Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for GAC AFR200 Series
Summary of Contents for GAC AFR200 Series
- Page 1 NGINE AFR200 Series OVERNING Air Fuel Ratio Controller YSTEMS PRODUCT USER GUIDE Governors America Corp., 720 Silver Street, Agawam, MA 01001 Tel: 413.786.5600, Fax: 413.789.7736 info@governors-america.com www.governors-america.com...
- Page 2 AFR200 Series, Product User Guide This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved...
-
Page 3: Table Of Contents
Application Considerations ....................... 21 6.2.2 Installation Procedure ........................21 This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved... - Page 4 11 Symptom Troubleshooting ..................... 46 12 Specifications ........................47 This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved...
-
Page 5: Introduction
Easy configuration and customization using GAC’s SmartVU software The system is applicable to a wide range of gaseous fueled engines ranging from 1L to 13L+. The AFR200 series controllers when used in conjunction with the ICM200 (Ignition Control Module) series offers a complete Fuel and Ignition Management Solution (FIMS) referred to as the FIMS500 system. -
Page 6: Product Variations
Starting Fuel Control for Lower Engine Exhaust Emissions • Full PID Adjustment Capability This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved... - Page 7 Diagnostic Timers and Logging Windows • 12 and 24VDC Compatible • High Reliability This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved...
-
Page 8: Operational Description
3.1 Overview The AFR’s fuel control algorithm maintains a stoichiometric air-fuel ratio for optimized emissions and engine performance. Engine speed can be governed in either isochronous or droop modes using GAC’s proprietary Electronic Digital Governor (EDG) algorithm. The AFR control operates the closed loop fuel system with five major components: •... -
Page 9: Engine Speed Sensor
The three fixed governed speeds and one variable governed speed are all selectable through two discrete inputs. An additional accessory input is available for connecting to GAC load sharing modules (generator set option). -
Page 10: Communication & Configuration
LEDs on the AFR itself. For more detailed diagnostics the SmartVU diagnostic interface provides a host of information including engine data, speed vs. load mapping and OBDII P-codes and GAC G-codes. This information is covered in greater detail in later sections. -
Page 11: Exhaust Gas Temperature (Egt) Sensor
This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved... -
Page 12: System Interconnect Diagram
AFR200 Series, Product User Guide 4 System Interconnect Diagram This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved... - Page 13 AFR200 Series, Product User Guide This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved...
-
Page 14: Afr Components And Optional Equipment
See information provided under Engine Sensor Magnetic Speed Sensors Numerous Installation & Information This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved... -
Page 15: Component Selection Information
5.2.1 GAC Actuator Throttle Bodies GAC has developed a matrix to help identify the correct bore size for a throttle body. The information needed to determine the sizing is the engine displacement as well as the operating RPM. When selecting the bore size ensure that the choice made offers some leeway both upward and downward to provide margin. -
Page 16: Air-Fuel Mixer / Control Valve Assembly
The actual application may dictate a different pairing. In some cases, there are more than one possible choice of mixer for a given throttle body. Contact your GAC representative for confirmation on mixer sizing prior to ordering. -
Page 17: Zero Pressure Gas Regulator
5.2.6 Engine Sensors Although each of the sensors offered by GAC has been fully validated and approved for use with the AFR system there is always the option of using an alternate supplier as long as the sensor is equivalent in electrical characteristics. - Page 18 Locking Shaft TP511 TP509 Knob Included TP508 Locking Shaft This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved...
-
Page 19: Component Information & Installation
Identification Sticker AFR Dimensions Dimensions shown as in. [mm] This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved... -
Page 20: Application Considerations
Ensure that each of the mounting bolts / screws is torqued evenly and gradually. This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved... -
Page 21: Gac Actuator Throttle Body (Atb)
6.2 GAC Actuator Throttle Body (ATB) A representation of the GAC Actuator Throttle Body (ATB) is shown in the following figure. The GAC part identification sticker is located on the top of the assembly for reference. The ATB is selected using the ATB Application Matrix which utilizes the displacement of the engine and the desired operating RPM detailed previously. -
Page 22: Air-Fuel Mixer & Control Valve Assembly
The mixer and control valve comes as one combined assembly from GAC for a simplified installation. A picture of a mixer / valve assembly mounted on top of an ATB is shown in the following figure. - Page 23 Top View of Medium Bore Mixer ATB Butterfly Valve The dimensions of the various mixers available for GAC ATB’s are shown in the following figures. Refer to the mixer selection guide to determine which mixer / control valve was selected.
-
Page 24: Application Considerations
This implies it is installed separately from the ATB. This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D... -
Page 25: Installation Instructions
ATB for a naturally aspirated engine is shown in the following figure. This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved... -
Page 26: Application Considerations
Use the dimensions provided in the following figure to determine a suitable location that will not be obstructed or prone to damage by other components. This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved... -
Page 27: Installation Instructions
If using barbed fittings use properly sized, high-quality hose clamps in pairs. This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved... -
Page 28: Electronic Gas Lockout Valve
Typical Electronic Gas Lockout Valve 6.5.1 Application Considerations • GAC recommends the installation of an electronic gas lockout (shutoff) valve for added safety. • The installation must comply with all local and government regulations and safety codes. •... -
Page 29: Application Considerations
Refer to the manufacturer’s guidelines for installation and application information. This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved... -
Page 30: Engine Sensor Information & Installation
Sensors which can be found at the following location: • http://www.governors-america.com/magnetic_speed_sensors.html GAC offers various lengths, electrical connections, and both US and metric threads for the speed sensors. The following is a picture of a typical variable reluctance magnetic engine speed pickup offered by GAC. Magnetic Speed Pickup 7.1.1 Application Considerations... -
Page 31: Manifold Absolute Pressure Sensor (Map)
7.2 Manifold Absolute Pressure Sensor (MAP) The Manifold Absolute Pressure sensor from GAC is available in three different pressure ranges (1, 2, or 3 Bar; 14.5, 29, or 43.5 PSI) supporting up to 30 psig of boost as detailed in the parts list section. Typically, naturally aspirated engines use the 1 bar model. -
Page 32: Installation Instructions
An internal heater element (12V only) allows the sensor to reach its activation temperature quickly for accurate measurements. Depending on the configuration selected you will have one (pre-catalytic converter) or two (pre- and post-catalytic converter) sensors. A representation of the GAC narrow-band oxygen sensors are shown in the following figure. -
Page 33: Application Considerations
The SOX 102 sensor is provided with a 1/4” barbed fender plug in order to secure the electrical connection point. This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved... -
Page 34: Installation Instructions
7.4 Engine Coolant Temperature Sensor (ECT) The engine coolant temperature sensor is an optional sensor provided from GAC. The coolant temperature sensor is monitored by the AFR for engine protection in the event of an engine over temperature situation. These limits can be calibrated within the AFR controller using SmartVU. -
Page 35: Installation Instructions
7.5 Engine Oil Pressure Sensor (EOP) The engine oil pressure sensor is an optional sensor available from GAC. The engine oil pressure sensor is monitored by the AFR for engine protection in the event of a low oil pressure condition during operation. These limits can be calibrated within the AFR controller using SmartVU. -
Page 36: Installation Instructions
7.6 Exhaust Gas Temperature Sensor (EGT) The exhaust gas temperature sensor is an optional sensor available from GAC. The engine exhaust temperature sensor is monitored by the AFR for engine protection in the event of a high exhaust temperature condition during operation. -
Page 37: Application Considerations
3. Once complete, turn the sensor 2 full turns past finger tight. This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved... -
Page 38: Electrical Connections
16 AWG Battery 12/24 Volt DC Battery Power 16 AWG This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved... - Page 39 O2 Sensor 2 Ground Oxygen Sensor 2 Ground 18 AWG This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved...
-
Page 40: Afr Wiring Diagram
AFR controller and uses both connectors J1 and J2) This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved... -
Page 41: System Interface Information
Two communications ports are available on the AFR: RS232 / Modbus and CAN / J1939. 8.3.4.1 RS232 / Modbus The RS232 inputs are used to configure the AFR using GAC’s SmartVU software. A DB9-F is the standard mating connector for diagnostic information for GAC products. -
Page 42: Fuel Valve (Stepper Motor) Control Output
Pin A Pin B Pin C Pin D Extend Retract This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved... -
Page 43: Afr Configuration & Calibration Procedure
This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved... -
Page 44: Fault / Warning Blink Codes
The AFR stores a chronological list of accumulated trouble codes. The AFR communicates malfunctions through this part of the interface with OBDII P-codes and GAC G-codes. The P-codes relay engine and sensor malfunctions as well as decreases in system performance. These issues may cause poor fuel consumption and excessive emissions output as well as potential engine failure. - Page 45 Engine Oil Pressure Sensor Circuit Low Voltage P0523 Engine Oil Pressure Sensor Circuit High Voltage The following table provides the GAC supported G-codes which are available for troubleshooting while using SmartVU. These G-codes are GAC specific fault codes available for view with SmartVU. AFR supported G-Codes...
-
Page 46: Symptom Troubleshooting
In most cases it is best to decrease the flow of the regulator to its minimum and increase the flow while cranking until the engine starts. This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved... -
Page 47: Specifications
*Maximum RPM is based on the Flywheel Teeth. RPM = Frequency x 60 / Flywheel Teeth. Maximum Frequency is 10,000 Hz. This document is subject to change without notice. Caution: None of GAC products are flight certified controls including this item PUG4144 D Copyright © 2010, Governors America Corp., All Rights Reserved...
Need help?
Do you have a question about the AFR200 Series and is the answer not in the manual?
Questions and answers