mm9110-i rev d1 4-08 microcommander manual

7/25/2019 MM9110-I Rev D1 4-08 MicroCommander Manual

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MicroCommander 9110X

Installation Operation

and Troubleshooting Manual

MM9110-I Rev D.1 4/08


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0 PREFACE

Page 0 -2

only to the Sections that apply to your vessel. If you w ish to use one of the available options li sted,please contact a ZF M arine Electronics Representative for f uther in form ation.


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T A B L E O F C O N T E N T S

TO C-1

SW15623.0

Table of Contents

MicroCommander 9110X

Installation Manual

0 PREFACE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 0 -10-1 M icroCom m ander 9110X Series Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 -1

0-2 Conventional Sym bols U sed in the M anual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 -10-3 Im portant Inform ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 -1

Table of Contents................................................................................................................................................................ TOC-1

List of Figures ..................................................................................................................................................................... TOC-7

List of Tables....................................................................................................................................................................... TOC-9

REVISIONS LIST ................................................................................................................................................................ TOC-11

1 INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 -11-1 M anual Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 -11-2 Basic Theory of O peration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -11-2.1 9110X Processor (Throttle - Servo, Shift - Servo, X = Number of Remote Station Pigtails) . . . . . . . . .1 - 1

1-3 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -11-3.1 Standard Processor Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1

1-3.2 Optional Processor Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -2

2 OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 -32-1 D C Pow er O n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 -32-2 Taking Com m and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -32-3 Basic O peration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -32-3.1 Normal Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3

2-4 Start Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -42-5 Station Transfer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -42-6 Em ergency Reversal Protection (Proportional Pause). . . . . . . . . . . . . . . . . . . . . . . . 2 -42-7 W arm -up M ode (Throttle O nly M ode). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -42-8 H igh/Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -52-8.1 Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 52-8.2 High Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -5

2-8.3 Selecting Between High and Low Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -52-9 O ne Lever M ode (M ulti Screw ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -52-9.1 Turning ON One Lever Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 62-9.2 Turning OFF One Lever Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -6

2-10 Engine Synchronization (M ulti Screw ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -62-10.1 Synchronization Criteria. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 72-10.2 Synchronization Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -72-10.2.1 Equal Throttle Servo Synchronization (default)........................................................................................2 - 7

2-10.2.2 A ctive Synchronization .......................................................................................................................... 2 -7

2-10.3 Synchronization Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -72-10.4 Turning Synchronization OFF/ON when Criteria is Met. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -8

2-10.4.1 Turning O FF:..........................................................................................................................................2 - 8

2-10.4.2 Turning O N :........................................................................................................................................... 2 -8

2-10.5 Turning Synchronization ON/OFF when Criteria is Not Met . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -8

2-11 Control System sConfigurability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -82-11.1 Processor Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 82-11.2 Throttle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -92-11.2.1 Basic Throttle Functions .........................................................................................................................2 - 9

2-11.2.2 Servo Throttle Functions........................................................................................................................ 2 -9

2-11.3 Clutch Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -92-11.3.1 Basic Clutch Functions ...........................................................................................................................2 - 9

2-11.3.2 Clutch Servo Functions.......................................................................................................................... 2 -9

2-11.4 Troll Functions (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -92-11.5 Troubleshooting Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -10

2-11.5.1 Basic Troubleshooting Functions ..........................................................................................................2 - 10

2-12 A udible Tones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -10


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2-12.1 Basic Processor Tones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 10

2-12.1.1 Slow Repetitive Tone ...........................................................................................................................2 - 10

2-12.1.2 O ne Long, Three Short Tones ............................................................................................................. 2 -10

2-12.1.3 Steady Tone ....................................................................................................................................... 2 -10

2-12.1.4 Five (5) Second Steady Tone .............................................................................................................. 2 -10

2-12.1.5 Three (3) Second Steady Tone ............................................................................................................ 2 -10

2-12.1.6 Five Seconds O n, Five Seconds O ff - H igh Repetitive Rate Tone ......................................................... 2 -10

2-12.2 Throttle (Servo 2) Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -10

2-12.2.1 O ne Long - Tw o Short Tones ...............................................................................................................2 - 10

2-12.2.2 O ne Long, Tw o Short - H igh Repetitive Tone ...................................................................................... 2 -10

2-12.3 Clutch (Servo 1) Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -112-12.3.1 O ne Long - O ne Short Tone .................................................................................................................2 - 11

2-12.3.2 O ne Long, O ne Short -High Repetitive Rate Tone ............................................................................... 2 -11

2-12.4 9001 Trolling Actuator Tones (Servo 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -11

2-12.4.1 O ne Long, Four Short Tones ................................................................................................................2 - 11

2-12.4.2 O ne Long, Four Short - High Repetitive Rate Tone............................................................................... 2 -11

2-13 Push Button Set U p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -112-14 Visual System D iagnostics, Set U p And Status Indication . . . . . . . . . . . . . . . . . . . 2 -112-15 Pluggable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -112-15.1 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 11

2-16 O ptional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -122-16.1 External Alarm Capability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 122-16.2 Clutch Pressure Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -12

2-16.3 Multiple Screw Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -12

2-16.4 Station Expander (SE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -122-16.5 9001 Mechanically Actuated Trolling Valve Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -12

3 PLAN THE INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - 3 -133-1 System Requirem ents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 -133-1.1 Processor(s). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 133-1.2 Control Head(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -14

3-1.3 Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -143-1.3.1 Control H ead H arnesses...................................................................................................................... 3 -14

3-1.3.2 Pow er, Start Interlock, Clutch Pressure (optional), Alarm (optional) H arness........................................ 3 -14

3-1.3.3 Serial C om m unication H arness............................................................................................................ 3 -14

3-1.4 Additional Harnesses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -15

3-1.4.4 Tach Sensor H arness........................................................................................................................... 3 -15

3-1.5 Electric Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -15

3-1.5.1 Control H ead Electric C able..................................................................................................................3 - 153-1.5.2 Pow er, Start Interlock, Clutch Pressure, A larm Electric Cable............................................................... 3 -153-1.5.2.1 Power Electric Cable Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 153-1.5.2.2 Start Interlock Electric Cable Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 -153-1.5.2.3 Clutch Pressure Interlock Electric Cable Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 -153-1.5.2.4 External Alarm Circuit Electric Cable Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 -163-1.5.3 Serial Com m unication ......................................................................................................................... 3 -16

3-1.5.4 Tach Sensor Electric Cable Requirem ents............................................................................................ 3 -163-1.5.4.1 AC Tach Input- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 163-1.5.4.2 Open Collector (Active) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 -16

3-2 Tachom eter Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -163-2.1 AC Coupled Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 163-2.2 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -163-2.3 Point side of the Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -16

3-2.4 Active Sensors (Open Collector Output) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -16

3-3 Installer Supplied Tools A nd Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -173-3.1 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 173-3.2 Optional Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -173-3.3 Required Parts for Servo Processors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -173-3.4 Engine Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -17

3-4 D C Pow er Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -173-4.1 Processor Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 17

4 INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 -194-1 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 -194-2 Control H ead(s). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -194-2.1 400, MC2000 and 700 Series Control Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 194-2.2 500 Series Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -19


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TO C-3

4-2.3 Handheld Remote Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -19

4-3 W ire H arness Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -194-3.1 Harness Plug Insertion and Extraction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 194-3.2 Standard Power/Start Interlock Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -19

4-3.2.1 D C Pow er Cable ...................................................................................................................................4 - 19

4-3.2.2 Start Interlock Cable ............................................................................................................................ 4 -20

4-3.2.3 External Alarm Circuit Cable (optional)................................................................................................ 4 -20

4-3.2.4 Clutch Pressure Sw itch Cable (optional).............................................................................................. 4 -20

4-3.3 Serial Communication Harness (Multi Screw). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -204-3.3.1 Tw in Screw ..........................................................................................................................................4 - 20

4-3.4 Standard Control Head Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -204-3.4.1 Control Head H arness w ith Tw o Plugs..................................................................................................4 - 20

4-3.4.2 Control H ead H arness w ith O ne Plug................................................................................................... 4 -21

4-3.5 Tach Sensor Harness (required for Active Synchronization) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -21

4-4 H ard-W ired Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -214-4.1 Liquid Tight Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 214-4.2 Processor Enclosure Cable Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -214-4.3 Hard-wire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -22

4-4.3.1 Seven-Conductor Control H ead Cable (Locations 1, 2, 3, 6, and 7).......................................................4 - 22

4-4.3.2 Start Interlock Cable (Location 4)......................................................................................................... 4 -234-4.3.2.1 Connection at the Starter Solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 234-4.3.2.2 Connection at the Processor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 -234-4.3.3 Pow er Cable (Location 5).................................................................................................................... 4 -24

4-4.3.4 Serial Com m unication Cable (Location 10).......................................................................................... 4 -24

4-4.3.5 Tachom eter Cable (Location 12).......................................................................................................... 4 -25

4-5 Engine Stop Sw itches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -264-6 Push-Pull Cable Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -264-6.1 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 264-6.2 Throttle Selector Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -26

4-6.3 Shift Selector Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -27

5 SET UP PROCEDURE - - - - - - - - - - - - - - - - - - - - - - - - - 5 -285-1 Processor Com ponents U sed In Set U p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 -285-1.1 Processor Display LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 28

5-1.2 Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -285-1.2.1 U p and D ow n Push Buttons..................................................................................................................5 - 28

5-1.2.2 Left and Right Push Buttons ................................................................................................................ 5 -29

5-1.2.3 Left Push Button O nly.......................................................................................................................... 5 -29

5-1.2.4 Right Push Button O nly........................................................................................................................ 5 -29

5-2 A ctivating Set U p M ode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -295-3 Storing Values To M em ory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -295-4 Function Codes A nd Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -295-5 System Program m ing and A djustm ents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -315-5.1 Processor Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 315-5.1.1 Function Code A0 Processor Identification........................................................................................ 5 -31

5-5.1.1 Function Code A1 N um ber of Engines...............................................................................................5 - 32

5-5.1.2 Function Code A2 O ne Lever O peration............................................................................................ 5 -32

5-5.1.3 Function Code A 3 SE (Station Expander).......................................................................................... 5 -32

5-5.1.4 Function Code A4 N eutral Indication Tone........................................................................................ 5 -33

5-5.2 Throttle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -33

5-5.2.1 Function Code E0 Throttle Servo D irection.........................................................................................5 - 33

5-5.2.2 Function C ode E7 Synchronization ................................................................................................... 5 -33

5-5.3 Clutch Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -345-5.3.1 Function Code C0 Clutch Pressure Interlock ......................................................................................5 - 34

5-5.3.2 Function Code C1 Clutch Interlock D elay.......................................................................................... 5 -34

5-5.3.3 Function Code C 4 Proportional (Reversal) Pause Ratio...................................................................... 5 -34

5-5.3.4 Function Code C5 Clutch Servo D irection ......................................................................................... 5 -35

5-5.3.5 Function Code C6 Servo Clutch A head Travel................................................................................... 5 -36

5-5.3.6 Function Code C7 Clutch A stern Travel............................................................................................. 5 -36

5-5.4 Troll Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -36

6 DOCK TRIALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6 -376-1 Control H eads (Engines Stopped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 -376-2 Start Interlock (Engines Stopped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -37


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6-3 Servo Throttle D ock Settings (Engines Stopped) . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -376-3.1 Function Code E3 Throttle Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 376-3.1 Function Code E2 Throttle Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 386-3.2 Function Code E1 Throttle in Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -386-3.3 Function Code E4 Throttle Maximum Astern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -386-3.4 Function Code E6 High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -39

6-4 Servo Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -396-4.1 Push-Pull Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 39

6-5 Engine Stop Sw itches (Engines R unning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -396-6 Control H ead Com m and Checks (Engines Running) . . . . . . . . . . . . . . . . . . . . . . . 6 -39

6-7 Throttle Pause Follow ing Shift (Engines Running). . . . . . . . . . . . . . . . . . . . . . . . . 6 -406-7.1 Function Code E5 - Throttle Pause Following Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 40

7 SEA TRIALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 -417-1 Full Speed Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 -417-2 Proportional (Reversal) Pause - C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -417-2.1 Reversal Pause Type Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 41

7-2.1.1 In-G ear D elay [C200]............................................................................................................................7 - 41

7-2.1.2 N eutral D elay [C 201]........................................................................................................................... 7 -41

7-2.1.3 Fixed N eutral D elay [C202] ................................................................................................................. 7 -41

7-2.2 Select Function Code C2 - Proportional (Reversal) Pause. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -42

7-3 Proportional (Reversal) Pause Tim e - C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -427-3.1 Determine C3 Pause Requirement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 427-3.2 Store C3 - Proportional Pause Time Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -42

7-3.3 Testing Proport ional (Reversal) Pause Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -43

7-4 Synchronization Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -437-4.1 Equal Thrott le Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 437-4.2 Active Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -43

7-5 Sea Trial Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -447-5.1 Control System Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 447-5.2 Record Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -467-5.3 Comments (Please use additional paper as necessary):. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -47

7-5.3.1 G eneral Installation C ondition ...............................................................................................................7 - 47

7-5.3.2 Any Irregularities:................................................................................................................................ 7 -47

8 CONTROL OPTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - 8 -488-1 External A larm Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 -488-1.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 48

8-2 Clutch Pressure Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -488-2.1 C0 - Clutch Pressure Interlock Methods of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 49

8-2.1.1 01 - Installed ........................................................................................................................................8 - 49

8-2.1.2 02 - Throttle Clutch Pressure Interlock ................................................................................................. 8 -49

8-2.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -49

8-3 Station Expander (SE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -498-4 9001 A ctuator Trolling Valve Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -50

9 PERIODIC CHECKS AND MAINTENANCE - - - - - - - - - - - - - - - 9 -519-1 Control H eads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 -519-2 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -519-2.1 Throttle Servo Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 519-2.2 Clutch Servo Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -51

9-3 Pow er. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -51

Appendix AMMC-280 Rev.L 12-04 .................................................................................................................................................................................... A-1

400 Series Standard Control Head Variations

MMC-307 Rev.H 8/06..................................................................................................................................................................................... A-5

700 Series Standard Control Head Variations

MMC-329 Rev.C 8/03 ...................................................................................................................................................................................... A-9

MC2000 Series Standard Control Head Variations


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MMC-279 Rev.B 7/02 .................................................................................................................................................................................... A-13

400 Series Weather Mount Enclosure

Deutsch Connector Assembly................................................................................................................................................A-15

S-214 Rev.F 3/05 .......................................................................................................................................................................................... A-17

Automatic Power Selector (APS) Model: 13505

Drawing 11488D-1 Twin Screw Single APS Connection & Alternate Remote Switch ..........................................................A-19

Drawing 11488D-2 Twin Screw Dual APS Connect ions ........................................................................................................A-21

Drawing 11488D-3 APS Notes Page......................................................................................................................................A-23

MMC-287 Rev.F 5/06 .................................................................................................................................................................................... A-25

Grounding (Bonding)MMC-288 Rev.E 8-03 ................................................................................................................................................................................... A-27

References and Parts Source

SER-161 Rev.B 5/03 ...................................................................................................................................................................................... A-29

Engine Tachometer Sender Requirements

MMC-289 Rev.- 6/01 .................................................................................................................................................................................... A-31

Morse Clutch and Thrott le Kit Selection

MMC-290 Rev.- 6/01 ..................................................................................................................................................................................... A-33

Universal Mounting Kit

MM13821 Rev.A 8/03 ................................................................................................................................................................................... A-35

43C Cable Conversion Kit

Revisions List .........................................................................................................................................................................A-35

MMC-165 Rev.E 2/05 .................................................................................................................................................................................... A-37

Electronic Propulsion Control Systems Three Year Limited Warranty

MMC-163 Rev.C 10/04 .................................................................................................................................................................................. A-39

Warranty Registration

Appendix B

B1 TROUBLESHOOTING GENERAL - - - - - - - - - - - - - - - - - - - - -B1-1B1-1 Control System Exam ples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-1B1-1.1 9110X (Throttle Servo, Clutch Servo, X = Pluggable Remote Stations) Processor . . . . . . . . . . . . . . . B1-1

B1-2 Typical System M ain Com ponents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-1B1-2.1 Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1- 1B1-2.2 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-1

B1-2.3 Power Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-1B1-2.4 Electrical Cables and Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-1B1-2.5 Push-Pull Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-1

B2 TROUBLESHOOTING QUESTIONS - - - - - - - - - - - - - - - - - - - -B2-3

B3 TROUBLESHOOTING PROBLEM RESOLUTION - - - - - - - - - - - - - -B3-5B3-1 D C Pow er. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5B3-2 Com ponent Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5B3-2.1 Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3- 5B3-2.2 Processors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5

B3-3 Com ponent Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5B3-3.1 Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3- 5

B3-3.2 Processors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5

B3-4 Interconnecting W iring and H arnesses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5B4 TROUBLESHOOTING DIAGNOSTIC MENU - - - - - - - - - - - - - - - -B4-7

B5 TROUBLESHOOTING AUDIBLE TONES - - - - - - - - - - - - - - - - - -B5-9B5-1 Basic Control System Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-9B5-1.1 Slow Repetitive Tone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5- 9

B5-1.2 One Long - Three Short Tones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-9B5-1.3 Steady Tone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-11B5-1.4 Three Second Steady Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-11

B5-1.5 Three Second Steady Tone, followed by a Slow Repetitive Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-11B5-1.6 Five Seconds On, Five Seconds Off - High Repetitive Rate Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-11B5-1.7 Five Second Steady Tone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-11
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B5-2 Servo 2 Control System Tones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-11B5-2.1 One Long - Two Short Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5- 11B5-2.2 One Long, Two Short - High Repetitive Rate Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-12

B5-3 Servo 1 Control System Tones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-13B5-3.1 One Long - One Short Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5- 13B5-3.2 One Long, One Short - High Repetitive Rate Tones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-13

B6 TROUBLESHOOTING STATION TRANSFER - - - - - - - - - - - - - - - B6-14B6-1 Com m and Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-14B6-2 A nalog to D igital (A /D ) Counts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-14

B6-3 Rem ote Station Select. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-15B6-4 Stuck Transfer Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-15

B7 TROUBLESHOOTING ERROR CODES - - - - - - - - - - - - - - - - - B7-16

B8 PROBLEM CAUSES AND SOLUTIONS - - - - - - - - - - - - - - - - - B8-19

B9 TROUBLESHOOTING PROBLEMS WITHOUT ERROR CODES - - - - - - B9-27B9-1 Basic w ithout Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B9-27B9-2 Servo Clutch C ontrol System Problem s W ithout Error Codes . . . . . . . . . . . . . . . . . B9-28B9-3 Servo Throttle C ontrol System Problem s W ithout Error Codes . . . . . . . . . . . . . . . . B9-28

B10 SYNCHRONIZATION TROUBLESHOOTING - - - - - - - - - - - - - - B10-29B10-1 Equal Throttle Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B10-29B10-1.1 Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B10- 29

B10-1.2 Servo Clutch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B10-29B10-1.3 Servo Throttle Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B10-29

B10-2 A ctive Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B10-30B10-2.1 Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B10- 30B10-2.2 Servo Throttle Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B10-31

B10-2.3 Servo Clutch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B10-31

B11 TROUBLESHOOTING WIRE HARNESSES - - - - - - - - - - - - - - - B11-32B11-1 Basic Control System H arnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11-32

B12 PROCESSOR PIGTAILS - - - - - - - - - - - - - - - - - - - - - - - B12-35B12-1 Basic Processor Pigtails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-35

MMC-151, Rev. Z-Z-I 9-05............................................................................................................................................................................ B-36

Factory Authorized Service Centers - North America

MMC-172 Rv Z-R 3-05................................................................................................................................................................................... B-44FASSC International

ENG-127 Rev.A 4-05...................................................................................................................................................................................... B-48

MicroCommander Qualitative Failure Analysis and Design Verification Test Procedure

Appendix C

C1 Drawing 12271A-1 Basic Pluggable System Diagram - - - - - - - - - - C-1

C2 Drawing 12271A-2 Basic Pluggable Processor Connect ions - - - - - - - C-3

C3 Drawing 12271A-3 Basic Pluggable Notes Page - - - - - - - - - - - - - C-5

C4 Drawing 12379A-1 Basic Hard-wired System Diagram - - - - - - - - - - C-7

C5 Drawing 12379A-2 Basic Hard-wired Processor Connect ions - - - - - - C-9

C6 Drawing 12379A-3 Basic Hard-wiring Notes Page - - - - - - - - - - - -C-11

C7 Language Translat ion Reference - - - - - - - - - - - - - - - - - - - -C-13
http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/


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List of Figures

2 OPERATIONFigure 1: Station taking Com m and ..............................................................................................................................................................2 -3Figure 2: Control H ead D etents ...................................................................................................................................................................2 -3Figure 3: Rem ote Stations Before Transfer of C om m and ..............................................................................................................................2 -4Figure 4: Rem ote Station Transfer after Transfer of Com m and .....................................................................................................................2 -4Figure 5: Control Head W arm -U p M ode ......................................................................................................................................................2 -4Figure 6: Control H ead N orm al O perating M ode ..........................................................................................................................................2 -5Figure 7: H igh/Low Idle M ode Selection ......................................................................................................................................................2 -5Figure 8: Step A ) O ne Lever O peration M ode ..............................................................................................................................................2 -6Figure 9: Step B) O ne Lever O peration M ode ..............................................................................................................................................2 -6Figure 10: Processor Connections View .......................................................................................................................................................2 -11

3 PLAN THE INSTALLATIONFigure 11: Processor D im ensions .................................................................................................................................................................3 -13

4 INSTALLATIONFigure 12: Connector and H arness Plug Keying ...........................................................................................................................................4 -19Figure 13: H arness Plug Locking M echanism ...............................................................................................................................................4 -19Figure 14: Start Interlock Connections .........................................................................................................................................................4 -20Figure 15: Tw in Screw Serial H arness Connections .....................................................................................................................................4 -20Figure 16: Liquid Tight Installation ...............................................................................................................................................................4 -21Figure 17: Processor Enclosure Cable H oles ................................................................................................................................................4 -21Figure 18: Processor C ircuit Board Term ination Points .................................................................................................................................4 -22Figure 19: Seven-Conductor Control H ead C able S hield W ire and H eat-Shrink ............................................................................................4 -23Figure 20: Clam p View s ...............................................................................................................................................................................4 -23Figure 21: Term inal Strip Cable Connections ...............................................................................................................................................4 -23Figure 22: Tw o-Conductor S tart Interlock Cable ...........................................................................................................................................4 -24Figure 23: Tw o-Conductor Pow er Cable ......................................................................................................................................................4 -24Figure 24: Four-Conductor Serial C om m unication Cable ..............................................................................................................................4 -24Figure 25: A C Type Tachom eter Cable .........................................................................................................................................................4 -25Figure 26: O pen Collector Tachom eter C able ..............................................................................................................................................4 -25Figure 27: Processor Cable Clam p Rotation .................................................................................................................................................4 -26Figure 28: Processor Push-Pull Cable Interior Connections ..........................................................................................................................4 -26Figure 29: Throttle Push-Pull Idle O rientation to Selector Lever ....................................................................................................................4 -26Figure 30: Shift Push -Pull Cable N eutral Connection at Transm ission ...........................................................................................................4 -27

5 SET UP PROCEDUREFigure 31: Typical Processor Cover ..............................................................................................................................................................5 -28Figure 32: Processor Shield Push Button and D isp lay LED Locations ............................................................................................................5 -28Figure 33: D isplay LED at N orm al O peration ................................................................................................................................................5 -28Figure 34: D isplay LED D esignations ...........................................................................................................................................................5 -28Figure 35: Push Buttons ..............................................................................................................................................................................5 -28Figure 36: D isplay LED Error M enu Exam ple ................................................................................................................................................5 -29Figure 37: D isplay LED Four D igit Value .......................................................................................................................................................5 -29Figure 38: D isplay LED Function A 0 .............................................................................................................................................................5 -31Figure 39: D isplay LED Function A 1 .............................................................................................................................................................5 -32Figure 40: D isplay LED Function A 2 .............................................................................................................................................................5 -32Figure 41: D isplay LED Function A 4 .............................................................................................................................................................5 -33Figure 42: Throttle Push-Pull C able O rientation ............................................................................................................................................5 -33Figure 43: D isplay LED Function E0 .............................................................................................................................................................5 -33Figure 44: D isplay LED Function E7 .............................................................................................................................................................5 -34Figure 45: D isplay LED Function C 0 .............................................................................................................................................................5 -34Figure 46: D isplay LED Function C 1 .............................................................................................................................................................5 -34Figure 47: D isplay LED Function C 4 .............................................................................................................................................................5 -35Figure 48: Clutch Push-Pull C able O rientation ..............................................................................................................................................5 -35Figure 49: D isplay LED Function C 5 .............................................................................................................................................................5 -35

Figure 50: Clutch Push-Pull Cable Ahead Position ........................................................................................................................................5 -36Figure 51: D isplay LED Function C 6 .............................................................................................................................................................5 -36Figure 52: Clutch Push-Pull Cable Astern Position ........................................................................................................................................5 -36Figure 53: D isplay LED Function C 7 .............................................................................................................................................................5 -36

6 DOCK TRIALSFigure 54: Throttle Push-Pull Cable Full Throttle Position .............................................................................................................................6 -38Figure 55: D isplay Function C ode E3 ..........................................................................................................................................................6 -38Figure 56: D isplay LED Function E 2 .............................................................................................................................................................6 -38Figure 57: D isplay LED Function E 1 .............................................................................................................................................................6 -38Figure 58: D isplay LED Function E 4 .............................................................................................................................................................6 -39Figure 59: D isplay LED Function E 6 .............................................................................................................................................................6 -39Figure 60: D isplay LED Function E 5 .............................................................................................................................................................6 -40

7 SEA TRIALSFigure 61: D isplay LED Function C 2 .............................................................................................................................................................7 -42Figure 62: D isplay LED Function C 2 .............................................................................................................................................................7 -42

8 CONTROL OPTIONSFigure 63: External A larm C onnections w ith Processor H arness Exam ple ....................................................................................................8 -48Figure 64: External Alarm Connections Processor H ard-W ired Exam ple .......................................................................................................8 -48Figure 65: Clutch Pressure Sw itch w ith Processor H arness ..........................................................................................................................8 -49Figure 66: Clutch Pressure Sw itch w ith Processor H ard-W ired ....................................................................................................................8 -49

B4 TROUBLESHOOTING DIAGNOSTIC MENUFigure B1: D isplay Function C ode ................................................................................................................................................................B 4-7Figure B2: D isplay Troubleshooting Function ................................................................................................................................................B4-7Figure B 3: D isplay Function Blinking .............................................................................................................................................................B 4-7Figure B 4: Exam ple D isplay of A pplied Battery Voltage .................................................................................................................................B 4-7Figure B5: Exam ple Display of Tach Sensor Frequency .................................................................................................................................B 4-7Figure B6: Exam ple D isp lay C ontrol H ead Lever Current Positions ................................................................................................................B4-7Figure B7: Exam ple D isp lay Control H ead Transfer Button Status View .........................................................................................................B 4-7Figure 1: Exam ple D isp lay of Softw are Revision Level View ........................................................................................................................B4-7

B5 TROUBLESHOOTING AUDIBLE TONESFigure B 1: D isplay Exam ples of Rem ote S tations ........................................................................................................................................B5-10Figure B2: D isp lay E xam ples of Rem ote Stations A/D Values ......................................................................................................................B5-10

B6 TROUBLESHOOTING STATION TRANSFERFigure B 3: N o Station Transfer Button D epressed .......................................................................................................................................B 6-15Figure B 4: Transfer Button D epressed for Stations 1 - 4 ..............................................................................................................................B6-15Figure B5: Transfer Button D epressed for Station 5 ....................................................................................................................................B6-15


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LIST OF TABLES

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List of Tables

0 PREFACETable 1: M icroCom m ander 9110X ...................................................................................................................................0 -1

2 OPERATIONTable 2: Processor Connections List...............................................................................................................................2 -11

4 INSTALLATIONTable 3: Circuit Board H ardw ire Term ination Table ........................................................................................................4 -22Table 4: Connections for Rem ote Stations (Refer to A ppendix A - Control H ead Sheets)................................................4 -23Table 5: Processor Circuit Board Connections for Serial Com m unication Cable..............................................................4 -25Table 6: Processor Circuit Board C onnections for Tachom eter.......................................................................................4 -25

5 SET UP PROCEDURETable 7: Processor Function Codes................................................................................................................................5 -30Table 8: Throttle S ervo Function Codes .........................................................................................................................5 -30Table 9: Solenoid C lutch Function C odes.......................................................................................................................5 -30Table 10: Trolling Valve Function Codes ..........................................................................................................................5 -31Table 11: Servo Troubleshooting Function Codes ............................................................................................................5 -31Table 12: Throttle Functions Perform ed during D ock Trials ..............................................................................................5 -33Table 13: Basic Clutch Functions Perform ed during Sea Trials.........................................................................................5 -34

7 SEA TRIALSTable 14: Vessel Inform ation............................................................................................................................................7 -44Table 15: Processor.........................................................................................................................................................7 -44Table 16: Pow er S upply...................................................................................................................................................7 -45Table 17: D ock Trials.......................................................................................................................................................7 -45Table 18: Sea Trials.........................................................................................................................................................7 -45

Table 19: Record Processor Functions.............................................................................................................................7 -46Table 20: Record Throttle Functions ................................................................................................................................7 -46Table 21: Record Clutch Functions..................................................................................................................................7 -46Table 22: Record Troll Functions .....................................................................................................................................7 -46

8 CONTROL OPTIONSTable 23: Figure 63: and Figure 64: D esignators..............................................................................................................8 -48Table 24: Figure 65: and Figure 66: D esignators..............................................................................................................8 -49

B3 TROUBLESHOOTING PROBLEM RESOLUTIONTable B1: Exam ples of Com ponents (Internal/External).....................................................................................................B3-5

B6 TROUBLESHOOTING STATION TRANSFERTable B2: Control H ead Lever A /D Counts.......................................................................................................................B6-15

B7 TROUBLESHOOTING ERROR CODESTable B 3: Basic Error Codes............................................................................................................................................B7-16Table B4: Servo 1 Error Codes........................................................................................................................................B7-18Table B5: Servo 2 Error Codes........................................................................................................................................B7-18

B8 PROBLEM CAUSES AND SOLUTIONSTable 1: Basic Control System Problem Causes and Solutions ......................................................................................B8-19Table B1: Servo 1 Clutch Problem Causes and Solutions.................................................................................................B8-25Table B2: Servo 2 Throttle Problem Causes and Solutions...............................................................................................B8-26

B11 TROUBLESHOOTING WIRE HARNESSESTable B3: Pow er, Start Interlock H arness Pin-O ut..........................................................................................................B11-32Table B 4: Pow er, Start Interlock , Clutch Pressure Sw itch H arness Pin-O ut...................................................................B11-32Table B5: Pow er, Start Interlock, Clutch Pressure Sw itch, and A larm H arness Pin-O ut..................................................B11-32Table B6: Serial Com m unication H arness Pin-O ut.........................................................................................................B11-33Table B7: Control H ead H arness Pin-O ut.......................................................................................................................B11-33Table B8: Control H ead H arness H ard-W ire ..................................................................................................................B11-33TableB 9: Tachom eter Sensor H arness Pin-O ut.............................................................................................................B11-34Table B 10:Tachom eter Sensor H arness w ith Pow er Pin-O ut..........................................................................................B11-34

B12 PROCESSOR PIGTAILSTable 1: Pow er, Start Interlock, Clutch Pressure Sw itch, Alarm Processor Pigtail Pin-O ut............................................B12-35Table 2: Serial Com m unication Processor Pigtail Pin-O ut............................................................................................B12-35Table 3: Control Head Pigtail Pin-O ut (U p to 5 Stations).............................................................................................B12-35Table 4: Tachom eter Processor Pigtail Pin-O ut............................................................................................................B12-35

C7 Language Translation ReferenceTable C1: Color Codes.....................................................................................................................................................C-13


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Page TOC -11

REVISIONS LIST

RevisionDate Revision Description

A 11/03 1. Preface-1 added last paragraph regarding hard-wiring per ELR 1099.2. Section 4-3.2.2 Fig 4-3 revised per ELR 1099 to 5 amperes.3. Section 8.1 Fig 8-1 & 8-2 revised per ELR 1099 to 0.5 amperes. CAUTION revised to

0.5 amperes and 100 volts.

B

4/04 Revised to new modular style.

C 2/05 1. Revised Company Name to "ZF Marine Electronics, LLC"2. Updated all forms to current levels.3. Corrected Cross-Referencing.4. Added Language cross-referencing.

D

8/06 1. Revising to current modular and formatting.2. Removed Battery Maintenance.3. Added Engine Stop Switch Warning to Operation Section4. Corrected Push-Pull Cable Instruction5. Revised Control Head Pigtail Connections6. Updated Appendix A Forms

D 1

4/08 1. Replaced Forms: MMC123 FASSC List (North America and MMC172-FASSC List(International).

2. Replaced MMC-165 - Warranty Policy with currect Rev F, 6/07


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Page TO C -12


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1 INTRODUCTION

Page 1 -1

1 IN TRO D U CTIO NThi s manual i s wri tten to document every possible system opti on. Your system may not i nclude every avail ableoption f or single or mul ti -screw reverse reduction gear appli cations. Only those sections that apply to yourspecifi c in stallati on are relevant to your vessel.

If additional options described within this manual are desired, contact your dealer for availability/compatibilitywi th your system.

1-1 M anual ContentsThi s manual i s divided i nto 12 Sections wh ich cover, in detail , the features and operation of your system:

Introduction (Section 1)

Operat ion (Section 2)

Plan the Installation (Section 3)

Instal lat ion (Section 4)

Set Up Procedures (Section 5)

Dock Trials (Section 6)

Sea Trials (Section 7)

Control Options (Section 8)

Periodic Checks and M aintenance (Section 9)

ZF M arine Electronics Service Sheets (Appendix A) Troubleshooting (Appendix B)

System Drawings (Appendix C)

1-2 Basic Theory of O perationThe MicroCommander Marine Propulsion Contr ol System (hereafter referred to as M icroCommander orSystem) is designed for pleasure and li ght commercial marine vessels that require remote control ofmechanically actuated engines and reverse reduction gears.

The System is electronic and requires a 12 or 24 VDC power supply, one Processor per engine/gear andone Control Head per remote station.

The M icroCommander commands the vessels throttl e and shif t using a single Control H ead l ever.

The Processor i s typically mounted in the engine room area and is connected mechanicall y to the vesselsmain engine throttle and transmission w it h standard 33C type push-pull cables.

One wire harness/electric cable per Control Head lever connects the remote station(s) to the Processor(s).Only one remote station w il l have command at a given time and the Station-in -Command i s indicated by ared li ght located on the Contr ol Head. Station tr ansfer is accompli shed by pressing the Contr ol Headmounted transfer button.

1-2.1 9110X Processor (Throttle - Servo, Shift - Servo, X = Number of Remote Station Pigtails)

The System i s designed for pleasure and li ght commercial m arine vessels that requir e remotecontrol of:

servo engine governors

servo activated clutches

1-3 System Features

1-3.1 Standard Processor FeaturesFurt her in form ation regarding the follow ing features can be found i n Section 2 - OPERATION.

Sequencing of Clutch and Engine Speed.

Station-in-Command indi cation.

Up to f ive Remote Stations.

Command of up to fi ve screws.

Single Control Head lever command of speed and di rection.

Start Interlock.

Push Button Station Transfer.

Proportional (Reversal) Pause on th rough Neutral Shif ts.

Warm-up M ode.


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1 INTRODUCTION

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High/Low Idle Selection.

One Lever M ode.

Engine Synchronization.

Furt her in form ation regarding the follow ing features can be found i n Section 5 - SET UPPROCEDURES.

Easil y conf igured to a vessels control requirements.

Push Button Set Up. Pluggable Connections.

Further information regarding the following feature can be found in Appendix B4 - DIAGNOSTICMENU.

Visual system di agnostics, set up, and status indication.

Further i nformation regarding the followi ng feature can be found i n A ppendix B5 - AUDIBLETONES.

Audi ble system d iagnostics and status indi cations.

1-3.2 Optional Processor Features

Furt her in form ation r egarding each optional f eature can be found in Section 2 - OPERATION"Optional Features".

System failur e external alarm contact.

Clutch pressure interlock. M ulti ple Screw I nstallations.

Station Expander (SE).

9001 Troll ing Valve Control


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2 OPERATION

Page 2 -3

2 O PERATIO N

2-1 D C Pow er O nWhen DC power is turned ON to the Processor:

A short steady tone, followed by an intermi ttent tone, wi ll sound at all Remote Stationsindicating that no station has command.

The Start Interlock relay contact wil l remain open, preventing engine start.

Throttle:Servo: The th rottl e servo w il l dri ve to Idle.

Shi f t:Servo: The Shift servo will drive to Neutral.

2-2 Taking Com m andThe Processor has zero (0) to fi ve (5) Remote Stati on Pigtai l connectors avail able for p luggable RemoteStation Contr ol H ead connection. If more Remote Stations are requir ed, refer to Section 8 - CONTROLOPTIONS "Station Expander".

To take command at any one of the Remote Stations:

Ensure all Control Heads lever(s) at the Station are in the Neutral detent (verti cal positi on).

Depress the transfer button for 1/2 second.

The Slow Repetitive tone will stop at all Stations, and the red LED indicator light will turn ON at theControl Head of the Station t hat had assumed command of the Control System.

The Operator i s now i n contr ol of the vessels propulsion system.

2-3 Basic O peration

2-3.1 Normal Operating Mode

A) The Control Head has thr ee detents; Ahead, Astern and Neutral.

B) Wi th the Control Head lever positi oned in the Neutral (verti cal) detent, the Processor wi ll

command Neutral and the throttle at Idl e revoluti ons per minute (RPM).

D) Further movement of the Control Head lever th rough the next 65 degrees, wil l i ncrease theengine RPM i n proporti on to the Control Heads lever positi on.

Figure 1: Station taking Command

N O TE: If Start Interlock is used: O nce a Station is in com m and the Start Interlock relay contact w ill close,

allow ing the engine to start.

N O TE: O nly one Station can have com m and at a tim e.

W ARN IN G : A n Engine STO P Sw itch M U ST be installed at every rem ote operating station. Refer to CFR 46,

Section 62.35-5 (U S Coast G uard) and ABYC P-24.5.8.

C) Movement of the ControlHeads lever 15 degrees to t heAhead or Astern detent w illcommand Ahead or Asternclutch engagement, w hi le theengine RPM remains at Idle.

Figure 2: Control Head Detents


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2 OPERATION

Page 2 -4

2-4 Start InterlockThe engine start signal i s blocked unl ess all of t he foll owing 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

Command can be transferred as follows:

A) The Station-in-Commands lever(s) may be left in any positi on.

B) Place the Control Heads lever(s) of t he receiving Station in the Neutral/Idl e detent positi on(refer to Figure 3:).

C) At the Station taking command (Receivi ng Station), depress and hold the transfer button for 1/2 second (refer to Figur e 4:). The red LED indi cator li ght at the receiving Stations Control H ead wi ll ill uminate, indi cating

that the Station has taken command. The red LED indicator li ght wi ll go OFF at the transferr ing Stations Control H ead, indi catin g

that the Station no longer is in command.

D) The commanded positi ons of the Throttle and Clutch w ill remain unchanged for one secondafter t he red LED l ights. This allows the operator ti me to move the Control Heads lever(s) to a

position approximately matching the last Station, which will allow the vessel to maintainpresent speed and direction.

2-6 Em ergency Reversal Protection (ProportionalPause)

The proport ional pause provi des a means of safely reversing the vessels dir ection. A var iable pause isin troduced into t he clutch command signal to all ow ti me for the engine RPM s to drop to Idle and for t hevessels speed through the water to slow. This pause is set dur ing Section 7 - SEA TRIALS.

2-7 W arm -up M ode (Throttle O nly M ode)

Thi s feature all ows the operator to i ncrease the engines RPM , wh il e the Clutch r emains in Neutral.Warm-Up M ode is operational only w hen the Control Head lever i s moved in the Ahead dir ection .

The system i s placed into Warm-Up M ode as follows:

A) At t he Station-in-Command, ensure that the Control Heads lever i s in the Neutral detentposition (refer to the following Figure).

B) Depress and hold the transfer button.

W ARN IN G : Personal Injury could occur if the follow ing steps are not follow ed exactly.

Figure 3: Remote Stations Before Transfer of Command Figure 4: Remote Station Transfer after Transfer of Command


C) After one second, move theControl Heads lever to theAhead detent, while continuingto hold the transfer button.

Figure 5: Control Head Warm-Up Mode


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2 OPERATION

Page 2 -5

D) Now release the transfer button.

The red LED indicator l ight wi ll blink slowly, indicating Warm-Up M ode is activated and theClutch has remained at Neutral.

E) The operator now can start the engine, if required, and increase the RPM thr ough the entir ethr ottle range by moving the Control Heads lever f orw ard th rough the next 65 degrees.

F) When the Control H eads lever i s returned to the Neutral detent, the red LED wil l di scontinue

blink ing and remain li t steady. Af ter one second in N eutral, the Processor wi ll automaticall yreset to normal operation with full control of the clutches and engine.

G) The next movement of the Control H eads lever w ill engage the Ahead or Astern clutch (NormalOperation).

2-8 H igh/Low IdleThe Control System provides the input to the engine, so that it m ay r un at t he standard Id le 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 setti ng is for Low Idl e Only.

When the System is initi ally powered-up, it w ill always command Low Idle, even w hen High Idl eis selected.

2-8.2 High Idle

If High I dle is desir ed, it may be programmed duri ng Dock Trials.

High Idle is programmable up to a maximum setting of 20% of Full Throttle.

Hi gh Idle is automatically selected when in Warm-Up Mode.

2-8.3 Selecting Between High and Low Idle

Refer to t he following Figure when selecting between Low and H igh Id le (or vice versa) at theStation-in-Command.

A) The Control Heads lever(s) may be in the Neutral, Ahead or A stern detents whenmaking a selection.

B) Depress and hold the transfer button for 1/2 second and then release.

If t he System was in Low Idle it w il l toggle to High Idle, and vice versa.

C) To return to the previous Idle setting, depress and hold the transfer button again for 1/2second and t hen r elease.

2-9 O ne Lever M ode (M ulti Screw )

Figure 6: Control Head Normal Operating Mode


Figure 7: High/Low Idle Mode Selection

N O TE: In M ultiple Srew applications:

Alw ays program all the Processors for the sam e am ount of H igh Idle.

All Processors w ill be in H igh or Low Idle at the sam e tim e.

N O TE: O ne Lever O peration m ay be used in Troll M ode or in N on-Troll M ode.


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2 OPERATION

Page 2 -6

The system supports a mode of operation referred to as One Lever Mode.

One Lever M ode all ows the operator to control tw o to fi ve engines and transmissions wi th a single ControlHead lever. Any of the Control Head levers at any Remote Station can be designated by the operator as

the Masterlever.

The designation can be changed by the operator at any time. M ost of t he features (synchr onization, t roll ,etc.) available in norm al operation are available whi le operating in One Lever M ode.

The Processor defaults to One Lever M ode disabled.

One Lever M ode can be disabled or enabled in the Set Up Procedures.

When One Lever M ode is enabled, the operation must be turned ON and OFF as describedbelow.

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 Holdthe transfer button whilemoving one of the Control H ead levers forw ard, outof t he Ahead detent. Do Not Release the Transfer Buttonuntil the green LED turns ON,indicating One Lever Operation i s now active.

The Control H ead lever wh ich the operator chose to move out of the Ahead detent,becomes the Masterlever.

The Control H ead lever w hich was left i n t he Ahead detent i s now inactive.

2-9.2 Turning OFF One Lever Operation

A ) Pl ace t he Masterleverinto the Neutral detent.

B) Place all inactive Control Head levers into the Neutral detent.

Whenever an inactive lever(s) is moved to the Neutral detent, One Lever Operation isturned OFF for that lever ONLY!

In applications wi th t hree or more screws, the green LED wi ll not turn OFF until all

inactive Control Head levers are returned to the Neutral detent.

2-10 Engine Synchronization (M ulti Screw )

Synchroni zation is automatic and onl y operates when t he Ahead clutch is engaged, consequently i t can beleft ON full time.

When synchr onization has been selected dur ing set up, the Control System wil l alw ays power-up w it hsynchronization ON.

N O TE: The G reen LED w ill alw ays be lit w hile in O ne Lever O peration, no m atter w hich position the M aster

Control H ead lever is in.


Figure 8: Step A) One Lever Operat ion Mode Figure 9: Step B) One Lever Operat ion Mode

N O TE: The Control H ead lever(s) designated by the operator to be inactive in O ne Lever O peration, m ay be

left in the Ahead detent or m oved fully forw ard. M oving the lever fully forw ard is recom m ended, because it

m oves it out of the w ay and prevents accidental bum ps w hile operating.

W ARN IN G : It is strongly recom m ended that the M aster lever be returned to the N eutral/Idle position prior to

turning O FF O ne Lever O peration.

D o not attem pt to transfer com m and from one R em ote Station to another w hile in O ne Lever O peration.

Alw ays turn O ne Lever O peration O FF prior to transferring.

Failure to observe these recom m endations m ay result in a sudden change in the vessels direction.

N O TE: The C ontrol System offers tw o types of synchronization, Active or Equal Throttle.


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2 OPERATION

Page 2 -7

In order for synchronization to become active (work toward synchr onizing the engines' RPM 's)the Synchronization Criteria listed below must be met.

2-10.1 Synchronization Criteria

Synchronization Criteri a is met when all of t he following are true:

Both Control Heads must be commanding 5% or greater of t he thr ottle range.

The Control Head levers must be wi th in 10% of one another (+/- approximately 6 degrees).

Both Control Head levers are commanding Ahead clutch engagement.

2-10.2 Synchronization Types

The foll owi ng types of synchroni zation use th

mm9110-i rev d1 4-08 microcommander manual

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