FRC PRO-S 1 User manual

PRO-SRev1104
1
FIRE RESEARCH CORPORATION
http://www.fireresearch.com
26SouthernBlvd.,Nesconset,NY11767
TEL ( 631 ) 724-8888 FAX ( 631 ) 360-9727 TOLL FREE 1-800-645-0074
PRESSURE GOVERNOR

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CONTENTS Table of Contents
CONTENTS ............................................................................................................... 2
List of Tables ......................................................................................................... 3
List of Figures........................................................................................................ 3
INTRODUCTION...................................................................................................... 4
Overview ................................................................................................................ 4
Features.................................................................................................................. 4
Specifications......................................................................................................... 5
GENERAL DESCRIPTION....................................................................................... 7
Components .......................................................................................................... 7
Controls and Indicators ......................................................................................... 8
INSTALLATION ...................................................................................................... 10
Install Control Module ......................................................................................... 10
Install Pressure Transducer.................................................................................. 11
Install Throttle Servomotor (Non-Electronic Engine Only) ................................. 12
Install Optional High Idle ..................................................................................... 14
OPERATION............................................................................................................ 15
Pressure Mode Operation.................................................................................... 16
RPM Mode Operation ......................................................................................... 17
Change Preset Setting (Pressure or RPM)........................................................... 17
System Options ................................................................................................... 18
CALIBRATION........................................................................................................ 19
RPM Calibration (PRO-S 3, 6, and 8)................................................................. 19
High Idle Option Calibration................................................................................ 20
3rd Gear Lock-up RPM Calibration (Ford 6.0L) ................................................ 20
DIAGNOSTICS ....................................................................................................... 21
WIRING ................................................................................................................... 22
Power................................................................................................................... 22
HighIdle .............................................................................................................. 23
Pressure Transducer ............................................................................................ 24
Common OME Connectors ................................................................................ 25
Cummins PRO-S 1 Cables .................................................................................. 26
Cummins Harness Connections........................................................................... 27
Detroit Diesel (Series 50 and 60) PRO-S 2 Cables.............................................. 30
Detroit Diesel (Series 50 and 60) Harness Connections ...................................... 31
Non-Electronic Engine PRO-S 3 Cables ............................................................. 32
Non-Electronic Harness Connections.................................................................. 33
Navistar and Detroit Diesel (Series 40) PRO-S 4 Cables .................................... 34
Navistar and Detroit Diesel (Series 40) Harness Connections ............................. 35
Caterpillar PRO-S 5 Cables................................................................................. 36
Caterpillar Harness Connections.......................................................................... 37

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List of Tables
Table 1. PRO-S Specifications.................................................................................. 5
Table 2. Pressure Transducer Output Voltage ........................................................... 6
Table 3. Diagnostic Codes....................................................................................... 21
List of Figures
Figure 1. Controls and Indicators .............................................................................. 9
Figure 2. Control Module Mounting Dimensions .................................................... 10
Figure 3. Pressure Transducer ................................................................................. 11
Figure 4. Fuel ControlArm...................................................................................... 12
Figure 5. Throttle Servo Motor................................................................................ 13
Figure 6. PRO-S Power Supply Wiring................................................................... 22
Figure 7. Optional High Idle Schematic ................................................................... 23
Figure 8. Pressure Transducer Wiring...................................................................... 24
Figure 9. Common OEM Connectors ..................................................................... 25
Figure 10. Cummins PRO-S 1 Wiring ..................................................................... 26
Figure 11. Detroit Diesel (Series 50 and 60) PRO-S 2 Wiring ................................. 30
Figure 12. Non-Electronic PRO-S 3 Wiring ............................................................ 32
Figure 13. Navistar and Detroit Diesel (Series 40) PRO-S 4 Wiring........................ 34
Figure 14. Caterpillar PRO-S 5 Wiring .................................................................... 36
Figure 15. Ford PRO-S 6 Wiring............................................................................. 40
Figure 16. Mack PRO-S 7 Wiring............................................................................ 46
Figure 17. Scania PRO-S 8 Wiring .......................................................................... 48
Figure 18. Mercedes PRO-S 10 Wiring ................................................................... 50
Figure 19. Flyback Diode Wiring............................................................................. 52
Ford PRO-S 6 Cables ......................................................................................... 40
Ford Harness Connections .................................................................................. 41
FordAdapter and Cable Detail (6.0 L Engines)................................................... 43
Ford Torque Lock-up Module (6.0 L Engines) ................................................... 44
Mack PRO-S 7 Cables ........................................................................................ 46
Mack Harness Connections................................................................................. 47
Scania PRO-S 8 Cables....................................................................................... 48
Scania Harness Connections ............................................................................... 49
Mercedes PRO-S 10 Cables................................................................................ 50
Mercedes Harness Connections .......................................................................... 51
FLYBACK DIODE WIRING................................................................................... 52

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INTRODUCTION
Overview
The Fire Research PRO-S pressure governor uses state of the art programmable
microprocessor technology. It will maintain a steady pump discharge pressure by
controlling the engine speed or maintain a selected engine RPM. The PRO-S will
operate in one of two modes, pressure or RPM.
In pressure mode the PRO-S 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 PRO-S maintains a constant engine RPM. The pump discharge
pressure is monitored, it can vary but will be limited to an increase of 30 PSI. If the
discharge pressure increases 30 PSI, the pressure governor will automatically lower
the engine RPM to reduce the discharge pressure.
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
Return to Engine Idle With the Push of a Button
High Idle Kit (Optional)
24 VDC (Optional)
KPa (Optional)

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Specifications
The PRO-S is available in various models. Each model is programmed to interface
with specific engines. All models provide the same functions, push button controls,
and digital readout for the management of pump discharge pressure. (Refer to Table 1
for detailed specifications.)
Table 1. PRO-S Specifications
Note1:24 VDCOptional
PRO-S 1 PRO-S 2 PRO-S 3 PRO-S 4 PRO-S 5 PRO-S 6 PRO-S 7 PRO-S 8 PRO-S 1
0
ENGINE Cummins
(IS Series)
Detroit Diesel
(Series 50 and
60)
Non-
Electronic
Navistar and
Detroit Diesel
(Series 40) Caterpillar Ford Mack Scania Mercede
s
SUPPLY
VOLTAGE
(See Note 1)
12 VDC 12 VDC 12 VDC 12 VDC 12 VDC 12 VDC 12 VDC 12 VDC 12 VDC
SUPPLY
CURRENT 1.0 AMP 1.0 AMP 3.0 AMP 1.0 AMP 1.0 AMP 1.0 AMP 1.0 AMP 1.0 AMP 1.0 AMP
RESPONSE
(Idle to full
governed speed)
5 SEC 5 SEC 30 SEC 5 SEC 5 SEC 5 SEC 5 SEC 5 SEC 5 SEC
RECOVERY
(After open or
close of valve)
1.5 SEC 1.5 SEC 1.5 SEC 1.5 SEC 1.5 SEC 1.5 SEC 1.5 SEC 1.5 SEC 1.5 SEC
RPM
CALIBRATION None None Manual None None Manual None Manual None
DATALINK
PROTOCOL J1587 J1587 J1587 J1587 J1587 J1587

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Table 2. Pressure Transducer Output Voltage
PRESSURE
(PSI) VOLTAGE (VDC)
00.5
100 1.917
150 2.625
200 3.33
250 4.04
300 4.75
Pressure Transducer
ModelNumber: PRO31PT2
Pressure Range: 0 - 300 PSI
Proof Pressure: 800 PSI
ExcitationVoltage: 5 VDC
OutputVoltage: 0.5 - 4.75 VDC
(See Table 2)

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GENERAL DESCRIPTION
The PRO-S pressure governors are compatible with the following engines:
PRO-S 1 Cummins ISB, ISC, ISM, and ISL
PRO-S 2 Detroit Diesel (Series 50 and 60)
PRO-S 3 Non-Electronic diesel and gasoline
PRO-S 4 Navistar and Detroit Diesel (Series 40)
PRO-S 5 Caterpillar PRO-S 6 Ford
PRO-S 7 Mack PRO-S 8 Scania
PRO-S 10 Mercedes
Components
The PRO-S pressure governors consists of the following components:
Control Module
Pressure Transducer
Throttle Servomotor (Non-electronic engines only.)
High Idle Kit (Optional)
Cables
Control Module
The pressure governor control module is waterproof and has dimensions of 4.25
inches high by 4.25 inches wide by 3.5 inches deep (4.5 inches deep on non-electronic
and 24 VDC units). All controls and indicators are located on the front of the control
module. (Refer to Controls and Indicators.)
Pressure Transducer
The pressure transducer is mounted on the pump discharge manifold. It provides
an input signal to the control module that is proportional to the discharge pressure.
Throttle Servomotor (Non-Electronic Engines Only)
The throttle servomotor is installed on engines that do not have electronic engine
control systems. It provides the mechanical connection between the control module
and the engine throttle. The travel of the linear actuator arm is 1.85 inches.
High Idle Kit (Optional)
The High Idle Kit provides the components to install this option including a DPDT
switch, 2500 ohm potentiometer, an indicator light, two diodes, and a cable.

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Controls and Indicators
Allcontrolsandindicatorsarelocatedonthefrontofthecontrolmodule.Itcontains
the push button electronic controls, LED indicators, and a digital display. (Refer to
Figure 1.)
PRESET Button
The green PRESET button sets the pump pressure or engine RPM to a
preprogrammed value. This button is also used in the programming of pressure or
RPM preset values.
IDLE Button
The red IDLE button immediately sets the engine to idle RPM. This button can be
used in an emergency or for a normal shut down after operations.
SETTING Display
The SETTING display will show a diagnostic error code, IdLE for engine idle,
the pressure setting or the RPM setting. The LED digital display has daylight bright
digits at least 0.56 inch high.
INCREASE Button
During operations the yellow INCREASE button raises pressure or RPM setting.
This button is also used in the programming of the pressure or RPM preset values.
DECREASE Button
During operations theyellow DECREASEbuttonlowerspressureorRPMsetting.
This button is also used in the programming of the pressure or RPM preset values.
RPM Button
The green RPM button selects the RPM mode of operation.
RPM LED
The red RPM LED is on to indicate operation in the RPM mode.
PRESSURE Button
The green PRESSURE button selects the pressure mode of operation.
PRESSURE LED
The amber PRESSURE LED is on to indicate operation in the pressure mode.

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Figure 1. Controls and Indicators
PRESSURE
Button
DECREASE
Button
IDLE
Button
PRESET
Button
INCREASE
Button
SETTING
Display
RPM
Button
PRESSURE
LED RPM LED

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INSTALLATION
Install Control Module
Note: The control module can be mounted anywhere on the pump panel. It
should be mounted close to the engine warning indicators.
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 3.75-inch diameter 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).
Note:If the optional remote high idle kit is not being installed, ensure that the
high idle cap (and pin B to pin C jumper wire) is installed on the end of the
control module high idle cable.
4. Connect cables at rear of the contol module. (Refer to Wiring section.)
Figure 2. Control Module Mounting Dimensions
Note:Non-electronic and 24 VDC
unitsare4.500".
Measurementsareininches.