FRC PumpBoss PBA100 Technical manual

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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
PRESSUREGOVERNORAND
ENGINE STATUS DISPLAY
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PBA100

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CONTENTS
Table of Contents
CONTENTS ............................................................................................................... 2
INTRODUCTION...................................................................................................... 4
Overview ................................................................................................................ 4
Features.................................................................................................................. 4
Specifications......................................................................................................... 5
GENERAL DESCRIPTION....................................................................................... 6
Controls and Indicators ......................................................................................... 8
INSTALLATION ...................................................................................................... 10
Install Control Module ......................................................................................... 10
Install Pressure Sensor......................................................................................... 12
Install Sensors...................................................................................................... 13
InstallBuzzer........................................................................................................ 13
OPERATION............................................................................................................ 14
Display Stored Data............................................................................................. 16
PROGRAMMING.................................................................................................... 18
Program Code Descriptions ................................................................................ 19
WIRING ................................................................................................................... 20
Pressure Transducer ............................................................................................ 20
Common OME Diagnostic Connector ................................................................ 21
Connectors and Cables........................................................................................ 22
Cummins Harness Connections........................................................................... 24
Detroit Diesel Harness Connections .................................................................... 25
Navistar Harness Connections............................................................................ 26
Caterpillar Harness Connections.......................................................................... 27
Mercedes Harness Connections .......................................................................... 28

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List of Tables
Table 1. Pressure Sensor Output Voltage .................................................................. 5
Table 2. Error Codes ............................................................................................... 15
Table 3. Fault Warning Codes.................................................................................. 15
List of Figures
Figure 1. Controls and Indicators .............................................................................. 9
Figure 2. Control Module Mounting Dimensions .................................................... 11
Figure 3. Pressure Sensor ........................................................................................ 12
Figure 4. Pressure Transducer Wiring...................................................................... 20
Figure 5. Common OEM 9-Pin Diagnostic Connector............................................ 21
Figure 6. 12-Pin Connector Wiring .......................................................................... 22
Figure 7. 8-Pin Connector Wiring ............................................................................ 23
Figure 8. Cummins PBA101 Wiring......................................................................... 24
Figure 9. Detroit Diesel PBA102Wiring ................................................................... 25
Figure 10. Navistar PBA104Wiring.......................................................................... 26
Figure 11. Caterpillar PBA105Wiring...................................................................... 27
Figure 12. Mercedes PBA110Wiring ...................................................................... 28

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INTRODUCTION
Overview
TheFire Research PumpBoss pressuregovernor uses state of the artprogrammable
microprocessor technology and operates in one of two modes, pressure or RPM. It
willmaintainasteadypumpdischargepressurewithin system capabilities by controlling
the engine speed. When selected, it will also maintain a selected engine RPM.
In pressure mode the PumpBoss 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 PumpBoss 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
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
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 with Throttle Ready LED
Return to Engine Idle With the Push of a Button
AutomaticAdjusting of LED Displays for Day/NightViewing
HighIdle
AudibleAlarmBuzzer(Optional)
Transmission Temperature Sensor (Optional)
KPa (Optional)

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Specifications
The PumpBoss 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.
Display Module
Supply Power: 9 - 30 VDC
Supply Current: 0.5 Amps
Dimensions: 4.625" Wide by 6.75" High
LED Bar Graphs
Oil Pressure: 10 - 100 PSI (10 PSI Increments)
Temperature (Engine Coolant): 130 - 240 °F (10° Increments)
BatteryVoltage: 11.5 - 16 Volts (0.5 Volt Increments)
Engine Sensors
Engine CoolantTemperature: 100 - 250 °F, 1/2" - 14 NPT
EngineOil Pressure: 0 - 100 PSI, 1/8" NPTF
Transmission Temperature: 140 - 320 °F, 1/8" NPTF
Pressure Sensor
ModelNumber: XE-PRO31PT2-S0A
Pressure Range: 0 - 300 PSI
Proof Pressure: 800 PSI
ExcitationVoltage: 5 VDC
OutputVoltage: 0.5 - 4.75 VDC (See Table 1)
Table 1. Pressure Sensor Output Voltage
PRESSURE
(PSI) VOLTAGE
(VDC)
00.5
100 1.917
150 2.625
200 3.33
250 4.04
300 4.75

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GENERAL DESCRIPTION
The PumpBoss pressure governors are compatible with the following engines:
PBA101 Cummins IS Series
PBA102 DetroitDiesel
PBA104 Navistar
PBA105 Caterpillar
PBA106* Ford
PBA107 Mack
PBA108 Scania
PBA109* GMC
PBA110 Mercedes
*Note: An adapter and cable assembly replaces the basic 8-pin cable when
connecting the to a Ford 6.0 or GMC engine. These engines may also
require seperate engine coolant and oil pressure sensors.
Components
The information available on the J1939 databus varies depending on the particular
engine type. Not all wires are used for all engines. Refer to the engine specific wiring
diagram for interface connections. The sensors (if any) that need to be installed will
also vary depending on the engine.
The PumpBoss consist of the following components:
Contol Panel
Pressure Sensor
Engine Coolant Temperature Sensor (As Necessary)
Engine Oil Pressure Sensor (As Necessary)
Transmission Temperature Sensor (Optional)
Cables

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Contol Panel
The control panel is waterproof and takes up 4 5/8 by 6 3/4 inches of panel space.
All controls and indicators are located on the front of the control panel. (Refer to
Controls and Indicators.)
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.
Engine Coolant Temperature Sensor
The engine coolant temperature sensor is installed as necessary.
Engine Oil Pressure Sensor
The oil pressure sensor is installed as necessary.
Audible Alarm Buzzer (Optional)
The optional buzzer is installed as required.
Transmission Temperature Sensor (Optional)
The optional transmission fluid temperature sensor is installed as required.
Cables
There are two cables that connect to the control module. The 8-pin connector is
for the remote throttle interface, the 12-pin connector is for the monitoring and display
interface.

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Controls and Indicators
All controls and indicators are located on the front of the control module. (Refer
to Figure 1.) See Operation and Programming Sections for more information.
OIL PRESSURE LED Display
Shows engine oil pressure. The LEDs will be green when the pressure is within
normal limits and red when it is not.
CHECK ENGINE LED
Repeats the check engine warning from the cab.
TEMPERATURE LED Display
Shows engine coolant temperature. The LEDs will be green when the temperature
is within normal limits and red when it is not.
RPM Display
Shows the current engine RPM in bright red digits. It also shows error codes,
stored data, and program features.
STOP ENGINE LED
Repeats the stop engine warning from the cab.
BATTERY VOLTAGE LED Display
Shows battery voltage. The LEDs will be green when the voltage is within normal
limits and red when it is not.
SILENCE Button
Press to suppress audio alarms.
PRESET Button
Press to set the pump pressure or RPM to a pre-programmed value.
THROTTLE READY LED
This LED will be on when the required interlock conditions are met to begin pump
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.
IDLE Button
When pressed immediately sets the engine RPM to idle.

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Figure 1. Controls and Indicators
Control Knob
When rotated changes the pressuer or RPM setting. The setting will increase or
decrease proportionally to the speed and direction the control knob is rotated.
RPM LED
The LED is on to indicate operation in the RPM mode.
PSI LED
The LED is on to indicate operation in the PSI mode.
MODE Button
Press to change modes. Used when accessing stored data and program features.
Day/Night Sensor
Adjusts the brightness of the LED displays for best day or night viewing.
MENU Button
Used when accessing stored data and program features.
RPM
Display
Message
Display
OIL
PRESSURE
LEDDisplay TEMPERATURE LEDDisplay
SILENCE
Button
MENU
Button
BATTERY
VOLTAGE
LEDDisplay
Control Knob IDLE
Button
THROTTLE
READY
LED
RPM
LED
PSI
LED
MODE
Button PRESET
Button
STOP
ENGINE
LED
CHECK
ENGINE
LED
Day/Night
Sensor

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INSTALLATION
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 3 7/16 by 5 11/16 inch hole.
3. Drill four holes, clearance or tapped, for 10-32 mounting screws.
4. Place control module in position and secure with screws.
5. Connect cables at rear of the control module. (Refer to Wiring section.)

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Figure 2. Control Module Mounting Dimensions
1 3/4" 4 5/8"
6 3/4"
Mounting holes are
clearance or tapped
for 10-32 screws.
3 7/16"
5 11/16"
Panel
Cutout 5 3/4"
4"
Maximum
Radius 1/2"

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Install Pressure Sensor
The discharge pressure sensor is mounted on the discharge manifold of the pump.
If there is a check valve in the discharge side of the pump, mount the discharge sensor
before the check valve. T-fittings can be used to mount the pressure sensors.
Note: Install the pressure sensor upright so water in the end of the sensor is
able to drain back into the pipe.
1. Screw the sensor into a 1/4-18 NPT hole.
Caution: Do not use the main body that houses the electronics to tighten the
pressure sensor. Damage to the sensor may occur.
2. Tighten the sensor with a 9/16-inch) wrench on the lower hex fitting.
3. Connect the pressure sensor cable from the control module to the pressure
sensor. (Refer to Wiring section.)
Figure 3. Pressure Sensor
Caution: Do not use the main
body that houses the electronics
to tighten the sensor. Damage to
the sensor may occur.
1/4-18 NPT
1.02"
0.86"
1234567890
1234567890
1234567890
1234567890
1234567890
1234567890
1234567890
1234567890
1234567890
1234567890
1234567890
0.80"
Lower Hex
Fitting
Supply
Voltage
Signal
Output
Ground
1.04"
Main Body

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Install Sensors
For most electronic engines, the PumpBoss receives engine RPM, oil pressure,
and coolant temperature data over the J1939 databus. Some engines do not broadcast
this data over the databus and sensors may need to be installed.
The sensors are wired to the 12-pin connector at the rear of the control module.
Refer to the Wiring section for pinout and wire color information.
An input is provided for an optional transmission temperature sensor.
Install Buzzer
Pin 6 on the 12-pin connector at the rear of the control module is provided to
connect an optional buzzer. Connect the ground side of the buzzer to pin 6. Maximum
current through pin 6 is 300 mA. The buzzer ordered from FRC requires a 1-1/8 inch
diameter mounting hole. (Refer to the Wiring section.)

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OPERATION
On power-up the PumpBoss will be in normal operating mode. The RPM display
will show engine RPM, the three LED bar graphs will be green indicating readings
within normal ranges, and the message display will alternate between showing the date
and time.
If a monitored function is not within normal parameters the displays will flash, the
RPM display will show an error code and a description will show in the message
display. (Refer to Table 2. Error Codes.) If one of the inputs displayed by the LED bar
graphs is not within normal range the LEDs will be red.
If a fault occurs the RPM display will show the fault code and a description will
show in the message display. (Refer to Table 3. Fault Warning Codes.)
When all necessary throttle enables are active and the interlock circuit is complete
the THROTTLE READY LED will light and the remote throttle will be controlling
engine RPM. The engine RPM control signal will be set at idle regardless of the control
knob position.
Remote Hand Throttle
The remote hand throttle is used to adjust PSI and RPM settings. The PumpBoss
will sense how fast and in what direction the control knob is rotated and send a signal
to the ECM to increase or decrease the engine RPM proportionally.
If the control knob is rotated quickly; the RPM will change quickly.
If the control knob is rotated slowly; the RPM will change slowly.
• Rotate the control knob clockwise to increase engine RPM.
• Rotate the control knob counterclockwise to decrease engine RPM.
• Press the red IDLE button to immediately return the engine to idle.
SILENCE Button
During normal operations the silence button is used to suppress an optional audio
alarm.
MENU Button
During normal operations the menu button is used to access the accumulated
hours mode.

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Table 2. Error Codes
Table 3. Fault Warning Codes
RPM Message
Display Display Probable Cause
E01 NO DATA >Datalinkcablenotconnected/connectedtowrongport
>Brokenwire/badconnectorcontactondatalinkcable
E02 NO RESP No responcetocontrolsignal
E03 NORPM >Datalinkcablenotconnected/connectedto wrong port
>Enginenotrunning/ ignition keyon
>Brokenwire/badconnectorcontactonalternatorcable
E04 N/A N/A
E05 NOPSR Pressuresensornotdetected
E06 N/A N/A
E07 N/A N/A
E08 TRANST’ >Sensorcablenotconnected
>Brokenwire/badconnectorcontactonsensorcable
>Defectivetemperaturesensor
E09 ENGOIL’ >Sensor cable not connected
>Brokenwire/badconnectorcontactonsensorcable
>Defectivepressuresensor
E10 ENGT’ >Sensorcablenotconnected
>Brokenwire/badconnectorcontactonsensorcable
>Defectivetemperaturesensor
RPM Message
Display Display Description
F01 N/A
F02 N/A
F03 HI RPM High RPM
F04 Pump Hot Pump overheat
F05 Pump cavitation
F06 Tran Temp High transmission temperature
F07 Low Batt Low battery voltage
F08 Hi Batt High battery voltage
F09 Low Oil Low engine oil pressure
F10 Eng Temp High engine coolant temperature

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Display Stored Data
Both the RPM and the message displays are used to show stored data.
Accumulated Hours
Accumulated hours are stored in memory for engine operation, pump operation,
last incident, and current incident. The menu button allows the operator to gain access
to this stored data. When in the accumulated hours mode the RPM display will show
the hours. The message display will show the following:
Pump Operating Hours
Engine Operating Hours
Last Incident Hours
Current Incident Hours
The accumulated hours mode is a display only mode and no changes can be made
to the data.
Press the MENU button to enter the accumulated hours mode.
Stored accumulated hours will be displayed.
The RPM display will show the number of hours.
The message display will show what the hours are for.
Press the MENU button to show the next stored hours.
Each time the MENU button is pressed the displays will change to show the
next block of stored accumulated hours.
Press and hold the MENU button for 5 seconds.
The displays will continuously cycle to show all of the stored accumulated
hours.
Press the SILENCE button to exit the accumulated hours mode.
Fault Warnings
Each time a fault occurs, the type of fault, date, and time are stored in memory.
The memory will hold the last ten (10) fault occurrences to be displayed at a later time.
Refer to the Programming section for details on retrieving fault warnings.
Maximum Engine RPM
The maximum RPM that the engine reaches will be stored in the memory to be
displayed at a later time. Refer to the Programming section for details on retrieving the
maximumengine RPM.

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PROGRAMMING
To gain access to the program features a four digit program code must be entered.
Review the Program Code Descriptions for the proper four digit code.
Both the MENU and SILENCE buttons are used to enter a program code. The
RPM display is used to show the codes.
Enter Program Code
Note: There is a time out feature that will return the program to normal
operation in three seconds if input is not detected at the buttons.
1. Press the SILENCE button and hold it for 3 seconds until the RPM display
shows four dashes. The program is ready for a three digit program code to be
input.
2. Press the MENU button. The RPM display will show the number 1000. Each
time the MENUbutton is pressed the first digit will scroll up by 1. Set the first
digit to the number desired.
3. Press the SILENCE button. Each time the SILENCE button is pressed the
second digit will scroll up by 1. Set the second digit to the number desired.
4. Press the MENU button. Each time the MENUbutton is pressed the third digit
will scroll up by 1. Set the third digit to the number desired.
5. Press the SILENCE button. Each time the SILENCE button is pressed the
fourth digit will scroll up by 1. Set the fourth digit to the number desired.
6. Wait a few seconds:
If a valid four digit program code is entered the display will change to show a
program value or an option.
If an invalid code is entered the display will show WRONG CODE.

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Program Code Descriptions
When a valid four digit program code has been entered, stored data or program
options will show in the displays. (Refer to Programming.)
The MENU and SILENCE buttons are used to change the data. The SILENCE
button will select the digit that is to be changed. The MENU button will change the
digit or change the option choice.
Data Display Codes 1000
1110 - Fault Warnings
This code will display the last ten (10) fault warnings that have occurred. The
RPM display will show a fault code and the message display will alternate between
showing the date and time that the fault occurred. Refer to Table 2. Fault Warnings
1120 - Maximum Engine RPM
This code will display the maximum RPM that the engine has attained.
Parameter Settings Codes 2000
2110 - Clock
This code will allow the clock display to be changed.
2120 - Date
This code will allow the date display to be changed.
2130 - Clear Fault Warnings
This code will allow the stored fault warnings to be cleared from memory. It will
clear the history of all five (5) fault warnings. SelectYES or no.
2140 - RPM Calibration
This code will allow the digits in the RPM display to be adjusted to match a
tachometer. This is for engines that do not receive RPM data over the datalink and
have the yellow RPM signal wire (pin 12 on the 12-pin connector) connected to an
RPM source.
2150 - Perform System Test
Exit Program Code Mode
Press the SILENCE button first then the MENU button and hold them both for 3
seconds to exit the program code mode and return to normal operation.

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WIRING
The following figures include the schematics, wiring diagrams, block diagrams,
and cables for the PumpBoss series governors.
Pressure Transducer
Figure 4. Pressure Transducer Wiring
Pressure Transducer
Cable from 12-Pin
Connector
Pressure
Transducer
Pressure Transducer
Cable 3-Pin Connector
Pin/Wire Description
A/Black Ground
B/Red SupplyVoltage
C/White Signal
Pressure Transducre
(Top View)
Supply
Voltage
Signal
Output
Ground