MATHERS CONTROLS MicroCommander User manual

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MicroCommander
Engine Control
Installation Instructions
585 Actuator
Manufactured by:
MATHERS CONTROLS INC.
675 Pease Road
Burlington, WA 98233
1-800-546-5455
Fax: [phone] MMC-180
e-mail: [email protected] Rev. 9

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TABLE OF CONTENTS
Section Page
1. GENERAL INFORMATION.........................................................1
2. REQUIRED PARTS AND TOOLS.................................................1
2.1Supplied By Your MicroCommander Dealer..............................1
2.1.1Control Head.................................................................1
2.1.2Actuator .......................................................................2
2.1.3Electric Cable ................................................................2
2.2Supplied By Installer............................................................3
2.2.1Tools Required For Installation .........................................3
2.2.2Push-Pull Cables ............................................................3
2.2.3Push-Pull Cable Connection Kits........................................3
2.2.4Control System Power 'ON' - 'OFF' (See Figure 3)...............3
2.2.5Engine 'STOP' Button......................................................4
3. PLAN THE INSTALLATION........................................................4
3.1Actuator Location................................................................4
3.2Remote Control Head Location ..............................................5
3.3DC POWER SOURCE ............................................................6
4. INSTALLATION......................................................................7
4.1The Actuator ......................................................................7
4.2The Control Heads...............................................................7
4.3Station Transfer Button........................................................8
4.4Engine 'START' Switch .........................................................8
4.5Engine 'STOP' Switches........................................................9
4.6Eight-Conductor Cable .........................................................9
4.7Control Head....................................................................10
4.8Bonding A.B.Y.C. E-1 46 CFR 111.05................................12

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4.9Actuator ..........................................................................12
4.10 Connect Dc Power To Actuator..........................................13
4.11 Install Start Interlock Cable..............................................13
5. ADJUSTMENTS (ENGINES STOPPED) ......................................14
5.1ACTUATOR.......................................................................15
5.2Check Remote Controls And Station Transfer.........................15
5.3Push-Pull Cables ...............................................................16
5.3.1Transmission Cable Adjustment......................................17
5.3.2Throttle Cable Adjustment.............................................18
5.4Station Transfer................................................................19
5.5Start Interlock..................................................................19
5.6Throttle Pause ..................................................................20
5.7Final Check ......................................................................20
6. TESTS................................................................................21
6.1Adjustments To Check Underway.........................................21
6.1.1Full-Speed Setting........................................................21
6.1.2Proportional Pause On Direction Change ..........................22
6.2Control Head Tone ............................................................22
7. CONTROL OPTIONS..............................................................23
7.1High ('HI') Idle .................................................................23
7.1.1High 'HI' Idle Setting ....................................................24
7.2Primary Station Isolation Switch..........................................25
7.3Alarm Capability ...............................................................25
7.4Clutch Oil Pressure Interlock...............................................26
8. OPERATOR INSTRUCTIONS ...................................................27
8.1Control Type ....................................................................27
8.2Control Start-up................................................................27
8.3Engine Start.....................................................................27

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8.4Station Transfer................................................................28
8.5'HI' Idle 'LO' Idle (Optional)...............................................29
8.6Master Station Isolation (Optional).......................................29
8.7Synchronization (Additional Option) .....................................29
9. MORSE CLUTCH AND THROTTLE KIT SELECTION ......................30
9.1Pre-Engineered Throttle Connection Kits ...............................30
9.2Pre-Engineered Clutch Connection Kits .................................30
9.3Outboard And I/O Cable Connection Kits...............................31
10.UNIVERSAL MOUNTING FOR 33C TYPE CABLE..........................31
11.REFERENCES ......................................................................32
11.1 American Boat and Yacht Council (ABYC)............................32
11.2 Code of Federal Regulations .............................................32
11.3 Society of Automotive Engineers.......................................32
11.4 National Marine Manufacturers Association..........................32
11.5 Underwriters Laboratories................................................33
12.PARTS SOURCE...................................................................33
12.1 Anti-Static Wrist Strap.....................................................33
12.2 Circuit Breaker...............................................................33
12.3 Fuse.............................................................................33
12.4 Wago Tool.....................................................................33
12.5 Relay 12 VDC.................................................................33
12.6 Relay 24 VDC.................................................................33
13.SINGLE SCREW CIRCUIT ......................................................35
14.TWIN SCREW CIRCUIT .........................................................37
15.TEMPLATE ..........................................................................39
16.MAINTENANCE ....................................................................41
16.1 Actuator........................................................................41
16.2 Control Head..................................................................41

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17.TROUBLE SHOOTING............................................................41
17.1 SYMPTOM: Cannot take control at one (1) station (both Port
and Starboard for twin screw), when the system is initially turned
'ON'. ................................................................................41
17.2 SYMPTOM: One side will not take control when initially
turning 'ON' the system ..........................................................42
17.3 SYMPTOM: The LED blinks at one (1) station when power is
initially turned 'ON' to the controls. Cannot transfer to any other
stations................................................................................43
17.4 SYMPTOM: The LED blinks when the transfer button is
depressed, and continues to blink after released (lever is in the
neutral/idle position). Cannot transfer to this station if another
station was previously in control...............................................43
17.5 SYMPTOM: The engine RPM varies, without moving the
control head lever (synchronization disabled). ............................43
17.6 SYMPTOM: The engine RPM reduces to IDLE, transmission to
NEUTRAL, the control head LED turns 'OFF', and a slow repetitive
tone is heard at all stations after reposi-tioning the control head
lever. ................................................................................44
17.7 SYMPTOM: No audible tone at a control head when power is
initially turned 'ON', but otherwise, works perfectly. ....................45
17.8 SYMPTOM: The control head LED doesn't light when in
control, but everything else works perfectly. ..............................45
17.9 SYMPTOM: Cannot obtain "Warm-up" Mode.....................46
17.10 SYMPTOM: Steady tone is heard from all control stations.
Cannot gain control at any stations...........................................46
17.11 SYMPTOM: No tones or lights at the control head, and no
LEDs lit on the circuit board.....................................................47
17.12 SYMPTOM: Rapid tone at all control stations. ...................47
17.13 SYMPTOM: The engine starts to turn over while starting, and
then stops. A slow repetitive tone is heard from all stations.........48

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17.14 SYMPTOM: The engine starter will not engage..................49
17.15 SYMPTOM: One (1) long - two (2) short tones from all control
stations................................................................................49
18.HAND HELD REMOTE CONTROL .............................................51
18.1 Purpose ........................................................................51
18.2 Safety...........................................................................51
18.3 Hand Held Installation Instructions....................................52
18.4 Operating Instructions.....................................................55
19.SYNCHRONIZATION.............................................................57
19.1 General Information Dwg.No. 0486-A ................................57
19.2 Parts Required ...............................................................57
19.3 Installation ....................................................................58
19.4 Operation Checks ...........................................................60
19.5 Synchronization Drawing 0486-A.......................................61
20.TROLLING VALVE CONTROL ..................................................63
20.1 Purpose Of A Trolling Valve ..............................................63
20.2 MicroCommander Control Operation ..................................63
20.3 Parts Required ...............................................................64
20.3.1 Supplied By Your MicroCommander Dealer...................64
20.3.2 Supplied By Installer ................................................65
20.4 Installation ....................................................................65
20.5 Set Up ..........................................................................65
20.5.1 Adjustments ...........................................................66
20.6 Trouble Shooting............................................................69
20.7 Trolling Valve Drawing 0490-B..........................................71
Table of Figures
Figure 1 – Actuator Dimensions 4
Figure 2 – Control Head Dimensions 5

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Figure 3 – Power Source 6
Figure 4 – Transfer Button Mounting Dimensions 8
Figure 5 – Start Interlock 8
Figure 6 – Control Head Connections 9
Figure 7 – Actuator Plug Removal 10
Figure 8 – Cable to Actuator 10
Figure 9 – Actuator Connections 11
Figure 10 - Bonding 12
Figure 11 – Terminal Connection 13
Figure 12 – SW1 Dip Switch 15
Figure 13 – Push-Pull Cable Connection 17
Figure 14 – Single Screw – Primary Station 25
Figure 15 – Twin Screw – Primary Station 25
Figure 16 – Taking Command 27
Figure 17 – Neutral Fast Idle 28
Figure 18 – Station Transfer 28
Figure 19 - Universal Mounting 31
Figure 20 – Hand Held Mount 51
Figure 21 – Safety Lanyard 52
Figure 22 – External Wiring 53
Figure 23 – Hand Held Control 53
Figure 24 – Distribution Box 54
Figure 25 – Diesel Engine 59
Figure 26 – Gas Engine 59
Figure 27 – Trolling Valve Lever 66
Figure 28 – Control Head Lever Movement 66

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1. GENERAL INFORMATION
The MicroCommander engine control provides single lever operation
of engine speed and shift from one to five remote stations. The
control system operates from a 12, 24, or 32 volt DC battery supply
and in the static condition draws seven watts. Maximum is 160
watts.
The engine speed and shift are sequenced such that the engine
throttle must be at Idle before shift, and shift must then be
completed before the engine throttle will advance.
The connection to the engine throttle and clutch is through standard
Type 33C push-pull cables. (Reference Section 11.)
The MicroCommander Engine Control offers an option to add
automatic engine synchronization and trolling valve control.
Sections 18. and 19. of this manual explains operation, installation,
and adjustments of these options.
Requirements:
•Throttle or clutch selector lever load should not exceed 40 lbs.
(18kg).
•MicroCommander Engine Controls require a reliable battery
source of 12 to 32 volts DC.
•The DC power required is to be supplied through a 10 ampere
circuit breaker. (One for each Actuator)
CAUTION: Avoid using the starting battery on 12 volt systems, if possible. A dedicated
battery for MicroCommander and other electronic equipment is recommended.
Do not use a power converter or battery charger without a battery.
2. REQUIRED PARTS AND TOOLS
2.1 SUPPLIED BY YOUR MICROCOMMANDER DEALER
2.1.1 Control Head Black Chrome Lever
Single Control Head (Single Screw) 450-1 453-1
Dual Control Head (Twin Screw) 460-1 or -2 463-1 or -2

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One station transfer button is included with each Control
Head, a twin screw remote station requires only one
transfer button.
The -2 includes a green LED for synchronization.
Included are gasket, wire, terminals, mounting screws,
and watertight cable grip (for cable entrance on
Actuator).
Optional Control Head levers are available. (Contact
Mathers Controls Inc.)
2.1.2 Actuator
One 585 Actuator for each engine. Included are
installation instructions, ferrite bead, wire, terminals, tie
wraps, anti-static wrist strap, and WAGO tool (See Figure
11). A WAGO tool and a spare fuse are taped inside the
Actuator. Also included are two cable grips for power
cable and for start interlock cable. Mounting hardware is
not included.
2.1.3 Electric Cable
Pc.No. 180
Eight- Conductor Cable (Control to Actuator) Pc.No. 350
500 foot (152m) spool
Shielded 20 AWG, 300 V, PVC Insulated: -20°C to +80°C, PVC Jacket.
Color Coded UL VW-1.
Pc.No. 212
Two- Conductor Power Cable Pc.No. 349
250 foot (76m) spool
14 AWG, 300 V, PVC Insulated: -20°C to +105°C PVC Jacket.
Red with purple stripe and black UL VW-1.
Pc.No. 183
Two- Conductor Cable Start Interlock Pc.No. 355
250 foot (76m) spool
16 AWG, 300 V, PVC Insulated: -20°C to +105°C PVC Jacket.
Yellow with red stripe UL VW-1.

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2.2 SUPPLIED BY INSTALLER
2.2.1 Tools Required For Installation
Anti-static wrist strap is included with Actuator.
Wire cutter (Recommend Thomas & Betts WT-2000)
Wire stripper (Recommend Thomas & Betts WT-2000)
Wire crimper (Recommend Thomas & Betts WT-2000)
7/16" Socket and medium extension
3/8" Wrench
7/16" Wrench
Screwdriver - medium phillips head #2
Screwdriver - medium straight slot
Screwdriver - small straight slot
Hole saw - 1" (25,4mm)
Drills - 9/32" (7,2mm) and 7/32" (5,6mm)
2.2.2 Push-Pull Cables
Type 33C push-pull cables. (two per engine) The cable
length is measured from end of thread to end of thread.
Cables are usually stocked in one foot (0,3m) increments.
2.2.3 Push-Pull Cable Connection Kits
The kits provide hardware to connect the Type 33C cable
to the engine throttle and transmission. Many engines
and out drives are delivered with factory mounted kits.
Morse standard connection kits are listed in Section 9. A
Universal Mounting kit, listing parts and dimensional data,
is shown in Section 10.
2.2.4 Control System Power 'ON' - 'OFF' (See Figure 3)
The power for controls should come from the same power
distribution panel as the other required engine function.
Each Actuator requires a switched 10 amp circuit breaker
with manual reset. If this is not possible, a circuit
breaker and relay may be mounted near the battery and

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power connected directly to the Actuator. Examples are
shown in Fig. 3. Use a relay with coil voltage to match
your DC battery voltage. (Reference Section 11.)
NOTE: Do not use the key switch as the DC power supply. The key switch must
only energize a relay as described above.
2.2.5 Engine 'STOP' Button
An engine 'STOP' button, or switch, MUST be located at
each remote station.
WARNING: An engine 'STOP' button at each station is an absolute requirement and
will cancel warranty, if the requirement is not followed.
3. PLAN THE INSTALLATION
3.1 ACTUATOR LOCATION
Considerations:
A) The Actuator is spray proof but
cannot be immersed.
B) Bulkhead mount is preferred for
ease of access for wiring and
adjustments, but the Actuator
can be mounted in any attitude.
If the clutch cable is connected
to an I/O drive outside the hull,
then the Actuator must be two
feet (0,6m) above water line. Do
not mount to the engine, or
transmission, or any location
that will allow excessive
vibration. Use 1/4" or M6
fasteners (four each).
C) Locate the Actuator so that the
push-pull cables from the
10459
Figure 1– Actuator Dimensions

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Actuator to the engine have easy bends, with the least total
degrees of bend and moderate length. EXAMPLE: Minimum
bend radius 10" (254mm) try for total degrees of bends of less
than 270 degrees - Cable length normally under 20 feet (6m).
D)The Actuator is usually located in the engine room. If the
engine room is too small, locate in any accessible area.
E) MicroCommander uses electronic circuits that can be
influenced by strong magnetic fields, and static charges.
Power source must be bonded (connected) to the hull. Do
not mount close to gas engine ignition systems, alternators,
or electric motors. Allow four feet (1,2m) of clearance, or
more.
F) Locate Actuator away from heat sources, such as engine
exhaust manifolds.
G)Locate Actuator to be accessible for electric, and push-pull
cable connections.
3.2 REMOTE CONTROL HEAD LOCATION
Considerations:
A) The Control Head is watertight when
properly mounted on a console, but
must be protected from water or
spray inside or below console.
B) The Control Head mounts flush to
the console. The only penetration of
the console is for wiring and
mounting screws. The control is
secured with screws from the bottom
side of the panel. Screws provided
are #8-32 x 1".
C) When mounting a control head that
may be weather exposed from the
Figure 2– Control Head
Dimensions

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underside, consider using a Weather Mounting Control Box
available from Mathers Controls Inc.
D)Retrofit applications will need to plan an adapter pad to cover
the old control cutout and to mount the control head.
Adapter and cover pads are available from Mathers Controls
Inc.
3.3 DC POWER SOURCE
The MicroCommander Actuator requires a battery source (12,
24 or 32 volts DC) protected by a 10 ampere circuit breaker. It
is not recommended to use engine starting batteries on 12 volt
systems, because the cranking voltage may be too low. It is
important to keep the length of power cable short to reduce
voltage drop. The 14 gauge twisted pair power cable, should
not exceed 20 feet (6m). If individual wires are used for supply
(+) and return ( - ) then the total wire length should not exceed
40 feet (12m).
DC Power Panel
Circuit Breaker
10 Ampere Red
Black
To
Actuator
Off On
To DC Common
10460-585
Fuse
Battery Bank
12, 24, or 32 VDC
To
Actuator
Red
Black
To DC Common
Battery Bank
12, 24, or 32 VDC
Circuit Breaker
10 Ampere Off On
Relay
Optional Key Switch or
On/Off Switch
Figure 3– Power Source

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NOTE:It is important that the wire size from the battery to the circuit breaker
panel is large enough to keep voltage drop due to current flow, to less than
3%. The DC return to the battery must be large enough to supply all current
requirements with a voltage drop of less than 1%. (Reference Section 11.)
4. INSTALLATION
Before starting the actual installation of the MicroCommander
Engine Control make sure you have the correct parts and tools on
hand. See Section 2- REQUIRED PARTS AND TOOLS. Read all the
instructions pertinent to each part before beginning the installation
of that part.
WARNING: Static electricity can destroy electronic components. Anytime the
Actuator cover is off, use the wrist strap provided and connect it to
the Actuator frame. This will drain any static charge you may have on
your person.
4.1 THE ACTUATOR
Secure the Actuator using ¼" or M6 fasteners. When the
Actuator cover is removed, connect the wrist strap to your
person and the ground connector to the Actuator frame. Install
the power cable grip and the start interlock grip in the top
frame holes as shown in Figure 7. When not working on the
Actuator, keep the cover in place to prevent damage to circuits.
4.2 THE CONTROL HEADS
Use the control head template, Section 15., to locate holes.
Drill the screw holes 7/32" (5,6mm) and the 1" (25,4mm) corner
cutout holes. The #8-32 x 1" mounting screws are for a ¾"
(19,1mm) maximum thick mounting surface. Check that the four
(4) mounting screws will start into the control head. Remove
the control and strip the adhesive cover from the gasket. Apply
the adhesive side to the console.

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4.3 STATION TRANSFER BUTTON
One station transfer button is required at each control station.
Locate carefully so that the button is accessible, but will not be
inadvertently depressed. Use the hole template, Section 15.
The station transfer button is waterproof. There are two
methods of mounting: Surface mount or Recessed mount for
thin panels (See Figure 4).
4.4 ENGINE 'START' SWITCH
MicroCommander is interlocked to
prevent engine 'start' until power is
'ON' and the transmission is in
'NEUTRAL'. The engine 'START' signal
must be connected through the
Actuator to the starter solenoid or
relay. (See Figure 5) The interlock will
function with a 'START' signal up to 50
volts DC and 30 amp maximum.
CAUTION: The circuit board is designed for a maximum
of 30 amps 'START' signal current. Greater
current will damage the interlock circuit.
Recessed Mount Surface Mount
Figure 4– Transfer Button Mounting Dimensions
Start Interlock
Connections
Maximum 30 Amperes
Key
Start
Interlock
Starter
SolenoidActuator
Starter
Battery DC Common
Bond
10457
Figure 5– Start Interlock

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4.5 ENGINE 'STOP' SWITCHES
Engine 'STOP' switches are required at all remote control
stations. The 'STOP' switches are installer supplied.
WARNING: Each remote station must have some method to stop the engine or
engines. This requirement must be followed or warranty is canceled.
4.6 EIGHT-CONDUCTOR CABLE
Install the eight-conductor electric cable (two cables if twin
screw) between each control head and the appropriate Actuator.
There can be as many as five remote stations. Label each
eight-conductor cable at both ends with the station it connects,
and port or starboard engine control.
The eight-conductors in the electric cable are color coded. Each
conductor shall be installed so that it is protected from physical
damage. Conductors shall be supported by clamps or straps
not more than 18" (0,5m) apart, unless contained in a conduit.
(Reference Section 11.)
Port
Starboard
Station
Transfer
Button
Violet Violet
Black Brown Red Orange Blue Green Yellow
Black Brown Red Orange Yellow Green Blue
Orange
White
Orange1234567812345678
Single Dual
Green
Red
Tone
Red
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
0651-585
Figure 6– Control Head Connections

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4.7 CONTROL HEAD
At the control head, strip back the PVC cover on the cable
approximately 2½" (63,5mm). Strip and cut off the shielding and
drain wire flush with the end of the PVC cover. The drain wire
at the control head is not connected to ground. The installer
must strip d" (9,5mm) insulation off each wire and crimp
connectors. Connections 5 and 7 of the control connector plug
are direction sensitive. The connections must be as follows:
Port Lever: Starboard Lever:
Terminal 5 Blue Terminal 5 Yellow
Terminal 7 Yellow Terminal 7 Blue
CAUTION: When making a twin screw installation, the white wire connects to Terminal 3
on the Port control only. The Starboard Terminal 3 is not connected. This is
true at all stations. See Circuit Dwg., Section 14. Cable must be supported to
eliminate load on Terminal Connections.
Power
Station 1
Station 3
Station 5
Actuator
Electric
Cable
Cable
Grip
Seal
Start
Interlock
Station 2
Station 4
Troll
0652A-585
Figure 7– Cable to Actuator
Hole
Plug
Actuator
Screwdriver
Push
0653A
Figure 8– Actuator Plug
Removal

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1
STA 2
STA 3
STA 5
JMPR 2
JMPR 3
JMPR 4
JMPR 1
R7R8
STA 4
SHIELD
BLUE
GREEN
YELLOW
ORANGE
RED
BROWN
BLACK
1
FUSE
6
5
4
3
2
1
7
8
START INTERLOCK GRIPPOWER CABLE GRIP
TIE WRAP
FERRITE BEAD
SHUNT
'ON''OFF'
JMPR 3
SHUNT
JMPR 2
SHUNT
JMPR 1
1 2 3
SHUNT
'ON''OFF'
JMPR 3
'ON''OFF'
JMPR 4
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
6 5 4 3 2 17
8
6
5
4
3
2
1
7
8
SHIELD
BLUE
GREEN
YELLOW
ORANGE
RED
BROWN
BLACK
STA 1
0654-585
Figure 9– Actuator Connections

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4.8 BONDING A.B.Y.C. E-1 46 CFR 111.05
All boats equipped with a
permanently installed
electrical system shall be
equipped with a bonding
system. The negative
terminal of all batteries
should be connected at only
one (1) point, the DC
common, and from DC
common to bond system or
hull.
Metal - Hull Vessels
The hull of a metal - hull
vessel may serve as the
common bonding conductor.
Any item to be bonded not
in contact with the hull
requires a bonding
conductor to the hull.
4.9 ACTUATOR
Remove the Actuator cover and connect your anti-static wrist
strap to the Actuator frame and your wrist. Remove the cable
hole plugs as required. (See Figure 8) Install the watertight
cable grip that is packaged with the control head. Station No. 1
will connect through 'Station 1' as shown in Figure 7. Strip the
PVC jacket and shielding back approximately 2" (50,8mm). The
wire leads can be staggered for length to match the Station 1
terminal strip, and must not come in contact with the frame.
Strip the wire 3/8" (9,5mm) on each lead. It is also recommended
that the wire be LIGHTLY tinned. Connect colors as shown on
Circuit Dwgs, Sections 13. and 14. A WAGO Tool, No. 236-332,
Actuator
Figure 10 - Bonding