SP Systems

Installation & Operator’s Guide

2000, 4000 & 6000 Series - Generation 2

Version 3.0

2
This guide is for use with all 2nd
Generation models of the EVO-SP®
System, including the 2500, 2600,
2700, 4600, 4700, 4800, 6700 and
6800 systems.

GEN
P/N: 850-00099-01 Last Revised: December 3, 2019

© 2019 GFS Corp

INDEX

Introduction 3 Gas Outlet Pressure (GOP) Sensor 23

Operation and Maintenance 3 Connect the Wiring Harness (2000 Series) 24
Icons Used in this Manual 4 Wiring Harness Diagram (2000 Series) 25
Safety Precautions 4 Connect the Wiring Harness (4000 Series) 26
Application 5 Wiring Harness Diagram (4000 Series) 27
Compatible Fuel Types 5 Connect the Wiring Harness (6000 Series) 28
Wiring Harness Diagram (6000 Series) 29
EVO-SP® System Overview 5
Controls 7 System Operation 30
Dynamic Setpoint Protection™ 7 Powering Up the System 30
Monitoring 7 System Shut Down 31
Remote Monitoring (Optional) 8 Commissioning and Software Updates 31

Warranty Activation & Required Tools 9 Warranty 32
Required Tools List 9 Warranty Claim Procedure 33
Additional Supplies Needed for Installation 9
Components 34
Before You Get Started 10 Gas Train 34
Materials Included in the Kit 10 Control Panel 36
Optional Parts 10 Mixer with Throttle Body 37
Before Getting Started with the Installation 10 MAF / Mixer with Throttle Body 38
Flame Detector 39
Installation 12
Air-Gas Mixers and Mass Air Flow Sensor 12 Commissioning Report 40
Gas Train 13
Manual Gas Valve 15
Filter 15
Low Pressure Regulator 15
Dual Modular Solenoid Valve 15
Gas Hose 16
Control Panel 16
Diesel Flow Meter 18
Flame Detector 20
Combustible Gas Detector 21
Remote Gas Shutoff Feature 21
Engine Sensors 22
Vibration Sensors (VIB) 22
EGT Thermocouples 22
Manifold Air Temperature Thermocouples 23
Manifold Air Pressure (MAP) Sensor 23
Gas Supply Pressure (GSP) Sensor 23

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INTRODUCTION
Introduction
The EVO-SP® System is a completely new way to
manage a fumigation based natural gas + diesel engine,
NG+D® conversion. Smart, fast and intelligent controls
safely and efficiently regulate the gas mixture to provide
the optimum substitution rate across the entire load
range.
The EVO-SP® System is a fully-integrated conversion
solution that allows stationary diesel engines to safely
operate on a combination of diesel and natural gas
while maintaining rated power and performance. The
EVO-SP® System reduces operating costs, extends
emergency runtime and improves sustainability in the
most demanding applications.
Using state-of-the-art controls and hardware, the EVO-
SP® System has been designed to seamlessly integrate
with modern, electronically-controlled diesel engines
operating in dynamic and challenging environments
such as drilling, fracking, pumping, paralleling
operations and critical emergency back-up power.
An easily installed design allows for easy and fast on-
site conversion. The EVO-SP® System includes
pre-assembled and tested components that can be
installed quickly and easily in the field with no engine
modifications and minimum downtime. The EVO-SP®
System is compatible with most compression ignition
(CI) engines including variable and constant speed
applications using either mechanical or electronic
governing/injection systems.
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READ THIS MANUAL THOROUGHLY BEFORE
INSTALLATION
We recommend that you read this manual completely
through at least once before beginning any part of the
installation. Before beginning the installation, make sure
you clearly understand the system, all of its components
and its operational theory. If you have any questions,
contact technical support at 954-693-9657 or email us
at support@GFS-corp.com. Phone support is available
from 9:00am to 4:00pm Eastern Time, Monday – Friday.
Email support is monitored continuously and you can
expect a response within 24 hours.
The EVO-SP® System should only be installed, com-
missioned and maintained by a factory authorized and
trained technician. Improper installation and operation
could result in serious injury or death and substantial
property damage.
Important Note:
Some individual components included in the kit
come with installation manuals provided by the
OEM. For simplicity, brief installation instructions
for these components have been included here.
Refer to the OEM instruction manuals included in
the back of this binder for details.
Operation and Maintenance
It is the operator’s responsibility to perform all safety
checks, to make sure that all maintenance for safe op-
eration is performed properly and promptly, and to have
the equipment checked periodically by a factory trained
technician. The EVO-SP® System is designed to require
minimum maintenance other than gas filter changes and
periodic inspections for loose fittings / connections and
possible hose / wiring chaffing. Normal maintenance
service and replacement of parts are the responsibility
of the owner/operator and, as such, are not considered
defects in materials or workmanship within the terms
of the warranty. Individual operating habits and usage
contribute to the need for maintenance service.
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SAFETY PRECAUTIONS
Icons Used in this Manual
Warning: This icon appears where not
properly following instructions or following
safety precautions could cause significant
delays or problems with the installation.
Caution: This icon appears where not properly
following instructions or following safety
precautions could cause significant damage
to the EVO-SP® System, the engine or cause
personal injury or death.
Electrical Shock: This icon appears when
there is risk of electrical shock.
Fire: This icon appears when there is a risk of
fire or explosion.
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Tip: This icon appears by tips that can help
expedite the installation or offer solutions to
commonly encountered problems.
Note: When you see this icon, make sure to
note and log values for future use.
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Safety Precautions
The manufacturer cannot anticipate every possible
circumstance that might involve a hazard. The
warnings in this manual, and on tags and decals
affixed to the unit are, therefore, not all-inclusive.
If using a procedure, work method or operating
technique the manufacturer does not specifically
recommend, ensure that it is safe.
• Despite the safe design of the EVO-SP® System,
operating this equipment imprudently, neglecting its
maintenance or being careless can cause possible
injury or death. Permit only responsible and capable
persons to operate and maintain this equipment.
• Obtain all required permits and follow all local
building codes and authority having jurisdiction (AHJ)
during installation of the EVO-SP® System.
• Wear protective eye wear during all drilling or
cutting operations.
• Do not install any damaged components. Request
replacements for any parts that may have been
damaged in shipment. Installation of damaged parts
could result in significant engine damage or failure of
the EVO-SP® System to operate properly.
• Have an appropriately rated and tested fire
extinguisher available at all times during the
installation. Natural Gas can be explosive in a
contained environment! Ensure adequate ventilation
at all times in order to prevent accumulation of natural
gas from undetected leaks. Be careful not to introduce
any ignition sources when gas may be present,
including sparks from power tools.
Take all necessary precau-
tions to ensure that the engine
CANNOT be started during the
installation of the EVO-SP®
System!
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SAFETY PRECAUTIONS

Application EVO-SP® System Overview

The EVO-SP® System was specifically designed as an
improvement over existing “bi-fuel” systems on the
market, designed to work well on today’s more
sophisticated, electronic diesel engines and to allow
high substitution rates in dynamic load conditions. The
system is designed for continuous duty operation and is
ideal for oil and gas drilling or fracking operations. Other
applications included prime power, stand-by power, peak
shaving, diesel engine driven pumps / compressors and
other industrial applications.
Compatible Fuel Types
NG+D® is designed to use methane based fuels only
such as pipeline gas, wellhead gas or associated gas.
Liquid Natural Gas (LNG) or Compressed Natural Gas
(CNG) can also be used with the addition of the proper
supplemental equipment. Hydrocarbon gases such
as propane or butane are not compatible with the
NG+D® System due to the unfavorable combustion
characteristics of these gases. The quality of natural
gas used is very important. Natural gas is methane
with a much smaller quantity of other gases in the mix.
See Figure 1 below as a sample of the quantities of
other gases in high quality pipeline gas. If there is any
doubt as to the quality of the gas, a gas analysis must
be performed and the results reviewed by GFS prior to
operation of the system. Lower quality gas will result in
lower gas substitution rates.
High Quality Pipeline
Gas / Composition
in Volume %
Methane 97.09%
Nitrogen 1.41%
Ethane 0.88%
Propane 0.26%
Carbon 0.12%
Butane 0.09%
Oxygen 0.00%
Figure 1
The EVO-SP® System is a retrofit technology that allows
high horsepower, stationary diesel engines to operate on
a combination of natural gas and diesel fuel. No
modifications to the engine are required.
The system consists of sensors that monitor the various
key engine parameters to ensure safe operation at all
times. A mass air-flow sensor measures incoming air
flow volume and feeds this information to an electronic
control unit (ECU). The ECU monitors all of the incoming
data 50 times per second and calculates the appropriate
amount of natural gas for any given condition in order to
control the air / gas mixture. Supply gas is first routed
through a gas train consisting of a gas regulator, a dual
modular gas valve and a 50 micron filter. There, the
incoming gas is regulated and filtered before being
routed to electronic throttle bodies that are integrated
into air / gas mixers located just before the turbo charger
inlet. As the ECU determines the required amount of gas,
signals are sent to the throttle bodies to regulate the gas
supply.
The ECU continuously monitors all of the installed engine
sensors and displays this information to the operator on
the system’s touch screen display installed in the control
panel. An easy to use, graphical user interface allows
the operator to determine the status of the system and
the real time gas substitution rate.
The ECU, using proprietary Dynamic Setpoint
Protection™, continuously monitors the engine’s
parameters to control the gas substitution rate
across the full power range of the engine to allow
maximum gas substitution while protecting the engine
components. The system’s display, via a password
protected interface, allows factory trained technicians
to access various setup screens where parameters
are set during the initial commissioning process. Other
diagnostics and data logging features are also included.

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 SYSTEM OVERVIEW
© 2019 GFS Corp

Version 3.0

A Gas Supply Pressure

B Regulator Output Pressure
C Manifold Air Pressure
D Manifold Air Temperature
E Exhaust Gas Temperature
F Engine Vibration
G Combustible Gas Detector
H Flame Detector
Diesel Fuel Flow Meter
Gas Flow Meter
6

32
.83 2.0 .84
.82 .83 .82
2
1.5
1
.5
0
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SP
Systems

Figure 2. System Diagram

SYSTEM OVERVIEW
Controls
The EVO-SP® System is supplied with an Electronic
Control Unit (ECU) and a HMI Control Panel incorporat-
ing a Graphic User Interface (GUI). The ECU controls all
functionality of the NG+D® System. The control panel’s
GUI simply displays the system’s status and is used in
the commissioning process to set the various control
and safety set points. The NG+D® system will continue
to operate, using gas, even in the unlikely event that the
GUI malfunctions. All control functions are performed in
the ECU. The control panel serves a display function only.
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The NG+D® system will continue
to operate, using gas, even in
the unlikely event that the GUI
malfunctions.
The ECU takes in information from the various system
sensors and processes the information using the NG+D®
System’s control algorithms and set points defined
during commissioning, to control the gas throttle bod-
ies, introducing the maximum amount of gas into the
engine’s air intake system that the engine can safely
accept. As the additional BTU’s of gas enter the cylin-
ders, the engine’s governor ramps back the diesel flow
in order to maintain constant RPM. No interface or tie in
is required between the engine governor and the NG+D®
System. The ECU continuously monitors mass air flow
in order to quickly react to the engines changing load
conditions.
Dynamic Setpoint Protection™
The EVO-SP® System’s sophisticated, fast and smart
controls include Dynamic Setpoint Protection™ to
provide superior engine protection compared to other
“bi-fuel” systems on the market. Unlike other systems
that are commissioned at maximum load settings and
provide safety set points only at one high power setting,
the EVO-SP® System provides protection across the
entire load range with multiple set-points.
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Monitoring
The EVO-SP® System is fully automatic and requires no
input from the user to operate after initial commission-
ing. However, a HMI Control Panel with Graphical User
Interface is provided to allow the user to see, in real
time, critical engine parameters and NG+D® System sta-
tus. The GUI normally displays the status page as shown
in Figure 3. The green border indicates that the NG+D®
System is functioning properly.
Figure 3
If the system senses a pre-alarm condition, the sys-
tem will temporarily stop using gas by closing the dual
solenoid valve and the throttle bodies, reverting to 100%
diesel operation. If this happens the GUI border will turn
yellow as shown in Figure 4. Once the engine param-
eters return to a safe level, the NG+D® System will
automatically revert to normal operation using gas and
the GUI border will turn green. The user is not required to
take any action during this process.
If the system detects a fault condition, the system
will shut off the gas automatically by closing the dual
solenoid valve and all throttle bodies reverting to 100%
diesel mode. The GUI border will turn red as shown in
Figure 5. This is a “hard fault” condition and requires
the user to reset the NG+D® System by pressing the
reset button on the GUI. If hard faults continue, the
system and the engine need to be checked by a qualified
technician. Please call your EVO-SP® System distributor.
Each of the above GUI screens has a “gauges” button
that can be pressed at any time in order to see the
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SYSTEM OVERVIEW

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No user interaction is required
with the NG+D® System to correct
a pre-alarm condition. The system
will return to normal operation
automatically.

Remote Monitoring / Telematics (Optional)

All data points monitored by the EVO-SP® System locally

can also be monitored remotely using the optional EVO
Connect™ System. The EVO Connect module, see Figure
Figure 4 8, simply mounts inside the EVO-SP® control panel and
connects via a serial connection. When ordered with the
EVO-SP® System these modules are already preinstalled
at the factory. EVO Connect is a cellular based system.
To utilize the cellular connection, the customer must
purchase a data only cell plan from a local cellular
provider. The cellular provider should supply a Mini, or
2FF size SIM card to be installed in the unit. These SIM
cards are 15mm x 25mm. When setting up the data
plan, ask the telcom provider for the “APN” associated
with the SIM cards.

Remote monitoring is accomplished via an iPad, not

included with the kit as shown in Figure 7. The end
Figure 5 user can choose the actual data points presented
and the system configured as specified during the
commissioning process. The end user can choose to
show all data points, or limit it to just the few they are
interested in.

Data is shown in near real time. Historical data is stored

on the EVO Connect servers and can also be viewed at
any time by the end user.

Figure 6

detailed gauges page as shown in Figure 6. From the

gauges page, you can easily return to the previous
screen by pressing the “Summary” button.

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WARRANTY ACTIVATION & REQUIRED TOOLS

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The fully completed commissioning
report must be submitted to GFS Corp
after commissioning is complete.

The warranty will NOT activate

until the report is received,
reviewed and approved.

Required Tools List

Figure 7
No specialty tools are required for the installation of
the EVO-SP® System. Each installation is different and
may require non-standard techniques. The following list
applies to most situations.

• ½” Electric drill
• Drill bit set up to 5/8 inch
Figure 8 • Flat Head and Phillips screwdriver sets including
#2 Phillips
Warranty Information • Combination wrench sets (both SAE and metric)
• Allen wrench sets (both SAE and metric)
The warranty on the EVO-SP® System is not activat- • Wire cutters
ed until the commissioning report is approved by GFS • Wire crimper
Corp and activation instructions are sent to the end
user of this equipment. The Commissioning Report is • Hacksaw or reciprocating saw
available in the back of this manual and can be faxed to • Metal chop saw
954.472.1447. Make sure to fully complete the form to • Pipe wrench set (up to 24 inch)
avoid delays in warranty activation.
Additional Supplies Needed for Installation
See page 32 of this manual for the full EVO SP System
warranty and warranty claim procedure. USB Computer Mouse (Highly Recommended)
DC-4 or similar silicon based lubricant
Hose assembly lube

This manual is for installation Required for some engines:

ONLY. Commissioning can only Counter bore and pilot bit
be done by a factory trained and McMaster Carr part numbers 3102A33 and 3103A64
authorized technician. http://www.mcmaster.com

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BEFORE GETTING STARTED

Materials Included in the Kit Before You Get Started with the Installation

The following items are included in standard EVO-SP® • Determine the status of the gas supply and make
kits. Some installations require customized kits. any needed arrangements to coordinate connection
of the gas supply line.
Refer to your packing list for the full list of items
shipped with the kit.
The Gas inlet pressure must be
1-5 psi. Higher gas pressures WILL
Control Panel
permanently damage the gas
Engine Control Unit – ECU pressure regulator.
Wiring Harness Set
Gas Train (2 on 6000 Series Kits)
Hose Fittings • Survey the site to determine the installation location
of the gas train. Brackets are included for installation
Wire Braided Hose (Different quantity for each System)
on a skid. Other installations may require additional
Air-Gas Mixer with Integrated Throttle Body mounting parts such as unistrut or all-thread rod.
(1 per Engine Turbo) Secure needed additional parts prior to installation.
Mass Air Flow Sensor

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Thermocouples (Different quantity for each System)
The gas train can be no further
Vibration Sensors (Different quantity for each System)
than 12 feet from the control panel
Compression Fittings (Different quantity for each System) due to wiring harness length.
Gas Outlet Pressure Sensor (GOP)
Gas Supply Pressure Sensor (GSP)
Manifold Air Pressure Sensor • Unpack and organize all EVO-SP® System parts and
GSP/GOP Adapter (2) components.
Humps Hoses (2 per mixer)

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Hump Hose Clamps (4 per mixer)
Check against your packing list to
Installation & Operation Manual
assure that the kit is complete.

Optional Parts
• Flame Detector
• Diesel Flow Meters Inspect all items for damage. Report any damaged or
• Primary Gas Pressure Regulator missing components to GFS Corp at +01 954-693-9657
• EVO Connect immediately or email support@gfs-corp.com. Phone
support is available from 9:00am to 4:00pm Eastern
Time, Monday – Friday. Email support is monitored
continuously and you can expect a response within 24
hours.

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BEFORE GETTING STARTED

• Survey the engine to determine the availability of

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factory access points for the installation of the vari- The ECU can be no more than 8 feet
ous sensors. Some additional parts may be required from the Control Panel.
to adapt sensors to the engine.

• Determine if the air inlet conduit is the same diam-

eter as the supplied air-gas mixers. If not, contact

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your EVO-SP® distributor for hump hose adapters.
The Control Panel can be no more
• Determine desired installation location for the control than 20 feet from the farthest
panel. The control panel should never be mounted sensor (EGT).
to the engine / generator or have any contact with
engine, generator or skid that could cause vibration
to the control panel. The standard wiring harness
requires the ECU to be no more than 8 feet from the Do NOT mount ECU to the engine.
control panel. The control panel can be no further The heat from the engine WILL
than 20 feet from the most remote sensor. damage the ECU.

PLEASE NOTE THE IMPORTANT OPERATIONAL

CONSIDERATIONS BELOW
BEFORE PROCEEDING !

The maximum operating

temperature for the Control
Panel Enclosure is 140 degrees
Fahrenheit.

The SP ® System requires a 24

volt DC, 15 AMP minimum power
supply.

The EVO-SP® System requires

a minimum of 24 VDC and a
maximum of 32 VDC power
supply.

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INSTALLATION
Installation
Follow installation procedures in the order that they are
written. These instructions have been ordered in the
best possible way to save time and avoid unwanted
complications.
Figure 9. Air-gas mixer with integral throttle body
Figure 10. Air-gas mixer with integral throttle body
and mass air flow sensor. Note: The Mass Air Flow
Sensor may have a different physical appearance
than in this photo.
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Install Air-Gas Mixers and
Mass Air Flow Sensor
The natural gas is introduced into the engine via air/gas
mixers installed just ahead of each turbo inlet. These
air/gas mixers are carefully designed as to provide
optimal mixing of the gas in order for each cylinder to
receive equal amounts of gas at any given time. Each
mixer is equipped with a fast acting throttle body that is
controlled by the EVO-SP®` electronic control unit (ECU).
Depending on the engine / system installed, there will be
two to six air/gas mixers. One of the mixers is equipped
with a mass air flow sensor. The mass air flow sensor
is the primary input to the ECU as to the load on the
engine. The ECU will shut down the EVO-SP® System
should it detect a problem with any throttle body or the
mass air flow sensor.
The air-gas mixers with factory installed integrated
throttle bodies are installed in-line on the air intake
system of the engine after the air filter and before the
turbo charger compressor inlet. Each application is
different so some creativity may be required. In the
simplest installations there will be enough room and
enough length of straight pipe somewhere between
the air filter and the turbo charger to install the mixer
and mass airflow sensor. In other applications air
filter housings may need to be relocated to provide
the needed length. Before installing the air-gas mixer
determine the approximate location and verify that
there are no space conflicts with the integrated throttle
body and the routing of the flexible gas line. The air-gas
mixers can be installed at any angle that is convenient to
maintain the original geometry of the air intake system.
Each system will have one mixer that also incorporates
an integrated mass air flow sensor as shown in Figure
10. This unit can be placed ahead of any turbo charger.
Do not use WD-40 on rubber hump
hoses as this product is a solvent
to rubber and will deteriorate the
hump hoses over time.
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INSTALLING GAS TRAIN AND GAS HOSE

Install the Gas Train

Ensure that the air-gas mixer is
installed in the proper orientation
with the arrow indicating the
direction of air flow.
• The air-gas mixer must be installed in the correct
orientation. It is marked on its outer surface to
show the correct direction of the airflow as shown
in Figure 11. The cone will be facing the air filter
and the diffuser will be facing the turbo charger
compressor inlet. Installing the air-gas mixer
incorrectly will cause the EVO-SP® System to
function improperly.
The EVO-SP® System is equipped with either one or two
gas trains depending on configuration. Each gas train
consists of several parts which are assembled at the
factory and are factory pressure tested.
Do NOT discard the two green seals shipped in a zip
lock bag attached to the gas train and shown in Figure
12. These seals will be installed onto the gas train after
commissioning as shown in Figures 13 and 14. The
technician performing the commissioning will need to
record the serial numbers of these seals and submit
them with the commissioning report.

Do not discard the (2) green seals.

They will be installed by the
commissioning technician.
Figure 11
• Ensure that the air-gas mixer will not touch any
metal parts as the engines vibration will result
in chaffing, eventual failure and dangerous gas
leakage from the air-gas mixer.

• The installation of the air-gas mixer should

not significantly alter the original air inlet geometry.

Once the location has been determined, mark the

location using the mixer as a guide and cut an
appropriate length section from the air inlet conduit.
Attach the mixer using 2 of the provided hump hoses Figure 12
and 4 of the supplied hump hose clamps. Tighten
sufficiently to ensure an airtight seal around the mixer. A
silicon based lubricant such as DC-4 can be use to help
fit the hump hoses onto the mixer and the air ducts.

Repeat this process at each engine turbo charger

location.

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INSTALLING GAS TRAIN AND GAS HOSE

Figure 13 Figure 15

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The gas train can be no more than
10 feet from the mixers due to the
length of the provided gas supply
hoses.

Figure 14
Also shipped attached to the gas train is a blue regulator
spring shown in Figure 15. Do NOT discard this spring
until after commissioning. A red spring is installed in
the regulator at the factory. Depending on gas pressure Figure 16. Installed Gas Train
supplied to the system, the blue spring may need to be
installed as a replacement to the red spring in order to
provide proper gas pressure out to the system. IMPORTANT !

Do NOT discard the blue spring

ALL LEAKS MUST BE FIXED
until AFTER commissioning. PRIOR TO OPERATION
IN NG+D® MODE

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INSTALLING GAS TRAIN AND GAS HOSE
Gas line should be routed to avoid
possible chaffing of the hose.
Manual Gas Valve
The gas enters the gas train via the yellow shut off valve.
With the handle of the gas shut off valve perpendicular
to the gas train, the valve is closed. To open the valve
rotate the handle until it is parallel with the gas train. The Dual Modular Solenoid Valve (DMV) is a DC powered,
Filter
The second component in the gas train is a 50 micron
filter. This filter protects the engine and the NG+D®
System from particulate contamination that may be
present in the gas pipeline. This filter is NOT intended
as a gas filter to enhance the gas quality. The filter
is contained in a cast aluminum housing and can be
accessed by removing the cover. The filter itself is
random laid non-woven polypropylene fabric with a
stainless steel support frame. This filter should be
replaced annually or anytime the pressure across the
filter drops more than .15psig (10mbar). When replacing Alternatively, the gas train can be supported from the
the filter element, replace the o-ring seal.
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The gas filter must be replaced
annually or anytime the pressure
across the filter drops more than
.15psig (10mbar).
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The low pressure regulator is
preset between 10-15 inches of
water column. Verify this setting
prior to continuous operation.
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Low Pressure Regulator
The pressure regulator consists of a cast aluminum
housing containing a diaphragm with an adjustable
spring and a preset counter spring set for between
10-15 inches of water column. Verify this setting by
looking on the control panel display before operating
continuously.
Dual Modular Solenoid Valve
normally closed, two stage gas control valve. The DMV
is supplied with 24 volt DC power from the control
panel when the ECU commands it to open. Both valves
open simultaneously. When the DMV is de-energized
by command of the system or from loss of power, both
valves close instantly and the engine reverts to 100%
diesel operation. The system includes a gas outlet
pressure sensor on the output side of the DMV.
Two brackets are included in the EVO-SP® kit to facilitate
mounting the gas train to an engine / generator skid.
The gas train can also be mounted on the floor by
using locally sourced “unistrut” and supplied brackets.
ceiling using all-thread rod or “unistrut”. Ensure that
the gas train is supported evenly at both ends with
the load well balanced. Do not cantilever the gas train.
Consideration should be given to the routing of the gas
inlet supply line and the flexible gas line / lines that will
route to the air-gas mixers. The location of the gas train
should not interfere with routine engine maintenance.
Note: 6000 series kits require 2 gas trains, one for each
cylinder bank. Install the second gas train using similar
mounting procedures.
* The gas train itself has been assembled and leak
tested at the factory. Prior to operating the engine on
NG+D® mode, all gas connections should be leak tested
using an industry standard leak detection fluid.
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INSTALLING THE CONTROL PANEL

Install the Gas Hose

The control panel MUST be grounded to an earth ground.
The gas hose is shipped in 10 foot lengths with one end DO NOT ground the control panel to an engine ground.
having a pre-installed JIC fitting. Temporarily connect
each gas hose to the gas train outlet and route the hose • Using the standard wiring harness, the control panel
to the throttle bodies to determine the proper length can be no more than 8 feet from the Engine Control
to cut the hose. Cut the gas hoses to the proper length Unit (ECU). Optional custom cables can be ordered to
using a miter saw with a metal blade. Use care to assure remote mount the control panel.
a straight, perpendicular cut on the hose. Trim any loose
fabric over-braid that remains. Blow out all debris from • The control panel can be no further than 20 feet
the inside of the hose using compressed air. Install the from the most remote sensor (EGT)
fitting sleeve with pressure and left hand turns until it is
fully seated, almost touching the end of the hose. Place
the hose end with the sleeve installed into a vise. Lube
both the inside of the hose and the JIC fitting using Eaton The control panel MUST be
Hose assembly Lube, Eaton P/N 222070 or equivelent. grounded to an earth ground. DO
Press the fitting into the hose using firm pressure. NOT ground the control panel to an
Once you have the fitting started into the hoseuse firm engine ground.
pressure and tighten the fitting until it is properly seated
using a pipe wrench. Follow the same procedure with
each gas hose. Attach each gas hose to the gas train and
to the throttle bodies. No thread sealant is required on The control panel mount can not
JIC fittings. contact both the engine / skid
and the floor / enclosure due to
Install Control Panel resulting harmonic vibrations that
will damage the unit.
The control panel and integral display, as supplied, are
housed in a weather resistant enclosure that can be
mounted on any available vertical surface that can be Do not mount the control panel
isolated from the engine / generator to prevent unwanted directly to the engine or the
vibration. If mounting on a wall, consideration must be generator itself.
given to the length of the wiring harness. A stand can be
constructed that the control panel can then be mounted
to or it can be hung from the ceiling using “unistrut”.
The preferred mounting method is shown in Figure
17. Consideration should be given to try to avoid light
reflections on the display.

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INSTALLING THE CONTROL PANEL

Figure 17. Recommended control panel mounting structure

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INSTALLING DIESEL FLOW METERS
Install Diesel Flow Meter (Optional)
Optionally, diesel flow meters are supplied with the EVO-
SP® System. Two sensors are required per kit.
Fluid Flow Sensor Kit EVO-SP® System
Part Number
M4AR 2500, 2600, 2700, 4600,
4700, 6700, 6800
M4AR
Figure 18. Diesel Flow Meters
i
Refer to the original equipment
manufacturer’s manual included
with this binder for additional
information and technical
specifications of this component.
Most diesel engines do not use all of the fuel that is
supplied to them by the fuel pump via the supply line.
A portion of the fuel is consumed by the engine, but
the majority of the fuel is used for cooling the injection
system and is returned to the fuel tank via the return
line.
The diesel flow meters operate in a differential mode,
and will measure the net fuel consumption of the engine
by separately measuring the fuel sent to the engine
via the supply line and the fuel returned to the fuel
tank from the engine via the return line. The difference
between these two readings is the fuel consumption
of the engine. Refer to figure 19 for a system diagram
demonstrating the location of the supply and return fuel
flow sensors in a diesel fuel system.
Version 3.0
© 2019 GFS Corp
The fuel flow sensor contains shafts on which the oval
rotors spin as shown in Figure 20. The fuel flow sensor
must be mounted so that these rotor shafts are always
in a horizontal plane (parallel with the ground). Please
refer to Figure 21 for examples of correct and incorrect
orientations.
Figure 19. Diesel Flow Meter installation diagram
The fuel flow sensors have anti-
i
tamper blue silicone on one or
more of the screws that hold the
body of the sensor together. Do not
remove these screws. Removing
these screws will void the warranty
on the sensor.
To prevent damage from dirt or foreign matter, it is
required that either 1) a diesel fuel filter capable of
filtering out 75 micron particles or 2) a wye or basket
type 60 mesh strainer be installed as close as possible to
the inlet side of the sensor.
Install so that the direction of the “FLOW” arrows on
the sensor label matches the direction of fuel flow. The
M4AR fuel flow sensor is fitted with ½” NPT female
threads.
Use a liquid thread sealant on all pipe threads. Do NOT
use Teflon tape. The fittings should be tightened hand
tight, then a further ½ to 1 turn. Do not over tighten.
Extreme care must be taken when installing the sensor.
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INSTALLING DIESEL FLOW METERS

NEVER blow or send compressed

air through the sensor as this may
over rev and damage the sensor.

Figure 20 Failure to mount the diesel flow

sensor in a horizontal orientation
Model M4AR will cause the EVO-SP® System to
operate incorrectly.

Install the feed diesel flow meter

AFTER the engine fuel filter. Failure
Figure 21 to do so WILL damage the sensor

Never disassemble the fuel flow Extreme care must be taken when
sensor. If you feel that the sensor installing the sensor. Pipe strain or
is not operating correctly, contact over tightening pipe connections
GFS Corp for technical support. can cause sensor damage.

Pipe strain or over tightening sensor connections can

cause sensor damage.

To prevent damage to the sensor from entrapped air

during initial commissioning or after maintenance, slowly
fill the system with fuel (this will prevent damage caused
by air purge). Failure to do this could damage the sensor.
NEVER blow or send compressed air through the
sensor as this may over rev and damage the sensor. The
sensors are pre-wired and simply plug into the DCP 7
wiring harness.

To prevent damage to the sensor

from entrapped air during
initial commissioning or after
maintenance, slowly fill the system
with fuel (this will prevent damage
caused by air purge). Failure to do
this could damage the sensor.

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INSTALLING FLAME DETECTOR

Install the Flame Detector (Optional)

The flame detector must be tested
The flame detector should be installed in the generator every 6 months or as dictated by
room and should be angled to view as much of the en- local codes and regulations. Refer
gine as possible, especially the turbochargers and to Section 4.1.2 of the UV Flame
exhaust manifolds. Place the tilt mount in its designated Detector Manual included at the
location and secure it with four (4) fasteners through back of this guide.
four (4) holes 7 mm in diameter. Use the four (4) screws
and spring washers according to the kit. Place the detec-
tor with its conduit/cable entries pointing downwards on
the holding plate of the tilt mount. Secure the detector
with 5/16” 18 UNC x 1” screw to the tilt mount. Release
the Horizontal and Vertical Locking Screws using 3/16”
Hex Key such that the detector can be rotated. Point the
detector towards the protected area and make certain
that the view of the area is unobstructed. Secure the
detector in position by tightening the locking screws on
the tilt mount. Connect mating connector when harness
is routed into place.

Figure 22. Flame Detector

Mount the flame detector on a rigid

surface which minimizes vibrations.

i
Refer to the original equipment
manufacturer’s manual included
with the EVO-SP® System
documentation package for
additional information and technical
specifications of this component.

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INSTALLING COMBUSTIBLE GAS DETECTOR

Install the Combustible Gas Detector Remote Gas Shutoff Feature

The combustible gas detector is mounted to a flat sur-
face with (2) screws using the installation tabs located
on each side of the meter. Mount the gas detector
vertically with the sensor oriented downward. Locate the
detector above the engine and above all gas supply lines
as natural gas is lighter than air and will rise.
During normal use the sensor is protected from dirt and
oil contamination by a sintered metal cover. If this cover
becomes clogged, the response of the sensor will be re-
duced. Protect the sensor from contamination by careful
placement, or by use of rain and dust shields.
The EVO-SP® System includes the ability to shut off a
remotely located gas valve anytime that the NG+D® Sys-
tem shuts off the gas locally at the engine because of a
detected gas leak. This feature works by using a
relay inside of the gas detector itself. The relay is provid-
ed with 24 volt power from the control panel via a wiring
harness, part # 385-00050-01. This wiring harness also
includes a connector that allows an extension harness
to be connected to a remote gas shut off valve. Anytime
that the gas detector detects a gas leak, the relay is
activated and sends a signal to the remote gas valve,
shutting down the gas supply at its source.

Sensor modules must not be painted. Paint may contain Mount the gas detector vertically
compounds which will contaminate the sensor. Paint as shown in Figure 23.
will cause clogging of the sintered metal cover and will
cause difficulties during attachment of the calibration
head or other maintenance activity. It is recommended
that the module be tagged “DO NOT PAINT”. The gas detector should not be
painted.

i
Refer to the original equipment
manufacturer’s manual included Tag “Do Not Paint”
with this binder for additional
information and technical
specifications of this component. Avoid routing the J4 harness
that contains the wiring for the
combustible gas detector next to
The gas detector must be high voltage wiring.
calibrated every 6 months. Failure
to perform this calibration could
result in the EVO-SP® System
faulting out. Refer to Section 6
of the Combustible Gas Detector
Manual included at the back of
this guide.

Avoid mounting the gas detector

above heat sources. The gas
detector’s maximum operating
temperature is 176° Fahrenheit or
80° Celsius.

Figure 23. Combustible Gas Detector

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INSTALLING ENGINE SENSORS
Install Engine Sensors
Vibration Sensors (VIB)
Vibration sensors are shipped from the factory
pre-assembled and pre-wired pig tail w/ connector.
Identify locations on the engine to install the sensors.
It is preferred on 2000 and 4000 series kits that the
locations are near the front and another near the rear
(diagonally opposed). Two sensors in the case of the
2000 series and four in the case of the 4000 series.The
VIB sensor is supplied with a 3/8”-16 threaded stud for
mounting to the engine. If pre-drilled and tapped loca-
tions are not available, find locations on the engine with
sufficient material thickness to drill and tap installation
holes. The Vibration Sensors included with the kit have a
sense range of 0-2 inches per second.
NOTE: When mounting the vibration sensors, remove
the paint on the engine to allow positive contact of
the vibration sensor to the engine. Paint will act as
an insulator and provide incorrect reading from the
vibration sensor. If the area is not flat, as is the case
with some engines, a counter bore must be created
to provide an adequate surface. The counter bore and
pilot bit are available from McMaster Carr. http://www.
mcmaster.com, part numbers 3102A33 and 3103A64.
Vibration sensors MUST be
mounted to a smooth, paint free,
flat area.
Figure 24. Vibration (VIB) Sensor
Version 3.0
© 2019 GFS Corp
i
Vibration sensors should ideally be
installed in the same plane as the
engine cylinders if at all possible.
Sensors may appear different than
the photograph shown here.
Exhaust Gas Temperature (EGT)
Thermocouples
EGT Thermocouples are supplied with a bore through
type adapter with 1/4” male NPT threads. The ther-
mocouples are installed in the engine exhaust system.
Some engines will have 1/4” male NPT ports where the
EGT’s can be installed. If no existing ports are provided,
drill and tap locations for the EGT’s. The location for
the EGT’s should they need to be drilled should be just
downstream of the turbo outlet.
Note: EGT readings will be approximately 200 de-
grees F lower if the EGT is installed after the turbo
charger.
Figure 25. Manifold Air Temperature (MAT)
Thermocouple
If the only location available to
drill and tap is before the turbo
charger, extreme care must be
taken to avoid metal shavings
being ingested into the turbo
charger.
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INSTALLING ENGINE SENSORS

Manifold Air Temperature (MAT)

When installing the GSP and
Thermocouples
GOP and other gas connections,
other than JIC fittings, always
MAT Thermocouples are supplied with a bore through
use a liquid thread sealant on all
type adapter with 1/4” male NPT threads. The MAT ther-
threaded connections.
mocouple should be installed AFTER the turbo compres-
sor in a position where it can sense the air temperature
of the combustion air. For engines with after coolers, Gas Supply Pressure (GSP) Sensor
install the MAT thermocouple AFTER the after cooler.
Install the GSP on one of the available OUTLET pressure
ports on the gas filter housing. Note: The GSP sensor
has a 0-15 psi input. See location of label indicated
Manifold Air Pressure (MAP) Sensor by the arrow.

The MAP sensor should be installed downstream of the

turbocharger outlet on the pressure side to sense the
amount of turbo boost pressure. On engines with after
cooling systems, install MAP sensors AFTER the cooling
circuit. On engines that have multiple turbo chargers in
series, install the MAP sensors after the final turbo char-
gers just before the charged air is introduced into the
engine. Remote mounting of the MAP sensor is required
if operating temperatures will exceed 200 degrees F or
93 degrees C. The Manifold Pressure Sensor provided
with the kit has a sense range of 0-50 PSI.

Figure 27. Gas Supply Pressure Sensor (GSP)

Gas Outlet Pressure (GOP) Sensor

Install the GOP sensor into the available port located on

the top of the outlet side of the dual solenoid valve just
after the pressure regulator. Note: The GOP sensor has
a 0-2 psi input. See location of label indicated by the
arrow.

Figure 26. Manifold Air Pressure Sensor (MAP)

Figure 28. Gas Outlet Pressure Sensor (GOP)

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 INSTALLING WIRING HARNESS

Connect the Wiring Harness (2000 Series)

Since factory installed connectors terminate the wiring harness, it is best to begin by attaching the connectors to the
control panel and then working your way to the individual components. Route all wiring away from hot areas. Avoid
routing in areas where vibrations can cause chaffing. Connect the wiring harnesses as follows: (Note: Connectors
marked DCP “x” (Display Control Panel) connect to the control panel. Connections marked J ”x” refer to the ECU.)

Part # 385-00004-01
J1 DCP 1
Part # 385-00019-01
J2 DCP 2
Gas Solenoid Valve
Gas Supply Pressure
Gas Outlet Pressure
Part # 385-00299-01
J3 DCP 3
Part # 385-00225-01
J4 #1 EGT Thermocouple
#2 EGT Thermocouple

Manifold Air Temperature Thermocouple (MAT)

#1 Vibration Sensor
#2 Vibration Sensor
Combustible Gas Detector
Part # 385-00018-01
J5 Flame Detector
Manifold Air Pressure (MAP)
DCP 4

Part # 385-00016-01 ‘
DCP 5 #1 Gas Throttle Body
#2 Gas Throttle Body
Mass Air Flow Sensor
Part # 385-00010-01
DCP 6 24 Volt DC
Part # 385-00011-01
DCP 7 Feed Diesel Flow Meter
Return Diesel Flow Meter
Part # 385-00025-01
DCP 8 Gas Flow Meter (Optional)
Part # 385-00050-01
DCP 9 Combustible Gas Detector
Combustible Part # 385-00049-01
Gas Detector Remote Gas Shutoff Valve

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INSTALLING WIRING HARNESS

Wiring Harness Diagram (2000 Series)

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 INSTALLING WIRING HARNESS

Connect the Wiring Harness (4000 Series)

Part # 385-00004-01
J1 DCP 1
Part # 385-00005-01
J2 DCP 2
Gas Solenoid Valve 1
Gas Solenoid Valve 2
Gas Supply Pressure
Gas Outlet Pressure 1
Gas Outlet Pressure 2
Part # 385-00300-01
J3 DCP 3
EGT 5
EGT 6
Part # 385-00014-01
J4 #1 EGT Thermocouple
#2 EGT Thermocouple
#3 EGT Thermocouple
#4 EGT Thermocouple
Manifold Air Temperature Thermocouple (MAT)
#1 Vibration Sensor
#2 Vibration Sensor
Combustible Gas Detector
Part # 385-00018-01
J5 Flame Detector
#3 Vibration Sensor
#4 Vibration Sensor
#1 Manifold Air Pressure (MAP)
#2 Manifold Air Pressure (MAP)
DCP 4
Part # 385-00015-01
DCP 5 #1 Gas Throttle Body
#2 Gas Throttle Body
#3 Gas Throttle Body
#4 Gas Throttle Body
Mass Air Flow Sensor
Part # 385-00010-01
DCP 6 24 Volt DC
Part # 385-00011-01
DCP 7 Feed Diesel Flow Meter
Return Diesel Flow Meter
Part # 385-00025-01
DCP 8 Gas Flow Meter (Optional)
Part # 385-00050-01
DCP 9 Combustible Gas Detector
Combustible Part # 385-00049-01
Gas Detector Remote Gas Shutoff Valve
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INSTALLING WIRING HARNESS

Wiring Harness Diagram (4000 Series)

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 INSTALLING WIRING HARNESS

Connect the Wiring Harness (6000 Series)

Part # 385-00004-01
J1 DCP 1
Part # 385-00005-01
J2 DCP 2
Gas Solenoid Valve 1
Gas Solenoid Valve 2
Gas Supply Pressure
Gas Outlet Pressure 1
Gas Outlet Pressure 2
Part # 385-00301-01
J3 DCP 3
EGT 5
EGT 6
Part # 385-00014-01
J4 #1 EGT Thermocouple
#2 EGT Thermocouple
#3 EGT Thermocouple
#4 EGT Thermocouple
Manifold Air Temperature Thermocouple (MAT)
#1 Vibration Sensor
#2 Vibration Sensor
Combustible Gas Detector
Part # 385-00018-01
J5 Flame Detector
#3 Vibration Sensor
#4 Vibration Sensor
#1 Manifold Air Pressure (MAP)
#2 Manifold Air Pressure (MAP)
DCP 4
Part # 385-00009-01
DCP 5 #1 Gas Throttle Body
#2 Gas Throttle Body
#3 Gas Throttle Body
#4 Gas Throttle Body
#5 Gas Throttle Body
#6 Gas Throttle Body
Mass Air Flow Sensor
Part # 385-00010-01
DCP 6 24 Volt DC
Part # 385-00011-01
DCP 7 Feed Diesel Flow Meter
Return Diesel Flow Meter
Part # 385-00025-01
DCP 8 Gas Flow Meter (Optional)
Part # 385-00050-01
DCP 9 Combustible Gas Detector
Combustible Part # 385-00049-01
Gas Detector Remote Gas Shutoff Valve

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INSTALLING WIRING HARNESS

Wiring Harness Diagram (6000 Series)

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SYSTEM OPERATION

Powering Up The System
 
The EVO-SP® System is totally automated and requires
little interaction by the user. To power up the system,
first start the engine. Ensure that the EVO-SP® System
manual gas shut off valve is in the open position. Next,
turn on the power switch of the EVO-SP® System
located on the inside door of the control panel. The
display screen will boot up in approximately 5 seconds
displaying the gauges page as shown in Figure 29 and
be ready to use.
Should the system go into a hard fault condition, the
summary page will turn red and the faulted condition
will be displayed in the location shown in Figure 30.
Hard faults require user input to clear. Simply go to the
test page and press the “Clear Fault” button as shown
in Figure 31. If the fault was caused by a transient
condition, this action will revert the system back to
NG+D® operation. Should the system hard fault out
again on the same parameter, call your EVO-SP® System
factory authorized distributor for service.

Figure 30
Figure 29

i
Ensure that the manual gas shut off
valve is in the open position prior to
operation of the EVO-SP® System.

To enable gas, simply turn on the NG+D® switch located

to the left of the main power switch. The system will
automatically begin using gas in NG+D® mode. The
system can be left operating with no further interaction
from the user. Three screens are available on the display,
the gauges page, the summary page, or the test page.
These pages can be scrolled through by pressing the
button on the lower left side of the screen as shown
in Figure 29. Users can choose to leave the system Figure 31
operating showing either the gauges page, to see more
detail of system and engine parameters, or the summary
page.

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SYSTEM OPERATION

System Shutdown The EVO-SP® System should only be commissioned by

 
The EVO-SP® System is easily shut down. First turn off
the NG+D® switch. Then turn off the main power switch.
The EVO-SP® System is shut down and the engine
will continue to run on diesel fuel only. If the EVO-SP®
System is going to be left in the off position for an
extended period of time, close the manual gas shut off
valve.
a factory trained and authorized technician. Refer to the
EVO-SP® System Commissioning Guide for instructions.
The EVO-SP® System should only
be commissioned by a factory
trained and authorized technician.

The EVO-SP® System is pre-loaded at the factory with

i
If the EVO-SP® System is not going to
be operational for an extended period
of time, close the manual gas shut of
valve.
Commissioning and Software Updates
the latest version of the graphical user interface (GUI)
and Firmware. The system can be updated as improved
versions of the software are released. These software
updates are available from your EVO-SP® System
Factory Authorized Distributor. Software updates must be
installed by a factory trained and authorized technician.

The EVO-SP® System’s control panel incorporates a USB Software updates must be installed
connector protected by a weather tight cap as shown by a factory trained and authorized
in Figure 32. Commissioning and software updates technician.
are accomplished by connecting a properly configured
laptop computer to this connection using a USB 2.0 Male
A to Male A cable. USB cables that incorporate a ferrite
core are not compatible.

i
USB cables that incorporate a ferrite
core are not compatible.

Figure 32

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WARRANTY

EVO-SP® System PRODUCT WARRANTY

The GFS Corp NG+Diesel products are warranted against failure in normal usage due to defects in workmanship
and materials when installed in accordance with the applicable instructions and good practice. Warranty periods are
defined as follows:

ITEM WARRANTY TIME PERIOD

Major system components: (mixers, regulators, 2 years from date of sale to first end user or 30 months from date
controllers, etc.) of shipment from GFS Corp, whichever occurs first

Transducers, thermocouples, vibration or 1 year from date of sale to first end user or 18 months from date of
other sensors shipment from GFS Corp, whichever occurs first
Engine damage related to failure of the EVO- 12 months or 1,000 operating hours, whichever occurs first
SP® System on a new engines (see below)

GFS Corp shall, at its sole option, repair, replace, or credit for the purchase price, any product which, after
examination by GFS Corp, is deemed defective. GFS Corp shall be contacted for explicit authorization prior to
returning products and/or parts for warranty consideration or service. All parts must be shipped prepaid to the GFS
Corp facility accompanied by a completed warranty claim form.

This warranty shall be deemed void in the event that the EVO-SP® System has been altered or modified without
permission of GFS Corp. GFS Corp specifically makes no warranty with respect to accidental or deliberate damages
resulting from product use, nor does it warranty damages caused by improper installation, operation, and/or misuse
or abuse of the product.

For a period of 12 months or 1,000 operating hours (whichever occurs first) following installation of the EVO-SP®
System on a new, previously unused diesel engine which is properly maintained under a maintenance contract, GFS
Corp will further warrant to the original purchaser that should a failure of the EVO-SP® System result in damage to
the converted engine, GFS Corp shall cover direct repair costs. Detonation damage shall be covered only if the GFS
Corp vibration protection package is in use. Customer shall provide a written report to GFS Corp detailing the cause
of engine damage within 48 hours of the occurrence. GFS Corp (or its designated technical representative) shall be
granted access to the damaged engine or engine components prior to commencement of repairs, unless otherwise
authorized by GFS Corp. Reimbursement shall be limited to the cost and direct labor of replacing said damaged
parts. This provision shall not apply to damages caused by gas quality and/or composition, nor shall it apply to
damages related to improper installation or operation of the EVO-SP® System or the converted engine.

This warranty does not apply to the cost of installation, cost of removal, consequential or concurrent damage. This
warranty is expressly in lieu of all other warranties, expressed or implied, including warranties of merchantability
and fitness for a particular purpose.

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WARRANTY

WARRANTY CLAIM PROCEDURE

1. All warranty claims must be submitted in writing through the original selling party.

2. Selling party must contact GFS Corp with full details and request a warranty claim form and a Return
Authorization number (RMA) prior to shipment of parts.

3. Materials being submitted for warranty consideration must be properly packaged to prevent damage in transit
and sent PREPAID.

Ship to:

GFS CORP
3360 Enterprise Ave
Suite 180
Weston, FL 33331

4. At the user’s discretion, the original selling party can provide a PO for replacement parts that, if available, will
be shipped and invoiced (standard payment terms apply) prior to receiving the parts at GFS Corp for warranty
consideration. At the sole discretion of GFS Corp, if the returned parts meet the conditions of the Warranty, and are
non-repairable or deemed to be unrepairable, GFS CORP will cancel the invoice generated against the PO.

5. If the returned parts are deemed by GFS Corp to be outside of the Warranty conditions, the customer will be
notified and asked to approve the cost of repair (if repairable) or final disposition of the part(s). Failure to respond
with such instructions for a period of 30 days will result in the parts being returned to the shipping source in their
current condition.

6. Parts covered by the Warranty will be returned by GFS Corp prepaid to the shipping source with the same level of
expedition with which they were shipped to GFS Corp. Repairs or replacements outside of the Warranty coverage will
be shipped COLLECT.

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COMPONENTS

Gas Train

FLOW DIVIDER
11.22 .25 in JCI 24
[285 6.4 mm]

38.37 .25 in
[975 6.4 mm]

4 5
2 6 7
3

1
12.25 .25 in
[311 6.4 mm]

INLET
2.5" NPTF

Pos. Description Part # Qty

1 Threaded Flange PN16 DN 65 - 2”1/2 NPT- Cast Steel 1
2 Z014 DN65 PN 16- Butterfly Valve - Lug Type­-Cast Iron - Pmax: 16 Bar (230 PSIg) 1
3 Gas Filter - DN65 PN16 - Pmax: 4bar (55psig) - Aluminum Housing - 50 microns filtration 1
4 FRS 5065 - Pressure regulator DN65 PN16- Pmax: SOOmbar (7 sig) 1
5 Double Solenoid valve - DN65 PN 16 - Pmax 7 PSIg(SOOmbar) - 24VDC - IP54 1
6 1/4” BSP Male I 1/4” NPT Female - Adapter- Iron 1
9 Tap 1/4” NPTM - Steel 1
10 Red Spring 10-22”WC - For FRS 50655080 (Note 1) 1

Note 1: Blue Spring shipped uninstalled

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© 2019 GFS Corp

Version 3.0

COMPONENTS
DN 65 Gas Train
DN 65 Gas Train
Item GFS Part Number Description QTY
1 532-00001-01 Threaded Flange 1
1) Threaded Flange
2 532-00002-01 Butterfly Valve 1
3 532-00003-01 Gas Filter 1
4 532-00012-01 Gas Filter Insert/Gasket 1
2) Butterfly Valve
5 531-00012-01 Gasket 2
6 532-00004-01 Pressure Regulator 1
7 532-00005-01 Double Solenoid Valve 1
3) Gas Filter
8 552-00002-01 O-Ring 1
9 513-00003-01 Mixer Connector 1

6) Pressure Regulator
35

7) Double Solenoid Valve

4) Gas Filter Insert / Gasket

9) Mixer Connector
Installation & Operation Guide

5) Gasket
SP
Systems

8) O-Ring
COMPONENTS

Control Panel

20.00

3.00 14.00 1.25

.44

24.00 25.25 26.50

1.13

8.00 8.96

20.00

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COMPONENTS

Mixer w/ Throttle Body - 5”, 6”, 7” & 8”

1) Mixer

4) 1/8” MNPT Plug

5) 9/16” O-ring
6) 15/16” O-ring

2) 1-11/16” O-Ring

7) Metal Mixer Plate

3) Flange JIC Adapter 8) Throttle Body

Item GFS Part Number Description Quantity

1 513-00007-01 5” Mixer 1
1 513-00006-01 6" Mixer 1
1 513-00005-01 7” Mixer 1
1 513-00009-01 8” Mixer 1
2 552-00001-01 1-11/16" O-Ring 2
3 513-00002-01 Flange JIC Adapter 1
4 525-00003-01 1/8" MNPT Plug 1
5 552-00003-01 9/16" O-Ring 1
6 552-00004-01 15/16" O-Ring 1
7 513-00011-01 Metal Mixer Plate 1
8 380-00001-01 Throttle Body 1

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COMPONENTS

MAF / Mixer w/ Throttle Body - 5”, 6”, 7” & 8”

1) Mixer

4) 1/8” MNPT Plug

5) 9/16” O-ring
6) 15/16” O-ring

2) 1-11/16” O-Ring

7) Throttle Body
Item GFS Part Number Description Qty
1 513-00007-01 5” Mixer 1
1 513-00006-01 6" Mixer 1
1 513-00005-01 7” Mixer 1
1 513-00009-01 8” Mixer 1
2 552-00001-01 1-11/16" O-Ring 2
3 513-00002-01 Flange JIC Adapter 1
3) Flange JIC Adapter
4 525-00003-01 1/8" MNPT Plug 1
5 552-00003-01 9/16" O-Ring 1
6 552-00004-01 15/16" O-Ring 1
7 380-00001-01 Throttle Body 1
8 375-00003-01 Mass Airflow Sensor 1

8) Mass Airflow Sensor

Note: Mass Air Flow Sensor may

have a different form factor than
shown here, P/N 370-00032-01.

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COMPONENTS

Flame Detector

4.75
4x .27

3.94
TYP
2.94
TYP

8.81
8.62

4.43
6.18
5.20

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COMMISSIONING REPORT
Configuration Engine Runs - Diesel Baseline vs. NG+D
Distributor Customer
Address Address
City City
State State
Zip Code Zip Code
Country
Contact Application
Phone Office Gas Supply
Phone Cell Pressure

Engine Make GFS Technician Software Version

Engine Mode Distributor Tech GUI & Firmware
Configuration Date Completed Kit Model
Engine Rating

Gas Throttle Output Settings Supervisory

MAF < CFM Throttle % Gas Subst % Flame Detector Pre-Alarm > Fault >
Setting 1
Gas Detector #1 %LFL
Setting 2
Gas Detector #2 %LFL
Setting 3
Setting 4 Pressures
Setting 5 Low Gas < Pre-Alarm > Fault >
Gas Out 1 InW
Setting 6
Gas Out 2 InW
Setting 7
Gas Inlet PSI
Setting 8
Setting 9 Gas Offsets
Setting 10 1 % 3 % 5 %
2 % 4 % 6 %
Calibrations
Diesel Flow Meters
Gas Inc Filter Sec. KWE Full Scale
Use Maritron / Pulsed
Gas Dec Filter Sec. Pre-alarm Recovery
Supply K-Fac
Gas Thr “100%” at % Gas On Delay
Return K-Fac
Analog In Filter Sec. Throttle Hysteresis
Vib Filter Sec. Vib Full Scale MAF at J4-15
MAF In Filter Sec. RPM Teeth Count MAP Bypass Out
Gas Thr Fdbk Err % Engine RPM Min Max Delay Sec.
Gas Flow Full Scale SCFH MAF Full Scale Scale X %
Dsl Flow Full Scale GPH MAF Drop % Recvr S Min Limit PSI
MAP Lowest High MAP Drop % GTB % Max Limit PSI

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COMMISSIONING REPORT
Configuration Engine Runs - Diesel Baseline vs. NG+D
Power Setting 1 Power Setting 2 Power Setting 3
Diesel NG+D Diesel NG+D Diesel NG+D
GSP GSP GSP
GOP 1 GOP 1 GOP 1
EGT 1 EGT 1 EGT 1
EGT 2 EGT 2 EGT 2
EGT 3 EGT 3 EGT 3
EGT 4 EGT 4 EGT 4
VIB 1 VIB 1 VIB 1
VIB 2 VIB 2 VIB 2
VIB 3 VIB 3 VIB 3
VIB 4 VIB 4 VIB 4
MAT MAT MAT
MAP 1 MAP 1 MAP 1
MAF MAF MAF
MAF TEMP MAF TEMP MAF TEMP
GPH GPH GPH
TBP TBP TBP
ENG POWER ENG POWER ENG POWER
GFM GFM GFM
Power Setting 4 Power Setting 5 Power Setting 6
Diesel NG+D Diesel NG+D Diesel NG+D
GSP GSP GSP
GOP 1 GOP 1 GOP 1
EGT 1 EGT 1 EGT 1
EGT 2 EGT 2 EGT 2
EGT 3 EGT 3 EGT 3
EGT 4 EGT 4 EGT 4
VIB 1 VIB 1 VIB 1
VIB 2 VIB 2 VIB 2
VIB 3 VIB 3 VIB 3
VIB 4 VIB 4 VIB 4
MAT MAT MAT
MAP 1 MAP 1 MAP 1
MAF MAF MAF
MAF TEMP MAF TEMP MAF TEMP
GPH GPH GPH
TBP TBP TBP
ENG POWER ENG POWER ENG POWER
GFM GFM GFM

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COMMISSIONING REPORT
Configuration Engine Runs - Diesel Baseline vs. NG+D
Power Setting 7 Power Setting 8 Power Setting 9
Diesel NG+D Diesel NG+D Diesel NG+D
GSP GSP GSP
GOP 1 GOP 1 GOP 1
EGT 1 EGT 1 EGT 1
EGT 2 EGT 2 EGT 2
EGT 3 EGT 3 EGT 3
EGT 4 EGT 4 EGT 4
VIB 1 VIB 1 VIB 1
VIB 2 VIB 2 VIB 2
VIB 3 VIB 3 VIB 3
VIB 4 VIB 4 VIB 4
MAT MAT MAT
MAP 1 MAP 1 MAP 1
MAF MAF MAF
MAF TEMP MAF TEMP MAF TEMP
GPH GPH GPH
TBP TBP TBP
ENG POWER ENG POWER ENG POWER
GFM GFM GFM
Power Setting 10
Diesel NG+D
GSP
GOP 1
EGT 1
EGT 2
EGT 3
EGT 4
VIB 1
VIB 2
VIB 3
VIB 4
MAT
MAP 1
MAF
MAF TEMP
GPH
TBP
ENG POWER
GFM

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COMMISSIONING REPORT
Power Window Configuration
Power Window 1 Power Window 2 Power Window 3
Max MAF Max MAF Max MAF
Alarm Fault Alarm Fault Alarm Fault
MAT #1 MAT #1 MAT #1
EGT #1 EGT #1 EGT #1
EGT #2 EGT #2 EGT #2
EGT #3 EGT #3 EGT #3
EGT #4 EGT #4 EGT #4
VIB #1 VIB #1 VIB #1
VIB #2 VIB #2 VIB #2
VIB #3 VIB #3 VIB #3
VIB #4 VIB #4 VIB #4
Ignore Vibs Below (EGT1) o
F Low High High Low High High
Pre < Pre > Fit > Pre < Pre > Fit >
Ignore Vibs Below (MAF) CFM MAP 1 PSI MAP 1 PSI
Low High High MAP 2 PSI MAP 2 PSI
Pre < Pre > Fit >
MAP 1 PSI
Serial Number Record
MAP 2 PSI
Delay check after gas ON Sec Control Panel
Touch Screen
ECU Seals
Gas Train Seals

Power Window 4 Notes

Max MAF
Alarm Fault
MAT #1
EGT #1
EGT #2
EGT #3
EGT #4
VIB #1
VIB #2
VIB #3
VIB #4
Low High High
Pre < Pre > Fit >
MAP 1 PSI
MAP 2 PSI

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