Modul-System Modul-Connect 2.0 User manual

Revision. 1.3
Revision date: 14 January 2020
Modul-Connect 2.0
Owner’s Manual

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For safe and optimum performance, the Modul-Connect 2.0 must be used properly. Carefully read
and follow all instructions and guidelines in this manual and give special attention to the CAUTION
and WARNING statements.
PLEASE KEEP THIS MANUAL FOR FUTURE REFERENCE
Disclaimer
While every precaution has been taken to ensure the accuracy of the contents of this guide,
Modul-System assumes no responsibility for errors or omissions. Note as well that specifications and
product functionality may change without notice.
Important
Please be sure to read and save the entire manual before using your Modul-Connect 2.0 box. Misuse
may result in damage to the box or switch panels and/or cause harm or serious injury.
Product Numbers
24000-03 Modul-Connect main box
24030-03 Modul-Connect switch panel
Document Part Number
MSMC 2.0_rev1
Service Contact Information
E-mail: [e-mail]
Phone: [phone]
Web: www.modul-system.com

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Contents
1. Introduction ............................................................................................................................. 3
2. Product description .................................................................................................................. 5
3. Preparing for installation .......................................................................................................... 6
4. Understanding the main box features ....................................................................................... 7
5. Installing the main box ............................................................................................................. 9
6. Main box output connections ..................................................................................................10
6.1 Wago connections ....................................................................................................................... 10
6.1.1 Wago connector outputs.....................................................................................................11
6.2 Molex connector.......................................................................................................................... 13
7. Inverter connection .................................................................................................................16
8. Switch panel (load area) ..........................................................................................................18
9. Configuring the product ...........................................................................................................20
10. Troubleshooting ....................................................................................................................21
11. Specifications ........................................................................................................................22
12. Warranty...............................................................................................................................24
13. Main box connection table.....................................................................................................25

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1. Introduction
Thank you for purchasing the Modul-Connect system. With our state of the art, easy-to-use design,
this product will offer you reliable service by simplifying the electrical installation in your service
vehicle.
This manual will explain how to use this unit safely and effectively. Please read and follow these
instructions and precautions carefully.
IMPORTANT SAFETY INFORMATION
This section contains important safety information for the Modul-Connect. Before using the system,
READ ALL instructions and cautionary markings on or provided with the box, and all appropriate
sections of this guide.
The main box contains user serviceable fuses. The switch panel contains a user serviceable
battery. The display switch panel contains no user-serviceable parts. See Warranty section for how to
handle product issues.
DANGER: Fire and/or Chemical Burn Hazard.
•Do not cover or obstruct any air vent openings and/or install in a zero-clearance compartment.
DANGER: Failure to follow these instructions can result in death or serious injury.
•When working with electrical equipment or lead acid batteries, have someone nearby in case of
an emergency.
•Study and follow all the battery manufacturer’s specific precautions when installing, using and
servicing the battery connected to the box.
•Wear eye protection and gloves when working with batteries.
•Avoid touching your eyes when working with batteries.
•Keep fresh water and soap on hand in the event battery acid comes in contact with eyes. If this
occurs, cleanse right away with soap and water for a minimum of 15 minutes and seek medical
attention.
•Batteries produce explosive gases. DO NOT smoke or have an open spark or fire near the
installation.
•Keep unit away from moist or damp areas.
•Avoid dropping any metal tool or object on the battery. Doing so could create a spark or short
circuit which goes through the battery or another electrical tool that may create an explosion.
DANGER: Shock Hazard. Keep away from children!
•Avoid moisture. Never expose the Modul-Connect box to snow, water etc.
DANGER: Explosion hazard!
•DO NOT use the box in the vicinity of flammable fumes or gases (such as propane tanks or large
engines).
•AVOID covering any ventilation opening. Always operate unit in an open area.
•Prolonged contact to high heat or freezing temperatures will decrease the working life of the unit.
•The box operates on DC power only. DO NOT connect any AC power source to the box like utility
power or generator. It will damage the box and may cause fire. Feeding AC into any connection of
the box is not covered by warranty.

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FCC and CE EMC INFORMATION
This equipment has been tested and found to comply with the limits for CE EMC Standard. These
limits are designed to provide reasonable protection against harmful interference in a residential
installation.
LIMITATIONS ON USE
Do not use in connection with life support systems or other medical equipment or devices.

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2. Product description
The Modul-Connect main box includes the items listed below.
•Modul-Connect main box
The Modul-Connect Switch Panel includes the items listed below.
•Switch panel back (plastic part)
•Switch panel front (plastic part)
•PCB
•Switch membrane
•Switch icon sheet
•Switch membrane cover
•CR2032 lithium batteries

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3. Preparing for installation
WARNING: All wiring should be done by a certified technician or electrician to ensure adherence to
the applicable electrical safety wiring regulations and installation codes. Failure to follow these
instructions can damage the box and could also result in personal injury or loss of life.
CAUTION: Before beginning installation, please consider the following:
•The box should be used or stored in an indoor area away from direct sunlight, heat, moisture or
conductive contaminants.
•When placing the box, allow a minimum of 25 mm (one inch) of space around the box for optimal
ventilation.

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4. Understanding the main box features
12V Battery Bank:
•The use of an AGM battery is highly recommended for any Modul-System power application.
•For battery sizing, you need to identify what you wish to operate, and for how long. It is
recommended that you purchase as much battery capacity as possible.
DC Fuse or Circuit Breaker:
•DC-rated fuse or DC-rated circuit breaker connected along the DC positive line is required. The
size of the input fuse must be compatible and calculated with the load required from the box and
to protect the DC cable input run.
M-S part number
MEGA input fuse ampage description
Colour
C-MEGA40-5
Mega fuse 40A black, 5 pcs
Black
C-MEGA60-5
Mega fuse 60A black, 5 pcs
Black
C-MEGA100-5
Mega fuse 100A yellow, 5 pcs
Yellow
C-MEGA125-5
Mega fuse 125A green, 5 pcs
Green
C-MEGA150-5
Mega fuse 150A orange, 5 pcs
Orange
C-MEGA175-5
Mega fuse 175A white, 5 pcs
White
C-MEGA200-5
Mega fuse 200A blue, 5 pcs
Blue
C-MEGA225-5
Mega fuse 225A brown, 5 pcs
Brown
C-MEGA250-5
Mega fuse 250A pink, 5 pcs
Pink
C-MEGA300-5
Mega fuse 300A grey, 5 pcs
Grey
C-MEGA350-5
Mega fuse 350A dark green, 5 pcs
Dark green
C-MEGA400-5
Mega fuse 400A purple, 5 pcs
Purple
C-MEGA1A-50
Mega fuse holder
CAUTION: Always disconnect the DC power between the box and the battery bank during service,
maintenance or troubleshooting.

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DC Input Cable Size:
•All DC cables require insulated multi-strand low resistance cable.
•The DC cables must be copper and must be rated to 105℃as a minimum.
Grounding Cable Size:
Important: The box is grounded through the ground stud to a vehicle OEM earth point or a point as
near as possible to the supplying battery. The cable size must be the same as the selected positive
cable size.
Ensure the connection is properly secure and grounded to the vehicle chassis before use.
Cable size and rating varies between manufacturer and cable run length.
Nominal ratings for cable size are as below:
Conductor Cross Section (mm²) Nominal Current Rating (Amps)
0.75
10
1
14
2
24
5
38
6
48
10
68
25
168
40
298
60
415

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5. Installing the main box
•Choose an appropriate mounting location.
•The box can be mounted in any direction. Ensure that adequate access can be made for cable
entry and removing any cover for fuse replacement.
•Where possible, mount directly to a metal surface for any heat dissipation.
•The box can be mounted with 4x M5 bolts or similar (not supplied).
•Use a mounting template to mark the positions of the mounting screws.
•Drill the four mounting holes, place the box in position and fasten the box to the mounting
surface.
IMPORTANT:M8 DC terminals tightening torque 12-13 Nm.
CAUTION: Reversing the polarity of the DC Input terminals will not damage the box but may damage
accessories connected to it (i.e. Inverter). Damage caused by reverse polarity connection is not
covered by the warranty.

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6. Main box output connections
6.1 Wago connectors
The main box has two banks of Wago connectors for the 2x 30A and 4x 20A outputs.
The Wago clap technology makes for faster installation and eliminates maintenance. These
connectors all use clamps to terminate fine stranded and solid stranded conductors.
Strip the insulation from the end of the cable to be inserted approximately 14mm.
To open the Wago connector, using a small flat blade screwdriver, push in the release button on the
top of each connector.
Once the wire is inserted into the connector, remove pressure from the screw driver, then test
pull the cable to ensure it is secure.
The Wago clamp secures the conductor and encloses its insulation.
The release buttons are marked in red on this diagram. On the box they are the same color as the
connector.

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Several cables can be put together into one output. Strip each cable approximately 14mm, open the
strands of each cable and twist all of strands together before inserting them into the Wago
connector.
Ensure that the total size of the cables does not exceed 6mm² in each Wago connector terminal.
6.1.1 Wago Connector Outputs
DC Polarity Positive +
Switching Output 6
Maximum fused Loading 20 a
DC Polarity Chassis Earth -
Switching Output 6
Maximum fused Loading 20 a
DC Polarity Positive +
Switching Output 5
Maximum fused Loading 20 a
DC Polarity Chassis Earth -
Switching Output 5
Maximum fused Loading 20 a
DC Polarity Positive +
Switching Output 4
Maximum fused Loading 20 a
DC Polarity Chassis Earth -
Switching Output 4
Maximum fused Loading 20 a
DC Polarity Positive +
Switching Output 3
Maximum fused Loading 20 a
DC Polarity Chassis Earth -
Switching Output 3
Maximum fused Loading 20 a
DC Polarity Positive +
Switching Output 2
Maximum fused Loading 30 a
DC Polarity Chassis Earth -
Switching Output 2
Maximum fused Loading 30 a
DC Polarity Positive +
Switching Output 1
Maximum fused Loading 30 a
DC Polarity Chassis Earth -
Switching Output 1
Maximum fused Loading 30 a

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Each of the main box output connections (through the Wago connectors) are protected by a mini
blade fuse.
The fuse size must be calculated as to be compatible with the load required from the box on the
required circuit and to protect the DC cable run.
Good Fuse Bad Fuse
M-S Part number
Description
Colour
C-MIF2-50
Mini Blade Fuse 2A – Pack of 50
Grey
C-MIF2-1000
Mini Blade Fuse 2A – Pack of 1000
Grey
C-MIF3-50
Mini Blade Fuse 3A – Pack of 50
Violet
C-MIF3-1000
Mini Blade Fuse 3A – Pack of 1000
Violet
C-MIF5-50
Mini Blade Fuse 5A – Pack of 50
Light Brown
C-MIF5-1000
Mini Blade Fuse 5A – Pack of 1000
Light Brown
C-MIF7.5-50
Mini Blade Fuse 7.5A – Pack of 50
Brown
C-MIF7.5-1000
Mini Blade Fuse 7.5A – Pack of 1000
Brown
C-MIF10-50
Mini Blade Fuse 10A – Pack of 50
Red
C-MIF10-1000
Mini Blade Fuse 10A – Pack of 1000
Red
C-MIF15-50
Mini Blade Fuse 15A – Pack of 50
Blue
C-MIF15-1000
Mini Blade Fuse 15A – Pack of 1000
Blue
C-MIF20-50
Mini Blade Fuse 20A – Pack of 50
Yellow
C-MIF20-1000
Mini Blade Fuse 20A – Pack of 1000
Yellow
C-MIF25-50
Mini Blade Fuse 25A – Pack of 50
Transparent
C-MIF25-1000
Mini Blade Fuse 25A – Pack of 1000
Transparent
C-MIF30-50
Mini Blade Fuse 30A – Pack of 50
Green
C-MIF30-1000
Mini Blade Fuse 30A – Pack of 1000
Green

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6.2 Molex connector
The main box has one 16 pin Molex connector. This Molex connector is designed for the 3 CAN
connections and 9 in/out switching input and output connections.
The pins on the Molex connector are referred to as Pin 1 top left, Pin 8 top right, Pin 9 bottom left
and pin 16 bottom right.
Molex connector as seen from outside Modul-Connect main box
Pin 1
External IN/OUT
*500mA max
Pin 2
External IN/OUT
*500mA max
Pin 3
External IN/OUT
*500mA max
Pin 4
External IN/OUT
*500mA max
Pin 5
External IN/OUT
*1A max
Pin 6
CAN 3 H
Pin 7
CAN 2 H
Pin 8
CAN 1 H
Pin 9
External IN/OUT
*500mA max
Pin 10
External IN/OUT
*500mA max
Pin 11
External IN/OUT
*500mA max
Pin 12
External IN/OUT
*500mA max
Pin 13
GND
Pin 14
CAN 3 L
Pin 15
CAN 2 L
Pin 16
CAN 1 L
Molex
Pin #
Pin Name Connection Value
M-S Accessory
Default Connection
Cable Color
1
External IN/OUT
*500mA max
Light bar - Dimming
White
2
External IN/OUT
*500mA max
Light bar - Pattern Select
Blue
3
External IN/OUT
*500mA max
Light bar - Left to Right Traffic Advisor
Yellow
4
External IN/OUT
*500mA max
Light bar - Right to Left Traffic Advisor
Orange
5
External IN/OUT
high capacity
1a max Weighing System - Power
Brown (in Yellow
Multicore)
6 CAN 3 High CAN 3 ONLY Weighing System
White (in Yellow
Multicore)
7
CAN 2 High
CAN 2 ONLY
8
CAN 1 High
CAN 1 ONLY
9
External IN/OUT
*500mA max
Ignition input +12v
Brown
10
External IN/OUT
*500mA max
Interior light feed input
Red / Red/White
11
External IN/OUT
*500mA max
Inverter On/Off
Red
12
External IN/OUT
*500mA max
Inverter Status
Black
13 Chassis Ground
Chassis Ground
output
Weighing System
Blue (in Yellow
Multicore)
14 CAN 3 Low CAN 3 ONLY Weighing System
Black (in Yellow
Multicore)
15
CAN 2 Low
CAN 2 ONLY
16
CAN 1 Low
CAN 1 ONLY
* The external IN/OUT have a maximum total loading when using more than one external IN/OUT
connection, please refer to section 11 ‘Specification table’ on page 22.

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To connect to the Molex, a plug housing is required (available separately).
M-S Part No
Description
Image
24200-03 Molex terminal housing
Termination pins are required to be crimped to the end of the required cable. The pin input and
maximum output will require a cable size of 0.75-1 mm².
M-S Part No
Description
Image
24210-03 Molex terminal 0.75-1 mm2, 20 pcs
24215-03 Molex terminal 0.75-1 mm2, 3000 pcs
Additional part numbers for connecting to the Molex are as below:
M-S Part No
Description
Image
24290-03 Molex crimping tool 0.75-1 mm²
24295-03 Molex terminal extraction tool
Molex crimping information can be found at:
https://www.molex.com/pdm_docs/ats/ATS-6382754HM.pdf
Molex terminal extraction tool information can be found on page 3 at:
https://www.molex.com/pdm_docs/ats/ATS-011030016-001.pdf

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If the terminal extraction tool is used the locking tangs needs to be restored to its original position or
the pin terminal needs to be replaced.
Visually inspect the terminal locking tangs before pushing them into the Molex terminal housing.
You can use the terminal extraction tool to carefully push out the tangs to their original position.
If they are damaged in any way, replace the pin terminal.
When inserting the Molex pin connectors into the Molex terminal housing, push the pin and cable
squarely into the connector in the correct position until a “click” is felt and heard. Then gently test
pull the cable to ensure that it is located and securely fitted/locked in the terminal housing.
The tang faces to the center of the Molex terminal housing.

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7. Inverter connection
Any Modul-System Inverter can be powered and controlled by the Modul-Connect main box.
The 400w, 600w, 1000w and 2000w inverters can be controlled through their remote ports.
The 3000w inverter will require the ignition start box (included with the inverter) for the control
connection to work.
+12v power is taken from the top terminal of the main box to the + positive terminal of the inverter.
-12v power can either be connected to the vehicle OEM earth point or a point as near as possible to
the supplying battery (fig 1) or to the main box (fig 2).
Ensure that the cable size is correct for the load (size of inverter).
(fig 1)
(fig 2)
The inverter fuse must be added to compliment the size of inverter as in the table below.
The main input fuse and cable size must be calculated to the full loading of the system.
M-S Part Number
MEGA Input Fuse
Ampage Description
Modul-System
Inverter
Modul-System
Inverter Part Number
C-MEGA40-5
40A
400W
21040-03
C-MEGA60-5
60A
600W
21060-03
C-MEGA100-5
100A
1000W
21100-03
C-MEGA200-5
200A
2000W
21200-03
C-MEGA300-5
350A
3000W
21300-03

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The Modul-System Inverters are controlled from the Modul-Connect main box.
The inverter requires an interface cable to communicate with the main box.
Two lengths of cable are available. The interface cable is fitted with an RJ11 plug on one end, which
plugs into the inverter, and two Molex pins on the other end which plugs into the Molex 24200-03
terminal housing.
One interface cable is required:
•24100-03 RJ11 interface cable 1.5 m
•24110-03 RJ11 interface cable 3.0 m
One Molex 24200-03 terminal housing is required:
The inverter interface connection is a twin core cable, one cable is red and the other cable is black.
The two cables connect into the 24200-03 Molex terminal housing in positions 11 and 12.
Pin 11 Red
Pin 12 Black
PIN 11
Inverter ON/OFF
+12v Pulse
RJ11 Red Cable
PIN 12
Inverter Status Input
Inverter Status Input
RJ11 Black Cable
A Molex plug in the main box showing Inverter Interface cable connection points:

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8. Switch panel (load area)
Building up the switch panel
•Remove the required switch icon from the sheet and place
it squarely in the required position on the required switch.
•Repeat this process for the remaining five switches (or the
required number).
•Remove the protection tape from the switch overlay,
place the membrane cover over the icons and secure
firmly.
First time configuration of the switch panel
•Insert the batteries to the battery slots to make the switch panel detectable.
•The switch panel will then enter its ‘discoverable’ configuration mode (the LED will flash the
LED indicator red and green in an alternating fashion) and the switch panel can now be set
up for its function via the phone APP.
•Search for the switch panel in the APP, alternatively scan the data matrix code supplied with
the switch.
•Follow the APP instructions.
•Continue until all the switch panels are programmed. The switches can then be clipped back
onto their backing plates.

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Re-programming the switch panel
•Remove the batteries.
•Hold down the two top switches (nearest the LED
indicator) of the switch panel and at the same time and
insert both batteries.
•The switch panel will then enter its ‘discoverable’
configuration mode (the LED will flash the LED indicator
red and green in an alternating fashion)
•The switch panel can now be set up for its function via
the phone APP.
•Search for the switch panel in the APP, alternatively scan the data matrix code supplied with
the switch.
•Follow the APP instructions.
•Continue until all the switch panels are re-programmed. The switches can then be clipped
back onto their backing plates.
Operation
When the Bluetooth connection is made, and the switch is programmed and connected to the main
box, the LED to the top of the switch panel will show green for a short time when a function is turned
on and red when a function is turned off.
The Modul-Connect switch panel can be fixed to any surface using double sided tape.