Cummins Onan. Energy Command 30. Manual - part 3

Page 9

• Brake: Brake light for all trailer, 5

wheel, and

pickup camper installations, or air brake on
diesel motor homes.

• Park: The park signal/neutral (transmission)

from motorized motor homes or van
conversions.

Press ENTER to store in permanent memory. This
will not have to be changed unless the type of safety
input is changed or the EC-30 is installed in a different
application.

Setting START/STOP @ Values - General

When AUTO< is selected Quiet Time prefill (charging
the battery two hours prior to the beginning of Quiet
Time) occurs if the battery level is less than FULL (all
three bars of the level gauge are on).

Care should be taken changing the settings. It is
recommended that these setting only be changed by
qualified personnel that understand the charging
system and have checked its operating voltages.

If STOP @ V has been changed to a user defined
value, then pre-fill occurs whenever the battery voltage
is less than the STOP @ V voltage setting.    When the
battery is full or reaches the user set STOP @ V the
genset will be stopped.

START @ V

The START @ V is the voltage to which the house
battery must fall to cause the genset to automatically
start due to a low battery. The default value is Auto
which starts the genset when one bar is displayed in
the battery level indicator. See the Operation section of
this manual. The START @ V voltage range is 10.5-
12.5 volts. A lower voltage will decrease the number of
starts due to a low battery. A higher voltage will
increase the number of start due to a low battery.
Setting the START @ V too high may result in frequent
“false” starts due to a “low battery” start.

Time @ START V

The Time @ START V is the length of time that the
house battery voltage must be below the START @ V
voltage before the genset will automatically start. The
default value is 15 seconds. The range is 5-60
seconds. Setting a shorter time will increase the
number of generator starts due to temporary voltage
dips, (increase the “sensitivity” to voltage dips). Setting
a longer time will decrease the “sensitivity” to
temporary voltage dips.

STOP @ V

The STOP @ V is the voltage to which the house
battery must rise to cause the genset to automatically

stop due to a full battery. The default value is Auto
which stops the genset when three bars are displayed
in the battery level indicator. See the Operation section
of this manual. The STOP @ V voltage range is 13.2-
14.5 volts. A lower voltage will not fill the battery as full
but it will reduce the amount of time the genset will run.
A higher voltage will fill the battery to a higher state of
charge, but increase the amount of genset run time. If
the charge system is unable to reach the STOP @ V
voltage, the result will be excessive genset running.
This setting does not change the battery charging
voltage.  Do not set STOP @ V above the voltage of
the battery charger.

Time @ STOP V

The Time @ STOP V is the length of time that the
house battery voltage must be above the Stop @ V
voltage to cause the genset to automatically stop due
to a full battery. The default value is one minute. The
range is 1-60 minutes. Setting a shorter time will
decrease the genset run time. Setting a longer time
will increase the length of time the genset runs to
charge the battery.

Selecting Appropriate Values

The selection of the start and stop voltages and the
time required to be at those voltages requires trade-
offs. It is a balance between the number of genset
starts, the length of genset run time, and the desired
battery charge level. The default values have been
selected to ensure that the battery stays charged and
the genset does not run excessively or needlessly start
for temporary voltage excursions. We recommend the
default values be used until the performance of the
system can be assessed.

Setting the START @ V higher will result in more
genset starts and a quicker response to voltage dips.
Setting the Time @ START V shorter will also increase
the response to voltage dips. Both will cause more
genset starts.

Setting the STOP @ Voltage higher will result in more
genset starts and shorter genset runtimes for battery
charging. Setting the Time @ STOP V longer will
increase the genset runtime for battery charging.

Remember charging current falls to very low levels at
the end of charge. Typically it is preferred to use shore
power and not the genset to “top off” or fully charge the
battery. Avoid running lightly loaded gensets. Run
the system through a complete automatic start/stop
cycle after changing setting to confirm proper
performance.

Page 10

Effect of Increasing START @ V OR Time @ START V

Effect of Increasing

# Starts

Runtime

Battery Level

START @ V

Less

Higher

Time @ START V

Less

Higher

STOP @ V

Less

Higher

Time @ STOP V

Less

Higher

TEST SYSTEM Displays

The TEST SYSTEM displays (see Figure #3 TEST
SYSTEM Displays) are used by the installer to verify all
input are connected and operate, and to test run the
genset. After installation the TEST SYSTEM displays
can be used to verify correct operation or to assist in
troubleshooting the system. The various test displays
request a specific action from the operator and
acknowledges that the action has been correctly
observed.

To ensure an orderly process be sure the GENSET
MODE is MANUAL and all inputs are in the off state
before beginning the test.   Meaning there are no
HVAC run requests, the ignition is off, the park brake
(or brake lights for a trailer) is off, and there is no shore
power connected.

SAFETY TEST Display

The SAFETY TEST display is used to verify the safety
input is operating correctly. The safety input may be
connected to the:

• Ignition: Input is connected to the vehicle

ignition system (motor homes or van
conversions).

• Brake: Brake light for all trailer, 5

wheel, and

pickup camper installations, or air brake on
diesel motor homes.

• Park: The park signal/neutral (transmission)

from motorized motor homes or van
conversions.

The safety type that is set is displayed.

To check proper operation, navigate to the SETUP &
INFO and press ENTER. Now go to the TEST
SYSTEM display and press ENTER again. SAFETY
TEST will be the first display, press ENTER. The
display will either say IGNITION, or BRAKE, or PARK,
ON & OFF. After the EC-30 sees the change of state
of the safety input it will display the safety type and ok
ENTER.  Pressing ENTER will acknowledge its correct
operation and exit back to the SAFETY TEST display.

HVAC (RUN REQUEST) Display

The HVAC RUN REQUEST system is tested by
sequentially turning on and off each input. There may
be up to three inputs. From the TEST SYSTEM
display, press ENTER and then navigate to HVAC
RUN REQUEST. Press ENTER. The first display will

say TURN ON HVAC1. It makes no difference which
HVAC system is connected to which terminal. Simply
turn on one, and leave all others off. If the EC-30
detects the input, the display will change to say HVAC1
OK Turn Off. Now turn off the HVAC. The displays will
now ask that HVAC2 be turned on. Turn on the next
HVAC unit and follow the displayed instructions. This
process allows a quick test of all HVAC RUN
REQUEST inputs. If there is only one or two HVAC
inputs, use the UP/DOWN key to go to the last display
which is ENTER to Exit.

Run Gen Display

Before testing the genset be sure that the location
is safe for running the genset and that its
installation is completed. This test verifies that the
start, stop, and switched B+ signals between the EC-
30 and the genset are ok. Navigate to the display that
says ENTER to Run Gen. Pressing ENTER will begin
a start and stop sequence which can only be
interrupted by manually stopping the genset using the
STOP switch. The EC-30 will go through a complete
start and stop sequence and it will display its results as
the test is happening. When the test is complete the
display will say Gen Ok ENTER. Pressing ENTER will
exit back to the display that says ENTER to Run Gen.
To continue testing other system components use the
UP/DOWN key for the next display.

Testing Shore AC Present

This test verifies that the EC-30 can sense when AC
power is available from the utility grid. Before starting
this test be sure that the Shore AC is disconnected.
Turn off the AC breaker at its supply or unplug the
vehicle or trailer from the AC grid system. Do not do
this test with the genset running. Navigate to the
Shore AC Present display and press ENTER. The
display will say Turn On Shore AC. Now plug the
shore AC back in or turn the breaker on. The display
will change to read AC Ok ENTER. Press ENTER to
exit the test.

Exiting TEST SYSTEM

To exit TEST SYSTEM use the UP/DOWN key until
ENTER to EXIT is displayed. Press ENTER and press
DOWN once and ENTER to Exit will be displayed.
Pressing ENTER will exit to the Main Display.

Page 11

Installing the Energy Command 30

Overview

This section describes how to install the Energy
Command 30 (EC-30).

General

This system is only for use with Onan Recreational
Vehicle genset (Quiet Diesel gensets, and
Gasoline/LP gensets).

The control circuitry is a 3-wire ground to start/stop
type. Before installing, refer to the System Diagram,
Figure 4, and select the appropriate wiring diagram,
Figures 5-7, for connection to your genset. Consult
an Onan distributor with any questions.

Appendix A shows the Onan gensets that are
compatible with the EC-30 and the correct wiring
figures and harnesses to use for each genset.

!CAUTION! For personal safety and prevention of
equipment damage, only experienced personnel
should install this system. The installer must wear
safety glasses and protective clothing necessary
for personal safety.

Installation Precautions

CAUTION! Always disconnect a battery charger
from its AC source before disconnecting the
battery cables. Otherwise, disconnecting the
cables can result in voltage spikes high enough
to damage the DC control circuits of the genset.

! WARNING! Unexpected starting of the genset
set while working on it can cause severe
personal injury or death. Prevent unexpected or
accidental starting by disconnecting the genset
battery cables {negative (-) first}, or by
disconnecting the remote harness at the genset.

!WARNING! Arcing can ignite explosive
hydrogen gas given off by batteries, causing
severe personal injury. Arcing can occur if the
negative (-) battery cable is connected and a tool
being used to connect or disconnect the positive
(+) battery cable accidentally touches the frame
or other grounded metal part of the genset set or
vehicle frame. To prevent arcing always remove
the negative (-) cable first, and reconnect it last.

Specifications

Operating
Temperature:

-20 to 70 degrees C
(-4F to 158F)

Storage
Temperature:

-40 to 70 degrees C
(-40F to 158F)

Battery System:

12 Volt DC

Voltage Range:

8 – 35VDC

Typical Current
Draw:

47mA @ 12V

L x W x D:

80.98 x 130.12 x 30.48 mm
(3.188 x 5.125 x 1.20 inches)

INSTALLATION CODES AND
STANDARDS FOR SAFETY

The vehicle builder or EC-30 installer bears sole
responsibility for the appropriate selection of
components, for proper installation and for obtaining
approvals from any authorities having jurisdiction for
the installation. EC-30 is suitable for installation in
accordance with:

• ANSI A 1192 (NFPA No. 1192)-Standard on

Recreational Vehicles

• NFPA No.70, Article 551-Recreational

Vehicles and RV Parks

• CAN/CSA-Z240.6.2 Recreational Vehicles

Federal, State and local codes, such as the California
Administrative Code - Title 25 (RV installation), might
also be applicable. Installation codes and
recommendations may change over time and vary
between countries, states and municipalities. It is
recommended that the standards in Table 2 be
obtained for reference.

TABLE 2 REFERENCE CODES AND STANDARDS

NFPA 70

National Electric Code

National Fire Protection

Association

470 Atlantic Avenue

Boston, MA 02210

ANSI A119.2 (NFPA 1192)

Standard on Recreational

Vehicles

Recreational Vehicle
Industry Association

14650 Lee Road

Chantilly, VA 22021

California Administrative Code

Title25, Chapter 3

State of California

Documents Section

P.O. Box 1015

North Highlands, CA 95660

CAN/CSA-Z240.6.2

Recreational Vehicles

Canadian Standards

Association Housing and

Construction Materials Section

I178 Rexdale Blvd

Rexdale, Ontario, Canada

M9W 1 R3

Page 12

OEM Supplied Equipment

Required for Installation

Manufacturer & PN

Mating Connector Housing

Tyco/AMP 770583-1

Pins (Up 16 required)

Tyco/AMP 171637-1

2 or 3 5A DC Inline Fuses

Installers choice

Tools

Pro-Crimper II W/Die 16-20

Tyco/AMP 189727-1

Contact Extraction Tool

Tyco/AMP 90760-1

Removing Magnetic Overlay

Insert fingernail beside the Stop/Start Switch and lift
gently to remove magnetic overlay.

Installation Procedure

This procedure describes the physical installation of
the unit.

Preparing to Mount the EC-30

1) Select a location:

a. Use the Mounting Template and the

EC-30 itself to determine an
appropriate location. It should be
located in a visible location where it
can be easily operated.

b. CAUTION! Check the backside

(inside) of the chosen location to
verify that nothing will interfere with
drilling and cutting the opening for
the remote, or with the fasteners,
harness plug, or enclosure on the
back of the EC-30.

c. Determine the feasibility of routing

the control wires from the genset to
the remote. Verify that the route of
the control wires meets all
applicable national and local codes.

Wires must be protected from all
hot, sharp, and abrasive surfaces.

2) Prepare the chosen location for the genset

controller.

a. Use scissors to cut out the template.
b. Tape the template to the mounting

surface to be cut out, make sure
that the template is “square or level”
with the mounting surface.

c. Using a center punch and a

hammer, punch a mark through the
template for each fastener and at
the perimeters of the cutout area.

d. Remove the template.

3) Drill the cutout starter holes at the four

corners of the cutout area. Cut between
them and remove the cutout.

NOTE: Because the location of the genset
controller will vary by installation, the tools
to be used and the cutout material (wood,
metal, plastic, etc.) will differ. Therefore, the
size of the cutout starter holes and the
procedure for cutting between the starter
holes must be determined by the installer.

4) Drill 1/8-inch diameter holes for the control

panel fastening screws.

5) This completes the preparation of the

mounting hole for the control panel. Do not
mount until wiring is complete.

Wiring Guidelines

The wiring for the EC-30 may be single conductors
of 16-20 AWG wire formed into a wiring harness.
The wire must be rated for the environment,
temperature, and applicable standards.

Separation from sources of Electro-magnetic
Interference (EMI): All cabling should be installed in
such a way as to comply with the minimum
separation of 5 inches (127 mm) from AC power
sources.

Tension: All wires should be free from tension at
both ends, as well as over the length of each run.

UTP cable bends: UTP cable bends or radii should
be no less than eight times the cable diameter.

!CAUTION! Incorrect connections can damage
genset controls, remote devices, and interconnect
wiring. Make sure that the leads between the
connections are properly connected.

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