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.)