FRC GOVERNOR PRO 3 User manual

REV03MAR99NB PRO3.P65
Page 1
FRC
IDLE
SETTING
PRESET
RPM
s
PRO
s
INCREASE
DECREASE
150150
150150
150
MODEL : PRO 3
OPERAOPERA
OPERAOPERA
OPERATING INSTRTING INSTR
TING INSTRTING INSTR
TING INSTRUCTIONSUCTIONS
UCTIONSUCTIONS
UCTIONS
FOR ALL NON-ELECTRONIC DIESEL AND GASOLINE ENGINES
PRESSURE GOVERNOR
PRESSURE
TEL ( 516 ) 724-8888 FAX ( 516 ) 360-9727 TOLL FREE 1-800-645-0074
26 Southern Blvd., Nesconset, NY11767
This version gets RPM data through a connection to the alternator
(for PRO serial numbers #1236 and later) If your application requires
the use of an RPM speed sensor, request a manual REV082797!

REV03MAR99NB PRO3.P65
Page 2
pRemote High Idle to maintain any engine speed between 800 RPM and 2400
RPM.
pThe IDLE switch will bring the engine to idle quickly after operations.
pThe PRESET switch can be used to raise the pump pressure or engine RPM to a
preset value. This feature is very useful when the operator always operates at a com-
monly used pump pressure or engine RPM. The pre-programmed pump pressure or
engine RPM value is field adjustable.
pDisplay instantly shows operator the chosen setting.
pUniversal mounting bracket on the servomotor allows the PRO 3 to be installed on
any non-electronic engine.
pSimple to install and easy to operate.
INTRODUCTION :INTRODUCTION :
INTRODUCTION :INTRODUCTION :
INTRODUCTION :
FEATURES :FEATURES :
FEATURES :FEATURES :
FEATURES :
GOVERNORGOVERNOR
GOVERNORGOVERNOR
GOVERNOR PROPRO
PROPRO
PRO
The PRO 3 is a pressure governor designed for non-electronic engines. It is compat-
ible with any diesel or gasoline engine. Designed with the latest microprocessor
technology, this system is capable of decision making with a built in artificial intelli-
gence. Two choices of operation are available: Pressure regulation or RPM regula-
tion. The PRO 3 is better and simpler to use than the conventional vernier throttle. It
acts like a cruise control for the pump. The PRO 3 regulates the discharge pressure
by quickly and accurately adjusting the engine RPM. It will return the engine to idle
when water supply is depleted. The PRO 3 is fast, easy to use, and accurate.

REV03MAR99NB PRO3.P65
Page 3
INSTALLATION
Before proceeding with any installation, please check to make sure you have the
following components. STOP and call the factory if any components are missing.
Components supplied are as follows :
1) PRO GOVERNOR controller
2) Extension cable for power
3) Throttle servomotor
4) Extension cable for servomotor
5) Extension cable for High Idle
6) Pressure transducer& Extension cable for pressure transducer
7) Alternator cable
Installation for PRO 3 is extremely simple. The control module can be mounted any-
where on the pump panel. PRO 3 control module has a square flange with an overall
dimensions of 4.25" X 4.25" . A cutout hole of 3.75" in diameter is required. To ensure
proper installation, follow the following procedures carefully:
1) CONTROL MODULE: Locate a suitable position on the pump panel and make sure
that check engine and stop engine indicators are closely mounted near PRO 3 controller.
a) Locate the center of the cutout hole and make a 3.75" diameter cutout.
b) Insert the PRO 3 controller into the cutout hole and locate the four 10-32 mount-
ing screw holes on the four corners of the flange.
c) The dimensions for locating the cutout hole and the mounting screw holes can be
found in Figure 9.
2) THROTTLE SERVO-MOTOR Mark the point at which the servo-motor arm exits
the housing at idle and then when the engine is at max. The distance between these
points is the total motion of the actuator rod. The total motion of the actuator rod is
approximately 1 7/8" inches. The motion of the throttle arm at the slip fitting must be
slightly more than 1 7/8" to prevent breakage of the arm. If it is not, you have 2 choices:
i) You may allow a little more clearance between the stop nuts and the slip fitting (1/
8" minimum is necessary to ensure correct engine idle). Doing that, however, may
delay the initial engine response somewhat.

REV03MAR99NB PRO3.P65
Page 4
INSTALLATION
ii) A better option may be to extend the throttle arm by attaching a longer arm
onto the throttle arm to obtain the desired throw. Test the motion by operating the
servo through the Increase/Decrease switches on the control box and noting the
distance of travel of the arm.
Note: In any case, the total motion at the slip fitting MUST NOT BE LESS THAN
1 3/8 inches because that may cause the engine to oscillate.
3) PRESSURE TRANSDUCER
The discharge pressure transducer can be mounted on the discharge manifold of the
pump. A 'T' fitting can be used to share the pressure gauge outlet on the discharge
manifold. If there is a check valve in the discharge side of the pump, mount the trans-
ducer before the check valve. Do not use a wrench on the main body that houses the
electronics to tighten the transducer, use an 1 1/8" wrench on the lower hex fitting.
4) WIRING Wiring for the PRO system is very simple. All extension cables are
supplied with connectors to simplify the interconnections. For complete wiring dia-
gram, refer to Figure 2.
a) Use the extension cable supplied, provide 12VDC and ground to the electronic
module.
b) Connect the extension cable from the PRO to the servomotor.
c) PUMP ENGAGED INTERLOCK: In most installations, the 12 VDC from
OK to pump signal can be used as an interlock. Wire this 12 VDC signal to the
white wire on the power supply cable. The PRO will not be active unless 12 VDC
is supplied to this white wire. If no interlock is provided, use Figure 3 or 5 for
wiring the interlock if HIGH IDLE feature is not required. If HIGH IDLE is
desired, use Figure 4 or 6 to wire the interlock.
5) At this point you are ready to test the PRO in pressure mode. You do not need to
connect the RPM cable to the alternator to run the PRO in pressure mode. This is a
good idea because if there is a problem at this point, you have already isolated it from
being related to the RPM input. Check to see that the unit responds properly to the
PRESET and INCREASE and DECREASE commands while in pressure mode.

REV03MAR99NB PRO3.P65
Page 5
INSTALLATION
10) HIGH IDLE For fire apparatus that require HIGH IDLE, use Figure 7 to com-
plete the wiring.
7) Once you are satisfied that the unit works in pressure mode, connect the wire
labeled RPM sensor to one of the small studs on the alternator. DO NOT connect
this wire to the large battery terminals! IMPORTANT: Connect the red wire to the
small positive (+) terminal and the black wire to chassis ground.
8) Proceed to RPM calibration on page 17
9) Test the PRO for proper operation in RPM mode.

REV03MAR99NB PRO3.P65
Page 6
Simple to use !
The PRO 3 is engineered with ease of operations in mind. All functions on the con-
trol module are self explanatory. The LED display which shows the desired pump
pressure or engine RPM setting is visible at day and night.
How to operate ... in RPM mode
When the PRO 3 is on, the display will show 'IDLE' to indicate that the engine is at
idle. The mode of operation is always default to PRESSURE after power up.
There are 6 pushbuttons on the control module :
1) Use "RPM" switch to select RPM operation and "PRESSURE" switch to select PSI
operation
2) The "Increase" and "Decrease" switches allow easy selection of desired RPM from
IDLE to maximum governed speed. Depress "Increase" to ramp the engine RPM up,
and depress "Decrease" to ramp the engine RPM down. The RPM will ramp up or
down at 10 RPM increment when press momentarily. When the pushbutton is held
down for more than 2 seconds, it will ramp up or down at a rate of 50 RPM and then
100 RPM increment. Release the pushbuttons when desired RPM is reached.
3) The "IDLE" switch will bring engine to idle immediately after operations.
4) The"PRESET" switch ramps engine to the preset RPM quickly and conveniently
with the momentary touch of a single button.
After the "PRESET" switch is used, the "Increase" and "Decrease" switches can still
be used to change the selected RPM easily. "IDLE" switch can bring the engine to
idle
How to change the preset RPM ?
The preset RPM setting can be easily changed. To change the setting, simply follow
steps (a) through (c):
a) Make sure the engine is at idle when changing the setting. If the engine RPM is not
at idle, press "IDLE" switch to bring engine to idle.
b) Press "PRESET" switch and hold it until the display is flashing. Use the "Increase"
or "Decrease" switch to program the new preset RPM.
c) When the new desired preset RPM is obtained, release the "PRESET" switch and
the new preset RPM will be stored in the memory.
OPERATIONS

REV03MAR99NB PRO3.P65
Page 7
How to operate : PSI Mode
There are 6 pushbuttons on the control module :
1) The "Increase" and "Decrease" switches allow easy selection of desired PSI from
45 PSI to 280 PSI. Depress "Increase" to bring the pressure up, and depress "De-
crease" to bring the pressure down. The pressure will ramp up or down at 1 PSI incre-
ments when pressed momentarily. When the pushbutton is held down for more than 2
seconds, it will ramp up or down at a rate of 5 PSI and then 10 PSI increments. Re-
lease the pushbuttons when desired PSI is reached.
2) The "IDLE" switch will bring engine to idle quickly after operations.
3) The "PRESET" switch brings pressure to the preset pressure quickly and conve-
niently with the momentary touch of a single button.
After the "PRESET" switch is used, the "Increase" and "Decrease" switches can still
be used to easily change the selected pressure. The "IDLE" switch can bring the
engine to idle.
4) The "PRESSURE" switch will change the operation to pressure mode while
"RPM" switch will change the operation to RPM mode.
How to change the preset PSI
The preset PSI setting can be easily changed. To change the setting, simply follow
steps (a) through (d):
a) Make sure the engine is at idle when changing the setting. If the engine RPM is not
at idle, press "IDLE" switch to bring engine to idle.
b) Select pressure mode by pressing " PRESSURE " switch.
c) Press "PRESET" switch and hold it until the display is flashing. Use the "Increase"
or "Decrease" switch to program the new preset PSI.
d) When the new desired preset PSI is obtained, release the "PRESET" switch and the
new preset PSI will be stored in the memory.

REV03MAR99NB PRO3.P65
Page 8
Open and Close Valves ...
The PRO will maintain the selected pressure setting regardless of the number of
discharges that are opened as long as the water supply is capable of supplying the
amount of water required. As more lines are opened the discharge pressure will drop
and the PRO will respond by raising the engine RPM to maintain the required pres-
sure. The PRO will reduce the engine RPM to maintain the required pressure when
one or more of the discharges are closed. The PRO, in this way acts like a ' cruise
control ' for the pump. The operator dials in the required pressure and the PRO will
quickly and accurately adjust the engine RPM to maintain the set pressure.
Out of Water ...
There are situations during pump operation when the system may run out of water
due to an empty water tank or if there is a problem on the intake line. If this situation
occurs, the PRO will increase the engine RPM trying to maintain the selected pres-
sure. The engine RPM will stay at a high RPM until the PRO detects a pressure that is
below 45 psi, then the engine RPM will be brought to idle. The engine RPM will stay
at idle as long as the discharge pressure is detected as being below 15 psi. At any time
that the discharge pressure becomes greater than 15 psi and the pressure setting is
above 45 psi, the PRO will resume normal operation.

REV03MAR99NB PRO3.P65
Page 9
SPECIFICATIONS
Dimensions :
Response : Idle to full governed speed
Pressure Recovery : On open/close valve
Max. RPM :
Discharge Pressure range :
4.25"W X 4.25"H X 3.75"D
7 seconds maximum
1 1/2 seconds
2400 RPM
45-280 PSI
Control Module :
RPM mode :
Pressure mode :
Idle to 2400 RPM
45 PSI to 280 PSI
Operational :
Electrical :
Power :
Current :
Microprocessor :
12 VDC
3 A continuous
8 Bit single chip MicroComputer
Mechanical :
Discharge pressure transducer assembly :
Transducer type : Stainless steel diaphragm type with a 4 pin connector
Range 0-280 PSI
Maximum overload 500 PSI

REV03MAR99NB PRO3.P65
Page 10
IDLE
SETTING
PP
PP
PRESET
RPM
s
PRO
s
INCREASE
DECREASE
150150
150150
150
1) The "IDLE" switch brings engine to idle immediately after operations
2) The "INCREASE" switch ramps engine RPM up
3) The "DECREASE" switch ramps engine RPM down
4) The "PRESET" switch ramps engine to the preset RPM quickly and conveniently
5) The "RPM" switch changes the mode of operation to RPM
5a - LED to indicate operation in RPM mode
6) The "PRESSURE" switch changes the mode of operation to PSI
6a - LED to indicate operation in pressure mode
7) The LED display to indicate RPM or PSI setting
7
1
2
3
4
5
5a
6
6a
FUNCTIONS OF SWITCHES
Figure 1
PRESSURE

REV03MAR99NB PRO3.P65
Page 11
Figure 2
SYSTEM WIRING BLOCK DIAGRAM
RED = 12 VDC
BLACK = GND
WHITE = 12 VDC OK to
pump interlock
2
1
Refer to Figure 7
Power cable
3
2
1
4
HIGH
IDLE
High Idle cable
Pressure Transducer
CONTROL MODULE
Servomotor
Throttle servomotor cable
Pressure
Transducer
4
3
5
Alternator
Alternator
5
Be advised that all PRO 3 models with labeled serial numbers higher than #1236
are set up for alternator signal input only. This change takes effect on Oct 28,
1997. If an RPM sensor is required for your application and you have one of
these newer units, contact FRC at [phone] for instructions.
See the page entitled RPM CALIBRATION for directions on how to synchronize
the PRO to the alternator output.

REV03MAR99NB PRO3.P65
Page 12
Parking Brake
Parking Brake
air pressure
Pump Shift Switch
Dashboard
OPEN : "ROAD"
CLOSED : "PUMP"
Switched 12VDC
N.O. Switch
Pump Engaged
Pump
Mode
Split
Shaft
PTO
Air
Relay A
C
C
TRANSMISSION OK to
Pump Indicator light
# 114
# 118
# 119
12VDC
Control Module
INT #110
Figure 3
C
C
N.O.
s
Relay A
12VDCDPDT
Indicator
Light
WITHOUT HIGH IDLE
with Allison WT
Transmission
N.C.
N.O.
N.C.
N.O.
N.O.
Allison WT
15 amp/DC
Relay A - Pump Engaged
Relay
Pump Engaged Interlock

REV03MAR99NB PRO3.P65
Page 13
Parking Brake
Parking Brake
air pressure
Pump Shift Switch
Dashboard
OPEN : "ROAD"
CLOSED : "PUMP"
Switched 12VDC
N.O. Switch
Pump Engaged
Pump
Mode
Indicator
Light
Split
Shaft
PTO
Air
Relay A
C
C
C
TRANSMISSION
Control Module
INT #110
C
C
C
N.O.
Relay B
Relay A, Relay B,
N.O.
N.C.
N.O.
N.O.
N.O.
N.C.
N.C.
N.O.
s
N.C.
s
High Idle
IDLE # 112
Refer to High
Idle wiring
OK to
Pump
Indicator light
12VDC
12VDC
C
N.C.
N.C.
N.O.
N.O.
s
C
Relay C
# 114
# 118
# 119
IDE # 111
Allison WT
Figure 4
12VDC
DPDT
15 amp/DC
Relay C
Relay A - Pump Engaged
Relay B - High Idle
Relay C - Pump Engaged
High Idle
Lock out
Pump Engaged Interlock with High Idle

REV03MAR99NB PRO3.P65
Page 14
Parking Brake
Parking Brake
air pressure
Pump Shift Switch
Dashboard
OPEN : "ROAD"
CLOSED : "PUMP"
Switched 12VDC
N.O. Switch
Pump Engaged
Pump
Mode
Split
Shaft
PTO
Air
Relay A
C
C
TRANSMISSION OK to
Pump Indicator light
Control Module
INT #110
Figure 5
C
C
N.O.
s
Relay A
12VDCDPDT
15 amp/DC
Indicator
Light
N.C.
N.O.
N.O.
N.O.
N.C.
C
N.O. Drive
Pump Engaged
Relay
WITHOUT HIGH IDLE
with non Allison WT
Transmission
Pump Engaged Interlock

REV03MAR99NB PRO3.P65
Page 15
Parking Brake
air pressure
Pump Shift Switch
Dashboard
OPEN : "ROAD"
CLOSED : "PUMP"
Switched 12VDC
N.O. Switch
Pump
Mode
Indicator
Light
Split
Shaft
PTO
Air
Relay A
C
C
C
TRANSMISSION OK to
Pump
Control Module
INT #110
Figure 6
C
C
C
N.O.
Relay B
Relay A, Relay B
12VDC
DPDT
15 amp/DC
N.O.
N.C.
N.O.
N.O.
N.O.
N.C.
N.C.
N.O.
s
N.C.
s
Indicator light
12VDC
s
C
C
N.O.
N.O.
DRIVE
NEUTRAL
High Idle
IDE # 111 IDLE # 112
Refer to High
Idle wiring
Pump Engaged
Parking Brake
Non Allison WT Transmission
Relay A - Pump Engaged
Relay B - High Idle
Pump Engaged Interlock with High Idle

REV03MAR99NB PRO3.P65
Page 16
RED = 12VDC BLACK = GND
POWER
PRO 3
EXTENSION CABLES
GOVERNOR
Figure 8
To Pressure Transducer
To High Idle inside cab
HIGH IDLE
Pressure
Transducer
TO SERVO
To Throttle Servomotor
RPM Sensor
Alternator
12'
5'
Deutsch DT series
High Idle
Power
3 pin receptacle
Deutsch DT series
3 pin plug
2 pin Packard plug 2 pin Packard receptacle
4 pin Deutsch DT series 4 pin Deutsch DT series
Pressure Transducer
Servomotor cable
12'
12'
2 pin Deutsch plug
bare leads
12'
RPM cable (to alternator)
Red = 12VDC
Black = GND
White = Interlock
(12VDC when OK to pump)
red
black

Page 17
REV120397NB
PRO 3 ALT (units with Alternator input)
RPM Calibration
Be advised that all PRO 3 units made after October, 1997 are set up to receive RPM
data via alternator input. If you have a PRO 3 with a serial number of 1236 or later,
then the installer must use this page to calibrate the PRO 3.
The PRO 3 with alternator pickup must be calibrated properly in order for the
unit to maintain the engine RPM correctly. Carefully follow the procedures
below to calibrate:
Press the button marked IDLE to bring the engine to an idle. The word IDLE will appear
in the PROs display window.
Press the button marked RPM to enter into RPM mode. Indicator lights located above the
RPM and PSI buttons let you know which mode you are in.
Double-click the button marked IDLE (press the button twice quickly). The word CAL
will begin to flash in the display.
Double Click the IDLE button again. The word CAL will stop flashing and will appear as
a steady reading in the display.
Press the PRESET button. The words SET and 1200 will alternately flash in the
display.
Use the  INCREASE  (s) or  DECREASE  (t) switches to change the engine speed until
the reference tachometer reads 1200 (The displayed value will NOT change)
When the reference RPM matches the displayed RPM (1200), press  PRESET  again to
accept the setting. The display will now show  IDLE  and the engine RPM will drop down to
idle.
The RPM reading is now calibrated.
1.
2.
3.
4.
5.
6.
7.

REV080497nb
Page 18
Figure 9
4.25"4.25"
3.5"3.5"
3.5"3.5"
2.375"2.375"
3.375"3.375"
3.750"3.750"
1"1"
4.25"4.25"
PANEL
CUTOUT
PRO 2
Please be advised of recent changes in dimension for
FOR THE RTU & PRO GOVERNORS
DIMENSIONS:

servo.p65 REV15AUG97
Page 19

PRO3100PT2.P65 REV03MAR99TM
Page 20
Red wire (pin 1)- DC5V for the pressure transducer
Black wire (pin 2) - Ground
White (pin 3) - signal output
Yellow (pin 4) - shielding for the cable
4 pin Deutsch Connector
1
23
4
Rear view 4 pin
Deutsch receptacle
PRESSURE TRANSDUCER
Extension cable
0.5
1.917
2.625
3.33
4.04
4.75
Pressure (psi) Voltage (volts)
0
100
150
200
250
300
Pressure Range Proof Pressure Excitation Output
0-300 PSI 800 PSI 5 VDC 0 .5 - 4.75 VDC
Note: PRO models manufactured after serial number #1800 are fit with the
transducer described below. If you have an older PRO, you will need an
adapter cable to make this transducer work with your display module.
MODEL # PRO3100PT2