newmar tech 98 08 07...bridge the main control and lighting control subsystems to allow generator...

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Technical Details

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Various Modules Used•Essex•King Aire

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Control Module

Types of Modules at Newmar

400ECM Electronic Control ModuleRelated Parts : Bezel and Graphic Overlay (Artwork)Calibration: Touch Regions RequiredWhere Used:

•Main System Control: Essex and King Aire•Lighting Control: King Aire Lighting ControlActs as an Interface to the system

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Control Module Graphic Overlay (Artwork)Types of Modules at Newmar

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Control Module PagesTypes of Modules at Newmar

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Module Specifics: Electronic Control Module400ECM – Electronic Control Module

•Cleaning

A soft lint-free cloth may be used dry, or lightly dampened with a mild cleaner.

Be sure the cloth is only lightly dampened, not wet. Never apply cleaner directly to touch panel surface, avoid contact with the edges of the film or glass, and with the flex-tail.

•Battery Life

All of the program data is stored in non-volatile EEPROM memory which is good for decades.

The battery is used only for calendar / time

Estimated battery life : 3 Years

Battery

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User Interface Modules


367TPD Touch Panel DisplayRelated Parts : Bezel and Graphic Overlay (Artwork)Calibration: Touch Regions RequiredWhere Used:

•Main System Control: Essex and King AireTank Bay Display

416TPS Touch Panel SwitchRelated Parts : Bezel and Graphic Overlay (Artwork)Calibration: Touch Regions RequiredWhere Used:

•Lighting Control King Aire : Kitchen•Optional: Bedroom, Bathroom, Stool Room, Dinette, Sofa and Living areas.

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FocusFocus –– 367TPD & 416TPS LED and Regions Configurations367TPD & 416TPS LED and Regions Configurations

Module Specifics: Touch Panel Display & Switch

367TPD367TPD 416TPS416TPS

LED 1

LED 2

LED 3

LED 4

LED 5

LED 6

LED 1

LED 7 (1B)

LED 3

LED 9 (3B)

LED 5

LED 2

LED 8 (2B)

LED 4

LED 10 (4B)

LED 6

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User Interface Modules


350LCD Touch Screen LCD (10”)Related Parts : NoneCalibration: Graphics and Design FilesWhere Used:

•Optional : Main System Control: King Aire

Consists of pages of information group such as:HVAC, Inverter, Energy Management, Generator, Preferences

345LCD Touch Screen Display (5.7”)Related Parts : NoneCalibration: Graphics and Design FilesWhere Used:

•Main System Control: Essex and King Aire•Optional: Bedroom and Additional Display

Consists of pages of information group such as:HVAC, Inverter, Energy Management, Generator, Preferences

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345LCD 5.7” LCD Display Pages


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System Interface Modules

361SIM Magnum Inverter InterfaceRelated Parts : NoneCalibration: NoneWhere Used:

•Main System Control: Essex and King Aire

360ACI Air Conditioning InterfaceRelated Parts : NoneCalibration: NoneWhere Used:

•Main System Control: Essex and King Aire

387EBM Bridge ModuleRelated Parts : NoneCalibration: NoneWhere Used:

•Main System Control: King AireBridge the main control and lighting control subsystems to allow generator and water pump control.

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Sensing ModulesTypes of Modules at Newmar

303TM1 Ambient Air SensorRelated Parts : NoneCalibration: Temperature CoefficientsWhere Used:

•Main System Control: Essex and King AireTemperature Zones 1-4 and Outside

318PFTG Pressure Tank Fuel GaugeRelated Parts : NoneCalibration: Tanks Shape CalibrationWhere Used:

•Main System Control: Essex and King AireFresh, Gray and Black Water Levels

319RSM Resistive Sense ModuleRelated Parts : NoneCalibration: Value Calibration Table RequiredWhere Used:

•Main System Control: Essex and King AireLP Gas Tank

336PFM Power Frequency ModuleRelated Parts : NoneCalibration: NoneWhere Used:

•Main System Control: Essex and King AireAC Distribution Measures Frequency, Volts, Current

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DC Distribution Modules Note: DC modules protected “Upstream” via traditional circuit protection.


325QMM Quad-MultimoduleRelated Parts : NoneCalibration: NoneWhere Used:

•Lighting Control: King Aire Lighting ControlBuilt-in dimming, (2 Channels) low limit detection and settable trip speed.Max 5 Amps per channel, 20 Amps TotalChannels can be used as inputs or outputs

366HMM Hexa-MultimoduleRelated Parts : NoneCalibration: NoneWhere Used:

•Lighting Control: King Aire Lighting ControlBuilt-in dimming, (2 Channels) low limit detection and settable trip speed.Per Channel Manual OverridesMax 15 Amps per Channel, 50 Amps TotalChannels can be used as inputs or outputs

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Distribution Modules : Indicators and Connections

A View of a DC Distribution (366HMM) Module Showing Status LEDs, Manual Overrides and Various Connections.

Channels: For AC & DC Distribution modules output is typically referred to as a channel and most distribution modules have many channels.

E-Plex Stream Activity Indicator: Most modules have a status LED that indicates the system is streaming Helpful in determining clock and the module are communicating.

Channel Status Indicators:On, Off, Blinking - Fault

Connecting E-Plex Data Lines:If E-Plex data bus connections positive (+) and negative (–) arereversed:•The module will not be harmed. However it will not operate.

Separate power feeds: Shouldnot be reversed as this could damage the module.

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Over CurrentTrip points and time duration via user programmable software settings.

Internal Short CircuitIf internal temperature exceeds designed operating limit module will shut down (Inrush).

Thermal Disconnect High Surge Currents / Voltages – Guard against failing to a thermal runaway condition.

Last Line of Defense : Zipper FuseUpon reaching amperage limit will disconnect loads from power source.

E-Plex Distribution Modules: Circuit ProtectionDistribution Modules: Circuit Protection

Power feed to module should always be protected with a traditional circuit breaker to

limit total current to the module.

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DC Distribution ModulesTypes of Modules at Newmar

369DRM Dual Reversing ModuleRelated Parts : NoneCalibration: NoneWhere Used:

•Lighting Control: King Aire Lighting ControlCan be used to drive motors forward and reverse.TV Lift, Shades and Curtains in various rooms

Note: DC modules protected “Upstream” via traditional circuit protection.

356DRIM Dual Relay Input ModuleRelated Parts : NoneCalibration: NoneWhere Used:

•Main System Control: Essex and King AireGenerator, Oasis Remote and Fan Control

•Lighting Control: King Aire Lighting ControlLights and Curtains in various roomsOptional Bath Vanity and Cosmetic Lights

Output relay contacts rated for 10 amps AC or 5 amps DC4 digital inputs active high or active low

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DC Distribution ModulesTypes of Modules at Newmar

172QR Quad Relay ModuleRelated Parts : NoneCalibration: NoneWhere Used:

•Lighting Control: King Aire Lighting ControlStool Room Lights, Fan and Heater

Note: DC modules protected “Upstream” via traditional circuit protection.

149CT30 Single 30Amp Relay ModuleRelated Parts : NoneCalibration: NoneWhere Used:

•Main System Control: Essex and King AireBlock Heater and Water pump

•Lighting Control: King Aire Lighting ControlFan and LightsOptional Bath Fan

Switches heavier loads

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E-Plex Module Details

What makes a module work:

Hardware : The Physical Module

Firmware : The programming that tells the module how to do its job.

Programming : Set points, trip points and speed, dimming settings, touch regions

Calibration Data : Tank Characteristics

Graphics : Files and Physical Overlays

Factory

Field

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Module Details : Optional Modules

Optional Modules:

•Program information for optional modules is retained in the Clock Module.

•They can be installed or removed in the field.

•Optional modules can be reset from the clock should they be removed.

•When adding optional modules be sure not to break the unique address rule.

Unique Address Rule: Only ONE module at a BLANK address can be installed at a time.

Otherwise an error will occur during programming (Unique Addresses!).

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Exercises:•Status Indication•Start Stop Streaming•Optional Modules•Interrogate Module for Hardware / Firmware Version•Search for Modules•Program Modules

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Clock Status and Diagnostics

UP DN STOP

Modules Found: 18 of 20

UP DN STOP

Missing Modules : Address : 84

Holding down on the AC Systems Button for 8 Seconds will display the status page.

Status Page : Missing Modules

Missing Modules:

UP DN STOP


UP DN STOP

Missing Modules : None

Missing Modules:

UP DN STOP


UP DN STOP


Active Touch Regions:

UP and DN: Scroll through the missing modules if there is more than 1

STOP: Halts System Communication (Streaming)

Touch Anywhere to Exit Diagnostics

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EE--Plex InterfacePlex Interface

E-Logic : E-Plex Interface

318PTFG Module Test Program – Calibration Mode

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Wiring and Bus Topologies

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Wiring and TopologyElectronic Control Module

•WiringShared Communication Channel

E-Plex 1: Bilge E-Plex 3: BridgeE-Plex 2: Port Bus E-Plex 4: Starboard Bus

Possible Wiring Configurations

Understanding the wiring configuration is important when diagnosing problems…

Why?

Note: Wiring DistanceFrom the Electronic Control Module 100’-200’

Depends on Module Type and Location.

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DC DistributionDC Distribution•• DC Distribution Modules are distributed throughout the vessel DC Distribution Modules are distributed throughout the vessel

close to the loads they control.close to the loads they control.–– If a module is damaged or fails where is it? If a module is damaged or fails where is it? –– How can it be isolated?How can it be isolated?

Wiring and Topology

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Important Information to share with customer / dealer / end user

For each module:•Provide the unique address & part number of each module.

•Specify which bus the module is connected to.

•A description of the module – DC, AC, Sensor

•A description or diagram of where the module located.

•What is connected on each channel.

Wiring and Topology

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1 578 Cockpit Color Rocker Switch (4 Positions)

1 961 Bilge Port Aft Port Aft Bilge Module1: Aft Bilge Lighting2: Aft Bilge Pump3: Aft Bilge Pump Float Switch4: Emergency Bilge Pump5: Unused6: Vacuum Pump

1 102 Cabin Fwd Bulkhead Forward Bilge Module1: Forward Bilge Lighting2: Forward Bilge Pump3: Forward Bilge Pump Float Switch4: Unused5: Port Bilge Blower6: Starboard Bilge Blower

1 132 Bilge Fwd Bulkhead Dual Reversing Module1: Windlass Solenoid Control2: Generator Solenoid Control

1 120 Bilge Fwd Bulkhead Solenoid Control Module1: Emergency Start Battery Switch Open2: Battery Switch A Closed3: Battery Switch A Open4: Battery Switch B Closed5: Battery Switch B Open6: Emergency Start Battery Switch Closed

+ E-Plex 4 : Starboard Bus+ E-Plex 3 : Bridge Bus+ E-Plex 2 : Port Bus+ E-Plex 1 : Bilge Bus

Bus | Address | Description• Channel ID: Description

Important Information to share with customer / dealer / end user

An Example:

Wiring and Topology

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400ECM Clock Diagnostics

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Electronic Control Module•Diagnostics Notification for Module and System Wide Status:

•Missing Modules•System Errors

Halt System Communication for : •Operation of Module Manual Overrides •Programming All or Specific Modules •Reset Optional Modules

Clock Modes•Streaming : Normal Operation•Streaming Inactive : Diagnostics Mode

Diagnostics Overview

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Electronic Control Module•Diagnostics

UP DN STOP


UP DN STOP


Holding down on the AC Systems Button for 8 Seconds will display the status page.

Status Page : Missing Modules

Missing Modules:

UP DN STOP


UP DN STOP


Missing Modules:

UP DN STOP


UP DN STOP


Active Touch Regions:

UP and DN: Scroll through the missing modules if there is more than 1

STOP: Halts System Communication (Streaming)

Touch Anywhere to Exit Diagnostics


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400ECM 400ECM –– DiagnosticsDiagnosticsCapabilities of the 400ECM for the entire E-Plex System

Because the electronic control module is necessary to coordinate communication between modules it also has the ability to display status information while providing maintenance and programming capabilities.

Status Information

If a module failure should be suspected or a system error message is displayed, further detail is available on the status page.

•By pressing the “Status” button, the status page will be displayed. As shown in figure 1, there should be three modules however only one has been found.

•“UP” and “DN” buttons will scroll through the missing module addresses.

•“ENTER” button will exit the status page.

Figure 1 – System Status

Missing Modules:

UP DN STOP

Modules Found:1 of 3

Missing Modules:Address: 84

UP DN STOP


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400ECM 400ECM –– DiagnosticsDiagnosticsMaintenance and Programming Capabilities

Each modules unique program is stored to support module replacement in the event of a failure. Once a replacement module has been installed it needs to be programmed so that system functionality can be restored.

•From the status screen shown (figure 1) press the “STOP” button. The main programming page is displayed (figure 2).

“STREAMING: INACTIVE” means normal communication is halted between the modules and the electronic control module.

•The system will now allow programming and operation of manual overrides at the module.

•Command Buttons for specific diagnostic tasks:

“RST” – Reset all optional modules. “ALL” – Re-Program all modules on the system.“STR” – Return to the system status page (figure 1).

Note: System will return to an operational state.“PRG” – Display the Programming Page (figure 3).

Figure 2 - Streaming Inactive

Figure 1 – System Status

Figure 3 – Programming Page

Missing Modules:

UP DN STOP


Missing Modules:Address: 84

UP DN STOP


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400ECM 400ECM –– DiagnosticsDiagnosticsMaintenance and Programming Capabilities – Continued

The Programming Page – Used to program individual modules using the unique module program stored in the 400ECM.

“UP” & “DOWN” – Scroll and Select the address you wish to program.

“PRG” – Begins the process of programming the selected module. Upon completion the message “PROG SUCCESS” (figure 4) will be displayed meaning that the module has been programmed successfully and should be operational once exiting.

This process can be repeated if more than one module should need replaced.

In the event that programming is not successful one of the following error messages will be displayed:

Time out programming module Data error programming module Time out verifying module. Data error verifying the moduleModule did not verify correctly.

Once programming is complete:Press “EXT” to return to the main programming page.Press “STR” to bring system online.

Figure 3 – Programming Page

Figure 4 – Programming Complete


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Missing Modules:

UP DN STOP

STREAMING: INACTIVE

RST ALL STR PRG

RST Resets Optional ModulesALL Program All ModulesPRG Program a Specific ModuleEXT Return to the Status Page

Electronic Control Module•Streaming Inactive : Halt System Communications

When the communication is halted the system is in Diagnostic Mode …

•Interfaces and Switches are non-functional.

•AC and DC Distribution Module Manual Overrides are Enabled and can be used to test the function of specific channels.

•Programming of all or specific modules can be performed allowingreplacement of damaged or faulty modules

•Optional modules can be reset

Streaming Inactive PageActive Touch Regions:


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Missing Modules:

UP DN STOP

STREAMING: INACTIVE

RST ALL STR PRG

Electronic Control Module

•Streaming Inactive : Halt System Communications

Using manual overrides on AC and DC Distribution modules to test the function of specific channels.

Manual Overrides1 102 Cabin Fwd Bulkhead N10 Forward Bilge Module1: Forward Bilge Lighting2: Forward Bilge Pump3: Forward Bilge Pump Float Switch4: Unused5: Port Bilge Blower6: Starboard Bilge Blower

1 132 Bilge Fwd Bulkhead N13 Dual Reversing Module1: Windlass Solenoid Control2: Generator Solenoid Control

1 120 Bilge Fwd Bulkhead N15 Solenoid Control Module1: Emergency Start Battery Switch Open2: Starboard Battery Switch Closed3: Starboard Battery Switch Open4: Port Battery Switch Closed5: Port Battery Switch Open6: Emergency Start Battery Switch Closed

DC Distribution


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Reversing E-Plex Data Lines

If E-Plex data bus connections positive (+) and negative (–) are reversed:

•The module will not be harmed. However it will not operate.

•Separate power feed should not be reversed as this could damage the module

Replacement of Modules

•Replacement Modules may ship at a “Blank Address”

Allows for identification and programming once installed.

Only ONE module at a BLANK address can be installed at a time. Otherwise an error will occur during programming (Unique Addresses!)

Modules may also include custom graphics and / or calibration data


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Missing Modules:

UP DN STOP

STREAMING: INACTIVE

RST ALL STR PRG


•Programming a Replacement Module (Blank Address)

Once the replacement module is installed and power restored:

• From the status page on the Electronic Control Module press the STOP regionon the blue screen.

• Press PRG to display the Programming Page.

• The UP or DN regions select the particular address / module to program.

Note: If replacing more than one module please check the following

•The address is selected that corresponds to the replacement module•It is the only Blank Module connected to the system

• Press PRG to begin the programming process for the selected module. •Various status messages will be displayed during the process.•Prog Success ! will be displayed once complete.

• Once complete press EXT to return to the STREAMING INACTIVE page• Press STR to bring the system online.

• The status page should now display all modules found, Missing Modules : None

UP DN STOP


UP DN STOP


Missing Modules:

UP DN STOP

ProgrammingMode

Module : 84

UP DN PRG EXT

Missing Modules:

UP DN STOP

Programming Mode

Module : 84Programming…Prog Success !

UP DN PRG EXT

Missing Modules:

UP DN STOP

ProgrammingMode

Module : 84

UP DN PRG EXTUP DN STOP


UP DN STOP


Missing Modules:

UP DN STOP

STREAMING: INACTIVE

RST ALL STR PRG

1

2

3

4

5

6

1

2

3

4

5

6


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Clock Diagnostic Display Summary

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Diagnostic Displays from a 400ECM or 450ECM “Clock”

Missing Modules:

UP DN STOP

STREAMING: INACTIVE

RST ALL STR PRG

UP DN STOP


UP DN STOP


Streaming Inactive•System is non-functional, used for module programming.•E-Plex Green Status LED WILL NOT be flashing or on at each module.•AC & DC Distribution Modules: Manual Overrides are Active•Displays, Touch Screens, Switches: Non-Functional

•If Replacing more than one module at a BLANK address:•Only ONE MODULE can be Connected at a time•For either a Program Module or a Program All.

System StatusUsually Accessed by Holding down a button for 8-10 Seconds•System is fully functional.•E-Plex Green Status LED WILL be flashing or on at each module.•AC & DC Distribution Modules: Manual Overrides are not active•Displays, Touch Screens, Switches: Functional

•Information Displayed: Missing Module and its Address•To have missing modules indicates that a module at a particular address is not communicating with the clock. •UP and DN: will scroll thorough modules that are missing.Consult appropriate reference material for module location and description information. •STOP: Stops the System (Streaming Inactive)•Symptoms include various features non-functional that would ordinary be provided at that module.

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Missing Modules:

UP DN STOP

Data Error INACTIVE

RST ALL STR PRG

Data Error!•System is NOT functional•Appears Automatically on the Clock•AC & DC Distribution Modules: Manual Overrides are Active•Displays, Touch Screens, Switches: Non-Functional

•A Module has become faulty that is connected to the system or two modules may have been programmed at the same address. •Isolate the Module or Modules:

•Disconnect Modules starting at the four E-Plex Pairs in the back of the clock one by one until the error goes away to determine which leg or bus has the faulty module. •After reconnecting the faulty pair in the back of the clock, disconnect each module one by one until the error goes away to determine which module or modules is at fault.

Rear View of Clock Module


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Missing Modules:

UP DN STOP

STREAMING: INACTIVE

RST ALL STR PRG

Programming a Replacement Module (Blank Address)Once the replacement module is installed and power restored:1.From the status page on the Electronic Control Module press the STOP region on the blue screen. 2.Press PRG to display the Programming Page. 3.The UP or DN regions select the particular address / module to program.

• Note: If replacing more than one module please check the following• The address is selected that corresponds to the replacement module• It is the only Blank Module connected to the system

4.Press PRG to begin the programming process for the selected module. • Various status messages will be displayed during the process. • Prog Success ! will be displayed once complete.

5.Once complete press EXT to return to the STREAMING INACTIVE page6.Press STR to bring the system online. 7.The status page should now display all modules found, Missing Modules : None

Note: During a Program All you may see Prog Time Out at particular addresses. • This may mean that various modules are options and are not present. • This can also mean that a present module is not connected to the system or operating correctly.

These modules will show up as missing modules once the status pages is displayed (step 7).

UP DN STOP


UP DN STOP


Missing Modules:

UP DN STOP

ProgrammingMode

Module : 84

UP DN PRG EXT

Missing Modules:

UP DN STOP

Programming Mode

Module : 84Programming…Prog Success !

UP DN PRG EXT

Missing Modules:

UP DN STOP

ProgrammingMode

Module : 84



UP DN STOP


Missing Modules:

UP DN STOP

STREAMING: INACTIVE

RST ALL STR PRG

1

2

3

4

6

7

5

Reversing E-Plex Data LinesIf E-Plex data bus connections positive (+) and negative (–) are reversed:•The module will not be harmed. However it will not operate. •Separate power feed should not be reversed as this could damage the module

Very Important•Replacement Modules may ship at a “Blank Address”Allows for identification and programming once installed.

Only ONE module at a BLANK address can be installed at a time. Errors will occur during programming (Unique Addresses!) if morethat one “Blank” Modules are Connected at one time.


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•Streaming Inactive : Programming a Replacement Module

Blank Address

UP DN STOPUP DN PRG EXTUP DN STOPUP DN STOP

DEMONSTRATION

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Common DiagnosticScenarios

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Common Diagnostics Scenarios

A Few Common Diagnostic Scenarios …

•Non-Functional Feature / Module

•Non-Functional System “System Error”

•Everything Looks Fine Nothing Works Error

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Common Diagnostic Scenarios

•Non-Functional Feature or Module

3 Strategies

•Isolate the Control Points

•Isolate the Module

•Wiring Issues

Manual Overrides

Manual Overrides


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Manual Overrides

Manual Overrides

Isolate the Control Points:

•Where is this feature controlled from?

•Do other features work from the same control point?

•Verify Modules Subject to Environmental Failure (Tank Senders, Rocker Switch Panels).

•From the status page on the Electronic Control Module:

Are there any modules missing? (Figure 1)


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Isolate the Module:

•Since one module can control many loads; locate the module controlling the feature in question, are other features connected to this module operating as expected?

•Stop Streaming and use the manual overrides to verify the operation of each channel.

Manual Overrides

Manual Overrides


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Wiring Issues:

•Supply Power•E-Plex Data Lines•Individual Channels / Loads

Manual Overrides

Manual Overrides


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•Non-Functional System “System Error”•Consider First Modules Subject to

Environmental Failure (Tank Senders, Rocker Switch Panels).

•Any Recent Changes to the System? – Undo!

•Prune the E-Plex Data Bus to Isolate the Module.

•1) Start by disconnecting each leg from the Electronic Control Module.

•2) Narrow to fewer modules.

•3) Isolate each module.

Missing Modules:

UP DN STOP

Programming Mode

Module : 84



UP DN STOP


System Error !

Bus Configuration


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•Everything Looks Fine Nothing Works Error

From the Status Page (Figure 1): No Module Miscounts or System Errors…

The Entire or Majority of the system does not work!

1.) Stop Streaming2.) Do a Program All

•Watch for Messages3.) Start Streaming4.) Exit the Status Page

Figure 1 – Status Page


Missing Modules:None

System Error!UP DN STOP



UP DN STOP




STEAMING:INACTIVE

RST ALL STR PRGV2.06 rev B2




Are you sure you wish to do a Program All?

No No No Yes




STEAMING:INACTIVE

RST ALL STR PRGV2.06 rev B2

Why?Some modules may have been programmed with a different compiled version of the original master program.

By doing a Program All from the Electronic Control Module, all modules now have the same compiled version.


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Thank You

newmar tech 98 08 07...bridge the main control and lighting control subsystems to allow generator...

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