Flexball WR CONTROLS 3500 Series Operating Manual Download Page 65

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Flexball Italiana S.r.l.

12.1.3. Mercruiser® stern drive push-pull cable

In case it is used the push-pull cable outgoing directly from the Mercruiser

stern driver, the plastic

Mercruiser

bracket is not necessary.

12.1.4. Johnson® push-pull cable

Summary of Contents for WR CONTROLS 3500 Series

Page 1: ...O Op pe er ra at ti in ng g m ma an nu ua al l m mo ou un nt ti in ng g i in ns st tr ru uc ct ti io on ns s...

Page 2: ...modification of Electronic Command Systems or their parts without previous consent of Flexball Italiana srl d The breakdown that is occurred due to the customer s negligence faulty maintenance misuse...

Page 3: ...er 3 is to move down the TRIM 18 4 6 Classification of indoor and outdoor installation 19 4 7 Advices about the mounting and preservation of the command station 21 4 8 Command station codes 21 5 Actua...

Page 4: ...systems with 1 engine 1 actuator and 2 ignition keys 54 10 1 6 Electrical installation of systems with 2 engines 2 actuators and 2 ignition keys 55 10 1 7 Electrical installation of systems with 2 en...

Page 5: ...to FPT engines through CANBus interface 88 Micro switch B4 here shown with tag 4 must be switched in OFF position in order to allow CANBus communication between Flexball Electronic Command System and...

Page 6: ...n of actuators and command stations as described at section 7 6 4 mount command stations and actuators with the help of drilling mask section 23 5 make electrical wiring section 10 6 install push pull...

Page 7: ...e room 2 3 System performance Temperature Operating temperature From 10 to 85 C Storage temperature From 40 to 90 C Humidity max operating limit 90 relative humidity Protection degree of main system c...

Page 8: ...ion look at the specific command station product instruction Each command station repeats the functionality of a traditional mechanical lever Moving the lever from the neutral position after an angle...

Page 9: ...n LED on the right are referring to the starboard engine while the push button and the green LED on the left side are referring to the port engine To engage the gear you must keep pressed the push but...

Page 10: ...l system isn t working correctly 3 2 Acquisition of the command It is possible to acquire the command of the boat from any Station in the following cases The boat isn t moving 1 Position all the lever...

Page 11: ...10 3 5 Fast Start up Mode This function is available on the first command station as described in section 7 6 of this manual When the configuration FSM Fast Start up Mode is enabled the command statio...

Page 12: ...ook at section 7 7 Depending on the application it is very important to set the dip switches present on the bottom part of the command station as described in sections 4 4 and 7 6 of this manual How t...

Page 13: ...Flexball Italiana S r l 13 4 1 2 Command station series 4000 4 1 3 Command station series 4200 160 120 200 96 25 170...

Page 14: ...ff and the command station deactivated 1 move both levers to maximum throttle position 2 place the fingers of your hand under the slot as shown by the arrow 3 pull up to the complete removal of the pr...

Page 15: ...em pressed for 6 seconds after power up the following push buttons Warn Sync Command in this case you want to change the number of actuators Engine left Engine right in this case you change the number...

Page 16: ...ith 1 engine Long 2 seconds Short 0 25 seconds Installation with 2 engines Short less than 0 25 second Short 0 25 seconds Note the number of flashes corresponding to the number of actuators present in...

Page 17: ...label with the black square Important 1 these configurations are valid according to scheme at section 7 1 for different system configurations please refer to schemes from section 7 2 to 7 5 where are...

Page 18: ...tation series 3500 Command station series 4200 Push buttons are placed in the back side of the control lever Press with finger 2 to lift up the TRIM Press with finger 3 is to move down the TRIM Comman...

Page 19: ...the place where will be mounted the command station is indoor or outdoor It follows a list of pictures and examples Indoor installation The command station is installed into a place bordered by ceilin...

Page 20: ...Flexball Italiana S r l 20 Outdoor installation The command station is installed at open air and it is exposed directly to rain water and splashes...

Page 21: ...on When unused put on the command station the protection cover as described in section 4 1 3 of the present manual In case the cover is not included into the supply it is possible to order it separate...

Page 22: ...electronic mechanical electronic hybrid It follows the mechanical drawings of the different types of actuators In the last page of this manual you find the footprint of the actuator in scale 1 2 5 1...

Page 23: ...le to the propulsion engine The actuator cannot be exposed directly to the source of vibrations e g it cannot be mounted directly on the engine on the gearbox or on the engine s basement Mount the act...

Page 24: ...V_out CH2 1 GND CH2 4 GND CH1 JP10 Engine left 2 MOD2 Rev 3 V_out CH3 4 poles 3 V_out CH4 1 GND CH4 4 GND CH3 Important connectors JP9 and JP10 are dedicated to the electronic engine ECU in case of hy...

Page 25: ...Trim 8 Trailer 9 Common neutral relays contact 10 NO contact neutral relays 11 NC contact neutral relays 12 Not used 13 Not used 14 Not used 15 Not used 16 Not used 17 Not used 18 Right engine Common...

Page 26: ...Trim 8 Trailer 9 Common neutral relays contact 10 NC contact neutral relays 11 Forward gear 12 GND 13 Reverse gear 14 GND 15 Right engine Forward gear 16 GND 17 Reverse 18 GND 19 Common neutral relays...

Page 27: ...tion PCB for analogue voltage signals This option can be used in those cases where there are voltage differences between different ground points on the boat A non optimum ground network can generate c...

Page 28: ...r l 28 5 4 6 VANCONV PCB It is used to generate 4 20mA PWM or CANBus signals to control the electronic engines via ECU This PCB replaces the ECAN PCB see section 5 4 4 in the new electronic systems wi...

Page 29: ...ical no trim neutral relay 4500 A 3 8 4 0 9 2 electronic engines V and 2 gearboxes mechanical no trim 4500 A 2 2 4 0 9 2 electronic engines V and 2 gearboxes mechanical no trim neutral relay 4500 A 2...

Page 30: ...c engines mA and 2 gearboxes solenoid driven no trim 4500 A 8 4 0 0 3 9 2 PWM engines and 2 gearboxes solenoid driven no trim 4500 A 4 4 0 0 3 9 1 electronic engine V and 1 gearbox solenoid driven wit...

Page 31: ...by hand the cable without too much efforts The best electrical connection and the max water protection of this connector is reached when screwed with around six turns Connector for throttle cables Eng...

Page 32: ...10000 6 1 2 CANBus extension cable Length Code L 30 m 3500 39 30000 6 2 Cable actuator electronic engine 6 2 1 Cable actuator for electronic engine 1 channel voltage PWM 4 20 mA Important this cable i...

Page 33: ...ngth Code L 3 m 4665 34 03000 L 5 m 4665 34 05000 L 7 m 4665 34 07000 Engine side Sumitomo connector 6 poles L Codifica B Code B Colore filo Wire colour Funzione Function Bianco White Ch 1 Segnale Ch...

Page 34: ...42 05000 L 7 m 4665 42 07000 Engine side AMP Superseal connector 6 poles This cable is to be used between the actuator and Nanni Diesel cables codes 4665 44 and 4665 45 Codifica B Code B Vista frontal...

Page 35: ...colour Funzione Function Pin Marrone Brown Segnale Signal A Verde Green GND B Colore filo Wire colour Funzione Function Pin Bianco White Segnale Signal 2 5 Giallo Yellow GND 1 4 L Colore filo Wire col...

Page 36: ...B Vista frontale Front view L Colore filo Wire colour Codifica B Code B Funzione Function Can H Can L Vista frontale Front view L Marrone Brown Verde Green Colore filo Wire colour Codifica B Code B Vi...

Page 37: ...nale Ch 1 Signal 2 Giallo Yellow Ch 1 GND 5 Marrone Brown Ch 2 Segnale Ch 2 Signal 1 Verde Green Ch 2 GND 4 L Vista posteriore Rear view 4 1 2 3 6 5 Codifica B Code B Vista frontale Front view Colore...

Page 38: ...0 36 07000 Important this cable is without connector on gearbox side Codifica B Code B Vista frontale Front view L Pin 3 2 4 5 Colore filo Wire colour Bianco White Giallo Yellow Marrone Brown Verde Gr...

Page 39: ...lexball code L 3 m 3500 46 03000 L 5 m 3500 46 05000 L 7 m 3500 46 07000 Important this cable is without connector on gearbox side Vista frontale Front view Funzione Function Nero 1 Black 1 M Avanti S...

Page 40: ...fer to section 6 4 Vista frontale Front view L Colore filo Wire colour Funzione Function Pin Nero 1 Black 1 1 Nero 2 Black 2 2 Nero 3 Black 3 Rel di neutro Neutral relay 3 Nero 4 Black 4 M Avanti GND...

Page 41: ...iler Blue Trim Verde Green Trailer Blue Trim Giallo Yellow Pompa Mercruiser Mercruiser pump Connettore Connector Aliment Supply non usato Rosso Red not used Connettore Connector Attuatore Actuator Tri...

Page 42: ...Italiana S r l 42 6 6 T Splitter Code N 85E010003 6 7 Power supply connector Code 3500 38 00000 Important cabling instruction of power supply connector are at section 10 1 1 of this manual 175 43 21...

Page 43: ...CANBus network The following installation schemes cover the most common application cases 7 1 Installation with 2 mechanical actuators solution A This installation scheme is valid for systems with Up...

Page 44: ...on scheme is valid for systems with Up to 3 command stations and 2 engines with mechanical throttle mechanical gearbox with without trim Up to 3 command stations and 2 hybrid engines with mechanical t...

Page 45: ...t trim Up to 3 command stations and 2 hybrid engines with mechanical throttle mechanical gearbox analogue outputs for electric engine inverter driven with without trim Cavo di trasmissione dati Data t...

Page 46: ...es with electronic throttle voltage or CANBus mechanical gearbox with without trim or flap up to 3 command stations and 1 or 2 engines with electronic throttle voltage or CANBus solenoid driven gearbo...

Page 47: ...s with electronic throttle voltage or CANBus mechanical gearbox with without trim or flap up to 3 command stations and 1 or 2 engines with electronic throttle voltage or CANBus solenoid driven gearbox...

Page 48: ...nder the base of the command station there is a plastic cap Unscrewing it you have access to the dip switches Operation unscrew the plastic cap set the dip switch position according to one of the conf...

Page 49: ...es of each command station please refer to the installation schemes reported from section 7 1 to section 7 5 Important 4 two engines command is configured from the factory to be mounted in systems wit...

Page 50: ...on Factory setting is JP19 ON line termination ON In some documentation alternative to ON or OFF are indicated YES or NO If JP14 ON address 1 If JP19 ON end of line is enabled The actuator configurati...

Page 51: ...hysically placed anywhere in the CANBus network but the CANBus must have at its ends the end of line terminations see sections from 7 1 to 7 6 Here below an example of a single actuator installation w...

Page 52: ...the display on the actuator doesn t show any light it means that there is no power supply on the actuator box Causes the electrical connection is missing check where the actuator has been supplied wi...

Page 53: ...stem with one ignition key and 10 1 4 for system with two ignition keys This last scheme allows to power the actuator box activating at least one of the two ignition keys If your application has doubl...

Page 54: ...ione Motore sinistro Ignition key Left engine Batteria Battery Segnale 15 Signal 15 A1 A2 Com NO D Batteria Battery Segnale 15 Signal 15 Batteria Battery D R A1 A2 F Com NO D Chiave d accensione Motor...

Page 55: ...e table at section 10 1 3 R Batteria Battery F Chiave d accensione Motore sinistro Ignition key Left engine Batteria Battery Segnale 15 Signal 15 A1 A2 Com NO D Batteria Battery Segnale 15 Signal 15 B...

Page 56: ...Minimum cross section is 2 5 mm2 In case electronic throttle it is very important to connect to a common GND point either GND buss bar or common bonding conductor or hull all the negative poles of eac...

Page 57: ...erpart If the cable has been inserted correctly it must be possible to screw completely by hand the cable without too much efforts around 6 full rotations There are basically 4 types of actuators clas...

Page 58: ...linkages This actuator is available in versions with neutral relay with or without trim and it is suitable for the following applications mechanical engine and mechanical gearbox only 1 propulsion gro...

Page 59: ...c interface Important in case of single engine installation use only the connectors for the right engine 10 2 4 Actuator with full electronic interface and neutral relay Important in case of single en...

Page 60: ...0 2 6 Wiring scheme to gearbox in case of actuator with neutral relay This wiring scheme refers to Actuators with neutral relay see sections 10 2 2 and 10 2 4 Gearbox cable code 3500 46 see section 6...

Page 61: ...rtant this conceptual scheme shows how to connect the electrical cables battery switch and protection devices e g fuses must be implemented according to local regulations 10 2 8 Wiring scheme from act...

Page 62: ...w possible to move from one parameter to the other using the keys UP and DOWN For the setting of the specific parameters follow this procedure 1 with the actuator turned on the display shows _ _ press...

Page 63: ...res dA is the delay that occurs when you move the lever from neutral to forward or reverse The actuator starts to accelerate only after the time set into dA expires With parameter CC you can check if...

Page 64: ...types of push pull cables For the connection of the push pull cable to the actuator it is necessary to use its proper connection kit The available kits are for Volvo cable E2 E3 C0 C3 C33 Johnson cab...

Page 65: ...l 65 12 1 3 Mercruiser stern drive push pull cable In case it is used the push pull cable outgoing directly from the Mercruiser stern driver the plastic Mercruiser bracket is not necessary 12 1 4 Joh...

Page 66: ...sumed that if you pull the cable the throttle speed increases 1 Adjust the fixing of the push pull cable in such a way that when the lever see arrow is at the minimum position engine idle the rod of t...

Page 67: ...For this operation follow steps from 1 to 7 section 13 1 The minimum speed throttle position is parameter UL 2 Verify that the position of the throttle lever is in idle position on the motor side as...

Page 68: ...red into the bracket slot 5A 6 Fix the black aluminium cube e against the bracket d using the fixing screw c 6A 6B 7 If the fixing position is not correct tune the push pull cable in such a way that w...

Page 69: ...ll cable to the gearbox side Position the gearbox lever in neutral the lever must be vertical 1 Adjust the fixing of the push pull cable in such a way that when the lever is in vertical position the c...

Page 70: ...position For this operation follow steps from 1 to 7 of section 14 1 The neutral position is parameter 0F 2 Verify that the position of the gearbox lever is in neutral on the motor side as described p...

Page 71: ...slot 5A 6 Fix the black aluminium cube e against the bracket d using the fixing screw c 6A 6B 7 If the fixing position is not correct tune the push pull cable in such a way that when the gearbox s lev...

Page 72: ...throttle and 3 for the gearbox Gearbox and throttle positions have to be set according to the parameters of the above table Actuators are delivered from factory with No throttle stroke Forward Reverse...

Page 73: ...display is flashing you have entered into the jog mode and if you press either the Up or the Down push button the left push pull cable will move according to the picture on the right Press Up or Down...

Page 74: ...ave stored the position 17 Press the Down push button and the display will move to 0H parameter of Gearbox Forward 18 Press the Enter push button and the display will start flashing Press Up until the...

Page 75: ...e right correspondence between the direction of the lever and the movement executed by the actuator e g you move the lever forward and the gearbox cable is pushing instead of pulling Changing the valu...

Page 76: ...verted min and max throttle positions are inverted Set A0 1 Both gear or throttle push pull cables positions are inverted Set A0 2 13 3 Specific parameters Display code Description Values Factory valu...

Page 77: ...per each gearbox Gearboxes positions have to be set according to the parameters of the above table Actuators are delivered from factory with Forward Reverse and Neutral positions coincident in the Ne...

Page 78: ...the position of Gearbox Reverse press Enter again When the display stops flashing it means that you have stored the position 7 Press the Down push button and the display will move to 0F parameter of...

Page 79: ...n the display stops flashing it means that you have stored the position 19 Press the Down push button and the display will move to 1H parameter of Gearbox Forward 20 Press the Enter push button and th...

Page 80: ...s not the right correspondence between the direction of the lever and the movement executed by the actuator e g you move the lever forward and the gearbox cable is pushing instead of pulling Changing...

Page 81: ...em Solution Positions of the right gearbox are inverted while the positions of the left gearbox are correct Set A0 3 Positions of the left gearbox are inverted while the positions of the right gearbox...

Page 82: ...rter driven Parameters to define the voltage output interface will be detailed at section 14 3 2 H1 L2 H2 L3 H3 L4 H4 CC To be used for the check up of the internal CANBus communication 14 3 1 Paramet...

Page 83: ...NA NA NA 10 NA NA NA NA NA NA NA L2 5 0 0 4 0 43 4 4 NA NA NA NA H2 21 50 50 21 50 13 24 22 NA NA NA NA L3 Motor SX 9 10 13 8 5 7 8 8 6 8 4 5 H3 43 38 40 42 43 37 48 44 45 42 45 28 P3 NA NA NA NA 10...

Page 84: ...are available 2 output relays For proper wiring please refer to sections 5 4 2 5 4 3 10 2 5 and 10 2 6 of this manual 15 4 Specific parameters Installations with electronic gearbox might require a del...

Page 85: ...alue Value shown on display factory value Note dI Delay in switching off the gearbox 0 9 9 s 0 0 s 00 dA Delay in start of throttle 0 9 9 s 0 0 s 00 dF Delay in neutral it occurs any time you move dir...

Page 86: ...e 17 2 2 CC CANBus communication 17 2 1 CANBus protocol Every CANBus interface card has one CANBus output Communication starts automatically at power up once the CP parameter has been set to a non zer...

Page 87: ...230 3900 02 N40 250 N40 ENTM 25 600 3200 03 N60 370 N60 ENTM 37 N60 400 N60 ENTM 40 3300 04 N67 450 N67 ENTM 45 N67 480 N67 ENT MW55 11 3350 TSC1 VE 11 N67 500 N67 550 N67 560 N67 ENTM 56 3300 TSC1 V...

Page 88: ...he electronic control switched off verify with a multimeter that the impedance between terminals JP4 4 and JP4 5 of the CANBus PCBoards on the actuator is 60 ohm or similar see section 5 4 4 In case o...

Page 89: ...with this module Voltage CANBus converter are NEF N60ENTM40 11 N67ENTM45 11 CURSOR C87ENTM38 C87ENSM24 C87ENTM62 C87ENTM65 C13ENTM C13ENSM C13ENAM C13ENTM83 C87ENAM13 2 Voltage CANBUs converter accor...

Page 90: ...10 2 19 System configuration in case of options 19 1 Commissioning of actuators for installations with Trim or Flap command option Trim or flap options don t require any programming on the actuator T...

Page 91: ...um current which can be commutated by the neutral relay is 10 A in case the actuator is not supplied you cannot start the engine unless you provide a by pass electrical circuit for emergency situation...

Page 92: ...le as reported in the diagram here below you need to define minimum and maximum voltage These values are defined through parameters L and H Parameters setting for installations with 1 engine Display R...

Page 93: ...The command station that had the control of the vessel has now lost the command To take the command again you must start again the following procedure move the lever to neutral press Command and then...

Page 94: ...side of the overloaded cable all the LEDs of the command stations start to blink Error E stands for overload failure Error P stands for position failure missed position target In case this alarm is p...

Page 95: ...nut requires 5 5 turns of the nut to be fully seated If power supply is still missing replace the CANBus data transmission cable Chapter 6 Without moving any lever of the command station the actuator...

Page 96: ...l actuators There isn t the right correlation between the position of the lever of the command station and the movement generated by the actuator Modify the setting of parameter A0 Scheme at sections...

Page 97: ...even if the lever is in neutral The push pull cable of the gearbox hasn t come to the assigned neutral position actuators with mechanical interface Check and remove the obstacle which doesn t permit...

Page 98: ...Flexball Italiana S r l 98 23 Drilling mask for command station 23 1 Command station series 3500 23 2 Command station series 4000...

Page 99: ...ball Italiana S r l 99 23 3 Command station series 4200 23 4 Command station series 4500 Attention drawings here depicted are not corresponding to the object s real physical size 134 75 14 1 68 114 4x...

Page 100: ...Flexball Italiana S r l 100 24 Drilling mask for actuator w Attention drawings here depicted are not corresponding to the object s real physical size 300 170...

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Flexball WR CONTROLS 3500 Series, Operating Manual

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