GAC AFR200 Series Product User Manual Download Page 1

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NGINE

OVERNING

YSTEMS

AFR200 Series

Air Fuel Ratio Controller

Governors America Corp., 720 Silver Street, Agawam, MA 01001

Tel: 413.786.5600, Fax: 413.789.7736

[email protected]

www.governors-america.com

PRODUCT USER GUIDE

Summary of Contents for AFR200 Series

Page 1: ...NG SYSTEMS AFR200 Series Air Fuel Ratio Controller 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 PRODU...

Page 2: ...oduct User Guide This document is subject to change without notice Caution None of GAC products are flight certified controls including this item Copyright 2010 Governors America Corp All Rights Reser...

Page 3: ...6 Optional Sensors 10 3 6 1 Post Catalytic Oxygen O2 Sensor 10 3 6 2 Engine Oil Pressure EOP Sensor 10 3 6 3 Engine Coolant Temperature ECT Sensor 10 3 6 4 Exhaust Gas Temperature EGT Sensor 11 3 7 Bi...

Page 4: ...llation Instructions 32 7 3 Exhaust Oxygen Sensor 32 7 3 1 Application Considerations 33 7 3 2 Installation Instructions 34 7 4 Engine Coolant Temperature Sensor ECT 34 7 4 1 Application Consideration...

Page 5: ...to as the FIMS500 system Each of these controllers has the ability to work independently of the other in the event of a failure The AFR200 series controller is ruggedly designed to be used in a wide v...

Page 6: ...selected as one for pre catalytic converter or no converter or two pre and post catalytic if additional diagnostic capability is desired for the catalytic converter itself Exhaust Temperature Input T...

Page 7: ...c Speed Pickup Exhaust Gas Temperature Sensor Type K Thermocouple Oil Pressure Sensor Coolant Temperature Sensor Inputs and Outputs Power Relay Output 2A Malfunction Indicator Lamp MIL Output Status L...

Page 8: ...c Converter Oxygen O2 Sensor The AFR uses a narrow band oxygen sensor located after the merge point in the exhaust manifold plumbing and before any exhaust conditioners This sensor output is between 0...

Page 9: ...for lower engine exhaust emissions The three fixed governed speeds and one variable governed speed are all selectable through two discrete inputs An additional accessory input is available for connec...

Page 10: ...certain variations of the AFR whereas the engine oil pressure and coolant temperature sensor inputs are available with all variations 3 6 1 Post Catalytic Oxygen O2 Sensor An additional narrow band st...

Page 11: ...side binary output for control of the power relay The power relay is used to provide power to the oxygen sensor heaters as well as control the shutdown of the engine This information is detailed grea...

Page 12: ...e This document is subject to change without notice Caution None of GAC products are flight certified controls including this item Copyright 2010 Governors America Corp All Rights Reserved 12 PUG4144...

Page 13: ...oduct User Guide This document is subject to change without notice Caution None of GAC products are flight certified controls including this item Copyright 2010 Governors America Corp All Rights Reser...

Page 14: ...egrated stepper motor control valve Stepper Motor Mating Connector EC1507 4 pin Delphi Mating Connector for Fuel Control Valve Stepper Motor Zero Pressure Gas Regulators RPR101 With 3 4 NPT Fittings R...

Page 15: ...cting the bore size ensure that the choice made offers some leeway both upward and downward to provide margin For GAC provided actuator throttle bodies refer to the following link to the ATB Applicati...

Page 16: ...at Size mm 45mm 55mm 65mm MXMB40 1 25 31 75 X MXMB42 1 3125 33 34 X X MXMB44 1 375 34 93 X X MXMB46 1 4375 36 51 X X MXMB48 1 5 38 10 X X MXMB50 1 5625 39 69 X Important Note The information provided...

Page 17: ...ation in the Component Information and Installation section for further information on selecting the correct electronic gas lockout valve 5 2 5 Air Filtration This is a non GAC provided item Refer to...

Page 18: ...fied controls including this item Copyright 2010 Governors America Corp All Rights Reserved 18 PUG4144 D Speed Trim Potentiometers GAC Part Number Turns Resistance Features TP510 10 1k TP501 1 5k Knob...

Page 19: ...ealed and has a wide operating temperature range allowing it to be mounted directly to the engine on a flat plate in an area that does not exceed the unit s environmental specifications A picture of t...

Page 20: ...visible for diagnostic and troubleshooting purposes Mount the AFR so that the connectors are not facing upward in order to avoid possible water intrusion Select a flat surface or bracket for mounting...

Page 21: ...take components and the air fuel mixer valve assembly using the provided dimensions Select the mounting bolts using the dimensions provided to ensure the length and diameter are appropriate Turbo char...

Page 22: ...ing the actuator assembly ensure the flow indication arrow is pointing toward the engine intake as indicated in the following figure 4 Torque the mounting bolts down to 9 14 lb in 1 1 6 N m Take cauti...

Page 23: ...e shows a top view of the air fuel mixer Take note of the butterfly valve of the ATB as indicated by the callout Top View of Medium Bore Mixer The dimensions of the various mixers available for GAC AT...

Page 24: ...el inlet is horizontally aligned in order to eliminate any effects of gravity on the flow of fuel Ensure there is adequate clearance above and around the mixer valve assembly using the provided dimens...

Page 25: ...ve assembly is covered in following sections 6 3 2 2 Turbocharged Engines 1 Clean the mounting area to the flange of the turbocharger inlet or adapter as well as the air filter connection from debris...

Page 26: ...omply with all local and government regulations and safety codes The gas regulator MUST be installed with the adjustment post pointing upward and the regulator body extended horizontally in order to g...

Page 27: ...and the pressure regulator using pipe unions or barbed fittings into the fuel inlet port for the air fuel mixer assembly Use an approved pipe thread sealant to ensure the connection is leak proof If b...

Page 28: ...being under fueled at startup then increase fuel regulator flow If the engine is over fueled at startup then decrease flow In most cases it is best to decrease the flow of the regulator to its minimum...

Page 29: ...er Direct Filter Connection to Mixer Intake 6 6 1 Application Considerations Running an engine without an air filter is not recommended due to contamination of the mixture or and engine back fire Sele...

Page 30: ...ation If this is the case determine the appropriate thread dimension US or metric and length sensor required If there is no pre drilled hole exists then drilling and tapping a hole or fabricating a br...

Page 31: ...fication 7 2 1 Application Considerations The MAP sensor is not required in the event that the multiple PID functionality is not needed This implies that the Governor PID Fuel PI Valve Position and O2...

Page 32: ...anifold which should a 6 4mm 0 25 in barb fitting Install a section of hose from the intake manifold to the MAP sensor Ensure the vacuum hose is positioned and cut to the appropriate length to avoid k...

Page 33: ...12 60 in 320mm Wire Length 13 80 in 350 5mm For the primary oxygen sensor the sensor should be located in the engine exhaust outlet as close to the merge of all cylinders as possible but prior to the...

Page 34: ...er jacket prior to the thermostat The sensor is ideally installed in a coolant passage on the engine block since this location represents engine temperature most accurately The sensor is mounted via a...

Page 35: ...The required electrical connections to the sensor are a pair of 1 4 female insulated quick connect terminals Connect the signal and ground terminals accordingly 6 Refill the engine cooling system for...

Page 36: ...hen installing the sensor 3 Once complete torque the sensor to a maximum of 30 N m using a 17mm wrench 4 The electrical connection points are M4 knurled nuts and the electrical connectors required are...

Page 37: ...ell within the outlet exhaust flow The sensor is mounted via a 1 8 in NPT fitting as shown in the following figure Drill and tap the determined mounting location using the provided dimensions Exhaust...

Page 38: ...sor 1 Ground 18 AWG 12 Mag Pickup Ground Magnetic Speed Pickup Sensor Ground 18 AWG 13 RS232 Transmit RS232 Communication Port 20 AWG 14 Not Used Not Used N A 15 Not Used Not Used N A 16 Not Used Not...

Page 39: ...f the AFR except the AFR200 and AFR210 Description Comment Gauge 1 Not Used Not Used N A 2 Not Used Not Used N A 3 Not Used Not Used N A 4 O2 Sensor 2 Oxygen Sensor 2 0 1V Analog Input 18 AWG 5 Not Us...

Page 40: ...ghts Reserved 40 PUG4144 D 8 2 AFR Wiring Diagram The following figure is a system wiring diagram which details the basic system schematic and mating connector representations for a typical applicatio...

Page 41: ...ions allow the user to select between the 3 fixed speed settings or the variable speed setting This is accomplished by tying the inputs to ground or leaving them open The variable speed setting requir...

Page 42: ...20 resistor at the other end of the trunk for a total parallel resistance of 60 8 3 5 Fuel Valve Stepper Motor Control Output The fuel valve used by the AFR is a high resolution bipolar stepper motor...

Page 43: ...cs 10 1 AFR Indication LEDs The AFR has 3 LEDs for determining the status of the unit The following figure identifies the three LEDs as the top red LED is the fault indicator the middle red LED is the...

Page 44: ...te Pressure Circuit High Input 10 Exhaust Gas Temperature Too High 10 3 Diagnostic Information The AFR diagnostics features both run timers and fault code s readout 10 3 1 Timers The Timers window log...

Page 45: ...agnostic Logging has been cleared G9007 Post O2 is Switching G9008 Post O2 Voltage is too low G9009 Advanced Stepper Control Enable G9010 Advanced Stepper Control Disable G9011 Advanced Limit Enable G...

Page 46: ...ation a Verify proper settings in SmartVU b Verify actuator duty cycle in SmartVU c Measure voltage to actuator d Check connections and wiring to actuator 4 Verify proper fuel valve operation a Verify...

Page 47: ...ERS Supply 12 24 VDC Battery Systems 6 5 to 33VDC Flywheel Teeth 50 250 Polarity Negative Ground Case Isolated Gain Stability Multiplier 1 100 Power Consumption 100mA Max Continuous plus Actuator Step...

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