Marex SB
Contents
1. counter bearing When adjusting the traveling range of the actuator stroke it must be ensured that both markings remain visible in the end positions The travel may not be blocked by exterior mechanical stops Misadjustment may lead to blocking and distruction of the electric actuators stroke 70 m 3 4 Electrical throttle control and gear shifting Electrical throttle control 71 72 73 74 75 76 77 78 79 80 81 82 shielded cable Typ LIYCY 4 20 mA 2x 0 75 mm galvanically separated lt 5 _ at both ends max 500 Ohm ECU EDC Engine Control Unit Engine Digital Control 12 Electrical gear shifting without feedback screened cable type LIYCY 7 x1 mm grounded at both ends LED set ahead 73 LED set astern 75 astern Vcc 2A 0 solenoid valve 1 Ar C gear feedback off relay with Ig free wheeling diode Solenoid valve not included in MAREX SB delivery The power supply for the gearbox must be fused separately An emergency manual override for gear shifting must be provided reversing gearbox If inductive loads shall be switched these must be provided with a free wheeling diode If not the digital output may be destroyed Operation Adjustment Wiring Overview General Error Analy2. shielded cable typeLIYCY 70 mm 2 4 x 1 mm 70 mm 100 N 100 N 70 mm 100 N Twin engine electrical throttle control mechanical gear shifting Throttle is actuated electrically 4 20 mA the gears are shifted by mechanical rods SYSCON l O extension board 1 actuation rpm port l O extension board 2 actuation rpm starboard shielded starboard cable typeLIYCY 4x1mm 4 20 mA E shielded cable shielded cable typeLIYCY typeLIYCY 2 x 0 75 mm 2 x 0 75 mm 70 mm 70 mm 100 N T 100 N T Twin engine mechanical throttle control electrical gear shifting Throttle is adjusted by means of mechanical rods gear shifting is controlled by 24 V signals shielded cable typeLIYCY 4x1mm SYSCON l O extension board 1 actuation gearing port l O extension board 2 actuation gearing starboard port starboard o n mF i LL 70 mm 100 N 24 V 24 V rz shielded cable shielded cable typeLIYCY typeLIYCY 7x1mm 7 1 mm Twin engine electrical throttle control gear shifting electrical Throttle is adjusted electrically 4 E 2 3 5 6 shielded cable typeLIYCY 4x 1mm shielded cable typeLIYCY 2x0 75 mm 20 mA gear shifting is operated by 24V signals l O extension board 1 SYSCON actuation gearing port actuation rpm port l O extension boar
3. Error description The system is configurated see chapter 2 in such a way that actuator 1 see chapter 3 3 directs mechanical gear shifting or soeed setting However the control states an error in the operation of the actuator Error elimination Check the plugs of actuator 1 for correct connection to the board of the control unit see chapter 3 3 If necessary connect actuator 1 to the terminal of actuator 2 on the control unit If the actuator works perfectly then the board of the control unit is defective and must be replaced If not replace the actuator Error type ACTUATOR 2 Error description The system is configurated see chapter 2 in such a way that actuator 2 see chapter 3 3 directs mechanical gear shifting or speed setting However the control states an error in the operation of the actuator Error elimination Check the plug of actuator 2 for correct connection to the board of the control unit See chapter 3 3 If necessary connect actuator 2 to the terminal of actuator 2 on the control unit If the actuator works perfectly then the board of the control unit is defective and must be replaced If not replace the actuator Error type 1 Error description The system see chapter 2 is configurated in such a way that the I O extension board directs electrical gear shifting or speed setting see chapter 3 4 However an error is stated in the activation of l D extension board 1 Error eliminat
4. male shielded sealing pressure taper cable insert screw sleeving loosen screws and lift housing cover AN 4 The data cable must be prepared as shown above The cables must not be squeezed when assembling the components after the wiring The sealing of the housing must be fitted correctly to guarantee protection type IP65 Entering the identification ID entered once at every control head e g control head bridge ID 1 control head To enable the control to identify the control heads an individual ID must be port ID 2 control head starboard ID 3 ID 0 is not admissible gt This procedure 15 not necessary if the automatic ID setting is used Chapter 4 2 To enter the ID the housing cover must be removed Adjustment ID 1 6 bottom side control head starboard side On every control head an individual ID must be entered once adjustment ID 1 6 ID 0 is not admissible LED power supply LEDcommunication ok port side Operation Adjustment Wiring Overview General Error Analysis Appendix O JIM jueunsn py jeuy 10413 SISA xipueddy Wiring control head optional switch station tranfer interlock The IDs of the control heads I required for ECR stations according to classification rules must be dif
5. 1ueuusn pe 9 CE M IM AQ 2 995 v ed 5 5 10 NOOSAS 41 4 52 56 5 m I O _ R ND engine start D 5 m CAN 1 T R 4 alarm CAN m mpm 6 EMI LA ME mj GND Le nd enses i an Vcc Control Unit Terminals n H D a General Overview Wiring Adjustment Operation Error Analysis Appendix Rexroth Bosch Group Subject to alteration This edition supersedes all previous ones Printed in Germany No part of this edition may be repro duced without Our prior permission Order no 883 890 060 3 2003 07 EN
6. Co oe battery E O engine Starter engine Starter m battery battery port starboard Engine start interlock will be released if both levers of the control heads port and starboard are in neutral position or warming up is active 3 Idle gas relay Single Engine 18 Twin Engine idle gas idle gas port idle gas starboard The idle gas relay is closed when the lever of the active control head is in neutral or 1 detent ahead astern Wiring l O extension board o 1 1 2 3 4 LED idle gas 022022220222122 closed when lever in neutral or in 1 detent ahead astern potential free relay contact max 30V DC max 2 e ejejejejeje ejejejeje 111 2 L relay function idle gas 71 72 73 74 75 76 77 78 9 0 81 82 3 C 4 shielded cable type LIYCY 2 x 0 75 mm earthed at both ends If inductive loads shall be switched these must be provided with a free wheeling diode If not the digital output may be destroyed When the function idle gas is applied the relay on the l O extension board is not available for the function engine start interlock Operation Adjustment Wiring Overview General Error Analysis Appendix sisAjeuy 10413 jueunsn py M9IAJI9AQ xipueddy 19 4 Adjustment 4 1 Hardware configuration Pos
7. e Indication if station is active Alarm lamps e Indication if an error exists Lamp synchronizing lamp alarm lamps e Indication if synchronizing is active In case of twin control heads the LED for command and alarm are assigned to the respective propulsion side In case of several control stations passive stations must be distinguished from the active one A command can always be set only from the active control station If a passive control station is to set the command a change of control station must be carried out before see chapter 5 3 On the active control station the command lamps are on on the passive station they are off active passive COMMAND station station ALARM m m SYNCHRO By means of an external switch see chapter wiring control head 3 2 the command transfer can be locked If this is the case ALARM the alarm lamps at the passive control station will be active SYNCHRO M 30 5 2 Activation and request of control station After switching on the power supply all control heads which work correctly are in condition lamp test all lamps and buzzer on The command can be requested from every control station by pressing the key once After the key has been pressed the condition lamp test will end for all control heads On the control head on which the key has been pushed the command lamps will flash and the buzzer sound The lamps flash slowly and the buzzer sounds at slow intervals
8. Industrial Hydraulics Electric Drives Linear Motion and Service Mobile Rexroth and Controls Assembly Technologies Pneumatics Automation Hydraulics Bosch Group Version 2 10 15 07 2003 Short Instructions Please do also see general advice in chapter 1 Select engine type chapter 2 overview Adjust SYSCON switch board in accordance with engine type chapter 2 overview Wire components and adjust switches Power supply chapter 3 1 Control head chapter 3 2 Attention Enter the control head ID and write it down Throttle and gear control mechanical chapter 3 3 electrical chapter 3 4 Extra functions if necessary alarm engine start interlock idle speed relay chapter 3 5 ff Commissioning zh 4 Enter control heads chapter 4 2 Enter additional functions of control heads if applicable For mechanical throttle control enter nominal value for idle speed chapter 4 3 For mechanical gear shifting adjust position ahead astern chapter 4 4 Enter extra functions if necessary power boost increased idle speed see chapter 4 3 synchronization buzzer in neutral change of control station see chapter 4 2 Mooring Trial Adjustment of delay times for gear shifting chapter 4 4 Adjustment of power boost if applicable chapter 4 3 Adjustment of increased idle speed if applicable chapter 4 3 Sea Trial 9 Adjustment of reversing delay times chapter 4 4 How to operate the
9. shifting Check power supply of the single control units LED readiness see chapter 3 1 If necessary replace synchronizing board Error type SYSCON warning only Error description The SYSCON switchboard which controls the system configuration see chapter 2 was adjusted while the system was active This is not admissible It may only be adjusted in voltage free condition Or the switchboard was turned to a value which was not admissible Error elimination If the SYSCON switchboard was misadjusted it must be reset correctly according to chapter 2 If the change was done on purpose the control must be switched on and off before the alteration can become effective In addition warnings can be issued In case of warnings the red error LED 1 will not be activated Furthermore in case of a warning the operation mode must be considered Mode Initialising LED RUN and SETUP on Error description The SYSCON switchboard is misadjusted for twin engines with mechanical actuation at the starboard system Error elimination Reset the SYSCON switchboard correctly for twin engines with mechanical actuation at the starboard system see chapter 2 Error type TWIN SLAVE Error description The SYSCON switchboard is misadjusted for twin engines with mechanical actuation at the po
10. done only if the driving engine is turned off In case of mechanical controlling the push pull cables should be disconnected Sep __ Initial condition PARSEL Resetting to default will reset the speed and gearing control values to their Activation of control command active lever in neutral Selection default set up PARSEL Turn switch to position E Selection of the system to be reset for single engines or twin engines portside system for twin engines starboard system Change to SET UP mode PARSEL Default position will be reached LED set up will be activated Storing the default set up PARSEL Change to RUN mode LED Setup off LED set up will be deactivated Operation Adjustment Wiring Overview General Error Analysis Appendix sisAjeuy 10413 jueunsn py NUMIM M9IAI9AQ xipueddy 29 5 Operation 5 1 General By means of the lever position both 1 detent 1 detent speed and gear position ahead ahead astern neutral astern are pre set disengaged engaged gn ahead ONE engaged astern full astern full ahead The following elements are available as user interfaces Keys Command transfer Command lamp e Acknowledge alarm buzzer e Activate special functions Command lamps
11. only sound at short intervals if both lever positions are correct 32 5 4 Warming up By means of the special function warming up a determined speed can be set without gear shifting This function is necessary to warm up the engines To activate warming up the key must be pushed at the active control station and at the same time the lever moved in ahead or astern Then the key may be depressed again To turn the function off the lever must be moved in neutral again When doing so the key must not be pushed When the function warming up is active the poe eee command lamp flashes Note for twin engines The function warming up can be activated and deactivated of both sides separately The command lamp is assigned to the respective lever 5 5 Increased idle speed By the special function increased idle speed a higher idle speed can be selected This function will be necessary if the driving engine shall operate a bow thruster in addition and the normal idle speed engine performance is not sufficient therefore To turn this function on and off the key on the active control station must be pushed The function can be switched on in neutral only and switched off at any time see chapter 4 3 soeed When this function has been entered synchronizing The function increased idle speed is available only if it has been set up before cannot be deactivated again 5 6 Synchronising If for twin engine systems the
12. positions of the port and starboard levers on the active control head deviate less than 10 from each other in the range of ahead the same nominal value of the port lever will be set If Synchronising is active this will be indicated COMMAND by the lamp Synchro SYNCHRO To switch off this function the key on the active control station must be pushed The function will activate again as soon as the levers deviate 10 maximum from each other again at another position Note for increased idle speed Synchronizing cannot be switched off if the function increased idle speed is active The function Synchronization is available only if it has been set up before see chapter 4 2 control head synchronizing Operation Adjustment Wiring Overview General Error Analysis Appendix sisAjeuy 10413 jueunsn py NUMIM M9IAI9AQ xipueddy 33 6 Error analysis 6 1 Errors at the control station Two errors at the control stations must be distinguished Warning For twin engines the alarm and command lamp are assigned to the respective engine side so that several lamp reactions as described above may combine The buzzer will be activated as soon as an During an alarm the setting of the cruising functions speed or gearing is disturbed On the active control head the red alarm lamp will be on and a buzzer will sound The buzzer signal c
13. ship veloccity shaft speed works engine speed against engine speed To avoid stalling the engine the control can wait an adjustable time reversing delay time before reversing The delay time depends on the given lever position of the control head The reversing delay time must be determined experimentally during a sea trial For this the ship must accelerate from 17 detent ahead to full ahead The time the ship needs to reach 2 3 of its maximum speed has to be preset as reversing delay time Afterwards reversing maneuvers need to be carried out covering the full soeed range If necessary the reversing delay time must be adjusted lengthened if the engine revolutions drop too heavily or shortened if no deceleration of the engine speed is recognisable If the reversing delay time is too short clutch gearing and engine may be damaged if it is too long the manoeuvrability may be restricted ef Xe reversing delay l During the reversing maneuvers start with a slow speed first and increase gently nominal spee delay time before clutch delay time after clutch reversing delay time power boot 4 I im nominal position gears ahead time 1 2 3 4 5 6 7 8 For applications with 2 control units only the portside system must be adjusted 28 4 5 Reset to default delivery status This procedure is irreversible A reset to default may be
14. when the control head lever is not in neutral position By a slow flashing of the command lamp the control head signals that the lever must be moved in neutral position first If the levers are already in neutral the command lamp will flash quickly and the buzzer sounds at high repetition The command can be taken over by pressing the key again conten COMMAND all lamps on permanently lamp test alllamps ALARM SYNCHRO permanent sound Jt push key condition lever not neutral pine in tal requesting command lamp flashes slowly ommand lamp flashes quickly station COMMAND COMMAND ALARM E E ALARM SYNCHRO slow bleeping fast bleeping lever in neutral push key Command lamp on permanently SYNCHRO condition COMMAND active ALARM station SYNCHRO As soon as control station has been activated gear position neutral and idle speed will be selected The command can then be set from the active control station see chapter 5 1 Note for control heads twin engine In this case both levers must be moved in neutral The function of the command lamps is assigned to the respective lever port starboard Note for possible error If on a control head the command lamps do not glow after the activation it failed to contact the control unit Wiring and ID see chapter 3 2 need to be controlled If necessary the procedure of entering the control heads into the sys
15. 2 viewing direction 2 l O extension board l actuation Heros Ww X31 X101 aE X102 control unit Bios extension board actuation port ZN 3 5 Alarm relays potential free relay contact closed in case of error max 30 V DC max 0 5 shielded cable type LIYCY 2 x 0 75 mm earthed at both ends LED alarm relay If not the digital output may be destroyed If inductive loads shall be switched these must be provided with a free wheeling diode 16 3 6 Engine start interlock single engine shielded cable type LIYCY 2 x 0 75 mm le UO Ca Starter engine battery port connection to l O extension board 1 twin engine configuration start interlock shielded cable type LIYCY 2 x 0 75 mm engine starboard connection to l O extension board2 The relay start interlock is closed whenever the active control head is in neutral or warming up see 5 4 warming up is active Wiring control unit engine start interlock via control unit max 30 V DC max 0 5 shielded cable type LIYCY LED start interlock potential free relay contact closed when lever in neutral or warming up active earthed at both ends If inductive loads shall be switch
16. Error elimination Check cable to the control head see chapter 3 2 Control the necessary bridges see chapter 3 2 Check LED power supply at the control head see chapter 3 2 Check ID see chapter 3 2 If necessary replace control head Error type ACT CTR HW Error description The hardware of the previous active control head reports an error e g potentiometer defective Error elimination Replace control head Error type POWER Error description The supply voltage see chapter 3 1 is beyond the admissible range for 24V 18 31 2V for 12V 9 15 6 V if no voltage range has been selected 9 31 2V Error elimination Charge battery Error type TEMPERATURE Error description The temperature is beyond the admissible range 25 70 C Error elimination The control may only be operated within the admissible temperature Operation Adjustment Wiring Overview General Error Analysis Appendix sisAjeuy 10413 jueunsn py M9IAJI9AQ xipueddy 37 Error type TWIN Error description The system was configurated for twin engines mechanical gear shifting and speed setting chapter 2 The communication between the control units port and starboard does not function Error elimination Check cable between the control units and the necessary bridges see chapter 3 2 special application twin engine with mechanical throttle control gear
17. an be acknowledged and thus switched off by pushing the key The command lamps indicate if the control head is active or passive 1 if this station can set commands or not Special case If the active control head is defective the passive heads will activate their buzzer and will go over into the condition request station In case of a warning the setting of the cruising function is not disturbed directly The red alarm lamp will be active but the buzzer will not sound alarm is signaled on one of the engine sides Example twin engine Port Alarm Starboard No Error In case of an alarm the alarm relay is activated In addition idle speed is set and the gears are The starboard system is error free and the control head is active The port system is in alarm condition no active command exists on this control station Cruising commands can no longer be set from this station disengaged if the remaining function of the system permit it active station COMMAND ALARM SYNCHRO COMMANDEM ALARM SYNCHRO L special case passive station Command lamp flashes COMMAND ALARM SYNCHRO COMMAND ALARM SYNCHRO COMMAND ALARM SYNCHRO COMMAND ALARM SYNCHRO 34 6 2 Error indication control unit To indicate errors 4 error LEDs are available LED SETUP altogether The top LED is red to facilitate or
18. as long as the key is pushed Storing of parameter Change to RUN mode E Setup LED Setup will be deactivated When modifying the parameters power boost or increased idle speed the maximum speed for clutch engagement see instructions of the gearing manufacturer must be considered Operation Adjustment Wiring Overview General Error Analysis Appendix sisAjeuy 10413 jueunsn py M9IAJI9AQ xipueddy 25 4 4 Gearing Positions for actuating the mechanical gear shifting The push pull cables at the actuators must be mounted in such a way that the neutral position of the gear system is actuated when the active lever is placed in neutral For systems configurated with 2 control units mechanical throttle control and gear shifting each control unit must be set separately If the gearing is operated mechanically the positions ahead and astern must pre adjusted When doing so the engines should be turned off The adjustment is possible only with the active control head lever in neutral position or if the active lever is in the position that corresponds to the gearing position which shall be adjusted e g lever in ahead if gear position ahead needs to be adjusted Sep arn __ 1 Initial condition PARSEL Activation of control command active lever in neutral or ahead if gear position ahead has to be adjusted or lever in astern if gear po
19. cal throttle control and gear shifting Throttle and gear shifting are operated by mechanical rods SYSCON d shielded cable typeLIYCY 4x1mm Single engine electrical throttle control mechanical gear shifting The throttle is adjusted electrically 4 20 mA the gears are shifted by mechanical rods shielded cable shielded cable typeLIYCY 2 x 0 75 mm Single engine mechanical throttle control electrical gear shifting Throttle is actuated by mechanical rods gear shifting is controlled by 24 V signals pm i SYSCON shielded cable shielded cable typeLIYCY 7 1 mm Single engine electrical throttle control and gear shifting Throttle is adjusted electrically 4 20 mA the gears are shifted using 24 V signals shielded cable typeLl YCY 4x 1mm shielded cable typeLIYCY 2x0 75 mm shielded cable typeLIYCY 7x1 mm Operation Adjustment Wiring Overview General Error Analysis Appendix sisAjeuy 10413 jueunsn py M9IAJI9AQ xipueddy 2 2 Twin engine Twin engine mechanical throttle control mechanical gear shifting Throttle and gear shifting are controlled by mechanical rods SYSCON SYSCON shielded cable typeLIYCY 4x 1mm 1 2 3 4 5 6 7 8 starboard
20. d 2 actuation gearing starboard actuation rpm starboard starboard shielded cable typeLIYCY 2x0 75 mm shielded cable shielded cable typeLIYCY typeLIYCY 7x1mm Operation Adjustment Wiring Overview General Error Analysis Appendix sisAjeuy 10413 jueunsn py NUMIM M9IAJI9AQ 2 xipueddy 3 Wiring 3 1 Voltage supply LED readyness fuse 10A T 3 2 Control head voltage voltage voltage 12 24 DC 12V DC 24 V DC ms 7 Sur 7 mo 7 1 1 1 2 2 2 switch for configuration 3 of engine type CI 4 4 4 see chapter 2 overview Co 5 5 5 16 6 6 Z 7 7 Z 7 ZI CE EHE Ie i supply line 2 5mm2 E length 10m max 2 GND screened 1 Vcc i 12V 24V DC eee main ia 10 A nominal current switch 30 A peak current acc to Lloyds Register earthing at one of the 4 mounting screws directly connection to ship mass For systems approved by classification societies the voltage range 12V or has to be selected If the supply voltage exceeds or falls below the range by 30 or 2596 respectively a corresponding error message will be issued Advice how to mount the connecting cable preparation connection cable
21. ed these must be provided with a free wheeling diode If not the digital output may be destroyed Wiring l O extension board configuration start interlock 71 LED start interlock closed when lever in neutral or Warming Up active potential free relay contact max 30V DC max 2A 72 73 74 75 76 77 78 79 80 81 82 shielded cable type LIYCY 2 x 0 75 mm earthed at both ends If inductive loads shall be switched these must be provided with a free wheeling diode If not the digital output may be destroyed Operation Adjustment Wiring Overview General Error Analysis Appendix sisAjeuy 10413 jueunsn py NUMIM 1 2 xipueddy 17 Two special cases must be considered when wiring the engine start interlock Engine start interlock special application 1 Twin engine with mechanical throttle control and gear shifting CH 1 1 Z 2 2 CH 3 CH 4 4 E 1 5 5 6 6 7 7 8 starboard port starboard shielded cable shielded cable 1 gt type LIYCY ae 2 x 0 75 mm ae 2 x 0 75 mm E E 1 E ud E Engine start interlock special application 2 Using the function idle gas relay on twin engines configuration Ape s idle gas relay a 2 1 2 M B 4 L1
22. ferent ITI I control head bja i control head control head ID 1 E ID 2 ID 3 screened line LIYCY 4x 1mm total length 60m max screened line grounded at both ends Terminal assignment control head white ws brown br yellow gb ___5 CANen ___6 _ J 7 At the last control head a bridge must be connected between terminals 4 and 5 Special application twin engine with mechanical throttle control and gear shifting Example 2 control head N The IDs of the control heads must be different remove bridge control head control head terminal 2 3 ID 1 ID 2 a _ starboard shielded cable 2 4 x 1 mm earthed at both ends shielded cable m2 4 earthed at both ends 10 3 3 Mechanical throttle control and gear shifting actuator 1 actuator 2 Es ri SYSCON la 5 5 o E e e le o E 5 5 CF The setting of switchboard SYSCON switches 1 6 assigns the function speed or gear control to the actuat
23. gin only after the feedback signal has been received The setting is evaluated only by the portside system for twin engines with mechanical throttle control and gear shifting nominal spee delay time before clutch delay time after clutch delay time after clutch reversing delay power boot idle spee time nominal position gearing Uis 00 ahead time delay time before clutch delay time after clutch Os 1s CONoOoaRWN 1 1 2 3 4 5 6 7 8 Operation Adjustment Wiring Overview General Error Analysis Appendix sisAjeuy 10413 jueunsn py M9IAJI9AQ xipueddy 27 Conditions when reversing from ahead to astern When reversing from ahead to astern the gearing 15 at first shifted to neutral the shaft is disengaged from the engine 1 As the ship continues to move ahead the propeller is driven like a windmill by the water streaming against it so that the shaft continues to turn When the gears are then shifted to astern the engine must work against the shaft which is still turning In an unfavourable case the engine might stall 1 gears neutral neutral ship I velocity shaft speed depends on ship velocity 2 gears astern astern
24. ientation ET The operation mode of the control is indicated by 2 additional LEDs RUN SETUP EE By pressing a key further error messages gy displayed 777 It must always be distinguished if the red LED1 flashes or stays on permanently LED on in mode permanent on LED on in mode flashing Red LED 1 steady light Error description Faulty parameter storage of the control unit Error elimination The parameters of the control must be re set to default see chapter 4 5 If afterwards the error is still occuring the board of the control unit must be replaced Error type SOFTWARE Error description The software of the control unit is defective e g EPROM not plugged The board of the control unit must be replaced Error elimination Switch the control on and off If necessary replace board of the control unit Error type CAN Error description The CAN controller reports an error Error elimination Control the wiring to the control heads chapter 3 2 Check the bridges see chapter 3 2 There may be a short circuit in the wiring between single veins i 2L 30 4L 1 _ 2 3 4 0 i 2L 4L i 2 4L Operation Adjustment Wiring Overview General Error Analysis Appendix sisAjeuy 10413 jueunsn py NUMIM M9IAJI9AQ xipueddy 35 Error type ACTUATOR 1
25. in engine at the starboard system is not signaled The control works without gear feedback Error elimination Check pressure sensor at the gearing Control LEDs on the extension board LED actual ahead or astern or collective feedback Check wiring 10 2 3 4 0 1L 2L 4L 1L 2 4L 1L 2L 30 Operation Adjustment Wiring Overview General Error Analysis Appendix sisAjeuy 10413 jueunsn py NUMIM M9IAJI9AQ xipueddy 39 Error type CTRL POS Error description Before adjusting parameters for speed and gear control the active control head must be placed in the correct position see chapter 4 3 or 4 4 It is not permitted to adjust the parameter in this lever position Error elimination Change to RUN mode step 1 in chapter 4 3 or 4 4 Move lever in correct position then and repeat the adjustment Error type PROCEDURE Error description Parameters were set chapter 4 in incorrect order e g adjustment of rotary switch PARSEL in SETUP mode ROD Error elimination Change to RUN mode step 1 in chapter 4 3 or 4 4 Move lever in correct position then and repeat the adjustment Error type ADJUST Error description has been tried to set a parameter chapter 4 that does not exist at all according to the system configuration chapter 2 rom starboard for a single engine system Or the rotary switch PARASEL was turned
26. included in the MAREX SB delivery The power supply for the gearbox must be fused separately i r An emergency manual override to shift gears must be provided reversing DUX If inductive loads shall be switched these must be provided with a free wheeling diode If not the digital output may be destroyed 14 Power supply for electrical gear shifting supply line 2 1 mm length max 10m The power supply shown above is recommended according to the classification rules Alternatively the control unit may supply the voltage for the electrical gear control ol E BH N N B 1 2 Bg 4 B BD oo 1 jee E mE I Y 1 1 q f gt 0 0 TN supply is not protected by fuse In this case the control unit must be protected When the control unit supplies the voltage for the electrical gear control the power separately see chapter 3 1 power supply Operation Adjustment Wiring Overview General Error Analysis Appendix sisAjeuy 10413 jueunsn py M9IAJI9AQ xipueddy Mounting the l O extension boards X101 X10
27. ing default condition 4 3 Speed setting Generally the parameters for speed setting can be set when the active control head is in neutral position Idle speed power boost and increased idle speed can also be set when the lever position is 1 detent ahead or astern The nominal speed parameters may also be set when the lever position is full ahead or full astern For system configurated with 2 control units mechanical throttle adjustment and gear shifting each unit must be set separately Step Bam ___ Initial condition PARSEL Activation of control command active lever in neutral LEP Setup or 1 detent ahead astern Selection of the parameter to be adjusted Idle speed PARSEL Turn switch to position 1 Or Nominal speed PARSEL Turn switch to position 2 Power boost PARSEL Turn switch to position A Increased idle speed PARSEL Turn switch to position B 24 Selection of the system for which speed fod parameters shall be set PARSEL for single engines or twin engines port system for twin engines starboard system Change to SETUP mode The selected position will be reached The LED Setup will be activated Adjustment of speed Direction Parameter will be adjusted as long as the key is pushed direction Direction Parameter will be adjusted
28. ion Check cable between l O extension board 1 and the control unit see chapter 3 4 electrical throttle control gear shifting installation of the l O extension board If necessary replace cable or l O extension board Error type 2 Error description The system is configurated see chapter 2 in such a way that I O extension board 2 directs electrical gear shifting or speed setting see chapter 3 4 However an error is stated in the activation of extension board 2 Error elimination Check cable between l O extension board 2 and 1 or 1 and the control unit see chapter 3 4 electrical throttle control gear shifting installation of the I O extension board If necessary replace cable or 36 Red LED 1 flashing Error type SYN CARD warning only Error description No extension board for synchronizing found Error elimination Check cable from synchronizing board to board of the control unit see instructions attached to the synchronizing board If necessary replace synchronizing board Error type SYN SIG warning only Error description The synchronizing board cannot measure the speed correctly Error elimination Check cable to the speed sensor see instructions attached to the synchronizing board If necessary replace speed sensor or synchronizing board Error type ACT CTR Error description The control unit reports a total failure of the active control head
29. nsfer 5 4 Warming Up 5 5 Increased idle speed 5 6 Synchronising 6 1 Error at control station 6 2 Error indication control panel Control unit Page 40 sisAjeuy 10413 jueunsn py NUMIM 1 xipueddy 1 General 1 1 System components o lt Control head single engine 362 241 100 0 Control head 362 241 000 0 twin engine Control unit 346 068 000 0 DC actuator 323 698 020 0 346 068 721 2 l O extension board Synchro board 346 068 7302 Push Pull cable 2m 323 699 4152 Mounting kit 323 699 006 2 Additionally required LIYCY _ 0 Olflex100 2 25 44ZD D 41 0 LIYCY LIYCY LIYCY Cable start interlock LIYCY 2x0 75mm if engine start interlock is connected Cable idle gas LIYCY 2 0 75 2 if idle gas is connected 1 2 General preconditions for the operation According to classification rules Indication of the current cruising command The current cruising command speed gearing position must be indicated on every control station Indication of active control station It must be indicated on every control station which control station is in command If from any control station any other station is visible the indication of current cruising command and active control station is not necessary e g on small yacht
30. ors see chapter 2 overview 3 3 1 Push pull cable The mechanical connection between actuator and lever for throttle adjustment or gear control at the engine is done by push pull cables 170 3 for half the stroke bat 76 stroke 110 x 33 E I 28 5 x radial excursion 8 max to all sides 5946 1 Z 9 46 When laying push pull cables as few direction changes as possible should be made The efficiency of the cables decreases with every deflection Deflection angle 90 usable force 82 of the force applied Deflection angle 360 usable force 55 of the force applied Operation Adjustment Wiring Overview General Error Analysis Appendix sisAjeuy 10413 jueunsn py M9IAJI9AQ 2 xipueddy 11 3 3 2 Mounting of the actuator Mounting work may only be carried out if the actuator N is idle Risk of injury 3 3 3 Connection at the throttle and gear adjusting lever To fix the push pull cable at the adjusting lever a ball joint may be used ball joint E gt o a EX i JF nut
31. r of the active control head is moved to neutral a short buzzer sound can signal this Short sound when lever in neutral With two control units only the port unit must be adjusted No sound default condition With two control units only the port unit must be adjusted Comparision of positions cruising ranges Compare position A change of control stations is possible only if the lever of the new control station is set in the same cruising range ahead neutral astern and in the same position maximum deviation 30 as the lever of the active control station According to the classification rules this mode has to be selected With two control units only the port unit must be adjusted Compare range A change of control stations is possible only if the lever of the new control station is set either in the same cruising range ahead neutral astern as the lever of the active control station or in neutral position With two control units only the port unit must be adjusted Operation Adjustment Wiring Overview General Error Analysis Appendix sisAjeuy 10413 jueunsn py M9IAJI9AQ xipueddy 23 Synchronising Synchronising active If the lever positions of the port and starboard control heads deviate at 1096 maximum the same nominal value will be preset automatically No synchroniz
32. rt system Error elimination Reset the SYSCON switchboard for twin engines with mechanical actuation at the port system see chapter 2 38 Mode RUN or SETUP LED RUN or LED SETUP on Error type GEAR MASTER Error description Gear feedback has been set at the l O extension board see chapter 3 4 The gear feedback is not signalled for twin engines on the port side The system works without gear feedback Error elimination Check pressure sensor at the gearing Control LEDs on l O extension board LED actual ahead or astern or collective feedback Check wiring Error type PAS CTRL Error description The control states a total failure of a passive control head Error elimination Check wiring see chapter 3 2 Check LED power supply at the defective passive control head If necessary replace control head Error type PAS CTRL HW Error description The hardware of a passive control head is defective e g potentiometer error Error elimination Replace defective control head Error type GEAR SLAVE Error description Gear feedback has been set at the l O extension board see chapter 3 4 The gear feedback on the tw
33. s Capacity of independent actuation Besides the remote control a second possibility of controlling speed and gearing must be provided Emergency stop button A separate emergency stop button for the engine must be installed on every control station independent from the remote control These components are not included in the MAREX SB delivery 1 3 Mounting advice Cables to be connected to the control unit must always be provided with the metallic cable joints supplied The joints are mounted as shown below shielded cable pressure screw sleeving conductors cable outside cone Inserted sealing Mounting work must be done only if the system is in voltage free condition The power supply must be secured against activation in this case Mounting and commissioning work must be carried out by skilled personnel and in accordance with the manual only 1 4 Operating advice Do not reach into the actuator while it is in operation You risk injuring The remote control MAREX SB has been designed for the control of Diesel engines If it is applied for petrol or gas propulsion systems its components must be installed outside the hazardous area The instructions for hazardous areas have to be followed Operation Adjustment Wiring Overview General Error Analysis Appendix sisAjeuy 10413 jueunsn py M9IAI19AQ xipueddy 2 Overview 2 1 Single engine Single engine mechani
34. sibilities of adjusting the control unit TIME seechapter 4 4 gearing lt P 2 delay time before clutch configuration of system type see chapter 2 overview delay time after clutch set voltage supply reversing delay time see chapter 3 wiring 3 1 voltage supply nnnm PARSEL setting of parameters e se chapter4 3 speed chapter4 4 gearing CTRHEAD see chapter 4 2 control head HB alignment BH 12 buzzer in neutral B range position comparision H synchronisation The hardware is configurated by means of the switchboard SYSCON The position of the switches can be changed only in deactivated condition The function of the switch board SYSCON system configuration is described in chapters 2 overview 3 wiring and 3 1 power supply The switch board TIME defines the delay times for the gear shifting The function is described in chapter 4 4 By the switches PARSEL parameter selection parameters are adjusted as e g for mechanical throttle control idle and nominal speed and for mechanical gear shifting the gear positions ahead and astern In addition parameters for special functions are preset see chapter 4 3 speed 4 4 gearing The switchboard CTRHEAD control head determines the function of the control head described in chapter 4 2 control head Possibilities of adju
35. sis Appendix O AIM jueunsn py jeuy 10413 SISA xipueddy 13 Electrical gear shifting with separate feedback TR LL 71 72 7 74 75 76 77 78 79 80 81 82 UT ejejejleje eje ejerejeje screened cable type LIYCY 7 x 1 mm grounded at both ends LED set ahead 73 LED set astern 75 LED act astern 78 LED act astern 76 Ee with free wheeling diodes mb 1 Eg 1 gear feedback on pressure switch R 11 x 2 Cu sep feedback on 4 Solenoid valve and pressure switch included in the MAREX SB delivery The power supply for the gearbox must be fused separately An emergency manual override to shift gears must be provided reversing gearbox If inductive loads shall be switched these must be provided with a free wheeling diode If not the digital output may be destroyed Electrical gear shifting with collective feedback Indication condition gearbox felelelelelelelelelelele screened cable type LIYCY 7 x 1 mm4 grounded at both ends a LED set ahead 73 LED set astern 75 LED collective feedback 76 Vcc 2A Vcc 2A SSS SSS SMSO N N 4 N N N solenoid valve F E Fg 1 1 gear feedback on 2 pressure switch 3 sep feedback off 4 Solenoid valve and pressure switch are not
36. sition astern needs to be adjusted 2 Selection of the parameter to be adjusted Ahead Turn PARSEL switch to position 4 Neutral Turn PARSEL switch to position 5 Astern Turn PARSEL switch to position 6 3 Selection of the system for which the parameters for gear actuation shall be set for single engines or twin engines portside gear system for twin engines starboard gear system 26 During step 4 it is possible that the gear position adjusts automatically the driving engine should therefore be turned off 1 Change to SETUP mode PARSEL The selected position will be reached LED Setup will be activated Adjusting the gear position Direction Position is adjusted as long as the key is pushed direction Direction Position is adjusted as long as the key is pushed Storing of parameter Change to RUN mode Eee LED Setup will be deactivated Delay times for gear shifting The delay time before clutch engagement must be long enough to ensure that a parameterized speed acceleration see chapter 4 3 speed adjustment can be completed safely The delay time after clutch engagement must be long enough to ensure the gearing has shifted safely This is important there is no feedback from the gearing In case of a feedback signal the delay time after clutch engagement will be
37. sting the l O extension board IOCONF i gears with without feedback see chapter 3 4 The switchboard IOCONF VO 2 startinterlock idle gas see chapter 3 6 3 7 configuration defines the function of 3 2 gear feedback double single see chapter 3 4 the electrical in outputs They are 4 reserved described in chapter 3 wiring in the respective paragraph 1 Switch 4 must be the position as N The l O extension board will only function shown here correctly if switch 4 is in the position described 20 4 2 Control head Introducing the control heads In order to inform the control about the number of control heads connected these must be introduced For twin engine controls with mechanical throttle control and gear shifting the procedure has to be carried out at the portside system The following steps have to be completed Se em em _ CTRHEAD switch 1 to close 2 adjusted 4 With two control units only the port unit must be CN L3 CTRHEAD switch 1 to open m With two control units only the port unit must be E adjusted TE 2 4 All control heads connected must be in condition lamp test see chapter 5 2 activation and request of control station Special case automatic ID setting If automatic ID setting shall be applied the software versions stated below must be provided for control unit and heads Con
38. system is described in chapter 5 In case of malfunction an error analysis as explained in chapter 6 has to be carried out Imprint The copyright of this user manual remains the property of Bosch Rexroth AG Included are instructions and technical drawings which may not be reproduced or copied either in part or whole nor may they be used for evaluation or distributed for competition purposes The diagrams and drawings used in this manual are for guidelines only and are not be used for the actual design This edition supersedes all previous ones Order No 883 890 060 3 Bosch Rexroth AG Tel 49 0 5 11 2136 2 51 Department Marine Technique Fax 49 0 5 11 2136 1 62 Bartweg 13 e mail marinesales boschrexroth de 30453 Hannover Internet http www boschrexroth de P O Box 91 07 62 30427 Hannover Table of Contents 1 General 2 Overview 3 Wiring 4 Adjustment 5 Operation 6 Error analysis Appendix 1 1 System components 1 2 General preconditions for the operation 1 3 Mounting advice 1 4 Operating advice 2 1 Single engine 2 2 Twin engine 3 1 Voltage supply 3 2 Control head 3 3 Mechanical throttle control gear shifting 3 4 Electrical throttle control gear shifting 3 5 Alarm relays 3 6 Engine start interlock 3 7 Idle gas relay 4 1 Hardware configuration 4 2 Control head 4 3 Speed 4 4 Gearing 4 5 Reset to default 5 1 General 5 2 Activation and request control station 5 3 Station tra
39. tem see chapter 4 2 must be repeated If there is no functioning control head the alarm relay will be activated Operation Adjustment Wiring Overview General Error Analysis Appendix sisAjeuy 10413 jueunsn py NUMIM M9IAI9AQ xipueddy 31 5 3 Station transfer A command transfer is possible in 2 different modes Which mode is applicable depends on the position of switch 3 on the switch board CTRHEAD see chapter 4 2 control head comparision of range position Always the key on the passive control station must be pushed to change the control station Mode compare direction condition passive ALARM station SYNCHRO ilL push key condition wrong lever position correct lever position requesting Command lamp flashes slowly Command lamp flashes quickl station COMMAND ALARM m COMMAND _ ALARM neca SYNCHRO slow bleeping fast bleeping push key SYNCHRO condition COMMAND active ALARM station l SYNCHRO Command lamp permanenly If the lever of the passive control station is placed in a range which is not admissible for command transfer the passive lever in astern when the active one is in ahead or neutral or the passive lever in ahead with the active one in astern or neutral the buzzer will sound at long intervals and the command lamps flash at low repe
40. tition If the lever of the passive control station is in the correct position for a command transfer the passive lever in ahead or neutral when the active lever is in ahead or the passive lever in astern or neutral while the active one is in astern the buzzer will sound at short intervals and the command lamps flash at high repetition By pressing the key again the command will be taken over Mode compare position In the mode compare position the position of the passive lever may deviate by 30 maximum from that of the active control head lever In addition the range ahead neutral astern must correspond before a command transfer can be carried out It is not necessary to push the key a second time The transfer will be executed as soon as the lever positions are correct This gives the operator the possibility after the first actuation of the key to move the lever until the correct range is found and the command transfers automatically If the correct range is not found within 30 seconds the command transfer will be stopped According to the classification rules the given cruising command must not change during a command transfer For this reason classified ships must choose the mode compare position Note for twin engines In case of control heads with two levers both levers must be placed correctly before the command can be transferred The function of the command lamp 15 assigned to the respective lever The buzzer will
41. to a value which was not admissible Error elimination Correct setting of switches and rotary switch PARSEL 40 Control Unit In and Outputs M9IAJ9AQ jnejop peeds 1500 J9MOd ulojse 9 peeds peeds uo uomneziuoJuou S uonisod uo 1922 9 jueujuDi e peeu ees dn s dnjas pueoquels uod 37135 995 jo Dunes 3SHVd p C wieje ejoJ 131 uelis 31 uni 037 dnies 031 M M M QVAHYLO uoinjo Joye Aejap jueunsn py ovx gt lt o LO gt lt N X SA _ O c op CO sF LO OF Bunea 1e1deuo oos st 0 sisAjeuy 10413 xipueddy N X X st II LO x lt x 10119 037 OOOO Ajddns 2 995 5
42. trol unit MSB V2 00 or higher Control head MSKG V2 00 or higher With this feature it is no longer necessary to define an ID at every control head as the system assignes IDs automatically to all heads connected After the automatic setting of control head 105 it is no longer possible to combine control heads with software below V2 00 with heads providing a higher software version Wiring Overview General Adjustment Operation Error Analysis Appendix sisAjeuy 10413 jueunsn py M9IAI9AQ xipueddy Procedure for automatic ID setting _ Hold down switch 51 Shift CTRHEAD switch 1 to close Do not further operate switch 51 E switch S1 The control head buzzers sound at short intervals In addition the control head LEDs are active see step 6 and flash in the same frequency as the buzzer Press the keys of the control heads one after another Signals after one keystroke The buzzer stops The ID which was stored is indicated by the LEDs of the control head The LEDs flash slowly 22 ID Indication LED off LED steadily lighted LED flashing E no ID assigned no automatic ID set yet 0 L ib L 0 22 O P C y Ws L L LI nre nr nre v v shift CTRHEAD switch 1 to open Buzzer in neutral When the leve
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