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Flexball Series 3500 Operating Manual & Installation Manual

Electronic command system for marine engines
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Flexball Italiana S.r.l.
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Summary of Contents for Flexball Series 3500

  • Page 1 & & Flexball Italiana S.r.l.

  • Page 2: Table Of Contents

    Fast Start-up Mode............................8 3.6. Emergency lever ............................8 Command station................................9 4.1. Dimensions..............................9 4.1.1. Command station series 3500 ........................9 4.1.2. Command station series 4500 ........................10 4.2. Friction adjustment ............................10 4.2.1. Command station series 3500 ........................10 4.2.2.
  • Page 3 Faults in the electrical network ......................... 65 21.3. Protection in case of overload or break of the push-pull cables..............65 21.4. Troubleshooting............................66 21.5. LED diagnosis on command station ......................67 How to start ................................. 68 Drilling mask ................................69 Version June 2011 Flexball Italiana S.r.l.

  • Page 4: Introduction

    Stroke can be set to between 5 and 80 mm Electrical features Power supply (*) from 9,0 to 16 V or from 9,0 to 28,0 V Max. current absorbed Current absorbed when the system isn’t loaded 0,5 A * according to the version of the actuator Flexball Italiana S.r.l.

  • Page 5: Pilot Instructions

    Moving the lever from the neutral position, after 16° forward or reverse automatically the electronic system clutches-in respectively the forward or reverse gear. The accelerator lever has a stroke of 62° both in forward and backward direction. Command station series 3500 Command station series 4500 Flexball Italiana S.r.l.

  • Page 6: Control Keypad

    3.1. Control keypad On the command station it is mounted an electronic keypad with 4 push-buttons and 4 LEDs. Command station series 4500 Command station series 3500 Description LEDs colour Engine (*) Green Warm/Sync Orange Command Engine (*) Green (*) In installations with single engine, both the green LEDs are referring to the same engine. In systems with 2 engines the push button and the green LED on the right are referring to the starboard engine while the push button and the green LED on the left side are referring to the port engine.

  • Page 7: Acquisition Of The Command

    Warm-up mode. If you move the lever. it is only affected the accelerator but not the gear. In Warm-up mode the LED Warm/Sync is blinking. After positioning again both levers in neutral and pressing for 1,5 seconds the Warm/Sync, the system comes back to the normal operation mode. Flexball Italiana S.r.l.

  • Page 8: Synchro Mode

    In order to reset the system, turn off completely (counter-clockwise) knob (A). The emergency lever automatically goes back to the position where it was before activating the emergency mode, at the first movement of the command lever. Flexball Italiana S.r.l.

  • Page 9: Command Station

    4.2 and 8.1 of this manual. 4.1. Dimensions 4.1.1. Command station series 3500 ► Important: in case the screws to fix command station to the dashboard panel are not long enough, don’t open the command station to replace them but ask for an adaptation kit.

  • Page 10: Command Station Series 4500

    4.1.2. Command station series 4500 4.2. Friction adjustment 4.2.1. Command station series 3500 To adjust the inner friction of the command lever, remove the PVC cap (A) and unscrew the fixing screw. It is possible to adjust the friction screwing and unscrewing the inner screw placed into the hole (B).

  • Page 11: Command Station Series 4500

    At the next normal power up, the command lever will make a sequence of 2 short flashes. 2. In case you need to configure again the command lever for installation with 2 motors and 1 actuator, repeat the procedure of point 1. Flexball Italiana S.r.l.

  • Page 12: Command Station Label

    Command station 1 motor series 3500 3500 . C - 1 1 0 0 0 5 Command station 1 motor series 3500 with TRIM option 3500 . C - 2 0 0 0 0 5 Command station 2 motors series 3500 3500 .

  • Page 13: Actuator

    1:1. 5.1. Drawing of actuators with mechanical interface ► Important: the part of the drawing identified with letter (A) doesn’t exist on actuators with mechanical interface either towards the motor or towards the gearbox. Flexball Italiana S.r.l.

  • Page 14: Drawing Of Full Electronic Actuator

    5.2. Drawing of full electronic actuator How to mount the actuator Do not install the actuator with the Mount the actuator leaving a space of at least 25 cm on each side connectors upwards Flexball Italiana S.r.l.

  • Page 15: Actuator Labels

    5.3. Actuator labels Inside the actuator there are two labels indicating code and serial number. Please write them down in case you call for assistance. Actuator code Serial number Flexball Italiana S.r.l.

  • Page 16: Actuator Codes

    Actuator for 2 electronic motors (mA) and 2 gearboxes solenoid driven (with trim) 3500 . A - 8 4 0 2 3 9 3500 . A - 4 4 0 2 3 9 Actuator for 2 PWM motors and 2 gearboxes solenoid driven (with trim) Flexball Italiana S.r.l.

  • Page 17: Electronic Actuator Boards

    4 poles Engine SX GND CH2 GND CH1 ► Important: channels 1 and 3 are dedicated to the electronic engine (ECU) while the channels 2 and 4 are dedicated to the inverter for electric motors (hybrid motor applications). Flexball Italiana S.r.l.

  • Page 18: Relays Pcb Version 1.0 For Electronic Gearboxes

    Relays PCB version 1.0 for electronic gearboxes Relè right Relè right Solenoid gearbox Trim command gearbox gearbox Forward (brown) Trim “-“ (nero) (yellow/green) (brown) Reverse (blue) Trim “+” (grey) Trim “–“ (brown) Trailer (yellow/green) (yellow/green) Trim “+” (blue) Flexball Italiana S.r.l.

  • Page 19: Relays Pcb Version 2.0 For Electronic Gearboxes

    Right engine - Reverse gear Right engine - Common neutral relays contact Right engine - NC contact neutral relays Right engine - Common trim contact Right engine - Trim + Right engine - Trim - Right engine – Trailer Flexball Italiana S.r.l.

  • Page 20: Canbus Pcb For Motor With Canbus Interface

    Electronic ECU with voltage signal  Electronic ECU with CANBus interface  Command of hybrid motors frequency converter driven through a voltage signal The PCB is mounted inside of the actuator and there aren’t any special precaution to follow durig commissioning. Flexball Italiana S.r.l.

  • Page 21: Accessories And Options

    If the cable has been inserted correctly, it must be possible to screw completely by hand the cable without too much efforts. Connector for throttle cables Polarization Wall mounted Cable connector connector Connector for CANbus data transmission cable Polarization Cable connector Wall mounted connector Flexball Italiana S.r.l.

  • Page 22: Canbus Data Transmission Cable

    L=7,5 m 3500.33-07500 L=10 m 3500.33-10000 L=15 m 3500.33-15000 6.2. Cable actuator – electronic motor (V) Grey Black Length Code L=3 m 3500.34-03000 L=5 m 3500.34-05000 L=7m 3500.34-07000 ► Important: this cable is without connector on motor side Flexball Italiana S.r.l.

  • Page 23: Nanni Diesel - Throttle Cable For Toyota Ecu

    4665/41-03000 L=5 m 4665/41-05000 L=7m 4665/41-07000 6.2.3. Nanni Diesel – Command cable for throttel and inverter (1° part, Y cable) Brown Blue Grey Black (Rear view) Length Code L=3 m 4665/42-03000 L=5 m 4665/42-05000 L=7 m 4665/42-07000 Flexball Italiana S.r.l.

  • Page 24: Nanni Diesel - Y Cable For Toshiba Motor Base (V) + Inverter (V)

    Black - GND Gauina grigia Ø5 Black Blue Grey Brown (Rear view) Channel 1: VM motor base with CANBus interface Blue – can L Brown – can H Length Code L=3 m 4665/45-03000 L=5 m 4665/45-05000 L=7 m 4665/45-07000 Flexball Italiana S.r.l.

  • Page 25: Fpt - Throttle Canbus Command Cable

    Nanni Diesel – Cable for gearbox solenoid driven Length Code L=3 m 4665/36-03000 L=5 m 4665/36-05000 L=7 m 4665/36-07000 6.3.2. FPT – Cable for gearbox solenoid driven Length Code L=3 m 15/36-03000 L=5 m 15/36-05000 L=7 m 15/36-07000 Flexball Italiana S.r.l.

  • Page 26: Nanni Diesel - Cable For Gearbox Solenoid Drive + Neutral Signal

    Nero 1 Nero 2 Black 2 Length Code L=3 m 3500.37-03000 L=5 m 3500.37-05000 L=7 m 3500.37-07000 6.4.1. Nanni Diesel – Cable for the trim/flap command Length Code L=3 m 4665/37-03000 L=5 m 4665/37-05000 L=7 m 4665/37-07000 Flexball Italiana S.r.l.

  • Page 27: Cable Actuator - Mercruiser® Trim Pump

    Yellow ® pump Mercruiser Actuator side side Length Code L=3 m 3500.40-03000 6.6. T-Splitter Code: N-85E010003 6.7. Power supply connector Code: 3500.38-00000 ► Important: cabling instruction of power supply connector are at section 10.1.1. of this manual. Flexball Italiana S.r.l.

  • Page 28: Trim/Flap Option

    For installations with two engines, in case of “Synchro” mode operation, the buttons on the right-hand side operate the trims of both engines simultaneously. Command station series 3500 1 engine version 2 engines version...

  • Page 29: System Types And Installation Schemes

     Components necessary to build an installation  Configuration of actuators and command stations in relation of their position on the CANBus network The following installation types and schemes cover the most common application cases. Flexball Italiana S.r.l.

  • Page 30: Installation With 2 Mechanical Actuators - Solution A

    Up to 3 command stations and 2 engines with mechanical throttle, mechanical gearbox, with/without • trim; Up to 3 command stations and 2 hybrid engines with mechanical throttle, mechanical gearbox, • analogue outputs for electric engine inverter driven, with/without trim. Flexball Italiana S.r.l.

  • Page 31: Installation With 2 Mechanical Actuators - Solution B

    Up to 3 command stations and 2 engines with mechanical throttle, mechanical gearbox, with/without trim;  Up to 3 command stations and 2 hybrid engines with mechanical throttle, mechanical gearbox, analogue outputs for electric engine inverter driven, with/without trim. Flexball Italiana S.r.l.

  • Page 32: Installation With 2 Mechanical Actuators - Solution C

    Up to 3 command stations and 2 engines with mechanical throttle, mechanical gearbox, with/without trim;  Up to 3 command stations and 2 hybrid engines with mechanical throttle, mechanical gearbox, analogue outputs for electric engine inverter driven, with/without trim. Flexball Italiana S.r.l.

  • Page 33: Installation With 1 Actuator - Solution D

    (or flap); up to 3 command stations and 1 or 2 hybrid engines with electronic throttle (voltage or CANBus), • solenoid driven gearbox, analogue outputs for electric engine inverter driven, with/without trim (or flap). Flexball Italiana S.r.l.

  • Page 34: Installation With 1 Actuator - Solution E

    (or flap); up to 3 command stations and 1 or 2 hybrid engines with electronic throttle (voltage or CANBus), • solenoid driven gearbox, analogue outputs for electric engine inverter driven, with/without trim (or flap). Flexball Italiana S.r.l.

  • Page 35: Configuration Of The Canbus Network: End Of Line Termination Resistor And Address Setting Of Command Stations And Actuators

    “Fast Start-up Mode” or “Command station in position A”. ► Important 3: To configure the dip-switches of each command station, please refer to the installation schemes reported from section 7.1. to section 7.5. Flexball Italiana S.r.l.

  • Page 36: Configuration Of The Actuator

    Enable the 120 Ω short-circuiting either terminals 8 and 9 of JP5 or JP19: YES (end-line) terminals 2 and 3 of JP3 JP13 JP11 JP10 Resistenza di fine linea (120 O) Indirizzo End-line resistance (120 O) Address Flexball Italiana S.r.l.
  • Page 37 JP14 = OFF right actuator is with JP14 = ON The setting of JP19 is depending if the actuator is in the middle (JP19 = OFF) or at the end of the CANBus network (JP19 = ON) Flexball Italiana S.r.l.

  • Page 38: Push-Pull Cables Installation

    6. loose the emergency knob and move the emergency lever until the device will reach the correct position (it will be automatically locked) ► Important: before the assembly, the throttle must be in minimum position and the gearbox must be in neutral position. Flexball Italiana S.r.l.

  • Page 39: Push-Pull Cable Outgoing From The Mercruiser® Stern Driver

    5. lock the aluminium device with the screw, the brass spacer and the washer at the distance indicated into the picture; 6. loose the emergency knob and move the emergency lever until the device reaches the correct position (it will be automatically locked) Flexball Italiana S.r.l.

  • Page 40: Electrical Installation

    Important: take care to connect properly the polarity of the cables (supply is marked with a red sign). Vdc (the plug is marked with red) Flexball Italiana S.r.l.
  • Page 41 ‘R1’ is a relay that is activated by the key of the port starboard engine engine while ‘R2’ is a relay that is activated by the key of the starboard engine Actuator Actuator Actuator Battery Battery Battery Battery Port engine Starboard engine Port engine Starboard engine Flexball Italiana S.r.l.

  • Page 42: Electrical Installation Of Systems With 1 Motor, 1 Actuator And 1 Dashboard

    24 V power Ref. Description supply supply Diode 10 A, 20 V 5 A, 24 V Relè 10 A, 12 V 5 A, 24 V Fuse 10 A Supply cable 2,5 mm 1,5 mm cross section Flexball actuator Flexball Italiana S.r.l.

  • Page 43: Electrical Installation Of Systems With 2 Motors, 1 Or 2 Actuators And 2 Dashboards

    Electrical installation of systems with 2 motors, 1 or 2 actuators and 2 dashboards Attuatore Flexball Flexball actuator The same scheme can be used in case there are 2 actuators instead of only one. For the detailed list of components, please refer to the table at section 10.1.2. Flexball Italiana S.r.l.

  • Page 44: Electrical Installation Of Systems With 1 Motor, 1 Actuator And 2 Dashboards

    10.1.4. Electrical installation of systems with 1 motor, 1 actuator and 2 dashboards Flexball actuator For the detailed list of components, please refer to the table at section 10.1.2. Flexball Italiana S.r.l.

  • Page 45: Dimensional Criteria Of The Power Cables For The Overall Installation

    In case of systems with electronic throttle, it is very important to connect to a common GND point (GND buss bar) all the negative poles (GND) of every electronic equipment. Bow thruster Buss bar for GND Motorino avviamento Motor starter Attuatore Flexball Flexball actuator Flexball Italiana S.r.l.

  • Page 46: Electrical Cabling Of The Outgoing Cables From The Actuator

    (only 1 propulsion group per actuator)  mechanical engine and solenoid driven gearbox (up to 2 propulsion groups per actuator)  electronic engine and mechanical gearbox (up to 2 propulsion groups per actuator) Flexball Italiana S.r.l.

  • Page 47: Cabling Of Actuators For Electronic Propulsion Systems

    Vdc trim/flap: brown e e flap Forward: black 1 Flap +: black 2 or grey Forward Backward M. avanti/Flap + M. indietro/Flap - Backward: black 2 Trim/flap + Trim/flap - Flap -: black 1 or black e e flap Flexball Italiana S.r.l.

  • Page 48: Programming Of The Actuator, General Guidelines

    5. to set the other parameters, scroll the menu using the keys “1” and “2” and when the parameter that you would like to change is reached, follow this procedure starting from the point 3. Flexball Italiana S.r.l.

  • Page 49: Actuator Parameters

    It is shown an underscore “_” It is shown an underscore “_” or or the left lever position if it is the right lever position if it is the the actuator of the left engine actuator of the left engine Flexball Italiana S.r.l.

  • Page 50: Setting Of The Strokes Of Push-Pull Cables

    (potentiometer); e. When the hole on the fork (or the ball joint) is aligned with the hole on the throttle lever (potentiometer), store the position with key “3”. Flexball Italiana S.r.l.

  • Page 51: Setting Of The Stroke Of The Gearbox Cable

    ► Important 6: in case of stern drive and outboard engines, if the motor isn’t running, it isn’t possible to set the strokes, because the clutch-in operation becomes very hard. In this is the case, actuate the rotation of the propeller manually, this will make easier the clutch-in of the gearbox. Flexball Italiana S.r.l.

  • Page 52: Programming Of The Actuator In Installations With Mechanical Motor And Gearbox

    Value A0 Throttle Gearbox Push Pull (direction UL) (direction OH) Push Push (direction UL) (direction OL) Pull Push (direction UH) (direction OL) Pull Pull (direction UH) (direction OH) Le impostazioni di fabbrica prevedono A0 = 4 Throttle Gearbox Flexball Italiana S.r.l.

  • Page 53: Specific Parameters

    Delay on the throttle 0 .. 9,9 s 0,0 s These parameters Proportional coefficient 0 .. 99 must not be Integral coefficient 0 .. 99 changed To be used for the check-up of the internal CANBus communication Flexball Italiana S.r.l.

  • Page 54: Programming Of Actuators For Installations With Electronic Motor And Mechanical Gearbox

    These parameters are present only in systems with electronic engine (ECU) and/or electric with electrical engine inverter driven. Parameters to define the voltage output interface will be detailed in the following pages. To be used for the check-up of the internal CANBus communication Flexball Italiana S.r.l.

  • Page 55: Parameter A0

    Positions of the left gearbox Set A0=2 are inverted while the positions of the right gearbox are correct Positions of both gearboxes Set A0=1 are inverted Gearbox Gearbox left engine right engine Flexball Italiana S.r.l.

  • Page 56: Parameters To Configure The Voltage Output Signal For Electronic Motors

    C*, where “*” means 1,2,3,4. ► Important: the graphic on the right represents the voltage profile defined by parameters L,C, H. Changes of factory values could cause a system malfunctioning. Before making any changes, contact our technicians. Lever stroke Flexball Italiana S.r.l.

  • Page 57: Programming Of Actuators For Mechanical Motors And Electronic Gearbox

    Delay in neutral; it occurs any time you move directly from forward to reverse or from reverse to forward. This delay does 0 .. 9,9 s 0,5 s not occur when from neutral you move to forward or reverse. Flexball Italiana S.r.l.

  • Page 58: Programming Of Actuators With Electronic Motor And Electronic Gearbox

    These parameters are present only in system with electronic engine with ECU and/or electric engine inverter driven. Parameters for the voltage outputs are described at section 14.2.2. To be used for the check-up of the internal CANBus communication Flexball Italiana S.r.l.

  • Page 59: Programming Of Actuators With Electronic Canbus Motor And Mechanical Gearbox

    Repetition rate Identifier 29 bit in according to CAN 2.0B default value default value description n° byte 250 Kbit/s 10 ms Priority Address Identifier: Identifier Priority Address Hexadecimal values (_) 0x_ _ 0x_ _ _ _ 0x_ _ Flexball Italiana S.r.l.

  • Page 60: Setting Of The Canbus Parameter Values

    2600 2900 TSC1-VE C13 500 C13 ENTM 50 2000 2300 C87 620 C87 ENTM 62 2400 2800 C87 380 C87 ENTM 38 2000 2300 C87 750 C87 ENTM 75 2600 2900 (it continues at the following page) Flexball Italiana S.r.l.

  • Page 61: Technical Data Of The Canbus Interface Card

    Operation to be don with the electronic control switched off: verify with a multimeter that the impedance between terminals JP4.4 and JP4.5 of the CANBus PCBoards on the actuator is = 60 ohm or similar (see section 5.4.4.). In case of different values, contact either Flexball or the FPT dealer. ...
  • Page 62 ON = the command from electronic control lever is disables (it doesn’t work properly) OFF = the command from electronic control lever is enabled (it works properly) Flexball Italiana S.r.l.

  • Page 63: Programming Of Actuators With Electronic Canbus Motor And Electronic Gearbox

    (without the trim option), as described in sections from 13. to 18. included. Use electrical cables between actuator and trim pump or from actuator and flap pump as specified in sections 6.4, 6.5. and 10.2.2. Verify that wiring is according to electrical scheme reported at section 10.2.3. Flexball Italiana S.r.l.

  • Page 64: Programming Of Actuators With The Option For Hybrid Motors

    Starting acceleration point on channel 4 right motor ► Important: change of factory setting might cause a wrong functioning of the system! It is therefore recommended to do not make any change without previously contacting the producer. Corsa della leva Flexball Italiana S.r.l.

  • Page 65: Behaviour Of The Electronic System In Case Of Failures

    In case this alarm is activated, turn off the system, verify the causes that have generated the alarm before turning on again the system. Flexball Italiana S.r.l.

  • Page 66: Troubleshooting

    • Check that throttle positions Minimum speed position on the command • Scheme at section 13.2 or are according to the scheme stations corresponds to maximum speed 15.1 • Check settings of parameter on the actuator • Section 14.2.1 Flexball Italiana S.r.l.

  • Page 67: Led Diagnosis On Command Station

    (50% ON, 50% OFF) of the command station There is a failure on mechanical actuators, To remove the falure refers All 4 LEDs are blinking probably due to an extra load at section 21.3. on push-pull cables Flexball Italiana S.r.l.

  • Page 68: How To Start

    (from section 13 to section 18 included) make the programming of the options, if your application requires it (sections 19 and 20) once you have set-up the electronic system, read the pilot instruction (section 3) and, good navigation! Flexball Italiana S.r.l.

  • Page 69: Drilling Mask

    Drilling mask Flexball Italiana S.r.l.

This manual is also suitable for:

4500 series3500 series

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