Intellitec INSTALLATION & SERVICE MANUAL
Contents
1. 3415 LIOA ZL S adWnr NOILd O ES 0123 09 14510 JLOWSY 1 918438 ILLINOIS 60148 FERETE j 131 EISENHOWER LANE NORTH LOMBARD 630 268 0010 1 800 251 2408 H3NOI1IQNOO 13S N39 S9INOH19313 TOULNOOD 1N3W3SVNVN A9Hd3N3 28 72 VOL QVO1 50 31 1VLSOWYSHL YANOILIGNOO HIV sayoq QaTIOULNOI NN OL SLIOA 021 HOLIMS 8345 1 OILVNOLNY 21212 2 2 2 j j NIYIN tec lli gt 42 G c G gt D B Z H E O Ay AOIAYAS 06 IVOIdAL Inte P N 5322100A100 2 1 POWERLINE Energy Management System ALL GROUNDS FROM AUTO TRANSFER SWITCH NEUTRALS O Z cc Lu gt gt co a lt O CURRENT SENSOR O u 131 EISENHOWER LANE NORTH Intellitec 1 ILLINOIS 60148 630 268 0010 1 800 251 2408 13 P N 5322100A100 Q31V10SNI 4 3415 LIOA Zt SYddWAP NOILdO 0123 09 14510 JLOWSY ILLINOIS 60148 630 268 0010 1 800 251 2408 LEERTE TH 131 EISENHOWER LANE NORTH LOMBARD 1N3NW3SVNVN ADHaNI H3NOI1IQNOO 13S N39 SOINOH109313 1OHd1NOO OdAre VO 50 31 1VLSOWYSHL HaNOILIONOD HIV2. Pi in 1 2 3 4 5 6 7 8 J5 6 position terminal block Will accept up to 12 GA or 14 GA copper wire ONLY Terminal Function Neutral From Circuit Breaker for Relay 2 Output of Relay 2 From Circuit Breaker for Relay 1 Line 1 L1 Input Output of Relay 1 Line 2 L2 Input I II E 131 EISENHOWER LANE NORTH LOMBARD ILLINOIS 60148 nte 630 268 0010 1 800 251 2408 8 5322100 100 POWERLINE Energy Management System Trouble Shooting If the following problems occur proceed with their analysis in the order in which the steps are listed I No 120 volt appliances working A Check incoming power source 1 Make sure that the shore power cord is plugged into the outlet 2 Check the circuit breaker at the shore power outlet to be sure it is set Turn it off and then back on to be sure 3 Check the Main circuit breaker in the distribution panel to be sure it is set Turn it off and then back on to be sure 4 Using a circuit checker be sure the 30 Amp shore power outlet has 120 volts available Check Change Over relay if so equipped 1 Measure the voltage at the incoming side of the Main 30 Amp breaker If voltage is NOT the same as the incoming line repair the change over Refer to the change over service literature for trouble shooting 120 volts available at non controlled appliances and receptacles Controlled appliances do not operate A Check 120 volt circuit breakers in the distribution pane
3. sayoq 3110 1 09 OL SLIOA 021 HOLIMS 8345 1 J ony e le le lele le e _ NIYIN tec lli gt 42 c G gt D c LLI B Z H E O Ay JOIAYAS 0S WVYOVIC IVOIdAL Inte P N 5322100A100 4 1 gt 42 G c G gt D c LLI B Z H E O Ay WALSAS dWV 0S SaNNOY9 Mes 9 HOLIMS H3ASNVUL YOSNIS 1N3duno 131 EISENHOWER LANE NORTH LOMBARD ILLINOIS 60148 630 268 0010 1 800 251 2408 Intellitec P N 5322100A100 15 POWERLINE Energy Management System 131 EISENHOWER LANE NORTH Intellitec LOMBARD ILLINOIS 60148 630 268 0010 1 800 251 2408 16 P N 5322100A100
4. Common Relay 3 Normally Closed Relay 4 Common Relay 4 Normally Closed Gen Set Run 12 VDC Input The 12 volts should be supplied from a source fused at 3 Amps minimum and capable of delivering up to 1 Amp of AVERAGE current Protecting this connection with a higher rated fuse is acceptable since the EMS is internally protected with 3 Amp fuse The low voltage wires are brought into the box through the large hole in the lower left hand corner of the back of the box The Relay 3 connections are typically made to the low voltage compressor control wires of the air conditioners The normally closed contacts are wired in series with the compressor control lead This means that the compressor control wire is cut and the two ends are wired to the Common and the Normally Closed contacts of Relay 3 In this way the EMS can interrupt the operation of the compressor just as the thermostat does The Relay 4 connections are typically made to the thermo stat wires of the air conditioners The normally closed contacts are wired in series with the thermo stat This means that the thermostat wire is cut and the two ends are wired to the Common and the Normally Closed contacts of Relay 4 In this way the EMS can interrupt the operation of the fan just as the thermostat does REMOTE PANEL Select a convenient location for the panel where it can be easily viewed by the owner Cut a hole in the panel for the panel as shown Remote Panel Cutout 131 EIS
5. Display Panel the numeric display should read 0 and the four load LED s should come on A clamp on type ammeter may be used to measure the current being supplied by the 30 Amp shore power cord Connect or turn on one of the controlled AC loads It should operate and the numeric display or the clamp on ammeter should show the amount of current that load is drawn Turn that appliance off and repeat this with each of the others To test the load shedding turn on all the controlled appliances The total current drawn should exceed 30 Amps If not add additional loads to the non controlled receptacles When the total amount of current exceeds 30 Amps the loads should begin to turn off to bring the total below 30 Amps 131 EISENHOWER LANE NORTH Intellitec LOMBARD ILLINOIS 60148 630 268 0010 1 800 251 2408 7 P N 5322100A100 POWERLINE Energy Management System CAUTION F1 3 Amp ATO type for EMS circuitry only DO NOT replace with a fuse of higher rating This could result in severe damage to the circuitry or create a possible fire hazard PLUGS PINS amp FUNCTIONS J3 4 pin Molex KK 156 Display Panel Connector Mating Housing Molex 09 50 3041 Pi Function Power Data Ground Select Line J4 8 pin in line Mate N Lock Mating housing AMP 640586 1 Function 12 Volts Ground Relay 3 Normally Open Relay 3 Common Relay 3 Normally Closed Relay 4 Common Relay 4 Normally Closed 12Vdc Generator Run indicator input
6. This value is placed in memory If the current remains above the service limit the system will turn off the next load in the shedding table Again it calculates the amount of current that was removed and places this value which is the value for that load in memory In like manner the system turns off loads until the total current falls below the service limit or all of the four controlled loads have been shed In this process the system has learned the amount of current that each particular load draws This feature compensates for the differences in current draw over a range of line voltage and ambi ent temperature by re learning the load each time it is turned off or shed The system now waits until the total current is lower than the service limit and enough current is available as compared with the amount in memory for the last load shed before it will turn that load back on This assures that there is sufficient current to operate the load There is a two minute minimum delay period after a load is shed before the load will be turned back on again to prevent air conditioners from turning on with a head of pressure OPERATION IN VEHICLES EQUIPPED WITH 120VAC 30 AMP SERVICE Initially the system automatically powers up and determines the nature of the power source If the generator is running 120 VAC will be present at the L1 and L2 inputs and a 12 VDC signal will be present at 4 pin 8 on the Control Module In this mode the energy ma
7. into the box The potential of lethal electrical shock is present in this box Inadvertent shorts at this box could result in damage and or injury All servicing of this box should be done only by a qualified Service Technician Diagnostic tools required Low current Test Light Accurate Voltmeter digital readout preferred Clamp on AC ammeter 131 EISENHOWER LANE NORTH Intellitec LOMBARD ILLINOIS 60148 630 268 0010 1 800 251 2408 1 P N 5322100A100 POWERLINE Energy Management System HOW IT WORKS ENERGY MANAGEMENT The main neutral line is routed through the magnetically coupled current sensor This sensor mea sures the current flowing through the neutral line which is the total amount being drawn by all the 120 volt appliances the RV When this current exceeds 30 Amps 20 Amps if the threshold has been set lower the PowerLine EMS will turn off the controlled loads in an effort to bring the total current to the limit of the incoming service CONTROLLED LOADS The system offers control of up to four powered loads Loads that are to be controlled are connected to one of the relay circuits of the EMS There are a total of four control relays in the EMS Two of these relays relays 1 and 2 are 10 Amp relays with normally closed contacts used to interrupt the 120 volt power to the loads These circuits are intended to control 120 volt appliances such as refrigera tor water heater washer dryer coffee maker etc Fo
8. service that the system is operating under If the GEN SET service indicator is lit the system has automatically detected the presence of 120 VAC at the L1 and L2 inputs and the presence of the 12 VDC run signal from the generator at the GEN SET input on the Control Module If the 50 AMP service indicator is lit the system has automatically detected the presence of 240 VAC at the L1 and L2 inputs on the control module If the 30 AMP service indicator is lit the system has automatically detected the presence of 120 VAC at the L1 and 12 inputs and the absence of the 12 VDC run signal from the generator input on the Control Module If the 20 service indicator is lit the user has selected that mode by momentarily pressing the 20 30 Amp select button Momentarily pressing this button again will switch the system back to the 30 Amp mode panel also be used to display the value of current stored memory for each of the four oads 131 EISENHOWER LANE NORTH Intellitec LOMBARD ILLINOIS 60148 630 268 0010 1 800 251 2408 4 P N 5322100A100 POWERLINE Energy Management System INSTALLATION The EMS Control Module has three jumpers on the board that determine the order of shedding of the loads These jumpers are labeled JP1 2 and See the following figure H O LIL REMOTE d DISPLAY CONNECTOR These jumpers are all installed at the factory Removing them will alter the order of shedding to suit 15
9. ENHOWER LANE NORTH Intellitec LOMBARD ILLINOIS 60148 630 268 0010 1 800 251 2408 6 P N 5322100A100 POWERLINE Energy Management System REMOTE PANEL continued Route the harness from the hole for the Display Panel to the EMS Control Module up to 40 feet of cable is acceptable Plug the cable into the EMS Control Module assuring it is properly seated on all four pins Note This cable is polarized the latches of each end of the connector mate to each other and will go on easily in the right direction but can be forced on in the reverse direction The Remote Panel should be plugged onto the harness observing the polarity as before The panel should then be installed in the hole and screwed in place using two 6 flat head screws through the holes in the panel The white function label should be lettered to correspond to the order of load shedding and installed The cover label should be placed against the front panel in the trim bezel snapped on to hold the label in place PERFORMANCE TEST The system is now ready for testing At the installers preference to assure there are no potential shorts a Hi Pot test can be performed on the installation The Hi Pot test should be conducted in accordance with standard procedures for the tester being used SYSTEM TEST Initially all the 120 volt loads should be turned off or disconnected Both 120 volt AC and 12 volt DC power should now be applied to the system Referring to the
10. POWERLINE Energy Management System INSTALLATION amp SERVICE MANUAL SERVICE TYPE GEN Hl SET AC LINE POWER STATUS 50 EE AMP 22 7 7 20 EE 30 20 5 SELECT LOAD METER POWER APPLIED by lintellitec WHEN LIGHT ON REFRIGERATOR Display Panel PowerLine EMS is a specialized power distribution and energy management system intended to be used in recreational vehicles The Control Module ishoused in the standard main distribution panel a sheet metal enclosure with removable front panel The Display Panel is mounted to a wall or suitable surface remotely from the distribution panel It provides a system of energy management to minimize the over loading and tripping of circuit breakers Energy Management the PowerLine EMS automatically senses the available power to the vehicle It determines whether it is connected to 120 VAC 30 Amp shore power source 240 VAC 50 Amp shore power source or Generator source Depending upon available power it controls the operation of the rear air conditioner fan and compressor using low voltage switch ing and also controls the refrigerator by switching the 120 VAC supply If the available power source is 120 VAC 30 Amp shore power it attempts to keep the total 120 volt current draw to lessthan 30 Amps CAUTION The POWERLINE Energy Management System is a specialized power switching center Power from the 120 240 volt power source is fed
11. dicators do not light and the GEN SET service indicator on the Remote Display does not light with the Generator Running A Check for the presence of 12Vdc at J4 pin 8 on the Control Module IX All Load Indicators do not light and the 50 AMP service indicator on the Remote Display does not light with the vehicle plugged into 240Vac 50 Amp shore power service A Check for the presence of 240Vac between J5 pin 4 L1 and J5 pin 6 L2 B Check 120 volt circuit breaker in the distribution panel supplying J5 pin 4 L1 on the Control Module 131 EISENHOWER LANE NORTH Intellitec LOMBARD ILLINOIS 60148 630 268 0010 1 800 251 2408 10 P N 5322100A100 POWERLINE Energy Management System DISPLAY E gt CONN NETOR LO gt CONNECTOR E 12VOLT gt DISPLAY gt CONNECTOR LOW VOLTAGE CIRCUIT gt FE 3A 12VOLT FU TO NEUTRAL BAR CURRENT SENSOR FROM AUTO TRANS SWITCH NEUTRAL BAR FROM REFER CONVERTER BREAKER TO CONVERTER TO REFER RECPT FROM GFICIR 1 BREAKER TO 4X 4 BOX GALLEY FROM GFI CIR 2 BREAKER BATH GFI RECPT 50 AMP SERVICE CONNECTIONS TO NEUTRAL BAR CURRENT SENSOR FROM AUTO TRANS SWITCH NEUTRAL BAR 30 AMP SERVICE CONNECTIONS 131 EISENHOWER LANE NORTH LOMBARD ILLINOIS 60148 630 268 0010 1 800 251 2408 14 P N 5322100A100 Intellitec Q31V10SNI
12. it for three hours the EMS will change its shedding threshold to 24 Amps and turn off loads until the 24 Amp limit is attained If the user selects the 20 Amp service mode this limit will translate to 16 Amps Because the EMS calculates a running 3 hour average if the average load current drops below the limit the system will restore power to loads based on their impact on the limit If the system is in the Averaging mode the decimal point at the lower right corner of the Load Meter display on the Display Panel will illuminate SERVICE TYPE GEN SET 50 AMP 30 ENN J0 REAR A C COMP 20 REAR 30 20 5 SELECT LOAD METER APPLIED by Mintellitec WHEN LIGHT ON REFRIGERATOR DISPLAY PANEL The Display Panel can be mounted remotely and connectsto the Control Module with a small gauge four wire cable Four Power Status LED s indicate whether power is applied to those loads These LED s are on when the power is applied A two digit display the Load M eter indicates the amount of current actually being drawn by all the appliances in the coach The Service Select button allows the current threshold to be set to either 30 Amps or 20 Amps to match the incoming service When power is first applied the system will always be in the 30 Amp mode Momentarily pressing this button will switch the system to the 20 Amp mode Four Service LED s indicate the type of
13. l 1 Reset circuit breakers if necessary 2 Check for presence of voltage at branch circuit breakers with voltmeter Some controlled appliances turn on others do not A Check wiring to and from EMS Control Module 1 Check wiring from circuit breakers to EMS Control Module 2 Check wiring from EMS Control Module to controlled appliance Branch circuit breaker trips when power is applied A Check wiring for shorts Air conditioner doesn t work A Check thermostat wiring and settings B Check air conditioner Shedding order incorrect A Check for jumpers in locations 1 2 and 3 on the EMS Control Module B Check relay wiring 131 EISENHOWER LANE NORTH Intellitec LOMBARD ILLINOIS 60148 630 268 0010 1 800 251 2408 9 P N 5322100A100 POWERLINE Energy Management System Vil Remote Display out or strange characters appear A Check the 3 Amp Fuse F1 on the EMS Control Module B Check the 4 pin cable from the EMS Control Module to the Display Panel for the following voltages Pin 1 12V 12V Pin 2 Data GND Pin 3 GND GND Pin 4 SW GND 12V when swithc on Display Panel is pressed Check the harness so that the plug at the EMS Control Module and the plug at the Display Panel are plugged in with the proper polarity and the pins correspond Wiring 1 1 2 2 3 3 4 4 Both the EMS and Display have internal protection Shorts or miswiring should not cause the units to fail VIII All Load In
14. nagement feature is disabled and the Control Module sends a signal to the Display Module which causes the load meter to actual load current the GEN SET service indicator to light and all power status indicatorsto light If 120 VAC is present at the 11 12 inputs and no 12 VDC signal is present at 4 pin 8 on the Control Module the EMS will assume that 120 VAC 30 Amp shore power is available and the energy management feature will be enabled If 20 Amp service is only available the user must select the 20 AMP service mode by momentarily pressing the 20 30 Amp select switch on the Control Panel Initially all relay contacts are closed The total current is monitored If the total current should exceed the service limit the system will turn off the first load in the shedding table Asit does this it calculates the amount of current that was removed which is the value for that load This value is placed in memory If the current remains above the service limit the system will turn off the next load in the shedding table Again it calculates the amount of current that was removed and places this value which is the value for that load in memory In like manner the system turns off loads until the total current falls below the service limit or all of the four controlled loads have been shed In this process the system has learned the amount of current that each particular load draws This feature compensates for the differences in curren
15. particular need of the installation Please consult the factory before modifying the installation of the jumpers PLACEMENT The EMS Control Module isinstalled inside the main distribution panel The metal mounting bracket should be placed as shown and the single screw mounting the breaker panel should be removed and replaced as shown The wiring to the box should be routed through the holes the back and secured using approved cable connectors The wires should be copper conductors ONLY with the appropriate size and insulation to meet N E C code The main White or neutral lead should be routed through the hole in the current sensor and then to the screw terminal on the Neutral Bar To connect the 120 volt controlled loads jumper wires should be connected from the respective circuit breakers to the associated screw terminals on the EMS Control Module The black wires to the controlled loads should be connected to the proper screw terminals on the EMS Control Module Be sure these wires are under the screw terminals and they are tight 131 EISENHOWER LANE NORTH Intellitec LOMBARD ILLINOIS 60148 630 268 0010 1 800 251 2408 5 P N 5322100A100 POWERLINE Energy Management System PLACEMENT continued The 12 VDC voltage connections are made through the 8 pin Mate N Lok plug on the low voltage side of the Control Module The connections are as follows Function 12 Volts Ground Relay 3 Normally Open Relay 3
16. r the 120 VAC switched loads power is routed from the individual branch circuit breakers to one of these 120 VAC relays The controlled load is then fed from that relay The remainder of the relays relays 3 and 4 are intended to switch low voltage loads Relay 3 isa single pole double throw relay with all contacts available Relay 4 is a single pole double throw relay with only the common and normally closed contacts available These are intended to control air conditioners or other appliances equipped with low voltage controls or thermostats The contacts of the relays are typically wired in series with the low voltage controls or thermostats of air condition ers so the EMS turns off only the compressor or the compressor and fan These circuits could also control other 120 volt appliances if an additional control relay is added externally If 120 VAC or 240 VAC is not available at the L1 or L2 inputs J5 pin 4 and 6 respectively to the Control Module the EMS shuts itself off and all relay contacts remain closed This feature is intended to prevent the EMS from drawing current from the 12 VDC battery supply when not in operation OPERATION IN VEHICLES EQUIPPED WITH 240VAC 50 AMP SERVICE In operation when the 120 VAC or 240 VAC power is applied the system automatically powers up and determines the nature of the power source If 240 VAC 50 Amp service is available the energy management feature is disabled and the Control Module sends a
17. signal to the Display Module which causes the load meter to go blank the 50 AMP service indicator to light and all power status indicators to light If the generator is running 120 VAC will be present at the L1 and L2 inputs and a 12 VDC signal will be present at J4 pin 8 on the Control Module In this mode the energy management feature is disabled and the Control Module sends a signal to the Display Module which causes the load meter 19 actual load current the GEN SET service indicator to light and all power status indicatorsto ight If 120 VAC is present at the L1 and L2 inputs and no 12 VDC signal is present at J4 pin 8 on the Control Module the EMS will assume that 120 VAC 30 Amp shore power 15 available and the energy management feature will be enabled If 20 Amp service is only available the user must select the 20 AMP service mode by momentarily pressing the 20 30 Amp select switch on the Control Panel Initially all relay contacts are closed The total current is monitored If the total current should exceed the service limit the system will turn off the first load in the shedding table 131 EISENHOWER LANE NORTH Intellitec 1 ILLINOIS 60148 630 268 0010 1 800 251 2408 2 P N 5322100A100 POWERLINE Energy Management System OPERATION IN VEHICLES EQUIPPED WITH 240VAC 50 AMP SERVICE continued As it does this it calculates the amount of current that was removed which is the value for that load
18. t draw over a range of line voltage and ambient tempera ture by re learning the load each time it is turned off or shed The system now waits until the total current is lower than the service limit and enough current is available as compared with the amount in memory for the last load shed before it will turn that load back on This assures that there is sufficient current to operate the load There is a two minute minimum delay period after a load is shed before the load will be turned back on again to prevent air conditioners from turning on with a head of pressure 131 EISENHOWER LANE NORTH Intellitec LOMBARD ILLINOIS 60148 630 268 0010 1 800 251 2408 3 P N 5322100A100 POWERLINE Energy Management System 3 HOUR AVERAGING The R V I A Recreational Vehicle Industry Association in conjunction with the N E C National Electrical Council have established rules regarding the rating of electrical systems and the use of energy management systems One of these rules requires that if an energy management system is used the average total load current for the system over a 3 hour period be limited to 80 of the service rating For that reason the PowerLine EMS calculates the average running current for the system and If it exceeds 80 of the service rating the EMS sheds loads to reduce the average current below that limit For example if a system operating under 120 VAC 30 Amp service has been run ning at the 30 Amp lim
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