FRC InControl TGA300 User manual

TGA300 Rev180405
1
PRESSURE GOVERNOR,
ENGINE MONITORING, AND
MASTER PRESSURE DISPLAY
MODELS: TGA300, TGA400
Document Number:
XE-TGA3PM-R0A
TGA300
TGA400
FIRE RESEARCH CORPORATION
www.reresearch.com
26 Southern Blvd., Nesconset, NY 11767
TEL [phone] FAX [phone] TOLL FREE 1.800.645.0074

TGA300 Rev180405
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CONTENTS Table of Contents
CONTENTS................................................................................................................ 2
INTRODUCTION ...................................................................................................... 4
Overview................................................................................................................ 4
Features.................................................................................................................. 4
Specications......................................................................................................... 5
GENERAL DESCRIPTION ....................................................................................... 6
Components ........................................................................................................... 6
Controls and Indicators.......................................................................................... 8
INSTALLATION ...................................................................................................... 10
Install Control Module......................................................................................... 10
Install Pressure Sensors ....................................................................................... 11
Install Sensors...................................................................................................... 12
Install Buzzer ....................................................................................................... 12
Install High-Idle Kit............................................................................................. 12
Install Remote Governor Option.......................................................................... 12
OPERATION ............................................................................................................ 13
Controls................................................................................................................ 13
Error Codes and Fault Warnings.......................................................................... 14
Pressure Mode Operation..................................................................................... 15
RPM Mode Operation.......................................................................................... 17
Switching Between Operating Modes ................................................................. 18
Pump Discharge Pressure is High at Engine Idle ................................................ 18
RPM Limit with Discharge Pressure Less than 100 PSI ..................................... 18
Remote Governor Option..................................................................................... 18
Detailed Information............................................................................................ 19
High-Idle.............................................................................................................. 19
Preset Settings (Pressure or RPM)....................................................................... 20
PROGRAMMING .................................................................................................... 21
Access Password Protected Programs ................................................................. 23
CALIBRATION........................................................................................................ 25
Pump Pressure Sensor (Code C1 and C2) ........................................................... 26
Engine RPM (Code C3)....................................................................................... 26
WIRING.................................................................................................................... 27
Connectors and Cables......................................................................................... 27
Secondary Controller, Cables and Connections................................................... 28
Pressure Sensor.................................................................................................... 29
Common OEM Diagnostic Connector................................................................. 30
Cummins Harness Connections........................................................................... 31
Detroit Diesel Harness Connections.................................................................... 32
Navistar Harness Connections............................................................................. 33
Navistar / International Chassis Harness Connections ........................................ 34

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List of Tables
Table 1. Pressure Sensor Output Voltage ........................................................................ 5
Table 2. Error Codes ..................................................................................................... 14
Table 3. Fault Warning Codes....................................................................................... 14
Table 4. Operator Password Protected Program Functions .......................................... 24
Table 5. Calibration Codes Quick Reference Chart...................................................... 25
List of Figures
Figure 1. Controls and Indicators.................................................................................... 9
Figure 2. Control Module Mounting Dimensions......................................................... 10
Figure 3. Pressure Sensor Dimensions.......................................................................... 11
Figure 4. TGA 12-Pin Connector Wiring...................................................................... 27
Figure 5. TGA 8-Pin Connector Wiring........................................................................ 28
Figure 6. Pressure Sensor Wiring.................................................................................. 29
Figure 7. Common OEM 9-Pin Diagnostic Connector................................................. 30
Figure 8. Cummins TGA301/401 Wiring ..................................................................... 31
Figure 9. Detroit Diesel TGA302/402 Wiring .............................................................. 32
Figure 10. Navistar TGA304/404 Wiring ..................................................................... 33
Figure 11. Navistar/International Chassis TGA304/404 Wiring.................................... 34
Figure 12. Caterpillar TGA305/405 Wiring.................................................................. 35
Figure 13. Ford TGA306/406 J1939 Translator Module Wiring................................... 37
Figure 14. Ford TGA306/406 PCM Wiring................................................................... 38
Figure 15. Mack TGA307/407 Wiring........................................................................... 39
Figure 16. Scania TGA308/408 Wiring—Type A.......................................................... 40
Figure 17. Scania TGA308/408 Wiring—Type D ......................................................... 41
Figure 18. Mercedes TGA310/410 Wiring ................................................................... 43
Figure 19. John Deere TGA316/416 Wiring.................................................................. 44
Figure 20. MAN TGA324/424 Wiring .......................................................................... 45
Figure 21. IVECO TGA326/426 Wiring........................................................................ 46
Figure 22. High Idle Wiring.......................................................................................... 47
Figure 23. Flyback Diode ............................................................................................. 48
Caterpillar Harness Connections ......................................................................... 35
Ford Harness Connections................................................................................... 36
Mack Harness Connections ................................................................................. 39
Scania Harness Connections—Type A ................................................................ 40
Scania BCI Harness Connections—Type D ........................................................ 41
Mercedes Harness Connections........................................................................... 42
ACTROS Wiring.................................................................................................. 43
John Deere Harness Connections ........................................................................ 44
MAN Harness Connections ................................................................................. 45
IVECO Harness Connections .............................................................................. 46
High-Idle Wiring.................................................................................................. 47
FLYBACK DIODE INFORMATION ...................................................................... 48

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INTRODUCTION
Overview
The Fire Research all-in-one pressure governor and instrument panel uses state-of-
the-art programmable, microprocessor technology. It maintains a steady pump discharge
pressure by controlling engine speed or holds a selected engine RPM. It offers complete
engine control and remote display in a single compact unit.
The governor operates in one of two modes, pressure or RPM. In pressure mode
it maintains a constant pump discharge pressure. The discharge pressure is monitored,
compared to the selected pressure setting, and the engine RPM is varied to keep the
discharge pressure at the selected setting. In RPM mode it maintains a constant engine
RPM. The pump discharge pressure is monitored and can vary, but, as a safety feature,
it will be limited to an increase of 30 PSI. If the discharge pressure increases 30 PSI
the governor automatically lowers the engine RPM to prevent a high pressure surge.
All controls and indicators are located on the front of the control module.
Features
J1939 CAN Bus for Engine Information and Control
Power Up in Pressure Mode
Automatic Regulation of Pump Discharge Pressure
Manual Control of Pressure or Engine RPM Settings
Programmable Presets
Diagnostic Capabilities
No Pressure or RPM Variation When Changing Modes
Limits Increase of Pressure When in RPM Mode
Recognition of No Water Condition with Automatic Response
Interlock Signal Recognition with Throttle Ready LED
Return to Engine Idle with the Push of a Button
Display Brightness Automatically Adjusts for Day or Night Operation
kPa, Bar, °C Options
Remote Governor Option

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Specications
The governor is available in various models. Each model is programmed to interface
with specic engines. All models provide the same functions, controls, and digital
readouts for the management of pump discharge pressure.
Control Module
Supply Power: 12/24 VDC
Supply Current: 1.8 Amp
Dimensions: 10 1/2" Wide by 5 1/2" High
Unit of Measure: PSI °F (Program Option for kPa, Bar, °C)
LED Bar Graphs
Engine Oil Pressure: 10 - 100 PSI
Engine Coolant Temperature: 150 - 240 °F
Transmission Temperature: 140 - 300 °F
Battery Voltage: 11.5 to 15.5 VDC (12 V)
23.0 - 30 VDC (24 V)
Pressure Sensor
Discharge Intake
Model Number: XE-FP4000PT3 XE-IO3100PT3
Pressure Range: 0 - 600 PSI -30 in/Hg - 600 PSI
Proof Pressure: 1200 PSI 1200 PSI
Excitation Voltage: 5 VDC 5 VDC
Output Voltage: 0.5 - 4.75 VDC (See Table 1)
Table 1. Pressure Sensor Output Voltage
0psi 100psi 150psi 200psi 250psi 300psi 600psi
Discharge Sensor
XE-FP4000PT3 0.5vdc 1.21vdc 1.56vdc 1.92vdc 2.27vdc 2.625vdc 4.75vdc
Intake Sensor
XE-IO3100PT3 0.604vdc 1.295vdc 1.640vdc 1.985vd 2.331vdc 2.667vdc 4.75vdc

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GENERAL DESCRIPTION
The all-in-one pressure governor and instrument panel is programmed from the
factory or during installation. It is compatible with the following engines types:
TGA301/401 Cummins IS Series
TGA302/402 Detroit Diesel
TGA304/404 Navistar
TGA305/405 Caterpillar
TGA306/406 Ford
TGA307/406 Mack
TGA308/408 Scania
TGA310/410 Mercedes
TGA316/416 John Deere
TGA324/424 MAN
TGA326/426 IVECO
All controls and indicators are located on the front of the control module.
Components
The information available on the J1939 databus varies depending on the particular
engine type. The sensors (if any) that need to be installed will also vary depending on
the engine.
The INControl pressure governor and instrument panel consist of the following
components:
Control Module
Intake Pressure Sensor
Discharge Pressure Sensor
Audible Alarm Buzzer
Engine Oil Pressure Sensor (As Necessary)
Engine Coolant Temperature Sensor (As Necessary)
Transmission Temperature Sensor (As Necessary)
Cables

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Control Module
The control module is waterproof and uses 10 1/2 by 5 1/2 inches of panel space.
All controls, indicators, and displays are located on the front of the control module.
The TGA300 Series uses push buttons to adjust pressure and RPM settings. The
TGA400 Series uses the FRC hand throttle style control knob to adjust pressure and
RPM settings. (Refer to Controls and Indicators.)
Intake Pressure Sensor
The pressure sensor is mounted on the pump intake manifold. It provides an input
signal to the control module that is proportional to the intake pressure.
Discharge Pressure Sensor
The pressure sensor is mounted on the pump discharge manifold. It provides an
input signal to the control module that is proportional to the discharge pressure.
Audible Alarm Buzzer
A ground is provided at the 8-pin connector pin 7 to activate the buzzer (max
current: 300mA). The buzzer will sound when a fault code becomes activated.
(See Table 3 for the Fault Warning Codes list/descriptions on page 15.)
Cables
There are two standard cables and one optional cable that connect to the control
module. One 8-pin connector and one 12-pin connector. (Refer to Wiring Section.)
High-Idle (Optional)
The governor programming includes a high-idle function. To activate the high-idle
provide a +12 VDC to High-Idle Active Input. (Refer to High-Idle Wiring.).
The high idle is set to 1000 RPM at the factory. (This value will vary depending on
the specic engine.) To adjust this setting refer to High Idle in the Operation Section.

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Controls and Indicators
All controls and indicators are located on the front of the control module. (Refer to
Figure 1.) Displays and LED brightness automatically adjusts for day or night operation.
PUMP DISCHARGE and PUMP INTAKE Displays
Shows the pump discharge and intake pressures during normal operations.
Message Display
The message display shows the pressure or RPM setting during normal operations
and warning alarms as they occur. It shows the time and date when the throttle ready
LED is off. It also shows stored data and program features.
PRESSURE Button and LED
Selects the pressure mode of operation, the LED is on to indicate operation in the
pressure mode.
RPM Button and LED
Selects the RPM mode of operation, the LED is on to indicate operation in the
RPM mode.
THROTTLE READY LED
This LED is on when the required interlock conditions are met and the governor
is ready to begin pump operations.
IDLE Button
When pressed immediately sets the engine RPM to idle. This button can be used
in an emergency or for normal shutdown after operations.
PRESET Button
Press to change/select a pre-programmed value for pressure or RPM setting.
DEC / INC Buttons (TGA300 Only)
During operations the buttons increase and decrease pressure or RPM setting.
Control Knob (TGA400 Only)
When rotated changes the pressure or RPM setting. The setting will increase or
decrease proportionally to the speed and direction the control knob is rotated.
RPM Display
Shows the engine RPM during normal operations.

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SILENCE Button
Suppresses audio alarms. Used when accessing program features.
MENU Button
Used to access detailed information and program features. The detailed information
includes the exact measure and units for monitored functions. Each time the MENU
button is pressed the display scrolls to show the next value
CHECK ENGINE / STOP ENGINE LEDs
Repeats the engine warnings from the cab.
Engine Oil Pressure LED Display
Shows pressure in safe range with green LEDs. The LEDs ash red when the
pressure is low.
Engine Coolant Temperature LED Display
Shows temperature in safe range with green LEDs. The LEDs ash red when the
temperature is high.
Pump Transmission Temperature LED Display
Shows temperature in safe range with green LEDs. The LEDs ash red when the
temperature is high.
Battery Voltage LED Display
Shows voltage in safe range with green LEDs. The LEDs ash red when the voltage
is outside normal limits.
Figure 1. Controls and Indicators
PUMP
DISCHARGE
Display
CHECK ENGINE/
STOP ENGINE
LEDs
Governor Controls
TGA300: IDLE, PRESET, INC, and DEC buttons
TGA400: Control Knob, IDLE and PRESET buttons.
MENU
Button
RPM
Button and
LED
PRESSURE
Button and
LED
RPM
Display
Message
Display SILENCE
Button
Battery
Voltage
Display
Transmission
Temperature
Display
Engine
Temperature
Display
Engine Oil
Pressure
Display
PUMP
INTAKE
Display

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INSTALLATION
When the governor is programmed at the factory there is a label on the governor
that species the engine type. If there is no label the engine type must be veried and/
or programmed.
Install Control Module
1. Measure and mark mounting location for control module panel cutout and
mounting screw holes. Make sure there is clearance behind the panel for
the module and cables before cutting holes. Refer to Figure 2 for layout and
dimensions.
2. Cut out a 9 3/4 by 4 1/4 inch hole and drill four holes for mounting screws.
3. Place control module in position and secure with four screws (10-32 mounting
hardware is recommended).
4. Connect cables at rear of the control module. (Refer to Wiring Section.)
Figure 2. Control Module Mounting Dimensions
Mounting holes are
clearance or tapped
for 10-32 screws.
4 7/8"
4 1/4"
9 3/4"
9 7/8"
Panel
Cutout
Maximum
Radius
1/4"
10 1/2"
5 1/2"
5 1/2"
1/2"
2"
1 3/4"
TGA300
TGA400