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

Method:

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

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.

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

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

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

Press the “reprogram” button

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

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

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.

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.

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.

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.

DO FUNCTIONAL TEST PRIOR TO POTTING PROCEDURE.

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

-Turn on PSU power and plug in the sender.

1. Open Monex 3.12
2. Holding the cable, do an E cal
3. 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.

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.

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.

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

. 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.

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.

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. 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.

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.

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

— Christine Walsh 11/10/202108:44 updated — Christine Walsh 12/04/2022 08:05updated