Aventics Marex ECS User manual

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
4AVENTICS | 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:
WMarex 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.
OObserve the instructions for the other system components.
OObserve 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
6AVENTICS | 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:
WWarning sign: Draws attention to the risk
WSignal word: Identifies the hazard level
WType and source of risk: Identifies the type and source of the
hazard
WConsequences: Describes the consequences of non-
observance
WPrevention: Describes how to avert the danger
SIGNAL WORD
Type and source of risk
Consequences
OPrecautions
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.
Osingle, 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
8AVENTICS | 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.
ORead these assembly instructions completely and carefully
before starting to operate the Marex ECS Control Unit.
OKeep these assembly instructions in a location where they
are accessible to all users at any time.
OAlways 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:
Wto output electric signals for the throttle control of marine
propulsions
Wto output electric signals for the control of marine
transmissions
Wto collect control signals via the STATION bus cable from the
control heads of Marex ECS
Wto transmit control signals via the STATION bus cable to the
mechanical actuators of Marex ECS.
Wto 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
WThe 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:
Wconnecting the Marex ECS Control Unit to inadmissible
supply voltage (see chapter 13, Technical data),
Wcombining the Marex ECS Control Unit with further
components which are not suitable for that purpose,
Wexposing 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
AVENTICS | ECS Control Unit | R419302112–BDL–001–AA 11
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
WObserve the valid regulations pertaining to accident
prevention and environmental protection.
WObserve the safety instructions and guidelines of the
country in which the product is used.
WOnly use AVENTICS products in technically perfect condition.
WCheck the product for obvious defects as for example cracks
in the housing or missing screws, caps or sealings.
WObserve all instructions on the Marex ECS Control Unit.
WPersons who install, operate, dismantle or maintain
AVENTICS products must not be under the influence of
alcohol, other drugs or medications which affect the
responsiveness.
WUse only accessories and spare parts approved by
AVENTICS in order to avoid hazards to persons as a
consequence of unsuitable spare parts.
WObserve the technical data and environmental conditions
stated in the product documentation.
WIf, 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.
WImproper installation and use as well as wrong handling will
invalidate the warranty.
2.6 Product- and technology-related safety
messages
Assembly OAlways 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.
OLay cables in such a way that they cannot be damaged and
nobody can trip over them.
OBefore 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 OMake sure that all electric ports are used or covered. Only
start up products which are fully installed.
Operation OOnly 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.
OEven 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
Wthe product is in technically perfect condition,
Wthe product is used as intended,
Wany staff handling the product has read and understood the
documentation,
Wusers of the product are trained and instructed,
Wthe 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 OCover all openings with suitable protective caps to prevent
that cleaning agent penetrates into the system.
ONever 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.
ONever use pressure washers or steam cleaners to clean the
product.
Disposal ODispose 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
2Mountingscrews
2Washers
2Hexagonnuts

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:
WMarex ECS Control Unit (R419302110)
WMarex ECS twin wiring harness (R419302202)
WControl stations equipped with Control Head Type 500-ECS-
twin (R417002880 or R417002808)
WActuator 12VDC (R417002894) or 24VDC (R417002895)
Fig. 1: System overview Marex ECS twin (example)
STATION
STATION
GEAR
GEAR BOX ENGINE GEAR BOX ENGINE
THROTTLE AUX GEAR THROTTLE AUX
ALARM
POWER
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
1Pressure equalization membrane
2Rubber mounts
3Bushings
494-pin socket
560-pin socket
1
2
34
5
32

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.
1Date of manufacture
2Material number
3Serial number
4Software version
1
2
3
4