Raymarine S1000 Autopilot Installation Instructions 87040 5
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Autopilot Installation Guide Document Number 870405 Date March 2007Welcome to the Raymarine S1000 on having bought a Raymarine S1000 Autopilot This is specifically designed to be easily integrated with your boats steering system andenable you to automatically control the steering S1000 Autopilot System Existing hydraulic steering system S100 REMOTE S100 Remote MODE STANDBY PILOT Course computer GPS input The S1000 requires GPS data SeaTalk or NMEA compatible Autopilot Pump control pump to operate correctly Alarm signal Safety alarm D75011The S1000 Autopilot is intended for use in HC5345 HC5347 HC5348 and HC5358 SeaStar steering systems Systems with HC4600 HC4645 HC4647 HC4648 and HC4658 BayStar steering rams Systems with Hynautic K6 steering rams SeaTalk is a Registered Trademark of Raymarine SeaStar is a Registered Trademark of Teleflex Incorporated BayStar is a Trademark of Teleflex Incorporated NMEA is a Registered Trademark of the National Marine Electronics Assocociation All other trademarks used in this document are acknowledged Copyright Raymarine UK Limited 2006S1000 Autopilot Installation Guide 1 Installation overview Connect the autopilot pump 1 to your existing steering system Page 9 2 Bleed the steering system Page 12 3 Secure the autopilot pump Page 16 4 Fit the course computer Page 17 5 Fit miscellaneous items Page 18 Inline S100 Remote power switch Safety alarm 6 Make electrical connections Page 21 7 Carry out post installation checks Page 28 D758312 S1000 Autopilot Installation GuideThis guideBefore starting to install your S1000 Autopilot please take time to read this guide In particular please take note of the safety and compatibility EMC information at theend of this guide WARNING This product must be installed and operated in accordance with the Raymarine instructions provided Failure to observe this could result in personal injury damage to the boat andor poor product performanceThe installation procedures are described in a rational sequence but because of variations inboat design space available etc you may need to adapt the sequence to suit your you start fitting your S1000 Autopilot we recommend you Unpack your S1000 Autopilot and check that all parts are present Plan your S1000 Autopilot installation so that you fit the components in the best possible noteThe S1000 Autopilot must receive position information from a suitable GPS inorder to function correctly GPS systems compatible with SeaTalk or NMEA orboth are suitable If you need advice as to which GPS to use please contactyour Raymarine dealerS1000 Autopilot Installation Guide 3What you need Parts supplied Elbow fitting x 4 Autopilot Pump Straight fitting x 2 Antivibration mounts x 2 T fitting x 2 High pressure Low pressure steering hoses transparent x 2 bleeding hose Nitrile gloves Wrench 12 mm AF x 19 mm AF Drill 34 mm Course Computer Safety alarm S100 REMOTE MODE STANDBY PILOT Drain cups Fill cups Belt clip assembly S100 Remote 2 x cradles 1 pint 05 liter hydraulic fluid Connector block Lanyard Power cable Data cable Miscellaneous Inline power Ferrite D73302 cable ties switch4 S1000 Autopilot Installation Guide Tools materials required Pencil Screwdriver No 2 Pozidriv Countersink bit Drill Screwdriver Screwdriver medium small Absorbent flat blade flat blade D73311 disposable wipesS1000 Autopilot Installation Guide 5PlanningIn order to make the installation as trouble free as possible we strongly recommend youspend adequate time planning the best locations for your autopilot components This isparticularly important when considering the position of the autopilot pump as hydraulichoses are supplied in fixed lengths so there are some limitations on the positioning of theautopilot pump with respect to the boats helm pumpIf you have internet access please view the installation video on line at you disturb your hydraulic steering system we strongly recommend that you consultthe manufacturer and read the steering system manuals Locating the course computer 5 5 5 5 5 5 5 5 At least 3 ft 1 meter D755216 S1000 Autopilot Installation Guide Locating autopilot pump Autopilot pump to be lower than helm pump Provide protection Install in a dry location from physical damage Res Bleed e rv o ir S c re w Po rt R es Bleed e rv o ir S c re w Po rt Do not fit in engine compartments near fuel tanks or in any other area where fuel vapor is likely No sharp bends kinks or chafing of tube Mount pump location either horizontally or with connector end up Do not mount pump with connector D73501 end downS1000 Autopilot Installation Guide 7 Using the hydraulic hoses Three preassembled hydraulic hoses are supplied Two of these are darkcolored high pressure steering hoses and the third is a transparent lowpressure hose The transparent hose is intended to help you check for air bubbles when bleeding the system and must be used only to connect the autopilot pump reservoir to the lower connector on the helm pump It must NOT be used anywhere else in the system Bleed S Res c re e rv w o ir rt Po Bleed Bleed S Res c re e S Res c rv w re e o rv ir w o ir rt Po rt Po D755328 S1000 Autopilot Installation Guide Sealing hydraulic joints CAUTION Do not use sealing tape on any part of a hydraulic system as this can disintegrate and the resulting particles can cause blockages in the hydraulic system Tapered thread Thread for hose Do not apply sealant to connection hose connection thread Note The hydraulic fittings supplied with the autopilot pump have sealant pre applied to the tapered threads You only need to apply sealant to any extra joints D75451 you may obtain The recommended sealant for doing this is Loctite 542 Installing tapered thread fittings 1 Hand tighten 2 CAUTION Do not exceed 13 ftlbs 176 Nm torque 15 turns From hand tight use a wrench to tighten the joint a further 15 turns This should make it leakproof 3 CAUTION Do not exceed 13 ftlbs 176 Nm torque DO NOT EXCEED 25 TURNS in total from hand tight To change the orientation of the joint to align it with the hose further tighten the joint to a maximum of one further turn until the joint is facing the required D75461 directionS1000 Autopilot Installation Guide 9Installation procedures1 Connecting the autopilot pump O Connecting the autopilot pump sheet 1 WARNING Do not allow hydraulic fluid to come into contact with your skin Wear the protective nitrile gloves provided when working with hydraulic fluid WARNING A sudden release of pressure from a hydraulic system could result in personal injury Before disconnecting any part of a hydraulic steering system safely release any pressure in accordance with the manufacturers instructions WARNING The autopilot pump is not suitable for use in the vicinity of engines fuel tanks or in any other area where fuel vapor is likely to be present CAUTION Do not use the transparent hose for connecting any part of the steering system other than between the autopilot pump reservoir and the lower connector on the helm pump 1 Secure the required hydraulic joints 2 Connect the hydraulic hoses to the elbow or straight into the autopilot autopilot pump Ensure the transparent pump as described under Installing hose is connected to the reservoir tapered thread fittings connector Starboard Reservoir connector connector Bleed S Res c re e rv w o ir rt Res Po Bleed e rv o ir S c re w Po rt Port connector D7345110 S1000 Autopilot Installation Guide 0 Connecting the autopilot pump sheet 2 3 Set steering to dead ahead 4 Remove retain the helm pump and do not move it until breather cap instructed 5 Remove retain the plug from the helm pump lower connector and 6 Label the port ram hose to aid future drain the fluid into one of the cups reassembly then disconnect both ram provided Discard the drained fluid in hoses straight connectors from the accordance with local regulations helm pump 7 Using the Installing tapered thread fittings procedure fit T connectors to the helm pump port and starboard connectors and a straight connector to the helm pump lower connector D74831 D74832S1000 Autopilot Installation Guide 11 Connecting the autopilot pump sheet 3 8 Connect hydraulic steering hoses from 9 Reconnect the ram hoses to the autopilot pump Port and Starboard appropriate helm pump T connectors connectors to the Port and Starboard connectors on the helm pump so that Port connects to Port and Starboard connects to Starboard to steering ram Bleed S Res c re e rv w o ir rt Po Bleed S Res c re e rv w o ir rt Po 10 Connect the transparent hose from autopilot pump reservoir hose to the straight connector at the helm pump lower connector This completes the connection of the autopilot pump Now bleed the steering system Bleed S Res c re e rv w o ir rt Po D7484212 S1000 Autopilot Installation Guide2 Bleeding the steering system WARNING Do not allow hydraulic fluid to come into contact with your skin Wear the protective nitrile gloves provided when working with hydraulic the autopilot pump will introduce air into the steering system making it feelspongy and lumpy to operate To return the steering system to smooth operation use theprocedure given here to bleed the air from the system Bleed procedure sheet 1 1 Top up the helm pump with hydraulic fluid 2 Loosen the autopilot pump bleed screw 2 full turns Bleed S Res c re e rv w o ir rt Po D73361S1000 Autopilot Installation Guide 13 Bleed procedure sheet 2 3 Using a suitable screwdriver turn the autopilot pump shaft so that the flat on the shaft is toward the PORT side of the pump 4 SLOWLY turn the wheel and observe the bubbles in the transparent tube Keep the helm pump reservoir topped up while doing this Keep turning the wheel until there are no more bubbles ie so the hydraulic fluid in the transparent tube is clear Bleed Bleed S S Res Res c c re e re e rv rv w w o o ir ir rt rt Po Po D7339214 S1000 Autopilot Installation Guide Bleed procedure sheet 3 5 Using a suitable screwdriver turn the autopilot pump shaft so that the flat on the shaft is toward the starboard STBD side of the pump 6 SLOWLY turn the wheel clockwise and observe the bubbles in the transparent tube Keep the helm pump reservoir topped up while doing this Keep turning the wheel until there are no more bubbles ie so the hydraulic fluid in the transparent tube is clear Bleed Bleed S S Res Res c c re e re e rv rv w w o o ir ir rt rt Po Po D73372S1000 Autopilot Installation Guide 15 Bleed procedure sheet 4 7 Top up the hydraulic fluid Correct fluid level Helm pump 8 Turn the autopilot pump bleed screw fully clockwise and handtighten it Bleed S Res c re e rv w o ir rt Po 9 Replace the helm pump breather cap This completes the bleed procedure Now secure the pump D7486116 S1000 Autopilot Installation Guide3 Securing the pump Securing the pump 1 Place the pump at the intended 2 Drill two 18 34 mm pilot holes location and mark holes for the for the fixing screws fixing screws Bleed S Res c re e rv w o ir rt Po 3 Countersink the pilot holes to prevent 4 Slide the antivibration mounts onto damage to the mounting surface the pump bracket feet then secure the pump with the screws provided Bleed S Res c re e rv w o ir rt Po When the autopilot pump is secure fit the course computer D74882S1000 Autopilot Installation Guide 174 Fitting the course computer Securing course computer 1 Mark holes for fixing screws 2 Drill two 18 34 mm pilot holes for fixing screws 3 Countersink the pilot holes to prevent 4 Partially screw in the screws provided damage to the mounting surface then slot the course computer onto the screws and tighten screws The course computer is now secure D7338118 S1000 Autopilot Installation Guide5 Fitting miscellaneous items Safety alarm Locating Securing 1 Mark holes for fixing screws 2 Drill two 18 34 mm pilot holes 3 Countersink the pilot holes to prevent 4 Secure the safety alarm with the damage to the mounting surface screws provided D76071 Fitting batteries in S100 Remote 2 x AAA batteries supplied When replacing use only highquality alkaline AAA size batteries D75042S1000 Autopilot Installation Guide 19 Fitting S100 Remote cradle At fixed position On belt clip 1 Mark holes for the fixing screws 1 2 Drill three 18 34 mm pilot holes for the fixing screws 2 3 3 Countersink the pilot holes to prevent damage to the mounting surface ck Cli 4 Secure the cradle To separate cradle from clip D7683120 S1000 Autopilot Installation Guide Inline power switch Locating Fit the inline power switch in a location Securing 1 2 Cut 1116 18 mm 1 inch5 mm 5 maximum Ensure the protrusion on the switch barrel goes fully into 3 the mounting hole 4 5 D75911 When all items have been fitted connect up the system electricsS1000 Autopilot Installation Guide 216 Electrical Summary WARNING Before making electrical connections to any part of the S1000 system ensure the power source for the system is switched off Course Computer Bleed S Res c re e rv w o ir Po rt Autopilot Pump RF ground See Diagram A See Diagram B Inline power switch See Diagram B Data NMEA Spur See Diagram C cable Diagram D Alarm See Diagram C SeaTalk See Diagram C D7522122 S1000 Autopilot Installation wiresWhen you need to join wires use the either the supplied Scotchlock connectors or terminalblock as Scotchlock connectors are suitable for joining thin data wires They are NOT suitable forconnecting the safety alarm D75471S1000 Autopilot GroundingThe S1000 Autopilot system requires an RF ground connection to be made to ensurecomplete conformance with the EU regulations requirements AFTER installation The RFground connection is also essential to maintain the performance of thesystem in all installations regardless of local regulations requirements world wideFailure to provide an RF ground when the S1000 Autopilot is installed could result in adegraded performance and may affect the operation of the systemThe recommended MINIMUM requirement for an RF ground lead is Flat tinned copper braid 025 inch 65 mm width minimum Equivalent stranded wire diameter 016 inch 4 mmS1000 Autopilot Installation Guide 23 Diagram A Connecting RF ground preferred method Course computer S1000 Autopilot 0191O Product Code A18107 POWER PUMP FCC ID PJ5S1000 IC 4069BS1000 Raymarine Ltd Portsmouth PO3 5TD England If the boat does not have a ground plate use the alternative method shown in the following diagram to connect the RF ground Boat hull RF Ground Plate Alternative method Note Use this method of connecting the terminal ONLY if the boat does not have an RF grounding plate When using this method do NOT connect the terminal to any other point Course computer S1000 Autopilot 0191O Product Code A18107 Product Code A18107 POWER PUMP FCC ID PJ5S1000 IC 4069BS1000 Raymarine Ltd Portsmouth PO3 5TD England Now connect the power the autopilot pump D7539224 S1000 Autopilot Installation Guide Diagram B Connecting power autopilot pump Course computer S1000 Autopilot 0191O Product Code A18107 POWER PUMP FCC ID PJ5S1000 IC 4069BS1000 Raymarine Ltd Portsmouth PO3 5TD England Brown Blue Integral 10 A fuse Integral ferrite Black Red 12 V Power supply Autopilot pump Inline power switch Now make the necessary Data Cable connections D75411S1000 Autopilot Installation Guide 25 Diagram C Connecting the Data Cable Course Computer GPS requirement The S1000 must receive GPS information to function correctly Use the Data Cable supplied to connect the Course Computer to a GPS using either of the following methods 1 To a Raymarine GPS via SeaTalk connections 2 To a Raymarine GPS via NMEA spur 3 To a nonRaymarine GPS via NMEA spur NMEA connector not Clip ferrite to supplied from GPS Data Cable as close to NMEA Spur the connector as possible When connecting NMEA data from an external source always connect via the NMEA spur on the Data Cable Do NOT connect NMEA data from an external source directly to the connector on the Course Computer Data cable For details of the NMEA Spur connections refer to Diagram D Each time power is applied to an S1000 Autopilot connected to a Raymarine GPS via NMEA or SeaTalk the S1000 will set the GPS filtering to WEAK Connector Purple block Red Safety White Black alarm Yellow SeaTalk Data Red SeaTalk 12 V SeaTalk Black SeaTalk 0 V If you want to connect to an external SeaTalk system ensure each of these SeaTalk wires connects to the wire of the same color in the external system When you have completed the electrical connections secure the wires at the Course Computer D7549126 S1000 Autopilot Installation Guide Diagram D NMEA connections Course Computer Using with Raymarine GPS If a Raymarine GPS such as the Raystar 120 or 125 is to be connected to the S1000 Autopilot via NMEA the NMEA in and out ve and ve lines must all be correctly connected Each time power is applied to an S1000 Autopilot connected to a Raymarine GPS via NMEA or SeaTalk the S1000 will set the GPS filtering to WEAK NMEA Pin 1 Connector Pin 2 NMEA Spur Pin 3 Pin 5 CAUTION Before making any changes to the Data Cable Data disconnect it from the Course Computer cable If it is more convenient to connect the NMEA spur to the GPS without using the NMEA connector you can remove the connector and prepare the cable end as appropriate for your preferred method of connection Refer to the wire identification table below as necessary Wire Pin NMEA signal Connection at color number at S1000 3rd party GPS Brown 1 ve out NMEA ve receive Green 2 ve out NMEA ve receive Orange 3 ve in NMEA ve transmit Blue 5 ve in NMEA ve transmit SeaTalk safety alarm When you have completed the electrical connections connections secure the wires at the see Diagram C Course Computer D75961S1000 Autopilot Installation Guide 27 Secure wires Course Computer POWER PUMP D75511This completes the installation procedure Now carry out the Post installation S1000 Autopilot Installation Guide7 Post you have completed the installation of your S1000 Autopilot use the to First carry out the Manual checks below to check the the steering operation and check the system for leaks then Carry out the Autopilot checks setup procedures below to check the autopilot operates the steering in the correct direction and to set up the autopilot checksWith autopilot power off turn the wheel from hard over port to hard over starboard If thesteering operates satisfactorily and turns in the correct direction proceed with the other checksIf the steering feels uneven andor less responsive than it was before you installed your S1000Autopilot you may need to bleed the entire steering system To do this use the purgeprocedure at the following web Check for leaks sheet 1 1 Ensure all hydraulic joints are secure then turn the wheel to port When the hard over point is reached continue turning to port to pressurize the port lines until the safety valve releases At this point the fluid in the port lines will be at maximum pressure and the wheel has a lumpy feel when turned further to port 2 With the port lines at maximum pressure check the port lines for leaks paying particular attention to the joints If a leak occurs turn the wheel to starboard to release the pressure then repair the leak and repeat steps 1 2 Continue on sheet 2 D75021S1000 Autopilot Installation Guide 29 Check for leaks sheet 2 3 Turn the wheel to starboard and when the hard over point is reached continue turning to starboard to pressurize the starboard lines until the safety valve releases At this point the fluid in the starboard line will be at maximum pressure and the wheel has a lumpy feel when turned further to starboard 4 With the starboard lines at maximum pressure check the starboard lines for leaks paying particular attention to the joints If a leak occurs turn the wheel to port to release the pressure then repair the leak and repeat steps 3 4 5 After 24 hours recheck the steering system to ensure there are still no hydraulic fluid leaks checks setup WARNING Before switching on power to the course computer make sure that personnel are clear of the steering gear and outboard motors and that the boat is securely moored1 Switch on power to the S1000 system2 Carry out the Checking direction of turn procedure below Checking direction of turn sheet 1 Before casting off check that the S1000 operates the boats steering system in the correct direction 1 At the S100 Remote hold down STANDBY for 2 SETUP seconds to enter Setup mode Continue on sheet 2 D7704130 S1000 Autopilot Installation Guide Checking direction of turn sheet 2 2 Hold down and in turn and as each of these is pressed ensure that the outboard motors turns to give the correct direction of steer 3 If the outboard motors doesdo not move correctly DO NOT USE THE BOAT At the S100 Remote hold down STANDBY for 2 seconds to leave Setup mode and return to Standby mode then check that the S1000 components have been installed correctly In particular check that the autopilot pump wiring and hydraulics are connected correctly D77052S1000 Autopilot Installation Guide Approved by FCC USA CE Europe IC pump Current consumption 4 A at 100 psi 69 kP 7 A at 500 psi 3449 kP Dimensions 65 in 165 mm x 25 in 65 mm x 32 in 82 mm Weight 3 lbs 14 kgCourse computer Voltage 10 V dc to 16 V dc Current consumption 4 A nominal with autopilot pump running Dimensions 65 in 165 mm x 67 in 170 mm x 173 in 44 mm Data InOut SeaTalk NMEA 0183S100 Remote Voltage 3 V supplied by two internal AAA batteries Dimensions S100 Remote only 101 mm x 605 mm x 35 mm Remote in cradle103 mm x 66 mm x 44 mm Waterproofing IPX 6 and IPX 7Hydraulic fittings Tapered thread NPT National Pipe Thread Hose connection thread 916 UNEF Unified Extra FineHydraulic fluid Recommended Type SeaStarBayStar Marine Steering Fluid Other suitable Types Texaco HO15 Shell Aero 4 Esso Univis N15 Chevron Aviation Fluid A Mobil Aero HFA Fluids meeting MIL H5606 S1000 Autopilot Installation GuideGeneral notices WARNING Product installation operation This equipment must be installed and operated in accordance with the Raymarine instructions provided Failure to do so could result in personal injury damage to your boat andor poor product performance WARNING Electrical safety Make sure you have switched off the power supply before you start installing this the best of our knowledge the information in this guide was correct when it went to press However accept liability for any inaccuracies or omissions it may containIn addition our policy of continuous product improvement may change specifications without notice cannot accept liability for any differences between the product and this guideEMC Installation GuidelinesAll Raymarine equipment and accessories are designed to the best industry standards for use in the design and manufacture conforms to the appropriate Compatibility EMC standards butcorrect installation is required to ensure that performance is not compromised Although every effort has been takento ensure that they will perform under all conditions it is important to understand what factors could affect theoperation of the productThe guidelines given here describe the conditions for optimum EMC performance but it is recognized that it may notbe possible to meet all of these conditions in all situations To ensure the best possible conditions for EMCperformance within the constraints imposed by any location always ensure the maximum separation different items of electrical equipmentFor optimum EMC performance it is recommended that wherever possible Raymarine equipment and cables connected to it are At least 3 ft 1 m from any equipment transmitting or cables carrying radio signals eg 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 in the power supply to our products 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 positionS1000 Autopilot Installation Guide 33Suppression FerritesThe following illustration shows typical cable suppression ferrites used with Raymarine equipment Always use theferrites supplied by Raymarine to Other EquipmentIf your Raymarine equipment is to be connected to other equipment using a cable not supplied by Raymarine asuppression ferrite MUST always be attached to the cable near the Raymarine unit 34 S1000 Autopilot Installation GuideRaymarine UK Ltd Raymarine IncQuay Point 21 Manchester Road New Hampshire PO6 3TD USAUnited Kingdom Tel 1 6038815200Tel 44 0 23 9269 3611 Fax 1 6038644756Fax 44 0 23 9269
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