ZF MMC-343 User manual

MMC-343 Rev - 09/11 Page 3
MMC-343 Rev - 09/11
MMC-343 Station Expander User Instructions
Station Expander User Instructions
Table of Contents
1 Features ............................................................................................................... 4
2 Required Parts ..................................................................................................... 4
3 Location ............................................................................................................... 4
4 Station Expander Power ...................................................................................... 5
5 Harnesses ............................................................................................................ 5
6 Tools For Installation............................................................................................ 6
6.1 Required .............................................................................................................................. 6
6.2 Optional ............................................................................................................................... 6
7 Installation ........................................................................................................... 7
7.1 Station Expander ................................................................................................................. 7
7.2 Power Cable ........................................................................................................................ 8
7.3 Control Head Harnesses...................................................................................................... 8
7.4 Engine Stop Switch ............................................................................................................. 8
7.5 Control Heads...................................................................................................................... 9
8 Set Up Procedures ............................................................................................... 9
8.1 Station Expander Components Used In Set Up................................................................... 9
8.2 Station Expander Display LED ........................................................................................... 10
8.3 Push Buttons...................................................................................................................... 10
9 Activating Set Up Mode and Storing a Value..................................................... 11
10 Set Up Functions & Values................................................................................. 12
10.1 A0 - Station Expander Identification.................................................................................. 13
10.2 H0 - Diagnostic .................................................................................................................. 13
10.3 H1 - Erase EPROM ............................................................................................................. 14
11 Dock Trials ......................................................................................................... 14
11.1 Control Head (Engines Stopped) ....................................................................................... 14
11.2 Engine Stop Switches Test (Engines Running).................................................................. 14
12 Periodic Checks and Maintenance .................................................................... 15
12.1 Station Expander ............................................................................................................... 15
12.2 Control Head...................................................................................................................... 15
13 Parts List ............................................................................................................ 15
13.1 Control Heads.................................................................................................................... 15
13.2 Cable (Electric) .................................................................................................................. 16
13.3 Wire Harness (Plug)........................................................................................................... 16
13.3 Wire Harness (Plug)........................................................................................................... 16
13.4 Test Unit ............................................................................................................................ 16
ZF Marine Electronics
12125 Harbour Reach Dr Ste B
Mukilteo, WA 98275
P - 425-583-1900
F - 425-493-1569
www.zf.com

Page 4 MMC-343 Rev - 09/11
MMC-343 Rev - 09/11
Figure ENG-283-1: Station Expander
The station expander (SE) is designed to be an addition to the 9000 Series / CruiseCommand
Processors. The station expander allows the user to install more than the maximum allowed control
heads (up to four).
1Features
• Station-in-Command Indication
• Audible and Visual Indicators
•Key-PadSetUp
• Plug-in Cable Connections
• Built-in Diagnostics
• Addition of One to Four Remote Stations
The Station Expander receives the variable DC voltage from the Control Head(s) and serially
communicates these inputs to the Processor.
2RequiredParts
• One Station Expander required per Processor.
• Mounting Hardware is installer supplied.
• System Operation Manual included with the Processor.
3Location
• Expanders are spray proof, but must not be immersed.
• An engine room location of the Expanders is preferred.
• If the engine room is too small, locate in any area where it is accessible for electrical connections.
Bulkhead mounting preferred for ease of access for wiring and adjustments.
The Expander can be mounted in any attitude as long as the LED on the front cover is readable.
Do not mount the Expander on the engine, on the transmission, or in any location that will subject it to
excessive vibration.
Refer to Figure ENG-283-4: Station Expander Dimensions, for Expander dimensions.
NOTE: Read the MMC-165 Warranty in the Sales and Service Information Appendix. Improper mounting
location may cancel warranty.

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MMC-343 Rev - 09/11
Locate Expander(s) away from heat sources, such as engine exhaust manifolds turbochargers. Allow 4
feet (1,2m) of clearance, or more, between the Expander(s) and such heat sources.
Do not mount close to gas engine ignition systems, alternators, or electric motors. Allow 4 feet (1,2m)
of clearance between the Expander and alternators or electric motors.
A threaded hole is provided for connection to the vessel’s bonding system.
4 Station Expander Power
The Station Expander requires:
• A battery source of 12 or 24 volts DC
• A 10 ampere circuit breaker with manual reset
• Automatic Power Selector (refer to S-214 Automatic Power Selector Model: 13505)
The power source should be the same as the processors power source which can be either 12 or 24
volts DC. It is important to keep the length of power cable short to reduce voltage drop.
It is recommended by ZF Marine Electronics that an Automatic Power Selector (APS) and a second
power source be used. Refer to S-214 Automatic Power Selector Model: 13505 and Section 7.2 Power
Cable.
5 Harnesses
Below is a general list of Wire Harnesses available to Station Expander. A complete harness list and
part numbers are located in section 13 Parts List.
Stations 2-4 connectors on the Station Expander are sealed with plugs at the factory. Every connector
should either have inserted a Wire Harness or plug. Do not leave a connector empty.
•(2) Power Wire Harness (Station Expander to Power connections)
•(4) Control Head Wire Harness (Station Expander to Control Head)
•(5) Serial Communication Wire Harness (Processor to Station Expander to 2nd (etc.) Processor)
CAUTION: Electro-magnetic fields can influence the Station Expander’s electronic circuits.
NOTE: The Processor and the Station Expander may use the same Automatic Power Selector, but the
Station Expander MUST have a separate circuit breaker.
CAUTION: 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% of 7 amps. The DC return to the battery must be
large enough to supply all current requirements with a voltage drop of less than 3%. Refer to ABYC E-9.

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MMC-343 Rev - 09/11
Figure ENG-283-2: Station Expander Harness Connector Locations
The Harnesses use one or both of the plug connector types detailed in Figure ENG-283-3: Harness Plug
Connectors. When connecting the plugs, ensure that the release button or buttons are depressed and
held until plug is fully connected or disconnected. Connecting or disconnecting plugs without
depressing and holding the release button or buttons will damage the plug.
Figure ENG-283-3: Harness Plug Connectors
Ensure that the harness cable lengths are long enough to make one complete run from the Station
Expander to:
•thepowersupply
•theremotestation.
• the Port and Starboard Processor
6 Tools For Installation
6.1 Required
• Screwdriver – med. Phillips #2
• Hole saw -- 1 inch (25,4mm)
• Drills -- 9/32 inch (7,2mm) and 7/32 inch (5,6mm)
• Saw (appropriate type of saw for cutting material Control Head will be mounted on)
6.2 Optional
Wire cutter, stripper, crimper (Recommend Thomas & Betts WT-2000) (if using single terminated
harnesses)
2
4
5
[
Cable
Depress & Hold
Depress & Hold
11230_ART
Depress
&
Hold
11232_ART
Processor Key
15137_ART
Connector
Keying
Connector
Keying
12 34
5678
15138_ART

MMC-343 Rev - 09/11 Page 7
MMC-343 Rev - 09/11
7 Installation
Before starting the actual installation of the Station Expander, make sure you have the correct parts and
tools. See section 6 Tools For Installation. Read ALL the instructions pertinent to each part before
beginning the installation of that part
7.1 Station Expander
Figure ENG-283-4: Station Expander Dimensions
A Place the Station Expander on the mounting surface and mark the three screw holes.
B Remove the Expander and drill the screw holes.
C Secure the Expander using 1/4 inch or M6 fasteners.
D Connect to the Bonding System.
A Insert the Wire Harness plug into the POWER connector on the Station Expander.
B Continue with the following Sections that apply to this application.
NOTE: When connecting the plugs, ensure that the release buttons are depressed and held until plug is
fully connected. To disconnect the plugs, the release buttons MUST be held depressed until plug is
disconnected.
NOTE: When installing the harness cable, support the cables using clamps or straps not more than 18
inches (0,5m) apart, unless contained in a conduit. Install each cable so it is protected from physical
damage. Refer to ABYC Standard E-9.
WARNING: When connecting the Power Harness to the Station Expander be sure the power is OFF.

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MMC-343 Rev - 09/11
7.2 Power Cable
It is critical to design and wire the Control System in a manner where the chance of losing power to the
Control System is kept to a minimum.
ZF Marine Electronics recommends that two power sources are utilized along with the APS see document
S-214 Automatic Power Selector Model: 13505 for more information.
A Install the Power cable from the Station Expander to the DC Power Source.
• Install each cable so it is protected from physical damage.
B Review the DC Power Supply documents to confirm termination points for power
connection.
7.3 Control Head Harnesses
There are two choices of Control Head Harnesses depending on the type of Control Head being used with
this application.
• Plug at Station Expander end of harness only. (terminal connection Control Heads)
• Plug at Station Expander and Control Head ends. (Plug connection Control Heads)
The distance of the Control Head from the Station Expander is limited to the length of an uninterrupted 7-
conductor harness. This cable may never be spliced.
A Install the Control Head Wire Harness between each Control Head and the appropriate
Station Expander.
BLabel each harness at both ends with the station it connects, and Port, Center, or
Starboard for Multi Screw applications.
Install each harness so it is protected from physical damage.
When installing the cable, support using clamps or straps not more than 18 inches (0,5m) apart, unless
contained in a conduit. Refer to the ABYC Standard E-9.
7.4 Engine Stop Switch
The Installer supplies the Stop Switches. Refer to the information supplied with the Stop Switches for
installation.
NOTE: Repeat for all Station Expanders.
CAUTION: Ensure that each Control Head is plugged into the same Numbered Station Connector on each
Station Expander.
EXAMPLE: Station 1 Control Head will plug into the Station 1 connector on the Port Station Expander and the
Station 1 connector on the Starboard Station Expander. Failure to do this will result in incorrect Station
Transfer.
WARNING: Each Station must have some method to stop the engine, refer to CFR 46, SEC. 62.35-5 and
ABYC P-24.5.8.

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MMC-343 Rev - 09/11
7.5 Control Heads
Refer only to the following Sections that relate to the Control Heads used.
•Mounting
• 400 Series Control Head:
A Use the template supplied in MMC-280 400 Series Control Head Variations and drill the
screw holes and the corner cutout holes.
B Saw between the corner cutout holes.
C Check that the four mounting screws will start into the Control Head.
D Remove the Control Head.
E Strip the adhesive cover from the gasket and apply the adhesive side to the console.
• 700 Series Control Head:
A Use the template supplied in MMC-307 700 Series Standard Control Head Variations
and drill the screw holes and the corner cutout holes.
B Drill the screw holes and the cable holes.
• MC2000 Series Control Head:
A Use the template supplied in MMC-329 MC2000 Series Standard Control Head
Variations and drill the screw holes and the corner cutout holes.
B Saw between the corner cutout holes.
•Check that the two mounting screws will start into the Control Head 500 Series Control Head
Assembly:
Refer to Installation Manual supplied with the 500 Series Control Head Assembly for installation
instructions.
8 Set Up Procedures
The Station Expander utilizes push buttons in conjunction with Display LED’s to program, adjust,
calibrate and set up the various features. The push buttons also allow you to access and display
information regarding the health of the System.
The following paragraphs explain how to locate and use the push buttons and Display LEDs:
8.1 Station Expander Components Used In Set Up
Figure ENG-283-5: Station Expander Display LED and Arrow Push Buttons
Each Station Expander has a Display LED and Arrow Push Buttons located on the front cover. (Figure ENG-
283-5: Station Expander Display LED and Arrow Push Buttons)
NOTE: Main Processor function should be set to A3-01 to enable station expander.
11573-1_ART
SERIAL
STA. 4
STA. 4
STA. 2
STA. 2
STA. 3
STA. 3
POWER
PART NUMBERPART NUMBER
SERIAL NUMBERSERIAL NUMBER

Page 10 MMC-343 Rev - 09/11
MMC-343 Rev - 09/11
• The Display LED is to view the Function Codes and Values. It consists of four 7-segment
display pads.
• The Arrow Push Buttons are used to scroll through and select the Function Codes, and set
the Values.
8.2 Station Expander Display LED
Figure ENG-283-6: Display LED at Normal Operation
• The Station Expander’s Display LED has four 7-segment LED’s, which light up to show either
letters or numbers.
• The Display LED during Normal operation has running red center dash lines (Figure ENG-283-6:
Display LED at Normal Operation)
• The first two digit Display LED’s to the left, indicate the Function Code, which is alphanumeric.
Figure ENG-283-7: Display LED Designations
• The second two digit Display LED’s indicate the numeric Value that is currently programmed into
the Station Expander for the Function Code displayed to the left.
• A decimal point indicator is located on the bottom right corner of each Display LED. (Figure ENG-
283-7: Display LED Designations)
8.3 Push Buttons
There are four Push Buttons with arrows located below the Display LED on the Station Expander cover.
These push buttons are used to scroll through, select, and store the Functions and Values. The direction of
the arrow indicates “Left”, “Down”, “Up”, and “Right”. See Figure ENG-283-5: Station Expander Display
LED and Arrow Push Buttons.
•“Up”and“Down”PushButtons
Pressing the “Up” or “Down” Push Buttons once has the following functions:
•Stops
Normal Operation Display (running red center dash lines) and activates the Function
Menu.
• While in the Function Menu, scrolls through the Function Codes one at a time.
• When in Set Up Mode, increases (Up) or decreases (Down) the Function Value one digit at
a time.
• When an Error Code is displayed, scrolls through the error messages one at a time.
NOTE: Refer to Troubleshooting section of the processor manual for steps to be taken for Error Messages.

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• “Left” and “Right” Push Buttons
Pressing and holding the “Left” and “Right” Push Buttons at the same time has the following
functions:
•Activates
Set Up Mode as indicated by the blinking Display LED. (Operator must hold the
buttons down until the blinking begins, then release.)
• While in Set Up Mode, deactivates Set Up Mode, saves the displayed Value to memory,
and returns to the Function Menu. (Operator must hold the buttons down until the blinking
stops, then release.)
•“Left“PushButtonOnly
Pressing the “Left” Push Button once has the following functions:
• Deactivates Set Up Mode WITHOUT any changes to the Function Value stored in memory.
(Operator must hold the button down until function code stops blinking, then release.) The
previously saved Function Value will then be displayed.
Figure ENG-283-8: Error Menu Example
• While in Function Menu, changes the Display LED to the Error Menu, if any errors are
present. (has no effect if there are no errors stored)
• While in the Error Menu, changes the Display LED back to the Function Menu.
• “Right” Push Button Only
Pressing the “Right” Push Button once has the following function:
• While in the Error Menu, clears inactive errors. (Active errors blink, inactive do not)
Pressing and holding the “Right” Push Button has the following function:
Figure ENG-283-9: Display LED Four Digit Value
• While in Set Up Mode, or Function Menu, allows the Function Value of the current
Function Code to be displayed with all four Display LEDs.
9 Activating Set Up Mode and Storing a Value
NOTE: To escape from the set up procedure at any time without saving the changed value. Depress the
LEFT Arrow Push Button. The Function Code will stop flashing and the Function will be saved with the
original value.
Depress
and
Hold
Throttle Maximum
Function Code and Default Value
Blinking
15340_ART

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Figure ENG-283-10: Display Normal Operating Condition
Figure ENG-283-11: Display Function Menu Activated
A The Display is in Normal Operating condition with red running center dash lines.
B Depressing either the Up or Down Arrow Push Button will activate the Function Menu. (refer to
Figure ENG-283-11: Display Function Menu Activated)
C Depressing either the Up or Down Arrow Push Button will scroll through the Function Menu one
at a time.
Figure ENG-283-12: Display with Set up Activated
D Once the desired Function Code is visible on the Display, depressing and holding the Left and
Right Arrow Push Buttons at the same time will activate Set Up. The left two Display pads will
begin to blink, indicating that the value is ready to be changed. Refer to Figure ENG-283-12:
Display with Set up Activated
E Depressing either the Up or Down arrow push buttons will change the Value of the Function.
Holding down either the Up or Down arrow push buttons will scroll quickly through the values.
F When the value required is displayed, depress and hold the Right and Left Arrow push buttons
until the Display Function Code stops blinking and becomes solid. The new Value is now set into
memory.
G Depressing either the Up or Down arrow push buttons will now scroll through the Function
Codes.
10 Set Up Functions & Values
The following table lists the various Function Codes, the Function’s Name, Default Value and Range.
Each Function will be explained in one of the following Sections.
Table ENG-282-1: Functions List
Function
Code Function Name Default Value Value Range or Options
STATION EXPANDER FUNCTIONS
A0 Station Expander Identification 01
01, 02, 03, 04, 05 (Must match Processor Identification set in the
9000 Series / CruiseCommand Processor the Expander is
connected to.)

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10.1 A0 - Station Expander Identification
In applications where there is more than one screw, the system must have some way of determining
which Station Expander is where. Every Station Expander must have it’s own identifying unique number
that corresponds to the Processor it is connected to. At no time can two Station Expanders be identified
by the same Station Expander Identification Number.
Figure ENG-283-13: Display with A0 - Station Expander Identification Set Up Activated
The values of this Function are 01 (Default Value), 02, 03, 04, and 05.
To change the value:
A Depress any Arrow Push-Button to stop running center dash lines.
B This is the first code on the Function Menu List and the Function Code for Station Expander
Identification.
C Activate Set Up Mode. Refer to Section 9 Activating Set Up Mode and Storing a Value.
D Depress either the Up or Down arrows to change the Value of the Function.
E When the value required is displayed, store the value. Refer to Section 9 Activating Set Up Mode
and Storing a Value.
10.2 H0 - Diagnostic
This Function is used during Troubleshooting. Refer to the 9000 Series / CruiseCommand Manual
supplied with the Control System for information on this Function.
Table ENG-282-2: Troubleshooting Functions
Functio
n Code Function Name Default Value Value Range or Options
H0 Diagnostic 00
Input Voltage (+/- 0.5VDC)
Tachometer Sensor Frequency
Station 1 Lever A/D
Station 2 Lever A/D
Station 3 Lever A/D
Station 4 Lever A/D
Transfer Button, Stations 1, 2, 3 & 4
Software Revision Level
H1 Erase EPROM 00 Store to Erase (For Authorized Personnel Only)
CAUTION: This feature MUST be the SAME value as set in the 9000 Series / CruiseCommand Processor the
Expander is connected to.

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10.3 H1 - Erase EPROM
This Function is used during Adjustments or Troubleshooting. (For Authorized Personnel Use ONLY)
11 Dock Trials
Ensure 9000 Series / CruiseCommand System has been installed, adjusted, and tested before
performing the following tests for the Station Expander.
11.1 Control Head (Engines Stopped)
ATurn the power ON to the control system.
B The Control Head at each station will produce an intermittent tone.
C Take command at a remote station.
D Perform each of the following steps on all Control Heads.
• Move each Control Head lever full Ahead and full Astern. Ensure correct 9000 Series /
CruiseCommand Processor and Station Expander reacts to lever movement.
• Place the Control Head levers in the Neutral detent position.
•Depressandhold
the station transfer button.
• Move the Control Head levers to the Ahead detent position before releasing the transfer
button.
• The red indicator light on the Control Head should blink, indicating 9000 Series /
CruiseCommand has been placed in Warm-up Mode. Warm-up Mode only operates in
the Ahead direction.
• If the red indicator light blinks, continue with Control Head testing
• If the red indicator light does not blink, check connections as stated in Section 7.5
Control Heads.
11.2 Engine Stop Switches Test (Engines Running)
AStartengine(s).
B Verify that all Engine Stop Switches function correctly at all stations.
Refer to information supplied by engine manufacturer or switch supplier for set up and adjustments.
WARNING: Turn OFF the control system power before disconnecting from the batteries. Do not disconnect
battery terminals when engine is operating.
NOTE: This will check that the Control Head is operating. * On Twin Screw or more applications ensure
the Port Control Head lever operates the Port Processor and the Starboard Control Head lever operates the
Starboard Processor, etc. *
CAUTION: An Engine Stop Switch at each station is an absolute requirement. Refer to CFR46, SEC. 62.35-
5 and ABYC P-24.5.8.
WARNING: Do not attempt to continue tests until Engine Stop Switches function correctly.

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12 Periodic Checks and Maintenance
12.1 Station Expander
Check all terminal connections for signs of corrosion or loose connections.
12.2 Control Head
Verify once a year that Control Head terminals are secure and free of corrosion. Apply a light coating of
Teflon grease, or corrosion block, to the contacts.
13 Parts List
Part No. Description
13.1 Control Heads
A Single Screw
450-3L or 3RLeft or Right Control Head, 'T' Lever
453-3L or 3RLeft or Right Control Head, Chrome Knob Lever
455-3L or 3RLeft or Right Control Head, Black Low Profile Lever
456-3L or 3R Left or Right Control Head, Chrome Low Profile Lever
456-3LP or 3R PLeft or Right Control Head, Chrome Low Profile Lever, Pluggable
521-4 Control Head, Single Lever Tournament Style - Aluminum
521-5 Control Head, Single Lever Tournament Style - Chrome
750-L or –RLeft or Right Control Head, Heavy Duty
MC2000-1L or 1RLeft or Right Black Control Head, Black Lever
MC2000-2L or 2RLeft or Right Chrome Control Head, Chrome Lever
MC2000-4L or 4RLeft or Right Black Control Head, Chrome Lever
MC2000-4LP or 4RPLeft or Right Black Control Head, Chrome Lever, Pluggable
MC2000-5L or 5RLeft or Right Black Control Head, Gold Lever
BTwinScrew
(Synchronization Indication)
460-4 Control Head, 'T' Lever
460-4P Control Head, 'T' Lever, Pluggable
463-4 Control Head, Chrome Knob Lever
463-4P Control Head, Chrome Knob Lever, Pluggable
464-4 Control Heads, Split, with Single Levers, Chrome Knobs (pair)
465-4 Control Head, Black Low Profile Lever
466-4 Control Head, Chrome Low Profile Lever
522-4 Control Head, Dual Lever Tournament Style - Aluminum
522-5 Control Head, Dual Lever Tournament Style - Chrome
760 Control Head, Heavy Duty
760P Control Head, Heavy Duty, Pluggable
MC2000-1 Black Head, Black Levers
MC2000-1PBlack Head, Black Levers, Pluggable
MC2000-2 Chrome Head, Chrome Levers
MC2000-2PChrome Head, Chrome Levers, Pluggable
MC2000-3 Gold Head, Gold Levers
MC2000-4 Black Head, Chrome Levers
MC2000-4PBlack Head, Chrome Levers, Pluggable
MC2000-5 Black Head, Gold Levers

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13.2 Cable (Electric)
180 8-Cond. Shielded CablePer/ft.
350 8-Cond. Shielded Cable500’ Spool
11811 8-Cond. Shielded Cable1000’ Spool
212 2-Cond. Power CablePer/ft.
349 2-Cond. Power Cable250’ Spool
183 2-Cond. Start Interlock CablePer/ft.
355 2-Cond. Start Interlock Cable250’ Spool
13.3 Wire Harness (Plug)
Replace the # after the Part Number with the length of harness required. EXAMPLE: 13316-10; 13316-
20; 13316-30
13316-# Serial Communication (Twin Screw)
13408-# Serial Communication (Multiple Screw)
15544-# Serial Communication - CruiseCommand (Multiple Screw)
13432-# Throttle, Voltage
13494-# Throttle, Current
13533-# Throttle, PWM
14363-# Throttle, MAN
15027-# Throttle, Frequency
13322-# Clutch – Ahead/Astern/Clutch Power
13324-# Clutch – Ahead/Astern/Neutral/Clutch Power
13240-# Clutch – Ahead/Astern/Troll/Troll CMD/Clutch Power
14310-# Clutch – Ahead/Astern/Troll CMD/Clutch Power
14925-# MAN with Troll
14542-# MAN without Troll
13239-# Magnetic Pickup or Pulse Transmitter
13422-# ZF Autotroll (MS70-13231 only)
15364- ZF Autotroll (MS570-15382 Cannon Connector only)
15208- ZF Autotroll (MS570-15382 Harting Connector only)
13552-# Power/Start Interlock/Clutch Pressure
13756-# Power/Start Interlock
15023-# Power
13557-# Control Head - 1 Connector
14261-# Control Head - 2 Connectors
13.4 Test Unit
13927 Service Field Test Unit
14000 Field Test Control Head - Dual