AVENTICS Marex ECS Control Unit Assembly Instructions

Assembly Instructions

R419302112/07.2016, EN

Control Unit

Marex ECS

English

Table of Contents

AVENTICS | ECS Control Unit | R419302112–BDL–001–AA 3

English

Table of Contents

1 About this documentation ............................................ 5

1.1 Validity of the documentation................................................5

1.2 Required and additional documentations..........................5

1.3 Presentation of information...................................................5

1.3.1 Safety messages ..................................................................... 6

1.3.2 Symbols ..................................................................................... 7

1.3.3 Designations ............................................................................. 7

1.3.4 Abbreviations ............................................................................ 8

2 Safety instructions ........................................................ 9

2.1 About this chapter..................................................................... 9

2.2 Intended use................................................................................ 9

2.3 Improper use ............................................................................10

2.4 Personnel qualifications........................................................11

2.5 General safety instructions ..................................................11

2.6 Product- and technology-related safety messages......12

2.7 Operator‘s obligations............................................................13

3 General notes regarding property damages and

product damages ........................................................ 14

4 Scope of delivery ......................................................... 15

5 About this product ....................................................... 16

5.1 Performance description ......................................................16

5.2 Product description ................................................................17

5.3 Product overview.....................................................................19

5.4 Product identification.............................................................20

5.5 Classification.............................................................................21

6 Transport and storage ................................................ 22

6.1 Product transport....................................................................22

6.2 Delivery check ..........................................................................22

6.3 Product storage .......................................................................22

7 Assembly ..................................................................... 23

7.1 Installation conditions and installation site ....................25

7.2 Installing the Marex ECS Control Unit...............................27

7.3 Connecting the Marex ECS Control Unit via the wiring

harness.......................................................................................29

Table of Contents

4 AVENTICS | ECS Control Unit | R419302112–BDL–001–AA

8 Commissioning ............................................................ 33

8.1 Starting the Marex ECS Control Unit up ...........................33

9 Maintenance and repair ............................................. 36

9.1 Cleaning......................................................................................36

9.2 Inspection...................................................................................36

9.3 Maintenance..............................................................................36

10 Disassembly and replacement .................................. 38

11 Disposal ....................................................................... 41

12 Error search and troubleshooting ............................ 42

12.1 Take control or change the control station .....................42

12.2 Alarm signals and acknowledgment.................................43

12.3 Troubleshooting the control head......................................44

12.4 Troubleshooting the actuator ..............................................45

13 Technical data ............................................................. 46

14 Accessories ................................................................. 47

15 Appendix ...................................................................... 49

16 Alphabetical Index ...................................................... 50

About this documentation

AVENTICS | ECS Control Unit | R419302112–BDL–001–AA 5

English

1 About this documentation

1.1 Validity of the documentation

These assembly instructions apply to the following products:

W Marex ECS Control Unit - R4193002110

The Marex ECS Control Unit is part of the Marex ECS ship control

system.

In context which refers to the ship’s direction of thrust, ’forward’

is used as equivalent term for ’ahead’ and ’reverse’ for astern.

These assembly instructions are intended for mechanics and

service technicians.

These assembly instructions contain important information for

properly and safely installing, starting up, operating,

maintaining and dismantling the Marex ECS Control Unit.

Read these assembly instructions completely, especially the

chapter 2, Safety instructions, before working with the product.

1.2 Required and additional documentations

Before powering up the product make sure to read and

understand the necessary documents.

O Observe the instructions for the other system components.

O Observe the boat’s operating instructions.

1.3 Presentation of information

For a quick start and safe operation of the product, consistent

symbols, terms and abbreviations are used and safety

instructions are given in a consistent manner. For easy

Table 1: Required and additional documentations

Title Document No. Document type

Marex ECS R419302113 Quick Guide

About this documentation

6 AVENTICS | ECS Control Unit | R419302112–BDL–001–AA

understanding, explanations are provided in the following

sections.

1.3.1 Safety messages

This documentation includes safety instructions placed before a

sequence of actions during which there is a risk of damage to

persons or property. The precautions described must be

observed.

Safety instructions are structured as follows:

W Warning sign: Draws attention to the risk

W Signal word: Identifies the hazard level

W Type and source of risk: Identifies the type and source of the

hazard

W Consequences: Describes the consequences of non-

observance

W Prevention: Describes how to avert the danger

SIGNAL WORD

Type and source of risk

Consequences

O Precautions

Table 2: Hazard classes according to ANSI Z535.6-2011

Warning sign

Signal word

Meaning

DANGER

Indicates a hazardous situation

which, if not avoided, will result in

death or serious injury.

WARNING

Indicates a hazardous situation

which, if not avoided, could result in

death or serious injury.

About this documentation

AVENTICS | ECS Control Unit | R419302112–BDL–001–AA 7

English

1.3.2 Symbols

The following symbols mark notices which are not relevant to

safety but contain useful knowledge for the proper operation of

the product.

1.3.3 Designations

In this documentation the following designations are used:

CAUTION

Indicates a hazardous situation

which, if not avoided, could result in

minor or moderate injury.

NOTICE

Property damage: The product or the

environment may be damaged.

Table 3: Meaning of symbols

Symbol Meaning

If this information is not observed, the optimal use or

operation of the product cannot be ensured.

O

single, independent step

1.

2.

3.

Numbered instructions:

The numbers indicate the steps which must be executed

in a given order.

Table 2: Hazard classes according to ANSI Z535.6-2011

Warning sign

Signal word

Meaning

About this documentation

8 AVENTICS | ECS Control Unit | R419302112–BDL–001–AA

1.3.4 Abbreviations

The following abbreviations are used in these assembly

instructions:

Table 4: Designations

Designation Meaning

Marex ECS Marex Easy Control System

(electronic ship remot control

system)

MarexLink Wireless network tool to modifiy

the settings of Marex ECS using

mobile devices.

Table 5: Abbreviations

Abbreviaton Meaning

CAN Controller Area Network

Asynchronous serial bus system for the networking

of control units

WLAN Wireless Local Area Network

GL Germanischer Lloyd

Classification society based in Hamburg, Germany

ABYC American Boat and Yacht Council

American association for the development of

standards in boating safety

single Single engine system

twin Twin engine systems

PORT Portside

STBD Starboard

Safety instructions

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English

2 Safety instructions

2.1 About this chapter

The control unit has been manufactured in strict compliance

with the generally accepted rules of technology. However, this

does not exclude the risk of damage to persons or property if the

general safety instructions in this chapter and the safety

instructions in this document are not observed.

O Read these assembly instructions completely and carefully

before starting to operate the Marex ECS Control Unit.

O Keep these assembly instructions in a location where they

are accessible to all users at any time.

O Always include these assembly instructions when passing

the Marex ECS Control Unit on to third parties.

2.2 Intended use

The Marex ECS Control Unit is used to control ship propulsions.

It is suitable for applications on boats, yachts and smaller work

boats and for the installation in the engine room. The MarexECS

Control Unit may only be used in applications with diesel

engines together with the MarexECS-system under the ambient

conditions described in this manual. An emergency stop switch

must be provided on every control station.

You may use the Marex ECS Control Unit as follows:

W to output electric signals for the throttle control of marine

propulsions

W to output electric signals for the control of marine

transmissions

W to collect control signals via the STATION bus cable from the

control heads of Marex ECS

W to transmit control signals via the STATION bus cable to the

mechanical actuators of Marex ECS.

W to transmit control signals via the STATION bus cable to the

electric control units of the corresponding engine control

units.

Safety instructions

10 AVENTICS | ECS Control Unit | R419302112–BDL–001–AA

W The control unit described in this document cannot be

combined with the components of the first generation

MarexECS:

R417002550

R417002400

R419302102

R417002102

R417002103

Intended use includes having fully read and understood this

documentation and especially chapter 2, Safety instructions.

2.3 Improper use

Any use other than as described in "Intended use" is improper

and thus inadmissible.

If, in applications relevant to safety, inappropriate products are

installed or used, unintended operating conditions can be

created in the application which may cause damage to persons

and/or property. Therefore only apply a product within

applications relevant to safety if this kind of use is clearly

specified and permitted in the product's documentation as for

example within explosive areas or in parts of a control system

which are relevant for functional safety.

Unintended use of the product does also include:

W connecting the Marex ECS Control Unit to inadmissible

supply voltage (see chapter 13, Technical data),

W combining the Marex ECS Control Unit with further

components which are not suitable for that purpose,

W exposing the Marex ECS Control Unit to ambient conditions

which are not admissible (see chapter 13, Technical data).

AVENTICS GmbH declines any responsibility for damage

resulting from unintended use. The user of the equipment is

fully responsible for any risk arising from unintended use of the

product.

Safety instructions

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English

2.4 Personnel qualifications

The activities described in these assembly instructions require

basic knowledge of electrics and of the corresponding

terminology. To ensure the safe use of the product, those

activities may only be performed by authorized personnel or by

instructed persons supervised by authorized personnel.

An authorized person is someone who due to his/her expert

training, knowledge and experience including his/her

knowledge of the relevant regulations can assess the assigned

tasks, recognize possible dangers and take appropriate safety

measures. Authorized personnel must comply with the

applicable specialist regulations.

2.5 General safety instructions

W Observe the valid regulations pertaining to accident

prevention and environmental protection.

W Observe the safety instructions and guidelines of the

country in which the product is used.

W Only use AVENTICS products in technically perfect condition.

W Check the product for obvious defects as for example cracks

in the housing or missing screws, caps or sealings.

W Observe all instructions on the Marex ECS Control Unit.

W Persons who install, operate, dismantle or maintain

AVENTICS products must not be under the influence of

alcohol, other drugs or medications which affect the

responsiveness.

W Use only accessories and spare parts approved by

AVENTICS in order to avoid hazards to persons as a

consequence of unsuitable spare parts.

W Observe the technical data and environmental conditions

stated in the product documentation.

W If, in applications relevant to safety, inappropriate products

are installed or used, unintended operating conditions can

be created in the application which may cause damage to

persons and/or property. Therefore only apply a product

within applications relevant to safety if this kind of use is

Safety instructions

12 AVENTICS | ECS Control Unit | R419302112–BDL–001–AA

clearly specified and permitted in the product's

documentation.

W Improper installation and use as well as wrong handling will

invalidate the warranty.

2.6 Product- and technology-related safety

messages

Assembly O Always disconnect the system from the power supply before

assembling the Marex ECS Control Unit, connecting or

disconnecting plugs. Secure the system against being

switched on unintentionally.

O Lay cables in such a way that they cannot be damaged and

nobody can trip over them.

O Before starting the product make sure that terminating

resistors and protective caps on connectors are properly

fixed and undamaged in order to prevent that liquids and

foreign particles penetrate into the product.

Commissioning O Make sure that all electric ports are used or covered. Only

start up products which are fully installed.

Operation O Only allow authorized persons to access the engine control

room.

WARNING

Danger due to failure or malfunction

Failures or malfunctions of the Marex ECS Control Unit can, in

the overall system, cause damage to persons and property.

O Even if no special danger arises from the Marex ECS

Control Unit, you have to consider the impact of failures

or malfunctions of the Marex ECS Control Unit on the

overall system.

Safety instructions

AVENTICS | ECS Control Unit | R419302112–BDL–001–AA 13

English

2.7 Operator‘s obligations

Installation and maintenance work is subject to the country-

specific safety regulations and standards of the application. As

an operator of a ship which shall be equipped with a Marex ECS

Control Unit and further components of a ship remote control

system, you are responsible that

W the product is in technically perfect condition,

W the product is used as intended,

W any staff handling the product has read and understood the

documentation,

W users of the product are trained and instructed,

W the regulations related to safety, accident prevention and

environmental protection are complied with.

General notes regarding property damages and product damages

14 AVENTICS | ECS Control Unit | R419302112–BDL–001–AA

3 General notes regarding

property damages and product

damages

Cleaning O Cover all openings with suitable protective caps to prevent

that cleaning agent penetrates into the system.

O Never use solvents or other aggressive cleaners. Clean the

product only by using a slightly moistened lint-free cloth.

Only use water or mild cleaning agents.

O Never use pressure washers or steam cleaners to clean the

product.

Disposal O Dispose of the product according to national provisions of

your country.

Scope of delivery

AVENTICS | ECS Control Unit | R419302112–BDL–001–AA 15

English

4 Scope of delivery

The standard product delivery includes:

For the assembly:

1 Marex ECS Control Unit R419302110

1 Assembly Instructions R419302112

1 Marex ECS Quick Guide R419302113

2Mounting screws

2Washers

2Hexagon nuts

About this product

16 AVENTICS | ECS Control Unit | R419302112–BDL–001–AA

5 About this product

5.1 Performance description

The Marex ECS Control Unit is used to actuate marine

transmissions and throttles of marine propulsions. The

Marex ECS Control Unit provides in- and outputs to collect,

process and output analog and digital signals.

The following in- and output variables can be processed:

2 analog output signals 0 - 20mA,

2 analog output signals 0 - 10V

2 analog output signals PWM

2 analog input signals (frequency … Hz)

5 digital outputs (high-side-switch)

10 digital outputs (low-side-switch)

10 digital inputs

The type and number of in- and outputs depends on the system

configuration and the related Marex ECS wiring harness.

The Marex ECS Control Unit is designed for the operation

with Marex ECS. Depending on the software some of the

functions which are described in these assembly

instructions may not be supported.

About this product

AVENTICS | ECS Control Unit | R419302112–BDL–001–AA 17

English

5.2 Product description

The Marex ECS Control Unit receives and processes the

operation commands which are set via the Marex ECS control

head(s) and transmits the resulting signals to the ship‘s

propulsion system to control the throttle and transmission

direction.

The Marex ECS Control Unit is connected to the Marex ECS

components by the STATION bus cable which is used for the

data communication between the components.

Between ship propulsion and Marex ECS Control Unit the data

can either be communicated via analog and digital interfaces or

the PROPULSION bus cable.

About this product

18 AVENTICS | ECS Control Unit | R419302112–BDL–001–AA

The following figure shows an example for Marex ECS twin

including these components:

W Marex ECS Control Unit (R419302110)

W Marex ECS twin wiring harness (R419302202)

W Control stations equipped with Control Head Type 500-ECS-

twin (R417002880 or R417002808)

W Actuator 12VDC (R417002894) or 24VDC (R417002895)

Fig. 1: System overview Marex ECS twin (example)

STATION

GEAR

GEAR BOX ENGINE GEAR BOX ENGINE

THROTTLE

AUX

GEAR

THROTTLE

AUX

ALARM

POWER

PROPULSION

About this product

AVENTICS | ECS Control Unit | R419302112–BDL–001–AA 19

English

5.3 Product overview

Fig. 2: Overview Marex ECS Control Unit

1 Pressure equalization membrane

2 Rubber mounts

3 Bushings

4 94-pin socket

5 60-pin socket

1

2

34

5

3

2

About this product

20 AVENTICS | ECS Control Unit | R419302112–BDL–001–AA

5.4 Product identification

Fig. 3: Type plate of Marex ECS Control Unit

Take down the control unit’s serial number in the space

provided on the Marex ECS Quick Guide, chapter 17. The

serial number is your password to access the wireless

MarexLink network if you wish to modify the settings of

your Marex ECS. Refer to the Marex ECS Quick Guide for

more information on MarexLink.

1 Date of manufacture

2 Material number

3 Serial number

4 Software version

1

2

3

4

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AVENTICS Marex ECS Control Unit Assembly Instructions

AVENTICS Marex ECS Control Unit Assembly Instructions

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