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====== 3271 Build Instructions ======

<note warning>**The 3271 PCB assembly contains components that are sensitive to electrostatic discharge (ESD) – please make sure you are wearing your wrist strap when handling.**</note>

**Tools:		
-	6mm Fine Round File 
-	Soldering Iron   	
-	Wiha Torque Vario	**	

**Method:**

<note important>**Check sender spread sheet for build requirements. identify sales order information and select packing slip**</note> 

<note>**before starting assembly, degrease inside sender body with acetone and allow time to dry. (Use gloves for this procedure)**</note>

**Fit 200581 Grommet to Fuel Sender Body as shown ensuring correct seating.**

{{:internal:proddocs:3271-1.png|}}

<note important>**Carefully thread the tinned ends of the Micro Cable Assembly 200583 through the Grommet so that approx 100mm of cable protrudes from the inside of the Sender Body.  Use 203012 Hellerine oil as a lubricant if required – do not use a silicone based lubricant.**</note>
{{:internal:proddocs:3271-2.png?600|}}

** Ease the cable back through the grommet to centralise the PCB Assembly in the sender Body, making sure the LED and Tank Instance dial are on top of the PCB.**

**Connect to Bench Power Supply. Ensure that voltage is set between 12.8 and 13.8 volts.**

{{:internal:proddocs:3271-3.png?600|}}

<note>**Make sure that only one device is connected to the CAN.**</note>

====== Programming ======
<note>**Connect the Sender head to the NMEA cable and power on the device
Connect the ST/LINK v2 to the programming header. You will need the PCB to be loose from the sender head to be able to access it, as it is on the under-side of the board.
Open STM32CubeProgrammer
Click the Icon on the left hand side:**** 5) Click the connect button.**</note>


{{:internal:proddocs:3271..1.png?600|}}


**Browse to the folder S:\Code\Production\3271 Fuel Level Sender\Program AFTER Rev J\
Then select 3271bootloader.bin**


{{:internal:proddocs:3271..3.png?600|}}

**Ensure the check boxes are as shown below and then select “Start Programming”**

{{:internal:proddocs:3271..4.png?600|}}


**Now, the blue LED should be on solid.
<note important>Open Monex 3.12, Select the Programming tab, and then press “3271”**</note>

{{:internal:proddocs:3271..5.png?600|}}

**Press the “reprogram” button**

{{:internal:proddocs:3271..6.png?600|}}

**Navigate to S:\Code\Production\3271 Fuel Level Sender\Program AFTER Rev J and select 3271-v5.bin, then press “open”.
**

{{:internal:proddocs:3271..7.png?600|}}


**The tool will now indicate it is programming, it will then show a CRC and PASS, and finally will reboot to application code.**

{{:internal:proddocs:3271..8.png?600|}}


**Clean the rods using Amber clean paying attention to the threaded area
Screw 200506 Threaded Nylon Spacer onto the threaded end of 200681 probe until 7 mm to 8 mm of thread protrudes from Spacer.**

<note>For Williams 3271-200 mm add two spacers, one at the top and one at the bottom</note>
**Assemble the Insulator mouldings to the Probe. Check the un-threaded end of the probe for burrs and de-burr if necessary. Slide 200622 Insulators onto the Probe, spacing them approximately 200 mm apart.
**
<note important>**The outer tube length for Williams is 198mm, the inner rod length is 214mm with CTS 081.
**</note>
<note important>Select tightly fitting spacers only – this is critical to prevent them sliding when fully assembled.</note>

{{:internal:proddocs:3271-6.png?600|}}

**The threaded end of the Probe is now inserted into the centre hole in the threaded end of the Sender Body until the thread protrudes through the centre hole in the PCB.**
<note important>**Assemble 200508 shake proof washer and M3 Nut 200507 onto the thread and tighten to a torque of 0.8Nm**</note>

**Ensure there are no burrs on the edges of the tube and that the inside is clean; now assemble 200738 Outer Tube carefully over the Insulators. The tube must be inserted into the body to the bottom of the hole.**

<note tip>**The 2 black 200812 M6 Grub Screws are screwed into the Tube retaining holes in the main thread. Check that the Tube is still pushed fully home, tighten Screws to 1.5Nm.  DO NOT over tighten as this could deform the Tube. Use ONLY the Wiha torque screwdriver for this process.
Repeat this operation with the 2 Silver 200813 Grub Screws using them to lock the black screws in position. Once tightened, ensure one final 200622 insulator is pushed on to the end of the rod (approx 5mm into the tube) to prevent the risk of shorting.**
</note>

{{:internal:proddocs:3271-7.png?600|}}


**DO FUNCTIONAL TEST PRIOR TO POTTING PROCEDURE.**

  -  	**OPEN THE LATEST VERSION OF MONEX**
  - 	**VERIFY SOFTWARE IS LOADED USING “GETPRODINFO”**
  -  	**ENSURE MODEL ID AND SOFTWARE VERSION ARE CORRECT**
  -  **CLICK GET CAL AND ENSURE CURRENT MEASURED VALUE DOES NOT READ AS 0**

====== Process ======

<note important>**This is a dry test only to check functionality, The new software is very sensitive and it will fluctuate**</note>

**  -Turn on PSU power and plug in the sender.**
  - **Open Monex 3.12**
  - **Holding the cable, do an E cal**
  -** Do an F cal, this will change on the INST**
 
**Check the Blue light is flashing every 2.5 seconds** 

**Before potting, allow the senders to acclimatise in the potting room for a couple of hours. This will reduce the chance of any condensation on the inner sender body.

**
**Suitable PPE should be worn when using the two-part Epoxy potting compound.

Warm the compound in the water bath (this should be set to 40 degrees), this takes approximately 10 minutes for the bath to come up to temperature and 5 minutes to warm a bag of compound. Do not warm above this temperature as it will greatly reduce the pot life of the compound.
Once warm, work the black potting BEFORE removing the clip and rail – this will help remove any lumps caused by the fillers that have settled over time. Then, place back into the bath for 2 minutes.
Remove the clip and rail, and mix thoroughly for approximately 2 minutes.**



{{:internal:proddocs:3271-8.png?600|}}


**REMEMBER TO TURN THE WATER BATH OFF ONCE YOU HAVE FINISHED WITH IT !
To avoid air gaps under the PCB and around the wiring, the sender must be at a slight angle – a cotton bud under one side is enough.
The compound can then be slowly poured into the lower side, as this allows the potting to fill up level with the board and prevents air pockets.
Once all air has been removed under the board, you should see a ring of potting all around the outside of the PCB.

At this point, the cotton buds can be removed so the sender is now flat and the sender can be topped up.

If any bubbles appear, these can be dispersed by gently using a hot air gun over the surface.

The Potting must now be left overnight to
Cure and harden.**

**No epoxy to be visible on the switch and overspill is to be wiped away. Epoxy must be flush to metal surface to avoid creating a recess for any fluid to accumulate when in use.**


{{:internal:proddocs:3271-9.png?600|}}


**Once the Potting has set, the Serial No Label 200303 can be applied. Position symmetrically as shown. The label MUST NOT overlap the switch, LED or metal edges of the body.**


{{:internal:proddocs:3271-10.png?600|}}


**Now connect the unit to the Monex system and assign the unit the serial number from the sticker and to do a final test after assembly to make sure the unit is still fully functioning and has not been damaged during the build procedure.

**Click SET SERIAL – input the serial number from the label
**
Click GET PRODUCT INFO to confirm Serial Number and software level
**
<note important>**For Williams use CTS file 081, cut the inner tube to 198 mm and the outer tube to 214 mm.
Only test on empty and full.**</note>


{{:internal:proddocs:3271-11.png?600|}}


**. To Calibrate Sender to empty out of the tank suspended vertically only holding on to the cable.

Turn rotary switch to ‘E’ position as indicated in the diagram.
**

{{:internal:proddocs:3271-12.png|}} 


**With a magnet locate the re calibration place on the top of the unit labelled MAGNET and you will see the blue led remain lit for 2.5seconds (you can repeat this as many times as you like until you are happy that you have set the EMPTY position.

This is checked with the GET CAL box which should display the EMPTY values.
**

{{:internal:proddocs:3271-13.png|}} {{:internal:proddocs:3271d.jpg?400|}}


**To calibrate sender to full, turn rotary switch to the ‘F’ position as indicated in the diagram.

The sender must be dipped into the tube of fuel to where, the fuel must reach the bottom of the threaded part of the sender body – ensure that the tube has sufficient fuel to reach this level. Keep clicking the Get Cal button until the Current measured value stops changing. This is a few seconds on a short sender, but could be up to a minute on a 2metre sender. When the value has stopped changing, then calibrate full at the required level. Check that the reading on the big red table goes down very slightly as the sender is raised. DO NOT RESET THE EMPTY, EVEN IF IT READS 2%

Now as for the empty calibration. With a magnet locate the re-calibration place on the top of the unit labelled MAGNET and you will see the blue led remain lit for 2.5 seconds (you can repeat this as many times as you like until you are happy that you have set the FULL position).

This is checked with the GET CAL box which should display the FULL values.**

{{:internal:proddocs:3271-14.png|}} {{:internal:proddocs:3271e.jpg?400|}}


**With calibration complete the rotary dial switch must now be returned to the required instance (0 for a single tank installation). Position as shown in the diagram.

With Calibration complete  check levels on screen at Empty, 25%, 50%, 75% and Full 
Tolerance for this test is +/- 2% over 10 seconds.

A member of the Production team must verify the Empty and Full calibration, Serial No, and that the instance is set to zero.
Affix the Label squarely to the flats on Sender Body.
**

{{:internal:proddocs:3271-15.png|}}

<note important>**BEFORE PACKING MAKE SURE THERE IS NO FUEL LEFT INSIDE THE SENDER ROD, AS THIS WILL CAUSE THE PACKAGING TO BE FLOODED WITH DIESEL DURING TRANSIT**</note> 


**The Sender is now ready for packing. The user instructions are packed into Poly Bag 200332 along with 1 off Insulator 200602.

Place sender in tube with Instructions.

Supply gasket as required.

Add Laser Label 200306 to Packaging Tube 200310 positioned as shown.

Add product indicator label to cap – highlight box 
To indicate product – Length and settings if required

Add colour coded label to cardboard tube

Blue – (203119) 1.5” NPT
Orange – (203120) 1.25” BSP
Green – (203121) SAE 5 bolt

Place completed assembly in finished Stock area
**

{{:internal:proddocs:3271-16.jpg?600|}}

 --- //[[chrissy@osukl.com|Christine Walsh]] 11/10/202108:44// updated
 --- //[[chrissy@osukl.com|Christine Walsh]] 12/04/2022 08:05//updated