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' Autohelm Raymarine: T100 300cc 300cc Autopilot Course Computer'



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       TYPE

100/300
     AUTOPILOT
Installation and Set Up
Contents                                                                                                            3




Contents
           Chapter 1: Introduction .......................................................................... 9
                   1.1 ST7000 Control Unit ................................................................. 10
                   1.2 ST6000 Control Unit ................................................................. 10
                   1.3 Course Computer ..................................................................... 11
                   1.4 Fluxgate Compass .................................................................... 11
                   1.5 Rotary Rudder Reference Transducer .......................................... 12
                   1.6 Linear Feedback Transducer ...................................................... 12
                   1.7 Type CR Interface Unit ............................................................... 12
                   1.8 Drive Systems .......................................................................... 13
                        Rotary Drive Units ..................................................................... 13
                        Reversing Hydraulic Pump ......................................................... 14
                        Linear Drive ............................................................................. 15
                        Hydraulic Linear ....................................................................... 15
                        Constant Running Hydraulic Pump .............................................. 16
                        Stern drive ............................................................................... 16
                   1.9 Options ................................................................................... 17
                        Hand-held Remote (Z101) .......................................................... 17
                        NMEA Interface (D153) .............................................................. 17
                        Auxiliary Alarm (Z035) ............................................................... 18
                        Joystick (Z147) ........................................................................ 18
                        Wind Transducer (sail only) ......................................................... 19
                            Masthead Wind Transducer (Z080, Long Arm Version Z188) ...... 19
                            Pushpit Wind Transducer (Z087) ............................................ 19
                        Gyroplus Transducer (Z179) ...................................................... 20
           Chapter 2: Installation .......................................................................... 2 1
                   2. General .................................................................................... 21
                        Planning the Installation ............................................................. 21
4                                 TYPE100/300 Operation and Installation Handbook




    2.1 Course Computer ..................................................................... 21
        Mounting ................................................................................. 22
        Cabling ................................................................................... 22
            Type 1 Drive Units/Stern Drive/Constant Running Pump ............ 23
            Type 2 Drive Units (12V) ........................................................ 23
            Type 2 Drive Units (24V) ........................................................ 23
            Type 3 Drive Units (12V) ........................................................ 24
            Type 3 Drive Units (24V) ........................................................ 24
    2.2 ST7000/6000 Control Unit ........................................................ 25
        Mounting ................................................................................. 25
        Cabling ................................................................................... 26
    2.3 Fluxgate Compass .................................................................... 28
        Mounting ................................................................................. 28
        Cabling ................................................................................... 29
    2.4 Rotary Rudder Reference Transducer .......................................... 30
        Mounting ................................................................................. 30
        Cabling ................................................................................... 32
    2.5 Linear Feedback Transducer ...................................................... 33
        Mounting ................................................................................. 33
        Cabling ................................................................................... 34
    2.6 Hydraulic Drive Systems ............................................................ 35
        Pump to Cylinder Specifications .................................................. 35
        Reversing Hydraulic Pumps (Type 1, Type 2 & Type 3) ................... 35
            Mounting ............................................................................ 35
            Cabling ............................................................................... 35
                  Type 1 Drive Unit ........................................................... 35
                  Type 2 Drive Unit (12V) ................................................... 36
                  Type 2 Drive Unit (24V) ................................................... 36
                  Type 3 Drive Unit (12V) ................................................... 36
                  Type 3 Drive Unit (24V) ................................................... 36
Contents                                                                                                   5




                   Plumbing ............................................................................ 37
                   Two line system ................................................................... 39
                   Two line pressurised system .................................................. 39
                   Three line system ................................................................. 40
                   Bleeding the system ............................................................. 40
               Constant Running Hydraulic Pump .............................................. 41
                   Mounting ............................................................................ 41
                   Cabling ............................................................................... 42
                         Pump Cable ................................................................. 43
                         Solenoid Cable ............................................................. 43
                   Plumbing ............................................................................ 44
               Hydraulic Linear Actuator ........................................................... 45
                   Installation .......................................................................... 45
                   Cabling ............................................................................... 48
                   Final Preparations Before use ................................................ 48
           2.8 Mechanical Drive Systems ......................................................... 49
               Rotary Drive Unit ...................................................................... 49
               Mounting ................................................................................. 49
               Cabling ................................................................................... 52
                   Type 1 Drive Unit .................................................................. 52
                   Type 2 Drive Unit (12V) ......................................................... 52
                   Type 2 Drive Unit (24V) ......................................................... 53
               Linear Drive Unit ....................................................................... 53
               Mounting ................................................................................. 54
               Cabling ................................................................................... 55
                   Type 1 Drive Unit .................................................................. 55
                   Type 2 Drive Unit (12V) ......................................................... 55
                   Type 2 Drive Unit (24V) ......................................................... 56
               Stern drive Actuator .................................................................. 56
               Mounting ................................................................................. 56
6                                         TYPE100/300 Operation and Installation Handbook




                    Volvo (Pre type 872215) ....................................................... 56
                    Volvo (Post type 872215) ..................................................... 58
                    Mercruiser/OMC/Yamaha ..................................................... 61
                    Mounting in a Restricted Area ................................................. 63
                Cabling ................................................................................... 64
           2.9 Auxiliary Alarm ......................................................................... 65
                Cabling ................................................................................... 65
           2.10 Joystick ................................................................................ 66
                Cabling ................................................................................... 66
           2.11 Masthead Transducer (sail only) ................................................ 67
                Mounting ................................................................................. 67
                Cabling ................................................................................... 68
           2.12 Interfacing to other manufacturer's equipment (NMEA) ................. 69
                Course Computer NMEA ports ................................................... 69
                    Input Port ............................................................................ 69
                    Output Port ......................................................................... 70
                    Cabling ............................................................................... 70
                ST6000/ST7000 Control Unit NMEA Input ................................... 71
                    Cabling ............................................................................... 72
                NMEA Interface ........................................................................ 73
                    Cabling ............................................................................... 74
    Chapter 3: Functional Test ................................................................... 7 6
           3.1 System test ............................................................................. 76
           3.2 Switch-on ................................................................................ 76
           3.3 Rudder angle sense .................................................................. 77
                ST7000 control unit .................................................................. 77
                ST6000 control unit .................................................................. 77
           3.4 Rudder angle alignment ............................................................. 77
           3.5 Operating sense ....................................................................... 78
           3.6 Rudder deadband ..................................................................... 78
Contents                                                                                                           7




                  3.7 Mechanical test (Linear, Rotary & Hydraulic Drives) ........................ 78
                       Current limit and cutout ............................................................. 78
                  3.8 Mechanical Test (Stern Drive) ..................................................... 79
                  3.9 Setting the Autopilot Rudder Limit (All drives) ................................. 79
                  3.10 GyroPlus Offset and Drift Compensation .................................... 80
                       Procedure ............................................................................... 80
           Chapter 4: Calibration .......................................................................... 8 1
                  4.1 Recommended Settings ............................................................ 81
                  4.2 Selecting calibration .................................................................. 82
                  4.3 Adjusting calibration .................................................................. 83
                       RudderGain ............................................................................. 83
                       Rate Level ............................................................................... 84
                       Rudder Offset (Helm Adjust) ....................................................... 84
                       Rudder Limit ............................................................................ 84
                       Turn Rate ................................................................................ 85
                       Cruise Speed ........................................................................... 85
                       Off Course Limit ....................................................................... 85
                       Trim Level ............................................................................... 86
                       Joystick Mode (Manual Type) ...................................................... 86
                       Drive Option ............................................................................. 86
                       Rudder Deadband (Rudder Damping) .......................................... 87
                       Magnetic Variation .................................................................... 87
                       Auto Adapt .............................................................................. 87
                       Latitude .................................................................................. 88
                       Wind Trim ................................................................................ 88
                       Response Level ........................................................................ 88
                       Auto Release (manual override) ................................................... 89
                  4.4 Saving Calibration Mode ............................................................ 89
                  4.5 Display Contrast Adjustment (ST7000 only) .................................. 90
                  4.6 Permanent Watch Alarm (SFIA) ................................................... 90
                  4.7 Recording Calibration Settings .................................................... 90
8                                           TYPE100/300 Operation and Installation Handbook




    Chapter 5: Initial Sea Trials ................................................................... 9 1
            5.1 Initial Sea Trials ........................................................................ 91
            5.2 Automatic Compass Heading Alignment and Deviation Correction ... 91
            5.3 Compass Alignment (without deviation correction) ......................... 93
            5.4 First Sea Trials ......................................................................... 93
            5.5 Response Control ..................................................................... 94
                 Level 1 - Automatic Sea State Control .......................................... 94
                 Level 2 - Automatic Sea State Inhibit ............................................ 94
                 Level 3 - Automatic Sea State Inhibit and counter rudder ................ 94
            5.6 Automatic Trim Control ............................................................. 95
            5.7 Rudder Gain Adjustment (Displacement Craft) ............................... 96
            5.8 Rudder Gain Adjustment (High Speed Planning Craft) ..................... 97
            5.9 Rudder Gain - Adjustment with Speed ........................................... 97
            5.10 Manual Override (Stern Drive Actuators only) .............................. 98
    Chapter 6: Track Control ...................................................................... 9 9
    Chapter 7: Windvane Control (Sail Only) ............................................. 101
    Index .................................................................................................. 103
Chapter 1: System Components                                                                       9




Chapter 1: Introduction
                     The Autohelm Type 100/300 autopilots are modular systems that can be
                     configured to suit the individual requirements of all types of vessels, using
                     a range of high efficiency rotary, linear or hydraulic rudder drive units to
                     match various types of steering systems.
                     The Autohelm system in its most basic form consists of a control unit,
                     course computer, drive unit, fluxgate compass and a rudder
                     reference transducer.
                     A full range of accessories are also available and include:
                     · Joystick (manual steering unit)
                     · Main alarm and interface
                     · Rate gyro
                     · Hand held remote control unit
                     · SeaTalk instrumentation
                     · Interface leads


                       Control
                       Unit
                                               Rudder
                                               Reference
                                                                                       Fluxgate
                                               Unit
                                                                        Gyro           Compass
                       Control
                       Unit
                                                                                       Course
                                                                                       Computer




                                                                                      Cable
                                                                                      Clamp
                                           Drive Unit



                                                                                              D726-1
10                                                                    TYPE 100/300 Operation and Installation Handbook




1.1 ST7000 Control Unit
                The ST7000 control unit is fully weather protected and designed for above
                or below deck istallation. The unit is connected to the course computer via
                the SeaTalk bus. NMEA navigation, speed and wind information can be
                received via a fixed socket on the rear of the case.
                Note: Additional control units can also be connected via the SeaTalk bus.

                                                177.8mm (7in)                                 38.75mm (1.5in)

                                                                                                              24mm (0.95in)



                       q     ­1                +1   q




                       q     ­10              +10   q
                                                                                                                    110mm
                                                                                                                    (4.33in)
                       STAND BY           AUTO             DISPLAY   TRACK      RESPONSE




                                                                                     ST7000
                                   TM




                                                                                                                        D727-1




1.2 ST6000 Control Unit
                The ST6000 control unit, like the ST7000, is fully weather protected and
                also designed for above or below deck installation. The unit is connected
                to the course computer via the SeaTalk bus. NMEA navigation, speed and
                wind information can be received via a fixed socket on the rear of the case.
                Note: Additional control units can also be connected via the SeaTalk bus.

                     110mm (4.33in)                                          38.75mm (1.5in)
                                                                                              24mm(0.95in)




                        ­1               +1             DISPLAY




                       ­10              +10
                                                                                                   110mm
                                                         TRACK

                                                                                                   (4.33in)
                     STAND BY           AUTO            RESPONSE




                                   TM

                                                          ST6000
                                                                                                         D728 -1
Chapter 1: System Components                                                                        11




1.3 Course Computer
                     The course computer, available in both 12V or 24V versions, houses a
                     microprocessor, drive unit electronic control circuitry and power amplifier.
                     It is the central distribution point for the autopilot, electrical wiring and
                     ship's power connection point.
                     The course computer also has NMEA input and outputs to allow operation
                     with other manufacturer's equipment.
                     The unit is only splash proof and must, therefore, be installed in a dry,
                     protected location.
                     Type 100 is used for Type 1 and Type CR 12V drives. Type 300 is used
                     with Type 2 and Type 3 drives.

                                         233mm (9.2in)              45mm (1.8in)




                                                                                    130mm (5.1in)
                                                                                     D865-1




1.4 Fluxgate Compass
                     The fluxgate compass contains a gimbal mechanism that permits
                     accurate readings with pitch and roll movements up to +/- 35 degrees.
                     The compass is designed for below deck, bulkhead mounting and
                     connects directly to the course computer.
                     On steel decked vessels the compass can be mounted above deck,
                     however, autopilot performance may be affected due to the increased
                     motion.

                           76mm (3in)




                                    TM



                                                                 76mm (3in)



                                                                        D729-1
12                                      TYPE 100/300 Operation and Installation Handbook




1.5 Rotary Rudder Reference Transducer
                 The rudder reference transducer provides the course computer with the
                 precise position of the vessels rudder. The unit is mounted on a suitable
                 base adjacent to the rudder stock. Its use is mandatory on all installations,
                 except when a linear rudder reference transducer is connected.

                             152mm (6in)
                              139.7mm (5.5in)




                                                                      61mm (2.4in)
                                                                                          69.5mm (2.7in)
                                                                                                           D730-1




1.6 Linear Feedback Transducer
                 The linear feedback transducer is designed for installations on `bullhorn'
                 style hydraulic outboard steering systems. The unit is totally weather proof
                 and mounted on the bullhorn ram. Its use is mandatory on all hydraulic
                 outboard installations.

                                                425mm (16.75in)




                                                                                                              32mm (1.3in)
                                                                                     TM




                                                                                                            D869-1




1.7 Type CR Interface Unit
                 The course computer can be connected to the solenoids on a constant
                 running hydraulic pump using the type CR interface. The unit also provides
                 connections to energise a solenoid operated bypass valve.

                            125mm (5.9in)
                                                     100mm (3.95in)




                                                                                                           (2.37in)
                                                                                                           60mm




                                                                                                             D734-1
Chapter 1: System Components                                                                      13




1.8 Drive Systems
                     A range of mechanical (rotary, linear and stern drive) and hydraulic drive
                     units are available for use with the Type 100/300 system. Rotary drives
                     are coupled to the steering system by a simple chain drive, linear drives
                     directly to the rudder stock at the tiller arm radius and stern drives directly
                     to the power steering valve block.
                     The type of hydraulic drive used is dependent on the size of the vessels
                     hydraulic cylinder.

          Rotary Drive Units
                     Autohelm rotary drive units provide smooth, powerful steering commands
                     with almost silent operation. A rugged electric motor drives a precision
                     epicyclic gearbox via a high tensile drive belt. An electronic clutch
                     transmits high torque loads with no slippage. The drive unit can be
                     mounted in any attitude to simplify installation.

                                                   274mm (10.8in)




                       195mm
                        (7.7in)




                               20mm (0.8in)          256mm (10in)



                                   60mm
                       184mm       (2.4in)
                        (7.2in)
                                   60mm
                                   (2.4in)

                                                   2 holes 12.5mm (0.5in) diameter
                                                                               D736-1
14                                 TYPE 100/300 Operation and Installation Handbook




     Reversing Hydraulic Pump
             The reversing hydraulic pump consists of a precision gear pump and an
             integral check valve block driven by a continuously rated servo motor. The
             pump is connected directly to the vessels steering cylinder, with the
             course computer regulating the peak pump pressure.
             There are three types of pump: type 1, type 2 and type 3. The different
             type relates to the steering ram capacity, which is directly related to the
             displacement of the vessel.
             Type 1: 80 to 230 cc (4.9 to 14cu in)
             Type 2: 160 to 350 cc (9.8 to 21cu in)
             Type 3: 250 to 460 cc (15 to 28cu in)




                                                                            103mm (4.07in)
                              'A'                      117mm (4.62in)
                Pump      Dimension 'A'
                Type 1    177mm (6.96in)
                Type 2    177mm (6.96in)
                Type 3    235mm (9.25in)
                                                                           D738-1
Chapter 1: System Components                                                                                                        15




          Linear Drive
                     The Autohelm linear drive unit is of outstanding design which features
                     powerful thrust, fast hard overtimes and near silent operation. When
                     backdriven the movement is smooth with minimal backdriven force. Using
                     a high tensile belt drive and epicyclic reduction gearbox the powerful
                     electric motor is controlled by an electronic fail-safe clutch.
                     The design is highly efficient and provides high performance for minimum
                     current consumption.

                                                                                         A
                       197mm (7.8in)




                                                                                                                       50mm (2in)
                                                                 79mm (3.1in)
                       114mm (4.5in)




                                                                                                              90°




                                                                                   Drive            Dimension 'A'
                                       4 off fixing holes suitable                 Type 1           700mm (27.5in)
                                       for 10mm (0.4in) bolts                      Type 2 (short)   700mm (27.5in)
                                                                                   Type 2 (long)    850mm (33.5in)   D1010-1




          Hydraulic Linear
                     The hydraulic linear drive unit is a self contained secondary steering
                     cylinder (with a built-in solenoid bypass valve). The unit is driven by a
                     reversing hydraulic pump to provide a totally isolated autopilot steering
                     system.
                                                                                                  A
                                                                                   457mm (18in)
                      (3.15in)
                       80mm



                                                 101.6mm (4in)
                                   152mm (6in)




                                                                                Drive    Dimension 'A'
                                                                                Type 2   540mm (21.25in)
                                                                                Type 3   690mm (27.15in)
                                                                                                                         D877-1
16                                    TYPE 100/300 Operation and Installation Handbook




     Constant Running Hydraulic Pump
              When steering loads require a ram capacity of over 460cc (28cu in) the
              constant running hydraulic pump provides the ideal autopilot drive system.
              Hydraulic fluid is supplied from a self contained reservoir and flow to the
              steering ram is controlled by integral solenoid operated valves.
              Used with a solenoid operated bypass valve and a separate hydraulic ram,
              this system is recommended for heavy duty applications on large
              mechanically steered vessels.




                                                                                        224mm (8.8in)
                              356mm (14in)                        262mm (10.3in)
                                                                                        D740-1




     Stern drive
              The stern drive actuator must only be used on stern drives with cable
              operated, power assisted steering.
              The drive unit operates the power steering valve in exactly the same way
              as the steering cable. A clutch disengages the drive unit to allow manual
              steering when the autopilot is disengaged.
              Installation kits are available for most popular types of steering manufac-
              turers.


               102.5mm
                (4.0in)




                   63.4mm
                    (2.5in)


                                  220mm (8.66in)            240mm (9.45in)

                                             460mm (18.1in) mid-stroke
                                                                               D743-1
Chapter 1: System Components                                                                          17




1.9 Options
                     The Type 100/300 autopilot system is available with the following optional
                     system components:

          Hand-held Remote (Z101)
                     The hand-held remote allows course changing from a position away from
                     the steering station. The hand held remote is connected to the autopilot via
                     the SeaTalk bus.



                            ­1        +1




                                                                     138mm (5.4in)
                            ­10      +10




                                       TM




                          65mm (2.5in)              14.5mm (0.6in)
                                                                     D1011-1




          NMEA Interface (D153)
                     Although the Type 100/300 has its own NMEA 0183 input and output
                     ports, you may wish to receive information from additional equipment
                     transmitting NMEA. The NMEA interface connects to the SeaTalk bus and
                     converts incoming data to SeaTalk. The interface also converts SeaTalk
                     data to NMEA 0183 format.

                                  117.5mm (4.6in)       37mm (1.5in)
                                                                                     87.5mm (3.4in)




                                                                                          D873-1
18                                      TYPE 100/300 Operation and Installation Handbook




     Auxiliary Alarm (Z035)
              The autopilot is provided with a comprehensive automatic off-course alarm
              system that sounds from all control units. This provides sufficient audible
              warning under most conditions. However, in cases where a high powered
              alarm is required, an auxiliary alarm can be fitted. The auxiliary alarm is
              connected to the SeaTalk bus via the NMEA interface box and will sound
              whenever the autopilot transmits one of the following alarm conditions.
              · Autopilot Off Course
              · Watch Alarm
              · Wind Shift
              · Low Battery
              · Large Cross Track Error
              · NMEA Data Error
              · No Autopilot Actuator Connected
              · Stern drive Auto Release
              · Waypoint Change Alarm




                    85mm (3.35in)              45mm (1.8in)
                                                          D732-1




     Joystick (Z147)
              The Joystick is an electro mechanical remote steering unit that uses the
              course computer and its drive unit to power steer the vessels rudder.

                   110mm (4.3in)           76mm (3in)         157mm (6.2in)
                                                                               110mm (4.3in)




                             JOYSTICK
                       TM




                                                                              D734a-1
Chapter 1: System Components                                                                     19




          Wind Transducer (sail only)
                     If the installation does not include a SeaTalk Wind instrument either the
                     masthead or pushpit wind transducer can be connected directly to the
                     NMEA interface box to supply wind angle information.
          Masthead Wind Transducer (Z080, Long Arm Version Z188)




                                     371mm (14.6in)
                                                                             D733-1




          Pushpit Wind Transducer (Z087)




                                                                   D1075-1
20                                 TYPE 100/300 Operation and Installation Handbook




     Gyroplus Transducer (Z179)
             The Autohelm Gyroplus is a transducer that measures the rate of turn of
             the vessel. This is used by the autopilot to give even better correction for
             boat yaw in adverse weather conditions. It is particularly beneficial
             downward and in following sea conditions.

                  90mm (3.5in)            51mm (2in)




                                                       115mm (4.5in)

                                                                       140mm (5.5in)
                           TM




                    GYROPLUS




                                                                       D872-1
Chapter 2: Installation                                                                              21




Chapter 2: Installation
2. General
                          This section describes how to install the autopilot and system components
                          described in chapter1.

            Planning the Installation
                          When selecting power cable it is important to use the stated wire gauge.
                          The cable you choose may meet the required current specification,
                          however, if too small, the voltage will drop between the supply and the
                          course computer. This will reduce the power of the drive unit and may
                          cause the electronics to malfunction.

2.1 Course Computer
                          The course computer must be located in a dry, protected location free
                          from high operating temperatures and excessive vibration. The unit must
                          be mounted vertically with free air flow to allow heat dissipation from the
                          power amplifier.
                          Avoid mounting the course computer:
                          · in an engine room
                          · where there is water splash/spray from bilge's or hatches
                          · where it can be subjected to physical damage from heavy items (such
                            as hatch covers, tool boxes etc.)
                          · where it will be covered by other on-board equipment
                          · where it will be close to sources of high RF energy transmissions
                             (generators/SSB radios/ antenna cables etc.)
22                                    TYPE 100/300 Operation and Installation Handbook




     Mounting




                                                                 Vert
                                                                     ical



                                                                            D881-1




               1. With the course computer located as required, outline the two
                  mounting holes.
               2. Drill two pilot holes for the fixing screws.
               3. Secure the course computer to the vessel using the two screws
                  provided.
               Note: If the mounting surface is less than 3mm (1/8in) thick, use the U
               clips provided.
               4. Drill three pilot holes for the cable clamp bar.
               5. Secure the cable clamp as shown.

     Cabling
               Note: If you are installing the Type 100/300 system with a constant
               running hydraulic pump, refer to page 40 before running the power cable.
               1. Having sited the course computer, measure the total cable length
                  between the course computer and the vessels central power
                  distribution panel. Using the following tables, select the appropriate
                  cable size and circuit breaker relative to the type of drive unit used.
Chapter 2: Installation                                                           23




            Type 1 Drive Units/Stern Drive/Constant Running Pump

                          Cable Length                Cable Gauge   Copper Area
                          (Distribution
                          panel to Course Computer)

                          Up to 3m (10ft)             12 AWG        2.5 mm

                          Up to 5m (16ft)             10 AWG        4 mm

                          Up to 7m (23ft)             8 AWG         6 mm
                          Up to 10m (32ft)            6 AWG         10 mm

                          Up to 16m (52ft)            4 AWG         16 mm
                                                                             81004-01




            Type 2 Drive Units (12V)

                          Cable Length                Cable Gauge   Copper Area
                          (Distribution
                          panel to Course Computer)

                          Up to 5m (16ft)             8 AWG         6 mm

                          Up to 7m (23ft)             6 AWG         10 mm
                          Up to 16m (52ft)            4 AWG         16 mm
                                                                             81004-02




            Type 2 Drive Units (24V)

                          Cable Length                Cable Gauge   Copper Area
                          (Distribution
                          panel to Course Computer)

                          Up to 3m (10ft)             12 AWG        2.5 mm

                          Up to 5m (16ft)             10 AWG        4 mm

                          Up to 7m (23ft)             8 AWG         6 mm
                          Up to 10m (32ft)            6 AWG         10 mm

                          Up to 16m (52ft)            4 AWG         16 mm
                                                                             81004-01
24                                     TYPE 100/300 Operation and Installation Handbook




     Type 3 Drive Units (12V)

               Cable Length                         Cable Gauge         Copper Area
               (Distribution
               panel to Course Computer)

               Up to 5m (16ft)                      8 AWG               6 mm

               Up to 7m (23ft)                      6 AWG               10 mm
               Up to 16m (52ft)                     4 AWG               16 mm
                                                                                         81004-02




     Type 3 Drive Units (24V)

               Cable Length                         Cable Gauge         Copper Area
               (Distribution
               panel to Course Computer)

               Up to 5m (16ft)                      8 AWG               6 mm

               Up to 7m (23ft)                      6 AWG               10 mm
               Up to 16m (52ft)                     4 AWG               16 mm
                                                                                         81004-02




               2. Remove the connector cover from the course computer.
               3. Connect the power supply cable to the course computer power
                  terminals.
               Note: The cable must be protected by a circuit breaker
               (see table for size).


                  ­
                 Power
                 Supply

                  +                                      ­ +     ­ +    1  2

                             Circuit                    CLUTCH   POWER MOTOR
                             breaker




                                                                                D882-1
Chapter 2: Installation                                                                                  25




                          Drive Unit                          Circuit Breaker Size

                          Type 1                              25

                          Type 2 (12V)                        40

                          Type 2 (24V)                        25

                          Type 3                              40

                          Sterndrive                          25

                          Type CR                             25
                                                                                                     81004-03



2.2 ST7000/6000 Control Unit
                          The ST6000 and ST7000 control units are identical in operation and
                          installation.The main ST7000/6000 control unit should be mounted close
                          to the steering station where it is:
                          · normally viewed straight on for the best display legibility
                          · well protected against physical damage
                          · at least 9in (230mm) from a compass
                          · at least 20in (500mm) from radio receiving equipment
                          · accessible from behind to install and run cables
                          Note: The rear case is designed to breathe through a small duct in the
                          cable boss to prevent the accumulation of moisture. Direct exposure to
                          the rear of the control unit must be avoided.

            Mounting
                                   3                                          2         1




                                                                          2         4
                                                                                            D746-1


                          1 Cable boss 2 Fixing stud 3 Thumb nut 4 Sealing gasket
26                                    TYPE 100/300 Operation and Installation Handbook




               1. Make sure that the mounting surface is smooth and flat.
               2. Use the template provided to mark the centres for the two fixing studs
                  and the cable boss.
               Note: Adjacent instruments should have 6mm (1/4in) separation to allow
               room for the protective covers.
               3. Drill two 4mm (5/32in) diameter holes.
               4. Using a 50mm (2in) diameter cutter, drill the hole for the cable
                  boss (1).
               5. Screw the two fixing studs (2) into the rear case of the control unit.
               6. Pass the cable tails through the large hole and secure the control unit
                  with the thumb nuts (3) provided.
               Note: The sealing gasket (4), is already attached to the rear case of the
               control unit.

     Cabling
               The control unit is provided with a SeaTalk cable fitted with a 3 pin socket
               on each end.
               1. Plug one end of the cable into one of the two SeaTalk sockets on the
                  back of the control unit.
               2. Run the SeaTalk cable back to the course computer.
               Note: If more than one control unit is fitted, the SeaTalk cable can be
               connected to the free SeaTalk socket on the first control unit.
               3. Cut the remaining plug from the SeaTalk cable and connect to the the
                  SeaTalk terminals on the course computer (as shown in the following
                  illustration).




                                                                      ­ +        ­ +
                                                   SeaTalk   SeaTalk CLUTCH     POWER




                                                    Grey (screen)    Red      Yellow
                                                                                       D1012-1
Chapter 2: Installation                                                                                                    27




                          If the vessel is already fitted with Autohelm instrumentation, this should be
                          connected to the course computer as shown, using one of the standard
                          SeaTalk interface cables. The course computer will then supply power for
                          the complete system.



                                                                  ST50 Instrument           ST7000 Control Unit
                                                              +                 +       +            +                 +
                                      ­ +         ­ +
                             SeaTalk CLUTCH      POWER




                                                              +                 +       +            +                 +




                              Grey (screen)    Red   Yellow
                                                                                                                  D1013-1




                                                                   ST50 Instrument             ST6000 Control Unit
                                                                   +                +            +       +        +
                                      ­ +         ­ +
                             SeaTalk CLUTCH      POWER




                                                                   +                +            +       +        +




                               Grey (screen)   Red       Yellow
                                                                                                                      D1014-1
28                                    TYPE 100/300 Operation and Installation Handbook




2.3 Fluxgate Compass
               Correct positioning of the fluxgate compass is crucial if ultimate perform-
               ance is to be achieved. To minimise gimbal disturbance, the fluxgate
               should ideally be positioned as near as possible to the pitch and roll centre
               of the vessel.




                                      X                                        Y




                       0.3L to 0.5L
                                          L




                                      X                                        Y



                       0.3L to 0.5L
                                          L
                                                                                    D194-2




       Mounting




                                          Vertical



                                                      D193-2
Chapter 2: Installation                                                                               29




                          1. Locate the fluxgate compass on a suitable vertical surface.
                          2. Drill four pilot holes and attach the fluxgate compass using the self-
                             tapping screws provided.
                          3. Make sure that the fluxgate is positioned at least 0.8m (2ft 6in) away
                             from the vessel's steering compass in order to avoid deviation of both
                             compasses. To avoid compass deviation and reduction in sensitivity
                             of the sensor, the fluxgate must also be positioned as far away as
                             possible from large iron masses.
                          Note: If any doubt exists over magnetic suitability of the chosen site, the
                          position may be surveyed using a simple hand bearing compass. The hand
                          bearing compass should be fixed in the chosen position and the vessel
                          swung through 360 degrees. Relative differences in reading between the
                          hand bearing compass and the vessel's main steering compass should,
                          ideally, not exceed 10 degrees on any heading.

            Cabling
                          1. Run the cable back to the course computer.
                          2. Connect the to the fluxgate terminals on the course computer.




                                                                 FLUXGATE        JOYSTICK




                                          Grey (screen)   Red   Green   Yellow      Blue
                                                                                            D890-1


                          Note: A 10m (30ft) extension cable is available for larger installations
                          (part no. D174).
30                                     TYPE 100/300 Operation and Installation Handbook




2.4 Rotary Rudder Reference Transducer
                The rotary rudder reference transducer must be connected directly to the
                tiller arm to provide accurate rudder position to the course computer. If it
                is more convenient, the unit may be installed upside down. However, if
                mounted this way, the red and green wires must be reversed at the
                course computer.

        Mounting
                1. Using the self tapping screws provided, mount the rudder reference
                   transducer on a suitable base adjacent to the rudder stock.




                                           Tiller arm

                             X




                                                        Mounting base
                                                                        D195




                2. Make sure that the base height of the rudder reference transducer
                   can maintain the correct vertical alignment between the rudder
                   reference transducer arm and tiller arm (as shown).
                · To give the precise rudder position, the rudder reference transducer has
                   a built in spring to remove any free play in the linkage to the tiller .
                · The rudder reference arm movement is limited to ± 60 degrees. Care
                   must be taken during installation to ensure that the rudder reference
                   arm is opposite the point of cable entry when the rudder is amidships.
                   Failure to do this could result in damage if the rudder reference arm is
                   driven onto its end stops by the steering system.
Chapter 2: Installation                                                                                     31




                                                                                ± 60°
                                                                                maximum
                                                                                travel
                                         Cable                                  permitted
                                         entry                                               Min
                                                                                             75mm
                                                                                             (3in)
                              Parallel
                                                                                             Max
                                                                 90°                         310mm
                                                                                             (12.2in)

                                     A


                              Rudder amidships


                                                      Min 101mm (4in)

                                                      'A' 140mm (5.5in)

                                                      Max 190mm (7.5in)
                                                                                                       D196/2




                          It is important to ensure that the dimensions (set out above) are within the
                          set limits and that the tiller and rudder reference arms are parallel to each
                          other.




                                                                                     Min 75mm
                                                                                     (3in)
                                                                                     Max 310mm
                                                                                     (12.2in)
                                                     40°max

                                                 A


                                                     40°max

                                             Min 101mm (4in)

                                             'A' 140mm (5.5in)

                                             Max 190mm (7.5in)
                                                                                                D197




                          1. With the rudder amidships, the rudder reference arm should be
                             opposite the point of cable entry and at 90 degrees to the connecting
32                                    TYPE 100/300 Operation and Installation Handbook




                   bar. Minor adjustments can be made by loosening the 3 securing
                   screws and rotating the transducer body.
               2. The tiller pin must be positioned within the limits shown. Ideally,
                  dimension `A' should be 140mm (5.5in). However, changes within the
                  given limits will not degrade the autopilot performance, but will slightly
                  alter the scaling of the rudder angle display on the control unit. The
                  tiller pin is secured to the tiller arm using the self tapping screws
                  provided.
               3. Cut the threaded rod to length and screw on the lock nuts `Y'and the
                  ball pin sockets - the sockets can then be pressed onto the pins. Move
                  the rudder from side to side to ensure the linkage is free from any
                  obstruction at all rudder angles.

     Cabling
               1. Run the rudder reference cable back to the course computer.
               2. Connect to the rudder reference terminals on the course computer.




                                                                                  + ­ + ­
                                                         GYRO 2     RUDDER REF.     NMEA




                                                         Grey (screen)   Red      Green   Blue
                                                                                           D894-1


               Note: A 10m (30ft) extension cable is available for larger installations
               (part no. D173).
Chapter 2: Installation                                                                                33




2.5 Linear Feedback Transducer
                          The Linear Feedback Transducer is designed for use with bullhorn type
                          outboard installations.

                                          2




                            7 8 3         9




                                                                                       12
                                    10        11
                                                       6      5       4                1
                                                                                            D717-1




            Mounting
                          1. Operate the steering system so that the `bullhorn' ram (1) is positioned
                             amidships.
                          2. Release the hydraulic pressure from the vessels hydraulic steering
                             system (if required). Refer to the manufacturer's instructions for
                             correct procedures.
                          3. Loosen the starboard bolt that secures the `bullhorn' ram (1) shaft to
                             the end bracket (2).
                          4. Assemble the U-bracket (3) over the end bracket (2) and the shaft of
                             the `bullhorn' ram (1).
                          5. Hand tighten the starboard `bullhorn' bolt to hold the U-bracket (3) in
                             position.
                          6. Fully open the hose clamps (6) using a flat bladed screwdriver.
                          7. Hang the hose clamps (6) over the `bullhorn' ram (1).
                          8. Site the spacers (4) on the `bullhorn' ram (1) and hold, temporarily,
                             with adhesive tape.
                          9. Pull the shaft (9) out of the linear feedback transducer (5) until the
                             alignment mark (10) is level with the end of the body (11).
34                                     TYPE 100/300 Operation and Installation Handbook




               10. Position the linear feedback transducer (5) on top of the spacers (4)
                   so that the threaded end of the shaft passes through the
                   U-bracket (3).
               Note: The linear feedback transducer should, under normal circum-
               stances, be assembled with the shaft (9) pointing towards starboard.
               However, if it is not possible to orientate the unit in this way, port installa-
               tion is possible providing the red and green wires are reversed at the
               course computer.
               11. With the adjustment screw and barrel aligned with the spacers, close
                   the hose clamps (6) around the linear feedback transducer (5) and the
                   `bullhorn' ram (1).
               12. Tighten the `bullhorn' bolt to retain the U-bracket (3).
               13. Fit and tighten the nut (7) and washer (8) to the shaft of the linear
                   feedback transducer (5).

     Cabling
               1. Run the linear feedback transducer cable back to the course
                  computer.
               2. Connect to the course computer rudder reference terminals.
               Note: To allow for movement of the bullhorn, leave a loop of cable at the
               end of the Linear Feedback Transducer.




                                            TM


                                                                                               + ­
                                                                        GYRO 2   RUDDER REF.     NM




                                                             Grey (screen)   Red      Green     Blue
                                                                                                 D895-1
Chapter 2: Installation                                                                             35




2.6 Hydraulic Drive Systems
                          This section covers the installation of hydraulic system components
                          together with relevant plumbing and cabling procedures.
                          For optimum autopilot performance it is important that the pump specifica-
                          tions given below match the vessel's steering ram.

            Pump to Cylinder Specifications

                          Pump                         Capacity

                          Type 1                       80 to 230cc (4.9 to 14cu in)

                          Type 2                       160 to 350cc (9.8 to 21cu in)

                          Type 3                       250 to 460cc (15 to 28cu in)

                          CR1                          350 to 500cc (21 to 30cu in)

                          CR2                          500 to 1200cc (30 to 73cu in)
                                                                                                81004-04



            Reversing Hydraulic Pumps (Type 1, Type 2 & Type 3)
            Mounting
                          The hydraulic pump should be mounted in a horizontal position clear of
                          spray and possible water immersion. It should also be located as near as
                          possible to the hydraulic steering cylinder.
                          Bolt the hydraulic pump to a substantial member to avoid vibration that
                          could damage the interconnecting pipework.
            Cabling
                          Using a suitably sized cable (see below) route the pump leads back to the
                          course computer and connect to the motor terminals.
                          Type 1 Drive Unit

                          Cable Length (Drive Unit             Cable Gauge         Copper Area
                          to Course Computer)

                          Up to 3m (10ft)                      12 AWG              2.5 mm

                          Up to 5m (16ft)                      10 AWG              4 mm

                          Up to 7m (23ft)                      8 AWG               6 mm
                          Up to 10m (32ft)                     6 AWG               10 mm

                          Up to 16m (52ft)                     4 AWG               16 mm
                                                                                                81004-05
36                            TYPE 100/300 Operation and Installation Handbook




     Type 2 Drive Unit (12V)

     Cable Length (Drive Unit              Cable Gauge        Copper Area
     to Course Computer)

     Up to 5m (16ft)                       8 AWG              6 mm

     Up to 7m (23ft)                       6 AWG              10 mm
     Up to 16m (52ft)                      4 AWG              16 mm
                                                                         81004-06




     Type 2 Drive Unit (24V)

     Cable Length (Drive Unit              Cable Gauge        Copper Area
     to Course Computer)

     Up to 3m (10ft)                       12 AWG             2.5 mm

     Up to 5m (16ft)                       10 AWG             4 mm

     Up to 7m (23ft)                       8 AWG              6 mm
     Up to 10m (32ft)                      6 AWG              10 mm

     Up to 16m (52ft)                      4 AWG              16 mm
                                                                         81004-05




     Type 3 Drive Unit (12V)

     Cable Length (Drive Unit              Cable Gauge        Copper Area
     to Course Computer)

     Up to 5m (16ft)                       8 AWG              6 mm

     Up to 7m (23ft)                       6 AWG              10 mm
     Up to 16m (52ft)                      4 AWG              16 mm
                                                                         81004-06




     Type 3 Drive Unit (24V)

     Cable Length                          Cable Gauge        Copper Area
     (Distribution Panel to
     Pump)

     Up to 3m (10ft)                       8 AWG              6 mm

     Up to 7m (22ft)                       6 AWG              10 mm

     Up to 16m (52ft)                      4 AWG              16 mm
                                                                         81004-07
Chapter 2: Installation                                                                             37




                          Note: The reversing hydraulic pumps do not require a clutch connection.
                          If the pump is to be used to drive a secondary steering ram, a bypass
                          valve will have to be fitted as shown in the following illustration.




                                      Relay
                                                                    ­ +      ­ +    1   2

                                                    Talk   SeaTalk CLUTCH   POWER   MOTOR




                             Power
                                                                                                  D915-1




                          Note: A 5 amp relay should be used to energise the bypass valve. The
                          relay should have a 12V coil (taking less than 500ma) and be driven by the
                          clutch output on the course computer connector.
            Plumbing
                          There are three basic types of hydraulic steering systems:
                          · two line system
                          · three line system
                          · two line pressurised system
                          Typical connection points for the autopilot pump are shown for each type.
                          In all cases it is strongly recommended that the steering gear
                          manufacturer is consulted.
                          All hoses used to fit the pump should match or exceed the specification of
                          those used in the existing steering system.
38                          TYPE 100/300 Operation and Installation Handbook




     It is also necessary to ensure that the helm pump is fitted with reversing
     check valves, otherwise the autopilot pump will drive the helm pump
     (sometimes referred to as motoring the wheel) in preference to moving the
     ram. Single helm pump systems without check valves should incorporate
     a double pilot check valve and block (available as part Z068). This is shown
     in the following illustration.




                                  Check valve (Z068)




                                                                D274-3



     Notes:
     1. A double pilot check valve may also be necessary on long tubing runs.
        Tubing expansion may result in poor autopilot performance. The valve
        should be installed close to the cylinder with the pump in between (as
        shown).
     2. If the vessel has two steering positions, check valves will already be
        fitted to ensure independent operation of the two wheels.
     Minimisation of hydraulic fluid loss during connection of the drive unit will
     help to reduce the time and effort required later to bleed the system of
     trapped air. Absolute cleanliness is essential since even the smallest
     particle of foreign matter could interfere with the correct function of the
     steering system precision check valves.
Chapter 2: Installation                                                                                39




            Two line system
                          A typical two line steering system is shown in the following illustration.
                          Hydraulic fluid can be pumped into the ram in either direction depending
                          on the direction of the helm pump rotation. The autopilot pump is con-
                          nected to the system as shown.




                                                                 D271-2




            Two line pressurised system
                          Two line pressurised systems have an external pressurised reservoir. This
                          reduces the possibility of inducing air into the system and any sponginess
                          felt due to pipe expansion. The autopilot pump is connected to the system
                          as shown in the following illustration.
                          Note: Refer to the manufacturer's instructions on depressurising the system.




                                                                 D272-2
40                                     TYPE 100/300 Operation and Installation Handbook




     Three line system
               In a three line system, hydraulic fluid flows in one direction only - out of the
               helm pump to the ram and then returning from the other side of the ram to
               the reservoir via a common return line.
               A uniflow valve block will be fitted in the system to ensure that all returned
               fluid from the ram is directed back to the reservoir.




                                                        D273-2




     Bleeding the system
               Correct bleeding of the hydraulic system is one of the most important
               steps when installing a hydraulic pump. The presence of air in the hydraulic
               system will not only reduce performance of the autopilot but also the
               overall operation of the steering system.
               Further to the manufacturer's instructions for bleeding the steering
               system, the following procedures should be carried out to bleed the
               autopilot pump.
              1. Press and hold the -10 degree key : the autopilot pump will try to drive
                 the rudder to port.
              2. Counter this rudder movement by turning the helm to starboard to
                 keep the rudder stationary. This will cause any air in the pump to rise
                 to the helm pump and exhaust into the reservoir.
Chapter 2: Installation                                                                              41




                          3. Reverse this action to clear any air on the other side of the pump as
                             follows:
                          4. Press and hold the +10 degree key: the autopilot will try to drive the
                             rudder to starboard.
                          5. Counter the rudder movement by turning the helm to port.
                          Note: Monitor the reservoir tank at all times during the bleeding proce-
                          dure, make sure it remains full of the hydraulic fluid recommended by the
                          manufacturer. If air is left in the system the steering will feel spongy,
                          particularly when the wheel is turned to the hardover position.

            Constant Running Hydraulic Pump
            Mounting
                          Bolt the constant running hydraulic pump to a suitable horizontal surface.
                          The service ports are tapped to 1/4in B.S.P. and the reservoir port is
                          tapped to 3/8in. B.S.P. Three N.P.T. adaptors are included for conversion
                          to N.P.T. where required.




                                Reservoir port (3/8in B.S.P.)   Service port (1/4in B.S.P.)
                                                                                        D765-1
42                                    TYPE 100/300 Operation and Installation Handbook




     Cabling
               The constant running interface must be used on all installations with
               constant running hydraulic pumps. The main power supply is led to the
               interface and then onto the course computer. The interface unit has
               connections for the solenoid valves and the bypass valve, if one is
               required. The pump should be wired (as shown) using the specified cable
               size and designated circuit breaker.

                 Supply                           Main breaker                                                   Clutch drive

                            3L (12V) ­ 50A
                          4.5L (12V) ­ 70A
                            3L (24V) ­ 30A
                          4.5L (24V) ­ 40A

                 To bypass
                 valve                            25A




                                                                                         Type CR
                                                                                         interface unit
                                                  Solenoid 'A' cable


                                                                               D2
                                                                                                 + ­




                                                                                    D1
                                                                                                       SOLENOIDS
                                                                                                               B
                                                   M1 M2 SUPPLY CLUTCH




                                                                                                 + ­
                                                                                                       A
                                                                         + ­




                                                                                                       BYPASS BATTERY
                                                                                                 + ­
                                                                         + ­




                                                                                                        VALVE
                                                                                                 + ­




                                                                               RLY1

                     Power pack motor supply
                                                                                                                            D778-1
Chapter 2: Installation                                                                                43




                          Pump Cable

                          Cable Length                         Cable Gauge          Copper Area
                          (Distribution Panel to
                          Pump)

                          Up to 3m (10ft)                      8 AWG                6 mm

                          Up to 7m (22ft)                      6 AWG                10 mm

                          Up to 16m (52ft)                     4 AWG                16 mm
                                                                                                   81004-07




                          Solenoid Cable

                          Solenoid Cable Length                Cable Gauge          Copper Area
                          (Course Computer to Pump)

                          Up to 7m (23ft)                      12 AWG               2.5 mm

                          Up to 12m (39ft)                     10 AWG               4.0 mm

                          Up to 17m (55ft)                     8 AWG                6.0 mm
                                                                                                   81004-08




                          An isolator switch should be installed in the power supply to the complete
                          system.
                          The solenoid valve connectors can only accept cable up to 12 AWG. If
                          larger cable is required, 18 inches of 12 AWG should be used to wire to
                          the connectors.
                          The Type CR Interface may also be connected to alternative constant
                          running hydraulic pump providing:
                          · the solenoid coils take less than 10 amps
                          · the response time of the solenoid valve is less than 80 milliseconds
                          · the operating voltage of the solenoid coils is the same as the course
                             computer supply voltage.
                          It is important to minimise the overall cable length between the pump and
                          the vessels power distribution panel.
44                                         TYPE 100/300 Operation and Installation Handbook




     Plumbing
                If the autopilot operated hydraulic cylinder is independent of the manual
                steering system, a solenoid operated bypass valve
                (Z079 (12V),Z122 (24V)) should be fitted to allow the cylinder to backdrive
                when manual steering. The bypass valve should be connected to the
                `bypass' connector on the Type CR Interface Unit.
                The bypass valve should be mounted between the autopilot steering
                cylinder ports and, under normal circumstances, be de-energised to allow
                the cylinder to backdrive. When the autopilot is engaged, the valve is
                energised by the Type CR Interface to allow the autopilot steering cylinder
                to drive the rudder.

                                 Hydraulic cylinder                  Bypass valve


                                                                           Autopilot
                                                                           hydraulic
                                                                           drive




                  Manual steering system     Cable to course computer 'Bypass' connector
                                                                                       D766-1




                Note: The bypass valve voltage must be matched to the course computer
                supply voltage, i.e. 12V or 24V.
                If the steering cylinder is unbalanced (single ended), a pilot operated
                pressure relief valve must be connected (as shown) to enable excess oil to
                be returned to the reservoir when the cylinder ram is retracting.
Chapter 2: Installation                                                                                     45




            Hydraulic Linear Actuator
                          The hydraulic linear actuator, with built in solenoid operated bypass valve
                          and load limiting system, is designed for use as a secondary autopilot
                          steering cylinder. The system is supplied prefilled and preplumbed for
                          ease of installation.

                                                              6                 2
                                         1

                                         5
                                         4
                                                              9   7                                10




                                                                  8        3             11

                                                                                    X

                              Drive     Dimension X
                              Type 2    180mm (7.1in)
                              Type 3    267mm (10.5in)
                                                                                                        D776-1


                          1 Reservoir 2 Pump 3 Cylinder 4 Tie-wrap 5 Clip 6 Reservoir hose 7 Pump hose A
                          8 Pump hose B 9 Cylinder hose 10 Cylinder ball joint 11 Quadrant

            Installation
                          Caution:
                          It is important to note that the hydraulic linear actuator can exert a
                          thrust of upto 2700 Ibs - this is the equivalent weight of a large
                          family saloon car. If there is any doubt about the strength of the
                          existing tiller arm or quadrant the steering gear manufacturer
                          must be consulted. Also, the mounting foot should be bolted to a
                          substantial member and always over engineer to ensure reliability
                          and maintenance of correct alignment.
46                         TYPE 100/300 Operation and Installation Handbook




     When siting the actuator the following points should be noted:
     1. The actuator mounting foot must be mounted to a horizontal surface.
        There is insufficient movement in the swivel joint for vertical mounting.




     View from above
                                                              D1034-1




     View from above
                        #                                     D1035-1




     2. The drive end must be at right angles to the hydraulic cylinder when
        the tiller is amidships.




                                                     90




                                                              D1037-1


     View from above
Chapter 2: Installation                                                                                     47




                          3. Accurate angular alignment between the hydraulic cylinder and the
                             tiller arm plane of rotation is extremely important ­ under no
                             circumstances should any misalignment exceed +/- 5 degrees.



                                                                            5° Max.

                                                                            5° Max.




                                                                                              D1036-1


                          View from astern

                          Caution: The push rod must not be shortened as it contains hydraulic fluid.
                          4. The push rod ball end must be attached to the tiller arm at the radius
                             specified on page 45. Use the supplied fixing bolt with its flange
                             positioned between the ball end and the tiller arm. It is very important
                             that this bolt is a tight fit in the tiller arm. Use Loctite 638 (or an
                             equivalent) to secure the tiller bar bolt and lock the securing nut.

                            A                                    C       Hole size X:
                                                                         Type 2, 11.96 - 12.06mm
                                                                 D       (0.471 - 0.475in)
                                                                         Type 3, 19.9 - 20mm
                                                                 E
                                                                         (0.783 - 0.787in)
                                                                 F
                            B
                                                                 G       A Spring clip B Washer
                                                                         C Washer D Push rod ball end
                                                                         E Fixing bolt flange F Tiller arm
                                                                         G Fixing nut

                                             X                                                          D1046-1


                          5. Position the reservoir (1) so that it is at least 150mm (6in.) above the
                             pump (2). The pump (2) should be sited above the cylinder (3).
                          6. Use the cable tie-wrap (4) to secure the reservoir (1) to the clip (5).
48                                   TYPE 100/300 Operation and Installation Handbook




     Cabling
               1. Run the pump and bypass valve cable back to the course computer.
               2. Wire to the course computer clutch and motor connections.




                                                               ­ +      ­ +    1   2

                                                              CLUTCH   POWER   MOTOR




                                                                                       D917-1



     Final Preparations Before use
               1. Remove the reservoir cap and replace with the supplied standard cap.
               2. Set the reservoir valve to the open position.
               Caution:
               Make sure the mechanical limits of the steering system stop
               rudder movement before the cylinder reaches its end stops -
               failure to do this will damage the steering cylinder and will invali-
               date the warranty.
               3. Switch the Autopilot to `Auto' mode and, using the 10 degree course
                  change keys, steer hard-over to hard-over to check for correct
                  operation and any possible leaks.
               4. Set-up the autopilot end stops as described in the autopilot installation
                  handbook.
               WARNING:
               KEEP CLEAR OF MOVING STEERING LINKAGES AT ALL TIMES.
Chapter 2: Installation                                                                                                                    49




2.8 Mechanical Drive Systems
            Rotary Drive Unit
                          The rotary drive is coupled to the steering by a chain drive. Most steering
                          gear manufacturer's supply special autopilot drive attachments (many
                          include this as standard). The Edson Company is a good source.

            Mounting
                          Having selected the position for attachment of the autopilot drive chain, it
                          is necessary to determine the chain reduction ratio.
                          Count the number of turns of the steering gear shaft (driven sprocket)
                          when the rudder is driven from hardover to hardover. Determine the
                          sprocket sizes required from the following table.

                                                                                               Rotary Drive Chain Reduction Ratios
                                                 Driven Sprocket
                               Driver Sprocket




                                                                                           7


                               17                76                                        6
                                                                   Chain Reduction Ratio




                               15                76
                                                                                           5
                               13                57

                                                                                           4
                               15                57

                               17                57

                               13                38                                        3
                               15                38
                               17                38
                               13                25                                        2                                 Type 2
                               15                25
                               17                25
                               19                25
                               25                25                                        1
                                                                                                                              Type 1

                                                                                                    1     2      3     4      5      6
                                                                                                     Number of Driven Sprocket
                                                                                                      Turns Hardover Hardover     D757-1



                          These ratios provide good steering performance for most vessels. If the
                          vessel is thought to have unusual steering characteristics, contact our
                          Product Support Department, or an authorised representative, for advice.
                          A standard 3/8in. or 1/2in. pitch chain is recommended for the chain drive
                          and, ideally, the drive sprocket should not have less than 15 teeth. Bore
                          and keyway dimensions for the drive unit sprocket are detailed in the
                          following illustration. It is essential that these bore and keyway dimensions
                          are strictly adhered to. All sprockets must be keyed, set screwed to their
                          shaft and finally secured with loctite.
50                            TYPE 100/300 Operation and Installation Handbook




        3.22mm ­ 3.24mm                         15.89mm ­ 15.9mm
       (0.127in ­ 0.1275in)                    (0.6256in ­ 0.6275in)




       Grub screw
                                                9.46mm ­ 9.61mm
                                               (0.3725in ­ 0.3785in)


        19mm
       (0.75in)                                         12.7mm
                                                         (0.5in)
                                                                   D758-1



     The drive unit must be bolted to a substantial frame member. The
     mounting foot is secured to the drive unit by four equally spaced allenhead
     screws and it may be rotated through 90 degrees to provide a more
     convenient mounting position, if required. In some cases it may be
     necessary to fabricate a special frame to mount the drive unit.
     It should be noted that chain tension can exceed 500 lb (230Kg) and,
     therefore, an extremely rigid mounting structure is vital to maintain good
     chain alignment. Installation failures can occur in this area and over-
     engineering is strongly recommended for drive unit mounting. All
     fastenings should be secured with lock washers.
     Provisions must also be made for chain adjustment. This is achieved by
     removable shims placed under the mounting foot or, alternatively, by
     elongated clearance holes in the mounting frame.
Chapter 2: Installation                                                                              51




                                                                                                  D759-1




                          Both sprockets must be accurately aligned to run in the same plane.
                          Correct alignment must be carefully checked by means of a straight edge.
                          The gearbox can be mounted in any position. Additionally, the drive
                          sprocket may face in any direction as the steering sense can, by reversing
                          the polarity of the drive motor connection, be corrected when installation is
                          complete.
                          Finally, the chain should be tensioned until it is just tight and there is
                          minimal lost motion to the drive system. Total lost motion between the
                          driven sprocket attached to the steering system and the rudder stock
                          should not, under any circumstances, exceed 2% of the total movement.
                          If lost motion exceeds this level it must be corrected, otherwise steering
                          performance will be impaired.
                          Having completed installation of the drive unit, turn the steering wheel from
                          hardover to hardover and check that the chain and sprockets driving the
                          actuator move freely and are in alignment.
52                                   TYPE 100/300 Operation and Installation Handbook




     Cabling
               The rotary actuator has electrical connections for both the drive motor
               (red/black cores) and clutch (twin cable with blue/red cores). Using a
               suitable size cable (see tables), route back to the course computer and
               connect to the clutch and motor terminals.




                                                                   ­ +      ­ +    1  2

                                                          SeaTalk CLUTCH    POWER MOTOR




                                                                                      D902-1




     Type 1 Drive Unit
               Cable Length (Drive Unit             Cable Gauge            Copper Area
               to Course Computer)

               Up to 3m (10ft)                      12 AWG                 2.5 mm

               Up to 5m (16ft)                      10 AWG                 4 mm

               Up to 7m (23ft)                      8 AWG                  6 mm
               Up to 10m (32ft)                     6 AWG                  10 mm

               Up to 16m (52ft)                     4 AWG                  16 mm
                                                                                    81004-05



     Type 2 Drive Unit (12V)
               Cable Length (Drive Unit             Cable Gauge            Copper Area
               to Course Computer)

               Up to 5m (16ft)                      8 AWG                  6 mm

               Up to 7m (23ft)                      6 AWG                  10 mm
               Up to 16m (52ft)                     4 AWG                  16 mm
                                                                                    81004-06
Chapter 2: Installation                                                                                  53




            Type 2 Drive Unit (24V)
                          Cable Length (Drive Unit               Cable Gauge            Copper Area
                          to Course Computer)

                          Up to 3m (10ft)                        12 AWG                 2.5 mm

                          Up to 5m (16ft)                        10 AWG                 4 mm

                          Up to 7m (23ft)                        8 AWG                  6 mm
                          Up to 10m (32ft)                       6 AWG                  10 mm

                          Up to 16m (52ft)                       4 AWG                  16 mm
                                                                                                   81004-05




            Linear Drive Unit
                          The linear drive unit connects directly on to the rudder stock at the tiller
                          arm radius (shown below).

                          Drive Unit                         Tiller Radius (B)

                          Type 1                             250mm (10in)

                          Type 2S                            250mm (10in)

                          Type 2L                            360mm (14in)
                                                                                                   81004-09



                          It is preferable to couple the linear drive unit to the rudder stock via an
                          independent tiller arm (Edson and Whitlock offer a standard fitting). In
                          certain cases, however, it may be possible to couple the pushrod to the
                          same tiller arm, or rudder quadrant employed, by the main steering
                          linkage.




                                                                     Mid Stroke




                                                                        90°            'B'



                                                                                      D760-1



                          Caution: The linear drive system can exert a thrust of over 1000Ib.
                          (450Kg). The steering gear manufacturer must be consulted if any doubt
                          exists about the strength of the existing tiller arm or rudder quadrant.
54                                 TYPE 100/300 Operation and Installation Handbook




     Mounting
            When siting the linear drive unit, the following points should be noted:
            · The drive unit mounting bracket can be attached to any horizontal or
               vertical surface. Also, the drive unit can be mounted upside down if
               required.
            · The ball end fitting will allow up to 5 degrees misalignment between the
               pushrod and tiller arm plane of rotation. Accurate angular alignment is
               extremely important and, therefore, under no circumstances should this
               limit be exceeded.
            · The drive unit must be at right angles to the tiller arm when the rudder is
               amidships.
            · The drive is clear of any bilge water.

                                        Tiller
                                        arm
                Fixing
                bolt flange



                Lock
                washer

                Hole dia.
                0.52in (13mm)

                                                                          D761-1



            · The mounting bracket should be bolted to a substantial frame member.
               Always over-engineer to ensure reliability and maintenance of
               correct alignment.
            The pushrod ball end must be attached to the tiller arm, using the adaptor
            pin (supplied), with its flange positioned between the ball end and the tiller
            arm. It is vitally important that the lock washer (supplied) is used and that
            the nut is tightened fully.
            The mounting bracket should be attached with four stainless steel 3/8in.
            bolts and locknuts/lock washers.
            Having installed the drive unit, turn the steering wheel from hardover to
            hardover and check that:
            · no part of the drive unit fouls the vessels structure.
            · the mechanical limit stop on the vessels steering system is reached
               before the actuator reaches its mechanical limit.
            · angular movement of the ball end fitting is less that 5 degrees.
Chapter 2: Installation                                                                               55




            Cabling
                          The linear drive unit has electrical connections for both the drive motor and
                          clutch. Using a suitable size cable (see tables), route back to the course
                          computer and connect to the clutch and motor terminals as shown.




                                                                              ­ +     ­ +    1  2

                                                                          lk CLUTCH   POWER MOTOR




                                                                                                  D902a-1




            Type 1 Drive Unit
                          Cable Length (Drive Unit              Cable Gauge           Copper Area
                          to Course Computer)

                          Up to 3m (10ft)                       12 AWG                2.5 mm

                          Up to 5m (16ft)                       10 AWG                4 mm

                          Up to 7m (23ft)                       8 AWG                 6 mm
                          Up to 10m (32ft)                      6 AWG                 10 mm

                          Up to 16m (52ft)                      4 AWG                 16 mm
                                                                                                81004-05



            Type 2 Drive Unit (12V)
                          Cable Length (Drive Unit              Cable Gauge           Copper Area
                          to Course Computer)

                          Up to 5m (16ft)                       8 AWG                 6 mm

                          Up to 7m (23ft)                       6 AWG                 10 mm
                          Up to 16m (52ft)                      4 AWG                 16 mm
                                                                                                81004-06
56                                        TYPE 100/300 Operation and Installation Handbook




     Type 2 Drive Unit (24V)
               Cable Length (Drive Unit                   Cable Gauge                   Copper Area
               to Course Computer)

               Up to 3m (10ft)                            12 AWG                        2.5 mm

               Up to 5m (16ft)                            10 AWG                        4 mm

               Up to 7m (23ft)                            8 AWG                         6 mm
               Up to 10m (32ft)                           6 AWG                         10 mm

               Up to 16m (52ft)                           4 AWG                         16 mm
                                                                                                          81004-05




     Stern drive Actuator
               The stern drive actuator can be fitted to power assisted Stern drive
               systems made by Volvo-Penta, Mercruiser, OMC and Yamaha. Different
               installation kits are available to cover most of these installations.
               Note: Older Volvo steering systems (Pre type 872215) require an adaptor
               bracket (D129).

     Mounting
     Volvo (Pre type 872215)
               Fitting to this type of engine requires an adaptor bracket (M81139).
               The stern drive actuator should be connected to the centre hole on the
               tiller arm. On twin engine installations, this is the position used to connect
               the engine tie bar to link the two tiller arms.

                                                         Adaptor pin              Adaptor pin
                                                         (Multi-engine mount)     (Single engine mount)



                                                           Small
                  Mounting                                 spring
                  bracket                                  clip
                                                                      Split pin




                                                                                            Nyloc nut

                  Hexagonal
                  key bolt    Spring           Bracket     Location
                  (2 off)     washer (2 off)   clamp       pin
                                                                                                   D768-1
Chapter 2: Installation                                                                                    57




                          1. Push the mounting bracket behind the steering cable, sliding the
                             location pins either side (top and bottom) of the Volvo power steering
                             block.
                          2. The bracket clamp hinges onto the mounting bracket and is located
                             using the two allenhead key bolts. Tighten the two bolts evenly until
                             the bracket is securely located.

                              D129 Mounting bracket

                              Steering
                              cable                                             Location pin




                              D129 Mounting bracket        Bracket clamp

                                                                                Volvo Penta
                                                                                steering valve block
                                                                               Valve shoulder to
                                                                               remain out of bracket
                              Steering cable        Cable clamp nut
                                         Bracket     Large diameter




                                                                               Valve block
                              Cable
                              clamp nut        Spool valve shoulder
                                                                                                  D769-1



                          3. Uncouple the engine tie bar from the outdrive tiller arm by bending
                             back the locking tabs and removing the cotter pin. This should be
                             replaced with the multi-engine adaptor pin. Make sure that it is
                             secured properly with a split pin (on single engine installations, fit the
                             single engine adaptor pin in the vacant middle hole in the tiller arm).
58                                  TYPE 100/300 Operation and Installation Handbook




                  Drive unit                 Valve block




                                                   Small spring clip             Engine tie bar




                 Drive unit      Split pin                   Split pin
                                                                                                  D770-1




              4. Attach the drive unit to the mounting bracket as shown above and
                 secure split pin provided. The small spring clip can then be used to
                 attach the drive unit to the adaptor pin.
              5. Slowly turn the steering system from hardover to hardover. It is most
                 important that the drive unit and the adaptor pin bracket do not touch
                 any part of the engine or steering system.
     Volvo (Post type 872215)
              1. Remove the locating pin that attaches the cable rod to the tiller end
                 block and replace with the girdle support bracket as shown.

                Safety clip              Locating bolts      Split pin
                                         Shakeproof
                                         washers




                Adaptor pin              Girdle support    Sprung location
                bracket                  bracket           pin          D744-1
Chapter 2: Installation                                                                             59




                                                                      Girdle support
                                                                      bracket




                                                                      Tiller end block
                                                                      Split pin




                                                                                  D745-1



                          2. Secure the assembly with the split pin (supplied).
                          3. Install the adaptor pin bracket to the cable end sheath.

                                                                            Adaptor
                                                                            bracket

                                                                            Aft



                                                                            Cable end
                                                                            sheath




                                                      Shoulder
                                                                                           D925-1



                          Note: The adaptor pin bracket must sit against, but not on, the shoulder of
                          the cable end sheath. Also, it is important that the securing bolts are
                          sternside of the steering cable end sheath.
                          4. Ensure that the bracket remains vertical and tighten the locking bolts.
                          5. Rotate the girdle support bracket so that locator pin is facing
                             forwards.
                          6. Position the stern drive actuator so as to locate the fixed support pin
                             on the girdle support bracket into the hole in the girdle tube.
60                           TYPE 100/300 Operation and Installation Handbook




                                               Girdle tube




                                                                        D926-1



     7. Carefully twist and lower the actuator into the girdle support bracket
        until the spring pin locates into the opposite side of the girdle tube.
     Caution: It is most important that both the solid and spring location pins
     are fully engaged in the actuator girdle tube. Failure to do so will result in
     autopilot failure and possible steering system damage.
     8. Position the drive unit pushrod over the top of the adaptor pin and
        secure with the safety clip.
     9. Slowly turn the steering system from hard-over to hard-over. The drive
        unit and the adaptor pin bracket must not touch any part of the engine
        or steering system. This includes any engine hoses that may have
        only passing contact with the autopilot actuator; after a time these
        will wear and ultimately fail.
Chapter 2: Installation                                                                                  61




            Mercruiser/OMC/Yamaha
                          1. Remove the locating pin that attaches the cable end sheath to the tiller
                             end block.
                          2. Replace the locating pin with the girdle support bracket as shown.

                                       Cable end sheath                               Girdle
                                                                                      support
                                                                                      bracket




                                                                                      Split
                                                                                      pin

                                                                                      Tiller
                                                                                      end block




                                                                                               R745a-1




                          3. Secure the assembly with the split pin (supplied).
                          4. With the helm turned hard to port, assemble the adaptor pin bracket
                             to the cable end sheath as shown.

                                                          6.5in (165mm)



                                                            Cable end
                                                            sheath




                            Adaptor
                            bracket             Forward                              D1003-1



                          Note: The securing bolts must be on the front or bow of the boat side
                          cable end sheath. Also, the bracket should be positioned 6.5in (165mm)
                          from the girdle support bracket.
62                        TYPE 100/300 Operation and Installation Handbook




     5. Make sure that the bracket remains vertical and tighten the two
        locating bolts.
     6. Rotate the girdle support bracket so that the spring locator pin is
        facing forwards.
     7. Position the stern drive actuator so as to locate the fixed support
        pin on the girdle support bracket into its location hole in the girdle
        tube.

                                             Girdle tube




                                                                   D1002-1




     8. Carefully twist and lower the actuator in to the girdle support
        bracket until the spring pin locates into the opposite side of the
        girdle tube.
     Note: Both the solid and spring location pins must be fully engaged in
     the actuator girdle tube; failure to do so will result in autopilot
     failure.
     9. Position the drive unit pushrod over the top of the adaptor pin and
        secure with the safety clip.
     10. Slowly turn the steering system from hard-over to hard-over.
     Note: It is most important that the drive unit and the adaptor pin
Chapter 2: Installation                                                                           63




                          bracket do not touch any part of the engine or steering system. This
                          includes any engine hoses that may have a passing contact with the
                          autopilot actuator; after a time these will wear and ultimately fail.
            Mounting in a Restricted Area
                          If an obstruction prevents installation of the drive unit as supplied, the
                          main body can be rotated relative to the mounting bracket as follows:
                          1. Remove the two fixing screws and carefully slide the cover
                             forwards, ensuring that the four cables do not pull away from the
                             plugs inside the cover.
                          2. Loosen off the lock nut and rotate the main body as required.
                          3. Re tighten the lock nut securely, making sure that the lock nut is
                             no more than one turn from the start of the thread.
                          4. Replace the cover taking care not to crimp any cables.
                          5. Using the steering wheel, move from hard over to hard over and
                             check that no part of the drive unit contacts any part of the vessel/
                             fittings.
64                                    TYPE 100/300 Operation and Installation Handbook




                                                  Fixing screw




                           Lock nut            Front cover
                                                                                D409-2




     Cabling
               1. Plug in the power cable, supplied with the drive unit, making sure
                  that the connector is locked in place by turning the locking ring
                  clockwise.
               2. Run the cable back to the course computer. Secure the cable
                  close to the drive unit but allowing sufficient free length to
                  accommodate the drive unit movement.
               3. Once again using the steering wheel to move the rudder from
                  hard over to hard over, check that the cable does not catch on
                  any part of the vessel/fittings.
               4. The actuator cable has electrical connections for both the drive
                  motor and the clutch. Connect to the course computer terminals
Chapter 2: Installation                                                                           65




                              labelled clutch and motor as shown.




                                                                           ­ +       ­ +   1  2

                                                                       lk CLUTCH    POWER MOTOR



                                                                    Black          Blue
                                                                    Red            Brown



                                                                                             D912-1




2.9 Auxiliary Alarm
                          The auxiliary alarm is waterproof and, therefore, can be mounted in
                          any position. A foam seal on the mounting flange ensures a watertight
                          joint to the mounting surface.
                          The auxiliary alarm must be connected to the system via an NMEA
                          interface.
                          1. Drill a 7/8in (22mm) diameter hole through the mounting panel
                             as shown.
                          2. Pass the two way connector block and cable through the drilled
                             hole.
                          3. Mount the auxiliary alarm in position using the four self tapping
                             screws (supplied).
66                                                                TYPE 100/300 Operation and Installation Handbook




        Cabling


                                                                                                      Grey (screen)




                                          ALARM SEATALK SEATALK
                       + ­
                         IN
                               NMEA
                                                                                                      Red

                       + ­
                         OUT
                                                                                               ­ +    Yellow
                                                                           SeaTalk   SeaTalk CLUTCH
                               WINDVANE




                                                                                                                      D982-1



                  Connect the NMEA interface to the alarm and course computer as
                  shown.

2.10 Joystick
                  The mounting surface must be smooth and flat to ensure that there is
                  adequate waterproofing.
                  1. Use the template provided to mark the centers for the two fixing
                     holes and outline of the body aperture.
                  2. Drill the fixing holes and cut-out the aperture for the body.
                  3. Remove the mounting template and peel off the protective paper
                     from the rear of the weather gasket and fix to the mounting
                     surface.
                  4. Pass the signal cable through the body aperture and secure the
                     Joystick with the thumb nuts provided.
Chapter 2: Installation                                                                                   67




                                                                              D1004-1




            Cabling
                          The Joystick is supplied with 26ft (8m) of cable which should be
                          connected to the course computer as shown.




                                                                   FLUXGATE             JOYSTICK   GYRO




                              Grey (screen)   Red   Green   Blue
                                                                                                      D984-1



                          Note: Only one joystick can be connected.

2.11 Masthead Transducer (sail only)
                          To enable wind information to be made available to the SeaTalk
                          system, the wind transducer must be connected to the NMEA
                          interface box.
68                                    TYPE 100/300 Operation and Installation Handbook




     Mounting
               1. With the threaded end of the mounting block facing forwards,
                  mark the position for the self tapping screws.
               2. Drill the holes using the supplied 4.0mm (5/32in.) drill.
               3. Attach the mounting block to the mast using a suitable sealing
                  compound.
               4. Tighten the locking ring securely.

                               1                 2




                                                                      D756-1



               1 Mounting block 2 Locking ring

     Cabling
               1. Cut the cable with sufficent length to run from the monting block
                  to the NMEA interface box.
               2. Feed the cable down the mast.
                   Note: If the mast is deck stepped the cable should be passed
                   through the deck and sealed using a proprietry gland fitting.
               3. Connect the cable to the NMEA interface box as shown.
Chapter 2: Installation                                                                              69




                                                    ALARM SEATALK SEATALK
                                 + ­
                                   IN
                                         NMEA
                                 + ­
                                   OUT
                                         WINDVANE




                                                       ­ +
                          SeaTalk            SeaTalk CLUTCH




                           Grey (screen)                                    Red   Yellow
                                                                                           D1021-1
70                                        TYPE 100/300 Operation and Installation Handbook




                     Note: The yellow connection from the mast head transducer is not
                     connected at the NMEA interface.

2.12 Interfacing to other manufacturer's equipment (NMEA)

        Course Computer NMEA ports
                     The type 100 and 300 course computers have NMEA 0183 input and
                     output ports. Sentances decoded are as follows.
        Input Port

                     NMEA 0183 Data          NMEA Header Received
                     Cross Track Error       APA, APB, RMB, XTE, XTR

                     Bearing to Waypoint     BPI, BWR, BWC, BER, BEC, RMB, APB

                     Distance to Waypoint BPI, BWR, BWC, BER, BEC, RMB, WDR, WDC

                     Waypoint Number         APB, BPI, BWR, BWC, BER, BEC, RMB, APA,
                                             WDR, WDC, BOD, WCV
                     Water Speed             VHW
                     (through the water)

                     Apparent Wind Angle VWR
                     Latitude/Longitude      GGA, GLL, GXA, RMA, RMC, GXP, GDF,
                                             GDP, GDA, GOF, GOP, GLF, GLP, GLA
                                             GOA, IMA, GXF
                     COG/SOG                 VTG, RMA, RMC, VTA

                     Variation               HDG, RMA, RMC, HVD, HVM


        Output Port
Chapter 2: Installation                                                                      71




                          NMEA 0183 Data                NMEA Header Transmitted

                          Cross Track Error             XTE

                          Bearing to Waypoint           BWC

                          Distance to Waypoint          BWC

                          Waypoint Number               BWC

                          Latitude and Longitude        GLL

                          Magnetic Heading              HDG, HDM, HDT

                          True Heading                  HDT

                          Locked Autopilot Heading      HSC
                          Course Over Ground            VTG

                          Speed Over Ground             VTG

                          Fix/No Fix                    GLL
                                                                                         81004-11




            Cabling
                          Connect the NMEA output from a GPS, Loran, Decca etc. to the
                          NMEA input terminals on the course computer.

                               Type 100/300
                              Course Computer



                                                               GPS
                             + ­ + ­
                                                              Loran
                               NMEA     SeaTalk
                                                              Decca



                                                                 NMEA out

                                                                      D1064-1
72                                   TYPE 100/300 Operation and Installation Handbook




             Connect the NMEA input on the radar etc. to the NMEA output
             terminals on the course computer.

                  Type 100/300
                 Course Computer




                + ­ + ­
                                                  Radar etc.
                  NMEA     SeaTalk




                                                       NMEA in

                                                               D1065-1




     ST6000/ST7000 Control Unit NMEA Input
             The ST6000/ST7000 control units are fitted with an NMEA input port.
             sentances decoded are as follows.
Chapter 2: Installation                                                                                73




                          NMEA 0183 Data                 NMEA Received Header
                          Bearing to Waypoint            APB, BPI, BWR, BWC, BER, BEC, RMB
                          Distance to Waypoint           WDR, WDC, BPI, BWR, BWC, BER,
                                                         BEC, RMB
                          Waypoint Number                APB, APA, BPI, BWR, WDR, BWC,
                                                         WDC, RMB, BOD, WCV, BER, BEC
                          Speed (through water)          VHW
                          Apparent Wind Speed and        VWR
                          Direction
                          Latitude and Longitude         GLL
                          COG and SOG                    VTG
                          Cross Track Error              XTE, XTR, APA, APB, RMB
                                                                                                   81004-12



            Cabling
                          Connect the NMEA output from either a GPS, Loran, Decca, Speed
                          or Wind instrument to the NMEA input on the control unit.

                                                                   ST7000 Control Unit
                                                               +             +           +

                                        GPS
                                       Loran
                                      Decca
                                  Wind Instrument
                                 Speed Instrument
                                                               +             +           +



                              NMEA out

                                            Data 0v                   Blue



                                            Data tx                   Red                D1066-1




            NMEA Interface
                          The NMEA interface is primarily designed to allow operation with
                          other manufacturers equipment by providing conversion between
                          SeaTalk and NMEA 0183 data format. Sentances decoded and
                          transmitted are as follows:
74                       TYPE 100/300 Operation and Installation Handbook




     Data                  SeaTalk instrument            Transmitted
                           required                      NMEA
                                                         Header

     Cross Track Error     Navcenter or Navdata or       APB
                           GPS
     Bearing to            Navcenter or Navdata or       BWC
     Waypoint              GPS
     Distance to           Navcenter or Navdata or       BWC
     waypoint              GPS
     Waypoint Number       Navcenter or Navdata or       BWC
                           GPS
     Apparent wind         Wind                          VWR
     speed and
     direction
     Boat Speed            Speed or Tridata              VHW
     (Through water)
     Water Depth           Depth or Tridata              DBT

     Longitude and         GPS or Navcenter or           GLL
     Latitude              Navdata
     Magnetic Heading      Compass or SeaTalk            HDM, HDG,
                           Autopilot                     VHW
     True Heading          Compass or SeaTalk            HDT, VHW
                           Autopilot
     Locked autopilot      SeaTalk Autopilot             HSC
     heading
     Water Temperature Speed or Tridata                  MTW

     Course over the       GPS or Navdata or             VTG
Chapter 2: Installation                                                                                        75




                          NMEA 0183 Data                        NMEA Header Transmitted

                          Cross Track Error                     XTE

                          Bearing to Waypoint                   BWC

                          Distance to Waypoint                  BWC

                          Waypoint Number                       BWC

                          Latitude and Longitude                GLL

                          Magnetic Heading                      HDG, HDM, HDT

                          True Heading                          HDT

                          Locked Autopilot
                                                                HSC
                          Heading
                          Course Over Ground                    VTG

                          Speed Over Ground                     VTG

                          Fix/No Fix                            GLL
                                                                                                          81004-11




            Cabling


                                                                        GPS
                                                                       Loran
                                             Radar etc.               Decca
                                                                  Wind Instrument
                                                                 Speed Instrument


                                                                          Grey (screen)   Red    Yellow



                                                  + ­   + ­
                                                  OUT      IN
                                       WINDVANE     NMEA

                                                                                               ­ +
                                   ALARM SEATALK SEATALK
                                                                         SeaTalk      SeaTalk CLUTCH




                                                                                                            D896-1




                          · Connect the NMEA interface box to the course computer SeaTalk
                            connection or alternatively any other SeaTalk product using one of
                            the available interface cables.
                          · Other manufacturer's equipment can now be connected to the
                            NMEA in or NMEA out connections.
                          Note: Only one transmitter should ever be connected to an NMEA
76                                       TYPE 100/300 Operation and Installation Handbook




Chapter 3: Functional Test
                  This section provides detailed information related to complete system
                  testing, equipment calibration and initial sea trials.

3.1 System test
                  The steering system and drive unit/rudder reference transducer should be
                  carefully inspected and the following points checked using the steering
                  wheel to drive the vessels steering from hardover to hardover.
                  · the steering system reaches the rudder end stops before the drive
                     actuator reaches its end stops (Linear/Stern Drive).
                  · no part of the autopilot drive system fouls any part of the steering
                     system or vessels structure through full travel.
                  · the mechanical alignment of the drive unit is as specified in this hand-
                     book.
                  · the mechanical alignment of the rudder reference transducer is as
                     specified in this handbook.
                  · all connecting wires are secured clear of the bilge and cannot foul any
                     part of the steering system. All connectors are tightly secured.
                  · all securing bolts are fully tightened and mechanical locking arrange-
                     ments as specified are in place.

3.2 Switch-on
                  Switch on the electrical supply from the main panel. All control units will
                  emit a short beep and display the autopilot type: either ST6000 or
                  ST7000. Within 2 seconds Standby will be displayed to indicate that the
                  autopilot is in Standby mode.
Chapter 3: Functional Test                                                                          77




3.3 Rudder angle sense

            ST7000 control unit
                        Move the wheel to produce a starboard turn. The rudder angle display
                        should move to the right.




                                30                           30
                                     20     RUDDER   20
                                          10  0   10


                                                                                     D1015-1



                        If the display moves to the left the red and green wires from the rudder
                        reference transducer must be reversed.

            ST6000 control unit
                        Press Display twice.
                        Move the wheel to produce a starboard turn. The rudder angle should
                                                              w




                        increase and the direction indicator ( ) be displayed.
                                                                           D1029-1
                              v




                        If the ( ) rudder angle indicator is displayed the red and green wires from
                        the rudder reference transducer should be reversed.

3.4 Rudder angle alignment
                        With the rudder amidships, see if the rudder angle display reads zero.
                        Misalignment up to +/- 7 degrees can be removed in the calibration
                        sequence which is explained later in this section. If the misalignment is
                        greater than 7 degrees the rudder reference should be mechanically
                        adjusted to be within the +/- 7 degree limit.
78                                      TYPE 100/300 Operation and Installation Handbook




3.5 Operating sense
                 The operating sense of the autopilot can be checked as follows:
                 1. Push AUTO.
                 2. Press the +10 degree key. This should move the rudder a few
                    degrees to produce a turn to starboard. If the rudder moves
                    hardover to port, the motor connections at the course computer
                    should be reversed.

3.6 Rudder deadband
                 The factory preset rudder deadband level will provide stable rudder
                 positioning on most steering systems. On some steering systems, where
                 a rotary or hydraulic drive unit is sited a long way from the rudder, slight
                 instability may occur. This can be removed by increasing the 'rudder
                 damping' level in calibration. Any increase should be minimised as it will
                 reduce the autopilots course keeping accuracy.

3.7 Mechanical test (Linear, Rotary & Hydraulic Drives)
                 WARNING: When the steering system is being moved manually, or
                 under drive from the autopilot, do not touch any part of the system.
                 The forces exerted are considerable and could cause injury.
                 1. Push AUTO.
                 2. Press the +10 degree key to drive the rudder hardover onto the end
                    stops
                 Note: This may require increasing the rudder limit in the calibration mode.
                 3. Make sure the drive unit mounting shows no sign of movement.
                 4. For hydraulic systems, make sure there is no seepage of hydraulic
                    fluid and that the steering ram moves smoothly.
                 Caution: If the installation is a non Autohelm Constant Running
                 Pump, firstly check that the system includes a pressure relief valve.
                 Failure to do this could cause damage to the steering system.
                 5. Repeat driving the rudder hardover to the opposite end stop.

        Current limit and cutout
                 When the rudder is driven onto the end stops the power to the drive will be
                 cut out after a few seconds - this is normal. Drive will only be restored if the
                 rudder moves away from the end stop or if drive is required in the opposite
                 direction.
Chapter 3: Functional Test                                                                        79




3.8 Mechanical Test (Stern Drive)
                        It is recommended that the Auto Release facility is used when a Autohelm
                        mechanical stern drive actuator is installed. This should be switched on in
                        calibration.
                        1. Manually drive the steering hardover to starboard
                        2. With the engines running, engage Auto and, with repeated presses of
                           the -10 degree key, drive the steering to the opposite lock (port).
                        3. The autopilot should drive the steering onto the end stops, sound an
                           alarm, display the 'Release' message and then revert to 'Standby'.
                        4. Re-engage the autopilot (Auto) and repeat the driving the steering
                           hardover to starboard using the +10 degree key.
                        5. The autopilot should again drive onto the end stop, sound an alarm,
                           display 'Release' and return to 'Standby'.
                        Note: If the unit sounds the alarm and displays Release before reaching
                        the opposite lock, carefully check the vessel's steering system for any
                        stiffness or mechanical jamming.
                        If the condition persists, set the Auto Release function to "off" (0) in
                        calibration and contact the Product Support Department at Autohelm for
                        further advice.
                        Note: The Auto Release function should always be set to "off" (0) in
                        calibration if using any drive unit other than a stern drive actuator.

3.9 Setting the Autopilot Rudder Limit (All drives)
                        Having checked the correct functioning of the drive unit and the appropri-
                        ate End Stop Cutout/Auto Release function the programmable rudder
                        angle unit should be set.
                        The rudder angle limit sets the maximum angle to which the autopilot will
                        move the rudder. This should be set to just less than the vessel's mechani-
                        cal limit stop to avoid putting the steering system under unnecessary load.
                        Using the rudder angle display whilst manually moving the helm, record
                        maximum rudder angle in both directions. Set up the rudder angle limit in
                        calibration mode (see page 82) to 5 degrees less than the minimum angle
                        recorded.
80                                       TYPE 100/300 Operation and Installation Handbook




3.10 GyroPlus Offset and Drift Compensation
                 The GyroPlus uses the latest generation solid-state rate gyro to enhance
                 steering performance at response level 3 (see Calibration for details). Like
                 all rate gyro's the GyroPlus is subject to offset and drift. However, this is
                 automatically compensated for whenever the autopilot is in AUTO mode.
                 When the GyroPlus is initially installed, it is important that offset and drift
                 compensation ( a once-only operation) is carried out before selecting
                 response level 3 - failure to carry out this procedure will result in rapid
                 course changes when level 3 is selected.

        Procedure
                 Compensation for offset and drift is achieved by simply using the autopilot
                 in response level 1 or 2 for at least 5 minutes before you select level 3.
                 Alternatively, if you want to use response level 3 as soon as you engage
                 AUTO, then the following procedure must be carried out.
                 1. Moor the vessel so that the heading remains constant.
                 2. Press AUTO and leave for at least 5 minutes.
                 3. After 5 minutes, press STANDBY to return to "standby" mode. The
                    autopilot will nor have stored the compensation value for future use.
Chapter 4: Calibration                                                                         81




Chapter 4: Calibration
4.1 Recommended Settings
                         As supplied the ST7000 can be switched on and tested safely without any
                         adjustments to the factory calibration settings.
                         The table below lists the suggested settings for sailing/power displace-
                         ment and planing power vessels. These will provide good performance for
                         initial sea trials and can be fine tuned later to optimise performance.

                                                                       Vessel Type

                                                              Displacement        Planing
                                                              Factory Preset      Set to
                         Rudder Gain (level)                  5                   4

                         Rate Gain (level)                    7                   4

                         Rudder Angle Limit                   30                  30
                         (degrees)
                         Turn Rate Limit                      20                  12
                         (degrees/sec)
                         Cruise Speed (knots)                 8                   25

                         Off Course Alarm                     20                  20
                         (degrees)
                         Trim Level                           1                   3

                         Auto Adapt                        off             on
                                                     Autopilot Drive Unit Type

                                           Mechanica Stern             Hydraulic Hydraulic
                                           Drive     Drive             Drive     Linear

                                           Factory       Set to        Set to         Set to
                                           Preset
                         Drive Type        3             3             4              3

                         Rudder            1             1             1              3
                         Position
                         Deadband
                         (level)
                         Auto Release off                on            off            off
82                                        Type 100/300 Operation and Installation Handbook




4.2 Selecting calibration
                 To select calibration:
                 · Press Standby.
                 · Press and hold Track and Display for 2 seconds to access the
                    following display.

                   ST7000




                         30                          30
                              20     RUDDER   20
                                   10  0   10



                   ST6000




                                                                   D1030-1


                 · Press and hold Track and Display for a further 2 seconds to access
                    the following display.

                   ST7000




                                                          Cal.

                   ST6000


                                                                 Cal.
                                                                   D1031-1
Chapter 4: Calibration                                                                                    83




4.3 Adjusting calibration
                         In calibration the Display key is used to scroll through the menu. The
                         displayed value is adjusted using the Response keys (hold down for fast
                         scroll).
                         Note: If the 'CAL' display reappears at any time during calibration, press
                         Display to advance to the next menu level.
                         Once calibration has been carried out, further adjustment can be made at
                         any time.

            Rudder Gain
                         Rudder Gain controls the amount of rudder the pilot will apply to turn onto
                         a new heading. A correctly set rudder gain will, for example, turns the
                         vessel crisply onto the new heading with an overshoot of no more than 2 to
                         5 degrees for a 40 degree course change. A high rudder gain setting will
                         result in oversteer, recognized as an overshoot of more than 5 degrees.
                         A rudder gain level that is too low will result in understeer giving poor
                         steering performance.
                         WARNING: It is most important that the rudder gain is correctly set
                         on planing craft. Incorrect adjustment will lead to poor steering
                         performance and is dangerous at high speeds.
                         The settings available are as follows:
                         Range                   1 to 9

                         Recommended             5   (Displacement)
                         setting                 5   (Semi displacement)
                                                 4   (Planing)
                                                 3   (Stern drive)
                                                                                                     81004-17
84                                  Type 100/300 Operation and Installation Handbook




     Rate Level
             Rate level controls the amount of rudder the pilot will apply to reduce the
             speed at which the vessel is turning. This is also known as counter rudder,
             and is only used in response level 3.
             The settings available are as follows:
             Range                   1 to 9

             Recommended             7   (Displacement)
             setting                 7   (Semi displacement)
                                     7   (Planing)
                                     5   (Stern drive)
                                                                                  81004-18




     Rudder Offset (Helm Adjust)
             Rudder Offset sets the control head to read zero degrees of rudder when
             the helm is positioned amidships.
             The range available is as follows:

             Range                   -7 to +7 degrees

             Default Setting 0
                                                                                  81004-19




     Rudder Limit
             Rudder Limit restricts autopilot rudder movement to just less than the
             steering systems mechanical stops. This avoids putting the steering
             system under unnecessary load.
             The range available is as follows:

             Range                   15 to 40 degrees
             Default setting 30 degrees
                                                                                  81004-20
Chapter 4: Calibration                                                                               85




            Turn Rate
                         Turn Rate is the rate in degress per second at which the vessel will turn
                         when course changes are made via the autopilot.
                         The settings available are as follows:

                         Range                   5 to 20 degrees per second

                         Default setting 20 degrees (Displacement)
                                         15 degrees (Semi displacement and
                                         planing)
                                           8 degrees (Stern drive)
                                                                                               81004-21

                         Turn Rate limit does not apply in power steer or joystick modes.

            Cruise Speed
                         Cruise Speed should be set to the vessel's normal cruising speed and is
                         used in track mode.
                         Note: If boat speed is available on either the SeaTalk bus or via the NMEA
                         input this will be taken and used in preference to the Calibration Cruise
                         Speed.
                         The range available is as follows:

                         Range                   4 to 60 knots
                         Recommended             6   (Displacement)
                         setting                 8   (Semi displacement)
                                                 20 (Planing)
                                                 20 (Stern drive)
                                                                                                81004-22




            Off Course Limit
                         Off Course Limit warns you if the autopilot is unable to maintain its set
                         course and has subsequently strayed more than the set limit for more than
                         20 seconds.
                         The off course alarm settings available are as follows:

                         Range                   15 to 40 degrees

                         Default setting 20 degrees
                                                                                                81004-23
86                                  Type 100/300 Operation and Installation Handbook




     Trim Level
             Trim Level sets the level for automatic trim which applies additional rudder
             to correct for unbalanced propeller torque on twin engine installations, or
             weather helm.
             The Trim Level settings available are as follows (rate of trim increases with
             trim level):

             Range                   0 to 4
             Default setting 2 (Displacement)
                             3 (Semi displacement, planing and
                             stern drive)
                                                                                    81004 24


     Joystick Mode (Manual Type)
             Power steer selects the Joystick mode of operation: Proportional or `Bang-
             Bang'.
             Proportional applies rudder in proportion to Joystick movement - the
             further the Joystick is held over the greater the applied rudder.
             Bang-Bang applies continous rudder drive in the direction of lever move-
             ment. To improve control the speed of rudder movement changes with the
             angle of the lever. For maximum speed push the lever hardover. If the lever
             is returned to the center position the rudder will remain in its current
             position.
             The settings available are as follows:

              Range                  0    OFF
                                     1    (Proportional)
                                     2    (Bang-Bang)

              Default setting 1
                                                                                    81004-25




     Drive Option
             Drive Option sets the type of drive used by your vessel: mechanical with
             rudder reference or hydraulic with rudder reference.
             The settings available are as follows:
             Range                   1 to 4

             Default setting 1           Future use
                             2           Future use
                             3           (Displacement and stern drive)
                             4           (All hydraulic installations)
                                                                                    81004-26
Chapter 4: Calibration                                                                                 87




            Rudder Deadband (Rudder Damping)
                         The factory setting for Rudder Deadband provides stable rudder position-
                         ing on most steering systems. However, some steering systems that use
                         a rotary or hydraulic drive unit a long way from the rudder may experience
                         slight instability. This instability can be minimised by increasing the setting.
                         The settings available are as follows:

                         Range                   1 to 9

                         Default setting 1
                                                                                                  81004-27



            Magnetic Variation
                         Variation tells other equipment the level of magnetic variation present at
                         the boats current position. Local variation should be entered using the
                         appropriate keys.
                         The settings available are as follows:

                         Range                    30 degrees West to 30 degrees East

                         Default setting Off
                                                                                                  81004-28




            Auto Adapt
                         It may be noticed that the autopilot tends to be a little less stable on
                         northerly headings in higher latitudes of the northern hemisphere and
                         southerly headings in the southern hemisphere. This is caused by the
                         increasing angle of dip of the earth's magnetic field at higher latitudes. This
                         has the effect of amplifying the rudder gain on northerly (southerly)
                         headings, affecting all magnetic compasses and getting worse the further
                         away from the equator you are.
                         The autopilot is able to compensate for this and provide precise course
                         keeping on all headings by automatically adjusting the gain of the autopilot
                         depending on the heading.
                         It is recommended that for high speed craft the Auto Adapt facility is
                         selected. This automatically reduces the effects of Northerly/Southerly
                         heading instability.
                         This feature is selected in calibration by entering the vessel's operating
                         latitude. When selected it automatically adjusts the Rudder Gain depending
                         on heading removing the need for manual adjustment.
88                                     Type 100/300 Operation and Installation Handbook




                Note: If Auto Adapt is not selected manual adjustment of rudder gain is
                normally required when going from Northerly to Southerly headings or vice
                versa. Failure to do so can lead to poor course keeping.
                The settings available are as follows:

                Range                   0: Off
                                        1: North
                                        2: South

                Default setting 1: North
                                                                                   81004-29




     Latitude
                Latitude is used to compensate for Northerly/Southerly headings errors.
                The settings available are as follows:

                Range                   0 to 80 degrees

                Default setting 0 degrees
                                                                                   81004-30




     Wind Trim
                Wind trim varies the response of the autopilot in Vane mode.

                                        1 -- Fast response
                Range
                                        2 -- Slow response

                Default setting 1
                                                                                   81004-31




     Response Level
                This sets the response level when the pilot is switched on.
                The settings available are as follows:
                Range                   Level 1: Automatic sea state control
                                        Level 2: Automatic sea state inhibit
                                        Level 3: Automatic sea state inhibit
                                        counter rudder

                Default setting Level 1
                                                                                   81004 32
Chapter 4: Calibration                                                                                   89




            Auto Release (manual override)
                         Auto Release provides emergency manual override, should it be neces-
                         sary, for example, to avoid an obstacle at the last moment. It is used with
                         an Autohelm stern drive actuator. For all other drive systems Auto release
                         should be turned off.
                         The settings available are as follows:

                         Range                   0 = Off
                                                 1 = On
                         Default setting N/A (Displacement)
                                         N/A (Semi displacement)
                                         N/A (Planing)
                                         1 (On) (Stern drive)
                                                                                                    81004-33




4.4 Saving Calibration Mode
                         To exit calibration mode and save all changes, press and hold Track and
                         Display for 2 seconds.
                         Changes made to calibration settings can, while still in the calibration
                         mode, be cancelled by quitting as follows:
                         Press Standby.
90                                      Type 100/300 Operation and Installation Handbook




4.5 Display Contrast Adjustment (ST7000 only)
                The contrast of the LCD display can be adjusted to suit a wide range of
                viewing angles.
                · Press Display and Track together momentarily.




                      30                            30
                           20     RUDDER   20
                                10  0   10




                                                                D1016-1
                                                         Cal.


                · Press Response (v) to increase contrast (suits viewing from below).
                · Press Response (w) to decrease contrast (suits viewing from above).

                                                                                Decrease
                                                                                contrast ratio




                                                                                   Normal
                                                                                   viewing
                                                                                   position




                                                                                Increase
                                                                                contrast ratio
                                                                                              D1017-1



                To store the contrast selection, press Display and Track together
                momentarily.

4.6 Permanent Watch Alarm (SFIA)
                If a permanent watch alarm is required, please contact the Autohelm
                Product Support Department or an authorised dealer for further informa-
                tion.

4.7 Recording Calibration Settings
                Having fined tuned the calibration settings during initial sea trials, record
                them in the following table for future reference.
Chapter 5: Initial Sea Trials                                                                          91




Chapter 5: Initial Sea Trials
5.1 Initial Sea Trials
                          Initial sea trials should be carried out in calm conditions with plenty of sea
                          room. As the vessel will be constantly changing heading, it is most
                          important to maintain a constant look out.
                          Before sea trials:
                          · Read the Operating section of this manual.
                          · Carry out the system test to verify that the autopilot is operating
                            correctly.

5.2 Automatic Compass Heading Alignment and Deviation Correction
                          The displayed compass heading requires alignment with the ships
                          compass. Until this procedure is carried out, the autopilot compass
                          display will not agree with the ships compass.
                          The autopilot will correct the fluxgate compass for most deviating
                          magnetic fields. This correction procedure should be carried out in calm
                          conditions preferably in flat water.
                          To select compass heading alignment and correction, push and hold
                          STANDBY for 2 seconds until the display shows:

                                ST7000




                                    30                        30
                                         20     RUDDER   20
                                              10  0   10
                                                                   Cal.



                                ST6000

                                                                     Cal.


                                                              Cal.

                                                                            D1019-1



                          1. Press DISPLAY
                          2. Keeping boat speed below 2 knots, turn the vessel slowly so that it
                             takes at least 3 minutes to complete 360 degrees.
92                           TYPE 100/300 Operation and Installation Handbook




                                                D919-1



     Keep turning until the display changes to show the amount of deviation the
     autopilot has corrected. This can take up to 2 full turns depending on the
     amount of deviation found.

          ST7000




              30                        30
                   20     RUDDER   20
                        10  0   10
                                             Cal.



          ST6000

                                               Cal.


                                        Cal.

                                                      D1019a-1




     Note: If the deviation exceeds 15 degrees, you should relocate the
     fluxgate compass.
     3. Steady the boat up on one heading and use the course change keys
        to adjust the displayed heading until it agrees with the steering
        compass or a known transit bearing.
     4. To exit fluxgate alignment/correction and store the settings, push and
        hold STANDBY for 2 seconds until the pilot returns to `STANDBY'
        mode.
     5. To exit fluxgate alignment/correction without saving any new settings,
        push STANDBY momentarily.
Chapter 5: Initial Sea Trials                                                                     93




5.3 Compass Alignment (without deviation correction)
                          It is possible to change the alignment between the fluxgate and the ship's
                          compass without carrying out the automatic deviation correction. Proceed
                          as follows:
                          1. Push and hold STANDBY for 2 seconds to select fluxgate alignment/
                             correction mode.
                          2. Use the course change keys to adjust the heading displayed.
                          3. To exit fluxgate alignment/correction and store the new setting push
                             and hold STANDBY for 2 seconds until the pilot returns to `STANDBY'
                             mode.
                          4. To exit fluxgate linearisation without saving the new setting push
                             STANDBY momentarily.

5.4 First Sea Trials
                          In clear waters, steer the boat on to the required heading.
                          1. Hold the course steady for 5 to 10 seconds.
                          2. Press AUTO to lock onto the current heading. In calm conditions a
                             perfectly constant heading will be maintained.
                          3. Alter course to port and starboard using the course change keys on
                             any control unit. Course changes should be prompt and without any
                             sign of overshooting.
                          4. Press STANDBY to disengage the autopilot for return to hand
                             steering.
94                                       TYPE 100/300 Operation and Installation Handbook




5.5 Response Control
                 There are three response levels to provide tighter than normal course
                 keeping when there is restricted sea room. Select each level in turn and
                 observe the autopilot activity.

        Level 1 - Automatic Sea State Control
                 · This provides the optimum compromize between power consumption
                    and course keeping accuracy and is suitable for most situations.
                 The automatic sea state control can be observed during the sea trial.
                 · When the autopilot is initially engaged in Auto mode it will respond to all
                   pitch and roll movements.
                 · During the first minute of operation, it will be noticed that repetitive
                   movements of the vessel are gradually neglected until finally the
                   autopilot will respond only to true variations in course.
                 · To ensure precise course adjustments the sea state control is automati-
                    cally reset whenever the course change knob is adjusted.

        Level 2 - Automatic Sea State Inhibit
                 · Where increased course keeping accuracy is required the automatic
                   sea state control can be inhibited by moving to response level 2.
                 · Autopilot activity and therefore power consumption will be increased.

        Level 3 - Automatic Sea State Inhibit and counter rudder
                 · Where maximum course keeping accuracy is required a Rate Gyro
                   transducer should be fitted. This introduces counter rudder (rate) to
                   increase the natural damping of the vessel. On power craft level 3 is
                   useful at slow speed where the natural damping of the vessel is
                   reduced. Autopilot activity and therefore power consumption will be at a
                   maximum.
                 The minimum response level necessary to achieve the desired course
                 keeping should be used to reduce power consumption and autopilot wear
                 and tear.
Chapter 5: Initial Sea Trials                                                                        95




5.6 Automatic Trim Control
                          The autopilot automatically corrects for trim. No adjustment of the pilot is
                          necessary.
                          After each course change the automatic trim is cancelled and the autopilot
                          will re-establish the correct trim for the new heading. It should be noted
                          that if a large course change is keyed in(greater than 60 degrees) the
                          autopilot will not assume the final selected course immediately. The vessel
                          will come to within say 10 degrees of the desired course and will only
                          settle onto course when the automatic trim has been fully established. This
                          may take up to two minutes.
                          It is recommended the following procedure is adopted for large course
                          changes:
                          · Note required heading
                          · Select STANDBY and steer manually
                          · Bring vessel onto new heading
                          · Select AUTO and let vessel settle onto course
                          · Bring to final course with 1 degree course change increments
                          It is sound seamanship to make major course changes only whilst steering
                          manually. In this way any obstructions or other vessels may be cleared
                          properly and due account taken of the changed wind and sea conditions
                          on the new heading prior to engaging the autopilot.
                          Note: If the autopilot trim control is switched off, regular checks on the
                          vessel's heading should be made as changes in standing helm will change
                          the course steered by the autopilot.
96                                        TYPE 100/300 Operation and Installation Handbook




5.7 Rudder Gain Adjustment (Displacement Craft)
                The factory set rudder gain level provides stable control for initial sea
                trials. However, vessels can vary widely in their response to the helm, and
                further adjustment to the rudder gain may improve the autopilot's steering
                characteristics. Rudder gain should be set in Response level 1.
                An excessively high rudder control setting will result in oversteer, which
                can be recognized by the vessel swinging from side to side of the
                automatic heading, accompanied by excessive rudder movement. In
                addition, distinct overshoot will be observed when the course is changed.
                This condition can be corrected by reducing the rudder setting.
                Similarly, an insufficient rudder control setting results in understeer which
                gives sluggish steering performance and is particularly apparent when
                changing course. This is corrected by increasing the rudder setting. These
                tendencies are most easily recognized in calm sea conditions where wave
                action does not mask basic steering performance.
                Typically, if at cruising speed a course change of 40 degrees results in an
                overshoot of between 2 - 5 degrees, the rudder gain is correctly adjusted.
                Push either RESPONSE key for access to Rudder Gain. Adjust either side
                of the calibrated setting to provide optimum autopilot steering.

                                           A             B




                    Correct    Rudder          Rudder
                    rudder     setting         setting
                    setting    too high        too low




                     New          New            New
                     heading      heading        heading
                                                         R173/2-1


                Note: Once the optimum setting has been found, the default calibration
                setting for rudder gain should be changed.

        Adjustment with Response Level 3
                Response level 3, by default, automatically sets the gain to 3 settings
                above the gain at response level 1. This can be adjusted as follows:
                Select response level 3 and then scroll to the gain display. Adjust the
                value as required and save the new value by pressing the up and down
                response keys together momentarily.
Chapter 5: Initial Sea Trials                                                                        97




5.8 Rudder Gain Adjustment (High Speed Planning Craft)
                          Warning:ItisparticularlyimportantthattheRudderGainiscorrectlyset
                          onhighspeedcraft.Incorrectadjustmentwillleadtopoorsteering
                          performanceandisadangerousconditionat
                          highspeed.
                          Adjust as follows:
                          · Set to Rudder Gain for optimum steering performance at the vessels
                             normal cruising speed.
                          · Push either RESPONSE key for access to Rudder Gain. Adjust either
                             side of the calibrated setting to provide optimum autopilot steering.

5.9 Rudder Gain - Adjustment with Speed
                          Due to the significant differences in dynamic stability between planing and
                          non-planing conditions, most high speed craft require Rudder Gain
                          adjustment when going from planing to displacement speeds or vice
                          versa. The required adjustment can be achieved automatically
                          or manually.
                          · When the autopilot is used with the speed input from an Autohelm
                            SeaTalk Speed instrument or is receiving boat speed via its NMEA
                            input. Rudder gain is automatically adjusted with boat speed. After
                            setting the gain at planing speed no further manual adjustment should
                            be required.
                          Warning: When speed information is fed to the autopilot via the
                          NMEA input always check the displayed speed is close to the
                          actual boat speed before locking the autopilot onto a heading.
                          Delays in data transmission could result in the 'pilot' applying too
                          much rudder after a large change in vessel speed.
                          · If no Speed input or NMEA is available manual adjustment should be
                             carried out to the Rudder Gain setting via the Response keys adjusting
                             as follows:
                          1. Speed decreases from planing to displacement
                             - Increase gain by 1 or 2 levels.
                          2. Speed increases from displacement to planing
                             - Decrease gain by 1 or 2 levels.
                          Warning: The manual gain adjustment must be made after
                          reducing from planing to displacement speed and before
                          increasing from displacement to planing speed.
98                                     TYPE 100/300 Operation and Installation Handbook




5.10 Manual Override (Stern Drive Actuators only)
                 Manual override should be selected in calibration only on installations
                 fitted with the stern drive actuator. When it has been selected, the
                 autopilot can be overridden to allow hand steering by turning the steering
                 wheel. This will return the autopilot to Standby and sound the control unit
                 buzzer for 10 seconds. There is a slight delay before the autopilot will
                 return to Standby.
                 CAUTION: Excessive force is not required and will not reduce this delay.
                 With the autopilot in Auto and clear of obstruction, turn the steering wheel
                 to observe the manual override. Repeat two or three times until you are
                 confident with its operation.
                 The manual override is intended for emergency use only. The autopilot
                 should normally be disengaged by pushing the STANDBY button on the
                 control unit.
Chapter 6: Track Control                                                                            99




Chapter 6: Track Control
                       Track control allows the autopilot to maintain track between waypoints
                       entered on a GPS, Decca or Loran Navigation System. The navigation
                       system must have a suitable autopilot NMEA output (refer to section 2.13).
                       If the navigation system transmits the correct NMEA 0183 sentences, the
                       autopilot will receive and display bearing to waypoint, distance to
                       waypoint, waypoint number and cross track error.
                       If it transmits NMEA 0180 only crosstrack error will be displayed.
                       Before attempting sea trials, make sure that the control unit is receiving
                       navigation data by using the Display key to bring it up on the control
                       unit LCD.
                       Note: If data is not being received it is impossible to select Track Mode.
100   TYPE 100/300 Operation and Installation Handbook
Chapter 7: Windvane Control                                                                 101




Chapter 7: Windvane Control (Sail Only)
                      Windvane control allows the autopilot to maintain an apparent wind angle.
                      There are two methods of supplying wind angle:
                      1. Using NMEA 0183 output from another manufacturer's instrument
                         system.
                      2. Using an Autohelm ST50 wind instrument connected using the
                         SeaTalk bus.
                      The autopilot uses wind trim to eliminate the effects of turbulence and
                      short term wind variations to provide smooth, precise performance under
                      windvane with minimum power consumption. Wind trim uses the fluxgate
                      compass as the primary heading reference, and as changes in the
                      apparent wind angle occur, the compass heading is adjusted to maintain
                      the original apparent wind angle.
102   TYPE100/300 Operation and Installation Handbook
Index                                                                          103




        A                                      Control Unit ST6000/7000
Index                                             Cabling 26
        Adjusting calibration 83                  Mounting 25
        Auto Adapt 87                          Course Computer
        Auto Release (manual override) 89         Cabling 22
        Automatic Compass Heading                 Mounting 22
               Alignment and Deviation 91      Cruise Speed 85
        Automatic Sea State Control 94         Current limit and cutout 78
        Automatic Sea State Inhibit 94
        Automatic Sea State Inhibit and        D
               counter rudder 94
        Automatic Trim Control 95              Display Contrast Adjustment
        Auxiliary Alarm                              (ST7000 only) 90
           Cabling 65                          Drive Option 86
           Mounting 65                         Drive Systems 13
                                                      Constant Running Hydraulic
        C                                             Pump 16
                                                      Hydraulic Linear 15
        Calibration 81                                Linear Drive 15
           Adjusting calibration 83                   Rotary Drive Units 13
           Auto Adapt 87                              Reversing Hydraulic Pump 14
           Auto Release 89                            Sterndrive 16
           Cruise Speed 85
           Display Contrast Adjustment 90      F
           Drive Option 86
           Joystick Mode 86                    First Sea Trials 93
           Latitude 88                         Fluxgate Compass
           Magnetic variation 87                   Cabling 29
           Off Course Limit 85                     Mounting 28
           Permanent Watch Alarm 90            Functional Test 76
           Rate Level 84
           Recommended settings 81
                                               G
           Recording Calibration Settings 90   GyroPlus Offset and Drift Compen-
           Response Level 88                        sation 80
           Rudder Deadband 87
           Rudder Gain 83                      H
           Rudder Limit 84
           Rudder Offset 84                    Hand-held Remote 17
           Saving Calibration 89               Hydraulic Drive Systems 35
                                               Hydraulic Linear Actuator 45
           Selecting calibration 82
                                                 Cabling 48
           Trim Level 86
                                                 Final Preparation before use 48
           Turn rate 85
                                                 Installation 45
           Wind Trim 88
        Compass Alignment (without
              deviation correction) 93
        Constant Running Hydraulic Pump
           Cabling 42
           Mounting 41
           Plumbing 44
104                             TYPE100/300 Operation and Installation Handbook




      I                                              NMEA Interface 73
                                                     Rotary Rudder Reference 30
      Initial Sea Trials 91                              Mounting 30
      Installation                                       Cabling 32
           Auxiliary Alarm 65                    Introduction
           Course computer 21                        Auxiliary Alarm 18
               Mounting 22                           Course Computer 11
               Cabling 22                            Drive Systems 13
           Control Unit ST6000/7000 25                   Constant Running Hydraulic
               Mounting 25                               Pump 16
               Cabling 26                                Hydraulic Linear 15
           Control Unit ST6000/7000 NMEA                 Linear Drive
               Input 71                                  Reversing Hydraulic Pump 14
           Fluxgate Compass 28                           Rotary Drive Units 13
               Mounting 28                               Stern Drive 16
               Cabling 29                            Fluxgate Compass 11
           Hydraulic Drive Systems 34                GyroPlus Transducer 20
               Constant Running Pump 41              Handheld Remote 17
                   Mounting 41                       Joystick 18
                   Cabling 42                        Linear Rudder Reference
                   Plumbing 44                           Transducer 12
               Reversing Hydraulic Pumps 35          NMEA Interface 17
                   Mounting 35                       Rotary Rudder Reference
                   Cabling 35                            Transducer 12
                   Plumbing 37                       ST6000 Control Unit 10
                   Two line system 39                ST7000 Control Unit 10
                   Two line pressurised 39           Type CR Interface 12
                   Three line system 40              Wind Transducer 19
                   Bleeding the system 40
           Interfacing to other manufacturer's   J
               equipment 69
                                                 Joystick
           Joystick 66
                                                    Cabling 66
           Linear Feedback Transducer 33
                                                    Mounting 66
               Mounting 33
                                                 Joystick Mode (Manual Type) 86
               Cabling 34
           Masthead Transducer 67                L
                   Mounting 67
                   Cabling 68                    Latitude 88
           Mechanical Drive Systems 49           Linear Drive Unit
               Linear Drive Unit 53                 Cabling 55
                   Mounting 54                      Mounting 54
                   Cabling 55                    Linear Feedback Transducer
               Rotary Drive Unit 49                 Cabling 34
                   Mounting 49                      Mounting 33
                   Cabling 52
               Sterndrive Actuator 56            M
                   Mounting 56
                                                 Magnetic Variation 87
                   Cabling 64
                                                 Manual Override (Stern Drive
                                                      Actuators only) 98
                                                 Masthead Transducer 67
Index                                        105




        S
        Saving Calibration Mode 89
        Selecting calibration 82
        Setting the Autopilot Rudder Limit
              (All drives) 79
        Sterndrive Actuator
           Cabling 64
           Mounting 56
        Switch-on 76
        System test 76

        T
        Track Control 99
        Trim Level 86
        Turn Rate 85

        W
        Wind Transducer
           Cabling 68
           Mounting 67
        Wind Trim 88
        Windvane Control (Sail Only) 101
106                         TYPE100/300 Operation and Installation Handbook




      Mechanical Drive Systems 49
           Linear Drive Unit 53
           Rotary Drive Unit 49
           Sterndrive Actuator 56
      Mechanical test (Linear, Rotary &
          Hydraulic Drives 78
      Mechanical Test (Stern Drive) 79

      N
      NMEA Interface
        Cabling 74

      O
      Off Course Limit 85
      Operating sense 78

      P
      Permanent Watch Alarm (SFIA) 90
      Planning the Installation 21
      Pump to Cylinder Specifica-
           tions 35

      R
      Rate Level 84
      Recording Calibration Settings 90
      Response Control 94
      Response Level 88
      Reversing Hydraulic Pump 14
      Rotary Drive Unit
         Cabling 52
         Mounting 49
      Rotary Rudder Reference Trans-
            ducer
         Cabling 32
         Mounting 30
      Rudder angle alignment 77
      Rudder angle sense 78
      Rudder deadband 78
      Rudder Deadband (Rudder
            Damping) 87
      Rudder Gain 83
      Rudder Gain - Adjustment with
            Speed 97
      Rudder Gain Adjustment (Displace-
            ment Craft) 96
      Rudder Gain Adjustment (High
            Speed Planning Craft) 97
      Rudder Limit 84
      Rudder Offset (Helm Adjust) 84
                                                                    81004-3
Nautech Limited, Anchorage Park, Portsmouth
             P03 5TD, England
Telephone (0705) 693611. Fax (0705) 694642


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