Autotroll
Autotroll
Autotroll
ZF-AUTOTROLL (EST-59)
General information
The following safety pointers are used in this manual:
NOTE This NOTE is used to refer to particular operations, methods, information, use of auxiliary equip-
ment etc.
CAUTION This is used if different or incorrect methods can result in product damage.
DANGER This is used if carelessness can lead to personal injury or loss of life.
Subject to change
Copyright by ZF
Not to be reproduced in part or in whole without our written approval.
Printed in Germany
Issued: 2004-11
ZF Friedrichshafen AG
D-88038 Friedrichshafen, Customer Service
Telephone: (07541) 77-0
ZF-AUTOTROLL (EST-59) Contens
1
General information ZF AUTOTROLL (EST-59)
3
ZF-AUTOTROLL (EST-59) Application and operating range
1.0 Application and operating range Trolling can be used from idling speed up to 45 % (up to
50 % with the ZF1900, ZF2000 and ZF2500 gearbox fa-
1.1 Application mily) of the rated engine speed but not more than 1000
The ZF-AUTOTROLL unit allows propeller speeds to rpm.
be steplessly adjusted at levels below the engine speed. These limits apply not to controllable pitch propellers
This allows the ship to travel at lower speeds than those and surface drives. With surface drives trolling can be
possible with a standard-control transmission at the lo- used from engine idling speed up to a maximum engine
west permissible engine speed. speed of 700 rpm.
Please note that it is essential to contact ZF for applicati-
ons with controllable pitch propellers and surface drives.
Typical applications include:
The ZF AUTOTROLL control unit shifts the transmissi-
• Where speed limits apply, e.g. passing through ons multiple-disc clutch into non-trolling mode when the
canals. engine speed exceeds the permissible range.
• Manoeuvring in ports, docks and at landing stages. The minimum propeller speed at operating temperature
(> 30°C) and with SAE 30 oil is preset to 50 rpm. The
• Maintaining position for police boats, rescue boats. maximum propeller speed is set by ZF depending on the
• Towing off small boats. application.
• Sport fishing at optimum trolling speed. With fixed pitch standard propellers (no surface drives)
trolling operation is possible without time limit for mo-
vement ahead and astern.
The boat can also be reversed in AUTOTROLL mode. With surface drives there can be heat losses in trolling
The reversing aids incorporated in the electronic system operation several factors higher than the losses with stan-
help to improve the ship's response considerably. - "Au- dard propellers. In this operation trolling is allowed up to
tomatic" and "Manual". a sump oil temperature of 100°C. If the temperature rises
above this temperature trolling must be switched off. For
this reason a suitable temperature monitoring and
The main features of the ZF-AUTOTROLL system are warning system need to be applied. For non-trolling ope-
as follows: ration it applies the oil temperature range given in the
monitoring layout.
• The propeller speed set via the control lever is auto-
matically kept constant. The ZF-AUTOTROLL system can be used in ships with
one or more propulsion units.
• The manual or automatic reversing sequence ensures
If there are several propulsion units, each one must be
problem-free manoeuvring (brief increase in clutch
equipped with an independently operating ZF-AUTO-
pressure). TROLL control unit.
• Foolproof transmission control. The transmission with the ZF-AUTOTROLL system is
controlled by the ship’s control system. The operation
The system automatically switches to non-trolling ope- and display functions described here may very depen-
ration in the event of a power failure. This ensures that ding on the manufacturer version and installation of the
the transmission operates normally in the event of a ca- ship’s control system. For further details please contact
ble break or a fault in the activating element. the supplier of the control system.
1-1
Functional description ZF-AUTOTROLL (EST-59)
2-1
ZF-AUTOTROLL (EST-59) Functional description
2-2
Actuation variants ZF-AUTOTROLL (EST-59)
The control lever has the following function for this ac-
tuation variant:
• Engine speed
• Transmission actuation (AHEAD; NEUTRAL;
ASTERN)
• Trolling control
3-1
ZF-AUTOTROLL (EST-59) Installation
4.0 Installation
4.1 Installation of the actuation device
(Not part of the ZF scope of supplies)
All AUTOTROLL control components are installed di-
rectly on the transmission. For the outboard (supplied by
the shipyard), external control components, as well as
the cabling, please refer to the AUTOTROLL terminal
diagrams. The following diagrams are available to suit
the system variant that has been selected:
• Single-lever operation
Drawing 3081 700 353
(For control via MTU 3081 700 352)
• Separate trolling actuation
Drawing 3081 700 354
4-1
Installation ZF-AUTOTROLL (EST-59)
5-1
ZF-AUTOTROLL (EST-59) AUTOTROLL - actuation
6-1
AUTOTROLL - actuation ZF-AUTOTROLL (EST-59)
6-2
ZF-AUTOTROLL (EST-59) AUTOTROLL - actuation
Connections:
Signal input: 0Ub Lamp OFF:
Trolling mode is switched off
System voltage: +Ub
Lamp ON:
Trolling mode is switched on
• Pos. H31 Lamp FLASHING:
Alarm lamp. . . . . . . . . . . . . . . . . . . . . . . . . .outboard The propeller speed in trolling mode is lower than the
Function: selected propeller speed (setpoint). At the selected set-
ting the transmission clutch would be operating in the
Lamp OFF:
stick-slip range.
Default condition
The ZF-AUTOTROLL control automatically avoids this
Lamp ON:
state. The operator can run the ship at this reduced pro-
Failure of the electronic control unit or the trolling on/off
peller speed. However, to be able to achieve the selected
valve (se section 8.4 and 8.5)
propeller speed, a higher engine speed must be set.
Lamp FLASHING: (Definition: Stick-slip means friction vibration at low
Malfunction in the trolling system clutch plate differential speeds.)
6-3
AUTOTROLL - actuation ZF-AUTOTROLL (EST-59)
6-4
ZF-AUTOTROLL (EST-59) AUTOTROLL - actuation
6-5
Description of terminals ZF-AUTOTROLL (EST-59)
C9 C8 C7 C6 C5 C4 C3 C2 C1
B8 B7 B6 B5 B4 B3 B2
A9 A8 A7 A6 A5 A4 A3 A2 A1
Supplier
PIN on Pos. Designation Connected Tolerance Notes
HAN 25 D load
connector
Shipyard
transient H30, H31, H32, H33
(max. 1,5 s)
Protected by fuse „F10“, T 7,5 A, required
+20% / -20%
A2 KL30 Continuous 24V DC constant Required:
supply +20% / -10%
transient Voltage must be present for at least 10 s
(max. 1,5 s) after switched supply (KL15) “off” for
+20% / -20% diagnostic purposes (Faults are loaded
into the data memory). Simultaneous
shutdown of switched supply and continu-
ous supply is in principle allowed, how-
ever in this case not all faults will be
written to the fault memory. Simultaneous
switching on is allowed.
Rest-current at KL30 with KL15 “OFF”:
< 1 mA
Idling current at KL30 with KL15 “ON”:
<0.5 A
Max. current at KL30 in trolling mode:
<2.0 A
Protected by fuse “F10”, T 7.5 A, required.
C8 KL31 Battery (-) Required
Shipyard
7-1
ZF-AUTOTROLL (EST-59) Description of terminals
7.2 Inputs
Suppl..
HAN 25 D Logic
connector
Shipyard
A5 S31 Switch 24V; 10 mA Optional
Autom./ DC
Manual
24 V
24 V
24 V 24 V
B5 S1 Switch for shift- 24V; 8,6W Required
B8
ing position DC (Not for MTU control)
enginewise
0V
0V
The following must apply: If „S1“
B7
24V then „S2“ 0V
Shipyard
for ZF 2000
3000 group
24 V
0V
0V
B5
27W
B7 S2 Switch for shift- 24V; 8,6W Required:
DC for ZF
Shipyard
ing position (Not for MTU control)The follo-
2000/3000
counter-engine- wing must apply: If „S2“ 24V then
group 27W
wise Counter-enginewise „S1“ 0V
B8 Current path 24V; 8,6W DC Required
(Not for MTU control)
NEUTRAL
Enginewise
Shipyard
magnet (depending on version in-
stalled)
C3 S3 Control signal 0V Required:
for trolling to „C2“ Control signal increasing linearly
between "XE" and "XT".
C2 Control signal IN „XN“ and
WITHOUT „XE“ -0,2 V The controlling signal specifies the
jumper X1 1,2 and between propeller trolling speed.
to 3,8 V „XN“ und The relationship between the control
„XE“ 1,2 V signal and the propeller speed is li-
Control signal
(0,3 V/+0 V) near. 1.2 V (5 mA) corresponds to
WITH
or 5 mA (- the minimum propeller speed. 3.8 V
jumper X1
1 mA/+0 m). (17 mA) corresponds to the maxi-
5 to 17 mA
mum propeller trolling speed. The
Between "XE" and "XT" linear- maximum propeller trolling speed is
ly increasing from 1.2 to 3.8 V (- programmed by the manufacturer in
0 V/+0.3 V) or 5 mA to 17 mA the Autotroll system for the specific
(-0 mA/+2 mA). In point "XT" application. The control signal must
Shipyard
7-2
Description of terminals ZF-AUTOTROLL (EST-59)
7.3 Outputs
Supplier
PIN on Pos. Designation Connected load Tolerance Notes
HAN 25D
connector
Shipyard
the LED.
Please consult ZF for inputting in
control units.
A6 H33 Check lamp Connection Optional
„Manual“ „H32“ is earth for Labelling: "Manual"
lamps.. Colour: White
Max. 2x2,5W Dimming is permissible.
Output is designed for ohmic loads
(lamps).
For LEDs the resistance 3.9 kOhm
must be connected in parallel with
Shipyard
the LED.
Please consult ZF for inputting in
control units.
B3 H30 Check lamp Connection Necessary for version as per
„Warning“ „H32“ is earth for section 6.1
lamps. Labelling: "Warning"
Max. 2x2,5W Colour: Yellow
Dimming is not permissible.
Output is designed for ohmic loads
(lamps).
For LEDs the resistance 3.9 kOhm
must be connected in parallel with
Shipyard
the LED.
Please consult ZF for inputting in
control units.
B2 H31 Check lamp Connection Required:
„Alarm“ „H32“ is earth for Labelling: "Alarm"
lamps. Colour: Red
Max. 2x2,5W Dimming is not permissible.
Output is designed for ohmic loads
(lamps).
For LEDs the resistance 3.9 kOhm
must be connected in parallel with
Shipyard
the LED.
Please consult ZF for inputting in
control units.
7-3
ZF-AUTOTROLL (EST-59) Description of terminals
7-4
Description of terminals ZF-AUTOTROLL (EST-59)
7.5 Diagnostics
The AUTOTROLL control unit offers control functions
as well as having an intelligent diagnostic system.
The diagnostic system is intended for the following:
• System monitoring, monitoring of performance
quantities, fault detection, generating operating pro-
perties for running under emergency conditions
• Warning the operator
• Recording faults that have occurred in the fault
memory and communicating with the "TESTMAN"
diagnostic unit.
7-5
ZF-AUTOTROLL (EST-59) Safety functions
8.0 Safety functions 8.3 Failure of the trolling power supply circuit
If the trolling power supply circuit fails, the trolling sy-
DANGER! stem is transferred to non-trolling mode. The maximum
clutch pressure is then applied. The ship can be operated
Trolling is to be deactivated on the occurrence as if it did not have a trolling device.
of a fault indicated by the alarm indicator (red).
Faults that result in the system automatically 8.4 Failure of the electronic control unit
being switched to non-trolling mode may lead If the control unit fails, the trolling system switches to
to a sudden increase in the ship's speed - risk of non-trolling mode. Normal operation can continue.
accident! The alarm lamp is on as a steady light.
8-1
Addition ZF-AUTOTROLL (EST-59)
9.0 Addition
9.1 Ambient and operating conditions
- Minimum ambient temperature: -20°C
- Maximum ambient temperature:+65°C
9-1