ZF Marine ClearCommand - User Manual

Page 1
MM13050 Rev.B 11/01
ClearCommand MS565-13050
SW13447.3
Table of Contents
MM13050 Rev.B 11/01................................................................................................................................................ 1
ClearCommand MS565-13050
Table of Contents ........................................................................................................................................................ 1
Revisions List ...............................................................................................................................................................1
1.0 INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.1 This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 ClearCommand System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.1 Features:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.0 OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
2.1 DC Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 1: Control Head Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Engine Start Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Station Transfer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 2: Station Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Warm-up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 3: Warm-up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Synchronization (Multi Screw). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6 Control Head Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.7 Speed Boost Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.0 REQUIRED PARTS AND TOOLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
3.1 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 4: Control Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Electric Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Tools Required For Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5 Push-Pull Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.6 Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 5: Wire Harness Connection Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.7 Engine Stop Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.8 Control System Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.0 PLAN THE INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
4.1 Processor(s) Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 6: Control Processor Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Control Head Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2.1 400 Series Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2.2 MC2000 Series Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2.3 700 Series Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.3 DC Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.0 INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
5.1 Eight-Conductor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 7: Plug Removal and Cable Grip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.3 Processor Connections and Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

ZF Marine ClearCommand Specifications

General

Brand	ZF Marine
Model	ClearCommand
Category	Controller
Language	English

Summary

1.0 INTRODUCTION

1.1 This Manual

Describes the purpose and scope of the ClearCommand System manual.

1.2 ClearCommand System

Overview of the ClearCommand Control Processor's design and capabilities.

2.0 OPERATION

2.1 DC Power On

Describes system behavior when DC power is initially turned on.

2.2 Engine Start Interlock

Details the interlocks preventing engine start under specific conditions.

2.3 Station Transfer

Procedure for transferring command between different stations.

2.4 Warm-up Mode

Explains the procedure for operating the system in Warm-up Mode.

2.5 Synchronization (Multi Screw)

Describes the dual lever synchronization feature for multi-engine systems.

2.6 Control Head Tones

Explains the meaning of different audible tones from the control heads.

2.7 Speed Boost Operation

Details the function and use of the Speed Boost feature.

3.0 REQUIRED PARTS AND TOOLS

3.1 Processor

Lists the required processor component and included items.

3.2 Control Head

Lists the required control head component and included items.

3.3 Electric Cable

Specifies types and requirements for electric cables.

3.4 Tools Required For Installation

Lists necessary tools for installing the ClearCommand system.

3.5 Push-Pull Cable

Details the type and requirements for push-pull cables.

3.6 Wire Harness

Information on available wire harnesses for system connection.

3.7 Engine Stop Switch

Mandatory requirement for engine stop switches at each station.

3.8 Control System Power

Specifies power requirements for the control system processor.

4.0 PLAN THE INSTALLATION

4.1 Processor(s) Location

Guidelines for selecting an appropriate location for the processor unit.

4.2 Control Head Location

Recommendations for mounting control heads in various configurations.

4.2.1 400 Series Control Heads

Specific mounting considerations for 400 Series Control Heads.

4.2.2 MC2000 Series Control Heads

Specific mounting considerations for MC2000 Series Control Heads.

4.2.3 700 Series Control Heads

Specific mounting considerations for 700 Series Control Heads.

4.3 DC Power Source

Guidance on selecting and connecting the DC power source.

5.0 INSTALLATION

5.1 Eight-Conductor Cable

Procedure for installing the eight-conductor cable.

5.2 Processor

Steps for securing and preparing the processor unit for connection.

5.3 Processor Connections and Set-up

Details on making electrical connections to the processor unit.

5.3.1 Processor Station Connections

Specific instructions for connecting station cables to the processor.

5.3.2 Power Cable

Procedure for connecting the power cable to the processor.

5.3.3 Start Interlock

Instructions for connecting the start interlock circuit.

5.4 Control Heads

Information on installing and connecting control heads.

5.4.1 Mounting

Steps for mounting various models of control heads.

5.4.2 Cable Connection

Procedure for connecting cables to the control head.

5.4.3 Aft Facing Control Heads

Specific wiring for control heads facing aft.

5.4.4 700 Series Control Head Only

Installation details specific to the 700 Series Control Head.

5.5 Engine Stop Switch

Information on installer-supplied engine stop switches.

5.5.1 Synchronization (Multi-Engine Only)

Interconnecting processors for multi-engine synchronization.

5.6 Push-Pull Cables

Procedure for connecting push-pull cables to the processor.

5.6.1 Push-Pull Connection at Processor

Detailed steps for connecting push-pull cables to the processor housing.

5.7 Main Engine Speed Control

Setup procedures for main engine speed control.

5.7.1 Throttle Wire Harness

Connecting the throttle wire harness to the processor and engine interface.

5.7.2 Auxiliary Circuit Board Jumper Setting

Procedure for setting the jumper on the auxiliary circuit board.

5.7.3 Engine Signal Selection

Procedure for selecting the engine signal type.

6.0 SET-UP PROCEDURES

6.1 Set-up Steps

General steps to follow before starting set-up procedures.

6.1.1 Dip Switch Settings

Instructions for configuring dip switches on the main circuit board.

6.1.2 Order of Set-up Adjustments

Recommended order for performing set-up adjustments.

6.1.3 Selecting Dip Switches

Guidance on how to select dip switches for configuration.

6.1.4 Run State (Normal Operating Mode)

Procedure to place the system in Run State for normal operation.

6.1.5 Enabling Set-up Mode

Steps to enable the set-up mode for configuration.

6.1.6 Storing Set-up Value

Procedure for saving the configured set-up values.

6.2 Number of Screws Selection [Single;Twin, etc]

Setting the number of screws for system configuration.

6.3 System ID # Selection

Procedure for selecting a unique System ID for multi-processor applications.

6.4 Clutch Pressure Time

Configuration of clutch pressure time settings.

6.5 Clutch Delay

Setting the clutch delay parameters for system operation.

6.6 Throttle Pause

Adjusting the throttle pause settings for smoother operation.

6.7 Engine Signal Selection

Selecting the appropriate engine signal type for the system.

6.8 In Gear;Neutral Delay

Configuring the delay timer for in-gear or neutral states.

7.0 ADJUSTMENTS AND TESTS (SECURED TO DOCK)

7.1 Control Head (Engines Stopped)

Testing control head functionality with engines stopped.

7.2 Start Interlock (Engines Stopped)

Verifying start interlock operation with engines stopped.

7.3 Clutch Travel (Engines Stopped)

Adjusting clutch cable travel with engines stopped.

7.3.1 Neutral Position

Procedure for adjusting clutch cable to neutral position.

7.3.2 Ahead Position

Procedure for adjusting clutch cable to ahead position.

7.3.3 Verify Neutral, Ahead, and Astern

Verifying correct clutch cable travel in all positions.

7.4 Engine Stop Switches Test (Engines Running)

Testing engine stop switches while engines are running.

7.5 Warm-Up Mode Test (Engines Running)

Testing warm-up mode functionality with engines running.

7.6 Electric Throttle Signal

Adjusting and verifying electric throttle signals.

7.6.1 Throttle Minimum Signal (Engines Stopped)

Procedure to adjust the minimum throttle signal output.

7.6.2 Throttle Maximum Signal

Procedure to adjust the maximum throttle signal output.

8.0 ADJUSTMENT UNDERWAY

8.1 Engine RPM

Procedure for warming up engines and checking operational RPM.

8.2 Speed Boost

Guidelines for adjusting speed boost parameters.

8.2.1 Speed Boost Percentage

Setting the percentage of maximum throttle for speed boost.

8.2.2 Speed Boost Timeout

Configuring the duration for which speed boost is applied.

8.2.3 Speed Boost Start Timeout

Setting the time delay before speed boost begins.

9.0 CONTROL OPTIONS

9.1 Alarm Capability

Details the single alarm connection for system failures.

9.2 Clutch Oil Pressure Interlock

Explains the interlock to prevent high RPM when clutch is not engaged.

9.3 Synchronization

Procedures for setting up and testing engine synchronization.

9.3.1 Serial Communication Wire Harness

Connecting processors using a serial communication wire harness.

9.3.2 Control Head Cable Connection

Connecting the violet lead to the starboard terminal on control heads.

9.3.3 Processor Control Head Cable Connections

Connecting violet lead to the starboard processor auxiliary board terminals.

9.3.4 Control Head Test (Secured to Dock)

Testing control head synchronization with engines running.

9.3.5 Synchronization Operation Tests

Performing operational checks for engine synchronization.

10.0 MAINTENANCE

10.1 Control Processor

Lists annual checks required for the control processor unit.

10.2 Control Head

Annual checks for control head terminals and contacts.

APPENDIX A.1 PARTS LIST

APPENDIX B.1

TROUBLESHOOTING

1.1 SYMPTOM - WHEN DC POWER IS TURNED ON, OPERATOR CANNOT TAKE COMMAND AT ONE STATION (BOTH PORT AND STARBOARD FOR TWIN SCREW).

Operator cannot take command at one station when DC power is on.

1.2 SYMPTOM - ONE SIDE WILL NOT TAKE COMMAND WHEN DC POWER IS FIRST TURNED ON.

One station fails to take command when DC power is first turned on.

1.3 SYMPTOM - THE ENGINE RPM VARIES, WITHOUT MOVING THE CONTROL HEAD LEVER.

Engine RPM varies without movement of the control head lever.

1.4 SYMPTOM - THE ENGINE RPM REDUCES TO IDLE, THE CONTROL HEAD INDICATOR LIGHT TURNS OFF, AND A SLOW REPETITIVE TONE EMITTED AT ALL STATIONS AFTER REPOSITIONING THE CONTROL HEAD LEVER.

Engine RPM drops to idle, indicator light off, and tone emitted after lever reposition.

1.5 SYMPTOM - NO AUDIBLE TONE AT A CONTROL HEAD WHEN SYSTEM IS FIRST TURNED ON, BUT OTHERWISE WORKS PERFECTLY.

No audible tone at control head on system startup, but otherwise functional.

1.6 SYMPTOM - AUDIBLE STEADY TONE FROM ALL STATIONS. CANNOT GAIN COMMAND AT ANY STATION.

Steady tone from all stations, preventing command acquisition.

1.7 SYMPTOM - THE CONTROL HEAD RED INDICATOR LIGHT DOES NOT LIGHT WHEN IN COMMAND, BUT EVERYTHING ELSE WORKS PERFECTLY.

Control head red indicator light fails, but other functions are normal.

1.8 SYMPTOM - NO TONES OR LIGHTED INDICATOR LIGHTS AT THE CONTROL HEAD, AND NO LIGHTED INDICATOR LIGHTS ON THE PROCESSOR CIRCUIT BOARD.

No tones or lights on control head or processor circuit board.

1.9 SYMPTOM - THE ENGINE STARTS TO TURN OVER WHILE STARTING AND THEN STOPS. A SLOW REPETITIVE AUDIBLE TONE FROM ALL CONTROL HEAD STATIONS.

Engine starts then stops during starting, with a slow repetitive tone.

1.10 THE ENGINE WILL NOT START.

Troubleshooting steps when the engine fails to start.

1.11 SYMPTOM - ONE LONG - ONE SHORT TONES FROM ALL CONTROL HEAD STATIONS.

Indicates a clutch feedback error.

1.12 SYMPTOM - THREE SHORT - ONE LONG TONE FROM ALL STATIONS.

Indicates control head malfunction due to loose connections.

1.13 SYMPTOM - CANNOT GET ANY SPEED ABOVE IDLE.

System cannot achieve speed above idle.

1.14 SYMPTOM - CANNOT GET ANY SPEED ABOVE IDLE.

System cannot achieve speed above idle.

1.15 SYMPTOM - A SLOW REPETITIVE TONE IS HEARD FROM ALL STATIONS WHEN POWER IS APPLIED TO THE SYSTEM. THE SLOW REPETITIVE TONE CEASES WHEN THE TRANSFER BUTTON IS DEPRESSED. SUBSEQUENTLY, A STEADY TONE IS HEARD WHENEVER THE TRANSFER BUTTON IS DEPRESSED. THE CONTROL HEAD LED DOES NOT LIGHT. THE TRANSMISSION AND ENGINE REMAIN AT THE NEUTRAL;IDLE POSITION REGARDLESS OF CONTROL HEAD LEVER POSITION.

System in Set-up Mode, preventing control commands.

1.16 SYMPTOM - A SLOW REPETITIVE TONE IS HEARD FROM ALL STATIONS WHEN POWER IS APPLIED TO THE SYSTEM. WHEN THE TRANSFER BUTTON IS DEPRESSED, THE TONE CEASES BUT THE RED LED DOES NOT LIGHT. FURTHER DEPRESSING OF THE TRANSFER BUTTON HAS NO EFFECT. THE TRANSMISSION AND ENGINE REMAIN AT THE NEUTRAL;IDLE POSITION REGARDLESS OF THE CONTROL HEAD LEVER POSITION.

Processor in Set-up Mode with an adjustment setting selected.

1.17 SYMPTOM - SET-UP MODE IS ENTERED AND THE NORMAL 3 SECOND STEADY TONE IS HEARD. THE MOTOR CONTROL RELAY “CLICKS” CONTINUOUSLY WHEN THE DIP SWITCHES ARE TURNED ON.

Indicates an invalid switch combination was selected.

1.18 SYMPTOM - THE MOTOR RELAY DOES NOT CLICK ONCE, INDICATING VALUES HAVE BEEN STORED, WHEN PB1 ON THE AUXILIARY CIRCUIT IS DEPRESSED.

Indicates set-up or adjustment steps were not followed correctly.

2.0 RESET ALL PARAMETERS TO FACTORY DEFAULT VALUES