How it Works
Class1
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ES-Key-USM
User Manual
30 pgs822.94 Kb0
Table of contents
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Class1 ES-Key-USM User Manual

Contents

Table of Contents
Contents ........................................................................................................... 1
Network .........................................................................................................2-3
Hardware....................................................................................................... 4-5
Addresses ........................................................................................................ 6
Logic................................................................................................................. 7
Power Modules ......................................................................................... 10-11
Motor Control ................................................................................................. 12
Solid State PDM ............................................................................................. 13
Switch Modules .........................................................................................14-15
USM 103383 .................................................................................................. 16
System Logic..................................................................................................17
MNGT Data .................................................................................................... 18
MPLX Data ..................................................................................................... 19
INTK Data....................................................................................................... 20
Fault Menu ..................................................................................................... 21
Module Menu ................................................................................................. 22
I/O-VOC Menu................................................................................................ 23
ENG Menu ..................................................................................................... 24
MNGT Menu ................................................................................................... 25
FILE Menu...................................................................................................... 26
USM 103383 .................................................................................................. 28
Make Card...................................................................................................... 29
Display ......................................................................................................30-31
1

Network

USM Network
TMTM
TM
The
Class1
ES-KES-K
ES-K
ES-KES-K
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.
TMTM
ee
y y
Sy Sy
stst
Sy
Sy Sy
em em
st
em
consists of several components that can be used in a vehicle
stst
em em
TMTM
TM
TMTM
ES-KES-K
ES-K
ES-KES-K
ee
y y
Expr Expr
eses
s s
e
y
Expr
ee
y y
Expr Expr
software allows you to create, read or modify
es
s
eses
s s
To other
J-1939 Devices
e
y
ee
y y
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
Logic
Logic
Logic
Logic
defaults to true.
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
Logic
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
SCROLL
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
SCROLL
SCROLL
9
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