MM12822 RvL 5-02 Handheld Installation Manual.book
Contents
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10. d dT dI IcI Nd MIJIS SUIS 51995 ON 10611 SUMABA
11. UN DNO 271 1621 ON lavd 9015 8 3715 SH3HIU A8 031 ddl 331SM8 SYSHLO 03179915 EE S00 XXX A L3Dd uu 10 XX 330 SOLINGNOD e SOLIMONDI c0 9 c JIVU 79 1 2 ar 2 10910 Nd Gavod LIMJATI NOSTIM W ONS Sana 0 508 8 T X08 NOLLINAC AV 138 81 183 73 S33H10 A8 O3I lads pl AOLINGNOD e ONIMVAQ NDILVTIVISNI 2 71 1621 OL G VIS Am o 2 Es 38 raawr EO 1 6286 VM NOLONITANME JAIXO JIJIJYd SIPI E SE JOA 30 I 038 094 fu el en VIS 90 NaML3a J0 278 EMO X m m 052 114142530 3190 A33 E 55 SNDISNAWIO ONTLNN Ol an Qa vDgav 15 RSEN LIN LIN LIN ADLIIJNNII ONY Salon 20 MW 8 0373841 3184 lt a IVWADH 0300Y 2478 WLIJ WU WU OL eo 03138471 3181 032 09 EH EIANF 2 0 Ac OS ZAW y ARE O y S id MOS 9 WDJ WO EL 2 VIS E la 2 39 10915 B cm Meses 7 ON ON 1 JN JN 9g IC O ce dOLS nog NAILS zal
12. DN ONG E Z 1 E121 ON Iavd d 3715 O31UN 5531 FA qe I Dico gavog LISTI 20 62 E 31Y0 DD 8 1 ava XD8 NOLLINAP AV138 NUS TIM W alles ONIMVAG NOTIVVIVISNI E Z I EIZI uus HB eres ET B DAY 80120002 Z 8 181 EEZBE YM NOLONITONS JAIXO II 1IVA z La TM hi El N rar ee TE JOA v aD 21 033 038 181 00 NOIIdIS2S30 3190 8 Jasa 1138 30 2v38 2078 O N Bu SNOISN3WIO b VIS YAN MN TANI TANI 77 SOLDINNO ONY S3LON 20 8 E E Ws sc KG 2 a 1 BO 30SS3J039 30140 9V T yg aaa8v7 318 2 X08 NOTLINAC AV 198 e v ON 0313847 3787 03 9 IMS zn C me 9 m B 5 19 O O 099 z MOSS 8 E Esch O S Zn an 49 0815 ogl 2 viS A x MOTTA O U ON ON 3 5 JN JN m 8 a 0 dOLS nog NASLS 98 O E J SSSHLO A8 O3IJddhs 301 ANION SOLINGNOD Z OSVOS 1102313 n SAJHLU Ag MUSS32U8d IDALNDI ud O Wm LIX 31041432034 051 OSI IE9ZISW SJSN E ETZI 11 31204143234 001 001 TE921SW S3SH 1
13. ON OMG EZ l E ON 19 3215 O3L0N SS31NM SAHHLU x ISN 031 15 GOO XXX M oa OMV pl JIVU 02 Way SUL ONU J NOSTIM W NAG ONS S33Nv33 101 A8 03 ldd ONIMVJQ NDILVTIVISNI 2 1 ETE Ne L un 3 3 I SOLIMON 70 EECBB YM NOLONITANG SAISU JIALIvd SIFI 83 La IE S VIS cL Bar ASHIVW AZ 9 JOA ve I 038 181 E 49119189530 2013 30 O N SN Bu 015N3 Y VIS YAAN RD PE PER 123NND2 ONY S3LON 20 MW a 2 gO UN UN UN 304 ONIMVAG 0300Y C a AOSSJIDA LVILLOV WE J WOJ WO 0 avi gy3 11 9 033 03 8 IMS TO F Dag mi Ne 9 g ESF a EO 033 SS napag O NO NO 09 ZAW NVI at v E B El e ys 9389 n O ON ON 2 3 SN JN 80 0 NOU nog NSILS 3snd L 1 N pe I N E Q O SI3HLO 031 T LIMON A8 OSVOS 11193152 NIVW OSS3IOAH IDSINDI 031 14415 M34 5 asvoa 110331 NOILINIF Av 738 43533 081 OSI IE 9ZISW SJSN E EbbI D d3338 001 OOI IEgZISW S3SH 2 EbbI 29193534 08 OS TE921SW S3SH I Errl L 21 i
14. 06811 ONG de dl 26r1 ON lava 401 E i A 58 AH 03179915 NIS S31SMaHL Salsa Q3I dns 10 530 vi MOG NAILS OMV 60 16 JIVU vdd SDLIMONO Z 301710405 NOSTIM W CO Hr 98 53283 101 S 3HID 03179915 ONIMVSQ NDILVIWLSNI d 42 41 2801 SOLINGNOD e g NOLONITANG JAIXO 21 2 SIPI ang ala _ SIJHLYN AZ TT JOA ve 50 21 038 5 033 2 DS Uqa LS 20 33v18 2 SN SN SN 03713841 318 2 RD ON TON ON i RO Ladd c D mu u NO NO Jv 18 33 23 9 gr 8v 033 JNVOSSVLS Di n B 53 ONSC a NO NO NO Fall 39 0815 ee 8 ON ON ON 5 JN JN JN HIV Id LJVIdd33a 401 MOS NSILS aL Ud Laud Ol 6 C J e va L SN3HID 5 ASSY OTIHONVH HLIM O3OT12NI LON 09713997 OMY yl 401 3NISN 3789 NUILO3NND2 NOTLVLS 50151905 2 davogay LS HLINIISX X 192b1 Nd SS3HLO A8 O3IJddhS 83925 gavOg 1103213 NOILINAP AY133 1 1 31v3S N NINTO IN V k JV J sed ZW LIX 312v143238 051 dOSI ZEIZISW S3SM JE 26b1 59179 ZW LIX 3719143338 001 dOOI ZE9ZISW S3SH
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16. 17 o Power zes sungen A 17 GOINST LLATION Sd e ee 18 6J Relay Box ar e et ai hrs 18 Figure 18 Relay Junction Box Par ada arado rada Far is 18 62 Receptatie a a EEE ei 18 Figur IO Receptacle Bulkhead Mounting sx oren asa EI eu 18 Figure 20 Receptacle Cable Strain Relief _ 19 6 2 1 Receptacle Protector with Hardwired Receptacles Optional 20 6 2 2 Receptacle Protector with Plug n Play Receptacles Optional 20 Figure 21 Receptacle Protector Dimensions 20 6 3 Receptacle Cable to Relay Junction Box 20 Figure 22 Junction Box Receptacle Cable Wiring Diagram 21 Od Power Cable Installa ote etn eee tra a le Qr dans Ned deed A 21 Figure 23 Junction Box Power Cable Wiring Diagram 21 6 gt Engine Stop Cable Installation 4 12 atum bad dina st ooh ect sc a a dae die b del ie 22 Figure 24 Junction Box Engine Stop Cable Wiring Diagram 22 6 6 Thr ster Cable Installation Optional au u raa Dr
17. Sa VI A8 l JOA ve dU cl d 20 9017 d Ava Ja HH Jiv Id d acts 031UN SSJINN h S00 XXX IHS IWS a 10 21 01 310 02 79 1 83 NOSTIM W NMO 79 dc NS ONIMY3IO NOIIVIIVISNI d2 d ISZI EECBG VM NOLONITAME MIST 21 1 E AZ 142 032 114142530 SLVG AG 4 ar 310N9v14 0300Y 20 E M V End gt Da N UAVUHAVI 7 Bez I S
18. 29 9 1 Handheld Unit and Relay Junction Box u u deu dde aa aa en 29 10 0 PARTS SOURCE 30 Table 22 Parts uha srta onda iia 30 NIMC 288 Rey C 7 0 ia 33 References Appendix A 1 1 0 TROUBLESHOOTING 1 1 1 Questions to ask before beginning troubleshooting 2 1 122 IMSPECTIONSOM Sy Steck eod diede Ne ole es 3 LS Lake Command uz o NI On cS uet ue neis suu A S 3 LA Command estint ua 4 1 555 tattons5c lect esto e ee letus ICM d pups lt 4 b6 Listot Possible Symptoms and Solullons u RRi Se ds E 4 1 7 Station Connection Cable Pin Out Plug n Play Only 5 Figure 1 Control Head Harness Pan Out erstere ee sasa sqa RU 5 Appendix B 1 Drawing 11442B No Thrusters Single Screw PN 1213 1 1 Drawing 11901 No Thrusters Single Screw PN 1213 1P 2P 3P 3 Drawing 11439B No Thrusters Twin Screw JPN 1214 1 2 3 5 Page 4 Drawing 11898 No Thrusters Twin Screw JP
19. er a LIX 312 163234 OS OS IEQZISW S3SH 1 El21 L NUISNHWICO UNI INHLW JINND L LIA 310V1d3238 E av Se ONY ZW 310438 GIJHONVI a 5 M wur GE 00 1 XO8 NOLLINMF 78621 05 114133330 SHV ld v NOLIN SI SNVAL SR e Bl Z VZ INN Or v QV3aHl 43425 319 15 D Dy 310438 CQ EHONVE 212 En RE jil A Eu qe We dOLS 3NION3 I ICI Nd 9225 I SUIS 19ISNAY L ON ATrrIT 9UIMEJQ 10611 deal Elel ON 14 d ED 031UN SSJINN h 600 XXX ERE ETS er 20 12 31v OO vat ava NUSTIM W NMO D HC CONS un SI3H1D A8 03179915 ONIMVSG NOIIVTIVISNI dE de dl EIZI bl 3IDLIMOND Z EEEBE NOLONITANG MIST JIdIJVd 7 47 Jan ve aD 214 038 8l O Nanl3a J0 IVIB SN SN SN ON ON ON lt 1 ald E WO NO J E X09 NOILINAF AV1323 O 23 ON 0373397 37979 k 038 9 db NOSSAIONd D ES MA m 5 SA napag O NO WD 09 ii 39 0815 7 d ENTER B ON ON ON 13 2 IN JN JN 05 2088 31Wld 319V1 43338 5 ASSY HLIM Q30R12NI LON Id8v1 318 2 9015 MOG 515 37184 NOLLISNNDI 1191 CHI9NJT X2 X 19ZY1 1 LJ SNSHIO A8 031 IddMs OMY yl 9015 SNION 50150005 2 SSAHLO A8 OSITddAS
20. 1 LJ SNSHIO A8 0317 OMY yl 9015 SNION 50150005 2 SSAHLO A8 OSITddAS MANTIS Gavog 110331 XO NOILINAr AV 133 71 291995 N NINIO 9SNILNII LV LIV ac SOM ZW LIS dadas OSI dOSI IE9ZISW SJSN dE Ert ZW LID 3719193333 001 dOOl IE9ZISW SJSN de Errl N N J SONIA 113 3JD9V143338 05 d0S IE9ZISW SJSN lt a NL NZ i 7 F soma ZW LIX 310V143238 a fa BEI av 52 ONY 2 and ZW 310038 GIHHONVH ne XO8 NOILINAr AV 13 78621 5 2 Xe JILSMSHL MUS 14142530 AWSLI m y NOD de ac dl EvvIi NOLING SSHSNVAL CO 2D NIW SL I I 331SMSHL MOG M38IS 3 79NIS ES U HHI H MV SNTE eds CJ 05 E 401 d dc dI trI Nd MITIS I SUIS 193snau 1 IUO 006 SUIMBIG
21. VIS 5 ao EX LC V CI 80 1904 1 L _ 21 oe as H8 IMS Di 31DV 143338 OST OSI ZE9ZISW SISN 121 4 IN 315193738 001 001 2 921SW 350 2 b121 e d LIX 31V1d3234 08 OS ZE9ZISW SJSN 1 121 v ze Cad NOLIN S3jJSNV31 me 2 vis raS lem 11 37091432440 oz La m 8n av Se ONY 907d ZW 310438 56 821 2 98 Sn E XD8 NOILJNHP AV133 78621 O Ss 14142530 l Yd 11 O m Is NDE c rene MINIS NIMI En gavog 1103313 8OSS3IDA4 IDSLNDI 301 1804 f 904 a 7 I pITI Nd MITIS ULA SI9JSNIUL ON 46EPII SUIMBIG
22. MANTIS Gavog 110331 XO NOILINAP Av 133 71 291995 N NINIO 9SNILNII IV k LIV ac SOM ld A LIA STV Las OSI dOSI IE9ZISW SJSN dE EIZI LIX SCIO be 3 001 dOOL IE9ZISW SJSN d se tel AS J SONIA 113 Soy lee S3SH dl Elel lt a NL SUE i i 7 7 soma ZW LIX 3707193999 E fa Ez av 52 ONY and ZW 310038 GIHHONVH XO8 NOILINAr AV 13 78621 5 2 Xe 14142530 WILI m y NOD de Y ac dl ElC NOLING SSHSNVAL 00 Z NIW SLID I MISIS 379NIS NV ES U HHI H gt a IS STA eges CJ 05 E 401
23. ON Lovd pe 8177 1715 SH3HIU A8 O3IJddhs E 0310N 5531 OMY Fl NIJ 600 XXX ETE en SOL MONO Z LAQA cO 9c E 310 Iva 2 Ol Q 10910 Nd Gavod LIMJATI 3 7 gt NOSTIM W ON3 ee leer 9 7 8 S33HID AB OSI dens XD8 NOLLINAP O La ADLINGNOD Z ONIMVSC NOILVTIVISNI Z l VIZI 2122 G VIS e O EECBE VM NOLONITANE JAIXO II DIVA SIPI z radar e 579 47 JOA v NO 21 038 038 En 22 ENS or NSMLJS J0 29978 ee 252202 O ar an E 025 011 9199 30 3190 8 pe ND ar SNUISN3WIO ONILNN ol go 0808315 Jr SOLIINNOD ONY SILON Z0 v B 037H8V1 318 2 lt a s S m 30 0300 4 2 8 IMS NOLLINAP AVTHB O ae cu MP co 03713977 37181 033 7 55 EA ro ao en E G5 GO MONG 9 VIS BE VIS g at 091S 1I 80 MOTA U J N JN 9g m dOLS nog 3515 35M4 o 9 TO ou COO SSSHLO A8 Iddns feta sl pl 0508 LITDSIJ SOL IMONDI e SOSS3IDeA WE Hamas IOSLNDI 3015 0 08 15 p N NIWIQ JNTINAHW SBLJINN O3I1ddNS 3455 EN i Hi 10910 NdILJ C1 CJ CJ EJ DJ CT 001 V p X preme LEPE mM 3 83 La 08 OL G VIS cuu 1 19 EC SAV ld v i OS Zl Ol SD Y2 JNM Ob v OV3BH EXE v VIS Tod
24. tioning Handheld may be approached in a similar fashion 1 1 QUESTIONS TO ASK BEFORE BEGINNING TROUBLESHOOTING Prior to getting heavily involved in making measurements with a Voltmeter it is advisable to find the answers to the following ques tions A How many Control Stations are there on the vessel e The Handheld must never be used as the Primary Control Sta tion Therefore there should be at least one other Station Check the operation of the Control System from the other Station s f the problem occurs from more than one Control Station the odds are that the Handheld Remote 15 not the cause of the mal function Ifthe problem only occurs at the Handheld Remote then further tests of that Handheld would be warranted B Are the Remote Handheld s LED s lit Understanding these various LED states may help point you into the cor rect direction or uncover the fact that what 1s perceived as a problem may actually be a Mode of Operation e The LED s will be in one of four states l Lit Steady 2 Not Lit 3 Blinking Slowly 4 Blinking Rapidly e When the LED is Lit Steady this indicates that the Handheld Remote is command and a normal operative mode e When the LED is Not Lit that station on that side is currently not in command Page 1 TROUBLESHOOTING Slow Blinking LED indicates that the Handheld Remote is currently in Warm up Mode e An LED which is Blinking R
25. 14 18 AWG TWIN SCREW ONLY STARBOARD ENGINE STOP CIRCUIT ___ TWO CONDUCTOR 14 18 AWG BOW THRUSTER OPTIONAL STERN THRUSTER OPTIONAL Figure 2 Plug n Play Typical Cabling Diagram Page 9 THEORY OF OPERATION The Handheld connects to a plug Receptacle This Receptacle 1s pre wired with three cables that are labeled as to their connection points Refer to Figure 3 One cable labeled RELAY JUNCTION BOX is for connection to the Junction Box One cable labeled PORT for Port and One cable labeled STBD for Starboard Actuator Processor connections These two cables are terminated with Deutsch connectors for the Plug n Play versions only Cable Labels Side View Pu of Receptacle STBD 10803C 2 s Detail 1 fear te Se PORT S G 3 gt T i RELAY JUNCTION BOX Receptacle and Cable for Hard Wired Connection SIDE VIEW OF RECEPTACLE mi CABLE LABELS CABLE TIES PS a HEAT SHRINK l1 _ lt SS RELAY JUNCTION BOX x
26. 9 Q 9 SU o C2 SS SYSHLO A8 O3I dans gt im dOLS 3NISN Liar AOLINGNOD e 08088915 NIVW S0SS3I0A4 3138 IDHINUJ 3018 cavogay Ls SAJHLU AS NOISNINIO UNIINIILW JINNU O311dANS 48425 10910 NNBODODODO As E 2 E 2 8 8 sup 52 001 c Lal 3 18a La 05 al G VIS 18 S33V1d v i 76 HHL ZI oi GO ve INN Or r QOv3aH Eg O ma x 80 1909 cuu zo JE _ uu 721 lt AILSMAHL MOS 0S g rm HAS 205 3199143938 OSI OSI ZE9ZISW SJSN 1621 59 a LID 31143238 001 OOI ZE9ZISW SISM 2 1621 LIX 3799193538 08 OS ZE9ZISW SISM 1 1621 ED Cad x NOLLNG 33J3SNV Fej ES vies 11 3DV1d3238 E oz LO O 80 gw 52 ar TE 911d ZW 310433 013HONVH 18621 2 JSM O XO8 NOILINAF AV138 v862 114193830 O 110 NHO ES So i e ASLSMAHL MOB HLIM M33IS NIMI G 05908 1103813 nl NIVW 30 37905 IOSLNDI 901 13Dd dOLS 3NIJNA a N T ISTI iNdl A949S UML 193SNAY L IUO SUMABA UN DMO de de 41 1501 UN lavd
27. Additional Lanyards are available refer to Table 2 on page 24 for ordering information N SUDDEN VESSEL WHICH MAY CAUSE S OR FATAL INJURY Figure 6 Control Knobs Vertical 2 4 ENGINE STOP SWITCH _ The Handheld is supplied with an Engine Stop Switch located engine stop switch at the top of the Handheld The Engine Stop Switch is ALWAYS operable when DC power is On to the Handheld System boro Figure 7 Engine Stop Switch The Handheld System does not need to be in command of the Actuator Processor to stop engines ARNING Each Station must have some method to stop the engine Connection of the Handheld Stop Switch to the engine s stop circuits is MANDATORY Refer to CFR46 SEC 62 35 5 and ABYC P 24 5 8 2 3 THRUSTER COMMAND OPTIONAL The Handheld Units for Thruster control are supplied with one or two Thruster switches The Thruster switches are located above and below the Transfer Button on the Hand Stern Thruster optional held Unit Bow Thruster optional Figure 8 DR Thruster command 15 ALWAYS operable when DC power Switches is On to the Handheld System The Handheld System does not need to be in command of the Actuator Processor or have the Safety Lanyard attached to command the Thruster Page 11 OPERATION 3 0 OPERATOR INSTRUCTIONS 3 1 SINGLE OR TWIN SCREW COMMAND A The S
28. aj Ud Laud C J E Be ASSY Q I3HUNVI LON 03 198 Y 37899 NOILISN 11915 HI9N319X X 192b1 Nd SSJHLU 031 lddlis S3 09s N Na3WIG LV k Bear lye NY i i ge OS l XZ XVW 00 2D NIN SL 19 AS Sov d v 6c B e XE A1JISTISHL MDE Sa SASHLO A8 O317ddM5 NID 331514 A8 031 nog OMY vl 30151005 Z 301510405 H UJ D O IN IN ko ON RO Lad E WO NO 3v 18 O 23 ON 033 7 JONVA D O AS NADA MO W WDD 0815 B ON 7 ON ON S JN IN JN IJV1d32dd 401 nog N331S tal SAJH10 A8 03114dMS OMY 9015 SNION SOL MONO QAVUHAV LS adsvoa 110331 AV ISA ss Di av 81 4051 2 SIS dE
29. gt x 11913A PN 14674 RECEPTACLE Receptacle and Cable for Plug n Play Figure 3 Side View of Receptacle and Cable The Relay Junction Box is wired to refer to Figure 1 on page 9 and Figure 2 on page 9 e DC Power Supply Engine Stop Circuit Port and Starboard for Twin Screw e One or Two Thrusters optional 2 3 SAFETY LANYARD The Handheld Unit is equipped with a Safety Lanyard with a Locking Key locking key This Safety Lan yard must be place to allow 18 operation of Handheld i Refer to Figure 4 Figure 4 Safety Lanyard Page 10 THEORY OF OPERATION NOTE DO NOT DISCARD LANYARD The Handheld System will not operate the Actuator Processor if the lanyard is not attached The lanyard 1s to be worn around the operator s wrist during Handheld operation In the event the locking key 1s pulled from 1ts socket e The main engine speed will reduce to Idle RPM e Clutch will shift to Neutral The Handheld Station may not regain command until both the follow ing have been accomplished Locking p The locking key of the lanyard has ct Vertical E been reinstalled in the Handheld Unit socket refer to Figure 5 les The control knobs are In the vertical position Refer to Figure 6
30. Technical Manual MM12822 NEN Page 31 PARTS SOURCE Page 32 MMC 288 Rev C 7 01 ZF Mathers LLC 1415 Pacific Drive Burlington WA 98233 3103 U S A 800 546 5455 360 757 6265 Fax 360 757 2500 References A REFERENCES 1 American Boat amp Yacht Council ABYC 3069 Solomons Island Road Edgewater MD 21037 1416 E 3 Wiring Identification on Boats E 9 DC Electrical Systems on Boats H 2 4e or 32 4g Ambient Temp 50 degrees C P 24 Electric Electronic Propulsion Controls 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 Society of Automotive Engineers 400 Commonwealth Drive Warrendale PA 15096 J1171 External Ignition Protection J1428 Marine Circuit Breakers J378 Marine Engine Wiring National Marine Manufacturers Association 401 North Michigan Avenue Chicago IL 60611 Underwriters Laboratories Page 33 Page 34 APPENDIX A 1 TROUBLESHOOTING 1 0 TROUBLESHOOTING As far as the Actuator or Processor 1s concerned the Handheld Remote operates the same fashion as a standard fixed Remote Control Station Therefore troubleshooting a suspected malfunc
31. ae io 23 6 6 1 Thruster Cable Connection at Junction 23 Figure 25 Junction Box Thruster Cable Wiring Diagram 23 6 6 2 Thruster Cable Connections at the Thruster 23 6 7 Receptacle Cable Installation to Actuator Processor 24 6 7 1 Port and Starboard Hardwire Receptacle Connection 24 Figure 27 Actuator Processor Watertight Cable Grip Installation 24 Figure 26 Typical Connections at Thruster us Ginea rt dt Pus qs 24 6 7 2 Port and Starboard Plug n Play Connection 25 26 WAGO ras odiada o XU ka ta EDS o data ena a 23 Figure 29 Typical Connections at 23 7 0 ADJUSTMENTS AND TESTS SECURED TO DOCK 26 21 Handheld Unit Ene ines SIUDDEG uu dos A watu ae asi e 26 72 Engine Stop switches Test Engines Runnin ur zwar IR I BE 26 7 3 Optional Thruster Switch Test Engines 21 8 0 ADJUSTMENTS AND TESTS UNDERWAY 28 9 0 MAINTENANCE
32. cable to ensure seal integrity See Figure 20 on page 19 SUGGESTED MOUNTING UGGESTED MOUNTIN Use the supplied protective cap and chain when Receptacle 15 not in use by the Handheld Unit Refer to Figure 15 TO HAND HELD Figure 14 Receptacle Mounting Location PN 13522 RECEPTACLE PROTECTOR e f Receptacle is to be mounted on PROTECTIVE CAP DO HANDHELD oe the deck or area of bulkhead that is PN MX00668 D L MSS LOCKWASHERS not protected a Receptacle Protec USESEALANTBETWEEN tor should be used Refer to Fig RECEPTACLE FLANGE AND RECEPTACLE PROTECTOR Figure 15 Receptacle Protector Assembly ure 15 3 2 HANDHELD LOCATION 6 20 Refer to Figure 11 on page 13 for 3 30 A MAE optional Bracket Mounting Dimen sions It 1 recommended that the Handheld 1s stored 1n a Bracket Mount to protect the Handheld from damage when not in use 10915E Figure 16 Handheld Dimensions 5 3 RELAY JUNCTION BOX LOCATION Reference Figure 17 Considerations The Relay Junction Box 1s water resistant but should be mounted in a dry location Page 16 PLAN THE INSTALLATION 6 00 A e Mount in any attitude easily accessible for 152 4mm Pa e 8 00 203 2mm electric connections Bulkhead mount is pre 3 00 ferred 76 2mm A FL e Do not mount to the engine or transmission or any location that will allow excessive Watertight Cable Grip vibration e
33. clamps or straps not more than 18 inches 0 5m apart unless contained in a conduit Install each cable so it is protected from physical damage Refer to Figure 20 page 19 B Remove the Relay Junction Box cover see Figure 18 on page 18 C Run the cable through a watertight connector supplied on the Relay Junction Box D Strip cable Jacket then strip each wire 3 8 inch 9 5mm E Install fork crimp terminals included with Relay Junction Box Thomas amp Betts PNF14 6SLF or equal F Connect two conductor cable ri 12 24 s DC setn NS K2 K4 K6 D 10947A DC Power ON ON ON PORT WOO WOD WOD Figure 23 Junction Box Power Cable Wiring Diagram Page 21 INSTALLATION G Replace Relay Junction Box cover 6 5 ENGINE STOP CABLE INSTALLATION A Install the cable between the Relay Junction Box and the Engine Stop Circuits CAUTION When installing the cable support the cables using clamps or straps not more than 18 inches 0 5m apart unless contained in a conduit Install each cable so it is protected from physical damage B Remove the Relay Junction Box cover see Figure 18 on page 18 C Run the cables through a watertight connector supplied on the Relay Junction Box D Strip cable jacket and then strip each wi
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35. returns to Neutral and Idle TAKING COMMAND In order to take command with a Handheld Remote two things must be true l The Handheld s Command Signal must be at the Neutral Idle position 2 The Handheld s Station Select signal must be pulled low when the Transfer Button is depressed Page 3 TROUBLESHOOTING 1 4 COMMAND SIGNAL TESTING This signal should be tested at the Actuator or Processor The signal 1s tested as follows A Measure the DC Voltage at Pins 5 and 7 yellow and blue wires at the Processor or Actuator Station to which the Handheld s connected This s referred to as the Reference Voltage Vref The measurement should be between 4 80 to 5 00 VDC B Measure the DC Voltage between Pins 5 and 6 yellow and green wires This 1s the Command Voltage With the Handheld commanding the Neutral Idle the measurement must be 48 to 50 of Vref 1 5 STATION SELECT TESTING This signal should be tested at the Actuator or Processor and 1s tested as follows A Measure the DC Voltage at pins 3 and 4 red and yellow wires The measurement should be 4 80 to 5 00 VDC B Continue to measure the DC Voltage at P ns 3 and 4 while the Handheld s Transfer Button s being depressed The measure ment should be lt 0 50 VDC 1 6 LIST OF POSSIBLE SYMPTOMS AND SOLUTIONS If a problem were to arise with the Handheld Remote the following are some of the most likely problems you may encounter and
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39. 18 inches 0 sm apart unless contained in a conduit Install each cable so it is protected from physical damage 6 6 1 Thruster Cable Connection at Junction Box A Remove the Relay Junction Box cover Refer to Figure 18 on page 18 B Run the cable through a watertight connector supplied on the Relay Junction Box C Strip the cable jacket then strip each wire 3 8 inch 9 5mm D Install female crimp terminals included with Relay Junction Box Thomas amp Betts RB14 250F or equal E Make cable connections at the Relay Junction Box as indicated n Fig ure 25 To Bow To Stern Thruster Thruster optional optional lt gt Fi STBD ON ON PORT WOO WOO gt 8 2 NO STBD 9 5 10947A Thruster 5 STOP Figure 25 Junction Box Thruster Cable Wiring Diagram F Replace Relay Junction Box cover 6 6 2 Thruster Cable Connections at the Thruster A Make connections at the Thruster Refer to the information supplied with the Thruster and Figure 26 page 24 CAUTION The Thruster Relays have normally open maximum 20 ampere and normally closed maximum 10 ampere contacts Page 23 INSTALLATION Thruster Solenoids Rel
40. 2 Adding information on the Plug n Play Handheld Review complete man ual for all additions and changes L 7 02 Revised Figure 3 Receptacle and Cable for Plug n Play Artwork 11913 to A per ELR 781 THEORY OF OPERATION 1 0 THIS MANUAL The purpose of the Handheld manual 1s Operation Section 3 0 e Installation Section 6 0 e Troubleshooting Appendix A 1 Keep this Manual on the vessel for future reference Throughout this manual special attention should be paid to the following NOTE Contains Helpful Information CAUTION Damage to equipment could occur if this message is disregarded x ARNING Personal Injury could occur if this message is disregarded 2 0 THEORY OF OPERATION The Handheld Remote Control System hereafter referred to as Handheld System s offered as an accessory for MicroCom mander ClearCommand or CruiseCommand Propulsion Control Systems hereafter referred to as Actuator Processor The Handheld System 1s utilized as a secondary Station while the primary Station 1s generally a fixed Bridge Station 2 1 FEATURES Handheld Systems offers Command of the vessel s main engine speed and direction Engine speed limited to approximately 80 Station in Command indication LED Push button station transfer Main engine emergency shutdown Engine Stop Switch e Safety Lanyard Optional e Thruster Control e Stainless steel mounting bracket Page 7 THEORY OF OPERATION
41. Actuator Processors Page 8 THEORY OF OPERATION Engine Stop Switch Bow Thruster optional 3 Stern Thruster optional E Hand Ha P Cable Length 25 feet 7 62m Receptacle Kit MS12631 Single Screw E or MS12632 Twin Screw Starboard Actuator Processor or Single Screw Eight Conductor Port Actuator Processor Eight Conductor Twin Screw Only Y Y y DC Power 12 or 24 VDC Relay Port Starboard Two Conductor 14 AWG or l E Dar on Actuator Actuator Box Processor Processor Port Engine Stop Circuit Two Conductor 14 18 AWG Twin Screw Only Starboard Engine Stop Circuit Two Conductor 14 18 AWG Bow Thruster optional 10905B Stern Thruster optional Figure 1 Pluggable Handheld Typical Cabling Diagram ENGINE STOP SWITCH WT STERN THRUSTER OPTIONAL BOW THRUSTER OPTIONAL HAND HELD RECEPTACLE KIT MS12631 SINGLE SCREW OR MS12632 TWIN SCREW Y e STARBOARD ACTUATOR PROCESSOR OR SINGLE SCREW EIGHT CONDUCTOR PORT ACTUATOR PROCESSOR EIGHT CONDUCTOR TWIN SCREW ONLY DC POWER 12 OR 24 VDC TWO CONDUCTOR 14 AWG OR LARGER 2 PORT STBD PROCESSOR PROCESSOR BOX PORT ENGINE STOP CIRCUIT 11902 TWO CONDUCTOR
42. Cable Extension 25 feet 7 62m e Additional Receptacles e Receptacle Protector e Additional Handheld Units Additional Safety Lanyards ZF Mathers LLC offers several different configurations of Handheld Systems Refer to Table 1 for a list of Handheld System configura tions Refer to Appendix B 1 Drawings for Installation Drawings Table 1 Handheld Systems ZF Mathers Part Number Handheld Systems Single Single Screw Twin Twin Screw Cable Length in Feet Screw Plug n Play Screw Plug n Play Main Engine Control Only 1214 1P 50 feet 15 24m 1214 2P 100 feet 30 48m 1214 3P 150 feet 45 72m One Thruster Control 1251 2P 100 feet 30 48m 1251 3P 150 feet 45 72m 1492 1P 50 feet 15 24m 1492 2P 100 feet 30 48m 1492 3P 150 feet 45 72 m Main Engine Control and Two Thruster Control Main Engine Control and 1251 1P 50 feet 15 24m 2 2 TYPICAL CABLING Refer to Figure 1 for a typical cabling diagram of a Pluggable Hand held System This diagram demonstrates all connection options for the different variety of Pluggable Handheld Systems available Refer to Figure 2 for a typical cabling diagram of a Plug n Play Hand held System This diagram demonstrates all connection options for the different variety of Plug n Play Handheld Systems available Refer to Appendix B 1 Drawings e for the Handheld System being used with this vessel e connections to the Handheld System e connections to the
43. Drill four mounting screw holes at mounting location B Place Receptacle Protector over the Receptacle L 38 1mmy 7 6 Am TYP C Secure Receptacle Protector to bulkhead with 4 screws 1 50 4mm 38 1mm TYP 6 2 2 Receptacle Protector with Plug n Play Receptacles Optional 300 1 Me ira See Figure 21 for Receptacle Protector dimensions A Remove the four screws holding the 0 218 5 5mm THRU d Tm Receptacle to the Bulkhead CSK 400 10 2mm x 82CSK THRU 4 PLACES B Place Receptacle Protector over the Receptacle 443mm us C Secure Receptacle Protector and the EN de Receptacle to the bulkhead using the 4 screws removed in Step A Y Figure 21 Receptacle Protector Dimensions 6 3 RECEPTACLE CABLE TO RELAY JUNCTION BOX CAUTION When installing the cable support the cables using clamps or straps not more than 18 inches 0 5m apart unless contained in a conduit Install each cable so it is protected from physical damage Ensure cable is not under stress or strain at the Receptacle Refer to Figure 20 page 19 A Remove the Relay Junction Box cover refer to Figure 18 B Run the cable labeled RELAY JUNCTION BOX through a watertight connector supplied on the Relay Junction Box C Strip the cable jacket then strip the black red orange brown green and yellow wires 3 8 inch 9 5mm D Insta
44. Handheld Installation Manual MM12822 Rev L 7 02 Table of Contents Handheld RT 1 MM12822 Rev L 7 02 Table Of Contents m RR IRRE la 3 MINIT 2822 REVISIONS List ses kiq ERS u IS RS elle 6 DO THIS VAN DAD er tet eee 7 20 THEORY OF OPERATION nee ee 7 7 Table Ts Handheld Systems A I PLU AVI CM C NE ae nen Md EIE 8 AA AS iri ja said ta Cd E ae 8 Figure 1 Pluggable Handheld Typical Cabling Diagram 9 Figure 2 Plug n Play Typical Cabling Diagram 1 1 9 Figure 3 Side View of Receptacle and Cable 10 2 3 Daley ANA 2 3 auto ie PEE A a een 10 Figure 4 Satety any ard eu 25 55 anode ae v pair d Seca E ND 10 Figure Locking Key 6 o sibarita taa a ANA 11 Fig re 6 Control Knobs Vertical AE AA AA ua Re 11 e e MA A ee 11 Figure Engine Stop Switch un e c oe eee ERES ales 11 2 5 bhri ster Command Optional s cadres we eate on eed oe ee OR EOD qox tet 11 Figure Thruster Switches a she eee e ka ba kuk 11 3 0 OPERATOR INSTRUCTIONS 12 3 1 Single OF Lwin Screw Command sac si a re nee 12 9 Statio
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46. Locate away from heat sources such as engine exhaust manifolds e The Relay Junction Box uses electronic cir cuits that can be influenced by strong mag netic fields and static charges Allow 4 feet 12m Of clearance between the Box and alter Figure 17 Relay Junction Box Dimensions nators or electric motors 5 4 ENGINE STOP SWITCH It is a requirement that Engine Stop Switches are available at all Sta tions The Handheld contains an internal Engine Stop Switch that requires connection to the engine s stop circuit This switch 1s ALWAYS active when power is supplied to the Handheld 5 5 DC INPUT POWER The Relay Junction Box must be supplied with 12 or 24 VDC power supply protected by 2 ampere rated circuit breaker The shipyard pro vides circuit breaker Page 17 INSTALLATION 6 0 INSTALLATION CAUTION Static electricity can destroy electronic components Anytime the Actuator Processor cover is off use an anti static wrist strap and connect it to the Actuator Processor frame This will drain any static charge you may have on your person OTE Refer to the Technical Manual supplied with your MicroCommander ClearCommand or CruiseCommand Control System for reference when connecting the Handheld System to your current control system 6 1 RELAY JUNCTION BOX CATUION Static electricity can destroy electronic components Connect the wrist strap provided to the Junction Box frame whenever working on t
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48. N 1214 1P 2 3P 7 Drawing 11441B One Thruster Single Screw PN 1443 1 2 3 9 Drawing 11900 One Thruster Single Screw PN 1443 1P 2P 3P 11 Drawing 11438B One Thruster Twin Screw JPN 1251 1 2 3 13 Drawing 11852A One Thruster Twin Screw JPN 1251 1P 2P 3P 15 Drawing 11440B Bow Stern Thrusters Single Screw PN 1444 1 2 3 17 Drawing 11899 Bow Stern Thrusters Single Screw PN 1444 1P 2P 3P 19 Drawing 11437B Bow Stern Thrusters Twin Screw PN 1492 1 2 3 21 Drawing 11896 Bow Stern Thrusters Twin Screw JPN 1492 1P 2P 3P 23 Page 5 MM12822 Revisions List Date Revision Description Previous Revision were not documented J 1 02 Added Revisions List Rewrote complete manual Review complete manual Added Troubleshooting Section under Appendix 1 and moved draw ings to Appendix 1 Drawing in Appendix B 1 revised to A K 3 0
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51. apidly indicates that the system is operating n Troll Mode Are any tones generated when the problem occurs e The Handheld Remote does not have a Sound Transducer and therefore does not produce any tones Since a vessel must have at least one Fixed Remote Station which does have a Sound Transducer a tone could be heard 1f one were generated Depending on whether the Handheld is connected to a ClearCommand or a MicroCommander system up to seven dif ferent tones could be generated These tones are as follows l Slow Repetitive This tone indicates that power has just been applied to the Control System and no Remote Control Station is in command This tone cannot be a result of a Handheld Remote prob lem Fast Repetitive This tone indicates a Servo Jam or the inability of the Push pull cable to get to a commanded position Once again the Remote Handheld cannot be the cause of this tone Steady This indicates that voltage has dropped too low to the Actuator Processor or that a component has failed on it s Circuit Board In either case the problem cannot be caused by the Hand held Remote Tone Over Tone This 15 a tone which indicates a potential problem with command of a Trolling Valve This is not something which can be caused by the Handheld Remote One Long One Short Indicates that the number 1 Servo s feed back is out of range This cannot be caused by the Handheld Re
52. ay Junction Box U N O To Other Controls Starboard COM V or V IWV or V 10952A Figure 26 Typical Connections at Thruster 6 7 RECEPTACLE CABLE INSTALLATION TO ACTUATOR PROCESSOR 6 7 1 Port and Starboard Hardwire Receptacle Connection Run 8 conductor cable labeled PORT from the Receptacle to the Port Actuator Processor and the 8 conductor cable labeled STARBOARD to the Starboard Actuator Processor CAUTION When installing the cable support the cables using clamps or straps not more than 18 inches 0 5m apart unless contained in a conduit Install each cable so it is protected from physical damage NOTE For Twin Screw Applications repeat the following on both the Port and Starboard Actua tor Processor A Remove the Actuator Processor cover B Connect the wrist strap to your person and the ground connector to the Actuator Processor frame CAUTION When not working on the Actuator Processor keep the cover in place to prevent dam age to circuits C Install a watertight cable grip on the Actuator Processor Watertight 7 Cable Grip A Q O ig 5 SN ae Hole P Ent Cable l PAR ug Entrance EN Cable Grip Body E 2 Watertight Push ET j Cable Grip Figure 27 Actuator Processor Watertight Cable Grip Installation D Strip the PVC jacket and shielding back approximately 3 inches 75mm CAUTION Stagger wire lead length to match the Station terminal stri
53. cure the protective cap s chain Protective cap and chain are supplied with the Receptacle Kit F From the inside secure the cable for strain relief Strain relief 1s to be supplied by the installer Strain Relief Required Receptacle G Once strain relief 1s complete run the electrical cable labeled RELAY JUNCTION BOX to the Relay Junction Box location 3 0 sz 76 2mm MIN Figure 20 Receptacle Cable Strain Depending the type of Handheld used e run the PORT cable to the Port Actuator Pro cessor STBD to Starboard Actuator Proces sor Plug a Station Connection Cable into the Port Connector Run the Station Connection Cable to the Port Actuator Processor Do the same for Starboard CAUTION When installing the cable support the cables using clamps or straps not more than 18 inches o 5 apart unless contained in a conduit Install each cable so it is protected from physical damage Ensure cable is not under stress or strain at the Receptacle NOTE When Receptacle is not in use ensure the protective cap is in place CAUTION When connecting plugs ensure that the release button or buttons are depressed and held until plug is fully connected or disconnected NOTE Additional Receptacles are available Refer to Table 2 on page 24 Page 19 INSTALLATION 6 2 1 Receptacle Protector with Hardwired Receptacles Optional See Figure 21 for Receptacle Protector dimensions A
54. e power leads are reversed 4 Control is lost for 4 A loose Safety Lanvard is sus 4 Properly install the Safety lanyard no apparent reason and the Gears and Engines go to Neu tral Idle pected if both port and starboard loose control 4a A loose connection of the yel low green or blue wire 4b There s a defective potenti ometer in the Handheld 4a Check the connections and perform the Command Signal Test 4b Replace the Handheld 1 7 PROCESSOR Termination A Conductor Color 8 1 Green Yellow N C Chassis Pin 2 LED Power 2 10 4 20 VDC DC Return for green 8 BLACK Tone 7 BLUE 5 VDC V REF 6 GREEN Signal 5 RED Ground boe 112990 STATION CONNECTION CABLE PIN OUT PLUG N PLAY ONLY Femme A 1 GREEN YELLOW SHIELD 2 BROWN Red LED 3 VIOLET Sync LED 4 ORANGE Transfer Button Plug Connector Starboard LED i Figure 1 Control Head Harness Pin Out 8 4 Orange Ping Station Select Transfer Button 5 00 VDC 0 00 VDC when depressed mE CO Command en _ in VREF Reference Voltage 4 80 5 00 VDC 88 Black Pini Alarm Tone 20 25 VAC when present 20 25 VDC when not present Page 5 TROUBLESHOOTING Page 6 APPENDIX B 1
55. eceptacle hook up is correct Page 27 ADJUSTMENTS AND TEST UNDERWAY 8 0 ADJUSTMENTS AND TESTS UNDERWAY ARNING Verify that all previous tests are completed and are correct Only then is the vessel ready to leave the dock DO NOT attempt to operate the Handheld away from the dock with any system abnormality A Apply DC power to the Handheld System The Control Head at each remote station will produce an intermit tent tone C Verify that Handheld Knobs are in the vertical position Refer to Figure 10 on page 12 D Depress the Transfer Button on the Handheld The red indicator light on the Handheld Unit should light showing that the Hand held is now in command Note that both red indicator lights must be lighted on dual Handhelds E Move the Handheld Knobs full Ahead and full Astern This will check that the Handheld 15 operating NOTE When the Handheld is the Station in Command throttle is limited to 80 of full Throttle when in full Ahead and full Astern Page 28 MAINTENANCE 9 0 MAINTENANCE 9 1 HANDHELD UNIT AND RELAY JUNCTION BOX The Handheld Receptacle and Relay Junction Box do not require scheduled maintenance but should be inspected periodically for cracked frayed or damaged cable covering Verify watertight integ rity of buttons and switches Page 29 PARTS SOURCE 10 0 PARTS SOURCE Table 2 lists the Handheld System s Parts available from ZF Mathers LLC Contact In
56. he Box This will drain any static charge you may have on your person CAUTION When not working on the Relay Junction Box keep the cover in place to prevent dam age to circuits BOX Cover B Mount the Relay Junction Box with 4 screws included with Relay Junction emove the kelay Junction Relay Junction Box 274 Screws g Caer Box Refer to Figure 17 on page 17 a Grip nelay Junction Box for Relay Junction Box dimensions and EE Su location of mounting screw holes C Replace the Relay Junction Box cover Figure 18 Relay Junction Box Parts 6 2RECEPTACLE Protective Cap Secure with screws Secure Protective Chain Place sealant around the Bulkhead hole Receptacle I Drill hole throughBulkhead Refer to Appendix 1 ES Drawing for appropriate size 11279 Figure 19 Receptacle Bulkhead Mounting A At the location decided to house the Receptacle cut a hole through the bulkhead Refer to the Appendix B 1 drawing for the type of Handheld being used for Receptacle Plate mounting dimensions and hole size of cutout Receptacle Cables Page 18 INSTALLATION B From the outside feed Receptacle cables through the hole in the bulkhead C Place sealant around the bulkhead hole D Place Receptacle into the bulkhead hole E Secure with 4 screws Use one of these screws to se
57. ll the fork crimp terminals included with Relay Junction Box onto the ends of the wires Thomas amp Betts PNF18 6SLF or equal E Make the cable connections within the Relay Junction Box as indicated on Figure 22 on page 21 Page 20 INSTALLATION Replace Relay Junction Box cover TB1 Blue Violet and Drain wires O are D o E o Not connected E Black 3 DC Return 3 Q lt z Rede 4 ES KG Cable labeled Port Bow Thruster RELAY JUNCTION Orangen ues BOX from the Browne Starboard Bo ruster Rece ptacle Port Stern Thruster O e 3 a Sten Thrusten 2 Yellow 8 5 E 2 K5 10947A Recep Cable STOP BOW STERN Figure 22 Junction Box Receptacle Cable Wiring Diagram NOTE Additional Receptacles are available Refer to Table 2 on page 24 CAUTION Two Receptacles can be wired to the same location at the Relay Junction Box but MUST be wired to their OWN Station Terminal at the Actuator Processor 6 4 POWER CABLE INSTALLATION A Run the length of two conductor power cable between the DC Power Supply and the Relay Junction Box CAUTION When installing the cable support the cables using
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59. mote One Long Two Short Indicates that the number 2 Servo s Feed back 1s out of range This cannot be caused by the Handheld Remote One Long Three Short This tone indicates the Command Signal of the Station in Command is out of range Unlike all of the previ ous tones this one may indicate a problem with the Handheld Page 2 TROUBLESHOOTING Remote Details for testing this can be found in the Command Sig nal Testing Section 1 4 page 4 1 2 INSPECTION OF SYSTEM Once you have the answers to the above questions there 1s a very good chance you have pretty good idea as to what could be causing the trouble In any case before you get heavily into troubleshooting it is a good practice to review the Drawing in Appendix B 1 Become familiar with the various components listed and their location on the vessel Carefully inspect the following Are the components installed in a location which 1s consistent with the recommendations of this manual e Is the condition of the various components acceptable Are the interconnecting wires terminated properly and free of corrosion The primary function of a Handheld Remote is to control a vessel s speed and direction If a malfunction were to occur 1t would more than likely fall into one of the following categories Cannot gain command with the Handheld e The actual Throttle Gear selected is different then what is com manded e Command is lost
60. n Transfer corned ae ae a ee dea ade 12 Figure 10 Taking Command at the Handheld 1 12 Figure 11 Optional Bracket Mounting 13 3 2 Moving from One Receptacle location to Another 13 Pieure2 Receptacle Protective C ap css etse ons di coe he qha re eee aed 13 3 9 4 hruster Control Optional seres aa Sheet AA base i ae ee ee ae eee 13 Figure 13 Bow amp Stern Thruster Switches ici rear 14 4 0 REQUIRED PARTS AND 1 8 15 As A O D ME 15 AD Tools Required OF Installat on aci 15 4 9Jandheld Remote Control a ERE SAO a rai 15 5 0 PLAN THE INSTALLATION l a l m a u da Coe ee 16 SA Receptacle Lokalen ee bl De aed Ae eee ki 16 Figure 14 Receptacle Mounting Location 16 Figure 15 Receptacle Protector Assembly 16 S Li iO eee ord cba A sehr cto ied g ad 16 Figure 16 Handheld Dimensions 2 39 22 opa ote IA A qasa us PES aq asua NAS 16 2 2 Relay Jane io Box Location cai ds da nenne Ra ee a h 16 Figure 17 Relay Junction Box Dimensions 17 34 Eneine
61. nto the receptacle sleeve until secure C Verify that the Engine Stop Switch on the Handheld stops the engine when switch 1s depressed NOTE If more than one Receptacle has been installed do Engine Stop Switch testing at EACH Receptacle to ensure Receptacle hook up is correct The Engine Stop Switch 15 ALWAYS operable when DC power 1s On to the Handheld System The Handheld System does not need to be in command of the Actuator Processor or have the Safety Lanyard attached to stop engines ARNING DO NOT attempt to continue tests if the Engine Stop Switch does not function cor rectly Refer to information supplied by engine manufacturer or supplier for set up and adjustments Refer to CFR 46 SEC 62 35 5 and ABYC P 24 5 8 Page 26 ADJUSTMENTS AND TESTS AT DOCK 7 3 OPTIONAL THRUSTER SWITCH TEST ENGINES RUNNING The Thruster switch is ALWAYS operable when DC power is On to the Handheld System The Handheld System does not need to be in command of the Actuator Processor or have the Safety Lanyard attached to operate Thrusters A Plug Handheld into a Receptacle by turning the plug clockwise into the receptacle leave until secure B Press the Thruster switch Port and Starboard C Verify corresponding Thruster is operating If Thruster is not operating correctly check all connections and retest NOTE If more than one Receptacle has been installed do Thruster Switch testing at EACH Recep tacle to ensure R
62. on Transfer Button E O z Thruster O Bow Thruster Stern Thruster 1 71 jJ 10905C Figure 13 Bow amp Stern Thruster Switches The Thruster switch 1s spring centered to the OFF position ressing and holding the switch Port or Starboard the Handheld Unit commands thrust from the thruster in either the Port or Starboard direction e Holding the switch will maintain thrust e Releasing the switch stops the thrust CAUTION The thruster switch and Engine Stop Switch are ALWAYS active when power is sup plied to the Handheld Unit The Handheld does not need to be in command of the Actuators Processors nor does the safety lanyard need to be connected in order to operate the thruster switch or the Engine Stop Switch Page 14 REQUIRED PARTS AND TOOLS 4 0 REQUIRED PARTS AND TOOLS 4 1 ELECTRIC CABLE Eight C onductor Cable Receptacle to Actuators Control Processors Relay Junction Box Shielded 20 AWG 300V PVC Insulated 20 degrees C to 80 degrees C UL VW 1 PVC Jacket Color Coded Two Conductor Power Cable Relay Junction Box to DC Power Supply 14 AWG 300V PVC Insulated 20 degrees C to 105 degrees C UL VW 1 PVC Jacket Red with purple stripe and black Two Conductor Cable Engine Stop to Relay Junction Box 14 16 AWG 300 V PVC Insulated 20 degrees to 105 degree
63. p Wire leads must not touch frame Page 24 INSTALLATION NOTE The Handheld may be connected on any unused Station Terminal strip within the Actua tor Processor For Twin Screw Applications ensure connection of the Handheld on both Port and Starboard Actuator Processors are the same numbered Station Terminal A jumper is required between terminals 5 and 6 on all unused Station Terminals on the Actu ator Processor circuit board NOTE A WAGO Tool is supplied with each Actuator Processor E Strip the wire 3 8 inch R tata otate waco 9 5mm on each lead Tool Terminal Strip Insert Tool and Rotate E Use a WAGO tool to lt Forward to Release Spring i LES Lock and Insert Wire End depress the spring lock for y One Wire of 2 B 0656B Figure 28 WAGO Tool nection to the terminal strip eee CLIP and INSULATE BLACK YELLOW G Connect colors as shown AND VIOLET WIRES on Figure 29 FROM HANDHELD Connect the shielding RECEPTACLE 1 2 3 4 ORANGE 5 El 2 6 C GREEN drain wire bare non insu 7 L3 BLUE 8 DRAIN lated wire to Terminal 8 AA clc rc Figure 29 Typical Connections at Actuator Processor on the terminal strip CAUTION The shielding drain wire MUST NOT touch any other components or Frame I Feed through a little slack cable and
64. re 3 8 1nch 9 5mm E Install female crimp terminals included with Relay Junction Box Thomas amp Betts RB14 250F or equal E Select contacts to be used connection to Normally Open Contacts shown K4 K 2 O O z z O E e h Starboard Port Engine NC onf ON Engine Stop COM a Stop Y Twin Screw only k u m uod dais 10947A Eng Stop Figure 24 Junction Box Engine Stop Cable Wiring Diagram CAUTION The Engine Stop Relays have normally open maximum 20 ampere and normally closed maximum 10 ampere contacts The normally open contacts are typically used for fuel shut off solenoids and should be wired in parallel with any existing fuel shut off circuits The normally closed contacts are used with ignition circuits and should be wired in series with any existing ignition circuits G Replace the Relay Junction Box cover H Refer to the information supplied by your engine dealer for con nection to the Engine Stop Circuits Page 22 INSTALLATION 6 6 THRUSTER CABLE INSTALLATION OPTIONAL Install the Thruster cable between the Relay Junction Box and the Thruster solenoid s CAUTION When installing the cable support the cables using clamps or straps not more than
65. s C UL VW 1 PVC Jacket Yellow with red stripe Engine Stop Switch Cable Engine to Relay Junction Box Port amp Starboard Supplied by the installer Refer to the information supplied with the Engine Thruster Cable Thruster to Relay Junction Box Supplied by the installer Refer to the information supplied with Thruster for cable specifications 4 2 TOOLS REQUIRED FOR INSTALLATION e Wago Tool e Anti static Wrist Strap Wire cutter stripper crimper Recommend Thomas amp Betts WT 2000 e Screwdriver med Phillips 2 e Screwdriver med straight slot e Screwdriver small straight slot e Hole saw 1 inch 25 4mm 1 75 44 5mm for Plug n Play e Drills 9 32 inch 7 2mm and 7 32 inch 5 6mm 4 3 HANDHELD REMOTE CONTROL Included are Optional Extras One Handheld Remote Control Additional Receptacle Kits One extra Safety Lanyard with Receptacle Protector Kit locking key e 25 Foot 7 62m Extension One Receptacle Kit Cable e One Relay Junction Box e Holding Brackets e Watertight cable grips Additional Handheld Units e Crimp Terminals Additional Safety Lanyards Page 15 PLAN THE INSTALLATION 5 0 PLAN THE INSTALLATION 5 1 RECEPTACLE LOCATION Considerations USE 2 Th R RECEPTACLE FL E 1 eceptacie IS water resistant SQUARE FLANGE vas when sealant is used between the Palm Receptacle flange and bulkhead e Strain relief 1 required for inside Y
66. secured to the operator s wrist by the safety lanyard When the Handheld 15 not in use it should be placed within a holding bracket Refer to Table 2 on page 24 for ordering information 23 5 8mm Diameter c Mounting Holes two places Base nn Horizontal Mount Vertical Mount rotated 180 Degrees for Vertical Mount 3 32 84 3mm Outline and Mounting Dimensions 10417 Optional Bracket ose Weight 70 Pounds 32 Kilograms Mounting Options Figure 11 Optional Bracket Mounting 3 2 MOVING FROM ONE RECEPTACLE LOCATION TO ANOTHER If a Handheld 1s to be moved to another Receptacle location Remove A Take command at one of the ZF Mathers Remote Stations B Unplug the Handheld from the Receptacle C Place the Protective Cap over the Receptacle D Turn clockwise gt to secure SS 2 Receptacle 11279 Rev A E Move to another Receptacle location and turn the Figure 12 Receptacle Protective Cap Cap counter clockwise to remove F Plug Handheld into the new Receptacle G Take command at the Handheld 3 3 THRUSTER CONTROL OPTIONAL When one Thruster 1s used e The Thruster switch is located just below the Station Transfer But ton on the Handheld Page 13 OPERATION When two Thrusters are used Bow Thruster switch 1s located just above the Station Transfer But ton e Stern or second Bow Thruster switch 1 located just below the Sta ti
67. side Sales at ZF Mathers 1 800 546 5455 The Handheld System s available as an additional Station for MicroCommander ClearCommand and CruiseCommand Sys tems Table 2 Parts List Anti Static Wrist Strap AWCC Thomas amp Betts Part No AWCC Fuse 5 1 Wickman Part No TR5 M 1 WAGO Tool 236 332 WAGO Part No 236 Manufacturer Part Part Name No Receptacle Kits Hardwired Plug n Play SINGLE SCREW Hardwired 50 foot 15 24m cable MS12631 50 MS12631 50P 100 foot 30 48m cable MS12631 100 MS12631 100P 150 foot 45 72m cable MS12631 150 MS12631 150P TWIN SCREW 50 foot 15 24m cable MS12632 50 MS12632 50P 100 foot 30 48m cable MS12632 100 MS12632 100P 150 foot 45 72m cable MS12632 150 MS12632 150P 200 foot 60 96m cable MS12632 200 MS12632 200P Station Connection Cable 14261 X Plug n Play Only X reflects Cable length Receptacle Protector Assembly 13523 Extension Cable 25 foot 7 62m Single Screw MS12935 Twin Screw MS12772 Bracket Mounting Assembly 1233 Safety Lanyard 81237 Comnav Part No 81237 Page 30 99 N PARTS SOURCE Tore co 2 Parts List Handheld er SS foot 7 62m cable SINGLE SCREW Main Engine Control Only Main Engine Control One Thruster Main Engine Control Two Thruster TWIN SCREW Main Engine Control Only Main Engine Control One Thruster Main Engine Control Two Thruster Relay Junction Box 12984 1
68. tation in Command Control Head levers may be left any position B Move to the Handheld Station Refer to Figure 9 Station in Commanc Indicator Lights Receiving Hand Held MicroCommander or ClearCommand Station Station in Command Figure 9 Station Transfer C Ensure the Handheld control knobs are in the vertical position and that the Safety Lanyard 1s attached refer to Figure 4 on page 4 Control Knob s Vertical Transfer Button 10915A Figure 10 Taking Command at the Handheld D Depress the Transfer Button to take command at the Handheld E The Station in Command red indicator lights next to the control knob s on the Handheld will light indicating command has been transferred to the Handheld Refer to Figure 9 page 12 for loca tion of the indicator lights NOTE On Twin Screw applications both Port and Starboard indicator lights on the Handheld Unit must be lit at the Handheld that is the Station in Command F The Handheld Svstem is now readv to command the ZF Mathers Control Svstem and optional Thrusters CAUTION Operate the Handheld only while on the vessel A person standing on the dock or another vessel should NEVER operate it When using the Handheld the operator should brace themselves against anv change in vessel motion Page 12 OPERATION The Handheld may be used Secured in a holding bracket refer to Figure 11 page 13 Held freely your hand while
69. their possible solutions In the event that you experience a problem not listed below you should be able to identify the cause using the infor mation provided above Symptom Che _ 1 Cannot take com 1 Verify that the Safety Lanyard is 1 Plug in the Safety Lanyard mand at Handheld installed la The Handheld s Knob is not positioned when the Transfer la The Command Voltage 1s not at the Neutral Idle position Reposi Button 1s between 48 50 of Vref tion depressed lb Test The Station Select cir The yellow green or blue wire 1s loose cuit or incorrectly terminated Correct lb The red or orange wire s are not con nected properly The Transfer Button is defective replace the Handheld Page 4 2 The Engine Shut down does not operate TROUBLESHOOTING Symptom Che _ 2 DC power is turned Off going to the Junction Box 2a The Junction Box fuse s blown 2b The positive and negative power leads are reversed 2 Turn power On to the Junction Box 2a Replace fuse Fl 2b Correct the polarity of the power going to the Junction Box 3 The Bow and 3 DC power is turned Off going 3 Turn power On to the Junction Box Stern Thruster s to the Junction Box 3a Replace fuse Fl are inoperable 3a The Junction Box Fuse is 3b Correct the polarity of the power going blown to the Junction Box 3b The positive and negativ
70. tighten the cable grip on the cable J Usea cable tie to secure cable to Actuator Processor frame 6 7 2 Port and Starboard Plug n Play Connection A Run the Station Connection Cable from the Receptacle to the Port and Starboard Actuator Processor B Connect on any unused Station connector NOTE For Twin Screw Applications ensure connection of the Handheld on both Port and Star board Actuator Processors are the same numbered Station connector Page 25 ADJUSTMENTS AND TESTS AT DOCK 70 ADJUSTMENTS AND TESTS SECURED TO DOCK 7 1 HANDHELD UNIT ENGINES STOPPED A Turn On power to the Control System B Plug Handheld Unit into a Receptacle by turning the plug clock wise into the receptacle sleeve until secure C Take command at the Handheld Unit by depressing the transfer button D Verify command indicator lights LED are lit E Move the Handheld control knob fully one way then the other e Ensure MicroCommander ClearCommand CruiseCommand System reacts correctly to the control knob command E Verify command is correct G Refer to your original MicroCommander ClearCommand CruiseCommand Manual for further testing of Control Heads NOTE If more than one Receptacle has been installed do Handheld System testing at EACH Receptacle to ensure Receptacle hook up is correct 7 2 ENGINE STOP SWITCHES TEST ENGINES RUNNING A Start engine s B Plug Handheld into a Receptacle by turning the plug clockwise i
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