Bosch Rexroth Marex SB User Manual
Marex SB
Manual / Marine
Version 2.10
15.07.2003
Short Instructions
Please 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")
- Wire components and adjust switches
3
- Power supply (chapter 3.1)
- Control head (chapter 3.2)
Attention: Enter the control head ID and write it down.
- Throttle and gear control ("mechanical" chapter 3.3, "electrical" chapter 3.4)
- Extra functions if necessary (alarm, engine start interlock, idle speed relay, chapter 3.5
ff.)
Commissioning
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 or
copied either in part or whole, nor may they be used for evaluation or distributed for
competition purposes.
The diagrams and drawings used in this manual are for guidelines only and are not be
used for the actual design.
This edition supersedes all previous ones.
Order No.: 883 890 060 3
Bosch Rexroth AG
Department Marine Technique
Bartweg 13
30453 Hannover
P. O. Box 91 07 62
30427 Hannover
Tel.: +49 (0)5 11-2136-2 51
Fax.: +49 (0)5 11-2136-1 62
e-mail: marinesales@boschrexroth.de
Internet: http://www.boschrexroth.de
Table of Contents
Page
1 General 1.1 System components 1
1.2 General preconditions for the operation 2
1.3 Mounting advice 2
1.4 Operating advice 2
2 Overview 2.1 Single engine 3
2.2 Twin engine 5
3 Wiring 3.1 Voltage supply 7
3.2 Control head 7
3.3 Mechanical throttle control / gear shifting 10
3.4 Electrical 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 analysis 6.1 Error at control station 33
6.2 Error indication control panel 34
Appendix Control unit 40
General
1
1 General
1.1 System components
Designation Code No. Photo
Control head
(single engine)
Overview Wiring Operation Error Analysis
Control head
(twin engine)
Control unit 346 068 000 0
Adjustment
DC actuator 323 698 020 0
Symbol
362 241 100 0
362 241 000 0
I/O-extension board 346 068 721 2
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 1mm²
Supply cable Ölflex 100 2 x 2,5mm²
Throttle cable LIYCY 2 x 0,75mm² for electrical throttle control only
Gearing cable LIYCY 7 x 1mm² for electrical gear shifting only
Appendix
Cable alarm LIYCY 2 x 0,75mm² if alarm system is connected
Cable start interlock LIYCY 2 x 0,75mm² if engine start interlock is connected
Cable idle gas LIYCY 2 x 0,75mm² if idle gas is connected
1
2
3
4
2
1.2 General preconditions for the operation
(According to classification rules)
Indication of the current cruising command*
The current cruising command (speed, gearing position) must be indicated on every control station.
Indication of active control station*
It must be indicated on every control station which control station is in command.
If, from any control station, any other station is visible, the indication of current cruising command and
active control station is not necessary (e. g. on small 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 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:
GeneralOverviewWiringAdjustment
shielded cable
sleeving
conductors
outside cone Inserted sealing
Mounting work must be done only if the system is in voltage-free condition. The power supply must be
secured against activation in this case.
Mounting and commissioning work must be carried out by skilled personnel and in accordance with
the manual only.
pressure screw
cable
1.4 Operating advice
Do not reach into the actuator while it is in operation. You risk injuring.
The remote control MAREX SB has been designed for the control of Diesel engines. If it is applied for
petrol or gas propulsion systems, its components must be installed outside the hazardous area. The
instructions for hazardous areas have to be followed.
Operation
Error AnalysisAppendix
2 Overview
2
2
General Overview Wiring Operation Error Analysis
2.1 Single engine
Single engine – mechanical throttle control and gear shifting
Throttle and gear shifting are operated by mechanical rods.
shielded cable
type LIYCY
4 x 1 mm
3
1
1
SYSCON
2
3
4
5
6
7
8
S1 S2
Adjustment
Single engine - electrical throttle control, mechanical gear shifting
The throttle is adjusted electrically (4 ... 20 mA), the gears are shifted by mechanical rods.
shielded cable
type LIYCY
4 x 1 mm
S1
70 mm
100 N
1
1
2
3
4
5
6
7
8
SYSCON
70 mm
100 N
4...20 mA
shielded cable
type LIYCY
2 x 0,75 mm
2
Appendix
70 mm
100 N
4
2
Single engine - mechanical throttle control, electrical gear shifting
Throttle is actuated by mechanical rods, gear shifting is controlled by 24 V-signals.
1
1
SYSCON
2
3
4
5
6
7
8
shielded cable
type LIYCY
4 x 1 mm
2
A2
General
OverviewWiringAdjustmentOperationError AnalysisAppendix
shielded cable
type LIYCY
7 x 1 mm
2
70 mm
100 N
24 V
Single engine – electrical throttle control and gear shifting
Throttle is adjusted electrically (4 ... 20 mA), the gears are shifted using 24 V-signals.
1
1
SYSCON
2
3
4
5
6
7
8
shielded cable
type LIYCY
4 x 1 mm
shielded cable
shielded cable
type LIYCY
7 x 1 mm
type LIYCY
2 x 0,75 mm
4...20 mA
2
2
24 V
2.2 Twin engine
5
General
Twin engine – mechanical throttle control, mechanical gear shifting
Throttle and gear shifting are controlled by mechanical rods.
Overview
shielded
type LIYCY
4 x 1 mm
Wiring
Adjustment
cable
1
1
SYSCON SYSCON
2
3
4
5
6
7
8
2
A1 A2
70 mm
100 N
port starboard
70 mm
100 N
1
1
2
3
4
5
6
7
8
A1 A2
shielded cable
type LIYCY
2 (4) x 1 mm
70 mm
100 N
2
70 mm
100 N
Twin engine – electrical throttle control, mechanical gear shifting
Throttle is actuated electrically (4 ... 20 mA), the gears are shifted by mechanical rods.
Operation
Error Analysis
Appendix
shielded
cable
type LIYCY
4 x 1 mm
1
1
SYSCON
2
3
4
5
6
7
8
2
A1 A2
70 mm
100 N
I/O-extension board 1:
actuation rpm port
I/O-extension board 2:
actuation rpm starboard
port
1
2
4...20 mA 4...20 mA
2
shielded cable
type LIYCY
2 x 0,75 mm
shielded cable
type LIYCY
2 x 0,75 mm
starboard
2
70 mm
100 N
6
Twin engine – mechanical throttle control, electrical gear shifting
Throttle is adjusted by means of mechanical rods, gear shifting is controlled by 24 V-signals.
1
I/O-extension board 1:
actuation gearing port
I/O-extension board 2:
actuation gearing starboard
shielded
cable
type LIYCY
4 x 1 mm
1
SYSCON
2
3
4
5
6
7
8
2
A1 A2
port starboard
General
1
2
70 mm
100 N
70 mm
100 N
24 V 24 V
shielded cable
type LIYCY
2
7 x 1 mm
shielded cable
type LIYCY
7 x 1 mm
2
Twin engine – electrical throttle control, gear shifting electrical
Throttle is adjusted electrically (4 ... 20 mA), gear shifting is operated by 24V-signals.
shielded
cable
type LIYCY
4 x 1 mm
1
1
SYSCON
2
3
4
5
6
7
8
2
port starboard
I/O-extension board 1:
actuation gearing port
actuation rpm port
I/O-extension board 2:
actuation gearing starboard
actuation rpm starboard
OverviewWiringAdjustmentOperationError AnalysisAppendix
shielded cable
type LIYCY
2 x 0,75 mm
1
2
4...20 mA 4...20 mA
shielded cable
2
type LIYCY
2 x 0,75 mm
2
24 V 24 V
shielded cable
type LIYCY
2
7 x 1 mm
shielded cable
type LIYCY
7 x 1 mm
2
3 Wiring
7
General
3.1 Voltage supply
Overview
LED -
Wiring
readyness
Adjustment
fuse
10A T
voltage
12...24 V DC
7
1
2
3
4
5
6
7
8
voltage
12 V DC
voltage
24 V DC
7
1
2
3
4
5
6
7
8
2
1
7
1
2
switch for configuration
3
of engine type
4
(see chapter 2 overview)
5
6
7
8
supply line 2,5mm2,
length. 10m max
GND
screened
Vcc
fuse
16A T
earthing at one of the 4 mounting screws directly
(connection to ship mass)
main
switch
+
-
12V / 24V DC
10 A nominal current
30 A peak current
(acc. to Lloyds Register)
For systems approved by classification societies, the voltage range 12V or has to
be selected. If the supply voltage exceeds or falls below the range by +30% or -
!
25% respectively, a corresponding error message will be issued.
3.2 Control head
Advice how to mount the connecting cable
Operation
Error Analysis
loosen screws and
lift housing cover
Appendix
preparation
connection cable
100 mm
male
taper
shieldedcable
sleeving
sealing
insert
pressure
screw
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.
8
Adjustment
ID (1...6)
bottom side control head
adjustment
ID (1...6)
LED
power supply
ok
LED
communication
ok
On every control head, an individual
once.
Entering the identification (ID)
To enable the control to identify the control heads, an individual ID must be
!
To enter the ID, the housing cover must be removed.
entered once at every control head (e. g. control head bridge 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)
General
OverviewWiring
starboard side
X1
7
6
5
4
3
2
1
port side
ID must be entered
ID 0 is not admissible.
Adjustment
!
OperationError AnalysisAppendix
Wiring control head
9
General
Overview
Wiring
Terminal assignment control head
Adjustment
!
gb
gr
br
ws
screened line
grounded at both ends
1
2
1
2
3
4
1
2
The IDs of the control heads
must be different.
control head
7
6
5
gr
4
gb
3
br
2
ws
1
ID 1
optional switch: station tranfer interlock
(required for ECR stations according to classification rules)
gr
gb
br
ws
control head
ID 2
7
6
5
4
3
2
1
7
6
5
gr
4
gb
3
br
2
ws
1
screened line
(LIYCY)
2
4 x 1 mm
total length 60m max.
+
7
-
6
5
gr
4
gb
3
br
2
ws
1
gr
gb
br
ws
control head
7
6
5
4
3
2
1
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 7 switch +
ID 3
7
!
6
5
4
bridge
3
at last
2
head
1
Operation
Special application: twin engine with mechanical throttle control and gear shifting
remove bridge
!
Error Analysis
Appendix
terminal 2/3
gb
gr
br
ws
At the last control head, a bridge must be connected between terminals 4 and 5.
!
Example: 2 control head
The IDs of the control heads
!
must be different.
gr
gb
br
ws
control head
ID 2
7
6
5
4
3
2
1
7
!
6
5
4
3
bridge
2
at last
1
head
shielded cable
2 (4) x 1 mm
earthed at both ends
2
control head
ID 1
7
1
2
gb
1
gr
2
3
4
1
2
6
5
gr
4
gb
3
br
2
ws
1
7
6
5
gr
4
gb
3
br
2
ws
1
port starboard
gb
gr
1
2
1
2
3
4
1
2
shielded cable
2
4 x 1 mm
earthed at both ends
3.3 Mechanical throttle control and gear shifting
10
actuator 1
SYSCON
1
2
3
1
2
3
2
1
2
1
actuator 2
The setting of switchboard SYSCON (switches 1 – 6) assigns the function (speed or gear control) to
the actuators (see chapter 2 overview).
3.3.1 Push-/pull-cable
The mechanical connection between actuator and lever for throttle adjustment or gear control at the
engine is done by push-/pull-cables.
76 stroke
170
+
for half the stroke
3
110
33 max
General
OverviewWiring
**
22,1
10-32 UNF-2A
radial excursion: 8° max. to all sides
**
min 5
3,27
8,5
min 5
9,46
6,35
9,46
Adjustment
OperationError AnalysisAppendix
When laying push-/pull cables as few direction changes as possible should be
made. The efficiency of the cables decreases with every deflection.
!
Deflection angle 90° usable force = 82% of the force applied
Deflection angle 360° usable force = 55% of the force applied
3.3.2 Mounting of the actuator
General
Overview
3.3.3. Connection at the throttle and gear adjusting lever
To fix the push-/pull-cable at the adjusting lever, a ball joint may be used.
11
Mounting work may only be carried out if the actuator
is idle.
!
Risk of injury!
Wiring
Adjustment
Operation
counter bearing
!
ball joint
"s"
hexagone nut
When adjusting the traveling range of the actuator (stroke), it must be ensured
that both markings remain visible in the end positions.
The travel may not be blocked by exterior mechanical stops. Misadjustment may
lead to blocking and distruction of the electric actuators.
stroke 70 mm
Error Analysis
3.4 Electrical throttle control and gear shifting
Electrical throttle control
Appendix
1
2
3
4
71 72 73 74 75 76 77 78 79 80 81 82
+ -
4...20 mA
galvanically separated
(max. 500 Ohm)
ECU, EDC
E
ngineControlUnit
E
ngineDigitalControl
shielded cable
Typ:LIYCY
2 x 0,75 mm
earthed at both ends
2
Electrical gear shifting without feedback
12
Indication gear condition
screened cable
1
1
2
2
3
3
4
4
LED set ahead (73)
LED set astern (75)
1
1
gear feedback off
2
3
4
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.
type LIYCY
7 x 1 mm
grounded at both ends
71 72 73 74 75 76 77 78 79 80 81 82
2
ahead
Vcc, 2A
solenoid valve
relay with
free-wheeling diode
reversing gearbox
astern
Vcc, 2A
General
OverviewWiring
!
If not, the digital output may be destroyed.
Adjustment
OperationError AnalysisAppendix
If inductive loads shall be switched, these must be provided with a free-wheeling diode.
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