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!

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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.

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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.

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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.

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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.