EC155 Power Control System
Important Version Identification
Please be aware that there are two revisions of the EC5x series control panels.
The older revision 1 panels have a green power LED and a black circuit board and are covered by the old
issue 1 instructions (see www.sargentltd.co.uk).
These issue 2 instructions only apply to the later revision 2 control panels which have a blue power LED
and a green circuit board.
1 Key Features
150W (~12A) combined Power Converter / Battery Charger - Converts the 230V mains supply into 12V
DC power to run the leisure equipment and charge the battery.
Low current switching reduces voltage drop in the circuit and improved circuit fusing provides better
protection for the harness and equipment.
Links to the EC5x series LED Control Panel to provide simple but intelligent control of the 12V
equipment and built in over discharge software protects the leisure and vehicle batteries.
2 System Overview
The following diagram shows the typical configuration of the EC155 system. The key component is
the EC155 power supply unit (PSU), which is the hub of the system and provides connectivity to the
ancillary components and the EC5x series control panel.
150W
Charger /
Power Supply
12v LEISURE
BATTERY
Relay Module
Mains Control
Equipment
EC155 Power Supply Unit
12v VEHICLE
BATTERY
230v
EQUIPMENT
12v
EQUIPMENT
SENSOR
INPUTS
230v
IN
EC51 Model Only
EC50 / 51 Control Panel
Issue 2
Page 1 of 11
June 2013
EC155 Power Control System
3 Power Supply Details
For the safe operation of all electrical equipment within your Leisure Vehicle it is important that you
read and fully understand these instructions. If you are unsure of any point please contact your dealer
/ distributor for advice before use.
The following diagram shows the EC155PSU layout.
Power
Switch
RCD &
3 MCB’s
DC
Fuses
WARNING
Under heavy loads the EC155PSU case may become hot. ALWAYS ensure the ventilation slots have
a clear flow of air. Do not place combustible materials against / adjacent to the EC155PSU. The PSU
will shutdown if overheated and will restart automatically when cool.
3.1
Battery Charger / Power Converter
The EC155PSU incorporates a fixed voltage battery charger / power converter. The battery charger /
power converter also powers the leisure equipment when the mains supply is connected. This module
supplies 13.8V DC to the leisure equipment up to a maximum of 12 Amps (155 Watts), therefore the
available power is distributed between the leisure load and the battery, with the leisure load taking
priority as per the following example:
Issue 2
Leisure load
Available power for battery charging
3A
9A
6A
6A
9A
3A
12A
0A
Page 2 of 11
June 2013
EC155 Power Control System
3.2
Residual Current Device & Miniature Circuit Breakers
The Residual Current Device (RCD) is basically provided
to protect the user from lethal electric shock. The RCD will
turn off (trip) if the current flowing in the live conductor
does not fully return down the neutral conductor, i.e. some
current is passing through a person down to earth or
through a faulty appliance.
To ensure the RCD is working correctly, the test button
should be operated each time the vehicle is connected to
the mains supply (see section 5.1)
The Miniature Circuit Breakers (MCB’s) operate in a similar
way to traditional fuses and are provided to protect the
wiring installation from overload or short circuit. If an
overload occurs the MCB will switch off the supply. If this
occurs you should investigate the cause of the fault before
switching the MCB back on.
Test
Button
RCD
MCB’s
The following table shows the rating and circuit allocation for the three MCB’s
3.3
MCB
Rating
Wire Colour
1
10 Amps
White
2
10 Amps
White (Yellow for heater)
3
6 Amps
Black (Blue for water heater)
Description
230V Sockets
Extra 230V Sockets / Heater
Fridge / Water Heater / 12V Charger
(internally connected)
Fuses
WARNING
When replacing fuses always replace a fuse with the correct value. NEVER replace with a higher value /
rating as this could damage the wiring harness. If a replacement fuse ‘blows’ do not keep replacing the
fuse as you could damage the wiring harness. Please investigate the fault and contact your dealer.
The following table shows the fuse allocation for the 12 fuses fitted to the EC155PSU.
Fuse
Rating
Fuse Colour
Wire Colour
Description
1
15 Amps
Blue
Red / Yellow
2
10 Amps
Red
Grey
3
5 Amps
Tan
Yellow/Green
Hob and Heater Igniters Supply
4
10 Amps
Red
Green / Blue
Water Pump / Toilet
5
10 Amps
Red
Black/Blue
6
10 Amps
Red
Pink
7
10 Amps
Red
Yellow / White
12V Sockets / TV Amplifier / Entertainment
8
5 Amps
Tan
Brown / Yellow
Permanent Supply (Radio / Fridge)
9
20 Amps
Yellow
Brown / Green
Vehicle Battery
10
20 Amps
Yellow
Brown / Blue
Leisure Battery
11
10 Amps
Red
Black/Red
12
15 Amps
Blue
----
Fridge (none compressor type)
Front Lights
Ventilation Fans
Rear Lights
Heater Fan
Charger
The following table shows details of the fuse(s) located at the Leisure battery.
Battery 1
Issue 2
20 Amps
Yellow
Brown / Blue
Page 3 of 11
Fuse remotely located near battery
June 2013
EC155 Power Control System
3.4
Battery
A) Type / Selection
For optimum performance and safety it is essential that only a proprietary brand LEISURE battery is
used with a typical capacity of 75 to 120 Ah (Ampere / hours). A normal car battery is NOT suitable.
This battery should always be connected when the system is in use.
The EC155PSU is designed to charge standard lead acid leisure batteries, however it may be used
with Gel batteries depending on their composition. Please consult the battery documentation for
further advice.
The battery feed is fitted with an inline fuse between the battery and the electrical harness, and is
usually located immediately outside the battery compartment or within 500mm of the battery. The
maximum rating of this fuse is 20A per battery.
B) Installation & Removal
Always disconnect the 230V mains supply and turn the EC155PSU charger switch to the OFF (0)
position before removing or installing the battery.
When connecting the battery, ensure that the correct polarity is observed (black is negative [-] and red
is positive [+]) and that the terminals are securely fastened. Crocodile clips must not be used.
WARNING
Explosive gases may be present at the battery. Take care to prevent flames and sparks in the vicinity
of the battery and do not smoke.
C) Operation / Servicing
Under normal circumstances it should not be necessary to remove the battery other than for routine
inspection of the terminals and “topping up” of the battery fluid where applicable. Please see
instructions supplied with the battery.
Note: Do not over discharge the battery. One of the most common causes of battery failure is when
the battery is discharged below the recommended level of approximately 10V. Discharging a battery
below this figure can cause permanent damage to one or more of the cells within the battery.
To prevent over discharge, the EC155PSU in conjunction with the EC5x series control panel
incorporates a battery protect circuit that warns and then disconnects the batteries when they fall
below the following conditions:
Battery
Vehicle
Leisure
Voltage
cut off
Action after cut off
Notes
10.9V
Battery selection is
changed from Vehicle
battery to Leisure
battery. If the leisure
battery is below 9v
then a further warning
will occur (see below).
This cut off level is designed to protect the vehicle
battery from over discharge. The 10.9V level
ensures there is sufficient power in the battery to
run the vehicle electronics and start the vehicle.
This cut off only applies to power drawn from the
battery by the leisure equipment; it will not protect
the battery if you leave the vehicle lights on.
Power is turned off
This is an emergency cut off level to protect the
battery from severe damage. You should not rely
on this cut off level during normal operation, but
manage your power consumption to a discharge
level of 10V.
This cut off only applies to power drawn from the
battery by the leisure equipment that is controlled
by the control panel power switch; it will not protect
the battery from discharge by the radio or other
permanently connected equipment.
9V
Note: the system also incorporates an over voltage cut-out which turns the system power off if either
battery voltage exceeds 15V (indicated by the level display top LED flashing).
Issue 2
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June 2013
EC155 Power Control System
4 Control Panel Details
Leisure
Select &
Level
Indicator
Lamps x5
Power
ON / OFF
+
L
-
Vehicle
Select &
Level
+
V
Level
Display
-
Pump(s)
ON / OFF
Auxiliary
ON / OFF
4.1
EC50 Control Panel
Layout and Buttons
The following diagram shows the control panel layout and button functions (EC50 control panel).
Note: to remove the decorative bezel, pull down and lift forward as indicated by the blue arrow.
4.2
Operation
Symbol
Function
Description
Main 12v Power
switch
This switch turns on (or off) the 12 volt power.
As the power is turned on the Leisure battery is automatically selected
and the LED display shows the battery voltage. The power is turned off
automatically when the engine is started. See also 4.3 below.
Water Pump power
switch
This switch turns on power to the internal water pump ready for use.
It can be used to turn off the pump over night to avoid any noise from the
pump. When the switch is on, the LED will show Blue when the fresh
water tank level is ¼ or above, and Red if the level is under ¼. See also
4.2.1 below.
Auxiliary power
switch
This switch turns the Awning, Entry or other Lighting on (or off). When
the switch is on the LED will show Blue.
-
Select LEISURE
battery and display
battery voltage
This switch is used to select the Leisure battery and to display the
battery voltage level. Press once to select and display the voltage. This
display will turn off automatically after 5 seconds. The LED next to the
button will show that the battery has been selected.
If the Leisure battery drops below 9V the LED will change to Red and an
alarm will trigger to warn you that the battery is low. This alarm lasts for
1 minute and then the power will be switched off to protect the battery.
See also 4.2.1 below.
+V -
Select VEHICLE
battery and display
battery voltage
This switch is used to select the Vehicle battery and to display the
battery voltage level. Press once to select and display the voltage. This
display will turn off automatically after 5 seconds.
The LED next to the button will show that the battery has been selected.
If the Vehicle battery drops below 10.9V the LED will change to Red an
alarm will trigger to warn you that the battery is low. This alarm lasts for
1 minute and then the battery selection will automatically switch over to
the Leisure battery to protect the vehicle battery. See also 4.2.1 below.
+
L
Issue 2
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June 2013
EC155 Power Control System
EC51 version of the control panel with water level display
Indicator
Lamps x5
Power
ON / OFF
Leisure
Select &
Level
+
L
-
+
Level
Display
VWaste
Full
Indicator
Pump(s)
ON / OFF
Water
Level
4.2.1
Vehicle
Select &
Level
EC51 Control Panel
Water Level test
This switch is used to display the fresh water level within the onboard
water tank. Press once to select the Fresh tank and show the water
level. The tank has 5 levels Empty, ¼, ½, ¾ and Full. This display will
turn off automatically after 5 seconds.
Waste Full indicator
The LED adjacent to the water level button is used to show when the
Waste Water Tank is full. The tank is full when the LED is illuminated.
Audible Warnings
The revision 2 control panels now include an audible warning.
If the leisure or vehicle battery warnings are triggered (see 3.4.C) a beeper will sound to draw your
attention to the problem. The beeper and the warning can be cancelled by pressing any button. To
avoid any warning becoming a nuisance it will only be delivered once whilst the power remains on.
The warning will be reactivated when the power has been off and then turned on again.
On EC51 control panels, if the pump is turned on and the fresh water level falls below ¼ a beeper will
sound to draw your attention to the problem. The beeper and the warning can be cancelled by
pressing any button. If the pump is turned on and the waste tank becomes full a beeper will sound to
draw your attention to the problem. The beeper and the warning can be cancelled by pressing any
button. To avoid any warning becoming a nuisance it will only be delivered once whilst the pump
remains on. The warning will be reactivated when the pump has been off and then turned on again.
Issue 2
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June 2013
EC155 Power Control System
4.3
System Disable
To meet EMC (Electro Magnetic Compatibility) directive 89/336/EEC the EC50 series control panel will
shutdown, and the electrical accessories within the vehicle will be disconnected while the vehicle is in
motion. During this state the Leisure and Vehicle button LED’s will flash to indicate the engine is
running and the leisure battery is being charged from the alternator.
When the engine is stopped the control panel returns to standby mode ready to be turned on by the
power button.
4.4
Bar Graph Technical data
LED
Colour
Voltage reading
Water reading
14V
Green
13.5 - 15 (>15 LED Flashes)
Full
13V
Green
12.5 - 13.5
¾
12V
Yellow
11.5 - 12.5
½
11V
Yellow
10.5 - 11.5
¼
10V
Red
<= 10.5 (<9 LED Flashes)
Less than ¼
5 Operational & Safety Information
5.1
Connecting to the Mains supply - Safety checks
For your safety it is IMPORTANT that you follow these connections instructions each time your Leisure
Vehicle is connected to a mains supply.
A) Ensure suitability of the Mains Supply. Your Leisure Vehicle should only be connected to an
approved supply that meets the requirements of BS7671. In most cases the site warden will hold
information regarding suitability of supply. If using a generator you also need to comply with the
requirements / instructions supplied with the generator. Please note that some electronic
generators may not be compatible with your leisure system.
B) Switch the EC155PSU internal Power Converter OFF. Locate the red ‘Charger’ power switch on
the EC155PSU and ensure the switch is in the OFF (0) position before connection to the mains
supply.
C) Connect the Hook-up Lead. Firstly connect the supplied hook-up lead (orange cable with blue
connectors) to the Leisure Vehicle and then connect to the mains supply.
D) Check Residual Current Device operation. Locate the RCD within the EC155PSU and ensure
the RCD is switched on (lever in up position). Press the ‘TEST’ button and confirm that the RCD
turns off (lever in down position). Switch the RCD back to the on position (lever in up position). If
the test button failed to operate the RCD see section 5.2.
E) Check Miniature Circuit Breakers. Locate the MCB’s within the EC155PSU (adjacent to the
RCD) and ensure they are all in the ON (up) position. If any MCB’s fail to latch in the on position
see section 5.2.
F) Turn the EC155PSU ON. Locate the red power switch on the EC155PSU and turn to the ON (I)
position. The switch will illuminate when turned on.
G) Check operation of equipment. It is now safe to check the operation of the 12V and 230V
equipment.
Issue 2
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June 2013
EC155 Power Control System
5.2
Common Fault Table
Fault
No 230 volt
output from PSU
Possible Cause
Connecting lead between
the site and Leisure
Vehicle not connected
Check and connect lead as per 5.1C
Check also input connector at the base of the EC155PSU
RCD switched off
Reset RCD as per 5.1D
RCD not operating
correctly
Check supply polarity; if the RCD continues to fail contact your
Dealer, as there is probably an equipment or wiring fault.
MCB switched off
Reset MCB by switching OFF (down position) then back ON (up
position), if the MCB continues to fail contact your Dealer, as there is
probably an equipment or wiring fault.
No or deficient supply
from site
Contact site Warden for assistance
Other fault
Contact your Dealer
Control Panel has no
display
Check batteries & fuses, turn EC155PSU charger switch on, and
ensure mains supply is connected.
Check control panel connecting lead at EC155PSU and behind
Control Panel
Contact your Dealer
12V Power turns off
Battery save feature has operated to protect the Vehicle battery and
or the Leisure battery. See 3.4C
Engine has been started; all equipment has been disconnected to
meet EMC requirements (Battery LED’s flashing). See 4.3
Control Panel display
corrupt / erratic function
Observe control panel handling instructions
Control panel software may have crashed. Reboot control panel by
turning off the EC155PSU charger switch and removing fuses 9 & 10
at the EC155PSU (2x20A fuses for leisure and vehicle batteries).
Wait 30 seconds then replace the fuses and turn the charger switch
on.
(Alternatively, remove the bezel at the control panel by pulling down
in the centre at the bottom, unplug the control panel multi-way
connector, wait 30 seconds, then plug back in and reassemble.)
No 230V supply
Check all above
Charger not switched on
Switch charger switch on (I) position, switch will illuminate
Battery not connected and
/ or charged
Install charged battery as per 3.4
Power switch on control
panel not switched to ON
Turn power on at control panel
Battery flat / Battery fuse
blown
Recharge battery, check fuses, check charging voltage is present at
battery
Fuse blown
Check all fuses are intact and the correct value fuse is installed as
per fuse table
Equipment switched off /
unplugged
Check equipment is switched on and connected to the 12V supply
PSU overheated / auto
shutdown operated
Reduce load on system. Allow PSU to cool down. PSU will
automatically restart when cool. See section 3
Other fault
Contact your Dealer
Fuse blown
Replace fuse
Pump turned off
Turn pump on by pressing the pump button at the EC155 control
panel (tap symbol)
Control Panel
Problems
No 12 volt output
from PSU
Pump not
working
Issue 2
Proposed Fix
Page 8 of 11
June 2013
EC155 Power Control System
6 Technical Data & Approvals
6.1
Outline Specification
INPUT 230V
OUTPUT 230V
INPUT 12V
OUTPUT 12V
Integrated CHARGER
230 Volts / 0 to 12 Amps
+ / - 10%
RCD protected, 3 x MCB outputs of 10, 10 and 6A via 2 x
9 way connectors
2 x 20A battery inputs via a single 9 way connector
20A total output via 4 x 16A switched channels protected
by 12 fused outputs via a 12 way connector
Input 220-240 Volts AC +/- 10%, Frequency 50 Hz +/- 6%,
Current 3A max.
DC Output 13.8 Volts nominal, Current 12 Amps max (155
Watts).
Signal INPUT
1 x Engine running via PSU connector (4 x Fresh water
level, 1 x Waste water level on EC51 version)
Data IN / OUT
Data communication and power to Control Panel via 8
way RJ45 connector
IP rating
Operating
temperature
6.2
Fresh & waster water negative
sensed
IP31
Ambient 0 to 35° Centigrade
PSU case temperature with full load 65° C Max
Automatic shutdown and restart
if overheated / overloaded
Overall size (HxWxD) 260 x 273 x 110mm
Fixing centres 262 x 224mm
Clearances 75mm above, 20mm below, 50mm left & right
Weight 2.2 Kg
Overall size (HxWxD) 80 x 140 x 30mm
Fixing centres 123mm
Cut-out size (HxW) 60 x 110mm
Weight 100 g
Dimensions
EC155PSU
EC50/51 Control
Panel
6.3
Approvals
System: BSEN 1648-1, BSEN1648-2 compliant, BS7671: 2008 compliant
Residual Current Device: RCD 40A 30mA trip to BS EN 61008
Miniature Circuit Breakers: MCB’s (10 & 6A) type C 6000A breaking capacity to BSEN 60898
Electro Magnetic Compatibility (EMC) directive 89/336/EEC
Integrated Charger Module: BS EN 60335-1/2.29, 89/336/EEC, IEC61000-3.2/3:1995, EMC certificate 5A121501E
rd
3 party tested.
6.4
Declaration of Conformity
Equipment: Leisure Power Control System
Model name: EC155PSU / EC50CP / EC51CP / EC52CP
I hereby declare that the equipment named above has been designed to comply with the relevant sections of the
above referenced approvals. The unit complies with all essential requirements of the Directives.
Signed:
Name:
Position:
I L Sargent
Technical Director
Date:
Issue 2
Page 9 of 11
Manufacturer:
Sargent Electrical Services Ltd
Unit 39, Tokenspire Business Park
Woodmansey, Beverley
East Yorkshire, United Kingdom
June 2013
EC155 Power Control System
6.5
Electrical Connection
A) Battery Input Connector
6
9
8
3
2
5
7
1
4
Pin
Function
Fuse
Wire Colour
1
Fridge 12V output
1
RED / YELLOW
2
Battery common earth 1
-
WHITE / ORANGE
3
Battery common earth 2
-
WHITE / ORANGE
4
Auxiliary 12V output
2
SLATE / RED
5
Vehicle battery input 1
9
BROWN / GREEN
6
Vehicle battery input 2
9
BROWN / GREEN
-
RED
7
Fridge power in / Engine run
8
Leisure battery input 1
10
BROWN / BLUE
9
Leisure battery input 2
10
BROWN / BLUE
Pin
Function
Fuse
Wire Colour
1
Radio
8
BROWN / YELLOW
2
12v Sockets 1
7
YELLOW / WHITE
3
12v Sockets 2
7
YELLOW / WHITE
4
Ignitions
3
YELLOW / GREEN
5
Front Lights 1
2
SLATE
6
Front Lights 2
2
SLATE
7
Heater fan
11
BLACK / RED
8
Rear Lights 1
6
PINK
9
Rear Light 2
6
PINK
10
Fans
5
BLACK / BLUE
11
Toilet Pump
4
PURPLE
12
Pump
4
PURPLE / BLACK
Pin
Function
Wire Colour
1
Not used
-
2
Earth
GREEN / YELLOW
3
Live
BROWN
4
Neutral
BLUE
B) 12v Output Connector
12
6
9
3
11
8
5
2
10
7
4
1
C) 230v Mains Input connector
Issue 2
1
2
3
4
Page 10 of 11
June 2013
EC155 Power Control System
D) 230v Mains output connector (2 off connectors wired identical)
1
2
3
4
5
6
7
8
9
Pin
Function
MCB
Wire Colour
1
Live
3
BROWN
2
Earth
3
GREEN / YELLOW
3
Neutral
3
BLUE
4
Live
2
BROWN
5
Earth
2
GREEN / YELLOW
6
Neutral
2
BLUE
7
Live
1
BROWN
8
Earth
1
GREEN / YELLOW
9
Neutral
1
BLUE
While every effort has been made to ensure the accuracy and completeness of this document, no guarantee is given against errors or
omissions. This document may be updated / improved over time therefore please check with your dealer / supplier for update
information or visit www.sargentltd.co.uk
Issue 2
Page 11 of 11
June 2013
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