EC300-system Operation and Maintenance
EC300-system Operation and Maintenance
INCORPORATED
System
Operation
and
Maintenance Marine
Manual Control System
Model:
EC300
Revision F
March 2018
B. The exclusive remedy provided by Twin Disc, Incorporated whether arising out of warranty within the applicable
warranty period as specified, or otherwise (including tort liability), shall at the sole option of Twin Disc,
Incorporated be either the repair or replacement of any Twin Disc, Incorporated part or product found by Twin Disc,
Incorporated to be defective and the labor to perform that work and to remove and reinstall (or equivalent credit).
In this context, labor is defined as the flat rate labor hours established by Twin Disc, Incorporated in the published
Twin Disc Flat Rate Schedule, required to remove, disassemble, inspect, repair, reassemble, reinstall and test the
Twin Disc, Incorporated product only. Authorized reasonable travel and living expenses will be considered for
payment on all Commercial Marine Products except on Electronic Control Systems. . Under no circumstances,
including a failure of the exclusive remedy, shall Twin Disc, Incorporated be liable for economic loss,
consequential, incidental or punitive damages.
The above warranty and remedy are subject to the following terms and conditions:
1. Complete parts or products upon request must be returned transportation prepaid and also the claims submitted to Twin
Disc, Incorporated within sixty (60) days after completion of the in warranty repair.
2. The warranty is void if, in the opinion of Twin Disc, Incorporated, the failure of the part or product resulted from abuse,
neglect, improper maintenance or accident.
3. The warranty is void if any modifications are made to any product or part without the prior written consent of Twin Disc,
Incorporated.
4. The warranty is void unless the product or part is properly transported, stored and cared for from the date of shipment
to the date placed in service.
5. The warranty is void unless the product or part is properly installed and maintained within the rated capacity of the
product or part with installations properly engineered and in accordance with the practices, methods and instructions
approved or provided by Twin Disc, Incorporated.
6. The warranty is void unless all required replacement parts or products are of Twin Disc origin or equal, and otherwise
identical with components of the original equipment. Replacement parts or products not of Twin Disc origin are not
warranted by Twin Disc, Incorporated.
C. As consideration for this warranty, the original customer and subsequent purchaser agree to indemnify and hold Twin
Disc, Incorporated harmless from and against all and any loss, liability, damages or expenses for injury to persons or
property, including without limitation, the original customer's and subsequent purchaser's employees and property, due to
their acts or omissions or the acts or omissions of their agents, and employees in the installation, transportation,
maintenance, use and operation of said equipment.
D. Only a Twin Disc, Incorporated authorized factory representative shall have authority to assume any cost or expense in
the service, repair or replacement of any part or product within the warranty period, except when such cost or expense is
authorized in advance in writing by Twin Disc, Incorporated.
E. Twin Disc, Incorporated reserves the right to improve the product through changes in design or materials without being
obligated to incorporate such changes in products of prior manufacture. The original customer and subsequent purchasers
will not use any such changes as evidence of insufficiency or inadequacy of prior designs or materials.
F. If failure occurs within the warranty period, and constitutes a breach of warranty, repair or replacement parts will be
furnished on a no charge basis and these parts will be covered by the remainder of the unexpired warranty which remains in
effect on the complete unit.
January 1, 2012 TDWP10098 rev 2012
©2018 Twin Disc, Incorporated Table of Contents
Table of Contents
Safety................................................................................. 1
Safety Alert Symbol................................................................................1
Signal Words...........................................................................................1
Terms and Definitions............................................................................2
Introduction....................................................................... 3
System Operation............................................................. 5
Digital Stainless Lever Calibration........................................................9
Analog Lever Calibration..................................................................... 11
Taking Command at a Station..............................................................12
Lever Function in Cruise Mode...........................................................13
Selecting Forward (Ahead)...................................................................... 13
Selecting Reverse (Astern)...................................................................... 13
Direction Reversal.................................................................................... 13
Lever Function in Express Mode........................................................14
Setting the Vessel Speed at Detent......................................................... 14
Lever Function in Troll Mode...............................................................15
Setting the Vessel Speed at Detent......................................................... 15
Lever Function in Single Lever Sync .................................................16
Mode Select Switch .............................................................................17
Legacy Display Features......................................................................18
Graphic Display Features....................................................................19
Station Transfer....................................................................................20
Station Transfer Signal............................................................................ 20
Station Transfer Types ............................................................................. 20
Instant Station Transfer........................................................................... 21
Neutral Station Transfer........................................................................... 22
Lever Match Station Transfer.................................................................. 23
Lever Match with Acknowledge Station Transfer.................................. 24
Emergency Transfer (Double button press)........................................... 25
Emergency Manual Mechanical Control.............................................25
Individual Engine Operations..............................................................26
Engine Start.............................................................................................. 26
Engine Warm-up while using Direction Disable Mode.......................... 27
Engine Shutdown..................................................................................... 27
Engine Synchronization.......................................................................28
Starting Engine Synchronization............................................................ 29
Ending Engine Synchronization............................................................. 29
Single Lever Synchronization ............................................................30
Flash Codes.................................................................... 31
Alarms....................................................................................................32
Fault Information Tables......................................................................33
Maintenance.................................................................... 85
Setting Drag..........................................................................................85
Setting Drag - Analog or Digital Control Head....................................... 85
Setting Drag - Side Mount Control Head................................................ 88
Stainless Steel Control Head Cleaning...............................................88
Safety
These messages convey important information about SAFETY. The safety
alert symbol and signal words described below are followed by safety
messages and appear throughout this manual.
All personnel must read, understand and follow all safety message instructions
prior to operation, maintenance or repair of this unit.
Signal Words
Signal words are used with the safety alert symbol to designate a level of
hazard seriousness. The signal words used are DANGER, WARNING,
CAUTION and NOTICE.
All people installing and operating this unit must employ safe operating
practices. Twin Disc Incorporated is not responsible for any personal injury
resulting from any unsafe and careless use of hand tools, power tools, lifting
equipment, or from any unsafe practices during installation and operation.
Because of the possible danger to people or property from accidents that
may result from the use of manufactured products, it is important that correct
procedures be followed. Products must be used in accordance with the
information specified.
Proper installation procedures must be used. Proper safety devices, such
as guards, may be required as specified in applicable codes. Safety devices
are not provided by Twin Disc Incorporated nor are they the responsibility of
Twin Disc Incorporated.
For the purpose of this document, the following terms and definitions apply:
DANGER Denotes that an extreme intrinsic hazard exists which would result in high prob-
ability of death or irreparable injury if proper precautions are not taken.
WARNING Denotes that a hazrd exists which can result in injury or death if proper precau-
tions are not taken.
CAUTION Denotes a reminder of safety practices or directs attention to unsafe prectices
which could result in personal injry or damage to the craft or components or to
the environment.
Introduction
The Twin Disc Incorporated Marine Control System allows the operator to
command one or more stern engines using analog or digital control heads via
the EC300 Control as shown below. See “System Operation” on page 5.
EC300
Control
Head
EC300
Control
® ®
J1 J2 J3 J4 J5 J6 J7 J1 J2 J3 J4 J5 J6 J7
4 6 4 6
3 1 3 1
J8 J9 J10 J11 J12 J13 J8 J9 J10 J11 J12 J13
Conventional
drive trains
NOTES
System Operation
The EC300 Control System consists of an EC300 Control, a Control Head,
an optional Servo Actuator, an optional Display, and several wire harnesses.
One EC300 Control System is required for each engine.
Mode Select
Port Lever Switch Starboard Lever
Neutral Station
Indicator LED Select
Button
Station Select
Indicator LED
NEUTRAL
ASTERN POSITION AHEAD
DETENT 40º DETENT
POSITION EXPRESS POSITION
15º 15º 55º 70º
55º THROTTLE
THROTTLE RANGE 30º
LOCKUP/
RANGE THROTTLE
NEUTRAL
AHEAD POSITION ASTERN
DETENT DETENT
POSITION 40º POSITION
EXPRESS
70º 55º 15º 15º
THROTTLE 55º
30º RANGE THROTTLE
LOCKUP/ RANGE
THROTTLE
Each lever, of both single lever and dual lever Control Heads, controls gear
selection and throttle for one engine/gear set. The Station Select button on
the Control Head takes command at a specific location. When the boat is
equipped with Single Lever Sync configured controls, the outboard levers
(port most or starboard most) control two or more engine/transmission sets.
The red (Analog control head) or green (digital control head) Station Select
LED next to the Station Select button verifies that the Control Head is active
when continuously illuminated. When the Station Select LED is off, the Control
Head is not active.
The Mode Select switch on the Control Head selects up to three engine cruise
speeds, up to three trolling speeds, and/or optional Engine Synchronization,
or Express Modes. The LEDs indicate as follows:
The yellow (analog control head) or green (digital control head) neutral
LED(s) provide for transmission status indication as follows:
Both the port and starboard levers can be calibrated at the same time.
2. Press and hold the Station Select button for at least 20 seconds to
enter Digital Stainless Lever Calibration mode. When Calibration mode
is entered, the Active station LEDs rapidly flash between Green and
off and then go out once the select button is released.
5. Reverse Detent Calibration Phase: The Neutral LED(s) is/are off, and
the Active LED(s) cycle between red, yellow, and green. Place the
lever(s) to the Reverse Detent position.
7. Select Neutral Calibration Phase: The Neutral and Active LED(s) cycle
between green and off. Place the lever(s) to the Neutral position.
10. Move the lever(s) to the Full Reverse position and hold for
approximately 1 second.
12. Cycle power to the EC300(s) by turning off the ignition power but not
removing battery power. Battery power must be present to enable the
EC300(s) to conduct a shutdown process and write the new Lever
Percentage values to memory.
Both the port and starboard levers can be calibrated at the same time.
2. Press and hold the Station Select button for at least 20 seconds to
enter Analog Lever Calibration mode. When Calibration mode is
entered, all of the LEDs flash and then go out.
10. Press the Station Select button for approximately 6 seconds. The
neutral LED(s) flash continuously, indicating acceptance of the settings
and completion of calibration.
When the neutral interlock switch is properly connected, the operator must
take command with a Control Head, and the levers must be at neutral, before
the engine(s) can be started.
On some vessels, a neutral interlock switch is not part of the starting system
and the engine(s) can be started without first selecting a control station.
In these applications, when the engine(s) have just been started, and the
Controls powered, the Transmission System is in the neutral operating
condition. The Control Head levers should be placed in the neutral position
prior to taking command.
Press the Station Select button (analog Control Heads) or operating mode
button (digital Control Head) to take command at that Station.
Move the lever toward the bow of the boat to the forward detent position in
order to select the forward vessel direction. At this position, the transmission
shifts into the forward gear. The remaining lever travel after the forward detent
position controls the engine throttle.
Move the lever toward the stern of the boat to the reverse detent position in
order to select the reverse vessel direction. At this position, the transmission
shifts into the reverse or reverse gear. The remaining lever travel after the
reverse detent position controls the engine throttle.
Direction Reversal
This mode allows the operator to achieve very low vessel speed by means of
a controlled slipping clutch when the lever is placed in the forward detent or
reverse detent position. Slight vessel speed variation at the detent position
is normal in Express Mode. In Express Mode, the propeller speed increases
as the lever is advanced, until the lever reaches a point where the clutch is
fully engaged and then engine speed increases as lever position increases.
The vessel speed at the forward detent position is configured by the operator
placing both the Port and Starboard lever in the forward detent position,
while in Express Mode, and then holding the Station Select button pressed
for more than two seconds. This puts the Control in the Set Detent Speed
mode, and the button can be released.
Advance the levers until the desired steady vessel speed is achieved, and
press the Station Select button twice within three seconds. Return the levers
to the neutral detent position. The propeller speed at the forward detent
position is now updated for both the port and starboard controls and setting
the speed at detent is now complete.
If the optional display is present, it prompts the user during this process.
This mode allows the operation of the vessel at low speed by means of a
controlled slipping clutch with the engine speed fixed, and the lever controlling
only the propeller speed.
The vessel speed at the forward detent position is configured by the operator
placing the port and starboard levers in the forward detent position, while
in troll mode, and then pressing the Station Select button for at least two
seconds. This puts the Control in the Set Detent Speed mode, and the button
can be released.
When the optional display is present, it prompts the user during this
process.
The Single Lever Sync feature allows multiple engine vessels to be operated
from the designated Master Lever at the active Control Station, in the forward
direction only. The designated master lever is determined at the time of
configuration or may be selected by a Master Lever switch if so configured
and equipped.
This feature is only active when the Operating mode is Express Sync or
Cruise Sync.
When the Single Lever Sync is active, all Controls in the system receive their
lever position commands from the designated master lever. All transmissions
on the vessel are in the forward gear, all Controls are operating in the same
mode, and all engines are operating at the same throttle setting. When the
Single Lever Sync feature cannot be engaged, all controls continue to use
their own lever and commands.
The Single Lever Sync feature is cancelled when any lever at the active
Control Station is moved out of the forward direction.
When the Single Lever Sync feature is cancelled, for any reason, each
Control reverts to receiving throttle commands from its own lever. When
the position of the designated lever is significantly different from the
position of the control’s own lever, a change is made in vessel speed.
The operations that can be controlled by the Mode Select switch depend on
the type of Control Heads that are installed on the boat. Control Heads are
available with a variety of function combinations. The following figures show
the labels from several different Control Head configurations, some of which
may be available in both single lever and dual lever Control Heads.
The Mode Select switch can be used to select any of the following, depending
on the Control Head type that is installed.
Cruise mode, and up to three preset engine speeds while in the cruise
mode.
Troll mode, and up to two preset engine speeds while in the troll mode.
Express mode.
When the Control is powered, and a Control Station selected, the top line of
the Display shows N, FWD, or REV, followed by CS1, CS2, etc, up to CS8
denoting the Control Station that is in command.
The lower line of the Display shows CRUISE, CRUISE S, EXPRES, EXPRES
S, or TROLL. This indicates the mode in which the Control is operating, and
whether it is operating in a synchronized condition or not.
The optional Display can be used to supply operating data at any time by
pushing either the up arrow button or the down arrow button to scroll through
the available information.
PROP SPD on the top line, and XXXX RPM on the bottom line
INPT SPD on the top line, and XXXX RPM on the bottom line
OIL TEMP on the top line, and XXX oC or XXX oF on the bottom line
OIL PRES on the top line with XXXX PSI or XXXX KPa on the bottom
line
For installations with individual displays, each display will show, and
can access, information for the associated control it is connected.
The display will also give an indication of active faults showing a Triangle with
an Exclamation point within. To view the active faults, depress the associated
button for Port or Starboard Diagnostics.
The display settings can be changed by depressing the associated “Setup”
Button. The Display Settings Options are the following:
Main
Port Diag Setup Stbd Diag
Station Transfer
With analog Control Heads, the mode does not change on Station
Transfer unless the lever(s) are at a detent position.
2. Place the levers in the desired position at the target Control Head.
4. Observe that the red Station Select LED next to the Station Select
button illuminates.
In this configuration, station transfers are only allowed when the Station Select
button on the target Control Head is pressed and the lever(s) on the active
Control Head and target Control Head are in the neutral detent position.
When the Station Select button on the target Control Head is pressed, and
the lever(s) are not in the neutral detent position, the neutral LEDs flash on
both the active Control Head and the target Control Head.
When the lever(s) on the target Control Head are moved to the neutral detent
position, the neutral LEDs stop flashing and the target Control Head becomes
the active Control Head.
When the target Control Head lever(s) are not moved to the neutral detent
position within 30 seconds of the request, the station transfer request shall
be cancelled and the neutral LEDs stops flashing.
In this configuration, station transfers are only allowed when the levers on the
target and active Control Heads are in matching positions. When the Station
Select button on the target Control Head is pressed, and the lever(s) on the
target Control Head are mismatched from those on the active Control Head,
the neutral LEDs on both the active Control Head and the target Control Head
flash. The greater the mismatch, the slower the LED flash rate becomes.
As the lever(s) on the target Control Head are moved closer to the position of
the lever(s) on the Active Control Head, the LED flash rate increases. When
the levers are matched, the target Control Head is automatically made active
and the Active Control Head made inactive.
The station transfer request is cancelled and the neutral LEDs stop flashing
when:
When the lever(s) at the active station and the target station are not matched,
the neutral LEDs on both the active and the target stations flash. As the
lever(s) at the target station are moved closer to the position of the lever(s)
at the active station, the flash rate of the LEDs increases.
When the lever(s) at the target station match the position of the lever(s) at the
active station, the neutral LEDs at both stations flash rapidly. This indicates
that the lever(s) at both stations are matched and the transfer may continue.
The transfer is completed when the Station Select button on a Control Head
at the target Control Station is pressed. The button press is only recognized
when the lever(s) are matched.
When no activity is sensed at either station after a transfer has been initiated
for a period of ten seconds, the transfer sequence is canceled. Also, when
the acknowledge has been made and the lever(s) on the active control station
are moved, the transfer is canceled.
This transfer type must be enabled in the configuration via the MFST.
Emergency Transfer (Double button press) operates in tandem with the
selected normal station transfer type and allows a station transfer under
emergency conditions or when the active station or station harness is
damaged. When the station select button on the target station is pressed
twice within 500 ms, the system executes an instant transfer to the target
station without regard for the selected normal station transfer type.
In the event of electrical or EC300 Control failure, see “Flash Codes” on page
31 for information about failure codes, and verify whether the vessel’s
transmissions have a manual gear select capability (come-home feature) in
addition to the electronic control.
In the event that the EC300 Control fails and the engine and or transmission
are controlled by push-pull cables, the push-pull cables are mechanically
and electrically free to move. The throttle, troll, or gear select lever may be
operated manually as required. When the servo actuator resists manual
control, unplug the connector at the servo actuator.
When the EC300 Control is partially functioning, and a Twin Disc Display is
present, the Neutral Start relay can be “forced on” in order to start the engine.
Refer to the Configuration and Troubleshooting Manual (1025568) for more
detailed information.
When the EC300 Control is not functioning, the engine can be started by
placing a jumper between the neutral start interlock pins 9 and 10 in the
cable connected to the EC300 Control’s Connector J5. This jumper should be
placed at the engine control if practical. Refer to the engine manufacturer’s
drawings and wiring diagrams.
Engine Start
1. At the selected Control Station, place the lever(s) in the neutral detent
position.
2. Place the ignition switch for the desired engine in the On position as
required to activate the EC300 Control System.
3. Press and release the Station Select button on the Control Head.
The red Station Select LED for the desired engine must illuminate.
4. Verify that the red Station Select LED(s) next to the Station Select
button is/are illuminated. This indicates that the station is in command.
6. Warm the engine using the Mode Select switch in a higher Cruise
position, or Direction Disabling ,as required.
The direction disable feature can be used any time that engine speed
above idle is required while keeping the transmission in neutral. The
engine speed can be varied from minimum to maximum.
1. Press and hold the Station Select button while moving the lever(s) in
either the forward or reverse direction.
3. When the engine is warm, return the lever(s) to the neutral detent
position.
When the lever is returned to the neutral detent position from the
Direction Disable mode, the Controller resets and normal operation
resumes. That is, the transmission shifts when the lever is moved in
the forward or in the reverse direction without pressing and holding
the Station Select button.
Engine Shutdown
1. At the selected Control Station, place the lever in the neutral detent
position.
2. Switch the ignition off to power down the EC300 Control System.
Engine Synchronization
The port most engine is the master. All other engines are slaves.
Automatically shuts off when any lever is moved out of the forward
direction.
With the master engine stable, the slave engine(s) are normally
brought to match the master engine’s speed within 5 rpm in 5 to 10
seconds. The timing depends on the differences between engine
speeds prior to engaging synchronization.
Synchronization occurs when all active slave levers are within 7 1/2
degrees (approximately two finger widths) of the master lever.
1. Move all levers together while setting the master engine to the desired
operating speed.
2. Move the Mode Select switch to the Cruise Sync or Express Sync
position on all Control Heads.
2. Observe that the starboard engine speed no longer follows the port
engine speed.
The master engine is either the port most engine, or the starboard most
engine, determined by the configuration or by the use of a Sync Master
Select Switch.
Automatically shuts off if any lever is moved out of the forward direction.
With the master engine stable, the slave engine(s) are normally
brought to match the master engine’s speed within 5 rpm in 5 to 10
seconds. The timing depends on the differences between engine
speeds prior to engaging synchronization.
Flash Codes
The EC300 Control provides a visual indication, LED flash codes, to the
operator when a fault condition exists. The fault conditions are classified as:
The optional display provides text messages about any fault conditions that
exist. The fault messages are displayed in a cyclical fashion with the main
display. This series of screens is repeated until the Control’s power is cycled,
at which point most faults are cleared, or the inhibit is cleared explicitly.
INHIBIT ACTIVE is displayed when a fault condition exists that inhibits
operation. Pressing both buttons while INHIBIT ACTIVE or a fault screen is
displayed provides additional information about the nature of the inhibit or
that fault, as applicable.
Depending on the installed control heads, the EC300 Control uses the
following LEDs:
Analog stations:
•• Station Active LED: Used for failure conditions that inhibits start and
invokes controller neutral. Failure codes are flashed whenever the
Control is turned on because the failure inhibits start and invokes
controller neutral by default.
•• Neutral LED: Used for failure conditions that do not inhibit start
nor invoke controller neutral. Failure codes are flashed only when
the active station’s lever is in neutral.
Digital stations:
•• Station Active LED: Used for all failure conditions. Failure codes
are flashed when a failure condition exists and the station is active.
•• Neutral LED: Used to indicate if marine gear is in Neutral or not
in Neutral.
Only the first fault to be written to the display will have its code flashed on
the appropriate LED. Subsequent faults will not be flashed via the LEDs.
When all fault conditions are cleared from the display the flashing diagnostic
code stops.
Alarms
The Control turns on the Alarm Relay (J8 pins 7 and 8) after initialization
when enabled in the MFST. When disabled, the Alarm Relay is not used.
When enabled, the Alarm Relay indicates a fault condition when a fault is
logged. The alarm remain on until the active station’s Station Select button
is pressed.
See your system installation documentation to see how the Alarm Relay
is wired in your system.
The digital stainless control head has an optional audible alarm that is
connected at the station, If an alarm condition occurs and the station has
the optional audible alarm, the alarm will sound at the active station. The
alarm remains on until the active station’s Station Select button is pressed.
Table 8. Inhibits
Flash Double Primary Description Inhibits
Code Button Message Cruise Express Troll Sync Start*
Press
Message
N.A. INPT INHIBIT - - - - -
SPD ACTIVE
TooLow
N.A. SELECT SELECT - - - - -
STATION STATION
N.A. SELECT SELECT - - - - -
NEU- NEU-
TRAL TRAL
227 INPT INHIBIT Transmission is unable Yes Yes Yes - -
SPD ACTIVE to engage because the
TooHigh input speed is higher
than 1000 rpm
722 INPT INHIBIT During cruise sync or - - - - -
SPD ACTIVE express sync the ec300
Fault controller has detected
a input speed sensor
fault
723 RS485 INHIBIT During cruise sync or - - - - -
Fault ACTIVE express sync the ec300
controller has detected
a rs485 communication
problem
724 PROP INHIBIT During express sync - - - - -
SPD ACTIVE the ec300 controller
Fault has detected a propel-
ler speed sensor fault
725 INDI- Other During cruise sync or - - - - -
RECT Control express sync one of the
INHIBIT controllers is unable to
sync
*Invokes controller neutral
Diagnostics Mode tests verify operation of the controller, the integrity and function of the
external circuits, and provide a means to energize clutches individually. They are also
helpful in troubleshooting the transmission. Sixteen separate tests can be individually
selected and performed via the display unit.
Diagnostics Mode tests verify operation of the controller, the integrity and function of the
external circuits, and provide a means to energize clutches individually. They are also
helpful in troubleshooting the transmission. Sixteen separate tests can be individually
selected and performed via the display unit.
The steps to enter can change slightly depending on the Display Type that is Setup. For
this procedure the “Dual – Forward Facing” type display is being used. To enter Diagnostic
mode, use the following steps:
1. Turn the ignition on for the Control you wish to enter Diagnostic and
do NOT select a control station.
You can turn on the ignition and enter diagnostic mode for both controls
at the same time if desired. The figures in this procedure will show both
controls turned on.
2. On the main screen (with no control stations selected) select the button
corresponding to either Port or STBD Diagnostics. (See Figure 10).
For the Dual type displays, if Port diagnostic is selected and entered
into Diagnostic mode per step 3, the display will re-boot because the
main power for the display is supplied by the Port control. When the
display re-boots, it will reboot to the Main Screen and you will need to
select “Port Diagnostic” again to see the Diagnostic Test Screens. If
entering Diagnostics for the STBD control, the display will not re-boot
and you will remain on the Diagnostic screens.
3. In the Port or STBD Diagnostic screen, you will see the screen flashing
back and forth between the Twin Disc Oval Logo and “SELECT
STATION,” push the button corresponding to the Select/Execute
( ) for approximately 6 seconds. For Dual Type display selecting
Port Diag or any Single Type display, continue to step 4. For Dual
Type display setting selecting STBD Diag, go to step 5.
SELECT
STATION TWIN DISC ®
Main Main
SELECT
STATION TWIN DISC ®
Main Main
4. Once the display re-boots, select the Port Diag button (for single
display type select the representative Diag button).
See Figure 13 and notice that after the re-boot, Port Diag. does not have
the Caution indicator ( ) above the “Port Diag”. This is because the
EC300 is in Diagnostic Mode.
Select
Engine RPM
Prop RPM Select 1 DSPLAY
Station Mode Station TEST
Temperature (°F)
Pressure (PSI)
Main
Port Diag Setup Stbd Diag
See Figure 14. Because the Display did not re-boot for STBD Diag., you
will see “SYSTEM CHECK” while the Starboard EC300 enters Diagnostic
Mode. Once entered, you will see “1 DSPLAY TEST” and it will begin
flashing back and forth with the Check Sum.
SYSTEM 1 DSPLAY
CHECK TEST
Main Main
5. You are now in Diagnostic Mode and can use the buttons corresponding
to the up and down arrows ( & ) to scroll through the Tests and
use the button corresponding to the Select/Execute ( ) to select
the desired test to enter and also to enter submenu tests.
At any time while in Diagnostic Mode, you can select the button
corresponding to Main ( Main ) and you will be returned to the main screen.
The control that has been placed in Diagnostic Mode will remain in
Diagnostic mode until the ignition power is cycled.
Pressing the up or down arrow button scrolls through the list of available tests, numbered
1 through 16. When the desired test identifier is displayed, enter the test if desired by
simultaneously pressing the up and down arrow buttons for Legacy Display or press the
select button for the Graphic Display. The following legend applies to all test diagrams in
this chapter:
In all screens, items appear only if the relevant option is enabled in the
configuration. The figures show all possible displays.
Troubleshooting Using the Display Module
To use the display module to perform tests and display fault messages, perform the
following procedure:
SWITCHES
SCROLL THRU AFTER 2 SECONDS
COILS LONG FAULTS WITH UP FAULT AND DATE/
LOG LIST OR DOWN TIME WILL
POWER ARROW ALTERNATE
SUPPLIES
INTERNAL
DEPRESS BOTH
FAULTS
SWITCHES TO
COMM EXIT TEST
FAULTS EXIT
SUB MENU END OF
EXIT LOG
TEST
5. Use the arrows to select SHORT LOG LIST or LONG LOG LIST as
required.
7. Identify all current faults, including intermittents that are not currently
active, to determine the appropriate Diagnostics Mode test to run.
8. Exit the log list by pressing the up and down arrows simultaneously
for Legacy Display or press the select button for the Graphic Display.
9. Press the up or down arrow to display the required Diagnostics Mode test.
10. To enter the desired Diagnostics Mode test, press the up and down
arrows simultaneously for Legacy Display or press the select button
for the Graphic Display.
In the troubleshooting tables the test paths are shown as in the following
example:
3 STATN TEST/STATIONn/POS VOLT
The “/” denotes a level in the test selection hierarchy and “n” denotes
the relevant control station number, such as “1”, “2”, or “3”.
11. Proceed to the appropriate Diagnostics Mode test section for the
specific test to be performed.
Internal Faults
If the primary message is CONTROL ERROR, SYSTEM CORRUPT, or TRAN SYS FAULT, it
indicates that the EC300 Control requires repair. CONTROL ERROR indicates that the controller
must be returned to the factory and SYSTEM CORRUPT indicates a bad configuration that
must be fixed using the MFST by a Certified Technician.
2 POWER TEST
The following tests are available: SUPPLY VOLTAGE, REFERENC VOLTAGE (reference
voltage), INTERNAL POWER, and EXIT TEST as shown in the following figure.
• MAIN AUX HI LO
• MAIN AUX HI HI
• MAIN AUX LO HI
• MAIN AUX LO LO
Input during operation: After the power up sequence, the controller
continually monitors the power inputs. If both power inputs are not
within the acceptable voltage range for more than five seconds, the
controller logs the fault and the following message appears on the
display:
• MAIN HIGH
• MAIN LOW
• AUX HIGH
• AUX LOW
Internal during operation: The controller monitors its internal reference
voltage for out of tolerance conditions. When an out of tolerance
condition occurs, the controller logs the appropriate fault. The controller
must be replaced and the failed controller returned to Twin Disc.
SUPPLY VOLTAGE displays the voltage level supplied to the primary and auxiliary power
input pins on the controller. Note that connecting voltage to the auxiliary pins is optional.
The display shows P:XX.XXV A:YY.YYV, where XX.XX is the voltage on the primary power
input, and YY.YY is the voltage on the auxiliary power unit. Below 8 volts causes a blank
display, and above 50 volts, the display flashes 50.00 V.
For normal operation, the primary and auxiliary supply must both be
less than 32.0 VDC and greater than 10.1 VDC.
REFERENC VOLTAGE displays the measured reference voltage for the analog to digital
converter. If the reference voltage is not 2.50 V ±50 mV, the controller cannot reliably
measure any analog signal. The display shows REF X.XX V where X.XX is the reference
voltage.
EXIT TEST returns the controller to the main menu at the point where it was when the
test was entered.
Use the following Power Faults table to troubleshoot Power Test faults indicated on the
display module.
3 STATN TEST
The Station Test (STATN TEST) allows inspection of the three control station ports on the
EC300 Control. Test options available are STATION1, STATION2, STATION3, or EXIT
TEST as shown in Figure 17.
LEVER
3 STATN
X.XX V
TEST MODE MODE
LEVER CRUISE X.XX V LEVER
MODE MODE MODE XXX.X %
CSYNC X.XX V
MODE MODE
STATION1 ESYNC X.XX V
MODE MODE
STATION2 EXPRESS X.XX V
STATION3 MODE MODE
TROLL X.XX V
EXIT
TEST POS VOLT X.XXV
STAT SEL
St1-PORT
OR STAT SEL
STAT SEL
X.XXV
STAT SEL
St1-STBD
POS CUR XXXmA
OPEN/
REV SWCH
CLOSED
OPEN/
FWD SWCH
CLOSED
TOGGLE WITH DOWN
NEU LITE ON/OFF
ARROW BUTTON
Port Most
SLS MAST Stbd Most
X.XXV
Error
EXIT SUB
When this test is entered, LEVER X.XXV is displayed. Momentarily pressing the down
arrow button displays LEVER YY.Y%, where X.XX or YY.Y is the Control Lever position
in volts or percent. These displays alternate each time the down arrow button is pressed.
Upon entering MODE, the display shows the voltage representing the position of the Mode
Select Switch. Momentarily pressing the down arrow button displays the Mode Select
Switch position. The positions listed depend on the Control Head Type that is installed. A
1020636G is used here as an example. Repetitively pressing the down arrow button causes
the display to alternate between two screens, such as MODE CRUISE and MODE X.XXV.
Other alternating displays with the Mode Select Switch in other positions may include
MODE CSYNC and MODE X.XXV, MODE ESYNC and MODE X.XXV, MODE EXPRESS
and MODE X.XXV, MODE TROLL and MODE X.XXV, where X.XX is the voltage level.
Upon entering POS VOLT, +X.XXV is displayed where X.XX is the voltage level.
Upon entering this test, STAT SEL X.XXV is displayed. Repetitively pressing the down
arrow button causes the display to alternate between STAT SEL X.XXV and STAT SEL
St1-PORT(or STBD), where X.XX is the voltage level, and PORT or STBD depends on
the controller being tested.
Upon entering POS CUR, +XXXmA is displayed, where XXX is the current level.
Upon entering REV SWCH, CLOSED or OPEN is displayed, indicating whether or not the
lever is in the reverse position.
Upon entering FWD SWCH, CLOSED or OPEN is displayed, indicating whether or not the
lever is in the forward position.
Upon entering NEU LITE, OFF or ON can be toggled using the down arrow button. The
Neutral position light turns on and off.
Upon entering SLS MAST, the voltage present at the switch input is displayed as X.XXV.
Pressing the down button shows PortMost, StbdMost, or Error depending on the state
of the single lever sync master switch and the condition of the signal present at the station
connector.
To exit the sub-menu, momentarily depress the up and down arrow button simultaneously
for Legacy Display or press the select button for the Graphic Display while EXIT SUB is
displayed. The test can be repeated for the other stations.
Use the Station Faults table to troubleshoot Station Test faults indicated on the display
module.
Lever Calibration
Perform the calibration procedures located in the “System Operation” section in this manual
under Digital Lever Calibration or Analog Lever Calibration to calibrate a lever head. Lever
head calibration is typically performed at installation only. If the lever head goes out of
calibration, it is usually the result of another problem. Recalibrating can be performed as
part of a problem solution, but if the lever head drifts out of calibration again or cannot be
calibrated, the lever head should be replaced.
The engines must be off. If the controller senses any transmission input
speed or an input speed sensor fault, it will not enter calibration mode.
4 SWITCH TEST
This test shows the status of the selected switches that are enabled on your installation.
Upon entering this test, SHFT BRK STATUS, OIL PRES STATUS, OIL FILT STATUS, LVR
ENB STATUS, DiagBoot STATUS, or EXIT TEST is displayed as shown in the figure below.
SHFT BRK
OPEN/CLOSED
OIL PRES
OPEN/CLOSED
4 SWITCH
TEST OIL FILT
OPEN/CLOSED
LVR ENB
OPEN/CLOSED
DiagBoot
OPEN/CLOSED
EXIT
TEST
Use the Switch Faults table to troubleshoot switch test faults indicated on the display
module.
5 SCAN TEST
The options RUN TEST and EXIT TEST are available as shown in the following figure.
EXIT
TEST
PRESS UP BUTTON
PRESS UP BUTTON
TO CONTINUE THRU
TEST
Upon selecting RUN TEST, the EC300 Control automatically checks all speed sensor and
coil circuits for continuity, and checks miscellaneous sensors to verify that the signal is in
the proper range. TESTING is displayed, followed by TEST PASSED if all functions are
normal. Pressing the up arrow button terminates the test and displays EXIT TEST. If a fault
is detected in a speed sensor circuit, the top half of the display indicates the sensor being
tested, and the bottom half of the display indicates the fault condition found. Pressing the
up arrow button allows the test to resume from that position, and continue until all sensors
have been tested. EXIT TEST is then displayed. The speeds tested are PROP SPD and
ENGN SPD. The coils tested are those enabled in the configuration such as FWD and REV.
6 SPEED RD TEST
The speed test allows testing of the transmission input speed (ENG SPD), and transmission
output speed (PROP SPD). The two test options and EXIT TEST are available as shown
in the figure below.
ENG SPD
XXXX RPM
6 SPEED PROP SPD
RD TEST XXXX RPM
EXIT
TEST
The choices are displayed on the first line of the display, and the appropriate data is shown
on the second line. The speed data is displayed as XXXX RPM. The display blinks if the
speed is above 9999 RPM. The display shows 0 RPM if the frequency is below 0 Hz. The
data value is displayed until the up or down arrow button is pressed, and when EXIT TEST
is selected, the EC300 Control returns to the main menu.
Use the Speed Sensor Faults table to troubleshoot temperature sensor faults.
7 SENSOR RD TEST
This test displays the data generated by the oil temperature sensor (OIL TEMP), and the
internal temperature sensor (INT TEMP) as shown in the example in the figure below.
The actual tests available are dependent on the configuration.
OIL TEMP
XXX O C
7 SENSOR INT TEMP
RD TEST XXX O C
EXIT TEST
When selected, the value is listed on the lower line of the display as SXXX °C (or °F, if
configured for Fahrenheit). The S stands for the sign of the number, and XXX is the current
temperature in degrees Celsius (or Fahrenheit). The data value is displayed until the up
or down arrow button is pressed, and when EXIT TEST is selected, the controller returns
to the main menu.
Use the Temperature Sensor Faults table to troubleshoot temperature sensor faults.
8 COIL TEST
Options available upon entering this test are FWD, REV, SHFT BRK, TROLL, NEUTRAL,
and EXIT TEST (depending on the software configuration) as shown in the example in
the following figure.
Activating the coil test will engage the coil being tested. This action
could cause the vessel to move that could cause injury to personnel or
damage to this vessel or others surrounding. It is highly recommend
to conduct this test with the engine(s) off.
NEUTRAL
After selection of an individual coil, a submenu is displayed, showing the following options:
FULL ON, MODULATE, PRESET, and EXIT SUB MENU.
If FULL ON is selected, the selected coil is powered with full on current. The display shows
the coil selected and FULL ON. Pressing the up arrow button turns the coil off and returns
the display to the submenu.
If PRESET is selected, current to the selected coil is ramped linearly from zero to full current
in 7.5 seconds, and then from full current to zero current over the next 7.5 seconds. This
ramp up/ramp down cycle is repeated until the up arrow button is pressed, which sets the
current to zero, and returns the EC300 Control to the submenu listing the choices. While
the cycling is continuing, the display identifies the coil, the percentage of full current, and
the current level.
Use the Coil Faults table to troubleshoot faults indicated by the EC300 Control on either
the display module.
9 COMM TESTS
This test may be used to confirm the functionality of an externally installed RS232
communication link.
EXIT INVALID
TEST
This test requires special test harnesses, and is for use by qualified electronic technicians
only. Listed selections are RS232, Address, RS485, and EXIT TEST.
If RS232 is entered, and proper RS232 connections are present (J4-1 (Tx to computer)
and J4-2 (Rx from computer)), the message BAD LINK CONNECT Rx TO Tx is displayed
if the test fails. WORKING is displayed if the test completes successfully.
If RS485 is entered, and proper RS485 connections are made (J10-1 (Comm+) and J10-
2 (Comm-)), the message RS485 WORKING is displayed. If the test fails, RS485 BAD
LINK is displayed.
Check the communications cables for proper connection and continuity. If communications
connections are good and the communications fault recurs, the controller must be replaced.
This test allows the operator to test the vessel’s tachometer readout by generating a
frequency via the EC300 Control.
Upon entering the test, TACH HZ and EXIT TEST are displayed. If TACH HZ (Tachometer
Hertz) is selected, the display shows TACH HZ on the top line, and 0500 on the bottom
line with the rightmost digit flashing to indicate it is selected for change. The flashing digit
can be changed using the up arrow. The other digits can be selected using the down
arrow. Select the desired test frequency using the arrow buttons. The selected frequency
is generated and sent to the tachometer output until the test is exited by simultaneously
pressing the up and down arrow buttons.
11 VERSN WARRANTY
SOFTWARE XXXXXXX
VERSION X.XX
HARDWARE XXXXXXX
VERSION X PRESS UP
11 VERSN
BUTTON
WARRANTY WARRANTY DDMMMYY TO EXIT
DATE
OR
EXIT NOT
TEST STARTED
If SOFTWARE VERSION or HARDWARE VERSION are selected, the part number and
the version are displayed. Pressing the up arrow button displays the submenu again. If
WARRANTY DATE is selected, the date is taken from memory and displayed in the format
DDMMMYY. If the warranty has not been initialized, NOT STARTED is displayed.
The Adjust Display function allows adjustment of the display backlight and contrast. The
display can also be set to the factory defaults. Options are ADJUST BACKLITE, ADJUST
CONTRAST, FACTORY DEFAULT, and EXIT TEST as shown in the following figure.
12 ADJST
DISPLAY
EXIT PRESS UP TO INCREASE
SUB MENU
PRESS DOWN TO DECREASE
PRESS BOTH TO EXIT
PRESS UP TO INCREASE
PRESS DOWN TO DECREASE
PRESS BOTH TO EXIT
ADJUST ADJUST
CONTRAST NOW
FACTORY 2
WORKING
DEFAULT SEC
EXIT
TEST
If ADJUST BACKLITE is selected, the options ADJUST BRITENES and EXIT SUB MENU
are available.
Selecting FACTORY DEFAULT returns the brightness and contrast levels to the factory
default settings. The message WORKING is displayed for two seconds. When FACTORY
DEFAULT is again displayed, the test can be exited by simultaneously pressing the up
and down arrow button, and then selecting EXIT TEST.
13 SERVO TEST
This test allows testing of the Servo Power driver and the servo position.
OVER
BAD
TEST CURRENT
IF
13 SERVO SERVO SERVO
GOOD
TEST EXIT XXX%
TEST
PRESS DOWN ARROW TO
SELECT DIGIT. PRESS UP
ARROW TO INCREMENT
DIGIT. PRESS BOTH TO
EXIT TEST
Upon entering the test, TEST SERVO and EXIT TEST are displayed. If TEST SERVO is
selected, the controller turns on the Servo Power driver, and OVER CURRENT or SERVO
XXX% is displayed.
If SERVO XXX% is displayed, the rightmost digit flashes to indicate it is selected for
change. The value of the flashing digit can be changed using the up arrow. The other
digits can be selected using the down arrow. Enter the desired percentage of full rotation
using the arrow buttons. The Servo is positioned to the percentage of full rotation shown
on the display. Press the up and down arrow buttons simultaneously for Legacy Display
or press the select button for the Graphic Display to set the servo output to zero, turn the
Servo Power driver off, and exit the test.
Use the Servo Faults table to troubleshoot servo test faults indicated on the display module.
14 SWITCH OUTPUTS
This test allows the operator to select switch outputs that are a part of the control system
and turn them on or off as desired. ALM DRV, NEUT RLY, RN RELAY, or EXIT TEST may
be selected as shown in the figure below.
ALM DRV
PRESS DOWN
Selected output
RN RELAY ARROW TO
OPEN or CLOSED
TOGGLE.
14 SWTCH
OUTPUTS NEUT RLY
EXIT TEST
When a relay is selected, it can be toggled between the open and closed condition, such
as ALMDRV OPEN, and ALMDRV CLOSED, by pressing the down arrow button. Press
the up arrow button to exit.
15 ENGINE THROTTLE
This test allows the operator to manipulate the throttle output. Upon entering, select TEST
THROTTLE, or EXIT TEST as shown in the figure below.
ThrotPwr
BAD
FAULT DEPRESS BOTH
TEST
IF SWITCHES TO
15 ENGIN THROTTLE THROTTLE EXIT TEST
THROTTLE GOOD
XXX%
EXIT
TEST
If TEST THROTTLE is selected, THROTTLE is displayed on the top line, and XX% is
displayed on the bottom line with the rightmost digit flashing, indicating that it is ready for
changing. Pressing the up arrow increments the flashing digit. Pressing the down arrow
selects the digit one position to the left. Select the desired throttle value using the arrow
buttons. The throttle is set to the value shown. Pressing both buttons simultaneously for
Legacy Display or press the select button for the Graphic Display resets the value to zero
and exits the test. If a problem exists, the message ThrotPwr FAULT is displayed.
The output signal can also be measured with a digital voltmeter if desired.
EC300 Marine Control System® - Operation and Maintenance Manual #1024221 83
Diagnostics with Optional Display ©2018 Twin Disc, Incorporated
NOTES
Maintenance
Setting Drag
Side Mount Control Head: See “Setting Drag - Side Mount Control
Head” on page 88
1. Remove the control head from the cutout by loosening the set screw
in the rear, as shown in Figure 30 (A), until the control head can be
rotated to release it from the base plate front edge.
2. Insert an 1/8 in. hex key wrench into the opening for each lever and set
drag by accessing the drag adjustment screw as shown in Figure 31.
3. Tighten the drag adjustment screw(s) until the desired drag is obtained
over the full lever travel.
4. Tilt the control head as shown in A in Figure 32 and engage the groove
internal to the control head.
5. When engaged, tilt the control head until it is flat and contacts the
gasket as shown in B.
6. Ensure that the control head fully engages the base plate and then
tighten the two set screws until they securely contact the base plate
and the control head is held securely in position. Tighten them against
the base plate to 1.13 Nm (10 lb-in.) maximum.
Figure 33. Drag Adjustment Screws for Side Mount Control Head
Assembly
2. Insert an 1/8 in. hex key wrench into the opening for each lever.
3. Tighten the drag adjustment screw(s) until the desired drag is obtained
over the full lever travel.
Due to environmental conditions, the stainless steel may stain or show signs
of corrosion. When this happens, wipe clean with rag and clean water that
does not contain chlorine. If stains or corrosion persist, use a commercial
stainless steel cleaning product that does not contain chlorine.
TWIN DISC ®