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BallastSystems

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MasterCraft University 2008-2009 • Ballast System •

any time during this op-eration by turning off the switch.

To drain the ballast tanks: Turn the switch to drain position. The bal-last pumps will empty the tanks until the tanks are empty. Pumps can be stopped at any time dur-ing this operation by turn-ing off the switch. To adjust the ballast man-ually, switch the pump to fill and drain accordingly until the desired wake is obtained.

Note: Always leave switches in the OFF po-sition when not in use. When the master battery switch is activated and the ballast switches are left in the fill or drian posi-tion, then the pumps will run.

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JabscoModel 18500-050

AI™Ballast Pump Control System

Features• Automatic shut-off• Hose block protection• Low voltage protection• Over ballast protection• Variable ballast adjustment

Normal Operation When the boat is first launched, switch the ballast pumps to drain and allow to shut off, which will re-set the system to default settings.

To fill ballast tanks: Turn the switch to the fill posi-tion. Ballast pumps will fill tanks to the factory pre-set time and stop automatically. Pumps can be stopped at

MasterCraft University 2008-2009 • Ballast Systems •

AI 1.1 – 18520-0520 & 18520-0520CProgramming InformationWiring Installation

Type Wiring Color PinonConnector -0520COnlyPump Connection +ve Orange 1 –ve Blue 2Power Connection +ve Red 1 –ve Black 2 Switch Connection Common Brown 1 LED Green 2 Drain White 3 Fill Yellow 4

Switch Set Up For DPDT Switch (as supplied with Jabsco Ballast Pumps)Connect Pin Connect Pin ConnectLED 8 7 XDrain 1 4 XCommon 2 X 5 XFill 3 6 X

Be sure to bridge common pins 2&5, otherwise LED operation may not work.

To Program Time in Unit1. Connect Switch and ensure switch is in OFF position.2. Connect +12 V DC to the AI box.3. Within 5 seconds, toggle the switch FILL-OFF-DRAIN-

OFF 5 times. This will enter programming mode.a. ADD TIME - If you want to add time click to

FILL and wait …. Count blinks, refer to chart for current setting.i. To add 30 secs, turn to OFF then FILL

and recount blinks (number of blinks in-creases by one each time), add remain-ing number of clicks OFF-FILL to get de-sired blinks from timing chart.

b. REMOVE TIME - If you want to take time off click to DRAIN and wait…Count blinks, refer to timing chart for current setting.i. To remove 30 secs, turn to OFF then

DRAIN and recount blinks (number of blinks Decreases by one each time), add remaining number of clicks OFF-DRAIN to get desired blinks from timing chart.

4. When counting blinks wait for second blink cycle after the pause, blinking starts as soon as repro-gramming has started and the first few will be missed.

5. When correct blinks are obtained, switch to OFF and wait 10 seconds to allow program to be set. This will now be stored in the AI unit.


Timing ChartBlinks Time (minutes) Blinks Time (minutes)1 2 14 8.52 2.5 15 93 3 16 9.54 3.5 17 105 4 18 10.56 4.5 19 117 5 20 11.58 5.5 21 129 6 22 12.510 6.5 23 1311 7 24 13.512 7.5 25 1413 8 26 14.5

Normal Operation When the vessel is first launched, set ballast pump switches to drain. This will re-set the system to zero. FILL – to fill the tanks, set switches to fill until desired wake is set, and/or the programmed amount of time has been reached.

DRAIN – to empty the tanks, set switches to drain un-til desired wake is set, and/or the tanks are empty when the pumps themselves will stop automatically. ALWAYS leave the pumps in the OFF position when not is use. If a fault occurs, the LED on the switch will blink, check fault finding guide accordingly.

Fill-Drain Time Set up• Obtain correct tank size.

• Pump fills at approx 10 GPM.

• Disconnect all battery from main boat connection for at least 30 seconds. Disconnect plug between pump and the Active Intelligence box until programming is complete. Reconnect power from battery and im-mediately start toggling switch to enter program mode.

• Push toggle to the fill position and toggle between fill and drain five (5) times stopping in the off position each time (fill-off-drain-off-fill-off, etc.) Do not rush. This should be done in a slow methodical one (1) second at each position pace. Unit will blink when you have entered program mode and the number of blinks will indicate the current fill time in 60 second intervals.

• To increase fill time, toggle between OFF and the fill position. Each toggle increases the fill time by 60 seconds.

blinking the corresponding code, if there is no block-age the unit then checks for open current, if there is an open in the motor then the unit shuts off blinking the corresponding code, if not then the unit runs normally.

• If during the operation the tank runs dry then the unit will, in seven seconds, shut off blinking one (1) blink to signify run dry.

• If the unit becomes clogged then the will, instanta-neously, shut off blinking two (2) blinks to signify high current draw.

• If the unit experiences an open condition, winding breaks, power removed between AI and pump, the unit will within 20 seconds, shut off blinking three (3) times to signify the open condition.

• If power to unit is below 9.5 VDC the unit will not turn pump on, as there is not sufficient power to run pump. The switch will blink four (4) blinks. Unit will not pow-er pump until power is restored to appropriate level.

• As long as there are no anomalies to the system the unit will allow the pump to run as long as needed. Once there is an anomaly the unit shuts down and alerts the user to the reason why.

• To decrease fill time, toggle between off and drain position, each toggle decreases by 60 seconds.

• Increments are 60 seconds (approx 9.75 gallons per toggle) with minimum fill time of 60 seconds and max-imum of 20 minutes.

• Reconnect power to pump and run pump in drain cycle until pump stops automatically. This must be done to reset unit to zero after programming.

Normal Operation• The pump switch is turned to the on position.

• The first thing AI does is check battery voltage. If the battery voltage is below 9.5 VDC the switch will blink four (4) times, signaling that the battery is too low to run the FIP pump. If the battery voltage is good the pump is turned on.

• The AI then checks the pump for prime, if the pump doesn’t prime then the AI shuts the unit off in 12 sec-onds and blink the corresponding code, if the pump primes the AI checks for line blockage, if there is line blockage (High Amperage) then the unit will shut off



Troubleshooting

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