Volvo Penta D4/D6/D9/D12/D16 Electronic Vessel Control (EVC EC-C) Installation Manual

EVC EC -C Electronic Vessel Control D4, D6, D9, D12, D16 Installation 1(1) B E

Installation Electronic Vessel Control EVC EC -C D4, D6, D9, D12, D16 Contents Safety precautions. .............................................. . 5 General information. ............................................ . 7 Engine monitoring and the EVC system. ........... . 10 . Engine.monitoring.system. ............................... . 10 . The.EVC-C.system.......................................... . 11 Installation tools and literature. .......................... . 13 Other special equipment..................................... . 14 Major components............................................... . 15 . General.view.................................................... . 15 Installation procedure, general. .......................... . 28 . Cable.routing. ................................................... . 29 . Marking.and.color.coding.of.cables ................. . 32 . Building.an.EVC.network................................. . 33 . Identiﬁcation.of.the.PCU.and.the.HCU ............ . 34 Installation procedure, engine room.................. . 35 . Location.and.mounting.of.the.PCU.and.HCU.. .35 . Engine–PCU.cable,.stern.drive. ....................... . 36 . Engine–PCU.cable,.Inboard.engine. ................ . 36 . Transmission.cables. ........................................ . 37 . Checking.rotation.of.propeller,.D4/D6.............. . 38 . Checking.rotation.of.propeller,.D9/D12/D16. .... . 39 . Volvo.Penta.Lowspeed.and.Trolling. ................. . 42 . PCU,.installation.. ............................................. . 43 . Fuel.and.fresh.water.level.senders. ................. . 43 . Rudder.indicator.. ............................................. . 46 . Standard.bus.cable.PCU–HCU.. ...................... . 45 . HCU,.installation .............................................. . 47 . Powertrim.system,.D4/D6.stern.drive .............. . 48 . Gear.shift.actuator,.D4/D6.stern.drive. ............. . 48 ©.2007.AB.VOLVO.PENTA All.rights.to.changes.or.modiﬁcations.reserved. Printed.on.environmentally-friendly.paper 3

Contents cont. Installation procedure, helm............................... . 49 . Y-connector...................................................... . 49 . Key.switch.and.relay ........................................ . 49 . Start/stop.panel. ............................................... . 50 . EVC.control.panel. ........................................... . 52 . Powertrim.panel............................................... . 54 . Relay.for.external.accessories. ........................ . 55 . Instruments...................................................... . 57 . Instrument,.panels.and.auxiliary.cable. ............ . 59 . Buzzer. ............................................................. . 60 . Auxilliary.dimmer.unit.(ADU). ........................... . 61 . Synchronizing.cable,.twin.installtions. .............. . 62 . EVC.system.display......................................... . 63 . NMEA.0183.interface. ...................................... . 68 . NMEA.2000.interface. ...................................... . 69 . Multisensor. ...................................................... . 71 . Controls,.electronic.......................................... . 72 . Adapter.for.mechanical.controls. ...................... . 75 . Controls,.mechanical ....................................... . 76 . Interface.4–20.mA. ........................................... . 79 EVC control panels.............................................. . 82 Calibration and settings...................................... . 83 . General ............................................................ . 83 . Calibration.mode. ............................................. . 84 . Auto.conﬁguration............................................ . 84 . EVC.control.lever.combinations.. . Calibration.summary. ....................................... . 86 . Lever.calibration. .............................................. . 88 . Select.language.and.units. ............................... . 91 . Powertrim.calibration. ....................................... . 92 . Powertrim.Assistance,.PTA. ............................. . 93 . Trolling.calibration............................................ . 94 . Slip.calibration. ................................................. . 95 . Idling.speed.calibration.................................... . 96 . OEM-mode. ...................................................... . 97 . Fuel.tank.settings. ............................................ . 97 . Fuel.tank.calibration. ........................................ . 98 . Multisensor.calibration..................................... . 100 . EVC.system.display......................................... . 102 Diagnostic function. ............................................. . 107 Fault register ........................................................ 109 Parameter settings. .............................................. . 117 Starting the engine .............................................. . 119 Wiring color and pin-out schematics. ................ . 123 Templates for controls and panels. .................... . 125 References to Service bulletins. ......................... 136 4 Contents. EVC-C

Important! The.following.special.warning.symbols.are.found.in. this.manual.and.on.the.engine. . WARNING!.Possible.danger.of.personal.injury,. damage.to.property.or.mechanical.malfunction.if. the.instructions.are.not.followed. IMPORTANT! Used.to.draw.your.attention.to. something.that.can.cause.damage.to.or.malfunction.of.a.product.or.damage.to.property . NOTE! Used.to.draw.your.attention.to.important.information.that.will.facilitate.the.work.or.operation.in. progress. A.summary.is.given.below.of.the.risks.and.safety.precautions.you.must.observe.or.carry.out.when.installing.and.calibrating.the.EVC.system. .Before.carrying.out.electric.arc.welding,.remove:. -.connector.from.the.engine.control.unit.. -.8-pin.connector.from.the.PCU. Safety precautions Introduction This.Installation.Manual.contains.the.information.you. will.need.to.install.and.test.the.Electronic.Vessel.Con- trol.(EVC).system. Read.this.Installation.Manual.carefully.before.installation. .Incorrect.installation.may.result.in.personal. injury.or.damage.to.property.or.the.engine.itself . If.you.do.not.understand.or.are.uncertain.about.any. operation.or.information.in.this.Installation.Manual,. please.contact.the.Volvo.Penta.organization. Installation This.Installation.Manual.is.intended.for.professional. use.only . The.Manual.must.be.used.in.conjunction.with.the.relevant.Engine.Operator’s.Manual. Volvo.Penta.will.not.assume.any.liability.for.damage. to.materials.or.personal.injury,.which.may.result.if.the. installation.instructions.are.not.followed.or.if.the.work. is.carried.out.by.non-professional.personnel. The.installer.is.responsible.for.ensuring.that.the. system.operates.in.accordance.with.this.Installation. Manual. . Work procedures These.instructions.are.for.use.by.suitably.qualified. personnel,.referred.to.as.the.installer.in.these.instructions. Refer.to.the.specific.Engine.Operator’s.manual.for. relevant.information.where.necessary,.especially.re- garding.safety.and.engine.operation. The.work.must.be.done.at.Volvo.Penta’s.service. workshops,.boat.builders.or.other.authorised.and. suitably.equipped.workshops.with.personnel.who. have.the.appropriate.qualifications.and.experience. D4 and D6 engines Press.the.lock.tab.down.and.pull.the.connector.out. . Refit.the.connector.to.the.engine.control.unit.after. disconnecting.the.welding.equipment. 5

D9, D12 and D16 engines Press.the.lock.tab.up.and.pull.the.connector/connectors.out. .Refit.the.connector.to.the.engine.control.unit. after.disconnecting.the.welding.equipment. Take.care.to.avoid.all.moving.parts.of.the.engine. during.testing.and.operation. .Approaching.an. engine.which.is.operating.is.a.hazard.to.personal. safety. .Loose.clothing.or.long.hair.can.become. entangled.in.moving.parts,.and.may.cause.serious.personal.injury . .Never.carry.out.work.on.an.engine.that.is.sus- pended.from.a.hoist. .The.engine.must.not.be.run.in.areas.where.there. are.explosive.materials.or.gases. .Only.start.the.engine.in.a.well-ventilated.area. . If.operating.the.engine.in.a.closed.area.ensure. that.there.is.exhaust.ventilation.leading.out.of.the. work.area.to.remove.exhaust.gases.and.crank- case.ventilation.emissions. .Never.allow.an.open.flame.or.electric.sparks.. near.the.batteries. .Never.smoke.close.to.the.batteries. .The.batteries.give.off.hydrogen.gas.during. charging,.which.can.form.an.explosive.mixture. when.mixed.with.air . .This.gas.is.easily.ignited. and.highly.flammable. .Incorrect.connection.of. the.battery.can.cause.a.single.spark,.which.is. sufficient.to.cause.a.gas.explosion. .Do.not.alter. the.battery.connections.when.attempting.to.start. the.engine.(spark.risk).and.do.not.lean.over.any. of.the.batteries. .Refer.to.the.instructions.in.the. Engine.Instruction.Manual. .Always.ensure.that.the.+.(positive).and.–.(nega- tive).battery.leads.are.correctly.installed.on.their. corresponding.terminal.posts.on.the.batteries. .In- correct.installation.can.result.in.serious.damage. to.the.electrical.equipment. .Refer.to.the.wiring. diagrams.in.the.Engine.Instruction.Manual. .Always.use.protective.goggles.when.charging. or.handling.the.engine.batteries. .The.battery. electrolyte.fluid.contains.sulfuric.acid.which.is. highly.corrosive. .If.the.battery.electrolyte.comes. into.contact.with.unprotected.skin,.wash.it.off.immediately.using.copious.amounts.of.clean.water. and.soap,.then.seek.medical.assistance. .If.the. electrolyte.fluid.comes.into.contact.with.the.eyes,. flush.your.eyes.immediately.(preferable.using.an. eye.bath).with.copious.amounts.of.clean.water,. and.obtain.medical.assistance.without.delay . .IMPORTANT!.AB.Volvo.Penta.has.developed. and.tested.the.complete.EVC.system.and.its. components. .However,.non.Volvo.Penta.components.or.components.installed.in.a.way.that.differ. from.the.instructions.may.cause.the.system.to. malfunction. .In.this.case.Volvo.Penta.do.not.accept.any.responsability . 6 Safety.precautions. EVC-C

General information About the Installation Manual This.publication.is.intended.as.a.guide.for.the.installation.of.Volvo.Penta.EVC.system.for.D4,.D6,.D9,. D12.and.D16.engines,.Aquamatic.and.inboard.use. . The.publication.is.not.comprehensive.and.does.not. cover.every.possible.installation,.but.is.to.be.regard- ed.as.recommendations.and.guidelines.applying.to. Volvo.Penta.standards. .Detailed.Installation.Instruc- tions.are.included.in.most.of.the.accessory.kits. These.recommendations.are.the.result.of.many.years. of.practical.experience.of.installations.from.all.over. the.world. .Departures.from.recommended.procedures.etc. .can.be.necessary.or.desirable,.however,.in. which.case.the.Volvo.Penta.organization.will.be.glad. to.offer.assistance.in.finding.a.solution.for.your.par- ticular.installation. It.is.the.sole.responsibility.of.the.installer.to.ensure. that..the.installation.work.is.carried.out.in.a.satisfac- tory.manner,.it.is.operationally.in.good.order,.the.approved.materials.and.accessories.are.used.and.the. installation.meets.all.applicable.rules.and.regulations. This.Installation.Manual.has.been.published.for. professionals.and.qualified.personnel. .It.is.therefore. assumed.that.persons.using.this.book.have.basic. knowledge.of.marine.propulsion.systems.and.are. able.to.carry.out.related.mechanical.and.electrical. work. Installation.of.electrical.systems.shall.only.be.carried. out.by.a.professional.boat.electrician. Only.components,.cables,.connections.etc,.delivered. or.approved.by.the.manufacturer.may.be.used. .The. manufacturer.will.accept.no.responsibility.what.so. ever.if.this.requirement.is.ignored. Volvo.Penta.continuously.upgrades.its.products.and. reserves.the.right.to.make.changes. .All.the.information.contained.in.this.manual.is.based.on.product. data.available.at.the.time.of.print. .Notification.of. any.important.modifications.to.the.product.causing. changes.to.installation.methods.after.this.date.will.be. made.in.Service.Bulletins. NOTE!.Commercial.and.classified.systems.including: -. MCC.system. -. CU.305.system. -. SDU.(Shut.Down.Unit) Please.refer.to.Installation Marine Propulsion, Die- sel Engines D5–D16. Plan installations with care Great.care.must.be.taken.in.the.installation.of.engines.and.their.components.if.they.are.to.operate. perfectly. .Always.make.sure.that.the.correct.specifica- tions,.drawings.and.any.other.data.are.available.before.starting.work. .This.will.allow.for.correct.planning. and.installation.right.from.the.start. Plan.the.engine.room.so.that.it.is.easy.to.carry.out. routine.service.operations.involving.the.replacement. of.components. .Compare.the.engine.Service.Manual. with.the.original.drawings.showing.the.dimensions. It.is.very.important.when.installing.engines.that.no. dirt.or.other.foreign.matter.gets.into.the.fuel,.cooling,. intake.or.turbocharger.systems,.as.this.can.lead.to. faults.or.engine.seizure. .For.this.reason.the.systems. must.be.sealed. .Clean.supply.lines.and.hoses.before. connecting.them.to.the.engine. .Only.remove.protective.engine.plugs.when.making.a.connection.to.an. external.system. Important Never.cut.or.modifiy.the.Volvo.Penta.EVC.cable.har- nesses. .For.extra.power.supply.use.the.Volvo.Penta. relay.for.accessories. . Refer.to.the.Relay for external accessories.section. Never.use.any.kind.of.grease.in.the.EVC.connectors. 7

Certified engines The.manufacturer.of.engines.certified.for.national. and.local.environmental.legislation.(Lake.Constance. for.example).pledges.that.this.legislation.is.met.by. both.new.and.currently.operational.engines. .The. product.must.compare.with.the.example.approved. for.certification.purposes. .So.that.Volvo.Penta,.as.a. manufacturer,.can.pledge.that.currently.operational. engines.meet.environmental.regulations,.the.following.must.be.observed.during.installation: •. Servicing.of.ignition,.timing.and.fuel.injection. systems.(gasoline).or.injector.pumps,.pump.settings.and.injectors.(diesel).must.always.be.carried.out.by.an.authorised.Volvo.Penta.workshop. . •. The.engine.must.not.be.modified.in.any.way.except.with.accessories.and.service.kits.developed. for.it.by.Volvo.Penta. . •. Installation.of.exhaust.pipes.and.air.intake.ducts. for.the.engine.compartment.(ventilation.ducts). must.be.carefully.planned.as.its.design.may.af- fect.exhaust.emissions. . •. Seals.may.only.be.broken.by.authorised.personnel. . IMPORTANT!.Use.only.Volvo.Penta.Genuine. Parts. . Using non-genuine parts will mean that AB Volvo Penta will no longer take responsibility for the engine meeting the certified design... All.damage.and.costs.caused.by.the.use.of.non- genuine.replacement.parts.will.not.be.covered. by.Volvo.Penta. Seaworthiness It.is.the.boat.builder’s.duty.to.check.that.the.security. requirements.apply.to.the.market.in.which.the.boat. is.sold. .In.the.USA.for.example,.these.are.the.US. Federal.Regulations.for.pleasure.boats.described. in.Title.46. .The.requirements.described.below.apply. to.the.EU.principles. .For.information.and.detailed. descriptions.of.the.safety.requirements.that.apply.to. other.markets,.contact.the.authority.for.the.country. concerned. As.of.June.16.1998,.pleasure.boats.and.certain.as- sociated.equipment.marketed.and.used.within.the. EU.must.bear.CE.labels.to.confirm.that.they.meet. the.safety.requirements.stipulated.by.the.European. Parliament.and.Council.of.Europe’s.directive.for.pleasure.boats. .The.normative.requirements.can.be.found. in.the.standards.drawn.up.to.support.the.directive’s. objective.of.uniform.safety.requirements.for.pleasure. boats.in.EU.countries. Certificates.that.grant.the.right.for.CE.label.use.and. confirm.that.boats.and.equipment.meet.safety.requirements.are.issued.by.approved.notified.bodies. . In.many.Member.States.the.classification.societies. have.become.the.notified.bodies.for.pleasure.boats,. e.g. .Lloyd’s.Register,.Bureau.Veritas,.Registro.Italiano. Navale,.Germanischer.Lloyd,.etc. . In.many.cases.completely.new.institutions.have.been. approved.as.notified.bodies. .The.directive.also.allows. boat.builders.and.component.manufacturers.to.issue. assurances.of.compliance.with.the.requirements.of. the.directive. .This.requires.the.manufacturer.to.store. the.prescribed.product.documentation.in.a.place.that. is.accessible.to.the.monitoring.authority.for.at.least. ten.years.after.the.last.product.is.produced. Life.boats.and.boats.for.commercial.activities.are.approved.by.classification.societies.or.by.the.navigation. authority.for.the.boat’s.registered.country . Joint liability Each.engine.consists.of.many.components.working. together. .One.component.deviating.from.its.technical. specification.can.cause.a.dramatic.increase.in.the. environmental.impact.of.an.engine. .It.is.therefore.vital. that.systems.that.can.be.adjusted.are.adjusted.prop- erly.and.that.Volvo.Penta.Genuine.Parts.are.used. . Certain.systems.e.g.components.in.the.fuel.system. may.require.special.expertise.and.special.test.equipment. .Some.components.are.sealed.at.the.factory.for. environmental.reasons. .No.work.should.be.carried. out.on.sealed.components.except.by.authorised.personnel. Remember.that.most.chemical.products.damage.the. environment.if.used.incorrectly . .Volvo.Penta.recom- mends.the.use.of.biodegradable.degreasing.agents. for.cleaning.engine.components,.unless.otherwise. indicated.in.a.Workshop.Manual. .Take.special.care. when.working.on.board.boats.to.ensure.that.oil.and. waste.are.taken.for.destruction.and.not.accidentally. pumped.into.the.environment.with.bilgewater . 8 General.information. EVC-C

Conversion factors Metric to U.S. or IMP. conversion factors: U.S. or IMP. to metric conversion factors: To convert To convert from To Multiply by from To Multiply by Length . mm.. inch.. 0.03937.. inch.. mm.. 25.40 . . cm.. inch.. 0.3937.. inch.. cm.. 2.540 . . m.. foot.. 3.2808.. foot.. m.. 0.3048 Area . mm².. sq.in. .. 0.00155.. sq. .in. .. mm².. 645.2 . . m².. sq. .ft. .. 10.76.. sq. .ft. .. m².. 0.093 Volume . cm³. .cu. .in. .. 0.06102.. cu. .in. .. cm³.. 16.388 . . litre,.dm³.. cu. .ft. .. 0.03531.. cu. .ft. .. litre,.dm³.. 28.320 . . litre,.dm³.. cu. .in. .. 61.023.. cu. .in. .. litre,.dm³.. 0.01639 . . litre,.dm³.. imp. .gallon.. 0.220.. imp. .gallon.. litre,.dm³.. 4.545 . . litre,.dm³.. U.S. .gallon.. 0.2642.. U.S. .gallon.. litre,.dm³.. 3.785 . . m³.. cu. .ft. .. 35.315.. cu.ft. .. m³.. 0.0283 Force . N.. lbf.. 0.2248.. lbf.. N.. 4.448 Weight . kg.. lb. .. 2.205.. lb. .. kg.. 0.454 Power . kW.. hp.(metric). 1) .. 1.36.. hp.(metric). 1) .. kW.. 0.735 . . kW.. bhp.. 1.341.. bhp.. kW.. 0.7457 . . kW.. BTU/min.. 56.87.. BTU/min.. kW.. 0.0176 Torque . Nm.. lbf.ft.. 0.738.. lbf.ft.. Nm.. 1.356 Pressure . Bar.. psi.. 14.5038.. psi.. Bar.. 0.06895 . . MPa.. psi.. 145.038.. psi.. MPa.. 0.006895 . . Pa.. mm.Wc.. .0.102.. mm.Wc.. Pa.. 9.807 . . Pa.. in.Wc.. 0.004.. in.Wc.. Pa.. 249.098 . . kPa.. in.Wc.. 4.0.. in.Wc.. kPa.. 0.24908 . . mWg.. in.Wc.. 39.37.. in.Wc.. mWg.. 0.0254 Energy . kJ/kWh.. BTU/hph.. 0.697.. BTU/hph.. kJ/kWh.. 1.435 Work . kJ/kg.. BTU/lb.. 0.430.. BTU/lb.. kJ/kg.. 2.326 . . MJ/kg.. BTU/lb.. 430.. BTU/lb.. MJ/kg.. 0.00233 . . kJ/kg.. kcal/kg.. 0.239.. kcal/kg.. kJ/kg.. 4.184 Fuel . g/kWh.. g/hph.. 0.736.. g/hph.. g/kWh.. 1.36. consump. . g/kWh.. lb/hph.. 0.00162.. lb/hph.. g/kWh.. 616.78 Inertia . kgm².. lbft².. 23.734.. lbft².. kgm².. 0.042 Flow, gas . m³/h.. cu.ft./min. .. 0.5886.. cu.ft./min. .. m³/h.. 1.699 Flow, liquid m³/h.. US.gal/min.. 4.403.. US.gal/min.. m³/h.. 0.2271 Speed . m/s.. ft./s.. 3.281.. ft./s.. m/s.. 0.3048. . . mph. knots. 0.869. knots. mph. 1.1508 Temp. . °F=9/5.x.°C+32.. . °C=5/9.x.(°F–32) . 1).All.hp.ﬁgures.stated.in.the.catalogue.are.metric. 9 EVC-C. General.information

Engine monitoring system The.engines.are.equipped.with.common.rail.system. and.electronically.controlled.injectors.(D4,.D6).or.unit. injectors.(D9,.D12,.D16).with.an.electronic.control. Engine monitoring and the EVC system unit. . The.injectors.contain.an.electro-magnetic.valve.which. sets.the.amount.of.fuel.injected.and.the.correct.timing. .The.monitoring.system.measures.the.charge.air. pressure.and.temperature,.and.calculates.the.available.air.mass. .This.determines.the.maximum.amount. of.fuel.that.can.be.injected.(smoke.limiter.function). The.system.also.limits.the.maximum.torque.available. at.the.engine.speed.registered.to.protect.the.engine. and.transmission.from.overload. To.protect.the.engine.at.too.high.coolant.or.charge.air. temperatures.and.boost.pressure.as.well.as.oil.pressure,.the.monitoring.system.reduces.the.amount.of. fuel.(reduced.engine.output).until.the.current.values. are.normalized. The.engine.monitoring.system.also.has.a.diagnostic. system,.which.helps.users.and.service.technicians.to. determine.the.cause.of.any.malfunctions.in.the.system.quickly.by.using.the.diagnostic.tool. . Any.fault.is.shown.on.the.EVC.system.tachometer. display./.EVC.system.display.and.the.VODIA.diagnostic.scan.tool. .The.diagnostic.tool.has.menus.in. several.languages. Diagnostics Engine.speed Throttle Oil.pressure Oil.temp. Cooling.temp. Charge.air.press. Charge.air.temp. Fuel.temp. Water.in.fuel Camshaft.pos. Ignition. timing Fuel.. quantity Engine Control Unit HCU. (Helm.station. Control.Unit) PCU. (Powertrain.. Control.Unit) ECU. (Engine.. Control.Unit) HCU. (Helm.station. Control.Unit) CAN.bus Actuator. (gear.shifting.. DPH/DPR) 10

Volvo Penta D4/D6/D9/D12/D16 Electronic Vessel Control (EVC EC-C) Installation Manual

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