Class1 ESM3 User Manual

Download

ESM_III

Standard Features .................................................................2

Display Panel .........................................................................3

System Configuration ............................................................4

Main Battery Only Configuration............................................5

Main and Isolated Battery Configuration................................6

Electrical System Manager II.................................................7

Specifications .................................................................... 8-9

Models and Functions .........................................................10

Sample Circuits ..............................................................11-12

Troubleshooting ...................................................................13

Notes ...................................................................................14

Standard Features

Sequence

All outputs sequence on (T1-T7) and off (T7-T1).

Automatic Load Reset

Any load which has been shed will remain off for a minimum of two minutes. The loads will be controlled back on (unshed) by the system when the system voltage rises above the unshed level. Shed loads can be turned on immediately by turning off the load management enable input.

Over-Voltage Indicator

The system manager continually monitors the system voltage and will activate output T15 ( SW1 switch 3 ON) when it detects that the system voltage has increased above 15.0 volts. 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

The system manager is capable of becoming a part of a system which controls a fast idle device. The fast idle output T15 (SW1 switch 3 OFF) will activate whenever the system voltage falls to 12.8 volts or below. The output will deactivate if the system manager is reset, load management disabled or when the system voltage recovers above 12.8 volts. This output should be utilized with appropriate safety interlocks.

Battery Warning

The Battery Warning feature is a special output (T 8) which indicates that the electrical system voltage has fallen below 11.9 VDC. The Class 1 system manager continuously monitors the electrical system. This output can be wired to a warning device that requires less than 250 mA or to a relay if higher current devices are used.

Isolated Battery Warning

This is an optional configuration used when an isolated (auxiliary) battery needs to be monitored. J9 must be in the ISO BATTERY position and SW1 switch 1 must be turned ON. T7 becomes the Isolated Battery Warning output and activates when the isolated battery voltage falls below 11.9 VDC. This output can be wired to a warning device that requires less than 250 mA or to a relay if higher current devices are used.

105519 08172000

Display Panel

STANDARD PANEL DISPLAY

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

The indicator panel consists of four LED’s:

POWER ON (GREEN WIRE) T13 This LED illuminates when power is applied to the System Manager.

BATTERY WARNING (YELLOW WIRE) T8 This LED activates when the system voltage drops below 11.9 VDC.

ISOLATED BATTERY LOW (BLUE WIRE) OPTION T7 This LED illuminates when an auxiliary battery voltage drops below 11.9 VDC.

OVER-VOLTAGE OR FAST IDLE (BROWN WIRE) T15 This LED illuminates when system voltage drops below 12.8 VDC or rises above 15.0 VDC as configured by SW1 switch 3.

GROUND (BLACK WIRE) Connected to system ground.

System Configuration

The Electrical System Manager is configured by the use of a 4 position DIP Switch SW1 and 9 shunts (jumpers) J1 - J9.

SW1 switch OFF ON 1 Main Battery Main and Isolated Batteries 2 Shed T1-T7 Shed T7-T1 3 Fast Idle Overvoltage

4 Shed all Don’t shed T1 or T2

J1 controls polarity of the Master Switch input. J2-J8 control the polarity of output T1 through T7 J9 controls whether T12 is tied to the Master Switch input T10 or independent for an Isolated Battery Input.

<=-CAUTION-=>

When J9 is in the MASTER SWITCH position T12 is tied directly to T10. A direct short circuit will occur if an Isolated Battery Input is at T12 and a ground Master Switch input is at T10.

<=-CAUTION-=>

T5T4T3T2T1

FT13

FB2

GND POS

R11

J3 J4 J5 J6 J7 J8

Out-1 Out-2 Out-3 Out-4 Out-5 Out-6 Out-7

GND POS

C2 C1

C13 C12

XT1

GND POS GND POS

U19U17

R7 R6R5

SW2

GND POS

REV B

GMC / AMS

04-27-2000

P.N. 104702

GND POS GND POS

C11C10 C9C8

RSP2

U22U21U20U18U16

D7 D6D5 D4

RSP1

U13U12U11U10U9U8U7

1 2 3 4

SHED O/I

TP1 TP2

TP3 TP4

BATTS

SHED

T15

R14

R13

SW1

U15U14

R21

R16

R18

R12

U24

C16

R17

ON OFF

MAIN/ISO

7 1

OVER VOLTS

234

TB 12 INPUT

MASTER SWITCH

ISO

BATTERY

R10

PHONE 352-629-5020

FAX 352-629-2902

http://www.class1.com

C15

R15

FT15

U23

R3 R2

C17

MAIN

1 7

FAST IDLE

YES

OFF

OCALA ,FL

FB1

C18

GROUND

POSITIVE

Master Switch

T15T14T13T12T11T10T9T8T7

FT14FT12FT11FT10FT8FT7FT6FT5FT4FT3FT2FT1

R19

R20

C14

105519 08172000

Main Battery Only Configuration

SW1 switch 1 OFF.

All seven load control outputs can be sequenced and shed. These outputs are at terminals #1 through #7 (T1 - T7). One method of wiring is shown below.

T 15

T 14

Fast Idle

OverVoltage

T 13

T 12

T 11

Load Manage

Ignition Switch

Main Batt

T 10

T 9

Enable Switch

Battery Warning

Master Switch

Relay 7

T 8

T 7

Load SW 7

T 6

T 5

T 4

T 3

T 2

T 1

Dash

Load SW 1

Load

Relay 1

Switches

Relays

MAIN AND ISOLATED BATTERY CONFIGURATION

ELECTRICAL SYSTEM

MANAGER

Over Voltage Lt

Ignition Sw

Main Batt

Isolated Batt

Shed Enable Switch

Master Sw

connected only

when ignition on

Rly 1

Rly 6

Load Sw 1

Load Sw 6

Dash Switches

Load Relays

Battery Warning Lt

Isolated Batt Lt

T 1

T 9

T 5

T 13

T 3

T 11

T 7

T 15

T 2

T 10

T 6

T 14

T 4

T 12

T 8

Jumper J9 placed in ISO BATTERY position and SW1 switch 1 is turned ON. The system manager will operate in main and isolated battery mode. A separate input for the isolated battery is located at T12 and an output for Isolated Battery Low is located at T7. This provides for six load control outputs (T1-T6) which can be sequenced and shed.

105519 08172000

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

N O

N C

N O

N C

N O

N C

N O

N C

N O

COM

N C

N O

N C

N O

N C

N O

COM

N C

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 sequenced on whenever the Master Switch is activated. The System Manager will control loads and the high idle function only when the Load Manage Enable input (terminal #11) is active. Loads are shed from lowest priority to highest priority, T-1 to T-7, unless SW1 switch 2 is turned ON. Then they shed T-7 to T-1.

The voltage points are respectively:

Shed Unshed SW1-2 T1 12.4 12.8 T7 T2 12.2 12.4 T6 T3 12.0 12.2 T5 T4 11.8 12.0 T4 T5 11.4 11.6 T3 T6 11.0 11.4 T2 T7 10.8 11.2 T1

If SW1 switch 2 is ON, then the order is reversed as shown in SW1-2 column. If SW1 switch 4 is ON, then T1 and T2 will not shed.

Voltage must drop below the shed point for 60 seconds for a load to shed and voltage must be above the shed point for 600 seconds for a shed load to unshed.

MANUAL 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.

105519 08172000

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 SW1 switch 3 .

OVER-VOLTAGE INDICATOR Activates at and above 15.0 VDC and deactivates below 15.0 VDC.

HIGH IDLE CONTROL The output will activate when the voltage drops below 12.8 VDC for more than 1 minute. The output will remain ON for a minimum of 5 minutes until the voltage exceeds 12.8 VDC.

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

safety interlocks for the intended application.

AUXILIARY BATTERY

When an auxiliary battery 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 11.9 VDC for more than 10 seconds. The output will remain on until the isolated battery voltage is greater than 11.9 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 battery source, only 6 loads

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

LOW VOLTAGE WARNING OUTPUT

Output from T8 is disabled when the monitored voltage is above 11.9 VDC. At and below this level, the output will turn on to indicate low voltage.

MODELS AND FUNCTIONS

Existing System Managers

and System Manager II’s

11111

lanimreTlanimreT

lanimreT

colB

kkkkk

noitcnuFnoitcnuF

noitcnuFnoitcnuFO/IO/I

noitcnuF

O/IO/I

O/I

ytiraloPytiraloP

ytiraloP

51thgilegatlovrevOtuptuOevitisoP

lortnocelditsaFtuptuOevitisoP

41dnuorGmetsyStupnIdnuorG

21yrettabdetalosItupnIevitisoP

01hctiwSretsaMtupnIdnuorG

9CN

7woLyrettaBdetalosItuptuOevitisoP

niam(noitingI

)yrettab

hctiwSretsaMtupnIevitisoP

elbanEdehS

)tnemeganaMdaoL(

woLyrettaB

thgiLgninraW

tupnIevitisoP

tupnIdnuorG

tuptuOevitisoP

tuptuOdnuorG

XXXXXXXXXXXXXXXXXXXXXXXXXXXXXX

XXXXXXXXXXXXXXX

XXXXXXXXXXXXXXXXXXXXXXXXXXXXXX

XXXXXXXXXXXXXXX

XXXXXXXXXXXXXXXXXXXXXXXXXXXXXX

XXXXXXXXXX

XXXXX

1-7

SHUNT AND S WITCH SETTINGS TO MATCH EXISTING UNITS FOR REPLACEMENT PURPOSES.

MASTER OUTPUT ISO MAIN SHED1-7 FAST IDLE SHED 0 & 1

1daoL-7daoLtuptuOevitisoP

tuptuOdnuorG

MASTER ISO 7-1 OVERVOLTAGE

XXXXXXXXXX

XXXXX XXXXX

Model J1 J2-8 J9 SW1-1 SW1-2 SW1-3 SW1-4

100633 GND POS ISO OPT OFF OPT OFF 101084 GND GND ISO OPT OFF OPT OFF 100767 POS POS MSTR OPT ON OPT ON 101119 POS GND MSTR OPT ON OPT ON

OPT indicates the switch should be positioned to match current operation.

105519 08172000

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

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

105519 08172000

TROUBLESHOOTING

Output Polarity

Jumpers

T5T4T3T2T1

FT13

FB2

Out-1 Out-2 Out-3 Out-4 Out-5 Out-6 Out-7

J3 J4 J5 J6 J7 J8

GND POS

R11

C2 C1

GND POS

XT1

C13 C12

GND POS GND POS

U19U17

SW2

R7 R6R5

P.N. 104702

GND POS

REV B

GMC / AMS

04-27-2000

GND POS GND POS

C11C10 C9C8

RSP2

D7 D6D5 D4

RSP1

FT9

U13U12U11U10U9U8U7

U22U21U20U18U16

1 2 3 4

TP1 TP2

TP3 TP4

BATTS

SHED

T15

SHED O/I

R14

R13

SW1

U15U14

R21

R18

R12

U24

C16

R17

ON OFF

MAIN/ISO

7 1

OVER VOLTS

234

BATTERY

R10

R16

R15

U23

C17

OFF

TB 12 INPUT

MASTER SWITCH

ISO

OCALA ,FL

PHONE 352-629-5020

FAX 352-629-2902

http://www.class1.com

C15

FT15

C18

R3 R2

MAIN

1 7

FAST IDLE

YES

Master Switch

FT14FT12FT11FT10FT8FT7FT6FT5FT4FT3FT2FT1

FT8

FB1

GROUND

POSITIVE

T15T14T13T12T11T10T9T8T7

Terminal 12

Control Jumper

C14

R19

R20

Caution: If this jumper is in the Master Switch position, it is tied directly to Terminal 10

Voltage Test Points: TP1 System Voltage TP2 Filtered Voltage TP3 +5 VDC TP4 Ground

SW1

configuration switch

Master Switch

Polarity Jumper

Visual check

Check jumpers J1-J9 and ensure that they are in the correct position for the application. Check switch SW1 that 1-4 are in the correct postion for the operation desired.

Voltage Supply check

Check for system voltage between terminals T14 (ground) and T13 (12VDC). Check for system voltage betweenTP4 (ground) and TP2 (12 VDC). These should be within 0.5 VDC. Check for 5 VDC between TP4 and TP3 (+5 VDC).

These voltages must be present for the system to operate.

Master Switch check

Verify that J1 is in the proper position for the Master Switch you are using. Check for the input at T10.

This controls load sequencing on and off.

Load Manage Enable check

Check for a ground at T11.

This inputs allows loads to shed and the Fast Idle output.

Output Test

Verify that jumpers J2 through J8 are in the correct position. With power on and a Master switch input there should be either 12 VDC or Ground on T1 through T7 dependent on the the position of J2-J8.

NOTES

105519 08172000

Class1 ESM3 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Standard Features

Display Panel

System Configuration

Main Battery Only Configuration

Electrical System Manager II

SPECIFICATIONS

MODELS AND FUNCTIONS

SAMPLE CIRCUITS

TROUBLESHOOTING

NOTES