Class1 ES-Key-USM User Manual

Network

USM Network

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The

Class1

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electrical system. The system is multiplexed using the Controller Area Network bus and the SAE J-1939 protocol. An electrical database is used by the Control Module to operate the vehicle electrical system. The this database. Troubleshooting of the system is also accomplished with the software.

The Controller Area Network (CAN) has specific requirements that should be met for

maximum reliability.

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consists of several components that can be used in a vehicle

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software allows you to create, read or modify

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To other

J-1939 Devices

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Control Module

Switch

Module

Vocation

Module

Output

Module

Main Controller

and

User Interface

Interface to

Switch Panel

Vocation Interlock

Trans/Engine

Interface

Power Switching

to Loads

To other Devices

on the Management

Network Segment

Network modules communicate with each other through the J-1939 Controller Area Network.

2

Network

Wiring Network Topology

The wiring topology for this CAN based network should be as close as possible to a linear structure in order to avoid cable reflections. In practice, it may be necessary to connect short cable tails to a main backbone cable, as shown in the figure below. To minimize standing waves, nodes should not be placed equally spaced on the network and cable tails should not all be the same length.

Where: n= # modules in network/

L= Bus length D= Node distance I= Cable tail length RL=Terminating resistor = 120Ω*

* Class 1 offers this resistor built into a harness connector DT06-3S-P006

30 maximum per network

• Recommended Cable Termination Procedure:

3

Hardware

The ES-Key System utilizes a variety of modules to perform various functions. With the exception of the USM Control Module, Display and Data Logger, there can be up to 16 of each type module. They are addressed in the system by device type and number. For instance, a Power Distribution Module can exist at address 0 through F (15) and a Switch Input Module could be set at the same address since it is a different type. The address is set on each module with either a Binary Coded Decimal (BCD 0-9) switch or a Hexadecimal Encoded (Hex 0-F) switch. Modules 10-15 are encoded as modules A-F respectively. A=10, B=11, C=12, D=13, E=14 and F=15.

0

9

1

8

7

2

3

6

4

5

0

F

E

D

C

B

A

BCD HEX

PDM 8

ES-Key

Module

1

2

3

4

5

6

7

8

9

4

Hardware

There are several modules available to perform various tasks in the system.

The Universal System Manager (USM) is the control module and performs load management, logic and main communications functions of the system. The USM contains the database for the system. Currently, there can be only one control module in a system.

A system can contain a Digital Display Module (Display). Four pages (4 lines by 20 characters) of greetings messages and 50 pages of extended messages can be stored in the display. In addition, live information about active and inactive circuits can be displayed and it can be used as an interface to the system.

A Modem Module (MODEM) can be added to any circuit and will allow the system to be accessed remotely by Express Software through a serial port or modem.

There can be up to 16 Power Distribution Modules (PDM) in a system. The PDM’s control the loads in a circuit. They come in two basic types, electromechanical (relay boards) and electronic (solid state). They can handle from 7.5 amps up to 40 amps dependent on the exact module specified. One of these modules is configured as an 8 input, 8 output, 4 motor driver (H-bridge). A low current (250 mA) 16 Output Module is available for use in indicator or driver circuits. The 16 output module comes in a variety of lowside and highside driver configurations. (Power or Ground outputs)

There can also be up to 16 Switch Input Modules (SIM) in a system. These come in either 16 positive input or 16 polarity selectable input versions. Any switch or input in the system needs to be tied to an input circuit on a module in the system.

Vocation Modules are available for interlocking and engine control tasks. These are enginetransmission specific and there can only be one in a system.

A data logger is available that stores system fault and interlock information. It can aso be configured to log specified circuit information. It will store 200 system faults and 6,000 events before it loops around and overwrites the oldest data. These events are all dated and time stamped to the nearest second. Up to 32 circuits can be tied to the data logger for troubleshooting or information purposes. It is also a true time clock and a temperature sensor can be wired into it. The time is displayed on the data logger. The temperature and time are displayed on the Display Module.

There are variations of some of the above modules available.

5

Addresses

Every INPUT and every OUTPUT in the system has a unique address. That address consists of a device type, a module number and a port on that device.

As an example, the first output on the first Power Distribution Module would be addressed as PDM 0, Output 0. In a typical system, it would be labelled for the load that is connected to it. If it were the Pump Panel Lights connected to the first output, then a name (tag or label) indicating Pump Panel Lights could be assigned to PDM 0, Output 0 and the operator would use the tag name instead of PDM 0, Output 0 when referring to that circuit.

--SYSTEM OUTPUTS--

CIR:Pump Panel Lgts

ESC

POWER MOD#0 OUT-00 [MNGT] [MPLX] [INTK]

Each device type in the system that can have multiple devices has an address that is set by either a hexadecimal (hex) or binary coded decimal (bcd) switch. Each module of the same device type must have a unique address (0-F). A power distribution module (PDM) located in the pump panel could be set to address 3 and would be accessed by the system as PDM 3. Any output or input on that PDM would be known as PDM 3 and it’s port number and function (Input/Output). PDM module addresses are 0-F, Output Ports 0-11 and Input Ports 0-7.

SCROLL

--SYSTEM OUTPUTS--

CIR:Rear Scene Lgts

ESC

POWER MOD#3 OUT-07 [MNGT] [MPLX] [INTK]

SCROLL

As an example, an 8 input, 8 output relay board with its address switch at position 3 would have input ports 0-7 and output ports 0-7. The inputs would be PDM 3, Input 0 through Input 7 and the outputs would be PDM 3, output 0 through output 7. Each of these inputs and outputs can be and usually are named for the circuit or function that they are connected to.

Each circuit must have a unique name (limited to 16 characters) and be tied to a device type, address and port.

--SYSTEM INPUTS--

CIR: Pump Lgt Switch

ESC

POWER MOD#0 IN-01

SCROLL

6

Logic

SCROLL

ESC

Each output is operated by the logic associated with it in the database.

There are three types of logic for each circuit.

AND All the conditions associated with the circuit must be ON for the circuit to be ON. OR Any of the conditions associated with the circuit can be ON for the circuit to be ON. NOT The associated condition must be OFF or false for the circuit to turn ON.

MUX: circuit name 1: Condition 1 LOGIC

ESC

2: Condition 2 [GO->1] [BACK] [GO->2]

SCROLL

MUX :Pump Panel LTS 1 :Pump LT Switch

[GO->1] [BACK]

Further there are three logic conditions that apply to every output.

Multiplex Logic ties an output to two conditions, these can be AND’ed, OR’ed or Inverted

(NOT). The default condition is false or OFF. The conditions can be inputs or

outputs

MUX: Work Lights 1: Work LT Switch OR

ESC

2: Marker LT Switch

SCROLL

[GO->1] [BACK] [GO->2]

Load Management Logic allows each output circuit to be sequenced on, shed (turned off

below a specific priority or voltage level), tied to either of two operational modes (A or B) and be staged (controlled by a discrete input). The default condition is true or ON.

MNG: circuit name SEQUENCE:1 SHED:0

ESC

MODE:A or B; STAGE:N

SCROLL

[BACK] [HELP]

Vocation Logic is available when a vocation module is installed. Each output can be tied to

any or all of several interlocks. The output can also be controlled by a NOT interlock, the circuit will only be operated if the interlock is OFF. The default condition for vocation logic is true (no connection).

INTERLOCKS: [SCROLL] CIR:Pump Panel LTS

ESC

INTERLOCK

: -X-

SCROLL

[BACK] [NEXT]

All three of the above logic conditions apply to every output and they are ANDed together. They all must be true for a circuit to operate.

7

Example

Example 1:

Pump Panel Lights Assigned to PDM 3 Output 0 Pump Panel Switch Assigned to PDM 3 Input 0 Marker Light Switch Assigned to SIM 0 Input 0

The Pump Panel Lights are set to come on with the Pump Panel Switch or the Marker Light Switch.

Multiplex ON whenever the Pump Panel Switch is ON OR the Marker Light Switch is ON.

Logic

Management

Vocation

Whenever the Marker Light Switch or the Pump Panel Switch is turned on, the Pump Panel Lights will turn ON.

Example 2:

The Pump Panel Lights are set to come on with the Pump Panel Switch OR the Marker Light Switch AND in Scene Mode.

Multiplex ON whenever the Pump Panel Switch is ON OR the Marker Light Switch is ON.

Management

Vocation

Whenever the Marker Light Switch or the Pump Panel Switch is turned on, the Pump

Panel Lights will turn ON

Logic

defaults to true.

AND

set to mode B (Scene Mode).

AND

defaults to true.

as long as the Park Brake is set

.

Example 3:

The Pump Panel Lights are set to come on with the Pump Panel Switch OR the Marker Light Switch AND in Scene Mode if it is Okay to Pump.

Multiplex ON whenever the Pump Panel Switch is ON OR the Marker Light Switch is ON.

Management

Vocation

Whenever the Marker Light Switch or the Pump Panel Switch is turned on, the Pump Panel Lights will turn ON transmission is in high range lockup.

8

Logic

AND

set to mode B (Scene Mode).

AND

set to Okay to Pump.

as long as the Park Brake is set

AND the pump is engaged and the

Example

--SYSTEM OUTPUTS--

CIR:Pump Panel Lgts

ESC

POWER MOD#3 OUT-00 [MNGT] [MPLX] [INTK]

--SYSTEM INPUTS--

CIR: Marker Lgt Switch

ESC

INPUT MOD#0 IN-00

--SYSTEM INPUTS--

CIR:Pump Panel Switch

ESC

POWER MOD#3 IN-00

SCROLL

--SYSTEM OUTPUTS--

CIR:Pump Panel Lgts

ESC

POWER MOD#3 OUT-00 [MNGT] [MPLX] [INTK]

SCROLL

MUX: Pump Panel Lgts• 1: Markew LT Switch OR

ESC

2: Pump Panel Switch [GO->1] [BACK] [GO->2]

MUX :Pump Panel LTS 1 :Pump LT Switch

ESC

[GO->1] [BACK]

MUX: Work Lights 1: Work LT Switch OR

ESC

2: Marker LT Switch [GO->1] [BACK] [GO->2]

SCROLL

9

Power Modules

The ES-Key System uses Power Distribution Modules (PDM’s) to supply current to electrical loads. Currently these are available in two basic styles and there can be up to 16 of them in the system.

Relay Modules use standard 30/40 Amp automotive relays and are available in 8 and 12 relay configurations. Both relay boards have two relays that the common terminal can be set to discrete inputs. The power to the board must be OFF any time that the switch for these outputs is changed. The rest are common bussed to system voltage. Both boards have eight inputs, 4 of which are polarity selectable and the other 4 are ground inputs. Each output has a feedback circuit to identify to the system it’s current status (OFF or ON). If an output is supposed to be on, but has no feedback, a fault is generated that can be easily traced. Whenever a PDM is installed or replaced, it is essential that the address switch be positioned correctly for it’s function in the system. Each load is turned on by device type, address and port. Relay #1 on relay board #1 would be addressed as PDM #1, Port #1 and most likely be named for the load that is connected to it. Any PDM whose address switch is at number 1 will respond to a turn on or off command unless there is an address conflict.

Connector Information

Amp Mini Universal Mate-N-Lok

Power Amp 172165-1 1) Power 2) Ground

CAN Amp 172166-1 1) Can HI 2) CAN LO 3) CAN Shield

Input Amp 770579-1 1) Input 0 select 5) Input 4 ground

2) Input 1 select 6) Input 5 ground

3) Input 2 select 7) Input 6 ground

4) Input 3 select 8) Input 7 ground

Amp Socket Terminals

Tin 101535 Gold 103374

10

4 3 2 1

8 7 6 5

Power Modules

Solid State Modules use an integrated circuit driver to supply current to its loads. Outputs are common bussed to system power and can deliver up to 7.5 Amps. Current levels above two (2) amps can be used to indicate whether an output is ON or OFF. These modules use a Hex switch for addressing and come in three (3) styles. 104434 Eight (8) output PDM-8 104528 Six output Two input PDM-(6/2) 104529 Four output Four input PDM-(4/4) Solid State Modules with inputs have polarity selectable inputs. Any output can be made to flash, the first four inputs flash at one instance and the second four flash at the opposite instance (anti-flash). The flash rate can be configured to 75 FPM or 150 FPM.

Connector Information DTM06-12SA Lock WM-12S Deutsch 20 Ga Sockets

1062-20-0122 for 16-10 Ga wire

0462-201-20141 for 18-24 Ga wire

0462-201-2031 Gold Contacts 18-24 Ga wire

PWR

BUS

COM

7 8 9 10 11 12 6 5 4 3 2 1

Eight Output Six OUT/Two IN Four OUT/Four IN

1 Output 0 1 Output 0 1 Output 0

2 CAN HI 2 CAN HI 2 CAN HI

3 CAN Shield 3 CAN Shield 3 CAN Shield

4 Output 2 4 Output 2 4 Output 2

5 Output 4 5 Output 4 5 Input 3

6 Output 6 6 Input 1 6 Input 1

7 Output 7 7 Input 0 7 Input 0

8 Output 5 8 Output 5 8 Input 2

9 Output 3 9 Output 3 9 Output 3

10 Output 1 10 Output 1 10 Output 1

11 CAN LO 11 CAN LO 11 CAN LO

12 Ground 12 Ground 12 Ground

Power Stud 10-32 thread/#10 Ring

11

Motor Control

The ES-Key Motor Control Module (PDM) is a solid state module capable of providing up to 15 Amps per output. It has 8 polarity selectable inputs, 8 positive outputs and 4 motor control circuits (H-bridge).

Connector Information Power, Ground CAN DT06-6SA Lock W-6S Inputs DT06-8SA Lock W-8S Outputs DT06-8SB Lock W-8S Motors DT06-8SC Lock W-8S

Deutsch 16 Ga Sockets

1062-20-0122 for 16-10 Ga wire

Output (Black) Input (Grey) Motor Control (Green) PWR,GND,CAN (Grey)

1 Output 0 1 Input 0 1 Motor 1 1 12 VDC 2 Output 1 2 Input 1 2 Motor 2 2 Ground 3 Output 2 3 Input 2 3 Motor 3 3 NC 4 Output 3 4 Input 3 4 Motor 4 4 CAN HI 5 Output 4 5 Input 4 5 Motor 4 5 CAN LO 6 Output 5 6 Input 5 6 Motor 3 6 CAN shield 7 Output 6 7 Input 6 7 Motor 2 8 Output 7 8 Input 7 8 Motor 1

12

Solid State PDM

Solid State Modules use an integrated circuit driver to supply current to it’s loads. Outputs are common bussed to system power and can deliver up to 7.5 Amps. Current levels above two (2) amps can be used to indicate whether an output is ON or OFF. These modules use a Hex switch for addressing and come in three (3) styles. 104434 Eight (8) output PDM-8 104528 Six output Two input PDM-(6/2) 104529 Four output Four input PDM-(4/4) Solid State Modules with inputs have polarity selectable inputs. Any output can be made to flash, the first four inputs flash at one instance and the second four flash at the opposite instance (anti-flash). The flash rate can be configured to 75 FPM or 150 FPM.

PWR

BUS

COM

7 8 9 10 11 12 6 5 4 3 2 1

The PWR LED indicates whether the system electronics have power or not. The BUS LED indicates whether or not there is power for the output loads. The green LED is on steady with good communications. A slow flash rate indicates that communications are down. A fast flash rate means that there is an address conflict with another module. If the LED is off, communications to and from the module are noit present.

13

Switch Modules

The ES-Key System uses Switch Input Modules (SIM’s) to provide switching information to the system. Currently these are available in two basic styles and there can be up to 16 of them in the system.

16 Positive (103372) Switch Input Module

Connector Information

Amp Mini Universal Mate-N-Lok

Power Amp 172165-1 1) Power 2) Ground

CAN Amp 172166-1 1) Can HI 2) CAN LO 3) CAN Shield

Input Amp 770579-1 1) Input 0 positive 9) Input 8 positive

2) Input 1 positive 10) Input 9 positive

3) Input 2 positive 11) Input 10 positive

4) Input 3 positive 12) Input 11 positive

5) Input 4 positive 13) Input 12 positive

6) Input 5 positive 14) Input 13 positive

7) Input 6 positive 15) Input 14 positive

8) Input 7 positive 16) Input 15 positive

Amp Socket Terminals

Tin 101535 Gold 103374

0

9

1

8

2

7

3

6

4

5

14

8 7 6 5 4 3 2 1

16 15 14 13 12 11 10 9

Wire Side

Switch Modules

6 5 4 3 2 1

Phone 352 629 5020 Fax 352 629 2902

http://www.class1.com

607 NW 27th Ave Ocala, FL 34475

IN 14

IN 12

CAN S

CAN H

PWR

PN 104409

IN 15

IN 13

CAN L

GND

7 8 9 10 1112

Switch Input Modules have 16 available inputs which are individually polarity selectable. These modules use a Hex switch for addressing and come in three (3) styles. 104508 Sixteen (16) Input SIM-16 104462 Sixteen Input Three Output SIM-16/3 10xxxx Sixteen Input/ One OUT/2 Analog SIM-16/1/2 All inputs are polarity selectable using DIP switches on the circuit card.

Connector Information DTM06-12SA Lock WM-12S DTM06-12SB Lock WM-12S Deutsch 20 Ga Sockets

1062-20-0122 for 16-10 Ga wire

0462-201-20141 for 18-24 Ga wire

0462-201-2031 Gold Contacts 18-24 Ga wire

DIGITAL INPUT

IN 5

IN 11

IN 9

IN 3

IN 1

IN 7

CAN L

GND

IN 15

IN 13

1 2 3 4 5 6

7 8 9 10 1112

12 1110 9 8 7

6 5 4 3 2 1

IN 12

IN 14

PWR

CAN S

CAN H

IN 6

IN 4

IN 2

IN 0

IN 10

IN 8

Phone 352 629 5020

607 NW 27th Ave

Fax 352 629 2902

Ocala, FL 34475

http://www.class1.com

PN 104409

DTM06-12SA DTM06-12SB

1 Power 1 INPUT 11

2 CAN HI 2 INPUT 9

3 CAN Shield 3 INPUT 7

4 (OUT 2) 4 INPUT 5

5 INPUT 12 5 INPUT 3

6 INPUT 14 6 INPUT 1

7 INPUT 15 7 INPUT 0

8 INPUT 13 8 INPUT 2

9 (OUT 0) 9 INPUT 4

10 (OUT 1) 10 INPUT 6

11 CAN LO 11 INPUT 8

12 Ground 12 INPUT 10

15

USM 103383

USM Control Module (PN 103383)

TMTM

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The USM Control Module is the primary module in the system. It has an

ES-KES-K

ES-K

ES-KES-K

to transfer information to and from the microprocessor memory as well as the capability to interface with a computer on the CAN bus. Direct access can be made through five switches and a twenty character by four line display on the USM. These are used to access the menu driven information, programming and diagnostic features. All logic and control for the system is handled by the USM Control Module. The menu is the user interface to the system allowing one to view information about the system, diagnose it and program load management functions.

Class1, Inc.

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SCROLL

ESC

ES-KES-K

ES-K

ES-KES-K

[MENU]

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y y

C C

arar

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C

C C

ar

arar

d d

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reader

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In normal operation, the center switch is active with [menu] being displayed just above it. The escape [ESC] switch is always active when in the menu system and will move up one level each time that it is pressed until the top level is reached. The [SCROLL] switches are active in certain menus to locate input or output data from a list. The three switches just below the display window are used to control the menu system. They become active and their function identified by text immediately above the switch. No text above a switch indicates that it has no function in that menu.

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Press the red switch directly under [MENU] to enter the

ES-KES-K

ES-K

ES-KES-K

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menu.

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In this section, a pressed switch is indicated by a black dot on the switch.

16

System Logic

The ES-Key System utilizes an electrical connection database for operation. This database is written by the OEM and contains all the information necessary to operate the ES-Key System for a specific vehicle. The system can be customized to the user’s needs without changing the physical wiring or hardware. This database can be ‘read’ by the user and is an ‘as built’ wiring diagram that stays with the system. Each ‘output circuit’ has three conditions of operation:

Multiplexing:

Two conditions of operation are available for each circuit. These conditions can be logically ‘AND’ed (both conditions must be true) or logically ‘OR’ed (either condition can be true) to each other. Additionally, either or both of these conditions can use ‘NOT’ logic. ‘NOT’ logic simply means that the condition must be false for the system to consider it true. The conditions can be inputs or outputs from anywhere in the system.

--SYSTEM OUTPUTS--

CIR:Pump Panel Lgts

ESC

POWER MOD#0 OUT-01 [MNGT] [MPLX] [INTK]

Load Management:

Outputs can be load managed to sequence on and sequence off. Outputs can be load managed to shed at a specific voltage level. Outputs can be managed to operate in Mode A, Mode B or both.

Outputs can be tied to a Staged input.

System Outputs CIR: PDM0 RLY 0

ESC

POWER MOD#0 OUT 0 [MNGT] [MPLX] [INTK]

MUX:circuit name

SCROLL

1:Condition 1 LOGIC

ESC

2:Condition 2

SCROLL

[GO->1] [BACK] [GO->2]

Fire Service Mode A is typically Response and Mode B is Scene.

Staging for the fire service is typically the Warning Master Switch.

MNG:PDM0 RLY 0

SCROLL

SEQUENCE:0 SHED:0

ESC

MODE B ONLY;STAGE:Y [BACK] [HELP] [EDIT]

SCROLL

Interlocking:

System Outputs CIR: PDM0 RLY 0

ESC

POWER MOD#0 OUT 0 [MNGT] [MPLX] [INTK]

Any output can be tied to any of several interlocks available from an ES-Key Vocation Module.

INTERLOCKS [SCROLL]

SCROLL

CIR:Circuit Name

ESC

Pump Shift : ON [BACK] [NEXT]

SCROLL

17

MNGT Data

ES-KEY USER MENU

SELECT OPTION

ESC

[UTIL] [DATA]

Selecting=xa^q^z=presents the system database for review.

SCROLL

ESC

-- SYSTEM OUTPUTS --

CIRCUIT NAME

CIR:

MODULE

TYPE ADDRPORT

SCROLL

ESC

-- SYSTEM INPUTS --

CIRCUIT NAME

CIR:

MODULE

TYPE ADDR PORT

SCROLL

[MNGT] [MPLX] [INTK]

The scroll arrows allow you to see all of the system inputs and outputs. The top line of the display indicates whether the circuit is an INPUT or OUTPUT. The second line shows the Circuit Name. The third line gives the module type, it’s address 0-15 and the port on the device that the circuit is assigned to. The fourth line is only active for OUTPUTS and allows the user to select one of three submenus for more information on the circuit.

[MNGT] provides a menu detailing the circuits load management information. [MPLX] provides a menu detailing the circuits multiplexing information. [INTK] provides a menu detailing the circuits interlock information.

-- SYSTEM OUTPUTS --

CIR: LIGHT BAR

ESC

POWER MOD#0 OUT-01

[MNGT] [MPLX] [INTK]

SCROLL

This screen indicates that the circuit ‘LIGHT BAR’ is an output located on a Power Module addressed as zero (0) and physically is on port one (1) of that module.

MNG:PDM 0 1 SEQUENCE:3 SHED:0

ESC

MODE:A OR B; STAGE Y [BACK] [HELP]

-- DEFINED BY OEM --

MODE A : RESPONSE

ESC

MODE B : SCENE STAGE : MASTER WARN

MNG:PDM 0 1 SEQUENCE:3 SHED:0

ESC

MODE:A OR B; STAGE Y [BACK] [HELP]

18

SCROLL

The Management screen shows that this output sequences on third, never sheds, will be on in either scene (mode a) or response mode (mode B) and is tied to the Master Warning Switch (staged).

The HELP screen displays the OEM’s defi- nition of Mode A and B as well as what the Staged input is. Press any key to return to the Management Screen.

Pressing the BACK Switch returns you to the ‘Circuits Menu’

MPLX Data

-- SYSTEM OUTPUTS --

CIR: LIGHT BAR

ESC

POWER MOD#0 OUT-01

[MNGT] [MPLX] [INTK]

Selecting [MPLX] brings up the system multiplex menu.

SCROLL

MUX: LIGHT BAR 1: Switch LIGHT BAR

ESC

[GO-1] [BACK]

MUX: LIGHT BAR 1: Switch LIGHT BAR

ESC

[GO-1] [BACK]

-- SYSTEM INPUTS --

CIR:Switch LIGHT BAR

ESC

POWER MOD#0 INP-01

SCROLL

The multiplex information screen shows the arguments that must be true for the circuit to operate. The scroll switches select different circuits. [BACK] returns you to the Circuits Menu.

Pressing the [GO-1] switch takes you to the circuit menu for that argument.

The circuit screen shows that condition 1 is the LIGHT BAR Switch and it is located on the power distribution module at address 0 and input #1 on that module. Scroll to the next circuit or escape to a higher level menu.

MUX: INNER LIGHT BAR 1: First Switch OR

ESC

2: Second Switch

[GO-1] [BACK] [GO-2]

Pressing the BACK Switch returns you to the ‘Circuits Menu’

-- SYSTEM OUTPUTS --

CIR: INNER LIGHT BAR

ESC

POWER MOD#0 OUT-02

[MNGT] [MPLX] [INTK]

SCROLL

If there are two arguments used, both of them will show on the MPLX screen and either the GO-1 or GO-2 switch can be accessed for information on the arguments.

19

INTK Data

-- SYSTEM OUTPUTS --

CIR: LIGHT BAR

ESC

POWER MOD#0 OUT-01

[MNGT] [MPLX] [INTK]

Selecting [INTK] brings up the system multiplex menu.

SCROLL

INTERLOCKS [SCROLL] CIR: LIGHT BAR

ESC

PARK BRAKE :OFF

[BACK] [NEXT]

INTERLOCKS [SCROLL] CIR: LIGHT BAR

ESC

PARK BRAKE :OFF

[BACK] [NEXT]

INTERLOCKS [SCROLL] CIR: LIGHT BAR

ESC

PUMP ENGAGED :ON

[BACK] [NEXT]

SCROLL

The interlock information screen shows the circuit name and allows you to view each of the interlocks and how it is related to the circuit. Either -X-, the interlock is not associated with the circuit or OFF or ON indicates whether the interlock must be on or off for the circuit to turn on.

This indicates that the Park Brake must be OFF for the LIGHT BAR to work. Pressing the [NEXT] switch takes you to the next interlock. Pressing the UP or DOWN arrow selects the next circuit to view in the interlock sub-menu.

This indicates that the pump must be engaged for the LIGHT BAR to work.

INTERLOCKS [SCROLL] CIR: LIGHT BAR

ESC

PUMP ENGAGED :-X-

[BACK] [NEXT]

INTERLOCKS [SCROLL] 1: Switch LIGHT BAR

ESC

PARK BRAKE :OFF

[BACK] [NEXT]

Pressing the BACK Switch returns you to the ‘Circuits Menu’

20

SCROLL

This indicates that the circuit LIGHT BAR doesn’t care if the Pump is engaged or not.

Pressing [BACK] selects the Circuits Menu.

Enter the menu system by pressing the switch immediately below [MENU].

ES-KEY USER MENU

SELECT OPTION

ESC

[UTIL] [DATA]

ES-KEY Utilities

ESC

[DIAG] [CARD]

Fault Menu

Class1, Inc.

ES-KEY SYSTEM

ESC

SCROLL

Version 2.02d

[MENU]

SCROLL

The two main sub-menu sections are utilities and data. Select [UTIL]

Under the utilities menu are three areas that can be accessed:

diagnostics, data logger (if it exists in

the system) and card. Select [DIAG]

ES-KEY DIAGNOSTICS

ESC

[OTHER] [FAULTS]

-SYSTEM FAULT CODES-

ESC

CURRENT/ACTIVE: 3

HISTORICAL LOG: 5

ES-KEY DIAGNOSTICS

ESC

[OTHER] [FAULTS]

SCROLL

Under ES-Key Diagnostics, a [FAULTS] Menu and an [OTHER] Menu is available. Select [FAULTS]

Displayed will be the number of current faults and the number of historical faults. Pressing ESC returns you to the ES-Key Diagnostics selection menu.

Selecting [OTHER] will take you to the Information on card, network or system selection menu.

Pressing [ESC] returns you to the Select [ES-Key DIAGNOSTICS] menu

21

Module Menu

Information on card,

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network or system?

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ESC

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[NET] [SYS] [CARD]

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Select Network I/O,

Modules, or Vocation

ESC

[MOD] [I/O] [VOC]

MOD:POWER ADDR:00 STATUS: LOCATED

ESC

v1.01 PDM 8-Relay Msg/sec:Tx=XX Rx=XX

SCROLL

The [NET] menu opens a selection window for information on the network modules, inputs, outputs or the vocation module.

Pressing [MOD] allows individual modules to be queried and module information to be displayed.

The display will indicate the Device Type, it’s address, communications status, software version, module type and the number of messages per second sent and received. Scroll through all the modules in the database to verify that they are on-line.

MOD:DISPLAY ADDR:00 STATUS: LOCATED

ESC

v1.03 Display 1 Msg/sec:Tx=XX Rx=XX

SCROLL

=MOD:DATA LOGGER STATUS: LOCATED

ESC

v1.01 Data Logger Developer’s Module

SCROLL

=MOD:VOCATION/INTLK STATUS: LOCATED v1.01 PTO/Drive Gear Developer’s Module

ESC

NOTE 1: THE CONTROL MODULE WILL ONLY LOOK FOR DEVICES THAT ARE CONTAINED IN THE ACTIVE DATABASE.

SCROLL

ANY MODULE WITH A STATUS: NOT LOCATED SHOULD BE INVESTIGATED. IF AN UNKNOWN MODULE APPEARS, THE DATABASE IS MORE THAN LIKELY CORRUPT.

MOD:INPUT ADDR:00 STATUS: NOT LOCATED

ESC

SCROLL

Pressing [ESC] will display the Select Network I/O, Modules or Vocation Select Menu. Locating all the modules in the system can let you know if there are any communications problems and where they might be located.

22

I/O-VOC Menu

Select Network I/O,

Modules, or Vocation

ESC

[MOD] [I/O] [VOC]

CIR:LIGHT BAR OUTPUT: OFF

ESC

CIR:LIGHT BAR SWITCH INPUT: ON

ESC

SCROLL

Selecting [I/O] brings up the input and out- put circuits page.

Each circuit on the vehicle can be looked at by using the up and down arrows to scroll through the circuits. The screen will show whether the circuit is an INPUT or an OUTPUT and whether it is ON or OFF.

Pressing [ESC] returns you to the Select Network I/O, Modules or Vocation menu.

Selecting [VOC] brings up the Interlock Sta-

tus Screen.

ESC

Select Network I/O,

Modules, or Vocation

SCROLL

[MOD] [I/O] [VOC]

CIR:PARK BRAKE INTERLOCK STATE: OFF

ESC

[BACK] [NEXT]

SCROLL

Each of the interlocks on the vocation module can be scrolled to using the

[NEXT] switch. It’s state will be shown as

either ON or OFF.

=CIR:OKAY TO PUMP INTERLOCK STATE: ON

ESC

SCROLL

[BACK] [NEXT]

Pressing the [BACK] or the [ESC] switch brings you back to the Select Menu.

Select Network I/O,

Modules, or Vocation

ESC

[MOD] [I/O] [VOC]

SCROLL

23

Information on card,

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network or system?

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ESC

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[NET] [SYS]

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[CARD]

ENG Menu

SCROLL

The [SYS] menu opens a selection window for information on Load Management, Engine or the database file.

Information on load man-

agement, Engine, or data-

ESC

base file?

[ENG] [MNGT] [FILE]

THROTTLE INPUT 000% OUTPUT:0.0V PWM:00%

ESC

FIDLE:00% REMOTE:00% [HSET] [IDLE] [EXIT]

CHANGE HIGH IDLE

SET-POINT TO 00% ?

ESC

[YES] [NO]

SCROLL

Pressing [ENG] brings up the Engine Fast Idle and Throttle Menu. This menu is used in conjunction with a Vocation Module. The engine will be controlled if the proper interlocks are present.

THROTTLE INPUT: displays the panel throttle position. OUTPUT: displays the analog engine control signal voltage. PWM: indicates the PWM engine control signal. FIDLE: displays the percentage of full throttle that a high idle signal will command. REMOTE: is the Throttle percentage commanded by the UP and DOWN switches.

With the proper interlocks, the engine can be operated to a desired RPM. Once this is accomplished, pressing [HSET] brings up the menu to set the current RPM as the HIGH IDLE RPM.

THROTTLE INPUT 000% OUTPUT:0.0V PWM:00%

ESC

FIDLE:00% REMOTE:00% [HSET] [IDLE] [EXIT]

SCROLL

Pressing YES or NO returns you to the Engine Menu. IDLE brings the engine to curb idle and EXIT returns you to the System Select Menu.

Information on load man-

agement, Engine, or data-

ESC

base file?

SCROLL

[ENG] [MNGT] [FILE]

Pressing Management [MNGT] brings you to the Load Management Display Screen.

24

Information on load man-

agement, Engine, or data-

ESC

base file?

[ENG] [MNGT] [FILE]

LOAD MNGT: DISABLED SEQ:4 SHED:7 STG:OFF

ESC

MODE A :Response VOLTS: 13.8

LOAD MNGT: ENABLED SEQ:4 SHED:7 STG:ON

ESC

MODE B :Scene VOLTS: 13.8

MNGT Menu

SCROLL

The [SYS] menu opens a selection window for information on Load Management, Engine or the database file.

Pressing [MNGT] brings up the Load Management View. The system Load Management data is presented. The sequence level, shed level and system voltage are displayed. The stage and mode conditions are shown as well as whether load management is enabled or disabled.

LOAD MNGT: ENABLED SEQ:4 SHED:7 STG:ON

ESC

MODE B :Scene FORCE VOLTS: 13.8

LOAD MNGT: ENABLED SEQ:4 SHED:4 STG:ON

ESC

MODE B :Scene FORCE VOLTS:12.4 HOL

SCROLL

Information on load man-

agement, Engine, or data-

ESC

base file?

[ENG] [MNGT] [FILE]

Using the UP and DOWN arrows results in a diagnostic mode where the voltage display is changed by 0.1 VDC per switch press. The system will act as if this were the actual system voltage. Range is 10.0 VDC to 13.8 VDC.

There are three Letters that can appear in the Bottom Right of the display. H indicates that a High Idle output is active. O means that a High Idle Override input is active. L indicates that the system Low Voltage Alarm is active. to the System Select Menu.

SCROLL

Pressing [ESC] returns you to the System Select Menu.

25

FILE Menu

Information on load man-

agement, Engine, or data-

ESC

base file?

[ENG] [MNGT] [FILE]

--ACTIVE CARD FILE--

ESC

FILE: Electrical Spec CREATED ON:04-15-00

Information on load man-

agement, Engine, or data-

ESC

base file?

[ENG] [MNGT] [FILE]

Information on card, net-

work or system?

ESC

[NET] [SYS] [CARD]

SCROLL

The [SYS] menu opens a selection window for information on Load Management, Engine or the database file.

Pressing [FILE] brings up a display that shows the file name and the date it was created.

Pressing any key returns you to the System Selection Menu.

Pressing ESC to return to the Card, Network or System selection menu.

- ES-KEY CARD DATA -

ESC

CARD: card title CREATED ON: 03-21-99

Press ESC to return to the Card, Network or System selection menu.

Pressing [ESC] returns you to the ES-Key Diagnostics Menu.

SCROLL

Information on card, net-

work or system?

ESC

[NET] [SYS] [CARD]

ES-KEY DIAGNOSTICS

ESC

[OTHER] [FAULTS]

Press CARD to see information on a card that has been inserted into the card reader.

SCROLL

26

USM 103383

USM Control Module (PN 103383)

TMTM

TM

The USM Control Module is the primary module in the system. It has an

ES-KES-K

ES-K

ES-KES-K

to transfer information to and from the microprocessor memory as well as the capability to interface with a computer on the CAN bus. Direct access can be made through five switches and a twenty character by four line display on the USM. These are used to access the menu driven information, programming and diagnostic features. All logic and control for the system is handled by the USM Control Module. The menu is the user interface to the system allowing one to view information about the system, diagnose it and program load management functions.

Class1, Inc.

ESC

ES-Key TM System

Version 2.02d

SCROLL

[MENU]

TMTM

ee

y y

C C

arar

y

y y

C

C C

ar

arar

d d

d

reader

d d

e

ee

In normal operation, the center switch is active with [menu] being displayed just above it. The escape [ESC] switch is always active when in the menu system and will move up one level each time that it is pressed until the top level is reached. The [SCROLL] switches are active in certain menus to locate input or output data from a list. The three switches just below the display window are used to control the menu system. They become active and their function identified by text immediately above the switch. No text above a switch indicates that it has no function in that menu.

TMTM

TM

Press the red switch directly under [MENU] to enter the

ES-KES-K

ES-K

ES-KES-K

TMTM

ee

y y

Sy Sy

stst

Sy

Sy Sy

st

stst

emem

em

menu.

emem

e

y

ee

y y

In this section, a pressed switch is indicated by a black dot on the switch.

27

Make Card

The ES-Key Card is a memory module that contains the database for system operation. This database is written by the OEM and contains all the information necessary to operate the ESKey System for a specific vehicle. This database can be ‘read’ by the user and is an ‘as built’ wiring diagram that stays with the system. The database can be transferred to an ES-Key Card from the USM. A simple menu driven routine allows you to perform this function.

Class1, Inc.

Select: [MENU]

Select: [UTIL]

ESC

ES-Key SYSTEM

Version 2.02d

[MENU]

ES-Key USER MENU

SELECT OPTION

[UTIL) [DATA]

SCROLL

Select: [MAKE]

Select: [WRITE]

ES_KEY

ESC

Card Utilities

[MAKE]

Overwrite the ES-KEY with current system configura-

ESC

tion?

[WRITE] [CANCEL]

Writing Card xx%

ESC

Verifying Card xx%

ESC

SCROLL

28

==== Transfer Successful

ESC

[ESC] To Continue

SCROLL

ESC

ES-KEY SYSTEM

[DIAG] [UTIL] [INFO]

Display

INFORMATION CENTER

Class 1

ES-Key System

11:53 [MENU] 73F

Pressing the switch under UTIL brings up the System Utilities Menu.

SCROLL

SYSTEM UTILITIES

ESC

[TIME] [U/M]

Set the Data Log

Date and Time

ESC

[DATE] [TIME]

TIME 00:00:00

_______________________

ESC

Hold and Scroll

[H] [M]

September 11, 2000

------------------------------

ESC

Hold and Scroll

[M] [D] [Y]

SCROLL

The Data Logger clock and the system units of measurement can be changed at the System Utilites Sub-menu.

Select either date or time for a menu that will allow you to set either the time or date.

Hold the switch for either hours or minutes and use the scroll arrows to change the time setting as desired.

NOTE: If no time is displayerd at the top level and the

time in the settings window is 00:00:00, then there is no datalogger in the system.

Operation to set the date is the same as for time. Hold the desired function while scrolling up or down.

29

-- SYSTEM OUTPUTS --

CIR: LIGHT BAR

ESC

POWER MOD#0 OUT-01

[MNGT] [MPLX] [INTK]

Display

SCROLL

MUX: LIGHT BAR 1: Switch LIGHT BAR

ESC

[GO-1] [BACK]

MUX: LIGHT BAR 1: Switch LIGHT BAR

ESC

[GO-1] [BACK]

-- SYSTEM INPUTS --

CIR: Switch LIGHT BAR

ESC

POWER MOD#0 IN-01

[MNGT] [MPLX] [INTK]

SCROLL

The multiplex information screen shows the arguments that must be true for the circuit to operate. The scroll switches select different circuits. [BACK] returns you to the Circuits Menu.

Pressing the [GO-1] switch takes you to the circuit menu for that argument.

The circuit screen shows that condition 1 is the LIGHT BAR Switch and it is located on the power distribution module at address 0 and input #1 on that module. Scroll to the next circuit or escape to a higher level menu.

30

If there are two arguments used, both of them will show on the MPLX screen and either the GO-1 or GO-2 switch can be accessed for information on the arguments.

Class1 ES-Key-USM User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Network

Hardware

Addresses

Logic

Example

Power Modules

Motor Control

Solid State PDM

Switch Modules

USM 103383

System Logic

MNGT Data

MPLX Data

INTK Data

Fault Menu

Module Menu

I/O-VOC Menu

ENG Menu

MNGT Menu

FILE Menu

Display