Class1 Electrical System Manager User Manual

Standard Features

 Main Battery bank monitoring

 Isolated Battery monitoring

 Electrical Load Sequencing

 Electrical Load Shedding

 Over Voltage Indication

 High Idle Control

 Automatic or Manual Reset Modes

 Reverse Polarity / Short Circuit Protected

 Rugged Metal Enclosure

 LED Status Display

 Battery Warning

A vailable Features



Positive or Ground Master Switch

 Integral Relay Distribution Board

 Positive or Ground Output for Loads

1

Standard Features

Sequence (J3d)

This mode will performs the function of sequencing the electrical loads on
and off.

Automatic Load Reset (J2b)

Any load which has been shed will automatically be controlled off for a mini­mum of five minutes, regardless of the state of the electrical system. After the
electrical system becomes stable, the loads will be controlled back on by the
system. Any shed load can be turned on immediately by performing a manual
load reset (see next section).

Manual Load Reset (J2a)

When this mode is enabled, any load which has been shed will remain off
until the system manager is manually reset.

Manually Resetting the System

There are two levels of manual reset. LOAD RESET and FULL RESET.

Load Reset: The shed loads are manually reset by toggling the master switch

off and then on again within two (2) seconds. When a load reset is per­formed, all loads which are currently shed of will be sequenced on. The
system manager will refrain from shedding any load for fifteen minutes. After
fifteen minutes, normal operation of the system manager will resume.

Full Reset: Full system reset will occur when the master switch is turned off for

at least two seconds. After full reset, the loads will be sequentially turned off
and the system will resume normal operation when the master switch is toggled
to the on position.

Over-Voltage Indicator (J4d)

The system manager continually monitors the system voltage and will acti­vate an output when it detects that the constant system voltage has increased
above 14.5 volts. As in all modes, the system will not react to the spurious
voltage transients which may exist in the electrical system as loads and de­vices are cycled.

Fast Idle Control (J4c)

The system manager is capable of becoming a part of a system which con­trols a fast idle device. The fast idle output will activate whenever the system
voltage is low. The output will deactivate if the system manager is reset or the
voltage becomes good.
This circuit must only be utilized when the appropriate interlocks are present.

2

Battery Warning

The Battery Warning feature is a special output which indicates different states
of the electrical system. The Class 1 system manager continuously monitors
the rate of discharge (voltage drop per unit time) of the electrical system. The
Battery Warning indicator will flash at a rate proportional to the discharge rate.
More simply, the faster that the voltage is dropping, the faster the indicator will
flash.

When sudden voltage drops are recognized by the system, the light will flash
quickly for three seconds to indicate an instantaneous voltage drop. After the
quick flash, the indicator will rever t back to its previous flash rate.

Once the voltage has dropped to a critical level which requires loads to be
shed, the indicator will burn steady and remain on as long as there are loads
in the shed state or loads are in the manual reset state and voltage is low.

The Battery Warning option can assist an operator in identifying a potential
low voltage situation in advance giving the opportunity to react to a poor
voltage situation before it happens.

NOTE: Refer to the section titled “Specifications” at the end of this manual for
more descriptive information on these available modes.

The indicator panel consists of four LED’s:

POWER ON (GREEN WIRE)
This LED illuminates when power is applied to the
System Manager.

BATTERY WARNING (YELLOW WIRE)
This LED is connected to terminal TB#8 and flashes
when system voltage drops below 13.2 VDC.

ISOLATED BATTERY LOW (BLUE WIRE) OPTION
This LED is connected to TB#7 and illuminates
when an auxiliary battery’s voltage drops below

11.8 VDC for more than two minutes.

ST ANDARD P ANEL DISPLA Y

The Class1 Electrical System Man­ager is supplied with an indicator
panel.The indicator panel is designed
to fit in a standard rocker s witch cut­ou t (7/8” x 1-1/2”).

OVER-VOLTAGE OR FAST IDLE (BROWN WIRE)
This LED is connected to TB#15.

GROUND (BLACK WIRE)
Connected to a good ground source.

3

System Configuration

The Electrical System Manager is configured by the use of five jumpers
labeled J1 through J5.
J1 and J5 control battery monitoring (MAIN or MAIN and ISOLATED.)
J2 controls the load reset method (MANUAL or AUTOMATIC.)
J3 controls Load Sequencing (OFF or ON.)
J4 controls when Terminal bar #15 is active (Low Voltage or High Voltage.)
The System Manager cover must be removed to change its operating mode.
J1 through J4 are located at the lower right edge of the circuit board, J5 is
located next to TB #10.

JMP DESCRIPTION

J1

J2

J3

J4

J5

TB#15
TB#14
TB#13
TB#12
TB#11
TB#10

TB#9
TB#8
TB#7
TB#6
TB#5
TB#4
TB#3
TB#2
TB#1

BATTERIES MAIN

RESET

SEQUENCE

TERMINAL #15

FUNCTION

JUMPERS

B

A

J5

POSITION

A

MANUAL

MAIN

POSITION

B

MAIN/

ISOLATED

AUTO

MAIN/

ISOLATED

POSITION POSITION

C

OFF

FAST IDLE
CONTROL

D

ON

OVER-VOLT

LIGHT

MODE CONFIGURATION

Figure1

4

Main Battery Only Configuration

Relay 1

Relay 6

Load

Relays

Dash

Switches

Load SW 1

Load SW 6Load SW 6

Jumper J1 and J5 are
placed in pos. A.
This provides for seven
load control outputs that
can be sequenced and
shed. These outputs are
at terminals #1 through #7.
The complete terminal de­scriptions for this mode
are shown in Figure 2,
and one method of wiring
is shown in Figure 3.

Over Voltage Lgt/

High Idle Control

Ground
Ignition

No Connection

Shed Enable

Master Switch

System Override

Battery Warning Lt

Load Level 7

Load Level 6
Load Level 5
Load Level 4
Load Level 3
Load Level 2
Load Level 1

TB #15
TB #14
TB #13
TB #12
TB #11
TB #10

TB #9
TB #8
TB #7
TB #6
TB #5
TB #4
TB #3
TB #2
TB #1

A

J5

B

MODE CONFIGURATION

J2 J4
J1

ACBD

J3

Figure 2

5

MAIN AND ISOLATED BATTERY CONFIGURATION

Jumper J1 and J5 are placed in position B.
The system manager will operate in main and isolated battery mode. This
provides for six load control outputs which can be sequenced and shed. A
separate input for the isolated battery is located at TB#12 and an output for
low isolated battery is located at TB #7. One method of wiring is shown in
Figure 5.

TB#15

TB#14

Over Voltage Lt

Ignition Sw

TB#13

TB#12

connected only

when ignition on

TB#10

TB#9

TB#11

Shed Enable Switch

ELECTRICAL SYSTEM

MANAGER

TB#7

TB#8

Battery Warning Lt

TB#6

Isolated Batt Lt

Load Sw 6

TB#5

TB#4

TB#3

TB#1

TB#2

Load Sw 1

Figure 5

Dash Switches

Main Batt

Rly 6

Isolated Batt

Master Sw

Rly 1

Load Relays

6

Electrical System Manager II

Relay Coil Input

Relay LED©s

The Electrical System Manager II is equipped
with 8 Printed Circuit Board Relays mounted in
an enclosure with the load manager. The re­lay coil input tab should be grounded for nor­mal installations. The common and output tabs
on each relay readily allow for custom installa­tions.

COM

COM

COM

COM

1

N O

N C

2

N O

N C

3

N O

N C

4

N O

N C

5

N O

COM

1
2
3
4
5
6
7
8

COM

COM

N C

6

N O

N C

7

N O

N C

8

N O

COM

N C

Over Voltage Light
High Idle Control

Ground
Ignition

No Connection

Shed Enable

Master Switch

System Override

Battery Warning Lt

Load Level 7
Load Level 6
Load Level 5
Load Level 4
Load Level 3
Load Level 2
Load Level 1

TB#15
TB#14
TB#13
TB#12
TB#11
TB#10

TB#9
TB#8
TB#7
TB#6
TB#5
TB#4
TB#3
TB#2
TB#1

A

J5

B

MODE CONFIGURATION

Figure 4

7

Electrical System Manager II

8

Terminal Block I/O Polarity

Negative Master Switch and Positive Output

PN 100633 ESM / PN 100756 ESM II

TB #15 + Output Overvoltage light or Fast idle control
TB #14 - Input System Ground
TB #13 + Input Ignition (Main battery monitor voltage)
TB #12 + Input Isolated Battery monitor voltage
TB #11 - Input Load Manage Enable (shed)
TB #10 - Input Master Switch
TB # 9 + Input System Override
TB # 8 + Output Batter y Low Warning Light
TB # 7 + Output Load 7 or isolated battery low light
TB # 6 + Output Load 6
TB # 5 + Output Load 5
TB # 4 + Output Load 4
TB # 3 + Output Load 3
TB # 2 + Output Load 2
TB # 1 + Output Load 1

Positive Master Switch and Positive Output

PN 100767 ESM / PN 101038 ESM II

NOTE:LOADS 1 & 2 DO NOT SHED, MAIN BATTERY MONITORING ONLY.

LOADS SEQUENCE ON 1-7, SEQUENCE OFF 7-1 AND SHED 7-3.

TB #15 + Output Overvoltage light or Fast idle control
TB #14 - Input System Ground
TB #13 + Input Ignition (Main battery monitor voltage)
TB #12 + Input Master Switch
TB #11 - Input Load Manage Enable (shed)
TB #10 No Connection
TB # 9 + Input System Override
TB # 8 + Output Batter y Low Warning Light
TB # 7 + Output Load 7
TB # 6 + Output Load 6
TB # 5 + Output Load 5
TB # 4 + Output Load 4
TB # 3 + Output Load 3
TB # 2 + Output Load 2
TB # 1 + Output Load 1

9

Terminal Block I/O Polarity

Negative Master Switch and Ground Output

PN 101084 ESM

TB #15 + Output Overvoltage Light or Fast Idle Control
TB #14 - Input System Ground
TB #13 + Input Ignition (Main battery monitor voltage)
TB #12 + Input Isolated Battery monitor voltage
TB #11 - Input Load Manage Enable (shed)
TB #10 - Input Master Switch
TB # 9 - Input System Override
TB # 8 - Output Batter y Low Warning Light
TB # 7 - Output Load 7 or isolated batter y low light
TB # 6 - Output Load 6
TB # 5 - Output Load 5
TB # 4 - Output Load 4
TB # 3 - Output Load 3
TB # 2 - Output Load 2
TB # 1 - Output Load 1

Positive Master Switch and Ground Output

PN 101119 ESM

NOTE:LOADS 1 & 2 DO NOT SHED, MAIN BATTERY MONITORING ONLY.

LOADS SEQUENCE ON 1-7, SEQUENCE OFF 7-1 AND SHED 7-3.

TB #15 + Output Overvoltage light or Fast idle control
TB #14 - Input System Ground
TB #13 + Input Ignition (Main battery monitor voltage)
TB #12 + Input Master Switch
TB #11 - Input Load Manage Enable (shed)
TB #10 No Connection
TB # 9 - Input System Override
TB # 8 + Output Batter y Low Warning Light
TB # 7 - Output Load 7
TB # 6 - Output Load 6
TB # 5 - Output Load 5
TB # 4 - Output Load 4
TB # 3 - Output Load 3
TB # 2 - Output Load 2
TB # 1 - Output Load 1

10

SPECIFICATIONS

OPERATING VOLTAGE

7.5 to 20 Volts DC

OUTPUTS

High Side Drivers Vmain @ 0.5 amp (source)
Low Side Drivers Ground @ 0.5 amp (sink)

ISOLATED BATTERY INPUT

0 to 20 Volts DC

TRANSIENT SUPPRESSION

Outputs are protected against thermal overload, direct shorts and transient
spikes from -50 to 60 Volts DC.

LOAD CONTROL

Loads will be cycled on whenever the Master Switch is activated.
The System Manager will control loads and the high idle function only when
the Shed Enable input (terminal #11) is active.
Loads are shed from lowest priority to highest priority, level 1 to level 7,
except for units with a positive master switch, they shed level 7 to level 3.
The voltage points are respectively:
L1-12.2, L2-11.95, L3-11.70, L4-11.45, L5-11.25, L6-11.10 and L7-10.95
VDC. Voltage must drop below the shed point for 30 seconds for a load to
shed and voltage must be above the shed point for 60 seconds for a shed
load to unshed.

NOTE: The unit can be configured so that the loads can be turned on only by a manual

reset.

No automatic recycling

MANUAL LOAD RESET

Toggling the Master Switch off and then on again within 2 seconds manu­ally resets the loads. Loads that were shed off will be cycled on and the
high idle control will be reset. The System Manager will disable itself for 15
minutes.

MANUAL FULL RESET
Toggling the Master Switch off for more than 2 seconds will cycle all loads
off. The system will return to normal operation when the Master Switch is
toggled back to the on position.

NOTE: A signal applied to terminal #9 (system override) will force allloads ON,

completely bypassing all load control functions of the unit.

11

SPECIFICATIONS

TERMINAL BLOCK #15

This output becomes active for the overvoltage light (high voltage) or for high
idle control (low voltage) dependent on the setting of jumper J4.

OVER-VOLTAGE INDICATOR
Activates at 14.5 VDC and deactivates at 14.0 VDC.

HIGH IDLE CONTROL
The output will activate when the voltage drops below 12.3 VDC for more
than 1 minute. The output will remain ON for a minimum of 5 minutes
until the voltage exceeds 13.0 VDC.

NOTE: This output must only be used in conjunction with the appropriate

safety interlocks for the intended application.

AUXILIARY BATTERY

When an auxiliary batter y is present and the system is configured for it, The
System Manager will monitor the auxiliary battery. Output (TB #7) is turned
on when the battery voltage drops below 11.8 VDC for more than 2 minutes.
The output will remain on for a minimum of 5 minutes and until the isolated
battery voltage is greater than 12.5 VDC. If the main battery bank voltage
exceeds 13 VDC, the output will deactivate and the system will then recheck
the isolated battery voltage after a short delay. This allows the system to
become part of a battery separation solenoid system.

and

NOTE: When configured to monitor a second batter y source, only 6 loads

can be controlled as output #7 is utilized for the isolated battery
indicator. All other functions are unchanged.

BATTERY LOW WARNING LIGHT

Output from TB #8 is disabled when the monitored voltage is above 13.2
VDC. Below this level, the output will flash to indicate a voltage drop. The
output will flash at a varying rate proportional to the discharge rate of the
battery. If the system detects a large instantaneous voltage drop, the light will
flash rapidly for 3 seconds and then rever t to its current flash rate.

NOTE: The output will remain steady if any load has been controlled off

or

the system has been manually reset.

12

MODELS AND FUNCTIONS

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13

Note:

SAMPLE CIRCUITS

A/C Control Circuit

Aux Control
Relay

As A/C control circuits vary by vehicle, the circuit shown is
representative only of one method which can be utilized to
interrupt the A/C control circuit. It is the responsibility of the
installer to utilize properly rated relays or circuit breakers in
the installation.
The loading on output #15 should not exceed 0.5 amps.

Alternator

Starter

Ignition Sw

BATT SEPARATOR SOLENOID

POWER TO VEHICLE LOADS

+

-

+

-

+

-

+

-

+

-

+

-

Batt Ground

POWER TO SEPARATED LOADS

TB#15
TB#14
TB#13
TB#12
TB#11
TB#10

TB#9
TB#8
TB#7
TB#6
TB#5
TB#4
TB#3
TB#2
TB#1

14

Fast Idle
Switch

OEM Fast Idle

Interlocks

OEM Fast
Idle Circuit

SAMPLE CIRCUITS

Ground

Relay

PSI Switch closed
when Park Brake set

Ignition

Shed Enable

Relay

TB#15
TB#14
TB#13
TB#12
TB#11
TB#10

TB#9
TB#8
TB#7
TB#6
TB#5
TB#4
TB#3
TB#2
TB#1

Signal From Brake Lights

Automatic FAST IDLE CIRCUIT, disabled when service brake is applied

15