MMSC5000 - SMARTCOMMAND USER MANUAL - ZF Marine …€¦ · MMSC5000 - SMARTCOMMAND USER MANUAL MARINE PROPULSION SYSTEMS. 2 EN 3340.758.001a - 2014-10 ORIT ... 2.4 Engine Start Interlock

INSTALLATION, OPERATIONAND TROUBLESHOOTING

MMSC5000 - SMARTCOMMAND USER MANUAL

MARINE PROPULSION SYSTEMS

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COPYRIGHT

Released by After Sales dept.

Data subject to change without notice. We decline all responsibility for the use of non-original components or accessories wich have not been tested and submitted for approval.

ZF reserves all rights regarding the shown technical information including the right to file industrial property right applica-tions and the industrial property rights resulting from these in Germany and abroad.© ZF Friedrichshafen AG, 2014.

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TABLE OF CONTENT

MMSC5000 Rev B 01/13 Page 3

MMSC5000 SmartCommand User ManualTable of Contents

Table of Contents

MMSC5000SW70327.0I

SmartCommand User Manual ........................................................1Table of Contents................................................................................. 3

List of Figures....................................................................................... 7

List of Tables ........................................................................................ 9

Revision List ....................................................................................... 13

Preface ............................................................................................... 15

1 Introduction........................................................................................ 171.1 SmartCommand System..................................................................................................................17

2 Operation ........................................................................................... 192.1 DC Power On ...................................................................................................................................192.2 Take Control ....................................................................................................................................192.3 Basic Operation ...............................................................................................................................202.4 Engine Start Interlock ......................................................................................................................212.5 Proportional Pause ..........................................................................................................................212.6 Station Transfer at Neutral ..............................................................................................................222.7 Station Transfer on the Fly ..............................................................................................................222.8 Warm Up Mode (Throttle Only) .......................................................................................................232.9 High / Low Idle ................................................................................................................................242.10 Twin Screw Synchronization ...........................................................................................................242.11 One Lever Operation Mode .............................................................................................................252.12 Cruise Mode (Default) ....................................................................................................................292.13 Proportional Pause ..........................................................................................................................292.14 Dimming Control Head LEDs ...........................................................................................................302.15 AutoTroll Mode (Optional) ...............................................................................................................302.16 EasiDock Mode (Optional)...............................................................................................................322.17 Two Speed Operation (Optional).....................................................................................................352.18 Mode Stacking.................................................................................................................................36

3 Installation: Planning.......................................................................... 393.1 Processor.........................................................................................................................................393.2 Tools For Installation .......................................................................................................................403.3 Control Heads..................................................................................................................................40

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3.4 Engine Stop Switch .........................................................................................................................413.5 Control System Power ....................................................................................................................423.6 Tachometer Connection ..................................................................................................................423.7 Wire Harnesses ...............................................................................................................................433.8 System Planning ..............................................................................................................................45

4 Installation ......................................................................................... 494.1 Processor.........................................................................................................................................494.2 Power, Start Interlock, Clutch Pressure, and Alarm Circuit Harness ..............................................504.3 Control Heads..................................................................................................................................544.4 Synchronization ...............................................................................................................................574.5 Main Engine Speed Control - Throttle Harness...............................................................................584.6 Clutch and Troll Control...................................................................................................................584.7 Engine Stop Switch .........................................................................................................................59

5 Set Up Procedures ............................................................................. 615.1 Processor Components Used in Set Up ..........................................................................................615.2 Activating Set Up Mode...................................................................................................................635.3 Set Up Functions & Values ..............................................................................................................655.4 System Function Codes (Required) ................................................................................................655.5 Assigning Station IDs.......................................................................................................................665.6 One Lever Mode (System Function Code A2) ................................................................................675.7 JMS Station Pairing (System Function Code A7) ............................................................................675.8 Engine Function Codes....................................................................................................................685.9 Clutch Function Codes ...................................................................................................................705.10 Troll Functions (AutoTroll) ...............................................................................................................745.11 Troll Functions .................................................................................................................................755.12 Docking Functions (EasiDock) ........................................................................................................795.13 Diagnostic Functions .......................................................................................................................80

ENG-289 Function Codes for SmartCommand, JMS, SBW, MCU and POD Systems ....... 81

6 Dock Trials: Adjustments and Tests Secured to Dock ....................... 936.1 Control Head (Engines Stopped) .....................................................................................................936.2 Start Interlock (Engines Stopped) ...................................................................................................936.3 Service Field Test Unit (Break-out Box) and Multimeter Use..........................................................936.4 E-2 Throttle Minimum and E-3 Throttle Maximum Signal (Engines Stopped).................................956.5 Engine Stop Switches Test (Engines Running)................................................................................986.6 Lever Movement at Control Heads..................................................................................................986.7 Warm-Up Mode Test (Engines Running).........................................................................................986.8 E1 - Throttle in Neutral ....................................................................................................................996.9 E4 - Throttle Maximum Astern.........................................................................................................996.10 E6 - High Idle .................................................................................................................................1006.11 E5 - Throttle Pause Following Shift ...............................................................................................102

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7 Sea Trials: Adjustments and Tests Underway ................................. 1037.1 Engine RPM ...................................................................................................................................1037.2 Reversal Pause On Direction Change............................................................................................1037.3 Synchronization Test .....................................................................................................................1047.4 J1 - Idle Lockup RPM.....................................................................................................................1057.5 L1 and L2 AutoTroll Minimum and Maximum Adjustments ..........................................................1057.6 L3 - Troll Throttle Limit ..................................................................................................................1087.7 L4 - Troll Pulse Duration ................................................................................................................1097.8 L5 - Troll Pulse Percentage............................................................................................................1107.9 d1 — Docking Minimum Pressure ..................................................................................................1107.10 d2 — Docking Maximum Pressure..................................................................................................1117.11 d3 - Docking Throttle Limit ............................................................................................................1117.12 d5 - Docking (EasiDock) Pulse Percentage ...................................................................................113

F-259 SmartCommand Sea Trial Report .......................................................................... 115

8 Control Options................................................................................ 1198.1 Alarm Capability ............................................................................................................................1198.2 Clutch Oil Pressure Interlock .........................................................................................................121

9 Periodic Checks and Maintenance .................................................. 1239.1 Control Processor ..........................................................................................................................1239.2 Control Head..................................................................................................................................1239.3 Battery ...........................................................................................................................................123

10 Troubleshooting ............................................................................... 12510.1 General ..........................................................................................................................................12510.2 Troubleshooting Questions............................................................................................................12910.3 System Inspection and Component Identification ........................................................................13210.4 LED Detailed Information...............................................................................................................13310.5 Diagnostic Menu............................................................................................................................13510.6 Audible Tones Detailed Information ..............................................................................................14210.7 Troubleshooting Station Transfer ..................................................................................................14510.8 Error Codes....................................................................................................................................14510.9 Problem Scenarios.........................................................................................................................14910.10 SmartCommand Control Head Replacement ................................................................................15310.11 SmartCommand Processor Replacement......................................................................................15610.12 Harnesses and Plug Pin-Outs ........................................................................................................159

11 Appendix A - System Components and Specifications.................... 179MMC-341 5000 Series Control Head Variations.............................................................. 181

MMC-337 4000 Series Control Head Variations.............................................................. 185

MMC-329 MC2000 Series Standard Control Head Variations......................................... 197

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MMC-280 400 Series Control Head Variations................................................................ 201

S-214 Automatic Power Selector Model: 13505 ............................................................. 207

Drawing 11488 DC Power Source Kit .............................................................................. 209

MMC-287 Grounding (Bonding) ...................................................................................... 219

MMC-288 References and Parts Source ......................................................................... 221

12 Appendix B - Sales and Service Information ................................... 223MMC-172 Factory Authorized Sales & Service Centers - International........................... 225

MMC-165 Warranty ......................................................................................................... 233

MMC-163 Warranty Registration..................................................................................... 235

13 Appendix C - System Drawings ....................................................... 237Drawing 13170 SmartCommand Twin Screw System Drawing........................................ 239

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LIST OF FIGURES


MMSC5000 SmartCommand User ManualList of Figures

List of FiguresFigure 2-1: Take Control at a Station................................................................................................................. 20Figure 2-2: Control Head Detents ..................................................................................................................... 21Figure 2-3: Warm Up LED ................................................................................................................................ 23Figure 2-4: One Lever LED................................................................................................................................ 25Figure 2-5: One Lever Mode: Inactive Lever Ahead........................................................................................... 26Figure 2-6: One Lever Operation: Inactive Lever in Neutral ............................................................................... 27Figure 2-7: Cruise Mode Response Function..................................................................................................... 29Figure 2-8: AutoTroll Lever Response Function ................................................................................................. 32Figure 2-9: EasiDock Response Function .......................................................................................................... 33Figure 3-1: Processor ....................................................................................................................................... 39Figure 3-2: System Configuration Showing CAN bus and Control Heads for Six Station Installation .................. 41Figure 3-3: Processor Harness Connector Locations ......................................................................................... 43Figure 3-4: Wire Harness Deutsch Pluggable Connectors ................................................................................. 44Figure 3-5: System Installation Diagram............................................................................................................ 45Figure 4-1: Processor Dimensions for Installation.............................................................................................. 49Figure 4-2: Wiring DC Power Using the APS..................................................................................................... 50Figure 4-3: Alternative Wiring for APS Power ................................................................................................... 51Figure 4-4: Connections for Start Interlock Circuit............................................................................................. 53Figure 4-5: Control Head Assembly .................................................................................................................. 54Figure 4-6: Deutsch Connector on 70269 Wire Harness ................................................................................... 55Figure 4-7: Turck Connector on 70269 Wire Harness........................................................................................ 55Figure 4-8: Daisy Chaining Control Heads......................................................................................................... 56Figure 5-1: Processor Display and Arrow Push Buttons..................................................................................... 61Figure 5-2: Processor Display and Push Buttons ............................................................................................... 62Figure 5-3: Control Head ID’s Not Set............................................................................................................... 63Figure 5-4: Display Normal Operating Condition ............................................................................................... 63Figure 5-5: Display Set Up Activated ................................................................................................................ 64Figure 5-6: Enter PIN ........................................................................................................................................ 64Figure 5-7: Change the Value of the Function Code.......................................................................................... 65Figure 6-1: Service Field Test Unit and Multimeter............................................................................................ 93Figure 6-2: E1, E2, E3, E4, E6, L3, and d3 Processor, Test Unit, and Multimeter Connections........................... 94Figure 6-3: L1, L2, d1, and d2 Processor, Test Unit, and Multimeter Connections............................................. 94Figure 7-1: Multimeter and Test Unit Connections ......................................................................................... 106Figure 8-1: Alarm Circuit Requirements .......................................................................................................... 119Figure 8-2: Alarm Circuit Example .................................................................................................................. 120Figure 8-3: Clutch Pressure Switch Showing Processor Wire Harness and Shuttle Valve................................. 121Figure 10-1: Basic Control System.................................................................................................................. 125Figure 10-2: System Diagram ......................................................................................................................... 126Figure 10-3: Three Power Sources.................................................................................................................. 128Figure 10-4: Control Head LEDs ..................................................................................................................... 133

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LIST OF FIGURES


MMSC5000 SmartCommand User ManualList of Figures

Figure 10-5: Processor Display in Run Mode................................................................................................... 135Figure 10-6: Display With Active Error ............................................................................................................ 135Figure 10-7: Display When No Control Heads Assigned.................................................................................. 136Figure 10-8: Display with A000 ...................................................................................................................... 136Figure 10-9: Display with H000 ...................................................................................................................... 136Figure 10-10: Display changing from H000 to voltage reading........................................................................ 136Figure 10-11: Output shaft frequency value display ........................................................................................ 137Figure 10-12: Input shaft frequency value display ........................................................................................... 138Figure 10-13: Absent decimal points indicating station number...................................................................... 139Figure 10-14: Expected A/D counts and processor response .......................................................................... 139Figure 10-15: Control/Set button closure displays........................................................................................... 141Figure 10-16: Software revision level display .................................................................................................. 141Figure 10-17: Control head mounting hardware ............................................................................................. 153Figure 10-18: Connections between control heads ......................................................................................... 154Figure 10-19: Control head bottom view......................................................................................................... 154Figure 10-20: Socket key................................................................................................................................ 155Figure 10-21: SmartCommand processor ....................................................................................................... 156MMC-341 Figure-1: 5200 Standard Control Head........................................................................................... 181MMC-341 Figure-2: 5200 Low-Profile Control Head ....................................................................................... 181MMC-341 Figure-3: 5100 Standard Control Head........................................................................................... 182MMC-341 Figure-4: 5100 Low-Profile Control Head ....................................................................................... 182Figure MMC-337-1: Cable / Harness Connections - Pluggable Drawing 14119-1............................................ 187Figure MMC-337-2: 9000 Hard Wired Drawing 14119-2 ................................................................................ 188Figure MMC-337-3: Port Processor - Hard wiring Drawing 13932A - 15B....................................................... 189Figure MMC-337-4: Starboard Processor - Hard wiring Drawing 13932A - 15A.............................................. 189Figure MMC-337-5: 4200 Control Head - Front View Dwg #14132................................................................. 190Figure MMC-337-6: 4200 Control Head - Side View Dwg #14133.................................................................. 191Figure MMC-337-7: 4100LP Control Head – Front View Dwg #13932ART-8................................................... 192Figure MMC-337-8: 4100LP Control Head – Side View Dwg 13932ART-9...................................................... 193Figure MMC-337-9: Control Head Mounting Holes and Cutout – Dwg #13293............................................... 194Figure MMC-337-10: Control Head Mounting Holes and Cutout – Dwg #14649............................................. 195Figure MMC-329-1: Part Numbering Configurations Detents Available ........................................................... 197Figure MMC-329-2: Dimensions ..................................................................................................................... 198Figure MMC-329-3: Terminal Connections ..................................................................................................... 199Figure MMC-329-4: AFT Facing Control Head ................................................................................................ 199Figure MMC-280-1: Part Numbering Configurations ...................................................................................... 201Figure MMC-280-2: Detents Available ............................................................................................................ 201Figure MMC-280-3: Dimensions ..................................................................................................................... 202Figure MMC-280-4: Terminal Connections ..................................................................................................... 203Figure MMC-280-5: AFT Facing Control Head ................................................................................................ 203

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LIST OF TABLES


MMSC5000 SmartCommand User ManualList of Tables

List of TablesTable 2-1: Steps to Take Control....................................................................................................................... 20Table 2-2: Warm Up Mode LED........................................................................................................................ 23Table 2-3: L0 Function Code Values.................................................................................................................. 30Table 2-4: d0 Function Code Values ................................................................................................................. 33Table 3-1: Maximum Cable Lengths for Control Heads ..................................................................................... 41Table 3-2: Key to Wire Harness Connections .................................................................................................... 44Table 3-3: Key for Figure 5: System Installation Diagram .................................................................................. 46Table 3-4: Control Stations ............................................................................................................................... 46Table 3-5: Control Head to Control Head Cables............................................................................................... 46Table 3-6: Control Head to Processor Cables .................................................................................................... 46Table 3-7: Wire Harnesses and Other Parts ...................................................................................................... 47Table 4-1: Wire Gauges for Cables at Flag 1..................................................................................................... 51Table 4-2: Wire Gauges for Cables at Flag 2..................................................................................................... 51Table 4-3: Identifiers for Figure 4-2: Wiring DC Power Using the APS............................................................... 51Table 4-4: Alternative Wiring for APS Power..................................................................................................... 52Table 4-5: Connections for Start Interlock Circuit .............................................................................................. 53Table 4-6: Connections Between Control Heads ............................................................................................... 56Table 5-1: Push Button Keys in Normal Operating Mode................................................................................... 62Table 5-2: Push Buttons in Function Menu (Function Code LED’s are illuminated steadily)................................ 62Table 5-3: Push Buttons in Set Up Mode (Function Code LED’s are blinking) .................................................... 62Table 5-4: Push Buttons at Password Prompt (PIn? Appears on display) ........................................................... 63Table 5-5: Push Buttons for PIN Entry ............................................................................................................... 63Table 5-6: Push Buttons In Error Code Display (’Er’ shows in Function Code).................................................... 63Table 5-7: Engine Throttle Profile Definitions .................................................................................................... 68Table 5-8: L0 Function Code Values.................................................................................................................. 74Table 5-9: Trolling Valve Type Selection............................................................................................................ 75Table 5-10: J6 and J7 Values as Related to J0.................................................................................................. 78Table 5-11: d0 Function Code Values ............................................................................................................... 79Table ENG-289-1: Revision List......................................................................................................................... 81Table ENG-289-2: System Definition Functions (SmartCommand) .................................................................... 82Table ENG-289-3: Engine Functions and Values (SmartCommand)................................................................... 83Table ENG-289-4: Dual Throttle Engine Functions and Values (SmartCommand).............................................. 84Table ENG-289-5: Clutch Functions and Values (SmartCommand) ................................................................... 84Table ENG-289-6: Troll Functions and Values (SmartCommand)....................................................................... 85Table ENG-289-7: Docking Functions and Values (SmartCommand)................................................................. 85Table ENG-289-8: Governed Electric Troll Functions and Values (SmartCommand)........................................... 86Table ENG-289-9: Troubleshooting Functions (SmartCommand) ...................................................................... 87Table ENG-289-10: Steering and Helm Functions (POD)................................................................................... 87Table ENG-289-11: Low Speed Configuration Functions (POD) ........................................................................ 87Table ENG-289-12: High Speed Configuration Functions (POD) ....................................................................... 88

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LIST OF TABLES



Table ENG-289-13: Sport Fish Mode Functions (Sport Fish) ............................................................................. 89Table ENG-289-14: Steering and Helm Functions (SteerCommand) ................................................................. 89Table ENG-289-15: Low Speed Configuration Functions (SteerCommand) ....................................................... 90Table ENG-289-16: High Speed Configuration Functions (SteerCommand) ...................................................... 90Table ENG-289-17: Two Speed Functions ........................................................................................................ 91Table ENG-289-18: Speed Boost Functions ...................................................................................................... 91Table ENG-289-19: System Definition Functions (MCU/JMS)............................................................................ 91Table ENG-289-20: Troubleshooting Functions (MCU/JMS).............................................................................. 92Table 6-1: Functions Requiring Service Field Test Unit and Multimeter ............................................................. 94Table 7-1: Output Shaft Idle Lockup RPM ....................................................................................................... 105Table 7-2: Troll Minimum and Maximum Values ............................................................................................. 107Table F-259-1: Processor Information ............................................................................................................. 116Table F-259-2: Power Supply.......................................................................................................................... 116Table F-259-3: Dock Trials .............................................................................................................................. 117Table F-259-4: Record at Dock ....................................................................................................................... 117Table F-259-5: Sea Trials ................................................................................................................................ 117Table F-259-6: Record During Sea Trial .......................................................................................................... 117Table F-259-7: Follow Up ............................................................................................................................... 118Table 10-1: System Components .................................................................................................................... 126Table 10-2: LED Indications ............................................................................................................................ 134Table 10-3: Diagnostic Values ........................................................................................................................ 137Table 10-4: Error Codes.................................................................................................................................. 145Table 10-5: Problem Scenarios with Error Codes and Possible Solutions......................................................... 149Table 10-6: Function Code Values .................................................................................................................. 157Table 10-7: Wire Harness - Processor to Processor (p/n 70261-XX)................................................................ 159Table 10-8: Wire Harness - Throttle, Voltage (IVECO, Cummins) (p/n 13432-XX)............................................ 160Table 10-9: Voltage Throttle Harness Pin-Out (p/n 14148-XX) ........................................................................ 160Table 10-10: Wire Harness - Throttle (Pulse Width Modulation [PWM]), (p/n 13533-XX)................................ 161Table 10-11: Wire Harness - Cable, Throttle, MAN EDC (p/n 14421-XX)......................................................... 161Table 10-12: Wire Harness- Throttle & Clutch Ahead/Astern w/Neutral Interlock, MAN- Sc (p/n 70588-XX) ... 162Table 10-13: Wire Harness- Throttle, Yanmar CAN Interface, SC (p/n 70766-XX) .......................................... 163Table 10-14: Wire Harness- Throttle, MTU Smartline- SmartCommand (p/n 70747-XX)................................ 163Table 10-15: Wire Harness- Throttle/Neutral Interlock, MAN (p/n 70263-XX) ................................................. 164Table 10-16: Voltage Throttle Harness Pin-Out (p/n 71262-XX) ...................................................................... 164Table 10-17: Wire Harness- Throttle, Dual Voltage- SmartCommand And MiniCommand (p/n 71589-XX) ...... 165Table 10-18: Wire Harness- Tach (Input And Output Shafts) SmartCommand (p/n 70494-XX) ....................... 165Table 10-19: Wire Harness- Clutch Ahead/Astern (p/n 15719-XX).................................................................. 166Table 10-20: Subassembly, Wire Harness Clutches with Troll (p/n 15725-XX) ................................................ 166Table 10-21: Wire Harness - Clutch/Troll Command (p/n 15732-XX) ............................................................. 167Table 10-22: Wire Harness - Clutch/Ahead/Astern/Troll Command/Troll On-Off (p/n 70390-XX)..................... 168Table 10-23: Wire Harness - Clutch/Ahead/Astern- ZFF Transmission (p/n 70673-XX) ................................... 169Table 10-24: Wire Harness - Clutch ZF Gear, MTU Smartline- SmartCommand (p/n 70901-XX) ..................... 170

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LIST OF TABLES



Table 10-25: Wire Harness - Clutch/Shaft Tach, SmartCommand (p/n 70259-XX) .......................................... 171Table 10-26: Power, Start Interlock Harness Pin-Out (p/n 13756-XX) ............................................................. 172Table 10-27: Wire Harness - Power, SI & Clutch Pressure Switch (p/n 13552-XX) .......................................... 172Table 10-28: Wire Harness - Power, SI, Clutch Pressure Switch & Alarm (p/n 13631-XX) ............................... 173Table 10-29: Wire Harness- Power Use w/ existing Start Interlock Only (p/n 15023-XX)................................. 173Table 10-30: Wire Harness- Power/Backup Input For MTU Start Interlock w/ SC (p/n 71021-XX) .................. 174Table 10-31: Wire Harness - Power, Start Interlock, Pressure SW, Alarm & Backup (p/n 71476-XX) ............... 175Table 10-32: Wire Harness- Control Head To OBOF Panel, Port and Stbd (p/n 71495-XX).............................. 176Table 10-33: Wire Harness - Control Head to Control Head (p/n 70268-XX) ................................................... 177Table 10-34: Wire Harness - Control Head to Processor (p/n 70269-XX) ........................................................ 177Table 10-35: Wire Harness - Iso CAN (p/n 70559-XX) .................................................................................... 178Table 10-36: CANtrak termination resistor (p/n 70540-XX) ............................................................................. 178

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REVISIONS LIST


MMSC5000 SmartCommand User ManualRevision List

Revision List

Rev Date Description

- 12/05

Cross Reference in Copyright Notices correctedFuse Value in Figure 14 in Section 3 correctedError codes included in Troubleshooting SectionSystem drawing in Appendix C updated to Rev. APassword instructions changed in Section 5

- 11/06

Some changes made in all Sections.Extensive changes and/or rewrites made to Section 2 - Operations; Section 5 - Set Up; Section 7 - Sea Trials; Appendix A (Section 11) and Appendix C (Section 13). Contact information updated for international sales and service centers in Appendix B (Section 12).

- 1/07 Text of Section 10, “Troubleshooting,” has been substantially updated and enhanced. Illustrations of pinouts for all major SmartCommand wiring situations were added.

- 9/07

Added Start Interlock to Section 2, Operation.Added Engine Stop Switch warning to Section 2, Operation.Added Mode Stacking to Section 2, OperationAdded E7 Values to Table 8, Section 5, Set Up Procedures

A 4/08 Replaced MMC-165 - Electronic Propulsion Limited Warranty

A.1 1/09 Replaced MMC-165 - Electronic Propulsion Limited WarrantyReplaced MMC-123, MMC-151, MMC-172 - Factory Authorized Sales & Service Centers Lists

A.2 11/11 Reformatted to FrameMaker, Restructured manual contents, Updated SW number, Various revisions per ELR00055, ELR00113, ELR00118 and ELR00130, updated all external documents

B 01/13 Revised per ELR00084, ELR00104, ELR00105, ELR00113, ELR00150, ELR00158, ELR00159, ELR00186 and ELR00202.

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PREFACE


MMSC5000 SmartCommand User ManualPreface

Preface

Conventional Symbols Used in the ManualThroughout this manual special attention should be paid to the following symbols

Important Information

IMPORTANT: Keep this manual in a safe place for future reference. It contains essential information about the installation and operation of the ZF Marine Propulsion Systems Miramar control system for your vessel.

WARNING: Personal Injury may result if this message is disregarded.

CAUTION: Damage to equipment may occur if this message is disregarded.

IMPORTANT: Contains essential information about a topic.

NOTE: Contains noteworthy information that may help to clarify a topic.

WARNING: Personal Injury could occur if the following steps are not followed exactly.

CAUTION: On Control Systems with more than one Processor, ZF Marine Propulsion Systems Miramar highly recommends that ALL UNITS utilize the same software revision for each Processor.

CAUTION: Electro-static discharge can damage this equipment. Personnel working on this equipment must be grounded to the chassis with an anti-static wrist strap.

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PREFACE


MMSC5000 SmartCommand User ManualPreface

How to Use the ManualThis manual is written describing all possible options available for this processor. Your vessel may not require all of these options. Refer only to the sections that apply to your vessel. If you wish to use one of the available options listed, please contact a technician from ZF Marine Propulsion Systems Miramar Sales & Service Organization (SSO). For more information on an SSO in your area, please see Section 12: Appendix B - Sales and Service Information.

CAUTION: Disconnect the power from the processor whenever welding is being done on the vessel. Failure to do so can cause permanent damage to the processor.

CAUTION: This equipment is designed to work with other ZF Marine Propulsion Systems Miramar designed equipment. DO NOT operate this equipment with any other manufacturer's equipment unless approved so in writing by ZF Marine Propulsion Systems Miramar Engineering Department.

NOTE: ZF Marine Propulsion Systems Miramar is not liable for any damage incurred if these notices are not followed exactly.

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INTRODUCTION


MMSC5000 SmartCommand User ManualIntroduction

1 Introduction

1.1 SmartCommand SystemThe SmartCommand System is designed for:

• Engines that require voltage, current (mA), PWM, or frequency speed command signals. SmartCommand systems work with all major electronic engine brands.

• Transmissions equipped with electric solenoid valves (on/off or proportional) and Controller Area Network (CAN) bus J1939 for connecting to ZF Marine Transmission Control Unit (MTCU).

1.1.1 Features

SmartCommand has the following performance features:

a Clutch and Engine Speed Sequencingb Start Interlockc High/Low Idled Multi Screw Engine Synchronizatione Electric Trolling Valve Controlf Emergency Reversal Protectiong Clutch Oil Pressure Interlock (optional)

Features that make the control head easy to use are:

a Indicator for Station-in-Commandb Six bi-color LEDs for indicating control system mode and statusc One to six Remote Stations, and up to three control heads on each of two independent CAN

bus lines, for commanding and controlling the vessel.d Sound transducer for system status indication.

The processor includes the following features:

a Four digit LED and key pad at main processor to simplify set up, configuration, and troubleshooting.

b Plug-in cable connectionsc SmartCommand failure alarm contact (optional)d Built-in diagnostics

Vessels that have more than one power source, which is recommended, should use an automatic power selector (APS). The APS (part number 13505, available from ZF Marine), compatible with 12 VDC or 24 VDC systems, increases the reliability of power delivery.

Cruise mode is the default mode of SmartCommand. This mode uses a single lever for clutch and throttle control, with one control lever for each screw. Automatic engine synchronization is enabled in Cruise mode.

Important: This manual contains information about all of the options available with the SmartCommand system. Your application might not use all of the options, so you can disregard those sections of the manual that do not apply to your configuration.

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INTRODUCTION


MMSC5000 SmartCommand User ManualIntroduction

1.1.2 Advanced Control Modes

SmartCommand has several advanced control modes:

mode gives you positive clutch response while ensuring easy and precise maneuvering ability in tight docking situations

mode maintains a constant propeller RPM while you have a full range of shaft speed control.

Warm up mode increases the engine RPM when the transmission is locked in neutral.

One lever mode allows you to have full shift and throttle control while operating multiple screws with a single lever.

Mode Stacking - allows use of One Lever and AutoTroll simultaneously.

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OPERATION


MMSC5000 SmartCommand User ManualOperation

2 OperationThis Section is intended for vessel operators. Generally speaking, most other Sections of this manual, while informative for users, contain information that is primarily useful for installers.

2.1 DC Power OnWhen DC power is turned ON, the SmartCommand control system:

• Commands neutral and idle from the processor.• Sounds an intermittent tone pattern at all stations indicating that no station has control. (Refer to

explanations of audible tones in section 10: Troubleshooting.)• Starts the transmission in the low speed gear. (If the vessel uses the Two Speed feature, the two

speed solenoid is de-energized.)

2.2 Take ControlThe system initializes with no control at any station. To take control at a station:

• Put control head levers in the neutral detent. The station cannot take control with the levers in any other position. The initialization tone pattern sounds.

• Press Control/Set at the station. The Control LEDs light steady green, indicating the station has control and the operator is commanding neutral. The tone pattern stops at all stations.

• Start the engine while commanding Neutral. If the control head levers are out of Neutral, the start interlock switch prevents the engines from starting.

• Move levers into the Ahead or Astern detent. The transmission shifts into gear and the Control LEDs light steady red, indicating the station is in control and the operator is commanding ahead or astern.

Warning: An Engine Stop Switch MUST be installed at every remote operating station. Refer to the Code of Federal Regulations (CFR) 46, 62.35-5 and the American Boat and Yacht Council (ABYC) standards on electric and electronic propulsion control systems (P-24.5.8). Personal Injury may result if this message is disregarded.

Important: The next control head lever movement shifts the transmission.

Note: Only one station has control at any time.

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OPERATION



Figure 2-1: Take Control at a Station

2.3 Basic OperationThe control head has three detents; Astern, Neutral, and Ahead, as shown in Figure 2-2: Control Head Detents. The system commands neutral/idle RPM with the control head levers positioned in the neutral detent. When you move the levers 15 degrees to the Ahead or Astern detent, the clutch(es) engage while the engine remains at idle RPM. In the throttle range, beyond the detents, engine RPM is incremented or decremented depending on the lever position.

Table 2-1: Steps to Take Control

Step Indicator Action Lever Position Response

1 A Move levers to Neutral Neutral Control head can take control

2 B Press Control/Set until CONTROL LEDs light Neutral Station takes control

3 C Move levers to ahead detent Ahead detent Vessel moves in response to lever position

Note: The Engine Start Interlock feature prevents the engines from starting if the DC power is not on, if a station is not in command, and if the control head levers are not in neutral. An exception to this rule is when the system is in Warm Up mode, when Start Interlock allows the engines to start with the levers in the throttle range.

Warning: An Engine Stop Switch MUST be installed at every remote operating station. Refer to the Code of Federal Regulations (CFR) 46, 62.35-5 and the American Boat and Yacht Council (ABYC) standards on electric and electronic propulsion control systems (P-24.5.8). Personal Injury may result if this message is disregarded.

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Figure 2-2: Control Head Detents

2.4 Engine Start InterlockEngine Start Interlock requires three steps to start the engine:

1. Turn ON DC power to the control system. The system must have power.2. Set the levers at the neutral detent.3. Take command at a station. One station must be in control.

2.5 Proportional PauseProportional pause provides a means of safely reversing vessel direction. Any time the levers are beyond the ahead or astern detent and you reverse direction, the clutch command signal is paused between ahead and astern. The pause allows time for the engine RPM to drop to idle and for the vessel to slow as it moves through the water. The pause interval depends on vessel speed, lever position, and the length of time the levers have been in that position. The proportional pause is configurable through proportional pause time and proportional pause ratio Function Codes C3 and C4, which are explained in section 5: Set Up Procedures.

Note: The neutral detent (the center of control head movement) is 10 degrees in the ahead direction. The degrees of lever movement are measured from this point, not from the vertical.

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2.6 Station Transfer at Neutral

To transfer control from one station to another with the levers in neutral:

1. Verify that both control head levers at the station in command are in the neutral detent.2. Verify that both control head levers at the station taking control are in the neutral detent.3. At the station taking control, press Control/Set.4. The Control LEDs on both sides illuminate steady green, indicating that this station has control.5. AutoTroll, EasiDock, and Warm Up modes, as well as the high idle function (see explanation of Function Code

E6 in section 5: Set Up Procedures), transfer to this station, and LEDs illuminate appropriately.6. The Control LEDs on the original station go out.7. Move the control levers into gear. The Control LEDs on both sides illuminate steady red. The LEDs stay red as

long as the vessel is in gear.

2.7 Station Transfer on the Fly

To transfer control from one station to another:

1. Leave the control head levers of the station in control in any position.2. Place the control head levers of the receiving station in the neutral detent position.3. At the station taking control, press Control/Set. The Control LEDs on both sides illuminate steady green. This

station now has control and AutoTroll, EasiDock, and Warm Up modes, as well as high idle (Function Code E6), are transferred to this station. LEDs illuminate to match the setting. One Lever mode does not transfer.

4. The Control LEDs on the control head at the original station go out.5. Throttle and clutch positions that had been commanded by the station from which control was taken remain

unchanged for one second after the Control LEDs on this station illuminate. This allows time for moving the control head levers at this station to approximate the same speed and direction.

6. Move the control levers into the position you want to command. The Control LEDs on both sides illuminate steady red.

Warning: Follow the steps in this section exactly. Personal Injury may result if this message is disregarded.



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2.8 Warm Up Mode (Throttle Only)Warm Up mode (throttle only) increases engine RPM while the clutch remains in neutral, when levers are in the ahead position. If you move the levers into the astern range, the engine remains at idle and the clutch remains in neutral. If the high idle function has been set (refer to Function Code E6 in section 5: Set Up Procedures), the engines idle at the high idle setting in Warm Up mode. The Warm Up LED shows steady red when you are in Warm Up mode.

Figure 2-3: Warm Up LED

2.8.1 Entering Warm Up Mode

You can start and warm up engines by moving the control head levers through the ahead throttle ranges, without the clutch engaging.

To put the system in Warm Up mode:

1. At the station in control, put the control head levers in the neutral detent position. Make sure the levers are definitely in neutral (i.e., the AutoTroll, EasiDock, or One Lever LEDs are not illuminated).

2. Press the Mode button and hold it down until the Warm Up LED blinks. Within 10 seconds, press the Control/Set button. (If Control/Set is not pressed with this amount of time, the Warm Up LED stops blinking and the mode does not change.)

3. The Warm Up LED changes from blinking to steady red.

Table 2-2: Warm Up Mode LED

LED State Meaning

Off Warm Up mode not selected or not available

Blinking Select Warm Up mode using Control/Set

Steady RED Warm Up mode is selected: transmission is in neutral


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4. At the station in control, position the control head levers in the ahead range. The percentage of throttle increases, while the transmission remains in Neutral. The Control LEDs blink green. If you move the levers into the astern range, the engine speed returns to idle and the clutch remains in neutral.

5. Warm Up mode is active (signified by the lighted Warm Up LED) until you deselect it by going to neutral as described below.

2.8.2 Exiting Warm-up mode

When the SmartCommand system is in Warm Up mode (Warm Up LED shows steady red), to exit:

1. At the station in control, place the control head levers in the neutral detent.2. The Warm Up LED illuminates steady red and the Control LEDs blink green.3. Press Mode and hold until the Warm Up LED extinguishes (approximately one second) and the Control

LEDs illuminate steady green.

4. Move the control head levers into the position you want to command in Cruise mode (Control LEDs illuminate steady red) or select another mode.

2.9 High / Low IdleThe SmartCommand system offers two engine idle RPM options:

• Low Idle — the normal engine idle RPM, the default setting, and the idle at power up.• High Idle — set with Function Code E6, which can be programmed during set-up. (See section 5: Set

Up Procedures.) High idle can be set to a maximum of 20% of full throttle. The default setting is the same as low idle.

To switch from low to high idle, move the control head levers to any of the detents. Press Control/Set on the control head and hold it down for one-half second. To switch back to low idle, move the control head levers to any of the detents and press and hold Control/Set for one-half second.

2.10 Twin Screw SynchronizationBy default, the SmartCommand System uses active synchronization if a tachometer signal is available and equal throttle synchronization if there is no tachometer signal. SmartCommand powers up with synchronization enabled. Synchronization is automatic, can be left on all the time, and is operable in One Lever mode.

In order for synchronization to activate and begin synchronizing the engines, the control head levers must be in the synchronization range. Engine speeds will match when both control head levers are in the Ahead throttle range (at least 5% forward of the detent) and throttles positioned within 10% of each other.

2.10.1 Setting Up Synchronization on the Processor

Choose Equal Throttle Synchronization, Active Synchronization, or no synchronization at processor set up (refer to the E7 Function Code in section 5: Set Up Procedures). When either Equal Throttle or Active Synchronization is set up, synchronization is enabled by default.

• Equal Throttle Synchronization — processor throttle signals are compared and matched, and the processors send the same signal to all engines. Once the signals match, the engines are considered to be synchronized. This type of synchronization is very effective in most cases.


Caution: Do not shift in High Idle, if the engine RPM at High Idle is higher than the maximum RPM recommended for your gears. For gear specifications and other information, refer to documentation provided with your transmission.

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• Active Synchronization — requires a tachometer signal representing the RPM of each engine, in addition to the throttle command signal. The function provides for the tachometer frequency to be measured and the throttle command signal outputs to be changed until both engines are running at the same RPM, as measured by the tachometer signals.

2.10.2 Disabling and Enabling Synchronization from the Control Head

To disable synchronization from a control head, while the levers are within the synchronization range, press the Control/Set button and hold for five seconds. The engines will now operate independently, regardless of the lever position.

If synchronization has been disabled, to enable it again from the control head, position the levers in the synchronization range, press the Control/Set button and hold for five seconds. The engines will now synchronize whenever the levers are in the synchronization range.

2.11 One Lever Operation ModeOne Lever mode allows you to control all vessel engines and gears with a single lever. This is useful for open water operation, but not for close quarter maneuvering. Either lever can be the active lever.

One Lever mode can be operated in two different ways — either with the inactive lever in neutral or with the inactive lever remaining stationary in the Ahead throttle range — selected through the A2 function at the time you set up the processors (see section 5: Set Up Procedures). Normal control sequencing and timing continue to operate on all engines when One Lever mode is in use. Engine synchronization and Two Speed operation work the same in One Lever mode as they do in Cruise mode.

Figure 2-4: One Lever LED

Warning: Whichever way you choose to use it, follow the steps to enable and disable One Lever Mode exactly. Personal Injury may result if this message is disregarded.

Note: One Lever mode can only be employed when you are in Cruise mode. The One Lever LED is always lit while in One Lever mode. The position of the active control head lever does not affect this LED.

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2.11.1 One Lever Operation: Option One (Inactive Lever Ahead)

The inactive lever ahead option of One Lever mode is set at the processor when a value of 01 is assigned to the Function Code A2 at the time set up procedures are performed (see section 5: Set Up Procedures). This option may be the best choice for sport fishers and other applications where it makes sense to leave the inactive lever stationary in the full forward position.

Figure 2-5: One Lever Mode: Inactive Lever Ahead1. At the active station, move both the control head levers to the Ahead Detent. AutoTroll, EasiDock, and

Warm Up LEDs cannot be illuminated. Press Mode once, twice, or three times until the One Lever LED blinks. (The number of button presses depends on the features installed on your vessel and the lever position.

2. Press Control/Set once to select One Lever mode.3. When the One Lever LED blinks green and red, choose a lever to control the system, by moving it

forward. This is the active lever.4. Move the active lever to the throttle position you want to command. The One Lever LED illuminates red

if the active lever is the port lever and green if the active lever is the starboard lever.

5. You can leave the inactive lever in the Ahead detent or move it further forward.• Disable One Lever Operation: (Inactive Lever Ahead)

The easiest way to break out of One Lever mode is to move both levers to the neutral detent for at least a half second. Alternatively, you can move the inactive lever to the neutral detent. Or you can put both levers at the Ahead detent, and press the mode button until the One

Note: Keep the inactive lever at the Ahead detent or further forward. If the inactive lever is moved to neutral (or through neutral to astern) One Lever mode is deactivated.

Note: Processor IDs determine which lever is considered port or starboard. The colors stated assume that the port processor has Processor ID 1 and the starboard processor has Processor ID 2.

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Lever LED goes out. You know you are out of One Lever mode, and that both levers are active again, when the One Lever LED is off. Both levers are now active.

2.11.2 One Lever Operation: Option Two (Inactive Lever in Neutral): Default Mode

In the default mode of operation, the inactive lever remains in the neutral detent when it is unused. Function Code A2 is set to a value of 02 at the processors for this mode of operation.

2.11.3 Enable One Lever Operation: Inactive Lever in Neutral.

Figure 2-6: One Lever Operation: Inactive Lever in Neutral1. At the active station, move both the control head levers to the Ahead Detent or more fully forward,

remaining within 15% of each other. AutoTroll, EasiDock, and Warm Up LEDs cannot be illuminated. Press Mode once, twice, or three times until the One Lever LED blinks. The number of button presses depends on the features installed on your vessel and the lever position.

2. Press Control/Set once to select One Lever mode. If no button is pressed within approximately 3 seconds, the LED stops blinking and the mode does not change.

3. The One Lever LED blinks green and red for a maximum of two seconds. Choose the lever you want to inactivate.

4. Move this lever to the neutral position within the two second time frame. The One Lever LED illuminates red if the active lever is the port lever and green if the active lever is the starboard lever.

Important: If you are in One Lever mode at one station and you transfer vessel command to another station, One Lever mode does not transfer. To use One Lever mode at the new station in command, set it at that station.

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The processor ID’s control which lever is considered port or starboard: the colors stated assuming the Port Control Processor has Processor ID 1 and the Starboard Control Processor has Processor ID 2.

Move the active lever to the throttle position you want to command. Do not move the inactive lever.

2.11.4 Disable One Lever Operation: Inactive Lever in Neutral

Use the control head buttons to exit One Lever mode:

1. Press Mode for approximately one second to deselect One Lever mode.2. The One Lever LED extinguishes. One Lever mode is disabled.

Alternatively, move the inactive lever out of the neutral detent. One Lever mode is disabled. The One Lever LED turns off. Both levers are active.

Note: Best Practice: To break out of One Lever mode, move both levers to neutral and press the Mode button until the One Lever LED extinguishes.

Warning: If you attempt to disable One Lever mode with one lever in Neutral and the other lever in ahead results in different engine speeds on the port and starboard sides. The vessel turns until the levers are brought closer together. Personal Injury may result if this message is disregarded.

Note: The One Lever function is only operational in Cruise mode.

Important: One Lever mode does not transfer when SmartCommand transfers stations. To use One Lever mode at the new station, set it at that station.

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2.12 Cruise Mode (Default) Cruise mode is the default mode. The clutch engages at the 15 degree (ahead or astern) detent position. As the lever rotates through the 60 degree throttle range, engine speed increases from Idle to Full and shaft RPM increases from minimum to maximum.

The example shown in Figure 2-7: Cruise Mode Response Function assumes a 2:1 gear ratio, and an engine with an idle speed of 600 RPM and full throttle at 2300 RPM. In this situation, shaft RPM increases from 300 to 1150 RPM. (In real life situations, values may be different.)

Figure 2-7: Cruise Mode Response Function

2.13 Proportional PauseThe Proportional Pause provides a means of safely and efficiently reversing the vessel’s direction in the shortest time possible. When commanding a change in direction:

• The throttle command signal drops to Idle.• The clutch remains engaged or, if a shaft brake is installed, the clutch is commanded to Neutral.• The propeller dragging through the water helps slow the vessel's progress.

The clutch command signal is paused in this position for a sufficient duration to allow the engine's RPM to reach Idle and the vessel's speed through the water to slow enough that a clutch reversal does not damage the gear box or stall the engine.

The opposite clutch engagement command is given. When sufficient clutch oil pressure is reached, a throttle signal above Idle provides thrust in the opposite direction.

The amount of time the clutch command pauses depends on the amount of speed commanded and how long that speed has been commanded. Maneuvering from Idle Ahead to Idle Astern has no delay.

The vessel must travel at full throttle for a period of six times the programmed pause in order to reach the maximum programmed pause time. For example, if the maximum proportional pause is set to five seconds, the vessel must travel at full throttle for 30 seconds (6 x 5) in order to reach the full five second pause. If full throttle is commanded for 15 seconds, the pause is 2.5 seconds. If 50% throttle is commanded for 15 seconds, the pause is just 1.25 seconds. See section 5.9.3: C2 — Reversal Pause through section 5.9.4: C3 — Reversal Pause Time.

Note: If your vessel uses ZF Friedrichshafen gears with an MTCU, there is a short pause at clutch engagement, and the throttle increases slowly for the first two seconds the clutch is engaged.

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The default pause from Astern to Ahead is one half the Reversal Pause value, since most vessels do not reach the same throttle in Astern as they do in Ahead. Use the C4 Function Code to change the Astern to Ahead relationship.

2.14 Dimming Control Head LEDsControl head LEDs are bi-color red/green daylight bright. If the LEDs are too bright, press the MODE button for at least 10 seconds and they will dim incrementally. Hold the button down until the desired brightness is reached, and then release. Continual pressing of the MODE button causes the LEDs to recede to minimum brightness and then revert to full bright, then cycle back, etc. At power-up, the LEDs are set to their maximum brightness.

Changing the LED brightness on one control head will not affect the brightness level of LEDs on other control heads.

2.15 AutoTroll Mode (Optional)

AutoTroll mode controls electric Trolling Valves using single solenoids or dual solenoids for Troll On/Off and Proportional. Set up AutoTroll and its Function Codes at the processor. After Function Codes have been set up, AutoTroll is enabled and disabled from the control heads. AutoTroll gives your vessel specific, repeatable shaft RPM for trolling. The gears installed in the vessel determine whether troll can operate with or without feedback. Gears with feedback have additional wire harness connections, either a tachometer signal or an MTCU. AutoTroll with feedback requires an output shaft sender to close the loop.

This system has three modes of operation when a troll valve is present and has been configured: AutoTroll, Cruise mode, and EasiDock. When the control system initially powers up, Cruise mode is selected by default. If the vessel uses the tachometer signal to provide shaft RPM feedback, and the tachometer signal is lost, AutoTroll operates in open loop troll. Slip is commanded without feedback and can vary.

In Cruise mode, the trolling valve is at the maximum gear oil pressure position (locked up). The trolling valve is not used in Cruise mode.

AutoTroll must be selected and deselected at the control head.

2.15.1 Adjustable AutoTroll Lever Range

The troll lever range can be adjusted to one of five values at processor set up, through the L0 Function Code. The values for L0 are:

Table 2-3: L0 Function Code Values

L0 ValueAutoTroll Range (in Degrees)

Control Head Lever at Ahead and Astern Detents

Movement through AutoTroll Range Movement Beyond Troll Range

00Default No Troll

Clutch Fully Engaged, throttle at idle NA

Clutch Fully Engaged, Neutral to Full Throttle

01 15 degrees Minimum Troll Clutch pressure, throttle at idle

Minimum to Maximum troll Clutch pressure, throttle from idle to maximum troll throttle

Clutch fully engaged, throttle from minimum to full






Clutch fully engaged, throttle limited to 75% of full




05 Detents OnlyOnly at detents, Minimum Troll clutch pressure, throttle at idle

No Movement Clutch fully engaged, throttle from minimum to full

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2.15.2 Enabling AutoTroll

1. Place both control head levers in the Neutral, Ahead, or Astern Detent. Both levers must be in the same detent. The EasiDock, One Lever, and Warm Up LEDs cannot be illuminated.

2. Press Mode until the AutoTroll LED blinks. If no button is pressed in ten seconds, the LED stops blinking and the mode does not change.

3. Press Control/Set once to illuminate the AutoTroll LED. AutoTroll mode is enabled.

2.15.3 Lever Movement in AutoTroll

By default, when SmartCommand enables AutoTroll, the AutoTroll solenoid pulses momentarily when the levers are placed into the Ahead or Astern detent. This starts the propeller shaft moving at minimum troll. The commanded value drops to 30% to 50% of the idle lockup RPM for AutoTroll operation.

• The throttle remains at Idle;• The transmission commands Ahead or Astern;• Control head AutoTroll LED illuminates steady red.• The Control LEDs blink red.

Continued control head lever movement through the troll range:

• Increases the propeller RPM from 30% to 50% of idle output shaft RPM to approximately 70% maximum output shaft RPM.

• Throttle remains at Idle or can be adjusted to increase up to 20% of maximum throttle within the Troll Range.

• The control head AutoTroll LED remains illuminated.• The Control LEDs blink red.

Moving the control head lever beyond the troll range:

• Clutch locks up (no slip).• Engine speed increases, maximum is defined by the L0 value.• The control head AutoTroll LED remains illuminated.• The Control LEDs illuminate steady red.

For the example shown in the figure below, the L0 Function Code has been set to 02: 30 degrees of the lever rotation angle is dedicated to trolling. As the lever rotates, shaft speed gradually increases from 90 RPM at the detent to 210 RPM at 30 degrees; engine speed remains at idle. For the last 30 degrees of lever rotation, the clutch is fully engaged and the engine speed increases linearly, up to the maximum throttle setting.


Note: If your vessel uses ZF Friedrichshafen gears with an MTCU, the throttle increases slowly for the first two seconds the clutch is fully engaged.

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Figure 2-8: AutoTroll Lever Response Function

The upper limit for the troll throttle percentage is 20% of full throttle. The default value for maximum troll throttle percentage is 0%: the engine always remains at idle. Only change the default value after completing the checks and calculations in section 7.6.2: Set the Troll Throttle Limit, and Throttle in Docking Range.

2.15.4 Disabling AutoTroll

Place the active control head levers in the Neutral, Ahead, or Astern detent.

Press Mode for approximately one second until the AutoTroll LED extinguishes. The clutch is locked up: it does not slip as it does in AutoTroll.

2.16 EasiDock Mode (Optional)

EasiDock mode gives you positive clutch response and appropriate thrust allowing you to modulate the clutches and control the engine speed for easy maneuverability in confined waters. It provides a rapid, smooth change from ahead to astern while docking the vessel.

SmartCommand commands a higher clutch pressure when SmartCommand enters EasiDock mode. The propeller shaft starts to move; the thrust is noticeable. After a short time, the pressure drops to a lower lockup percentage. Clutch pressures in EasiDock can be optionally configured at setup, either at a specific value or through a range. If the tachometer feedback used by EasiDock is lost, the vessel drops out of EasiDock mode.

EasiDock mode commands decreased clutch pressure at the Ahead or Astern detents, and in the EasiDock range. The clutch engages fully if the levers move past the EasiDock range; there is no slip.

Caution: To prevent damage to the clutch pack, the maximum throttle percentage in AutoTroll mode is limited. Most transmissions require that throttle be limited to less than 1000 RPM. If the throttle limit is set with the L3 Function Code, the upper limit must be chosen carefully. Detailed information about choosing the upper limit can be found in section 7.6.1: Calculating the highest throttle percentage allowed.

Caution: If the vessel is underway in AutoTroll with the control head levers in the Ahead or Astern detent and AutoTroll is disabled, the vessel enters Cruise mode. The vessel accelerates to normal idle in gear speed.

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In the example graph, docking mode is active the first 40 degrees from the detent position and allows a smooth but quick prop response (from 150 to 330 RPM) due to the combined action of clutch slip and engine speed increasing from 600 to 940 RPM. For the remaining 20 degrees, the clutch is fully engaged and engine speed increases to 75% of the full engine speed, to 1875 RPM.

Figure 2-9: EasiDock Response Function

The upper limit for the EasiDock throttle percentage is 20% of full throttle. The default value for the EasiDock throttle percentage is 0%: the engine always remains at idle. Only change the default value after completing the checks and calculations in section 7.6.1: Calculating the highest throttle percentage allowed.

2.16.1 Adjustable EasiDock Lever Range

The lever range in EasiDock mode can be adjusted to one of five values at set up, through the d0 (“lowercase d”) Function Code. The values for d0 are:

Caution: The maximum throttle percentage in EasiDock mode is limited to prevent damage to the clutch pack. Most transmissions require that the throttle is limited to less than 1000 RPM. Detailed information about choosing the upper limit is found in section 7.6.1: Calculating the highest throttle percentage allowed.

Table 2-4: d0 Function Code Values

d0 Value Docking Range Control Head Levers at

Ahead and Astern Detents Movement through Docking RangeMovement Beyond Docking

Range

00Default No docking

Clutch Fully engaged, throttle at idle NA


01 15 degrees Minimum Docking Clutch pressure, throttle at idle

Minimum to maximum docking clutch pressure, throttle from idle to maximum docking throttle


02 30 degrees Minimum docking clutch pressure, throttle at idle



03 40 degrees Minimum docking clutch pressure, throttle at idle



04 50 degrees Minimum Docking Clutch pressure, throttle at idle

Minimum to Maximum docking Clutch pressure, throttle from idle to maximum docking throttle


05 Detent Only Minimum Docking Clutch pressure, throttle at idle No movement in docking.Clutch fully engaged, throttle from minimum to full*

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* If the d0 Function Code is set to 05, you can exit EasiDock while the levers are in the ahead range.

2.16.2 Enabling EasiDock

1. Place both control head levers in the Neutral, Ahead, or Astern Detent. Both levers must be in the same detent. The AutoTroll, Warm Up, and One Lever LEDs cannot be illuminated.

2. Press Mode until the EasiDock LED blinks. If no button is pressed in ten seconds, the LED stops blinking and the mode does not change.

3. Press Control/Set once to light the EasiDock LED. The Control LEDs blink green. EasiDock mode is enabled.

The output shaft tachometer signal must be present for the vessel to enter EasiDock mode. If EasiDock is set up, and no tachometer signal can be detected, the system delays two to three seconds. If no tachometer signal is detected after the delay:

• The station in command generates an error tone.• A fault code appears on the processor:

- fault code 92 if the input shaft sensor faults,

or

- fault code 93 if the output shaft sensor faults.

• The EasiDock LED blinks rapidly.• The clutch remains fully engaged.

EasiDock mode does not enable until the processor receives the tachometer signal.

2.16.3 Lever Movement in EasiDock

When EasiDock is selected, clutch pressure is increased for a short time determined by the docking pulse duration Function Code. After this pulse has been applied, the clutch is allowed to slip again.

• The throttle remains at Idle.• The transmission commands Ahead or Astern.• Control head EasiDock LED is illuminated.• The Control LEDs blink red.

Continued control head lever movement through the docking range:

• Increases the propeller RPM from minimum shaft RPM to maximum shaft RPM.• Throttle remains at Idle or can be adjusted to increase within the docking range.• The control head EasiDock LED remains illuminated.• The Control LEDs blink red.

Moving the control head lever beyond the docking range:

• Clutch locks up (no slip).• Engine speed increases, maximum is defined by the d0 value.• The control head EasiDock LED remains illuminated.• The Control LEDs illuminate steady red.

2.16.4 Disabling EasiDock

In order for EasiDock mode to be disabled, the EasiDock LED must be illuminated. Place the active control head levers in the Neutral, Ahead, or Astern detent. If Function Code d0 is set to 05 - Docking in Detents Only, you can exit while the levers are in any detent or in the ahead range. Press Mode for


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approximately one second until the EasiDock LED extinguishes and the clutch is locked up; the clutch does not slip as it does in EasiDock.

There is no additional acceleration if you disable EasiDock in the ahead range when d0 is set to 05. The clutch is already fully engaged and you are traveling at the normal in-gear speed.

2.17 Two Speed Operation (Optional)SmartCommand two-speed reverse reduction gears are controlled by a solenoid choosing the gear. You can manually or automatically control the up-shift and down-shift RPM, depending on the installation.

For Two Speed operation to be functional, two-speed gears must be installed and two-speed Function Codes must be set. Additional switches and wiring are required to switch gears manually.

2.17.1 Automatic Shift Operation

The up-shift and down-shift RPM for automatic shift are set through software. The vessel begins in the first (low) gear when ahead is commanded. When engine speed for both engines increases to the up-shift RPM, SmartCommand commands the transmission to shift to second gear on both engines simultaneously.

If the engines are running at different speeds, the gears shift when the slower engine reaches the up-shift speed.

As the engines decelerate, the shift to first gear is controlled by the down-shift RPM. Both engines down shift automatically and simultaneously. SmartCommand down shifts the gears when the faster engine reaches the down-shift speed.

2.17.2 Manual Shift Operation

Manual shift operates with two installer-supplied switches. The first switch specifies whether the system is in Automatic Shift mode or in Manual Shift mode. The second switch determines whether the system commands first or second gear in manual shift operation.

You can shift to second gear at any time.

SmartCommand controls the maximum downshift RPM. The maximum downshift RPM prevents shifting into first gear when the engines and gears are operating at a higher speed than is safe for a downshift. The maximum downshift RPM is software selectable and can be different from the downshift RPM used for automatic shift.

Caution: Disabling Easidock if the vessel is underway with the control levers in the Ahead or Astern detent causes SmartCommand to enter Cruise mode. The vessel accelerates to normal idle in gear speed.

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2.18 Mode Stacking

Mode Stacking - allows use of One Lever and AutoTroll simultaneously.

2.18.1 Norma

Documents

MMSC5000 - SMARTCOMMAND USER MANUAL - ZF Marine …€¦ · MMSC5000 - SMARTCOMMAND USER MANUAL MARINE PROPULSION SYSTEMS. 2 EN 3340.758.001a - 2014-10 ORIT ... 2.4 Engine Start Interlock