ELECTRONIC CLIMATE CONTROL
Contents
1. The Current Sensor should be mounted in one of the knockouts the 120 VAC box so that the donut shaped head is inside the box The black wire feeding the 30 Amp main breaker in the 120 VAC panel should pass through the hole in the Current Sensor 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www intellitec com 6 P N 53 00591 597 Rev 041205 ELECTRONIC CLIMATE CONTROL SERVICE MANUAL USE OF THE ECC WITH AUXILIARY GENERATOR SETS USE WITH 4KW GENERATOR In systems using 4KW generator sets the main system includes a manual or automatic change over which selects the 30 Amp power feed from either the shore power or generator In this situation all ECC load shedding features will remain unchanged BREAKER BOX CURRENT ACi 2 BR1 SENSOR E CHANGE OVER TO RECEPTACLES 15A BRANCH CIRCUIT 3 15A BRANCH CIRCUIT 2 15A BRANCH CIRCUIT 1 12 VDC POWER RELAY CONTROLLED 5A FUSE 2 REAR AIR CONDITIONER LOW VOLTAGE WIRING WALL MOUNT ECC THERMOSTAT CONTROL MODULE ELECTRONIC CLIMATE CONTROL LOW VOLTAGE THERMOSTAT WIRING P N 00 00597 000 or 100 P N 00 00591 200 AUTO COOL LOW VOLTAGE WIRING RELAY CONTROLLED 1 FRNT AIR CONDITIONER 4 0 KW GENERATOR 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www intellitec com 7 P N 53 00591 597 Rev 041205 ELECTRONIC CLIMATE CONTROL SER2. Control Module operates the air conditioner compressors and fans via three relays with 12 VDC coils supplied by the A C manufacturer and mounted in their equipment The contacts on these relays are internally wired by the A C manufacturer to the 120 VAC supply line for each unit and connect the compressor with the low or high speed taps on the fan motor to that supply line when operated The wiring between the Control Module and these relays is low voltage 12 VDC wiring The Control Module uses high side switching to operate the corresponding relays One side of each of the relay coils is connected together This common lead is connected to ground through the Control Module and should not be grounded anywhere else The other side of each of the coils is brought out to one of three separate leads These leads are connected to the Control Module via a four pin connector J2 for the A C1 unit and J3 for the A C2 unit The corresponding pigtail connectors PC2 and are supplied with the system the A C2 rear connector is marked in red in order to differentiate it from 2 The following table indicates the connection and control states MODULE PIGTAIL CONN WIRE FUNCTION OFF PIN COLOR VOLTAGE VOLTAGE lt 1 VDC 12 VDC 12 VDC 12 VDC lt 1 VDC 12 VDC 12 VDC COMPRESSOR 12 VDC lt 1 VDC NOTE The PC2 and PC3 pigtail wire colors are included for reference only to identify the function of the wires emanating from
3. ECC Control Module 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www intellitec com 2 P N 53 00591 597 Rev 041205 ELECTRONIC CLIMATE CONTROL SERVICE MANUAL THE ECC TEMPERATURE PROBES These Temperature Probes are thermistors mounted in protective plastic housings so they can sense the temperature of the air without being influenced by the mounting surface temperature Thermistors vary their electrical resistance inversely with temperature which means the higher the temperature the lower the thermistors resistance The thermistors utilized in this system have a resistance of about 10 000 Ohms at 77 degrees There are two temperature probes one for each of the front A C1 and rear A C2 systems They are located remotely from the thermostat panel to sense temperatures in the front and rear The connections to the ECC Thermostat are via small 2 pin connectors labelled J1 A C1 and J4 2 Since the devices are not polarity sensitive the two wires leading to them can be reversed without harm However it is necessary to connect the A C1 and A C2 TEMPERATURE TEMPERATURE PROBE to the correct connector to ensure the ECC Thermostat interprets the PROBE correct ambient temperatures associated with the front A C1 and rear A C2 of the coach THE ECC CONTROL MODULE The Control Module performs the timing sequencing switching and load shedding functions for the furnace s a
4. feature included in the Control Module circuitry is the Automatic Load Shedding function This circuitry measures the total current being drawn by all of the 120 VAC operated equipment in the coach being fed through the main panel The Current Sensor is mounted in the main panel and supplies an input signal to the Control Module When enough 120 volt appliances are operated so that the current exceeds 30 Amps for more than approximately 3 seconds the Control Module begins to shed shut off the A C compressors and fans to bring the current back below the 30 Amp limit This prevents nuisance tripping of the main 30 Amp breaker The shedding sequence occurs in the following order Rear A C2 compressor if running Front A C1 compressor if running Rear A C2 fan if running Front A C1 fan 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www intellitec com 5 P N 53 00591 597 Rev 041205 ELECTRONIC CLIMATE CONTROL SERVICE MANUAL When the Control Module sheds any of the loads it returns a signal to the ECC Thermostat to light the corresponding front or rear SHED indicator Based on the shedding sequence the rear SHED indicator will always be the first to light If enough appliances are operated to generate a load current of 30 Amps the Control Module will proceed through the entire shedding sequence and essentially shut down both A C compressors and fans It is important t
5. for shorts to find which one is at fault The SHORT indicator operates in the OFF and TEST modes of the TEST SWITCH The Control Module also includes protection circuitry to eliminate the possibility of short cycling the A C compressors Short cycling causes undue stress on the compressor motor when refrigerant pressures are not allowed to stabilized prior to restarting the compressor Atwo minute timer is incorporated in each of the control systems for the front A C1 and rear A C2 compressors The timer is started each time one of three conditions is encountered 1 If the Control Module shuts down the associated A C compressor during the shedding sequence or if the ambient temperature has reached the set point 2 Ifthe 120 VAC line current sensed by the Current Sensor goes below 1 This will occur during an interruption of power ifthe generator is not running or ifthe shore power cord is not plugged in 3 If 12 VDC power is not applied to the Control Module The Control Module does not allow the compressor to be re energized until the two minute period has elapsed If during this period the coach requires cooling or if the unit is recovering from load shedding the Control Module will signal the ECC Thermostat to alternately flash the ON and indicators on the control panel until the period has elapsed After the two minute period has elapsed the system will return to normal operation An important
6. reversed 2 Check the continuity of the Comp Relay lead between the Control Module and the A C2 unit Check to make sure that the connector PC1B from the Current Sensor is plugged into J1 pins 1 and 2 and that the 120 VAC supply lead to the 30 Amp breaker in the distribution panel passes through the hole in the Current Sensor lf OK then 1 Unplug the Current Sensor from the Control Module and measure the resistance across the leads to the Current Sensor The resistance should be approximately 40 Ohms If NOT A Replace the Current Sensor IV ON indicator is lit but fans do not operate in LOW FAN or HIGH FAN modes Make sure that the coach is plugged in to a live shore power outlet Check the 120 VAC circuit breakers in the distribution panel Slide test switch on Control Module towards J2 A C1 compressor and high fan should turn on If OK replace Control Module If NOT 1 Check wiring between PC2 and A C1 unit Slide test switch on Control Module towards J3 Rear compressor and high fan should turn on replace Control Module If NOT 1 Check wiring between and rear A C unit V ON indicator is lit but the furnace does not operate in HEAT mode at any thermostat setting A Check the fuse or circuit breaker feeding the furnace B Move the set point control up to the highest and down to the lowest temperature settings Somewhere in between these settings an audible click should be heard fro
7. the current being drawn by all of the 120 VAC electrical appliances including the air conditioners and will control the operation of the air conditioners to prevent them from over loading the circuit breakers Once the system turns the air conditioners off it will keep them off until there is enough power available to restore normal operation CAUTION The system has been designed to operate from 120 VAC 30 Amp service only Connecting the coach to any other power source will cause the system to operate improperly f only 20 Amp service is available load management must be done manually by the owner and only one air conditioner can be operated at a time unless the auxiliary generator is utilized 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www intellitec com 1 P N 53 00591 597 041205 ELECTRONIC CLIMATE CONTROL SERVICE MANUAL HOW IT WORKS The System contains two major components the ECC Thermostat and the ECC Control Module along with additional external sensors which are connected to these modules THE ECC THERMOSTAT The Thermostat allows the owner to set the A C1 and 2 air conditioning and heating systems modes and temperatures The electronics in this panel measure ambient temperatures via two external temperature probes front and rear Based on the mode and set point temperature settings the probes send appropriate control signals to the ECC Control M
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9. ELECTRONIC CLIMATE CONTROL SERVICE MANUAL ELECTRONIC CLIMATE CONTROL vy TEMP TEMP 90 HEAT 90 ie 2 OFF LOW FAN He HI FAN ie LOW COOL _ HI COOL _ l HI COOL 2 AUTO COOL AUTO COOL Mi 50 ONE sD A C1 2 00 00591 000 Master Controller 00 00597 000 Display Panel PRODUCT DESCRIPTION The ELECTRONIC CLIMATE CONTROL ECC System offers automatic and manual control of the A C1 and A C2 roof top air conditioners and furnace s in the Motor home The system includes an energy management system that shuts off the air conditioners when necessary to prevent electrical over load It also includes number of features that provide the owner with the most comfortable temperature controlled environment possible In the HEAT mode the system offers automatic control of the furnace s in a manner identical to standard wall mount thermostats In either the LOW COOL or HIGH COOL modes the air conditioner fans run continuously at the selected speed and the compressors are controlled to maintain the set point temperature When in the AUTO mode the unit automatically controls the compressors and selects the appropriate air conditioner fan speed based on the difference between the set point temperature and the ambient temperature in the Motor home In addition to controlling the temperature within the coach the system constantly monitors
10. Rev 041205 ELECTRONIC CLIMATE CONTROL SERVICE MANUAL Trouble Shooting If the following problems occur proceed with their analysis using the steps below in the order in which they are listed I No green ON indicator lit Thermostat in any functional position A Slide the test switch on the Control Module towards J2 A C1 compressor and high fan should turn on If NOT 1 Make sure that the power connector PC1A is plugged into J1 the control module Make sure that the pigtail keying matches connector keying 2 Check the 5A fuse in the distribution panel for Control Module power 3 Check for 12VDC atpin 4 of J1 on control module and ground at pin 6 Check the IPX SIG IPX GND connections to the ECC Thermostat If OK 1 Measure the DC voltage between the IPX SIG and IPX GND lugs and measure the voltage between pins 7 and 8 of J1 on the Control Module The voltage should read greater than 4 VDC and be the same at both locations Ifthe voltage is OK at both locations replace the Thermostat If NOT a Check the wiring b Replace the Control Il ON indicator is lit but the position of the set point temperature controls on the ECC Thermostat have no effect on heat and cool functions on either A C1 or A C2 systems In the HEAT mode the furnace stays on all the time In the COOL modes the fan comes on but the A C compressor never comes on A Check the installation of the Temperature probes The front p
11. VICE MANUAL USE WITH 5 KW GENERATOR In systems using 5 KW generator sets an additional change over or transfer relay is used to transfer the load of the larger A C system usually the front 1 system to the generator s second output to utilize generator s full output capability In this situation the ECC load shedding features will remain unchanged but the Current Sensor will not measure the load current going to the larger A C1 front system when the generator is running If the measured load currents through the current sensor continue to exceed 30 Amps with the smaller A C2 rear system shed the ECC Control Module will shed the larger A C1 front system to prevent over load of the generator BREAKER BOX AC1 2 BR1 CURRENT SENSOR BR2 BR3 30 SHORE POWER CORD 12 VDC POWER 5A FUSE TO RECEPTACLES 15A BRANCH CIRCUIT 3 15A BRANCH CIRCUIT 2 15A BRANCH CIRCUIT 1 RELAY CONTROLLED A C2 REARAIR CONDITIONER LOW VOLTAGE ECC CONTROL MODULE P N 00 00591 200 LOW VOLTAGE WIRING TRANSFER RELAY DELAY 0000568 000 5 0KW GENERATOR Intellitec www intellitec com 8 WALL MOUNT THERMOSTAT ELECTRONIC CLIMATE CONTROL THERMOSTAT P N 00 00597 000 or 100 TL Tt LOW VOLTAGE WIRING HEAT HIGH COOL AUTO COOL RELAY CONTROLLED A C1 FRNT AIR CONDITIONER 131 Eisenhower Lane North Lombard IL 60148 630 268 0010 1 800 251 2408 P N 53 00591 597
12. dding is active HIGH COOL The air conditioner fan is energized on high speed The air conditioner compressor is turned on when the ambient temperature is 2 degrees above the set point temperature and shuts off when the ambient temperature reaches the set point temperature Load shedding is active AUTOCOOL Both the air conditioner compressor and high fan are on when the ambient temperature goes 5 degrees above the set point temperature When the ambient temperature drops to within 2 degrees of the set point the fan switches to low speed When the temperature drops to the set point the compressor turns off When the ambient temperature drops 2 degrees below the set point the fan turns off As the ambient temperature rises the reverse procedure happens Load shedding is active INDICATOR LIGHTS There are two indicator lights on the control panel for each of the front A C1 and rear A C2 systems The green ON indicator will be lit when the associated function switch is in any mode except the OFF mode and the system has not shed the associated air conditioner compressor or fan The red SHED indicator will be lit when the associated function switch is in any mode except the OFF mode and the system has shed the associated air conditioner compressor or fan The ON and SHED indicators will blink alternately when the system is holding off operation of the air conditioner compressor during the 2 minute short cycle protection cycle see
13. ir conditioner fans and compressors It is often located under the refrigerator The circuitry in this module decodes the control signals sent to it via the multiplexed communication link from the ECC Thermostat The Control Module operates the furnace s by closing a set of relay contacts The relay contacts for the front furnace are connected to pins 1 and 2 of connector J4 and the contacts for the rear furnace are connected to pins 4 and 5 of the same connector The relay contacts are electrically isolated from all other circuitry on the Control Module The contacts are functionally equivalent to the contacts on a wall mounted thermostat and are wired to the blue and black thermostat leads from each furnace The coach may be equipped with one or two furnaces On coaches equipped with one furnace the furnace should be wired to pins 1 and 2 of connector J4 ELECTRONIC CLIMATE CONTROL ENERGY MANAGEMENT UNIT MASTER CONTROLLER J4 swich Y2 J1 LED 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www intellitec com 3 P N 53 00591 597 Rev B 041205 ELECTRONIC CLIMATE CONTROL SERVICE MANUAL The pigtail connector supplied with the system PC4 utilizes the following color codes PC4 4 FUNCTION COLOR pin 2 3 4 5 2 FRONT FURNACE THERMOSTATIBLAGK a reven norcomecte SSCs a Rear FURNACE THERWOSTATI UAGK ean FuRNAce THERWOsTAT LUE The
14. m the relay in the control module If NOT 1 Replace the Control Module Disconnect plug PC4 from the Control Module Placing a shorting jumper between PC4 pins 1 and 2 should cause the front furnace to energize Placing a shorting jumper between PC4 pins 4 and 5 should cause the rear furnace to energize If NOT 1 Check the wiring between PC4 and the furnace 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www intellitec com 10 P N 53 00591 597 Rev 041205 ELECTRONIC CLIMATE CONTROL SERVICE MANUAL VI SHED indicator is on in the HEAT mode A This occurs normally within 20 seconds of system power up Ifthe shed indicator stays lit and a test of the rest of the system functions checks OK replace the Thermostat VII SHED indicator is lit when in the FAN or COOL modes A Current draw is above 30 Amps Remove 120 VAC appliance loads from the line by turning off all of the breakers in the distribution panel other than the 30 Amp main and A C breakers If the SHED indicator still stays on replace the Control Module VIII ON and SHED indicators flash alternately in any of the COOL modes This occurs normally within a two minute period after the following situations 1 2 3 4 IX ON Shore power is plugged in Generator is started and shore power is not plugged in The 12 volt power to the control module is first applied The Control Module has
15. o note that if the Control Module has shed all four loads and the line current continues to exceed the 30 Amp limit it is likely that the 30 Amp line breaker will open ALTERNATING OPERATION If the total current being drawn is such that only one A C can operate and the ECC Thermostat continues to demand that both A C compressors operate the Control Module will alternate operation of A C1 and A C2 compressors every 30 minutes When the line current is low enough to allow operation of both air conditioners the Control Module will restore their operation in a reverse order to the shedding sequence The front A C1 or rear A C2 SHED indicators on the ECC Thermostat will remain lit until the corresponding A C compressor and fan are restored to normal operation SYSTEM INTERCONNECTS 12 VDC power is supplied to the Control Module via connector J1 This connector also provides the signal connections between the Control Module and ECC Thermostat and the Current Sensor Connector PC1B is part of the Current Sensor assembly The pigtail connector PC1A is supplied with the system and is wired per the following table 1 PC1B THE ECC CURRENT SENSOR The Current Sensor is a transformer which converts the AC current passing through its core into a corresponding voltage A functional Current Sensor has a resistance of approximately 40 Ohms and produces an voltage of 0 1 VAC per Amp of current passing through the core 10 Amps 1 0 VAC
16. odule These signals are sent via a two wire multiplexed communication link labeled IPX SIG and IPX GND There are two identical sets of controls on the panel one for each of the front A C1 and rear A C2 systems The potentiometers allow the user to select a desired temperature for each system in the range of 50 to 90 degrees Fahrenheit Moving the controls down lowers the set point temperature The two seven position function switches are used to select the furnace s and air conditioners operating modes Abrief description of each mode is as follows HEAT The Thermostat controls the furnace s to maintain the desired temperature in the coach The furnace s will be energized at an ambient temperature 2 degrees below the set point temperature and shut off when the ambient temperature is at the set point temperature Load shedding is not active in this mode OFF All control settings are disabled and the Thermostat is placed in a low current sleep mode in order to minimize battery drain 35 45 mA LOW FAN The air conditioner fan is energized low speed Load shedding is active HIGH FAN The air conditioner fan is energized on high speed Load shedding is active LOW COOL The air conditioner fan is energized on low speed The air conditioner compressor is turned on when the ambient temperature goes 2 degrees above the set point temperature and shuts off when the ambient temperature reaches the set point temperature Load she
17. robe should be connected to J1 and the rear probe to J4 on the Thermostat If OK measure the resistance of the Temp Probe at the connector Resistance should be 7 500 to 15 000 Ohms If NOT 1 Replace Temp Probe 2 Replace ECC Thermostat indicator is lit but the A C compressor never comes in either the LOW COOL HIGH COOL or AUTO COOL mode even when the set point control is set to its lowest cool position In the HEAT mode the furnace works properly in conjunction with the set point control Slide the test switch on the Control Module towards J2 Front compressor and high fan should turn on If NOT 1 Check to make sure that the leads on 2 are connected to their corresponding function at the A C1 unit The wire colors may or may not match Itis likely that the common and high fan leads are reversed 2 Check the continuity of the Comp Relay lead between the Control Module and the front A C unit 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www intellitec com 9 P N 53 00591 597 Rev 041205 ELECTRONIC CLIMATE CONTROL SERVICE MANUAL Slide the test switch on the Control Module towards J3 Rear compressor and high fan should turn on If NOT 1 Check to make sure that the leads PC3 are connected to their corresponding function at the A C2 unit The wire colors may or may not match Itis likely that the common and high fan leads are
18. shed an A C compressor because line current has exceeded 30 Amps If the indicators continue to flash after the two minute period replace the Control Module indicator is lit air conditioners won t function properly SHORT indicator is lit Control Moduleis ON A Oneormore of the wires to the air conditioner s are shorted to ground 1 Unplug either air conditioner connector J2 or J3 from the Control Module to see if the SHORT indicator goes out The other air conditioner should operate normally 2 Check individual wires of suspect connector for short to ground 3 Repair short in wires Temp Probe Cables 2 65 ft 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www intellitec com 11 P N 53 00591 597 Rev 041205 T Fa 2 O 2 T Tr SERVICE MANUAL YAMOd SONVHO Wows OVAOZL 000 200 100 N d YOSNAS LNIYYNO OL OVA0ZL YOLSINYSHL 000 69900 00 N d LINN OL SAVY LINN LNs ZON AHS Av Tad MOT nia NOWWOO ONS er 26 59 8 HOLIMS 1891 2 002 16900 00 N d AINGOW 293 YOLOW 13A TVNOIS Xdl LON daHS NO 1009 OLNV 1009 OLNV 1009 1009 1009 1009 MOI NY4 H IH NY
19. the Control Module The wire colors emanating from the A C1 and A C2 units may or may not agree with these colors Always refer to the installation manual supplied with the A C unit or see Identifying control lead functions on the A C unit in order to match the wire color functions with those on the Control Module 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www intellitec com 4 P N 53 00591 597 Rev 041205 ELECTRONIC CLIMATE CONTROL SERVICE MANUAL TEST SWITCH The Control Module incorporates a three position test switch located between J2 and J3 to verify proper wiring to each A C unit relay Sliding the test switch towards the J2 operates A C1 and high fan by connecting J2 3 and J2 4 to 12V Sliding the test switch towards the J3 operates A C2 and high fan by connecting J2 3 and J2 4 to 12V The test switch must be placed in the CENTER or OFF position for normal operation SHORT INDICATOR The 12 volt wires feeding the air conditioners are protected from short circuits If any of these wires are shorted to ground the SHORT indicator will be lit indicating the short To help locate the short the plugs feeding the air conditioners should be unplugged one at a time to see which cable is at fault When the shorted cable is unplugged the SHORT indicator will go out and the other air conditioner will operate normally The individual wires of the shorted plug can be tested
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