FRC TotalControl 200 User manual

TCA200 Rev171031
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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

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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

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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

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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).

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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

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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"

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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 discharge
sensor before the check valve. T-ttings can be used to mount the pressure sensors.
Note: Install the pressure sensor upright so that the water in the end of the
pressure sensor 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 sensor may occur.
2. Tighten the sensor with a 7/8 inch wrench on the lower hex tting.
3. Connect the pressure sensor cable from the control module to the pressure
sensor. (Refer to Wiring Section.)
Figure 3. Pressure Sensor Dimensions
Caution: Do not use the main
body that houses the electronics
to tighten the sensor. Damage to
the sensor may occur.
Caution: The discharge and intake
pressure sensors are the same size.
Ensure the correct sensor is installed on
the correct manifold. Refer to Table 1.
1/4-18 NPT
7/8" Hex
0.75 [18.95]
2.37 [60.30]
Inch [mm]
Packard
Metri Pack
Connector
0.87 [22.05]
Across Flats

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OPERATION
On power-up the governor is in the pressure mode of operation. The RPM display
shows engine at idle RPM, the four 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 ashes, the RPM
display shows an error or fault warning code and a description shows in the message
display. (Refer to Table 2. Error Codes or Table 3. 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 THROTTLE READY LED lights and the governor is ready to control the engine
RPM.
Controls
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.
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 changes by 5 PSI twice and then by 10 PSI until the button is released.
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
changes by 50 RPM twice and then by 100 RPM until the button is released.
MODE Button
Switches between pressure and RPM modes.
MENU Button
Shows detailed information in the message display.
SILENCE Button
The silence button is used to suppress an optional audio alarm.
PRESET Button
Selects a pre-programmed value for pressure or RPM setting.

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Table 2. Error Codes
Table 3. Fault Warning Codes
RPM
Display
Message
Display
Probable Cause
Note: Not all inputs are used for all engines. For systems that use
a datalink to pass information the datalink cable and connectors or
ECM programming would be the probable cause.
E01 No Data >Datalink cable not connected / connected to wrong port
>Broken wire / bad connector contact on datalink cable
E02 No RPM Engine RPM not detected
>Datalink cable not connected / connected to wrong port
>Engine not running / ignition key on
E03 No Trans T.
Sensor
No Transmission Data Detected
>Datalink cable not connected / connected to wrong port
>Broken wire / bad connector contact on datalink cable
E04 No Eng Oil
Sensor
No Engine Oil Pressure Data Detected
>Datalink cable not connected / connected to wrong port
>Broken wire / bad connector contact on datalink cable
E05 No D.
Sensor
No Discharge Pressure Sensor Detected
>Sensor cable not connected
>Broken wire / bad connector contact on sensor cable
>Defective pressure sensor
E06 No I.
Sensor
No Intake Pressure Sensor Detected
>Sensor cable not connected
>Broken wire / bad connector contact on sensor cable
>Defective pressure sensor
E07 No Eng
T.Sensor No Coolant Temperature Data Detected
>Datalink cable not connected / connected to wrong port
>Broken wire / bad connector contact on datalink cable
RPM
Display
Message Display Description
F01 Hi Batt High Battery Voltage
F02 Low Batt Low Battery Voltage
F03 Hi Trans High Transmission Temperature
F04 Low Oil Low Engine Oil Pressure
F07 Hi Eng T. High Engine Coolant Temperature
F08 No Water Out of Water Mode
F09 No Resp Engine Does Not Respond

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Pressure Mode Operation
In the pressure mode of operation the PRESSURE LED is on. The governor
maintains a constant discharge pressure within system capabilities. It adjusts the engine
RPM automatically to compensate for variations in pressure.
Note: When changing from RPM to pressure mode during operations, hold
the MODE button for 3 seconds. The pressure setting is the pressure that
the pump was operating at in RPM mode.
1. Press and hold MODE button for 3 seconds.
Result: PRESSURE LED goes on.
2. Press PRESET and/or the INC DEC buttons to select pressure setting.
Result: Message display shows pressure setting, engine RPM changes.
3. Press IDLE button after operations to bring engine to idle RPM.
Result: Message display shows IDLE, engine at idle RPM.
Opening/Closing Discharge Valves
In pressure mode the governor maintains the pressure setting regardless of the
number of discharge lines that are opened or closed providing there is a sufcient water
supplied. As lines are opened the discharge pressure starts to drop, and the governor
raises the engine RPM to maintain the required pressure. As lines are closed and the
discharge pressure starts to rise, the governor lowers the engine RPM to maintain the
required pressure.
Operating From a Pressurized Supply
When operating from a pressurized water source (hydrant, in-relay, etc.), the intake
supply should be routed through a valve. If the pressurized source fails, the pump
operator can close the valve. This eliminates the chance of sharp pressure spikes at
the pump intake if the supply is resumed suddenly. The operator must open this valve
slowly when the supply is resumed to help prevent pressure spikes.

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Running Away From Water, Low Water, or No Supply Water
There are situations during pump operations when there may be low or no supply
water. This can be due to an empty water tank, a problem on the intake line, air in the
pump, changing the water source, or an insufcient water supply.
The governor constantly monitors discharge pressure and compares it to the engine
RPM. It is programmed to limit RPM increases when conditions arise that fall outside
normal operating parameters.
Running Away From Water: If the discharge pressure starts dropping while
operating in pressure mode, the governor will increase the engine RPM and attempt to
maintain the selected pressure setting. If pressure drops and an increase in RPM does
not bring the pressure back up, the governor recognizes this as a running away from
water condition. When this condition occurs the governor will switch to the RPM limit
mode and limit the engine RPM accordingly.
RPM Limit Mode: When the RPM limit mode is in effect the PRESSURE LED
will stay on. To alert the operator the RPM LED and the RPM display ash, and the
message display ashes LO WATER. When the pressure comes back up, the RPM
limit mode is canceled and the governor switches back to normal operation in pressure
mode with the existing pressure setting.
In some cases the pressure may not come back up but remains at a level above
45 PSI. In the RPM limit mode the governor will behave like a manual throttle and
the operator can raise or lower the engine RPM by pressing INC/DEC buttons. In this
mode the pressure setting will not change, the PRESET button is disabled, and if the
engine is set to idle using the IDLE button, the governor comes out of RPM Limit
Mode and cancels the pressure setting.
Low Water Cycle: If the discharge pressure is below 45 PSI but stays above 15
PSI the governor goes into a low water cycle. It sets the engine at 1100 RPM, if the
pressure does not rise above 45 PSI in 7 seconds the governor sets the engine at idle
RPM. The governor repeats this low water cycle as long as the discharge pressure is
between 15 and 45 PSI. When the pressure rises above 45 PSI the governor resumes
normal operation. (The values for RPM and PSI in the low water cycle are programmable
and may vary for some engine/pump combinations.)
No Supply Water: If the discharge pressure is below 15 PSI the engine RPM is
set to idle. If within 3 minutes the discharge pressure rises above 15 PSI the governor
enters the low water cycle. If the discharge pressure does not rises above 15 PSI within
3 minutes the governor stays at engine idle and cancels the pressure setting. To restart
pumping the operator will have to take action (press PRESET and/or INC/DEC buttons
to select pressure setting).

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RPM Mode Operation
In the RPM mode of operation the RPM LED is on. The governor maintains a
constant engine RPM.
The pump discharge pressure can vary but, as a safety feature, the governor limits
the increase in pressure to 30 PSI over the last established PSI value. As the discharge
pressure approaches this limit the governor will automatically lower the RPM to prevent
a high pressure surge. The RPM LED blinks as the governor sets a lower RPM. This
lower RPM will be the new operating RPM setting.
Note: When changing from pressure to RPM mode during operations, hold
the MODE button for 3 seconds. The RPM setting is the RPM that the
pump was operating at in pressure mode.
1. Press and hold MODE button for 3 seconds.
Result: RPM LED goes on.
2. Press PRESET and/or the INC DEC buttons to select RPM setting.
Result: Message display shows RPM setting, engine RPM changes.
3. Press IDLE button after operations to bring engine to idle RPM.
Result: Message display shows IDLE, engine at idle RPM.

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Switching Between Operating Modes
• No variation in discharge pressure or RPM occurs when changing between
pressure and RPM modes.
• When changing to RPM mode, the RPM setting is the RPM that the pump was
operating at in pressure mode.
• When changing to pressure mode the pressure setting is the pressure that the
pump was operating at in RPM mode.
When the engine is at idle RPM:
Press the MODE button and the governor switches modes immediately.
When the engine RPM is above idle:
Press and hold the MODE button for 3 seconds and the governor changes
modes. (This is to avoid an accidental change over if the buttons get bumped.)
Pump Discharge Pressure is High 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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Detailed Information
The four LED bar graphs provide a constant display of the safe operating ranges for
engine oil pressure, engine coolant temperature, transmission temperature, and battery
voltage. They do not show exact numbers or units of measure. Detailed information
is shown in the message display when the MENU button is pressed. Engine hours and
pump hours are also shown.
Show Detailed Information
Note: Detailed information is a display only mode and no changes can be
made to the data.
The MENU button allows the operator to gain access to detailed information. Each
time the MENU button is pressed the display scrolls to show the next value.
The message display will show the following:
Eng Oil ###PSI (programmable for kPa or Bar)
Eng Temp ###°F (programmable for °C)
Trans T. ###°F (programmable for °C)
Batt VDC ##.#
Eng Hrs ####
Pump Hrs ####
The message display reverts to normal operation after 20 seconds if no buttons are
pressed or immediately when a button other than the MENU button is pressed.

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Preset Settings (Pressure or RPM)
The preset button allows the operator to go to a pre-programmed pressure or
RPM setting during operations. The setting will be shown in the message 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 THROTTLE READY LED must be on).
1. Press IDLE button.
Result: Engine goes to idle RPM
2. Press MODE button to select which setting to change.
Result: LED indicator goes on for mode selected.
Note: The message display must show IDLE before changing the preset.
3. Press and hold PRESET button. (Continue to hold through step 4.)
Result: Message display ashes then shows preset... after 5 seconds the current
setting shows.
4. Press the INC DEC buttons to change preset setting.
5. Release PRESET button.
Result: The new preset is programmed. Message display shows IDLE.
High Idle
The governor programming includes a high idle function. 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: The pump must NOT be engaged when using the high idle function
and the THROTTLE READY LED will be off.
Change High Idle Setting
Note: The high idle is set at about 1000 RPM at the factory.
1. With the engine running, set the high idle switch to ON.
2. Press and hold PRESET button for 3 seconds.
Result: Message display will ash the high idle setting.
3. Keep pressing the PRESET button and press the INC/DEC buttons to set
desired RPM.
4. Release PRESET button to store the new high idle setting.

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PROGRAMMING
The following program functions are always available to view and change:
P1 - Software Program Revision Number - Read Only
P2 - Product Manufacturing Date - Read Only
P3 - Set Current Date - Read/Write
P4 - Set Current Time - Read/Write
P5 - Retrieve Fault Codes - Read Only
Access Program Features
Note: When the program (P) code is ashing in the PUMP INTAKE display,
press the INC or DEC button to scroll through the P-codes or press the
SILENCE button to exit the programming mode.
1. Press the SILENCE button and hold it until the RPM display shows four dashes – – – –
and the message display shows ENTER--- . Release the button.
Result: P 1 ashes in the PUMP INTAKE display. The message display shows the
program revision number PROG REV V100.03.
2. Press the INC button.
Result: P 2 ashes in the PUMP INTAKE display. The message display shows the
manufacturing date MFG DATE 09AUG'07 (ddmmm'yy).
3. Press the INC button.
Result: P 3 ashes in the PUMP INTAKE display. The message display shows the
current date SET DATE 17AUG'07.
4. To Change the Date: (If not go to step 5.)
a. Press the MENU button.
Result: P 3 stops ashing. The message display shows the current date with the
year ashing.
b. Press the INC or DEC button to change the year.
c. Press the MENU button.
Result: The month ashes.
d. Press the INC or DEC button to change the month.
e. Press the MENU button.
Result: The day ashes.
f. Press the INC or DEC button to change the day.
g. Press and hold the SILENCE button to store the new date.
Result: P 4 ashes in the PUMP INTAKE display. The message display shows
SET TIME 10:30AM . Go to step 6.