FRC TotalControl 200 User manual

TCA200 Rev171031
1
PRESSURE GOVERNOR,
ENGINE MONITORING, AND
MASTER PRESSURE DISPLAY
MODEL TCA200
Document Number:
XE-TCA2PM-R0A
FIRE RESEARCH CORPORATION
www.reresearch.com
26 Southern Blvd., Nesconset, NY 11767
TEL [phone] FAX [phone] TOLL FREE 1.800.645.0074

TCA200 Rev171031
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CONTENTS
Table of Contents
CONTENTS................................................................................................................ 2
INTRODUCTION ...................................................................................................... 4
Overview................................................................................................................ 4
Features.................................................................................................................. 4
Specications......................................................................................................... 5
GENERAL DESCRIPTION ....................................................................................... 6
Components ........................................................................................................... 6
Controls and Indicators.......................................................................................... 8
INSTALLATION ...................................................................................................... 10
Install Control Module......................................................................................... 10
Install Pressure Sensors ....................................................................................... 11
OPERATION ............................................................................................................ 12
Controls................................................................................................................ 12
Pressure Mode Operation..................................................................................... 14
RPM Mode Operation.......................................................................................... 16
Switching Between Operating Modes ................................................................. 17
Pump Discharge Pressure is High at Engine Idle ................................................ 17
Detailed Information............................................................................................ 18
Preset Settings (Pressure or RPM)....................................................................... 19
High Idle .............................................................................................................. 19
PROGRAMMING .................................................................................................... 20
CALIBRATION........................................................................................................ 22
Calibration Programs ........................................................................................... 22
Pump Sensor (Code C1 and C2).......................................................................... 23
WIRING.................................................................................................................... 24
Connectors and Cables......................................................................................... 25
Pressure Sensor.................................................................................................... 26
Common Diagnostic Connector........................................................................... 27
Detroit Diesel ECU Connections......................................................................... 28
Detroit Diesel Harness Connections.................................................................... 29
High Idle Wiring .................................................................................................. 30
FLYBACK DIODE INFORMATION ...................................................................... 31

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List of Tables
Table 1. Pressure Sensor Output Voltage ................................................................... 5
Table 2. Error Codes ................................................................................................ 13
Table 3. Fault Warning Codes.................................................................................. 13
List of Figures
Figure 1. Controls and Indicators............................................................................... 9
Figure 2. Control Module Mounting Dimensions.................................................... 10
Figure 3. Pressure Sensor Dimensions..................................................................... 11
Figure 4. TCA200 12 and 8-Pin Connector Wiring ................................................. 24
Figure 5. TCA200 Interface Wiring......................................................................... 25
Figure 6. Pressure Sensor Wiring............................................................................. 26
Figure 7. Common OEM 9-Pin Diagnostic Connector............................................ 27
Figure 8. DDEC III ECU Wiring TCA202-A00 ...................................................... 28
Figure 9. DDEC IV, V & VI Series Wiring TCA202-C00....................................... 29
Figure 10. High Idle Wiring..................................................................................... 30
Figure 11. Flyback Diode......................................................................................... 31

TCA200 Rev171031
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INTRODUCTION
Overview
The all-in one pressure governor and instrument panel uses state-of-the-art
programmable microprocessor technology. It maintains 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 governor operates in one of two modes, pressure or RPM. In pressure mode
it maintains a constant pump discharge pressure. The discharge pressure is monitored,
compared to the selected pressure setting, and the engine RPM is varied to keep the
discharge pressure at the selected setting. In RPM mode it 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 automatically lowers 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 message display shows pressure and RPM settings; fault and error
code information; detailed engine data and program features. There are four LED
bar graphs that provide a constant display of the safe operating ranges for engine oil
pressure, engine coolant temperature, transmission temperature, and battery voltage.
(For detailed information with the exact numbers and units of measure the MENU
button is pressed.)
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
Diagnostic Capabilities
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 Throttle Ready LED
Return to Engine Idle With the Push of a Button
Accumulated Engine and Pump Hours

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Table 1. Pressure Sensor Output Voltage
Specications
The panel provides the functions, controls, and digital readouts needed for the
management of pump discharge pressure.
Control Module
Supply Power: 12 VDC (Program Option for 24 VDC))
Supply Current: 0.8 A Low Light - 1.2 A Bright Light
Dimensions: 7 1/2" Wide by 6" High by 2 1/4" Deep
Unit of Measure: PSI °F (Program Option for kPa, Bar, °C)
LED Bar Graphs
Engine Oil Pressure: 10 to 100 PSI
Engine Coolant Temperature: 150 to 240 °F
Transmission Temperature: 140 to 300 °F
Battery Voltage: 11.5 to 15.5 VDC
Pressure Sensor
Discharge Intake
Model Number: XE-FP4000PT3 XE-IO3100PT3
Pressure Range: 0 - 600 PSI -30 in/Hg - 600 PSI
(0 to 4000 kPa) (-100 to 4000 kPa)
Proof Pressure: 1200 PSI 1200 PSI
Excitation Voltage: 5 VDC 5 VDC
Output Voltage: 0.5 - 4.75 VDC (See Table 1)
0psi 100psi 150psi 200psi 250psi 300psi 600psi
Discharge Sensor
XE-FP4000PT3 0.5vdc 1.21vdc 1.56vdc 1.92vdc 2.27vdc 2.625vdc 4.75vdc
Intake Sensor
XE-IO3100PT3 0.604vdc 1.295vdc 1.640vdc 1.985vdc 2.331vdc 2.667vdc 4.75vdc

TCA200 Rev171031
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GENERAL DESCRIPTION
All controls and indicators are located on the front of the control module.
Components
The pressure governor and instrument panel consist of the following components:
Control Module
Intake Pressure Sensor
Discharge Pressure Sensor
Audible Alarm Buzzer
Cables
Control Module
The control module is waterproof and takes up 7 1/2 by 6 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 module that is proportional to the intake pressure.
Discharge Pressure Sensor
The pressure sensor is mounted on the pump discharge manifold. It provides an
input signal to the control module that is proportional to the discharge pressure.
Audible Alarm Buzzer
A ground is provided at the 8-pin connector pin 2 to activate the buzzer (max
current: 300mA).

TCA200 Rev171031
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High Idle Wiring
The programming includes a high idle function. To activate the high idle provide
a +12 VDC High Idle Active Input. (Refer to Figure 8. 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. Refer to the wiring diagram. The pump must NOT be engaged
when using the high idle function.
The high idle is set at about 1000 RPM at the factory. (This value will vary
depending on the specic engine.) To adjust this setting refer to High Idle in the
Operation Section.
Cables
There are two connectors on the control module for all input/output signals, one
8-pin connector and one 12-pin connector.
When replacing an older Detroit Diesel governor, connectors with wiring are
provided to utilize some of the existing harness. New wiring is required for the intake
pressure sensor and engine control. Refer to the Wiring Section.

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Controls and Indicators
All controls and indicators are located on the front of the control module. (Refer
to Figure 1.)
PUMP DISCHARGE and PUMP INTAKE Displays
Shows the pump discharge and intake pressure during normal operations and codes
during programming.
MODE Button
Selects the pressure or RPM mode of operation.
RPM LED
The red LED is on to indicate operation in the RPM mode.
PRESSURE LED
The amber LED is on to indicate operation in the pressure mode.
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.
PRESET Button
Press to change/select a pre-programmed value for pressure or RPM setting.
INC / DEC Buttons
During operations the buttons increase and decrease pressure or RPM setting.
VOLTS LED Display
Shows battery voltage safe range with green LEDs. The LEDs ash red when the
voltage is outside normal limits.
TRANS.° LED Display
Shows transmission temperature safe range with green LEDs. The LEDs ash red
when the temperature is high.
ENG.° LED Display
Shows engine coolant temperature safe range with green LEDs. The LEDs ash
red when the temperature is high.
OIL LED Display
Shows engine oil pressure safe range with green LEDs. The LEDs ash red when
the pressure is low.

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MENU Button
Used when accessing detailed information and program features. (Detailed
information shown includes engine oil pressure, engine coolant temperature,
transmission temperature, battery voltage, engine hours, and pump hours with the
exact measure and units.)
SILENCE Button
Suppresses audio alarms and used in programming.
STOP ENGINE / CHECK ENGINE LED
Repeats the engine warnings from the cab.
RPM Display
Shows the engine RPM during normal operations.
Message Display
The message display shows the pressure or RPM setting during normal operations,
warning alarms as they occur, and detailed information when the menu button is pressed.
It shows the time and date when the throttle ready LED is off. It is also used to show
stored data and program features.
THROTTLE READY LED
This LED is on when the required interlock conditions are met and the governor
is ready to begin operations.
Figure 1. Controls and Indicators
A sensor adjusts LED
brightness to day/night
conditions.
PUMP
DISCHARGE
Display PRESSURE
LED
CHECK
ENGINE
LED
STOP
ENGINE
LED
PRESET
Button
MODE
Button
MENU
Button
RPM
LED
RPM
Display
SILENCE
Button
Battery
Voltage
Display
Transmission
Temperature
Display
Engine
Temperature
Display
Engine Oil
Pressure
Display
INC
Button
DEC
Button
THROTTLE
READY
LED
Message
Display
IDLE
Button
PUMP
INTAKE
Display

TCA200 Rev171031
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INSTALLATION
Install Control Module
1. Measure and mark mounting location for control module 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 6 5/8 by 5 1/8 inch hole.
3. Drill four holes for mounting screws (10-32 mounting hardware is
recommended).
4. Place control module in position and secure with four screws.
5. Connect cables at rear of the control module. (Refer to Wiring Section.)
Figure 2. Control Module Mounting Dimensions
6 3/4"
5 1/4"
5 1/8"
6 5/8"
Panel
Cutout
Mounting holes are
clearance or tapped
for 10-32 screws.
Maximum
Radius
3/8"
1/2"
1 1/2" 7 1/2"
6"