FRC InControl TGA100 User manual

TGA100 Rev0106
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FIRE RESEARCH CORPORATION
www.fireresearch.com
26SouthernBlvd.,Nesconset,NY11767
TEL ( 631 ) 724-8888 FAX ( 631 ) 360-9727 TOLL FREE 1-800-645-0074
PRESSUREGOVERNOR,
ENGINE MONITORING,AND
MASTER PRESSURE DISPLAY
TGA100
TGA200
DocumentNumber:
XE-TGA1PM-R0A

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CONTENTS
Table of Contents
CONTENTS ............................................................................................................... 2
INTRODUCTION...................................................................................................... 4
Overview ................................................................................................................ 4
Features.................................................................................................................. 4
Specifications......................................................................................................... 5
GENERAL DESCRIPTION....................................................................................... 6
Components .......................................................................................................... 6
Controls and Indicators ......................................................................................... 8
INSTALLATION ...................................................................................................... 10
Install Control Panel............................................................................................. 10
Install Pressure Sensors....................................................................................... 11
Install Engine Sensors .......................................................................................... 12
InstallBuzzer........................................................................................................ 12
InstallHighIdleKit .............................................................................................. 12
OPERATION............................................................................................................ 13
Pressure Mode Operation.................................................................................... 14
RPM Mode Operation ......................................................................................... 15
Switching Between Operating Modes .................................................................. 15
High Pump Discharge Pressure at Engine Idle..................................................... 15
Change Preset Setting (Pressure or RPM)........................................................... 16
HighIdle .............................................................................................................. 17
PROGRAMMING.................................................................................................... 18
Program Governor Response Speed................................................................... 18
Program Engine Type .......................................................................................... 18
DIAGNOSTICS ....................................................................................................... 20
WIRING ................................................................................................................... 22
Connectors and Cables........................................................................................ 22
Pressure Sensor ................................................................................................... 24
Common OME Connectors ................................................................................ 25
Cummins Harness Connections........................................................................... 26
Detroit Diesel (Series 50 and 60) Harness Connections ...................................... 28
Navistar Harness Connections............................................................................. 29
Caterpillar Harness Connections.......................................................................... 30
Mercedes Harness Connections .......................................................................... 33
High IdleWiring ................................................................................................... 34
FLYBACK DIODE INFORMATION ...................................................................... 35

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List of Tables
Table 1. Pressure Sensor Output Voltage .................................................................. 5
Table 2. Engine Type Setting ................................................................................... 19
Table 3. Fault Codes................................................................................................ 21
List of Figures
Figure 1. Controls and Indicators.............................................................................. 9
Figure 2. Control Panel Mounting Dimensions ........................................................ 10
Figure 3. Pressure Sensors ...................................................................................... 11
Figure 4. TGA12-Pin Connector Wiring................................................................. 22
Figure 5. TGA8-Pin Connector Wiring................................................................... 23
Figure 6. Pressure Sensor Wiring ............................................................................ 24
Figure 7. Common OEM Connectors ..................................................................... 25
Figure 8. Cummins TGA101/201 Wiring ................................................................. 26
Figure 9. Detroit Diesel (Series 50 and 60) TGA102/202Wiring............................. 28
Figure 10. Navistar TGA104/204Wiring ................................................................. 29
Figure 11. CaterpillarTGA105/205 Wiring .............................................................. 30
Figure 12. Mercedes TGA110/210 Wiring ............................................................... 33
Figure 13. High IdleWiring...................................................................................... 34
Figure 14. Flyback Diode ........................................................................................ 35

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INTRODUCTION
Overview
The Fire Research INControl pressure governor and all-in-one instrument panel
uses state of the art programmable microprocessor technology. It will maintain a steady
pump discharge pressure by controlling engine speed or hold a selected engine RPM.
It offers complete engine control and remote display in a single compact unit.
The INControl operates in one of two modes, pressure or RPM. In pressure
mode the INControl maintains a constant pump discharge pressure. The discharge
pressure is monitored and compared to the selected pressure setting, the engine RPM
is varied to keep the discharge pressure at the selected setting. In RPM mode the
INControl 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 will automatically lower
the engine RPM to prevent a high pressure surge.
The panel has three 4-digit LED displays for pump discharge, pump intake, and
engine RPM. The LEDs are more than 1/2" high. There is an LED bar graph to show
PSI or RPM setting depending on the mode, and three LED bar graphs that provide a
constant display of the battery voltage, engine coolant temperature, engine oil pressure,
and optional transmission temperature.
All controls and indicators are located on the front of the control module.
Features
Power Up in Pressure Mode
Automatic Regulation of Pump Discharge Pressure
Manual Control of Pressure or Engine RPM Settings
Field Programmable Presets
DiagnosticCapabilities
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 and OK To Pump LED
Return to Engine Idle With the Push of a Button
Off-The-Shelf Programmable for EngineType
TGA200 with Transmission Temerature Display
kPa °C Option

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Specifications
The INControl is available in various models. Each model is programmed to
interface with specific engines. All models provide the same functions, controls, and
digital readouts for the management of pump discharge pressure.
Control Panel
Supply Power: 12 VDC
Supply Current: 1.0 Amp
Dimensions: 9 3/4" Wide by 4 3/4" High by 2 3/4" Deep
LED Bar Graphs
EngineOilPressure: 10 to 90 PSI
Engine CoolantTemperature: 150 to 240 °F
Transmission Temperature: 140 to 300 °F
BatteryVoltage: 11.5 to 15.5 VDC
Intake Pressure Sensor
ModelNumber: XE-IO3100PT2
Pressure Range: Absolute - 600 PSI
Proof Pressure: 1200 PSI
ExcitationVoltage: 5 VDC
OutputVoltage: 0.5 to 4.75 VDC
Discharge Pressure Sensor
ModelNumber: XE-FP4000PT1
Pressure Range: 0 to 600 PSI
Proof Pressure: 1200 PSI
ExcitationVoltage: 5 VDC
OutputVoltage: 0.5 to 4.75 VDC
Table 1. Pressure Sensor Output Voltage
0psi 100psi 150psi 200 psi 250 psi 300psi 600psi
IO3100PT2 0.604 vdc 1.295 vdc 1.640 vdc 1.985 vdc 2.331 vdc 2.677 vdc 4.85 vdc
FP4000PT1 0.5 vdc 1.21 vdc 1.56 vdc 1.92 vdc 2.27 vdc 2.625 vdc 4.75 vdc

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GENERAL DESCRIPTION
The INControl pressure governor and all-in-one instrument panel engine type
canbe programmedformthefacyoryor or or duringinstallation.(RefertoProgramming
section.) It is compatible with the following engines:
TGA101/TGA201 Cummins IS Series
TGA102/TGA202 DetroitDiesel
TGA104/TGA204 Navistar
TGA105/TGA205 Caterpillar
TGA110/TGA210 Mercedes
All controls and indicators are located on the front of the control module.
Components
The information available on the J1587 databus varies depending on the particular
engine type. The sensors (if any) that need to be installed will also vary depending on
theengine.
The INControl pressure governor and monitoring display consist of the following
components:
Control Panel
Intake Pressure Sensor
Discharge Pressure Sensor
AudibleAlarm Buzzer
Engine Coolant Temperature Sensor (As Necessary)
Engine Oil Pressure Sensor (As Necessary)
Transmission Temperature Sensor (TGA200 As Necessary)
Cables
Control Panel
The control panel is waterproof and takes up 9 3/4 by 4 3/4 inches of panel space.
All controls, indicators, and displays are located on the front of the control panel.
(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 panel that is proportional to the intake pressure. (See Pressure
Sensor Calibration Note.)

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Discharge Pressure Sensor
The pressure sensorr is mounted on the pump discharge manifold. It provides an
input signal to the control panel that is proportional to the discharge pressure. (See
Pressure Sensor Calibration Note.)
Pressure Sensor Calibration Note: The displays for the pump intake and
discharge pressure are self calibrating. There are no adjustments that can
be made to the sensors or to the pressure shown in the display. When
power is applied to the INControl the program looks at the signal from
each sensor, assumes this to be 0 PSI, and calibrates the display to show
0. If there is pressure in the plumbing where the sensor is mounted this
will cause the display to be calibrated to a false 0. To avoid this FRC
recommends:
Drain the pump and plumbing to ensure there is no residual pressure.
Provide power to the INControl prior to engaging the pump.
AudibleAlarm Buzzer
A ground is provided at the 12-pin connector pin 6 to activate the buzzer (max
current: 300mA) +12 VDC needs to be supplied to the buzzer.
Engine Coolant Temperature Sensor
The engine coolant temperature sensor is installed as necessary.
Oil Pressure Sensor
The oil pressure sensor is installed as necessary.
Transmission Temperature Sensor (TGA200 only)
The transmission fluid temperature sensor is installed as necessary.
Cables
There are two cables that connect to the control module. One 8-pin connector and
one 12-pin connector.

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Controls and Indicators
All controls and indicators are located on the front of the control module. (Refer
to Figure 1.) The LED digital display has daylight bright digits at least 0.56 inch high.
PUMP DISCHARGE Display
Shows the pump discharge pressure during normal operations.
PSI LED
The red PSI LED is on to indicate operation in the pressure mode.
PSI Button
Selects the pressure mode of operation.
PRESET Button
Press to change/select a pre-programmed value for pressure or RPM setting..
PSI/RPM Setting Display
The display will show the pressure or the RPM setting.
RPM Button
Selects the RPM mode of operation.
RPM LED
The red RPM LED is on to indicate operation in the RPM mode.
RPM Display
Shows the engine RPM during normal operations.
SILENCE Button
Suppresses audio alarms.
VOLTS LED Display
Shows battery voltage. LEDs will flash when the voltage is outside normal limits.
TRANS. °F LED Display
Shows transmission temperature. LEDs will flash when the temperature high.
°F LED Display
Shows engine coolant temperature. LEDs will flash when the temperature high.
PSI LED Display
Shows engine oil pressure. LEDs will flash when the pressure low.

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Figure 1. Controls and Indicators
PSI/RPM
Setting
Display
IDLE
Button
PUMP
DISCHARGE
Display
PUMP
INTAKE
Display
RPM
Display
PRESET
Button
DEC
Button
SILENCE
Button
RPM
Mode
Button
PSI
Mode
LED
OK TO
PUMP
LED
Battery
Voltage
Display
Engine
Temperature
Display
Idle
LED
PSI
Mode
Button
RPM
Mode
LED
EngineOil
Pressure
Display
INC
Button TGA200
Transimssion
Temperature
Display
INC Button
During operations the button raises pressure or RPM setting.
DEC Button
During operations the button lowers pressure or RPM setting.
OK TO PUMP Light
ThisLEDwillbeon when therequiredinterlockconditionsaremet and thegovernor
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 shut down after operations.
Idle LED
This LED is on to indicate the engine RPM is at idle.
PUMP INTAKE Display
Shows the pump intake pressure during normal operations.

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INSTALLATION
When the governor is programmed at the factory there will be a label on the
governor specifying the engine type. If there is no label on the governor the engine type
must be verified/programmed per the Programming procedure.
Install Control Panel
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 by 3 15/16 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 contol module. (Refer to Wiring section.)
Figure 2. Control Panel Mounting Dimensions
Panel
Cutout
Maximum
Radius 1/2" 9"
3 15/16"
9 1/16"
4 1/16"
9 11/16"
4 11/16"
2 3/4"
5/8"
1/4"
10-32mounting
hardware is
recommended.