CEC

MODELS AFFECTED: ATGL, VHP, VGF

The purpose of this service bulletin is to identify the current software version of the Custom Engine Control Air/Fuel Module (AFM) User Interface Program, provide retrofit information, explain software and EPROM chip compatibility, and provide atmospheric pressure transducer installation instructions. The AFM User Interface Program has been updated. The current version of the AFM software is version 4.0a (P/N 740411D) replacing version 4.0 (P/N 740411C) and version 2.8a (P/N 740411B). All existing AFM modules in the field, regardless of software version, can be retrofitted to AFM version 4.0a. The upgrade to version 4.0a allows the AFM User Interface Program to run on PCs with high speed processors (750 MHz or less). With previous versions of AFM software, PCs with high speed processors could not be used to program the AFM. This latest software release corrects this error. If you are currently running your AFM system using version 4.0 and are unable to program the AFM system due to a high processor speed, you must upgrade your AFM software to version 4.0a. NOTE: Refer to the Custom Engine Control Air/Fuel Module Installation, Operation and Maintenance Manual, Form 6286 (First Edition) for more information on the AFM system, installation, and programming.

TOPIC: IDENT NO: SUPERSEDES: DATE:

Electronic Controls 17--2713B 17--2713A May 15, 2001

SUBJECT: CEC AFM Software Version Update And Retrofit Instructions

On VHP inline, all VGF and all ATGL engines, the primary and secondary fuels are regulated by one actuator and one regulator. On VHP vee engines one actuator is used on each engine bank (a total of two actuators installed on the engine). On each engine bank, the primary and secondary fuels are regulated by one actuator and one regulator. When operating a simple fuel system, a different data--set for each fuel is programmed, but the AFM User Interface Program only tracks for the fuel currently being used. Because there is only one actuator, the engine will have to be shut down and the start position re--initiated to switch fuels/maps. Complex Fuel Systems: A complex fuel system is when both fuels have their own regulator and actuator. On VHP inlines, all VGF, and all ATGL engines two actuators are used: one actuator for primary fuel and one for secondary fuel. On VHP vee engines, four actuators are used on the engine. Two actuators are used per engine bank. On each bank, one actuator regulates primary fuel and one regulates secondary fuel. When operating a complex fuel system, a different data--set for each fuel is programmed and the AFM User Interface Program keeps track of each actuator position. Because two positions are tracked, there is no need to shut down the engine or re--initiate the start position when switching fuels (as long as the start positions were initiated once before starting the engine). REMOTE START CAPABILITY The AFM offers remote start capability that allows an operator to activate certain AFM functions from a remote location. The operator can operate the AFMs control logic remotely over telephone lines or a network using on--site logic controls. Instead of being at the engine and using the manual mode to start the engine

AFM FEATURES (SOFTWARE VERSION 4.0a)

DUAL FUEL CAPABILITY The AFM allows for dual fuel applications. Dual fuel capability allows for control of air/fuel ratio on engines that have two discrete fuel sources. Dual fuel engine applications can either be designed to be a simple fuel system or complex fuel system. Simple Fuel Systems: A simple fuel system is when the same regulators and actuators are used for both primary and secondary fuels.

Waukesha

WAUKESHA ENGINE DRESSER, INC. WAUKESHA, WI 53188-4999

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Service Bulletin No. 17-2713B

with AFM, the start position can be set for auto mode and closed loop control. INTAKE MANIFOLD PRESSURE TRANSDUCER RANGE The intake manifold pressure transducer range is 0 -- 100 psi. Maps in the AFM User Interface Program are designed to run at high pressures (up to 60 psia). With this pressure range, engines with higher intake manifold pressure requirements can be accommodated. The intake manifold pressure transducer is used in catalyst and lean burn applications only. In addition, a pressure snubber is installed between the intake manifold pressure transducer and the intake manifold to protect the transducer from exposure to excessive pressures that can result from intake manifold explosions or surges. ATMOSPHERIC PRESSURE TRANSDUCER (LEAN BURN ONLY) An atmospheric pressure transducer is installed in the AFM module to improve overall system accuracy when using lean burn control mode (see Figure 1). ACTUATOR DESIGN The actuator was designed for operator convenience. The proximity switch is located inside the actuator housing to prevent accidental breakage. The small size and weight of the actuator results in less chance of vibration damage to engine components and makes it easier to package the actuator to the engine. HIGHER PROCESSOR SPEED Version 4.0a has the system capability to run the AFM User Interface Program on PCs with high speed processors (750 MHz or less).

AFM RETROFIT INFORMATION AND PART NUMBERS

All existing AFM modules in the field, regardless of software version, can be retrofitted to AFM version 4.0a. COMPONENTS NEEDED FOR RETROFIT FROM VERSION 4.0 To upgrade to version 4.0a from version 4.0, it is only necessary to install the new software on your PC and then program the AFM system using the new software. Program your AFM module using software version 4.0a following the programming instructions provided in one of the following chapters in the Custom Engine Control Air/Fuel Module Installation, Operation and Maintenance Manual Form 6286 (First Edition): Chapter 3 for Catalyst Programming, Chapter 4 for Best Power/Economy Programming, or Chapter 5 for Lean Burn Programming. COMPONENTS NEEDED FOR RETROFIT FROM VERSION 2.8a

ATMOSPHERIC PRESSURE TRANSDUCER

Figure 1. Atmospheric Pressure Transducer Installed In AFM Module

ENGINE LOADED PRECAUTION If the intake manifold pressure is greater than 17 psia, the operator cannot set the actuator(s) to the start position using the <F1> <STRT POS> command. If the operator presses <F1> and then <STRT POS> on the AFM module keypad, a message will be displayed on the AFM LCD telling the operator that the request was ignored because the engine is loaded. This prevents errant shutdowns and damage to engine components that might occur should the engine be loaded and the <F1> <STRT POS> command used.

To upgrade to AFM version 4.0a and use the features associated with the new software, you need to upgrade or install the components listed in Table 1. On lean burn engines, you must also install the atmospheric pressure transducer assembly. The components of the atmospheric pressure transducer are listed in Table 2.

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Waukesha

WAUKESHA ENGINE DRESSER, INC. WAUKESHA, WI 53188-4999

Service Bulletin No. 17-2713B

Table 1. Components Needed For AFM 4.0a Retrofit (Rich Burn And Lean Burn) QTY.
1 1 1 1 1

DESCRIPTION
Core EPROM Chip Display EPROM Chip Software/Manual Assembly Intake Manifold Pressure Transducer1,2 Pressure Snubber2 (If Not Already Installed)

P/N
740407B 740408B C740015B 740111C 211893

AFM 4.0a RETROFIT INSTRUCTIONS FROM AFM 2.8a

The following sections provide AFM 4.0a retrofit instructions from version 2.8a for the EPROM chips, User Interface Program, intake manifold pressure transducer with snubber, actuator, and atmospheric pressure transducer (lean burn only). Complete the entire AFM 4.0a retrofit following the instructions in this service bulletin. When the entire retrofit is complete, program your AFM module using software version 4.0a following the programming instructions provided in one of the following chapters in the Custom Engine Control Air/Fuel Module Installation, Operation and Maintenance Manual Form 6286 (First Edition): Chapter 3 for Catalyst Programming, Chapter 4 for Best Power/Economy Programming, or Chapter 5 for Lean Burn Programming. CORE AND DISPLAY EPROM CHIP RETROFIT If you upgrade to version 4.0a from version 2.8a, the core and display EPROM chips inside the AFM module must be updated. EPROM chip upgrading is necessary because the core and display EPROM chips must be matched with the AFM software version number for correct compatibility. If the versions of the EPROM chips are not the same as the software version number, the potential for errant operation exists and programming will not work. NOTE: If you are upgrading to version 4.0a from version 4.0, you do not need to upgrade EPROM chips. Refer to Section 6.05 EPROM Chip Replacement in the Custom Engine Control Air/Fuel Module Installation, Operation and Maintenance Manual Form 6286 (First Edition) for instructions on replacing the core and display EPROM chips inside the AFM module. The version number is labeled on the top of the EPROM chips. AFMDXX is labeled on the display EPROM and AFMCXX is labeled on the core EPROM (where XX is the version number) (see Figure 2). Table 4 lists the software and EPROM chip part numbers required for proper operation.

NOTE: 1 You must use intake manifold pressure transducer P/N 740111C (or superceding P/N) with AFM version 4 series software. This pressure transducer has a range of 0 - 100 psi. Using an incorrect pressure transducer, will cause the AFMs map structure to be incorrect resulting in poor engine performance. 2 The intake manifold pressure transducer with pressure snubber is not used in Best Power/Economy operation.

Table 2. Atmospheric Pressure Transducer Assembly Components (Lean Burn Only) QTY.
1 1 2 2 2 1 1 1

DESCRIPTION
MAP Sensor MAP Sensor Connector Assembly #10--24 x 3/4 Headscrew #10 Flat Washer #10--24Flex Lock Nut 1/4--20 Flex Lock Nut Mounting Plate Assembly 3/16 OD Tubing

P/N
740113 740115 21834 Y18813E 28700 28102 A214027 296438

NOTE: The actuator used with previous AFM versions is interchangeable and can be used with AFM version 4.0a. You do not need to retrofit the actuator. The current actuator features a smaller size and relocated proximity switch. If you want to upgrade your actuator(s), refer to Table 3 for correct part numbers.
Table 3. Upgraded Actuator Part Numbers ENGINES USING ...
S211, S201, 66, 66Z, or 133L Fisher gas regulator(s) 99 or 1098 Fisher gas regulator(s)

ORDER ACTUATOR P/N1

A740500A A740502A

NOTE: 1If you upgrade your actuator(s), you will also need to order a new harness(es) (P/N 740207C). The same harness is used for both actuator sizes. The harness being replaced is the harness that connects the actuator to the junction box. The harness that connects the junction box to the AFM module does not need to be replaced.

Waukesha

WAUKESHA ENGINE DRESSER, INC. WAUKESHA, WI 53188-4999

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Service Bulletin No. 17-2713B

LABEL WITH VERSION NUMBER

INTAKE MANIFOLD PRESSURE TRANSDUCER AND PRESSURE SNUBBER RETROFIT NOTE: The intake manifold pressure transducer with pressure snubber is used in catalyst and lean burn applications only. Refer to Section 2.00 Mounting AFM System Components in the Custom Engine Control Air/Fuel Module Installation, Operation and Maintenance Manual Form 6286 (First Edition) for instructions on mounting the intake manifold pressure transducer with pressure snubber. The mounting instructions are on Page 2.00-16 of the manual under the heading, Mounting The Intake Manifold Pressure Transducer With Pressure Snubber. The wiring schematics for the AFM system are located in Section 2.05 AFM System Electrical Connections of the manual. Refer to the appropriate wiring schematic to connect the intake manifold pressure transducer to the AFM system. The intake manifold pressure transducer has three wires identified 1, 2, and 3. See Table 5 for wire identification.
Table 5. Intake Manifold Pressure Transducer Wire Identification WIRE NUMBER
1 2 3

Figure 2. Core And Display EPROM Chips Table 4. AFM User Interface Program Version 4.0a EPROM Requirements VERSION 4.0A DISK P/N
740411D

DISPLAY EPROM P/N

740408B

CORE EPROM P/N

740407B

For example: AFMD40 (display EPROM P/N 740408B) and AFMC40 (core EPROM P/N 740407B) are the chips that have been programmed for AFM User Interface Program version 4.0a. NOTE: The display EPROM is visible inside the AFM module on the back of the door. To view the core EPROM, the control board assembly must be removed and disassembled. Refer to Section 6.05 EPROM Chip Replacement in the Custom Engine Control Air/Fuel Module Installation, Operation and Maintenance Manual Form 6286 (First Edition) for disassembly instructions. USER INTERFACE PROGRAM SOFTWARE INSTALLATION For information on installing the AFM User Interface Program, refer to the white card at the back of the Custom Engine Control Air/Fuel Module Installation, Operation and Maintenance Manual Form 6286 (First Edition) that holds the 3-1/2 inch diskette.

FUNCTION
SUPPLY + SUPPLY / SIGNAL -SIGNAL +

ACTUATOR RETROFIT NOTE: The actuator used with previous AFM versions is interchangeable and can be used with AFM version 4.0a. You do not need to upgrade the actuator. Refer to Section 2.00 Mounting AFM System Components in the Custom Engine Control Air/Fuel Module Installation, Operation and Maintenance Manual Form 6286 (First Edition) for instructions on mounting the upgraded actuator(s). The mounting instructions begin on Page 2.00-16 of the manual under the heading, Mounting The Stepper Motor(s). The wiring schematics for the AFM system are located in Section 2.05 AFM System Electrical Connections of the manual. Refer to the appropriate wiring schematic to connect the actuator to the AFM system.

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Waukesha

WAUKESHA ENGINE DRESSER, INC. WAUKESHA, WI 53188-4999

Service Bulletin No. 17-2713B

INSTALLING ATMOSPHERIC PRESSURE TRANSDUCER (LEAN BURN ONLY) When using lean burn control mode, an atmospheric pressure transducer must be installed in the AFM module to improve overall system accuracy (see Figure 3). Follow the instructions provided to install the atmospheric pressure transducer in the AFM module. Disconnect all electrical power supplies before making any connections or servicing any part of the electrical system. Electrical shock can cause severe personal injury or death. 1. Turn off 24 VDC power to the AFM module. 2. Open the AFM module. 3. Remove the two #10--24 x 1/2 screws (location shown in Figure 4) from the plate on the bottom of the AFM module and discard.

SCREWS TO BE REMOVED ATMOSPHERIC PRESSURE TRANSDUCER

Figure 4. Location Of Screws To Be Removed From Bottom Of AFM Module

4. Replace the two screws removed in Step 3 with #10 flat washers (P/N Y18813E) and #10--24 x 3/4 head screws (P/N 21834) (see Figure 5).
Figure 3. Atmospheric Pressure Transducer Installed In AFM Module

5. Place the mounting plate (P/N A214027) inside the AFM module over the threads from the screws installed in Step 4. Make sure the stud on the mounting plate is up and that the tab on the plate is in front (see Figure 5). 6. Secure the mounting plate inside the AFM module with two #10--24 lock nuts (P/N 28700).

Do not install, set up, maintain, or operate any electrical components unless you are a technically qualified individual who is familiar with the electrical elements involved. Electrical shock can cause severe personal injury or death.

Waukesha

WAUKESHA ENGINE DRESSER, INC. WAUKESHA, WI 53188-4999

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Service Bulletin No. 17-2713B

SENSOR CONNECTOR ASSEMBLY P/N 740115

3/16 OD TUBING P/N 296438 1/4-20 LOCK NUT P/N 28102

ATMOSPHERIC PRESSURE TRANSDUCER P/N 740113

#10-24 LOCK NUT P/N 28700

#10 FLAT WASHER P/N Y18813E #10-24 HEAD SCREW P/N 21834

MOUNTING PLATE P/N A214027

Figure 5. Atmospheric Pressure Transducer Components Installed In AFM Module

ALIGN ATMOSPHERIC PRESSURE TRANSDUCER WITH TAB ON MOUNTING PLATE MOUNTING PLATE

ATMOSPHERIC PRESSURE TRANSDUCER

VIEW FROM BOTTOM OF AFM MODULE

Figure 6. Pressure Transducer Aligned With Mounting Plate

7. Slide the atmospheric pressure transducer (P/N 740113) over the mounting plate stud (see Figure 5). Align the pressure transducer with the tab on the mounting plate as shown in Figure 6. 8. Secure the atmospheric pressure transducer to the mounting plate stud with the 1/4--20 lock nut (P/N 28102). 9. Locate the (P/N 740115). sensor connector assembly

10. Align plug tabs of sensor connector with the atmospheric pressure transducer. 11. Snap sensor connector into the atmospheric pressure transducer (see Figure 5). 12. Route the sensor connector assembly wires inside the AFM module to the correct location on the terminal identification strip: ANALOG IN 2+, ANALOG IN 2--, and LEFT HOME + (see Figure 7). 13. Cut wires to length and strip ends of wire.

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Waukesha

WAUKESHA ENGINE DRESSER, INC. WAUKESHA, WI 53188-4999

Service Bulletin No. 17-2713B

14. Loosen the screws at the ANALOG IN 2+, ANALOG IN 2--, and LEFT HOME + terminals in the AFM module (see Figure 7). 15. Insert wires into the correct terminal and tighten terminal screws. Wires are marked for proper location on the terminal strip. 16. Locate 3/16 tubing (P/N 296438). 17. Slide one end of 3/16 tube over the orifice on the atmospheric pressure transducer. 18. Using a nylon cable strap, secure the other end of the tubing to the pressure transducer bracket. Make sure tube opening faces down as shown in Figure 5. 19. Complete entire AFM 4.0a retrofit including the new EPROM chips, software, and intake manifold pressure transducer with pressure snubber following the instructions in this service bulletin. 20. Program the AFM module using software version 4.0a following the programming instructions provided in Chapter 5 Lean Burn Programming of the the Custom Engine Control Air/Fuel Module Installation, Operation and Maintenance Manual Form 6286 (First Edition). -

CEC AFM MODULE

INT MAN PRES + INT MAN PRES -ANALOG IN 2 + ANALOG IN 2 -ANALOG IN 3 + ANALOG IN 3 --

LEFT HOME + LEFT HOME IN LEFT HOME -RIGHT HOME + RIGHT HOME IN RIGHT HOME --

LEFT HTR + LEFT HTR -RIGHT HTR + RIGHT HTR --

LEFT LEAN 02 + LEFT LEAN 02 -RIGHT LEAN 02 + RIGHT LEAN 02 --

LEFT T.C. + LEFT T.C. -RIGHT T.C. + RIGHT T.C. --

ERROR OUT REMOTE START ALT. FUEL

24 VDC 24 VDC GND GND

Figure 7. Atmospheric Pressure Transducer Wiring Inside AFM Module

ATMOSPHERIC PRESSURE TRANSDUCER

Waukesha

WAUKESHA ENGINE DRESSER, INC. WAUKESHA, WI 53188-4999

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