1.03.002 GILL AF120 AFR controller Initial Setup and Troubleshooting Guide

This Policy is completed waiting on Field Service, Engineering & Safety approval.

Purpose

The purpose of this procedure is to establish the minimum requirements for the initial set up of the GILL AF120 AFR (Air Fuel Ratio) controller that maybe equipped on some of the gas engine drive Flogistix units as laid out in this procedure.

Procedure

This procedure applies to all skids equipped with the GILL brand of Air Fuel Ratio controller on gas engine drive units that are currently in service in the Field, Test Loop, at a Repair Shop, or in Storage Yards. Flogistix Service Technicians will perform the initial set up of the GILL AFR as outlined in this procedure.

Before any work is performed a JSA needs to be done according to Flogistix procedure along with any Customer requirements before any work is started.

Initial Set Up Information Guide steps

When performing the initial set up for the GILL AFR the following steps need to be done. It is a good practice to read through all the steps before starting the initial set up. Get your self familiar with the GILL controller and GILL software that is installed on the laptop that is to be used. The initial set up needs to be done so that the GILL AFR controller will control the engine exhaust emissions. There are a few things that need to be checked on the engine before the GILL set up is started.

• Has the Ignition System been checked to insure ignition timing is set properly?

• Have the sparkplugs been replaced and the Sparkplug gap been properly set?

• Have the sparkplug wires been checked to make sure they are not worn, cracked including the sparkplug and distributor boots?

• Has the Distributor been checked and distributor Cap and Rotor replaced?

• Check the fuel system for proper fuel setting and gas regulator operation.

• Has the carburetor diaphragm been checked/cleaned/or replaced?

• A good starting set pressure for the supply gas to the carburetor would be 2 to 5 inches of water column.

• Has the engine cylinder compression been checked on all cylinders?

• If applicable have the correct valve lash been checked/set on each cylinder (for engines with adjustable valve setting)

After the previous steps have been completed the GILL AFR controller is now ready to be set up. Follow the next steps to do the initial setup of the AFR controller.

1. With the engine not running does the GILL AF120 power lights come on when the compressor panel has been reset and the engine is ready to run?

2. If lights do not come on Refer to Step 1 of the Power Supply diagnostic Guide

3. If lights do come continue to Step 4

4. Connect your Laptop to the GILL AF120 Control Module and open the GILL AFP COM program on Laptop.

5. If Laptop communicates with GILL controller continue to Step 6. If Laptop does not communicate to GILL Control Module Refer to Step 1 of the Module Diagnostic Guide

6. When the GILL program is open on the Laptop there will be a picture of Cloud with Lightning. At the top left of the page there will be "FILE" "VIEW" "CONNECT" "HELP" click on the "VIEW"

7. After clicking on the "VIEW" there should be a drop down box. in the drop down box click on the "FUEL VALVE CONTROL"

8. Go to the FUEL VALVE SCREEN then go to MODE click the circle box labeled "REZERO"

9. Shut the ball valve for the supply gas to the GILL FUEL CONTROL VALVE. Do Not Open GILL FUEL CONTROL VALVE until instructed

10. Start the Engine. With Engine running and valve closed to the GILL FUEL CONTROL VALVE, run engine from Idle to Full Load.

11. Does the Engine run to Full Load? If Yes continue to Step 12. If No Make adjustments to Engine Fuel or Ignition System until Engine runs to Full Load.

12. Connect Emissions Tester to Engine Exhaust Outlet.

13. With the Engine running and the GILL FUEL CONTROL VALVE still closed. Run engine to FULL RPM and Load. Adjust Fuel on engine to meet required engine emissions NOX and CO that need to be maintained for Permitting Requirements.

14. Go to the Fuel Valve Control Screen in the GILL Program on your Laptop.

15. Go to CONTROL on the middle of the Screen, Click on SetPoint Box and type in the same number as the UEGO Input Box on the left side of the screen. **The UEGO number will be constantly changing up or down so try to put the average of what the UEGO number is reading. Make sure there are five (5) numbers after the decimal point.

16. As a starting point set the supply gas pressure going to the GILL Fuel Control Valve at 2 to 5 psig.

17. Open the supply gas valve to the GILL Fuel Control Valve slowly so the GILL Controller will start trying to control the engine.

18. After the fuel supply gas valve going to the GILL Fuel Control Valve has been open allow a few minutes for the Controller to stabilize.

19. In the Fuel Valve Control screen look at the OUTPUT box in the lower left side of the screen, ideal percentage is 40% to 50%.

20. Is percentage in the ideal range? If Yes continue to Step 21. If No Adjust Fuel pressures starting with the supply pressure going to the GILL Fuel Control Valve until percentages are in the ideal 40% to 50% range.

21. Check the Exhaust Gas Analyzer and look at what the NOX and CO numbers are.

22. Go to the CONTROL box in the Fuel Valve Control screen. If the engine is running Rich change the Setpoint number to a lesser negative number (towards a positive number). than what is was originally set at in the previous step. If the engine is running Lean change the Setpoint number to a greater negative number( a more negative number) than what it was originally in the previous step.

23. See examples in Step 24 to go Rich and Step 25 to go Lean and continue with those steps until Engine is running at needed Emission limits.

24. To go Rich - Original Setpoint may have been -0.09000 If needing to go Rich change number to -0.10000

25. To go Lean - Original Setpoint may have been -0.09000 If needing to go Lean change number to -0.08000

26. Make small steps at a time to bring emissions numbers where they are needed.

27. Once Engine is running at desired emission limits and stabilized go to the GILL opening program page that has the cloud with the lightning and click "View" at the top left of screen. In the drop down box click "Configuration"

28. In Configuration page click "File" in the top left of the screen. In the drop down box click "Write to NVM"

29. Another box will appear and ask of you want to reset module. Always answer No

30. Allow at least 12 hours for the Catalyst to burn in. Engine will need to be rechecked to make sure if any additional tuning may need to be done after Catalyst has burned in.

Gill AF120 AFR Controller Troubleshooting Guide

Has the Gill Controller been in Service and has been controlling the engine? If Yes proceed to Step 1 of this Troubleshooting Guide. If No - go to the Initial Set Up Information Guide steps

1. Is the LED on the left side of the GILL Controller flashing when powered? If Yes proceed to next step. If No proceed to Step 1 of the Power Supply Diagnostics

2. On the GILL Controller is the Center LED on or blinking? If Yes proceed to the next step. If No proceed to Step 1 in the Oxygen Sensor guide or Fuel Valve guide

3. Is the Engine low on power?

4. Is the Engine surging or runs rough at idle but has power at the set RPM?

5. Is Engine Exhaust temperature high or Pre & Post temperature High?

Power Supply Diagnostics:

• 1. GILL AF120 Controller does not seem to be powering up? Is there 12-24 volts positive (+) DC at connections supplying voltage to the GILL AF120 Controller wiring harness? If Yes proceed to next step. If No restore 12-24 volts positive (+) DC power to GILL Controller wiring harness.

  2. Is the LED in the left side of the GILL Controller flashing? If Yes proceed to Step 5 If No is there 12-24 volts positive (+) DC to both connection points on GILL Controller wiring harness going to pins #1 and #11 (both are white with red color wire). If if Yes proceed to Step 4 if No proceed to Step 3

  3. If there is no 12-24 volts positive (+) DC at both the connection points supply or restore 12-24 volts positive (+) DC to both wires going to pins #1 and #11.

  4. If there is positive (+) power to both connection points on GILL Controller wiring harness pins #1 and #11 check the Ground (-) wire to GILL Controller it will be pin #2 and will be a Black with a White racer wire to make sure it has a negative (-) ground. If there is not a (-) ground, supply a negative (-) ground to the black with white wire.

The GILL Controller has Power and LED is flashing but is not controlling the Engine. Has the GILL Controller been in service and has controlled the engine? If No proceed to Initial Set Up Information Guide steps If Yes proceed to Oxygen Sensor Trouble Shooting

• 1. If Oxygen Sensor diagnostic is OK proceed to Fuel Valve Troubleshooting.

  2. If Fuel Valve diagnostic is OK replace GILL Controller.

  3. After replacing GILL Controller is Controller controlling engine? If Yes proceed to Initial Set Up Information Guide steps If No contact Flogistix Engineering or the Emissions Manager in the Powder River Business Unit.

Oxygen Sensor Troubleshooting Guide

Connect the GILL AF120 Controller to a Laptop with the GILL AFP COM program installed.

1. Open the Gill AFP program

2. When the GILL program is is open there will be a picture of a Cloud with lightning. At the top left of the page there will be "FILE" "VIEW" "CONNECT "HELP" Click on "View"

3. After clicking on "VIEW" there will be a drop down box. Click on the MONITOR

4. On the right side of the MONITOR page look under status.

5. If any of the boxes are checked that would be the problem why the Controller is not working properly. Are they any boxes checked? If No proceed to Step 6 if Yes proceed to Step 11

   1. If no boxes are checked under Status on the Monitor page the Check Heater Resistance.

6. Heater Resistance (located on the Monitor Page on left side of screen) The figure for Heater Resistance should be 8.0 to 8.5 Ohms. Is the resistance higher or lower than the normal 8.0 to 8.5 Ohms if Yes proceed to step 8. If resistance is 8.0 to 8.5 Ohms proceed to Step 9

7. If resistance is higher than the normal 8.0 to 8.5 Ohms replace the Oxygen Sensor

8. If Resistance Ohms is in the normal range check Lambda Reading in the next step.

9. Lambda Control is located on the Monitor Page in the middle of the page on the right side called Lambda Control Lambda Setpoint should have the same number as the Lambda box. Is it the same number? If Yes the Oxygen Sensor checks out OK. If No proceed to step 11

10. For Example of Lambda reading is -6.5 to 6.5 Ohms check the wiring harness between the Oxygen Sensor and the GILL Controller and repair the or replace the wiring harness. Typically it will be the Grey wire on #27 pin

11. If there is one or more of the boxes that are checked on the right side of the Monitor Page choose the following for further instructions

• • Control Not Closed Loop - Checked - Go to Fuel Valve Control Page then go to MODE make sure CLOSED LOOP Box is checked

  • TEMP OOR (Out of Range) - Checked - Oxygen Sensor not up to Temperature - Proceed to Step 1 of the Oxygen Sensor Troubleshooting Guide

  • Valve Position OOR (Out of Range) - Checked - Fuel Valve is out of Range. Rich is 0% Lean is 100% - Check fuel pressure at GILL Fuel Valve if OK proceed to Fuel Valve page and check valve position. Follow instructions on Fuel Valve Diagnostic Guide

  • Heater Current OOR (Out of Range) - Checked - Oxygen Sensor Resistance is to High or Low - Replace Oxygen Sensor

  • Configuration Error - Checked - Software Error If this happens call Emissions Manager in Powder River Business unit or Flogistix Engineering

  • Control Enable IP Low - Checked - If this happens call Emissions Manager in Powder River Business unit or Flogistix Engineering

  • Start-up Not Expired - Checked - Warm-up timer is Enabled (This should clear after 90 seconds)

  • Alarm Disabled - Checked - Probable cause open wires in GILL wiring harness going to ground - If wires in GILL wiring harness are OK and it is still Faulted call Emissions Manager in Powder River Business unit or Flogistix Engineering

Fuel Valve Troubleshooting Guide

Connect the GILL AF120 Controller to a Laptop with the GILL AFP COM program installed.

1. Open the GILL AFP Program

2. When the GILL program is is open there will be a picture of a Cloud with lightning. At the top left of the page there will be "FILE" "VIEW" "CONNECT "HELP" Click on "View"

3. After clicking "VIEW" there will be a drop down box. Click on the FUEL VALVE CONTROL

4. Look on the bottom left corner of the screen listed OUTPUT. If Output is at 0% or at 100% Fuel Valve will be out of range. If No proceed to Step 5 If Yes Proceed to Step 9

5. If the Output is at 0% or at 100% go to MODE on the Fuel Valve Screen and click Open Loop

6. Go to OPEN LOOP STEP, Click UP and see if Valve opens by looking at the INPUT on the right side of the screen. In the UEGO box the reading should go to a higher number. Did the number go higher? If Yes proceed to Step 14. If No proceed to Step 7.

7. Shut Ball Valve for supply gas to GILL Fuel Valve. Remove the motor off of the GILL Fuel Valve housing. Go to OPEN LOOP Step. Click UP and see if Valve Plunger goes either up or down. Does the Plunger go Up or Down? If No proceed to Step 8. If Yes proceed to Step 14

8. Replace the Stepper Motor of the Fuel Valve Assembly

9. In the Fuel Valve Control screen is the Green Line steady? If Yes proceed to Step 14. If No proceed to Step 10

10. Check Fuel Pressure going to the GILL Fuel Valve (Ideal pressure is 2 to 5 psig) If fuel pressure was adjusted to GILL Control Valve is the Green line now steady? If Yes proceed to Step 14. If No proceed to Step 11.

11. Check to make sure Oxygen Sensor is reading correctly refer to Step 3 of the Oxygen Sensor Troubleshooting Guide. Is Oxygen Sensor reading correctly? If No refer back to all steps of the Oxygen Sensor Troubleshooting Guide starting with Step 3. If Yes proceed to Step 12.

12. If Oxygen Sensor is reading correctly go to the Fuel Valve Control screen and then go to MODE click circle box labeled REZERO. Is the Green line now steady on the Fuel Valve Control screen? If Yes proceed to Step 14. If No proceed to step 13.

13. If the green line is fluctuating and looks like a roller coaster check engine manifold pressure to see if engine is lightly loaded. If engine is lightly loaded the GILL controller will fluctuate the valve position trying to control the engine. If engine is lightly loaded increase engine load. (If engine is driving a rotary screw increase discharge pressure to increase load on engine.) If the green line still fluctuates after increasing engine load call Emissions Manager in Powder River Business unit or Flogistix Engineering

14. If you selected Yes to a step and it referred to go to Step 14 the Fuel Valve is OK and should be working properly.

Module Diagnostic Troubleshooting Guide

Laptop does not Communicate with the GILL AF 120 Control Module

1. If Laptop does not Communicate with the GILL AF 120 Control Module disconnect the 12-24 volt power to the GILL Control Module and then reconnect the 12-24 volt power. This will reboot the control module.

   1. Does the Laptop now connect to and communicate with the GILL Control Module? If Yes communication to Control Module has been corrected. If No proceed to Step 3

2. If communication was not restored after 12-24 volts was reconnected replace the GILL Control Module

3. After replacing the GILL Control Module proceed to the Initial Set-up Information Guide for the GILL Control Module

Wiring Harness Diagnostic Guide

GILL Wiring Harness:

1. Check continuity on each wire of the GILL wiring harness. Is there continuity in all wires? If Yes wiring harness is good and then proceed to Step 6. If No proceed to Step 2

2. Does GILL wiring harness appear damaged? If No proceed to Step 3. If Yes and wiring harness is repairable proceed to Step 3 if non repairable replace GILL wiring harness

3. Is there power to GILL wiring harness but GILL Control Module does not have power? Check the plug on the GILL wiring harness that plugs into the GILL Control Module and check pins #1 and #11 for 12-24 volts (+) positive. If there is no power to pins #1 and #11 check for open connections in wires or replace GILL wiring harness.

4. Has the GILL wiring harness been spliced? If Yes proceed to Step 5. If No check for open connections or replace GILL wiring harness.

5. If the GILL wiring harness has been spliced check that the correct wires are connected to each other. if still no connectivity replace the GILL wiring harness

6. If there is connectivity to all wires in GILL wiring harness then Perform Troubleshooting Diagnostic tests as outlined in the Initial Set-up Information Guide, Oxygen Sensor Troubleshooting Guide, Fuel Valve Troubleshooting Guide, and Module Diagnostic Guide.

Responsibilities

Management - Management is responsible for implementing, supporting, and enforcing the requirements of this procedure to their respective locations/area.

EHSS - Responsible to assist in the implementation of this procedure and to review for effectiveness.

Employees, Contractors, Vendors, ETC. - Are responsible to follow the follow the requirements outlined in this procedure and ask for assistance

Scope

This procedure applies to all Natural Gas Engines equipped with the GILL AFR controller on Flogistix skids. With the outlined procedure controlling of the required engine exhaust emissions to be in compliance with local, State, or Federal requirements and is applicable to all Flogistix employees, contractors, and temporary employees.

Hazards

Employees need to be aware of the possibility of extremely hot exhaust pipe surfaces, potential exposure and the inhalation of engine exhaust. Employees should be aware that units could contain flammable and toxic gasses. Potential for the possible hazards of gas ignition or fire, hot surfaces & fluids, rotating equipment. Risk of possible concentration of H2S. Hazardous gases could be in the units pressure vessels, cooler, or associated piping and risk of inhalation of hazardous gas fumes.

Safety

All Personal Protective Equipment (PPE) for normal Field Mechanical duties apply for this procedure.

Four Gas Monitor, which is outlined in the Flogistix EHSS Manual, PPE Section 8, Procedure 8.3

This procedure applies to all units in service in the field, at a service shop, or in any storage yard.

Insure Flogistix personnel have proper safety certification or site orientation if required by the Flogistix Customer.

Insure Flogistix personnel adhere to all Customers safety practices.

Proper use of required tools

Training

All employees shall be initially trained on the following topics:

• Employee Personal Protective Equipment (PPE)

• Lock Out Tag Out (LOTO) procedure according to Flogistix policy

• Emission set up knowlege for Natural Gas Engines

• Methods and Observations that may be used to detect the presence or release of a hazardous chemicals or gas in the work place

Tools & Equipment Required

All employees performing this procedure shall be required to have the listed tools to perform job tasks:

• All required PPE according to Flogistix Safety Policy

• Lock Out Tag Out LOTO items to properly perform LOTO procedure according to Flogistix policy

• Basic Hand Tools

• GILL AFR software installed called the GILL AFP COM

• 9 pin to USB adapter cord to connect Laptop to GILL AFR controller

• Engine Timing Light

• Ounce or Water Column gauge.

• Portable Emissions analyzer

• Voltage tester

Approvals

Field Service approved by:

Date:

Engineering approved by:

Date:

EHSS approved by:

Date: