MarexSB V2 1 EN - ÖZMAR · PDF fileShort Instructions Please do also see the general advice in chapter 1. Step Description 1 Select engine type (chapter 2 "overview") Assembly 2 Adjust

Version 2.1015.07.2003

Manual / Marine

Marex SB

Short InstructionsPlease do also see the general advice in chapter 1.

Step Description

1 Select engine type (chapter 2 "overview")

Assembly

2 Adjust SYSCON switch board in accordance with engine type (chapter 2 "overview")

3 - 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 3.5ff.)

Commissioning

4 Enter control heads (chapter 4.2)Enter additional functions of control heads if applicable.

5 For mechanical throttle control: enter nominal value for idle speed (chapter 4.3)

6 For mechanical gear shifting: adjust position ahead / astern(chapter 4.4)

7 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

8 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 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 orcopied either in part or whole, nor may they be used for evaluation or distributed forcompetition purposes.The diagrams and drawings used in this manual are for guidelines only and are not beused for the actual design.This edition supersedes all previous ones.Order No.: 883 890 060 3

Bosch Rexroth AGDepartment Marine TechniqueBartweg 1330453 HannoverP. O. Box 91 07 6230427 Hannover

Tel.: +49 (0)5 11-2136-2 51Fax.: +49 (0)5 11-2136-1 62e-mail: [email protected]: http://www.boschrexroth.de

Table of ContentsPage

1 General 1.1 System components 11.2 General preconditions for the operation 21.3 Mounting advice 21.4 Operating advice 2

2 Overview 2.1 Single engine 32.2 Twin engine 5

3 Wiring 3.1 Voltage supply 73.2 Control head 73.3 Mechanical throttle control / gear shifting 103.4 Electrical throttle control / gear shifting 113.5 Alarm relays 153.6 Engine start interlock 163.7 Idle gas relay 18

4 Adjustment 4.1 Hardware configuration 194.2 Control head 204.3 Speed 234.4 Gearing 254.5 Reset to default 28

5 Operation 5.1 General 295.2 Activation and request control station 305.3 Station transfer 315.4 Warming Up 325.5 Increased idle speed 325.6 Synchronising 32

6 Error analysis 6.1 Error at control station 336.2 Error indication control panel 34

Appendix Control unit 40

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1 General1.1 System components

Designation Code No. Photo Symbol

Control head(single engine)

362 241 100 0

Control head(twin engine)

362 241 000 0

Control unit 346 068 000 0

DC actuator 323 698 020 0

I/O-extension board 346 068 721 21234

Synchro-board 346 068 730 2

Push-/Pull-cable 2m 323 699 415 2

Mounting kit 323 699 006 2

Additionally required:Data cable LIYCY 4 x 1mm²Supply cable Ölflex 100 2 x 2,5mm²Throttle cable LIYCY 2 x 0,75mm² for electrical throttle control onlyGearing cable LIYCY 7 x 1mm² for electrical gear shifting onlyCable alarm LIYCY 2 x 0,75mm² if alarm system is connectedCable start interlock LIYCY 2 x 0,75mm² if engine start interlock is connectedCable idle gas LIYCY 2 x 0,75mm² if idle gas is connected

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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 andactive control station is not necessary (e. g. on small yachts).

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 stationindependent from the remote control.

*These components are not included in the MAREX SB delivery.

1.3 Mounting adviceCables to be connected to the control unit must always be provided with the metallic cable jointssupplied. The joints are mounted as shown below:

Mounting work must be done only if the system is in voltage-free condition. The power supply must besecured against activation in this case.

Mounting and commissioning work must be carried out by skilled personnel and in accordance withthe manual only.

1.4 Operating adviceDo 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 forpetrol or gas propulsion systems, its components must be installed outside the hazardous area. Theinstructions for hazardous areas have to be followed.

shielded cablesleeving

outside cone Inserted sealing

pressure screw

conductors cable

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2 Overview2.1 Single engine

Single engine – mechanical throttle control and gear shifting

Throttle and gear shifting are operated by mechanical rods.

12345678

1

S1 S2

70 mm100 N

70 mm100 N

shielded cabletype LIYCY4 x 1 mm2

SYSCON

Single engine - electrical throttle control, mechanical gear shifting

The throttle is adjusted electrically (4 ... 20 mA), the gears are shifted by mechanical rods.

12345678

1

S1

4...20 mA

70 mm100 N


shielded cabletype LIYCY2 x 0,75 mm2

SYSCON

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Single engine - mechanical throttle control, electrical gear shifting

Throttle is actuated by mechanical rods, gear shifting is controlled by 24 V-signals.

12345678

1

A2

70 mm100 N

24 V

shielded cable

type LIYCY4 x 1 mm2


SYSCON

Single engine – electrical throttle control and gear shifting

Throttle is adjusted electrically (4 ... 20 mA), the gears are shifted using 24 V-signals.

12345678

1

24 V

4...20 mA




SYSCON

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2.2 Twin engine

Twin engine – mechanical throttle control, mechanical gear shifting

Throttle and gear shifting are controlled by mechanical rods.

12345678

1

A1 A2

12345678

1

A1 A2

port starboard

70 mm100 N

70 mm100 N

70 mm100 N

70 mm100 N

shielded cabletype LIYCY2 (4) x 1 mm2

shieldedcable

type LIYCY4 x 1 mm2

SYSCON SYSCON

Twin engine – electrical throttle control, mechanical gear shifting

Throttle is actuated electrically (4 ... 20 mA), the gears are shifted by mechanical rods.

12345678

1

A1 A2

70 mm100 N

70 mm100 N

4...20 mA 4...20 mA

12

port starboard

I/O-extension board 1:actuation rpm port

I/O-extension board 2:actuation rpm starboard

shieldedcable

type LIYCY4 x 1 mm2



SYSCON

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Twin engine – mechanical throttle control, electrical gear shifting

Throttle is adjusted by means of mechanical rods, gear shifting is controlled by 24 V-signals.

12345678

1

A1 A2

12

port starboard

70 mm100 N

70 mm100 N

24 V 24 V

I/O-extension board 1:actuation gearing port

I/O-extension board 2:actuation gearing starboard

shieldedcable

type LIYCY4 x 1 mm2



SYSCON

Twin engine – electrical throttle control, gear shifting electrical

Throttle is adjusted electrically (4 ... 20 mA), gear shifting is operated by 24V-signals.

12345678

1

12

port starboard

24 V 24 V

4...20 mA 4...20 mA

I/O-extension board 1:actuation gearing portactuation rpm port

I/O-extension board 2:actuation gearing starboard

actuation rpm starboard

shieldedcable

type LIYCY4 x 1 mm2




shielded cabletype LIYCY

2 x 0,75 mm2

SYSCON

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3 Wiring

3.1 Voltage supply

!For systems approved by classification societies, the voltage range 12V or has tobe selected. If the supply voltage exceeds or falls below the range by +30% or -25% respectively, a corresponding error message will be issued.

3.2 Control headAdvice how to mount the connecting cable

loosen screws andlift housing cover

100 mm

shielded-cablesleeving

maletaper

sealinginsert

pressure-screw

preparation connection cable

!The data cable must be prepared as shown above. The cables must not besqueezed when assembling the components after the wiring.The sealing of the housing must be fitted correctly to guarantee protection typeIP65.

1

2

Vcc

GND

12V / 24V DC10 A nominal current30 A peak current(acc. to Lloyds Register)

fuse16A T

+

-

12345678

7

12345678

7

12345678

7

voltage12...24 V DC

voltage12 V DC

voltage24 V DC

supply line 2,5mm2, length. 10m maxscreened

earthing at one of the 4 mounting screws directly(connection to ship mass)

fuse10A T

LED -readyness

mainswitch

switch for configurationof engine type(see chapter 2 overview)

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Entering the identification (ID)

!To enable the control to identify the control heads, an individual ID must beentered once at every control head (e. g. control head bridge ID 1, control headport ID 2, control head starboard ID 3)

ID 0 is not admissible.

à This procedure is not necessary, if the automatic ID setting is used. (Chapter4.2)

To enter the ID, the housing cover must be removed.

AdjustmentID (1...6)

starboard side

port side

X1

bottom side control head

adjustmentID (1...6)

LED power supply ok

LEDcommunication ok

!

7654321

On every control head, an individualID must be entered once.

ID 0 is not admissible.

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Wiring control head

7654321

7654321

7654321

7654321

7654321

7654321

screened line(LIYCY)4 x 1 mm2

total length 60m max.

optional switch: station tranfer interlock(required for ECR stations according to classification rules)

control headID 1

control headID 2

control headID 3

grgbbrws

grgbbrws

grgbbrws

grgbbrws

grgbbrws

bridge at last head

!

!

The IDs of the control headsmust be different.

4

3

2

1

2

1

2

1

ws

br

gr

gb

screened linegrounded at both ends

+

-

Terminal Designation Colour1 0 V white (ws)2 +8 V brown (br)3 CAN – yellow (gb)4 CAN + green (gr)5 CAN end6 switch -

Terminal assignment control head

7 switch +

!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

7654321

7654321

7654321

7654321

control head

ID 1

control head

ID 2

grgbbrws

grgbbrws

grgbbrws

bridgeat lasthead

!

!

The IDs of the control headsmust be different.

4

3

2

1

2

1

2

1

ws

br

gr

gb

shielded cable4 x 1 mm2

earthed at both ends

gr

gb

4

3

2

1

2

1

2

1

gr

gb

port starboard

shielded cable2 (4) x 1 mm2


! remove bridgeterminal 2/3

Example: 2 control head

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3.3 Mechanical throttle control and gear shifting

actuator 2

21

321

actuator 1

123

12

SYSCON

The setting of switchboard SYSCON (switches 1 – 6) assigns the function (speed or gear control) tothe actuators (see chapter 2 overview).

3.3.1 Push-/pull-cableThe mechanical connection between actuator and lever for throttle adjustment or gear control at theengine is done by push-/pull-cables.

radial excursion: 8° max. to all sides**

8,5

76 stroke 110 33 max

10-3

2 U

NF

-2A

22,1

for half the stroke170 3+

9,46

6,35

9,46

min 5

min 5

3,27

**

!

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 appliedDeflection angle 360° usable force = 55% of the force applied

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3.3.2 Mounting of the actuator

3.3.3. Connection at the throttle and gear adjusting leverTo fix the push-/pull-cable at the adjusting lever, a ball joint may be used.

3.4 Electrical throttle control and gear shiftingElectrical throttle control

1

23

4

71 72 73 74 75 76 77 78 79 80 81 82

+ -

4...20 mAgalvanically separated

(max. 500 Ohm)

ECU, EDCEngine Control Unit

Engine Digital Control

shielded cableTyp:LIYCY2 x 0,75 mm2

earthed at both endsgeerdet

!Mounting work may only be carried out if the actuatoris idle.

Risk of injury!

"s"

hexagone nutcounter bearing

ball joint

!When adjusting the traveling range of the actuator (stroke), it must be ensuredthat 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 mm

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Electrical gear shifting without feedback

!If inductive loads shall be switched, these must be provided with a free-wheeling diode. If not, the digital output may be destroyed.

71 72 73 74 75 76 77 78 79 80 81 82

aheadVcc, 2A

asternVcc, 2A

solenoid valve

reversing gearbox

screened cabletype LIYCY7 x 1 mm2

grounded at both ends

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.

LED set ahead (73)LED set astern (75)

1234

gear feedback off

1

Indication gear condition

1234

1234

relay withfree-wheeling diode

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Electrical gear shifting with separate feedback71 72 73 74 75 76 77 78 79 80 81 82

VorausVcc, 2A

ZurückVcc, 2A

solenoid valvewith free-wheeling diodes

reversing gearbox

screened cabletype LIYCY, 7 x 1 mm2


Solenoid valve and pressure switch are not included in the MAREX SB delivery.


An emergency manual override to shift gears must be provided.


LED act. astern (78)LED act. astern (76)

1234

gear feedback on

sep. feedback on

1

Indication gear condition

1234

1234

pressure switch


Electrical gear shifting with collective feedback71 72 73 74 75 76 77 78 79 80 81 82

VorausVcc, 2A

ZurückVcc, 2A

reversing gearbox

screened cabletype LIYCY, 7 x 1 mm2


Solenoid valve and pressure switch are not included in the MAREX SB delivery.


An emergency manual override to shift gears must be provided.


LED collective-feedback (76)

1234

gear feedback on

sep. feedback off

1

Indication condition gearbox

1234

1234

solenoid valvewith free-wheeling diodes

pressure switch


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Power supply for electrical gear shifting

12

34

fuse2A T

+

-

71 72

Vcc GND

supply line 2 x 1 mm2,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:

1234

1234

71 72

Vcc GNDVcc GND

1 2

!

!When the control unit supplies the voltage for the electrical gear control, the powersupply is not protected by fuse. In this case, the control unit must be protectedseparately (see chapter 3.1 "power supply").

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Mounting the I/O-extension boards

viewing direction

X101 X102

X101 X102

X31

I/O-extension board I (actuation port )

I/O-extension board II (actuation starboard )

12

1

2

control unit

3.5 Alarm relays

1

2max. 30 V DCmax. 0,5A



LED alarm relay

1

2potential-freerelay contact

closed in caseof error


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3.6 Engine start interlock

supply -battery

+-

starter-battery

+

-engine

single engine

12

twin engine

1234

2

configurationstart interlock

portconnection to

I/O-extension board 1

starboardconnection to

I/O-extension board2

+-

+

-engine

+-

+

-engine



The relay "start interlock" is closed whenever the active control head is in neutral or warming up (see5.4 "warming up") is active.

Wiring control unit

1

2max. 30 V DCmax. 0,5A

shielded cabletype LIYCYearthed at both ends

LED start interlock

1

2potential-freerelay contact

closed ,whenlever in neutral orwarming up active

engine start interlock via control unit


Wiring I/O-extension board

1234

2

configurationstart interlock

potential-freerelay contactmax. 30V DCmax. 2 A



71 72 73 74 75 76 77 78 79 80 81 82LED start-

interlock

12

3

4

closed when,lever in neutral or

Warming Up active


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!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

12345678

1

A1 A2

12345678

1

A1 A2

port starboard

+-

+

-engine

+-

+

-engine

port starboard



Engine start interlock, special application 2:Using the function "idle gas relay" on twin engines

12

1234

2

configurationidle gas relay

-

port starboard

+-

+

-engine

+-

+

-engine

supply -battery

Starter-battery

Starter-battery

+

!Engine start interlock will be released if both levers of the control heads (port andstarboard) are in neutral position or warming up is active.

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3.7 Idle gas relay

1 12

Single Engine Twin Engine

idle gasidle gas port idle gas starboard

The idle gas relay is closed when the lever of the active control head is in neutral or in 1st detentahead/astern.

Wiring I/O-extension board

relay function : idle gas1234

2

potential-freerelay contactmax. 30V DCmax. 2 A



71 72 73 74 75 76 77 78 79 80 81 82

LED idle gas

1

23

4

closed when,lever in neutral or in1. detent ahead /astern


!When the function "idle gas" is applied, the relay on the I/O-extension board is notavailable for the function "engine start interlock".

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4 Adjustment4.1 Hardware configuration

Possibilities of adjusting the control unit

SYSCON

12345678

configuration of system typesee chapter 2 "overview"

set voltage supplysee chapter 3 "wiring" -

3.1 "voltage supply"

TIME

12345678

delay time before clutch

reversing delay time

delay time after clutch

see chapter 4.4 "gearing"

1234

CTRHEAD

alignment

range / / position comparisionsynchronisation

see chapter 4.2 "control head"

buzzer in neutral

0 12

34

56

789A

BC

DE

F

PARSEL

setting of parameters

seechapter 4.3 "speed"chapter 4.4 "gearing"

!The hardware is configurated by means of the switchboard SYSCON. The positionof 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 inchapter 4.4.By the switches PARSEL (parameter selection), parameters are adjusted as e. g., for mechanicalthrottle control, idle and nominal speed and, for mechanical gear shifting, the gear positions aheadand 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 inchapter 4.2 "control head").

Possibilities of adjusting the I/O-extension board

1234

IOCONF

gears with/without feedback (see chapter 3.4)start interlock/idle gas (see chapter 3.6/3.7)

reserved

1234

4

!The I/O-extension board will only functioncorrectly, if switch 4 is in the position described.

gear feedback double/single (see chapter 3.4)

The switchboard IOCONF (I/O-configuration) defines the function ofthe electrical in-/outputs. They aredescribed in chapter 3 "wiring" in therespective paragraph.

Switch 4 must be in the position asshown here.

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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 becarried out at the portside system. The following steps have to be completed:

Step Action Diagram

1 Activation of the control

2 CTRHEAD switch 1 to close

(With two control units, only the port unit must beadjusted.)

1234

1CTRHEAD

3 Wait 3 seconds

4 CTRHEAD switch 1 to open

(With two control units, only the port unit must beadjusted.)

1234

1CTRHEAD

All control heads connected must be in condition "lamp test" (see chapter 5.2 "activation and requestof control station").

Special case "automatic ID-setting"If automatic ID-setting shall be applied, the software versions stated below must be provided forcontrol unit and heads:

Control unit: MSB V2.00 or higherControl head: MSKG V2.00 or higher

With this feature, it is no longer necessary to define an ID at every control head as the systemassignes IDs automatically to all heads connected.

!After the automatic setting of control head IDs, it is no longer possible to combine control heads with software below V2.00 with heads providing a higher software version.

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Procedure for automatic ID-setting

Step Action Diagram

1 Activate control.

2 Hold down switch S1.

switch S1

3 Shift CTRHEAD switch 1 to close.

1234

1CTRHEAD

4 Do not further operate switch S1.

switch S1

5 The control head buzzers sound at short intervals.

In addition, the control head LEDs are active (see step6) and flash in the same frequency as the buzzer.

6 Press the keys of the control heads one after another.

COMMAND

ALARM

SYNCHRO

key

7 Signals after one keystroke:

The buzzer stops.

The ID which was stored is indicated by the LEDs ofthe control head.

The LEDs flash slowly.

COMMAND

ALARM

SYNCHRO

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ID Indication

8 Shift CTRHEAD switch 1 to open.

1234

1CTRHEAD

Buzzer in neutral

When the lever 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.) 1234

2CTRHEAD

No sound (default condition)

(With two control units, only the port unit must be adjusted.) 1234

2CTRHEAD

Comparision of positions/ cruising ranges

Compare position

A change of control stations is possible only, if the lever of thenew control station is set in the same cruising range (ahead,neutral, astern) and in the same position (maximum deviation30%) as the lever of the active control station. According to theclassification rules, this mode has to be selected.

(With two control units, only the port unit must be adjusted.)

1234

3

CTRHEAD

Compare range

A change of control stations is possible only, if the lever of thenew control station is set either in the same cruising range(ahead, neutral, astern) as the lever of the active control stationor in neutral position.

(With two control units, only the port unit must be adjusted.)

1234

3

CTRHEAD

LED off

LED steadily lighted

LED flashing

no ID assignedno automatic ID set yet

ID 1 ID 2 ID 3 ID 4 ID 5

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Synchronising

Synchronising activeIf the lever positions of the port and starboard control headsdeviate at 10% maximum, the same nominal value will bepreset automatically.

1234

4CTRHEAD

No synchronizing (default condition)

1234

4CTRHEAD

4.3 Speed settingGenerally, the parameters for speed setting can be set when the active control head is in neutralposition. Idle speed, power boost and increased idle speed can also be set when the lever position is1st detent ahead or astern. The nominal speed parameters may also be set when the lever position isfull ahead or full astern.For system configurated with 2 control units (mechanical throttle adjustment and gear shifting) eachunit must be set separately.

Step Action Diagram

1 Initial condition

Activation of control, command active, lever in neutralor 1st detent ahead/astern

1234

1PARSEL

LED Setupoff

Selection of the parameter to be adjusted

Idle speed

PARSEL Turn switch to position 1or

0 12

34

56

789A

BCD

EF

Nominal speedPARSEL Turn switch to position 2

or

0 12

34

56

789A

BCD

EF

Power boostPARSEL Turn switch to position A

0 12

34

56

789A

BCD

EF

2

Increased idle speedPARSEL Turn switch to position B

0 12

34

56

789A

BCD

EF

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Selection of the system for which speedparameters shall be set

for single engines

or twin engines: port system

1234

2PARSEL

3

for twin engines: starboard systemPARSEL

1234

2

!During step 4, it is possible the engine revolutions adjust automatically.

4 Change to SETUP-mode

The selected position will be reached. The LED Setupwill be activated.

1234

1PARSEL

LED Setupon

Adjustment of speed

Direction +

Parameter will be adjusted as long as the key ispushed.

1234

4PARSEL

direction +

5

Direction –

Parameter will be adjusted as long as the key ispushed.

PARSEL

1234

4

direction -

6 Storing of parameter

Change to RUN-mode.LED Setup will be deactivated.

1234

1PARSEL

LED Setupoff

!When modifying the parameters "power boost" or "increased idle speed", themaximum speed for clutch engagement (see instructions of the gearingmanufacturer) must be considered.

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0 12

34

56

789A

BCD

EF

4.4 Gearing

Positions for actuating the mechanical gear shifting

The push-/pull-cables at the actuators must be mounted in such a way thatthe neutral position of the gear system is actuated when the active lever is placed in neutral. Forsystems configurated with 2 control units (mechanical throttle control and gear shifting) each controlunit must be set separately.

!If the gearing is operated mechanically, the positions ahead and astern must bepre-adjusted. When doing so, the engines should be turned off.

The adjustment is possible only with the active control head lever in neutralposition or if the active lever is in the position that corresponds to the gearingposition which shall be adjusted (e. g. lever in ahead if gear position ahead needsto be adjusted).

Step Action Diagram

1 Initial condition

Activation of control, command active, lever in neutralor ahead, if gear position "ahead" has to be adjustedor lever in astern if gear position "astern" needs to beadjusted.

1234

1PARSEL

LED Setupoff

Selection of the parameter to be adjusted

AheadTurn PARSEL-switch to position 4

0 12

34

56

789A

BCD

EF

2

NeutralTurn PARSEL-switch to position 5

AsternTurn PARSEL-switch to position 6

0 12

34

56

789A

BCD

EF

3 Selection of the system for which the parametersfor gear actuation shall be set

for single engines

or twin engines: portside gear system

1234

2PARSEL

for twin engines: starboard gear systemPARSEL

1234

2

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!During step 4, it is possible that the gear position adjusts automatically, the drivingengine should therefore be turned off.

4 Change to SETUP-mode

The selected position will be reached.LED Setup will be activated.

1234

1PARSEL

LED Setupon

Adjusting the gear position

Direction +

Position is adjusted as long as the key is pushed.

1234

4PARSEL

direction +

5

Direction –

Position is adjusted as long as the key is pushed.PARSEL

1234

4

direction -

6 Storing of parameter

Change to RUN-modeLED Setup will be deactivated.

1234

1PARSEL

LED Setupoff

Delay times for gear shiftingThe delay time before clutch engagement must be long enough to ensure that a parameterized speedacceleration (see chapter 4.3 "speed adjustment") can be completed safely. The delay time afterclutch engagement must be long enough to ensure the gearing has shifted safely. (This is important ifthere is no feedback from the gearing.) In case of a feedback signal, the "delay time after clutchengagement" will begin only after the feedback signal has been received. The setting is evaluated onlyby the portside system (for twin engines with mechanical throttle control and gear shifting).

nominal speed

ahead

nominal position gearing

time

time

idle speed

power boost


TIME

12345678






12345678

12345678

12345678

12345678

1 1 1 1

0,0 s 0,5 s 1,0 s 1,5 s


12345678

12345678

12345678

12345678

3 3 3 3

0 s 1 s 2 s 3 s

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Conditions when reversing from ahead to astern:When reversing from ahead to astern, the gearing is at first shifted to neutral, the shaft is disengagedfrom the engine (1). As the ship continues to move ahead, the propeller is driven like a windmill by thewater streaming against it so that the shaft continues to turn. When the gears are then shifted toastern, the engine must work against the shaft which is still turning. In an unfavourable case, theengine might stall.

engine

engine

1 gears neutral

2 gears astern

ship -velocity

ship -veloccity

neutral

astern

shaft speed dependson ship velocity

engine speedshaft speed worksagainst engine speed

To avoid stalling the engine, the control can wait an adjustable time (reversing delay time) beforereversing. 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 mustaccelerate from 1st detent ahead to full ahead. The time, the ship needs to reach 2/3 of its maximumspeed, has to be preset as reversing delay time. Afterwards, reversing maneuvers need to be carriedout covering the full speed range.

!During the reversing maneuvers, start with a slow speed first and increase gently.If necessary, the reversing delay time must be adjusted (lengthened, if the enginerevolutions drop too heavily or shortened if no deceleration of the engine speed isrecognisable.If the reversing delay time is too short, clutch, gearing and engine may bedamaged, if it is too long, the manoeuvrability may be restricted.

nominal speed

ahead

nominal position gears time

time

idle speed

power boost


TIME

12345678




TIME reversing delay time

12345678

5

0 s 1 s 2 s 3 s

astern

4 s 5 s 6 s 7 s 8 s 9 s 10 s 11 s 12 s 13 s 14 s 15 s

For applications with 2 control units, only the portside system must be adjusted.

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4.5 Reset to default

!Resetting to default will reset the speed and gearing control values to theirdelivery status. This procedure is irreversible.A reset to default may be done only if the driving engine is turned off. In case ofmechanical controlling, the push-/pull-cables should be disconnected.

Step Action Diagram

1 Initial condition

Activation of control, command active, lever in neutral1234

1PARSEL

LED Setupoff

2 Selection default set-upPARSEL Turn switch to position E.

0 12

34

56

789A

BCD

EF

Selection of the system to be reset

for single engines

or twin engines: portside system

1234

2PARSEL

3

for twin engines: starboard systemPARSEL

1234

2

4 Change to SET-UP-mode

Default position will be reached.LED set-up will be activated.

1234

1PARSEL

LED Setupon

5 Storing the default set-up

Change to RUN-mode.LED set-up will be deactivated.

1234

1PARSEL

LED Setupoff

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5 Operation5.1 GeneralBy means of the lever position both,speed and gear position, (ahead,neutral, astern) are pre-set.

neutral1. detentahead

1. detentastern

fullahead

fullastern

engagedahead

engagedastern

disengaged

The following elements are available as user interfaces:Keys • Command transfer• Acknowledge alarm-buzzer• Activate special functionsCommand lamps• Indication, if station is active.Alarm lamps• Indication, if an error exists.Lamp synchronizing• Indication, if synchronizing is active.

In case of twin control heads, the LED forcommand and alarm are assigned to therespective propulsion side.

COMMAND

ALARM

SYNCHRO

key

lamp

Command lamp

alarm lamps

In case of several control stations, passive stations must be distinguished from the active one. Acommand can always be set only from the active control station. If a passive control station is to setthe 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.

COMMAND

ALARM

SYNCHRO

passivestation

COMMAND

ALARM

SYNCHRO

activestation

By means of an external switch (see chapter "wiring" - controlhead 3.2), the command transfer can be locked. If this is the case,the alarm lamps at the passive control station will be active.

COMMAND

ALARM

SYNCHRO

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5.2 Activation and request of control stationAfter 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 thekey 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 buzzersound. The lamps flash slowly and the buzzer sounds at slow intervals when the control head lever isnot in neutral position.

By a slow flashing of the command lamp, the control head signals that the lever must be moved inneutral position first. If the levers are already in neutral, the command lamp will flash quickly and thebuzzer sounds at high repetition. The command can be taken over by pressing the key again.

COMMAND

ALARM

SYNCHRO

condition:lamp test

permanent sound

all lamps on permanently

push key

COMMAND

ALARM

SYNCHRO

condition:requestingstation

slow bleeping

COMMAND

ALARM

SYNCHRO

fast bleeping

lever not in neutral lever in neutral

lever in neutralpush key

condition:activestation

COMMAND

ALARM

SYNCHRO

Command lamp on permanently

command lamp flashes slowly Command lamp flashes quickly

all lamps on

As soon as a 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 tothe 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 thecontrol unit. Wiring and ID (see chapter 3.2.) need to be controlled. If necessary, the procedure ofentering the control heads into the system (see chapter 4.2) must be repeated.

If there is no functioning control head, the alarm relay will be activated.

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5.3 Station transferA command transfer is possible in 2 different modes. Which mode is applicable, depends on theposition of switch 3 on the switch board CTRHEAD (see chapter 4.2 control head – comparision ofrange / position). Always, the key on the passive control station must be pushed to change the controlstation.

Mode "compare direction"

push key

COMMAND

ALARM

SYNCHRO

condition:requestingstation

slow bleeping

COMMAND

ALARM

SYNCHRO

fast bleeping

wrong lever position correct lever position

push key

condition:activestation

COMMAND

ALARM

SYNCHRO

Command lamp on permanenly

COMMAND

ALARM

SYNCHRO

condition:passivestation

Command lamp flashes slowly Command lamp flashes quickly

If the lever of the passive control station is placed in a range which is not admissible for commandtransfer (the passive lever in astern when the active one is in ahead or neutral or the passive lever inahead with the active one in astern or neutral), the buzzer will sound at long intervals and thecommand lamps flash at low repetition.

If the lever of the passive control station is in the correct position for a command transfer (the passivelever in ahead or neutral when the active lever is in ahead or the passive lever in astern or neutralwhile the active one is in astern), the buzzer will sound at short intervals and the command lampsflash 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 fromthat 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. Thetransfer 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 thecorrect range is found and the command transfers automatically. If the correct range is not foundwithin 30 seconds, the command transfer will be stopped.

!According to the classification rules, the given cruising command must not changeduring a command transfer. For this reason, classified ships must choose themode "compare position".

Note for twin engines:In case of control heads with two levers, both levers must be placed correctly before the commandcan be transferred. The function of the command lamp is assigned to the respective lever. The buzzerwill only sound at short intervals if both lever positions are correct.

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5.4 Warming upBy 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, thecommand lamp flashes.

COMMAND

ALARM

SYNCHRO

Command lamp flashes

Note for twin engines: The function "warming up" can be activated and deactivated of both sidesseparately. The command lamp is assigned to the respective lever.

5.5 Increased idle speedBy the special function "increased idle speed" a higher idle speed can be selected. This function willbe necessary if the driving engine shall operate a bow thruster in addition and the normal idle speedengine performance is not sufficient therefore.

To turn this function on and off, the key on the active control station must be pushed. The function canbe switched on in neutral only and switched off at any time.

!The function "increased idle speed" is available only if it has been set up before(see chapter 4.3. speed). When this function has been entered, "synchronizing"cannot be deactivated again.

5.6 SynchronisingIf, for twin engine systems, the positions of the port and starboard levers on the active control headdeviate less than 10% from each other in the range of "ahead", the same nominal value (of the portlever) will be set.

If "Synchronising" is active, this will be indicatedby the lamp "Synchro".

COMMAND

ALARM

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 atanother position.

Note for „increased idle speed“: "Synchronizing" cannot be switched off if the function "increased idlespeed" is active.

!The function "Synchronization" is available only if it has been set up before (seechapter 4.2 "control head", synchronizing).

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6 Error analysis6.1 Errors at the control stationTwo errors at the control stations must be distinguished:

COMMAND

ALARM

SYNCHRO

active station

COMMAND

ALARM

SYNCHRO

passive station

Alarm During an alarm, the setting of the cruisingfunctions (speed or gearing) is disturbed. Onthe active control head, the red alarm lamp willbe on and a buzzer will sound. The buzzersignal can be acknowledged and thus switchedoff by pushing the key.

The command lamps indicate if the controlhead is active or passive, i. e. if this station canset commands or not.

Special case:If the active control head is defective, thepassive heads will activate their buzzer and willgo over into the condition "request station".

special case:

COMMAND

ALARM

SYNCHRO

passive station

Command lamp flashes

COMMAND

ALARM

SYNCHRO

active stationWarning In case of a warning, the setting of the cruisingfunction is not disturbed directly. The red alarmlamp will be active, but the buzzer will notsound.

COMMAND

ALARM

SYNCHRO

passive station

For twin engines, the alarm and command lamp are assigned to the respective engine side so thatseveral lamp reactions as described above may combine. The buzzer will be activated as soon as analarm is signaled on one of the engine sides.

Example twin enginePortAlarmStarboardNo Error

The starboard system is error-free and thecontrol head is active. The port system is inalarm condition, no active command exists onthis control station. Cruising commands can nolonger be set from this station.

COMMAND

ALARM

SYNCHRO

In case of an alarm, the alarm relay is activated. In addition, idle speed is set and the gears aredisengaged if the remaining function of the system permit it.

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6.2 Error indication control unit

To indicate errors, 4 error LEDs are availablealtogether. The top LED is red to facilitateorientation.

The operation mode of the control is indicated by2 additional LEDs (RUN, SETUP).By pressing a key, further error messages can bedisplayed.

1

2

3

4

error LED

LED RUN LED SETUP

key

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"

LED off

Red LED 1 steady light

Error type: HARDWARE

Error description: The board of the control unit contains a hardware fault.

1234 Error elimination: Replace board.

Error type: PARAMETER

Error description: Faulty parameter storage of the control unit.

1234

Error elimination: The parameters of the control must be re-set to default (see chapter4.5). 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.

1234

Error elimination: Switch the control on and off. If necessary, replace board of the controlunit.

Error type: CAN

Error description: The CAN-controller reports an error.

1234 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.

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Error type: ACTUATOR 1

Error description: The system is configurated ( see chapter 2) in such a way that actuator1 (see chapter 3.3) directs mechanical gear shifting or speed setting. However, the controlstates an error in the operation of the actuator.

1234

Error elimination: Check the plugs of actuator 1 for correct connection to the board of thecontrol unit (see chapter 3.3).

If necessary, connect actuator 1 to the terminal of actuator 2 on the control unit. If theactuator works perfectly then, the board of the control unit is defective and must bereplaced. If not, replace the actuator.

Error type: ACTUATOR 2

Error description: The system is configurated (see chapter 2) in such a way that actuator2 (see chapter 3.3) directs mechanical gear shifting or speed setting. However, the controlstates an error in the operation of the actuator.

1234

Error elimination: Check the plug of actuator 2 for correct connection to the board of thecontrol unit (see chapter 3.3).

If necessary, connect actuator 2 to the terminal of actuator 2 on the control unit. If theactuator works perfectly then, the board of the control unit is defective and must bereplaced. If not, replace the actuator.

Error type: I/O-CARD 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 I/O-extension board 1.

1234

Error elimination: Check cable between I/O-extension board 1 and the control unit (seechapter 3.4. electrical throttle control / gear shifting, installation of the I/O-extension board).

If necessary replace cable or I/O-extension board.

Error type: I/O-CARD 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.

1234

Error elimination: Check cable between I/O-extension board 2 and 1 or I/O-card 1 and thecontrol unit (see chapter 3.4 electrical throttle control / gear shifting, installation of the I/O-extension board).

If necessary, replace cable or I/O-board.

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Red LED 1 flashing

Error type: SYN-CARD (warning only)

Error description: No extension board for synchronizing found.

1234

Error elimination: Check cable from synchronizing board to board of the control unit (seeinstructions 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.

1234

Error elimination: Check cable to the speed sensor (see instructions attached to thesynchronizing 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.

1234

Error elimination: Check cable to the control head (see chapter 3.2). Control thenecessary bridges (see chapter 3.2). Check LED power supply at the control head (seechapter 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).

1234

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).

1234

Error elimination: Charge battery.

Error type: TEMPERATURE

Error description: The temperature is beyond the admissible range(-25 ... +70 °C).

1234

Error elimination: The control may only be operated within the admissible temperaturerange.

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Error type: TWIN

Error description: The system was configurated for twin engines – mechanical gearshifting and speed setting (chapter 2). The communication between the control units portand starboard does not function.

1234

Error elimination: Check cable between the control units and the necessary bridges (seechapter 3.2 – special application twin engine with mechanical throttle control / gearshifting).

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 (seechapter 2), was adjusted while the system was active. This is not admissible. It may only beadjusted in voltage-free condition. Or, the switchboard was turned to a value which was notadmissible.

1234

Error elimination: If the SYSCON switchboard was misadjusted, it must be reset correctlyaccording to chapter 2. If the change was done on purpose, the control must be switchedon 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 type: TWIN-MASTER

Error description: The SYSCON switchboard is misadjusted for twin engines withmechanical actuation at the starboard system.

1234

Error elimination: Reset the SYSCON switchboard correctly for twin engines withmechanical actuation at the starboard system (see chapter 2).

Error type: TWIN-SLAVE

Error description: The SYSCON switchboard is misadjusted for twin engines withmechanical actuation at the port system.

1234

Error elimination: Reset the SYSCON switchboard for twin engines with mechanicalactuation at the port system (see chapter 2).

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Mode RUN or SETUP (LED RUN or LED SETUP on)

or

Error type: GEAR MASTER

Error description: Gear feedback has been set at the I/O-extension board (see chapter3.4). The gear feedback is not signalled (for twin engines on the port side). The systemworks without gear feedback.

1234

Error elimination: Check pressure sensor at the gearing. Control LEDs on I/O-extensionboard (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.

1234

Error elimination: Check wiring (see chapter 3.2). Check LED power supply at thedefective 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. potentiometererror).

1234

Error elimination: Replace defective control head

Error type: GEAR SLAVE

Error description: Gear feedback has been set at the I/O-extension board (see chapter3.4). The gear feedback on the twin engine at the starboard system is not signaled. Thecontrol works without gear feedback.

1234

Error elimination: Check pressure sensor at the gearing. Control LEDs on the I/Oextension board (LED actual ahead or astern or collective feedback). Check wiring.

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Error type: CTRL-POS

Error description: Before adjusting parameters for speed and gear control, the activecontrol head must be placed in the correct position (see chapter 4.3 or 4.4). It is notpermitted to adjust the parameter in this lever position.

1234

Error elimination: Change to RUN-mode (step 1 in chapter 4.3 or 4.4). Move lever incorrect position then and repeat the adjustment.

Error type: PROCEDURE

Error description: Parameters were set (chapter 4) in incorrect order (e. g. adjustment ofrotary switch PARSEL in SETUP-mode).

1234

Error elimination: Change to RUN-mode (step 1 in chapter 4.3 or 4.4). Move lever incorrect position then and repeat the adjustment.

Error type: ADJUST

Error description: It has been tried to set a parameter (chapter 4) that does not exist at allaccording to the system configuration (chapter 2) (e. g. rpm starboard for a single enginesystem). Or, the rotary switch PARASEL was turned to a value which was not admissible.

1234

Error elimination: Correct setting of switches and rotary switch PARSEL.

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Control Unit – In- and OutputsS

YS

CO

N 1 2 3 4 5 6 7 8

conf

igur

atio

n of

sys

tem

type

(see

cha

pter

2 O

verv

iew

)

adju

stm

ent p

ower

sup

ply

(see

cha

pter

3 W

iring -

3

.1 P

ower

sup

ply)

TIM

E

1 2 3 4 5 6 7 8

dela

y tim

e be

fore

clu

tch

reve

rsin

g d

ela

y tim

e

dela

y tim

e af

ter

clut

ch

(se

e c

ha

pte

r 4

.4 G

ea

rin

g)

1 2 3 4

CT

RH

EA

D

RU

N /

cont

rol h

ead

alig

nmen

t

com

pare

pos

ition

/ co

mpa

re r

ange

off /

syn

chro

niza

tion

on

see

chap

ter

4.2

Con

trol

hea

d

off / bu

zzer

on

in n

eutr

al

01

23 4 5

67

89

ABCD

EF

PA

RS

EL

setti

ng o

f par

amet

ers

see

chap

ter

4.3,

4.4

, 4.5

LED

set

up a

ctiv

e

LED

run

act

ive

LED

rel

ay s

tart

inte

rlock

LED

rel

ay a

larm

fuse

LED

err

or

1 2 3 4

RU

N /

SE

TU

P

- dire

ctio

n s

etup

port

/ st

arbo

ard

key

setu

p

1 i

dle

spee

d2

rat

ed s

peed

4 a

head

6 a

ster

nA

po

wer

boo

stB

in

crea

sed

idle

spe

edE

de

faul

t

01

23 4 5

67

89

ABCD

EF

H4

H6

H8

H5

X4

1

H1

H3

H2

H7

X4

0

X1

X2

2

X5X6X2

1X

11

X3

X4 X5

X1

2

X3

0X

31

S4

S2

S6

S1

S3

S5

41

Gen

eralO

verviewW

iring

Op

eration

Erro

r An

alysisA

pp

end

ixA

dju

stmen

t

Control Unit - Terminals

1 2G

ND

Vc

c

1 2 1 2

4 3 2 12 1 2 1C

AN

-

CA

N

+

CA

N

-

CA

N

+

CA

N

term

ina

l

CA

N

GN

D

head +8

V

head

0 V

al

ar

m

engine start

interlock

actuator 1

actuator 2

Vc

cG

ND

Vc

cG

ND

H4

H6

H8

H5

X4

1

H1

H3

H2

H7

X4

0 X1

X2

2

X5

X6

X2

1X

11

X3

X4

X5

X1

2

X3

0X

31

S4

S2

S6S

1

S3

S5

Rexroth Mecman GmbHBartweg 13D-30453 HannoverPhone: +49 – 5 11 – 21 36 – 0Fax: +49 – 5 11 – 21 36 – 2 69www.boschrexroth.com

Subject to alteration.This edition supersedesall previous ones.Printed in Germany.No part of this edition maybe repro-duced withoutour prior permission.Order no. 883-890-060-3/2003-07/EN

Documents

MarexSB V2 1 EN - ÖZMAR · PDF fileShort Instructions Please do also see the general advice in chapter 1. Step Description 1 Select engine type (chapter 2 "overview") Assembly 2 Adjust