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33

General

Overview

Wiring

Operation

Error Analysis

Appendix

Adjustment

6 Error analysis

6.1 Errors at the control station

Two 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 cruising

functions (speed or gearing) is disturbed. On
the active control head, the red alarm lamp will
be on and a buzzer will sound. The buzzer
signal can be acknowledged and thus switched
off by pushing the key.

The command lamps indicate if the control

head is active or passive, i. e. if this station can
set commands or not.

Special case:
If the active control head is defective, the

passive heads will activate their buzzer and will
go over into the condition "request station".

special case:

COMMAND

ALARM

SYNCHRO

passive station

Command lamp flashes

COMMAND
ALARM

SYNCHRO

active station

Warning

In case of a warning, the setting of the cruising
function is not disturbed directly. The red alarm
lamp will be active, but the buzzer will not
sound.

COMMAND
ALARM

SYNCHRO

passive station

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

Example twin engine

Port
Alarm
Starboard
No Error

The starboard system is error-free and the
control head is active. The port system is in
alarm condition, no active command exists on
this control station. Cruising commands can no
longer be set from this station.

COMMAND

ALARM

SYNCHRO

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

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Summary of Contents for Rexroth Marex SB

Page 1: ...Version 2 10 15 07 2003 Manual Marine Marex SB ...

Page 2: ...al 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 c...

Page 3: ...ctrical throttle control gear shifting 11 3 5 Alarm relays 15 3 6 Engine start interlock 16 3 7 Idle gas relay 18 4 Adjustment 4 1 Hardware configuration 19 4 2 Control head 20 4 3 Speed 23 4 4 Gearing 25 4 5 Reset to default 28 5 Operation 5 1 General 29 5 2 Activation and request control station 30 5 3 Station transfer 31 5 4 Warming Up 32 5 5 Increased idle speed 32 5 6 Synchronising 32 6 Error...

Page 4: ...2 1 2 3 4 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 1mm Supply cable Ölflex 100 2 x 2 5mm Throttle cable LIYCY 2 x 0 75mm for electrical throttle control only Gearing cable LIYCY 7 x 1mm for electrical gear shifting only Cable alarm LIYCY 2 x 0 75mm if alarm system is connected Cable start interlock LIYCY 2 x ...

Page 5: ...e installed on every control station independent from the remote control These components are not included in the MAREX SB delivery 1 3 Mounting advice Cables to be connected to the control unit must always be provided with the metallic cable joints supplied The joints are mounted as shown below Mounting work must be done only if the system is in voltage free condition The power supply must be sec...

Page 6: ...operated by mechanical rods 1 2 3 4 5 6 7 8 1 S1 S2 70 mm 100 N 70 mm 100 N shielded cable typeLIYCY 4 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 1 2 3 4 5 6 7 8 1 S1 4 20 mA 70 mm 100 N shielded cable typeLIYCY 4 x 1 mm2 shielded cable typeLIYCY 2 x 0 75 mm2 SYSCON ...

Page 7: ...V signals 1 2 3 4 5 6 7 8 1 A2 70 mm 100 N 24 V shielded cable typeLIYCY 4 x 1 mm2 shielded cable typeLIYCY 7 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 1 2 3 4 5 6 7 8 1 24 V 4 20 mA shielded cable typeLIYCY 4 x 1 mm2 shielded cable typeLIYCY 7 x 1 mm2 shielded cable typeLIYCY 2 x 0 ...

Page 8: ...N shielded cable typeLIYCY 2 4 x 1 mm2 shielded cable typeLIYCY 4 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 1 2 3 4 5 6 7 8 1 A1 A2 70 mm 100 N 70 mm 100 N 4 20 mA 4 20 mA 1 2 port starboard I O extension board 1 actuation rpm port I O extension board 2 actuation rpm star...

Page 9: ...Y 4 x 1 mm2 shielded cable typeLIYCY 7 x 1 mm2 shielded cable typeLIYCY 7 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 1 2 3 4 5 6 7 8 1 1 2 port starboard 24 V 24 V 4 20 mA 4 20 mA I O extension board 1 actuation gearing port actuation rpm port I O extension board 2 actuation gear...

Page 10: ...essure screw preparation connection cable The data cable must be prepared as shown above The cables must not be squeezed when assembling the components after the wiring The sealing of the housing must be fitted correctly to guarantee protection type IP65 1 2 Vcc GND 12V 24V DC 10 A nominal current 30 A peak current acc to Lloyds Register fuse 16A T 1 2 3 4 5 6 7 8 7 1 2 3 4 5 6 7 8 7 1 2 3 4 5 6 7...

Page 11: ...e ID 1 control head port 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 Chapter 4 2 To enter the ID the housing cover must be removed Adjustment ID 1 6 starboard side port side X1 bottom side control head adjustment ID 1 6 LED power supply ok LEDcommunication ok 7 6 5 4 3 2 1 On every control head an individual ID must ...

Page 12: ...line grounded at both ends Terminal Designation Colour 1 0 V white ws 2 8 V brown br 3 CAN yellow gb 4 CAN green gr 5 CAN end 6 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 7 6 5 4 3 2 1 7 6 5 4 3 2 1 7 6 5 4 3 2 1 7 6 5 4 3 2 1 contro...

Page 13: ...e mechanical connection between actuator and lever for throttle adjustment or gear control at the engine is done by push pull cables radial excursion 8 max to all sides 8 5 76 stroke 110 33 max 10 32 UNF 2A 22 1 for half the stroke 170 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...

Page 14: ...4 20 mA galvanically separated max 500 Ohm ECU EDC Engine Control Unit Engine Digital Control shielded cable Typ LIYCY 2 x 0 75 mm2 earthed at both ends geerdet Mounting work may only be carried out if the actuator is idle Risk of injury s hexagone nut counter bearing ball joint When adjusting the traveling range of the actuator stroke it must be ensured that both markings remain visible in the en...

Page 15: ...3 74 75 76 77 78 79 80 81 82 ahead Vcc 2A astern Vcc 2A solenoid valve reversing gearbox screened cable type LIYCY 7 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 1 2 3 4 gear feedback off 1 Indication gear con...

Page 16: ...e switch If inductive loads shall be switched these must be provided with a free wheeling diode If not the digital output may be destroyed Electrical gear shifting with collective feedback 71 72 73 74 75 76 77 78 79 80 81 82 Voraus Vcc 2A Zurück Vcc 2A reversing gearbox screened cable type LIYCY 7 x 1 mm2 grounded at both ends Solenoid valve and pressure switch are not included in the MAREX SB del...

Page 17: ...y shown above is recommended according to the classification rules Alternatively the control unit may supply the voltage for the electrical gear control 1 2 3 4 1 2 3 4 71 72 Vcc GND Vcc GND 1 2 When the control unit supplies the voltage for the electrical gear control the power supply is not protected by fuse In this case the control unit must be protected separately see chapter 3 1 power supply ...

Page 18: ...ion port I O extension board II actuation starboard 1 2 1 2 control unit 3 5 Alarm relays 1 2 max 30 V DC max 0 5 A shielded cable type LIYCY 2 x 0 75 mm2 earthed at both ends LED alarm relay 1 2 potential free relay contact closed in case of error If inductive loads shall be switched these must be provided with a free wheeling diode If not the digital output may be destroyed ...

Page 19: ...max 0 5 A shielded cable type LIYCY earthed at both ends LED start interlock 1 2 potential free relay contact closed when lever in neutral or warming up active engine start interlock via control unit If inductive loads shall be switched these must be provided with a free wheeling diode If not the digital output may be destroyed Wiring I O extension board 1 2 3 4 2 configuration start interlock pot...

Page 20: ...6 7 8 1 A1 A2 port starboard engine engine port starboard shielded cable type LIYCY 2 x 0 75 mm2 shielded cable type LIYCY 2 x 0 75 mm2 Engine start interlock special application 2 Using the function idle gas relay on twin engines 1 2 1 2 3 4 2 configuration idle gas relay port starboard engine engine supply battery Starter battery Starter battery Engine start interlock will be released if both le...

Page 21: ...y function idle gas 1 2 3 4 2 potential free relay contact max 30V DC max 2 A shielded cable type LIYCY 2 x 0 75 mm2 earthed at both ends 71 72 73 74 75 76 77 78 79 80 81 82 LED idle gas 1 2 3 4 closed when lever in neutral or in 1 detent ahead astern If inductive loads shall be switched these must be provided with a free wheeling diode If not the digital output may be destroyed When the function ...

Page 22: ...wiring and 3 1 power supply The switch board TIME defines the delay times for the gear shifting The function is described in chapter 4 4 By the switches PARSEL parameter selection parameters are adjusted as e g for mechanical throttle control idle and nominal speed and for mechanical gear shifting the gear positions ahead and astern In addition parameters for special functions are preset see chapt...

Page 23: ...nds 4 CTRHEAD switch 1 to open With two control units only the port unit must be adjusted 1 2 3 4 1 CTRHEAD All control heads connected must be in condition lamp test see chapter 5 2 activation and request of control station Special case automatic ID setting If automatic ID setting shall be applied the software versions stated below must be provided for control unit and heads Control unit MSB V2 0...

Page 24: ... 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 step 6 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 of the control head The LED...

Page 25: ... is possible only if the lever of the new control station is set in the same cruising range ahead neutral astern and in the same position maximum deviation 30 as the lever of the active control station According to the classification rules this mode has to be selected With two control units only the port unit must be adjusted 1 2 3 4 3 CTRHEAD Compare range A change of control stations is possible...

Page 26: ...astern The nominal speed parameters may also be set when the lever position is full ahead or full astern For system configurated with 2 control units mechanical throttle adjustment and gear shifting each unit must be set separately Step Action Diagram 1 Initial condition Activation of control command active lever in neutral or 1 st detent ahead astern 1 2 3 4 1 PARSEL LED Setup off Selection of th...

Page 27: ...sition will be reached The LED Setup will be activated 1 2 3 4 1 PARSEL LED Setup on Adjustment of speed Direction Parameter will be adjusted as long as the key is pushed 1 2 3 4 4 PARSEL direction 5 Direction Parameter will be adjusted as long as the key is pushed PARSEL 1 2 3 4 4 direction 6 Storing of parameter Change to RUN mode LED Setup will be deactivated 1 2 3 4 1 PARSEL LED Setup off When...

Page 28: ...ver in neutral position or if the active lever is in the position that corresponds to the gearing position which shall be adjusted e g lever in ahead if gear position ahead needs to be adjusted Step Action Diagram 1 Initial condition Activation of control command active lever in neutral or ahead if gear position ahead has to be adjusted or lever in astern if gear position astern needs to be adjust...

Page 29: ...ized speed acceleration see chapter 4 3 speed adjustment can be completed safely The delay time after clutch engagement must be long enough to ensure the gearing has shifted safely This is important if there is no feedback from the gearing In case of a feedback signal the delay time after clutch engagement will begin only after the feedback signal has been received The setting is evaluated only by...

Page 30: ...ng delay time must be determined experimentally during a sea trial For this the ship must accelerate from 1 st detent ahead to full ahead The time the ship needs to reach 2 3 of its maximum speed has to be preset as reversing delay time Afterwards reversing maneuvers need to be carried out covering the full speed range During the reversing maneuvers start with a slow speed first and increase gentl...

Page 31: ...gram 1 Initial condition Activation of control command active lever in neutral 1 2 3 4 1 PARSEL LED Setup off 2 Selection default set up PARSEL Turn switch to position E 0 1 2 3 4 5 6 7 8 9 A B C D E F Selection of the system to be reset for single engines or twin engines portside system 1 2 3 4 2 PARSEL 3 for twin engines starboard system PARSEL 1 2 3 4 2 4 Change to SET UP mode Default position ...

Page 32: ...heads the LED for command and alarm are assigned to the respective 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 A command can always be set only from the active control station If a passive control station is to set the command a change of control station must be carried out be...

Page 33: ...ain COMMAND ALARM SYNCHRO condition lamp test permanent sound all lamps on permanently push key COMMAND ALARM SYNCHRO condition requesting station slow bleeping COMMAND ALARM SYNCHRO fast bleeping lever not in neutral lever in neutral lever in neutral push key condition active station COMMAND ALARM SYNCHRO Command lamp on permanently command lamp flashes slowly Command lamp flashes quickly all lam...

Page 34: ...sive lever in ahead or neutral when the active lever is in ahead or the passive lever in astern or neutral while the active one is in astern the buzzer will sound at short intervals and the command lamps flash at high repetition By pressing the key again the command will be taken over Mode compare position In the mode compare position the position of the passive lever may deviate by 30 maximum fro...

Page 35: ...on and the normal idle speed engine performance is not sufficient therefore To turn this function on and off the key on the active control station must be pushed The function can be switched on in neutral only and switched off at any time 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 b...

Page 36: ...al case COMMAND ALARM SYNCHRO passive station Command lamp flashes COMMAND ALARM SYNCHRO active station Warning In case of a warning the setting of the cruising function is not disturbed directly The red alarm lamp will be active but the buzzer will not sound COMMAND ALARM SYNCHRO passive station For twin engines the alarm and command lamp are assigned to the respective engine side so that several...

Page 37: ... hardware fault 1 2 3 4 Error elimination Replace board Error type PARAMETER Error description Faulty parameter storage of the control unit 1 2 3 4 Error elimination The parameters of the control must be re set to default see chapter 4 5 If afterwards the error is still occuring the board of the control unit must be replaced Error type SOFTWARE Error description The software of the control unit is...

Page 38: ...chapter 3 3 If necessary connect actuator 2 to the terminal of actuator 2 on the control unit If the actuator works perfectly then the board of the control unit is defective and must be replaced If not replace the actuator Error type 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...

Page 39: ...rol unit reports a total failure of the active control head 1 2 3 4 Error elimination Check cable to the control head see chapter 3 2 Control the necessary bridges see chapter 3 2 Check LED power supply at the control head see chapter 3 2 Check ID see chapter 3 2 If necessary replace control head Error type ACT CTR HW Error description The hardware of the previous active control head reports an er...

Page 40: ...as turned to a value which was not admissible 1 2 3 4 Error elimination If the SYSCON switchboard was misadjusted it must be reset correctly according to chapter 2 If the change was done on purpose the control must be switched on and off before the alteration can become effective In addition warnings can be issued In case of warnings the red error LED 1 will not be activated Furthermore in case of...

Page 41: ... total failure of a passive control head 1 2 3 4 Error elimination Check wiring see chapter 3 2 Check LED power supply at the defective passive control head If necessary replace control head Error type PAS CTRL HW Error description The hardware of a passive control head is defective e g potentiometer error 1 2 3 4 Error elimination Replace defective control head Error type GEAR SLAVE Error descrip...

Page 42: ...adjustment Error type PROCEDURE Error description Parameters were set chapter 4 in incorrect order e g adjustment of rotary switch PARSEL in SETUP mode 1 2 3 4 Error elimination Change to RUN mode step 1 in chapter 4 3 or 4 4 Move lever in correct position then and repeat the adjustment Error type ADJUST Error description It has been tried to set a parameter chapter 4 that does not exist at all ac...

Page 43: ...ntrol head alignment compare position compare range off synchronization on see chapter 4 2 Control head off buzzer on in neutral 0 1 2 3 4 5 6 7 8 9 A B C D E F PARSEL setting of parameters see chapter 4 3 4 4 4 5 LED setup active LED run active LED relay start interlock LED relay alarm fuse LED error 1 2 3 4 RUN SETUP direction setup port starboard key setup 1 idle speed 2 rated speed 4 ahead 6 a...

Page 44: ...1 2 G N D V c c 1 2 1 2 4 3 2 1 2 1 2 1 C A N C A N C A N C A N C A N C A N h e a d h e a d a l a r m engine start a c t u a t o r 1 a c t u a t o r V c c GND V c c GND H 4 H 6 H 8 H 5 X 4 1 H 1 H 3 H 2 H 7 X 4 0 X 1 X 2 2 X 5 X 6 X 2 1 X 1 1 X 3 X 4 X 5 X 1 2 X 3 0 X 3 1 S 4 S 2 S 6 S 1 S 3 S 5 ...

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Page 48: ...one 49 5 11 21 36 0 Fax 49 5 11 21 36 2 69 www boschrexroth com Subject to alteration This edition supersedes all previous ones Printed in Germany No part of this edition may be repro duced without our prior permission Order no 883 890 060 3 2003 07 EN ...

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