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Fuel Flow sensor Install

  • Jack Martin
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1 week 4 days ago #18783 by Jack Martin
Jack Martin created the topic: Fuel Flow sensor Install
I want to install an FT-60 fuel flow sensor on my Rotax 912ULS. My concern is caring for the beautiful hose that Rotax provided between the engine driven fuel pump and the carburetors. What is the recommended method of installing the FT-60?
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1 week 4 days ago #18785 by Roger Lee
Roger Lee replied the topic: Fuel Flow sensor Install
The FT60 should be in the supply hose not the out pressured hose. It should be horizontal for 6" on each side and have a fine mess filter before the FT60. Google FT60 installation instructions.

static1.squarespace.com/static/5282b286e...80/FT_60_install.pdf

Roger Lee
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Tucson, AZ Ryan Airfield (KRYN)
520-574-1080 Home (TRY HOME FIRST)
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  • Bill Hertzel
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1 week 4 days ago #18787 by Bill Hertzel
Bill Hertzel replied the topic: Fuel Flow sensor Install
912uls engines are now supposed to utilize a restricted flow, Fuel Return line, to purge vapors.
You will also need a second flow meter in the Fuel Return Line to measure fuel that was not used by the engine.
Otherwise, the measurement will be falsely high.
More fuel circulates through the fuel lines than the engine actually uses.
The Flow Meter will need to subtract the Return Flow from the Gross Forward flow to compute the Net Flow to the Carbs.

This is a common configuration for the 914, 915 and the 912is. It is now Required/Highly Recommended for All 912 series engines.
See the 912 Installation Manual Section 73-00-00, Page 3

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1 week 4 days ago #18788 by Roger Lee
Roger Lee replied the topic: Fuel Flow sensor Install
Hi Bill,

Do as Flight Design did with there's. Put the return line in downstream of the transducer. You would only need two of these if you put the return line back upstream of the transducer.

Roger Lee
LSRM-A & Rotax Instructor & Rotax IRC
Tucson, AZ Ryan Airfield (KRYN)
520-574-1080 Home (TRY HOME FIRST)
520-349-7056 Cell

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1 week 3 days ago #18790 by Bill Hertzel
Bill Hertzel replied the topic: Fuel Flow sensor Install
Roger,
Re-read your last post.
I think you got an "Upstream/Downstream" and a "One/Two reversed. ;)
If you put the Transducer Downstream of the Return Line, you would only need One.

The installation Instructions suggest installing it "Between the Engine driven pump and the Carburetor".
The Specs quote a 100psi Working Pressure.
They have no restrictions in placing it in the High-Pressure, Out-Flow side of the pumps.

Jack,
It will need to go After the Fuel Pump and the Return Line but Before it splits to the Carbs.
And, Yes! You WIll be cutting those pretty Hoses. :ohmy:
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1 week 3 days ago #18795 by Roger Lee
Roger Lee replied the topic: Fuel Flow sensor Install
Yes your right. Downstream of the FT60. Like on a Flight Design. The fuel goes through a fine filter then the FT60, then through the gascolator and up to the pump. Then the
re-circulation line goes back down to the top of the gascolator which is downstream of the FT60. So all the fuel only passes through the FT60 one time. The re-circulated is is only accounted for that one time.

Roger Lee
LSRM-A & Rotax Instructor & Rotax IRC
Tucson, AZ Ryan Airfield (KRYN)
520-574-1080 Home (TRY HOME FIRST)
520-349-7056 Cell

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1 week 2 days ago #18802 by Jack Martin
Jack Martin replied the topic: Fuel Flow sensor Install
Roger,
Which "fine filter" do you recommend? Placing the FT-60 before the gascolator means the fuel pressure at the FT-60 entrance in due to the fall from the High wing tanks plus the suction from the fuel pumps on the output side of the FT-60. Correct?

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1 week 2 days ago #18803 by Roger Lee
Roger Lee replied the topic: Fuel Flow sensor Install
Most any fuel filter you would use on an aircraft is fine. The reason to put the filter before the FT60 if to keep debris out that may clog or restrict its flow.
Something like a 10 micron, but it doesn't have to be exact. Just something before the transducer.

Roger Lee
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Tucson, AZ Ryan Airfield (KRYN)
520-574-1080 Home (TRY HOME FIRST)
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1 week 2 days ago #18804 by Bill Hertzel
Bill Hertzel replied the topic: Fuel Flow sensor Install
Agreed!
Any filter will do the job.
The flow meter is a miniature paddle wheel.
As the fuel flows, the circuitry counts the revolutions. 68,000 per gallon.
The mechanism is built like a fine watch, so any dirt big enough to see is too big.

The sensor can measure flow rates approaching 100 gallons/Hour
Do NOT blow into it to see if it is working.
A light breath from a foot away will make it spin.
Most normal individuals can muster a peak breath flow rate exceeding 100 Gallons/Minute!
Extremely Overspeeding the tiny jeweler's bearings in the sensor.

As tempting as it is to try... Don't do it!

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1 week 1 day ago #18813 by David HEAL
David HEAL replied the topic: Fuel Flow sensor Install
I have heard that fuel filters with "paper" elements are inappropriate for use with gasoline containing ethanol.

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1 week 1 day ago #18816 by Genival Pacheco
Genival Pacheco replied the topic: Fuel Flow sensor Install
True

Ethanol contains water that cause the filter to clog

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1 week 1 day ago #18824 by James Ott
James Ott replied the topic: Fuel Flow sensor Install
A couple of things:
1- It was strongly recommended to me that the FT-60 not be mounted on the engine due to heat and vibrations. I mounted mine in the cockpit in the fuel supply line.
2-Yes it measures total flow including bypass flow. I did not want the expense and complexity of using two flowmeters as was suggested, so it was a simple matter to recalibrate my pulses/gal "K" factor to give an accurate reading at cruise rpm. I manually measured my actual fuel used for a straight and level x-country trip and compared this with the FT-60 reading, which gave me a % to modify the "K" factor. Admittedly, this only gives an accurate reading when cruising at the rpm used for calibration, but that is all I really care about anyway.
3- I did not use a fine filter ahead of the FT-60, just the coarse strainers in the wing tanks. My fine filter is ahead of the fuel pump. This system has been working fine for 600 hours. If you look thru the hole in the FT-60 and the little paddle wheel, you will see that there is actually quite a large area to pass particles of fairly large size.

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1 week 1 day ago #18831 by Bill Hertzel
Bill Hertzel replied the topic: Fuel Flow sensor Install

David HEAL wrote: I have heard that fuel filters with "paper" elements are inappropriate for use with gasoline containing ethanol.


Water in Diesel fuel causes issues because there is no Ethanol to dissolve the water.
Algae can grow in the water and clog the filters, Paper or otherwise.

The alcohol in MoGas dissolves any water up to ~1/2% of the tank. (~6oz per 10 gal)
This water harmlessly passes through the engine in the same manner as the water that is dissolved (evaporated) in the air used by the engine.

250 million U.S. Automobiles use Paper Fuel Filters with Gasoline containing Ethanol every year without issues.

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1 week 1 day ago #18836 by Rob Seaton
Rob Seaton replied the topic: Fuel Flow sensor Install
Bill, I have learned that automobile comparisons are tricky. You do have to be more careful with aircraft as you dealing with altitude, longer storage times and aircraft are often built using a mixture of technology such as fuel components and materials, possibly un-tested in combination with each other. Autos are designed and tested as a complete package.
So paper filters have been proven to be a problem in aviation and should be avoided.
But can you even tell if it is paper? the Rotas 912iS fine filter is a composite material but it sure looks like paper....

Roger, I would not recommend an inline 10 micron filter for the carby engines; this is much too fine and due to the very small surface area of an in-line filter it can can plug up almost immediately with crappy fuel use.

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1 week 1 day ago #18841 by Roger Lee
Roger Lee replied the topic: Fuel Flow sensor Install
Hi Rob,
"Roger, I would not recommend an inline 10 micron filter for the carby engines; this is much too fine and due to the very small surface area of an in-line filter it can can plug up almost immediately with crappy fuel use."

You're probably right. I see some use 40-70 micron.

Roger Lee
LSRM-A & Rotax Instructor & Rotax IRC
Tucson, AZ Ryan Airfield (KRYN)
520-574-1080 Home (TRY HOME FIRST)
520-349-7056 Cell

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