Kobelt 6505 - User Manual

Kobelt Manufacturing Co. Ltd.
6505 Electronic Control Head
Owner’s Operation, Installation &
Maintenance Manual

Summary

Introduction

Contact Information

Provides contact details for Kobelt Manufacturing Co. Ltd., including phone, fax, email, and website.

Safety Guidelines

Details safety alerts, notices to installers, and product hazards for safe operation and installation.

Product Description

Overview and Features

General overview of the 6505 electronic control head, its functions, and key components.

Technical Specifications

Details technical data like handle travel, output, terminals, ambient temperature, finish, and weight.

Model Configuration Key

Provides the key for understanding model variations based on control, finish, and handle options.

Installation

Mechanical Installation

Instructions for physically mounting the control head securely on a flat surface, considering flexing and room.

Electrical Connections

Guide to making electrical connections, including cable specifications, shielding, and wiring for signal integrity.

DIP Switch Settings

Instructions for setting DIP switches to assign network addresses to each control head for proper communication.

Functional Test Procedure

Steps to verify correct operation after installation, including power-up checks and clutch engagement tests.

Operation

Control Head Functions

Explains the functions of the four membrane buttons: Station Select, Station Lock, Throttle Override, and Synchronizer.

Maintenance

Preventative Maintenance Schedule

Outlines recommended preventative maintenance tasks for quarterly checks and bi-annual inspections.

Potentiometer Calibration

Step-by-step guide to centering the potentiometer and calibrating the output for accurate control.

Potentiometer Wiring

Instructions for correctly wiring potentiometers to connector P1, referencing terminal connections.

Lubrication Recommendations

Specifies approved greases for lubricating the detent track to prevent premature wear.

Recommended Spare Parts

Lists essential spare parts and kits recommended to be kept on hand for service and maintenance.

Warranty Information

Warranty Terms and Conditions

Details the warranty coverage, exclusions, and procedures for making a claim.

Installation Dimensions

Dimensional Drawings

Provides detailed diagrams with measurements for control head installation and mounting.

Parts List

Component Identification

Shows an exploded view of the control head with numbered components and refers to the detailed parts list.

Installation Cut-out Template

Template Diagram

Provides a template for the correct cut-out dimensions for mounting the control head on a surface.

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features
5. Calibration
6. Spare Parts

The Kobelt 6505 Electronic Control Head is a compact electronic control unit designed for marine applications, providing precise control over engine throttle, clutch engagement, or propeller pitch. It communicates via CANbus and offers a 10-bit digital output proportional to the handle position. This control head is an integral part of Kobelt's Mighty Mariner controller system.

Function Description:

The primary function of the 6505 control head is to translate the operator's handle movements into electronic signals for controlling marine propulsion systems. It features a handle with three distinct detent positions: one at Top Dead Center (TDC) for neutral, and two others corresponding to clutch activation points for both ahead and astern propulsion. This design ensures clear tactile feedback for clutch engagement.

Beyond basic throttle and clutch control, the unit incorporates a keypad with four membrane buttons, enabling several advanced operational features:

• Station Select: This function allows the operator to transfer engine control to another station. Upon power-up, control is automatically assigned to station 1 (typically the main bridge station).
• Station Lock: This feature enables the operator to lock out other control stations, preventing unintended control transfers.
• Throttle Override: This mode disables the clutch function, allowing the engine to be operated at full throttle without engaging the propellers. This is particularly useful for engine warm-up or testing purposes. To return to normal operating mode, the handle positions must be returned to neutral (TDC), and the button pressed again.
• Synchronizer: When activated, this feature enables propeller speed synchronization. It utilizes external speed sensors to measure engine speeds and allows the controller to match them. The operator only needs to adjust one throttle handle to control both engine speeds. The synchronizer light flashes during synchronization and remains solid once speeds are within the controller's dead-band. It's important to note that the synchronizer function is not available when propulsion controls are in trolling mode, and using more than one synchronizer function simultaneously can lead to unpredictable states.

Important Technical Specifications:

• Handle Travel:
  • Neutral: 0° (detented)
  • Clutch in: +/- 20° (detented)
  • Full travel: +/- 68°
• Output: CANbus (maximum cable length of 132 ft [40m])
• Terminals: 22-16 AWG, screw clamp type
• Ambient Temperature: 14°F to 122°F (-10 °C to +50°C)
• Finish: Polyester powder coat, textured black
• Weight: 6.2 lbs [2.8 kg]
• Model Configuration Options:
  • Control Options: Single Engine (S) or Twin Engine (T)
  • Finish Options: Chrome plated (C), polished brass (L), or black painted dome & chrome plated handles (B)
  • Handle Options: Elegant Handle (E)

Usage Features:

The 6505 control head is designed for ease of use and robust performance in a marine environment. Its compact design and intuitive keypad simplify operation. The detented handle positions provide clear tactile feedback for critical control points. The unit is designed for direct mounting to a flat, strong, and stiff surface, ensuring stability during operation. Electrical connections are made via two cable glands, accommodating 0.20 inch [5 mm] to 0.47 inch [12 mm] OD cable with 18 AWG conductors. Shielded twisted pair cable is recommended for signal integrity. Up to eight control heads can be connected in a 'daisy chain' configuration, with the last unit requiring a 120 ohm resistor between data terminals.

Maintenance Features:

Regular maintenance is crucial for the longevity and reliable operation of the 6505 control head. The manual outlines a preventative maintenance schedule:

• Quarterly (4 times per year):
  • Lubricate the detent track (using a grease with MoS2 additives like CHEVRON DELO MOLY 5% EP2, MOBIL XHP-322, or SHELL S3 V460).
  • Ensure the friction amount is adequate.
• Every 2 years:
  • Inspect the detent plate and replace if necessary.
  • Replace the shaft seal.

Calibration:

If the potentiometer is replaced or its setting becomes disturbed, a calibration procedure is required to center the output:

1. Position the handle in the neutral (center) position.
2. Remove the control head bottom cover.
3. Locate the potentiometer.
4. Connect a multimeter to the Pot – (white wire) and Pot Wiper (green wire) to read resistance.
5. Loosen the two locking set screws on the pinion gear with a 1/16-inch Allen key.
6. Using a short flat head screwdriver, rotate the potentiometer shaft until the meter reads half of the rated output (e.g., 2500 ohms for a 5K potentiometer), balancing the output between the wiper and Vref+ to wiper and Vref-.
7. Tighten the two locking set screws and replace the cover. After centering, the throttle output must be calibrated to the 6525 controller by setting DIP switch #4 to OFF, following the controller's prompts, and then returning DIP switch #4 to ON.

Spare Parts:

Kobelt recommends keeping a minimum set of spare parts on hand, including:

• One friction kit
• One detent kit
• One potentiometer

It is advised that any service work be performed by a factory-authorized service representative. The manual includes an appendix with a detailed parts list and installation dimensions for reference.

Kobelt 6505 Specifications

General

Brand	Kobelt
Model	6505
Category	Controller
Language	English