FRC InControl TGA100 User manual

TGA100/TGA200 Rev0305
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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
PRESSUREGOVERNOR,
ENGINE MONITORING,AND
MASTER PRESSURE DISPLAY
TGA100
TGA200
DocumentNumber:
XE-TGA1PM-R0A

TGA100/TGA200 Rev0305
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CONTENTS
Table of Contents
CONTENTS ............................................................................................................... 2
INTRODUCTION...................................................................................................... 4
Overview ................................................................................................................ 4
Features.................................................................................................................. 4
Specifications......................................................................................................... 5
GENERAL DESCRIPTION....................................................................................... 6
Components .......................................................................................................... 6
Controls and Indicators ......................................................................................... 8
INSTALLATION ...................................................................................................... 10
Install Control Panel............................................................................................. 10
Install Pressure Sensors....................................................................................... 11
Install Engine Sensors .......................................................................................... 12
InstallBuzzer........................................................................................................ 12
OPERATION............................................................................................................ 13
Pressure Mode Operation.................................................................................... 14
RPM Mode Operation ......................................................................................... 15
Change Preset Setting (Pressure or RPM)........................................................... 15
HighIdle .............................................................................................................. 16
PROGRAMMING.................................................................................................... 18
Program Governor Response Speed................................................................... 18
Program Engine Type .......................................................................................... 18
DIAGNOSTICS ....................................................................................................... 20
WIRING ................................................................................................................... 22
12-Pin Connector................................................................................................. 22
8-Pin Connector................................................................................................... 23
Pressure Sensor ................................................................................................... 24
Cummins Harness Connections........................................................................... 26
Detroit Diesel (Series 50 and 60) Harness Connections ...................................... 28
Navistar and Detroit Diesel (Series 40) Harness Connections ............................. 29
Caterpillar Harness Connections.......................................................................... 30
Mercedes Harness Connections .......................................................................... 33
FLYBACK DIODE WIRING................................................................................... 34

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List of Tables
Table 1. Pressure Sensor Output Voltage .................................................................. 5
Table 2. Engine Type Setting ................................................................................... 19
Table 3. Fault Codes................................................................................................ 21
List of Figures
Figure 1. Controls and Indicators.............................................................................. 9
Figure 2. Control Panel Mounting Dimensions ........................................................ 10
Figure 3. Pressure Sensors ...................................................................................... 11
Figure 4. 12-Pin ConnectorWiring .......................................................................... 22
Figure 5. 8-Pin Connector Wiring ............................................................................ 23
Figure 6. Pressure Transducer Wiring...................................................................... 24
Figure 7. Cummins TGA101 Wiring........................................................................ 26
Figure 8. Detroit Diesel (Series 50 and 60) TGA102 Wiring ................................... 28
Figure 9. Navistar TGA104 Wiring (and Detroit Diesel Series 40 TGA102B) ........ 29
Figure 10. CaterpillarTGA105 Wiring ..................................................................... 30
Figure 11. Mercedes TGA110 Wiring ...................................................................... 33
Figure 12. Flyback Diode Wiring............................................................................. 34

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INTRODUCTION
Overview
The Fire Research INControl pressure governor and all-in-one instrument panel
uses state of the art programmable microprocessor technology. It will maintain a steady
pump discharge pressure by controlling engine speed or hold a selected engine RPM.
It offers complete engine control and remote display in a single compact unit.
The INControl operates in one of two modes, pressure or RPM. In pressure
mode the INControl 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
INControl maintains a constant engine RPM. The pump discharge pressure is
monitored and can vary but, as a safety feature it will be limited to an increase of 30
PSI. If the discharge pressure increases 30 PSI the governor will automatically lower
the engine RPM to prevent a high pressure surge.
The panel has three 4-digit LED displays for pump discharge, pump intake, and
engine RPM. The LEDs are more than 1/2" high. There is an LED bar graph to show
PSI or RPM setting depending on the mode, and three LED bar graphs that provide a
constant display of the battery voltage, engine coolant temperature, engine oil pressure,
and optional transmission temperature.
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 and OK To Pump LED
Return to Engine Idle With the Push of a Button
Off-The-Shelf Programmable for EngineType
TGA200 with Transmission Temerature Display
kPa °C Option

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Specifications
Control Panel
Supply Power: 12 VDC
Supply Current: 1.0 Amp
Dimensions: 9 3/4" Wide by 4 3/4" High by 2 3/4" Deep
LED Bar Graphs
EngineOil Pressure: 10 to 90 PSI
Engine CoolantTemperature: 150 to 240 °F
Transmission Temperature: 140 to 300 °F
BatteryVoltage: 11.5 to 15.5 VDC
Intake Pressure Sensor
ModelNumber: XE-IO3100PT2-S0A
Pressure Range: Absolute - 600 PSI
Proof Pressure: 1200 PSI
ExcitationVoltage: 5 VDC
OutputVoltage: 0.5 to 4.75 VDC
Discharge Pressure Sensor
ModelNumber: XE-FP4000PT1-S0A
Pressure Range: 0 to 600 PSI
Proof Pressure: 1200 PSI
ExcitationVoltage: 5 VDC
OutputVoltage: 0.5 to 4.75 VDC
Table 1. Pressure Transducer Output Voltage
0psi 100psi 150psi 200 psi 250 psi 300psi 600psi
IO3100PT2 0.604 vdc 1.295 vdc 1.640 vdc 1.985 vdc 2.331 vdc 2.677 vdc 4.85 vdc
FP4000PT1 0.5 vdc 1.21 vdc 1.56 vdc 1.92 vdc 2.27 vdc 2.625 vdc 4.75 vdc

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GENERAL DESCRIPTION
The INControl pressure governor and all-in-one instrument panel engine type
canbe programmedformthefacyoryor or or duringinstallation.(RefertoProgramming
section.) It is compatible with the following engines:
TGA101/TGA201 Cummins IS Series
TGA102/TGA202 DetroitDiesel
TGA104/TGA204 Navistar
TGA105/TGA205 Caterpillar
TGA110/TGA210 Mercedes
All controls and indicators are located on the front of the control module.
Components
The information available on the J1587 databus varies depending on the particular
engine type. The sensors (if any) that need to be installed will also vary depending on
theengine.
The INControlpressure governor and monitoring display consist of the following
components:
Control Panel
Intake Pressure Sensor
Discharge Pressure Sensor
Buzzer
Engine Coolant Temperature Sensor (As Necessary)
Engine Oil Pressure Sensor (As Necessary)
Transmission Temperature Sensor (TGA200 As Necessary)
Cables
Control Panel
The control panel is waterproof and takes up 9 3/4 by 4 3/4 inches of panel space.
All controls, indicators, and displays are located on the front of the control panel.
(Refer to Controls and Indicators.)
Intake Pressure Sensor
The pressure sensor is mounted on the pump intake manifold. It provides an input
signal to the control panel that is proportional to the intake pressure. (See Pressure
Sensor Calibration Note.)

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Discharge Pressure Sensor
The pressure sensorr is mounted on the pump discharge manifold. It provides an
input signal to the control panel that is proportional to the discharge pressure. (See
Pressure Sensor Calibration Note.)
Pressure Sensor Calibration Note: The displays for the pump intake and
discharge pressure are self calibrating. There are no adjustments that can
be made to the sensors or to the pressure shown in the display. When
power is applied to the INControl the program looks at the signal from
each sensor, assumes this to be 0 PSI, and calibrates the display to show
0. If there is pressure in the plumbing where the sensor is mounted this
will cause the display to be calibrated to a false 0. To avoid this FRC
recommends:
Drain the pump and plumbing to ensure there is no residual pressure.
Provide power to the INControl prior to engaging the pump.
Buzzer
The buzzer ground is supplied through the control panel, +12 VDC needs to be
supplied to the buzzer.
Engine Coolant Temperature Sensor
The engine coolant temperature sensor is installed as necessary.
Oil Pressure Sensor
The oil pressure sensor is installed as necessary.
Transmission Temperature Sensor (TGA200 only)
The transmission fluid temperature sensor is installed as necessary.
Cables
There are two cables that connect to the control module. One 8-pin connector and
one 12-pin connector.

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Controls and Indicators
All controls and indicators are located on the front of the control module. (Refer
to Figure 1.) The LED digital display has daylight bright digits at least 0.56 inch high.
PUMP DISCHARGE Display
Shows the pump discharge pressure during normal operations.
PSI LED
The red PSI LED is on to indicate operation in the pressure mode.
PSI Button
Selects the pressure mode of operation.
PRESET Button
Sets the pump pressure or engine RPM to a pre-programmed value.
PSI/RPM Setting Display
The display will show the pressure or the RPM setting.
RPM Button
Selects the RPM mode of operation.
RPM LED
The red RPM LED is on to indicate operation in the RPM mode.
RPM Display
Shows the engine RPM during normal operations.
SILENCE Button
Suppresses audio alarms.
VOLTS LED Display
Shows battery voltage. LEDs will flash when the voltage is outside normal limits.
TRANS. °F LED Display
Shows transmission temperature. LEDs will flash when the temperature high.
°F LED Display
Shows engine coolant temperature. LEDs will flash when the temperature high.
PSI LED Display
Shows engine oil pressure. LEDs will flash when the pressure low.

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Figure 1. Controls and Indicators
PSI/RPM
Setting
Display
IDLE
Button
PUMP
DISCHARGE
Display
PUMP
INTAKE
Display
RPM
Display
PRESET
Button
DEC
Button
SILENCE
Button
RPM
Mode
Button
PSI
Mode
LED
OK TO
PUMP
LED
Battery
Voltage
Display
Engine
Temperature
Display
Idle
LED
PSI
Mode
Button
RPM
Mode
LED
EngineOil
Pressure
Display
INC
Button TGA200
Transimssion
Temperature
Display
INC Button
During operations the button raises pressure or RPM setting.
DEC Button
During operations the button lowers pressure or RPM setting.
OK TO PUMP Light
ThisLEDwillbeon when therequiredinterlockconditionsare met andthegovernor
is ready to begin pump operations.
IDLE Button
When pressed immediately sets the engine RPM to idle. This button can be used
in an emergency or for normal shut down after operations.
Idle LED
This LED is on to indicate the engine RPM is at idle.
PUMP INTAKE Display
Shows the pump intake pressure during normal operations.

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INSTALLATION
When the governor is programmed at the factory there will be a label on the
governor specifying the engine type. If there is no label on the governor the engine type
must be verified/programmed per the Programming procedure.
Install Control Panel
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 9 by 3 15/16 inch 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).
4. Connect cables at rear of the contol module. (Refer to Wiring section.)
Figure 2. Control Panel Mounting Dimensions
Panel
Cutout
Maximum
Radius 1/2" 9"
3 15/16"
9 1/16"
4 1/16"
9 11/16"
4 11/16"
2 3/4"
5/8"
1/4"
10-32mounting
hardware is
recommended.

TGA100/TGA200 Rev0305
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Install Pressure Sensors
The two pressure sensors are mounted on the discharge and intake manifolds of
the pump. If there is a check valve in the discharge side of the pump, mount the
dischargetransducer before the check valve.T-fittingscanbeusedtomountthepressure
transducers.
Note: Install the pressure sensor upright so water in the end of the pressure
transducer 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 transducer may occur.
2. Tighten the sensor with a 9/16-inch (3/4 for alternate part) wrench on the lower
hexfitting.
3. Connect the pressure sensor cable from the control module to the pressure
sensor. (Refer to Wiring section.)
Caution: Do not use the main body
that houses the electronics to tighten
the sensor. Damage to the sensor
may occur.
Figure 3. Pressure Sensors
1/4-18 NPT
1234567890
1234567890
1234567890
1234567890
1234567890
1234567890
1234567890
1234567890
1234567890
1234567890
1234567890
Lower Hex
Fitting
Supply
Voltage
5 VDC
Output
Signal
Ground
Main Body
1.04" 1.06"
1.02"
0.86"
0.80"
0.53"
0.78"
1.12"
Intake - IO3100PT2 Discharge - FP4000PT1

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Install Engine Sensors
For most electronic engines, the INControl receives engine RPM, oil pressure,
and coolant temperature data over the J1587 databus from the engine ECM. 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 and 8-pin connector at the rear of the control
module. Refer to the Wiring section (Figures 4 and 5) for pinout and wire color
information.
An input is also provided for the optional transmission temperature sensor.
Standard Mounting Thread Size
Engine Oil Pressure 1/8" NPTF
Engine Coolent Temperature 1/2-1/4" NPT
TransmissionTemperature 1/8" NPTF
Install Buzzer
Installthebuzzerclose tothecontrolpanelso theaudiblewarningiseasily associated
with the visual warning on the display.
The optional buzzer provided by FRC requires a cutout hole of 1-1/8" (1.125").
Pin 7 on the 8-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 7. (Maximum
current through pin 7 is 300 mA.) Refer to the Wiring section (Figure 5).

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OPERATION
On power up the INControl will be in the pressure mode of operation. The RPM
display will show IdLE. If there is a problem, the RPM display will show an error
code. Refer to the Diagnostics section for error code descriptions.
The minimum pump discharge pressure must be greater than 15 PSI for
the INControl governor to take control of engine speed.
No variation in discharge pressure or RPM will occur when changing between
pressure and RPM modes.
INC/DEC Buttons
The INC and DEC buttons are used to change pressure and RPM settings or
program preset values. The rate and amount the numbers change when a button is
pressed depends on the mode and how long the button is held.
In Pressure Mode. Press either button momentarily to change the pressure setting
by 1 PSI. Press and hold the button for more than 2 seconds and the pressure
setting will change by 5 PSI twice and then by 10 PSI until the button is released.
In RPM Mode. Press either button momentarily to change the RPM setting by
10 RPM. Press and hold the button for more than 2 seconds and the RPM
setting will change by 50 RPM twice and then by 100 RPM until the button is
released.
Switching Between Operating Modes
• No variation in discharge pressure or RPM will occur when changing between
pressure and RPM modes.
• When changing to RPM mode, the RPM setting will be the RPM that the
pump was operating at in pressure mode.
• When changing to pressure mode the pressure setting will be the pressure that
the pump was operating at in RPM mode.
When the INControl RPM display shows IdLE:
Press the mode button and the INControl switches modes immediately.
When the INControl RPM display shows a value (operating at some setting):
Press and hold the mode button for 3 seconds and the INControl changes
modes. (This is to avoid an accidental change over if the buttons get bumped.)
High Pump Discharge Pressure at Engine Idle
Once the governor has set the engine to idle, it can do no more to reduce discharge
pressures. To reduce discharge pressure the pump operator can gate incoming water,
reduce pressure at the intake relief valve, gate discharges, or disable the pump.

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Pressure Mode Operation
In the pressure mode of operation the PSI LED will be on. The INControl will
maintain a constant discharge pressure. It will adjust the engine RPM automatically to
compensate for variations in pressure.
Note:When changing from RPM mode to pressure mode the pressure setting
will be the pressure that the pump was operating at in RPM mode.
1. Press and hold PSI mode button for 3 seconds.
Result: PSI LED goes on.
2. Press PRESET and/or INC/DEC button to select the operating discharge
pressure.
3. Press IDLE button after operations to bring engine to idle RPM.
Result: Display shows IdLE.
Switching Supply Water
When switching the water supply source from tank to hydrant, draft to hydrant, or
draft to relay, water flow through the pump can become turbulent and the positive
pressure from these sources may generate a sudden pressure surge. It is recommended
that the INControl be set in RPM mode before changing the water supply source.
No or Low Supply Water
There are situations during pump operations when there may be no or low supply
water. This can be due to an empty water tank, a problem on the intake line, or when
switching the water supply source.
In pressure mode the INControl will increase the engine RPM and attempt to
maintain the selected pressure setting. If the discharge pressure drops below 45 PSI
but stays above 15 PSI the INControl will go into a low water cycle. It will set the
engine to 1100 RPM, if the pressure does not rise above 45 PSI in 7 seconds the
INControl will set the engine at idle RPM. The INControl will repeate the low water
cycle as long as the discharge pressure is between 15 and 45 PSI.
If during the prime cycle the discharge pressure drops below 15 PSI the engine
will be set at idle RPM. When the discharge pressure rises above 45 PSI the INControl
will resume normal operation.
Opening/Closing Discharge Valves
In pressure mode the INControl will maintain the pressure setting regardless of
the number of discharge lines that are opened or closed providing there is a sufficient
water supply. As lines are opened the discharge pressure will start to drop and the
INControl will raise the engine RPM to maintain the required pressure. As lines are
closed the discharge pressure will start to rise and the INControl will lower the engine
RPM to maintain the required pressure.

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RPM Mode Operation
In the RPM mode of operation the RPM LED will be on. The INControl will
maintain a constant engine RPM.
The pump discharge pressure can vary but, as a safety feature, the INControl
limits the increase in pressure to 30 PSI. As the discharge pressure approaches this
limit the INControl will automatically lower the RPM to prevent a high pressure surge.
The RPMLED will blink as the INControl sets a lower RPM. This lower RPM will be
the new operating RPM setting.
Note: When changing from pressure mode to RPM mode the RPM setting
will be the RPM that the pump was operating at in pressure mode.
1. Press and hold RPM mode button for 3 seconds.
Result: RPM LED goes on.
2. Press PRESET and/or INC/DEC button to select the operating RPM.
3. Press IDLE button after operations to bring engine to idle RPM.
Result: Display shows IdLE.
Change Preset Setting (Pressure or RPM)
The preset button allows the operator to go to a pre-programmed pump pressure
or engine RPM during operations. The setting will be shown on the PSI/RPM setting
display. This procedure is to change the setting in the program.
Note: The engine must be running and the pump engaged interlock circuit
must be closed (the OK TO PUMP LED must be on).
1. Press IDLE button.
Result: Display shows IdLE.
2. Press PSI or RPM mode button to select the setting to be changed.
Result: LED indicator goes on for mode selected.
Note: The RPM display must show IdLE before changing the preset.
3. Press and hold PRESET button. (Continue to hold through step 4.)
Result: PUMP DISCHARGE or RPM display flashes previous programmed
preset.
4. Press INC or DEC button to change preset setting.
5. Release PRESET button.
Result: The new preset is programmed. RPM display shows IdLE.

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High Idle
The INControl has a built in high idle function that can be used as necessary. A
high idle switch needs to be installed that will provide a ground to pin 4 of the 8-pin
connector. (Refer to Figure 5.) When the switch is closed, the high idle function will be
engaged. The high idle is set at the factory at 1000 RPM.
Note: The interlocks must be made for the governor to control the engine.
Change High Idle Setting
Note: The high idle is set at the factory at 1000 RPM.
1. Set the High Idle switch to ON (this switch is installed to provide a ground
when in the ON position).(Refer to Figure 5.)
Result: Engine RPM goes to high idle.
2. Press and hold PRESET button.
Result: RPM display will flash and show the high idle setting.
3. Press INC/DEC button to change the high idle RPM setting.
4. Release PRESET button to store the new high idle setting.

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Thispage intentionally left blank.

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PROGRAMMING
This program information is provided for installers and should not be changed
once the apparatus is put into service. The governor response speed may need to be
adjusted if changes are made in the pump drive system after the governor is installed.
Program Governor Response Speed
Due to variations in pump drive systems the INControl program may be adjusted
if necessary to improve performance. There are five programmable speed settings (S1
to S5) for pressure and RPM that adjust how fast the governor reacts to changes in
pressure or RPM. The default setting for both is S3.
Note: The engine must be running and the pump engaged interlock circuit
must be closed (the OK TO PUMP LED must be on).
1. Press IDLE button.
Result: RPM display shows IdLE.
2. Press PRESSURE or RPM mode button.
Result: LED indicator goes on for mode selected.
3. Press and hold PRESET button. (Continue to hold through step 4.)
Result: The selected mode display will flash; wait for the current preset setting
to be shown.
4. Press IDLE button.
Result: RPM display shows responce speed current setting (default is S3).
5. Press INC or DEC button to change the setting (S1 is fastest S5 is slowest).
6. Release PRESET button.
Result: Display will return to normal. The new response speed setting is
programmed.
Program Engine Type
Note: The engine type is programmed from the factory or during installation
and will not need to be changed once the governor is in service.
Engine Type Must be Verified
When the engine type is programmed at the factory there will be a label on the
governor specifying the engine type.
If there is no label on the governor the engine type must be verified/programmed
per the following procedure.

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Preliminary Set-up
ThisprocedurecanbeperformedpriortoinstallingtheINControlontheapparatus.
Connect 12 volt power as follows:
12-Pin connector pin 1 (red wire) +12 VDC
12-Pin connector pin 2 (black wire) Ground
If the INControl is installed on the apparatus, turn on electrical power. Do not
operate the engine. The pump engaged interlock circuit must be open. No input
information from sensors or the engine is needed.
Enter Engine Type
Note: Do not operate the engine. The pump engaged interlock circuit must
be open to do this procedure (the OK TO PUMP LED must be off).
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 5 seconds until the RPM display
shows four dashes. The program is ready for a three digit program code to be
input.
Note: The RPM and PSI buttons are used to enter the code. The RPM
button will select the digit that is to be changed. The PSI button will
change the digit.
2. Enter code 441.
Results:After a few seconds the RPM display will flash the current engine type
setting. The timeout feature is disabled.
4. Press INC or DEC button to change the setting. (Refer to Table 1.)
5. Press the SILENCE button and hold it for 5 seconds.
Result:Displaywillreturntonormal.Thenewenginetypesettingisprogrammed.
Table 2. Engine Type Setting
Engine Model Engine Type
Setting
Cummins 101A
Detroit Diesel (Series 50 and 60) 102A
Detroit Diesel (Series 40) 102b
Navistar 104A
Caterpillar 105A
Mercedes 110A

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DIAGNOSTICS
Transducer Calibration Note: The displays for the pump intake and
discharge pressure are self calibrating. There are no adjustments that can
be made to the transducers or to the pressure shown in the display. When
power is applied to the INControl the program looks at the signal from
each transducer, assumes this to be 0 PSI, and calibrates the display to
show0.Ifthereis pressureintheplumbingwherethe transducer ismounted
this will cause the display to be calibrated to a false 0. To avoid this FRC
recommends:
Drain the pump and plumbing to ensure there is no residual pressure.
Provide power to the INControl prior to engaging the pump.