B&G Network Pilot User Manual
NETWORK
ACP PILOT
INSTALLATION &
COMMISSIONING
MANUAL
BROOKES & GATEHOUSE LTD
Premier Way
Abbey Park
Romsey
Hampshire SO51 9DH
England
Tel: (+44) 01 794 518448
Fax: (+44) 01 794 518077
SECTION 1 SYSTEM UNITS
SECTION 1 SYSTEM UNITS................................................................1
SITING THE ACP UNIT..................................................................4
MOUNTING PROCEDURE............................................................4
ACP REMOTE COMPASS UNIT..........................................................5
DESCRIPTION...................................................................................5
SITING THE COMPASS UNIT.......................................................6
MOUNTING PROCEDURE............................................................6
NETWORK PILOT DISPLAY................................................................7
SITING THE PILOT DISPLAY HEAD.............................................8
MOUNTING PROCEDURE............................................................8
NMEA INTERFACING .......................................................................9
NMEA INPUT .................................................................................9
NMEA OUTPUT ...........................................................................10
HAND-HELD CONTROLLER .............................................................11
DESCRIPTION.................................................................................11
SITING THE HAND-HELD UNIT..................................................11
MOUNTING PROCEDURE..........................................................11
MAN OVERBOARD BUTTON (MOB) ................................................12
DESCRIPTION.................................................................................12
SITING THE MAN OVERBOARD ALARM BUTTON...................12
MOUNTING PROCEDURE..........................................................12
ACP JOYSTICK ..................................................................................13
DESCRIPTION.................................................................................13
SITING THE JOYSTICK UNIT .....................................................13
MOUNTING PROCEDURE..........................................................14
RUDDER REFERENCE UNIT (RRU)..................................................15
DESCRIPTION.................................................................................15
Key Points When Installing The RRU...........................................16
LINEAR FEED BACK UNIT................................................................20
1 - 1
ADVANCED CONTROL PROCESSOR UNIT
DESCRIPTION
The Advanced Control Processor (ACP) Unit contains all the electronics
for the autopilot operation and control of the rudder drive options. It is
designed to be mounted on a vertical, flat , smooth surface. The unit
has a hinged lid to provide easy access to the electrical connections
within. The unit requires the ACP Compass Unit (see next section).
The ACP Unit is available in two configurations:
ACP 1 12V only 12 amps max. output current
ACP 2 12/24V 25 amps max. output current
1 - 2
The 12V ACP 1 Unit will control the following rudder drive options:
Size 1/12V Hydraulic Ram Drive RAM-T1-12V blue
•
Size 1/12V Hydraulic Pump PMP-T1-12V blue
•
12V Rotary Drive Unit RDU-T1-12V
•
Stern Drive Unit SDU-T1-12V
•
The 24V ACP 2 unit will control the following rudder drive options:
•
Size 1/12V Hydraulic Ram Drive RAM-T1-12V blue
•
Size 2/12V Hydraulic Ram Drive RAM-T2-12V blue
•
Size 3/24V Hydraulic Ram Drive RAM-T3-24V blue
•
Size 1/12V Hydraulic Pump PMP-T1-12V blue
•
Size 2/12V Hydraulic Pump PMP-T2-12V blue
•
Size 3/24V Hydraulic Pump PMP-T3-24V blue
•
12V Rotary Drive Unit RDU-T1-12V
•
24V Rotary Drive Unit RDU-T3-24V
•
Stern Drive Unit SDU-T1-12V
•
1 - 3
SITING THE ACP UNIT
It is recommended that the ACP unit is mounted with the cable entry
•
points downwards. It must not be mounted with the cable entries
uppermost as water may run down the cables and into the unit.
Ensure that there is sufficient space to allow the unit to be hinged
•
open to make connections to terminals inside, and that the hinges of
the two halves of the case may be slid apart.
Select a position sheltered from the direct effects of the environment
•
and from physical damage.
Do not mount the unit within 1m/3ft of engines, starter motors and
•
cables, and other cables carrying heavy current, etc., or 3m/10ft of
Radar or SSB installation cables.
MOUNTING PROCEDURE
Undo the two screws at the corner of the unit, and open fully.
•
The hinges are designed to come apart. This enables the electronics
•
to be split from the base of the unit i.e. the connection and terminal
blocks.
Disconnect the cables between the two halves of the casing.
•
Firmly push the two halves of the computer unit apart.
•
Using the base of the unit as a template, mark the positions of the
•
three mounting screw holes.
Using the self-tapping screws provided secure the base of the unit in
•
position.
Push the two halves of the unit together again and reconnect the
•
cables.
1 - 4
ACP REMOTE COMPASS UNIT
DESCRIPTION
IMPORTANT NOTE:
This external fluxgate compass unit can
ONLY
be used with ACP Pilot Systems or Network Compass displays.
Remove the transit screw after mounting on bulkhead and before
inserting cable connector.
The ACP Remote Compass Unit is a gimbal mounted electronic
fluxgate for use with ACP Pilot Systems. The unit is housed in a sealed
casing constructed of high impact plastic. It is therefore suitable for on
or below deck mounting.
If installed in a vessel with a steel or reinforced concrete hull it may be
necessary to install the external compass unit outside the magnetic
screening affect of the hull and super-structure.
It is supplied with a 12m/36ft, 6-core screened cable, one end with a
sealed connector for the compass unit and the other connecting directly
into the ACP Unit.
1 - 5
SITING THE COMPASS UNIT
Mount the unit upright on a flat, vertical bulkhead.
•
A safe distance from external magnetic interference:
•
1m/3ft from VHF, RDF, loudspeakers, depth sounders, engines,
•
power cables carrying heavy current, etc.,
3m/10ft from Radar and SSB Equipment.
•
Reasonably well protected from direct physical damage.
•
With the connector downwards as shown in the above diagram.
•
MOUNTING PROCEDURE
Secure the unit in the selected site using the non-magnetic self-
•
tapping screws provided.
Route the cable to the computer unit avoiding other cables
•
carrying heavy currents, e.g. engine starter, trim tab, etc.
Secure in place with cable clips or tie-wraps.
•
Avoid bending the cable through a tight radius especially near the
•
connector as this may damage the wires inside the cable.
1 - 6
NETWORK PILOT DISPLAY
DESCRIPTION
The Network Pilot Display is designed to be mounted above or below
deck. The display head allows control of the autopilot and by installing
multiple display heads, gives control at any station. It can be connected
to all other Network Instruments via the network cable tails to provide an
integrated autopilot and navigational system. It is essential that the
autopilot is initialised before operation, details are given in the
commissioning section of this manual.
In an integrated system boat speed is supplied from Network SPEED or
QUAD units and wind speed and wind angle from Network WIND via
the system network for Steer to Compass and Steer to Vane modes.
Boat speed can also be set using the display head when required.
Plus
When a GPS
the Pilot via the network cable connection. Without a GPS
is included in the system all required data is carried to
Plus
on the
system, NMEA 0183 (v1.5) data can be input to the Pilot via the 3 pin
socket located on the rear of the display unit.
The display heads are supplied with a clip-in mounting bracket which
allows for easy installation, access from behind is not necessary to
secure the unit in place. However to prevent theft or if removal of the
unit is not required then locking studs and thumb-nuts are supplied to
allow for permanent fixing.
1 - 7
SITING THE PILOT DISPLAY HEAD
All Network Instruments are designed for mounting on or below deck.
Select a display site that is:
At a convenient position within easy reach of the helmsman
•
On a smooth and flat surface
•
At a compass safe distance 100mm (4")
•
Reasonably well protected from physical damage
•
Accessible from behind for fitting locking studs if required
•
The rear boss of the unit has a breather hole to prevent
•
condensation, protect the rear cover from direct splashes of water.
MOUNTING PROCEDURE
• Use the cutting template supplied to mark the centres of the holes
for the self-tapping screw, the fixing stud holes and the mounting
bracket.
• The template allows 4mm (5/32") between adjacent units or
118mm/ 4 11/16” between centres for the suncover. Increase this
distance if required to maximum of 60mm (2 3/8") between units or
180mm (7 1/8") between centres.
• For greater distances between units extension cables are available.
• Use a 70mm (2 3/4") diameter hole-cutter for the mounting bracket
hole.
• Use a 2.9mm(1/8”) drill for the self-tapping screws.
• Use a 5mm (3/32") drill for the locking stud holes.
• Secure the mounting bracket to the bulkhead with the self-tapping
screws supplied.
• Fit the rubber sealing gasket around the mounting bracket.
• Screw the locking studs into the back of the display head.
• Carefully pass the cable tails through the mounting bracket hole,
connect the power, interconnecting and NMEA input cables to the
display head (if fitted).
1 - 8
• Clip the display head into the mounting bracket.
• Secure the display head with the thumb nuts supplied (if required).
NMEA INTERFACING
The Network PILOT can be interfaced to any NMEA 0183 (v1.5)
compatible position fixer. If more than one source of NMEA data is to be
used then it will be necessary to use two Network PILOT display units.
NMEA INPUT
The Network PILOT display head has an NMEA input connector at the
rear, use a special 3m NMEA input cable 612-OA-053 (Red sig+, Blue
sig-).
The Network PILOT uses the follow data from NMEA:
Cross Track Error (XTE), Speed Over Ground (SOG), Bearing: current
position to destination waypoint, Bearing: origin waypoint to destination
waypoint, Distance: current position to waypoint
Waypoint number
The following NMEA sentences are decoded, Note $ID is any NMEA
talker:
$IDAPA XTE, bearing origin to destination waypoint
$IDAPB XTE, bearing origin to destination waypoint,
bearing to waypoint
$IDRMB XTE, bearing and distance to waypoint
$IDXTE XTE
$IDVTG Speed over Ground
$IDBWR Bearing and Distance to waypoint rhumb,
waypoint number
$IDBWC Bearing and Distance to waypoint great circle,
waypoint number
1 - 9
NMEA OUTPUT
NMEA output is via the network cable connection tail, use a special 3m
NMEA output cable 610-OA-030 (Red sig+, Blue sig-).
Dependent on system devices, the following sentences are transmitted:
$IIHDM Heading
$IIVHW Speed and heading
$IIDBT Depth below transducer
$IIVWR Apparent wind angle and speed
$IIMTW Water temperature
1 - 10
HAND-HELD CONTROLLER
DESCRIPTION
The hand-held remote controller is a waterproof unit that has six
function buttons and a status LED to indicate the operating mode of the
autopilot. The unit provides palm-of-the-hand control of the PILOT. The
cable has a 10 metres /30ft straight section, plus a coiled length that
extends from 1 metre to 3 metres.
SITING THE HAND-HELD UNIT
At a convenient position within easy reach of the helmsman.
•
Ensure at all times the hand-held remote controller's cable does not
•
become snagged on any moving parts e.g. throttle controls.
MOUNTING PROCEDURE
Heavy duty self-adhesive Velcro strip is supplied with the unit.
•
Clean and de-grease the site, stick the Velcro firmly in place.
•
1 - 11
MAN OVERBOARD BUTTON (MOB)
DESCRIPTION
The man overboard alarm button (MOB) is a large red waterproof switch
with 15 metres/45ft of two-core screened cable. This button starts the
MOB sequence of operations when pressed and the audible alarm
sounds (if fitted).
SITING THE MAN OVERBOARD ALARM BUTTON
Select a suitable bulkhead, easily accessible in an emergency.
•
MOUNTING PROCEDURE
With a 32mm (1 1/4") hole-cutter cut a clearance hole for the button
•
body.
Remove the nut and washer, then ensuring the sealing gasket is in
•
place to prevent leakage, carefully feed the cable through the hole.
From behind the bulkhead, fit the washer and nut and tighten.
•
1 - 12
ACP JOYSTICK
DESCRIPTION
The joystick allows direct control of the vessel's rudder via the autopilot
control electronics. The unit is deck-mountable, allowing it to be used
inside or outside the steering positions. A 10m/30ft 6-core screened
cable connects the unit directly into the ACP Units terminals.
Joystick steering is engaged and disengaged with the separate red
button. The lever can only be moved to port or to starboard.
SITING THE JOYSTICK UNIT
At a convenient position within easy reach of the helmsman.
•
1 - 13
MOUNTING PROCEDURE
To ensure correct steering sense the unit is marked with two indents,
•
the unit must be installed with these forward.
The unit requires at least 65mm/2.5" clearance behind the selected
•
mounting position.
Use a 40mm (1 9/16th") hole cutter for the joystick body.
•
Ensure the gasket is fitted under the joystick body flange.
•
Secure in place with self-tapping screws.
•
R oute the cable to ACP unit. Connect as per instruction in Section 4
•
of this handbook.
For details on how to install the controller button refer to the MOB
section.
1 - 14
RUDDER REFERENCE UNIT (RRU)
DESCRIPTION
The Rudder Reference Unit (RRU) is a sealed high specification
potentiometer in a robust casing, providing rudder position information
to the Computer Unit. The operating arm is constructed in aluminium
with three positions pre-drilled for the adjustable drag-link. The
drag-link, has ball-joints at each end that connect the unit operating arm
to the tiller arm or steering quadrant. The unit base has four holes to
allow for mounting. The unit is supplied with 10 m/30ft of 3-core
screened cable.
1 - 15
KEY POINTS WHEN INSTALLING THE RRU
General consideration must be given to the steering system and its
•
geometry before starting the RRU installation. Many factors must be
contemplated for a practical solution, the information given here is for
guidance only, although where a maximum or a minimum value is
given these must be adhered to.
Mount the RRU on a flat surface next to the tiller arm or steering
•
quadrant, construct a small platform if necessary.
Do not lengthen the drag-link arm as this can transmit excessive
•
vibration loads to RRU and will invalidate the warranty.
The unit operating arm can be rotated through 360º, the mid-point of
•
the RRU travel is when the operating arm is opposite the cable entry
point.
When the rudder is moved from hard-over port to hard-over starboard
•
the RRU arm should swing through a minimum of 90º, this will ensure
that there is sufficient voltage output to the autopilot. Measure the
voltage difference between the green and blue wires of the RRU,
there should be a minimum of 1 volt change from hard over to hard
over. N.B. If there is less than 1 Volt change the Pilot will not
commission.
After installation check full movement of the steering system ensuring
•
that there is no fouling between the steering gear, RRU parts and
ram drive unit if fitted.
Ensure that there is no backlas h in the linkage between the RRU and
•
the steering gear, otherwise incorrect operation of the autopilot will
occur.
1 - 16
The example shown is a plan view of a typical system with a tiller arm
and quadrant. When viewed in elevation, the ram drive arm and rudder
reference unit drag-link must not be more than ±9º from horizontal.
Ideally everything should be horizontally aligned, this prevents
excessive stress during operation.
1 - 17
1 - 18
ARIA
The RRU can be mounted in many different positions and orientations
depending on the layout of the steering system.
If the maximum rudder angle is less than 90º then the position of the
RRU or the drag-link must be adjusted so that the operating arm of the
RRU swings through a minimum of 90º and the output voltage
difference is greater than 1 volt from port to starboard lock. Measure the
output of the RRU between the green and blue wires. N.B. If there is
less than 1 Volt difference the Pilot will not commission
.
1V MINIMUM
V
TION
90° MINIMUM RRU AN G LE
1 - 19
The rudder hard over angle should only be limited by the rudder stops
and not the RRU linkage. Check that when hard over the RRU arm and
drag-link, do not form a straight line. If this occurs the steering system
could become damaged or jammed endangering the boat and crew.
Rectify this immediately by adjusting the position of the RRU.
LINEAR FEED BACK UNIT
Where installation of the conventional Rudder Reference unit is difficult
or physically impossible a Linear Feedback unit can be used. The
Linear Feedback unit comprises of a tube approximately 23mm/ 7/8” in
diameter and 324mm/ 12 3/4” long. This assembly is clamped to the
side of the Linear actuator using a special bracket kit. The Linear Feed
Back shaft is attached to the tiller bracket using the pin supplied with all
Blue rams.
This unit requires careful installation and alignment which should be
carried out by your dealer / supplier. For electrical connection see
section 4.
1 - 20
SECTION 2 RUDDER DRIVE OPTIONS
RAM DRIVE UNIT __________________________________2
DESCRIPTION _____________________________________2
BLUE RAMS(DRIVE DATA) __________________________2
SIZE 1 & 2 HYDRAULIC DRIVE PUMP DIMENSIONS _____6
RAM DRIVE UNIT INSTALLATION _____________________7
Key Points On Installation ___________________________8
A Typical Ram Drive Unit Layout (REFER TABLE 2-5) _____9
Ram Mounted Parallel To Vessels Centre-Line __________10
KEY POINTS ON INSTALLATION. ___________________11
MOUNTING A BLUE RAM ON A VERTICAL BULKHEAD__11
SPLITTING THE RAM DRIVE UNIT____________________13
BLUE HYDRAULIC DRIVE PUMPS ___________________14
DESCRIPTION ____________________________________14
Pump Data ______________________________________14
Key Points On Installation __________________________15
HYDRAULIC DRIVE PUMP DIMENSIONS ______________ 16
HYDRAULIC DRIVE PUMP INSTALLATION EXAMPLES__19
2 - 1
RAM DRIVE UNIT
DESCRIPTION
A compact DC driven reversible hydraulic pump and hydraulic cylinder
assembly for boats without hydraulic steering systems. Three sizes of
ram drive are available giving a wide thrust range to suit all sizes and
types of vessel.
BLUE RAMS(DRIVE DATA)
Type 1 and type 2 rams combine motor, pump and hydraulic cylinder as
one unit referred to as an actuator. Type 3 rams are supplied split into a
separate motor/pump unit, reservoir and hydraulic cylinder, connected
by 1 metre/ 3ft hoses. Longer hoses are available, contact your dealer.
The units can also be mounted on a vertical bulkhead see page 2-12.
2 - 2
RAM
DRIVE
TYPE
ACP UNIT
MOTOR
SUPPLY
SOLENOID
VALVE
SUPPLY
PEAK
THRUST
PEAK
CURRENT
MAXIMUM
STROKE
FULL
BORE
AREA
ANNULUS
AREA
ROD
DIAMETER
TILLER
ARM
for 700
rudder
MAXIMUM
TORQUE
WEIGHT
HELM TO
HELM TIME
extend
retract
RAM SIZE1
BLUE
ACP1 ACP2 ACP2 only ACP2 only
12V DC 12V DC 12V DC 24V DC
12V DC
1.25A (max)
425 kg force
935 lbs-force
14A @
12V
254mm
10"
1208 mmsq,
1.872 "sq
1005
mmsq,
1.558 "sq
16 mm,
0.623 "
214 mm
8.4 "
892 Nm
7867 lb.ins
7 kg,
15 lbs 6oz
15.7 sec
13.4 sec
(8Kg force)
RAM SIZE 1
BLUE
12V DC
1.25A (max)
680 kg
force
1496 lbs-
force
20A @
12V
254mm
10"
1208 mmsq,
1.872 "sq
1005
mmsq,
1.558 "sq
16 mm,
0.623 "
214 mm
8.4 "
1427 Nm
12574 lb.ins
7 kg,
15 lbs 6oz
15.7 sec
13.4 sec
(8Kg force)
RAM SIZE 2
BLUE
12V DC
1.25A (max)
680 kg
force
1496 lbs-
force
25A @
12V
254mm
10"
1208 mmsq,
1.872 "sq
1005
mmsq,
1.558 "sq
16 mm,
0.623 "
214 mm
8.4 "
1427 Nm
12566 lb.ins
7 kg,
15 lbs 6oz
11.9 sec
10.2 sec
(200Kg
force)
RAM SIZE 3
BLUE
24V DC
0.8A (max)
1062 kg
force
2342 lbs-
force
17A @
24V
305mm
12 "
1885 mmsq,
2.921 "sq
1570
mmsq,
2.434 "sq
20 mm,
0.623 "
257
mm
10.16 "
2688 Nm
23780 lb.ins
10.3 kg,
22lbs 11oz
14.6 sec
12.6 sec
(200Kg
force)
The following table may be used to determine the steering system
geometry for different maximum rudder angles and ram type. The last
three columns show the peak torque available (in Kgm), amidships
position and at the maximum rudder angle, with the latter two with the
motor running at 50% duty cycle.
Refer to the diagrams on page 2-6, 2-10, 2-11, 2-13.
2 - 3
RA M-T1-12V
568
5
2
1/2 m a x Tiller arm Offs e t Thrus t To rq u e at T o rq u e at Torq u e
rudder angle m m mm (peak m idships midships (at max
a b c Kgf) (peak Kgm) (50% Kgm) 50% Kgm)
25 290 272 425 123 123 118
30 245 227 425 104 104 90
35 214 196 425 91 91 74
40 190 172 425 81 81 62
45 173 155 425 74 74 52
50
RA M-T1-12V
1/2 m a x Tiller arm Offs e t Thrus t To rq u e at T o rq u e at Torq u e
rudder angle m m mm (peak m idships midships (at max
a b c Kgf) (peak Kgm) (50% Kgm) 50% Kgm)
25 290 272 680 197 197 179
30 245 227 680 167 167 144
35 214 196 680 145 145 119
40 190 172 680 129 129 99
45 173 155 680 118 118 83
50 160 142 680 109 109 70
RA M-T2-12V
1/2 m a x Tiller arm Offs e t Thrus t To rq u e at T o rq u e at Torq u e
rudder angle m m mm (peak m idships midships (at max
a b c Kgf) (peak Kgm) (50% Kgm) 50% Kgm)
25
30
35 214 196 680 145 95 77
40 190 172 680 129 84 64
45 173 155 680 118 77 53
50 160 142 680 109 71 4
RA M-T3-24V midstroke = 690mm ACP2 only d= 51mm
1/2 m a x Tiller arm Offs e t Thrus t To rq u e at T o rq u e at Torq u e
rudder angle m m mm (peak m idships midships (at max
a b c Kgf) (peak Kgm) (50% Kgm) 50% Kgm)
25 350 326 1062 372 372 337
30 295 271 1062 313 313 271
35 257 233 1062 273 273 223
40 230 206 1062 244 244 187
45 210 186 1062 223 223 157
50 193 169 106
midstroke = 505mm ACP1 only d= 73.3
160 142 42
midstroke = 505mm ACP2 only d= 73.3mm
midstroke = 505mm ACP2 only d= 73.3mm
290 272 680 197 128 116
245 227 680 167 108 94
205 205 131
68 44
°
°
°
°
2 - 4
RAM DRIVE UNIT DIMENSIONS - BLUE SIZE 1 AND 2 ACTUATORS
AND BLUE RAMS.
2 - 5
SIZE 1 & 2 HYDRAULIC DRIVE PUMP DIMENSIONS
PUMP AND RAM DRIVE UNIT DIMENSIONS - BLUE SIZE 3
(REFERTO TABLE 2-5)
2 - 6
RAM DRIVE UNIT INSTALLATION
General consideration must be given to the steering system and its
geometry before starting the installation. Many factors must be
contemplated for a practical solution, the information given here is for
guidance only, although where a maximum or minimum value is given
this must be adhered to. It is essential that the unit is only installed in a
fully functional steering system, with no backlash or stiffness when
operating. Rectify any steering problems before installation of the ram
drive unit or the autopilot will not function correctly.
2 - 7
KEY POINTS ON INSTALLATION
Check that the steering gear is in good condition. Rectify any steering
•
defects prior to installation of the ram.
The ram drive unit must be secured onto a flat, rigid base, it maybe
•
necessary to construct a platform section for the mounting plate. For
angled rudder stocks an angled platform section will have to be
constructed.
All setting up and aligning of the ram drive unit with the steering
•
system should be carried out with the rudder in the amidships
position and the ram arm at the centre point of its travel.
The angle between the ram arm and the tiller arm should be as
•
shown in the next two diagrams.
The ram arm should ideally be at right-angles to the rudder stock.
•
The ball-joint on the end of the ram arm will allow a
MAXIMUM
of ±9º
of misalignment.
FOR TYPE 3 RESERVOIR INSTALLATION
Do not turn the black reservoir tap on or attempt to move the
piston rod until all of the following are completed:
The base foot of the ram and pump have been bolted into position.
•
The reservoir has been fixed to a bulkhead above the ram and pump.
•
The sealed reservoir transit cap has been replaced by the breather
•
cap supplied.
The reservoir has been filled with the oil supplied.
•
The reservoir tap has been switched to the
•
position allowing the
‘ON’
oil to flow between the reservoir and the pipe.
(TAP ‘ON’ POSITION IS IN LINE WITH THE PIPE)
2 - 8
A TYPICAL RAM DRIVE UNIT LAYOUT (REFER TABLE 2-5)
b = tiller arm
length
a=half max rudder angle
d
2 - 9
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