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Aventics Marex ECS, Assembly Instructions Manual, Page: 2 / 60

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Summary of Contents for Marex ECS

Page 1: ...Assembly Instructions R417002911 07 2016 Actuator 12VDC 24VDC Marex ECS English ...

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Page 3: ...nel qualifications 9 2 5 General safety instructions 10 2 6 Product and technology related safety messages 11 2 7 Operator s obligations 11 3 General notes regarding property damages and product damages 12 4 Scope of delivery 13 5 About this product 14 5 1 Performance description 14 5 2 Product description 14 5 2 1 Characteristics and features 14 5 3 Marex ECS Actuator product view 15 5 3 1 Overvi...

Page 4: ...cal connection 29 8 Commissioning 30 8 1 Switches and LEDs 30 8 2 Setting the actuator s function 31 8 3 Starting the auto configuration 33 8 4 Connecting the push pull cable 37 8 5 Setting up the actuator for the gear control 41 8 6 Setting up the actuator for the throttle control 42 9 Maintenance and repair 44 9 1 Cleaning 44 9 2 Inspection 44 9 3 Maintenance 44 10 Disassembly and replacement 45...

Page 5: ...ese assembly instructions are intended for mechanics and service technicians These assembly instructions contain important information for properly and safely installing starting up maintaining and dismantling the Marex ECS Actuator Read these assembly instructions completely especially the chapter 2 Safety instructions before working with the product 1 2 Required and additional documentations Bef...

Page 6: ...ges 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 hazard Identifies the type and source of the hazard W C...

Page 7: ...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 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 thi...

Page 8: ...ectronic ship remote control system MarexLink Wireless network tool to modifiy the settings of Marex ECS using mobile devices Table 5 Abbreviations Abbreviation 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 single Single engine system twin ...

Page 9: ...y time O Always include these assembly instructions when passing the control head on to third parties 2 2 Intended use The Marex ECS Actuator is used to control ship propulsion systems It is designed for the application in the engine control room power generation distribution area of small boats yachts or small commercial vessels It may be used with diesel engines only The Marex ECS Actuator may o...

Page 10: ...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 Actuator to inadmissible supply voltage see chapter 13 Technical data W combining the Marex ECS Actuator with further components which are not suitable for that purpose W exposing the Marex ECS Actuator to ambient ...

Page 11: ...untry 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 You must not modify or convert the Marex ECS Actuator W Persons who install operate dismantle or maintain AVENTICS products must not be under the influence of alcohol other drugs or medicat...

Page 12: ...nt that liquids and foreign particles penetrate into the product Commissioning W Make sure that all electric ports are used or covered Only start up products which are fully installed Operation W Only allow authorized persons to access the engine control room 2 7 Operator s obligations Installation and maintenance work is subject to the country specific safety regulations and standards of the appl...

Page 13: ...ings with suitable protective caps to prevent that cleaning agent penetrates into the system 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 Never use pressure washers or steam cleaners to clean the product Disposal Dispose of the product according to national provisions of your country ...

Page 14: ...2V DC R417002894 or 1 Marex ECS Actuator 24V DC R417002895 W Assembly instructions W 1 Mounting kit including the following items 1 Ball joint 1 Clamp 2 Cheese head screws M5x12 wrench size 4 1 Cheese head screw M6x16 wrench size 5 1 Washer Ø 6 4mm 1 Spring washer Ø 6 4mm 3 Hexagon screws M8x45 wrench size13 3 Washers Ø 8 4 3 Hexagon nuts M8 wrench size 13 ...

Page 15: ...travel of 76 mm In addition the lever of the Marex ECS Actuator can be used as an emergency handle The Marex ECS Actuator 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 Refer to the operating instructions of the complete system for the available functions before starting Marex ECS ...

Page 16: ...ew 5 3 1 Overview on operating elements The following figure shows the operating and indicating elements of the Marex ECS Actuator which are located under the transparent cover 5 1 Lever 2 Ball joint 3 Push Pull cable not included in delivery 4 Clamp 5 Transparent cover 6 2 PROPULSION bus M12 connectors male 7 Power jack 8 Grounding screw 9 Mounting screw M8 with nut and washer included in deliver...

Page 17: ...ation on its state of operation Each LED has three modes of operation which are combined to form a visual signal In this document the LED modes are illustrated by the following symbols 10 Rotary coding switch 11 Device status LED green 12 Device status LED red 13 Push button S3 14 Slide switch S2 Table 6 LEDs Modes of operation Symbol Meaning LED is off LED flashes LED is permanently on 10 11 12 1...

Page 18: ...er 2 Test Requirements for Electrical Electronic Equipment and Systems Edition 09 2012 W Environmental Category D DIN EN ISO 25197 W Kleine Wasserfahrzeuge Elektrische elektronische Regelsysteme für Steuerung Schaltung und Antrieb Ausgabe 03 2015 Regulations of American Boat and Yacht Council ABYC W ABYC Standard P24 Electric Electronic Propulsion Control Systems issue 2007 1 QR code 2 Material nu...

Page 19: ...ubmit a claim 6 3 Product storage O Do not destroy the packaging and only remove it shortly before installation O Adhere to the following conditions for storage Only store Marex ECS Actuator in its original packaging Do not store packages outside Store the packages in a dry and dust free place Do not expose the packages to aggressive media NOTICE Damage due to improper transport Improper transport...

Page 20: ...storage AVENTICS ECS Actuator R417002911 BDL 001 AA 19 English Protect the packages against solar radiation O Observe the admissible ambient temperature of 248 to 350K 25 C to 77 C see also chapter 13 Technical data ...

Page 21: ...sh pull cable as little as possible when connecting it to the adjusting lever of the throttle or gearbox NOTICE Property damage due to improper installation or mounting work Improper installation can cause damage to property O The Marex ECS Actuator may only be installed by AVENTICS or qualified personnel as specified in chapter 2 4 O Install or uninstall the Marex ECS Actuator only if the compone...

Page 22: ...f the power supply may be 5m away at maximum 10m with 24 V systems Even under full load of all consumers connected the power at the connection point must not fall below 25 Prepare the assembly of the Marex ECS Actuator 1 Make sure that all Marex ECS components are powered off before installing the Marex ECS Actuator Table 7 Max cable lengths Power 12V 5m max Power 24V 10m max Propulsion 250m max t...

Page 23: ...ng template which is included in the delivery to determine the exact position of the bores Fig 5 Drilling template of Marex ECS Actuator 3 Mount the Marex ECS Actuator to the wall or ceiling of the engine room fig 4 using the mounting material supplied and applying the recommended tightening torque fig 6 7 2 283 mm 123 mm ...

Page 24: ...Assembly AVENTICS ECS Actuator R417002911 BDL 001 AA 23 English Fig 6 Mounting the Marex ECS Actuator M8 10 Nm GND M8 10 Nm M8 10 Nm POWER PROPULSION BUS ...

Page 25: ... following figure shows the cable connections of the Marex ECS Actuator Before the start of operation the electrical connections to the MarexECS control unit the power supply and to other actuators must be established Fig 7 Cable connections at the Marex ECS Actuator PROPULSION push pull cable PROPULSION ...

Page 26: ...ctions Fig 8 Sockets and grounding screw 8 6 7 Table 8 Type and function of sockets and screw Socket Type Description Connection required Function 6 5 pin male M12 PROPULSION bus yes connect PROPULSION cable or connect an optional Marex ECS Actuator or apply terminating resistor 7 3 pin male superseal POWER yes power supply 8 screw GROUNDING yes connect grounding cable ...

Page 27: ...Plug the PROPULSION cable into one of the sockets 6 fig 8 of the Marex ECS Actuator 3 Connect the other end of the PROPULSION cable to one of the PROPULSION plugs on the Marex ECS Wiring Harness Further Marex ECS Actuators are either connected to the second PROPULSION plug on the wiring harness or plugged into the second socket 6 fig 8 of the of the preceding Marex ECS Actuator 4 If your system in...

Page 28: ... resistor 7 2 3 Connecting the power supply You can connect the MarexECS Actuator either to one or two batteries dual battery operation Different cables are available for every option see chapter 18 Connecting a second battery is a safety measure by means of which the power supply can be switched over to a second battery if the first one is too low to operate the actuator The dual battery power ca...

Page 29: ...with the higher voltage available Fig 9 Marex ECS POWER cable for one battery R419801567 5m R419801316 10m suitable only for 24 VDC Fig 10 Marex ECS POWER cable for dual battery R419801568 5m R419801522 10m suitable only for 24VDC Fig 11 Power cables options one or two batteries POWER COMMON GND 1 2 1 2 POWER 1 2 ...

Page 30: ...e grounding screw of the actuator 8 fig 8 and to a grounding screw of the ship Proceed in the same way to connect other actuators if applicable The electrical connections are then complete 7 3 Mechanical connection Before providing the mechanical connection via the push pull cable the function of the actuator gearbox throttle control and the automatic configuration auto config must be carried out ...

Page 31: ...operation Marex ECS features auto configuration auto config to facilitate this process However the actuator s function must be set before starting the Marex ECS autoconfig Make sure to set the actuator s function before starting the Marex ECS auto config see 8 1 step 5 8 1 Switches and LEDs The actuator provides three switches and two LEDs for the settings and operational status indication These a...

Page 32: ...st be stored teach in Always perform the following steps if you have installed a new Marex ECS if you have replaced an actuator if you have enhanced the system and added another actuator if you have removed and reinstalled an actuator 1 Power Marex ECS completely off 15 14 13 10 11 15 12 10 Rotary coding switch S1 define function 11 Device status LED green 12 Device status LED red 13 Switch S3 sto...

Page 33: ... Turn the cover sideways 5 Turn the rotary coding switch S1 10 fig 12 to define the actuator s function Refer to table 10 for information on the functions See also the actuator s type plate as shown in fig 3 Table 10 Rotary coding switch S1 settings No Function 0 No Function delivery state 1 SINGLE throttle TWIN throttle portside 2 SINGLE gear TWIN gear portside 3 Alternative 4 Alternative 5 SINGL...

Page 34: ...tion must be assigned to every actuator The rotary coding switches S1 must be set to different figures 8 3 Starting the auto configuration Auto config Marex ECS features automatic configuration auto config Only few steps are required to log on and configure components Always perform those steps W if you have installed a new Marex ECS W if you have replaced a control head W if you have enhanced the...

Page 35: ...Commissioning 34 AVENTICS ECS Actuator R417002911 BDL 001 AA head W if you have removed and reinstalled a control head Fig 14 Marex ECS Wiring Harness with auto config connector ...

Page 36: ...Assembly 3 Disconnect the auto config plug from the Marex ECS Wiring Harness as shown in fig 15 Fig 15 Disconnect the auto config plug 4 Switch the power supply on The auto config is running The process may take a few minutes The control head is being registered and configured with standard settings The device status LEDs flash alternately red and green on all Marex ECS components When the LEDs fl...

Page 37: ...h to modify settings you can now make the necessary changes using the wireless MarexLink network Refer to the MarexECS QuickGuide for further information see chapter 1 2 Required and additional documentations 6 Test all system functions first at standstill Verify if the levers of all actuators connected move corresponding to the functions which have been set The commissioning is completed if all f...

Page 38: ...of cable Please note the push pull cables are not included in the delivery see also chapter 14 Accessories Proceed as follows 1 Select the lever at the throttle or gearbox which shall be connected first 2 Check if it is already prepared for the connection of a push pull cable If not a mounting kit is available including ball joint and mounting material 3236990062 Connect the push pull cable follow...

Page 39: ...nd insert the ball joint into the ball on the adjusting lever 6 Make sure that the adjusting lever with the push pull cable can move over the complete range without any obstructions Now mount the other end of the push pull cable on the corresponding MarexECS Actuator Make sure to use the shortest possible way and avoid bends when routing the cable Be aware that the efficiency of the push pull cabl...

Page 40: ... gearbox a stroke smaller than 51mm is required For a longer stroke use the other threaded hole fig 18 17 Fig 18 Marex ECS Actuator with lever and mounting bores for the ball joint 8 Screw the ball joint onto the push pull cable fix the jacket of the push pull cable to the counter bearing of the MarexECS Actuator by means of the clamp and insert the ball joint onto the ball on the lever fig 19 16 ...

Page 41: ... later at your choice 10 If the stroke of the MarexECS Actuator is not sufficient to adjust the lever on gearbox or throttle reduce the stroke required by relocating the fixation point on the adjusting lever of throttle or gearbox in the direction of the pivoting point You have established all connections which are necessary for the operation of the MarexECS Actuator O Proceed accordingly with the...

Page 42: ...switch S2 14 to ON The red and green LEDs flash 4 Reattach the ball joint on the ball bearing on the actuator fig 19 and move the lever of the actuator manually so that the adjusting lever of the gearbox is in the FORWARD position 5 Push switch S3 to confirm the setting The red and greed LEDs stay on for a short time The position is stored 6 Move the lever of the actuator manually so that the adju...

Page 43: ...for the throttle control Proceed as follows to store the positions which the actuator s lever shall approach teach in It is essential that you store the positions in the order given in the following instructions 1 Detach the ball joint from the ball bearing on the actuator fig 19 in order to avoid unintended hitting against the end positions 2 Switch the power supply on 3 Set the slide switch S2 1...

Page 44: ...red and green LEDs stay on for a short time The position is stored 8 Set switch S2 to OFF The teach in process is complete The actuator is ready for use now The red LED is off The green LED is permanently illuminated 9 With twin engines proceed accordingly with the second actuator for the throttle control Assembly setting and commissioning of the MarexECS Actuator are now complete O Test all syste...

Page 45: ...egularly for visual damage Make sure all connectors fit securely 9 3 Maintenance The Marex ECS Actuator does not require maintenance Notice Do not attempt to repair a damaged actuator yourself In case of defects always replace the complete actuator NOTICE Product damage due to inappropriate cleaning Cleaning agents containing solvents may damage the product s surface and cause premature aging O Do...

Page 46: ...rex ECS Actuator 6 If applicable install a new Marex ECS Actuator by following the steps described in chapter 7 Assembly CAUTION Injury hazard and material damage due to unmaneuverable boat If you dismantle or replace the Marex ECS Actuator while the boat is in motion the ability to steer may be lost O Only dismantle the actuator if the boat is not in operation NOTICE Material damage due to applie...

Page 47: ...ble way NOTICE Environmental damage due to improper disposal Electronic components require special waste treatment and must only be disposed of by approved specialist companies O Dispose of electronic scrap in an environmentally sound way Consult the responsible local authorities regarding the environmentally sound disposal ...

Page 48: ...roceed as described in chapters 7 and 8 and repeat the Marex ECS auto config 8 1 This actuator works fine but another actuator may be affected Check the function of all other actuators if available Refer to the instructions in this table The actuator has stopped working due to overload Check manually if the actuator s adjusting lever can move freely by pulling the push pull cable Eliminate the cau...

Page 49: ...range for the actuator Table 12 Admissible power range O Check if the polarity is correct O Check if appropriate functioning fuses are installed Table 13 Fuses If after verifying power cables connectors and battery voltage you cannot identify the failure refer to www marex shipcontrols com for further information and support MarexECS Actuator 12 VDC 9 31 2V MarexECS Actuator 24VDC 18 31 2V MarexEC...

Page 50: ...ical current consumption 6A 12V 3A 24V Maximum current consumption 12A 12V 6 A 24V Rated stroke 76mm 3 inch Rated force 150N Temporary force max 180N Admissible ambient temperature 248 to 350K 25 C to 77 C Admissible storage temperature 233K to 358K 40 C to 85 C Protection class IP 65 EN 60529 IEC 60529 Vibration resistance IEC 60068 2 6 Range 2 13 Hz 1 6mm Range 13 100 Hz 4g Shock resistance 10g ...

Page 51: ... 4 20 mA 20m R419801321 THROTTLE control cable 0 5V 10m R419801322 THROTTLE control cable 0 5V 20m R419801323 THROTTLE control cable PWM 10m R419801324 THROTTLE control cable PWM 20m R419801325 AUX control cable start interlock contact safety stop high idle 10m R419801344 AUX control cable start interlock contact 10m R419801345 ALARM control cable alarm and monitoring system interface 10m R4198013...

Page 52: ...500 ECS single chrome plated R417002881 Control head type 500 ECS twin chrome plated R417002880 Control head type 500 ECS single black R417002810 Control head type 500 ECS twin black R417002808 Control unit Marex ECS control unit R419302110 Terminating resistor Bus terminating resistor 8941054274 Actuator Marex ECS actuator 12 V DC R417002894 Marex ECS actuator 24 V DC R417002895 Part Material No ...

Page 53: ...Appendix 52 AVENTICS ECS Actuator R417002911 BDL 001 AA 15 Appendix 15 1 Installation drawings Fig 20 Installation drawing Marex ECS Actuator R417002102 and R417002103 ...

Page 54: ...breakers 29 Classification 17 Germanischer Lloyd 17 Cleaning 12 44 Commissioning 30 Define actuator function 31 Safety instructions 11 Settings S1 32 Store lever positions 41 Teach in 41 Connect actuator 24 Connect power supply 27 Connect push pull cable 30 Control unit 51 W D Define function 31 Delivery Scope 13 Delivery check 18 Description actuator 14 Designations 6 Dimensions 49 Disassembly 45...

Page 55: ...n 14 Marex ECS Actuator identifcation 17 Marex ECS Actuator overview 15 Marex ECS auto config 30 Material and product da mage notes 12 Mechanical connection 30 Mounting actuator 23 W O Operating elements 15 Operation safety instructions 11 Operator s obligations 11 Overview mounting the actuator 23 W P Performance description 14 Personnel qualification 9 POWER cable one battery 28 POWER cables 50 ...

Page 56: ...gy related 11 Scope of delivery 13 Set function S1 32 Settings rotary switch S1 32 STATION PROPULSION bus cables 50 Storage temperature 49 Stroke rated 49 Supply voltage 49 W T Teach in 41 Technical data 49 Temperature Ambient 49 Storage 49 Terminating resistor 51 Transport 18 Troubleshooting 47 Type plate 17 W U Use Improper 9 Intended 8 W V Validity of documentation 4 View product 15 W W Weight ...

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Page 60: ...m the obligation of own judgement and verification It must be remembered that our products are subject to a natural process of wear and aging An example configuration is depicted on the title page The delivered product may thus vary from that in the illustration Translation of the original operating instructions The original operating instructions were created in the German language R417002911 BDL...

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