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FRC TCA200, Manual

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TCA200 Rev171031

3

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

Summary of Contents for TCA200

Page 1: ...NOR ENGINE MONITORING AND MASTER PRESSURE DISPLAY MODEL TCA200 Document Number XE TCA2PM R0A FIRE RESEARCH CORPORATION www fireresearch com 26 Southern Blvd Nesconset NY 11767 TEL 631 724 8888 FAX 631 360 9727 TOLL FREE 1 800 645 0074 ...

Page 2: ...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 Det...

Page 3: ...trol 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 ...

Page 4: ...e 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 trans...

Page 5: ...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 10...

Page 6: ...e 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 inp...

Page 7: ...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 specific 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 gove...

Page 8: ...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 flash red when the voltage is outside normal limits TRANS LED Displa...

Page 9: ... 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...

Page 10: ...e 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 f...

Page 11: ...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 fitting 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 sens...

Page 12: ... 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 press...

Page 13: ...o 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 connecto...

Page 14: ... 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 sufficient 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...

Page 15: ...th 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...

Page 16: ...essure 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 t...

Page 17: ...en 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 discha...

Page 18: ... 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 progra...

Page 19: ...t 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 ...

Page 20: ...play shows the program revision number PROG REV V100 03 2 Press the INC button Result P 2 flashes 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 flashes 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 Resu...

Page 21: ... button to change the hours g Press and hold the SILENCE button to store new time Result P 5 flashes in the PUMP INTAKE display The message display shows WARNING CODES 7 Press the MENU button Result P501 shows in the PUMP INTAKE display and the message display shows the most recent error or fault code The date and time that the error or fault code was recorded scrolls in the message display 8 Pres...

Page 22: ...m code is flashing in the RPM display 1 Press the SILENCE button and hold it until the RPM display shows four dashes and the message display shows enter Release the button 2 Press the MENU button within three seconds The RPM display shows the number 1000 Each time the MENU button is pressed the first digit scrolls up by 1 Set the first digit to the number desired 3 Press the SILENCE button to move...

Page 23: ...is Drain the pump and plumbing to ensure there is no residual pressure before running the calibration procedure 1 Apply power to the display module 2 Enter the calibration password See Calibration Programs 3 Scroll to code C1 or C2 use the INC or DEC button 4 Press the MENU button D Sensor or I Sensor Set P 0 flashes 5 Press the MENU button again to set Press 0 6 Press and hold the SILENCE button ...

Page 24: ...k J1587 or CAN L J1939 9 Red J1587 or CAN H J1939 10 White Interlock Input VDC 11 Black Ground 12 Red Supply Voltage 12 24 VDC USB Access Port Rear View 12 and 8 Pin Connectors Top Pin 1 Pin 1 8 Pin Connector Cable Pin Wire Color Description 1 N A 2 Brown Buzzer Ground 300mA 3 N A 4 N A 5 White High Idle Active Input VDC 6 Orange Throttle Signal To ECU 7 Black Signal Return From ECU 8 Red 5 VDC Re...

Page 25: ...ngine Control DDEC III ECMs Refer to Figure 8 To J1587 Datalink J1939 Datalink To Existing Harness to Discharge Pressure Sensor 12 Pin Connector 8 Pin Connector Connectors and Cables 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 ...

Page 26: ...ire Description A Black Ground B Red Supply Voltage C White Signal Pressure Sensor Top View Pressure Sensor Cable Caution The discharge and intake pressure sensors are the same size Ensure the correct sensor is installed on the correct manifold and the correct sensor cable is connected Refer to Table 1 Signal Output Supply Voltage Ground ...

Page 27: ...ption A Battery Ground B 12 VDC C J1939 CAN D J1939 CAN E J1939 Shield F J1587 DATA BUS G J1587 DATA BUS H Plug J Plug Figure 7 Common OEM 9 Pin Diagnostic Connector Common Diagnostic Connectors Typical 6 pin Deutsch diagnostic connector Commonly found under the driver side dashboard Pin A J1587 Datalink Positive Pin B J1587 Datalink Negative E D A B C F FRONT VIEW ...

Page 28: ... J1587 Datalink J1587 Datalink ECU Detroit Diesel ECU Connections Interface Information for DDEC III 1998 engines and older TCA202 A00 Connect the Engine Control extension cable to the Variable Speed Governor input on the engine ECU There may be a 3 pin Packard connector Variable Speed Governor Harness Connector installed by the chassis manufacturer located behind the pump panel to plug into for t...

Page 29: ...s Connector For DDEC IV and V 1999 to 2006 engines ECU J1939 CAN J1939 SHIELD J1939 CAN 2 16 2 17 2 18 DDEC VI Red Wire Black Wire 12 Pin Connector Refer to Figure 4 Vehicle Interface Harness 18 Pin Connector 2 Shield For DDEC VI 2007 and newer engines Detroit Diesel Harness Connections Interface Information for DDEC IV V VI Series Wiring TCA202 C00 Note Refer to Figure 4 for power and interlock c...

Page 30: ...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 specific engine To adjust this setting refer to High Idle in the Operation Section Figure 10 High Idle Wiring To 12 Pin Connector Pin 10 White Wire Interlock Input To 8 Pin Connector Pin 5 White Wire High Idle Active ...

Page 31: ...that a flyback diode be installed on inductive devices that share a common power source ground with a FRC governor Figure 11 Flyback Diode Typical circuit showing a flyback diode installed across an inductive load Diagram showing a flyback diode connected on a typical pump primer motor solenoid Primer Motor Solenoid 12 VDC Supply From Primer Motor Switch To Primer Motor GND Diode Diode Inductive L...

Page 32: ...TCA200 Rev171031 32 ...

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