FRC ThrottleXcel ELA100 User manual

ELA100 Rev0808
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FIRE RESEARCH CORPORATION
www.fireresearch.com
26 Southern Blvd., Nesconset, NY11767
TEL ( 631 ) 724-8888 FAX ( 631 ) 360-9727 TOLL FREE 1-800-645-0074
ENGINE THROTTLE
with DISPLAY and MONITORING SYSTEM
MODEL: ELA100
Document Number:
XE-ELA1PM-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 ......................................................................................... 8
INSTALLATION......................................................................................................10
Install Control Module ........................................................................................ 10
Install Engine Sensors .........................................................................................10
Install Buzzer.......................................................................................................10
Install High Idle Kit ............................................................................................10
OPERATION ............................................................................................................ 12
Display Stored Data............................................................................................. 14
High Idle.............................................................................................................. 15
PROGRAMMING.................................................................................................... 16
Program Code Descriptions ................................................................................17
WIRING ...................................................................................................................18
Connectors and Cables........................................................................................18
Cummins Harness Connections ..........................................................................20
Detroit Diesel (Series 50 and 60) Harness Connections..................................... 22
Navistar Harness Connections ............................................................................23
Caterpillar Harness Connections......................................................................... 24
Ford Harness Connections .................................................................................. 27
Mack Harness Connections................................................................................. 30
Scania Harness Connections ............................................................................... 31
GMC Harness Connections................................................................................. 32
Mercedes Harness Connections .......................................................................... 33
High Idle Wiring.................................................................................................. 34
FLYBACK DIODE INFORMATION ...................................................................... 35

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List of Tables
Table 1. Error Codes................................................................................................13
Table 2. Fault Warning Codes .................................................................................13
List of Figures
Figure 1. Controls and Indicators.............................................................................. 9
Figure 2. Control Module Mounting Dimensions................................................... 11
Figure 3. ELA 12-Pin Connector Wiring ................................................................ 18
Figure 4. ELA 8-Pin Connector Wiring ..................................................................19
Figure 5. Cummins ELA101 Wiring ....................................................................... 20
Figure 6. Detroit Diesel (Series 50 and 60) ELA102 Wiring ................................. 22
Figure 7. Navistar ELA104 Wiring .........................................................................23
Figure 8. Caterpillar ELA105 Wiring ..................................................................... 24
Figure 9. Ford 7.3L ELA106-A Wiring................................................................... 27
Figure 10. Ford 6.0L and 6.4L ELA106-B Wiring .................................................. 28
Figure 11. Mack ELA107 Wiring............................................................................30
Figure 12. Scania ELA108 Wiring.......................................................................... 31
Figure 13. GMC ELA109 Wiring ........................................................................... 32
Figure 14. Mercedes ELA110 Wiring ..................................................................... 33
Figure 15. High Idle Wiring .................................................................................... 34
Figure 16. Flyback Diode........................................................................................ 35

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INTRODUCTION
Overview
The ThrottleXcel is an all-in-one instrument panel that integrates a traditional
styleremote hand throttlewith engine monitoringand display.It offerscomplete remote
display and engine control (as a remote throttle, the ThrottleXcel is not an engine
governor) in a single compact unit.
The panel has a 4-digit LED display for engine RPM, three LED bar graphs that
provide a constant display of the engine oil pressure, engine coolant temperature, and
battery voltage. It has a message display that shows the time and date during normal
operations and fault warning alarms as they occur. When selected by the operator it
shows monitored information, stored data, and program options.
The ThrottleXcel panel has a built-in FRC infinityPRO remote engine throttle.
This hand throttle uses optical technology with an Infrared Encoder (IRE) to detect
the direction and speed of the control knob as it is rotated. There is no potentiometer,
electromechanical switch, or mechanical stop. The electrical signal from the encoder
is interpreted by a microprocessor and the engine RPM control signal is adjusted.
This causes the engine RPM to increase or decrease proportionally to how fast the
control knob is rotated. The engine RPM control signal is set at idle when power is
applied to the ThrottleXcel regardless of the control knob position.
Engine information is input via the J1939 data bus and/or installed sensors.
Features
Always Starts From Idle RPM
Large RPM Display
Three Bi-Color LED Bar Graphs
Message Display
Visual Warning Alarms
Programmable Alarm Levels
Records Date and Time of Warning Alarm Occurrences
Records Accumulated Hours
Interlock Signal Recognition
Remote Hand Throttle with Idle Button and No Mechanical Stops
High Idle Function
Audible Alarm Buzzer (Optional)
Interconnected Multiple Panels (Optional)

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Specifications
The ThrottleXcel is available in various models. Each model is programmed to
interface with specific engines. All models provide the same functions, controls, and
digital readouts.
Display Module
Supply Power: 12/24 VDC
Supply Current: 0.5 Amps
Dimensions: 4 5/8" Wide by 6 3/4" High
LED Bar Graphs
Oil Pressure: 10 - 100 PSI (10 PSI Increments)
Temperature (Engine Coolant): 130 - 240 °F (10° Increments)
Battery Voltage: 11.5 - 16 Volts (0.5 Volt Increments)
Engine Sensors
Engine Oil Pressure: 0 - 100 PSI, 1/8" NPTF
Engine Coolant Temperature: 100 - 250 °F, 1/2" - 14 NPT
Transmission Temperature: 140 - 320 °F, 1/8" NPTF
Audible Alarm Buzzer (Optional)
Voltage: 12 VDC
Volume: 96 dB

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GENERAL DESCRIPTION
The ThrottleXcel all-in-one instrument panel with remote hand throttle is
compatible with the following engines:
ELA101 Cummins IS Series
ELA102 Detroit Diesel
ELA104 Navistar
ELA105 Caterpillar
ELA106* Ford
ELA107 Mack
ELA108 Scania
ELA109* GMAC
ELA110 Mercedes
*Note: An adapter and cable assembly replaces the basic 8-pin cable when
connecting the ThrottleXcel to a Ford or GMAC engine.
The ThrottleXcel is a remote engine display with monitoring and has a remote
throttle for engine RPM control, it is not an engine governor.
Components
The information available on the J1939 data bus varies depending on the particular
engine type. The sensors (if any) that need to be installed will also vary depending on
the engine.
The ThrottleXcel consist of the following components:
Contol Module
Engine Coolant Temperature Sensor (As Necessary)
Engine Oil Pressure Sensor (As Necessary)
Audible Alarm Buzzer (Optional)
Transmission Temperature Sensor (Optional)
Cables
Contol Module
The control module 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 module. (Refer
to Controls and Indicators.)

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Engine Coolant Temperature Sensor
The engine coolant temperature sensor is installed as necessary.
Oil Pressure Sensor
The oil pressure sensor is installed as necessary.
Audible Alarm Buzzer (Optional)
The optional buzzer is installed as required. A ground is provided at the 12-pin
connector pin 6 to activate the buzzer (max current: 300mA).
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.
RPM Display
Shows the current engine RPM in bright red digits during normal operations. It is
used to show error codes, fault warnings, stored data, and program features.
SILENCE Button
Pressed to suppress audio alarms. Used when accessing stored data and program
features. See the Programming Section for more information.
BATTERY VOLTAGE LED Display
Shows the real time battery voltage. The LEDs are green when the voltage is
within normal limits and red when it is not.
OK TO PUMP LED
This LED are on when the required interlock conditions are met and the throttle is
ready to begin pump operations.
Remote Hand Throttle Control Knob
When rotated changes the engine RPM. The engine RPM increases or decreases
proportionally to the speed and direction the control knob is rotated.
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.
Message Display
The message display shows the time and date during normal operations and
warning alarms as they occur. It is used when accessing stored data and program
features.
TEMPERATURE LED Display
Shows real time engine coolant temperature. The LEDs are green when the
temperature is within normal limits and red when it is not.
OIL PRESSURE LED Display
Shows real time engine oil pressure. The LEDs are green when the pressure is
within normal limits and red when it is not.
MENU Button
Used when accessing stored data and program features.

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Figure 1. Controls and Indicators
RPM
Display
Message
Display
OIL PRESSURE
LED Display
TEMPERATURE
LED Display
SILENCE
Button
MENU
Button
BATTERY
VOLTAGE
LED Display
Remote Hand
Throttle
Control Knob
IDLE
Button
OK TO PUMP
LED

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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 1/2 by 5 3/4 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.)
Install Engine Sensors
For most engines, the ThrottleXcelreceives engineRPM, oil pressure,and coolant
temperature data over the J1939 databus from the engine ECM. Some engines do not
broadcast this data over the data bus and sensors may need to be installed.
Note: The ThrottleXcel may need a programming change for some sensor
inputs to be recognized. If the sensor was not ordered as part of the
Throttlexcel kit you may need to contact FRC technical support for
programming information.
The sensors are wired to the 12-pin connector at the rear of the control module.
Refer to the Wiring Section for pinout and wire color information.
An input is provided for an optional transmission temperature sensor.
Install Buzzer
Pin 6 on the 12-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 6. (Maximum
current through pin 6 is 300 mA.) Refer to the Wiring Section. FRC buzzer requires a
1 1/8 inch hole.
Install High-Idle Kit
The high-idle is activated when + VDC is provided to pin 7 (High-Idle Active
Input) of the 12-pin connector and pin 6 (Interlock Input) of the 8-pin connector.
Refer to High-Idle Wiring.
Note: It is important that the connection to the Interlock Input from the
High-Idle circuit be isolated from the apparatus interlock wiring with the
two diodes. The pump must NOT be engaged when using the high-
idle function and the OK TO PUMP LED will be off.

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Figure 2. Control Module Mounting Dimensions
Mounting holes are
clearance or tapped
for 10-32 screws.
4 5/8"
6 3/4"
Maximum
Radius 1/2"
1 3/4"
3 1/2"
5 3/4"
Panel
Cutout 5 3/4"
4"

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OPERATION
On power-up the ThrottleXcel is in normal operating mode. The RPM display
shows engine RPM, the three LED bar graphs are green indicating readings within
normal ranges, and the message display alternates between showing the date and time.
If a monitored function is not within normal parameters the display flashes, the
RPM display shows an error or fault warning code and a description shows in the
message display. (Refer to Table 1. Error Codes or Table 2. Fault Warning Codes.)
If one of the inputs displayed by the LED bar graphs is not within normal range
the LEDs will be red.
When all necessary throttle enables are active and the interlock circuit is complete
the OK TO PUMP LED will light and the remote throttle will be controlling engine
RPM. The engine RPM control signal is set at idle regardless of the control knob
position.
Remote Hand Throttle
The remote hand throttle is used to adjust engine RPM. The ThrottleXcel senses
how fast and in what direction the control knob is rotated and sends a signal to the
ECM to increase or decrease the engine RPM proportionally.
If the control knob is rotated quickly; the RPM changes quickly.
If the control knob is rotated slowly; the RPM changes slowly.
• Rotate the control knob clockwise to increase engine RPM.
• Rotate the control knob counterclockwise to decrease engine RPM.
• Press the red IDLE button to immediately return the engine to idle.
SILENCE Button
During normal operations the silence button is used to suppress an optional audio
alarm.
MENU Button
During normal operations the menu button is used to access the accumulated
hours mode.

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Table 2. Fault Warning Codes
Table 1. Error Codes
RPM Message
Display Display Probable Cause
E01 NO DATA >Datalink cable not connected / connected to wrong port
>Broken wire / bad connector contact on datalink cable
E02 N/A N/A
E03 NO RPM >Datalink cable not connected / connected to wrong port
>Engine not running / ignition key on
>Broken wire / bad connector contact on alternator cable
E04 N/A N/A
E05 N/A N/A
E06 N/A N/A
E07 N/A N/A
E08 Trans >Sensor cable not connected
>Broken wire / bad connector contact on sensor cable
>Defective temperature sensor
E09 ENG OIL’ >Sensor cable not connected
>Broken wire / bad connector contact on sensor cable
>Defective pressure sensor
E10 ENG T’ >Sensor cable not connected
>Broken wire / bad connector contact on sensor cable
>Defective temperature sensor
RPM Message
Display Display Description
F01 - N/A
F02 - N/A
F03 HI RPM High RPM
F04 - N/A
F05 - N/A
F06 HI BATT High battery voltage
F07 LOW BATT Low battery voltage
F08 TRAN TEMP High transmission temperature
F09 LOW OIL Low engine oil pressure
F10 ENG TEMP High engine coolant temperature

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Display Stored Data
Both the RPM and the message displays are used to show stored data.
Accumulated Hours and Transmission Temperature
Accumulated hours are stored in memory for engine operation, pump operation,
last incident, and current incident. The menu button allows the operator to gain access
to this stored data. When in the accumulated hours mode the RPM display shows the
hours. The message display will show the following:
Pump Operating Hours
Engine Operating Hours
Last Incident Hours
Current Incident Hours
Transmission Temperature
The accumulated hours mode is a display only mode and no changes can be made
to the data.
The engine must be in idle to access the accumulated hours.
Press the MENU button to enter the accumulated hours mode.
Stored accumulated hours will be displayed.
The RPM display shows the number of hours.
The message display shows what the hours are for.
Press the MENU button to show the next stored hours.
Each time the MENU button is pressed the displays change to show the next
block of stored accumulated hours.
Press and hold the MENU button for 5 seconds.
The displays continuously cycle to show all of the stored accumulated hours.
Press the SILENCE button to exit the accumulated hours mode.
Fault Warnings
Each time a fault occurs, the type of fault, date, and time are stored in memory.
The memory holds the last ten (10) fault occurrences to be displayed at a later time.
Refer to the Programming Section for details on retrieving fault warnings.
Maximum Engine RPM
Themaximum RPM thatthe engine reaches is stored in the memory to bedisplayed
at a later time. Refer to the Programming Section for details on retrieving the maximum
engine RPM.

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High-Idle
The ThrottleXcel programming includes a high-idle function that is controlled
by a High-Idle Switch.
To activate the high idle, set interlocks as called for by SOP (normally this would
include the transmission in neutral and the parking brake on ). Set the High Idle switch
to ON.
Note:Thepump mustNOTbeengagedwhenusing thehigh-idlefunction
and the OK TO PUMP LED will be off.
Change High-Idle Setting
The high-idle is set at about 1000 RPM at the factory. (This value will vary
depending on the specific engine.)
1. With the engine running, set the high-idle switch to ON.
Result: Engine RPM goes to high-idle.
2. Press and hold the IDLE button for 10 seconds.
3. Keep pressing the IDLE button and rotate the control knob to the desired
RPM.
4. Release the IDLE button to store the new high-idle setting

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PROGRAMMING
To gain access to the program features a four digit program code must be entered.
Review the Program Code Descriptions for the proper four digit code.
Both the MENU and SILENCE buttons are used to enter a program code. The
RPM display is used to show the codes.
Enter Program Code
Note:There is a time out feature that returns 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 3 seconds until the RPM display
shows four dashes. The program is ready for a four digit program code to be
input.
2. Press the MENU button. The RPM display shows the number 1000. Each
time the MENU button is pressed the first digit increments by 1. Set the first
digit to the desired number.
3. Press the SILENCE button. Each time the SILENCE button is pressed the
second digit increments by 1. Set the second digit to the desired number.
4. Press the MENU button. Each time the MENU button is pressed the third
digit increments by 1. Set the third digit to the desired number.
5. Press the SILENCE button. Each time the SILENCE button is pressed the
fourth digit increments by 1. Set the fourth digit to the desired number.
6. Wait a few seconds:
If a valid four digit program code is entered the display changes to show a
program value or an option.
If an invalid code is entered the display will show WRONG CODE.

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Program Code Descriptions
When a valid four digit program code has been entered, stored data or program
options will show in the displays.
The MENU and SILENCE buttons are used to change the data. The SILENCE
button will select the digit that is to be changed. The MENU button will change the
digit or change the option choice.
Data Display Codes 1000
1110 - Fault Warnings
This code will show the last ten (10) fault warnings that have occurred. The RPM
display will show a fault code and the message display will alternate between showing
the date and time that the fault occurred. Refer to Table 2. Fault Warnings
1120 - Maximum Engine RPM
This code will display the maximum RPM that the engine has attained.
1130 - Software Revision
This code will display the current software revision code.
Parameter Settings Codes 2000
2110 - Clock
This code will allow the clock display to be changed.
2120 - Date
This code will allow the date display to be changed.
2130 - Clear Fault Warnings
This code will allow the stored fault warnings to be cleared from memory. It will
clear the history of all ten (10) fault warnings. Select YES or no.
2140 - RPM Calibration
This code will allow the digits in the RPM display to be adjusted to match a
tachometer. This is for engines that do not receive RPM data over the datalink and
have the yellow RPM signal wire (pin 12 on the 12-pin connector) connected to an
RPM source.
Exit Program Code Mode
Press the SILENCE button first then the MENU button and hold them both for 3
seconds to exit the program code mode and return to normal operation.

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Notes:
- Not all wires are used for all engines.
- For Ford 6.0L, 6.4L engines the yellow RPM signal wire, pin 12, should be connected to the
Clean Tachometer Output [for 6.0L green/white wire, circuit #76] [for 6.4L dark blue wire].
- High idle not available for Ford, Mack, or GMC.
- The J1939 CAN bus is terminated with a 120 ohm resistor.
- When using an FRC provided sensor cable, the red wire is sensor signal and the black wire
connects to a ground.
WIRING
The following figures include the schematics, wiring diagrams, block diagrams,
and cables for the ThrottleXcel.
Connectors and Cables
Figure 3. ELA 12-Pin Connector Wiring
12-Pin
Deutsch
Connector
Butt
Connectors
12 Pin Connector/Cable
Pin Wire Color Description
1NC -
2NC -
3NC -
4 Blue Engine Oil Press. Sensor Signal
5 Orange Engine Coolant Temp. Sensor Signal
6 Brown Buzzer Ground (300mA)
7 Violet High Idle Active Input (+ VDC)
8NC -
9 Black CAN J1939 (–)
10 Red CAN J1939 (+)
11 Green Transmission Temp. Sensor Signal
12 Yellow RPM Signal
NC
NC
NC
BLU
ORG
BRN
VIO
WHT
BLK
RED
GRN
YEL
12-Pin Cable
12
12
12
12
12
1
1
1
1
1

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Figure 4. ELA 8-Pin Connector Wiring
Notes:
- Not all wires are used for all engines. Refer to the engine specific wiring diagram for interface
connections.
- An adapter and cable assembly replaces the basic 8-pin cable when connecting the ThrottleXcel
to a Ford 6.0, 6.4 or GMC engine. Refer to the engine specific wiring diagram.
Butt
Connectors
12-Pin
Connector
Pin 1
Control Module
Rear View
8-Pin
Connector
Pin 1
Vent
8-Pin Cable
RED
BLK
ORG
WHT
GRN
YEL
BLU
BRN
12
12
12
12
12
1
1
1
1
1
8-Pin
Deutsch
Connector
+12 (24)
VDC
Ignition Key
+12 (24) VDC
Pump Engaged
Interlock
GND
8 Pin Connector/Cable
Pin Wire Color Description
1 Red Supply Voltage (12/24 VDC)
2 Black Ground
3 Orange +5 VDC Reference From ECM
4 White Throttle Signal To ECM
5 Green Signal Return From ECM
6 Yellow Interlock Input (+ VDC)
7 Blue Throttle Enable Signal Output
8 Brown Foot Pedal Signal Input

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Cummins Harness Connections
Interface Information
The ECM RemoteAccelerator (Throttle) Option hasto beset to ON.The diagnostic
tool cannot be used to do this, an Insight service tool must be used. Refer to an
authorized dealer to program this option.
Figure 5. Cummins ELA101 Wiring
(Sheet 1 of 2)
2007
ISB07/ISC07/ISL07 CM 2150D Model Engines
+12 (24)
VDC
Ignition Key
GND
+12 (24) VDC
Pump Engaged
Interlock
8-Pin Cable
(Refer to
Figure 4 )
RED
BLK
ORG
WHT
GRN
YEL
BLU
BRN
12
12
12
12
12
ECM 60-Pin
J2 Connector
ECM Return (Sensor)
Remote Accelerator Position Sensor
Sensor Supply (5VDC)
Remote Throttle Switch
Max Operating Speed/Governor Type Switch
J1939 Datalink (–)
Black Wire
Red Wire J1939 Datalink (+)
12-Pin
Connector
(Refer to
Figure 3)
26
37
22
08
07
21
01