FW Murphy AFR-64L Installation And Operation Manual
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FW Murphy AFR-64L Installation And Operation Manual

Lean burn air/fuel ratio controller
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AFR-64L
Lean Burn Air/Fuel Ratio Controller
Installation and Operations Manual
Please read manual for hazard and safety advisement.
00-02-0707
2013-05-22
Section 40

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  • Page 1 AFR-64L Lean Burn Air/Fuel Ratio Controller Installation and Operations Manual Please read manual for hazard and safety advisement. 00-02-0707 2013-05-22 Section 40...
  • Page 2 Please read the following information before installing. BEFORE BEGINNING INSTALLATION OF THIS FW MURPHY PRODUCT:  Read and follow all installation instructions.  Please contact an FW Murphy U.S. Master Distributor immediately if you have any questions. http://www.fwmurphy.com/where-to-buy/us- sales-distributors  Additional contact information is located on the back page of this...

  • Page 3: Table Of Contents

    Table of Contents ....................................1 AFETY ..................................3 NTRODUCTION ................................5 ARTS AND UPPLIES AFR-ND-L-64L-11-FA## – Full Authority Valve (Single O2 Sensor – Single Fuel Valve) ................5 AFR-ND-L-64L-21-FA## – Full Authority Valve (Single O2 Sensor – Dual Fuel Valve) .................. 7 AFR-ND-L-64L-22-FA## –...
  • Page 4 Wiring Connections ....................................40 Engine Mounting Requiring Disassembly of Engine ..........................40 AFR-64L W ..............................41 IRING CHEMATIC General Wiring Termination – All Valves ..............................41 Butterfly Full Authority (FA) Valve Field Wiring Schematic – Lower Tier (tall) ..................42 Butterfly Full Authority (FA) Valve Field Wiring Schematic –...
  • Page 5 General Control Display Group ................................97 Fault Display Group....................................99 Software and Hardware Group ................................100 SET-UP SCREEN (Screen No. 2) ................................101 Engine Monitoring Group .................................. 103 General Controls Display Group ................................ 105 Oxygen Sensor Feedback Control Group ............................107 Valve Control Group ..................................
  • Page 6 AFR-ND-L-64L-22-FA## (Dual Bank, High Pressure Carburetor, Common Exhaust Manifold Full Authority Valve) ........ 139 AFR-ND-L-64L-11-FA## (Dual Bank, High Pressure Carburetor, Common Intake Manifold Full Authority Valve) (Cat 3500 series) ..140 ..................................141 NGINE Software v2010.03.15 -iv- 00-02-0707 2013-05-22...
  • Page 7 THIS PAGE INTENTIONALLY LEFT BLANK Software v2010.03.15 00-02-0707 2013-05-22...
  • Page 8 THIS PAGE INTENTIONALLY LEFT BLANK Software v2010.03.15 00-02-0707 2013-05-22...

  • Page 9: Safety

    Safety  The electrically actuated fuel control valves supplied with this product are designed to control fuel flow only. They are not designed to replace a fuel shut-off valve or a fuel shut-off system. Therefore the product relies on the installation and use of an automatically closing fuel shut-off valve (user supplied) to stop fuel flow during and after engine shutdown and is necessary for safe product use.
  • Page 10 This product is often used in retrofit applications. It is the responsibility of the installer(s)/end user(s) to assess the safety and suitability of the product with regard to the end user’s or users’ specific application. This responsibility is not shared by FW Murphy. Software v2010.03.15...

  • Page 11: Introduction

    Introduction This manual describes the basic installation, setup, operation and maintenance of the FW Murphy Lean Burn Air/Fuel Ratio Control System; the AFR-64L is used to control lean-burn, four stroke, spark-ignited, gaseous fuel engines. Software v2010.03.15 00-02-0707 2013-05-22...
  • Page 12 This is done without operator intervention after the initial program setup. The FW Murphy AFR-64L air/fuel ratio controller represents cutting edge technology in many areas: hardware, microprocessor power, control system software, operator interface options, adaptability to variable engine conditions and control requirements, software upgrade capability, in addition to comprehensive on-board diagnostics system (OBD).

  • Page 13: Parts And Supplies

    One 2" NPT Flange, Gkt & Hdwr for FT-33, 60, & 68 (2)a 47050834 ADAPTER,3" FT Flange Assy One 3" NPT Flange, Gkt & Hdwr for FT-75 00020707 AFR-64L Manual AFR-64L I/O Manual 47000470 AFR-64R/L-CD AFR-64R/L PC Software (1)u 47700330 AFR-ND-L-64L Control Unit Enclosure;...
  • Page 14 00031025 MAT Sensor Intake Manifold Temp Sensor 00031029 NM-10 Null Modem Cable 10' Length 00031030 O2 NUT 18mm x 1.5 Threaded, Coupling for O2 Sensor 00031039 UEGO Cable-50 UEGO Sensor Cable 50' 00031040 UEGO Sensor Heated Wideband Oxygen Sensor (1)v 47700033 Valve Assy,FL-25 25 MM Full Authority (FA) Butterfly Valve...

  • Page 15: Afr-Nd-L-64L-21-Fa## - Full Authority Valve (Single O2 Sensor - Dual Fuel Valve)

    One 2" NPT Flange, Gkt & Hdwr for FT-33, 60, & 68 (4)a 47050834 ADAPTER,3" FT Flange Assy One 3" NPT Flange, Gkt & Hdwr for FT-75 00020707 AFR-64L Manual AFR-64L I/O Manual 47000470 AFR-64R/L-CD AFR-64R/L PC Software (1)u 47700330 AFR-ND-L-64L Control Unit Enclosure;...
  • Page 16 00031030 O2 NUT 18mm x 1.5 Threaded, Coupling for O2 Sensor 00031039 UEGO Cable-50 UEGO Sensor Cable 50' 00031040 UEGO Sensor Heated Wideband Oxygen Sensor (2)v 47700033 Valve Assy,FL-25 25 MM Full Authority (FA) Butterfly Valve (2)v 47700034 Valve Assy,FL-50 50 MM Full Authority (FA) Butterfly Valve (2)c Indicates only 1 cable Assy style is used, depending on the valve type used...

  • Page 17: Afr-Nd-L-64L-22-Fa## - Full Authority Valve (Dual O2 Sensor - Dual Fuel Valve)

    One 2" NPT Flange, Gkt & Hdwr for FT-33, 60, & 68 (4)a 47050834 ADAPTER,3" FT Flange Assy One 3" NPT Flange, Gkt & Hdwr for FT-75 00020707 AFR-64L Manual AFR-64L I/O Manual 47000470 AFR-64R/L-CD AFR-64R/L PC Software (1)u 47700330 AFR-ND-L-64L Control Unit Enclosure;...
  • Page 18 00031030 O2 NUT 18mm x 1.5 Threaded, Coupling for O2 Sensor 00031039 UEGO Cable-50 UEGO Sensor Cable 50' 00031040 UEGO Sensor Heated Wideband Oxygen Sensor (2)v 47700033 Valve Assy,FL-25 25 MM Full Authority (FA) Butterfly Valve (2)v 47700034 Valve Assy,FL-50 50 MM Full Authority (FA) Butterfly Valve (2)c Indicates only 1 cable Assy style is used, depending on the valve type used...

  • Page 19: Spare/ Loose Parts

    UniOP Display Daughter Board for secondary Modbus 00002138 CONVERTER 12 to 24 Volts DC to DC converter 47000005 ECM-L-64L Engine Control Module for the AFR-64L 47050831 ENCLOSURE-CSA CSA Approved Enclosure 47000016 FL Cable 50 FL Valve Cable - 50' Length...
  • Page 20 47050860 UNIOP COM Cable-Panel UniOP Communications Cable – 6' 47050861 UNIOP COM Cable-Remote UniOP Communications Cable - 50' 47000013 UNIOP Display AFR-64L AFR-64L Display Only 47050820 UNIOP Gasket Gasket seal for mounting UniOP in panel 47050845 UNIOP Power Cable UniOP Pwr Cable – 18" Length...

  • Page 21: Parts Identification

    Parts Identification Please remember your specific kit may not include all of these parts. Refer to the Installation section of this manual for a parts listing of each kit. ECM-L-64L CONTROL MODULE The terminal connector board consists of:  three (3) tier screw terminal strip where all systems connections are made The ECM (Engine Control Module) consists of a molded enclosure designed to protect the Printed Circuit Board.
  • Page 22 The UEGO (Universal Exhaust Gas Oxygen) sensor is a Zirconia-type wide band sensor used in conjunction with the AFR-64L to calculate the excess exhaust oxygen concentration in the exhaust stream. The UEGO sensor is a five (5) wire, heated sensor used to provide the primary signal to the controller in a closed loop mode.
  • Page 23 Available in 33mm, 50mm, 60mm, 68mm & 75mm length of 50 feet, terminated on one end with a modular connector for the fuel valve connection. 50 feet is the maximum recommended length for this cable. Harness sheath color is green. Warning: Not a fuel shut-off valve! An electronically actuated, full authority valve, controls fuel flow to the carburetor or mixer.
  • Page 24 used to estimate an engine load for the default valve positions in the event of sensor failure. 5/8” x 18 thread x 4” long MAP CABLE ASSEMBLY Used to measure the speed of the engine A magnetic pickup (instead of G-Lead) reduces the chances of RF noise interference.
  • Page 25 used in conjunction with other inputs to determine the mass airflow rate to the engine, which also determines the mass fuel flow rate and engine load. MAT Sensor Cable Assembly This thermocouple with its ungrounded design, is used by the controller to monitor the catalyst inlet, outlet and differential temperatures.
  • Page 26 18mm coupling for installation of the UEGO Sensor into the exhaust piping 304 SS female The O2 Nut is constructed of 304 stainless steel, machined Used when the UEGO sensor is remotely mounted – to 18mm x 1.5P threads for the sensor. The face of this 18mm x ¼”...

  • Page 27: Installation

    Installation Installation Checklist 1. Before installing the AFR-64L, make sure the engine is in good mechanical condition and the ignition and fuel systems are in good shape. By this, all cylinders have good compression, the valves are adjusted to factory...
  • Page 28 8. Install the Manifold Air Temperature (MAT) Senor in a suitable location in the intake manifold that will be a relative reading of the actual air temperature in the manifold. 9. Butterfly Full Authority (FA). Locate piping where the valve will be installed. This should be a place downstream of the engine fuel shutdown valve and the final cut regulator.

  • Page 29: Safeguarding Electronics

    (EMP). Follow these precautions when working with or near the control. 1. Before welding on engine skid, the AFR-64L Control Module and the Terminal Connector Board (TCB) should be removed from the enclosure and placed in an antistatic protective bag.

  • Page 30: Matching The Kit To The Application And Parts Verification

    Matching the Kit to the Application and Parts Verification Often the individual who has ordered this product and the individual faced with installing it are not one and the same. To save the installer potential time and grief, it will prove beneficial to verify the decisions made by the purchaser.

  • Page 31: Installation Guidelines For Components

    Installation Guidelines for Components General Guidelines for Mounting the Full Authority (FA) Valve Mounting Required tools and hardware:  Necessary tools for the removal of piping and associated supports (pipe wrenches; hand tools)  Required pipe nipples and fittings to modify fuel piping ...
  • Page 32 To prevent catalyst and/or engine damage, most engine manufactures  recommend a specific engine shutdown procedure. Consult your engine manufacture for these procedures. If the procedures are not available, a general rule to follow would be to 1 turn off the engine’s fuel system and then turn off the ignition system 5 to 10 seconds later.
  • Page 33 The table below matches a given valve to its flange adapter size. Some applications will require bushings to match the fuel line size to the given flange adapter. Butterfly Valve Size Flange Size (NPT) FL 25 1” FT 33 2" FL 50 2”...
  • Page 34 3 1 2 " Ø 7 16 " Ø 7 16 " 3 1 2 " Ø1" Ø 7 16 " Ø 7 16 " 16 " Illustration 5 - Dimensions for Making FT Full Authority Valve Mounting Bracket Software v2010.03.15 -26- 00-02-0707 2013-05-22...

  • Page 35: Uego Sensor Installation General Guidelines

    UEGO Sensor Installation General Guidelines UEGO Sensor  See ‘Installation Suggestion on Various Engine Types’.  The UEGO sensor(s) should be mounted as close as practical to the engine exhaust manifold(s), after any turbo charger system.  On any engine installation where there is a common intake or exhaust manifold, only one pre catalyst UEGO sensor will be needed.

  • Page 36: Uego Sensor Mounting

    UEGO Sensor Mounting For an ambient temperatures less than 250F. Illustration 5 indicates the installation procedure used when the O2 Coupling that is optional with the kit is used. The mounting location of the pre catalyst sensor should be as close as practical to engine but should never be mounted pre turbocharger.
  • Page 37 Unacceptable Acceptable Acceptable Unacceptable Illustration 6 - Allowed mounting orientations for UEGO Sensor on a horizontal pipe run Software v2010.03.15 -29- 00-02-0707 2013-05-22...

  • Page 38: Uego Sensor Mounting Using Uego Sensor Block

    UEGO Sensor Mounting Using UEGO Sensor Block For a sensor ambient temperatures greater than 250F. When the ambient temperature at the mounting point for the UEGO Sensor is greater than 250°F, or the exhaust back pressure is greater than 18” water column, the UEGO Sensor Block is used. It is usually mounted by 1-3/4”...
  • Page 39 Illustration 7 – Illustration – Correct installation Incorrect installation UEGO Sensor is mounted in the 12:00 o’clock UEGO is mounted in the 6:00 o’clock position position In Illustration 7, this is an example of an incorrect installation due to the orientation of the sensor. The sensor should never be mounted below the horizontal plane.
  • Page 40  The UEGO block and the pitot tubes should be orientated to avoid low spots where moisture could accumulate.  The inlet tube/pipe must be 3/8” diameter and must be orientated so as the opening of the tube /pipe is facing into the exhaust flow.
  • Page 41 This design will allow the exhaust gas to be forced into the UEGO Block via the 3/8” tube/pipe and sucked out of the UEGO Block via the 1/2” tube/pipe. " Tube/Pipe (inlet) " Tube/Pipe (outlet) Illustration 10 - UEGO Sensor Block Mounting using Pitot Tube Installation on a Naturally Asperated Engine Software v2010.03.15 -33- 00-02-0707...

  • Page 42: Map Sensor Installation

    MAP Sensor Installation The MAP Sensor has a barbed nipple for 3/16” ID flexible automotive type petroleum fuel resistive tubing, or hose. It can be secured on that barbed nipple with an automotive style hose clamp. The following illustration shows the MAP Sensor mounting foot print. Ø...

  • Page 43: Mat Sensor Installation

    MAT Sensor installation The Manifold Air Temperature (MAT) sensor can be mounted anywhere in the intake manifold. The sensor requires a 3/8” NPT port in the intake manifold for mounting. It is designed to be weather resistant.  See the Appendix for installation suggestion on various engine types ...

  • Page 44: Enclosure Mounting And Conduit Entries

    The controller requires a speed input. This can be from a G-Lead connection on the ignition or from the optionally supplied Magnetic Pickup. In some situations, the speed signal can be from a Magnetic Pick-Up used for a tachometer or controller. Never share the MPU signal used by an electronic governor or ignition system with the controller! Different components have different electrical characteristics and the consequences of failure are severe.

  • Page 45: Conduit Considerations

    1 3/8 1 1/4 1 3/4 1 1/2 Conduit Considerations Conduit size and the choice of flex conduit versus rigid conduit must be made like any other installation. The choice of conduit pull boxes and junction boxes may be affected by the size of the plugs on the harnesses. Always pull a harness using the free wire end from the location where the plug will be.

  • Page 46: Wire Termination

    Wire Termination Refer to the table at the end of this section when making wiring connections to the Terminal Connection Board (TCB). For single bank engine applications all connections should be made to the Left Bank. The rare dual bank applications using only one pre catalyst oxygen sensor (UEGO) should have that sensor connected to the left bank pre catalyst UEGO input and both fuel valves wired to the left bank as well.
  • Page 47 13 1 2 " 3" 5" 12" 8" 12 3 4 " Illustration 11 - Enclosure Mounting Dimensions, Recommended Conduit Locations, and Wire Separation Software v2010.03.15 -39- 00-02-0707 2013-05-22...

  • Page 48: Wiring Connections

    Wiring Connections Wherever possible, use stranded tinned copper (do not solder). Raw copper wiring will corrode easily. Make any splices inside a weather-proof conduit fitting. Always provide extra lengths of wiring at termination points so if there is a need to redo a connection, there will be plenty of wire to work with. It is much better to have a service loop of extra wire than to be short.

  • Page 49: Afr-64L Wiring Schematic

    AFR-64L Wiring Schematic General Wiring Termination – All Valves Software v2010.03.15 -41- 00-02-0707 2013-05-22...

  • Page 50: Butterfly Full Authority (Fa) Valve Field Wiring Schematic - Lower Tier (Tall)

    Butterfly Full Authority (FA) Valve Field Wiring Schematic – Lower Tier (tall) NOTE: If system is setup for “Single Bank” operation, only the Left Bank oxygen sensor and control valve is active. Software v2010.03.15 -42- 00-02-0707 2013-05-22...

  • Page 51: Butterfly Full Authority (Fa) Valve Field Wiring Schematic - Middle Tier

    Butterfly Full Authority (FA) Valve Field Wiring Schematic – Middle Tier NOTE: Either the Magnetic Pickup or the G-Lead is used, not both NOTE: If system is setup for “Single Bank” operation, only the Left Bank oxygen sensor and control valve is active. Software v2010.03.15 -43- 00-02-0707...

  • Page 52: Butterfly Full Authority (Fa) Valve Field Wiring Schematic - Upper Tier (Short)

    Butterfly Full Authority (FA) Valve Field Wiring Schematic – Upper Tier (short) NOTE: If system is setup for “Single Bank” operation, only the Left Bank oxygen sensor and control valve is active. Software v2010.03.15 -44- 00-02-0707 2013-05-22...

  • Page 53: Start-Up And Commissioning

    Start-Up and Commissioning 1. Having installed the controller and all end devices, prepare for the commissioning by having: a. A laptop computer with the Compliance Controls software installed, and a good battery or power adapter. No other software should be running while the software is running. An open serial COM port (com 1 through 8) must be available to the controller software.
  • Page 54 pressure applied to the regulator. On turbocharged engine, the manometer will be connected to the regulator’s outlet side and the air side will be connected to the carburetor’s inlet air somewhere between the turbocharger and the carburetor air horn, refer to illustration 12. On naturally aspirated engines (non- turbo charged), there are two possible measurement styles depending on whether the regulator is equipped with a balance line between the carburetor’s air inlet and the air side of the regulator or whether the engine is equipped with a non-balanced regulator.
  • Page 55 Butterfly Valve Final Cut Regulator CARBURATOR / MIXER Ambient Air Pressure Illustration 13 – Fuel/Air Measurement – Butterfly Valve – Naturally Aspirated Engine - Non Balanced Regulator Software v2010.03.15 -47- 00-02-0707 2013-05-22...
  • Page 56 Enter the password and click OK. It is possible to accidentally login to the Rich Burn software for the AFR-64R controller. ® Make sure you use the AFR-64L password. The password can also be copied and pasted from the Windows Excel spread sheet or a basic text file that can be found in the Compliance Controls folder on the PC’s hard drive.
  • Page 57 On the PC screen, you will see something like this, depending on your screen size and resolution (the image shown if from a resolution of 1280 x 1024). Note the green box under Display_L1 that says “Connected”, and the box to the right of the Compliance Controls logo that says “Connected at 19,200 bps.
  • Page 58 If that happens, go to the troubleshooting section of this Manual. NOTE: Depending on your screen resolution, you may have to use the slider bars for up and down, or side to side to see various parts of each page, or screen. Software v2010.03.15 -50- 00-02-0707...
  • Page 59 Look down and to the right of this screen. In the cell marked “Current MOT File”. This file number should read “F” at the end of the file name. This means you have the current version of firmware. If you have an earlier revision, you will want to go to the instructions for loading the newer version.
  • Page 60 When the file has been loaded, you will get this window: Software v2010.03.15 -52- 00-02-0707 2013-05-22...
  • Page 61 Click “Done” after you see “*** Finished ***”. Software v2010.03.15 -53- 00-02-0707 2013-05-22...
  • Page 62 Next press the Page Up or Page Down key, or click the left or right arrow keys to go to Screen No. 4, the Eng_Config screen. Here you will go to the thermocouple setup, labeled in the top right box as “Exhaust Temperature Shutdowns and Alarms”, as shown below.
  • Page 63 If you are done with the thermocouple set-up, click “Yes”. All changes are now saved to the onboard memory of the controller. 10. Even if you used a CAL file, you should review all the parameters to make sure they are in agreement with the engine and the air/fuel controller kit equipment.
  • Page 64  Single Bank (One Pre Cat O2 Sensor) – Uses only the Left Bank signals  Dual Bank (Two Pre Cat O2 Sensor) – Uses both the Left and Right Bank signals RPM Input Configuration gives choices of:  Disconnected ...
  • Page 65 For the Valve Type, choose the setting “Butterfly Valve.” Next go to the box for Engine Configuration shown below. Choose the correct number of cylinders and liters displacement using the number editing window explained before. (If you are not sure of the Engine Displacement, there is a table in the back of the manual showing a list of common engines.) Engine Displacement is typically known as CID (Cubic Inches Displacement), which must be converted into Liters by dividing CID by 61.
  • Page 66 11. Also, while on this page, if Modbus communications is desired, for the UniOP, or remote monitoring, go to this part of the screen. Default setting for the ModBus communications from the controller is as seen above. These settings are appropriate for use with the optional UniOP display but may need to be modified if another device is used to monitor the controller’s operation.
  • Page 67 13. Next, press Page Up, or click the left arrow to go to Screen No. 3, Valv_Setup as shown below. 14. Prior to cranking the engine, a safe starting point for the “Valve Cranking Position” is 50%. While cranking the engine, if it seems the engine is starving for fuel and the Butterfly (FA) Valve is being used, raise the Cranking Valve Position 5.0 % at a time until it seems it is not starving for fuel.
  • Page 68 Percent Engine Load Percent Valve Position If there are two valves, do the same for the second valve. You may have to manually set the valve position in order to get the engine to full load. 16. Put an Exhaust Gas Analyzer in the exhaust. Adjust the load screw(s) on the carburetor(s) until the desired emissions levels are achieved.
  • Page 69 Software v2010.03.15 -61- 00-02-0707 2013-05-22...
  • Page 70 18. Note the Sensor Values as seen in the General Control Display window as shown below. The Sensor Value in Phi should ideally read in a range from 0.700 to 0.450 depending on the required exhaust oxygen concentration. The higher the Phi value, the lower the exhaust oxygen concentration will be.
  • Page 71 For example, what is shown starts at 3.0 psia, and has increments up to 35 psia. For the engine being controlled, make reasonable assumptions about the reasonable range of MAP. The increments do not have to be even. It is important that the maximum engine RPM and MAP setting in these tables be set above the highest possible operating ranges of the engine.
  • Page 72 Next, enter the Sensor Value reading from the General Control Display into the red highlighted cells in the Oxygen Sensor Target Table. While entering the desired values in the working cell, the values can be entered one cell at a time or multiple cells can be tagged for change.
  • Page 73 Next, you will want to save all the settings by having it “Flashed” in the controller. Without doing that, the data will be lost if power is interrupted. Click on Flash and then “Save Changes”. Once you choose to save the changes you will get the “Commit Flash” message window that cautions about flashing the memory hundreds of times.
  • Page 74 It is recommended to save your work by saving the cal file. Click on File, then Save Calibration to Disk > will give the following choices: Save Diagnostic Calibration Save Tagged Cal Variables Save User Calibration Settings Save Cal Variables from List Update Existing Cal File Choose “Save User Calibration Settings”.
  • Page 75 Make sure you have the path and folder location you want, and give the file a name. A suggestion for “File name” would be to use the unit number, engine type, and the date. File name cannot exceed 64 characters. You can now remove the Emissions Analyzer, the manometer, shut down the PC software, and unplug your PC.

  • Page 76: Initial Setup And Commissioning Outline

    Initial Setup and Commissioning Outline 1. Tools and equipment required prior to engine startup and commissioning PC with the latest Compliance Controls display software, currently version 2010.03.15. PC must have 1 open com port b. Female x Female null modem communications cable (provided with kit) Password for full access control d.
  • Page 77 Exhaust Temperature Alarm and Shutdown i. TC High Temperature Fault Action ii. TC Trip Point iii. TC Low Temperature Fault Action iv. TC Open Fault Action b. After the Exhaust Temperature parameters have been set, the changes must be “Flashed” to the EEPROM prior to continuing the setup of the controller.
  • Page 78 i. Minimum Valve Position – Set at 0% ii. Maximum Valve Position – FT/FL Valve = 85% iii. Cranking Valve Position – FT/FL Valve = application specific, typically 50% 11. Change to “Screen 2 – Set_Up_L1” 12. Start the engine. 13.
  • Page 79 An increase in the target value = Richer b. A decrease in the target value = Leaner 24. Repeat steps 23 and 24 as many times as possible to cover as much of the table’s operating range as possible. 25. Return the engine to a standard, stable load. 26.

  • Page 80: Troubleshooting, Maintenance And Replacement

    The following troubleshooting guidelines are provided for you to use when corrective action is needed. However, if you need technical assistance please contact your distributor. To find an FW MURPHY distributor in your area, please visit our web site at www.FWMurphy.com...

  • Page 81: Visual Troubleshooting And Meter Checking

    Visual Troubleshooting and Meter Checking The TCB (Terminal Connector Board) connected to the ECM has indicator LED’s (Light Emitting Diodes, or lights). They are Power, Alarm, Shutdown, and Auxiliary. The Alarm, Shutdown, and Auxiliary LED’s are connected to relays, which have Form “C”...
  • Page 82 If the Power LED is not lit, and DC power is measured with a meter at terminals 49 (Battery Input +) and 52 (Battery Input -), then check the fuses. Both fuses are used are connected parallel. Try measuring with the red probe of the volt meter at the bottom end of the fuses, the end away from the terminal blocks and the black probe of the meter at terminal 52 or 53.
  • Page 83 With the unit powered, and running, the following list of voltage ranges are normal for the terminals listed: (NOTE: All Voltages have a tolerance of measurement. These values are given as a guideline, and are not expected to be exact. These are ball park values unless specified otherwise. 0 VDC means Power Supply minus (-). The values were measured with the black probe of the meter on terminal 52.) 1.
  • Page 84 38. 0 VDC 39. Mag Pick-Up +, 0.2 1- 100 VAC rms, 8 – 10,000 Hz (10 kHz) 40. 0 – 250 VDC pulsing, G Lead for Ignition Speed Signal 41. Pulse Width Modulated 100 Hz, DC reading will vary from Power Supply Plus to near Power Supply Minus depending on duty cycle (90 % will give close to minus, and 10% will give close to plus) this is the transistor output for the PWM for the UEGO heater.
  • Page 85 See Charts for mV vs. deg. F for Type K thermocouples, VDC vs. PSIA for the MAP Sensor. Software v2010.03.15 -77- 00-02-0707 2013-05-22...

  • Page 86: Thermocouple Mv Vs. Temperature

    Thermocouple mV vs. Temperature Software v2010.03.15 -78- 00-02-0707 2013-05-22...

  • Page 87: Map Sensor Vdc Vs. Psia

    MAP Sensor VDC vs. PSIA FT Valve Position Testing Software v2010.03.15 -79- 00-02-0707 2013-05-22...
  • Page 88 At the plug connector for the FT valve, on the FT Valve side, voltage can be read to see what the valve position feedback signal is. See the diagram below to see how to connect the Multi-meter to read Volts DC. The readings will be in the range of 0 –...

  • Page 89: Ft Valve Position Feedback Vs. Driven Position

    FT Valve Position Feedback vs. Driven Position Software v2010.03.15 -81- 00-02-0707 2013-05-22...

  • Page 90: Troubleshooting Action Steps

    Troubleshooting Action Steps When values are read at the terminal block different than what was listed, follow these steps: 1. Disconnect the wiring at the TCB for the trouble points. 2. Disconnect the device at the other end of the wires. 3.
  • Page 91 The Ohms between Heater + and Heater – should be approximately 7. 3. Magnetic Pick-up 1000 Ohms 4. MAP Sensor with the plug connector at the top, and the red meter probe always on the left, Left to Center 5.46 k Ohms Center to Right 9.59 k Ohms Left to Right...

  • Page 92: Troubleshooting Communications With The Pc

    Troubleshooting Communications with the PC If the PC will not communicate with the controller, there are several things to check. 1. Check the Com Port settings in the software. The choices are: Automatic, COM1, COM2, COM3, COM4, COM5, COM6, COM7, or COM8 Usually Automatic will work fine.
  • Page 93 Pin 9 Pin 9 4. Make sure no other software “owns” the COM port. You may have to disable or uninstall the conflicting software. Software v2010.03.15 -85- 00-02-0707 2013-05-22...
  • Page 94 5. If you click on “COM Port”, then “Show Stats”, you will get this window shown below. Software v2010.03.15 -86- 00-02-0707 2013-05-22...

  • Page 95: Loading A Mot File

    Loading a MOT file To reload the controller’s operating software (MOT file), follow these steps: 1) Insure that the engine is shutdown and controller is powered up. 2) Start the “Display Software” on your PC. 3) Click on the “File” pull down menu at the top left hand side of the screen (on any screen) 4) Click on the “Reprogram Target”...

  • Page 96: Plot Example

    When saving plots, only the data displayed on the screen at the time when the “Save” button is pressed will be saved. To save the plot, follow these steps: 1) Press the “SAVE” button 2) Choose a file name and a file location. 3) Press the save button at the bottom right hand side of the screen.
  • Page 97 Software v2010.03.15 -89- 00-02-0707 2013-05-22...

  • Page 98: Maintenance

    Excessive engine oil consumption can also cause these effects over longer periods of time. The AFR-64L system will relieve the operator of constant carburetor tuning for emissions compliance, but consistent engine maintenance is still required.

  • Page 99: Troubleshooting Guide

    Troubleshooting Guide Problem/Fault Trigger Point Possible Cause Correction MAP High Pressure MAP Pressure greater than 42 Faulty MAP sensor Replace MAP sensor psia - Disables Adaptive Learn Wiring harness shorted Replace harness MAP sensor connected to port Move connection to intake other than intake manifold manifold Shorted connection on TCB...
  • Page 100 Problem/Fault Trigger Point Possible Cause Correction MAT voltage less than 0.050 Incorrect MEC-R MOT file Reload most recent MEC-R MAT Low Voltage volts DC - Disables Adaptive loaded MOT file Learn MOT file corrupted Reload most recent MEC-R MOT file MAT Temperature exceeds 150 Incorrect MEC-R MOT file Reload most recent MEC-R...
  • Page 101 Problem/Fault Trigger Point Possible Cause Correction 5VE Low Voltage 5 volt extermal voltage supply Faulty ECM control module Replace controller less than 4.6 volts DC - Disables MOT file corrupted Reload most recent MEC-R Adaptive Learn MOT file Observed engine speed greater Pulses per revolution set Adjust pulses per revolution Fuel Rev Limit...
  • Page 102 Problem/Fault Trigger Point Possible Cause Correction UEGO Heater Supply High HEGO sensor heater supply HEGO sensor failure Replace faulty HEGO sensor heater voltage persistanty high MOT file corrupted Reload most recent MEC-R Voltage MOT file Faulty TCB Replace TCB Faulty ECM controller Replace ECM controller UEGO Heater Supply Low HEGO sensor heater supply...

  • Page 103: Pc Display Screen Description

    PC Display Screen Description Display Screen (Screen No. 1) On the “Display Screen (Screen No. 1)”, all engine operating parameters monitored by the controller and all of the controller’s operational parameters can be seen. Software v2010.03.15 -95- 00-02-0707 2013-05-22...

  • Page 104: Engine Operating Parameters Group

    Engine Operating Parameters Group Engine Speed – Actual engine speed. Expressed in Revolutions Per Minute (RPM). MAP – Intake Manifold Absolute Pressure. Expressed in Pounds per Square Inch Absolute (PSIA). MAT – Intake Manifold Air Temperature. Expressed in degrees Fahrenheit Run Mode - Indicates the mode of operation of the engine as determined by the engine speed input.

  • Page 105: General Control Display Group

    General Control Display Group Control Mode – Indicates the operating mode of the controller.  Open Loop – The control system has not yet met all of the requirements to go into Closed Loop. In this mode no input from the UEGO sensors are required for operation. The controller only operates at predetermined valve positions.
  • Page 106 Sensor Target – These are the Phi values used by the controller to drive the engine air/fuel ratio to a desired point. Valve Position – These are the actual fuel valve position expressed as a percent open: 0% being fully closed and 85% being fully open.

  • Page 107: Fault Display Group

    Fault Display Group Active Fault Box – (Left) In this box all current faults are displayed. Once the fault clears itself, the fault is removed from this box. Only Current or Active faults are displayed. A list of Faults and possible causes can be found in Chapter 11 – “Troubleshooting and Maintenance”.

  • Page 108: Software And Hardware Group

    In this group all information about the controller hardware and the installed software appear. Current MOT File – Indicates which software (MOT file) is currently loaded onto controller. At this time all, AFR-64L controllers are shipped with a MOT file number 1587400 followed by a revision letter such as “F” and dated, 4-16- 2010.

  • Page 109: Set-Up Screen (Screen No. 2)

    SET-UP SCREEN (Screen No. 2) Software v2010.03.15 -101- 00-02-0707 2013-05-22...
  • Page 110 From the “SETUP” Screen (Screen No. 2), all of the controller’s targeting parameters can be set, as well as monitoring of the engine’s real time operating parameters. This screen’s main purpose is for the setup and fine adjustment of the controller. This screen is divided into four main groups: Engine Monitoring, General Control Display, Oxygen Sensor Feedback Control and Valve Control.

  • Page 111: Engine Monitoring Group

    Engine Monitoring Group Run Mode – Indicates the mode of operation of the engine as determined by the engine speed input. Three operating modes are seen though out the operation of the controller from engine start to engine shutdown:  STOP – any engine speed below 25 RPM; ...
  • Page 112 Manifold Air Temperature – Intake Manifold Air Temperature (MAT) – Expressed in degrees Fahrenheit (°F) TC1 Temperature – The actual exhaust gas temperature. Expressed as Degrees Fahrenheit (F). TC2 Temperature – The actual exhaust gas temperature. Expressed as Degrees Fahrenheit (F). Alarm and Shut Down Indicator Lamps –...

  • Page 113: General Controls Display Group

    General Controls Display Group Control Mode – Indicates the operating mode of the controller. In this cell there are four (4) possible operating modes:  Open Loop – The control system has not yet met all of the requirements to go into Closed Loop. In this mode no input from the UEGO sensors are required for operation.
  • Page 114 Sensor Average – These values are calculated rolling averages of the Sensor Values and are used by the controller drive the engine to the appropriate air/fuel ratio. Sensor Target – These are the Phi values used by the controller to drive the engine air/fuel ratio to a desired point.

  • Page 115: Oxygen Sensor Feedback Control Group

    Oxygen Sensor Feedback Control Group Manually Force Into Open Loop – In this pull down menu there are two choices for operation.  On – This setting forces the controller into Open Loop operation regardless of load point (effectively disabling oxygen sensor closed loop feedback). ...
  • Page 116  None – Indicates that there is no cause for the Closed Loop to be inactive. At this point the controller is in automatic operation. Oxygen Sensor Target Table – In this group, the user defines the control target for the Left and Right Banks.

  • Page 117: Valve Control Group

    Closed Loop Cells – The remaining cells to the right of the Speed Cells and below the MAP Cells are the Open Loop Cells. These cell ranges will need to be defined by the user during the system setup according to the desired open loop position at varying loads and speeds. Valve Control Group Valve Control Mode –...

  • Page 118: Valve Set-Up (Screen No. 3)

    RPM. This value is typically between 10 to 85%, depending on the amount of fuel needed to start the engine. Valve Set-Up (Screen No. 3) From the “VALVE SET-UP” screen (screen no. 3), the controller gains are adjusted and the fuel control valves are matched to the engine.

  • Page 119: Gain Setting Group

    Gain Setting Group Valve Reaction Gain – This gain setting adjusts the time that the valve(s) reacts to the error between the sensor reading and the sensor targets. The factory default is sufficient for most applications. Setting this value lower slows down the response rate of the controller (and setting higher speeds it up).

  • Page 120: Valve Control

    Valve Control Valve Control Mode – In this pull down menu there are two (2) modes of valve operation:  Auto – In this mode the controller is in control of the operation of the valves and determines their positions according to the desired UEGO sensor target. ...

  • Page 121: Open Loop/Default Valve Position Group

    Minimum Valve Position - This is a user defined field. In this cell, the minimum closing position of the valve is defined. With all valve types, it is recommended to set this position at 0% to allow the controller have the widest possible control range. Cranking Position –...
  • Page 122  Nominal Valve Position - These cells are used as a reference as to the calculated nominal valve position of the controller during normal operation. This is the valve position that the system would default to in the event of a UEGO sensor failure. During normal operation, this position should be as close as possible to the actual valve position.

  • Page 123: Engine Configuration (Screen No. 4)

    Engine Configuration (Screen No. 4) From the “ENGINE CONFIGURATION” screen (screen 4), the controller is configured for the particular engine that it has been installed on as well as the exhaust temperature shutdown and alarm functions. This screen’s main purpose is for the matching of the controller to the engine.
  • Page 124 Engine Bank Configuration – In this pull down menu, the number of valves and UEGO sensors needed are determined  Single Bank (One Pre Cat O2 Sensor) – Designed for inline engines or “V” Bank design engines using a common exhaust manifold or a common intake manifold. This mode allow for the use of one (1) pre catalyst UEGO sensor and one (1) fuel control valve output.
  • Page 125 This option should only be used when advised by a FW Murphy service technician.  Discrete – +V = Running – Not currently activated. This feature is designated for future application expansion of the controller.

  • Page 126: Exhaust Temperature Shutdown & Alarm Group

    Pulses Per Revolution – In this cell the number of pulses per revolution are entered. If a Magnetic Pickup is used, this is the number of teeth on the flywheel ring gear. If a G-Lead is used this number is typically ½ of the total number of cylinders of the engine. See the Appendix –...
  • Page 127  Alarm Relay – The controller sets an alarm on the fault screens and the Alarm/Fault relay is activated.  Shutdown Relay - The controller sets an alarm on the fault screens and activates the Shutdown relay. TC Trip Point - “When the Thermocouple Temperature is greater than” – In these cells the thermocouple high temperature trip points are set.

  • Page 128: Valve Selection Group

     TK Valve or ICV Valve – not used with the AFR-64L  Butterfly Valve – This is the valve used for the AFR-64L controller and therefore the correct setting. It is a full authority type control valve and thus enables the controller to manipulate all of the fuel to the engine.
  • Page 129 In this group, the controller is matched to the engine. This information is vital to the proper operation of the controller. This data is used by the controller to calculate load points during its operation and should be as accurate as possible. Number of cylinders –...

  • Page 130: Modbus Rs-485 System Configuration Group

    ModBus RS-485 System Configuration Group This group is divided into 5 basic sections and is used to define the communication type and control to an outside communication device. On this screen the communication capabilities of the controller are enabled, disabled and monitored.

  • Page 131: Appendix

    Appendix Terms and Definitions Atmospheric (pressure), 14.7 psia at sea level (29.92 inches mercury, 1.01 bar) C Degrees Celsius/Centigrade  Closed Loop (CL) Control using feedback signals from the controlled parameters A DB9 (RS232) communication port, mounted on the “Interface Module”, used COM Port for communication and controller setup via a PC computer.
  • Page 132 F Degrees Fahrenheit  Fault Indicates a system malfunction. Also known as Alarm. Faults will not shutdown the engine, unless configured to do so. Gain A percentage of a predetermined time frame in which the controller sees a change until the time it reacts to the change G-Lead Ignition pulse output signal (high voltage) used to measure engine speed UEGO Sensor...
  • Page 133 Manifold Absolute Temperature sensor. Used to monitor the intake manifold temperature over a wide temperature range. Magnetic Pickup – speed sensor Open Loop Control without feedback from any controlled parameters Personal Computer Printed Circuit Board A measurement of excess fuel in the exhaust stream. Phi is the inverse of Phi () Lambda (1/lambda).
  • Page 134 Status Module A user interface module that only incorporates 3 status lights (power, alarm & shutdown) Stereo Separate fuel systems for each bank of cylinders including intake manifolds, throttles, and carburetors on a multi-bank engine. A chemically balanced mixture (all reactants are mutually consumed) – in the Stoichiometric case of an engine air/fuel ratio mixture, just enough air to theoretically burn all of the fuel...

  • Page 135: System Specification

    System Specification System Power Specifications (dependent on number of end devices) Steady State Steady State Device @ 24V DC (amps) @ 12V DC (amps) UNIOP Display 0.25 0.50 (when used with optional 12 to 24V DC converter for 12 volt operation) 0.15 0.15 Oxygen Sensor (each)
  • Page 136 Valve Sizes Fuel Piping Sizes 25mm Up to 1” NPT 50mm Up to 2“ NPT Supply Power 10 - 32 volts DC Signal Power 0 - 32 volts DC (application specific) Signal Pulse Width Modulated (PWM) Full Authority (FT) Valve Valve Sizes Fuel Piping Sizes 33mm...
  • Page 137 INPUTS UEGO Sensor (Heated Zirconia Oxygen Sensor) Voltage 0.0 to 1.0 volts DC (sensor generated) Ambient Temperature 500 F (260C) shell temperature maximum Operating Temperature 660 to1350 F (349F to 733C) sensor tip Heater Circuit 1 amp maximum MAP Sensor Input Power 0-5 volts DC Pressure Range 0-3 bar absolute 0-43.5 pounds per square inch absolute...

  • Page 138: Notes, Warnings & Precautions

    4 amps at 30 volts UniOP Display Power Supply 24 VDC with optional 12 to 24V DC converter for 12 volt operation Power Consumption 0.25 amps maximum @ 24V (0.50 amps with 12 to 24V converter) Text Display 4 Line x 20 Character per line Environmental Operating Temperature -4...
  • Page 139  If the installer is unfamiliar or unable to complete any of the installation requirements listed above, contact your FW MURPHY distributor for information on qualified installers. See Chapter 12 – Product Support for contact information.
  • Page 140 WARNINGS & PRECAUTIONS  To avoid damage to the Full Authority valve, the butterfly plate should never be removed.  To avoid damage to the ECM and circuit board, these items should be removed from the enclosure before any welding is performed on the engine skid or attached equipment. The ECM is attached to a mounting plate for easy removal and re-installation.
  • Page 141  The controller’s fuel control valves are not designed as a positive sealing valve. These fuel control valves should be installed downstream of a fuel shut off device to prevent fuel gas leaks while the engine is not running!  The UEGO sensor maximum shell temperature (melt down point) is 500F (260C). These sensors should never be installed in areas where the ambient air is stagnant and/or where the ambient air conditions exceed 250F (121C).

  • Page 142: Psia Vs. Intake Manifold Pressure In Inches Of Mercury

    PSIA vs. Intake Manifold Pressure in Inches of Mercury Software v2010.03.15 -134- 00-02-0707 2013-05-22...

  • Page 143: Installation Layouts Examples

    Installation Layouts Examples AFR-ND-L-64L-11-FA## (Single Bank, High Pressure Carburetor, Full Authority Valve) Software v2010.03.15 -135- 00-02-0707 2013-05-22...

  • Page 144: Afr-Nd-L-64L-11-Fa## (Single Bank, High Pressure Carburetor, Full Authority Valve)

    AFR-ND-L-64L-11-FA## (Single Bank, High Pressure Carburetor, Full Authority Valve) Software v2010.03.15 -136- 00-02-0707 2013-05-22...

  • Page 145: Afr-Nd-L-64L-22-Fa## (Dual Bank, High Pressure Carburetor, Full Authority Valve)

    AFR-ND-L-64L-22-FA## (Dual Bank, High Pressure Carburetor, Full Authority Valve) Software v2010.03.15 -137- 00-02-0707 2013-05-22...

  • Page 146: Afr-Nd-L-64L-22-Fa## (Dual Bank, Low Pressure Carburetor, Full Authority Valve)

    AFR-ND-L-64L-22-FA## (Dual Bank, Low Pressure Carburetor, Full Authority Valve) Software v2010.03.15 -138- 00-02-0707 2013-05-22...
  • Page 147 AFR-ND-L-64L-22-FA## (Dual Bank, High Pressure Carburetor, Common Exhaust Manifold Full Authority Valve) Software v2010.03.15 -139- 00-02-0707 2013-05-22...
  • Page 148 AFR-ND-L-64L-11-FA## (Dual Bank, High Pressure Carburetor, Common Intake Manifold Full Authority Valve) (Cat 3500 series) Software v2010.03.15 -140- 00-02-0707 2013-05-22...
  • Page 149 Engine Data Engine Number of Displacement Flywheel Engine Manufacture Model Cylinders Liters Tooth Count Caterpillar G3304 Caterpillar G3306 10.5 Caterpillar G3406 13.4 Caterpillar `G3408 17.9 Caterpillar G3412 26.9 Caterpillar G3508 33.7 Caterpillar G3512 50.5 Caterpillar G3516 67.4 Caterpillar G342 20.4 Caterpillar G379 32.2...
  • Page 150 Waukesha F817 13.4 Waukesha F1197 19.6 Waukesha 11.0 Waukesha 18.0 Waukesha 24.0 Waukesha 36.0 Waukesha 48.0 Waukesha F1905 31.2 Waukesha F2895 47.5 Waukesha F3521 57.7 Waukesha H2475 40.6 Waukesha L3711 60.8 Waukesha L5108 83.7 Waukesha L5790 94.9 Waukesha L7042 115.4 Waukesha P9390 153.9...
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