FRC EGP User manual

TEL ( 516 ) 724-8888 FAX ( 516 ) 360-9727 TOLL FREE 1-800-645-0074
OPERATING INSTRUCTIONS
MODEL : EGP
26 Southern Blvd., Nesconset, NY11767

1. INTRODUCTION
The Electro Governor is an automatic
control system that constantly measures
the pump pressure (using the transducer),
and adjusts the engine speed (using the
stainless steel push/pull control rod on the
Governor motor), to the dialed-in pressure
on the control panel.
There are three major components :
1. PRESSURE TRANSDUCER : An
electrical device that screws into the pump
housing and has an electrical output
voltage that is proportional to the pressure
applied.
2. GOVERNOR MOTOR : This is a small
electrical motor connected to a push/pull
rod that moves back and forth with an
electrical signal supplied by the control
unit.
It moves 1 - 7/8" and has two electrical
stops and a built-in pin that shears when
the unit pushes or pulls more than 100
pounds. The rod is connected to the
engine speed control (carburetor or fuel
rack).
3. CONTROL UNIT : This box controls all
functions of the Governor system. In
manual, it sends 10 volts to the motor when
the "INC" button is pressed, and 12 volts
when the "DEC" button is pushed, causing
the motor to move in the desired direction.
The Manual mode operates without the
electronics or the fuse.
In Automatic, the desired pressure must
be dialed-in (between 75 and 300 psi) on
the right hand control knob. The pressure
on the pump must exceed 50 psi in
automatic or the system will decrease to
idle (this is the low pressure, out of water
shut down function).
To get above 50 psi, momentarily push
the "INC" button (the buttons override the
automatic mode whenever they are
pushed). The Governor will now advance
to the desired pressure. (For optimum
performance, see the Adjustment
Procedure section).
The control unit constantly receives a
feedback from the pressure transducer and
compares it with the dialed-in pressure,
and if there is a difference, it sends a
correction signal to the Governor motor,
causing the RPM to adjust and, thus,
correcting the pump pressure. If the fuse
blows or is removed, the automatic function
will not operate.
2. INSTALLATION
Step 1 : For Panel Mount Unit, cut hole in
panel where Governor is to be placed.
Control unit requires clearance of 11"
behind the panel. *Four 3/16" dia.
mounting holes are centered on the
corners of a 3.7" X 6.25" rectangle.
Step 2 : Mount the Governor motor, using
mounting bolts, firmly to the engine so that
the rod is in the line of motion of the control
arm of the fuel rack (carburetor). Increase
arrow on Governor motor should be
pointing in the direction of Throttle
increase.
Step 3 : The motor can be either used to
push or to pull up to 100 pounds. Attach
extension rod (not supplied). It will pull or
push the rod in about 2". Use flexible rod
or push pull cable, such as used on vehicle
carburetor. Make sure that the travel span
is between 2-1/4" to 2" (Ref. Figure
THROTTLE SERVO MOTOR).
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If chain is used as the interconnection,
be careful it is not the type of chain that
can loop on itself, and make sure it cannot
grab on anything in its movement area.
This will definitely cause the throttle to be
stuck in the open position.
Step 4 : Install the pressure transducer
on the pressure side of the pump. This
Solid State transducer will operate over a
pressure range of 0-300 psi. Pressures
to 500 psi will not harm it, but consult the
factory if you operate the pump with
pressure over 500 psi.
The transducer should not be mounted
using any tube. It SHOULDN'T be
mounted directly over the volute, but before
any check valves.
Step 5 : IMPORTANT : Connect RED wire
to Pump Engaged switch and the BLACK
wire to ground.
The 12V supply for the Governor
should only be supplying 12V when the
apparatus is in pump.
Connect the YELLOW wire to the
chassis ground. If you have a 24 Volt
vehicle, make sure the unit was
purchased with the 24VDC option.
Consult factory for details.
Step 6 : Connect extension cables from
control unit to the Governor motor and
pressure transducer.
Step 7 : With engine off, switch to
MANUAL. Press "INC" button. Check the
Governor motor travel. It should pull the
throttle for a distance of at least 2". Press
"DEC" button. Make sure that the rod on
the servo motor stops at the end of the
travel.
Step 8 : Turn the unit to MANUAL, and
run Governor motor up and down with
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increase and decrease switches to check
the travel and stops. In the MANUAL and
in the AUTO mode, when the "INC" or
"DEC" button is pushed, the electronics
are completely bypassed and the system
operates as a straight DC motor.
This unit will operate in this fashion
even if the electronics failed, the fuse is
missing or is blown.
Step 9 : Put the pump in operation. Turn
to AUTO. Set pressure selector to
approximately 150 psi. Press "INC" button
until RPM advances sufficiently to give
pump pressure greater than 50 psi.
Release the "INC" button. Automatic
operation will proceed and bring pump
pressure to 150PSI.
The governor automatically resets
the rpm to idle any time the pump
pressure drops below 50 psi. The
pressure must exceed 50 psi for the
automatic mode to be effective.
Below 50 PSI, it automatically shuts
itself off. Therefore in "Auto" mode, either
the incoming pressure must exceed 50
psi, or pump pressure must exceed 50
psi using the "INC" button.
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NOTE :
1) The pressure select dial is a rough dial
for the pressure desired. Use your master
pump gage as your reference.
2) Make sure the transducer is mounted
on the pressure side of the pump, away
from any pressure disturbances.
3) Check that the ground goes right to the
chassis of the vehicle and not just the
body, as many bodies and some of the
pumps are insulated from the body by
rubber or wood. Grounding directly to
the negative side of the battery is best.

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Adjustment Procedure
There are two adjustments on the
control box. In the factory they are set
approximately at the half-way points.
1) Set the system in "AUTO", and dial in
150 psi.
2) Press the "INC" button. When the
pressure is above 50 psi, release the
button and your automatic Governor will
now take over.
If the Governor's reaction time is
satisfactory in all the various modes of
fire fighting that you will encounter, no
further adjustments are necessary. If,
however, it is reacting too fast, too slow,
or is unstable in certain conditions, there
are adjustments that you can make to
change the respond of the system.
There are two potentiometers ( Ref.
Figure 3) .Potentiometer " Fast Increase "
adjusts the general speed of the system
when it is both increasing or decreasing
the engine speed; i.e., it speeds the engine
up or slows it down. Clockwise rotation
on this potentiometer makes the system
faster.
Potentiometer "Clock" changes the
engine speed as it approaches the desired
pressure. Turning it clockwise will make
the rate of increase faster.
Step A. If the Governor is reacting fast,
but is unstable ( surging up and down ),
turn Potentiometer "Fast Increase"
counterclockwise in small steps. This will
slow down the response of the Governor.
If it becomes too slow, turn
Potentiometer "clock" clockwise in very
small steps until the desired rate is
achieved. Test this setting under all
operating conditions; i.e., hydrant, tank,
draft, etc.
Step B. The Governor is reacting slowly
(on increase). Turn Potentiometer "Fast
Increase" in small steps clockwise until
the response is satisfactory. Then turn
Potentiometer "Clock" counterclockwise in
small steps until the desired respond is
achieved. Test the system under all
pumping conditions.
The Governor should be tested under
various sources of water and by opening
and closing the valves with flows ranging
from 0 to maximum rated capacity of the
pump. Test reactions with multiple lines
to make sure you have the optimum speed
adjustment.
3. Operations
There are 3 operation modes : OFF,
MANUAL, and AUTOMATIC.

OFF
In the OFF position, there is no
electricity to the system. However the
Governor will bring the engine RPM down
to idle when the system is shut off.

MANUAL
In the MANUAL position, the two
buttons on the lower left and right activate
the throttle mechanism via an electric
motor.
When the "INC" button is pushed, the
motor will pull the throttle at a set speed,
depending on the setup.
When the "DEC" button is pushed, the
motor will decrease at a faster rate of
speed than in the increase mode.
When your finger is taken off the button,
the Governor motor will stop and engine

speed remains at that RPM.
If the fuse is blown, the increase and
decrease buttons will still operate. If the
increase and decrease buttons are pushed
simultaneously, the decrease button will
control the system. However, this should
be avoided.

AUTOMATIC
In the AUTOMATIC mode, you simply
dial the approximate pressure that is
required, press "INC" to bring pressure
above 50 psi and the system will achieve
that pressure and hold it. For fine
adjustments, use the master pressure
gage as a reference.
This Governor has an automatic
shutdown circuit on it. Any time the
discharge pressure does not exceed
approximately 50 psi in the AUTOMATIC
mode, this system will shut down. This is
a very useful feature since it helps prevent
the engine from running away if there is
no water in the pump or if the tank runs
out of water.
If the pump is working from draft or the
tank, it is normally required to push the
increase button until the gage pressure
exceeds 50 psi. In a hydrant situation, it
is normally not necessary to use the
increase button.
It also should be remembered that in
the AUTOMATIC mode, the increase and
decrease buttons are not only functional,
but they override the AUTOMATIC mode.
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NOTE : FUSE
The 5 amp standard fuse is designed
to operate in the AUTOMATIC mode. If
the fuse blows, you still have increase
and decrease control of the carburetor/
fuel rack, in either the AUTOMATIC or
MANUAL position, by pushing the
appropriate buttons.
4. Trouble-Shooting
The following are guidelines for simple
troubleshooting :
1) Inspect all connectors. Make sure that
the red wire is connected to + (plus) of
the truck, and the black wire is connected
to - (minus) of truck.
2) With engine off, switch to manual.
Press "INC". Check the Governor motor
travel. It should pull the throttle for a
distance of 1-7/8". Press decrease. Make
sure that by the end of travel it stops.
If this test is successfully done, it will
verify that the Governor motor section is
functioning properly and that the power to
the unit is connected properly. (See
Instructions for Installation section.)
3) If in AUTOMATIC the Governor is not
functioning, check the fuse. Do not attempt
to replace it with a fuse higher than 5
ampere.
If your Governor is still not operating
as expected, call our Service Department.
Do not try to troubleshoot the unit further
by yourself.
If you have any questions or feel that
additional information can help you, do not
hesitate to call our Engineering
Department. We will be more than happy
to assist you with any problems you might
encounter.
Fire Research Corporation strives for
quality, perfection, and excellence in
all its products. We are at your service.
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5. SPECIFICATIONS
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CONTROL
Response : Idle to full throttle 7 sec. maximum
Pressure Recovery : On open/close values 3 sec. typical
Pressure dial range : 0-300 PSI
Minimum discharge pressure control point : 50 PSI
( out of water, engine is returned to idle )
ELECTRICAL
Power 12 VDC or 24 VDC optional
Current 3A intermittent, ½A continuous
Fuse 5A slow blown fuse
MECHANICAL
Discharge pressure transducer assembly : Range 0-300 PSI
Max. overload 500 PSI
Transducer type : Stainless steel diaphragm type with integral 8 foot connecting cable
with a 4 pin connector
Throttle servo : 12 VDC motor
Total linear motion 1 7/8 inches
Maximum actuator load 200 lb. axial
Operating cable length 8 foot with 2 pin connector
Additional extension cables : Optional in 8 ft. increments
TEL ( 516 ) 724-8888 FAX ( 516 ) 360-9727 TOLL FREE 1-800-645-0074
26 Southern Blvd., Nesconset, NY11767