FW Murphy AFR-64L User manual

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Section 40
AFR-64L
Lean Burn Air/Fuel Ratio Controller
Installation and Operations Manual
Please read manual for hazard and safety advisement.

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
document.

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Table of Contents
SAFETY................................................................................................................................................................................. 1
INTRODUCTION ...................................................................................................................................................................... 3
PARTS AND SUPPLIES............................................................................................................................................................... 5
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## –Full Authority Valve (Dual O2 Sensor –Dual Fuel Valve) ....................................................................................9
Spare/ Loose Parts....................................................................................................................................................................................11
PARTS IDENTIFICATION .......................................................................................................................................................... 13
INSTALLATION...................................................................................................................................................................... 19
Installation Checklist.................................................................................................................................................................................19
Safeguarding Electronics ..........................................................................................................................................................................21
MATCHING THE KIT TO THE APPLICATION AND PARTS VERIFICATION ................................................................................................ 22
Verify Package Contents ...........................................................................................................................................................................22
INSTALLATION GUIDELINES FOR COMPONENTS ............................................................................................................................ 23
General Guidelines for Mounting the Full Authority (FA) Valve Mounting ...............................................................................................23
UEGO Sensor Installation General Guidelines ...........................................................................................................................................27
UEGO Sensor........................................................................................................................................................................................27
UEGO Sensor Mounting .......................................................................................................................................................................28
UEGO Sensor Mounting Using UEGO Sensor Block...................................................................................................................................30
MAP Sensor Installation............................................................................................................................................................................34
MAT Sensor installation............................................................................................................................................................................35
Mounting Thermocouples.........................................................................................................................................................................35
Mounting Magnetic Pickup.......................................................................................................................................................................35
Enclosure Mounting and Conduit Entries..................................................................................................................................................36
Conduit Considerations.............................................................................................................................................................................37
Wire Termination......................................................................................................................................................................................38

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Wiring Connections...................................................................................................................................................................................40
Engine Mounting Requiring Disassembly of Engine..................................................................................................................................40
AFR-64L WIRING SCHEMATIC ................................................................................................................................................ 41
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 –Middle Tier .................................................................................................43
Butterfly Full Authority (FA) Valve Field Wiring Schematic –Upper Tier (short).......................................................................................44
START-UP AND COMMISSIONING ............................................................................................................................................. 45
INITIAL SETUP AND COMMISSIONING OUTLINE ............................................................................................................................ 68
TROUBLESHOOTING,MAINTENANCE AND REPLACEMENT............................................................................................................... 72
Product Support........................................................................................................................................................................................72
Visual Troubleshooting and Meter Checking............................................................................................................................................73
Thermocouple mV vs. Temperature ....................................................................................................................................................78
MAP Sensor VDC vs. PSIA.....................................................................................................................................................................79
FT Valve Position Testing .....................................................................................................................................................................79
FT Valve Position Feedback vs. Driven Position ...................................................................................................................................81
Troubleshooting Action Steps..............................................................................................................................................................82
Troubleshooting Communications with the PC ...................................................................................................................................84
Loading a MOT file....................................................................................................................................................................................87
Plotting Techniques and Diagnostics ........................................................................................................................................................87
Plot Example ........................................................................................................................................................................................88
Maintenance.............................................................................................................................................................................................90
Replacement Information .........................................................................................................................................................................90
Troubleshooting Guide .............................................................................................................................................................................91
PC DISPLAY SCREEN DESCRIPTION................................................................................................................................. 95
Display Screen (Screen No. 1) ...................................................................................................................................................................95
Engine Operating Parameters Group...................................................................................................................................................96
TC2 Temperature –The actual TC2 exhaust gas temperature . Expressed as Degrees Fahrenheit (F)..............................................96

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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 ..........................................................................................................................................................................109
Valve Set-Up (Screen No. 3) ....................................................................................................................................................................110
Gain Setting Group ............................................................................................................................................................................111
Valve Control .....................................................................................................................................................................................112
Open Loop/Default Valve Position Group..........................................................................................................................................113
Engine Configuration (Screen No. 4).......................................................................................................................................................115
Basic Configuration Group .................................................................................................................................................................115
Exhaust Temperature Shutdown & Alarm Group ..............................................................................................................................118
Valve Selection Group........................................................................................................................................................................120
Engine Configuration Group ..............................................................................................................................................................120
ModBus RS-485 System Configuration Group ...................................................................................................................................122
APPENDIX......................................................................................................................................................................... 123
Terms and Definitions.............................................................................................................................................................................123
System Specification ...............................................................................................................................................................................127
Notes, Warnings & Precautions..............................................................................................................................................................130
PSIA vs. Intake Manifold Pressure in Inches of Mercury .........................................................................................................................134
INSTALLATION LAYOUTS EXAMPLES......................................................................................................................................... 135
AFR-ND-L-64L-11-FA## (Single Bank, High Pressure Carburetor, Full Authority Valve) ..........................................................................135
AFR-ND-L-64L-11-FA## (Single Bank, High Pressure Carburetor, Full Authority Valve) ..........................................................................136
AFR-ND-L-64L-22-FA## (Dual Bank, High Pressure Carburetor, Full Authority Valve) ............................................................................137
AFR-ND-L-64L-22-FA## (Dual Bank, Low Pressure Carburetor, Full Authority Valve) .............................................................................138

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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
ENGINE DATA .................................................................................................................................................................... 141

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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. Such valves are widely available.
FUEL REGULATOR
SHUTDOWN
SAFETY
VALVE
FUEL FLOW
FULL
AUTHORITY
VALVE
FUEL
Butterfly Valve shown properly installed downstream of automatic fuel shutoff valve
Automatic and/or semiautomatic fuel shut-off valves are mandated by the National Fire
Protection Association’s “NFPA 37 –Standard for the Installation and Use of Stationary
Combustion Engines and Gas Turbines.” We recommend reading the National Fire Protection
Association’s codes and standards, NFPA 37 and NFPA 54 along with any other national, state,
and local codes and standards relevant to your application.
Do not open the controller’s enclosure when a hazardous atmosphere is present. Wiring
connections that could spark are present inside the enclosure.
Do not connect or disconnect end devices or make wiring changes while power is supplied to
the product unless the area is known to be non-hazardous. Electrical sparks may occur.
Separate non-incendive and intrinsically safe wiring from any other wiring.
Do not share the speed signal supplied to an electronic governor or ignition system with this
product.

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Do not operate components beyond their respective safety ratings (maximum/minimum
pressure, voltage, current, etc.).
All electrical connections should be performed by qualified personnel and should meet all
Federal, State, Local and End User electrical codes.
If the installer is unfamiliar with Federal, State, Local and End User electrical codes or is unable
to safely complete any of the installation requirements put forth in this manual, contact your
FW MURPHY distributor for information on qualified installers.
Failure to follow the safety instructions of this manual could void the product warranty.
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.

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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.

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The system is designed to maximize the efficiency, maintenance, and emissions of the engine by
maintaining a constant air/fuel ratio in relation to varying engine load, speed, fuel quality, ambient
temperature and barometric pressure. 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).

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Parts and Supplies
AFR-ND-L-64L-11-FA## –Full Authority Valve (Single O2 Sensor –Single Fuel Valve)
Quantity
Part #
Model #
Description
(2)a
47050835
ADAPTER,2" FT Flange Assy
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
(1)
00020707
AFR-64L Manual
AFR-64L I/O Manual
(1)
47000470
AFR-64R/L-CD
AFR-64R/L PC Software
(1)u
47700330
AFR-ND-L-64L Control Unit
Enclosure; ECM; TCB; Display & Hdwr
(1)u
47700329
AFR-WD-L-64L Control Unit
Enclosure; ECM; TCB; Display & Hdwr
(1)c
47000016
FL Cable 50
FL Valve Cable - 50' Length
(2)a
47000001
FL-25-Flange Assy
One 1" NPT NPT Flange, Gkt & Hdwr for FL-25
(2)a
47000003
FL-50-Flange Assy
One 2" NPT NPT Flange, Gkt & Hdwr for FL-50
(1)c
47050836
FT Cable 50
FT Valve Cable - 50' Length
(1)v
00031008
FT-33
33mm Full Authority Fuel Control Valve
(1)v
00031009
FT-60
60mm Full Authority Fuel Control Valve
(1)v
00031010
FT-68
68mm Full Authority Fuel Control Valve
(1)v
00031011
FT-75
75mm Full Authority Fuel Control Valve
(1)
00031022
MAG PU
Magnetic Pick-up 4" Length
(1)
00031023
MAG PU Cable-50
Magnetic Pick-up Cable 50'
(1)
47050819
MAP Cable - 50
MAP Sensor Cable 50'
(1)
00030997
MAP Sensor
Intake Manifold Press Sensor
(1)
00031024
MAT Cable-50
MAT Sensor Cable 50'

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(1)
00031025
MAT Sensor
Intake Manifold Temp Sensor
(1)
00031029
NM-10
Null Modem Cable 10' Length
(1)
00031030
O2 NUT
18mm x 1.5 Threaded, Coupling for O2 Sensor
(1)
00031039
UEGO Cable-50
UEGO Sensor Cable 50'
(1)
00031040
UEGO Sensor
Heated Wideband Oxygen Sensor
(1)v
47700033
Valve Assy,FL-25
25 MM Full Authority (FA) Butterfly Valve
(1)v
47700034
Valve Assy,FL-50
50 MM Full Authority (FA) Butterfly Valve
(1)c
Indicates only 1 cable Assy style is used, depending on the valve type used
(1)v
Indicates only 1 of the valve types are used
(1)u
Indicates only 1 of the Control Units are used, depending on the display option
(2)a
Indicates only 1 flange adaptor style is used, depending on the valve type used

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AFR-ND-L-64L-21-FA## –Full Authority Valve (Single O2 Sensor –Dual Fuel Valve)
Quantity
Part #
Model #
Description
(4)a
47050835
ADAPTER,2" FT Flange Assy
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
(1)
00020707
AFR-64L Manual
AFR-64L I/O Manual
(1)
47000470
AFR-64R/L-CD
AFR-64R/L PC Software
(1)u
47700330
AFR-ND-L-64L Control Unit
Enclosure; ECM; TCB; Display & Hdwr
(1)u
47700329
AFR-WD-L-64L Control Unit
Enclosure; ECM; TCB; Display & Hdwr
(2)c
47000016
FL Cable 50
FL Valve Cable - 50' Length
(4)a
47000001
FL-25-Flange Assy
One 1" NPT NPT Flange, Gkt & Hdwr for FL-25
(4)a
47000003
FL-50-Flange Assy
One 2" NPT NPT Flange, Gkt & Hdwr for FL-50
(2)c
47050836
FT Cable 50
FT Valve Cable - 50' Length
(2)v
00031008
FT-33
33mm Full Authority Fuel Control Valve
(2)v
00031009
FT-60
60mm Full Authority Fuel Control Valve
(2)v
00031010
FT-68
68mm Full Authority Fuel Control Valve
(2)v
00031011
FT-75
75mm Full Authority Fuel Control Valve
(1)
00031022
MAG PU
Magnetic Pick-up 4" Length
(1)
00031023
MAG PU Cable-50
Magnetic Pick-up Cable 50'
(1)
47050819
MAP Cable - 50
MAP Sensor Cable 50'
(1)
00030997
MAP Sensor
Intake Manifold Press Sensor
(1)
00031024
MAT Cable-50
MAT Sensor Cable 50'
(1)
00031025
MAT Sensor
Intake Manifold Temp Sensor
(1)
00031029
NM-10
Null Modem Cable 10' Length

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(1)
00031030
O2 NUT
18mm x 1.5 Threaded, Coupling for O2 Sensor
(1)
00031039
UEGO Cable-50
UEGO Sensor Cable 50'
(1)
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
(2)v
Indicates only 1 of the valve types are used
(1)u
Indicates only 1 of the Control Units are used, depending on the display option
(4)a
Indicates only 1 flange adaptor style is used, depending on the valve type used

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AFR-ND-L-64L-22-FA## –Full Authority Valve (Dual O2 Sensor –Dual Fuel Valve)
Quantity
Part #
Model #
Description
(4)a
47050835
ADAPTER,2" FT Flange Assy
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
(1)
00020707
AFR-64L Manual
AFR-64L I/O Manual
(1)
47000470
AFR-64R/L-CD
AFR-64R/L PC Software
(1)u
47700330
AFR-ND-L-64L Control Unit
Enclosure; ECM; TCB; Display & Hdwr
(1)u
47700329
AFR-WD-L-64L Control Unit
Enclosure; ECM; TCB; Display & Hdwr
(2)c
47000016
FL Cable 50
FL Valve Cable - 50' Length
(4)a
47000001
FL-25-Flange Assy
One 1" NPT NPT Flange, Gkt & Hdwr for FL-25
(4)a
47000003
FL-50-Flange Assy
One 2" NPT NPT Flange, Gkt & Hdwr for FL-50
(2)c
47050836
FT Cable 50
FT Valve Cable - 50' Length
(2)v
00031008
FT-33
33mm Full Authority Fuel Control Valve
(2)v
00031009
FT-60
60mm Full Authority Fuel Control Valve
(2)v
00031010
FT-68
68mm Full Authority Fuel Control Valve
(2)v
00031011
FT-75
75mm Full Authority Fuel Control Valve
(1)
00031022
MAG PU
Magnetic Pick-up 4" Length
(1)
00031023
MAG PU Cable-50
Magnetic Pick-up Cable 50'
(1)
47050819
MAP Cable - 50
MAP Sensor Cable 50'
(1)
00030997
MAP Sensor
Intake Manifold Press Sensor
(1)
00031024
MAT Cable-50
MAT Sensor Cable 50'
(1)
00031025
MAT Sensor
Intake Manifold Temp Sensor
(1)
00031029
NM-10
Null Modem Cable 10' Length

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(2)
00031030
O2 NUT
18mm x 1.5 Threaded, Coupling for O2 Sensor
(2)
00031039
UEGO Cable-50
UEGO Sensor Cable 50'
(2)
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
(2)v
Indicates only 1 of the valve types are used
(1)u
Indicates only 1 of the Control Units are used, depending on the display option
(4)a
Indicates only 1 flange adaptor style is used, depending on the valve type used

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Spare/ Loose Parts
Part #
Model #
Description
47050835
ADAPTER,2" FT Flange Assy
One 2" NPT Flange, Gkt & Hdwr for FT-33, 60, & 68
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
47700330
AFR-ND-L-64L Control Unit
Enclosure; ECM; TCB; Display & Hdwr
47700329
AFR-WD-L-64L Control Unit
Enclosure; ECM; TCB; Display & Hdwr
47050823
BACK Panel SCE-12P20
Enclosure Back Plate
47050824
COM KIT AFR
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
47000001
FL-25-Flange Assy
One 1" NPT NPT Flange, Gkt & Hdwr for FL-25
47000003
FL-50-Flange Assy
One 2" NPT NPT Flange, Gkt & Hdwr for FL-50
47050832
FLOTECH 2" Gasket
2" Flange gasket only
47050836
FT Cable 50
FT Valve Cable - 50' Length
00031007
FT2 Spool Piece
2" NPT Spacer FT Valve removal
00031008
FT-33
33mm Full Authority Fuel Control Valve
00031009
FT-60
60mm Full Authority Fuel Control Valve
00031010
FT-68
68mm Full Authority Fuel Control Valve
00031011
FT-75
75mm Full Authority Fuel Control Valve
47050833
Gasket,3",FT Flange
3" Flange gasket only

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00031021
KTC-12
Type “K” thermocouple (12” probe)
00031022
MAG PU
Magnetic Pick-up 4" Length
00031023
MAG PU Cable-50
Magnetic Pick-up Cable 50'
47050819
MAP Cable - 50
MAP Sensor Cable 50'
00030997
MAP Sensor
Intake Manifold Press Sensor
00031024
MAT Cable-50
MAT Sensor Cable 50'
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
00031012
O-RING,FL-25-FLG
FL-25 Flange o-ring
00031019
O-RING,FL-50-FLG
FL-50 Flange o-ring
00031031
PLUG,MALE,18MM
Male Plug (18mm) for a Vacant Oxygen Sensor Hole
47050841
TCB
Terminal Connector Board
47050018
UEGO Block
Lean Burn O2 Mounting Block
00031039
UEGO Cable-50
UEGO Sensor Cable 50'
00031040
UEGO Sensor
Heated Wideband Oxygen Sensor
47050859
UNIOP COM Cable
UniOP Communications Cable –18"
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
47050846
UNIOP Power Cable - Remote
UniOP Pwr Cable - 50' Length
47700033
Valve Assy,FL-25
25 MM Full Authority (FA) Butterfly Valve
47700034
Valve Assy,FL-50
50 MM Full Authority (FA) Butterfly Valve