Raymarine 150-400 User Manual

Type 150/400 Autopilot System

Installation Guide

Document number: 81173-3 Date: June 2001

ii Type 150/400 Autopilot System: Installation Guide

Autohelm, HSB (High Speed Bus), SailPilot, SeaTalk and SportPilot are registered trademarks of Raymarine Ltd.

Raymarine, AST (Advanced Steering T echnology), AutoAdapt, AutoLearn, AutoRelease, AutoSeastate, AutoTack, AutoTrim, FastTrim, GyroPl us, RayGyro, RayPilot and W indTrim are trademarks of Raymarine Ltd.

Handbook contents © Raymarine Ltd 2001.

Preface iii

Contents

About this handbook ............................................................v

Important Information ........................................................vi

Warranty .....................................................................................vi

Safety notices .............................................................................vi

EMC conformance ....................................................................vii

Handbook information ..............................................................vii

Step 1: Check the Installation Kit ............................................1

1.1 Read this handbook ...................................................................1

The autopilot system – core pack contents ................................1

The autopilot system – other key compone nts .......................... 3

The autopilot system – extended systems ................................. 3

1.2 Obtain installation tools ............................................................4

1.3 Check parts supplied ................................................................. 4

Step 2: Check Locations ............................................................6

2.1 Identify suitable locations .........................................................6

2.2 EMC installation guidelines ..................................................... 7

Step 3: Install the Course Computer .......................................9

3.1 Select the location ...................................................................10

Suitable locations ....................................................................10

Unsuitable locations ................................................................11

Orientation ..............................................................................11

3.2 Secure the course computer ....................................................12

3.3 Remove the connector cover ...................................................12

Connecting cables to the terminals .........................................14

Using the fuses ........................................................................14

3.4 Attach the power cables .......................................................... 15

Step 4: Install the Compass ....................................................17

4.1 Select the location ...................................................................18

4.2 Mount the compass ................................................................. 20

4.3 Connect to the course computer ..............................................20

4.4 Connecting SeaT alk or NMEA compasses ............................. 21

Step 5: Install the Rudder Position Sensor ...........................22

5.1 Rotary rudder position sensor - installation ............................ 22

Introduction ............................................................................ 22

Ensuring correct alignment .....................................................23

Securing the sensor to the boat ................................................24

iv Type 150/400 Autopilot System: Installation Guide

Attaching the sensor to the tiller arm ...................................... 24

Checking alignment ................................................................25

Connecting to the course computer .........................................25

5.2 Linear rudder position sensor - installation ............................. 26

Introduction ............................................................................ 26

Mounting ................................................................................ 26

Step 6: Install the Drive Unit .................................................. 28

Step 7: Install the Control Unit ..............................................29

Step 8: Clamp the Cables ........................................................ 30

Step 9: Integrate the System ................................................. 31

9.1 Connecting SeaT alk equipment .............................................. 32

Possible systems .....................................................................32

9.2 Connecting NMEA equipment ............................................... 36

Course computer NMEA inputs/outputs ................................36

Control unit NMEA inputs ..................................................... 38

SeaTa lk/NMEA interface .......................................................38

Connecting several items of NMEA equipment .....................38

9.3 Connecting optional components ........................................... 40

GyroPlus yaw sensor .............................................................. 40

Handheld remotes ................................................................... 40

External alarm ......................................................................... 40

Wind vane (sail b oats) .............................................................40

Off switch ............................................................................... 41

Other manufacturers’ drive units ............................................ 41

9.4 Setting-up the autopilot ...........................................................42

Maintenance ........................................................................ 43

Regular checks ...........................................................................43

Fault-finding ..............................................................................43

Servicing ....................................................................................43

EMC, servicing and safety guidelines .................................... 44

Product support ..........................................................................44

Specifications ...................................................................... 45

Control unit functionality ..........................................................46

Glossary ................................................................................ 47

Index ..................................................................................... 49

Preface v

About this handbook

W elcome to the installation guide for the Raymarin e Typ e 150/400 autopilot system. This autopilot system will steer your boat to a heading automatically, accurately and reliably .

This handbook explains how to install the parts pro vided with T ype 150, T ype 150G, Type 400 and T ype 400G autopilot system core packs. The installation process involves the following steps:

Check the Installation Kit page 1

Check Locations page 6

Install the Course Computer page 9

Install the Compass page 17

Install the Rudder Position Sensor page 22

Install the Drive Unit page 28

Install the Control Unit page 29

Clamp the Cables page 30

Integrate the System page 31

At the end of this handbook we have also included:

• maintenance information

• product specifications

• glossary and index

• installation template

• the warranty statement

Note: T his handbook contains important information about the installation and maintenance of your new Raymarine product. To get the best from the product, please read this handb ook thoroughly.

vi Type 150/400 Autopilot System: Installation Guide

Important Information

Warranty

T o register your new product, please take a few minutes to fill out the warranty card. It is important that you return the card to the factory to receive full warranty benefits.

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 pr oduct performance, personal injury and/or damage to your boat.

Because correct performance of the boat’s steering is critical for safety , we STRONGLY RECO MMEND tha t an Autho rized Raymarine Service Representative fits this product. Y ou will only receive full warranty benefits if you can show that an Authorized Raymarine Service Representative has installed or commissioned this product.

WARNING: Electrical safety

Make sure the power supply is switched off befor e you make any electrical connections.

WARNING: Calibration

We supply this pr oduct calibrated to default settings. To ensure optimum performance on your boat, this product MUST be calibrated before use. Do NOT use the product until it has been calibrated using the instructions supplied.

WARNING: Navigation aid

Although we have designed this pr oduct to be accurate and reliable, many factors can affect its performance. As a result, it should only be used as an aid to n avigation and should never replace common s ense and navigational judgement. A lways maintain a permanent watch so you can respond t o situations as they develop.

Preface vii

Y our Raymarine autopilot will add a new dimension to your boating enjoymen t. Howeve r, i t is the sk ipper’s responsibility to ensure the safety of the vessel at all times by following these basic rules:

• Ensure that someone is present at the helm A T ALL TIMES, to take manual control in an emergency .

• Make sure that all members of crew know how to disengage the autopilot.

• Regularly check for other boats and any obstacles to navigation – no matter how clear the sea may appear, a dangerous situation can develop rapidly.

• Maintain an accurate record of the boat’s posit ion by using either a navigation aid or visual bearings.

• Maintain a continuous plot of your boat’s position on a current chart. Ensure that the locked autopilot heading will steer the boat clear of all obstacles. Make proper allowance for tidal set – the autopilot cannot.

• Even when your autopilot is locked onto the desired track using a navigation aid, always maintain a log and make regular positional plots. Navigation signals can produce signifi cant errors under some circumstances and the autopilot will not be able to detect these errors.

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

T o 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 improv ement may change specifications without notice. As a result, Raymarine cannot accept liability for any differences between the product and th e handbook.

viii Type 150/400 Autopilot System: Installation Guide

Type 150/400 autopilot system

Key components

Rudder position sensor

Drive unit

Course computer

Standard fluxgate compass

Control unit

Typical drive units

Hydraulic pump

Options

External GyroPlus yaw sensor

Wind vane

Linear drive

Rotary drive

Other equipment

External alarm

SeaTalk equipment

SeaTalk

handheld remote

NMEA equipment

Active compass

D5191-2

Step 1: Check the Installation Kit 1

Step 1: Check the Installation Kit

The first step is to get ready for installation by:

• reading through all installation steps

• obtaining the necessary installation tools

• checking the parts supplied

WARNING: Product installation

This equipme nt must be inst alled and opera ted in accord ance with the ins tructions containe d in this handboo k. Failure to do so could result in poor p roduct performance, personal in jury and/or damage to your boat.

Because correct performance of the boat’s steering is critical for safety, we STRONGL Y RECOMMEND that an Authorized Raymarine Service Representative fits this product. You will only receive full warranty benefits if you can show that an Authorized Raymarine Service Representative has installed or commissioned this product.

1.1 Read this handbook

T o prepare for the system installation, read through the following information and the rest of this handbook to familiarize yourself with the autopilot system and how to install it.

Step 1

The autopilot system – core pack contents

Course computer

The course computer lies at the heart of the autopilot system. It processes information from the sensors in the syst em (e.g. rudder position and compass) so it can steer the boat using the drive unit:

• it contains a microprocessor, electronic circuitry to control the drive unit and a powe r amplif ier for th e drive mo tor .

• it is the central distribution point for the autopilot system, with terminals to take power from the boat’s distribution p anel and inputs/outputs for all other autopilot componen ts

• it has inputs/outputs for SeaT alk and NMEA so you can connect it to Raymarine and other manufacturer’s equipmen t.

2 Type 150/400 Autopilot System: Installation Guide

Course computer versions

Version Supply voltage Drive unit compatibility

Step 1

Type 150

Type 150G

Type 400

Type 400G

*Note: The Raymarine GyroPlus yaw sensor measures the boat’s yaw (its rate of turn). The autopilot system uses this informa tion to enhance course keeping in adverse weather and sai lin g conditions (such as sailing downwind in following seas). The Type 150G and Type 400G course computers contain a built-in GyroPlus yaw sensor as standard. The Type 150 and Type 400 course computers do not contain a built-in GyroPlus, but have the option of an external GyroPlus or dealer-fitted internal GyroPlus.

12 V

12 V or 24 V

All Raymarine Type 1 12 V drives and pumps (including 12 V Constant Running pump).

All Raymarine 12 V and 24 V Type 1, Type 2 and Type 3 drives and pumps. Drive voltage must be

matched to boat’s supply voltage.

All Raymarine 12 V and 24 V Type 1, Type 2 and Type 3 drives and pumps. Drive voltage must be matched to boat’s supply voltage.

Built-in GyroPlus*?

Yes

CAUTION:

Before installing the course computer and drive unit, check that they are the correct voltage for your boat’s supply.

For course computer installation information, see page 9

For course computer specifications, see page 45

Compass

The compass is the direction sensor for the autopilot system. It provides the course computer with precise information about the boat’s heading.

Raymarine supplies a standard fluxgate compass for the autopilot system.

For more information, see page 17

Rudder position sensor

The rudder position sensor (or rudder reference transducer) provides the course computer with the exact position of the boat’s rudder.

Step 1: Check the Installation Kit 3

Raymarine produces two alternative types of rudder sensor:

• the rotary rudder position sensor is suitable for all steering systems (apart from ‘bullhorn’ style hydraulic outboards)

• the linear rudder position sensor is specifically designed for ‘bullhorn’ style hydraulic outboard steering systems

For more information, see page 22

The autopilot system – other key components

Drive unit

The drive unit translates instructions from the course computer into rudder movement, so the course computer can steer the boat. Raymarine produces a wide range of drive units to suit different types of steering systems.

For more information, see page 28

Control unit

The control unit is the your interface with the autopilot system. Y ou can use it to:

• engage and disengage the autopilot

• adjust the boat’s course when the autopilot is engaged

• view information about the autopilot system’s status and perform

a range of other functions

Step 1

Raymarine produces a range of control units to suit di fferent boats and user requirements.

For more information, see page 29

The autopilot system – extended systems

Around these key components of the autopilot system, you can extend the system by adding options su ch as:

• connections to additional control units, SeaT alk equipment or other manufacturers’ equipment (via NMEA)

• a GyroPlus yaw sensor (if you have a T ype 150 or T ype 400 course computer without a built-in GyroPlus )

4 Type 150/400 Autopilot System: Installation Guide

• handheld remotes (the ST600R full-function remo te control or the SeaT alk handheld remote control)

Step 1

• pushpit or masthead wind vanes (for sail boats without a suitable wind instrument)

• an external alarm (through an E85001 interface)

For more information about extended systems, see page 31.

1.2 Obtain installation tools

T o install the core pack you will need the following items:

• tape measure (metric/imperial)

• screwdrivers:

• cross-head/pozi-drive

• flat-bladed (large and small)

• drill and 3 mm drill bit

• center punch, pencil and masking tape

• for the rudder position sensor:

• hacksaw

• small adjustable spanner

• bolts, nuts and lockwashers (if required for tiller pin)

• for the course computer power supply:

• suitabl e power ca ble (see page 16)

• suitable fuse/circuit breaker (see page 16)

Note: Y ou will also need the tools and equipment required to install the control unit and drive unit. For full detai ls, refer the information supplied with control unit and drive unit .

1.3 Check parts supplied

Use the diagram on the following page to check the parts supplied.

CAUTION:

Before you start installing the course computer, check that it is the correct voltage for your boat’s power and your drive unit.

Step 1: Check the Installation Kit 5

Core pack – parts supplied

Course computer components

No8 x 3/4 inch pan-head self-tapping screws (x5):

• 2 for course computer

• 3 for cable clamp

Ferrite (for power cable)

Course computer

Cable clamp Tie-wrap (for cable clamp)

Compass components Rudder position sensor components

Fluxgate compass with 8 m (26 ft) cable

Step 1

Tiller pin

Worldwide Distributor List

Compass

warning label

COMPASSAREA

No8 x 3/4 inch pan-head self-tapping screws (x4)

Type 150/400 Autopilot System

Installation Guide

Installation Guide (includes warranty documents and fitting templates)

Rudder position sensor with 10 m (32 ft) cable

Connecting rod (M6), nuts (M6 x2) and ball-pin sockets (x2)

No8 x 3/4 inch pan-head self-tapping screws (x3) for rudder position sensor

No8 x 3/4 inch countersunk self-tapping screws (x2) for tiller pin

Worldwide Distributors

Note: This illustration shows the parts supplied with Type 150, 150G, 400 and 400G autopilot core packs.

D5377-1

6 Type 150/400 Autopilot System: Installation Guide

Step 2: Check Locations

2.1 Identify suitable locations

Typical locations

Step 2

After reading the following EMC installation guidelines (see page 7), identify suitable locations for each part of the system.

D5378-1

Course computer location:

• mount vertically on a flat bulkhead below decks

• dry , protected and well-ventilated

• free from high operating temperatures and excessive vibration

For more information, see page 10

Compass location:

• mount vertically, with cable exiting at the base

• as near as possible to the boat’s pi tch and roll center

• at least 0.8 m (2 ft 6 in) away from the boat’s steering compass

• in the back two-thirds of the boat

• away from potential sources of magnetic interference

For more information, see page 18

Step 2: Check Locations 7

Rotary rudder position sensor location:

• suitable base alongside the rudder stock and tiller arm.

• so the ball-joints at each end of the connecting rod are level

• so the sensor arm is between 75 mm (3 in) and 310 mm (12 in)

from the tiller arm

For more information, see page 23

Drive unit and control unit locations

Refer to the information supplied with these units to identify suitable locations.

Cabling:

• consider how you will run cables to and from each component

• avoid running cables through bilges where p ossible

• avoid running cables close to fluorescent lights, engi nes, radio

transmitting equipment etc.

Note: When cutting cables to length, we recommend that you include a loop of extra cable so you can cut and strip the cables a few ti mes in the future (if necessary).

Step 2

2.2 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 b een 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 op timum 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 possibl e between different items of electrical equipment.

8 Type 150/400 Autopilot System: Installation Guide

For optimum EMC perform ance, we recommend that wherever possible:

• Raymarine equipment and cables connected to it are:

• At least 3 ft (1 m) from any equipment transmitting or cable s

carrying radio signals e.g. VHF radios, cables and antennas. In the case of SSB radios, increases the distance to 7 ft (2 m).

• More than 7 ft (2 m) from the path of a radar beam. A radar

Step 2

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 manu al.

• If a suppression ferrite is attached to a cable, this ferrite should no t be removed. If the ferrite needs to be removed d uring installation it must be reassembled in the same position.

Suppression ferrites

This following illustration shows t ypical cable suppression ferrites used on Raymarine equipment. Always use the ferrites supplied by Raymarine.

D3548-2

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.

Step 3: Install the Course Computer 9

Step 3: Install the Course Computer

Installing the course computer involves these tasks:

Select the location page 10

3.1

Secure the course computer page 12

3.2

Remove the connector cover page 12

3.3

Attach the power cables page 15

3.4

Main cover

Step 3

Connector cover catch

Connector cover

Mounting screws, No 8 x 3/4 in (x5)

Course computer - main parts

Mounting lug

Keyhole slot

Suppression ferrite

Tie-wrap

Cable clamp

Cables for autopilot system components and power

D5413-2

10 Type 150/400 Autopilot System: Installation Guide

3.1 Select the location

Course computer – installation dimensions

307 mm (12.1 in)

288 mm (11.3 in)

277 mm (10.9 in)

70 mm (2.8 in)

Step 3

Keyhole slots for No 8 screws (pan-head)

133 mm (5.2 in) 133 mm (5.2 in)

26 mm

(1.0 in)

Suitable locations

The course computer is designed to be mounted on a vertical and flat bulkhead below decks. Select a location that is:

• dry , protected and well-ventilated

• free from high operating temperatures

• free from excessive vibration

• non-metallic

• accessible for cable routing and sufficiently large to secure the

cable clamp under the computer

On sailboats, we also recommend mounting the course computer

across the boat on a transverse bulkhead. Notes:

min 50 mm (1.9 in) (recommended)

cable clearance: min 50 mm (1.9 in) (recommended)

195 mm (7.7 in)

D5260-1

1. If the only possible location has a meta llic surface, you must

insulate the base of course computer so it is not earthed.

2. When selecting the mounting location, also refer to the EMC

installation guidelines (on page 7).

Step 3: Install the Course Computer 11

Unsuitable locations

WARNING:

The course computer is NOT designed to be mounted in engine compartments.

Do NOT install the course computer:

• where there might be flammable vapors (such as in an engine room or compartment, or in a fuel tank bay)

• where there is water splash or spray from bilges or hatches

• where it is at risk from physical damage from heavy items (such

as hatch covers, tool boxes, etc.)

• where it might be covered by other equipment

Orientation

CAUTION:

Y ou MUST mount the course computer so it is level and within +/- 10° of the vertical.

The T ype 150G and T ype 400G course computers contain a buil t-in GyroPlus yaw sensor that will NOT work correctly if you mount the computer in any other orientation. This orientation also maximizes the air flow to cool the course computer and provides optimum resistance to dripping water .

±10˚

Step 3

level

D5379-1

Note: Type 150G and Type 400G course computers are supplied with a temporary ‘Mount vertically’ label stuck to the case. Remove this label after installation.

12 Type 150/400 Autopilot System: Installation Guide

3.2 Secure the course computer

1 2 3 4

6mm

minimum

Step 3

Follow these steps to secure the course computer:

1. Hold the course computer in place against the mounting location so you can mark the centre of the keyhole slots:

• these marks should be level and 288 mm (1 1.3 in) apart

• remove the course computer then drill the two pilot holes

using a 3 mm (

/8 in) drill bit

2. Screw the supplied self-tapping screws (No 8 x into the holes, so the head of each screw is at least 6 mm ( from the surface.

3. Place the keyhole slots over the screw heads, then move the course computer down, so the screw heads are at the top of the keyhole slots.

4. Tighten the screws to hold t he course computer securely against the mounting surface.

3.3 Remove the connector cover

To remove the connector cover:

• unlock the cover:

• use a flat-bladed screwdriver or small coin to rotate the catch

turn (90°) in either d irection – until you hear a click and the

slot is horizontal

• lift off the cover

D5196-1

/4 in, pan-head)

/4 in)

+ 44 hidden pages