:
VAF Instruments B.V. Tel. +31 78 618 3100

Vierlinghstraat 24, 3316 EL Dordrecht Fax +31 78 617 7068
P.O. Box 40, NL-3300 AA Dordrecht E-mail: sales@vaf.nl
The Netherlands Internet: www.vaf.nl
Or your local authorized VAF dealer.

Their addresses can be found on www.vaf.nl
1.2 SYMBOLS
The following symbols are used to call attention to specific types of information.
A warning to use caution! In some instances, personal injury or damage to the EcoVAF
unit or control system may result if these instructions are not followed properly.
1.3 COPYRIGHT
This Technical Manual is copyrighted with all rights reserved.
While every precaution has been taken in the preparation of this manual, no responsibility for
errors or omissions is assumed. Neither is any liability assumed for damages resulting from the
use of the information contained herein. Specifications can be changed without notice.
3
2. SYSTEM DESCRIPTION
The Fuel Consumption Monitor (FCM) is a microprocessor based instrument that will accurately
calculate the fuel consumption of the engines onboard a vessel.
In this manual we assume that the installation consists out of one main engine and auxiliary
engine(s).
Many other configurations are possible.
In order for the FCM to work accurately it will need flow and temperature data from 3 flow meters
with PT100.
A. Flow meter, supply to aux engine
B. Flow meter, return from aux engine
C. Flow meter, common supply fuel system
However, there is an option to switch the temperature correction off.

Please note that with the temperature correction off, the amounts of fuel will not be
corrected for temperature and therefore will not be accurate.
To calculate the consumption per nautical mile, the FCM will need the ship speed information
either from a GPS unit or from a ship speed unit that has pulses as an output.
3. TECHNICAL SPECIFICATIONS
3.1 FUEL CONSUMPTION MONITOR
3.1.1 General
Display Touch screen 1/4VGA (320x240)

Flash EPROM memory 192kByte
CPU 40Mhz with 128k Ram
Real Time Clock
Communication Port Combined RS232/RS485 programming port
Power Requirements 24 Volts, 1.0A max
operating temperature 0 to 50 ºC
Dimensions 246 x 146 x 155 mm (w x h x d)
3.1.2 Inputs
Digital 4 (3) Flowmeters (Hall switches)

(1) Ship speed (from relay, potential free)
Analogue 3 PT 100
Serial 1 GPS
4
3.1.3 Outputs
Analogue 3 Fuel consumption (see chapter 6)
Relays 3 Alarm outputs (see chapter 6)
4. INSTALLATION INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS
To ensure the safety of personnel en equipment:
 Always follow the safety and installation recommendations in this manual.
 Always use insulated tools when working on electrical installations.
 Ensure that local safety regulations are met when installing and operating the equipment.
 All personnel who operate and service the equipment should read this manual completely
and make themselves acquainted with the equipment before installing or operating the
equipment.
5. UNPACKING
Let the instruments acclimatize in the location where they are going to be installed for at least one
hour inside their shipment box. This is to avoid moisture build-up inside the instrument, or on the
connectors and wires.
Be careful when unpacking the FCM.
Do not press on the FCM’s touch screen.
Be careful not to damage any of the connectors, or the wiring.
5
6. INSTALLATION AND FIRST USE
The FCM will be delivered with the correct cards and software installed.
First connect all inputs and outputs to the FCM.

The 24volt wires should be connected last.
NOTE: There is no On/Off switch on the FCM. When the 24 volt is switched on the FCM will turn
on.
Check if the inputs show any errors. If the is the case, the connection or connected equipment
should be checked and corrected.
Figure 1
6
6.1 CONNECTION SENSORS
In order for the system to work correctly, all sensors must be connected to the correct input on the
FCM.
Please refer to chapter 17.
6.2 CABLE SHIELD CONNECTION
The electric shield of each cable must only be connected on one side.
If the shield is connected on both sides or non of the sides, electrical interference may
cause the FCM to malfunction.
Please refer to Chapter 17 for recommendations.
7
6.3 CABLE SPECIFICATION
8
6.4 CONFIGURATION OF THE SYSTEM
6.4.1 Measurement values
This unit can measure the following values:
 Fuel flow (3x)

 Fuel temperature (3x)
 Ship speed via GPS or via pulse
The sensor specifications can be entered via the display on the controller.
The password for this screen is 2345.
6.4.2 Fuel flow

The system has three flow meters that work with a pulse signal connected to a digital input.
The maximum frequency is 80Hz. Via the sensor configuration you can select 1, 3 or 10 K-factors
of the sensor.
6.4.3 Fuel temperature

The system has three temperature sensors that work with a PT100 (3 wire) The PT100 signals are
connected directly to the special PT100 inputs on the FCM.
6.4.4 Ship speed input options

Ship speed via pulse signal.
The ship speed is measured via a (relay) pulse signal on a standard digital input. The range can be
adjusted in the sensor configuration screen.
Ship speed via GPS.

Via the serial port on the monitor, the ship speed is read in knots by means of NMEA-0183
protocol.
Serial Input.
The format of the serial connector C8 can be changed from RS232 to RS485 by connecting pins 7
and 1 (ground)
Figure 2
9
6.4.5 Output signals
The controller has the following analogue outputs that can be used for external equipment.
(Depends on the configuration)
 Corrected consumption main engine ME (0 – Max : 4 - 20mA)
 Corrected consumption auxiliary engine AE (0 – Max : 4 - 20mA)
 Total Consumption (0 – Max : 4 - 20mA)
6.4.6 Alarms
When a sensor fails, or the measured value is too high (adjustable) a alarm message is generated
and a alarm relay is made low (fail-safe).
Following alarms are detected:
 Flow A (supply) < Flow B (return) (after adjustable time)  Flowsensor A error
 Flow A (supply) >> 0 en Flow B (return) = 0 (after adjustable time)  Flowsensor B error
 Flow C (Main) = 0 (after adjustable time)  Flowsensor C error
 Temperature sensor broken (< 2% van temperature range) (5 sec.)  Temperature sensor
error
 Temperature supply or return is too high (adjustable level) (2,5 sec.)  Flow temperature
too high
 Power failure of monitor  Under voltage controller
Connection No High Temp. Sensor Flow Monitor

C6 Alarms Alarm Alarm Alarm Power Off
General Alarm 1-2 Closed Open Open Open Open

(N.C.)
General Alarm 3-4 Open Closed Closed Closed Open
(N.O.)
Temp Alarm 5-6 Open Closed Open Open Open
(N.O.)
10
7. OPERATING INSTRUCTIONS
7.1 GENERAL
The FCM will accurately calculate the fuel consumption of 2 Engines.
The names chosen for the Engines are Main Engine (ME) and Auxiliary Engine (AE).
The flow meters are called A, B and C.

Flow meter A: Supply Auxiliary engine.
Flow meter B: Return Auxiliary engine.
Flow meter C: Supply total system.
Please refer to figure-1 for the correct location of the flow meters.
The FCM will measure the total fuel delivered to both engines and the flow to and from the
Auxiliary engine. For accurate calculation, the temperature of the fluids are needed from each flow
meter.
From the flow and temperature information of the three flow meters the fuel consumption of the ME
and the AE is calculated as well as the total consumption, per minute.
In combination with the speed of the vessel a consumption per Nautical Mile is calculated.
On Main Screen 1 you will see the calculated consumption of the ME, AE and the total, with and
without temperature correction (T.C.).
The consumption with T.C. will be displayed in volume(l or m3) and mass (kg or ton) per minute.
Main Screen 2 will give more details about the AE.

Main Screen 3 will give more details about the ME.
7.1.1 Important settings

For correct calculation of the fuel consumption, it is important that the parameters as in Chapter
7.10 are set correctly. Typical customer settings that have an influence on the results, with our
standard settings are:
Temperature correction on
Specific gravity at reference temperature 0,997 kg/l
Thermal coefficient of expansion 0,070 %/°C
Reference temperature 15°C
7.1.2 Formulas
For the calculation of the displayed fuel consumption, the following formulas are used:
Consumption AE AE = flow A – flow B [l/min]

Consumption ME ME = flow C – (flow A – flow B) [l/min]
For the calculation of the displayed temeparture corrected fuel consumption, the following formulas
should be applied to the flowrate:
Temperature difference ∆T = T – Tref [°C]

Expansion γTot = γ * ∆T [%]
11
Flowrate temperature corrected QcorV = QV / (1 + γTot/100) [l/min]
Massa flowrate QM = QcorV * ρ [kg/min]
7.1.3 Example calculation

With above mentioned standard settings, the following flowrates are assumed for example
calculation:
Flow C 97,2 l/min 91,1°C

Flow A 45,3 l/min 132,4°C
Flow B 32,5 l/min 128,3°C
Uncorrected consumption:
AE = 45,3 – 32,5 = 12,8 l/min
ME = 97,2 – (45,3 – 32,5) = 84,4 l/min
Flowrates calculated back to reference temperature:

Flow C = 97,2 / (1 + 0,07 * (91,1 – 15) / 100) = 92,3 l/min
Flow A = 45,3 / (1 + 0,07 * (132,4 – 15) / 100) = 41,9 l/min
Flow B = 32,5 / (1 + 0,07 * (128,3 – 15) / 100) = 30,1 l/min
Temperature corrected consumption:
AE = 41,9 – 30,1 = 11,8 l/min AE = 11,8 * 0,997 = 11,8 kg/min

ME = 92,3 – (41,9 – 30,1) = 80,5 l/min ME = 80,5 * 0,997 = 80,3 kg/min
7.1.4 Temperature compensation and accuracy of results

Fuel consumption measurement in return systems
In so called return systems, it is necessary to have two flowmeters installed in the system: one in
the fuel supply line and one in the fuel return line. When measuring with two flow meters in such a
return system it is absolutely necessary to have temperature compensation on the measured flow,
since a different temperature will mean that the flowmeters will indicate a different volume flow.
The error introduced when not compensating for temperature will be almost 1% per 10°C
temperature difference. Due to the fact that the circulation will be x times the consumption, this
means that the error will be multiplied by x, when compared with the consumption.
Unifuel
The same phenomenon occurs in so called unifuel systems, in which the total supply to the
systems is measured by a flowmeter in the cold part of the system (“common flow”). The hot
system is split after the viscosity control into a circulation over the main engine and a circulation
over the auxiliary engine(s). The consumption of the auxiliary engines is measured by flowmeters
in both the supply and the return line. The consumption of the main engine can be obtained by
subtracting the auxiliary consumption from the total consumption: ME consumption = common flow
– (supply AE – return AE).
Due to large temperature differences between cold part (approx. 70°C) and hot part (approx.
145°C), it is also in this case very important that all three measurements are compensated for
temperature, as otherwise large errors might be introduced (see above calculation)
12
Multiplication of error
Due to the fact that in return systems the fuel consumption is small when compared to the
circulation flow, this means that every error that is made in measuring flow or for not compensating
for temperature, the error per flowmeter will be multiplied by the circulation factor when compared
with the consumption.
7.2 DISPLAY
The display has the following screens:
 Screen 1: Main screen 1

 Screen 2: Main screen 2 (auxiliary engine and total consumption)
 Screen 3: Main screen 3 (main engine and total consumption)
 Screen 4: Alarm screens
 Screen 5: History screen main engine
 Screen 6: History screen auxiliary engine
 Screen 7: History screen total
 Screen 8 Set up
 Screen 9 Actual flows and temperatues
 Screen 10: General settings
 Screen 11: Configuration flowmeters
 Screen 12: Configurations ship speed
 Screen 13: Configurations range output
 Screen 14: Time and Date (for alarm log)
 Screen 15: Contrast LCD
13
7.3 MAIN SCREEN 1
This screen will appear after the system has booted.
Consumption ME xxxx.x l/min
T.C. consumption ME xxxx.x l/min

xxxx.x kg/min
Consumption AE xxxx.x l/min
T.C. consumption AE xxxx.x l/min

xxxx.x kg/min
______________________________________________________________________________________
SETUP SYSTEM
ALARM
__________________________________________________________________________________________
The units change from l and kg into m3 and tons.
In the top part of the screen you will find the consumption of the ME, AE and the total consumption.
The Temperature compensated values (T.C.) are shown in volume and weight.
SETUP: Go to the configuration screen.
ALARM: Go to the alarm screen. This button will flash if there is an alarm.
Go to main screen2.
:
When a sensor signal is not present ‘###.#’ will appear instead of a value.
14
7.4 MAIN SCREEN 2
Auxiliary engine Accumulative

Total 12.6 ton 9999.9 ton
121 m³ 12005 m³
Average (24hr) 12 kg/hr 14 l/hr

Consumption ( 5hr) 55 kg 65 l
__________________________________________________________________________________________
Total consumption Accumulative
345 m³ 29000 m³

Consumption (5hr) 100 kg 124 l
____________________________________________________________
Spec. consumption ME 31 kg/NM

Ship speed 18.2 knots
SETUP RESET SYSTEM HISTORY

__________________________________________________________________________________________
TOTALS ALARM
The units change from l and kg into m3, ton and kiloton.
In the top part of this screen you will see all the detail from the Auxiliary engine.
You will find the following information:
- Average consumption over a certain period, that is set in General Setting Menu, up to 99
hours.
- Total consumption over a certain period, that is set in General Setting Menu, up to 99 hours
- Accumulative consumption, since last time it was reset.
The same details for the total consumption can be found in the middle part of the screen.
In the bottom part of the screen the consumption per Nautical mile and the ship speed can be
seen.
SETUP: Go to configuration screen.
RESET TOTALS: Will reset totals
ALARM: Go to alarm screen. This button will flash if there is an alarm.
HISTORY: Go to the history screens
Go to main screen 3.
:
15
When a sensor signal is not present ‘###.#’ will appear instead of a value. If the temperature is too
high the value will flash.
When the total counter reaches its maximum it will start again at 0.
When the selected time for consumption has passed the values are put into the history list and the
time and counting will start again.
The totals can be reset with the button on the bottom of the screen. They will be reset after
confirmation. All three totals (Aux, Main en Total) will be reset at the same time.
16
7.5 MAIN SCREEN 3
Main engine Accumulative

Total 22.6 ton 9999.9 kiloton
224 m³ 17015 m³

Consumption ( 5hr) 45 kg 69 l
__________________________________________________________________________________________
Total consumption Accumulative
345 m³ 29000 m³

Consumption (5hr) 100 kg 124 l
__________________________________________________________
Spec. consumption ME 31 kg/NM

Ship speed 18.2 knots
SETUP RESET SYSTEM HISTORY

TOTALS ALARM
__________________________________________________________________________________________
The units change from l and kg into m3, ton and kiloton.
In the top part of this screen you will see all the detail from the Main engine.
You will find the following information:
- Average consumption over a certain period, that is set in General Setting Menu, in Kg/hr
and l/hr.
- Total consumption over a certain period, that is set in General Setting Menu, up to 24
hours.
- Accumulative consumption, since last time it was reset.
The same details for the total consumption can be found in the middle part of the screen.
In the bottom part of the screen the consumption per Nautical mile and the ship speed can be
seen.
SETUP: Go to configuration screen.
RESET TOTALS: Will reset totals
ALARM: Go to alarm screen. This button will flash if there is an alarm.
HISTORY: Go to the history screens
Go to main screen 3.
:
17
When a sensor signal is not present ‘###.#’ will appear instead of a value. If the temperature is too
When the total counter reaches its maximum it will start again at 0.
When the selected time for consumption has passed the values are put into the history list and the
time and counting will start again.
The totals can be reset with the button on the bottom of the screen. They will be reset after
confirmation. All three totals (Aux, Main en Total) will be reset at the same time.
18
7.6 ALARMS SCREEN
When the button [SYSTEM ALARM] flashes, an alarm is active.
If the button is pressed a screen will appear with only the active alarms.
By means of the arrow buttons you can go to the alarm log (see next screen).
Alarm log #01

__________________________________________________________________________________________
Flowsensor A error
Alarm ON
Date: 23 June 2005

Time: 12:04:06
___________________________________________________________________________________________
ESC
The last 24 messages can be read back with the arrow buttons.
Also a message is given when an alarm is cancelled.
Esc will take you back to the previous screen.
The following messages will be used:
 Flowsensor A error (supply < return)

 Flowsensor B error (supply flow on, no return)
 Flowsensor C error (C=0)
 Temperature sensor A error
 Temperature sensor B error
 Temperature sensor C error
 Flow A temperature too high
 Flow B temperature too high
 Flow C temperature too high
 Under voltage controller
19
7.7 HISTORY SCREEN (SAME FOR ME EN TOTALS)
Auxiliary engine
02-04-05 13:38 03-04-05 13:38 13.3 m³ 13.2 ton

03-04-05 13:38 04-04-05 13:38 14.2 m³ 14.0 ton
04-04-05 13:38 05-04-05 13:38 14.3 m³ 14.1 ton
__________________________________________________________________________________________
When the maximum number of lines has been reached, the last one (at the bottom) will be
substituted by a new one at the top.
With the arrow you will proceed to the next screen.
7.8 SETUP
CONFIG DATE LCD ACTUAL ESC

SYSTEM TIME
20
- Pressing [CONFIG SYSTEM] will take you to the system configuration menu’s (password
2345).
- Pressing [DATE TIME] will take you to the menu where the current date and time can be
entered.
- Pressing [LCD] will take you to the menu where the brightness and the screensaver time
can be adjusted.
- Pressing [ACTUAL] will show the actual flowrates and temperature for each sensor.
- [ESC] will take you back to the previous menu.
7.9 ACTUAL FLOWS AND TEMPERATURES

This screen shows the actual flows and temperatures for each sensor. All values are measured
values and are not compensated for temperature.
[ESC] will take you back to the previous menu.
Flow C: xxxx.x l/min Temp.: xx.x°C

Flow A: xxxx.x l/min Temp.: xxx.x°C
Flow B: xxxx.x l/min Temp.: xxx.x°C
__________________________________________________________________________________________
ESC
When a sensor signal is not present “####.#” will appear instead of a value. If the temperate is too
21
Explanation for the screens in the next chapters:
With the arrow buttons you can go up or down. The selected value will be shown in inverse and
can be changed by pressing CHANGE. After the change press [ESC] to return to the menu as
shown above.
7.10 GENERAL SETTINGS

To enter the General Settings menu you will have to enter a password.
This password is 2345.
General settings:
Temperature correction on/off
Specific gravity at ref. temperature 0,997 kg/l
Thermal coefficient of expansion 0.070 %/°C
Reference temperature 15.0 ºC
Alarm settings:
Flow A: Max. temp.: 150 ºC
Flow B: Max. temp.: 150 ºC
Flow C: Max. temp.: 90 ºC
Alarm delay flow failure ME 40 s
Alarm delay flow failure AE 5 s
Time settings:
Timebase average 10 h
Timebase consumption 12 hRESET
ALL
Totals
CHANGE ESC
__________________________________________________________________________________________
General.
Select “Temperature correction” and select [CHANGE] to switch between ON and OFF.
If OFF has been selected only the “Specific gravity” and the time settings can be changed.
Enter the Specific gravity, expansion coefficient and the reference temperature of the fluid used in
the system. Please note that these values will have an influence on the temperature compensated
consumption in volume and weight.
Alarm settings.
Enter maximum temperature for each flow meter. An alarm will be activated if the temperature of
the fluid is above the entered temperature.
Enter the time after which the alarms for the flowsensors come in. Alarm comes in, if there is no
signal coming from the flowmeters during the specified period of time. The delay for flow failure ME
corresponds with flowmeter C, and the delay for flow failure AE corresponds with flowmeters A and
B.
22
Time settings.
Enter the time for the average consumption and the total consumption calculation.
These times are used in main screen 2 and 3.
The average and total consumption will be calculated over the time period entered here.
After the time period has ended the total consumption will reset and displayed in the history
screen. The average consumption calculation will start over again.
Press [RESET ALL] to reset the timers and the counters.

The timers for the average and total consumption will start at 0 (zero).
Values are changed with the help of the following screen:
Maximum temperature 125 °C
Enter new value

____________________________________________________________
The new value can be entered and acknowledged with the ENTER key.
With the EXIT key you can return without changes.
23
7.11 CONFIGURATION FLOWMETERS
Setup flow settings
Nr of K-factors per flowmeter 1
ME Net flow cut-off C-(A-B) 7 l/min

AE Net flow cut-off (A-B) 9 l/min
Debounce time: 5 ms
__________________________________________________________________________________________
CHANGE ESC
K-factors.
The flow meter is calibrated at a certain amount of flows. These are called K-factors.
Select the number K-factors here (1, 3 or 10)
Flow cut-off.
The flow used in the FCM will be set to 0 (zero), if the calculated consumption is less than the
entered number. This function will only set the temperature compensated values to zero.
Debounce time.
The debounce time is used to ignore the bouncing of a reed relay when closing and/or opening.
If there is an extra pulse within the time entered here, it will be ignored.
24
7.12 FLOW METER A, B EN C
Depending on the number of k-factors chosen.
(1, 3 or 10 input values will appear on the next screen.)
Setup flowsensor A
K-factor 1: 14.35 pls/l

Calc. B*
Max. flow range xxx l/min
Actual flowfactor 14.40
Calculated K-factor*
__________________________________________________________________________________________
CHANGE ESC
Enter the K-factors that are delivered with the flow meter.
The flow in between two K-factors is calculated by means of interpolation.
The maximum flow range value, is the maximum flow range as indicated on the flow meter.
The actual flow factor shows the actual flow factor (K-factor) used.
* Calculated K-factor is only shown at flowmeter A and B. The [Calc. B] button can be used during
circulation only (without consumption!), and it will calculate the K-factor of flowmeter A (B)
based on the equation that the temperature compensated volumes of A and B should be equal.
25
7.13 CONFIGURATION SHIP SPEED
Ship speed selection: GPS/pulse
Pulses per mile: 200 p/mile
__________________________________________________________________________________________
CHANGE ESC
Select if the speed input to the FCM is coming from a ships speed log (pulse) or GPS.
If pulse is selected, the number of pulses per Nautical mile must be entered.
26
7.14 CONFIGURATION OUTPUT RANGE
Output at 20 mA:
Main engine 300 l/min

Auxiliary engine 200 l/min
Total 1000 l/min
__________________________________________________________________________________________
CHANGE ESC
These setting are for the optional remote displays of FCM (see chapter 6 & 17).
The outputs are 4-20mA.
Enter the flow of the meter at 20mA (maximum) for each flow meter.
27
7.15 TIME AND DATE
25-02-2006 14:01:34
__________________________________________________________________________________________
New time:
Hours: 14
Minutes: 01
Seconds: 34
New Date:
Day: 25
Month: February
Year: 2006
__________________________________________________________________________________________
CHANGE STORE ESC
Enter the time and date.

The new time and date entered will be stored after [STORE] had been selected.
Select [ESC] to abort any changes.
28
7.16 LCD
LCD setup___________________________________________________
Brightness_________________________________________________
DARK LIGHT
Screensaver________________________________________________
Wait: 10 min (0 = off)
-1 +1
___________________________________________________________
ESC
Pressing [DARK] OR [LIGHT] will change the display brightness.
Pressing [-1] or [+1] will change the time after which the display will darken.
If 0 is chosen, the display backlight will stay on.
29
7.17 FORMULAS
Fuel consumption:
Auxiliary engine: flow A – flow B

Main engine: flow C – (flow A – flow B)
Average:
The average is calculated as follows:

Every second a sample is taken from all input signals.
Per minute the average of 60 samples is calculated. From these values a hourly average is
calculated.
E.g. if the timeline is 24 hours, a value is shown that is the average over the time past since the
start. If the time has passed, the average calculation will start over again.
Example:
Every second:
45, 46, 44, 42, 41, 44, …, 51, 49  after 1 minute 46 is recorded (46 on screen).
E.g. after 60 minutes 43 is recorded.

After 60 minutes 41 is recorded.
After 2 hours and 3 minutes: (60x43 + 60x41 + 39 + 41 + 42) / 123 = 42.
After 24 hours all stored values are deleted and the calculations will start again.
As an option the time period over which the calculation has taken place is show on screen.
Average (02:03 / 24:00) 6 kg/hr 8 l/hr
30
8. MAINTENANCE
No special maintenance is needed for the FCM.
The screen can be cleaned with a dry and clean cloth.
Do not use any cleaning product or chemical on the screen.
9. REPAIR
Nothing on the FCM can be repaired on site.
10. TAKE OUT OF SERVICE

Switch off the 24 Volts.
11. REMOVAL AND STORAGE OF EQUIPMENT

Switch of the 24 volts.
Make sure that all wires that are connected to the FCM are labelled correctly so that re-installation
of the FCM can be done without any errors.
Disconnect all the input and output wires.
Store the FCM in a box, in a cool and dry place, so that the BCM can not be damaged.
12. MALFUNCTION AND SEND FOR REPAIR

If the FCM stops working completely contact VAF for instructions.
in the event the FCM has to be send back for repair, you can send it directly to:
VAF Instruments B.V.

Vierlinghstraat 24
NL-3316 EL Dordrecht
The Netherlands
13. ENVIRONMENT
The FCM has no negative influence on the environment during normal operation.
14. DISPOSAL
Laws and restriction for disposal of equipment will be different in most countries. If in doubt or
unable to dispose the equipment, it can be send back to VAF Instruments.
VAF Instruments will dispose the equipment in a correct way.
The FCM has the following possible environmentally unfriendly components.

- Electronic Components.
31
15. TROUBLE SHOOTING
If the FCM does malfunction, power the FCM down, check all wiring and power the FCM back up
again.
This will restart the program.
Problem Possible cause Corrective action
No flow indication No Flow Open valves to and from the flowmeter
Loose wire Check all wire connections between FCM

and flow meter
Hall switch broken Replace Hall switch/PT100 assembly
No temperature indication Loose wire Check all wire connections between FCM
and flow meter
PT100 broken Replace Hall switch/PT100 assembly
TC Off in Config Switch on TC in Config System

System
No ship speed indication Loose wire Check all wire connection between FCM
and Ships log or GPS receiver
Log or GPS – OFF Switch ON the ships log or GPS receiver
16. CERTIFICATES
All certificates are delivered separately.
32
17. DRAWINGS
Figu
re 3
33
Figure 4
34
Figure 5
35
18. ABBREVIATIONS
PT100 Temperature Sensor

FCM Fuel Consumption Monitor
GPS Global Positioning System
TC Temperature Correction
19. SPARE PARTS

19.1 PART NUMBERS
Monitor type SAM-174 0270-0255

PCB 2 x analogue output galv. isolated 0397-0342
PCB analogue in – 6X + 3XPT100 input 0397-0341
36
20. WARRANTY CONDITIONS
1. Without prejudice to the restrictions stated hereinafter, the contractor guarantees both the
soundness of the product delivered by him and the quality of the material used and/or delivered
for it, insofar as this concerns faults in the product delivered which do not become apparent
during inspection or transfer test, which the principal shall demonstrate to have arisen within 12
months from delivery in accordance with subarticle 1A exclusively or predominantly as a direct
consequence of unsoundness of the construction used by the contractor or as a consequence
of faulty finishing or the use of poor materials.
1A. The product shall be deemed to have been delivered when it is ready for inspection (if
inspection at the premises of the contractor has been agreed) and otherwise when it is
ready for shipment.
2. Articles 1 and 1a shall equally apply to faults which do not become apparent during inspection
or transfer test which are caused exclusively or predominantly by unsound assembly/installation
by the contractor. If assembly/installation is carried out by the contractor, the guarantee period
intended in article 1 shall last 12 months from the day on which assembly/installation is
completed by the contractor, with the understanding that in this case the guarantee period shall
end not later than 18 months after delivery in accordance with the terms of subarticle 1A.
3. Defects covered by the guarantee intended under articles 1, 1a and 2 shall be remedied by the
contractor by repair or replacement of the faulty component either on or off the premises of the
contractor, or by shipment of a replacement component, this remaining at the discretion of the
contractor. Subarticle 3A shall equally apply if repair or replacement takes place at the site
where the product has been assembled/installed. All costs accruing above the single obligation
described in the first sentence, such as are not restricted to shipment costs, travelling and
accommodation costs or disassembly or assembly costs insofar as they are not covered by the
agreement, shall be paid by the principal.
3A.If repair or replacement takes place at the site where the product has been
assembled/installed, the principal shall ensure, at his own expense and risk, that:
a. the employees of the contractor shall be able to commence their work as soon as they
have arrived at the erection site and continue to do so during normal working hours, and
moreover, if the contractor deems it necessary, outside the normal working hours, with the
proviso that the contractor informs the principal of this in good time;
b. suitable accommodation and/or all facilities required in accordance with government
regulations, the agreement and common usage, shall be available for the employees of
the contractor;
c. the access roads to the erection site shall be suitable for the transport required;
d. the allocated site shall be suitable for storage and assembly;
e. the necessary lockable storage sites for materials, tools and other goods shall be
available;
f. the necessary and usual auxiliary workmen, auxiliary machines, auxiliary tools, materials
and working materials (including process liquids, oils and greases, cleaning and other
minor materials, gas, water, electricity, steam, compressed air, heating, lighting, etc.) and
the measurement and testing equipment usual for in the business operations of the
principal, shall be available at the correct place and at the disposal of the contractor at the
correct time and without charge;
37
g. all necessary safety and precautionary measures shall have been taken and adhered to,
and all measures shall have been taken and adhered to necessary to observe the
applicable government regulations in the context of assembly/installation;
h. the products shipped shall be available at the correct site at the commencement of and
during assembly.
4. Defects not covered by the guarantee are those which occur partially or wholly as a result of:
A. non-observance of the operation and maintenance instructions or other than foreseeable
normal usage;
B. normal wear and tear;
C. assembly/installation by third parties, including the principal;
D. the application of any government regulation regarding the nature or quality of the material
used;
E. materials or goods used in consultation with the principal;
F. materials or goods provided by the principal to the contractor for processing;
G. materials, goods, working methods and constructions insofar as are applied at the express
instruction of the principal, and materials or goods supplied by or on behalf of the principal;
H. components obtained from third parties by the contractor insofar as that party has given no
guarantee to the contractor.
5. If the principal fails to fulfil any obligation properly or on time ensuing from the agreement
concluded between the principal and the contractor or any agreement connected to it, the
contractor shall not be bound by any of these agreements to any guarantee regardless of how it
is referred to. If, without previous written approval from the contractor, the principal commences
disassembly, repair or other work on the product or allows it to be commenced, then every
agreement with regard to guarantee shall be void.
6. Claims regarding defects must be submitted in writing as quickly as possible and not later than
14 days after the discovery of such. All claims against the contractor regarding faults shall be
void if this term is exceeded. Claims pertaining to the guarantee must be submitted within one
year of the valid complaint on penalty of invalidity.
7. If the contractor replaces components/products under the terms of his guarantee obligations,
the replaced components/products shall become the property of the contractor.
8. Unless otherwise agreed, a guarantee on repair or overhaul work carried out by the contractor
or other services shall only be given on the correctness of the manner in which the
commissioned work is carried out, this for a period of 6 months. This guarantee only covers the
single obligation of the contractor to carry out the work concerned once again in the event of
unsound work. In this case, subarticle 3A shall apply equally.
9. No guarantee shall be given regarded the inspection conducted, advice given and similar
matters.
10.Alleged failure to comply with his guarantee commitments on the part of the contractor shall not
absolve the principal from his obligations ensuing from any agreement concluded with the
contractor.
11.No guarantee shall be given on products which form a part of, or on work and services on,
goods older than 8 years.
38
Revision 0906:
Drawings 0897-2096, 0897-2097 and 0897-0013 changed.
6.4.6 Text for alarms changed
7.10 Screen layout changed
Text for alarm settings changed
7.11 Text flow cut-off added
Revision 0107:
 Connection drawings 0897-2096 and 0897-2097 changed
 Drawing 0897-0013 removed
 Screen lay-out updated
 “Actual values” screen added
 Text for “calculated K-factor” added
 Chapter 7.1.1 – 7.1.4 added
Revision 0409:
Hall switch instead of reed switch
Connection drawings changed
Revision 0711:
House style change
39
Represented by
VAF Instruments B.V. Specifications subject to change without notice.

Vierlinghstraat 24, 3316 EL Dordrecht, The Netherlands Agents and distributors in more than 50 countries.
P.O. Box 40, 3300 AA Dordrecht, The Netherlands
T +31 (0) 78 618 3100, F +31 (0) 78 617 7068
sales@vaf.nl, www.vaf.nl

Technical Manual: Fuel Consumption Monitor For Use With "Ecovaf"

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Technical Manual

Instructions for installation,

For any additional information contact:

VAF Instruments B.V. Tel. +31 78 618 3100

Or your local authorized VAF dealer.

However, there is an option to switch the temperature correction off.

Display Touch screen 1/4VGA (320x240)

Digital 4 (3) Flowmeters (Hall switches)

Analogue 3 Fuel consumption (see chapter 6)

Relays 3 Alarm outputs (see chapter 6)

First connect all inputs and outputs to the FCM.

6.2 CABLE SHIELD CONNECTION

Please refer to Chapter 17 for recommendations.

 Fuel flow (3x)

6.4.2 Fuel flow

6.4.3 Fuel temperature

6.4.4 Ship speed input options

Ship speed via GPS.

Connection No High Temp. Sensor Flow Monitor

General Alarm 1-2 Closed Open Open Open Open

The flow meters are called A, B and C.

Main Screen 2 will give more details about the AE.

7.1.1 Important settings

Consumption AE AE = flow A – flow B [l/min]

Temperature difference ∆T = T – Tref [°C]

7.1.3 Example calculation

Flow C 97,2 l/min 91,1°C

Flowrates calculated back to reference temperature:

Temperature corrected consumption:

AE = 41,9 – 30,1 = 11,8 l/min AE = 11,8 * 0,997 = 11,8 kg/min

7.1.4 Temperature compensation and accuracy of results

 Screen 1: Main screen 1

Consumption ME xxxx.x l/min

T.C. consumption ME xxxx.x l/min

Consumption AE xxxx.x l/min

T.C. consumption AE xxxx.x l/min

The units change from l and kg into m3 and tons.

SETUP: Go to the configuration screen.

Auxiliary engine Accumulative

Average (24hr) 12 kg/hr 14 l/hr

Average (24hr) 18 kg/hr 22 l/hr

Spec. consumption ME 31 kg/NM

SETUP RESET SYSTEM HISTORY

SETUP: Go to configuration screen.

RESET TOTALS: Will reset totals

ALARM: Go to alarm screen. This button will flash if there is an alarm.

HISTORY: Go to the history screens

Main engine Accumulative

Average (24hr) 6 kg/hr 8 l/hr

Average (24hr) 18 kg/hr 22 l/hr

Spec. consumption ME 31 kg/NM

SETUP RESET SYSTEM HISTORY

SETUP: Go to configuration screen.

RESET TOTALS: Will reset totals

ALARM: Go to alarm screen. This button will flash if there is an alarm.

HISTORY: Go to the history screens

Alarm log #01

Date: 23 June 2005

Esc will take you back to the previous screen.

The following messages will be used:

 Flowsensor A error (supply < return)

02-04-05 13:38 03-04-05 13:38 13.3 m³ 13.2 ton

CONFIG DATE LCD ACTUAL ESC