FRC TACHPLUS+ TPA400 User manual

TPA400 Rev0509
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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
ENGINE DISPLAY AND MONITORING SYSTEM
MODELS: TPA400, TPA420, TPA450
DocumentNumber:
XE-TPA4PM-R0A

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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 ......................................................................................... 6
INSTALLATION ........................................................................................................ 8
Install Control Module ........................................................................................... 8
InstallBuzzer.......................................................................................................... 8
Install Oil Pressure Sensor................................................................................... 10
Install Engine Coolant Temperature Sensor......................................................... 10
Install Transmission Temperature Sensor ............................................................ 10
Install Pump Overheat Sensor (Optional) ............................................................ 10
Install Generator Engaged Sensor (Optional) ...................................................... 10
Install RPM Sensor.............................................................................................. 11
Install Hourmeters ................................................................................................ 11
OPERATION............................................................................................................ 12
Operation Displays .............................................................................................. 13
CALIBRATION........................................................................................................ 16
Fuel Level Sender ................................................................................................ 16
DIAGNOSTICS ....................................................................................................... 18
WIRING ................................................................................................................... 20
TPA400 Wiring .................................................................................................... 21
TPA420 Wiring .................................................................................................... 22
TPA406/TPA450Wiring ...................................................................................... 23
FLYBACK DIODE INFORMATION ...................................................................... 24

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List of Tables
Table 1. Message DisplayAbbreviations ................................................................. 15
Table 2. Diagnostic Codes....................................................................................... 18
List of Figures
Figure 1. Controls and Indicators .............................................................................. 7
Figure 2. Control Module Mounting Dimensions ...................................................... 9
Figure 3. Fuel Level Calibration ............................................................................... 17
Figure 4. Common Wiring ....................................................................................... 20
Figure 5. TPA400 Wiring ......................................................................................... 21
Figure 6. TPA420 Wiring ......................................................................................... 22
Figure 7. TPA406/TPA450 Wiring ........................................................................... 23
Figure 8. Flyback Diode .......................................................................................... 24

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INTRODUCTION
Overview
The TACHPLUS+ is an all-in-one instrument panel with integrated monitoring
anddisplay capabilities that saves valuablepump panel space. It combines upto thirteen
(13) different instruments in one waterproof unit. It will and provide both audible and
visual warning alarms if specified parameters go out of norm.
The TACHPLUS+ has a 4 digit LED display for engine RPM, and 2 LED bar
graphs to display the engine oil pressure and engine temperature.Adot-matrix message
display will show battery voltage during normal operation and warning messages as
they occur. When selected by the operator stored data and monitored input information
is shown.
The TACHPLUS+receives input information over the J1587 data link, hardwired
sensors, or the power-on condition of a monitored system.
TPA400 Engine inputs are from the J1587 datalink.
TPA406 Engine inputs are from an alternator input or RPM sensor, oil pressure,
and coolant temperature sensors.
TPA420 Engine inputs are from J1587 datalink and an oil pressure sensor.
TPA450 Engine inputs are from the alternator or RPM sensor, oil pressure, and
coolant temperature sensors.
Features
DigitalEngineRPMDisplay
LED Oil Pressure Display with Low Pressure Warnings
LED Engine Temperature Display with High Temperature Warnings
Battery Voltage Display with Low and Over Voltage Warnings
Acculmates Operational Hours for Multiple Systems
Audible and Visual Warnings for Monitored Parameters

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Specifications
Display Module
Supply Power: 12 VDC
Supply Current: 1.5 Amps
Dimensions: 4.4" by 4.4" by 3.5"
AudibleAlarm Buzzer
Voltage: 12 VDC
Volume: 95 dB
Sensors
Note: Sensors are used when information is not available on the J1587 data
link. The sensors needed will vary with the specific engine.
Oil Pressure: 0 - 100 PSI, 1/8" NPTF, 240-33 Ohms
CoolantTemperature: 100 - 250 °F, 1/2"-14 NPT
50 - 300 °F, 5/8" - 18 UNF (Ford 6.0 L)
Gen. Engaged Sensor: 120 VAC
Trans. Temp. Sensor: 140 - 320 °F, 1/8" NPTF, 240-33 ohm
Pump Overheat: Close 130 °F; Reset 115 °F
RPM: Input signal from alternator or flywheel
Note: For TPA406 Ford 6.0L engines it is best to pick up the RPM from the
CleanTachometerSignal(green/white)wire.If connecting to the alternator,
ensure the signal is not a low level (less than 1.5 volts), if it is the flywheel
or magnetic pick-up connection must be used.

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GENERAL DESCRIPTION
The information available to the TACHPLUS+ control module on the J1587 data
link varies depending on the particular engine. The sensors supplied will vary wiht the
engine type and options ordered.
Components
The TACHPLUS+ consist of the following components:
DisplayModule
Buzzer
Cables
Oil Pressure Sensor (As Required)
Engine Coolant Temperature Sensor (As Required)
Transmission Fluid Temperature Sensor (Optional)
Pump Overheat Sensor (Optional)
Generator Engaged Sensor (Optional)
Controls and Indicators
Allcontrols and indicators are located onthe front of the control module.Itcontains
the push button electronic controls, LED indicators, and digital displays. (Refer to
Figure 1.)
MODE Button
The MODE button is used to select the information scroll mode and to scroll
through the system and options information.
RPM Display
EngineRPMisshowninbright red LEDs with digits larger than ½" (0.56"). Display
will flash fault warn codes.
Message Display
Battery voltage is shown in the display during normal operations. This display will
flash warnings as they occur. When in the information scroll mode this display will
show system and options information.
SILENCE Button
The SILENCE button is to activate or de-activate the audible warning alarm. It is
also used to exit the information scroll mode

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Figure 1. Controls and Indicators
RPM
Display
OIL Pressure
LED Bar Graph
SILENCE
Button
COOLANT Temperature
LED Bar Graph
MODE
Button
Message
Display
OIL Pressure LED Bar Graph
Oil Pressure display is a vertical bar graph in 10 psi increments.
COOLANT Temperature LED Bar Graph
Engine Coolant Temperature is a vertical bar graph in 10 degree increments.

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INSTALLATION
For most electronic engines, the TACHPLUS+receives engine RPM, oil pressure,
and coolant temperature information over the J1587 data link from the engine ECM.
Some engines do not broadcast complete engine information over the data link and will
require that seperate sensors are installed.
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 3.75-inch diameter hole.
3. Drill four holes, clearance or tapped, for 10-32 mounting screws.
3. Place control module in position and secure with screws.
4. Connect cables at rear of the contol module. (Refer to Wiring section.)
Install Buzzer
Abuzzer is supplied with the TACHPLUS+. Install the buzzer close to the control
module so the audible warning is easily associated with the visual warning on the
display. A cutout hole of 1-1/8" (1.125") is required on the pump panel. (Refer to
Wiring section.)

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Figure 2. Control Module Mounting Dimensions
2.7"
4.4"
3.45"
123
1
2
3
1
2
3
1
2
3
123
3.72"
4.4"
3.75"
Diameter
Hole
Mounting holes are
clearance or tapped
for 10-32 screws.
3.5"
3.5"

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Install Oil Pressure Sensor
The oil pressure sensors has a single wire connection, the ground connection is
made by the threads to the engine block. The thread size for this sensor is 1/8" NPTF.
Install the sensor directly into the engine block oil pressure port. DO NOT USE A
PIPE WRENCH ON THE SENSOR BODY. Tighten the sensor into the pressure port
with a minimum of 5 turns. Check for leaks immediately on start-up. (Refer to Wiring
section.)
Install Engine Coolant Temperature Sensor
The engine coolant temperature sensor (except Ford 6.0L) has a sealed, 2-wire
connection which will eliminate corrosion and loss of ground return. This sensor is
compatible with the non-conductive housings. The thread size for this sensor is 1/2" -
14 NPT thread with 1-1/16" (1.0625") hexagonal head.
The Ford 6.0L has two sensor options, a single wire connection with the ground
connection made by the threads to the engine block and a two wire insulated ground
type. The thread size for these sensosr is 5/8" - 18 UNF. (The single wire type sensor
comes with a 16 mm adapter.)
DO NOT USE A PIPE WRENCH ON THE SENSOR BODY. Install the sensor
directly into the engine block coolant port and tighten with the hexagonal head. Check
for leaks immediately on start-up. (Refer to Wiring section.)
Install Transmission Temperature Sensor
The transmission fluid temperature sensor has a single wire connection, the ground
connection is made by the threads to the transmission. The thread size for this sensor
unit is 1/8" NPTF. Install the sensor directly into the transmission fluid pan. DO NOT
USE A PIPE WRENCH ON THE SENDER BODY. Tighten the sensor into the pan
with a minimum of 5 turns. Check for leaks immediately upon start-up. (Refer to
Wiring section.)
Install Pump Overheat Sensor (Optional)
The pump overheat sensor is mounted onto the pump casing. Make sure the
sensor is in direct contact with the surface of the pump body. (Refer to Wiring section.)
Install Generator Engaged Sensor (Optional)
Note: TheAC generator engaged sensor is needed if a 12 VDC signal is not
available to indicate that the generator is activate.
The AC generator engaged sensor should be mounted inside or near the circuit
breaker box. This will avoid the need to run long wires with AC voltage. The sensor
can be secured using 4 tie wraps.
DO NOT WIRE 240 VAC TO THE SENSOR.

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Install RPM Sensor
For engines that do not provide RPM information on a data link, the RPM signal
can be supplied by the alternator, or a magnetic pickup sensor. [For TPA450-6 Ford
6.0L engines it is best to pick up the RPM from the Clean Tachometer Signal (green/
white) wire.] Refer the Wiring section. The RPM display will have to be calibrated for
correct RPM measurement. Refer to the RPM Calibration section.
Install Hourmeters
The hourmeters are built into the control module. Inputs of 12 VDC must be
provided to the control module when the generator and aerial are engaged. (Refer to
Wiring section.)

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OPERATION
The TACHPLUS+ displays crucial engine information to the pump operator. The
audiblealarm is a clear distinctivewarning that sounds when a monitored inputexceeds
normal parameters. Visual warnings for the two LED displays will flash to indicate
warnings visually to the pump operator.
The Message Display will show all warning messages or other requested
information.
Message Mode Operation
There are two buttons on the TachPlus: a MODE and a SILENCE button. In
message mode, system messages are shown in the message display. To enter message
mode, press the MODE button. Every push of the MODE button displays the next
message. Each message remains in the window until the MODE button is pressed
again. If there is any warning, the message will be shown in the message display in 10
second intervals. This message will flash to indicate that it is a warning. Press the
SILENCE button to return to the normal display. Once exiting the message mode,
pressing the MODE button again will show the last displayed message.
To scroll through the messages, press and hold the MODE button and press the
SILENCE button. In scroll mode, the display will continuously scroll through all
messages available. If there is any warning, it will be added to the bank of scrolling
messages every 10 seconds. The warning message will flash to alert the operator.
Pressing the SILENCE button will bring the display back to the normal mode.
VisualAlarm
Wheneverthereisamonitored failure or problem, the visual alarm will be activated.
This alarm cannot be reset or cancelled manually. The alarm will stop automatically
when the problem has been taken care of.
AudiableAlarm
The Tachplus has a very unique sound feature. TheAudible Status Warning System
gives a short clear distinctive signal as the pump is engaged. It sounds continuously if
there is a monitored failure such as low oil pressure or high engine temperature. It
sounds a dual burst for low fuel warning.
Silencing Audible Alarm
All audible alarms can be cancelled by pressing the SILENCE button. Pressing
the SILENCE button for 2 seconds turns the buzzer or audible warning off. Pressing
it for 2 seconds again will reactivate the audible warning. Pressing the SILENCE
button will not change the visual warning.

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Operation Displays
Refer to Table 1. Message Display Abbreviations for descriptions of message
abbreviations.
Engine RPM
The engine RPM is displayed constantly under normal conditions. The engine
RPM is shown steadly in 10 RPM increments.
Engine oil pressure
The 10 segment LED bar graph will display engine oil pressure from 10-100 PSI
(each segment is equal to 10 PSI). Next to the readout is a color-coded graph for easy
identification of the engine oil pressure status. The RED zone indicates that the engine
oil pressure is low whereas the GREEN zone indicates that the pressure is normal. The
visual and audible warnings are activated if the engine oil pressure drops below 8 PSI.
The LED bar will flash and LOW OIL will flash in the message display. The audible
alarm is a long solid tone and can be canceled by pressing and holding the SILENCE
button until the sound goes away. For electronic engines, the LOW OIL activating
point is determined by the engine ECM.
Coolant Temperature
The engine temperature is displayed from 150 to 240 °F in 10 °F increment. The
GREEN zone indicates normal temperature condition and the RED zone indicates the
engine is too hot. The visual warning will be activated when the temperature rises
above 220°F. The LED bar will flash and HI TEMP will flash in the message display.
Theaudiblealarm is activated when the coolant temperature exceeds230°F.Theaudible
alarm can be silenced by pressing and holding the SILENCE button until the buzzer
stops beeping.
Battery Voltage
Under normal conditions the battery voltage is shown in the message display.
Visual and audible warnings are activated when the battery voltage drops below 11.7
VDC when the engine is not running, or below 11.8VDC when the engine is running. If
the voltage rises above 15.4 VDC, the high voltage warning will be activated. The low
battery voltage warning is indicated by LOW BATT and the high battery voltage is
indicated by "HI BATT", these will flash in the message display.
Low Fuel
Low engine fuel warning is activated when the fuel level drops below 25% of the
tank level. LOW FUEL will flash in the message display.
Note: The Tachplus has to be calibrated in order to read the fuel
level correctly, refer to the Calibration section.

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Hourmeters
TheTachplusisdesignedwithaninternaltimertokeeptrack of the various operating
hours. The operating hours that the Tachplus is able to time are :
Engine hours - total operating hours of the engine (ENG. HRS)
Pump hours - total operating hours of the pump (PUMP HRS)
Current Incident hours - (INC. HRS)
Last Incident hours - (LAST INC)
Aerial hours - total operating hours of the aerial (AER. HRS )
Generator hours - total operating hours of the generator (GEN. HRS ).
The hour information is displayed in decimals. Each tenth of a point is equal to 6
minutes or 1/10 of a minute (12.3 is 12 hours and 18 minutes).
Manifold Temperature
The manifold temperature information is supplied on the data link and is available
on electronic engines only. For an over temperature condition MAN. TEMP will flash
in the message display.
Pump Overheat (Option)
With this option, the Tachplus receives a signal from the pump overheat sensor.
The pump overheat warning is activated when the pump temperature rises above 130°F.
PUMP HOT will flash in the message display and audible alarm is activated.

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Table 1. Message Display Abbreviations
Note: For TPA406 Ford 6.0L there is a three mminute delay after power is applied
for the battery voltage warning.
Message
Abbreviation Description
AER. HRS Aerial operating hours
ENG. HRS Engine operating hours
FUEL % Percent of fuel in tank
GEN. HRS Generator operating
HI BATT High battery voltage
HI TEMP High engine coolant temperature warning
INC. HRS Incident hours
LAST INC Last incident hours
LOW BATT Low battery voltage warning
LOW FUEL Low fuel level warning (below 1/4 tank)
LOW OIL Low oil presure warning
MAN. TEMP Manifold temperature
PUMP HRS Pump operating hours
PUMP HOT High pump temperature warning
TRAN OIL High transmission fluid temperature warning

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CALIBRATION
RPM Calibration for Non-Electronic Engines
The RPM display has to be calibrated for all nonelectronic engines. No tools are
required.
1. Run the engine at1400RPM.TheRPMneedstobesteadyduringthecalibration
process.
2. Press the SILENCE button twice.
Result: The message display will show CAL RPM? .
Note: If no action is taken within 3 seconds, the calibration mode will be
cancelled.
3. Press the SILENCEbutton twice again to proceed with the calibration process.
Result:Themessage display will show WAIT.Whenthecalibrationiscompleted
it will show DONE ! and 1400 will show in the RPM display.
Fuel Level Sender
In order to use the existing sender in the fuel tank, the Tachplus has to be set for
the voltage level when the fuel tank is full and when it is empty.This adjustment is set at
the factory but may need to be adjusted in the field. There is a cable with 2 adjustment
pots behind the Tachplus, one of them is for adjusting the voltage level when the fuel
tank is full and the other one is for adjusting the voltage level when the fuel tank is
empty. When adjusting the pots, the message display will indicate which pot you are
adjusting and the large readout above the display will show the voltage level thus
eliminating the need of a voltmeter.
Note: The voltage levels set on the 2 pots (full and empty) have to be 1/2 the
actual voltage sent by the fuel level sender to the fuel level gauge.
Since theTachplus is able to use the existing fuel level sending unit that is mounted
on the fuel tank, there is no fuel sensor supplied with the unit. The Tachplus will not
affect the reading on other level gauges.
The Tachplus is factory calibrated to work with a 0-90 ohm fuel level sending unit
that is driving a VDO fuel level gauge. If the truck you are working on has a different
combination of sensor and gauge, you will have to recalibrate the Tachplus.Also, if the
truck has multiple fuel gauges, you may need to recalibrate.
Please call FRC if you need any further technical assistance.

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Fuel Level Calibration
Determine the voltage level from the sending unit when the fuel tank is full and the
voltage level from the sending unit when the fuel tank is empty.
This information can be obtained from the gauge manufacturer or you can measure
these voltages. To measure the voltages without actually filling and draining the tank,
youwillneed:
Avoltmeter, preferably a digital voltmeter, and a 250 or 1000 ohm potentiometer.
1. Disconnect the fuel level sending unit from the fuel level gauge at the signal
terminal wire (refer to Figure 3).
2. Connect one lead from the test potentiometer to the signal terminal of the level
gauge and connect the other leads to ground (or chassis).
3.Adjust the test potentiometer until thegaugeshows full tank. Measure the voltage
from the signal wire (TP-1) to ground, divide the voltage by 2 and record it.
4. Adjust the test potentiometer until the gauge shows empty tank. Measure the
voltage, divide the voltage by 2 and record it.
There is a cable at the rear of the Tachplus with 2 potentiometers. As each pot is
adjusted the message display on the Tachplus will show "F- full" or "F- empty" and
the RPM display will show the voltage level that was set at the factory. Use a small
screwdriver to adjust each of the potentiometers slowly.
1. When the message display shows "F- full, adjust the potentiometer until the
voltage shown in the display is equal to the recorded full tank voltage (make sure the
voltage level was divided by 2).
2. When the message display shows "F- empty" adjust the potentiometer until the
voltage shown in the display is equal to the recorded empty tank voltage (make sure the
voltage level was divided by 2).
3. Connect the fuel level sending unit back to the fuel level gauge.
250 or 1000 ohm
TestPotentiometer
signal
terminal
TP-1
RED BLACK
VoltmeterSeton
VDCPosition
FuelLevel
Sender
FuelLevel
Gauge
Gnd
EF
Disconnectfuelsender and
connectthepotentiometerto
signalterminaloffuelgauge
Gnd
Gnd
Gnd
EXAMPLE
Set the Potentiometer so the fuel
gauge pointer shows empty.
Thevoltmeter reads 8.00 VDC
Dividebytwo=4.00VDC
(this is the empty tank voltage)
Set the Potentiometer so the fuel
gauge pointer shows full.
Thevolt meter reads 2.00VDC
Dividebytwo=1.00VDC
(this is the full tank voltage)
Use the two values to set the
two fuel calibration
potentiometers on the tach plus
display unit.
Figure 3. Fuel Level Calibration

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DIAGNOSTICS
The information listed in Table 2 is to aid in troubleshooting a problem with the
TACHPLUS+. The diagnostic code will be shown in the Message Display on the
control module.
Table 2. Diagnostic Codes
Message
Display Problem Probable Cause
E1 NO DATA >Datalinkcablenotconnected/connectedtowrongport
>Brokenwire/badconnectorcontactondatalinkcable
E2 BAD DATA >Noiseinterference(radiofrequencyorelectrical)
E3 NORPM >Datalinkcablenotconnected/connectedto wrong port
>Enginenotrunning/ ignition keyon
>Brokenwire/badconnectorcontactonalternatorcable
E4 NO DATA >Novoltageat interlockinput
FROMECM >Internaldatalinkproblem
>Datalinkshorted
E5 N/A N/A
E6 N/A N/A
E7 N/A N/A
E8 MEMORY >ContactFRC
FAIL
E9 OIL >Sensorcablenotconnected
PRESSURE >Brokenwire / bad connector contact on sensor cable
>Defectivepressuresensor
E10 ENGINE >Sensorcablenotconnected
TEMP >Brokenwire/badconnectorcontactonsensorcable
>Defectivetemperaturesensor

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WIRING
Figure 4. Common Wiring
POWER
Red = 12 vdc
Black = Ground
White = 12 VDC from
OK to pump
Sensor Cable B
6 pins Deutsch plug
1-Blue - Pump overheat
2-Orange - Aerial Hour
6-Green - Gen. Hour
Fuel Tank Cal.
Electronic engines
Data link cable
Nonelectronic engines
RPM sensor cable
Sensor Cable A
6 pins Deutsch plug
1- Blue - Oil Pressure
2-Orange - Temp. Signal
Transmission on TP400\TP420
Coolant on TP450
3-Green - Coolant Temp. Return
4-Brown - Fuel level
5-Black - Buzzer (-)
6-Red - Buzzer (+)