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3830 - SO02471 [96202 SW15623_0H Dwg13068A] Donovan

1. O O UP 11653 G NY DATION mA IDLE VALI 2 BREAK OUT BOX Figure 2 6 Throttle Connection PWM with DC Voltmeter Insert the Break out Box between the number 1 Processor connector pigtail and the Throttle Harness as shown in Figure 2 6 labeled and the red lead into the socket labeled PWM Turn power On to the Caterpillar ECM Electronic Control Module Only Do Not apply power to the Processor at this time Depending on the type of Caterpillar ECM PEEC or ADEMS the measurement should be approximately 5 00 or 12 00 VDC Record the measurement as shown in Drawing Figure 2 6 Set up the Multimeter to DC Volts and plug the black lead into the Break out Box black socket Turn power On to the Processor and take command at any Remote Station H Record the DC Voltage at this time The measurement should be 7 9 of the voltage measured in step f I Move the Control Head lever to the Full Throttle position while depressing the Transfer Button Throttle Only Mode J The measurement should be 91 93 of the voltage measured in step F e g Idle 8 of 12 VDC reference or 0 96 VDG Full Throttle 92 of 12 VDC reference or 11 04 VDC MM13927 Page 2 2 2 1 4 SERVICE FIELD TEST UNIT PWM Pulse Width Modulation with Duty Cycle Meter A Ensure powe
2. connector pigtail BY C Insert the Break out Box N between the number 3 i GEAR BOX Processor connector pigtail Il and the Clutch Harness as 5 SRINCONNECTORS shown in Figure 2 10 T B C D Set up the Multimeter to j Break out Box socket TROLL ON OFF Y a OO labeled CLUTCH and the Go Or red lead into the socket Go Ort BREAK OUT BOX e KH NS JQ O Y LO Figure 2 10 Clutch Connection Ahead Solenoid F The measurement should be 0 VDC and the adjacent LED should not be lit labeled AHEAD E Turn power On to the Processor and take command at any Remote Station with the lever in the Neutral Idle position A 2 PE ae D Mi measure DC Volts and plug JO LN mio Ol AUD the black lead into the 3 y a y E END MM13927 Page 2 4 G H SERVICE FIELD TEST UNIT Position the Control Head lever into the Ahead detent The measurement should be 12 or 24 VDC depending on the Ahead Solenoid s rating The LED adjacent to the Ahead plug on the Break out Box should be lit Return the Control Head lever to the Neutral Idle position
3. Bug PN Y PN H UJ f 1C 2 0l NJ NJ KO US que J LJ O gt gt lt A wy E kd seen Toe DS T O A m nr 7 HA PRUVIDE AN APPRUPRIATE FI AND FU LUDER SUGGESTED A gt E E NE Sl 3 De PART NU UE WG MI 11488 A 19 180101D 3 05 A 20 180101D 3 05 MMC 287 Rev D 8 03 ZF Marine Electronics LLC Mukilteo Plant Bonding A B Y C E 11 46 CFR 111 05 All boats equipped with a permanently installed electrical system shall also be equipped with a bonding system The negative terminal of all batteries should be connected at only one point the DC common and from DC common to bond system or hull Metal Hull Vessels The metallic hull of the vessel may also serve as the common bonding conductor If it is desirable for the item being installed to be bonded to the vessel bonding system and the installation or mounting method does not provide the desired path a separate bond
4. T CLUTCH OLL ON COMMAND i 2 O AHEAD N O yp BREAK OUT BOX Figure 2 4 Throttle Connection DC Voltage H The appropriate Full Throttle Voltage for the application should be measured at this time 2 1 2 Current mA C Insert the Break out Box between the number 1 Processor connector pigtail and the Throttle Harness as shown in Figure 2 4 Set up the Multimeter to measure DC Volts and plug the black lead into the Break out Box black socket labeled and the red lead into the socket labeled VDC Turn power On to the Processor and take command at any Remote Station The appropriate Idle Voltage for the on should be measured at this time Move the Control Head lever to the Full Throttle position while nn the Transfer Button Throttle Only Mode A Ensure power is removed from both the Engine Electronics and the Processor B Disconnect the Throttle Harness from the number 1 Processor connector pigtail C Insert the Break out Box between the number 1 Processor connector pigtail and the Throttle Harness as shown in Figure 2 Ju D Setup the Multimeter to measure current mA and plug the black lead into the Break out Box black socket labeled and the red lead into the socket labeled mA E Turn power On to the Processor and take command at any Remote Station MM13927 Page 2 1 SERVICE FIEL
5. ere CN 12 PIN CONNECTORS JL ECM a em Botzt SS OO Go Q Qo 0 6 6006 me ON QQ IDLE VALIDATION mA O gt OF E O y BREAK OUT BOX DV OO l off C Disconnect the Throttle Harness from the number 1 Processor Insert the Break out Box between the number 1 Processor connector pigtail and the Throttle Harness as shown in Figure 2 8 Set up the Multimeter to measure Frequency and plug the black lead into the Break out Box black socket labeled and the red lead into the socket labeled FREQ Turn power On to the Processor and take command at any Remote Station The appropriate Idle Frequency for the application should be measured at this time Move the Control Head lever to the Full Throttle position while depressing the Transfer Button Throttle Only Mode Figure 2 8 Throttle Connection Frequency Hz H The appropriate Full Throttle Frequency for the application should be measured at this time MM13927 Page 2 3 SERVICE FIELD TEST UNIT 2 2 CLUTCH TESTING 2 2 1 Neutral Solenoid Testing A Ensure power is removed from both the Processor and the Clutch
6. iz seer DC COMMON Y all RETURN 1 Sh E D o INE HEB CEUS ULDER N jd JER 2 ae Ne AGE Y FUSE ADDED AGNUTES 5 AND 7 JCB 01 REVISED WIRING TU APS 1 N N gt TI SE N N N N N N sus SEE ANOTE EIN SABEL amp er gt N x PART NU SEE NOTE 5 DWG NUI 11488 180101D 3 05 180101D 3 05 Drawing 11488D 3 APS Notes Page gt gt WIR CREF ABYC E9 15 9 10 GC IF THIS CONFIGURATION ISED WITH AN EL di UN CTRONIC ENGINE LER MI E ANG I V RLUIT BREA MUS E TURN A 4 METRIC EQUIVALENT oy Eu VEO ri L P IGURE 1 B W FUR TH IGGESTED HARDWAR ACK g UE es dd ING MEL re E TPB HS p REM TEE PN 13905 CAUTUMATIC PUW IOR gt EE U7 SLUCKWASHER d d E C NUT 2 METRIC ENUIVALE 2r CRING TERMINAL a
7. d Se CLUCK WASHER o gt WIRE SIZE CRECUMMENDED TWISTED PAIR H 4 OUDE POWER SYSTEM B NUT 2 A J o O M e AW 2 je M E E T V Al E N T y o 20 30 6 1 9 1M 12 AWG 4 ZANVDE POWER YSTEM 2 5 METERLE ERUTVALENTD A y APS OUTPUT IS STRICTLY FOR ZF MATHERS CONTROLS Lae KIT edge 13983 D MW 4 03 REVIS LALN ADDED FLAGNUTE 8 V ELAGNUTE D Qo NJ AUTOMATIC POWER SELECTOR gt A k A S U U gt Or KLL 3 Se J E A E lt lt lt lt M NJ A A P mt A i D OCR gt i X R l N HEB CFUSE AULUER B TJI7 02 ADDED FLAGNOTES 6 AND 7 A JCIG O1 kA W CREW KIT PN 13984 REV BY DATE D TS HIR A Vi d po bk re YA I HEK fo d p ee ae es spat I y l L f Tf KH f m If I TONI CIA Non PACIFIC DRIVE BURLINGTON WA 98233 ZF MATHERS CONTRO C POWER SOURCE NG A PN
8. 2 2 3 Astern Solenoid Testing A Ensure power is removed from both the Processor and the Clutch Supply Power command at any Remote B Disconnect the Clutch Harness from the number 3 Processor connector pigtail C Insert the Break out Box N between the number 3 my m Processor connector pigtail and the Clutch Harness as NONE shown in Figure 2 11 25 AL D Set up the Multimeter to oe hell Ns measure DC Volts and plug o F Bie OI HI the black lead into the 90 VASE Break out Box socket Gi OG Af labeled CLUTCH and em zeg e the red lead into the socket Go o E labeled ASTERN 5 Cum Turn power On to the mm om a BEER Processor and take NOU E era IDLE VALI N IAN d OOO Tol Y DATION mA O A E Station with the Control Head lever in the Neutral 4 Idle position Figure 2 11 Clutch Connection Astern Solenoid F G H The measurement should be 0 VDC and the adjacent LED should not be lit Position the Control Head lever into the Astern detent The measurement should be 12 or 24 VDC depending on the Astern Solenoid s rating The LED adjacent to the Astern
9. Ensure that the blue conductor is properly crimped to pin 7 at both connectors and there is continuity Replace Station No 3 Control Head Ensure that the green conductor is properly crimped to pin 6 at both connectors and there is continuity Ensure that the blue conductor is properly crimped to pin 7 at both connectors and there is continuity Replace Station No 4 Control Head Ensure that the green conductor is properly crimped to pin 6 at both connectors and there is continuity Ensure that the blue conductor is properly crimped to pin 7 at both connectors and there is continuity Replace Station No 5 Control Head Ensure that the green conductor is properly crimped to pin 6 at both connectors and there is continuity Ensure that the blue conductor is properly crimped to pin 7 at both connectors and there is continuity Replace Station No 6 Control Head Ensure that the green conductor is properly crimped to pin 6 at both connectors and there is continuity Ensure that the blue conductor is properly crimped to pin 7 at both connectors and there is continuity Replace Station No 7 Control Head Ensure that the green conductor is properly crimped to pin 6 at both connectors and there is continuity Ensure that the blue conductor is properly crimped to pin 7 at both connectors and there is continuity Replace Station No 8 Control Head Ensure that the green conduc
10. DK 2630 Taastrup DENMARK T 54 11 4580 0444 F 54 11 4580 0440 Rodney Lean T 61 0 2 9679 5555 F 61 0 2 9679 5500 mailbox zf com au www zf com au Antonio Tucunduva T 5515 235 2301 F 5515 235 2233 Tang Zhou Qing T 0086 21 6301 4338 F 0086 21 6301 6449 M 13901655780 Elisabeth Q Sibbern T 45 0 43 436243 F 45 0 43 432643 frank kiessling zf com www zf marine com FINLAND 7655 Mastervolt Finland Powerduo Oy Haikankatu 2 FIN 21200 Raisio FINLAND FRANCE 2190 Seimi mail B P 30307 Brest Cedex FRANCE 29603 ship Z I P Du Moulin Blanc Rue Alain Colas 29200 Brest FRANCE 3590 Vidal Diffusion Marine mail B P 97 Toulon Cedex 9 FRANCE ship Z I Toulon Est Toulon Cedex 9 FRANCE 7252 ADS Van Stigt Avelingen West 30 NL 4202 MS Gorinchem NETHERLANDS 7636 Otto Piening GMBH Piening Propeller AM Altendeich 83 Gluckstadt 25348 GERMANY B14 5 Vesa Saarinen Ari Bragge T 358 2 433 9990 F 358 2 435 0085 Mr L Gautier T 33 2 98 46 11 02 F 33 2 98 43 37 49 info seimi com www seimi com David Elderkin T 33 494 08 68 20 F 33 494 08 26 59 d elderkin vidalmarine com GERMANY Jan Hogenkamp T 31 0 183 650000 F 31 0 183 650001 vs vanstigt nl Mathias Pein T 49 4124 916812 M 49 171 4853376 pein piening propeller de 2386 Amaltheia 13 Papaflessa Str 143 43 N Halkidona
11. Figure B4 2 Display simultaneously until the HO begins to blink Figure B4 3 E neon ROBO Release the Push Buttons the applied battery voltage will now be displayed The displayed value is in real time and provides a rough estimate of the DC voltage applied to the Processor The reading is accurate to within 0 50 DC Refer to Figure B4 4 Figure B4 3 Display E In addition to the applied battery voltage scrolling through Troubleshooting Function Blinking the Diagnostics Menu by pressing the Up or Down Push Button can also show the Tachometer Sender Frequency Figure B4 5 e The information shown is the actual frequency outputted by the Tachometer Sender This signal is utilized in Closed E RU d Loop Synchronization or Closed Loop Troll future pplied Battery Voltage systems The Control Heads lever position and the resulting outputs of Stations 1 2 3 4 and 5 s Control Heads can always be This is M of Eu is in Eialire BAG Example Disolawot command or not Note the placement of the decimal points nee in the examples below San show all five Stations with the lever positioned at the Neutral Idle position This will be covered in further detail later Station 1 Station 2 Station 3 Station 4 Station 5 Lever A D Count Lever A D Count Lever A D Count Lever A D Count Lever A D Count Ae e 05 te Figure B4 6 Example Display Control Head Lever Current Positions F The current status of all
12. K Clip the exposed drain wires flush with the Clamps L Connect the conductors to the terminal block as listed in Table 4 2 Table 4 2 Processor Circuit Board Connections for Serial Communication PORT PROCESSOR STARBOARD PROCESSOR Conductor Color Termination A Termination B IR 8 Silver Drain Wire 4 4 4 6 Tachometer Cable Location 12 A Run a two or three conductor shielded cable from the Port Processor to the Port engine s tachometer source Refer to Section 3 1 6 page 3 5 Sy NOTE Three conductor cable is required with Open Collector Type Hall Effect Tachometer Senders only B Run a two or three conductor shielded cable from the Starboard Processor to the Starboard engine s tachometer source C Install a 1 2 inch 12 7mm liquid tight cable grip into hole No 9 of the Port and Starboard Processors Refer to Figure 4 6 page 4 4 for entry hole location and Figure 4 5 page 4 4 for cable grip installation Strip back 2 inches 50 8mm of PVC jacketing from both ends of the cable Strip the ends of each conductor back 3 8 inch 9 5mm F Clip off the drain wire flush with the PVC jacketing at the Tachometer source side only Place a 7 8 inch 22 23mm section of shrink tubing over each end of the cable H Atthe Processor side bend the drain wire back and tuck it under the shrink tubing so that the drain wire end is exposed past the shrink tubing Refer to Figure 4 14 and Figure 4 1
13. No continuity between pin 7 s of the Control Head Harness connectors The Station No 7 Control Head is defective No continuity between pin 6 s of the Control Head Harness connectors No continuity between pin 7 s of the Control Head Harness connectors The Station No 8 Control Head is defective No continuity between pin 6 s of the Control Head Harness connectors No continuity between pin 7 s of the Control Head Harness connectors The Station No 9 Control Head is defective No continuity between pin 6 s of the Control Head Harness connectors No continuity between pin 7 s of the Control Head Harness connectors The Station No 10 Control Head is defective No continuity between pin 6 s of the Control Head Harness connectors No continuity between pin 7 s of the Control Head Harness connectors The Station No 1 transfer button was held down for 15 seconds or longer The Station No 1 Control Head transfer button is defective The Control Head Harness is miswired The Control Head s Pigtail is miswired The Station No 2 transfer button was held down for 15 seconds or longer The Station No 2 Control Head transfer button is defective The Control Head Harness is miswired The Control Head s Pigtail is miswired Page B9 2 Replace Station No 2 Control Head Ensure that the green conductor is properly crimped to pin 6 at both connectors and there is continuity
14. A value of 1 0 is 1 second A value of 99 0 is 99 0 seconds If this option is going to be used please contact a ZF Marine Electronics Representative for further information Page 8 6 PERIODIC CHECKS AND MAINTENANCE 9 PERIODIC CHECKS AND MAINTENANCE The items listed below should be checked on an annual basis or less when noted 9 7 Control Heads Check the terminal strip for signs of corrosion or a loose connection If used disconnect the Deutsch connector and check the pins and sockets for signs of moisture and corrosion 9 2 Processor Check all terminal connections for signs of corrosion or loose connections Un plug and inspect all Deutsch connectors for signs of moisture or Corrosion 9 3 Power Supply 9 3 1 Battery WARNING Batteries contain sulfuric acid and emit hydrogen gas while charging Therefore specific safety precautions must be adhered to while handling and servicing Specific information on handling and servicing batteries can be obtained from the Battery Council International Battery Service Manual preventing access to the electrolyte for water level and specific gravity tests e CAUTION In many newer batteries the vent cap is permanently attached Q Attempting to pry off these caps could result in premature battery failure The following tests should be performed in the intervals specified 9 3 1 1 Quarterly Every 3 Months Check the level of the water electrolyte with
15. Damage due to accidents improper installation or handling and or improper storage Damage due to faulty repairs performed by an unauthorized service representative Damage due to conditions modifications or installation contrary to published specifications or recommendations Original installation charges or start up costs Battery service including labor charges related to battery service Rental of equipment during performance of warranty repairs Unauthorized repair shop labor without prior approval from ZF Marine Electronics Service Department 10 Shop supplies such as connectors wire cable etc C Warranty Service Please go to www zf marine com or Call 1 425 583 1900 or U S only 1 800 546 5455 for your nearest ZF Marine Electronics Factory Authorized Dealer 1 Prior to returning any product to the factory you must contact ZF Marine Electronics Service Department for a Service Return Authorization SRA number Return the product freight prepaid marked clearly with the SRA number and a description of the malfunction 2 Ifthere is a defect covered by warranty ZF Marine Electronics will at its option either repair or replace the defective part or product If after inspection ZF Marine Electronics determines that the product is not oe ZF Marine Electronics will charge a testing fee and return the product to the sender freight collect Repair or replacement during the warranty period will not extend the warranty period All c
16. Figure 4 10 Table 4 1 4 4 4 2 4 4 4 3 4 4 4 3 1 4 4 4 3 2 Figure 4 11 4 4 4 4 Figure 4 12 4 4 4 5 Figure 4 13 Table 4 2 4 4 4 6 Figure 4 14 Figure 4 15 Table 4 3 4 4 5 4 4 5 1 Figure 4 16 224 5 2 Figure 4 17 Table 4 4 4 4 6 Figure 4 18 Table 4 5 4 5 Sc Figure 5 1 Figure 5 2 5 1 1 Figure 5 3 Figure 5 4 5 1 2 Figure 5 5 5 1 2 1 5 1 2 2 5 1 2 3 Figure 5 6 5 1 2 4 Figure 5 7 5 2 5 3 Table 5 1 Table 5 2 Table 5 3 Table 5 4 5 4 Figure 5 8 Table 5 5 Table 5 6 Table 5 7 Table 5 8 Table 5 9 05D 5 5 1 Sack Figure 5 1 959 1 2 Figure 5 2 5 5 1 3 Figure 5 3 5 5 1 4 Figure 5 4 Seven Conductor Control Head Cable Shield Wire and Heat Sbnmnk cee eee 4 5 E ee WEE 4 6 Terminal Strip Cable Connections qae aa dd AC p ee ee Soe Ses 4 6 Processor Circuit Board Connections for Remote Stations ccccscceceeceececcecceccecsececcecscsccscceccscseceecescsceeces 4 6 ELEVENSC ONDUCTOR IDE GABE TE OCATION 2 ANO STATION EE 4 6 START INTERLOCK EE EE 4 6 Connection at theStarter 80lenod Fre Tea A E es A duce de C A A e A E A A 4 6 EE EE e ac itin E SL de A E REA O RN E O a oic BA A E 4 6 Two Conductor Start Interlock Cable 245 duis il ree Sh de ame eal a ted mato Spe 4 6 POWER CABEN LOCATION O EE 4 7 Two Conductor Power Ga Oley a ete a eo BS Be ee d nap DAR ASA A 4 7 SERIAL COMMUNICATION CABLE TOCA TION KEE 47 our conductor Serial Communi
17. Pu i anemia Pina Groen Yellow Pmi Shea au am mi Brown mi REA ED E mm um Pai Vile Pms Green LED s i o Pma Orange Pina Transfer Button E J E mo Rd y Pias Cmd I eee Bis Grem Pme erer Command Signal Bae te Ee Pin7 Blue Pin VREF svDC Port Connections Pina Black Pins Tone WZ PROCESSOR PIGTAIL CONTROL HEAD TERMINAL STRIP 13557 X Inn pavo Termination A Conductor Color rermination s Description TE Zi mi Green Yellow NG at Pin mom Pnz Red LED sa Orange Pina rie Bunte Fut anne Coon Pin 6 Green Pine Lever Command Signal bs Pin 7 Blue Pin 5 Port VREF 5VDC Pin 7 Stbd 20 AWG E J E E RE E AO AE i3 NOTE STARBOARD Jumper Pins 3 to 5 BLACK O BROWN TON ORANGE 02 BLUE GREEN LA Cn GREEN 0 9 BLUE ON VIOLET oo RED N O BLACK BROWN PORT Jumper Pins 3 to 7 iiem Stbd Terminal Connections Table B12 6 Tachometer Sensor Harness Pin Out PROCESSOR PIGTAIL EE EEN SENSOR 4 Green Termination A Conductor Color Termination B Description Yellow 2 2 Red Pin Red PinB Tachometer Pin3 Black Pin Tachometer EES Green Yellow N C Shield able B12 7 lachometer Sensor Harness with Power Pin Out PRO
18. Test Control Head Dual 14000 MM13927 Page 3 1 APPENDIX C Drawing 13068A 1 Notes Page 4 3 2 1 MATERIAL LIST NOTES 5 INSURE THAT SHIELD ON THE SHIELDED CABLE IS ITEM TY PART NUMBER DESCRIPTION CONNECTED ONLY AT ONE END TO THE CHASSIS ml o AND THAT THE DRAIN WIRE DOES NOT TOUCH ANY i 2 96202 CONTROL PROCESSOR 1 DO NOT MOUNT CONTROL SYSTEM COMPONENTS ON ENGINE OTHER CONDUCTIVE SURFACE REFER TO THE REDUCTION GEAR OR IN ANY LOCATION SUBJECT TO EXCESSIVE INSTALLATION MANUAL FOR DETAILED INFORMATION 2 3 Mc2000 2P CONTROL HEAD l 3 2 14261 xx CONTROL HEAD CABLE DOUBLE ENDED ee MI gt INSURE THAT DRAN WIRE ON SHIELDED CABLE IS 4 BY OTHERS 13756 xx WIRE HARNESS POWER START INTERLOCK D A CONNECTED ONLY WHERE INDICATED INSIDE HOUSING MAXIMUM ALLOWABLE AMBIENT TEMPERATURE IS 70 C AND THAT DRAIN WIRE DOES NOT TOUCH ANY OTHER ds 2 13533 XX WIRE HARNESS THROTTLE PWM 3 DO NOT MOUNT CONTROL COMPONENTS NEAR SOURCES OF GE Es St Ee fel 2 ix WIRE HARNESS AHEAD ASTERN CLUTCHES SERIAL COMMUNICATION PIGTAIL SHIELD TERMINATION STRONG ELECTROMAGNETIC FIELDS STARTERS GENERATORS ETC GE ACTOR WEEE TOG HEHHE WIRE HARNESS SERIAL COMMUNICATION 4 MOUNT CONTROL COMPONENTS IN A LOCATION ACCESSIBLE INSTALLATION MANUAL FOR ADDITIONAL INFORMATION FOR CHECKOUT MONITORING AND MAINTENANCE 8 2 fso CIRCUM BREAKER 10 AMP EE CO urne mex sm 5 ALL ELECTRICAL C
19. 96202 r TWIN SCREW 1 ee SYSTEM DRAWING Ke SUPPLIED BY SHIPYARD Ke S KEE NONE PART NO SHEET ne Fs 4 3 2 Page C 3 Page C 4 Drawing 13068A 3 Processor Connections 4 3 2 1 PROCESSOR 1 SHOWN OTHERS SAME D RED START INTERLOCK 12 PIN g e CONNECTOR RED g 5 BLACK S RED CLUTCH PRESSURE E ASTERN CLUTCH PRESSURE 5 SOLENOID BLACK gt 5 voir fo D BLUE o OP C GREEN to aE ORANGE Elie 5 RED o Ino 8 BROWN Ho o OR EH BLACK ELO E O GH ORANGE Om DT arm i o o Om N lo 08 z o ott BLUE rio oO O Lo BLACK Dom L IO Q x on GREEN a Plog E Elo RED E B 4 ri Plo a 5 ou z B ou 5 B E o el Elo y D Old gt 185 S E i 4 s d DIGITAL INPUTS pe pu SE 6 PIN 8 PIN T mu E CONNECTOR a a CONNECTOR 4 PIN CONNECTOR E SEE BER EE E EEE Sa ER in E I 8094 IJ we TACHOMETER ZF MARINE ELECTRONICS LLC CONNECTION 12125 HARBOUR REACH DR SUITE B MUKILTEO WA 98275 OPTIONAL ame START INTERLOCK nN Seen at 96202 A CLUTCH PRESSURE OPTION 3 TWIN SCREW TATIO POWER IN ALARM OPTION SONA SYSTEM DRAWING PILOT HOUSE s SIZE CAGE CODE DWG NO A TO OTHER PROCESSORS AE NONE PART NO SHEET 3 OF 4 Page C 5 Page C 6 Drawing 13068A 4 Control Head Connections 4 E 2 1 PART NUMBER
20. Athens GREECE GREECE Demetris Kyriazis T 30210 25 88 985 F 30210 25 89 986 ICELAND 6525 Hrafn Sigurdasson Johann Olafur Arsaelsson Merkur Akralind 2 201 Kopavogur ICELAND 7326 ZF Great Britain Ltd Abbeyfield Road Lenton Nottingham UNITED KINGDOM NG7 25X ENGLAND 7093 SAIM SPA Via Donizetti 9 11 20090 Assago MI ITALY 6477 ZF Hurth 38062 Arco TN Italy Via S Andrea 16 ITALY 7244 ZF Padova S p A Via Panghe N 48 Selvazzano Padova ITALY 1 35030 T 354 568 1044 F 354 568 9958 M 354 863 0312 hrafn merkur is olafur murker is IRELAND Adi Licence T 44 115 986 9211 F 44 115 986 9261 ITALY Antonio Renzetti Alessandro Busetto T 39 02 488 531 F 39 02 45703070 antonio renzetti saim group com alesandro busetto saim group com Vittorio Rasera T 011 390 464 580 555 F 011 390 464 580 544 T 39 049 8299 550 F 39 049 8299 550 info zfpadova zf com www zf marine com TAPAN 7253 Y Ikeda ZF Marine Japan Co Ltd T 81 0 3 5808 4521 Fujikoshi Bldg 1 10 11 Iriya Taito ku Tokyo 110 0013 JAPAN F 81 0 3 5808 4531 www zf marine com KOREA 1415 M G Song SE Jung Engineering Co T 82 51 415 0591 35 4 Namhangdong 1KA Yeongdogu F 82 51 412 6361 Pusan KOREA sjeng88 kornet net NETHERLANDS Holland 7252 Jan Hogenkamp ADS Van Stigt T 31 0 183 650000 Avelingen West 30 NL 4202 MS Gorinchem F 3
21. MC2000 3 Gold Head Gold Levers MC2000 4 Black Head Chrome Levers MC2000 4PBlack Head Chrome Levers Pluggable MC2000 5 Black Head Gold Levers CONTROL HEAD ADAPTER PADS 400 and MC2000 Series Only 1002 Pad Kit white blank 1003 Pad Kit black blank 1004 Pad Kit teak blank 1005 Pad Kit white machined 1006 Pad Kit black machined 1007 Pad Kit teak machined PageA 1 APPENDIX A 13316 13432 13494 13533 14363 15027 15719 15732 15725 13239 13631 13552 13756 15023 13557 14261 TEST UNIT 13927 14000 CABLE Electric 180 8 Cond Shielded Cable Per ft 350 8 Cond Shielded Cable 500 Spool 11811 8 Cond Shielded Cable 1000 Spool 212 2 Cond Power Cable Per ft 349 2 Cond Power Cable 250 Spool 183 2 Cond Start Interlock Cable Per ft 355 2 Cond Start Interlock Cable 250 Spool WIRE HARNESS Plug Replace the after the Part Number with the length of harness required EXAMPLE 13316 10 13316 20 13316 30 Serial Communication Twin Screw Throttle Voltage Throttle Current Throttle PWM Throttle MAN Throttle Frequency Clutch Ahead Astern Clutch Power Clutch Ahead Astern Troll CMD Clutch Ahead Astern Troll Troll CMD Magnetic Pickup or Pulse Transmitter Power Start Interlock Clutch Pressure Alarm Circuit Power Start Interlock Clutch Pressure Power Start Interlock Power Control Head 1 Connector Control Head 2 C
22. Power Supply B Disconnect the Clutch Harness from the number 3 Processor connector pigtail C Insert the Break out Box E between the re 3 dE Processor connector pigtal ol and the Clutch Harness as Peconic RE U shown in Figure 2 9 O pl ue D Turn power On to the mifi he Processor and take Ir AR o O ill ll command at any Remote CT me Station with the Control e Head lever in the Neutral NO Idle position e E The en s n er Neutral Test Point shou I uu m x y i be 12 or 24 VDC b Seri STE rating and the M Vis Y LED adjacent to the socket 4 should be illuminated Figure 2 9 Clutch Connection Neutral Solenoid F Move the Control Head lever to the Ahead Detent position The voltage should drop to 0 VDC in CruiseCommand systems and remain at 12 or 24 VDC in ClearCommand systems The adjacent LED should go out in CruiseCommand systems and stay on in ClearCommand systems 2 2 2 Ahead Solenoid Testing A Ensure power is removed from both the Processor and the Clutch Power Supply B Disconnect the Clutch Harness from the number 3 Processor
23. Suite B Telephone 425 583 1900 Mukilteo WA 98275 Telefax 425 493 1569 A 9 Deutsch Connector Assembly DT Type Step 1 Contact Removal 1 Remove wedgelock using needlenose pliers or a hook shaped wire Pull wedge straight out 2 To remove the contacts gently pull wire backwards while at the same time releasing the locking finger by moving it away from the contact with a screwdriver 3 Hold the rear seal in place as removing the contact may displace the seal Step 3 Contact Crimping Use Crimp Tool HDT48 00 1 Strip insulation from wire See Step 2 2 Raise selector knob and rotate until arrow is aligned with wire size to be crimped 3 Loosen locknut turn adjust ing screw in until it stops SEH 4 Insert contact with barrel up Turn adjusting screw counter clockwise until contact is flush with indentor cover Tighten locknut 5 Insert wire into contact Contact must be centered between indicators Close handles until crimp cycle is A completed i 6 Release handles and remove crimped contact 7 Inspect terminal to ensure that all strands are in crimp barrel NOTE Tool must be readjusted for each type size of contact Use HDT04 08 for size 8 and 4 contacts Step 2 Wire Stripping Contact Part Number 0460 202 20141 0462 201 20141 0460 202 16141 0462 201 16141 0460 215 16141 0462 209 16141 0460 204 12141 0462 203 12141 0460 204 08141 0462 203 08141
24. The green LED is lit solid though the Engine RPM s differ by a significant amount Causes Solutions a Function Code E7 is set to 00 and the a Scroll to Function Codes E2 and E3 on both Processors and compare the Values Throttle Minimum and Throttle Maximum The Values of E2 and E3 must be the same for both Processors Adjust as Values differ between the Port and necessary Starboard Processors b The engines run at different RPM s with b Active Synchronization MUST be Enabled the same throttle command signals B11 2 2 2 SYMPTOM One or both of the engines continually changes RPM hunts Will not synchronize properly Causes Solutions a A Station in Command Control Head s a Scroll to the Diagnostic Menu Function Code H0 Go to the appropriate Station A Command Signal is varying D Count s display The Value should not change by more than 1 A D Count If so check the connections and if good replace the Control Head b One or both of the Tach Signals isn t being b Scroll to Function Code HO on both Processors and display the frequency of the read intermittently Function Code E7 is Tach Signal If variations of the signal are measured the cause must be set to a Value of 01 or 03 determined Page B11 1 TROUBLESHOOTING B11 2 2 3 SYMPTOM Synchronization does not function The Control Head s green LED does not light Causes The Processors think Astern is bein commended when the Control Head le
25. direction A variable pause is introduced into the clutch command signal to allow time for the engine RPM s to drop to Idle and for the vessel s speed through the water to slow 2 7 Warm up Mode Throttle Only Mode This feature allows the operator to increase the engine s RPM while the Clutch remains in Neutral Warm Up Mode is operational only when the Control Head lever is moved in the Ahead direction A WARNING Personal Injury could occur if the following steps are not followed exactly Move To the Ahead The system is placed into Warm Up Mode as follows A At the Station in Command ensure that the T Control Head s lever is in the Neutral detent puse id position refer to Figure 2 3 nn B Depress and hold the transfer button Puch amp Hola C After one second move the Control Heads lever iio i MN Se to the Ahead detent while continuing to hold Figure 2 3 Control Head Warm Up Mode the transfer button a D Now release the transfer button The red LED indicator light will blink slowly indicating Warm Up Mode is activated and the Red indicator Light wil Clutch has remained at Neutral E Normal Operating Mode E The operator can start the engine if required J UN and increase the RPM through the entire d throttle range by the Control Head s Figure 2 4 Control Head Normal lever forward through the next 65 degrees Operating Mode F When the Control Head s lever is returned to the Ne
26. does not have much value in narrowing down the source of the problem Ifthe System is installed on a Twin or more Screw application this question is quite useful if you ask the following question 1 Does the problem or symptom occur on the Port Starboard or both sides If the problem or symptom occurs on one side only you have effectively eliminated 50 of the possible causes For example the symptom only occurs on the Port side All of the components on the Starboard side have been eliminated as otential causes What is the Part Number and Serial Number of the Processor Whenever the factory is called for technical assistance the part number and serial number will be required These numbers provide the Service Technician information about the operating characteristics of the Processor The numbers are esto on the Processor s front cover How many Remote Stations are there If only one Remote Station is present not much will be gained by asking this question However if more than one Remote Station is being used command should be taken from one of the other Stations to see if the problem occurs from another Station If the problem occurs from more than one Remote Station the odds are that the Control Heads are not the cause of the trouble If the problem occurs at one Remote Station only there is a era chance of the Control Head or the Control Head Harness of being the cause Are any tones generated when the p
27. en shy Ge E Er Se PA A E ee den qe 5 9 Display LED Function E5 Set Up Activated WEE 5 9 F nction Code E6 High didle eo e 5 sr cae ee S com Bea Hos E e c e Sie 5 9 Display LED Function E6 Set Up Activated WEE tee Std ET SENS 5 9 F ncHon COS E 7 Synehronizaton ee RAE RE E e E ote nate SES 5 10 Display LED Function E7 Set Up Activated EE 5 10 THROTTLE ELECTRONIC FUNCTIONS E E2 EE 5 10 Function Code EO Engine Throttle Profile EE Ee e A A EE ee eee e 5 10 Display LED Function EO Set Up Activated WEE 5 10 FURCHOM CODE E2 TREOTUS Minin Ee 5 10 Display LED Function E2 Set Up Activated WEE 5 10 F nction Code E9 Throttle Maximum gt dem Hen 222 Ba ann E PES E boxeo E A sx 5 11 Display LED Function E3 Set Up Activated KEE EE 5 11 Clutch FUNCTIONS EE EE 5 11 CHUTCH BASIC FUNCTIONS ACO THROUGH CA EB ee a td E eects ed Nd de 5 11 Function Code CO Clutch Press re Interlock eus a a ot oe esce ce aoa A ca e A A 5 11 Display LED Function CO Set Up Activated e ls moh ea ah are ale 5 11 Fonction Code Chen Inteiock Delay cc m as SEAS AE AA Sree E AI EA 5 11 Display LED Function C1 Set Up Activated ib dre eed S es ER RETE Rt wince coke ble oat 5 11 Function Code CA Proportiondi Pa se a aie mos a o e Sua ana IS Fes elena a ute AE 5 11 Display LED Function C2 Set Up Activated WEE 5 12 Function Code C3 e Proportional Pause Time E E DE E A a ame AA E 5 12 Display LED Function C3 Set Up Activated WEE 5 12 Function Code C4 Proport
28. generated 2 Place the Control Heads lever s in the Neutral position 3 Depress and hold the Station transfer button while moving the GE Head s lever s to the Ahead detent Release the transfer utton The red LED on the Control Head should blink indicating Warm up Mode has been entered Warm up Mode only operates in the Ahead direction 6 2 Start Interlock Engines Stopped A Turn the Processor DC power OFF Verify that the engine s will not start B Turn Processor DC power ON Do not take command at a Remote Station Verify that the engine s will not start C Take command at a Remote Station Place the Control Head s lever s to approximately 50 of the throttle range Verify that the engine s will not start D Place the Control Head s lever s in the Neutral Idle position Take command at a Remote Station Verify that the engine s will start in this position 6 3 Engine Stop Switches Start the engine s and verify that the Stop switches normally push buttons function correctly at all Remote Stations High Idle A Place the Station in command into Warm up Mode B Adjust Function Code E6 to the desired engine RPM as described in Section 5 6 2 1 2 page 5 10 C Return the Control Head s lever to the Neutral Idle position 6 5 Control Head Solenoid Command A Start the engine s and let them run at Neutral Idle B Place one Control Head lever at a time into the Ahead detent the Astern detent a
29. 1 Basic Control System Tones These basic tones are as follows B5 1 1 Slow Repetitive Tone OO Aa Do O OO A IS Figure B5 1 Slow Repetitive Tone The Slow Repetitive Tone also referred to as the Initialization Tone is the tone you hear at all Remote Stations when power is initially applied to the control system When this tone is heard you know for a fact that the following are true Power has just been applied to the system The Software Program is running normally The Processor is commanding the throttle to Idle The Processor is commanding the clutch to Neutral This is a normal tone when power has first been applied to the Processor and no Control Head has taken ana However the tone may also be an indication of a problem if during normal operation the engine s throttle drops to Idle followed by the clutch to Neutral the Control Head s red LED goes out and a slow repetitive tone is heard at all remote stations This indicates that the voltage at the Processor has momentarily dropped below 8 VDC and then returned to a normal operational level This could be due to Loose battery power cable connection Under charged or defective battery Voltage drop due to current flow In order to pinpoint the exact cause of the low voltage at the Processor perform the following checks A Check the Display on the Processor for Error Messages Error Message 57 may appear indicating Under Voltage One or more of Error M
30. 10 1 AC Tach Input e Two conductor twisted shielded e 20 AWG 0 5 metric Page 3 4 PLAN THE INSTALLATION 300 V 165 C UL VW1 stranded tinned copper Maximum outside diameter 0 390 inches 9 9mm 3 1 5 10 2 Open Collector Active Three conductor twisted shielded e 20 AWG 420 5 metric 300 V 165 C UL VW1 stranded tinned copper Maximum outside diameter 0 390 inches 9 9mm 3 1 5 11 Throttle Electric Cable Requirements If Throttle is hard wired no plugs to the Processor the electric cable may be ordered from ZF Marine Electronics or must meet the following specifications e Two conductor red and black twisted shielded e 16 AWG 1 5 metric e 300V 105 degrees C UL VW1 stranded tinned copper wire Maximum outside diameter 0 390 inch 9 9mm 3 1 5 12 Clutch Electric Cable 3 1 5 12 1 Clutch Electric Cable Requirements If Clutch Solenoids are hard wired no plugs to the Processor the electric cable may be ordered from ZF Marine Electronics or must_meet the following specifications e Two conductor red and black twisted 16 AWG 1 5 metric 300V 105 degrees C UL VW1 stranded tinned copper wire Maximum outside diameter 0 390 inch 9 9mm 3 1 6 Tachometer Sensors There are two types of Tachometer Sensors available through ZF Marine Electronics Mechanical p n 8902 and Magnetic Pickup p n 8912 Both types provide two separate outputs one for the rt the second EE provides the
31. 4 6m In 24 volt systems the maximum cable length is 20 feet 6 1m ZF Marine Electronics highly recommends using an Automatic Power Selector APS and a second power source battery to supply power to each Processor Refer to Appendix A Automatic Power Selector APS for examples of power supplies 3 3 1 Processor Power The items listed below will help ensure optimum performance from your control system e The Processor requires a battery source of 12 or 24 VDC Two 5 ampere when isolated power supplies are required or one 10 ampere trip free thermal circuit breaker s with manual On Off actuation The use of an APS Automatic Power Selector is strongly recommended Power should come from the vessel s DC Distribution Panel The cables feeding power from the battery to the Processor must be sized large enough to keep voltage drop due to current flow below 10 Reference Appendix A Automatic Power Selector The Processor s power cable s maximum lengths are listed in Appendix A Parts List and examples of the various wiring options are shown in Appendix A Automatic Power Selector Ultimately it is the boat builder or installer s responsibility to ensure that the vessel s wiring meets the requirements of American Boating amp Yachting Councel standard E 11 for AC and DC Electrical Systems on Boats Page 3 6 INSTALLATION 4 INSTALLATION NOTE Before starting the actual installation of the Control Syste
32. Alarm Normally Open contact opens with 11 Black Circuit fault or loss of power 10 Red 3 a External Alarm Normally Open contact opens with Back L fault or loss of power 7 Light Blue Ml 6 Light Blue Clutch Pressure Normally Open contact that closes Switch when transmission manufacturer s minimum safe operating pressure is reached Fig Rd beyo pove OOOO oS mi Back en a 12 Yellow w Red Starter ae contact when In command and at Neutral Trace Wire at the Starter ll an PROCESSOR PIGTAIL a ION PROCESSOR Termination A Conductor Color Termination B Description s 1 Black Pini Mack Pini CANLow s 2 Red Pin Re Pin CAN Fgh Yellow Green N C Shield 11145B 1 Yellow w Red Trace 000000 0000090 1 Yellow w Red Trace 8 9 10 M 2 00060090 6 Light Blue 7 000000 F A 1 Yellow w Red Trace 2 Red 3 Black 7 8 9 10 n D 000000 000000 6 Light Blue Page B12 1 TROUBLESHOOTING ZE Table B12 5 Control Head Harness Pin Out and Hard Wire CONTROL HEAD PIGTAIL PROCESSOR PIGTAIL 14261 X Termination A Conductor Color rermination B _Deseription
33. Barringer Jeff Carter T 410 604 3320 www zf marine com Jimmy Wong Steve Vu T 847 478 6868 F 847 478 6789 www zf marine com USA ZF Marine LLC Irvine Service Center 1350 Reynolds Ave Suite 110 Irvine CA 92614 ZF Marine LLC North Carolina 1350 Sensation Weigh Beaufort NC 28516 USA ZF Marine LLC Rhode Island 1 Mastead Drive Warwick RI 02886 USA B14 8 Cherie McAdams T 949 251 0140 F 949 251 0150 cherie mcadams zf com Phil Organ T 252 504 3700 F 252 504 3773 www zf marine com John Shea Gil Bashaw T 401 541 9014 F 401 541 7223 www zf marine com Service Field Test Unit Reference Manual MM13927 Rev D 10 03 MM13927 Table of Contents MMT3927 Table of COntents oi a il tesa e ln cU S TOC 1 Ste te ke RE TOC 2 1 INTRODUCTION 1 1 Figure 1 1 Semice Field Test UN Break OUT BOX er a Fa ER Tea Figure 1 2 CruiseCommand Connector Locations io SEs dac S hes e UR CREER ER 1 2 Figure 1 3 Example of ClearCommand Pigtail Locations 2 2644444465644 4d etd tel 1 2 Table 1 7 Connector Pigtail Deseriptions une 1 2 2 PROCEDURE A 2 1 Tarore signal HOSTING EE 2 1 2 1 1 BNO Ea eer e snc EE E EE os a 2 1 Figure 2 4 Tnr ttle Connection DC Voltage erris uen PS AS miu E ea OA So ich 2 1 21 2 COG AA EI e de Bee Tage 2 7 Figure 2 5 Throttle Connection Current MA ss eras aonb e sorted dee od a dete d RC e 2 2 21 8 PWM Pulse Wi
34. Control Head transfer button The receiving Remote Station accepts command by pressing the receiving Remote Station s Control Head transfer button 2 With both options a 1 2 second ON followed by a 1 2 second OFF tone wi sounded when the transfer is initiated 3 Once command has been taken the command to the engine and gear will respond to the Control Head lever s position immediately 04 Neutral Only Request Relinquish Receive 1 The operator has two options when selected Option 1 is a three step process This option requires the operator at the receiving Remote Station request control by pressing the transfer button on the receiving Remote Station s Control Head The Station in Command relinquishes control by pressing the transfer button on the Station in Command Control Head The receiving Remote Station must press the receiving Remote Station Control Head transfer button a second time to receive command Option 2 requires that the operator at the Station in Command relinquishes control by press the Station in Command s Control Head transfer button The receiving Remote Station accepts command by pressing the receiving Remote Station s Control Head transfer button 2 With both options a 1 2 second ON followed by a 1 2 second OFF tone wi sounded when the transfer is initiated Page 5 17 SET UP PROCEDURES 5 5 6 2 2 3 Once command has been taken the command to the engine and gear will respond t
35. Electronics LLC Mukilteo Plant MMC 163 Rev C 10 04 Warranty Registration Processor Serial Serial Number of Remote Stations Purchase Date Dealer s Name Installer s Name Phone Number Cell Number Fax Number E Mail Address Purchaser s Name Street Address City State Zip Phone Number YOUR VESSEL Engine Make amp Model Length Manufacturer ZF Marine Electronics LLC Product First Seen At Boat Show Dealer Magazine Friend ZF MARINE ELECTRONICS L L C e Mukilteo Washington 12125 Harbour Reach Drive Suite B Telephone 425 583 1900 Mukilteo WA 98275 Telefax 425 493 1569 Page A 29 ZF Marine Electronics LLC 12125 Harbour Reach Drive Suite B Mukilteo WA 98275 Page A 30 APPENDIX B TROUBLESHOOTING B1 TROUBLESHOOTING GENERAL The ClearCommand Control System consists of one Processor per engine typically mounted in the engine room and one to five Control Heads located at the vessel s Remote Stations In the event that a malfunction occurs review the appropriate System Diagram and become familiar with the various components their functions and locations on the vessel Section B1 2 page B1 1 is a list of the main components that make up a typical system along with a brief description of their functions B1 1 Control System Examples B1 1 1 96202 Throttle Electronic Clutch Solenoid Two Station Processor The 96202 is designed to precisely control speed and direction
36. Electronics Representative for further information Page 2 14 PLAN THE INSTALLATION 3 PLAN THE INSTALLATION 10D NOTE ZF Marine Electronics recommends that the system be installed in accordance with ABYC E 11 and P24 3 1 System Requirements The first step when installing a System is to carefully plan the installation This includes finding proper mounting locations for the Processor s and Control Heads The decision must be made on where power is going to be sourced and how the power will be routed to the Processor s Once the locations have been decided lengths of electrical wiring and Harnesses and must be determined 10 71 272mm l 320 5 Mei I P 10 40 264 2mm 4 75 120 7mm 10 25 260 4mm Figure 3 1 Processor Dimensions Grounding Bonding is required for maximum electromagnetic compatibility EMC performance Refer to Appendix A Bonding Only when the previous items have been determined should you start the actual installation The following sections describe the requirements for installing the components and selecting mounting locations 3 1 1 Processor s Processors required per engine Twin Screw Two 2 Processors Mounting Hardware is installer supplied Installation Troubleshooting Manual is included with the Processor The following items must be taken into account when selecting the locatio
37. Lever Operation tis strongly recommended that the Master lever is returned to the Neutral ldle position prior to turning OFF One Lever Operation e Do not attempt to transfer command from one Remote Station to another while in One Lever Operation Always turn One Lever Operation OFF prior to transferring Failure to observe these recommendations may result in a sudden change in the vessel s direction AJ Place the Master lever into the Neutral detent B Place all inactive Control Head levers into the Neutral detent Whenever an inactive lever is moved to the Neutral detent One Lever Operation is turned OFF for that lever ONLY n applications with three or more screws the green LED will not turn OFF until all inactive Control Head levers are returned to the Neutral detent NOTE E 2 Multiple Srew applications always program all the Processors for the same amount of High e In Multiple Screw applications all Processors will be in High or Low Idle at the same time High SCH is not available when Transfer Mode 03 or 04 are selected or when a DP system is in control 2 1 Engine Synchronization Multi Screw Engine Synchronization must be selected during Set Up to have automatic synchronization Key NOTE The Control System offers two types of synchronization Active or Equal Throttle Synchronization is automatic and only operates when the Ahead clutch is engaged consequently it can be left ON full time Whe
38. MC2000 2P PEN SS ER REFERENCE INFORMATION SIDE VIEW 15 STBD D THROTTLE AA c gt PS THROTTLE 65 65 20 AWG C JUMPER DEEN 18 GA SEVEN OUTLINE DIMENSIONS ee Ar CABLE PART NUMBER MC2000 2P CONTROL HEAD CONNECTIONS l B im TYP 4 66 6 25 6 1mm THRU 118 4mm 2 HOLES MOUNTING SCREWS 1 4 20 ZF MARINE ELECTRONICS LLC 46 11 7mm 12125 HARBOUR REACH DR SUITE B MUKILTEO WA 98275 II CLEARCOMMAND gt 6202 X PANEL CUT DIMENSIONS SYSTEM DRAWING SCALE PART NO SHEET NONE ee 4 OF 4 4 2 1 Page C 7 Page C 8
39. OPENS this indicates the software program has quit running due to a component failure or loss of DC power A full explanation is provided in Section 8 1 page 8 1 Clutch Pressure Interlock The purpose of the Clutch Pressure Interlock is to prevent high engine RPM when the Clutch is not fully engaged A full explanation of the Clutch Pressure Interlock is provided in Section 8 2 page 8 2 Station Expander SE The SE is a separate Processor housed in an enclosure that allows the connection of up to five additional Remote Control otations The SE communicates with the Processor over the serial communication line A full explanation of the installation operation and adjustment E E SE is provided in the Installation Manual provided with the SE If this option is going to be used please contact a ZF Marine Electronics Representative for further information Trolling Valve Operation When the Control System is set up to control trolling valves the operation is quite different from Normal Operating Mode Troll Mode is a feature that must be turned On and Off at the Control Head On initial power up Troll Mode is disabled If this option is going to be used please contact a ZF Marine Electronics Representative for further information Engine Room Only Remote Switch Station No 1 is typically designated as the Engine Room Station when this feature is used When the switch is CLOSED Station No 1 will take com
40. Processor s tachometer signal requirement If a sensor other than one supplied by ZF Marine Electronics is used it must meet the criteria provided below for each type 3 1 6 13 AC Coupled Sensors The signal must have a minimum amplitude of 1 5 V 3 0 V P P The signal s maximum amplitude must not exceed 100 V 200 V P P The frequency of the signal must be no lower than 30 Hz at Idle e The signal s frequency may not exceed 8 KHz at Full Throttle 3 1 6 14 Alternator The pre rectified stator AC terminal may be used as the tach source The signal is inputted to the AC Coupled Sensor input The signal must meet the same criteria as any AC Coupled Sensor Signal refer to Section 3 17 6 13 3 1 6 15 Point side of the Coil e When the signal is sourced from the coil or an electronically produced tach signal used on some gasoline engines the signal is connected to the AC Coupled Sensor input The signal must meet the same criteria as any AC Coupled Sensor Signal refer to Section 3 17 6 13 3 1 6 16 Active Sensors Open Collector Output e The sink current ability of the Sensor may be no lower than 2 mA The operational current may not exceed 50 mA e The Sensor must have a maximum saturation voltage of 0 8 V An operational voltage requirement of 9 10 VDC A minimum frequency of 5 Hz at Idle Page 3 5 PLAN THE INSTALLATION e A maximum frequency of 8 KHz at Full Throttle 3 2 Installer Supplied T
41. Sequence Relinquish Receive Modes P003 amp P004 2 2 TRANSFER REQUEST SEQUENCE REQUEST RELINQUISH MODE P0O3 2 STEP atus ba eret eoe e e ta ete e 2 3 TRANSFER REQUEST SEQUENCE REQUEST RELINQUISH RECEIVE MODE P004 3 STEP olann 2 3 PIODOMIO Mal PAUSE tr its eS a teh hk tds 3A nd ee 2 4 Warm up Mode Throttle Only Model 2 4 Control Head Warm Up MOC S eege ty Shae io ieee a ca ee adh e da ede en 2 4 Control Head Normal Operating Mode ENEE 2 4 Sigi ee AA A SER EEE ERS EEE ERREGER 2 4 EE AA Des EOE ae xe PE ES A d es 2 4 FIG Idee ee a nC 2 4 Selecting Between High and Low Idle 1 ee eee eee on o 2 5 leie ow Idle Mode Selection aa E E AAA DO AE e IE A Re etae 2 5 One Lever Mode Mult SCREW EEN 2 5 Turning ON One Lever Operation no 2 5 Step A One Lever Operation Mode sets a Gehl caves LS ated A cred woe he Vente woes des aes 2 6 Step B One Lever Operation Mode e dada Sew he Bd oe reads a Se are acd lee et ebe eat Nb Sx 2 6 J rmpng OFF One Lever ODClOuOn ii Rd a 2 6 Engine Synchronization Multi EE 2 6 SVBCHFODIZUTIOTEC HILeFIO di Se A SANAR 2 6 HERE A AAA A he de eed a VE UE dee 2 6 EQUAL THRO TILE SYNCHRONIZATION DEFAULT ENABLED bebe ag as e anne 2 7 ACTIVE SYNCHRONIZATION DEFAULT DISABLED ee AAA AA 2 7 TABLE OF CONTENTS 3 2 10 3 2 10 4 210 41 2 10 4 2 2 10 5 ze 2 11 1 2 11 2 2 11 2 1 2 11 2 2 211 3 2 11 3 1 2 11 3 2 2 11 4 2711 5 2 11 6 2 11 7 2 11
42. Transfer Button again for approximately 2 seconds until the red LED begins blinking at a fast rate Troll Mode Indication G The measurement should be 0 VDC H Position the Control Head lever to the Ahead detent The measurement should now be 12 or 24 VDC depending on the Solenoid s rating I Position the Control Head lever further forward while monitorin the DC Voltmeter The measurement should go from 12 or 24 VD to 0 VDC at the same time the red LED on the Control Head becomes lit solid Troll Command Proportional Solenoid Testing with Amp Meter A Ensure power is removed from both the Processor and the Clutch Power Supply B Disconnect the Clutch Harness from the number 3 Processor 8 PIN CONNECTORS connector pigtail C Insert the Break out Box between N the number 3 Processor GEAR BOX connector pigtail and the Clutch T LS Harness as shown in Figure 2 s 19 D Set up the Multimeter to measure c fo N COMM ON FLIP SWITCH i E BT en m cu mA and connect the black lead cx De Ro COMMAND t to black socket and the red lead SIGNAL to the red socket labeled TROLL Or e COMMAND as shown in Figu
43. Trials Refer to Section 6 6 page 6 2 To change the Value Refer to Sections 5 2 and 5 3 page 9 2 S Scroll to Function Code E5 B Activate Set Up Mode C Scroll Up or Down to the desired Value D Store the Value to memory Figure 5 8 Display LED Function E5 Set Up Activated 5 5 2 1 4 Function Code E6 High Idle This Function Code Programs the RPM of the second elevated Idle The available Values for this Function are 00 0 to 20 0 of Throttle Maximum The Default Value is 00 0 The Value selected is a percentage of the Value selected in Function Code E3 Throttle Maximum 10D NOTE This Function is typically programmed during Dock Trials or Sea Trials Refer to Section 6 4 page 6 1 Function Code is Blinking a El Figure 5 9 Display LE D Function E6 Set Up Activated To change the Value Refer to Sections 5 2 and 5 3 page 9 2 Scroll to Function Code E6 Activate Set Up Mode Scroll Up or Down to the desired Value Store the Value to memory GOs Page 5 9 SET UP PROCEDURES 5 5 2 1 5 Function Code E7 Synchronization This Function Code selects the type of Synchronization if Synchronization is required The types are described in Section 2 10 page 2 6 The available Values for this Function are 00 Equal Throttle Open Loop Synchronization 01 Active Closed Loop Synchronization reverts to Equal Throttle Synch if there is no Tachometer Sensor signal 02 No S
44. accompanied by one of the following error codes 1 Clutch Astern Shorted 2 Clutch Astern Open 5 Clutch Ahead Shorted 6 Clutch Ahead Open Page B5 4 TROUBLESHOOTING TROUBLESHOOTING STATION TRANSFER In order to transfer command from one Remote Station to another the following must occur B6 B6 1 B6 2 There must be a valid Command Signal at the Station being transferred to The Command Signal must indicate that the Control Heads lever s is at the Neutral Idle position The Transfer Button must be depressed which takes the Station Select signal from 5 00 VDC to 0 00 VDC If a transfer from one Remote Station to another is requested but does not take place the items required for successful transfer can be tested as follows Command Signal The Command Signal is a DC voltage which varies in relationship to the Control Head s lever position The Processor provides each Control Head 5 00 0 20VDC which is referred to as the Reference Voltage The Reference Voltage is applied to a 5K Ohm Potentiometer in the Control Head The potentiometer s Wiper taps off a portion of the Reference Voltage and sends it back to the Processor The amount of DC voltage which is ta ped off is dependant on the osition of the Control Head s lever When the lever is fully Astern a small portion of the Reference Voltage is tapped off by the wiper and therefore the voltage is at its lowest po
45. after ALL information has been recorded in the previous Section Control Checks Table 7 1 Record Processor Functions Function d xeler to section 5 5 1 page 5 6 Ao Processor identification Ai Number of Engines A one Lever Operation EL A3 BE Station Expander AA Re Noutral Tndication on CT 1 Table 7 1 Record Throttle Functions A S8 LLLI F0 EmsneThn leProle L Ip Tino A TE To eMiimum E TE __ fThrotile Maximum F1 ThmotleMaxmumAsem ES ThrtlPauseFolwigShit A F6 IN EE TE Em L Table 7 1 Record Clutch Functions Function 2 fRefer to Section 5 3 page 511 CO Clutch Pressure Interlock L Ci fClutch interlock Delay OA Cz Proportional Pause SSS OOS C3 Proportional Pause tim NANA C4 Proportional Pause Rao NANA C Shift Solemoid Type NANA C6 ZFHuthDuyCydeAhad TE C ZFHuthDuyCydeAsem OC NAAA C Fixed Neutral Delay IT 7 5 4 Comments Please use additional paper as necessary 7 5 4 1 General Installation Condition 7 5 4 2 Any Irregularities INSPECTOR DATE Page 7 6 CONTROL OPTIONS i3 8 CONTROL OPTIONS 8 1 External Alarm Capability CAUTION The Processor s Alarm circuit is limited to a maximum
46. and Figure 1 3 the typical pigtail plugs on a 9000 Series ClearCommand Processor BEIER lt PAS s Se O j 118738 NOTE Not all ClearCommand Processors have all of the pigtails shown in Figure 3 Only the pigtails that are required for a specific application are installed in a ClearCommand Processor 3 a x 1 11339 Example Figure 1 2 CruiseCommand Connector Locations Figure 1 3 Example of ClearCommand Pigtail Locations H Description 1 Black 8 Pin 2 Black 12 Pin 3 Gray 12 Pin 4 Gray 8 Pin 5 Gray 6 Pin 6 Gray 4 Pin Harness Type Throttle Connector Pigtail Power Connector Pigtail Clutch Connector Pigtail Control Head Connector Harness Use The throttle signal is output from this connector pigtail The signal may be in the form of Pulse Width Modulation PWM Voltage Current or Frequency This connector pigtail contains the inputs and outputs for Main Processor Power Start Interlock Clutch Oil Pressure Interlock and External Alarm Circuit The external connections for Clutch Power Ahead Astern and Neutral Solenoids Troll On Off and Proportional Solenoids are made at this connector pigtail All the required connections for the Remote Gol Stations are made at these connectors Serial Communication Connector The Serial Communication connections between multiple Pigtail Tachometer Sensor Connector Pigtail Processors in a
47. and connected to pin 3 of the Control ead s terminal block TROUBLESHOOTING 91 Table B9 1 Basic Control System Problem Causes and Solutions 5 Causes Solutions a The Station No 9 transfer button was held down for 15 The Station No 10 transfer button was held down for 15 seconds or longer The Station No 9 Control Head transfer button is defective The Control Head Harness is miswired The Control Heads Pigtail is miswired seconds or longer b The Station No 10 Control Head transfer button is defective The Control Head Harness is miswired The Control Head s Pigtail is miswired The Serial Harness is in excess of 120 feet 37m b The Processor is defective The Serial Harness s shield is not properly terminated The Serial Harness is in excess of 120 feet 37m b The Processor is defective The Serial Harness s shield is not properly terminated The Serial Harness is not connected at one or more Processors The Serial Harness is incorrectly wired Loss of power to one of the Processors a The Serial Harness is in excess of 120 feet 37m The Processor is defective The Serial Harness s shield is not properly terminated The Serial Harness is in excess of 120 feet 37m b The Processor is defective The Serial Harness s shield is not properly terminated The Serial Harness is in excess of 120 feet 37m b The Processor is defective The Se
48. are wired to separate terminals on the APS and internal diodes maintain total isolation between them A single output terminal is wired to the ZF Marine Electronics Propulsion Control System The APS is rated for loads of up to 70 Amps on 12 24V systems The unit is ruggedly constructed with heavy duty wiring studs and epoxy potted components in an anodized aluminum case B APS SPECIFICATIONS Model 13505 Maximum Load Current 70 amps Operating Temperature 40 degrees C to 80 degrees C derate linearly from 100 50 degrees C to 70 80 degrees Voltage Drop 0 7 VDC 50 load 0 9 VDC full load Dimensions 3 25 x 4 5 x 3 1 8 3 x 11 4 x 7 9 cm C MATERIALS PROVIDED The single APS is supplied with a hardware packet containing 6 hex nuts 3 lock washers 4 self tapping mounting screws 1 instructions diagram 10D NOTE Not all of the hardware will be used in the installation some spares are provided 7 Nut size is M 6 The twin APS is supplied with 2 single APS hardware packets D INSTALLATION Refer to the installation Drawing 11488D 1 Shut off all charging sources and disconnect the negative ground side of each battery which will be wired to the APS 2 Mount the APS s in a suitable location which will keep wire runs to a minimum length and is preferably ventilated for cooler operation The case of the APS is electrically iso lated from the internal diodes so mounting on either a metal or non meta
49. current of 0 5 S Amperes and a maximum voltage of 100 Volts DC Exceeding these limits will permanently damage the Alarm circuit The Processor comes equipped with a normally open relay contact for connection to an external Status Indication circuit The relay energizes closing the contact when the Circuit Board has power applied and the software program is running normally In the event of a power loss or the software program detects an anomaly the relay de energizes and the contact opens EXAMPLE OF CONTROL SYSTEM STATUS INDICATION PROVIDED BY OTHERS een ee ee e ee Me CONTROL SYSTEM FAIL INDICATOR LIGHT AND OR AUDIO ALARM DC POWER SOURCE i QUNM BLACK 12 OR 24VDC YU R Xy gi 77 RED FUSE ALARM INDICATION 7 nae pe CIRCUIT ON OFF SWITCH RELAY WITH A NORMALLY CLOSED CONTACT AND A DIODE ACROSS THE COIL FOR SURGE SUPPRESSION MEN 11873 VAR 0000 BEE EEE For V 12 VDC POWER PIGTAIL CONNECTOR R Load gt 0 37 Ohm For V 24VDC POWER HARNESS R Load gt 0 18 Ohm PROCESSOR i MAX CURRENT 0 5 A T gt PROCESSOR POWER START INTERLOCK CLUTCH PRESSURE INTERLOCK Figure 8 1 External Alarm Connections with Processor Harness Example EXAMPLE OF CONTROL SYSTEM STATUS INDICATION PROVIDED BY OTHERS CONTROL SYSTEM FAIL INDICATOR LIGHT AND OR AUDIO ALARM D
50. draw with no more than 10 voltage drop B1 2 4 Electrical Cables and Harnesses The function of the Electrical Cables and Harnesses are to move electrical information from one point to another The ZF Marine Electronics System has electrical cables and or pluggable Harnesses These Harnesses may have plugs on one end or both depending on its purpose There are Harnesses available for Control Head Interface DC Power Start Interlock Clutch Oil Pressure Interlock and External System Status Indication Circuit In addition the application may require Harnesses for one or more of the following Engine Interface Shift Interface Serial Communication Tachometer Sensor Signal Prior to attempting to troubleshoot the System get as much information as possible from the owner or operator Inspect the System for signs of misadjustments loose connections physical damage or water incursion Pay special attention to the following items DC Power Source Component Location Component Condition Interconnecting Wiring and Harnesses Wire Terminations Plug and Socket Pins Page B1 1 TROUBLESHOOTING B2 TROUBLESHOOTING QUESTIONS Prior to lifting a tool or stepping on board the vessel many problems can be resolved by asking the customer the following basic questions A B C D E F Is the System installed on a Single Twin or Multiple Screw vessel Ifthe System is installed on a Single Screw vessel this question
51. eh de dre ben deba ac a x eri Abad des da TAS Equal Throttle SynchronizatiOn x 5 4 3 a du d IO CX a aU dx CES oS VE A 7 3 Active SYNCHFONIZALION 2 4 uw a a ERS 7 3 SO E RS EE 74 Vessel InfoHmutiofm ou dus AS A e ERE A appa Tu es 7 4 Control System Checks nata ARS ia CALIX ES AA a 7 4 Seg TridE Processor MOUNTING GE 7 4 Seu Tngl POWERSUDPIV ere AE 7 4 DOCK RE 7 5 Sed E 7 5 HeCcord Para meters El Shae he eb eler ace CAHSEE WE ge BEL 7 6 Record Processor FUNCUONS EEN 7 6 Record Throttle FUNCTIONS EN 7 6 Record Clute Functions EE 7 6 Comments Please use additional paper as gecessgrl eee ees 7 6 GENERA REEL 7 6 aM CUA EE tei noie ta iode bte c Pene EE 156 CONTROL OPTIONS e 81 External Alai Ea Da Ia EIA a X ek aa 8 1 External Alarm Connections with Processor Harness Example 000000 eee eee eee 8 1 External Alarm Connections Processor Hard Wired Example cen 8 1 lee e SE 8 2 Clutch Pressure InterloG e usua qoe oe wi dey tte Ryu ge om utes BOR deed tad 8 2 CO Methods of ODSFULIOD aci u t t eH reb A dud b doo dde da as ara 8 2 OMA AE NUNC B2 OZ KEE E CLUTCH PRE SUREINTERIOCK E 2 Clutch Pressure Switch with Processor Harness Diagram eee 8 3 Clutch Pressure Switch with Processor Hard Wired Diagram eee 8 3 la Sy qo OOM TEE 8 3 Stalon Expander oE Var 8 dedu dere da EEN 8 3 Tolling Valve e Le a a ee ee pe a re 8 4 Engine Room Only Remote Switch SEENEN 8 4 Eoo KO E eta ea E EEEE a E E T
52. ends Two of the plugs are for Remote Stations and one s for Power Start Interlock Serial Communication and Tach Sensor Additional Harnesses required will depend on the actual installation Four different styles of plugs are utilized but are inserted in an identical fashion as follows 4 3 1 Plug Insertion and Extraction een A Prior to inserting the plug pay close attention to the E m number of pins and the keying of the plug The plug og H is designed to be inserted one way SE but En e E Nemes e incorrectly forced together in the opposite HM NIS orientation Refer to Figure 4 1 to insert plug an e correctly Figure 4 1 Harness Plug Keying B When connecting the plugs ensure that the locking mechanisms are depressed and held until the plug is vm Rer fully connected or disconnected Refer to Depress amp Hold ee Figure 4 2 Detail I Detail I Large Plug Side View Small Plug End View Figure 4 2 Harness Plug Locking Mechanism 4 3 2 Standard Power Start Interlock Harness The Power Harness has a minimum of two cables DC Power and Start Interlock and may have two more optional cables Clutch Pressure Interlock and External Alarm Circuit 4 3 2 1 DC Power Cable Refer to Appendix A Automatic Power Selector A Insert the black twelve pin
53. engine WARNING The available range for this Function is 0 0 to 20 0 Using a value of 20 will likely damage the transmission This range is provided to allow as much leeway as possible when using this Function but is not intended to use 20 O NOTE A value of 0 0 for Function Code F0 means Idle Speed Units Percent of Throttle Range Throttle Range Throttle Maximum E3 Throttle Minimum E2 Default Value 0 0 Range 0 0 to 20 0 Page 8 5 CONTROL OPTIONS 8 10 2 8 10 3 8 10 4 Examples A value of 0 0 results in no Speed Boost being used The Throttle Command Signal remains at Idle as the Clutch engages A value of 5 0 results 1n a 596 increase in the Throttle Command Signal during Clutch engagement If Throttle Maximum were set to 4 5 VDC and Throttle Minimum at 0 5 VDC the Throttle Range would be 4 0 VDC 596 of 4 0 VDC equals 0 2 VDC The Speed Boost Throttle Command Signal would be 0 5 VDC 0 2 VDC 0 7 VDC Speed Boost Duration F1 This Function programs how long the elevated speed Speed Boost Signal is applied The duration time programmed begins when Function Code F2 Speed Boost Start Delay has ended Units Seconds Default 0 0 Range 0 0 to 20 0 Examples A value of 0 0 is 0 0 seconds A value of 2 5 is 2 5 seconds A value of 5 0 is 5 0 seconds Speed Boost Start Delay F2 This Function determines the amount of time after the Ahead or Astern clutch engagement co
54. enter a Value of 02 B11 2 Active Synchronization B11 2 1 Basic Troubleshooting B11 2 1 1 SYMPTOM The green LED is lit solid though the Engine RPM s differ by a significant amount Causes Solutions a The Tach Sender signal has been lost by a Scroll to Function Code HO Go to the Value for the Tach Sender s input vacent one or both Processors If the a A d is 0000 the signal has been lost and the system diverted to Equal Throttle Synch Correct the wiring or replace the Sender B11 2 1 2 SYMPTOM Will not synchronize Causes Solutions Synchronization is Disabled a At the Station in Command move both Control Head levers to more than 5 of the speed range Press and hold the transfer button for 5 seconds If synch is disabled the green LED will light as long as the button is pressed If synch was enabled the green LED would have blinked twice The Serial Communication Harness is not b Plug the Serial Communication Harness into both Processors plugged into both Processors The Port and Starboard Processors have On the Port Processor scroll to Function Code AO and enter a Value of 01 the same ID number On the Starboard Processor scroll to Function Code AO and enter a Value of 02 The Port and Starboard Processors are not d Scroll to Function Code A1 on the Port and Starboard Processor Enter a Value of set up for twin screw operation 02 into both Processors B11 2 2 Electronic Throttle B11 2 2 1 SYMPTOM
55. have read the descriptions of their usage and have verified their need Refer to Section 8 10 page 8 5 No adjustments should be made to speed boost until Function Codes C2 Proportional Pause C3 Proportional Time and C4 Proportional Pause Ratio have been properly adjusted 5 5 6 1 1 Function Code FO Speed Boost Percent Contact ZF Marine Electronics if this Function Code is going to be changed from the default setting 5 5 6 1 2 Function Code F1 Speed Boost Duration Contact ZF Marine Electronics if this Function Code is going to be changed from the default setting 5 5 6 1 3 Function Code F2 Speed Boost Start Delay Contact ZF Marine Electronics if this Function Code is going to be changed from the default setting 5 5 6 1 4 Function Code F3 Speed Boost Bypass Clutch Delay Contact ZF Marine Electronics if this Function Code is going to be changed from the default setting 5 5 6 2 Transfer Function Codes PO P1 5 5 6 2 1 Function Code PO Transfer Mode There are four different Modes of Station Transfer available The Default Value is 00 00 Neutral Only Default Value 1 When selected transfer from one Remote Station to another can ONLY be accomplished when the receiving Remote Station s Control Head lever is in the Neutral detent 2 After the receiving Remote Station s Control Head LED lights there is a 1 second delay before the receiving Remote Station s Control Head lever has command This allows the oper
56. here when an Open Collector Type Tach Sender is used Drain wire Shield connection 4 4 5 Clutch Cable Location 8 A single four conductor cable must connect the two Shift cables to the Processor through a 12 pin plug 4 4 5 1 Processor Termination A Install a liquid tight connector into hole no 10 B Run a 32 inch 0 82m piece of four conductor cable through the liquid tight connector and tighten leaving 16 inches 0 41m outside of the Processor C Strip back 4 inches 101 6mm of the PVC jacket inside the Processor Slide a 1 inch 24 5mm piece of heat shrink over the end of the cable as shown in Figure 4 16 D inch 4 inches 3 8 inch 25 4mm 101 6mm 9 53mm L s u Tr Pa 12263 Ba Heat Shrink d Figure 4 16 Clutch Cable Heat Shrink in Processor E Strip back 3 8 inch 9 53mm from the four conductors and connect to the Processor as shown in Figure 4 7 page 4 4 4 4 5 2 Plug Termination A Strip back 2 1 4 inches 57 15mm of PVC jacketing Figure 4 17 Clutch Cable Plug Termination Connections B Slide the boot onto the cable C Strip back 1 4 inch 6 35mm from the four conductors D Crimp Pins onto the eight conductors E Insert the pins into the appropriate terminations as shown in Table 4 4 F Slide the boot over the connector G Tie wrap the boot in place Page 4 9 INSTALLATION Table 4 4 Clutch Termination Table Ahead Clutch Solenoid TH TETIS 4 4 6 Thro
57. of calibration 2 The potentiometer is defective 3 A high resistance connection exists on pin 6 green wire between the Control Head and Processor f the A D value is less than 75 1 There is an open wire between pin 6 green wire of the Control Head and the Processor 2 There is an open wire between pin 7 blue wire of a right hand Control Head and the Processor 3 There is an open wire between pin 5 blue wire of a left hand Control Head and pin 7 Dr wire of the Processor Steady Tone B5 1 4 Figure B5 5 Steady Tone The Steady Tone is an indication to the operator that something has dap wrong within the Control System The Steady Tone will typically e accompanied by an Error Message on the Processor s Displav If the tone is heard the Processor s Display must be referred to in order to further diagnosis the problem The Transfer Button is shorted Tone will cease when command is taken at another Station If the Transfer Button becomes shorted for 12 seconds or more during Normal Operation a steady tone will be produced at all Remote Stations as long as the Transfer Button remains shorted Full System control remains Transferring to another Remote Station silences the Steady Tone Command cannot be regained at the Station until the problem is rectified Three Second Steady Tone Eo ooo e Figure B5 6 Three Second Tone This tone could indicate one of three things e Transfer Button on the Control Head in
58. pigtail B Runthe two conductor Alarm cable to the location of the Status Indication Circuit C Connect the black and red conductors to the Status Indication Circuit as shown in Figure 8 1 or Figure 8 2 8 2 Clutch Pressure Interlock S NOTE The Clutch Pressure Interlock CO must be set to be used Refer to the Section 5 6 3 1 1 page 5 13 for Function Code CO Clutch Pressure Interlock The Clutch Pressure Interlock uses a Pressure Switch which monitors the Ahead and Astern Clutch pressures The Pressure Switch must have a Normally Open N O contact that closes when adequate Clutch pressure is reached The primary function of the Interlock is to prevent high engine RPM when the Clutch is not fully engaged The Interlock option must be selected with Function Code CO There are two selectable methods of operation as described below CO Methods of Operation 8 2 1 8 2 1 1 8 2 1 2 01 Installed When selected the Interlock will command the Throttle to Idle if low or a loss of pressure occurs while cruising The Interlock is activated when the Pressure Switch s contact opens for the minimum period of time selected with Function Code C1 If adequate Clutch pressure is not reached in the time programmed in Function Code E5 throttle will be allowed to increase above Idle The Throttle will remain at this commanded speed for the time programmed in Function Code C1 and then returned to Idle unless adequate pressure is rea
59. so that the Serial Harness is less than 120 feet 37m b Replace the faulty Processor Ensure that the shield is terminated and the termination is at one side only Reposition the Processor s so that the Serial Harness is less than 120 feet 37m b Replace the faulty Processor Ensure that the shield is terminated and the termination is at one side only Ensure that the Serial Harness is properly seated at all Processors Refer to the Serial Plug pin out in Appendix B Correct or replace the Harness Restore Power to the Processor a Reposition the Processor s so that the Serial Harness is less than 120 feet 37m Replace the faulty Processor Ensure that the shield is terminated and the termination is at one side only Reposition the Processor s so that the Serial Harness is less than 120 feet 37m b Replace the faulty Processor Ensure that the shield is terminated and the termination is at one side only Reposition the Processor s so that the Serial Harness is less than 120 feet 37m b Replace the faulty Processor Ensure that the shield is terminated and the termination is at one side only Reposition the Processor s so that the Serial Harness is less than 120 feet 37m b Replace the faulty Processor Ensure that the shield is terminated and the termination is at one side only Connect the Serial Harness into Processor ID No 1 I
60. speed The Values listed for Function Code C3 Proportional Pause Time are the zero The time required to build up to the maximum pause is six times the Value selected In addition in order to build up to the maximum delay Value the System must be commanding Full Throttle The Pause when s E Astern to Ahead is either half or the same as the Ahead to Astern delay depending on the Va ue selected for Function Code C4 Proportional Pause Ratio IRC NOTE A stop watch is required to accurately program the Proportional Pause Time The amount of pause required is determined as follows A Place the Control Head lever s to the Full Ahead position B Leave the Control Head lever s at this position for whichever of the following two is longer Sixty seconds The vessel s speed through the water reaches maximum C Quickly move the Control Head lever s to Ahead Idle or Neutral depending on Function Code C4 setting while starting the stop watch D When the engine s RPM reaches Idle and the vessel s speed through the water is within two knots of the standard Idle Ahead speed stop the stop watch E Program Function Code C3 Proportional Pause Time as described in the Set Up Procedures to the time expired on the stop watch 7 3 1 Testing The Proportional Pause CAUTION It is critical that the Proportional Pause is tested as outlined below to ensure Q that it was properly programmed Failure to do so could cause dam
61. system eh occurred no Remote Station has command the operator can accept command at any Remote Station One Long Three Short Tones NEN WW i el me i Page 2 10 OPERATION This tone indicates that the command signal from the Station in Command has gone out of the acceptable range 2 12 1 3 Steady Tone This tone indicates that the software program within the Processor has quit running due to low voltage or component failure 2 12 1 4 Five 5 Second Steady Tone BS This tone indicates that there has been a loss of Serial Communication 2 12 1 5 Three 3 Second Steady Tone ETA This tone is heard if there is a stuck transfer button or when entering Back up Mode or if a Troll Solenoid error occurs Back up Mode and Troll Solenoid is not available for all Processors 2 12 1 6 Five Seconds On Five Seconds Off High Repetitive Rate Tone HEHEHE amp HEHEHE amp HEHEHE E HEHEHE EE This tone indicates a loss of communication with the Station Expander 2 12 2 Clutch Solenoid Tones 2 12 2 1 One Long One Short Tone Po sa Ho This tone indicates that a fault was detected with the Ahead Neutral or Astern Clutch Solenoid 2 12 3 Troll Integrated Solenoid Tones If Troll is used 2 12 31 Three Second Steady Tone Lo This tone indicates that the Troll Solenoid is OPEN or shorted Refer to the Error Code displayed for further information 2 12 4 Transfer Tones 2 12 4 1 1 2 Second ON 1 2 Second OFF Tones EEE BE
62. the Astern detent D Scroll to Function Code C7 Activate Set Up Mode Scroll Up or Down until the appropriate minimum Figure 5 22 Display LED Function C7 Set Up current level is reached Function Code is Blinking Activated G Store the Value to memory H Return the Control Head lever to the Neutral Idle position 5 5 4 Troll Functions NOTE The only Troll function initially displayed is LO Whe LO is set to any Value other than 00 the remainder of the Troll functions L1 through L6 will be displayed D 5 5 4 1 Troll Basic Functions LO L4 L5 5 5 4 1 1 Function Code LO Troll Enable and Control Head Lever Troll Range There are four types which can be used to control any trolling valve The available Values are 00 No Troll Default Value 01 20 Degrees Type 1 02 35 Degrees Type 2 03 45 Degrees Type 3 Throttle limited to 75 04 55 Degrees Type 4 Throttle limited to 10 Contact ZF Marine Electronics if this Function Code is going to be changed from the default setting 5 5 5 Troubleshooting Functions 5 5 5 1 Basic Processor Troubleshooting Functions 5 5 5 1 1 Function Code HO Diagnostics This Function is used during troubleshooting and is explained in detail in Appendix B Section B4 5 5 5 1 2 Function Code H1 Return to Factory Defaults This Function may be used during troubleshooting Do not make any adjustments to this Function Code unless directed to do so by Z
63. the Throttle range E Check the engine tachometers to see if they are within 1 of one another F Move both Control Head levers side by side to approximately 75 of the Throttle range G Check the engine tachometers to see if they are within 196 of one another H Move both Control Head levers side by side to 100 of the Throttle range I Check the engine tachometers to see if they are within 1 of one another While synchronized if the tachometers have a greater than 196 percent difference at any engine RPM or if they appear to be oh hunting for the correct RPM refer to the Appendix B Troubleshooting Section Page 7 3 SEA TRIALS 7 5 Sea Trial Report The purpose of this Sea Trial Report is to provide a convenient checklist and record of installation dock trial set up and sea trial performance of the ZF Marine Electronics Propulsion Control System Please enter ALL of the information We recommend that this form remains aboard the vessel and a copy is sent to ZF Marine Electronics with the Warranty Registration located at the end of this manual 7 5 1 Vessel Information Vessel Name Hull No Trial Date Vessel Type BEEN Dwg No nl Se Owner Owner s Representative oo Tels ENGINE DATA Make Modi HP KW RPM PROPELLER DATA No of Screws Propeller Type Fixed g Other g GEAR DATA Make 0 Model Ratio No of Remote Stations Locations 1 4 mE PB Bo 7 5 2 Control System Checks Make the
64. the Value Refer to Sections 5 2 and 5 3 page 5 2 Function Code is Blinking A Scroll to Function Code AO B Activate Set Up Mode C Scroll Up or Down to the desired Value Figure 5 1 Display LED Function AO Set Up Activated D Store the Value to memory 5 5 1 2 Function Code A1 Number of Engines The total number of engines must be entered into the memory of each of the Processors All Processors in an installation must have the same value entered The available Values for this Function are 01 Single Screw Default Value 02 Twin Screw 03 Triple Screw 04 Quad Screw 05 Quint Screw NOTE If Processors are not connected by a serial communication cable leave the A1 function code at Default Value Page 5 6 SET UP PROCEDURES 10D NOTE Twin screw or more a require Function Code A1 Values changed on all Processors prior to changing the Value of Function Code AO To change the Value Reter to Sections 5 2 and 5 3 page 5 2 A Scroll to Function Code A1 H1 D Activate Set Up Mode B C Scroll Up or Down to the desired Value Figure 5 2 Display LED Function A1 Set Up Activated D Store the Value to memory NOTE Before continuing set up wait 5 minutes or cycle power 5 5 1 3 Function Code A2 One Lever Operation In Twin Screw or more applications the System has the ability to command all engines and transmissions to the same speed and direction with a single Control Head lever This Functio
65. the drain wire at the Control Head is not connected to ground Strip 3 8 9 5mm insulation off each wire Twist the individual strands of the wires to minimize fraying Crimp a locking fork terminal included with each Control Head to each of the conductors Make connections to the Control Head as indicated in the fol lowing TERMINAL CONNECTIONS diagrams ALWAYS REFER TO THE MANUAL THAT IS SUPPLIED WITH THE CONTROL SYSTEM FOR ANY UNIQUE CONTROL HEAD CONNECTIONS FOR YOUR SYSTEM When cable connections are complete MOUNT Control Head to the console using the two 2 Pluggable Strip back the PVC cover on the shielded cable approximately Plug Control Head cable into the 2 1 pigtail at the Control Head Ensure the correct Processor Cable is being plugged into the corresponding Control Head lever pigtail age the plug mounting screws and washers supplied with the Control Head Plug or Terminal When connecting the plugs ensure that the release button or are depressed and held until plug is fully connected or disconnected Connecting or disconnecting plugs without depressing and holding the release button or buttons will dam CABLE HARNESS CONNECTIONS Dual Control Head Connections TERMINAL CONNECTIONS CruiseCommand 9000 Series 585CE and Earlier MicroCommander and Pluggable 585CE MicroCommander and MS Series ClearCommand Pluggable MS Series ClearCommand Port Connections Starboard
66. to the Processor reporting the reporting the fault fault 53 54 55 c No power to the SE c Turn power On to the SE 96 8 9 a The battery is being overcharged a Repair or replace the charging system o resa los teria on tne batery while being hugo Clean ag to battery pos and terminals 57 a Battery will not take a charge and is defective a Replace the battery u b The battery is not being properly charged b Repair or replace the charging system c There s a high resistance connection between the battery c Locate and repair the high resistance connection and the Processor 58 a External Interference such as a lightning strike a If the error message is displayed once and you are able to clear the error take no further actions at this time If the error cannot be cleared replace the Processor b Component failure b Replace the Processor 59 la External Interference such as a lightning strike a If the error message is displayed once and you are able to clear the error take no further actions at this time If the error cannot be cleared replace the Processor b Component failure b Replace the Processor a External Interference such as a lightning strike a If the error message is displayed once and you are able to clear the error take no further actions at this time If the error cannot be cleared replace the Processor b Component failure b Replace the Processor 61 a External In
67. 0 0 Seconds F2 Speed Boost Start Delay 00 0 0 to 10 0 Seconds Fs Speed Boost Bypass Clutch Delay 00 eRe Section 5 5 6 2 page 5 16 Transter Mode 00 Neutral Only Not Used Lever Match and Neutral 03 Request Relinquish or Relinquish Receive 04 Request Relinquish Receive or Relinquish Receive P1 Transfer Timeout 0 0 to 99 0 Seconds 5 4 Field Service Test Unit Break out Box and Multimeter Use Refer to Appendix A MM13927 Manual for more information on the use of the Field Service Test Unit Break out Box VW 8 PIN CONNECTORS 12 PIN CONNECTORS To aid in adjusting the list of ELT E Processor signals in the tables 0 below ZF Marine Electronics o I Su recommends the use of ZF o O Se Marine Electronics Field Service Go o0 Test Unit P N 13927 Break out dl EC 09905 Multi Meter RS Box and a calibrated Multimeter Ce O RO Q9 9 Bum Figure 5 8 Service Field Test Unit and Multimeter Page 5 5 SET UP PROCEDURES ZF Hurth Duty Cycle Ahead Section 5 5 3 2 2 ZF Hurth Du Section 5 5 3 2 3 hrottle in Neutral Section 5 5 2 1 1 hrottle Minimum Section 5 5 2 2 2 hrottle Maximum Section 5 5 2 2 3 hrottle Maximum Astern Section 5 5 2 1 2 High Idle Section 5 5 2 1 4 Table 5 9 Throttle Functions Requiring Ser
68. 0 3 2 10 4 2 10 4 1 2 10 4 2 2 10 5 Active Synchronization default Disabled Active Synchronization must be enabled n Set Up and a Tachometer Sensor Wire Harness must be used The Processors each receive a tachometer signal representing engine RPM from their respective engines These signals are compared with one another over a serial communication line If the Synchronization Criteria Section 2 10 1 page 2 6 is met the throttle command signal of the engine s running at the higher RPM is lowered until the RPM s of all engines match Synchronization Indications The green LED located on the Control Head indicates the status of synchronization n Active Synchronization the green LED blinks every time there is a change in the commanded throttle When the green LED is lit steady the engines are synchronized When the green LED is not lit the engines are not synchronized and the Control System is not attempting to do so Turning Synchronization OFF ON when Criteria is Met Turning OFF When the criterial listed in Section 2 10 1 page 2 6 is met synchronization is automatic and does not need to be turned ON E s operator elects to turn OFF synchronization follow the steps elow A Ensure that the Control Head s levers are positioned to a point where Synchronization Criteria are met B Atthe Station in Command press and hold the transfer button until the green LED blinks and then goes out approximately 2 secon
69. 0 inch 9 9mm Clutch Pressure Interlock Electric Cable Requirements When the Clutch Pressure Interlock option is utilized a pressure switch with a normally open contact must be installed on the transmission along with a Shuttle Valve If the Clutch Pressure Switch is hard wired no plugs the electric cable may be ordered from ZF Marine Electronics or must meet the following specifications Two conductor both light blue 16 AWG 21 5 metric 300V 105 degrees C UL VW1 stranded tinned Copper wire Maximum outside diameter 0 390 inch 9 9mm External Alarm Circuit Electric Cable Requirements If the External Alarm Circuit is hard wired no plugs the electric cable may be ordered from ZF Marine Electronics or must meet the following specifications Two conductor red and black twisted 16 AWG 21 5 metric 300V 105 degrees C UL VW1 stranded tinned Copper wire Maximum outside diameter 0 390 inch 9 9mm Serial Communication Serial Communication Harnesses are required in EE Screw applications All Processors come equipped with Seria Communication Pigtail Plugs installed The Serial Communication Harness mates with these IE It is strongly recommended that only factory manufacture Harnesses are installed Refer to Appendix A Parts List for part numbers and available lengths Tach Sensor Electric Cable Requirements The cable selected depends on what type of Sensor is being used 3 1 5
70. 0460 204 0490 0462 203 04141 Solid Contacts Wire Gauge Range 16 18 amp 20 AWG 16 18 amp 20 AWG 128 14 AWG 128 14 AWG 8 amp 10 AWG 8 amp 10 AWG Strip Length inches 156 218 156 218 250 312 250 312 250 312 250 312 222 284 222 284 430 492 430 492 430 492 430 492 Step 4 Contact Insertion 1 Grasp crimped contact approximately 25 2 mm one inch behind the contact barrel 2 Hold connector with rear grommet facing you 3 Push contact straight into connector grommet until a click is felt A slight tug will confirm that contact is properly locked in place 4 Once all contacts are in place insert wedgelock with arrow pointing toward exterior locking mechanism The wedgelock will snap into place Rectangular wedges are not oriented They may go in either way NOTE The receptacle is shown use the same procedure for plug DEUTSCH d Lape INDUSTRIAL PRODUCTS DIVISION xc een Aormarteed US Dese 800 223 1236 A12 ZF Marine Electronics LLC Mukilteo Plant S 214 Rev F 3 05 Automatic Power Selector APS Model 13505 A GENERAL INFORMATION The APS Automatic Power Selector Model 13505 provides a simple solid state solution to the need for routing redundant DC power sources for vital electronic equipment while maintaining isolation of the DC power sources Two independent batteries rated at the same nominal voltage
71. 1 0 183 650001 NETHERLANDS vs vanstigt nl 5446 Dick Straathof Straathof Scheepselectra T 31 321 382315 Van de Plasschelaan 4 8251 PG Dronten NETHERLANDS F 31 321 336151 scheepselectra com MMC CL CR MC NEW ZEALAND 6948 ZF Australia Pty LTD mail Locked Bag 6305 Blacktown BC NSW AUSTRALIA 2148 ship 14 Lidco Street Arndell Park NSW AUSTRALIA VS CL CR Rodney Lean T 61 0 2 9679 5555 F 61 0 2 9679 5500 mailbox zf com au www zf com au NORWAY 7029 Karl Baumgart KGK Norge AS T 47 22 884 680 Casper Storms Vei 19 Oslo N 0664 NORWAY F 47 22 720 902 toma wulff zf group com www z group no MMC CL CR RUSSIA 7313 ZF Transmissia 000 Suite 313 71 Marata Street St Petersburg RUSSIA 191119 T 7 812 324 54 72 F 7 812 140 18 15 zf sp ru SCOTLAND Adi Licence T 44 115 986 9211 7326 ZF Great Britain Ltd Abbeyfield Road Lenton Nottingham UNITED KINGDOM NG7 25X ENGLAND F 44 115 986 9261 adi licence zf group it SINGAPORE Steven Wee T 65 6 44 88266 157 Mammoth Enterprises Pte Ltd mail PO Box 283 Siglap Post Office SINGAPORE 914503 ship 6 A Waringin Park SINGAPORE 416320 F 65 6 44 89800 mament singnet com sg Daniel Poone T 65 0 8 610177 7045 ZF South East Asia Pte 11 Tuas Drive 1 Singapore 638678 Rep of SINGAPORE F 65 0 6861 9173 daniel poon zf group com sg www zf mar
72. 1 51 Comm Error Time out Communication with System 1 has been too long without a Refresh message System 2 52 Comm Error Time out Communication with System 1 has been too long without a Refresh message System 3 53 Comm Error Time out Communication with System 1 has been too long without a Refresh message System 4 Comm Error Time out Communication with System 1 has been too long without a Refresh message System 5 SE Communication Error Communication with the Station Expander has been too long without a Refresh message High Battery Voltage Fault The applied battery voltage is 30VDC or higher for at least two seconds Low Battery Voltage Fault The applied battery voltage is 10VDC or lower for at least two seconds O to Software The system has had an unexpected Reset due to a software hardware fault Watchdog Reset Due to Software Fault The system has had an unexpected Reset due to a software fault EN ie to Hardware The system has had an unexpected Reset due to a software hardware fault Watchdog Oscillator Watchdog The system s Oscillator has had an unexpected fault B8 1 Clutch Solenoid Error Codes Table B8 2 Clutch Solenoid Control System Error Codes 6 Clutch Ahead Open The Ahead Clutch Solenoid should be drawing current butis not Page B8 2 TROUBLESHOOTING B9 BASIC PROBLEM CAUSES AND SOLUTIONS The following table lists the various Error Codes and provides possible causes and solutions Error
73. 1 3 This Function works together with Function Code CO Clutch Pressure Interlock Refer to Sections 8 2 page 8 2 for operational details The available Values are 00 5 to 10 0 seconds The Default Value is 01 0 seconds To change the Value Refer to Sections 5 2 and 5 3 page 9 2 A Scroll to Function Code C1 B Activate Set Up Mode C Scroll Up or Down to the desired Value D Store the Value to memory Function Code C2 Proportional Pause This Function selects whether the Clutch stays Or at Neutral when performing a Full Speed Reversal The In Gear Delay is most commonly used The Neutral Delay is used when a Shaft Brake is installed Page 5 11 SET UP PROCEDURES Function Code is Blinking sch The amount of time is adjustable with Function Code C3 Proportional Pause Time The delay programmed is maximum and EES when Values 00 and 01 are used The programmed delay is fixed when Value 02 is selected and Function Code C4 Proportional Pause Ratio is setto 01 1 1 Ratio When C4 is set to 00 the pause from Astern through Neutral to Ahead is 1 2 of the selected value The available Values are 00 In Gear Default 01 Neutral 02 Fixed Neutral Delay Enabled To change the Value Refer to Sections 5 2 and 5 3 page 9 2 A Scroll to Function Code C2 B Activate Set Up Mode C Scroll Up or Down to the desired Value D Store the Value to memory Figure 5 16 Display LED Function C2 Set U
74. 12 8 Ahead Astern Clutch Harness e TEE B12 2 B12 2 1 AheGd Ne Uta VASTEN EE B12 3 Table B12 9 Ahead Neutral Astern Clutch Harness Pin Out ee ENNER B12 3 B12 3 Marcia is ee Se A EA B12 3 B12 3 1 Cunen t MAN e Di A AA A ee esa qd qois B12 3 Table B12 10 Current MAN Throttle Harness Fun ic B12 3 B12 3 1 FEFEQUENCV dee ge A A A a Oe B12 3 Table B12 11 Frequency Throttle Harness PIiFOUE idera eege Dee CU CU M rus xS E Eo UI ee B12 3 B12 3 1 FUNN EE BERT B12 3 Table B12 12 PWM Throttle Harness PIN Out ccsccsccescssccsecnsccscsccsscssceecssceeecsccsecssceeeeescseceecaeceeececeeeceseeescesceeeaseeeeceses B12 3 B12 3 1 ee ASS AS A EEE EE B12 3 table B 12 13 Voltage Throttle Harness EE B12 3 B13 PROCESSOR PIGTAILS B13 1 B13 1 Basile OCS SSO lr FI Call E ct eee Se aet a ent tetur da B13 1 Table B13 1 Power Start Interlock Clutch Oil Pressure Switch Alarm Pigtail Pin Out REENEN B13 1 Table B13 2 Serial Communication Pigtail Pin EE B13 1 Table B13 3 Control Head Pigtail Pin Out Up to 5 St tions s eo iii Ra B13 1 B13 2 TOE Pae RC RR TR EE B13 1 Table BASA Throttle Pigtail PIN OUT ee ar RR ee B13 1 B13 3 Els aio ee E Se gek be e Ee B13 2 10bleB133 Glutch Pigtall EE B13 2 B13 4 Tachometer en sor PIOA maere er ae ee a B13 2 Table B13 6 Tachometer Sensor Pigtall PIR SA EA A NU eei UR EP N ER VENETO UAE ER DUE B13 2 ENG 143 Ver 1 OF EE B 3 ClearCommand 9000 Series Electronic Throttle Solenoid Clutc
75. 5 PROCESSOR TACHOMETER SENDER 3 8 inch 3 5 inches inch inch 3 5 inches 3 8 inch 9 53mm 88 9mm 25 4mm 25 4mm 88 9mm 9 53mm a e lt FT AN A G Nao Wrapped Drain Wire a gf 12263 E Heat Shrink A Clip Drain Wire Figure 4 14 AC Type Tachometer Cable PROCESSOR TACHOMETER SENDER 3 8 inch 3 5 inches 1 inch 1 inch 3 5 inches 3 8 inch 9 53mm 88 9mm EE Wespsed Drain Wire ES 889mm 9 53mm it 1 mg A 12263 Heat Shrink d Clip Drain Wire Figure 4 15 Open Collector Tachometer Cable Page 4 8 INSTALLATION D Shrink the tubing with a heat gun J Insert the cable ends through the liquid tight connectors and tighten the nuts K Secure the cables internally using a Clamp as shown in Figure 4 9 page 4 6 Make certain that the drain wire makes contact with the Clamp s metallic surface L Clip the exposed drain wires flush with the Clamps M Connect the conductors to the terminal block as listed in Table 4 3 Table 4 3 Processor Circuit Board Connections for Tachometer Conductor m Sensor Supply 9VDC Required when Open Collector i e Hall Effect Sensors only TB9 2 Green AC Type Tachometer Input The aes wire connects here when AC Type Tach Sensors i e Mechanical Senders Magnetic Pickup Alternator AC etc are being used TB9 3 Green Open Collector Tachometer Input The green wire connects
76. 5 Red Astern Solenoid 24 VDC when Astern 8 Neutral BLACK 5 Astern RED Clutch Selected 7 Neutral RED 6 Astern BLACK Pin6 Black Astern Solenoid VDC Return Astern Clutch Plug Connector Pin7 Red Neutral Solenoid 24 VDC at all times 11146A Pin 8 Black Neutral Solenoid VDC Return for Neutral Solenoid B12 3 Throttle Harnesses B12 3 1 Current MAN Table B12 10 Current MAN Throttle Harness Pin Out PROCESSOR PIGTAIL Joga ENTE Description 1 Plug Seal Not Used 2 Plug Seal Not Used 3 Ahead RED 4 Ahead BLACK 7 8 9 10 11 12 900000 000000 pa Ius Een Ree 8 GREEN na Fin 1 Black Engine e Throttle NE Return 7 Plug Seal Not Used O Plug Seal Not Used Rat tes 6 Plug Seal Not Used e CO RED mA 5 Plug Seal Not Used O or Plug Seal Not Used Pina 3 ECM 0 00 21 0 mA Throttle Signal w A 4 Plug Seal Not Used o Plug Connector me GA 0 NS B12 3 1 Frequency Table B12 11 Frequency Throttle Harness Pin Out PROCESSOR PIGTAIL PROCESSOR PIGTAIL ENGINE ENGINE ei gie EE Termination Description 8 GREEN Pin1 Black Engine Dc Bus Throttle Signal Return 7 RED Hz 2 Plug Seal Not Used B JN 7 EN pes 120 64 463 50 Hz 6 Plug Seal Not Used 3 Plug Seal Not Used E P sii Signal 5 Plug Seal N
77. 6 of the Throttle range B If previously disabled enable the synchronization by depressing the transfer button for two seconds The green LED on the Control Head should illuminate indicating synchronization C Check the engine tachometers to see if they are within 196 of one another D Move both Control Head levers side by side to approximately 5096 of the Throttle range E Check the engine tachometers to see if they are within 1 of one another F Move both Control Head levers side by side to approximately 75 of the Throttle range G Check the engine tachometers to see if they are within 196 of one another H Move both Control Head levers side by side to 100 of the Throttle range D Check the engine tachometers to see if they are within 1 of one another While synchronized if the tachometers have a greater than 1 difference at any engine RPM Active Synchronization is recommended Active Synchronization A Move both Control Head levers side by side to approximately 2596 of the Throttle range B If previously disabled enable the synchronization by depressing the transfer button for two seconds The green LED on the Control Head may blink while driving toward synchronization Once the engine RPM s are within 196 of one another the green LED will remain solidly lit C Check the engine tachometers to see if they are within 196 of one another D Move both Control Head levers side by side to approximately 5096 of
78. 8 2 11 8 1 2 12 2 12 1 2 12 0 4 2819 1172 212 18 2 12 1 4 2 12 1 6 2 12 2 2 19 52 2 12 3 2 129 2 12 4 2 12 4 1 2 12 4 2 213 2 14 Figure 2 8 2 15 2 15 1 Figure 2 9 2 16 2 16 1 2 16 2 2 16 3 2 16 4 2 16 5 2 16 6 2 16 7 2 16 8 2 16 9 2 16 10 3 1 Figure 3 1 31 1 3 1 2 3 1 3 3 1 3 1 3 1 3 2 3 1 3 3 3 1 4 SVACHLONIZOUON INGICQUONS EE EE Ee ee eet AREE NE PE C RECS 2 7 Turning Synchronization OFF ON when Criteria is Met o o o oooooooo ooo oo 2 7 IAN OF ere ERR meee eA ee RR 2 7 TURNING RE 2 7 Turning Synchronization ON OFF when Criteria is Not Met lee 2 7 Control Systems E eege TE elt 2 8 PIOCESSOF FUNCTIONS EE 2 8 throtle FUNCTIONS 3 1 3 3 932 3 Sao RA a av v DRAG SAREE OE ERASERS 2 8 EE Re e 2 8 EREECHEN 2 8 CIUICIVEUDGLDIOIS vana a dd da E EE 2 9 LE EE Ren EE 2 9 HEN AS Ee geet a taceo ets 2 9 Speed Boost Functions Optional 0 ee eee eee eee eee eens 2 9 TOM FUNCION SODIO See e AA AAA Os ek We 2 9 Integrated Troll Solenoid Functions cc ee eee eee hs 2 10 TrODSTer EE 2 10 Troubleshooting FUNCTIONS sud pea UE SOS Y NONE Qaa OWS AR EK Ru AS 2 10 BA IC TROUBLE SHOOTING FUNCTION sissies ec AS AAA AAA aes m dp c bem tal td 2510 AMOS OVC o sas kas ani ee AC tee EE a nd Gah ee 2 10 BASIC PFOCOSSOI TOMES 29 208 0 27 A E oae o CN ce 2 10 EOE E Ee GEES 2210 ONE EONO THREE SHORT ONES Sas e A A A 2 10 STEADY VONE rieti AAA AA EA AAA A AA E
79. A A se 3 4 External Alarm Circuit Electric Cable Requirements Fra ARE A RN A A A AA 3 4 SERIA COMMUNICATION CA EE 34 TACH SENSOR ELECTRIC CABLE REQUIREMENTS ne A A AE A A AAA A Nels 34 VC Om DUE exe aee ADS AN PA ENE AE er ELA AA O angie ts 3 4 Open Collector Active cec se cmm a E dee ope em oe O A A Sy ent ne 3 5 THROTTEE ELECTRIC CABLE REQUIREMENTS usara ee a ad 3 5 CLUTCH ELECTRIC TABLE ee Ee Ee Ed 3 5 CIO Elec Cable Requirements s 22 ier soo dm ES RR sens cer us den EE ei A a a tres 3 5 Tachometer Sensors EE 3 5 AC COUPLED SENSORS ad a A A AA dt tddi xb rA adsis EN Rm 3 5 POINT SIDE OE THE COll seen AAA GE 35 ACHVESENSORSMOPENKEGELEESTOR OUTRUT EE 3 5 Installer Supplied Tools And MH CEET 3 6 Reguired TOS aa a RARE AA ed AR sans 3 6 Optional Tools 4 siat ooa bee CARRIE LS BERRIES TEAS SAREE SER ee o dis 3 6 Engine Stop SWIC i sued ee PEER EA RE OCS EOE EAE PE 3 6 EE EE ek EE eet E te Ee 3 6 FFOCCSSONTF e 3 6 INSTALLATION 2 4 HA wien nk ae A Bile ed BAS Be Be aN Seats ON 4 1 CORTO DIOS S cun etait ee Rue ae cse e Ae e ud ala ERI ee 4 1 400 MC2000 and 700 Series Control Heads n 4 1 500 Series Control Heads ve em Ue ee XR ee iw BSE ORES 4 1 Handheld Remote Gohtrols ivre v NE RES RR ure rede Ne RR 4 1 Wie Re EE e EEN 4 1 Plug Insertion and E e de e EE 4 1 ENEE EIER acus Ee ft 2h oOo eeu Be ae eo Ee ee A OE EEO LE ue a o 4 1 Harness Plug Locking Mechanism 22 25 wur 3 ur a a a Ar a Da ir a a a er 4 1 Standar
80. ABLES ARE TO BE SUITABLE FOR MARINE APPLICATION POWER INPUT START INTERLOCK OUTPUT CLUTCH a gv omers 13505 SE AND MEET ALL APPLICABLE REGULATORY REQUIREMENTS PRESSURE INPUT ALARM OUTPUT THE EXTERNAL WIRE HARNESS ATTACHED TO THIS CONNECTOR DETERMINES i START INTERLOCK RELAY HAS NORMALLY OPEN CONTACTS CONTACTS WHICH FUNCTIONS ARE USED POWER AND START INTER ARE CLOSED WHEN SYSTEM IS OPERATING AND COMMANDING NEUTRAL LOCK ARE REQUIRED CLUTCH PRESSURE AND ALARM A MRAM I DA MAYBE OPTIONAL BASED ON CUSTOMER OR REGULATORY Ke THE CONTROL PROCESSOR WILL BE PROVIDED SHIPS SUPPLY OF REQUIREMENTS 12 OR 24 VDC PROTECTED BY A 10 AMP RATED CIRCUIT BREAKER CONTROL FAILURE ALARM RELAY CONTACTS RATED FOR A MAXIMUM OF 0 54 MAXIMUM CONTACT DRY RATING OF 100V DO NOT EXCEED THIS RATING IT IS THE SHIPYARDS RESPONSIBILITY TO UTILIZE THE ALARM CONNECTION IN AN APPROPRIATE ALARM CIRCUIT I gt CAUTION THIS PART CONTAINS ELECTRONIC COMPONENTS WHICH CAN BE DESTROYED BY STATIC ELECTRICITY PERSONNEL SHOULD GROUND THEMSELVES TO DISSIPATE ANY STATIC ELECTRICITY PRIOR TO WORKING INSIDE THE PART PRESSURE SWITCH SETPOINT N O CONTACTS MUST BE SET AT 150 PSI OR AS AS RECOMMENDED BY TRANSMISSION MANUFACTURER WHEN CONTACTS CLOSE THIS INDICATES TO THE CONTROL PROCESSOR WHEN THE CLUTCH IS SUFFICIENTLY ENGAGED TO ALLOW A SPEED COMMAND ABOVE IDLE SPEED IT IS A SAFETY FEATURE THAT PROTECTS THE CLUTCH AND ITS USE IS RECOMMENDED gt THE CONTROL PROCESSOR S MOUNTING
81. APS Ee Power Selector b Battery charge is too low b Recharge replace the battery or supply battery power from two sources through an APS SYMPTOM Active Synchronization is inoperable Page B10 1 TROUBLESHOOTING Cause Remedy a There is no Tachometer Sensor signal at a The Tachometer Sensor frequency can be the Port or Starboard Processor seen on the Processor s Display by accessing the Diagnostic Menu HO If the frequency is not measured check the Tachometer Sensor and the wiring b Loss of Serial Communication between b If Active Synchronization is inoperative due the Processors to a lack 2 Serial Communications one or more Error Codes will be displayed indicating the loss of communication c The Processor s Identification number s c All Processors must have a unique have not been set properly identification number as set with Function Code AO Refer to Section 5 5 0 1 page 5 7 d The correct number of engines has not d All Processor must have the same number of been set engines selected as programmed with Function Code A1 Refer to Section 5 5 0 2 page 5 7 B10 2 Solenoid Clutch Control System Problems Without Error Codes A SYMPTOM Cannot obtain Warm up Mode while moving the Control Head lever in the Ahead direction only in the Astern direction Cause Remedy The Processor is sensing that Depress the Transfer Button while moving the Control the Control Head s lever is Head lever in the Astern dire
82. B11 1 B11 2 2 Electronte Taro Te EE atio Aa DE EE OER ee AO ER n GR HEN ES B11 1 B11 2 2 1 SYMPTOM THE GREEN LED Is LIT SOLID THOUGH THE ENGINE RPM S DIFFER BY A SIGNIFICANT AMOUNT B11 1 B11 2 2 2 SYMPTOM ONE OR BOTH OF THE ENGINES CONTINUALLY CHANGES RPM HUNTS WILL NOT SYNCHRONIZE PROPERLY B11 1 B11 2 2 3 SYMPTOM SYNCHRONIZATION DOES NOT FUNCTION THE CONTROL HEAD S GREEN LED DOES NOT LIGHT B11 2 B12 TROUBLESHOOTING CABLE HARNESSES B12 1 B12 1 Basic Control System Harness ah u ede E edic wey BU a B12 1 Table B12 1 Power Start Interlock Harness PIDn OUI icu au eisen la Aa nein B12 1 Table B12 2 Power Start Interlock and Pressure Switch Harness Pin Out eee eee B12 1 Table B12 3 Power Start Interlock Pressure Switch and Alarm Harness Pin Out eee B12 1 Table B12 4 Serial Communication Harness PIN OU csccsscesccsccncceecasccsccsecsecseccecescesecsececsecseeesccseceecesscssceeeeeceseeeees B12 1 Table B12 5 Control Head Harness Pin Out and Hard Wire ccce esee eee eese esee eee eene nente st entente testet enses seen B12 2 Table B12 6 Tachometer Sensor Harness PIn UE EE B12 2 Table B12 7 Tachometer Sensor Harness with Power Pin Out csccssccsccsscecsccceccsecsscasceecesccsscseceeceecesecsscseceecesceeceees B12 2 B122 EUCH Plate SSC TORT CET E AS A Ee E N B12 2 B12 2 1 ANCAMASTO MTS OAE E AA aha Res DDr ee B12 2 Table B
83. C POWER SOURCE ET BLACK 12 OR 24VDC gt Vt Rj FUSE ALARM INDICATION d MGE CIRCUIT ON OFF SWITCH RELAY WITH A NORMALLY CLOSED CONTACT AND A DIODE ACROSS THE COIL FOR SURGE SUPPRESSION EE CERN MAX CURRENT WEI o a 0 5 A TB6 6 D ES BLACK PROCESSOR SE For V 12 VDC Rare ol R Load gt 0 37 Ohm e ou sb For V 24VDC RED ph R Load gt 0 18 Ohm TB6 5 a ae gt N N Pi FIN S a DD oc ol MEF ko TIL U N ounv NIo o KT Figure 8 2 External Alarm Connections Processor Hard Wired Example Page 8 1 CONTROL OPTIONS 8 1 1 Installation Refer to Figure 8 1 or Figure 8 2 The following items should be considered when designing and installing the Status Indication Panel The Power Wire Harness p n 13631 must be used if an External Alarm is ren The Processor s Alarm Circuit uses a dry contact Therefore the polarity of the conductors is not a concern The External Status Indication Circuit must not use the same ower source as the Processor Since the External Status Indication Circuit is activated on a loss of power to the Processor an On Off Switch is strongly recommended Figure 8 1 and Figure 8 2 are an example of a suitable circuit but not necessarily the only circuit acceptable A Plug the Power Wire Harness into the Processor s Power
84. CESSOR PIGTAIL TACHOMETER SENSOR Termination A Conductor Color Termination B Description een Pini Red AsRequied Sensor Supply 9VDC Yellow Pm2 Green AsRoquired Tachometer 3 Black 2 2 Green Pins Black As Required Tachometer D Green Yellow N C Shield B12 2 Clutch Harnesses B12 2 1 Ahead Astern Table B12 8 Ahead Astern Clutch Harness Pin Out PROCESSOR PIGTAIL rea GEARBOX GEAR BOX Mee Eeer Conductor Termination Description Description 12 Plug Not Used Color 11 Plug Not Used Pa 3 Red Ahead 24 VDC when Ahead 10 Plug Not Used Solenoid Clutch Selected 9 Plug Not Used 1 Plug Not Used 2 Plug Not Used 3 Ahead RED 4 Ahead BLACK 5 Astern RED 6 Astern BLACK 8 Pin 4 Black Ahead VDC Return for Ahead 8 Plug Not Used Solenoid Clutch 7 Plug Not Used Pin 5 Red Astern 24 VDC when Astern Solenoid Clutch Selected Pin 6 Black Astern VDC Return for Astern Solenoid Clutch 7 000000 900000 Plug Connector 11146A d Page B12 2 TROUBLESHOOTING B12 2 1 Ahead Neutral Astern Table B12 9 Ahead Neutral Astern Clutch Harness Pin Out PROCESSOR PIGTAIL GEAR BOX Termination Conductor Termination A Color B a Ahead Solenoid 24 VDC when Ahead EE Clutch Selected 9 10 Plug Seal Not Used Pin4 Black Ahead Solenoid VDC Return Ahead Clutch 9 Plug Seal Not Used Pin
85. ClearCommand 96202 Installation Manual SM3830 Rev A1 10 05 SYSTEM GENERAL INFORMATION ZF Marine Electronics LLC ClearCommand System Specifications Sept 2005 Rev A October 2005 Rev A1 Quality Shipyard Hull 1247 February 2005 Rev Vessel Specifications Power Twin Screw Caterpillar 3508 1050 HP 1600 RPM Electric Selection Transmission Twin Disc MG5170 5 421 1 Reduction Ratio Solenoid Selection Stations One Remote Station ClearCommand Specifications Control Processor 96202 replacing 785CE System Serial Number 3830 Sales Order Number S002471 96202 Replacement System S000549 Original System Parts amp Manual S000550 Original CruiseCommand Processor Drawing Number 130684 4 pages This System originally shipped with CruiseCommand 785CE Processors These Processors are being replaced by ClearCommand 96202 Processors Page 1 MATERIAL LIST System 3830 Material List Material List for 3830 50002471 Quantity Description 96202 CLEARCOMMAND ELECT ENG SOL GEAR 2 STA 15719 20 WIRE HARNESS CLUTCH AHEAD ASTERN 20 FT SM3830 SSN 3830 INSTALLATION MANUAL Page 1 1 PREFACE IMPORTANT It is important to keep this Manual in a safe place for future reference The manual contains answers to questions that may arise during operation or installation of the ZF Marine Electronics Control System and its options Preface 1 ClearCommand 96202 ZF Marine Electronics ENGINE CLU
86. Codes appearing on the Port side Processor s Display LED are port side errors and vice versa The Causes and Solutions provided are the most likely but are not the only possible causes for the Errors Codes listed Basic Control System Problem Causes and Solutions Table B9 1 Basic Control System Problem Causes and Solutions Error e 9 Causes Solutions Station No 1 Control Head is defective a Replace Station No 1 Control Head No continuity between pin 5 s of the Control Head Harness b Ensure that the red conductor is properly crimped to pin 5 at fa B9 1 14 15 16 17 19 20 21 D 23 No lli connectors Control Head jumper pin 3 to 5 or 7 is missing The Station No 2 Control Head is defective No continuity between pin 5 s of the Control Head Harness connectors Control Head jumper pin 3 to 5 or 7 is missing The Station No 3 Control Head is defective No continuity between pin 5 s of the Control Head Harness connectors Control Head jumper pin 3 to 5 or 7 is missing The Station No 4 Control Head is defective No continuity between pin 5 s of the Control Head Harness connectors Control Head jumper pin 3 to 5 or 7 is missing The Station No 5 Control Head is defective No continuity between pin 5 s of the Control Head Harness connectors Control Head jumper pin 3 to 5 or 7 is missing The Station No 6 Control Head is defective No co
87. Connections Port Connections Starboard Connections o 20AWG uz E O z E Eu 82 2 Sei SE Gm I 7 CONDUCTOR Cable Jumper connections 5 and 7 at the Port and Starboard terminal block are direction sensitive MicroCommander ClearCommand CruiseCommand 9000 Series Port Lever Starboard Lever Port Lever Starboard Lever Terminal 3 Red Terminal 3 Red Terminal 3 Red amp JUMPER Terminal 3 Red amp JUMPER Terminal 5 Blue Terminal 5 Yellow Terminal 5 Blue Terminal 5 JUMPER Terminal 7 Yellow Terminal 7 Blue Terminal 7 JUMPER Terminal 7 Blue PLUGGABLE CONNECTIONS Pluggable Control Heads are supplied with a harness pigtail for each lever When disconnecting connecting the plugs ensure that the release button or buttons are depressed and held until plug is fully disconnected or connected Disconnecting connecting plugs without depressing and holding the release button or buttons WILL damage the plug Aft Facing Control Heads LEVER FOR STARBOARD i PROPULSION LEVER FOR CONTROL u E PORT xs PROPULSION N CONTROL For dual lever Control Head Sta tions that have the user facing aft Reverse connections 5 and 7 For single lever Control Head Sta tions that have the user facing aft and the one Control Head lever on 7 the user s right reverse connec tions5 and 7 FORE Handheld Control is an option Contact your ZF Marine Electronics Dealer fo
88. D TEST UNIT F 12 PIN CONNECTORS No p AT e TT we 11653 C SS 1 WHILE DEPRESSING O VALIDATIO O BREAK OUT BOX ME Va in SCH mA PUSH BUTTON Figure 2 5 Throttle Connection Current mA Depress and hold the Push button Switch labeled mA The appropriate Current mA for the application should be measured G Move the Control Head lever to the Full Throttle position while depressing the Transfer Button Throttle Only Mode H Depress and hold the mA Push button The RE riate Full Throttle Current mA for the application should be measured at this time 2 1 3 PWM Pulse Width Modulation with DC Voltmeter A Ensure power is removed from both the Engine Electronics and the Processor B Disconnect the Throttle Harness from the number 1 Processor connector pigtail C KE 12 PIN CONNECTORS gt oH a oe o En Y Y S S 8 ASTERN A O Os e
89. Down to the desired Value D Store the Value to memory Figure 5 17 Display LED Function C3 Set Up Activated 5 5 3 1 5 Function Code C4 Proportional Pause Ratio 00 2 1 Ratio This is the default setting and determines how the value set in the Proportional Pause Time C3 Function is Page 5 12 SET UP PROCEDURES applied The number of seconds selected is for an Ahead to Astern maneuver only An Astern to Ahead maneuver will be 1 2 of the Proportional Pause Time selected This is the typical selection since most vessels do not reach the same throttle in Astern as they would in Ahead Therefore the time required to get to a sufficient water speed for a safe reversal is significantly less 01 1 1 Ratio When this setting is selected the value set in the Proportional Pause Time C3 is the same for both Ahead to Astern as with Astern to Ahead maneuvers This may be selected when the vessel reaches the same water speed in both directions as would be the case with a Double Ended Ferry Another application where this option may be selected would be the control of a Bow or Stern Thruster This Function Code selects whether the Proportional Pause Time is the same in Ahead and Astern or whether the time in Ahead is twice that in Astern Standard vessels with a bow and a stern typically select a pause which is twice as much in Ahead compared to Astern This is because much more speed is obtainable in Ahead then Astern Consequently mo
90. E BE BB BE EB EB BB BE BE HEHE This tone indicates that a Transfer Sequence has been initiated while in Transfer Mode 03 or Mode 04 2 12 4 2 One Second Steady Tone This tone indicates a press of the transfer button during a transfer sequence in Transfer Mode 03 or Mode 04 2 13 Push Button Set U There are four push buttons mounted to the Processor s circuit board These push buttons allow the installer technician access to all of the Functions required for programming and troubleshooting the Processor A full description of their usage is provided in Section 5 1 2 page 5 2 2 14 Visual System Diagnostics Set Up And Status Indication There are four seven segment LED s hereafter referred to as the Displa LED mounted to the Processor s circuit board The Display LED is visible through a transparent window in the Processor s cover The information displayed is used in conjunction with the push buttons to program the Processor The v ed LED also displays Error Codes in the event that an anomaly is detected For a full description of the Display LED its capability and usage refer to Section 5 1 1 page 5 1 Page 2 11 OPERATION Push Button Location LED Locati n Figure 2 8 Circuit Board Shield Layout 2 15 Pluggable Connections 2 15 1 Processor The Processors come from the factory with enclosure mounted pigtail connectors for easy mistake free installations 96202 2 Station pigtails 5 standard pigtails The f
91. EE lada E ie ee 8 4 DEMODE ee Ee seerne ee ED e ee d ege eA Ge A 8 4 Bet a A IN 8 4 Display IP antel us svedese d ae asas aieo dls ae acd y iS A sil 8 4 Back CONTO VSte iem 3 xs urat ur dd ET RUE bbe Swe ben ee E 8 5 SPECIAL a DS A eg 8 5 Speed Boost Usage race ARES ANS ERA AAA AAA US 8 5 Speed Boost Percent E0 aso bx d AA EA ORS PERSE ide 8 5 Speed Boost Duration F1 s vies is A AS was o a 8 6 Speed Boost Stam Delay FZ secon alee ir Y a ORNARI RR E Ea Re eke E e 8 6 Speed Boost Bypass Clutch Delay F3 ee ee eee hn 8 6 PERIODIC CHECKS AND MAINTENANCE 97 E OO mco Sido ea ps o eee ae oes die be 9 1 AA AA E SI el ere Sa eA 9 1 TABLE OF CONTENTS 9 3 POWVE UDOV MED Pr UIT 9 1 9 3 1 EE e e A eege ee Res 9 1 9 3 1 1 QUARTER EVER VS MONTHS ala A a aos 9 1 Table 9 2 Fully ee BOTELY EE EE 9 1 9 3 1 2 SEMI ANNUALLY EVERY e EE 9 1 9 3 1 3 ANNA E VER TEZIMONTE EE 9 1 9 3 2 Power Cables Distribution Panels etC oooooooooo moron hn 9 2 Appendix A PARTS EIST bas A 1 MMC 329 REV C OOS EE A 3 MC2000 Series Standard Control Head Variations Ville EN 7 1 OD EE A 9 400 Series Weather Mount Enclosure Deutsch Connector Assembly aia RER I En a A 11 SZ A EEN A 13 Automatic Power Selector APS Model 13505 Drawing 11488D 1 Twin Screw Single APS Connection amp Alternate Remote Switch A 15 Drawing 11488D 2 Twin Screw Dual APS Connections ccecescsececsececsececsscee
92. F Marine Electronics Service or Engineering Departments 5 5 5 1 3 Function Code H2 Driver Fault Detection Enable The H2 Function is available only on Processors with integrated Clutch and or Troll Solenoids De 9120 9121 9122 and 9221 The Processor can be programmed to monitor the current flow through the Clutch and or Troll solenoids When this option is selected if the current level is too high or too low an alarm is sounded and an Error Code is produced Table 5 10 lists the required value that needs to be entered to monitor the Ahead Astern Neutral Troll Command and Troll ON OFF solenoids NOTE Function Codes 32 through 63 are reserved for future expansion and should not be used at this time gt Table 5 10 Solenoid Error Status Enable Troll Command Troll On Off Vale L1 HL Hl HL H HL LL 0 0 0 p A O O PP O0 9 L0 LH J 1 p 0 0 9 I 1 Page 5 15 SET UP PROCEDURES Table 5 10 Solenoid Error Status Enable Astern Troll Command Troll On Off AA o o 9 E o mmu 0 mE AAA AAA OA CET Amem Neura Troll Command 7 O Lot INSI EE IES 0 9 BE 0 9 0 31 1 9 9 1 1l 9 9 9 34 0 34 9 1 3 1 9 Pa EN RN OA OA Oo o SS BEST SS ee 5 5 6 Premium Functions 5 5 6 1 Speed Boost ere Codes FO F3 Do Not attempt to adjust any of the Speed Boost Function Codes until you
93. F2 Speed Boost Start Delay gt ar yum eem Er E e cen tr na 5 16 Function Code F3 Speed Boost Bypass Clutch Delay e 25 20 EE AA E ee 5 16 TRANSFER FONCTION GODE EA E EE 5 16 F ction coded Transter Mode Sert EAS E A EE o s eras ee S Aut 5 16 F nction CodePT Transter 1118290 7 eoe o En AA DR AO ASA A A EES 5 18 DOCK TRIALS e 64 Control Heads ENGINES STOPPEN EE 6 1 Start inter lock ENGINES SONDEO EEN 6 1 EIS ES DD CIEN cor cred utet staret daa taa aid dad re 6 1 ao AAA IN A Cees eet e BOL Ge ER 6 1 TABLE OF CONTENTS 6 5 6 6 7 22 1 2 7 2 1 7 2 2 7 2 3 ED 7 3 1 7 4 7 4 1 7 4 2 7 5 7 5 1 7 5 2 Table 7 1 Table 7 1 Table 7 1 Table 7 1 7 5 3 Table 7 1 Table 7 1 Table 7 1 7 5 4 7 5 4 1 75 4 2 8 8 1 Figure 8 1 Figure 8 2 8 1 1 8 2 8 2 1 8 2 1 1 8 2 1 2 Figure 8 3 Figure 8 4 8 2 2 8 3 8 4 8 5 8 6 8 7 8 8 Figure 8 5 8 9 8 10 Figure 8 6 8 10 1 8 10 2 8 10 3 8 10 4 9 1 92 Control Head Solenoid Command rer ee er Sie ar 6 1 Throttle Pause Following Solenoid Shift osx 243 244403 an ee 6 2 SEA TRIALS e T4 Full Speed Seting Electronic Ra EE 7 1 SM all Se EE EE 7 1 In Gear Delay 16200 24 2 erst Y S arena Ca Nec e dope at b ed 7 1 Neutral Delay 16 20 TT sus iv Ede AA d AS AS ADA 7 1 Fixed Neutral Delay T6202 EE 7 1 Calculating Proportional Pause Time C3 llle K Testing The Proportional Pause cv sx 1 AAA ch ER 7 2 ovnmnelronizatO res diia
94. FEET MUST BE CONNECTED TO THE VESSELS BONDING SYSTEM gt NOT USED FREQUENCY INPUT FOR ENGINE SYNCHRONIZATION INPUT PULSES EITHER AC TYPE TACH INPUT OR OPEN COLLECTOR TYPE INPUT AC COUPLED INPUT TB9 2 MINIMUM FREQUENCY 30Hz MAXIMUM FREQUENCY 8000Hz OPEN COLLECTOR INPUT TB9 3 MINIMUM SINK CURRENT 2mA MAX SENSOR OUTPUT SATURATION VOLTAGE 0 8V e 2S 08 25 05 08 25 05 08 25 05 REFER TO THE CONTROL SYSTEM MANUAL FOR ADDITIONAL INFORMATION DESCRIPTION REVISION 15 NOT USED INDEX Are ZF MARINE ELECTRONICS LLC SHEET DESCRIPTION GENERAL NOTES MATERIAL LIST SYSTEM DIACRAM CLEARCOMMAND 96202 PROCESSOR CONNECTIONS CENE ER dee MFG THE INFORMATION CONTAINED HEREIN IS PROPRIETARY TO MC2000 SERIES CONTROL HEAD CONNECTIONS up AS ZF MARINE ELECTRONICS LLC AND SHALL NOT BE SIZE CAGE CODE DWG NO REV KEEN pl 13068 POSSESSES DIRECT WRITTEN AUTHORIZATION FROM ZF MARINE ELECTRONICS LLC SCALE NONE SHEET 1 OF 4 3 2 1 Page C 1 Page C 2 Drawing 13068A 2 System Diagram 4 3 2 REVISION SEE SHEET 1 PILOT HOUSE D SERIAL COMM C THROTTLE THROTTLE AQ LB 1 i gt B START E START INTERLOCK INTERLOCK ALARM E gt em of CLUTCH Du E REDUCTION GEAR CIRCUIT BREAKER CIRCUIT BREAKER REDUCTION GEAR N A MEE ZF MARINE ELECTRONICS LLC POWER POWER d 12125 HARBOUR REACH DR SUITE B MUKILTEO WA 98275 GROUND as mU GROUND CLEARCOMMAND
95. Harbour Reach Drive Suite B Telephone 425 583 1900 Mukilteo WA 98275 Telefax 425 493 1569 Diesel ele It may be necessary to manufacture a une plate for the magnetic pickup Diesel MAN 2840 2842 2848 2866 amp 2886 2842 2848 2866 amp 2886 8912 E e Perkins 1980 1980 and earlier earlier 8902 Diesel I 4 EES amp 6 354 ee M Part No 8875 drive needed on 1980 and newer RED Diesel Perkins 4 107 4 108 amp M 800T 8902 Diesel E A NNNM 154 a E Part No 8709 Magnetic Sensor c be used in lieu of SAE drive Diesel Perkins M 135 M225 M 300 amp M30 8912 70 100 amp 120 A or B Series E Volo 3 3 6A 17 amp 30 17 amp 30 8912 Volvo 31 amp DNE 41 c Part No 8709 Magnetic Sensor must be used in lieu of SAE drive Volvo 40 60 61 amp Up 71 amp Up 100C amp Up Magnetic pickup already installed on 102 121C amp Up 122 2010 amp 2020 cam gear Diesel Volvo 42 amp 43 Connect at blower box Black wire is ground and grey is signal Diesel Volvo 2030 amp 2040 N A Magnetic pickup already installed on cam gear Diesel Yanmar All Engines N A A metric Magnetic pickup is already installed on all engines P N 8902 Dual Mechanical Sender P N 8912 Dual Magnetic Pickup 3 4 16 P N 8922 Single Magnetic Pickup 5 8 18 Available through Aetna Engineering only A 26 MMC 165 Rev E 2 05 ZF Marine Electronics LLC Mukilteo Plant Electro
96. Idle position The following table shows the appropriate A D Counts for various Control Head lever positions Table B6 1 Control Head Lever A D Counts Control Head Lever Position A D Count Lever Out of Range Low 100 Ahead Shift Point 537 Lever Out of Range High B6 3 Remote Station Select The second required item for taking command is Station Select or T of the Transfer Button The Transfer Button can be tested by entering t e Diagnostic Menu HO A Depress the Up or Down scroll Push Button until four zeroes are displayed without decimal points as shown in Figure B6 1 Figure iis E B OA iind SH Station B For Stations 1 4 when the Transfer Button is EE depressed the 0 which represents that remote station will change to a 1 as shown in Figure B6 2 28 For Station 5 when the Transfer Button is depressed all four decimal points will light as Figure B6 2 Example Display Station A D s shown in Figure B6 3 Transfer Button Depressed for Stations 1 4 e Whenever command cannot be gained ata particular remote station the Station Select and Command Signals are the first to be investigated If either the and Signal is out of range or Figure B6 3 Display Station A D s Transfer Button the Station Select is inoperable command will Depressed for Station 5 not be accepted at that remote station Page B6 2 TROUBLESHOOTING STATION TRANSFER B5 TROUBLESHOOTING STUCK TRANSFER BUTTON The Transfer Bu
97. NDER san aaa ee DS Display LED Function A3 Set Up Activated 1 usu a ee a e P oc a Re ire Oe ees 5 7 TABLE OF CONTENTS 5 5 1 5 igure 5 5 5 9 1 6 5 5 2 5 5 2 1 ON Figure b 6 5 5 2 1 2 Figure 5 7 5 5 2 1 3 Figure 5 8 5 5 2 1 4 Figure 5 9 5 5 2 1 5 Figure 5 10 5522 5 5 2 2 1 Figure 5 11 5 5 2 2 2 Figure 5 12 5952223 Figure 5 13 5 5 3 5 5 3 1 5 5 3 1 1 Figure 5 14 IDI N2 Figure 5 15 DO Ted Figure b 16 5 5 38 1 4 Figure 5 17 59 3 1 Figure 5 18 5 5 38 1 6 Figure 5 19 5 5 3 2 5 5 3 2 1 Figure 5 20 55 322 Figure 5 21 05 32 9 Figure 5 22 5 5 4 5 5 4 1 5 5 4 1 1 5 5 5 5 5 5 1 IDD EU 5 5 5 1 2 5 5 5 1 3 Table 5 10 5 5 6 5 5 6 1 5 5 6 1 1 5 5 6 1 2 5 5 6 1 3 5 5 6 1 4 5 5 6 2 5 5 6 2 1 5 5 6 2 2 6 1 6 2 6 3 6 4 FUNCTION CODE A4 NEUTRAL EI el Ke e 5 7 Display LED Function A4 eege er EE a 5 7 FUNCTION CODE A5 ENGINE ROOM LOCKOUT STATION NO 2 LOCKOUT coti dac bear ee 5 8 FUNCTION CODE AG STA MON NOD AD PS Na 5 8 Reen Te EE EE 5 8 THROTTLE BASIC FUNCTIONS F1 E4 THROUGH E7 e toca edet A tN od acco a nee ita orae dtd ei 5 8 FUNCUOn EE Throttle in NEU Fre E EE A SO A RA E ds 5 8 Display LED Function E1 Set Up Activated EENEG 5 9 Function Code E4 Throttle Maximum Astern Free 230 S e s no re E E end E 5 9 Display LED Function E4 Set Up Activated ENEE 5 9 Function Code E5 Throttle Pause Following Shift
98. OUBLESHOOTING B8 ERROR CODES As stated previously if a problem with the Control System is detected the Processor is p to display numerous Error Codes to aid in the isolation of the cause The following tables list these Error Codes along with a brief description B8 1 Basic Control System Error Codes Table B8 1 Basic Control System Error Codes 13 Station No 1 Station No 1 Control Head s lever position is out of range Faulted High The input appears to be too high 14 Station No 2 Station No 2 Control Head s lever position is out of range Faulted High The input appears to be too high 15 Station No 3 Station No 3 Control Head s lever position is out of range Faulted High The input appears to be too high 16 Station No 4 Station No 4 Control Head s lever position is out of range Faulted High The input appears to be too high 17 Station No 5 Station No 5 Control Head s lever position is out of range Faulted High The input appears to be too high 18 Station No 6 Station No 6 Control Head s lever position is out of range Faulted High The input appears to be too high 19 Station No 7 Station No 7 Control Head s lever position is out of range Faulted High The input appears to be too high 20 Station No 8 Station No 8 Control Head s lever position is out of range Faulted High The input appears to be too high 21 Station No 9 Station No 9 Control Head s lever position is out of range Faulted High The input appears t
99. Processor s frame Serial Communication Cable Location 10 A Install 1 2 inch 12 7mm liquid tight cable grips into hole No 8 of the Port and Starboard Processors Refer to Figure 4 6 page 4 4 for u hole location and Figure 4 5 page 4 4 for cable grip installation B Run a four conductor shielded cable from the Port to the Starboard Processors C Strip back 3 inches 76 2mm of PVC jacketing from both ends of the cable D Strip each wire 3 8 inch 9 5mm E Clip the drain wire flush with the PVC jacketing on the Starboard Processor only F Place a 1 inch 25 4mm section of shrink tubing over each end of the cable G On the Port end of the cable bend the drain wire back and tuck it under the shrink tubing so that the drain wire end is exposed past the shrink tubing Refer to Figure 4 13 PORT PROCESSOR STARBOARD PROCESSOR 3 inches 76 2mm 25 4mm lt gt 1 inch 1 inch 3 inches 3 8 inch mE 5 Drain Wire 25 4mm 76 2mm 9 53mm P P 12263 Heat Shrink P Clip Drain Wire N Figure 4 13 Four Conductor Serial Communication Cable Page 4 7 INSTALLATION H Shrink the Tubing with a heat gun I Insert the four conductor cable through the liquid tight connectors and tighten the nuts J Secure the cables internally using a Clamp as shown in Figure 4 9 page 4 6 Make certain that the drain wire makes contact with the Clamp s metallic surface
100. S AI Oe Alaa na da aed 2 11 FEAS SECONDS CAD TONE E EE 2 11 THREE 3 SECOND STEADY ONE Eet Eege Ee AA A an ZN FIVE SECONDS ON FIVE SECONDS OFF HIGH REPETITIVE RATE TONE e d fes eub tes 2 11 e Solenoid e 2 11 SS eae NES Bi Le 2 11 Troll Integrated Solenoid Tones If Troll is used 2 ee eee eee 2 11 TAREE SECOND STEADT ONE ne en ee ee ee us ee 2 11 Transfer TONGS La a AS eg A AA ded acad 2 11 1 2 SECOND ON 172 SELONBOERTONE EEE Re 2 11 UNE SECONDISTEADY EE EE Ee 2 11 BE WE ta ee UD ENEE 2 11 Visual System Diagnostics Set Up And Status Indication 2 11 Circuit Board Shield Layout s aset a ops tos a ste tad x are cn ea EE 2 12 Bee e Connec e EE 2 12 SEET Beer AA BIE ORE CRE uda tea dire EE 2 12 Processor Pluggable Connections View eos pens Bee I en Oe eR eke od wee 2 12 CGE OMe Fedes cues qM ada esp a et aa quud E ieee acd 212 External Alami Capabllity 555 ou uae A AA EE 2 12 Cte PressurednterlO isa autores cd ete ERE Au ta ctun DR Ap b ce uitia e a p 2 13 Station Expander SE 3243 v dea ESA dox E Eam e WE eaa A S d 2 13 TOMO Valve ODOFOLOFE ave sce ein alae C pa epu deste AR EREC ENE OA 2 13 Engine Room Only Remote Switch hn 2 13 Ree e ee EE EE een 2 13 BDF MODE xcci E E te ci deed ess E We ge aaa oe 2 13 DISDIGV POMC da ars oo ta quie SOE teo o E Ut I dd us 2 14 Backup Control System 2 POE As mar aad e Feri bd EE x ct 2 14 SPOLU BOOS e ee Dad hod Duos dee aa 2 14 PLAN THE INSTALLATION
101. SERE e Ee TEMERE 2 Display LED Error Menu Example tee dale ar gees area er ES IS de area 5 2 RIGHT PUSE BUTTON CON reelle ee et cna E ir deg Display LED Four Digit Value s oso tbe ea tt ed a in ere Ae debe de A a dae Ee in s 5 2 Leg le re ee TEE 5 2 Storm Vales To MEMO tas ES Ze RAR AA DES Processor FUNCTION Codes ee e 5 3 Throttle FUNCTION CODECS iio 5 3 Gl teh ee 85001 M RON Nm 5 4 Troll Functtom Codes Eeer 5 4 Field Service Test Unit Break out Box and Multimeter Use 5 5 Service Field Test Unit and Multimeter ise ain ded Uf ves que US amp Meee bet ATUS S d 5 5 Troubleshooting FUNCTION RE 5 5 Speed Boost Premium Only Function COMES iii AA iaa 5 5 Station Transfer Premium Only Function COCES cscccceecsecsececcsccsccscscceccecsecsccscceccecesceceeccecsessecsseeccecescescs 5 5 Clutch Functions Requiring Service Field Test Unit and Multimeter ue 5 6 Throttle Functions Requiring Service Field Test Unit and Multimeter Lecce eese eee eene nennen 5 6 System Programming And Adjustments 33 quo Xs RE EY RENEW Us D 6 FrOCESSOr FUNCTIONS il decer at SS A A o o os 5 6 E NEE 5 6 Display LED Function AO Set Up Ee e WEE 5 6 FUNCTION CODE A1 NUMBER OF LENSINES ar AA AAA AA AAA 5 6 Display LED Function A1 Set Up Activated ee el odd eu bg RESI SEEN Dey FUNCTION CODE A2 ONE LEVER OPERATION std de dll EE re tat o ter eui 5 7 Display LED Function A2 Set Up ACH VA WEE 5 7 FUNCTION CODE AS SE STA NON EXPA
102. TCH Number of Pluggable EE Table Preface 1 ClearCommand 96202 This manual is intended for use with the above Processors Preface 2 Conventional Symbols Used in the Manual Throughout this manual special attention should be paid to the following WARNING Personal Injury could occur if the following steps are not followed exactly CAUTION On Control Systems utilizing more than one Processor ZF Marine Electronics highly recommends that ALL UNITS be upgraded to the most current Processor on this equipment must be grounded to the chassis with the Anti static Wrist Strap provided CAUTION Disconnect the Power Harness from the Power Pigtail whenever welding is being done on the vessel Failure to do so can cause permanent damage CAUTION Electro static discharge can damage this e e ment Personnel working is equipment is designed to work with other arine Electronics designed e equi ment DO NOT operate this un ment with any other manufacturers 7 equipment unless approved so in writing by ZF Marine Electronics Engineering Department For the purpose of this manual the drawings illustrate pluggable systems with two Remote Stations The Processors described within may in fact be installed with anywhere from one to five Remote Stations Page Preface 1 TABLE OF CONTENTS OW 15623 0H Table of Contents ClearCommand 96202 Installation Manual System 3830 Material Listas coi 1 1 Preface 1 Clear on mMand 99209 e don
103. Termination A Conductor Color Color Termination B B Description 12 Yellow w Pin 1 Yellow Conductor Color Red icem AEEA Closed contact when In command Red Trace Trace and at Neutral 11 Black Pinio Red Battery 12 or 24VDC SEN P Black Bateryg DCReum Pin 12 Yellow w Red Starter BT contact when In command Trace Wire at the Starter land at Neutral Solenoid PROCESSOR PIGTAIL ENGINE and BATTERY Conductor Color Color Termination B B Description 12 Yellow w NN 1 Yellow Conductor Color Red iem E Closed contact when In command Red Trice ri 3 and at Neutral 11 Black Pin 6 Light Blue Clutch Pressure Normally Open contact that closes 10 Red Switch when transmission manufacturer s minimum safe operating pressure is reached 7 Light Blue Pin 7 Light Blue Clutch Pressure Normally Open contact that closes Switch when transmission manufacturer s minimum safe operating pressure is reached Pinto Red a Black Zu ou DESS 12 Yellow w Red Starter Sch A contact when In command and at Neutral Trace Wire at the Starter Solenoid Table B12 3 Power Start Interlock Pressure Switch and Alarm Harness Pin Out PROCESSOR PIGTAIL PROCESSOR PIGTAIL ENGINE and BATTERY Termination A Conductor Color Termination B Deseripton Pin 1 Yellow w Red Starter Solenoid Closed contact when In command 12 Yellow w Trace and at Neutral Red Trace Pin 2 Red External
104. Throttle Profile 01 Caterpillar PWM 02 Cummins Centry Voltage 0 9 to 4 5 VDC 03 Cummins Quantum Voltage 0 9 to 1 2 4 0 VDC 04 Detroit Diesel Voltage 0 64 to 4 65 VDC 05 MTU or MAN Current 4 0 to 20 0 mA 06 Scania Voltage 0 42 to 2 95 VDC 07 John Deere Voltage 0 5 to 4 5 VDC 08 Volvo Voltage 0 6 to 3 6 VDC 09 Detroit Diesel Frequency 120 64 to 360 9 Hz 10 Detroit Diesel Frequency 120 64 to 463 5 Hz E1 Throttle in Neutral 00 0 to 25 0 of Throttle Range Throttle Range Throttle Maximum E3 Throttle Minimum E2 00 0 to 20 0 E2 Throttle Minimum Must be 10 or more below Throttle Maximum E3 E3 Throttle Maximum 59 0 10 0 to 100 0 of Maximum Throttle Allowable Must be 10 or more above Throttle Minimum E2 Page 5 3 SET UP PROCEDURES Table 5 2 Throttle Function Codes Function Code Er sin Value Range or Options Section 5 5 2 page 5 8 Throttle Maximum Astern 00 0 to 100 0 of Throttle Maximum E3 Throttle Pause Following Shift 00 0 to 05 0 Seconds E6 High Idle 00 0 to 20 0 of Throttle Range Throttle Range Throttle Maximum E3 Throttle Minimum 2 ji Synchronization 00 Equal Zeen Open Loop Synchronization 01 Active Closed Loop Synchronization reverts to Equal if Tach Signal lost 02 No Synchronization 03 Active Closed Loop Synchronization no synchronization if Tach Signal is lost Function Code Re Value Range or Options Sec
105. Up procedure at any time without saving the GER value to memory deel pees the Left Push Button The Function Code will stop flashing and the Function will be saved with the original Value A The Display LED is in Normal operating condition with the red running Processor Part Number B Depressing either the Up or Down Push Button will activate the Function Menu C Depressing the Up or Down Push Button will scroll through the Function Codes one at a time D Once the desired Function Code is visible on the Display LED press and hold down the Left and Right Push Buttons simultaneously until the Function Code begins to blink E Depressing the Up Push Button will increase the Value of the Function while pressing the Down Push Button will decrease the Value of the Function Pressing and holding the Up or Down Push Button will increase or decrease the Value rapidly Page 5 2 SET UP PROCEDURES 5 3 Storing Values To Memo Once the desired Value TT been reached in Set Up Mode the Value is stored to memory as follows A Depress and hold the right push button first Then while still depressing the right button depress and hold the Left push button until the Function Code stops blinking The new Value is now programmed into memory Set Up Mode is exited B Depress the Up or Down Push Button until the next required Function Code is reached C Reactivate Set Up Mode cx NOTE If no Push Buttons are p
106. a Remote Station the control system will remain in the same Mode Cruise or Troll Transfer Mode 03 or 04 is selected 10D NOTE High Idle and One Lever Mode are not available when a DP system is in command or If this option is going to be used please contact a ZF Marine Electronics Representative for further information Display Panel The Display Panel shows various system information including but not limited to Station in Command Control Head lever PES engine RPM propeller shaft RPM etc The Panel provides transfer direction for Transfer Modes 03 04 The Panel receives information via the serial communications line Figure 8 5 Display Panel Page 8 4 CONTROL OPTIONS The Panel accepts 12 or 24 VDC power supplies A full explanation of the installation operation and adjustment of the Display Panel is provided in Appendix A MM70179 Display oe and the manufacturers EE included with T Panel If this option is going to be used please contact a ZF Marine Electronics Representative for further information 8 9 Backup Control System The Backup Control System provides a control system which is fully independent from the ZF Marine Electronics Control System The Backup can control the gear as well as the engine but it does not include ZF Marine Electronics control logic safety interlock and timing circuits In other words there is no protection for operator errors such as shifting into gear a
107. abled Default Value 01 Tone sounds when the Control Head s lever reaches Neutral 02 Tone sounds when the Processor commands Neutral To change the Value Refer to Sections 5 2 and 5 3 page 5 2 A Scroll to Function Code AA B Activate Set Up Mode C Scroll Up or Down to the desired Value D Store the Value to memory Figure 5 5 Display LED Function A4 Set Up Activated Page 5 7 SET UP PROCEDURES 5 5 1 6 5 5 1 7 5 5 2 5 5 2 1 Function Code Ab Engine Room Lockout Station No 2 Lockout This Function Code provides the installer with four different options The available Values for this Function are 00 Both Disabled Default Value 1 When selected all five Remote Stations behave in the same manner 2 No Station has transfer priority or lockout capability 01 Engine Room Lockout Enabled 1 When the Engine Room switch is closed control is transferred to Station No 1 2 When the Engine Room switch is closed no other station can take command away from Station No 1 3 When closed on power up Station No 1 will be in command without pressing the transfer button 02 Station No 2 Lockout Enabled 1 When the Station No 2 switch is closed control is transferred to Station No 2 2 When the Station No 2 switch is closed no other station can take command away from Station No 2 3 When closed on power up Station No 2 will not be in command unless the transfer button is pressed However no other station can t
108. age to the transmission B OSition the boat in Open Water and slowly increase the Throttle to 25 of the speed range Leave the Control Head lever s at this position for at least 60 seconds Quickly move the Control Head lever s to Idle Astern The engine s RPM should drop to Idle The Clutch should stay engaged or shift to Neutral for 25 of the time selected with Function Code C3 Proportional Pause Time Once the time has expired the Clutch should Shift to Astern The engine RPM will drop slightly when the Astern load is placed on the engine but not to the point where it comes close to stalling Increase the Throttle slightly until the vessel starts moving in the opposite direction If the engine stalled or came very close to stalling increase the Value of Function Code C3 by one second Repeat steps A through C If the engine does not stall or come close to stalling proceed with the next step Repeat steps A through D with the Throttle at 50 75 and 100 of the speed range Page 7 2 SEA TRIALS If the engine stalls at any time increase the Value of Function Code C3 by one second and repeat the steps A through D again F Once a Full Speed Reversal is successful without coming close to stalling the Proportional Pause is properly adjusted Synchronization Test 7 4 1 7 4 2 Equal Throttle Synchronization A Move both Control Head levers side by side to approximately 259
109. ake command on power up 03 Both enabled 1 When both switches are closed control is transferred to Station No 1 2 When both switches are closed no other station can take command away from Station No 1 3 When both switches are closed on power up Station No 1 will be in command without pressing the transfer button Contact ZF Marine Electronics if this Function Code is going to be changed from the default setting Function Code A6 Station No 5 DP This Function allows Station No 5 to be set up as a standard Remote Station or as an interface for a Dynamic Positioning DP system The available Values for this Function are 00 DP Disabled Default Value When disabled Station No 5 is configured to operate with a Standard Control Head 01 DP Enabled with Troll Station No 5 is configured to operate the clutch throttle and trolling valve in DP Mode 02 DP Enabled without Troll Station No 5 is configured to operate the clutch and throttle in DP Mode Contact ZF Marine Electronics if this Function Code is going to be changed from the default setting Throttle Functions Throttle Basic Functions E1 E4 through E7 5 5 2 1 1 Function Code E1 Throttle in Neutral This Function allows the engine RPM at Neutral to be adjusted independently of the RPM at Idle Ahead and Astern The available Values for this Function are 00 0 to 25 0 percent of the Throttle Range The Default Value is 00 0 To change the Value Refer to Sect
110. al Idle position B Depress and hold the transfer button until a solid tone is heard for one second which indicates that transfer has been activated If equipped with Indication Panels the message Push Transfer Button at New Station will be displayed at all Stations A distinctive 1 2 second ON 1 2 second OFF tone pattern will sound at all Remote Stations for up to the time set with Function Code P1 Transfer Timeout C The Operator at the Remote Station taking command MUST place the Control Head levers in the Neutral Idle position D The Operator MUST depress and hold the transfer button within the preset time period until a solid tone is heard to gain command Page 2 2 OPERATION 2 5 3 1 2 5 3 2 If the Operator at the Station taking command does not press the transfer button within the preset time period the transfer process is aborted the text message disappears if so equipped and the tone is silenced If the Operator at the Station taking command does take command within the preset time period the new Station in Command text will appear on the Panel and the text message will disappear The Remote Station that accepted command is now the Station in Command as indicated by the lit red LED s Transfer Request Sequence Request Relinquish Mode P003 2 Step A At any Remote Station not in command place the Control Head lever into the Neutral Idle position B Depress and hold the transfer but
111. al Station pigtails the cables must enter the enclosure through Liquid Tight Connectors in the appropriate holes as shown in Figure 4 5 1 Station No 3 2 Station No 5 optional DP 3 Station No 1 4 Alarm Clutch Pressure and Start Interlock optional 5 DC Power 6 Station No 4 7 Station No 2 8 Clutch Solenoids 9 Troll Solenoids optional 10 Serial Communication 11 Throttle Tachometer optional Processor Circuit Board Connections On a 9000 Processor in lieu of using Harnesses for Control Heads Power Serial Communication and Tachometer the Processor can be ordered with no pigtails installed The above connections then must be hard wired directly to the circuit board Also additional Stations may also be connected to the Processor by connecting pigtails or hard wiring directly to the circuit board Refer to Figure 4 7 for specific termination points x a S RED START INTERLOCK gt LP EE START INTERLOCK CH O sm IRS INTERLOCK loa ou O D D D D D M lo SEKR Station 2 QO Q E GREEN G BLUE VIOLET ORANGE Station 4 ott GREEN G BLUE GJ 3 VIOLET E Tachometer 2 DP Sensor Interface 1 O seria Throttle 1 Communication 13211A ART Figure 4 7 Processor Circuit Board Hard Wired Termination Points Page 4 4 INSTALLATION Hole Terminal Connection 55 Terminal Connection Wire Cable Conn
112. ariety of vessels Below you will find a list and a brief description of the groups of these functions 2 11 1 Processor Functions Within this section of adjustable parameters there are up to seven different adjustments AO Processor Identification Assigns each Processor in multi screw application a unique identifying number This function must be the second function set during Set Up A1 Number of Engines Lets the Processor know how many other Processors need to be communicated with This function must be the FIRST FUNCTION SET during Set Up A2 One Lever Operation Allows the installer to disable or enable One Lever Mode capability A3 Station Expander Optional Allows the Processor to communicate with the Station Expander SE which provides additional Remote Stations Contact the factory if this feature is required A4 Neutral Indication Tone When enabled produces a short 200 Hz tone to indicate Neutral A5 Engine Room Remote Switch Sta HlOptional and Lockout Sta 2 Optional Allows the installer to enable or disable one or both of these features A6 DP Sta 5 Optional Allows the installer to enable or disable DP Mode with or without trolling valve operation Detailed information on each Function is found in Section 5 5 1 page 5 6 2 11 2 Throttle Functions 211 21 Basic Throttle Functions This section applicable to both electronic and servo Throttle adjustment E1 Throttle in Neutral Adjusts th
113. at the lever s are positioned to the Neutral Idle position whenever transferring from one station to another B The Operator at the Remote Station taking command MUST place the Control Head lever s in the Neutral Idle position C Depress and hold the receiving Station s Transfer Button until the Control Head s LED s is lit Transfer of command is now complete 2 5 2 Lever Match and Neutral Mode P002 WARNING DO NOT U H VIODE O RAN R UN N REMCO STATIONS ARE IN CLOSE PROXIMITY AND WITHIN SIGHT OF ONE ANOTHER Extreme care must be taken when transferring command with the receiving Station s Control Head lever s not in the Neutral Idle position First of all the vessel is moving while no person is physically at the Helm Secondly the engine s RPM s can change by as much as 10 resulting in a sudden increase or decrease in the vessel s speed i e otation in Command s lever s may be In any position The Operator at the Remote Station taking command MUST have a good view of the Station in Command s lever positions B Position the lever s of the Station taking command to Neutral or E Ce proximity within 10 of the Station in Command s ever s C Depress and hold the receiving Station s Transfer Button until the Control Head s LED s is lit Transfer of control is now complete 2 5 3 Forward Pass Sequence Relinquish Receive Modes P003 amp P004 A Atthe Station in Command place the Control Head levers into the Neutr
114. atio Station 4 Station 5 Station 2 tation 3 Full Ahead Commanded Full Astern Commanded No Control Head Connected Neutral Commanded Figure B5 4 Display Examples of Remote Stations A D Value Page B5 2 2134 TROUBLESHOOTING B5 1 3 E An A D value of 910 or greater will generate an Error Code The code will be 13 to 22 Control Head Faulted High depending on which Station has the high Command Signal Ifthe AJD value is d than 910 but less than 990 one of the following may be the cause 1 The Control Head s potentiometer is out of calibration 2 The potentiometer is defective In either case it is recommended that the Control Head is replaced e If the A D value is 995 or higher most likely the potentiometer s ground has been lost Right hand Control Heads have a jumper between pins 3 and 5 i a Harness is used This jumper provides the potentiometers ground Left hand Control heads have a jumper between pins 3 and 7 is a Harness is used This jumper provides the potentiometers ground The potentiometer ground connection for Control Heads iia are hard wired to the Processor is d the yellow wire pin 5 on right hand and pin 7 on left hand F If the A D value is 100 or less one of Error Codes 23 32 Control Head Faulted Low will be shown f the A D value is less than 100 but greater than 75 the following may be the cause 1 The Control Head s potentiometer is out
115. ator time to match the position of the previous Remote Station s Control Head lever Page 5 16 SET UP PROCEDURES 3 Once command has been taken the engine and gear will respond when the Control Head levers are moved Ahead or Astern 02 Lever Match and Neutral 1 The operator has two options when selected Option 1 requires that the receiving Remote Station s Control Head lever is at the Neutral detent for a transfer to occur Option 2 requires that the receiving Remote Station s Control Head levers to be within 10 10 Percent 33 ADs 7 5 Degrees of the Station in Command s Control Head levers for a transfer to take place 2 In both options there is a 1 second delay after the Control Head s re LED is lit before the receiving Remote Station s Control Head levers have command 3 Once command has been taken the command to the engine and gear will respond to the Control Head lever s position immediately 03 Request Relinquish or Relinquish Receive 1 The operator has two options when selected Option 1 requires the operator at the receiving Remote Station request control by pressing the transfer button on the receiving Remote Station s Control Head The Station in Command may now relinquish control by pressing the transfer button on the Station in Command Control Head Option 2 requires that the operator at the Station in Command relinquishes control by press the Station in Command s
116. block Ensure that the red conductor is crimped to pin 5 of the connector and connected to pin 3 of the Control Head s terminal block Clear the Error Code from memory Replace the Control Head Ensure that the orange conductor is crimped to pin 4 at both ends and the red wire is crimped to pin 5 at both ends of the Harness Ensure that the orange conductor is crimped to pin 4 of the connector and connected to pin 4 of the Control Head s terminal block Ensure that the red conductor is crimped to pin 5 of the connector and connected to pin 3 of the Control Head s terminal block Clear the Error Code from memory Replace the Control Head Ensure that the orange conductor is crimped to pin 4 at both ends and the red wire is crimped to pin 5 at both ends of the Harness Ensure that the orange conductor is crimped to pin 4 of the connector and connected to pin 4 of the Control Head s terminal block Ensure that the red conductor is crimped to pin 5 of the connector and connected to pin 3 of the Control Head s terminal block Clear the Error Code from memory Replace the Control Head Ensure that the orange conductor is crimped to pin 4 at both ends and the red wire is crimped to pin 5 at both ends of the Harness Ensure that the orange conductor is crimped to pin 4 of the connector and connected to pin 4 of the Control Head s terminal block Ensure that the red conductor is crimped to in 5 of the connector
117. c ae x 242 oes A BREE RES CROPS dare NEE ROS SN 2 4 Ahead Solenold TESTA 50 ES A aed Sra as 2 4 Clutch Connection Ahead Solenoid rar ga owls Dt a ee dE Shwe ew pter bi ode Bee 2 4 Astermm Solenoid TESUNG EE 2 5 Clutch Gonmechom Asten Solenoid gs dsd ann odie ik OY ed os eli e dee 2 5 TROLLE TE OWING 1 sra A EEN 2 6 Troll ONO SOlCN OIG EEN 2 6 Troll Connection ON OFF Solenoid 3 s sos du feed Ss a Milt Seed aa 2 6 Troll Command Proportional Solenoid Testing with Amp Meter 2 6 Troll Connection Proportional Solenoid with Amp Meter 2 6 Paris List SH 2 ae om etapa AO i ie tee A OS POT ES B EE EE 3 1 Appendix C Drawing 1306841 NOLES Page asien C 1 Drawing 13068A 2 System Diagramm nen C 3 Drawing 1306843 Processor Connections sicot dee C5 Drawing 13068A 4 Control Head Connections cceccsceccecsccecsecsccscsccscescecssceccessccsccecsccsceccssescecesees C 7 TOC T0 REVISIONS LIST Revisions List Rev Date Revision Description 2 05 This manual is created from MM14330 1 RevF 11 04 CruiseCommand Installation Manual Refer only to the Sections appropriate for your System Refer to Appendix C System Drawing for System Specific Information A Al 9 05 10 05 Processor replaced a 96202 ClearCommand Per JimM Engine and Ratio Chg Dus 13068 revised to A PageTOC 11 REVISIONS LIST PageTOC 12 1 INTRODUCTION n T N INTRODUCTION This manual is written to document e
118. cation Cable e oet ura list S eerte last 4 7 Processor Circuit Board Connections for Serial Communication AANEREN NNN 4 8 TACHOMETER CABLE LOCATON T2 E 4 8 AC Type Tachometer Cable as puta Ee E e AE 4 8 Open Collector Tachometer Cable a2 e E A a o Ni eds dete es 4 8 Processor Circuit Board Connections for Tachometer ANNER RENE 4 9 Clutch Cable LOCOUON 8 aus de a re da 4 9 EECHER E 4 9 Clutch Cable Heat Shrink in Processor 2 2m re OS eS Natu urn s ER a Lea le BIST ee ge d E A 4 9 EE TERMINA TON A A A ENER 4 9 Clutch Cable Plug Termination Connections er a Bla our ete eta turca Due duet ou Et Poiret rettet 4 9 Gluten EENEG 4 10 Ihrottle Gable Location 11 2 s ym er Bi hk Be REC Meam eae du ie 4 10 ENGINE SEN KEEN 4 10 Processor Circuit Board Connections for Throttle ia ini nn ee TV aaa vue ibid ine 4 10 ENGINE SLO WILCHE eh Stace e ahs dca Gian Ue oe dates aded oe cir domi ae Len it dst afecte 4 10 SET UP PROCEDURE ccc oorr 5 Processor Components Used Insee pa a 23222 i dts da Sol A eR E e 5 1 Typical Processor EE EE 5 1 Processor shield Push Button and Display LED Locations 324 4422 4 28 4 242 Sara au e REI ORE eed 5 1 PIOCOeSSOF DISDIQV LED A adole ees alot ee Sua ue es 5 1 Display LED at Normal Operation EE 5 1 Display RRE EE 5 1 PUSH BUIOHS gt lt SS da e e 5 1 EIREUIE Board PUSH IBUMONS nase ea ae a eee RR V Cr RN Aa E o ade a o dens 5 1 PFAND DOWN FUSER BUTTON cR 52 sigues e odes EROS MEI NES 19 2 zc aci ES
119. cecsceccecsccsceesecesees A 17 Drawing 114989D 3 APS Notes te CN A 19 MIMIG 28 7 REV 8 03 ocean A 21 Bonding A B Y C E 11 46 CFR 111 05 VMIVIG 288 E EE A 23 References and Parts Source SER Fo UBL EE A 25 Engine Tachometer Sender Requirements MME 165 ReVE 2 08 ne ee cdas A 27 Electronic Propulsion Control Systems Three Year Limited Warranty MME 163 REV eer KA TN DEE A 29 Warranty Registration Appendix B B1 TROUBLESHOOTING GENERAL B1 1 B1 1 Control System Examples 4 2534 2 4442 racoare ende ee B1 1 B1 1 1 96202 Throttle Electronic Clutch Solenoid Two Station ProcessSor B1 1 B1 2 Typical System Main Components amp sud ddr tede deo ee B1 1 B1 2 1 CONT Ol HOGG EE B1 1 B1 2 2 PIOCOSSDILS e Ge Ee no De ts res NEE Lie ee ates BS oF Zn B1 1 B1 2 3 POWBOI SOULCB S Aca et are I eodd e Ave eq DAS a EVER SU Dien B1 1 B1 2 4 Electrical Cables and Harnesses usa Re o PA E LYON RR RENE YE B1 1 B2 TROUBLESHOOTING QUESTIONS 7 7 gt B2 1 B3 TROUBLESHOOTING PROBLEM RESOLUTION B3 1 B3 1 Bex o PCT B3 1 TABLE OF CONTENTS B3 2 B3 2 1 B3 2 2 B3 3 B3 3 1 B3 3 2 B3 4 Table B3 1 B4 Figure B4 1 Figure B4 2 Figure B4 3 Figure B4 4 Figure B4 5 Figure B4 6 Figure B4 7 Figure B4 8 B5 Bb 1 B5 1 1 Figure B5 1 B5 1 2 Figure B5 2 Figure B5 3 Figure B5 4 B5 1 3 Figure B5 5 B5 1 4 Figure B5 6 B5 1 5 Figure B5 7 B5 1 6 Figure B5 8 B5 1 7 Fig
120. ched during this time The Throttle will remain at Idle until the Control Head s lever is returned to Idle the Pressure Switch contact closes and a speed command above Idle is commanded 02 Throttle Clutch Pressure Interlock This option is typically selected when the Clutch takes longer than five seconds to reach full pressure The Throttle will remain at Idle until there is a closure of the Pressure Switch s contact This prevents speeds above Idle prior to full Clutch engagement In the event of a loss of Clutch pressure while cruising the Throttle will be returned to Idle after the time selected with Function Code C1 has expired Once a closure of the Switch is sensed indicating adequate pressure the Throttle immediately returns to the commanded signal without having to return the Control Head lever to Idle first as is the case with Value 01 Page 8 2 CONTROL OPTIONS To External Status Indication Circuit Hydraulic Line Shuttle Valve To Processor Power Wire Pigtail DC Power Harness Source To Starter Solenoid 12281 Hydraulic en d START Line Green N Pressure Clutch Pressure 3 Blue Ben Shuttle Valve Fo ol Clutch Pressure 200000 0 Vloo O oo inmnmuaagauugngj EI EJ E El Tu SUUS CUT Tm 6600D Lis at on el e Processor 12281 Figure 8 4 Clutch Pressure Switch with Processor Hard Wired Diagram 8 2 2 Installation The in
121. ck becomes active C2 Proportional Pause Selects between an In Gear Neutral or Fixed Neutral delay C3 Proportional Pause Time Selects the maximum delay time during a full speed reversal C4 Proportional Pause Ratio Determines if the Ahead and Astern reversal times are the same or if Astern is 1 2 of Ahead time C8 Fixed Neutral Delay Provides an adjustable fixed Neutral delay regardless of commanded speed and direction Detail information on each function is found in Section 5 5 3 1 page 5 11 2 11 3 2 Solenoid Clutch Functions This section along with the Basic Clutch Functions Section allows the adjustment of Clutch Solenoid related items IMPORTANT The following Functions are to be used on Hurth gears with two 2 proportional solenoids ONLY Do not use on Hurth gears with ON OFF solenoids 5 ohiit Solenoid lype Selects the approximate current levels for the 12 or 24 VDC ZF Hurth Solenoids C6 ZF Hurth Duty Cycle Ahead Fine tunes the maximum current level to the Ahead Proportional Solenoid C7 ZF Hurth Duty Cycle Astern Fine tunes the maximum current level to the Astern Proportional Solenoid Detail information on each function is found in Section 5 5 3 2 page 5 13 2 11 4 eee Boost Functions Optional This section applies to electronic throttle signals FO Speed Boost Percentage Programs the amount of throttle applied during initial clutch engagement F1 Speed Boost Duration Programs how long the elevat
122. command is stuck If the Processor for this System includes the use of Back u Mode this tone would indicate that there has been a switc closure requesting Back up Mode Page B5 3 TROUBLESHOOTING If the Processor for this System includes Integrated Solenoid Trolling Valve control this tone would indicate that there has been a Troll Solenoid error Refer to the Error Code displayed B5 1 5 Three Second Steady Tone followed by a Slow Repetitive Tone oT oo oo oo Figure B5 7 Three Second Tone followed by a Slow Repetitive Tone B5 1 6 WW DD D Figure B5 8 B5 1 7 This tone indicates that there has been a shorted Transfer Button on power up Command can be gained at any other Remote Station which silences the Slow Repetitive Tone Five Seconds On Five Seconds Off High Repetitive Rate Tone HEHEHE E WWW WW WWW Five Seconds On Five Seconds Off High Repetitive Rate Tone Loss of communication with Station Expander SE or the Troll Actuator p n 9001 This tone cannot be cleared unless all Error Codes Active and In Active have been cleared Five Second Steady Tone EE Figure B5 9 Five Second Steady Tone Loss of Serial Communication B5 2 Clutch Solenoid Control System Tones B5 2 1 eT One Long One Short Tone NEN e Il Figure B5 10 One Long One Short Tone This tone can be produced if solenoid monitoring is turned ON with Function Code H2 When this tone is sounded this tone will also be
123. cond Harness is designed for Active Sensors with an Open Collector output such as Hall Effect Sensors This Harness is only required when Active Synchronization is required One Harness per Processor is required The Harness is plugged on one end only Determine the source of the tachometer signal which can be provided by a mechanical tachometer sender magnetic pickup alternator s pre rectified output the negative side of the coil gasoline engine or an engine s electronically produced signal Refer to Engine Tachometer Sender Requirements located in Appendix A 3 1 4 5 Throttle Harness One Harness required per Processor There are 4 types of Throttle Harnesses Voltage Current PWM Pulse Width Modulation and Frequency e Most Throttle Harnesses are plugged at the Processor side only SC Throttle harness types are available with plugs on both ends 3 1 4 6 Clutch Harness One Harness required per Processor The Harness consists of 2 two conductor cables The cables supply power to the Ahead and Astern Clutch Solenoids All of the cables in the Harness are the same length Therefore order a length that will reach all of the previously mentioned items if required 3 1 5 Electric Cables Refer to Appendix A Parts List Tr SEN may use Harnesses Electric Cables or a combination of both The following lists the various equivalent electric cables 3 1 5 7 Control Head Electric Cable If the Control Head is hard wi
124. ction If the LED begins to moving in the Astern direction blink the Control Head is incorrectly wired e Check the colors of the wires at pins 5 and 7 e A right hand Control Head should have yellow at pin 5 and blue at pin 7 e A left hand Control Head should have blue at pin 5 and yellow at pin 7 e Ahead and Astern Solenoid Wires need to be reversed B10 3 Electronic Throttle Control System Problems Without Error Codes A SYMPTOM The engine RPM s vary without moving the Control Head lever synchronization disabled Cause Remedy a Problem with the Governor a Connect the Break out Box p n 13927 as shown in the Throttle Testing Section of the Service Field Test Unit Manual If variations are seen proceed to Step B If no variations are seen contact a certified engine mechanic b Erratic Command Signal b Refer to Command Signal testing If variations of the A D counts occur connect the Control Head to another Station if available on the Processor If variations persist replace the Control Head B SYMPTOM The engine s Idle is too high Cause Remedy a Idle was not adjusted mechanically a Adjust the Throttle Push Pull cable as correct at the Idle stop specified in Section 5 6 2 2 1 page 5 12 b Function Code E2 Throttle Minimum is b Adjust Throttle Minimum as specified in incorrectly set Section 5 6 2 2 2 page 5 13 c The Governor or Carburetor is c After Causes a and b have been eliminated incorrect
125. d Single Lever Tournament Style Aluminum Junction Box 521 5L or 4RLeft or Right Control Head Single Lever Tournament Style Chrome 521 5LB or 4RBLeft or Right Control Head Single Lever Tournament Style Chrome Junction Box 750 L or RLeft or Right Control Head Heavy Duty MC2000 1L or 1RLeft or Right Black Control Head Black Lever MC2000 2L or 2RLeft or Right Chrome Control Head Chrome Lever MC2000 4L or 4RLeft or Right Black Control Head Chrome Lever MC2000 4LP or 4RPLeft or Right Black Control Head Chrome Lever Pluggable MC2000 5L or 5RLeft or Right Black Control Head Gold Lever TWIN SCREW Synchronization Indication 460 4 Control Head T Lever 460 4P Control Head T Lever Pluggable 463 4 Control Head Chrome Knob Lever 463 4P Control Head Chrome Knob Lever Pluggable 464 4 Control Heads Split with Single Levers Chrome Knobs pair 465 4 Control Head Black Low Profile Lever 466 4 Control Head Chrome Low Profile Lever 522 4 Control Head Dual Lever Tournament Style Aluminum 522 4B Control Head Dual Lever Tournament Style Aluminum Junction Box 522 5 Control Head Dual Lever Tournament Style Chrome 522 5B Control Head Dual Lever Tournament Style Chrome Junction Box 760 Control Head Heavy Duty 760P Control Head Heavy Duty Pluggable MC2000 1 Black Head Black Levers MC2000 1PBlack Head Black Levers Pluggable MC2000 2 Chrome Head Chrome Levers MC2000 2PChrome Head Chrome Levers Pluggable
126. d Power Start Interlock Horness 4 1 DCFPOWER CABI usais st sa a 41 ARUN RO CE RE 4 2 Start Interlock Connections cad dept ete rcs is a Qe di GO RE CERT o deidad tadas ee 4 2 EXTERNAL ALARM CIRCUIT CABLE OPTIONAL Jr He caches Ee deeg Dee 4 2 GLUTCE ARE SSURE S IT CABREO PUNO NA A A ie otis Pau 4 2 Serial Communication HarnesS oooooooooo ooo 9 e ees 4 2 RE KEE 4 2 Twin Screw se al Harness Connections EE 4 2 Standard Control Head Re el 4 2 CONTROL HEAD HARNESS WITH TWO CONNECTORS ae rate san 4 3 CONTROL HEAD HARNESS WITH ONE PLUG EEN 4 3 Tach Sensor Harness required for Active Synchronization we eee ewes 4 3 SEELEN ges alos le Ree a cet Ue he ag he we aa eae 4 3 SIE ER E e EE 4 3 E EE BEE 4 3 PAra A IET Ss RETE ECT CTETUR 4 4 Liguid TIGnt CONOCIO out la dte pare Ware on t pude cie d e ee 4 4 Liquid Tight Installation es costas ee eh oy CUT eee EE 4 4 Processor Enclosure Cable HoleS lt s utter ed br Be etre ees ace an cog eo eve ieri e dt 4 4 Processor Enclosure Cable e ioo ee arse etta Sake ok data whe gules Sod quidne Ph png v wr ede 4 4 Processor Circuit Board Connections cc ee ee ee s 4 4 Processor Circuit Board Hard Wired Termination Points 43 ssec ER EE Ey oe ex ee C 4 4 Hard Wire Installation lt A a e CER er OE etse ew td epo at wis guber Ste os 4 5 SEVENSCONDUCTOR CONTROL HEAD CABLE LOCATIONS 1 2 3 6 AND 7 ege totes AAA 4 5 TOC 9 TABLE OF CONTENTS 5 Figure 4 8 Figure 4 9
127. d to pin 4 of the Control Head s terminal block Ensure that the red conductor is crimped to pin 5 of the connector and connected to pin 3 of the Control Head s terminal block TROUBLESHOOTING 35 e b 36 37 38 39 0 Table B9 1 Basic Control System Problem Causes and Solutions pb Causes Solutions a Clear the Error Code from memory The Station No 3 transfer button was held down for 15 seconds or longer The Station No 3 Control Head transfer button is defective The Control Head Harness is miswired The Control Head s Pigtail is miswired The Station No 4 transfer button was held down for 15 seconds or longer b The Station No 4 Control Head transfer button is defective The Control Head Harness is miswired The Control Head s Pigtail is miswired The Station No 5 transfer button was held down for 15 seconds or longer The Station No 5 Control Head transfer button is defective The Control Head Harness is miswired The Control Head s Pigtail is miswired The Station No 6 transfer button was held down for 15 seconds or longer The Station No 6 Control Head transfer button is defective The Control Head Harness is miswired The Control Head s Pigtail is miswired The Station No 7 transfer button was held down for 15 seconds or longer The Station No 7 Control Head transfer button is defective The Control Head Harness is miswired The Control Head s Pigtail is misw
128. deline for making this determination There is no need to troubleshoot the system to any point further than one of the main components listed above If the fault is found to be with a Control System component that component is simply replaced If the fault is found to be with one of the external components replace or repair the defective component or contact a qualified mechanic Page B3 1 TROUBLESHOOTING B4 TROUBLESHOOTING DIAGNOSTIC MENU The Processor has built in diagnostics designed to assist the technician in determining the cause of a problem The following information is available to view at any time Applied Battery Voltage Tachometer Sender Frequency Stations 1 5 A D s Stations 1 5 Transfer Button Status Servo 2 Feedback A D s if applicable Servo 1 Feedback A D s if applicable Software Revision Level In order to access this information follow the steps below A Locate the Display LED on the Port or Starboard Processor The Display LED will have the Processor Part Number D displayed in a running pattern moving from left to right while the program is running in Normal Operation Figure B4 1 Display Function B Depress the Up or Down Push Button to activate the Function SES Code List The characters A001 will be shown on the Display like Figure B4 1 C Depress the Up or Down Push Button repeatedly until H000 is D I displayed like Figure B4 2 D Depress and hold the Left and Right Push Buttons
129. dentify one of the Processors as ID No 1 with the AO function Restore power to Processor ID No 1 Connect the Serial Harness into Processor ID No 2 Identify one of the Processors as ID No 2 with the AO function Restore power to Processor ID No 2 TROUBLESHOOTING Table B9 1 Basic Control System Problem Causes and Solutions Error Causes Solutions a The Serial Harness is not connected at Processor ID No 3 a Connect the Serial Harness into Processor ID No 3 b None of the Processors has ID No 3 selected b ee one of the Processors as ID No 3 with the AO unction c Loss of power to Processor ID No 3 c Restore power to Processor ID No 3 a The Serial Harness is not connected at Processor ID No 4 a Connect the Serial Harness into Processor ID No 4 b None of the Processors has ID No 4 selected b O one of the Processors as ID No 4 with the AO unction u c Loss of power to Processor ID No 4 c Restore power to Processor ID No 4 u a The Serial Harness is not connected at Processor ID No 5 a Connect the Serial Harness into Processor ID No 5 b None of the Processors has ID No 5 selected b ee one of the Processors as ID No 5 with the AO unction c Loss of power to Processor ID No 5 c Restore power to Processor ID No 5 a The Serial Harness is not connected to the SE a Connect the Serial Harness to the SE b The Serial Harness is not connected to the Processor b Connect the Serial Harness
130. ds C Synchronization is now OFF Turning ON Synchronization is automatic and does not need to be turned ON unless previously turned OFF as described in Section 2 10 4 1 A Ensure that the Control Head s levers are positioned to a oint where Synchronization Criteria are met B At the Station in Command press and hold the transfer button until the green LED lights approximately 2 seconds The green LED will blink as the system is working toward synchronization The green LED will become solid when the engines are synchronized Turning Synchronization ON OFF when Criteria is Not Met The actual synchronizing of the engines occurs when the Control Head levers are within the 1096 approximately 6 degrees window of Page 2 7 OPERATION one another However synchronization can be turned ON or OFF when the Control Head levers are apart more than the 10 A At the Station in Command press and hold the transfer button for at least two seconds If synchronization is being turned ON the green LED will light after two seconds and stay lighted as long as the transfer button is depressed When transfer button is released the LED will go out If synchronization is being turned OFF after two seconds the green LED will blink twice and then stay off 2 11 Control Systems Configurabilit The Processor is designed in a way which allows it to be easily configured by the installer to meet the varying needs of a wide v
131. dth Modulation with DC kvoirmerer llle 23 Figure 2 6 Throttle Connection PWM with DC Voltmeter see 2 3 FAA PWM Pulse Width Modulation with Duty Cycle Meter 24 Figure 2 7 Throttle Connection PWM with Duty Cycle Meter o RR 2 4 21 5 Freguency HZ O ri tet amp Boa BU or cio Beitr our nin eos d 2 4 Figure 2 8 Throttle Connection Frequency Hz eus eat A EPA eee eae ERE 2 5 2 2 CLUTCH E RA rotad k n naaie aAa a 2 6 22 Neutral SOlCNOIO TESTING sonent a eoo EE ert b RR les b dc eed 2 6 Figure 2 9 Clutch Connection Neutral Solenoid a rara we m e dem pm Rn 2 6 222 Ahead e E e ur een dodge Ge BAR her dio de cR ge E 2 8 Figure 210 utet Connection Ahead SONO st AOS ERA AE age 2 4 2 2 9 Astern Solenoid Testing ur o dao aco do Gio ms ats ae m Reda to Qu iA pee 227 Figure 2 11 Cluteh Connection Astern Solenoid nh ib oo dd E x dea 2 8 233 HAETT RE IEN 2 9 eg VOU ORI OT SCION OIG EE 29 Figuire 2 12Tr011 Connection ON OFF Solenoid 2er 4 rar a a aeg 2 9 29 2 Troll Command Proportional Solenoid Testing with Amp Meter 2 10 Figure 2 13 Troll Connection Proportional Solenoid with Amp Meter 2 10 2 4 POP EE TE S INGE ss see E E by EURO oodd et 2 11 zT HO EE 2 71 Figure 2 14 2 Spead CONMe CON EE 211 2 4 2 NOIR IE E ee E A e ce dd ada Ke ee 2 11 Oe LSE 5658 E de roi EE EE EE ims vea Table E Pare i EE 3 1 TOC 1 REVISIONS LIST Revision List Rev Date Revisio
132. e Port Processor The Harness from the Starboard side of a Control Head is always routed to the Starboard Processor Power Start Interlock Clutch Pressure Alarm Harness e One Harness required per Processor e The Harness is plugged at one end only n addition to the DC power and Start Interlock the Harness options for Clutch Oil Pressure Switch and External Alarm Circuit are available Page 3 2 PLAN THE INSTALLATION All of the cables in the Harness are the same length Therefore order a length that will reach all of the previously mentioned items if required The Harness is available in lengths up to 30 feet 9 14m 3 1 3 3 Serial Communication Harness The Serial Communication Harness is only required in Multi Screw applications when an LCD Display is utilized or an external trolling valve actuator 9001 is utilized The Harness interconnects the Processors to each other A plug is attached at both ends of the Serial Harness Twin Screw One 1 Serial Harness part no 13316 X 3 1 4 Additional Harnesses Refer to Appendix A Parts List The following lists the additional Harnesses that plug into the Processor 3 1 4 4 Tach Sensor Harness There are two Tach Sensor Harnesses available 1 The first is the AC Coupled Sensor Harness which is designed for inputs from items such as Mechanical Senders Magnetic Pickup Sensors the Alternator AC Stator Terminal or the negative Coil Terminal 2 The se
133. e Sheets for information on the various Control Heads available and their dimensions e The 400 and MC2000 Series Control Heads are spray proof from the top but must be protected from the weather on the underside The 700 Series Control Heads are fully water proof Control Heads are available with pluggable pigtails or may be hard wired no pigtails When a 400 or MC2000 Series Control Head must be mounted in a location where the underside may be exposed to the weather consider using a Weather Mount Enclosure Refer to the Appendix A Weather Mount for specific information Ensure that the clearance is sufficient for the Control Head s lever to reach full Ahead and full Astern e Retrofit applications may require an Adapter Pad to cover the old Control Head cutout A variety of Adapters and Cover Pads are available Refer to Appendix A Parts List for details i mounted at any location on the vessel as long as all of the criteria listed above are met Wire Harnesses Refer to Appendix A Parts List The following lists the various Harnesses that plug into the Processor Control Head Harnesses One Control Head Harness is required for every Control Head lever at every Remote Station e The Control Head Harnesses are available in various lengths e Harnesses are available with plugs on both ends or a plug on the Processor side only The Harness from the Port side of a Control Head is always routed to th
134. e Throttle when in Neutral independent of the throttle output when the clutch is engaged E5 Throttle Pause following Shift Allows the adjustment of time between clutch engagement command and when throttle begins to increase above Idle E6 High Idle Programs a second elevated Idle RPM E7 Synchronization Allows the installer to select synchronization and select the type of synchronization Detail information on each function is found in Section 5 5 2 1 page 9 8 2 11 2 2 Electronic Throttle Functions This section along with Basic Throttle Functions allows the adjustment of the Electronic Throttle E0 Engine Throttle Profile Selects the throttle signals type and range Page 2 8 OPERATION E2 Pole Minimum Allows fine tuning of the throttle signal at Idle E3 Throttle Maximum Allows fine tuning of the throttle signal at Full E4 Throttle Maximum Astern Allows the installer to limit the amount of throttle allowed when Full Astern is commanded Detail information on each function is found in Section 5 5 2 2 page 5 10 2 11 3 Clutch Functions 2 11 3 1 Basic Clutch Functions The following functions are available for all types of clutches CO Clutch Pressure Interlock Selects the Clutch Oil Pressure Interlock option The interlock prevents a throttle signal above Idle from being applied unless adequate clutch pressure is available C1 Clutch Interlock Delay Determines when the Clutch Oil Pressure Interlo
135. e switch is CLOSED Station No 1 will take command away from any other Remote Station including DP It also prevents other Remote Stations from taking command away from Station No 1 If this option is going to be used please contact a ZF Marine Electronics Representative for further information Lockout Switch This feature prevents any Remote Station other than Station No 2 from taking command If this option is going to be used please contact a ZF Marine Electronics Representative for further information DP MODE Refer to the information supplied with the DP system for operational guidelines The ClearCommand and the DP systems cannot be in command at the same time When DP Mode is selected with the DP system 1 A one second tone is heard at all Remote Stations 2 The Station in Command LED s are not lit at any Remote Station 3 If equipped with an Indication Panel DP Station will be displayed at the top of the Panel The ClearCommand system can take control away from the DP system at any time by taking command at a Remote Station The ClearCommand system can be programmed for DP1 operation with or without Trolling valve operation 1 When DP operation is programmed with Trolling operation the system will always operate in Troll Mode Type 3 35 degrees when the DP system is in control This is regardless of the type selected with Function Code LO 2 When control is taken away from the DP system with
136. ead or Astern The Control System pauses at this position until the delay has timed out The Transmission shifts to the opposite gear Astern or Ahead The Throttle position moves to ibo Control Head s present lever position 7 2 2 Neutral Delay C201 The Throttle position drops to Idle The Transmission shifts to Neutral The Control System pauses at this position until the delay has timed out The Transmission shifts to the opposite gear Astern or Ahead The Throttle position moves to the Control Head o present lever position 7 2 3 Fixed Neutral Delay C202 CAUTION The Fixed Neutral Delay feature was added in order to accommodate Thruster Q Control installations Damage to the drive train may occur when used for reverse reduction gear applications The Throttle drops to Idle e The Transmission shifts to Neutral Page 7 1 SEA TRIALS The Control System pauses at this position for the amount of time programmed duration with Function C3 Proportional Pause Time regardless of prior throttle setting The Transmission shifts to the EE gear Port or Starboard The Throttle position moves to t e Control Head s present commanded position 7 3 Calculating Proportional Pause Time C3 NOTE The pause on a through Neutral shiit is proportional to the speed commanded and the maximum possible delays When shifting from Idle Ahead to Idle Astern or vice versa the delay is Sj time at that
137. ections TB utch 1511 black 1 Station 5 TB3 not used with DP Brown 2 Station 1 TB1 Yellow 5 Station 4 TB4 Green 6 Station 2 TB2 Violet 8 8 amp 9 Clutch Troll TB11 Black 1 Brown 2 Orange 4 Red 3 Gray 5 Orange 4 Green 6 Yellow 5 Blue 7 Green 6 Blue 7 Violet 1 White 8 Tan 2 Red Black 4 Brown 6 10 erla White 6 Black 5 Communication TB7 Green 7 Red 8 Clutch Pressure TB6 Green 4 Black 9 Blue 3 Drain 10 Start Interlock PB2 Red 1 11 rottle 1B8 Brown 3 Yellow 2 Red 4 Orange 5 Ground TB6 Orange 2 White 6 Black 7 Backup Input TB6 White 1 5 Power In PB1 Black Negative 12 achometer 1 B9 Red 1 Red Positive Green 2 Black 4 4 4 4 4 4 4 1 Hard wire Installation Ay Kun the neo Control Head Cable Locations 1 2 3 6 and 7 A Run the seven conductor cable from the Remote Station to the Processor Support the cables using clamps or straps not more than 18 inches 0 5m apart if not contained in a conduit Verify cable location protects the cable from physical damage Label each seven conductor cable at both ends with the station it connects and Port or Starboard Place on your wrist the anti static wrist strap provided attach the strap to ground and then remove the cover from the Processor Run the seven conductor cable for each remote station through the corresponding liquid tight cable grip on the Processor
138. ed on the Control Head Station transfer is ere i sel y la pressing the Control Head mounted transfer button 1 2 1 96202 Processor Throttle Electronic Shift Solenoid 2 Pluggable Remote Stations The System is designed for pleasure and light commercial marine vessels that require remote control of electronic engine governors solenoid activated clutches System Features 1 3 1 Standard Processor Features Station in Command indication Section 2 2 Single Control Head lever command of speed and direction Section 2 3 Start Interlock Section 2 4 Push Button Station Transfer Section 2 5 Proportional Pause on through Neutral Shifts Section 2 6 Warm up Mode Section 2 7 High Low Idle Selection Section 2 8 One Lever Mode Section 2 9 Engine Synchronization Section 2 10 Page 1 1 INTRODUCTION Easily configured to a vessel s control requirements Section 2 11 Audible system diagnostics and status indications Section 2 12 Push Button Set Up Section 2 13 Visual system diagnostics set up and status indication Section 2 14 Pluggable Connections Section 2 15 1 3 2 Optional Processor Features System failure external alarm contact Section 2 16 1 Clutch pressure interlock Section 2 16 2 Station Expander SE Sections 2 16 3 Integrated Solenoid Trolling Valve Control Section 2 16 4 Engine Room Only Remote Switch Section 2 16 5 Lockout Switch Section 2 16 6 DP Mode Secti
139. ed throttle signal will be applied after initial clutch engagement F2 Speed Boost Start Delay Programs the amount of time required after jet engagement is commanded until the Speed Boost is applied Detail information on each nn is found in Section 5 5 6 1 page 5 16 2 11 5 Troll Functions Optional The LO Troll function is the only Troll function code displayed unless Troll is activated using LO When activated Function Codes L1 through L6 are displayed Page 2 9 OPERATION 2 11 6 2 11 7 2 11 8 2 11 8 1 LO Troll Enable and Control Head Lever Range Enables and disables Troll Selects the amount of Get Head lever movement dedicated to Trolling Valve Control L4 Troll Throttle Limit Programs the maximum throttle allowed during trolling operation L5 Troll Pulse Duration Adjusts how long a throttle boost is applied when troll operation is initiated L6 Troll Pulse Percentage Adjusts how much the throttle is boosted when troll operation is initiated Detail information on each function is found in Section 5 5 4 page 5 15 Integrated Troll Solenoid Functions This section along with the Basic Troll Functions Section allows the adjustment of solenoid Trolling Valve related items L1 Troll Valve Function Selects the current output characteristics If ZF Hurth Gears with two 2 proportional solenoids are used this Function must be the 3RD function set L2 Troll Minimum Pressure Adjusts the amount of c
140. ed too long or Button Stuck Closed has been closed since power up 34 Station No 2 Station No 2 Control Head s Transfer Button has either been closed too long or Button Stuck Closed has been closed since power up 35 Station No 3 Station No 3 Control Head e Transfer Button has either been closed too long or Button Stuck Closed has been closed since power up 36 Station No 4 Station No 4 Control Head s Transfer Button has either been closed too long or Button Stuck Closed has been closed since power up 37 Station No 5 Station No 5 Control Head s Transfer Button has either been closed too long or Button Stuck Closed has been closed since power up 38 Station No 6 Station No 6 Control Head s Transfer Button has either been closed too long or Button Stuck Closed has been closed since power up Page B8 1 TROUBLESHOOTING ZE Table B8 1 Basic Control System Error Codes Error un 39 Station No 7 Station No 7 Control Head s Transter Button has either been closed too long or Button Stuck Closed has been closed since power up 40 Station No 8 Station No 8 Control Head s Transfer Button has either been closed too long or Button Stuck Closed has been closed since power up 41 Station No 9 Station No 9 Control Head s Transfer Button has either been closed too long or Button Stuck Closed has been closed since power up 42 Station No 10 Station No 10 Control Head s Transfer Button has either been closed too long or Button Stuc
141. er to Plan the Installation Section for requirements B3 3 Component Condition B3 3 1 Control Heads Inspect for any signs of corrosion due to water incursion If hard wired ensure that all the fork connectors are properly secured to the terminal Verify all wires are fully crimped and do not pull loose B3 3 2 Processors Inspect the Processor for any signs of physical damage B3 4 Interconnecting Wiring and Harnesses A Inspect the wire terminations for loose connections corrosion or wire strands B Inspect the Harness s pins and sockets for bent pins torn boots or any signs of corrosion The first step in troubleshooting a problem with the Propulsion System is to determine if the problem is with the Control System or something external to the System In ali cases a Control System dicis will alert the operator of the potential problem This is accomplished through the audible tone ed at all Remote Stations When an audible tone is emitted it will be accompanied by an Error Message at the Processor Also in many cases the Control System will alert the operator to a problem external to the Control System The following are examples of components both internal and external to the Control System which could be a source of trouble Table B3 1 Examples of Components Internal External 1 Processor 1 DC Power Source 2 Control Head 2 Engine 3 Interconnecting Wiring Harnesses 3 Transmission The following pages should give you a good gui
142. erlock Cable Page 4 6 INSTALLATION 3 8 inch 9 53mm 7 44 4 4 F Crimp fork or ring terminals to the wires G Connect the two conductor cable to PB2 red lead to the terminal labeled 1 and yellow lead to the terminal labeled 2 as indicated on Figure 4 7 page 4 4 H Tie wrap the start interlock cable to the Processor s frame Power Cable Location 5 A Run the length of two conductor power cable between the DC Power Source and the Processor B Make the connections at the vessel s DC Power Source but do not turn power ON C Install a liquid tight connector into the DC POWER entry hole No 5 Refer to Figure 4 6 page 4 4 for entry hole location and Figure 4 5 page 4 4 for cable grip installation D Run enough of the two conductor power cable through the liquid tight cable grip so that it can be routed as shown in Figure 4 7 page 4 4 E Strip back 3 inches 76 2mm of the PVC jacketing Refer to Figure 4 12 F Strip each wire 3 8 inch 9 5mm G Place a 3 8 inch 9 5mm section of shrink tubing over the cable and heat 3 8 inch 9 5mm 3 inches mm 76 2mm 4 4 4 5 12263 A Figure 4 12 Two Conductor Power Cable H Crimp fork or ring terminals to the wires I Connect the two conductor cable to PB1 red lead to the terminal labeled and black lead to the terminal labeled as indicated on Figure 4 7 page 4 4 J Tie wrap the power cable to the
143. essages 43 through 54 may also be displayed This is due to the momentary loss of serial communication between the two Processors Take note that the Under Voltage error is not only dependent on low voltage it is also dependent on the duration of the low voltage The possibility exists that an error message would not be dl s if the duration of the low voltage was short enough However the other symptoms mentioned above still occur B In either case follow the procedure listed under Diagnostic Menu Section B4 until im Applied Battery Voltage is displayed Take note of the applied voltage C Go to the battery or Main Distribution Panel which is feeding power to the Processor With a DC Voltmeter measure the voltage at this power source The battery voltage should be greater than 12 4 Volts in 12 VDC systems and 24 8 Volts in 24 VDC systems If not the battery or it s charging system needs servicing D The voltage differential between the power source and the Processor should not exceed 1 2 Volts in 12 VDC systems and 2 4 Volts in 24 VDC systems If so there is high resistance somewhere between the battery and Processor NOTE It an APS is being utilized in the power circuit take into account the 0 7 VDC torwar voltage drop of the diodes This would increase the permissible differential between power source and Processor from 1 2 to 1 9 VDC in 12 VDC circuits and 2 4 to 3 1 VDC in 24 VDC Y circuits EJ High resistance result
144. est Procedure The ClearCommand 9000 Series electronic throttle solenoid clutch version Propulsion Control System is compliant to the environmental design standards in 46 CFR 62 25 30 The following test procedure covers the 2 items included in the Qualitative Failure Analysis 1 Failure Control Head Potentiometer failure a Results The Processor will shift to Neutral if needed and throttle will go to Idle if needed b Test Procedure i Turn power on to both Port and Starboard Processors Take command at a Control Head ii Move the Port and Starboard Control Head levers to approximately Ahead iii Locate the green wire coming from the Port Control Head in command connecting to pin 6 of the respective terminal block on the ClearCommand 9000 Series circuit board Disconnect it from the ClearCommand 9000 Series circuit board 1 The Port Processor will shift to Neutral and throttle will go to Idle 2 The Port Control Head will give an alarm tone indicating a faulty potentiometer iv Move the Port and Starboard Control Head levers back to Neutral Reconnect the green wire v Repeat for Starboard side 2 Failure Power failure to ClearCommand 9000 Series A power failure to the ClearCommand 9000 Series circuit board will have the same results as a failed microprocessor a Results i Throttle signal to Idle and shift to Neutral ii LED at Control Heads will not be lit iii Opposite engine still under power has full control b Te
145. following checks prior to applying power to the Processor Table 7 1 Sea Trial Processor Mounting PORT STBD Processor Serial Numbers YES NO YES NO i Ge Is the Processor subject to excessive heat Above 70 degrees C YES At least 4 feet 1 2m from strong magnetic fields YES Accessible for checkout adjustments and maintenance YES Are the Processors bonded grounded YES Are all Electric Cables supported every 18 inches 45 72cm KE Are the electrical cable connections tight at the Processors and Control Heads YES Is the Processor s Start Interlock Circuit being used Is there an Engine Stop Switch installed at each Remote Station s Does Shift operate in the correct direction YES NO YES NO am Does Throttle operate in the correct direction YES NO YES NO Ge GE Is there an Engine Room Remote Switch installed at the Engine Room Remote Station YES NO YES NO Na ASNO Is there an Lock out Switch installed at Remote Station 2 1 j Table 7 1 Sea Trial Power Supply PORT STBD Outside Outside gt Processor Serial Numbers What is the source of Processor power and how is it charged YES Is there a backup power supply APS or other explain Page 7 4 SEA TRIALS i Table 7 1 Sea Trial Power Supply PORT STBD Outside Outside Processor Serial Numbers YES NO YES NO f a pos pu Are the power cables protected by 10 Ampere Circuit Breakers YES If separate power supplies are used f
146. g surface it needs protection from water or spray Consider using a Weather Mount Enclosure which is available from ZF Marine Electronics MOUNTING AND INSTALLATION Select the desired mounting locations and make cutouts per template Refer to the Dimensions Diagram Check that the two mounting screws will start into the Control Head Remove Control Head from cutout Run cable harnesses between Processor and Control Head Label both ends with Station it con nects EXAMPLE Port Center or Starboard Port Thrust Port Throttle etc ZF MARINE ELECTRONICS L L C a Mukilteo Washington 12125 Harbour Reach Drive Suite B Telephone 425 583 1900 Mukilteo WA 98275 Telefax 425 493 1569 A 3 Dimensions 165 4mm 8 97 227 9mm 10789A There are two types of Control Head connections available Connected Both types may be used with MicroCommander ClearCommand or CruiseCommand using the appropriate cable or harness Follow the appropriate TEMPLATE DIMENSIONS 1 90 48 3mm e Radius 3 80 25 6 4mm a 4 66 46 118 4mm 11 7mm y e 25 Dia thru 2 Places steps for the Control Head that has been supplied for your system Standard Cable 2 63 5mm atthe Control Head At the Control Head end of the cable strip and cut off the shielding and drain wire flush with the end of the PVC cover
147. h Version 1 0 Service Field Test Unit Reference Manual NMIVIT392 7 Tableof COMENS EE TOC 1 TABLE OF CONTENTS Revision List Figure 1 1 Figure 1 2 Figure 1 3 Table 1 1 2 2 1 2 1 1 Figure 2 4 2 1 2 Figure 2 5 2 1 3 Figure 2 6 2 1 4 Figure 2 7 2 1 5 Figure 2 8 2 7 2 2 1 Figure 2 9 2 2 2 Figure 2 10 2 2 3 Figure 2 11 253 2 3 1 Figure 2 12 2 3 2 Figure 2 13 Table 3 2 INTRODUCTION 7 2 etre le Service Field Test Unit Break out Box east ESA AAA ES 174 CruiseCommand Connector Locations au a freie Sob Emus ad d iced arena don din opos 1 1 Example of ClearCommand Pigtail ee e 1 1 t ER e CN 1 1 PROCEDURE e A lef ere Signal iere EE 2 1 DC VOlTUUE aie nee die ach td ausente tos arai E ug es I aN 2 1 Throtdedonnectuopdabo Voltdge s a ems d t Cano es cde ute bu edic dee UC ede i fep Dm eta dta and EROR 2 1 Current HIA ME 2 1 Throttle Connection Current at ne Ba ee ne oe 2 2 PWM Pulse Width Modulation with DC Moltmeter n 2 2 Throttle Conneetien XPVVIMI with BE VII NEE 2 2 PWM Pulse Width Modulation with Duty Cycle Meter lees 2 3 Throttle Connection PWM with Duty Cycle Meter oo qiiia aano diues A ied e dee ee 2 3 Fregueney HAZI E e e ee e ee ee ee 2 3 Porte Connection RA ee E el plz gs edad ls bee dd oe ut y BSS wie eis Seat ewe tad 2 3 CEUTA MES WN EEN 2 4 NeutrorSOlenold Testing iD A e EE Ss ee ae es 2 4 Clutch Connection Neutral Solenoid n
148. h connectors Install a jumper from pin 3 to 5 on right hand and 3 to 7 on left hand Control Heads Replace Station No 4 Control Head Ensure that the red conductor is properly crimped to pin 5 at both connectors Install a jumper from pin 3 to 5 on right hand and 3 to 7 on left hand Control Heads Replace Station No 5 Control Head Ensure that the red conductor is properly crimped to pin 5 at both connectors Install a jumper from pin 3 to 5 on right hand and 3 to 7 on left hand Control Heads Replace Station No 6 Control Head Ensure that the red conductor is properly crimped to pin 5 at both connectors Install a jumper from pin 3 to 5 on right hand and 3 to 7 on left hand Control Heads Replace Station No 7 Control Head Ensure that the red conductor is properly crimped to pin 5 at both connectors Install a jumper from pin 3 to 5 on right hand and 3 to 7 on left hand Control Heads Replace Station No 8 Control Head Ensure that the red conductor is properly crimped to pin 5 at both connectors Install a jumper from pin 3 to 5 on right hand and 3 to 7 on left hand Control Heads Replace Station No 9 Control Head Ensure that the red conductor is properly crimped to pin 5 at both connectors Install a jumper from pin 3 to 5 on right hand and 3 to 7 on left hand Control Heads Replace Station No 10 Control Head Ensure that the red conductor is p
149. he Control Head is in Throttle Only Mode Warm up Mode Blinking Rapidly A red LED that is Blinking Rapidly indicates that the System is in Troll Mode G Has anything on the vessel changed shortly prior to or when the problem arose This question is often overlooked but should be considered Obvious changes such as additions or changes to the electrical electronic equipment onboard can affect the electrical load and in turn the Processor s power supply Ask the operator if any changes or maintenance to the vessel s machinery have occurred lately Items which are significant to you the technician may not seem so to the casual owner or operator An example would be changes to the engine s fuel system Ask about changes that when initially considered appear to have nothing to do with the Control System An example where this really occurred was on a vessel which had recently been repainted For unknown reasons the painter took it upon himself to disconnect the connections at a Control Head and then reconnected it incorrectl In many cases these simple questions can rohe a problem with no further action from you the technician Take the time to consider these questions In the long run you will save yourself and the customer a lot of time and money Page B2 2 TROUBLESHOOTING B3 TROUBLESHOOTING PROBLEM RESOLUTION If the problem could not be resolved by asking the questions in the previous section a careful in
150. ication Panels the message Station X Rqsts Xfer will be displaved at all Stations A distinctive 1 2 second ON 1 2 second OFF tone pattern will sound at all Remote Stations for up to the time set with Function Code P1 Transfer Timeout C The Operator at the Station in Command MUST place the Control Head levers into the Neutral Idle position and press the transfer button until a solid tone is heard for one second to allow the transfer to take place A distinctive 1 2 second ON 1 2 second OFF tone pattern will sound at all Remote Stations for up to the time set with Function Code P1 Transfer Timeout f equipped with an Indication Panel the message Push Transfer Button At The New Station will be displayed at all otations D The Remote Station that requested the transfer must depress the transfer button for a second time f the Operator at the Station requesting control does not press the transfer button within the preset time period the Page 2 3 OPERATION transfer process is aborted the text message disappears if so equipped and the tone is silenced If the Operator at the Station requesting control does press the transfer button within the preset time period control is transferred to the new station the new Station in Command text will appear on the Panel and the text message will disappear 2 6 Proportional Pause The proportional pause provides a means of safely reversing the vessel s
151. ich is independent of the engine s speed control c Apropulsion engine control system including pilothouse control must be designed so that a loss of power to the control system does not result in an increase in shaft speed or propeller pitch The ZF Marine Electronics ClearCommand 9000 Series electronic throttle solenoid clutch ver sion marine engine controls offer single lever control of speed and direction Each enclosure houses an independent Control Processor and requires separate power supplies The system operates on 12 or 24VDC power and can have up to five remote stations depending on the appli cation The system sequences the operation of speed and shift in order to prevent an inexperi enced operator from mishandling the engine or transmission A standard feature is an alarm contact normally open to interface with the main alarm system of the vessel This switch will open and activate the alarm system with a power loss or CPU fail ure In addition ZF Marine Electronics provides audible tones at the Control Head locations to indicate system faults Hu COMPONENT STATUS RESULT OUTCOME 1 ZF Marine Electronics Audible Tone Will Sound At Throttle Resets To Idle No Increase In Engine RPM Control Hea Control Head Clutch Shifts To Neutral No Increase In Shaft Speed Loss Of Power Supply Alarm Circuit Will Open Throttle Resets To Idle No Increase In Engine Rpm Clutch Shifts To Neutral No Increase In Shaft Speed Design Verification T
152. in the Lead Acid batteries The plates must be covered If not add a small amount of distilled water Check the voltage of the battery The battery must have a chance to rest no E and no load for a couple of hours pues to testing The following table represents a fully charged battery Table 9 2 Fully Charged Battery Lead Acid Batteries Gel Cell or AGM Batteries 12V 12 6 to 12 8V 12V 12 4 to 12 6V 24V 25 2 to 25 6V 24V 25 0 to 25 4V x eck the battery terminals for signs of corrosion acid build up or loose connections 9 3 1 2 Semi Annually Every 6 Months Check the specific gravity of your Lead Acid battery s with a Hydrometer The reading for a fully charged lead acid battery is 12 60 to 12 80 9 3 1 3 Annually Every 12 Months WARNING The Battery Load Test should be performed by a qualified Marine Electrician only The tests performed on quarterly and semi annual basis give a relatively good indication of the batteries health However the only way to accurately determine the actual health of your battery is to perform a Battery Load Test There are two types of Battery Load Tests performed in the field Performance and Service In order to determine the actual health of vour battery a Performance Load Test is recommended The Service Load Test determines how well your battery performs in the boat and doesn t take into Page 9 1 PERIODIC CHECKS AND MAINTENANCE account the battery s o
153. inal block The actual value read by the Processor is 2 below that value or 15 17 of 1023 A D Counts 153 173 A D Since the Command Signal is based on a percentage of the Reference Voltage the distance of the Control Head from the Processor has no impact on the performance of the system Page B6 1 TROUBLESHOOTING The amount of voltage drop due to current flow is the same for both the Reference and Command Voltages The relationship between the Reference and Command Voltages when thought of as a percentage will remain the same regardless of distance For instance here are two examples Example 1 Reference Voltage 5 00 VDC 1023 A D Counts Command Voltage 2 45 VDC 501 A D Counts Example 2 Reference Voltage 4 80 VDC 1023 A D Counts Command Voltage 2 35 VDC 501 A D Counts As you can see by the examples even though the Command Voltages are different between Examples 1 and 2 the resulting A D counts are the same because of the different Reference Voltages This would result in the Processor commanding the identical outputs Clutch amp Throttle in both cases A The A D count for a specific Control Head s lever can be seen on the Processor s Display by following the steps outlined in Section B4 B Once the appropriate remote station is reached ensure that the displayed A D Count represents the Neutral Idle position 485 505 A D counts SEET will not be accepted SCHER the Control Head o lever is at the Neutral
154. ine com SOUTH AFRICA 7261 ZF South Africa Pty Ltd mail PO Box 2098 Kempton Park 1620 SOUTH AFRICA ship C O Barlows Power Systems T 27 11 453 1818 F 27 11 453 7506 Cnr Peter Barlow and Kasselss Vlei Rd SPAIN 5556 ZF Espana S A Avda Fuentermar 11 Coslada Madrid 28820 SPAIN Juanma Raposa T 34 91 4852699 F 34 91 6733931 www zf marine com B14 7 SWEDEN 7234 KG Knutsson AB Transmissionsdivisionen Hammarbracken 8 S 191 81 Sollentuna Karl Henry Pragsten T 46 0 8 923 312 F 46 0 8 929 599 SWEDEN zf marine kgk se SWITZERLAND 2419 Marine Parts Heimgartner Pfaffikerstrasse 6 CH 8604 Volketswil Zurich SWITZERLAND Rolf Heimgartner T 41 1997 4090 F 41 1997 4094 info marineparts ch www marineparts ch TAIWAN 9399 Mike Ou Asia Diesel Electric Corp T 886 7 333 1191 20th Floor 34 Min Chuan 1st Road Kaohsuing R O C TAIWAN F 886 7 334 6808 THAILAND 7283 ZF Thailand Co Ltd 159 33 Soi Vipawasee 64 Vipawadee Rangsit Road Laksi Bangkok Bangkok 10210 Reungpoj V T 66 2 521 6520 F 66 2 521 6523 NE terrapong zf thai co th www zf marine com TURKEY 7223 Mr Georg Weinstabl Niveko Makina Dis Ticaret Kollektif Sti Lorenz Severin Moritz Wwinstabl ve Ortaklan Hasan Yelmen Cad No 15 TR 34957 Tuzla Istanbul Deri Serbest Bolgesi TURKEY T 90 212 287 27 80 F 90 212 287 65 71 georg
155. ing conductor may be required ACTUATOR PROCESSOR Lo o MOUNTING SCREW o gt TO RAILS BONDING CONDUCTORS 5 gt TO MAST OR TOWER ELECTRICAL ACCESSORY NON CURRENT CARRYING HULL METAL PARTS GROUND PLATE e ADDITIONAL TO POWER BATTERY N DISTRIBUTION STARTER CURRENT CARRYING CONDUCTORS e BATTERY 2 DC COMMON BATTERY i e J D gt P di X ENGINE ENGINE E NEGATIVE ENGINE STARTER O TERMINAL O Q O O Y z O a O e JUMPER 5 Ee FUEL FUEL TANK S TANK O BONDING gy CONDUCTOR R ZF MARINE ELECTRONICS L L C e Mukilteo Washington 12125 Harbour Reach Drive Suite B Telephone 425 583 1900 Mukilteo WA 98275 Telefax 425 493 1569 A 22 MMC 288 Rev E 8 03 ZE ZF Marine Electronics LLC Mukilteo Plant References and Parts Source A REFERENCES 1 American Boat amp Yacht Council ABYC 3069 Solomons Island Road Edgewater MD 21037 1416 E 3 Wiring Identification on Boats E 11 AC and DC Electrical Systems on Boats H 2 4e or 32 4g Ambient Temp 50 degree
156. ing in a differential voltage of 1 2 Volts 12 VDC Systems or 2 4 Volts 24 VDC Bus or greater may be the result of corroded or tarnished connections dirty or pitted relay contacts or an improperly sized power cable Page B5 1 TROUBLESHOOTING B5 1 2 Station 1 Station 1 Neutral Commanded F If the voltage differential is less than 1 2 Volts 12 VDC Systems or 2 4 Volts 24 VDC Systems which is what you would typically expect a loose connection may exist between the power source and the Processor The vibration experienced while the vessel is underway may intermittently cause the circuit to open Check all the connections between the power source and the Processor for a loose bolts nuts etc One Long Three Short Tones me 9 oT WO EEE NEN Figure B5 2 One Long Three Short Tones This tone indicates that there is an invalid command signal at the Station in Command The Processor expects a DC voltage representative of the Control Head s present lever position This voltage is referred to as the Command Signal In normally functioning Control Heads the command signal is between approximately 0 8VDC at Full Astern to 4 10 VDC at Full Ahead The command signal is converted by the Processor to a digital representation referred to as an A D Count More on A D Counts later If the command signal drops below 0 6VDC or exceeds 4 40 VDC the tone will be generated At the same time the tone is heard thro
157. int approximately 0 80 VDC When the lever is positioned fully Ahead a larger portion is tapped off and the voltage is at its E er point approximately 4 10 VDC A to D Counts Since all the calculations within the control system are performed digitally these DC voltages are expressed as and converted to a digital representation The Reference Voltage approximately 5 00 VDC by which all Sie inputs are based is represented as 1023 A D ica to Digital Counts This allows for the possibility of a 1024 possible positions when 0 is included in the count The value of the Command Voltage with the lever at the Neutral Idle position is 49 51 of the Reference Voltage when measured at the Station terminal block The actual value read by the Processor Kir below that value or 47 to 49 of 1023 A D Counts 485 505 A D NOTE The A D values listed for Full Ahead and Full Astern represent the point where maximum throttle is reached The A D count when the Control Head lever is physically at it s maximum point will be higher but may not exceed the out of range values listed in Table B6 1 page B6 2 The Command Signal at Full Ahead is 82 84 of the Reference Voltage when measured at the Station terminal block The actual value read by the Processor is 2 below that value or 80 82 of 1023 A D Counts 821 841 A D The Command Signal at Full Astern is 17 19 of the Reference Voltage when measured at the Station term
158. ion supplied with the switch and the engine installation instructions for manufactures recommendations WARNING An Engine Stop Switch at each Remote Station is an absolute requirement Refer to CFR 46 SEC 62 35 5 and ABYC P 24 5 8 Page 4 10 SET UP PROCEDURES 5 SET UP PROCEDURE The Processor utilizes push buttons in conjunction with Display LED s to program adjust calibrate and set up the various features The push buttons also allow you to access and display information regarding the health of the System The following paragraphs explain how to locate and use the push buttons and Display LEDs 5 1 Processor Components Used In Set U T H Each Processor has a Display LED and oL Push Buttons Window The Display LED can be viewed through a window on the Processor s cover as d shown in Figure 5 1 e The Processor enclosure cover must be removed to access the Push Buttons as shown in Figure 5 2 The Display LED is used to view the Function Codes and the Values for e Functions Section 5 1 1 page 5 1 e The Push Buttons are used to scroll through Function Codes select Function Codes and set the Values of Figure 5 2 Processor Shield Push Button and Display LED the Function Codes Section 5 1 2 Locations page 5 1 5 1 1 Processor Display LED Starts the Processor Part Number again one number at a time BIB BIB 8 aS 88 B18 EXAMPLE Running Processor Part Nu
159. ional Pause Ratio rat ER EE REF E AR E RO E AE 5 72 Display LED Function C4 Set Up Activated 2 EE 5 13 Function Code C8 Fixed Neutral 5232 606 HD A A EE E E ap 5 13 Display LED Function C8 Set Up Activated a er eae EE EE AAA 5 13 CLUTCH BR Seele GEELEN els Function Code EE Type St CH HERE ES PRI SS IT ve Jv Dar E 5 13 Display LED Function C5 Set Up Activated WEE 5 14 Function Code C6 ZF Hurth Duty Cycle Ahead ar Be Fan DEE PAS AA A EE Be ae o 5 14 Display LED Function C6 Set Up Activated EE 5 14 Function Code C7 ZF Hurth Duty Cycle Astern E Se aa ZE aes A A AS 5 14 Display LED Function C7 Set Up Activated an Sb Gace weasel dd datada eae A ES 5 15 ee e EE 5 15 TROLL BASIC FUNCTIONS LO L4 L5 EE 5 15 Function Code Lo Troll Enable and Control Head Lever Troll Range 5 15 Troubleshooting ee de EE o A SEAS 5 15 BASIC PROCESSOR TROUBLESHOOTING FUNCTIONS asocio tede tr ee AAA ca ite m E A sae 5 15 Function Gode HO EE mr Fan man mn E E SE EN RA RR A ueste 5 15 Function Code H1 Return to Factory Defaults Se en AS SE E Eer ee EE 5 15 Function Code H2 Driver Fault Detection 5 28 ie Le ue e E dec r dee day qo eec e 5 15 SONO Error Status e EE 5 15 Fremum FUNCTIONS iS ISS OSA NUS Wr TREE EE 5 16 EIERE EE Re e ODES AEO ES EE 5 16 Function Code FO Speed Boost Percent Sos tes E A TuToa EE sage er EE en E 5 16 F n ction Code FT Speed Boost MULATION 19 9 9720 79 NARA SA A NA EEE 5 16 Function Code
160. ions 5 2 and 5 3 page 9 2 Page 5 8 SET UP PROCEDURES Function Code is Blinking Scroll to Function Code E1 Activate Set Up Mode Scroll Up or Down to the desired Value Store the Value to memory Sou Figure 5 6 Display LED Function E1 Set Up Activated Function Code is Blinking 5 5 2 1 2 Function Code EA Throttle Maximum Astern This Function limits the amount of Throttle permitted in Astern The available Values for this Function are 00 0 to 100 0 The Default Value is 100 0 of Throttle Maximum The Value selected is a percentage of the Value selected in Function Code E3 Throttle Maximum Example A Value of 50 0 will allow 50 of Throttle Maximum when commanding Astern The Value selected is a matter of personal preference To change the Value Refer to Sections 5 2 and 5 3 page 9 2 A Scroll to Function Code E4 B Activate Set Up Mode C Scroll Up or Down to the desired Value D Store the Value to memory Figure 5 7 Display LED Function E4 Set Up Activated Function Code is Blinking Is 5 5 2 1 3 Function Code E5 Throttle Pause Following Shift The available Values for this Function are 00 0 seconds to 05 0 seconds The Default Value is 00 5 seconds This Function programs the amount of delay between the point that Clutch engagement is commanded and throttle is allowed to increase above Idle QO NOTE This Function is typically programmed during Dock
161. ired The Station No 8 transfer button was held down for 15 seconds or longer The Station No 8 Control Head transfer button is defective The Control Head Harness is miswired The Control Head s Pigtail is miswired Page B9 3 b Replace the Control Head C Ensure that the orange conductor is crimped to pin 4 at both ends and the red wire is crimped to pin 5 at both ends of the Harness Ensure that the orange conductor is crimped to pin 4 of the connector and connected to pin 4 of the Control Head s terminal block Ensure that the red conductor is crimped to pin 5 of the connector and connected to pin 3 of the Control Head s terminal block Clear the Error Code from memory b Replace the Control Head Ensure that the orange conductor is crimped to pin 4 at both ends and the red wire is crimped to pin 5 at both ends of the Harness Ensure that the orange conductor is crimped to pin 4 of the connector and connected to pin 4 of the Control Head s terminal block Ensure that the red conductor is crimped to pin 5 of the connector and connected to pin 3 of the Control Head s terminal block Clear the Error Code from memory Replace the Control Head Ensure that the orange conductor is crimped to pin 4 at both ends and the red wire is crimped to pin 5 at both ends of the Harness Ensure that the orange conductor is crimped to pin 4 of the connector and connected to pin 4 of the Control Head s terminal
162. is not followed Adjust the Function Codes as needed to meet this requirement Some vessels have the tendency to stall an engine when engaging the clutch or during emergency reversals In some applications this can be minimized or eliminated by applying Speed Boost Processors equipped with this feature can be programmed to temporarily increase the Speed Command Signal to the Governor at the precise time the Clutch Plates begin to come in contact with one another NOTE Zed SY 1 Speed Boost is NOT required for most applications Its primary use is with engines that have mechanical Governors and where the engine stalls upon clutch engagement or clutch reversal going from Ahead to Astern or vice versa This is typically due to a high reduction gear ratio 4 1 or higher or underpowered engine 2 Speed Boost has been used in some electronic engines where there is a stalling problem due to the engine not being able to respond quickly enough to a sudden load change clutch SE This is especially true with vessels that have a high reduction ratio 4 1 or greater 3 Speed Boost may also be used to reduce the droop drop in engine speed as the clutch engages 4 rm of Speed Boost does not guarantee that an engine will not stall Ultimately the engine must be capable of producing the power required in the time frame necessary to handle the sudden load during clutch engagement If this option is going to be used please contact a ZF Marine
163. ivate Set Up Mode C Scroll Up or Down until the the desired Value is displayed Figure 5 11 Display LED Function EO Set Up Activated D Store the Value to memory 5 5 2 2 2 Function Code E2 Throttle Minimum This Function allows the throttle signal at Idle to be fine tuned from the Value provided by the EO Throttle Profile The available Values for this Function are 00 0 to 20 0 The Default Value is 08 096 To change the Value Refer to Sections 5 2 and 5 3 page 9 2 Funci n Code Blaine A Scroll to Function Code E2 d EE Set U uen s i C Scroll Up until the engine RPM at Idle begins to E c 38 nn above a DJ Scroll Down until Idle RPM is reached Figure 5 12 Display LED Function E2 Set Up Activated E Store the Value to memory Page 5 10 SET UP PROCEDURES 5 5 2 2 3 Function Code E3 Throttle Maximum This Function allows the throttle signal at Full to be fine tuned from that provided by the EO Throttle Profile The available Values for this Function are 10 0 to 100 0 The Value entered is the percentage of the throttle s range from Idle to Full EXAMPLE A Value of 50 0 will equal a 2 10 VDC throttle signal when the Volvo profile is selected which has a throttle range of 0 6 to 3 6 VDC The Default Value is 59 0 To change the Value Refer to Sections 5 2 and 5 3 page 9 2 A Take command at a Remote Station Function Code is Blinking B Move the Control Head lever to the Fu
164. ive Remote Stations are being used The following Tables describe the pin outs and functions of the conductors within the various Pigtails B13 1 Basic Processor Pigtails Table B13 1 Power Start Interlock Clutch Oil Pressure Switch Alarm Pigtail Pin Out CIRCUIT BOARD PLUG Termination A Conductor Color Termination B Description PZ Yelow Pi Starimtenock gt Tees Brown IL Pin Mam xO JI Yellow a 2 12 Red Thes Black Pms Alarm Commo 2 Brown 2 11 BlacRe Conductor TH amp z Orange Pi Backup Cut ron 4392806 o IS 19 Had cuc TB i White Pms Backup Cint 5 Whie 2i S mme Blue Pins Clutch Pressure Switch 8 Blue Je 7 Green perc Red IL Pm De Powe PH Black Pinar DC Power PB21 Red Pin12 Startinterlock Table B13 2 Serial Communication Pigtail Pin Out CIRCUIT BOARD PLUG Termination A Conductor Color Termination B Description 3 Plug Seal TB76 White Pin2 CAN High Nat Used fre A ea 4 7 Black TB7 7 Green CAN Low 2 White e jea 5 Red ere Black Pi CAN High 1 Green U 2 6 Black mera Red Pins CANLow F TB710 Black Pins Shield Table B13 3 Control Head Pigtail Pin Out Up to 5 Stations CIRCUITBOARD PLUG a EE Red LED 5 au iom 6 Green ie 2 3 Violet S Red y 4 Orange m B13 2 Throttle Pigtail Table B13 4 Thr
165. k Closed has been closed since power up 4 2 CAN Communication The Control Area Network protocol has detected an error in communication Stuffing Error with other devices on the network The error type is a stuffing error 44 CAN Communication The Control Area Network protocol has detected an error in communication Form Error with other devices on the network The error type is a form error 45 ICAN Communication The Control Area Network protocol has detected an error in communication Acknowledge Error with other devices on the network The error type is an acknowledge error 46 CAN Communication The Control Area Network protocol has detected an error in communication Bit 1 Error with other devices on the network The error type is a Bit 1 error 47 CAN Communication The Control Area Network protocol has detected an error in communication Bit 0 Error with other devices on the network The error type is a Bit 0 error 48 CAN Communication The Control Area Network protocol has detected an error in communication CRC Error with other devices on the network The error type is a CRC error 49 ICAN Communication The Control Area Network protocol has detected an error in communication Bus Error with other devices on the network The error type is a Bus failure error The error cannot be recovered from without cycling power to the Processor 50 Comm Error Time out Communication with System 1 has been too long without a Refresh message System
166. k a desk brn ee ee ee Oe Oe Preface 1 Table Pretace T Clearcommand QOZO2 ENEE Preface 1 Preface 2 Conventional Symbols Used in the Manual irc daa EE Preface 1 Preface 3 important IE PODER NODIS cas ua iia do eos dt der eo Preface 1 Table or el EE TOC 1 BEVISIONS LIST EE TOC 11 1 1 1 2 1 MES 1 3 1 1 3 2 2 2 1 2 2 Figure 2 1 2 9 2 3 1 Figure 2 2 2 4 2 5 2 5 1 2 5 2 2 5 3 2 591 2 6 2 Figure 2 3 Figure 2 4 2 8 2 8 1 2 8 2 2 8 3 Figure 2 5 279 2 9 1 Figure 2 6 Figure 2 7 2 9 2 2 10 2 10 1 2 10 2 2 10 21 210 22 INTRODUCTION sss I redd Manual Conteris sd ia dos Lo a ib QR 1 1 basic Theon ene ge is FE kal 96202 Processor Throttle Electronic Shift Solenoid 2 Pluggable Remote Stations 1 1 Si AA Socata ne ok AA Y 1 1 Standard Processor EE 1 1 Optional Processor Featules sod doa A AA E Ree e LS as 1 2 OPERATION e A KR ss a A E TES A ER 2 RE te od COMAE RR a ra ee le IO 2 1 Station taking Command d oaks ee ee e rr aoe ed xd ee re ee xs id ea a 2 1 BASICO 2100 e E Et DE ee N 2 1 Normal Operating Mod 5 wu pad Es Enc v ERR Rund NU edP RAE pue 2 1 Controlled Petes rs ed e IRR e dr ee dire dS eR ded e S Does edid ten eee 2 1 otan Interloek IT Us Sag EE 2 2 NS 4 nA a dete an Ee AS 2 2 Neutral Only Transfer Mode POOO 0 ccc ee ee eee eee eee eee eee eee 2 2 Lever Match and Neutral Mode POO2 0 cc ce ee ee ee 9 eee 2 2 Forward Pass
167. l surface is acceptable 3 Complete the wiring as indicated on either Drawing 11488D 1 or 11488D 2 4 Reconnect the negative battery posts E IMPORTANT NOTE ABOUT BATTERY SOURCES Whenever the load is turned on it can be drawing power from the batteries Therefore if the batteries are not simultaneously being recharged or if charging will not be available for an risa period it is recommended that the load be shut off to prevent complete discharge of atteries ZF MARINE ELECTRONICS L L C a Mukilteo Washington 12125 Harbour Reach Drive Suite B Telephone 425 583 1900 Mukilteo WA 98275 Telefax 425 493 1569 A 13 180101D 3 05 A 14 180101D 3 05 Drawing 11488D 1 Twin Screw Single APS Connection amp Alternate Remote Switch S LUNG CABLE RUN 2EM ICH IN EXCESS SE FUSE HOLDER AGE 38 FUS D MW 4 03 S C TJ SEE SHEET 180101D 3 05 180101D 3 05 Drawing 11488D 2 Twin Screw Dual APS Connections DES gt pe TO ACTUATOR ACTUA TOR G IS BLACK OR YELLOW SS O AMP CLIT I
168. laims must be submitted within 30 days from date of service Claims for over 3 hours must be pre approved by the ZF Marine Electronics Service Department oe oou p This Warranty is expressly in lieu of all other Warranties express or implied Except to the extent prohibited by applicable law ZF Marine Electronics hereby disclaims all other implied or express warranties of any kind including warranties of merchantability and fitness for a particular purpose Under no circumstances shall ZF Marine Electronics be liable for any consequential damages sustained in connection with the product or its use including any costs or damages which result from loss of use of the product or any engine or boat with which it is used ZF Marine Electronics does not authorize any representative or agent to assume for it any obli gation or liability other than those expressly set forth above Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you All implied warranties if any are limited to the duration of this express warranty This warranty gives you legal rights and you may have other rights which may vary from State to State ZF MARINE ELECTRONICS L L C e Mukilteo Washington 12125 Harbour Reach Drive Suite B Telephone 425 583 1900 Mukilteo WA 98275 Telefax 425 493 1569 Page A 27 Page A 28 ZF Marine
169. lay Station A D s Transfer Button Depressed for Groatonb oo B6 2 TROUBLESHOOTING STUCK TRANSFER BUTTON B5 1 ERROR CODES 72 77 BE Basie COMO System EE elt ie Dir a lat d aut E B8 1 BASIC CONTOLS VS E e B8 1 Glteh Solenoid EMOT CodeS re owes zd TR oo Efe deeds de Do Clutch Solenoid Control System Error Codes eo E eese eene eene nennen EEN heaters teens eere nates renun B8 2 BASIC PROBLEM CAUSES AND SOLUTIONS B9 1 Basic Control System Problem Causes and Sohutons oo B9 1 Basic Control System Problem Causes and Solutions NENNEN NENNEN ENNEN B9 1 TOC 8 TABLE OF CONTENTS B10 PROBLEMS WITHOUT ERROR CODES B10 1 B10 1 Basic Control System Problems Without Error Codes 0 200000 B10 1 B10 2 Solenoid Clutch Control System Problems Without Error Codes B10 2 B10 3 Electronic Throttle Control System Problems Without Error Codes B10 2 B11 SYNCHRONIZATION TROUBLESHOOTING B11 1 B11 1 Equal ThrotleSvnehroRrZetloli s uuu edendo te Easter 511 B11 1 1 Basic TroubDleshootlllu suu SS EE oda B11 1 Bad SYMPTOM WEE NOT SYNCARON ZE ee ee ee B11 1 B11 2 BELIVESYNCNION ZA ON er EE B11 1 B11 2 1 Basic Troubleshooting IA ren ae ae B11 1 BEZAIA SYMPTOM THE GREEN LED IS LIT SOLID THOUGH THE ENGINE RPM S DIFFER BY A SIGNIFICANT AMOUNT B11 1 B11 2 1 2 SMETTO ME WIE NOT SYNCHRONIZE E E
170. ll Ahead position C Measure the throttle signal D Scroll to Function Code E3 E Activate Set Up Mode F Scroll Up until the throttle signal is at Full Throttle Figure 5 13 Display LED Function E3 Set Up G Store the Value to memory Activated H Return the Control Head oor to the Neutral Idle position 5 5 3 Clutch Functions 5 5 3 1 Clutch Basic Functions CO through C4 C8 5 5 3 1 1 Function Code CO Clutch Pressure Interlock This adjustment is to be set to Enabled only if the optional Clutch Pressure Switch is being used with this application Function Code is Blinking nl Figure 5 14 Display LED Function CO Set Up Activated 6 5 3 1 2 This Function enables or disables the feature and allows for two different modes of behavior when a Clutch Pressure Switch is used Refer to Section 8 2 page 8 2 for detailed information The available Values for this Function are 00 Not Installed Default Value 01 Installed 02 Throttle Clutch Pressure Interlock Mode To change the Value Refer to Sections 5 2 and 5 3 page 9 2 A Scroll to Function Code CO B Activate Set Up Mode C Scroll Up or Down to the desired Value D Store the Value to memory Function Code C1 Clutch Interlock Delay This adjustment is to be set to Enabled only if the optional Clutch Pressure Switch is being used with this application Function Code is Blinking Figure 5 15 Display LED Function C1 Set Up Activated 5 5 3
171. ltage at pins 2 amp 3 at the open Control The measurement will be approximately 2 20 VDC when the red LED is lit If 4 00 VDC is measured the red LED or its circuit is open Replace the Control Head SYMPTOM When power is turned ON to the Processor there are no tones from any of the Remote Stations the Control Head red LED does not light when the Transfer Button is pressed and the Display is not lit at the Processor Cause Remedy a No power to the Processor a Disconnect the Power Harness from the Processor Measure the DC voltage at pins 10 and 11 of the Harness plug If 12 or 24 VDC is not present check the circuit breakers switches and cables feeding power to the Processor Correct the power source as required b The battery s polarity is reversed at the b Disconnect the Power Harness from the Processor Processor Connect a voltmeter s red lead to pin 10 and the black lead to pin 11 of the Harness s plug If negative voltage is measured reverse the wires c Defective Processor c If Causes a and b were not the fault replace the Processor SYMPTOM The engine begins to turn over while starting and then stops A slow repetitive tone is heard from all Remote Stations Cause Remedy a The voltage available at the Processor a Supply power to the Processor from a battery has dropped too low due to the starter s other that the starting battery or supply current requirement ower from two sources through an
172. ly adjusted contact a certified engine mechanic to properly adjust Page B10 2 TROUBLESHOOTING ZE B11 SYNCHRONIZATION TROUBLESHOOTING If you encounter a problem with Synchronization it will more than likely one of the following failure to attempt to synchronize synchronizing at different RPM s or RPM variations of one or both engines while synchronized Each problem is distinct and the cause may differ depending on the type of Synch Therefore each type is discussed individually B11 1 Equal Throttle Synchronization B11 1 1 Basic Troubleshooting B11 1 1 1 SYMPTOM Will not synchronize Causes Solutions Synchronization is Disabled a At the Station in Command move both Control Head levers to more than 5 of the speed range Press and hold the transfer button for 5 seconds If synch is disabled the green LED will light as long as the button is pressed If synch was enabled the green LED would have blinked twice The Serial Communication Harness is not b Plug the Serial Communication Harness into both Processors plugged into both Processors The Port and Starboard Processors are not c Scroll to Function Code A1 on the Port and Starboard Processor Enter a Value of set up for Twin Screw operation 02 into both Processors The Port and Starboard Processors have On the Port Processor scroll to Function Code A0 and enter a Value of 01 the same ID number On the Starboard Processor scroll to Function Code AO and
173. m make sure you have the correct parts and tools on hand Refer to MM9000 I Plan the Installation Section Read ALL the J instructions pertinent to each part before beginning the installation of the part strap provided to the Processor frame whenever working on the Processor with the e CAUTION Static electricity can destroy electronic components Connect the wrist O enclosure cover open This will drain any static charge you may have on your person 4 1 Processor A Secure the Processor to the mounting surface with three 1 4 inch or M6 fasteners leaving the fourth fastener unused at this time B Connect the Processor to the Hull or Bonding Bus by running a 12 AWG or larger wire between the Processor s fourth mounting fastener and the Bonding Bus The Processor is bonded if mounted directly to a metallic surface that is connected to a metal hull Refer to Appendix A Bonding 4 2 Control Head s 4 2 1 400 MC2000 and 700 Series Control Heads Refer to the appropriate Control Head Dimensions and Variations Service Sheet in Appendix A for installation 4 2 2 500 Series Control Heads Refer to the Installation Manual supplied with the 500 Series Control Head Assembly for installation instructions 4 2 3 Handheld Remote Controls Refer to the Installation Manual supplied with the Handheld Remote for installation instructions 4 3 Wire Harness Installation The standard Off the Shelf Processor has five Pigtails with plugs on the
174. m the pilothouse must enable 1 Control of the speed of each propulsion engine 2 Control of the direction of propeller shaft rotation 3 Control of propeller pitch if a controllable pitch propeller is fitted and 4 Shutdown of each propulsion engine c The propulsion control system operable from the pilothouse may constitute the remote stopping system required by Sec 129 540 of this subchapter d Each propulsion control system including one operable from the pilothouse must be designed so that no one complete or partial failure of an easily replaceable component of the system allows the propulsion engine to overspeed or the pitch of the propeller to increase 184 620 Propulsion engine control systems a A vessel must have two independent means of controlling each propulsion engine Control must be provided for the engine speed direction of shaft rotation and engine shutdown 1 One ofthe means may be the ability to readily disconnect the remote engine control linkage to permit local operation 2 A multiple engine vessel with E remote propulsion control for each engine need not have a second means of controlling each engine ZF MARINE ELECTRONICS LLC 12125 Harbour Reach Drive Suite B Telephone 425 583 1900 Mukilteo WA 98275 Fax 425 493 1569 Page B 3 b In addition to the requirements of paragraph a a vessel must have a reliable means for shutting down a propulsion engine at ihe main pilothouse control station wh
175. mand away from any other Remote Station including DP It also Ban other Remote Stations from taking command away rom Station No 1 This feature is defaulted OFF and therefore must be enabled during set up Refer to Section 5 5 1 6 page 5 8 If this option is going to be used please contact a ZF Marine Electronics Representative for further information Lockout Switch This feature prevents any Remote Station other than Station No 2 from taking command This feature is defaulted OFF and therefore must be enabled during set up Once enabled the feature is selectable with a toggle switch The Engine Room Only Remote switch can override the Lockout feature If this option is going to be used please contact a ZF Marine Electronics Representative for further information DP MODE Refer to the information supplied with the DP system for dE guidelines The ClearCommand and the DP systems cannot be in command at the same time O NOTE High Idle and One Lever Mode are not available when a DP system is in command Page 2 13 OPERATION If this option is going to be used please contact a ZF Marine Electronics Representative for further information 2 16 8 Display Panel The Display Panel supplies various system information including but not limited to e Station in Command Control Head lever position Engine RPM Propeller shaft RPM If this option is going to be used please contact a ZF Marine Electronics Rep
176. mber during Normal Operation 92 10 Figure 5 3 Display LED at Normal Operation The Processor s Display LED has four 7 segment LED s which light up to show either letters or numbers Function Code Value The Display LED will have the Processor Part Number showing in a running pattern during Normal operation Figure 5 3 The first two digit Display LED s to the left indicate the Function Code which is alphanumeric The second two digit Display LED s indicate the numeric Value that m is programmed into the Processor for the Function Code displayed to Figure 5 4 Display LED the left Designations A decimal point indicator is located on the bottom right corner of each Display LED 5 1 2 Push Buttons UPO The Processor has four Push Buttons located on the Circuit LEFT e RIGHT Board They are identified by the words LEFT RIGHT UP and DOWN silk screened on the Shield covering the Circuit DOwn Board Figure 5 5 Circuit Board Push Buttons Page 5 1 SET UP PROCEDURES 5 1 2 1 Up and Down Push Buttons Pressing the Up or Down Push Buttons once has the following functions Stops Normal Operation Display running Processor Part Number and activates the Function Menu While in the Function Menu scrolls through the Function Codes one at a time When an Error Code Refer to Section B 1 9 page B 21 is displayed scrolls through the error messages one at a time When in Set Up Mode increases Up or dec
177. mmand has been given movement of the Control Head lever to the point where Speed Boost is applied NOTE This is an open loop method of applyin Te boost just a to the load hitting the engine Clutch engagement timing is a function of oi have no method of actually measuring clutch pressure Therefore in order to accurately adjust J the F2 Function it is best to warm up the gear first viscosity and heat and these Processors Units Seconds Default 0 0 Range 0 0 to 10 0 Examples A value of 0 0 is 0 0 seconds A value of 0 1 is 100 milliseconds A value of 2 0 is 2 seconds Speed Boost Bypass Clutch Delay F3 In some applications speed boost is only required when performing an emergency reversal Engaging the Ahead or Astern clutch from Neutral or Idle Ahead to Idle Astern maneuvers do not load the engine to the point where a stall occurs Only when momentum is built up in the Ahead or Astern direction and an emergency reversal is required is the load on the engine significate enough to stall the engine In these situations speed boost is not required every time a Clutch engagement is commanded This Function allows the speed boost to be applied ONLY WHEN the time programmed is exceeded during a reversal The time required to perform a refersal is programmable with Function Code C3 Proportional Pause Time Units Seconds Default 0 0 Range 0 0 to 99 0 Examples A value of 0 0 is 0 0 seconds
178. mote Stations ua aan a a a B5 2 Display Examples of Remote Stations A D Value 5 24 ue dy e eek a a B5 2 Steddy TONO eue Sca E EE EE Bae cad B5 3 LOCO TOM en e e ea a rn e EE e Eer B5 3 three Second Steady TONG dixe n aca a EE ege lt A dee as B5 3 Three Second TONG sen SE We wee iem s qnd QE REA CASE AA are B5 3 Three Second Steady Tone followed by a Slow Repetitive Tone B5 4 Three Second Tone followed by a Slow Repetitive Ion B5 4 Five Seconds On Five Seconds Off High Repetitive Rate Tone B5 4 Five Seconds On Five Seconds Off High Repetitive Rate fong B5 4 FIVE Second Ste ad Y TODB 3 wea ara o rav A A A ex daa dan SEES B5 4 FIVE Second steady lO 2 25 2 Bos ass steven ote borden ab ee la dd Siete ae Bb 4 Clutch Solenoid Control System Tones ud ue Sk ow daw dX san E e X oe Bb 4 One Long One Short TONE osten Po cs eS s PS aU d Ae geg ve dE ob WR oR RES B5 4 One Long One Sun I OR unid oe hin e e Bw eed keys Zea an ewe ak dE du eee ea Bw ees B5 4 TROUBLESHOOTING STATION TRANSFER B6 1 Command EE pra y Oo av eee a d ge BSS e Es EAD eee a aS B6 1 PONDS TS e ett Ut eet Abee O AS B6 1 Control He d Lever A D COUM uii cea v EE er as A as B6 2 Remote Station Select dt AS A A AE das B6 2 Display Station A D s No Station Transfer Button Depressed oo B6 2 Example Display Station A D s Transfer Button Depressed for Stations 1 4 0 0 oo B6 2 Disp
179. n Description A 11 02 Revised Section 1 0 Table 1 B 2 03 Revised manual to current ZF Marine Electronics manual standards Revised Section 3 0 C 4 03 Deleted Section 2 1 6 D 10 03 Revising to add 9000 Series and 2 Speed information PageTOC 2 SERVICE FIELD TEST UNIT 1 INTRODUCTION 8 A M 12 PIN CONNECTORS Clutch and Troll Only Cable Length A 6 Feet 1 5m N Q Q S P on JO op O SC Field Test Unit Break Out Box 00 OOc OO EH IDLE V e o Q Multimeter O L E ATI S 4 Key Refer to Bulletin 02 008 for Service Field Test Unit Part No 13927 recommendations Refer to Figure 1 1 for an example of the Test Unit and a Multimeter The Service Field Test Unit hereafter referred to as the Break out Box is SS recommended for use with all CUR CruiseCommand Processors Part No 785CE and with A ClearCommand Processors Part NS No 9XXX Series that have NS luggable Pigtail Throttle Clutch or Troll Connections Figure 1 1 Service Field Test Unit Break out Box The procedures for testing the various outputs of the ClearCommand and CruiseCommand Processors are similar with the exception of where they connect to the respective Processor Figure 1 2 indicates the location of the connectors on the CruiseCommand Processor
180. n allows this Feature to be enabled or disabled Refer to Section 2 9 page 2 5 for operation instructions The available Values for this Function are 00 Disabled Default Value 01 Enabled To change the Value Refer to Sections 5 2 and 5 3 page 5 2 A Scroll to Function Code A2 B Activate Set Up Mode C Scroll Up or Down to the desired Value Figure 5 3 Display LED Function A2 Set Up Activated D Store the Value to memory 5 5 1 4 Function Code 3 SE Station Expander NOTE This Manual does not go into detail on the Station Expander installation and adjustments For further information on the Station Expander contact your local ZF Marine Electronics Representative The SE 1s a separate unit which gives the System the ability to increase the number of Remote Stations if more than five Remote Stations are required Refer to Section 8 3 page 8 4 for further information The available Values for this Function are 00 Disabled Default Value 01 Enabled To change the Value Refer to Sections 5 2 and 5 3 page 5 2 A Scroll to Function Code A3 B Activate Set Up Mode C Scroll Up or Down to the desired Value Figure 5 4 Display LED Function A3 Set Up Activated D Store the Value to memory 5 5 1 5 Function Code A4 Neutral Indication Tone This Function allows the installer to turn ON a 1 2 second low frequency tone to indicate Neutral The available Values for this Function are 00 Dis
181. n for the Processor s The Processor is spray proof but not water proof Therefore an area must be selecte that PEE stays dry The engine room is the preferred location for mounting the Processor If the engine room is too small locate in any area where it is easily accessible as long as all of the criteria listed are met Page 3 1 PLAN THE INSTALLATION Bulkhead mounting is the preferred method due to ease of access for wiring and adjustments However the Processor can be mounted in any attitude as long as the Display LED window and push buttons are accessible Do not mount the Processor on the engine transmission or in any location that will subject it to excessive vibration Do not mount the Processor to the transom when the vessel is equipped with a surface piercing drive system due to vibration concerns Locate the Processor s away from sources of high heat such as engine exhaust manifolds or turbochargers Allow 4 feet 1 2m of clearance or more Do not mount the Processor s in close proximity to gas engine ignition systems alternators generators or any equipment producing strong magnetic fields Allow 4 feet 1 2m clearance or more y CAUTION Strong magnetic fields can influence the Processor s electronic circuits 7 and void your warranty 3 1 2 3 1 3 3 T 3 1 31 3 2 e The Control Head can Control Head s Refer to Appendix A Control Head Variations Servic
182. n synchronization has been selected during set up the Control System will always power up with synchronization ON In order for synchronization to become active work toward synchronizing the engines RPM s the Synchronization Criteria listed below must be met 2 10 1 Synchronization Criteria Both Control Heads must be commanding 5 or greater of the throttle range The Control Head levers must be within 10 of one another approximately 6 e Both Control Head levers are commanding Ahead clutch engagement Page 2 6 OPERATION 2 10 2 2 10 2 1 Synchronization Types The following GL of synchronization use the same criteria indications and are turned ON and OFF as described in following Sections Equal Throttle Synchronization default Enabled Equal Throttle synchronization simply commands the same throttle to all engines In applications where the engine governor requires a voltage signal the exact same voltage signal will be applied to all governors With Equal Throttle Synchronization the Processors do not receive tachometer signals representative of the engines RPM s the 10 throttle window is exceeded a 10 increase or decrease in engine RPM would CAUTION The Control System will remain synchronized as long as the Control Head s levers are in close proximity to one another If a lever is moved to a point where occur with one engine resulting in a sudden change in the vessel s direction 2 10 2 2 2 1
183. nd then Neutral Confirm that the movement of the vessel is in the correct direction Page 6 1 If incorrect reverse the electric cable connections at the shift solenoids C Place the Control System into Warm Up Mode and confirm that there is control of speed D Run the throttle up to approximately 20 of the throttle range for at least 10 seconds E Return the lever to the Neutral Idle position F Repeat steps A thru E at the remaining Control Head levers 6 6 Throttle Pause Following Solenoid Shift NOTE A Test Control Head and a stop watch are recommended to determine the correct setting DOCK TRIALS for the Throttle Pause If a Test Control Head is not available a second person may be needed ove the Station in command s lever to the Ahead detent start the stop watch while monitoring the Shaft B When the Shaft begins to rotate stop the stop watch C Record the time expired on the stop watch D Program Function Code E5 as described in Section 5 5 2 1 3 page 5 9 10D NOTE If the time recorded in Section 6 6 step C exceeds 5 0 seconds a Clutch Pressure Interlock is required Refer to Section 8 2 page 8 2 Page 6 2 SEA TRIALS 7 SEA TRIALS ded in the previous Sections has been read and followed precisely prior to attempting a Sea Trial If any of the following tests fail discontinue the Sea Trial immediately and return to the dock Consult Appendix B Troubleshooting Section or a ZF Facilit
184. nic Propulsion Control Systems Three Year Limited Warranty Your ZF Marine Electronics product has been designed and manufactured by experienced engineers and craftsmen ZF Marine Electronics LLC warrants for the period indicated below each product to be free from defect in material and workmanship Repair or replacement at ZF Marine Electronics option will be provided if the product upon ZF Marine Electronics inspection is found to be properly installed d operated in accordance with ZF Marine Electronics Manual This warranty does not apply to malfunction caused by damage unreasonable use misuse repair or service by unauthorized persons or normal wear and tear A Coverage Under Warranty Three years from the date of purchase by the original end user Year One No charge for equipment repair parts and labor Up to three hours labor toward troubleshooting and replacement of defective equipment Year Two and Three There is no charge for equipment repairs performed at the factory that are covered under warranty No labor allowance for troubleshooting and replacement of defective equipment B No Coverage Under Warranty The following will not be covered under warranty Travel to and from the job site 1 Adjustment or calibration of any ZF Marine Electronics equipment 2 Adjustment or calibration of any associated equipment which may include but not limited to push pull cables engine governor or carburetor transmission or trolling valve
185. niveko com U A E 7030 ZF Middle East LLC mail PO Box 26093 Sharjah U A E ship 4502 Golden Tower Building M Narasimhan NARSI T 971 6 574 7074 T harasimhan manian zf com F 97 1 6 574 7174 Sharjah zfmarine emirates net ae U A E narsi zf marine com MMC CL MC E UNITED KINGDOM Eneland 6932 Atlantis Marine Power Ltd Western Wood Way Langage Science Park Plymouth Devon Plymouth PL7 5BG ENGLAND USA ZF Marine Electronics LLC 12125 Harbour Reach Drive Suite B Mukilteo WA 98275 USA MMG CL CR MC 6427 ZF Marine LLC US Headquarters 3131 SW 42nd Street Fort Lauderdale FL 33312 USA ZF Marine LLC Gulf Coast Facility 161 James Drive West Suite 120 St Rose LA 70087 USA Richard Dix T 44 1752 208810 F 44 1752 208811 richard atlantismarine co uk www atlantismarine co uk T 425 583 1900 F 425 493 1569 www zf marine com Kelly Friedenberg T 954 581 4040 F 954 581 4078 www zf marine com Randy Tredinich Marc Kloor T 504 443 0501 F 504 443 0504 www zf marine com Kevin Zwicker Keith Kaelberer ZF Marine LLC West Coast 12125 Harbour Reach Drive Suite B Mukilteo WA 98275 USA ZF Marine LLC Annapolis 301 Pier One Road Suite 102 Stevensville MD 21666 USA ZF Marine LLC Chicago 777 Hickory Hill Drive Vernon Hills IL 60061 USA T 425 583 1900 F 425 493 1579 www zf marine com Stafford
186. nking Function Code C6 ZF Hurth Duty Cycle Ahead This function adjusts the maximum current available to the Ahead Proportional Solenoid Failure to limit the current may result in permanent damage to the solenoid The available Values are 00 0 to 100 0 percent Duty Cycle of the applied voltage The Default Value is 100 To change the Value Refer to Sections 5 2 and 5 3 page 9 2 A ED that Troll is not selected no rapidly blinking B Connect an amp meter in series with the Ahead solenoid signal Move the Control Head lever to the Ahead detent Scroll to Function Code C6 Activate Set Up Mode Scroll Up or Down until the appropriate maximum Ed O A Figure 5 21 Display LED Function C6 Set Up current level is reached Activated 0 5 3 2 3 Store the Value to memory H Return the Control Head lever to the Neutral Idle position Function Code C7 ZF Hurth Duty Cycle Astern This function limits the amount of current delivered to the Astern Proportional Solenoid Failure to limit the current may result in permanent damage to the solenoid The available Values are 00 0 to 100 0 percent Duty Cycle of the applied voltage The Default Value is 10096 To change the Value Refer to Sections 5 2 and 5 3 page 9 2 A m that Troll is not selected no rapidly blinking LED B Connect an amp meter in series with the Astern solenoid signal Page 5 14 SET UP PROCEDURES C Move the Control Head lever to
187. ntinuity between pin 5 s of the Control Head Harness connectors Control Head jumper pin 3 to 5 or 7 is missing The Station No 7 Control Head is defective No continuity between pin 5 s of the Control Head Harness connectors Control Head jumper pin 3 to 5 or 7 is missing The Station No 8 Control Head is defective No continuity between pin 5 s of the Control Head Harness connectors Control Head jumper pin 3 to 5 or 7 is missing The Station No 9 Control Head is defective No continuity between pin 5 s of the Control Head Harness connectors Control Head jumper pin 3 to 5 or 7 is missing The Station No 10 Control Head is defective No continuity between pin 5 s of the Control Head Harness connectors Control Head jumper pin 3 to 5 or 7 is missing The Station No 1 Control Head is defective No continuity between pin 6 s of the Control Head Harness connectors No continuity between pin 7 s of the Control Head Harness connectors Page B9 1 both connectors Install a jumper from pin 3 to 5 on right hand and 3 to 7 on left hand Control Heads Replace Station No 2 Control Head Ensure that the red conductor is properly crimped to pin 5 at both connectors Install a jumper from pin 3 to 5 on right hand and 3 to 7 on left hand Control Heads Replace Station No 3 Control Head Ensure that the red conductor is properly crimped to pin 5 at bot
188. o High Depress and Hold Transfer Button C Idle and vice versa for Ys second to toggle between _ i C To return to the previous Idle setting depress and hold the transfer button again for 1 2 second and then Figure 2 5 High Low Idle Mode Selection release Idle In Twin Screw applications both the Port and Starboard Processors will always be in Hig C NOTE In Twin Screw ne always program both Processors for the same amount of High or Low Idle at the same time 2 9 One Lever Mode Multi Screw NOTE The Green LED will always be lit while in One Lever Operation no matter what position es Key the Master Control Head lever is in The system supports a mode of operation referred to as One Lever Mode One Lever Mode allows the operator to control two to five engines and transmissions with a single Control Head lever Any of the Control Head levers at any Remote Station can be designated by the operator as the Master lever The designation can be changed by the operator at any time Most of the features synchronization troll etc available in normal operation are available while operating in One Lever Mode The Processor defaults to One Lever Mode disabled One Lever Mode can be disabled or enabled in the Set Up Procedures When One Lever Mode is enabled the operation must be turned ON and OFF as described below ZN WARNING Personal Injury could occu
189. o be too high 22 Station No 10 Station No 10 Control Head s lever position is out of range Faulted High The input appears to be too high 23 Station No 1 Station No 1 Control Head s lever position is out of range Faulted Low The input appears to be too low 24 Station No 2 Station No 2 Control Head s lever position is out of range Faulted Low The input appears to be too low 25 Station No 3 Station No 3 Control Head s lever position is out of range Faulted Low The input appears to be too low 26 Station No 4 Station No 4 Control Head s lever position is out of range Faulted Low The input appears to be too low 27 Station No 5 Station No 5 Control Head s lever position is out of range Faulted Low The input appears to be too low 28 Station No 6 Station No 6 Control Head s lever position is out of range Faulted Low The input appears to be too low 29 Station No 7 Station No 7 Control Head s lever position is out of range Faulted Low The input appears to be too low 30 Station No 8 Station No 8 Control Head s lever position is out of range Faulted Low The input appears to be too low 31 Station No 9 Station No 9 Control Head s lever position is out of range Faulted Low The input appears to be too low 32 Station No 10 Station No 10 Control Head s lever position is out of range Faulted Low The input appears to be too low 33 Station No 1 Station No 1 Control Head s Transfer Button has either been clos
190. o the Control Head lever s position immediately Contact ZF Marine Electronics if this Function Code is going to be changed from the default setting Function Code P1 Transfer Timeout The Value selected for this Function determines how much time an opterator has to respond to a transfer request or relinquish The available Values are 00 to 99 seconds The Default Value is 15 seconds Contact ZF Marine Electronics if this Function Code is going to be changed from the default setting Page 5 18 DOCK TRIALS 6 DOCK TRIALS WARNING It is imperative that the information provided in the previous Sections have been read and followed precisely prior to attempting a Dock Trial CAUTION With I O or Outboard applications do not attempt to shift into or out of gear Q with engines stopped This may cause a jam condition or damage to the linkage to some clutch configurations 10D NOTE On multiple screw a the following tests must be performed on both sides If any of the following tests fail consult Appendix B Troubleshooting 6 1 Control Heads Engines Stopped A Turn power ON to the Control System B The Control Head at each Remote Station should produce an intermittent tone C Perform each of the following steps on all Remote Stations 1 Move the Control Head s lever s full Ahead and full Astern Ensure that there are no obstructions to the movement the Processor reacts to the lever movement and that no tones are
191. o the Control Head to relieve the strain on the connections E Repeat Steps A thru D for the Starboard Processor F Repeat Steps A thru E with Station 2 G When Stations 3 4 and 5 are to be installed they each require the removal of the watertight seal located on the Processor enclosure in the Station cable entry holes Control Head Harness with One Plug A At the Port Processor insert the grey eight pin plug into the Station 1 pigtail plug B Run the cable to the Port side of the Control Head located at Station 1 C Connect the conductors to the Control Head as described in the appropriate Control Head Dimensions and Variations Service Sheet in Appendix A D Provide a strain relief in close proximity to the Control Head s terminal block Repeat Steps A thru D for the Starboard Processor Repeat steps A thru E with Station 2 G When Stations 3 4 and 5 are to be installed they each require the removal of the watertight seal located on the Processor enclosure in the Station cable entry holes EE Tach Sensor Harness required for Active Synchronization A On all Processors remove the watertight seals from the Tach Sender pigtail plugs Insert theTach Sensor Harness s grey four pin plug into the Tach Sender pigtail plug at each Processor Run the Tach Sensor Harness cables to the Tach signal source for each engine Connect the conductors to the Tach source in the appropriate manner keeping in mind that
192. ock up Preset for 7F2000 24 VDC Systems 05 Inverse No Current when at Lock up Preset for ZF6000 1900 and 2500 24VDC Systems 06 Preset for 12VDC ZF Hurth Systems with two 2 proportional solenoids 07 Preset for 24VDC ZF Hurth Systems with two 2 proportional solenoids 12 Troll Minimum Pressure 14 01 0 to 80 0 Must be at least 10 below Troll Maximum L3 Page 5 4 SET UP PROCEDURES Table 5 4 Troll Function Codes Only Available and Displayed When Troll is Enabled Section 5 5 4 page 5 15 Troll Maximum Pressure 25 20 0 to 100 0 EE TI Must be at least 10 above Troll Minimum L2 TITRE m Troll Range Troll Max Troll Range Troll Maximum L3 Troll Minimum L2 00 6 00 0 t0 09 9 Seconds DD 35 0 00 119 100 0 of available Troll Range Value Range or Options Section 5 5 5 page 5 15 E Diagnostic nput Voltage 0 5VD Tachometer Sensor Frequency Station No 1 Lever A D Station No 2 Lever A D Station No 3 Lever A D Station No 4 Lever A D Station No 5 Lever A D Transfer Button Stations 1 2 3 4 amp 5 Software Revision Level H1 Return to Factory Defaults Store to Return to Factory Defaults For Authorized Personnel Only H2 Driver Fault Detection Enable Allows the Processor to monitor the clutch and or troll a Section 5 5 6 page 5 16 F0 Speed Boost Percent 0 0 0 0to 50 0 of Throttle Range Fi Speed Boost Duration 00 0 00 2
193. ol Head lever positioned in the Neutral vertical detent the Processor will command Neutral and the throttle at Idle revolutions per minute RPM aT ee me C Movement of the DETENT A DETENT DETENT Control Head s lever 15 o a a 15 80 degrees to the Ahead or Astern detent will command Ahead or o Astern clutch engagement while the SECH RPM remains at Idle Further movement of the Control Head lever through FULL FULL the next 65 degrees will de on increase the engine RPM in proportion to the Control SSISISISISIS S 10853 Heads lever position Figure 2 2 Control Head Detents Page 2 1 OPERATION 2 4 Start Interlock if used The engine start signal is blocked unless all of the following are true DC power has been turned ON to the Control System A Remote Station is in command The Control System is commanding Neutral 2 5 Station Transfer IN WARNING Personal injury could occur if the following steps are not followed exactly These Processors otter 4 different means ot Station Transfer Neutral Only Mode P000 Lever Match amp Neutral Mode P002 Relinquish Receive or Request Relinquish Mode P003 Request Relinquish Receive Mode P0004 The transfer type is selected during initial system setup 2 5 1 Neutral Only Transfer Mode P000 A The Station in Command s lever s may be in any position However it is recommended th
194. ollowing is a list of the pigtail connectors supplied for your System The figure represents all of the pigtails Your System may not use them all Refer to Figure 2 19 for pigtail locations Serial Ze Communication Ej Throttle Tachometer UI Sensor Cs dr 1 0 16 prr Station R Ind CA Station 7 Zi m 2 E dd gt FI IL pu Clutch Power Start Interlock Figure 2 9 Processor Pluggable Connections View Two pigtail connectors are provided for connection to the Remote Station Control Heads One pigtail connector provides the connections for DC Power Start Interlock Clutch Oil Pressure Interlock and an External Alarm contact One pigtail connector is provided for serial communication between multiple Processors One pigtail connector is provided for the Tachometer Sensor input used in multi screw active synchronization One pigtail connector provides connection to the throttle n igtail connector provides connection to the solenoid clutch 2 1 Optional Features 2 16 1 External Alarm Capability This optional feature is designed to provide a status signal to an external visual or audible alarm circuit Page 2 12 OPERATION 2 16 2 2 16 3 2 16 4 2 16 5 2 16 6 2 16 7 The status signal is in the form of an OPEN or CLOSED relay contact When the contact is CLOSED the Processor is functioning normally When the contact
195. on 2 16 7 LCD Panel Section 2 16 8 Backup Control System Section 2 16 9 Speed Boost Section 2 16 10 Page 1 2 OPERATION 2 OPERATION 2 1 DC Power On When DC power is turned ON to the Processor A short steady tone followed by an intermittent tone will sound at all Remote Stations indicating that no station has command The Start Interlock relay contact will remain open preventing engine start Throttle Electronic The throttle signal will be commanded to Idle Shift Solenoid The Ahead and Astern shift solenoids will be de energized commanding Neutral 2 2 Taking Command To take command at any one of the Remote Stations Pas Ensure all Control Head s lever s at that Station are in the Neutral detent vertical en Depress the transfer button for 1 2 second Transfer N The Slow Repetitive tone will stop at all Stations and the SES red LED indicator light will turn ON at the Control Head of the Station that had assumed command ot the Control 10454 System Figure 2 1 Station taking Command NOTE If Start Interlock is used Once a Station is in command the Start Interlock relay contact will close allowing the engine to start NOTE Only one Station can have command at a time The Operator is now in control of the vessel s screws ES 2 3 Basic Operation 2 3 1 Normal Operating Mode A The SEN Head has three detents Ahead Astern and Neutral B With the Contr
196. on allows the adjustment of Clutch Solenoid related items 5 5 3 2 1 Function Code C5 Shift Solenoid Type This Function Code must be left at the default value unless a ZF Hurth Gear is installed with proportional Ahead and Astern Solenoids Page 5 13 SET UP PROCEDURES NOTE New ZF Hurth Gears utilize standard On Off solenoids for Clutch selection If unsure of your type contact the ZF Gear Manufacturer en values 01 or D2 are selected the current is limited to the solenoids The available Values are 00 All Shift Solenoids except ZF Hurth DEFAULT 01 ZF Hurth Proportional Solenoids with 12V Power 02 ZF Hurth Proportional Solenoids with 24V Power The default value of 00 is used with most types of solenoids with the exception of the ZF Hurth Gears with proportional Ahead and Astern solenoids The maximum amount of current to urth proportional solenoids Y MUST be limited by the control system Failure to do so can cause permanent d damage to the solenoids Depending on the voltage applied to the solenoids adjust the Value to 01 for 12V power and 02 for 24V power Function Code is Blinking 5 mn LA UI To change the Value Refer to Sections 5 2 and 5 3 page 9 2 A Scroll to Function Code C5 B Activate Set Up Mode C Scroll Up to change the Value D Store the Value to memory Figure 5 20 Display LED Function C5 Set Up Activated 5 5 3 2 2 Function Code is Bli
197. on vessels equipped with electronic Throttle and solenoid Clutch selection B1 2 Typical System Main Components B1 2 1 Control Head The primary function of the Control Head is to send out a variable DC voltage to the Processor This DC voltage is representative of the Control Heads present lever position In addition to the primary function the Control Head also has audible Sound iden and visual LED status indications along with a Transfer Button for taking command and performing other system functions B1 2 2 Processor The Processor receives the variable DC voltage from the Control Head s and converts these inputs to the EE riate electronic or electric outputs at the correct time and sequence to the Governor and Gear Box The information regarding throttle type throttle clutch sequencing etc are all stored on memory within the Processor B1 2 3 Power Source All electronic equipment must have power in order to operate Ensuring a properly charged reliable power source is available is The Processor requires a 12 or 24 VDC power system The minimum voltage at which the Processor will continue to operate is 8 00 VDC The maximum allowable voltage is 30 VDC Exceeding these limits will not damage the Processor but will render it unusable temporarily The power supply must be capable of delivering 10 amperes to each Processor on a continual basis and current surges up to 20 amperes All cable calculations should be based on a 10 ampere
198. onnectors Service Field Test Unit Field Test Control Head Dual PageA 2 MMC 329 Rev C 8 03 ZF Marine Electronics LLC Mukilteo Plant MC2000 Series Standard Control Head Variations This Service Sheet reflects all current variations of the standard 3 detent ZF Marine Electronics MC2000 Series Control Heads Part Numbering Configurations Detents Available R Right Lever STANDARD VERSION L Left Lever P Plug Pigtail RE NT DETENT SINGLE LEVER A 159 159 CONFIGURATIONS TI 65 STO 65 This digit represents the Control Head and Lever finish J Refer to the current Catlog Price List for finishes available d DUAL LEVER CONFIGURATIONS MC2000 EN i THREE DETENTS P Plug Pigtail PA for Aft Facing MP 7777777000000 nm REQUIREMENTS MicroCommander ClearCommand one 1 8 Conductor Cable per Control Head lever Pluggable MicroCommander ClearCommand one 1 Control Head Harness per Control Head lever CruiseCommand one 1 Control Head Harness per Control Head lever Included with the Control Head Mounting screws Terminals For 8 Conductor or 1 Connector Harnesses Watertight cable grip for the cable entrance on the Processor For 8 Conductor When the Control Head is properly mounted on a console it is spray proof from the top only An adhesive gasket is on the bottom of the Control Head to ek to the mounting surface However below the mountin
199. ools And Parts 3 2 1 Required Tools e Screwdriver medium Phillips 2 Hole saw 1 inch 25 4mm e Saw with blade suitable for Console Top Panel Drill Motor with 9 32 inch and 7 32 inch drill bits 3 2 2 Optional Tools e Calibrated Digital Multimeter Fluke 80 Series or equivalent e Service Field Test Unit P N 13927 available through ZF Marine Electronics Wire cutter EUM crimper Recommend Thomas amp Betts WT 2000 Required 1f using single terminated harnesses 3 2 3 Engine Stop Switch An engine STOP switch MUST be located at each Remote Station WARNING An Engine STOP Switch MUST be installed at every remote operating station Refer to CFR 46 Section 62 35 5 US Coast Guard and ABYC P 24 5 8 3 DC Power Source One of the most important and often overlooked items for proper a of your control system is a clean dedicated and reliable source ot DC Power The wiring used to supply power from the power source battery through the various components aes distribution panel relays etc to the Processors must be sized for a voltage drop of 10 or less using 10 amps as the maximum current draw Refer to ABYC Standard E 11 Table X to determine the appropriate wire gauge for the necessary conductor length When using ZF Marine Electronics supplied 14 gauge power cable and in accordance with ABYC Standard E 11 the distance from a 12 volt power source battery or DC Distribution Panel shall not exceed 15 feet
200. or each Processors do they have a common ground At At At Processor Battery Processor At Battery What is the Voltage when not being charged VDG VDG VDG VDG At At At At Battery Processor Battery Processor What is the Voltage when connected to Shore Power VDG VDG VDG VDG At At At At Battery Processor Battery Processor What is the Voltage when the engines are running VDG VDG VDG VDG Table 7 1 Dock Trials PORT STBD Outside Outside Processor Serial Numbers MS Does the engine start when the Control System is turned OFF ES Does the Engine Stop Switch function at all Stations regardless of RPM AES Can all Remote Stations take command Z Does the Warm up Indicator Light blink in Ahead YES pe What is the Low Idle RPM EEE YES e High Idle RPM optional EEE YE NO YES NO BEIN E EEN Does the vessel surge forward with Control Head lever in the Ahead Detent L T 1 7 Table 7 1 Sea Trials PORT STBD Outside Outside BEEN Processor Serial Numbers SM RPM E What is the Full Throttle RPM MER Do the Dual Control Head levers match position and RPM throughout the speed range SE feet The Full Speed Reversal Delay is set for how many seconds YE N YES NO 2 MESA Is Synchronization operational STA TA 4 Sun What is the length of the Control Head Harness Sr Page 7 5 SEA TRIALS 7 5 3 Record Parameters Record information onto the following Tables only
201. ot Used 4 Plug Seal Not Used Fame 8 Green N C Po Plug Connector Yellow 111508 B12 3 1 Base B12 12 PWM Throttle Harness Pin Out PROCESSOR PIGTAIL ENGINE ENER ee EE Description 8 GREEN 1 BLACK DC Return YELLOW Shield 2 RED PWM Se ngine Dc Bus Throttle Signal Return 7 Seal Plug Not Used E or Plug Not Used Raa 2 eee PWM Throttle Det E 100 Duty 0 100 Duty 6 Seal Plug Not Used 3 Seal Plug Not Used Te 0 100 Duty 0 500Hz 5 Seal Plug Not Used 4 Seal Plug Not Used nn 8 Green BE Yellow i N A gt Plug Connector 111508 B12 3 1 Voltage Table B12 13 Voltage Throttle Harness Pin Out PROCESSOR PIGTAILS ENGINE Termination A nod Termination B Description 8 GREEN PRIOK YELLOW Shield BLACK DC Return Pin 1 Black Engine DC Bus _ Throttle Signal Return 7 Plug Seal Not Used Plug Seal Not Used Pin 2 4 ees 0 00 5 00 VDC 6 Plug Seal Not Used vw 3 Plug Seal Not Used a Signal 5 Plug Seal Not Used y EE Se Page B12 3 TROUBLESHOOTING ZE B13 PROCESSOR PIGTAILS The number and types of Pigtails used varies with the different Processors and their configurations The basic off the shelf Processors are available with no Pigtails hard wired or pre wired for for up to a total of eight Pigtails when all f
202. ote Stations Station 1 thru 5 Pin 4 Station 1 thru 5 Pin 6 Station 1 thru 5 Pin 7 Station Thru 5 Pin 8 Psu per between Pins 3 and 7 Jumper between Pins 3 and 5 4 4 4 2 Eleven Conductor DP Cable Location 2 NO Station 5 If this option is to be used please contact ZF Marine Electronics 4 4 4 3 Start Interlock Cable Location 4 4 4 4 3 1 Connection at the Starter Solenoid A Run the length of two conductor cable between the Engine s Starter Solenoid and the Processor B Disconnect the Starter Switch wire from the Solenoid C Strip back the appropriate amount of PVC jacketing and conductor insulation D Connect one of the conductors to the Solenoid s Starter Switch terminal E Butt splice the second wire to Starter Switch wire 4 4 4 3 2 Connection at the Processor A Install a liquid tight connector into entry hole No 4 Refer to Figure 4 6 page 4 4 for entry hole location and Figure 4 5 page 4 4 for cable grip installation B Run enough of the two conductor power cable through the liquid tight cable grip so that it can be routed to PB2 on the Circuit Board as shown in Figure 4 7 page 4 4 C Strip back 2 inches 50 8mm of the PVC jacketing Refer to Figure 4 11 D Strip each wire 3 8 inch 9 5mm E Place a 3 8 inch 9 5mm section of shrink tubing over the cable and heat 3 8 inch 9 5mm 3 inches T 76 2mm BEE e O 12263 A Heat Shrink Figure 4 11 Two Conductor Start Int
203. ottle Pigtail Pin Out PWM 9 1 Black amp fo 8 Green Yellow 2 Brown w S Red i Frequency 4 Orange Page B13 1 TROUBLESHOOTING B13 3 Clutch Pigtail Table B13 5 Clutch Pigtail Pin Out CIRCUIT BOARD PLUG Termination A Conductor Color Termination B Description SC TBII Bak Pms Listen Chr A ESN mz Brown Pms Ahead Clutch te a 6 Yellow mz Yelow Pme Astern deckt TB116 Green Pin AheadClutch B13 4 Tachometer Sensor Pigtail Table B13 6 Tachometer Sensor Pigtail Pin Out CIRCUITBOARD PLUG Termination A Conductor Color Termination B Description TAN Ti Red Pin Sensor Supply 9VDC IT Black ee eee NE ae XC ie a o IE U 25 Seo TB9 3 Open Collector Tach Input EA TEE green wire is moved from 4 Drain pS 2 to TB9 3 when an Open Collector Tach is used Pa Return for Tach Input EE Page B13 2 ENG 143 Ver 1 4 04 s ZF Marine Electronics LLC Mukilteo Plant ClearCommand 9000 Series Electronic Throttle Solenoid Clutch Qualitative Failure Analysis amp Design Verification Test Procedure Version 1 0 Document AUTHOR CHECKED APPROVED DATE ENG 143 Tim Jones Jim D Smith Robert Anderson 4 19 04 Qualitative Failure Analysis The following qualitative failure analysis is provided to show compliance with Subchapter K Small Pas
204. p Activated Proportional Pause Time will set the Fixed Neutral Delay duration NOTE If C2 Proportional Pause is set to 02 Fixed Neutral Delay Enabled Function C3 5 5 3 1 4 Function Code C3 Proportional Pause Time The Proportional Pause Time feature provides engine deceleration followed by a pause in throttling to the commanded speed in the new desired direction upon a Full Speed Reversal This pause time is proportional to how much throttle is being commanded and for how long In order to build up to the pause value set the vessel must be at full throttle and Ahead six 6 times the pause set The default pause from Astern to Ahead is 1 2 the Proportional Pause C2 value set When C2 Proportional Pause is set to 00 the throttle position drops to Idle and the transmission remains engaged Ahead the pause that follows is in proportion to the prior Control Head lever position and how long the lever had been in that position before the reversal This Function selects the amount of time that the Clutch will stay engaged or at Neutral depending on C2 setting while performing a Full Speed Reversal The available Values are 00 to 99 seconds The default Value is 03 seconds NOTE The Value for this Function Code should be determined during the Sea Trial Function Code is Blinking Ted To change the Value Refer to Sections 5 2 and 5 3 page 9 2 A Scroll to Function Code C3 B Activate Set Up Mode C Scroll Up or
205. plug into the Processor s Power Start Interlock Pigtail s Socket Page 4 1 INSTALLATION B Run the cable to the DC Distribution Panel or the optional Power Relay C Strip back the appropriate amount of PVC jacketing and conductor insulation D Crimp the appropriate connectors to the conductors E Terminate the conductors to the DC Power Source 4 3 2 2 Start Interlock Cable Start Interlock Power N O Contact Start Switch Start Interlock Pigtaij May 5 Amps A Run the cable to the Engine s Starter I Cable Solenoid Beie PROCESSOR B Disconnect the Starter Switch wire from the S Splices Solenoid C Strip back the appropriate amount of PVC jacketing and conductor insulation D Connect one of the conductors to the Solenoid s Starter Switch terminal E Butt splice the second wire to Starter Switch Ground 13248 ART wire Figure 4 3 Start Interlock Connections 4 3 2 3 External Alarm Circuit Cable optional Refer to Section 8 1 page 8 1 for installation information 4 3 2 4 Clutch Pressure Switch Cable optional Refer to Section 8 2 page 8 2 for installation information 4 3 3 Serial Communication Harness 4 3 3 5 Twin Screw Refer to Figure 4 4 A At the Processors remove the watertight seals from the Serial pigtail plugs B At the Port Processor insert the Serial harness s grey six pin plug into the Serial pigtail plug C Run the harness to the Starboard P
206. plug on the Break out Box should be lit Return the Control Head lever to the Neutral Idle position MM13927 Page 2 5 2 3 SERVICE FIELD TEST UNIT TROLL TESTING 2 3 1 Troll On Off Solenoid A Ensure power is removed from both the Processor and the Clutch Power Supply B Disconnect the Clutch Harness from the number 3 Processor connector pigtail C Insert the Break out Box between N the number 3 Processor Y connector pigtail and the Clutch l Harness as shown in Figure 2 12 une I Al D Set up the Multimeter to measure Tw DC Volts and connect the black Gm me ON Ir ll i lead to the socket labeled we G0 m eS CLUTCH and the red lead to 0 OQ f the socket labeled TROLL ON No Os 5 OFF as shown in Figure 2 12 Y 1 E Turn power On to the Processor BREAK OUTBOX ae Sg y E and the Clutch Power Supply and OOOO dh gm DE take command at a Remote Station e with the Control Head lever in the ww O SS Figure 2 12 Troll Connection ON OFF Solenoid S y co FUNG em NU e he o BREAK OUT BOX m 2 3 2 S Neutral Idle position F Depress the
207. pplications with more than one Processor at this connector pigtail The input signal from a Tachometer or Shaft Speed Sensor connects to this connector pigtail Table 1 1 Connector Pigtail Descriptions MM13927 Page 1 1 SERVICE FIELD TEST UNIT PROCEDURE The actual procedures for using the Break out Box are the same for CruiseCommand and ClearCommand Processors However the adjustment within the Processor to obtain the correct output may differ The appropriate Installation Manual must be referred to when making the adjustments 2 1 Throttle Signal Testing Depending on which Processor is being tested it may have the capability of sourcing one or all of the following DC Voltage Current PWM Pulse ClearCommand Processors Width Modulation or Frequency NOTE The following procedures and drawings pertain to both the CruiseCommand and 2 1 1 DC Voltage A Ensure that power is removed from the Engine Electronics and the Processor B Disconnect the Throttle Harness from the number 1 Processor connector pigtail 12 PIN CONNECTORS aw O NEUTRAL TROLL ON O ASTERN PWM mA
208. r further informa tion on Handheld requirements and options ZF MARINE ELECTRONICS L L C e Mukilteo Washington 12125 Harbour Reach Drive Suite B Telephone 425 583 1900 Mukilteo WA 98275 Telefax 425 493 1569 A b ZF MARINE ELECTRONICS L L C e Mukilteo Washington 12125 Harbour Reach Drive Suite B Telephone 425 583 1900 Mukilteo WA 98275 Telefax 425 493 1569 A 6 0 25 Diameter 6 1mm through Holes 2 Holes e ZF MARINE ELECTRONICS L L C e Mukilteo Washington 12125 Harbour Reach Drive Suite B Telephone 425 583 1900 Mukilteo WA 98275 Telefax 425 493 1569 ZF MARINE ELECTRONICS L L C e Mukilteo Washington 12125 Harbour Reach Drive Suite B Telephone 425 583 1900 Mukilteo WA 98275 Telefax 425 493 1569 A 8 MMC 279 Rev B 7 02 ZF Marine Electronics LLC Mukilteo Plant 400 Series Weather Mount Enclosure y X Ry T Single or Dual Control Head Gasket Control Head 75 inch Diameter Hole non Locate where required Holes two if Dual Control Head E gt 3 54 Enclosure E A 89 9mm D e Watertight D Cable Grip 6 29 Kei 2 two if Dual Control Head 159 8mm Ae 4 72 10241 119 9mm Deck Mount or Exposed Mount Ideal for outside Weather Mount To prevent internal condensation and moisture build up the mountis drilled to allow air circulation Part No 12110 ZF MARINE ELECTRONICS L L C e Mukilteo Washington 12125 Harbour Reach Drive
209. r if the following steps are not followed exactly 2 9 1 Turning ON One Lever Operation A At the Station in Command move all the Control Head levers to the Ahead detent B Depress and Hold the transfer button while moving one of the Control Head levers forward out of the Ahead detent Do Not Release the Transfer Button until the green LED turns ON indicating One Lever Operation is now active The Control Head lever which the operator chose to move out of the Ahead detent becomes the Master lever The Control Head lever which was left in the Ahead detent is now inactive Page 2 5 OPERATION AE e IT 4 n ibi Green Indicator Light will Push and Hold S PASE turn ON when One Lever T Detent ransfer Button Operation Mode is Active while immediately moving the Master lever out of the Ahead Detent Release the Transfer Push amp Hold Transfer Button d X while moving the Button when Green f Master lever Indicator Light turns ON 10161 RA STATION IN COMMAND 10161 Figure 2 6 Step A One Lever Operation Mode Figure 2 7 Step B One Lever Operation Mode lt J NOTE The Control Head lever designated a the operator to be inactive in One Lever Operation IRC may be left in the Ahead detent or moved fully forward Moving the lever fully forward is recommended because it moves it out of the way and prevents accidental bumps while operating 2 9 2 Turning OFF One
210. r is removed from both the Engine electronics and the Processor B connector pigtail E Figure 2 7 Throttle Connection PWM with Duty Cycle Meter 2 1 5 12 PIN CONNECTORS ECM N PWM we FREQ Be y QOO R o IDLE VALIDATION J BREAK OUT BOX C 2 Disconnect the Throttle Harness from the number 1 Processor Insert the Break out Box between the number 1 Processor connector pigtail and the Throttle Harness as shown in Figure 2 7 Set up the Multimeter to measure Duty Cycle and plug the black lead into the Break out Box black socket labeled and the red lead into the socket labeled PWM Turn power On to the Caterpillar ECM Electronic Control Module and to the Processor The measurement should be approximately 8 duty Cycle Move the Control Head lever to the Full Throttle position while depressing the Transfer Button Throttle Only Mode H The measurement will increase from 8 to 91 93 Frequency Hz A Ensure power is removed from both the Engine Electronics and the Processor B connector pigtail EN C 27 Ama
211. re Os 2 135 SM eM SM MS E E Turn power On to the Processor ooo OO LE and ihe Clutch Power Supply and 20 o Lo take command at a Remote Station with the Control Head lever in the Neutral Idle position Figure 2 13 Troll Connection Proportional Solenoid with Amp Meter MM13927 Page 2 6 SERVICE FIELD TEST UNIT Depress the Transfer Button again for approximately 2 seconds until the red LED on the Control Head begins blinking at a fast rate Troll Mode Indication Flip switch away from Troll Command to read current through meter Move the Control Head lever to the Ahead detent The current measurement should be the correct value for minimum clutch pressure shaft rotations This value varies depending on the type of Marine Gear Refer to the Literature provided with the Trolling Valve and the Processor for specifics Slowly advance the Control Head lever while monitoring the current The current should increase or decrease depending on the Gear type in proportion with the Control Head lever movement Once again refer to the Literature provided with the Trolling Valve and the Processor for specific Vues Continue to move the Control Head lever forward until the red LED stops blinking lit steady The current should drop to 0 mA MM13927 Page 2 7 SERVICE FIELD TEST UNIT 3 PARTS LIST Table 3 2 Parts List Service Service Field Test Unit Test Unit 13927 T AA Manual MM13927 Multimeter
212. re time is required to slow down from Ahead as compared to Astern NOTE When the Controls are installed on a vessel such as a double ended Ferry or the Controls are being used to control a thruster the proportional pause should be the same in Ahead as Astern or port and starboard in the case of a thruster The available Values for this Function are 00 2 1 Ahead to Astern vs Astern to Ahead Default Value 01 1 1 Ahead to Astern vs Astern to Ahead To change the Value Refer to Sections 5 2 and 5 3 page 9 2 Function Code is Blinking Ge A Scroll to Function Code C4 e nm B Activate Set Up Mode L Lt C Scroll Up or Down to the desired Value D Store the Value to memory Figure 5 18 Display LED Function C4 Set Up Activated 5 5 3 1 6 Function Code C8 Fixed Neutral Delay This function provides a pause at Neutral whenever a change in direction is commanded This pause is in addition to any proportional delay programmed into the system The available Values for this Function are 00 0 to 04 0 seconds and are programmable in one tenth of a second intervals To change the Value Refer to Sections 5 2 and 5 3 page 9 2 p A Scroll to Function Code C8 B Activate Set Up Mode C Scroll Up or Down to the desired Value l D Store the Value to memory Figure 5 19 Display LED Function C8 Set Up Activated 5 5 3 2 Clutch Solenoid Functions C5 through C6 This section along with the Clutch Basic Functions Secti
213. reases Down the Value one digit at a time 5 1 2 2 Left and Right Push Buttons Pressing and holding the Left and Right Push Buttons simultaneously has the following functions Activates Set Up Mode as indicated by the blinking Display LED must hold the buttons until the blinking begins While in Set Up Mode deactivates Set Up Mode saves the displayed Value to memory and returns to the Function Menu must hold the button until the blinking stops 51 23 Left Push Button Only Pressing the Left Push Button once has the following functions Deactivates Set Up Mode without any changes to the Value being stored to memory The Left Push Button must be held down until function code stops blinking The default value will then be displayed While in Function Menu changes the Display LED to the Error Menu if any errors are present has no effect if there are no errors stored e While in the Error Menu changes the Display LED back to the Function Menu Figure 5 6 Display LED Error Menu Example 5 1 2 4 Right Push Button Only Pressing the Right Push Button once has the following functions e While in the Error Menu clears inactive errors Active errors blink inactive do not While in Set Up Mode or Function Menu allows the Value of p ai the current Function Code to be displayed with all four Figure 5 7 cen Four Digit Display LEDs 5 2 Activating Set Up Mode gt NOTE To Escape from the Set
214. red no plugs the electric cable may be ordered from ZF Marine Electronics or must meet the following specifications e Seven conductor with shield twisted Page 3 3 PLAN THE INSTALLATION 3 1 5 8 31 9 9 3 1 5 10 Color Code black brown red orange green blue and 18 AWG nearest metric equivalent 1 300V 105 degrees C UL VW1 stranded tinned copper wire Maximum outside diameter 0 390 inch 9 9mm Power Start Interlock Clutch Pressure Alarm Electric Cable 3 1 5 8 1 3 1 5 8 2 3 1 5 8 3 3 1 5 8 4 Power Electric Cable Requirements If Power is hard wired no plugs the electric cable may be ordered from ZF Marine Electronics or must meet the following specifications Two conductor black and red with violet stripe twisted 14 AWG 42 5 metric or 12 AWG 4 metric may be used to crimp directly to the Processor terminals Refer to Automatic Power Selector in Appendix A for cable length and additional wire size requirements 300V 105 degrees C UL VW1 stranded tinned copper wire Maximum outside diameter 0 390 inch 9 9mm Start Interlock Electric Cable Requirements If Start Interlock is hard wired no plugs the electric cable may be ordered from ZF Marine Electronics or must meet the following specifications ju conductor both yellow with red stripe twisted 16 AWG 21 5 metric 300V 105 degrees C UL VW1 stranded tinned Copper wire Maximum outside diameter 0 39
215. resentative for further information 2 16 9 Backup Control System The Backup Control System provides a control system which is fully independent from the ZF Marine Electronics Control System The Backup can control the transmission as well as the engine but it does not include ZF Marine Electronics control logic safety interlock and timing circuits In other words there is no protection for operator errors such as shifting into gear at elevated rpm s If this option is going to be used please contact a ZF Marine Electronics Representative for further information 2 16 10 Speed Boost Q Misapplication of the Speed Boost feature can damage the transmission or other equipment Before using Speed Boost the transmission representative must be consulted about its use and any limitations on clutch engagement as a function of engine speed The person s implementing Speed Boost have the responsibility for ensuring it is properly adjusted and for any damage that might occur O With a properly set and timed Speed Boost signal the engine speed should not increase significantly if at all during clutch engagement Engine speed should remain at or slightly above idle as the clutch begins to engage A certain amount of droop below idle is normal as the clutch pressure rises and the clutch plates begin to come into contact The idle speed should not rise until the clutch plates are fully engaged Transmission damage may occur if this
216. ressed for five minutes the selected Mode of operation is 10D automatically exited and the System returns to Normal Mode If no Push Buttons are pressed for five minutes while in Set Up Mode it will be exited without the changes stored to memory The following tables list the Function Codes Name Default Value and Range or available Options Each of the Function Codes are explained in further detail in the referenced sections NOTE 10D SINGLE SCREW APPLICATIONS The Function Values may be entered and stored in any order MULTI SCREW APPLICATIONS The A1 Function must be set FIRST and the AO Function must be set SECOND The rest of the Function Values may be entered and stored in any order Table 5 1 Processor Function Codes Section 5 5 1 page 5 6 AO Processor Identification 00 01 02 03 04 08 A2 One Lever Operation 00 Disabled 01 Enabled A3 SE Station Expander 00 Disabled 01 Enabled A4 Neutral Indication Tone 00 No Tone 01 Tone upon engaging Neutral Detent 02 Tone upon shifting to Neutral A5 Engine Room Lockout Station 00 Both Disabled 03 Both Enabled Value 2 Lockout 01 Engine Room Lockout Enabled 00 DP Disabled Station 5 Enabled 01 DP with Troll Enabled Station 5 Disabled 02 DP without Troll Enabled Station 5 Disabled Section 5 5 2 page 5 8 02 Station 2 Lockout Enabled MT able rottle Function Codes alue H EO Engine
217. rial Harness s shield is not properly terminated The Serial Harness is in excess of 120 feet 37m b The Processor is defective The Serial Harness s shield is not properly terminated The Serial Harness is not connected at Processor ID No 1 None of the Processors has ID No 1 selected Loss of power to Processor ID No 1 The Serial Harness is not connected at Processor ID No 2 None of the Processors has ID No 2 selected Loss of power to Processor ID No 2 Page B9 4 Clear the Error Code from memory b Replace the Control Head Ensure that the orange conductor is crimped to pin 4 at both ends and the red wire is crimped to pin 5 at both ends of the Harness Ensure that the orange conductor is crimped to pin 4 of the connector and connected to pin 4 of the Control Head s terminal block Ensure that the red conductor is crimped to pin 5 of the connector and connected to pin 3 of the Control Head s terminal block Clear the Error Code from memory b Replace the Control Head Ensure that the orange conductor is crimped to pin 4 at both ends and the red wire is crimped to pin 5 at both ends of the Harness Ensure that the orange conductor is crimped to pin 4 of the connector and connected to pin 4 of the Control Head s terminal block Ensure that the red conductor is crimped to pin 5 of the connector and connected to pin 3 of the Control Head s terminal block Reposition the Processor s
218. riginal rating which could result in misleading results The Performance Load Test places an accurate load on the battery and compares the results to the battery manufacture s specification The battery should be replaced if the results are 80 or less than the manufacture specifications 9 3 2 Power Cables Distribution Panels etc Check all of the connections from the battery to the DC Distribution Panel to the APS for loose or corroded connections Measure the voltage at the battery and at the Processor while the Clutch or Throttle is driving There should be no more than 10 difference between these two points If so check all devices and connections for excessive voltage drop NOTE If an APS is used in the circuit to supply power to the Processor account for the 0 7V drop across the APS Example 12 6V battery 1 26V 10 drop 0 7V APS drop 10 64V Minimum allowable voltage Page 9 2 APPENDIX A APPENDIX A PARTS LIST PART NO DESCRIPTION CONTROL HEADS SINGLE SCREW 450 3L or 3RLeft or Right Control Head D Lever 453 3L or 3RLeft or Right Control Head Chrome Knob Lever 455 3L or 3RLeft or Right Control Head Black Low Profile Lever 456 3L or 3R Left or Right Control Head Chrome Low Profile Lever 456 3LP or 3RPLeft or Right Control Head Chrome Low Profile Lever Pluggable 521 4L or 4RLeft or Right Control Head Single Lever Tournament Style Aluminum 521 4LB or 4RBLeft or Right Control Hea
219. rine Electronics LLC Mukilteo Plant Engine Tachometer Sender Requirements Gasoline Inboard 3 4 6 8 Cylinder Point Side of the Coil a wal Most Older amp 3208 D336 D346 D348 8902 Get W s D399 amp D334 nali Caterpil 3116 3126 3176 3196 3406 3408 6922 Some use 8912 New engines have lar 3306 3412 3056 3512 amp 3516 Magnetic Pickup already installed on flywheel ore All Electronic _ eege Use ECM output Outputs 12 PPR lar Most Older kann 8902 Diesel Cummins B amp eege Series KTA19M3 MTA855 m Most have Magnetic already KTA1150M installed on flywheel Diesel Detroit DDEC Electronic System 8902 Must have Detroit data link output module Diesel Detroit 53 71 amp 92 Series 8902 Engines manufactured before 1976 use Aetna Part No 8152 drive key with Sender Diesel Detroit 8 2 Liter 2 Cycle Some 71 amp 92 Series _ een Hino All Engines 250 HP Tach drive on front Port side of engine 310HP Tach drive on rear center just below the head wn foe Older Engines 8902 Tach drive usually at rear Starboard side of engine E Newer 8912 LEN Pickup usually already ee LEN Ver Diesel Lehman _ Engines 8902 Engine built after 1977 require the Ford Aetna Part No 8619 tachometer drive m a Diesel E An extension cable Aetna Part No 9212 is usually required ZF MARINE ELECTRONICS L L C e Mukilteo Washington 12125
220. roblem occurs The tones are used to bring the operator s attention to a possible condition or problem The following basic tones can be produced on all Systems Slow Repetitive Tone Refer to Section B5 1 1 page B5 1 One Long Three Short Tones Refer to Section B5 1 2 page B5 2 Steady Tone Refer to Section B5 1 3 page B5 3 Three Second Steady Tone Refer to Section B5 1 4 page B5 4 Five Seconds On Five Seconds Off High Repetitive Rate Tone Refer to Section B5 1 6 page B5 4 Five Second Steady Tone Refer to Section B5 1 7 page B5 4 The following tone can be produced on all Systems using Solenoid Clutches One Long One Short Tone Refer to Section B5 3 1 page B5 6 Are there any Error Messages displayed on the Processor s Display LED In addition to generating a tone at any time the system detects a malfunction or fault an error message will be displayed at the Processor Refer to Table B8 1 Basic Control System Error Codes for an explanation of the errors What is the status of the Control Head in command s red LED The red LED s will be in one of the following states Lit Steady When the red LED is Lit Steady this indicates that the Station is in command and in Normal operative mode Not Lit When the red LED is Not Lit that Station is not in command or there is no power to the Control System Page B2 1 TROUBLESHOOTING Blinking Slowl A Slow Blinking red LED indicates that t
221. rocessor D Insert the harness s grey six pin plug into the Starboard Processor s Serial pigtail plug E Secure the Serial Harness at least every 18 in 457 2mm Serial Communication Harness EE A E i gt S A f S L i e Ww L oe E C3 LES LJ X C I Fen C U fe y peu p ZN b dl kJ EE Li C 6 pes s rom STARBOARD ID 1 13242 ART ID 42 Figure 4 4 Twin Screw Serial Harness Connections 4 3 4 Standard Control Head Harness Depending on whether a pluggable or hard wired not pluggable Control Head s is selected will determine the procedure for terminating the Harness at the Remote Station The first installation procedure Section 4 3 4 1 below is written for the pluggable Control Head If a hard wired Control Head s is selected follow the information provided in the second procedure Section 4 3 4 1 page 4 3 NOTE or Twin Screw Dual Lever Control Heads must be connected to the same numbered Station on both Processors Page 4 2 INSTALLATION 4 3 4 1 4 3 4 2 4 3 5 4 3 6 4 3 6 1 4 3 6 2 Control Head Harness with Two Connectors A Atthe Port Processor insert the grey eight pin plug into the Station 1 pigtail plug B Run the cable to the Control Head located at Station 1 C Insert the grey eight pin plug into the Control Head s Port pigtail plug D Ensure that the cable has a strain relief close t
222. roperly crimped to pin 5 at both connectors Install a jumper from pin 3 to 5 on right hand and 3 to 7 on left hand Control Heads Replace Station No 1 Control Head Ensure that the green conductor is properly crimped to pin 6 at both connectors and there is continuity Ensure that the blue conductor is properly crimped to pin 7 at both connectors and there is continuity TROUBLESHOOTING O 4 20 26 27 28 29 30 31 32 33 34 Table B9 1 Basic Control System Problem Causes and Solutions The Station No 2 Control Head is defective No continuity between pin 6 s of the Control Head Harness connectors No continuity between pin 7 s of the Control Head Harness connectors The Station No 3 Control Head is defective No continuity between pin 6 s of the Control Head Harness connectors No continuity between pin 7 s of the Control Head Harness connectors The Station No 4 Control Head is defective No continuity between pin 6 s of the Control Head Harness connectors No continuity between pin 7 s of the Control Head Harness connectors The Station No 5 Control Head is defective No continuity between pin 6 s of the Control Head Harness connectors No continuity between pin 7 s of the Control Head Harness connectors The Station No 6 Control Head is defective No continuity between pin 6 s of the Control Head Harness connectors
223. s C P 24 Electric Electronic Propulsion Controls 2 Code of Federal Regulations 33 CFR 183 Subpart I Electrical Systems 33 CFR 183 410 Ignition protection 33 CFR 183 415 Grounding 33 CFR 183 425 Conductors General 33 CFR 183 430 Conductors in circuit of less than 50 Volts 33 CFR 183 445 Conductors Protection 33 CFR 183 455 Over current and Protection General 46 CFR 111 01 15 b Ambient Temp Machinery Spaces 50 degrees C 46 CFR 111 05 System Grounds 3 Society of Automotive Engineers 400 Commonwealth Drive Warrendale PA 15096 J1171 External Ignition Protection J1428 Marine Circuit Breakers J378 Marine Engine Wiring 4 National Marine Manufacturers Association 401 North Michigan Avenue Chicago IL 60611 5 Underwriters Laboratories B PARTS SOURCE Anti Static Wrist Strap Automatic Power Selector Circuit Breaker UL Approved Fuse Relay 12 VDC Relay 24 VDC Service Field Test Unit Break out Box WAGO Tool Field Test Control Head Dual ZF MARINE ELECTRONICS L L C e Mukilteo Washington P N 517 Thomas amp Betts P N AWCC P N 13505 P N 810 E T A P N 41 2 514 LN2 10 P N 1030 Bussman P N GDC 1A P N 1114 Potter Brumfield P N KRPA5D6 12 P N 1122 Potter Brumfield P N KRPA5D6 24 P N 13927 P N 397 P N 14000 WAGO P N 236 332 12125 Harbour Reach Drive Suite B Mukilteo WA 98275 Telephone 425 583 1900 Telefax 425 493 1569 A 24 SER 161 Rev B 5 03 ZF Ma
224. scc 34 Ovetelimeduireltief bs uu en ac atem e ohh eigo eor qoe udo tab edo Aa EC te 3e Processor DIMENSIONS usais a rures bet he Bee MS cs See s d 3 1 PIOCCSSOMS ears ete ael ed 3 1 CONTEO FCGO S EE 3 2 a e TAOS SOS u ane t eu pd s ten Se aiU Lists dame eos qu did 32 CONTROLA EA Dt HARNES Eo EES Rud POWER START INTERLOCK CLUTCH PRESSURE EE ee oae am rus a 3 2 SERA E COMMUNICATION HARNESS ira lis ade iia cab a 3 3 Additional Harnesses vs A A A A A A ES 3 3 TABLE OF CONTENTS 31 4 4 31 4 5 31 4 6 3 1 5 31 547 3 1 5 8 959 4 319 82 9 158 9 3 1 5 8 4 31 5 9 31 5 10 94 50 35 102 chalet SPA SE 3 1 6 3716 13 3 1 6 14 31 615 331 6 16 32 3 2 1 3 2 2 3 2 3 3 3 3 3 1 4 4 1 4 2 4 2 1 4 2 2 4 2 3 4 3 4 3 1 Figure 4 1 Figure 4 2 4 3 2 2 9 2 1 4 3 2 2 Figure 4 3 4 3 2 3 4 3 2 4 4 3 3 4 3 3 5 Figure 4 4 4 3 4 4 3 4 1 4 3 4 2 4 3 5 4 3 6 4 3 6 1 4 3 6 2 4 4 4 4 1 Figure 4 5 4 4 2 Figure 4 6 4 4 3 Figure 4 7 4 4 4 4 4 4 1 NEO EE EE e AARNE OS art td A o Eds anui IOUS EICCHIC Cables x xo es AAA ES BRE AA ne E GOR BRET 3 3 CONTRO HEADELEOTRIC CABLE ud Eet 3 3 POWER START INTERLOCK CLUTCH PRESSURE ALARM ELECTRIC CABLE ans di ea tie nte eee cnt ate 34 P wer El ctrie Cable TCOUITE MENG ee ESAS SEAS ARA E A A 3 4 Stan Ihtelockibleowedgble meg eT Zar EE e RO E Vn per bo oe PE O O E A 3 4 Clutch Pressure Interlock Electric Cable Requirements meom Her een
225. senger Vessels 46 CFR 121 620 Subchapter L Offshore Supply Vessels 46 CFR 130 120 Subchapter T Small Passenger Vessels 46 CFR 184 620 121 620 Propulsion engine control systems a A vessel must have two independent means of controlling each propulsion engine Control must be provided for the engine speed direction of shaft rotation and engine shutdown 1 One of the means may be the ability to readily disconnect the remote engine control linkage to permit local operation b A multiple engine vessel with independent remote propulsion control for each engine need not have a second means of controlling each engine c In addition to the requirements of paragraph a of this section a vessel must have a reliable means for shutting down a propulsion engine at the main pilot house control station which is independent of the engine s speed control d A propulsion engine control system including pilothouse control must be designed so that a loss of power to the control system does not result in an increase in shaft speed or propeller pitch e All microprocessor or computer based systems must meet the requirements of part 62 in subchapter F of this chapter 130 120 Propulsion control a Each vessel must have 1 A propulsion control system operable from the pilothouse and 2 A means at each propulsion engine of readily disabling the propulsion control system to permit local operation b Each propulsion control system operable fro
226. some sources are polarity sensitive black wire negative red wire positive Additional Harnesses Throttle Harness The appropriate Throttle Harness should have been selected in Section 3 1 4 5 page 3 3 The Processors Throttle pigtail connects directly to the engine interface using this Throttle Wire Harness A Connect the plug end of the Harness into the Throttle pigtail connector at the Processor B Run the cable to the engine interface C Refer to the engine documentation for termination points at the engine interface D If Twin Screw repeat steps A thru C on the opposite side Clutch Harness A Plug the grey 12 pin plug into the Clutch pigtail connector at the Processor B Run the cables to the transmission C Plug the DIN connector into the Ahead and Astern Solenoids D Repeat steps A thru C for each transmission Page 4 3 Grommet 4 4 2 Sr qe gegen c 7 9 Figure 4 6 Processor Enclosure Cable Holes 12 4 4 3 5 Power Start Interlock Alarm Clutch Pressure INSTALLATION 4 4 Hard Wired Cable 4 4 1 Liquid Tight Connector Processor Enclosure All cables that enter the Enclosure must go through a Liquid Securing Nut Body Cable Mus oy of the Processor These connectors must be e assemb Tight Connector in order to maintain the moisture resistant d as shown in Figure 4 5 Processor Enclosure Cable Holes When hard wiring a Processor or installing addition
227. spection of the Control System may be the next step Even in situations where the problem was found and corrected it is good to always perform a careful inspection of the entire Control System each and every time you are asked aboard a boat Always verify that the installation of the System is in compliance with the Installation Manual by carefully inspecting the following B3 1 DC Power A Ensure that the Processor s is connected to a properly charged 12 or 24 VDC battery through a 10 Ampere circuit breaker B To ensure reliable power to the Processors an APS Automatic Power Selector is doe recommended The APS take inputs from two separate nme sources Whichever power source is at the higher voltage level will e automatically switched through Refer to Automatic Power Selector information in Appendix A B3 2 Component Location B3 2 1 Control Heads There are virtually no restrictions regarding the location of the 400 Series and MC2000 Series Control Heads as long as the bottom is protected from the environment The 500 Series Control Heads must be mounted to a console and the 700 Series are waterproof from top to bottom Refer to Appendix A Control Head Reference Sheet for Installation requirements B3 2 2 Processors The Processors are typically mounted in the engine room while maintaining a minimum distance of 4 feet 1 22m from sources of high heat and EMI Electro Magnetic Interference or RFI Radio Frequency Interference Ref
228. st Procedure i Turn power on to both Port and Starboard Processors Take command at a Control Head ii Move the Port and Starboard Control Head levers to approximately Ahead iii Turn power off to the Port side only 1 Port side will go to Neutral Idle 2 LED on the Port side of the Control Head in command will go off 3 The Port Control Head will no longer have command of the engine and gear 4 The Starboard Control Head will still have full command of the Starboard engine and gear iv Turn power on to the Port Processor Take command of the Port side 1 The Port Control Head will operate as usual Non volatile memory v Repeat test for Starboard Processor Page B 4 MMC 172 Rev Z R 3 05 ZF Marine Electronics LLC Mukilteo Plant Factory Authorized Sales amp Service Centers International ARGENTINA Carlos Dorian Friedlander 3205 Trimer S A mail PO Box 1772 Attn Mariano Castroverde 1000 Buenos Aires ARGENTINA ship Fray J S M de Oro 2030 40 1425 Buenos Aires ARGENTINA AUSTRALIA 6948 ZF Australia Pty Ltd mail Locked Bag 6305 Blacktown BC NSW 2148 AUSTRALIA ship 14 Lidco Street Arndell Park NSW 2148 AUSTRALIA BRAZIL 7000 ZF do Brazil S A Avenida Conda Zepplin 1935 CEP 18103 0000 Soroc BRAZIL CHINA 6953 ZF Shanghai Rep Office Room 2504 Jiangnan Building No 600 Luban Rd Shanghai 200023 PR CHINA DENMARK 7297 ZF Danmark APS Taastrupgaardsvej 8 10
229. stallation of the Clutch Pressure Switch is the same for both methods of operation Refer to Figure 8 3 or Figure 8 4 A Install a Shuttle Valve on or near the Transmission B Connect hydraulic line from the Ahead and Astern Clutches C Connect a hydraulic line that is no longer than 5 feet 1 524m and at approximately the same height between the Shuttle Valve dud the Pressure Switch D Connect the Power Wire Harness s Clutch Pressure Interlock cable to the Pressure Switch s normally open contact E Calibrate the Pressure Switch to close when adequate Clutch Pressure is reached Refer to the Transmission manufactures Installation Manual 8 3 Station Expander SE The Processor allows up to five Remote Stations The SE allows up to an additional four Remote Stations for a total of nine Stations The SE and Processor communicate via the Serial Communication cable Control Heads connected to the SE offer all of the functionality of a standard Remote Station For detailed information on the operation installation and adjustment of the SE refer to the Station Expander Installation Manual supplied with the Expander Page 8 3 CONTROL OPTIONS 8 4 8 5 Trolling Valve Operation If this option is going to be used please contact a ZF Marine Electronics Representative for further information Engine Room Only Remote Switch Station No 1 is typically designated as the Engine Room Station when this feature is used When th
230. t elevated rom e Provides redundant throttle and clutch signals in the event of a failure of the Main Control System May be selected at any time by the operator A full explanation of the installation operation and adjustment of the Backup Control System is ey DE in the Installation Manual supplied with the Backup System If this option is going to be used please contact a ZF Marine Electronics Representative for further information 8 10 Speed Boost There are four different Function Codes on os associated with Speed Boost FO F1 F2 and COMMAND F3 They all work in conjunction with each gien ort __ other to apply the right amount of speed boost TIME at the correct time and duration on No adjustments should be made to speed boost PRESSURE Br until Function Codes C2 Proportional Pause rem me C3 Proportional Time and C4 Proportional SPEED de ERA Pause Ratio have been properly adjusted COMMAND OUTPUT T Ch The primary function of speed boost is to IDLE mo an d from stalling when a heavy nen E load is applie ENGINE E Pam Without Speed Boost SPEED zs en Do Not attempt to adjust any of the Speed RPM Boost Function Codes until you have read the descriptions of their usage and have verified their need Figure 8 6 Speed Boost Usage Graph 8 10 1 Speed Boost Percent FO This Function programs the amount of throttle which will be applied when the load is first being applied to the
231. terference such as a lightning strike a If the error message is displayed once and you are able to clear the error take no further actions at this time If the error cannot be cleared replace the Processor b Component failure b Replace the Processor Page B9 5 TROUBLESHOOTING PROBLEMS WITHOUT ERROR CODES In addition to the Error Codes listed above some problems may not necessarily generate Error Codes The following give some examples where the Processor may not detect a fault though the operation may not be perfect Basic Control System Problems Without Error Codes B10 B10 1 A E SYMPTOM No audible tones heard at one Control Station when power is first applied to the Processor All other features function normally Cause Remedy a Incorrectly wired Station Harness Cable a Verify that the black wire is properly or Pigtail connected to pin 1 on the Control Head and Pin 8 at the Processor b The Control Head s Sound Transducer is b Measure the AC voltage at pins 1 amp 3 of the defective Control Head If 20 25 VAC is present replace the Control Head SYMPTOM The Control Head s red LED doesn t light when in command but otherwise functions properly Cause Remedy a Incorrectly wired Station Harness Cable a Verify that the brown wire is properly or Pigtail connected to pin 2 on the Control head and pin 2 at the Processor b The Control Head s red LED or circuit is b Measure the DC vo
232. the Control Head e Transfer Buttons can be monitored within the Diagnostic Menu A 1 indicates a closure depressed Transfer Button of the switch while a 0 indicates an open switch Station 1 Station 42 Station 43 Station 44 Station 4 5 Transfer Button Depressed Transfer Button Depressed Transfer Button Depressed Transfer Button Depressed Transfer Button Depressed 10 0 188 10 Figure B4 7 Example Display Control Head Transfer Button Status View Page B4 1 Function Code is Blinking 2 J TROUBLESHOOTING G Depressing the Up or Down Push Button one more time will show the current revision level of the software This feature will provide invaluable information in the years to come Determining the characteristics or capabilities of a certain Processor will be as simple as selecting this feature q9 Figure B4 8 Example Display Software Revision Level View H Pressing the Up or Down Scroll Push Button once more returns you to the Applied Battery Voltage Figure B4 4 I The Diagnostic Menu can be exited two ways Do not touch any Push Buttons for 5 minutes The system will automatically exit Depress the Left Push Button until H000 appears You may now scroll through the Set Up Menu Page B4 2 TROUBLESHOOTING B5 TROUBLESHOOTING AUDIBLE TONES As mentioned previously there are various tones emitted from the Control Head if an error were to occur B5
233. tion 5 5 3 page 5 11 utch Pressure Interloc 00 Not Installec 01 Installed 02 Throttle Clutch Pressure Interlock Mode E gnati nerok Delay os 00 5 to 10 0 Segonds Proportional Pause 00 In Gear 01 Neutral 02 Fixed Neutral Delay Enabled NOTE If C2 is set to 02 Pu setting of C3 will set Fixed Neutral Delay C8 Proportional Pause Time 04 j 00to99 Seconds C4 Proportional Pause Ratio 00 2 1 Ahead to Astern vs Astern to Ahead 01 1 1 Ahead to Astern vs Astern to Ahead Shift Solenoid Type 00 All Shift Solenoids except ZF Hurth with proportional solenoids 01 ZF Hurth with two 2 Proportional Solenoids with 12V Power 2 ZF Hurth with two 2 Proportional Solenoids with 24V Power ZF Hurth Duty Cycle Ahead 00 Top to 100 Duty Cycle ZF Hurth Duty Cycle Astern 00 00to 100 Duty Cycle Fixed Neutral Delay BN 00 0 to m Seconds In addition to any Proportional Del 23 nab Troll Lever Renee 01 20 Degrees Type 1 02 35 Degrees Type 2 03 45 Degrees Type 3 Throttle limited to 7596 of Throttle Range 04 55 Degrees Type 4 Throttle limited to 1096 of Throttle Range Troll Valve Function 0 Normal No Current when at Lock up 01 Inverse No Current when at Lock u p 02 Normal Maximum Current when at Lock up Preset for ZF220 550 12VDC Systems 03 Normal No Current when at Lock up Preset for ZF220 550 24VDC Systems 04 Normal No Current when at L
234. to the appropriate Station terminal block Do not tighten cable grip at this time Strip the PVC jacket and shielding back approximately 4 1 2 inches 114 3mm on the seven conductor cable Strip the wire 3 8 inch 9 5mm on each lead Pull the Shield wire back against the PVC jacket and slide and shrink a piece of 3 8 inch W X 1 inch L heat shrink over the cable as shown in Figure 4 8 9 5 C mm gt 3 88 9mm A 12263 Shield Heat Shri Figure 4 8 Seven Conductor Control Head Cable Shield Wire and Heat Shrink I Secure the seven conductor cable to the frame using a conductive Clamp Ensure that the Clamp and Shield wire come in contact with one another Refer to Figure 4 9 Page 4 5 INSTALLATION Top View Side View CLAMP FRAME OIG 00000000 amp LZ OT AS 4 a Jl FRAME O 12266A O CO O Figure 4 9 Clamp Views J Clip the Shield wire so that it is flush with the Clamp K Connect the conductors to the appropriate pins as shown on Table 4 1 using a small slotted screwdriver as shown in Figure 4 10 D Figure 4 10 Terminal Strip Cable Connections L Connect the other station s seven conductor cables to the appropriate station terminal strips in the same way Table 4 1 Processor Circuit Board Connections for Rem
235. ton until a solid tone is heard for one second Release the transfer button to activate transfer If equipped with Indication Panels the message Station X Rqsts Xfer will be displayed at all Stations A distinctive 1 2 second ON 1 2 second OFF tone pattern will sound at all Remote Stations for up to the time set with Function Code P1 Transfer Timeout C The Operator at the Station in Command MUST place the Control Head levers into the Neutral Idle position D Depressing the transfer button within the preset time relinquishes control If the Operator at the Station in Command does not press the transfer button within the preset time period the transfer process is aborted the text TEE disappears if so equipped and the tone is silenced If the Operator at the Station in Command does press the transfer button within the preset time period control is transferred to the new station the new Station in Command text will appear on the Panel and the text message will disappear E The Remote Station that requested control is now the Station in Command as indicated by the lit red LED s Transfer Request Sequence Request Relinquish Receive Mode P004 3 Step A At any Remote Station not in command place the Control Head lever into the Neutral Idle position B Depress and hold the transfer button until a solid tone is heard for one second Release the transfer button to activate transfer If equipped with Ind
236. tor is properly crimped to pin 6 at both connectors and there is continuity Ensure that the blue conductor is properly crimped to pin 7 at both connectors and there is continuity Replace Station No 9 Control Head Ensure that the green conductor is properly crimped to pin 6 at both connectors and there is continuity Ensure that the blue conductor is properly crimped to pin 7 at both connectors and there is continuity Replace Station No 10 Control Head Ensure that the green conductor is properly crimped to pin 6 at both connectors and there is continuity Ensure that the blue conductor is properly crimped to pin 7 at both connectors and there is continuity Clear the Error Code from memory Replace the Control Head Ensure that the orange conductor is crimped to pin 4 at both ends and the red wire is crimped to pin 5 at both ends of the Harness Ensure that the orange conductor is crimped to pin 4 of the connector and connected to pin 4 of the Control Head s terminal block In addition ensure that the red conductor is crimped to pin 5 of the connector and connected to pin 3 of the Control Head s terminal block Clear the Error Code from memory Replace the Control Head Ensure that the orange conductor is crimped to pin 4 at both ends and the red wire is crimped to pin 5 at both ends of the Harness Ensure that the orange conductor is crimped to pin 4 of the connector and connecte
237. ttle Cable Location 11 A 2 conductor shielded cable is required when hard wiring the engine to the Processor A Install a 1 2 inch Liquid Tight Connector into hole no 12 of the Processor B Run the throttle cable through the connector so that 4 inches 101 6mm of the cable is pulled through C Tighten the Liquid Tight Connector nut D Strip back the PVC jacket to within 1 2 inch 12 7mm of the enclosure Clip the shield wire to 3 4 inch 19 1mm of length Pull back the shield wire and solder to a 2 1 2 inch 63 5mm 18 AWG green yellow wire as shown in Figure 4 18 Ve 75 inch 19 1mm Cable of Cable Shield 12286 Solder Wire to Shield p inch 2 5 inch 63 5mm of 9 65mm 18 AWG Green Yellow Wire Figure 4 18 Engine Shield G Slide a 1 inch 25 4mm section of heat shrink over the soldered connection and shrink H The termination point on TB8 depends on the type of engine to which the Processor is interfacing The following table lists the termination points Table 4 5 Processor Circuit Board Connections for Throttle Throttle Type Termination DC Voltage 0 to 5 0 VDC Signal TB8 5 Return TB8 7 Current 4 0 to 20 0 mA Signal TB8 4 Return TB8 7 Idle Validation TB8 1 TB8 2 4 5 Engine Stop Switches n engine stop switch s must be located at all Remote Stations and capable of stopping the engine at any RPM Refer to the installation instruct
238. ttle command drops to Idle and the clutch will be commanded to Neutral The following items will cause this to occur An open or high resistance connection between the Control Head and Processor Out of calibration Control Head A defective Control Head A defective A D Converter in the Processor The exact cause of the malfunction can be found as follows A Check the Processor s Display for error messages Most likely one of error messages 13 thru 32 will be shown The exact number shown depends on which remote station is experiencing the problem and whether the command signal was too high or too low Enter the Diagnostic Menu as outlined in Section B4 Depress the Up or Down Scroll Push Button until the appropriate Remote Station is displayed The Remote Station are identified by the position of the decimal points Station 1 has no decimal point after the first digit to the far right The remaining three digits all have decimal points If the digit to the far left had no decimal point following it but the remaining three do this would represent Station 4 OW Station 2 Station 3 Station 4 Station 5 Figure B5 3 Display Examples of Remote Stations D The e in Figure B5 3 are shown with no Control Heads connected to any Remote Stations When a Control Head is connected the EE A D Analog Digital value for the present position of the Control Head s lever will be shown as in the examples below St
239. tton is a normally open momentary switch The only time the switch should close is when it is depressed to take command or when entering or departing various other functions In the event that the Transfer Button became stuck in the closed position the following will occur e The Transfer Button would have to be closed for 15 seconds or more e The throttle and clutch are not affected Asolid tone is heard from all remote stations until the button s contact opens or transfer to another remote station has taken place If a Control Head that is not in command has a stuck transfer button the following will happen If Control Head levers are positioned at Neutral Idle a solid tone is heard from all remote stations If Control Head levers are positioned other than Neutral Idle a three 3 second tone is heard from all remote stations Error Code 33 42 depending on which remote station will be shown on the Processor Display Command can be taken at any other operational remote station After one 1 second command can be at the remote station with the stuck button as long as the problem has been corrected by depressing the transfer button If a stuck Transfer Button is suspected this can be verified by looking at the Station Select status 1 or 0 as outlined in Section B6 3 page B6 2 An Error Code 33 42 will be shown on the Display depending on which Station is experiencing the problem Page Bb 1 TR
240. ure B5 9 B5 2 B5 2 1 Figure B5 10 B6 B6 1 B6 2 Table B6 1 B6 3 Figure B6 1 Figure B6 2 Figure B6 3 B5 B8 B8 1 Table B8 1 B8 1 Table B8 2 B9 B9 1 Table B9 1 COMPONER LOCH ION ee A eae eee i D ee B3 1 CODITOl A COGS eismod RR SAR AS AN OM A Mis dier CES B3 1 er B3 1 CCOmDODeHE CONCILION aa dr ERR EU RC a ee a ar B3 1 Control Heads ia tenti e RAS AS Ced B3 1 PIOCESSORS PP D we dae B3 1 Interconnecting Wiring and Harnesses iles B3 1 Examples of Components Internal External ue B3 1 TROUBLESHOOTING DIAGNOSTIC MENU B4 1 Bis vales ARA A A assai ae dS Ra ee aye ene a ea te heed ie B4 1 Display Troubleshooting Function EE EE B4 1 Display Troubleshooting Function BIINKING EE B4 1 Example Display of Applied Battery Voltage eee ee ss B4 1 Example Display of Tach Sensor Frequency scsi Ae re A ad Rm ee Re eei Ge ba hb Ge eh id Les B4 1 Example Display Control Head Lever Current Positions 0 00000000 es B4 1 Example Display Control Head Transfer Button Status View B4 1 Example Display Software Revision Level View B4 2 TROUBLESHOOTING AUDIBLE TONES Bb 1 Basie CONTO System REENEN Bb 1 SIOW REDCHUVE e B5 1 Slow Ee B5 1 One Long Three ShO TONES 2a Era Ri A A SHE eS B5 2 One Long Three Short Toner acutius Sunt er dana Sui SAR HES a OE Sed Bet DAS ES Bard B5 2 Display Examples of Re
241. urrent at minimum Shaft rotation L3 Troll Maximum Pressure Adjusts the amount of current at maximum Shaft rotation Sot maximum pressure Detail information on each function is found in Section 5 5 4 page 5 15 Transfer Functions PO Transfer Mode Selects the various options available when transferring from one Remote Station to another P1 Transfer Timeout In certain Transfer Modes selects the amount of time allowed for the transfer sequence to be completed Detail information on each function is found in Section 5 5 6 2 page 5 16 Troubleshooting Functions Basic Troubleshooting Functions HO Diagnostics Allows the installer technician to look at various inputs to the Processor H1 Return to Factory Defaults Returns all settings to the factory default values H2 Driver Fault Detection Enable Allows the Processor to monitor the clutch and or troll solenoids Detail information on each function is found in Section 5 5 5 page 5 15 2 12 Audible Tones Detailed information on the following tones are in Appendix B 2 12 1 2 12 1 1 Basic Processor Tones The Processor can produce numerous tones which inform the operator of the status of the system or if any faults were to occur These tones are emitted from all Remote Stations regardless of whether they are in command or not Slow hepetitive Tone 2 12 1 2 SCENE A This tone is normal when DC power is first applied to the System This tone indicates that
242. utral detent the red LED will discontinue blinking and remain lit steady After one second in Neutral the Processor will automatically reset to normal operation with full control of the clutches and engine G The next movement of the Control Heads lever will engage the Ahead or Astern clutch Normal Operation 2 8 High Low Idle The Control System provides the input to the engine so that it may run at the standard Idle speed typically adjusted at the governor or carburetor or it can provide a second elevated Idle speed 2 8 1 Low Idle The factory default setting is for Low Idle Only When the System is initially powered up it will always command Low Idle even when High Idle is selected 2 8 2 High Idle 2 on Idle is desired it may be programmed during Dock rials Page 2 4 OPERATION Se Idle is programmable up to a maximum setting of 20 of Full Throttle High Idle is automatically selected when in Warm Up Mode 2 8 3 Selecting Between High and Low Idle WARNING Personal Injury could occur if the following steps are not followed exactly Refer to Figure 2 5 when selecting between Low and High Idle or vice versa at the Station in Command C A The Control Head s lever s may be in the Neutral Control Head Ahead or Astern detents when making a selection Neo Acid B Depress and hold the transfer button for 1 2 second and or Astern Detent then release f the System was in Low Idle it will toggle t
243. ver is positioned to the Ahead Detent The Serial Communication Harness is not b properly installed The Processors are not programmed for twin screw Both Processors are set to the same ID number Function Code E7 Value is set to 02 Function Code E7 is set to 03 and no Tach Signal is present Solutions Place both the Port and Starboard Processor into Warm up Mode by Lea the Transfer Button while moving the Control Head levers to the Ahead detent Both Control Head s red LEDs should be blinking If not the 7 conductor s connections at pins 5 and 7 are reversed Ensure the Serial Harness plugs are fully inserted into the Port and Starboard Processor s Pigtails Scroll to Function Code A1 on both Processors and verify that the Value of both is set to 02 Scroll to Function Code AO and verify that the Port and Starboard Processors have different ID numbers Depending on the installation change the Value of E7 to 00 01 or 03 Determine why there is no Tach Signal present Page B11 2 TROUBLESHOOTING ZE B12 TROUBLESHOOTING CABLE HARNESSES The following Sections list the various Harnesses manufactured for use with the Processor These tables are invaluable when troubleshooting a suspected interface problem or when manufacturing your own Harnesses B12 1 Basic Control System Harnesses Table B12 1 Power Start Interlock Harness Pin Out PROCESSOR PIGTAIL ENGINE and BATTERY
244. very possible system option Your system may not include every available option for single or multi screw reverse reduction gear applications Only pens sections that apply to your specific installation are relevant to your vessel If additional options described within this manual are desired contact your dealer for availability compatibility with your system Manual Contents This manual is divided into 12 Sections which cover in detail the features and operation of your system Introduction Section 1 Operation Section 2 Planthe Installation Section 3 Installation Section 4 Set Up Procedures Section 5 Dock Trials Section 6 Sea Trials Section 7 Control Options Section 8 e Periodic Checks and Maintenance Section 9 ZF Marine Electronics Service Sheets Appendix A Troubleshooting Appendix B System Drawings Appendix C Basic Theory of Operation The ClearCommand Marine Propulsion Control System will hereafter be referred to as ClearCommand or System The System is electronic and requires a 12 or 24 VDC power supply one Processor per engine gear and one Control Head per remote station The ClearCommand commands the vessel s throttle and shift using a single Control Head lever One electric cable per Control Head lever connects the remote station s to the Processor s Only one remote station will have command at a given time and the Station in Command is indicated by a red light locat
245. vice Field Test Unit and Multimeter 5 5 System Programming And Adjustments NOTE 10D MULTIPLE SCREW APPLICATIONS The A1 Function must be set FIRST and the AO Function must be set SECOND The rest of the Function Values may be entered and stored in any order 10D NOTE Power must be turned ON to the Processors when programming or making any adjustments to the System NOTE In order to prevent nuisance alarms when first setting up a System some Function Codes take up to 5 minutes to become ACTIVE The Functions affected by this are the functions that rely on the Serial Communication such as AO A1 A2 A3 E7 and LO Cycling power Off then On expedites these features making the Functions available immediately RIR 5 5 1 Processor Functions 5 5 1 1 Function Code AO Processor Identification In applications where there is more than one screw the system must know which Processor is where Every Processor must have its own unique identifying number At no time can two or more Processors be identified by the same Processor Identification Number The available Values for this Function are 00 Default Value 01 02 03 04 and 05 NOTE If Processors are not connected by a serial communication cable leave the AO function code at Default Value NOTE In twin screw or more applications the Value of Function Code AO can be changed only after the Value in Function Code A1 has been changed to 02 or higher To change
246. y prior to resuming the Sea Trial x NOTE In multi screw applications the following tests must be performed on all engines During 10D D course of the Dock Trial and Sea Trials fill out the Trial Report Retain this information for future use 71 Full Speed Setting Electronic Throttle A Warm up the engine s and transmission s and slowly move into open water B Gradually move the lever s to Full speed C Ifsynchronization is installed disable synchronization as explained in Section 5 5 2 1 5 page 5 10 Ifthe engine RPM is low refer to Appendix B Service Field Test Unit Manual Ifthe engine RPM is high decrease by using Function Code E3 as explained in Section 5 5 2 2 3 page 5 11 D For twin screw applications check that matching Idle Demon and Full speed Control Head lever positions cause equal RPM in bot engines 7 2 Proportional Pause The proportional pause feature provides engine deceleration when making a direction change The pause is variable and in proportion to The Control Head e lever position prior to the reversal How long the Control Head s lever has been in that position prior to the reversal The pause is In Gear or at Neutral depending on the Function Code C2 Proportional Pause setting The sequence of events are as follows for the three different Reversal Pause types 7 2 1 In Gear Delay C200 The Throttle position drops to Idle The Transmission remains engaged in Ah
247. ynchronization Default Value 03 Active Closed Loop Synchronization reverts to no Synchronization if there is no Tachometer Sensor signal The Default Value is 02 To change the Value Refer to Sections 5 2 and 5 3 page 9 2 Function Code is Blinking A Scroll to Function Code E7 B Activate Set Up Mode C Scroll Up or Down to the desired Value D Store the Value to memory Figure 5 10 Display LED Function E7 Set Up Activated 5 5 2 2 Throttle Electronic Functions EO E2 E3 This section along with the Throttle Basic Functions Section allows the adjustment of Throttle electronics related items 5 5 2 2 1 Function Code EO Engine Throttle Profile This Function selects the appropriate Throttle Signal range for various engines The available Values for this Function are listed below 01 Caterpillar PWM 8 to 9296 02 Cummins Centry Voltage 0 9 to 4 5 VDC 03 eoe uas Quantum Bos 0 9 to 1 2 4 0 VDC 04 Detroit Diesel Voltage 0 64 to 4 65 VDC 05 MTU or MAN Current 4 0 to 20 0 mA 06 Scania Voltage 0 42 to 2 95 VDC 07 John Deere Voltage 0 5 to 4 5 VDC 08 Volvo Voltage 0 6 to 3 6 VDC 09 Detroit Diesel Frequency 120 64 to 360 9 Hz 10 Detroit Diesel Frequency 120 64 to 463 5 Hz The Default Value is set to 06 Scania Profile To change the Value Refer to Sections 5 2 and 5 3 page 9 2 Function Code is Blinking A Scroll to Function Code EO B Act

3830 - SO02471 [96202 SW15623_0H Dwg13068A] Donovan

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