Replacing the PCB in an

Engine Control Module (ECM)

The Engine Control Module (ECM) is the only MECS module that cannot be easily replaced
by simply unplugging one unit and fitting another. This is because the ECM has to be
configurable to suit many different engine and gearbox combinations, all of which have
different inter-connection styles. The connections to engine and gearbox are therefore hard-
wired, i.e. they do not use the standard MECS connectors. For this reason, in the event of an
ECM failure we replace the printed circuit board inside the unit.

This requires a higher level of expertise than with straightforward module replacements, and
should only be carried out by competent personnel.

No soldering is required, as internal PCB connections are by easily removable plugs, but care
is needed to ensure that the plugs and sockets mate correctly.

There may also be a requirement for links and switches to be set, as well as adjustment of
potentiometers on the PCB itself. If possible however, these may be set to suit the vessel
concerned, before the spare unit is sent out.

There will still be a need for the ECM to be programmed; a number of engine and gearbox
configuration settings are stored in the ECM. This is done by entering the Jet Setup and
System setup modes at the JCM. Note that you can only enter System Setup or Jet Setup
within 2 minutes of power on, or of exiting either setup mode, on a particular Jet Control
Module. (If the setup options do not appear in the main menu, the setup time window has
passed and the MECS system will require to be powered down and up again before the setup
options will be available).

Use these instructions in conjunction with the manual and the list of parameters for the vessel
concerned, which will have been produced after the commissioning.

Modules are identified in the setup menus by their initials and their number on the system. For
example, ECM 1/2 is ECM No.1 of jet No.2, CPM 2/3 is CPM No.2 (Station2) of jet No.3.

Jets are numbered from port to starboard, the outermost port jet being No.1.

Before commencing, ensure that you have:

• The password to be able to enter setup in the Jet control module, (often 0000).
• An ECM PCB with the same or later software as the faulty unit. The software number
is on a label on the EPROM.
• A test meter and suitable tools to remove the ECM PCB.

Then proceed as follows:

1 TURN OFF THE POWER

Power down MECS control system. Make sure that both Primary and Secondary power
supplies are off.

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2 REPLACEMENT OF THE PCB

1. Open the lid of the ECM and secure it back. The ECM PCB has a number of
connectors around the edge of the PCB. These need to be carefully unplugged. The
connectors are held in place by a small locking tab, which springs in to place.
Carefully slide a small screwdriver down between the tab and the connector to allow it
to release easily.
2. The PCB is removed complete with the aluminium chassis it is mounted on. Using a
4mm hexagon key, remove the screws at the lower corners of the PCB chassis.
Then, using a small flat blade screwdriver, prize the chassis off the hinges.
3. Insert the new assembly by positioning one hinge first, and, again using a small
screwdriver, ease the other side in. Refit the two screws in the bottom corners of the
chassis.
4. CAREFULLY replace all the plugs. Take care to ensure that the correct plugs are
positioned correctly and accurately on the pins. It is possible to fit a plug on the wrong
pins. If you are unsure where a plug goes, look at another ECM to compare.
5. Once all plugs are fitted, check them again to ensure they are all correctly fitted.
6. If the PCB links have not been set prior to shipment, continue with Section 3, below. If
the links are set, move on to section 4.

3 SETTING THE PCB

IT IS BENEFICIAL THAT THE SWITCHES AND LINKS ON THE PCB ARE CONFIGURED
BY HAMILTON JET PRIOR TO SHIPMENT.

However, if the PCB has not previously been configured for the vessel, it will be necessary to
check and alter if necessary some links and switch settings on the PCB. EXERCISE
EXTREME CARE WHEN HANDLING THE PCB.

Refer to the Commissioning section in the manual, in particular the sub-section Initial
Setting Up of the Electronic System. You will find a diagram showing the positions of the
links, switches and potentiometers on the PCB.

The switches are located under the CPU PCB. To remove this PCB, it is necessary to gently
squeeze the tab on the plastic mounting pillar, to allow the PCB to lift over it. Take care when
lifting the PCB to keep it level, as there are connecting pins underneath which can be easily
damaged.

The settings can be checked by comparing the new PCB with the old. Configure the new PCB
in a similar way.

1. Compare the positions of the links:

§ VISEL1 & VISEL2,

§ J1 & J2,
§ OP1, OP2, OP3, OP4 & OP5.

2. Compare the settings of SW2 and SW5.

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Replace the CPU PCB, pushing it over the mounting pillars, with care ensuring the connector
pins are aligned.

The potentiometers R16, R34, R52 and R59 may need adjustment, but this is done after the
system is powered up.

4 SETTING UP THE MODULE

This is to designate the ECM to the jet, and register it on the system, and is done by entering
the System Setup mode.

To enter System Setup:

1. At the JCM, press the <ESCAPE> button.

2. Using the <↑> and <↓> buttons scroll down to System Setup.
3. Press and hold the <ENTER> button until the password entry page
appears.
4. Enter the password, number by number, pressing the <ENTER> button
to transfer to the next number.
5. The display will show the first page indicating the number of jets.
6. Press the <ESCAPE> button repeatedly to move through the menus and
exit System Setup.
7. The display will return to the Jet Data display.

No data needs to be entered; the process of just going in and out of System Setup designates
the ECM to the rest of the system.

5 ENGINE & GEARBOX SET UP

It is then necessary to set up the engine and gearbox parameters. This is done by entering
the Jet Setup mode.

To enter Jet Setup:

1. At the JCM, press the <ESCAPE> button.

2. Using the <↑> and <↓> buttons scroll down to Jet Setup menu item.
3. Press and hold the <ENTER> button until the password entry page
appears.
4. Enter the password, number by number, by pressing the <ENTER>
button to transfer to the next number.
5. The display will show Finding modules… then Module: JCM#1/1*
6. Scroll through the module list checking that all the modules for that jet are
present.

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 7. Select the ECM. Display will show Module: ECM #1/1*.
8. Press the <ENTER> button.
9. Using the <↓> button scroll down to the Param: All menu item.
10. Press the <ENTER> button.
11. The display will show Eng Type. Set the type accordingly.
12. Press the <ENTER> button. The display moves on to the next parameter.
13. Set the remaining parameters according to the parameter list.
14. When all parameters have been set, the display will return to Select
Module: ECM #1/1*.
15. Press the <ESCAPE> button to exit from the ECM setup and press it
again to exit from setup.

* Number dependant on jet being set up.

6 THROTTLE ADJUSTMENT

Even if the links and switches were set before shipment of the PCB, the throttle signal may
still require adjustment.

Reference should once again be made to the section of the manual referred to earlier. Also in
this section is a table showing the different throttle arrangements of the various engines.
Refer to the appropriate engine.

It will be necessary to know to what terminals in the ECM the throttle signal is connected. This
information should have been provided with the PCB, possibly in the form of the ECM
connection diagram, produced for the commissioning.

It may be necessary to remove the two hexagon head screws and hinge the PCB assembly
up to gain access to the terminals.

When adjusting the throttle, the system should be powered on, and switched to Local 1 or
Local 2 at the ECM.

Proceed as follows:

1. First, switch to Local 1. With the test meter set to the correct range, check the
reading at the idle (minimum) position, (as it will be at power on). Adjust R34 to
achieve the desired reading.
2. Using the <+> button on the ECM, ramp up the throttle to full. (This can be seen as
the LED segments light up on the PCB). Adjust R16 for the desired value.
3. Using the <-> button on the ECM, return the throttle to minimum. Re-adjust R34 as
necessary.
4. Return to full throttle, and re-adjust as necessary.
5. Repeat from full to idle until readings are steady.

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On some installations, e.g. MTU, this completes the throttle setup, as the secondary throttle is
controlled by contact closures and does not require adjustment. On other systems however,
e.g. Cummins, Caterpillar, it will be necessary to repeat this procedure. In this case, simply
measure on the appropriate terminals, (may be the same ones), and repeat the procedure,
but when switched to Local 2, and using R52 for the minimum level, and R59 for maximum.
Note that there is no LED indication on the ECM PCB when in Local 2.

7 FINALLY

1. Acknowledge any alarm messages still present by pressing the Cancel

button on the CPM.
2. Switch back to Remote at the ECM, and all Jets to Normal, and check
that no alarms present.

The system is now ready for a complete functional test.

Ø Note that some of module conflict alarms require a complete power down
to clear.
Ø Each separate alarm will require to be acknowledged by pressing Cancel.