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' Autohelm Raymarine: Linear Drive St6000 Linear Drive'



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RTN in this manual should be
  interpreted as Raymarine.
The names Raytheon and RTN
       are owned by the
     Raytheon Company.
Linear Drive
Installation Guide
Drives covered:
M81130    Type 1 Linear Drive 12 V
M81131    Type 2 (short) Linear Drive 12 V
M81132    Type 2 (long) Linear Drive 12 V
M81133    Type 2 (short) Linear Drive 24 V
M81134    Type 2 (long) Linear Drive 24 V




Document number: 81175-3
March 2001
2                                                 Linear Drive - Installation Guide


Important information
    Safety notices
           WARNING:         Product installation
           This equipment must be installed and operated in accordance
           with the instructions contained in this handbook. Failure to do so
           could result in poor product performance, personal injury and/
           or damage to your boat.
           Because correct performance of the boat's steering is critical for
           safety, we STRONGLY RECOMMEND that an Authorized
           Raymarine Service Representative fits this product.
           WARNING:         Navigation aid
           Although we have designed this product to be accurate and
           reliable, many factors can affect its performance. As a result, it
           should only be used as an aid to navigation and should never
           replace commonsense and navigational judgement. Always
           maintain a permanent watch so you can respond to situations as
           they develop.

    EMC conformance
           All Raymarine equipment and accessories are designed to the best
           industry standards for use in the recreational marine environment.
           The design and manufacture of Raymarine equipment and
           accessories conform to the appropriate Electromagnetic
           Compatibility (EMC) standards, but correct installation is required to
           ensure that performance is not compromised.

    Handbook information
           To the best of our knowledge, the information in this handbook was
           correct when it went to press. However, Raymarine cannot accept
           liability for any inaccuracies or omissions it may contain. In addition,
           our policy of continuous product improvement may change
           specifications without notice. As a result, Raymarine cannot accept
           liability for any differences between the product and the handbook.

            Raymarine Ltd 2001.
Linear Drive - Installation Guide                                                                 3


Introduction
       Product description
                   Welcome to the installation guide for the Raymarine linear drive.
                   This product is intended to operate the boat's steering mechanism as
                   part of a Raymarine autopilot system. It is designed for boats with
                   existing mechanical steering systems
                   CAUTION:
                   This drive moves the rudder directly from the tiller arm or
                   rudder quadrant. Before installing the drive, check that the
                   boat's steering system can be backdriven from the rudder.
                   The outstanding design of the Raymarine linear drive unit provides:
                          powerful thrust, fast hardover times and quiet operation
                          low backdrive force, to minimize the drive's effect on the boat's
                           steering when the autopilot is in standby
                          a powerful electric motor controlled by an electromagnetic fail-
                           safe clutch, using a high tensile belt drive and epicyclic gearbox
                          high performance for minimum current consumption

                       Clutch cable
                                                                       Push rod     Rod end

                       Motor cables




                                            Motor, gearbox and
                            Mounting foot
                                            clutch assembly
                                                                                        D5075-1


                   Figure 1: Main parts of the linear drive

       Contents
                   This guide contains:

                       1     Product specifications                       page 4


                       2     Installation instructions                    page 5


                       3     Maintenance information                      page 14
4                                                       Linear Drive - Installation Guide


Specifications
    Drive specifications
    Table 1: Drive specifications

     Performance*                   Type 1 (T1)        Type 2 short         Type 2 long
     (at nominal voltage)           M81130 (12 V)      (T2S)                (T2L)
                                                       M81131 (12 V)        M81132 (12 V)
                                                       M81133 (24 V)        M81134 (24 V)

     Maximum boat displacement      10,000 kg          15,000 kg            20,000 kg
                                    (22,000 lb)        (33,000 lb)          (44,000 lb)
     Peak thrust                    295 kg             480 kg               480 kg
                                    (650 lb)           (1,050 lb)           (1,050 lb)

     Maximum stroke                 300 mm             300 mm               400 mm
                                    (12 in)            (12 in)              (16 in)

     Hardover to hardover time      11 sec             11 sec               14 sec
     (+/- 35, no load)

     Maximum rudder torque          735 Nm             1,190 Nm             1,660 Nm
                                    (6,500 lb.in)      (10,500 lb.in)       (14,700 lb.in)

     Power consumption              18-36 W                     48-72 W (12 V)
     (typical average)                                          66-96W (24 V)

     Other information              (applies to Types 1 and 2 short/long)

                                    protected for use in engine compartments

                                    CE approvals - conforms to:
                                    89/336/EC (EMC), EN60945:1997
                                    94/25/EC (RCD), EN28846:1993
Linear Drive - Installation Guide                                                                                          5


       Drive dimensions

                                                                        A (midstroke)




                       197 mm (7.8 in)




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




                                                                                                     90




                                                                      Drive             Dimension 'A'
                                         4 fixing holes suitable      Type 1            700 mm (27.5 in)
                                         for 10 mm (0.4 in) bolts     Type 2 (short)    700 mm (27.5 in)
                                                                      Type 2 (long)     850 mm (33.5 in)   D5081-1


                   Figure 2: Linear drive dimensions

Installation instructions
       Parts required
                   To install this drive you will need:
                                  Parts supplied:
                                    linear drive
                                    mounting foot assembly, consisting of: foot, pivot pin, washer
                                      (x2), R-clip (x2)
                                    tiller pin assembly (see Figure 6) consisting of: tiller pin,
                                      R-clip, top washer, lock washer, nut (1/2 inch UNC nylock)
                                  Additional parts:
                                    suitable securing bolts and lock nuts/lock washers (see
                                      page 10)
                                    suitable cable and electrical connectors for the drive motor
                                      and clutch (see page 12)
                   Note: Make sure you have obtained these additional parts before you
                   start installation.
6                                                         Linear Drive - Installation Guide


    Installation steps
           WARNING: Electrical safety
           Make sure you have switched off the power supply before you
           start installing this product.
           Follow these steps to install your linear drive unit:

               1     Consult the EMC installation guidelines.         page 6

                                          
               2     Mount the drive.                                 page 8

                                          
               3     Connect to the course computer.                  page 12

                                          
               4     Complete the post-installation check.            page 14


    1. EMC installation guidelines
           All Raymarine equipment and accessories are designed to the best
           industry standards for use in the recreational marine environment.
           Their design and manufacture conforms to the appropriate
           Electromagnetic Compatibility (EMC) standards, but correct
           installation is required to ensure that performance is not
           compromised. Although every effort has been taken to ensure that
           they will perform under all conditions, it is important to understand
           what factors could affect the operation of the product.
           The guidelines given here describe the conditions for optimum EMC
           performance, but it is recognized that it may not be possible to meet
           all of these conditions in all situations. To ensure the best possible
           conditions for EMC performance within the constraints imposed by
           any location, always ensure the maximum separation possible
           between different items of electrical equipment.
           For optimum EMC performance, it is recommended that wherever
           possible:
                  Raymarine equipment and cables connected to it are:
Linear Drive - Installation Guide                                                               7

                           At least 3 ft (1 m) from any equipment transmitting or cables
                            carrying radio signals e.g. VHF radios, cables and antennas.
                            In the case of SSB radios, the distance should be increased to
                            7 ft (2 m).
                        More than 7 ft (2 m) from the path of a radar beam. A radar
                            beam can normally be assumed to spread 20 degrees above
                            and below the radiating element.
                      The equipment is supplied from a separate battery from that used
                       for engine start. Voltage drops below 10 V, and starter motor
                       transients, can cause the equipment to reset. This will not damage
                       the equipment, but may cause the loss of some information and
                       may change the operating mode.
                      Raymarine specified cables are used. Cutting and rejoining these
                       cables can compromise EMC performance and must be avoided
                       unless doing so is detailed in the installation manual.
                      If a suppression ferrite is attached to a cable, this ferrite should not
                       be removed. If the ferrite needs to be removed during installation
                       it must be reassembled in the same position.

                   Suppression ferrites
                   The following illustration shows typical cable suppression ferrites
                   used with Raymarine equipment. Always use the ferrites supplied by
                   Raymarine. This product has ferrites mounted internally.




                                                                                          D3548-2


                   Figure 3: Typical suppression ferrites

                   Connections to other equipment
                   If your Raymarine equipment is to be connected to other equipment
                   using a cable not supplied by Raymarine, a suppression ferrite MUST
                   always be attached to the cable near to the Raymarine unit.
8                                                      Linear Drive - Installation Guide


    2. Mounting the drive
           Mounting the drive unit involves four main steps:
                ensuring correct drive alignment
                securing the drive to the boat
                connecting the drive to the steering system
                completing a steering check

           Drive alignment
           When mounting the linear drive unit, check that it is aligned
           correctly:
                The main drive assembly must be at right angles to the mounting
                 surface (see Figure 4).
                The drive unit must be at right angles to the tiller arm when the
                 rudder is amidships (see Figure 4).
                                         A (mid stroke)
               Side view


                     90




                                        Drive             A (mid stroke)     B (tiller arm radius)
                                        Type 1            700 mm (27.5 in)   250 mm (10 in)
                                        Type 2 short      700 mm (27.5 in)   250 mm (10 in)
                                        Type 2 long       850 mm (33.5 in)   355 mm (14 in)

               Top view
                                                                                    B (tiller arm
                                                                  90
                                                                                    radius)



                                                                                             D5077-1


           Figure 4: Drive unit alignment
            The push rod must be accurately aligned with the tiller arm plane
               of rotation. The ball end fitting only allows up to 5 degrees
               misalignment between the push rod and tiller arm plane of
               rotation (see Figure 5).

           CAUTION:
           Accurate angular alignment is extremely important. You must
           not exceed this +/- 5 degree limit under any circumstances.
Linear Drive - Installation Guide                                                              9




                                                                 5 Max.

                                                                 5 Max.




                                                                                     D5078-1


                   Figure 5: Alignment between push rod and tiller arm plane of rotation

                   Securing the drive
                   Mounting location
                   Before you secure the drive to your boat, you must first check the
                   suitability of the mounting location.

                   CAUTION:
                   Consult the boat manufacturer if you have any doubt about the
                   strength or suitability of the mounting location.
                      Structural strength:
                        This drive produces a considerable amount of force, so you
                          must mount it on a solid structure (i.e. a substantial frame
                          member) in the boat. In some cases you may need to build a
                          special frame to mount the drive unit.
                        To prevent excess noise and vibration, do not attach this drive
                          to any structures that support cabins.
                      Drive orientation:
                        You can attach the drive unit mounting foot to any suitable
                          horizontal or vertical surface. If required, you can also mount
                          the drive unit upside down.
                      General position:
                        Refer to the EMC installation guidelines (page 6)
                        Make sure the drive will be accessible for future servicing.
                      Environment:
                        This drive is not waterproof, so you should mount it in a dry
                          location, clear of any bilge water.
10                                          Linear Drive - Installation Guide

     Securing bolts
     Attach the mounting foot with four stainless steel M10 (3/8 inch) bolts
     and lock nuts/lock washers.
     Note: Always mount the drive as securely as possible to make sure it
     performs reliably and remains correctly aligned.

     Connecting to the steering system
     CAUTION:
     Consult the steering gear manufacturer if you have any doubt
     about the strength of the existing tiller arm or rudder quadrant.
     This drive produces a considerable amount of force, so you must
     ensure that your tiller arm or rudder quadrant can cope with the peak
     thrust specified in the Table 1, Drive specifications.
     Use one of these methods to attach the push rod to the rudder stock:
     1. Independent tiller arm: we recommend that you attach the
        linear drive unit to the rudder stock via an independent tiller arm
        (the Edson and Whitlock companies offer standard fittings for
        their steering systems).
     2. Steering linkage tiller arm or rudder quadrant: in certain
        cases, you may be able to attach the push rod to the same tiller arm
        or rudder quadrant used by the main steering linkage. Consult the
        steering manufacturer before you modify the rudder quadrant.

     Attaching the rod end
     Use the supplied tiller pin assembly to attach the rod end to the tiller
     arm, at the tiller arm radius shown in Figure 4.
     1. Attach the tiller pin to the tiller arm:
         insert the tiller pin through the tiller arm hole, so the flange
           remains above the arm (see Figure 6)
         make sure that the tiller pin is a tight fit in the tiller arm
         use the supplied lock washer and fully tighten the lock nut
     Note: If necessary, you will need to drill a 13 mm (0.52 in) hole in the
     tiller arm at the radius shown in Figure 4.
     2. Attach the rod end to the tiller pin:
         place the rod end onto the tiller pin
         secure with the supplied washer and R-clip (see Figure 6)
Linear Drive - Installation Guide                                                          11


                                    R-clip
                                    Washer
                                    Rod end
                                    Flange
                                                                    Tiller arm

                                    Lock                            Lock nut
                                    washer
                                                                    Tiller pin
                                    Hole diameter
                                    13 mm (0.52 in)
                                                                                      D5076-1


                   Figure 6: Attaching the push rod to the tiller arm

                   Steering check
                   When you have mounted the drive unit, turn the boat's steering wheel
                   from hardover to hardover and check that:
                      Angular movement of the ball end fitting is less than 5 degrees
                       (see Figure 5). If you exceed this 5 degree limit, the drive will
                       catch on the tiller arm/rudder quadrant and the ball joint will bind.
                      No part of the drive unit fouls the boat's structure when the push
                       rod moves in and out.
                      The total rudder movement is limited to +/- 35 degrees by the
                       steering system end stops rather than the linear drive's end limits
                       (see Figure 7).


                                    Steering system                Steering system
                                    end stop                       end stop




                                                      35    35
                                                                                      D5079-1


                   Figure 7: Total rudder movement

                   CAUTION:
                   Make sure rudder movement is limited by the steering system
                   end stops before the push rod reaches its end stop. Failure to do
                   this could damage the drive and will invalidate the warranty.
12                                                 Linear Drive - Installation Guide

            WARNING:
            Keep clear of moving steering systems at all times. Protect
            moving parts from access during normal use.

     3. Connecting to the course computer
            WARNING: Electrical safety
            Make sure the power supply is switched off before you make any
            electrical connections.
            The linear drive unit has electrical connections for:
               the drive motor: two single-core cables: red and black
               the clutch: a two-core cable with red (+) and blue (-) cores
            Follow these steps to connect the linear drive to the course computer:
            1. Measure the distance of cable run from the drive unit to the course
               computer:
                use Table 2 to identify the appropriate motor cable size
                use at least 1.5 mm2 (16 AWG) copper cable for the clutch
            2. Join these cables to the drive cables using appropriate electrical
               connectors or junction boxes at the correct power rating.
            3. Route the cables back to the course computer, taking into account
               the EMC installation guidelines (see page 6).
            4. Connect the cables to the course computer (see Figure 8):
                CLUTCH cable: red core to +ve, blue core to -ve
                MOTOR cables: at this stage you can connect either motor
                   cable to either terminal. You will check these connections
                   after installing the rest of the autopilot system.
Linear Drive - Installation Guide                                                                           13




                                     +   A B            +                  +        +   1  2
                           OFF
                          SWITCH
                                   POWER MOTOR   SOLENOID CLUTCH          lk CLUTCH    POWER MOTOR




                             Type 150/400 course computer               Type 100/300 course computer
                                                                                                       D5080-1


                   Figure 8: Cable connections at course computer
                   Table 2: Recommended cable sizes

                     Cable length                                  Cable gauge        Copper area
                     (drive unit to course computer)               (AWG)              (mm2)

                     Type 1 drive
                                up to 3m (10ft)                    14                 2.5
                                up to 5m (16ft)                    12                 4
                                up to 7m (23ft)                    10                 6
                                up to 10m (32ft)                   8                  10
                                up to 16m (52ft)                   6                  16

                     Type 2 drive 12 V (short/long)
                                up to 5m (16ft)                    10                 6
                                up to 7m (23ft)                    8                  10
                                up to 16m (52ft)                   6                  16

                     Type 2 drive 24 V (short/long)
                                up to 3m (10ft)                    12                 4
                                up to 5m (16ft)                    10                 6
                                up to 10m (32ft)                   8                  10
                                up to 16m (52ft)                   6                  16
14                                                Linear Drive - Installation Guide


     4. Post installation checklist
            Check the following points after installing the drive:
            1. Is the mounting foot secured to a substantial structure on the boat?
            2. Is the drive unit correctly aligned, i.e:
                Is the mounting foot correctly oriented?
                Is the drive mounted at right angles to the tiller arm, in a mid-
                    stroke position, when the rudder is amidships?
                Is the push rod accurately aligned with the tiller arm plane of
                    rotation (less than 5 degrees variation)?
            3. Is the linear drive rod end:
                securely attached to the tiller arm or quadrant?
                attached at the recommended tiller arm radius for the boat?
            4. Are the motor and clutch cables correctly routed and securely
               connected to the course computer?
            5. Have you completed a hand-steering check (see page 11)?
            Note: When you have installed the entire autopilot system, you will
            need to complete an autopilot steering check. Refer to the control unit
            handbook for more details.

Maintenance
            On a regular basis:
               check all connections and mountings are secure
               check drive alignment
               check cables for signs of wear or damage
            Note: If this drive is used heavily, we recommend that it is serviced
            every two years by a Raymarine Authorized Service Representative.

     EMC servicing and safety guidelines
               Raymarine equipment should be serviced only by authorized
                Raymarine service technicians. They will ensure that service
                procedures and replacement parts used will not affect
                performance. There are no user serviceable parts in any
                Raymarine product.
               Some products generate high voltages, so never handle the
                cables/connectors when power is being supplied to the
                equipment.
Linear Drive - Installation Guide                                                       15

                      When powered up, all electrical equipment produces
                       electromagnetic fields. These can cause adjacent pieces of
                       electrical equipment to interact with one another, with a
                       consequent adverse effect on operation. In order to minimize
                       these effects and enable you to get the best possible performance
                       from your Raymarine equipment, guidelines are given in the
                       installation instructions, to enable you to ensure minimum
                       interaction between different items of equipment, i.e. ensure
                       optimum Electromagnetic Compatibility (EMC).
                      Always report any EMC-related problem to your nearest
                       Raymarine dealer. We use such information to improve our
                       quality standards.
                      In some installations, it may not be possible to prevent the
                       equipment from being affected by external influences. In general
                       this will not damage the equipment but it can lead to spurious
                       resetting action, or momentarily may result in faulty operation.

       Product support
                   Raymarine products are supported by a worldwide network of
                   distributors and Authorized Service Representatives.
                   If you encounter any difficulties with this product, please contact
                   either your national distributor, or your service representative, or the
                   Raymarine Technical Services Call Center. Refer to the back cover
                   or the Worldwide Distributor List for contact details.
16                                                    Linear Drive - Installation Guide




Raymarine Ltd                   Raymarine Inc
Anchorage Park                  22 Cotton Road, Suite 280
Portsmouth, Hampshire           Nashua
England PO3 5TD                 NH 03063-4219, USA
Telephone +44 (0)23 9269 3611   Telephone +1 603 881 5200
Fax +44 (0)23 9269 4642         Fax +1 603 864 4756
www.raymarine.com               www.raymarine.com
Raymarine Technical Services Call Center
UK: +44 (0)23 9271 4713 or    USA: +1 603 881 5200 or
+44 (0)23 9269 3611 ext. 1083 1-800-539-5539 ext. 2333


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