Kobelt 6300-0100 Instruction Manual

May 2023 (rev A)
Kobelt Steering System
6300-0100 Controller & 6300-0200 Station
Owner’s Operation, Installation & Maintenance Manual

Kobelt Steering System Kobelt Manufacturing Co. Ltd.
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NOTES:
RECORD DATA BEFORE INSTALLATION FOR FUTURE REFERENCE
Model #:
Serial #:
Date of Purchase:
Date of Installation:

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TABLE OF CONTENTS
1Introduction.................................................................................................................... 8
1.1 Contact............................................................................................................................... 8
1.2 Compliant Use ................................................................................................................... 8
1.3 Copyrights & Trademarks .................................................................................................. 8
2Safety ............................................................................................................................. 9
2.1 Safety Alerts....................................................................................................................... 9
2.2 Notice to Installer .............................................................................................................. 9
2.3 Product Hazards............................................................................................................... 10
3Scope............................................................................................................................ 11
4Terminology and Definitions ......................................................................................... 12
4.1 Stations............................................................................................................................ 12
5Kobelt Steering System overview .................................................................................. 13
5.1 System Description.......................................................................................................... 13
5.2 System Features .............................................................................................................. 16
5.3 Controller......................................................................................................................... 17
5.4 Steering Station ............................................................................................................... 17
5.5 Technical Specifications................................................................................................... 18
6Installation.................................................................................................................... 19
6.1 Location Requirements.................................................................................................... 19
6.2 Mechanical....................................................................................................................... 19
6.3 Additional components ................................................................................................... 19
6.4 Compass safe distance .................................................................................................... 20
6.5 EMC installation guidelines ............................................................................................. 20
6.6 Electrical considerations for installation ......................................................................... 21
6.7 Controller Field Wiring Connections ............................................................................... 23
6.8 Steering Station Field Wiring Connections...................................................................... 38
7Configuration................................................................................................................ 46
7.1 Configuration Checklist.................................................................................................... 46
7.2 Menu Structure Overview ............................................................................................... 49
7.3 Configuration Parameters ............................................................................................... 68
7.4 Default Configuration ...................................................................................................... 68
8Commissioning.............................................................................................................. 69
8.1 Commissioning Checklist ................................................................................................. 69
8.2 Steering Station ID Selector Interface ............................................................................. 73

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8.3 Calibration and Adjustment ............................................................................................ 74
8.4 Functional Test ................................................................................................................ 82
9Operation ..................................................................................................................... 86
9.1 Station Transfer Mode..................................................................................................... 86
9.2 Station Control................................................................................................................. 87
9.3 Steering Control............................................................................................................... 91
9.4 Steering Modes................................................................................................................ 91
9.5 Local Emergency Backup Control .................................................................................... 94
9.6 Autopilot Control............................................................................................................. 95
9.7 Autopilot Settings............................................................................................................ 97
9.8 Virtual End-stop............................................................................................................... 99
9.9 Alarms............................................................................................................................ 100
9.10 SD Card .......................................................................................................................... 100
10 Maintenance............................................................................................................... 102
10.1 Battery Replacement..................................................................................................... 102
10.2 Real Time Clock.............................................................................................................. 104
10.3 Preventative Maintenance ............................................................................................ 104
10.4 Recommended Spare Parts ........................................................................................... 104
11 Troubleshooting.......................................................................................................... 106
11.1 Controller information screens ..................................................................................... 106
11.2 Alarms, Warnings, and Cautions corrective actions...................................................... 114
11.3 Serial Number................................................................................................................ 116
11.4 USB Interface................................................................................................................. 117
12 Warranty .................................................................................................................... 118
13 Appendix A: Configuration Parameters........................................................................ 119
14 Appendix B: Station Cutout Template.......................................................................... 125

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LIST OF FIGURES
Figure 1: Single Rudder Steering System Block Diagram (Simplified)..........................................................................14
Figure 2:Dual Rudder Steering System Block Diagram (Simplified).............................................................................15
Figure 3: Steering System Block Diagram Render........................................................................................................16
Figure 4: KNET Ferrite Choke.......................................................................................................................................21
Figure 5: Wheel Connector EMC Clamp Diagram........................................................................................................21
Figure 6 Controller Picture Overview ..........................................................................................................................23
Figure 7: The Controller Wiring ...................................................................................................................................24
Figure 8: Electrical Connector for Valve Power ...........................................................................................................24
Figure 9: Electrical Connector for Valve #1 (Channels A/B).........................................................................................25
Figure 10: Electrical Connector for Valve #2 (Channels C/D) ......................................................................................26
Figure 11: Valve Wiring for Solenoid Valves (4-Wire)..................................................................................................27
Figure 12: Valve Wiring for Solenoid Valves (Common Negative)...............................................................................27
Figure 13: Valve Wiring for Solenoid Valves (Common Positive) ................................................................................27
Figure 14: Electrical Connector for RFU #1..................................................................................................................29
Figure 15: Electrical Connector for RFU #2..................................................................................................................30
Figure 16: RFU Wiring for 1 Rudder with 1 Potentiometer Sensor .............................................................................31
Figure 17: RFU Wiring for 2 Rudders with 2 Potentiometer Sensors ..........................................................................31
Figure 18: RFU Wiring for 1 Rudder with 1 Current Sensor.........................................................................................32
Figure 19: RFU Wiring for 2 Rudders with 2 Current Sensors......................................................................................33
Figure 20: Electrical Connector for Autopilot Interface...............................................................................................33
Figure 21: Autopilot Wiring for Autopilot with Solenoid Valve Outputs (Sinking or Sourcing outputs)......................34
Figure 22: Autopilot Wiring for Autopilot with Reversing Pump Outputs...................................................................34
Figure 23: KNet Male Connector Pinout for The Controller ........................................................................................34
Figure 24: Electrical Connector for External Alarm Buzzer & Alarm Dry Contact........................................................35
Figure 25: Wiring of External Buzzer ...........................................................................................................................36
Figure 26: Utility digital inputs.....................................................................................................................................36
Figure 27: Utility Digital Outputs .................................................................................................................................37
Figure 28: Head Input/Output Connections ...............................................................................................................38
Figure 29: KNet Male Connector Pinout for the Station..............................................................................................38
Figure 30: SBW Wheel Female Connector Pinout. ......................................................................................................39
Figure 31: Electrical Connector for FFU Input Device..................................................................................................40
Figure 32: FFU Wiring with 1 Potentiometer Sensor...................................................................................................41
Figure 33: Electrical Connector for NFU Interface.......................................................................................................42
Figure 34: NFU Wiring for 1-Speed Jog Lever (Common Negative).............................................................................42
Figure 35: NFU Wiring for Two-Speed Jog Lever (8-Wire)...........................................................................................43
Figure 36: NFU Wiring for Two-Speed Jog Lever (Common Negative)........................................................................43
Figure 37: Brightness Wiring for Dimming potentiometer..........................................................................................44
Figure 38: Electrical Connector for External Alarm Buzzer & Alarm Dry Contact........................................................44
Figure 39: Wiring of External Buzzer ...........................................................................................................................45
Figure 40: Controller buttons for navigation and configuration .................................................................................49
Figure 41: Root Menu Structure..................................................................................................................................50
Figure 42: Password Select Screen ..............................................................................................................................51
Figure 43: Steering System Configuration Menu Overview.........................................................................................52
Figure 44: Steering System Setup................................................................................................................................52
Figure 45: Configuration Management Screen............................................................................................................53
Figure 46: Factory Reset Confirmation Screen ............................................................................................................54

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Figure 47: Restore Configuration Confirmation Screen...............................................................................................54
Figure 48: Save Configuration Confirmation Screen....................................................................................................55
Figure 49: Success or Failed Screen .............................................................................................................................55
Figure 50: Set Date/Time Screen .................................................................................................................................56
Figure 51: Set Valve Type Screen.................................................................................................................................56
Figure 52: Set FRU Type Screen...................................................................................................................................56
Figure 53: Setup Jog Control Screen............................................................................................................................57
Figure 54: Autopilot Type Settings ..............................................................................................................................58
Figure 55: Number of Stations Screen.........................................................................................................................59
Figure 56: Station Activation Screen............................................................................................................................59
Figure 57: Steering Station Configuration Menu Overview.........................................................................................60
Figure 58: Station Select Screen ..................................................................................................................................60
Figure 59: Station Setup Screen...................................................................................................................................61
Figure 60: Set Station Name Screen ............................................................................................................................61
Figure 61: Steering Wheel Setup Screen .....................................................................................................................62
Figure 62: NFU Input Type Screen ...............................................................................................................................64
Figure 63: FFU Input Screen.........................................................................................................................................64
Figure 64: LED Strip Style Screen .................................................................................................................................65
Figure 65: Station Backlight Colour Screen..................................................................................................................65
Figure 66: Setup Rudder(s) ..........................................................................................................................................66
Figure 67: Rudder/Valve Setup Screen........................................................................................................................66
Figure 68: Toe in configuration....................................................................................................................................67
Figure 69: Toe out configuration .................................................................................................................................67
Figure 70: Station ID Selector location ........................................................................................................................73
Figure 71:Valve Dead-band Graph...............................................................................................................................75
Figure 72: RFU Calibration Screens..............................................................................................................................77
Figure 73: Entering Active Menu .................................................................................................................................79
Figure 74: Active Menu Overview ...............................................................................................................................79
Figure 75: Position Control Menu Screen....................................................................................................................80
Figure 76 Head Picture Overview ................................................................................................................................87
Figure 77: System with Local Emergency Backup Control...........................................................................................95
Figure 78: Autopilot Automatic Disengage State Diagram ..........................................................................................97
Figure 79: Autopilot Manual Disengage State Diagram...............................................................................................98
Figure 80: Autopilot Always Live State Diagram..........................................................................................................99
Figure 81 - Acknowledge Alarm Button.....................................................................................................................100
Figure 82 - Alarm & Warning Log page......................................................................................................................100
Figure 83: Single Rudder Main Monitoring Screen....................................................................................................106
Figure 84: Dual Rudder Main Monitoring Screen ......................................................................................................107
Figure 85: Rudder Feedback Screen ..........................................................................................................................108
Figure 86:Valves Status Screen..................................................................................................................................108
Figure 87: FFU Status Screen .....................................................................................................................................109
Figure 88: Jog Status Screen ......................................................................................................................................109
Figure 89: Controller Health Screen ..........................................................................................................................110
Figure 90: Autopilot Status Screen ............................................................................................................................110
Figure 91: Controller and Head Version Screen ........................................................................................................111
Figure 92: KNet IO Status Screen...............................................................................................................................112
Figure 93: Fault Log Screen........................................................................................................................................113
Figure 94: Fault Inspector Screen ..............................................................................................................................113
Figure 95: Mini USB Female B Connector..................................................................................................................117

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LIST OF TABLES
Table 1: Technical Specifications Controller and Head................................................................................................18
Table 2: KNet Cable Properties....................................................................................................................................22
Table 3: KNet Network Properties...............................................................................................................................22
Table 4 Controller Overview Table ..............................................................................................................................23
Table 5: Valve Power Connector .................................................................................................................................25
Table 6: Valve #1 Connector........................................................................................................................................25
Table 7: Valve #2 Connector........................................................................................................................................26
Table 8: RFU #1 Connector ..........................................................................................................................................29
Table 9: RFU #2 Connector ..........................................................................................................................................30
Table 10: Autopilot Connector ....................................................................................................................................33
Table 11: KNet Network Connector.............................................................................................................................34
Table 12: List of Alarm Dry Contact States ..................................................................................................................35
Table 13: Alarm Output Connector .............................................................................................................................35
Table 14: Station Back Connections ............................................................................................................................38
Table 15: KNet Network Connector.............................................................................................................................39
Table 16: SBW Wheel Connector.................................................................................................................................39
Table 17: FFU Connector .............................................................................................................................................40
Table 18: NFU Connector.............................................................................................................................................42
Table 19: List of Alarm Dry Contact States ..................................................................................................................44
Table 20: Alarm Output Connector .............................................................................................................................45
Table 21 HMI Keypad Overview ..................................................................................................................................49
Table 22 Head Overview Table....................................................................................................................................87
Table 23: List of Steering Modes .................................................................................................................................91
Table 24: Recommended Spares ...............................................................................................................................104
Table 25: Common Troubleshooting Problems .........................................................................................................114
Table 26: Alarm Indicator Error Codes ......................................................................................................................116

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1INTRODUCTION
1.1 CONTACT
Kobelt Manufacturing Co. Ltd.
8238 129th Street
Surrey, British Columbia
Canada, V3W 0A6
Sales Tel:
Fax:
Email:
Website:
[phone]
[phone]
[email protected]
www.kobelt.com
This document is intended to clearly present comprehensive product data and provide technical information to
assist the end user in design applications. Kobelt reserves the right, without notice, to change the design, or
construction, of any products and to discontinue or limit distribution of any products. Kobelt also reserves the right
to change, or update, without notice, any technical information contained within this document.
Kobelt recommends that customers visit our website to check for updates to this Manual. Once a product has been
selected for use, it should be tested by the user to ensure proper function in all possible applications. For further
instructions, please contact our distributors or visit our website.
1.2 COMPLIANT USE
This device is only intended for use by persons trained in operating marine systems.
The installer shall:
•Only use non-defective products.
•Check the safety of operation and the condition of the device before
each use.
•Verify that the product is operational at all times and keep it in good
working conditions.
Only Kobelt Manufacturing Co. Ltd. Authorized Dealers or Authorized Technicians are to repair Kobelt products.
1.3
COPYRIGHTS &TRADEMARKS
All product names, logos and brands are property of their respective owners. All company, product and service
names used in this manual are for identification purposes only. Use of these names, logos, and brands does not
imply endorsement.

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2SAFETY
2.1 SAFETY ALERTS
Throughout this manual, the following symbols are used to alert the user to special instructions concerning a
service or operation that may be hazardous if performed incorrectly or carelessly. The associated risk levels are
stated below.
This symbol indicates an imminently hazardous situation which, if not avoided, will result
in death or serious injury.
This symbol indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury.
This symbol indicates a hazardous situation, which if not avoided, could result in minor or
moderate injury.
This symbol informs the reader of events not related to personal injury but which there is
a risk of damage to property or equipment.
This symbol informs the reader of safety-related instructions or procedures.
2.2 NOTICE TO INSTALLER
Disregarding the following safety measures can result in an accident, causing severe injury to personnel and
damage to material assets.
•Only use the product as directed in this manual.
•Never put the product into service if there is evidence of visible damage.
•Never put the product into service before fully completing installation
and commissioning.
•Do not carry out any modifications to the product.
•Only use authentic Kobelt spare parts.
•Observe all local regulations, directives, and laws during the installation
of this product.
•All installation, commissioning, and maintenance work must be
conducted by qualified personnel. (For the purpose of this manual,
qualified personnel are people who are familiar with the assembly,
installation, commissioning, and operation of the product and who have
the qualifications necessary for their occupation.)
•Observe all specifications in this manual. If these guidelines are not
followed and damage occurs, the warranty will be voided.

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2.3 PRODUCT HAZARDS
Equipment Starts Automatically: The Kobelt Steering Controller valve outputs are
controlled remotely and/or through a control loop. They may be driven unintentionally
through improper closed loop feedback and or unintentional operator commands. Ensure
all power sources are disconnected or locked out prior to performing system maintenance
or repair.
Disconnect Power: Turn off power at distribution panel before beginning installation to
protect installer from electrical hazards.
Voltage and Power Compatibility: Confirm that the power and voltage requirements of
the system are compatible. Ensure that the voltage drops from cabling is within the
specifications of the product. If voltage drops are excessive the system could fail due to
low voltage conditions resulting in abnormal behavior and or loss of function.
Voltage and Current Compatibility: Confirm that the power source is compatible with the
maximum voltage and current ratings of is product variant. Failure to do so could result in
damage or fire.