Three60 Precision Control System Configuration Parameters Caterpillar


Configuration Parameters
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1.1. Configuration
2.2. Configuring a New Powertrain Control Installation
3.2. Changing an Existing Powertrain Control Configuration
4.2. Changing an Existing Powertrain Control Configuration Off Line
5.2. Configuring Station Heads
6.3. Single Lever Sync Mode
7.2. Configuring Engines
8.2. Configuring Transmissions
9.3. Setting Direction Reversal Inhibit Parameters
10.3. Verifying and Setting the Lever Map
11.3. Forward Prefill Level Percent and Reverse Prefill Level Percent
12.2. Configuring Operational Options
13.2. Configuring Joysticks
14.2. Entering Vessel Information
15.2. Configuring a New Joystick Control Installation
16.2. Configuring Joystick Stations
17.2. Configuring Thrusters/Transmissions
18.3. Thruster Control Station
19.2. Viewing Tuning Data
20.2. Configuring Alarms
21.1. Troubleshooting the Powertrain Control Using the Support Tool

Configuration

After installation in the boat, the Joystick Control and Powertrain Controls must be configured in order that the operational parameters match the installed hardware, desired operational configurations, and optional equipment.

Configuration is performed by a technician using the Three60 Precision Control System Support Tool (support tool). The information required for the configuration process is provided by the following:

  • System drawing set produced by AVSpare for the vessel.

  • Installation drawings produced by the installer for the specific vessel that documents details not covered in system drawings mentioned above.

Prior to connecting the computer to a control, complete the configuration forms provided in Appendix A. The forms follow the support tool screens and helps ensure that all relevant parameters are identified prior to starting the configuration process on-site. The support tool provides the following configuration processes:

To configure a new installation, perform Field Setup:

  1. Copy the forms in "Appendix A: Configuration Form" and complete the forms.

  2. Configure the Powertrain Controls as outlined in "Configuring a New Powertrain Control Installation"

  3. Configure the Joystick Control as outlined in "Configuring a New Joystick Control Installation"

    Note: Verify that the Powertrain Controls are connected to the leverheads as indicated in the system drawing set, and that the correct power-on sequence is followed during configuration so that the Powertrain Controls are addressed correctly. It is suggested that each Powertrain Control is labeled to ensure correct identification during configuration. See “Powertrain Control System” inTroubleshooting, "Programmable Parameters".

  4. Calibrate the joysticks as outlined in "Joystick Station Calibration"

To change the configuration of a connected control, perform Field Modify:

  • Powertrain Control: See "Changing an Existing Powertrain Control Configuration"

  • Joystick Control: See "Changing an Existing Joystick Control Configuration" on page 94.

To change the configuration of a control for download at a later time perform Off Line Modify:

  • Powertrain Control: See "Changing an Existing Powertrain Control Configuration Off Line" on page 68.

  • Joystick Control: See "Changing an Existing Joystick Control Configuration Off Line" on page 97.

Configuring a New Powertrain Control Installation

When the Powertrain Control is shipped from the factory, all features and parameters are initially programmed with default values. During Field Setup, all features and parameters are programmed with valid values. To configure a newly installed system, perform the following procedure.

  1. Connect the laptop to the installed Powertrain Controls as outlined in "Connecting to a Controller" on page 39.


    Illustration 1g03509001

  2. Confirm that the power supplied to the controller is within specification by accessing "Power Diagnostics Window" on page 171. Verify that either the primary supply voltage (denoted by P:) or the auxiliary supply voltage (denoted by A:) is greater than 10.0 V and both are less than 28.0 V.

    Note: Only one supply voltage must be greater than 10.0 V. Many installations have no connection to the auxiliary power input.

    • If the power supply or supplies meet the stated requirements, proceed to the next step.

    • If the power supply or supplies do not meet the stated requirements, correct the problem before proceeding.

    For multiple engine systems: Connect the Powertrain Control RS-485 port (J10) to the laptop USB port, via a USB to RS-485 adapter Accomplish this action by disconnecting one of the terminating resistors at the J10 "T" connector and then connecting the communication harness. Refer to Illustration 1.



    Illustration 2g03509030

  3. Launch the support tool by double-clicking the shortcut on the desktop or selecting “AVSpare” from the Start menu, then select support tool from the submenu. The preceding AVSpare Login window opens.

  4. Type your user name and password.


    Illustration 3g03509037

  5. Click “OK”. The “Powertrain or Joystick Control” selection pane opens.


    Illustration 4g03509043

  6. Select “Powertrain” and click “OK”. The Powertrain support tool window opens.

  7. Power up the port controller first and then the starboard controller. The status changes and both controls must communicate with the support tool.

    • If the status indicates that the controls are communicating with the support tool, then proceed to the next step.

    • If you encounter communication problems, check the COM port setting and cycle power in the controllers. Always power up the port controller first.

    Note: If the leading digit of the address is not zero, the field setup portion of the configuration was either completed or partially completed at some earlier time and the field setup feature will not function properly. Contact AVSpare for assistance.



    Illustration 5g03509083

  8. Click “Field Configuration”. The “Field Configuration” window opens.


    Illustration 6g03509084

  9. Click “Field Setup”. The Field Setup window opens.


    Illustration 7g03510162

  10. Verify the connections and click “Yes”. The above screen is displayed, showing the drive train detected.

    Note: Each drive train is identified by an address. These addresses will be assigned to each installed Powertrain Control during setup. It is important that each drive train is correctly identified during this procedure.

  11. In the space provided, type the name of the boat. The configuration file is stored in a directory corresponding to the boat name. Be descriptive so that the configuration file is easily identified.


    Illustration 8g03510179

  12. Click “Next”. The “Source of Configuration Data” pane opens as shown above.

    If you want to use an existing archive file as a template, click “Open” and perform the steps that follow. A Windows Explorer window opens.



      Illustration 9g03510196

    1. Double-click the “Apps” directory.


      Illustration 10g03510200

    2. Double-click the installation directory that contains the archive files you want to use for this installation. In this example, the “NewBoat” directory contains the desired files.


      Illustration 11g03510217

    3. Double-click the file with address “00” appended to it. This file is the file for the first control. The above window opens.

    4. Click “Next” to use this archive file for the new installation.

    5. Proceed to the next step.

      If you want to create this configuration file from scratch, click “Next”.

      The Field Setup screen opens.

      Note: The Field Setup screen prompts you to power down all controls if the controls were powered on.



    Illustration 12g03510237

  13. Select the number of controls in this installation from the drop-down list in the lower right corner of the Field Setup window as shown above and power down both controls. Immediately after selecting the number of drive trains (two in this example), the Field Setup window directs you to power up controller #1 as shown above.

  14. Power up controller #1 as directed. You are instructed to wait while the support tool takes control.

    1. The support tool reads the data of the connected controller.


      Illustration 13g03510497

    2. The support tool updates the configuration data of the connected controller as shown above.

    3. The support tool updates the backup configuration data of the connected controller.


    Illustration 14g03510657

  15. Power down controller #1 when directed, as shown in the above screen.

    Note: Be sure to wait until prompted by the software.

  16. Power up controller #1 when directed.


    Illustration 15g03510844

  17. Power up controller #2 when directed, as shown above.


      Illustration 16g03510859

    1. Data is transferred to the controller.

    2. After updating the configuration data, a backup file is created and saved.

  18. Power down controller #2 when directed.

  19. Power down controller #1 when directed.

  20. Power up controller #1 when directed.


    Illustration 17g03510997

  21. Power up all other controls (controller #2 in the above example).


    Illustration 18g03511001

  22. Allow the support tool to take controller as shown in the above screen.


    Illustration 19g03511020

  23. When the process completes, the following screen is displayed.

    You can now configure each of the Powertrain system controls by clicking the appropriate drive trains. The currently selected drive train and Powertrain Control is shown in yellow on the boat graphic on the screen. To complete the configuration process, set the options and parameters in each of the configuration windows as described in the appropriate subsections:

    • “Configuring Station Heads” on page 71

    • Configuring Engines" on page 73

    • Configuring Transmissions" on page 74

    • Configuring Operational Options" on page 81

    • Configuring Joysticks" on page 83

    Note: If the “Update All” button is on, both controls are configured but only the information for the highlighted controller is displayed.

Changing an Existing Powertrain Control Configuration

To change the configuration of a connected Powertrain Control perform, the following procedure.

  1. Connect the laptop to the installed Powertrain Control as outlined in "Connecting to a Controller" on page 39.

  2. Confirm that the power supplied to the controller is within specification by accessing "Power Diagnostics Window" on page 171. Verify that either the primary supply voltage (denoted by P:) or the auxiliary supply voltage (denoted by A:)is greater than 10.0 V and both are less than 28.0 V.

    Note: Only one supply voltage must be greater than 10.0 V. Many installations have no connection to the auxiliary power input.

    • If the power supply or supplies meet the stated requirements, then proceed to the next step.

    • If the power supply or supplies do not meet the stated requirements, then correct the problem before proceeding.

  3. Connect the Powertrain Control RS-485 port (J10) to the laptop USB port, via an RS-232 to RS-485 adapter, by disconnecting one of the terminating resistors at the J10 "T" connector and then connecting the communication harness. Refer to Illustration 1


    Illustration 20g03511477

  4. Launch the support tool by double-clicking the shortcut on the desktop or selecting AVSpare from the Start menu, then select support tool from the submenu.

  5. Type your user name and password.


    Illustration 21g03511536

  6. Click “OK”. The Powertrain or Joystick Control selection pane opens.


    Illustration 22g03513658

  7. Select “Powertrain Controller” and click “OK”. The Powertrain Controller Support Tool window opens.

  8. Power up the port controller first and then the starboard controller. The status will change and all controls must communicate with the support tool.

    • If the status indicates that the controls are communicating with the support tool, then proceed to the next step.

    • If you encounter communication problems, check the COM port setting and cycle power in the controllers, always power up the port controller first.

    Note: If the leading digit of the address is not zero, the field setup portion of the configuration was either completed or partially completed at some earlier time and the field setup feature will not function properly. Contact AVSpare.



    Illustration 23g03513679

  9. Click Field Configuration. The Field Configuration window opens.

    If the support tool determines that the connected Powertrain Control software is not the latest version, the following window opens. Click “Yes” to update the controller software.

    Note: After the software update, confirm all parameters in the configuration before the boat is put in service.



    Illustration 24g03548344

  10. Click “Field Modify”. The support tool starts reading the configuration data of the connected controller.

    When the support tool has completed reading the controller data, the above screen is displayed.

  11. Modify the configuration of the Powertrain Control installed in the boat, as described in the appropriate subsections in this chapter:

    • Configuring Station Heads" on page 71

    • Configuring Engines" on page 73

    • Configuring Transmissions" on page 74

    • Configuring Operational Options" on page 81

    • Configuring Joysticks" on page 83

  12. When you have completed the required modification, close “Field Modify” by clicking “Exit” in the lower right corner.

  13. You will be prompted to enter a comment to identify the reason for change.

Changing an Existing Powertrain Control Configuration Off Line

The “Off Line Modify” function allows an existing configuration file to be changed without being connected to an installed Powertrain Control. Off Line Modify alters the archived files for an installed system, so the archived files must be present on the computer you are using. The modified configuration files can then be downloaded to the control system on the boat the next time the support tool connects to a control. To change the configuration of an installed system, perform the following procedure.

  1. Verify that the archived system files to be modified are on the computer you are using. The default location is “C:\Three60\Apps\"boat name"”, where “boat name” is the name of the boat that was entered during field setup. If required, then copy the files to the computer.


    Illustration 25g03548406

  2. Launch the support tool by selecting Three60 from the Start menu, then selecting support tool from the submenu.


    Illustration 26g03548438

  3. Click “Field Configuration”. The Field Configuration Menu opens as shown above.


    Illustration 27g03548457

  4. Click “Off Line Modify”. The Off-Line Application Selection window opens as shown above.

  5. Select the boat installation to be modified from the Boat List. The File List pane shows the associated configuration files that will be modified.


    Illustration 28g03548476

  6. Click “OK”. The Offline Modify window opens.

    Note: If there are errors found in the file, an error screen similar to the above example is displayed. Review the errors, then click “Close” to proceed, or click “Print” to print the error list to use as a reference if desired.

  7. You can now modify the configuration of the Powertrain Control archive files. If you do not want to modify all archive files, then deselect the “Update All” function. The currently selected Powertrain Control archive file is shown in yellow. To complete the modification process, set the options and parameters in each of the configuration windows as described in the appropriate subsections in this chapter:

    • Configuring Station Heads" on page 71

    • Configuring Engines" on page 73

    • Configuring Transmissions" on page 74

    • Configuring Operational Options" on page 81

    • Configuring Joysticks" on page 83

    The modified archive files can be uploaded to the Powertrain system controls at a later time.

Configuring Station Heads

To access and configure the Station Heads configuration screen, perform the following procedure:



    Illustration 29g03548556

  1. At the configuration screen, click the “Station Head” button. The Station configuration window is opened as shown above.

    Note: The “Update All” function ensures that both Powertrain Controls are simultaneously updated when the selected Powertrain Control configuration is modified.

  2. Enable the appropriate stations.

  3. Click the appropriate master for Single Lever Sync.

  4. Calibrate the Leverheads as discussed in “Lever Calibration” on page 120.

Single Lever Sync Mode

The Powertrain Control supports single lever sync. The mode switch must be at either the Classic Sync or Precision Sync position and all levers at the active control station must be at or past the forward detent.

In Single Lever Sync (SLS) mode, the sync master controller is determined by the configuration and can be either the port or starboard engine.

When operating in SLS, all levers must be at or past the forward detent. The lever position of the sync master determines the input speed of all drive trains. The lever of the sync slave controller can be in any position at or past the forward detent. The master controller commands each engine to the same speed.

If anything happens to cause the system to drop SLS mode, the slave controls slowly ramp the throttles to the current position of the levers to prevent abrupt changes in boat speed.

If any lever is moved from forward, that controller will no longer be in sync mode. It is possible to have the mode switch in a sync position and still maneuver the boat by putting one or all drive trains in reverse. Sync mode is re-entered when all levers are returned to forward regardless of the sync type.

Configuring Engines

To access and configure the Engine configuration screen, perform the following procedure:



    Illustration 30g03550121

  1. At the configuration screen click the “Engine” button. The Engine configuration window is opened as shown above.

  2. 2. When “PWM” is selected, the values shown for “Troll Idle (%)” and “Classic Idle (%)” are updated with default values associated with the selected engine. Adjust this setting for your specific installation as follows:

    Note: The following step is important to prevent the boat from moving during this test.

    1. To ensure that the boat cannot move during this test, disconnect the J7 harness at the Powertrain Controls to disconnect the transmissions from the PWM signals that will become active.


      Illustration 31g03550136

    2. Click the Test button for Troll Idle (%). The above window opens.

    3. Start the engine. At 0%, the setting is the minimum engine RPM and is displayed in the “Engine RPM” display. To change the “Troll Idle (%)”, slide the “Level 1 (%)” slider until the engine rpm displayed in the “Engine RPM” display attains the desired level.

    4. Click Update to save the level %.


      Illustration 32g03550156

    5. Click the “Test” button for “Classic Idle (%)”. The above window opens.

    6. At 0%, the setting is the minimum engine RPM and is displayed in the Engine RPM display. To change the “Classic Idle (%)”, slide the “Level 1 (%)” slider until the engine rpm displayed in the “Engine RPM” display attains the desired level.

      Note: When adjusting Idle speed, do not exceed 1000 RPM. The controller will inhibit an engagement when the idle is greater than 1000 RPM.

    7. Click “Update” to save the level %.

    8. Shut off the engine.

    9. Reconnect the J7 harness to the Powertrain Controls.

Configuring Transmissions

This procedure provides information for configuring the transmission using the support tool. To access and configure the Transmission configuration screen, perform the following procedure.



    Illustration 33g03550397

  1. At the configuration screen click the “Transmission” button. The Transmission configuration window is opened as shown above.


    Illustration 34g03550416

  2. Select the appropriate transmission from the “Transmission Type” drop-down list.

    When a new transmission is selected, a confirmation window similar to the one above is displayed, requesting that you confirm that you do want to change the transmission.

    • Click “Cancel” to keep the transmission displayed prior to your new selection.

    • Click “OK” to accept the new transmission selection.

    As a transmission type is selected or changed, the values displayed in the Transmission configuration window are updated with default values associated with the selected transmission and a Transmission Parameters window opens.

    Proceed to specify the transmission parameters as required by the transmission selected.

  3. Select the appropriate Gear Ratio. The tooth count is adjusted based on the gear selection and is accurate for the speed sensor locations as shipped from the transmission supplier.

    Note: Enter the tooth count manually when the sensors are mounted in the engine flywheel housing or with an external speed wheel on the propeller shaft.

  4. Verify and set all other transmission parameters displayed in the Transmission configuration window.

  5. Experimentally determine and enter the "Setting Direction Reversal Inhibit Parameters" on page 77.

    Note: Each installation is unique, therefore the default settings may not provide the proper Direction Reversal Inhibit Parameters to protect personnel and equipment. Failure to properly determine and set the Direction Reversal Inhibit Parameters may result in malfunction or accident, causing injury to personnel and/or serious damage to the equipment. AVSpare absolves itself of any responsibility resulting from failure to properly set the Direction Reversal Inhibit Parameters.

  6. Verify troll engagement as discussed in "Verifying and Setting the Lever Map" on page 78.

  7. Set the minimum troll and precision speeds as outlined in "Forward Prefill Level Percent and Reverse Prefill Level Percent" on page 80.

Setting Direction Reversal Inhibit Parameters

Note: The use of default values could damage the propulsion system and/or stall the engine in a crash reversal situation.

Default values are inserted into the configuration that provide a reasonably safe startup condition for many vessels. These default values are not intended for any specific vessel and therefore must be addressed prior to the completion of setup and commissioning of the vessel.

Note: Maximum speed may not be achievable due to weather conditions, sea state, currents, and so on. Sea conditions must be such that the vessel can achieve within 1/2 knot of full speed in order to complete this procedure.

Perform the following procedure:

  1. Determine the Acceleration Time (Seconds) as follows:

    1. Determine the maximum speed of the vessel.

    2. Turn on both controls and engines and set the active station to Classic mode.

    3. At the active station, move the lever to forward detent and wait until the boat attains the forward detent speed, then move the lever to full throttle in a normal 1 to 2 second sweep and using a stop watch, record the time the vessel takes to attain full speed.

    4. Record this value for Acceleration Time (Seconds).

  2. Determine the Deceleration Time (Seconds) as follows:

    1. From the full speed condition, pull the lever back to the forward detent position, and using a stop watch, record the time the engine takes to slow down to a speed of 150 RPM over engine idle RPM, or 900 RPM, whichever is lower. No shaft reversal shall take place at speeds greater than 900 RPM.

      Example:

      • Engine idle is 700 RPM + 150 RPM = 850 RPM. Use a value of 850 RPM.

      • Engine idle is 800 RPM + 150 RPM = 950 RPM. Use a value of 900 RPM.

    2. Record this value for Deceleration Time (Seconds).

  3. Determine the Neutral Hold Time (milliseconds) as follows:

    The default neutral hold time is 100 ms. For transmissions with a ratio less than 2.5:1 this setting will normally not need modification. Modifications to the Neutral Hold Time are required if the engine tends to stall, run rough, or smoke when shifting from forward to reverse at low idle.

  4. Enter the value determined for Acceleration Time (Second) in Acceleration Time (Seconds) in the Transmission configuration window.

  5. Enter the time in Deceleration Time (Seconds) in Deceleration Time (Seconds) in the Transmission configuration window.

  6. Record this value in Neutral Hold Time (milliseconds) in the Transmission configuration window.

Verifying and Setting the Lever Map

Troll speeds are normally maintained via closed loop feedback from the output speed sensor. If the sensor fails, the Lever Map is used to set valve coil current in relation to lever position. This map must be properly set to achieve optimum troll operation in the event of a transmission output speed sensor failure. Perform this procedure to verify the lever map.

  1. Disconnect the harness connectors from the output speed sensors.

    Note: The following values can be identified by modulating the solenoid current with the engine running in powertrain diagnostics.

  2. Identify the solenoid current that gives the proper pressure to the clutch during minimum speed at troll.

  3. Identify the solenoid current that gives the proper pressure to the clutch during maximum speed at troll.


    Illustration 35g03551840


    Illustration 36g03552061

  4. Click the “Lever” button on the Transmission screen as shown in Illustration 35.

    The Lever Response Mapping - Gear screen is displayed as shown in Illustration 36.



    Illustration 37g03552075

  5. Right click the “0% Lever (% above detent)” end point. The above window opens.

  6. Click “Properties”. The Point Properties window opens as shown below.

  7. Via the keyboard adjust the “Coil Current” value.

  8. Click Close.

  9. Save the new configuration to the controls and exit the support tool.

  10. Start the engines.

  11. Place the active station in Troll mode.

  12. Move the lever forward from neutral detent and evaluate clutch engagement and vessel speed during troll.

    • If vessel speed is correct for troll operation, the mapped coil current to lever position is adequate. Reconnect the harness connectors to the output speed sensors and return to the next step in “Configuring Transmissions”.

    • Return to step 2 to reevaluate clutch engagement.

  13. Return to step 2 to reevaluate clutch engagement.

Forward Prefill Level Percent and Reverse Prefill Level Percent



Illustration 38g03552236

The Precision/Troll Prefill is a configurable value set in the support tool. The ability to access this feature is available on the Transmission Screen. Refer to Illustration 33

The default value is dependent of the type of transmission selected, and in most cases, does not need any adjustment. When engaging Precision or Troll at the forward detent, if the shaft comes up to proper speed in a quick but soft manner, then there is no need to adjust the prefill levels. If there is a slight delay when moving the lever from neutral to the forward detent, while in Precision, followed by a noticeable nudge or "bite," this situation can be improved or eliminated by increasing the prefill level. The prefill level should be adjusted in 1% increments per try to find the proper level for achieving rapid shaft rotation with smooth engagement.

Note: See The Owners and Maintenance Manual for the procedure to set minimum Precision or Troll speed

Configuring Operational Options

This section provides information for configuring the installed options. To access and configure the Operational configuration screen, perform the following procedure:



    Illustration 39g03552256

  1. At the configuration screen click the “Operational” button. The Operational configuration window opens as shown in the illustration above.

  2. Configure all installed options appropriately as outlined in Table 20:

    Table 1
    Operational Options 
    Parameter  Description 
    Oil Pressure Corrective Action  Set the controller response in the event of Low Main Pressure:
    · Reduce the throttle to Idle or
    · Report the event only 
    Tachometer Output  Set this parameter to specify the installed tachometer location:
    · Tachometer output or
    · Propeller
    and the number of pulses per revolution. 
    Oil Filter Switch  Set this parameter to enable the oil filter bypass switch alarm and specify the alarm state of the installed switch, the filter is bypassed when the switch is:
    · Open or
    · Closed 
    Stabilizer Disable  For systems with a stabilizer: Set this parameter to specify whether it is enabled or disabled when the system is in neutral. When enabled (checked) select:
    · Coil Off: Stabilizer disabled only in reverse.
    · Coil On: Stabilizer disabled in neutral and reverse. 

Configuring Joysticks

This section provides information for configuring the joysticks for use with the powertrains when the system is in Joystick mode. This procedure configures the joystick output for input to the engines as was done for the leverhead output in "Configuring Engines". To access and configure the Joystick configuration screen, perform the following procedure:



    Illustration 40g03552542

  1. At the configuration screen click the “Joystick” button. The Joystick configuration window is opened as shown in the illustration above.

Table 2
Joystick 
Parameter  Description 
Joystick Mode Input Idle Speed (RPM)  Speed of the engine when Joystick mode is selected. 
Commanded Propeller Speed (RPM)  Sets the minimum propeller speed. 
Base Transmission Input Idle Speed (RPM)  Set this parameter to the base transmission input idle speed. 
Max Transmission Input Speed (RPM)  Set this parameter to the wide open throttle speed. 
Transmission Input Idle  Adjust only if you wish to increase or decrease the ramp of input speed to "Joystick Mode Input Idle Speed":
· Min: 70
· Max: 110. 
LU Entry/Exit  The "Joystick Lockup Phase Entry / Exit" window (shown in the lower right corner of the Joystick configuration window on the previous page) is opened by clicking this icon. 
Propeller Speed Command  Command position to achieve lockup as a percent of base transmission input speed. 
Actual Propeller Speed  Actual position to achieve lockup as a percent of base transmission input speed. 
Propeller Speed Command  Command position to exit lockup as a percent of base transmission input speed. 

Entering Vessel Information



Illustration 41g03556717

Information specific to the installation can be added to the configuration data using the “Vessel Info” button. When the button is clicked the screen shown below is displayed, allowing the user to enter information in the text fields.

The following fields can be completed only at initial configuration:

  • Boat Manufacturer

  • Boat Model

  • Controller Serial Number

  • Boat Hull Number (Complete): Must be three characters minimum.

  • Marine Project Number (Optional):

  • Original Setup User Name

  • Original Setup Date (MM/DD/YY)

The Most Recent Change and the Previous Change can be entered whenever a configuration change is made and AVSpare suggested that all changes be noted to maintain an accurate record of all changes.

When done, click the “Update” button to write the information to the configuration file.

Configuring a New Joystick Control Installation

The Field Setup function configures a new installation. You can configure a new installation in one of two ways:

  1. Connect to the Joystick Control as outlined in "Connecting to a Controller" on page 39.


    Illustration 42g03556736

  2. Click Field Configuration. The Field Configuration Menu opens as shown above.


    Illustration 43g03556776

  3. Click Field Setup. The above window opens.


    Illustration 44g03556806

  4. Enter the name of the boat and go to step 6 or click “Browse” to store the new configuration under an existing boat name. After clicking “Browse” the above window opens.

    Note: AVSpare highly recommends that the boat name of the Powertrain Control configuration is used. This action ensures that all configuration files for the system are stored in the same directory.



    Illustration 45g03556819

  5. If the selected application directory already contains a Three60 Precision Control System file, navigate to the appropriate Apps directory and click “OK”. The message window above opens.

    Note: This message is advisory only and is displayed because the support tool does not expect to find an existing configuration file for a new installation. If the Three60 Precision Control System file in the selected application folder matches the serial number of the control you are setting up, then the file will be overwritten with the new configuration uploaded to the control. If the serial number does not match any “Three60 Precision Control System” files in the selected folder, then a new “Three60 Precision Control System” file will be created, and there will be multiple “Three60 Precision Control System” files in that folder.

  6. Click “Yes” and proceed to step 6 if the selected directory is acceptable, otherwise click “No” and return to step 3.


    Illustration 46g03556847

  7. Upon entering the name of the boat or selecting an existing boat, the above window opens, displaying the boat name entered or selected.


    Illustration 47g03556879

  8. Click “Next”. The following above opens.


    Illustration 48g03556896

  9. To use the configuration already loaded in the control, click “Next” and go to step 9. Alternatively, click “Open” to select a configuration file to load in the control. After clicking “Open”, the preceding window opens.


      Illustration 49g03556910

    1. Select the desired *.PCJ configuration file and click “Open”. The above window opens displaying the default configuration file to be used.

      Note: DEFAULTS.PCJ in the main support tool directory of an existing PCJ file (normally saved under a boat name in the “Apps” directory) may be used as a template for the new configuration.

    2. Click “Next” and proceed to step 9.


    Illustration 50g03556916

  10. After clicking “Next”, the above window opens.


    Illustration 51g03556939

  11. Ensure that the control is connected to the laptop and turn it on. The support tool detects the control and when the tool connects, the following window opens.

    When the support tool connects to the control, the tool downloads the configuration data.

  12. After the configuration update/verification process is complete, you are instructed to power down and then power up the controller.


    Illustration 52g03556978

  13. When the controller completes the boot process, the above screen is displayed for entering information about the current activity, even if this event is the first event for this controller.

  14. Enter the appropriate text for this event and click the “Update” button.

  15. Modify the configuration of the control, as described in the appropriate subsections in this chapter:

    Note: Some parameters are read-only and are displayed as gray text. These parameters cannot be altered.

    • "Configuring Joystick Stations"

    • "Configuring Thrusters/Transmissions"

    • "Viewing Tuning Data"

    • "Configuring Alarms"

  16. Close the support tool. The file is updated automatically.

Configuring Joystick Stations

To access and configure the joystick station configuration screen, perform the following procedure:



    Illustration 53g03556999

  1. At the configuration screen, click the “Joystick Station” button on the tool bar or from the panel menu. The Joystick Station configuration window is opened as shown above.

  2. At least one joystick station is required to be enabled and up to eight are supported. Enable all installed stations.

  3. Configure disable switches to match the installed system by clicking the appropriate “Disable Switch Installed” check boxes. If these settings conflict with the actual hardware configuration as installed, then a fault may be detected.


    Illustration 54g03557056

  4. Click the “Maps” button to verify the set sensitivity for each enabled joystick. The figure above provides an example of the sensitivity map for the x axis. Each axis has a designated map.

Configuring Thrusters/Transmissions

This section provides information for configuring the thrusters and transmissions. To access and configure the “Thrusters/Transmissions” configuration screen, perform the following procedure:



    Illustration 55g03557100

  1. At the configuration screen click the “Thruster/Tran” button on the tool bar or from the panel menu. The Thrusters/Transmissions configuration window is opened as shown in the above example.

  2. Set the correct number of stations with optional thruster control panels installed and the quantity of optional thruster control panels at each station.

    Note: Slew rates are changed when acceptable joystick operation cannot be achieved with tuning. In these cases the slew rates can be adjusted to compensate. For additional information contact AVSpare.



    Illustration 56g03557136

  3. To change the number of thrusters/transmissions, click the “Click To Change” button. The above window opens.

  4. Click the appropriate radio button and when done click the “OK” button, or the “Cancel” button if no changes are to be made.

  5. Configure the Thrusters settings to match the installation. See "Thruster Control Station" below for information about configuring the thruster control stations.

  6. Set the Joystick Active Indication as required for your system. Select the “Joystick Active Indication is Set when Manual Panels are Active”. This setting allows Joystick State 2 to connect to Joystick State Common whenever the Manual Panels are active. For information about Joystick Active indication see "Alarm 2 Signals (J5)".

Thruster Control Station

A thruster control station is defined as either one panel that can only command the bow thruster, or a pair of panels installed at the same location where the first panel commands the bow thruster and the second panel commands the stern thruster. All of the thruster control stations of a boat are configured identically, for example it is not possible to configure some stations as bow-only and some stations as bow and stern.

  • Bow thruster-only systems can only be configured for bow-only stations (one panel per station).

  • Bow and stern thruster systems can be configured either for bow-only stations (one panel per station) or bow and stern stations (two panels per station).

Configuring a bow and stern thruster system for bow-only manual thruster stations prevents the operation of the stern thruster while the Joystick Control is in leverhead mode, but has no effect on the ability of the Joystick Control to command the stern thruster while a joystick station is active.

Configure the control stations and panels as follows:

  1. Set the number of panels per station to 1 if only the bow thruster is to be commanded from the manual panels. Set the number of panels per station to 2 to configure the system for manual operation of bow and stern thrusters.

  2. Set the number of thruster control stations to the number of unique locations where panels are installed.

    Note: The total number of panels installed should equal the number of thruster control stations times the number of panels per station.

Viewing Tuning Data

To tune a system, see "Tuning the System".

To view the stored tuning data, click the “Tuning” button on the tool bar or from the panel menu. The Tuning configuration window is opened.



Illustration 57g03557177
This example shows a system that has no tuning data.


Illustration 58g03557178
This example shows a system that has tuning data stored.

Tuning data may be cleared by clicking the “Reset Tuning Data” button. This action causes the following dialog box to be displayed.

Click “OK” to clear the tuning data saved in the control. Click “Cancel” to close the warning box without clearing the tuning data.

Configuring Alarms

The Joystick Control allows groups of faults to be configured to trigger alarms to notify the operator of the fault condition.

Note: Alarms are an optional fault indication in addition to the flash codes displayed on the joystick stations if a fault occurs. Enabling and disabling alarms has no effect on the ability of the Joystick Control to detect faults and display the associated flash codes.

To access and enable the desired alarms, perform the following procedure:



    Illustration 59g03557624

  1. At the configuration screen click the “Alarms” button on the tool bar or from the panel menu. The Alarm configuration window is opened as shown above.

  2. Enable the appropriate alarms by selecting the appropriate choice from the list:

    • “None”: No alarm is activated upon detection of the fault.

    • “J1939 ACS Message”: Alarm indicated to the Powertrain Controls over the J1939 bus.

    • “Alarm 2 Relay”: Alarm indication provided by closure of the normally open contacts of the Alarm 2 relay (J5 pins 9 and 10).

    • “Alarm 1 Relay”: Alarm indication provided by closure of the normally open contacts of the Alarm 1 relay (J8 pins 7 and 8).

    Note: When thruster control panels are installed, the Alarm 2 relay is dedicated to the Oil Level Low fault and the Alarm 1 relay is dedicated to the Oil Temperature High fault and are not configurable. This condition is indicated by these selections being unavailable (gray) as shown in the example above. These relays are also not available for other fault categories.

Troubleshooting the Powertrain Control Using the Support Tool

The following figures provide examples of the diagnostics windows provided by the support tool application. The “Save Image to File” button saves “controller test” screen shot as an Image for future reference. Controller Test is visible after selecting a controller and when first entering the diagnostic screens. This window provides basic controller information. The controller clock is Greenwich Mean Time (GMT).



Illustration 60g03640485
Powertrain Controller Information Window


Illustration 61g03640786
Power Diagnostics Window

Either the Main Battery Voltage or the Auxiliary Battery Voltage must be greater than 10.0 v and both must be less than 28.0 v. The status of the power supplies is as follows:

  • Green: Indicates that the voltage is within the specified range.

  • Red: Indicates that the voltage is not within the specified range.

The Main Battery voltage is the voltage measured across J13 pins 1 and 3.

The Auxiliary Battery voltage is the voltage measured across J13 pins 2 and 4.

Note: It is only necessary that one supply voltage is greater than 10.0 V. Many installations have no connection to the auxiliary power input.

If the voltages are not within specification, then troubleshoot and repair. Starting at the power supply, check all cables and connections to the Powertrain Control to verify that the supply voltage does not change due to long cable runs, poor electrical connections, or shorts to other power sources or power draws. Correct any low power or power loss problems before proceeding.

The remaining screens shown below provide examples of the other diagnostics available in the support tool.



Illustration 62g03640900
Station Diagnostics Window

This screen is used to troubleshoot a station (leverhead).

  1. First select the station to be tested.

  2. The neutral LEDs can be activated via the On/Off button under Station Indicators. This is used to check for a faulty LED or wiring

  3. Lever Sensor - the voltage and percentage displayed change according to lever position. The percentage varies from 0-100% and 0-8V from neutral in forward and reverse

  4. Switch Status - There are forward and reverse switches in the lever.

    • When the lever is in neutral both switches will be open.

    • When the lever is forward of the forward detent, the reverse switch will close and the forward switch will remain open.

    • When the lever is aft of the aft detent the reverse switch will close and the forward switch will remain open.

  5. Station Select Sensor - Voltage

    • Port Controller: 0 V when not depressed; 4 V when pressed

    • Starboard Controller: 3 V when not depressed; 0 V when pressed

  6. Station Select Sensor - Status

    • Port Controller: Port when not depressed; Active when depressed

    • Starboard Controller: Starboard when not depressed; Active when depressed

  7. Power Supply - This is the leverhead power supply from the selected controller. 8 V is and 110 mA are typical values. The voltage should be constant. The current will vary depending on the load from the leverhead – light status, lever position, and so on.

  8. Mode Sensor

    • Voltage - This voltage corresponds to the position of the mode select switch. The leverhead uses a voltage divider.

    • Mode - This field shows a text representation of the mode select switch.

Note: The leverhead is connected to both powertrain controllers. With this screen you are viewing the leverhead from one controller at a time - selectable via “Controller Select”. The lever sensor and switch status will correspond to the powertrain controller selected.



Illustration 63g03640977
Switch Input Diagnostics Window

This screen shows the status of the manual override function on the transmission. The manual override is used to shift the gear without electronic control – refer to the marine gear manufacturer instructions.



Illustration 64g03640998
Boundary Scan Diagnostics Window

This screen allows the technician to test the connections from the selected controller to the transmission input speed sensor, propeller speed sensor, forward valve coil, and reverse valve coil. When entering this mode, the following warning is displayed: “Warning: Testing the coils with the engines running will engage the transmission(s) and move the vessel." This test should be performed without the engines running.”



Illustration 65g03641007
Speed Input Diagnostics Window

This screen shows the transmission input and propeller speed as read by the selected controller. The impedance across these circuits is also shown.



Illustration 66g03641013
Analog Input Diagnostics Window

This screen shows the selected controller internal temperature, transmission oil temperature, and oil pressure as read by the selected controller. The alarm set-points vary by transmission model and are automatically set when the transmission model is selected in the configuration screens.



Illustration 67g03641022
Powered Coil Diagnostics Window

This screen is used to manually actuate the transmission valve coils and solenoid valves. This test can be used to troubleshoot a faulty coil or valve. When entering this screen, the following warning is displayed: “Warning: Testing the coils with the engines running will engage the thruster(s) and move the vessel.” This test should be performed without the engines running.

Readings/Display:

  • Oil Current – when selected, this display provides values in Amps

  • % Modulation – when selected, this display provides values in percentages from 0-100%

Control and activation:

  • Full On – selecting this button drives the coil to open the valve fully. Once Full On is selected the text on this button changes to Full Off. When Full Off is selected, the control stops driving the coil and the valve closes

  • Ramp On – selecting this button slowly increase the current to the coil driving the valve to open. One the valve is fully open the controller will reduce the current until the valve is closed and repeat the process until Ramp Off is selected. When Ramp Off is selected, the control stops driving the coil and the valve closes.

  • Modulate – when Modulate is selected the technician can manually drive the coils to open and close the valve using the slider. Once Module is selected the text on this button changes to Modulate Off. When Modulate Off is selected, the control stops driving the coil and the valve closes.


Illustration 68g03641037
Speed Output Diagnostics Window

This screen is used to test the tachometer output on J8.



Illustration 69g03641057
Switch Output Diagnostics Window

This window allows the technician to operate output switches independent from system parameters.

  • Alarm - this will open the normally closed connections, J8 pins 7 and 8, that are used for an external alarm – customer supplied.

  • Neutral Start Relay - this will open and close connections, J5 pins 9 and 10, that are used for a neutral start relay. When overriding the Neutral start Relay use caution. The following warning is displayed, “Warning: Closing the Neutral Start Relay will allow the engine to start.”


Illustration 70g03641076
Gear Shift Counter Diagnostics Window

This window provides shift counts. These are useful in tracking gear and clutch life.

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