Raymarine autopilot + ST4000+ Owner's Handbook Manual

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ST4000+ Wheel & Tiller Autopilots

Owner’s Handbook

Document number: 81131-6 Date: August 2001

ii ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

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

Raymarine, AST (Advanced Steering T echnology), A utoAdapt, AutoLearn, AutoRelease, AutoSeastate, AutoT ack, AutoTrim, FastT rim, GyroPlus, RayGyro, RayPilot and W indT rim are trademarks of Raymarine Ltd.

Handbook contents © Raymarin e Ltd 2001.

Preface iii

ST4000+ autopilot system layout

Wheel drive

Tiller drive

Fluxgate compass

SeaTalk instrument

Boat's electrical

distribution panel ST4000+ control unit

Rudder position sensor (optional fit for wheel pilot only)

NMEA instrument or navigator

D5332-1

iv ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

Preface v

Contents

About this handbook ...........................................................ix

Important Information .........................................................x

Warranty ......................................................................................x

Safety notices ..............................................................................x

EMC conformance .....................................................................xi

Handbook information ............................................................... xi

Chapter 1: Introduction ............................................................1

1.1 Features .....................................................................................1

1.2 Extended systems ......................................................................2

Chapter 2: Basic Operation .......................................................3

2.1 Using the control unit ................................................................4

Key functions ............................................................................ 4

Display layout ........................................................................... 5

2.2 Using Auto mode ......................................................................6

Engaging the autopilot (Auto mode) .........................................6

Disengaging the autopilot (Standby mode) ..............................7

Changing course in Auto mode .................................................8

Dodging obstacles in A uto mode ..............................................8

Returning to the previous locked heading (LAST HDG) .........9

Automatic tack (AutoT ack) ....................................................10

Making major course change s ................................................10

Gusting conditions .................................................................. 11

2.3 Adjusting autopilot performance ............................................12

Changing the response level (AutoSeastate) ..........................12

Changing the rudder gain ........................................................13

2.4 Autopilot alarms .....................................................................14

Responding to alarms .......................................................... ....14

2.5 Adjusting display and keypad lighting ................................... 18

Chapter 3: Advanced Operation ............................................19

3.1 Using Track mode ...................................................................20

Selecting Track mode .............................................................20

Exiting Trac k mode .................................................................22

Cross track error ......................................................................22

Tidal stream compensation .....................................................23

W aypoint arrival and advance .................................................24

Dodges in T rack mode ............................................................25

Safety in Track mode ..............................................................25

vi ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

3.2 Using W ind V a ne mode ..........................................................27

Selecting Win d V ane mode .....................................................27

Exiting Wind V a ne mode ........................................................ 28

Adjusting the locked wind angle .............................................28

Returning to the previous apparent win d angle

(LAST WND) .........................................................................28

Dodges in Wind Vane mode ....................................................29

Wind shift alarm ......................................................................29

Using AutoT ack in W ind Vane mode ......................................30

Operating hints for Wind Vane mode ......................................30

3.3 Displaying data pages .............................................................31

Chapter 4: Maintenance & Fault Finding ..............................33

4.1 Fault finding ............................................................................34

4.2 General maintenance ..............................................................36

Wheel drive ............................................................................. 36

Control unit ............................................................................. 38

EMC advice ............................................................................39

4.3 Product support .......................................................................40

Software version .....................................................................40

Chapter 5: Installing the ST4000+ ..........................................43

5.1 Planning the installation ......................................................... 44

T ools required .........................................................................44

EMC installation guidelines ...................................................46

5.2 Control unit ............................................................................. 48

Location ..................................................................................48

Mounting procedure ............................................................... 49

Cable connectors .....................................................................51

Power supply connection ........................................................ 51

SeaT alk connections ............................................................... 52

NMEA connections ................................................................53

5.3 Fluxgate compass ................................................................... 55

Location ..................................................................................55

Mounting ................................................................................ 57

Connecting to the control unit ................................................. 58

5.4 Tiller drive (tiller pilots only) .................................................. 59

Critical dimensions ................................................................. 59

Basic installation ..................................................................... 60

Installation accessories ...........................................................61

Connecting to the control unit ................................................. 68

Preface vii

5.5 Wheel drive (wheel pilots on ly) ..............................................70

Installation stages ....................................................................70

Drilling the spoke clamp h oles ................................................71

Securing the wheel drive to the w heel .....................................74

Attaching the pedestal bracket ................................................75

Connecting to the control unit .................................................79

5.6 Rudder position sensor (wheel pilot option) ........................... 81

Ensuring correct alignment .....................................................81

Securing the sensor to the boat ................................................83

Attaching the sensor to the tiller arm .......................................83

Checking alignment ................................................................84

Connecting to the control unit .................................................84

Chapter 6: Setting-up the ST4000+ ........................................85

6.1 Functional test .........................................................................86

Switch on ................................................................................86

Autopilot steering direction ....................................................86

Checking connections .............................................................88

6.2 Check rudder sensor operation (if fitted) ................................ 90

6.3 Initial sea trial .......................................................................... 91

Overview ................................................................................ 91

Correcting the compass deviation ..........................................92

Adjusting the heading alignment ............................................95

Checking autopilot operation ..................................................95

Checking the rudder gain ........................................................96

6.4 Autopilot calibration techniques .............................................98

Step 1 - Switch on ancillary equipment ...................................98

Step 2 - Apply initial settings ..................................................98

Step 3 - Adjust the rudder damping .........................................99

Step 4 - Adjust the rudder gain ................................................99

Step 5 - Adjust the AutoTrim setting .......................................99

Step 6 - Further adjustments ....................................................99

Chapter 7: Customizing the ST4000+ ..................................101

7.1 User setup ..............................................................................102

Compass deviation correction (SWING COMP ASS) .......... 102

Deviation display (DEVIA TION) ........................................102

Heading alignment (ALIGN HDG) ......................................102

Heading mode (HDG MAG/TRU) .......................................102

Bar selection (RUDD BAR/STEER BAR/NO BAR) .......... 104

Data pages 1-7 (DA T A P AGE) ............................................ ..104

viii ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

7.2 Dealer setup ..........................................................................106

Calibration lock (CAL LOCK) ............................................. 108

Pilot type (4000 WHL/TILL) ...............................................108

Rudder gain (RUDD GAIN) .................................................108

Response level (RESPONSE) ..............................................108

Turn limit (TURN RA TE) .....................................................108

Rudder alignment (ALIGN RUD) ........................................ 108

Rudder limit (RUD LIMIT) .................................................. 109

Off course alarm (OFF COU RSE) ........................................109

AutoT ack angle (AUT OT ACK) ...........................................109

AutoTrim (AUT OTRIM) ..................................................... 110

Drive type (DRIVE TYP) ..................................................... 110

Magnetic variation (VARIATION) ....................................... 110

AutoAdapt (AUTOADAP T) .................................................111

Latitude (LA TITUDE) ...........................................................11 1

Rudder damping (RUDD DAMP) ........................................ 112

Cruise speed (CRUISE SP) .................................................. 112

Specifications .................................................................... 113

Glossary .............................................................................. 115

Index ................................................................................... 117

Preface ix

About this handbook

W elcome to the handbook for the ST4000+ wheel and tiller autopilot syst ems. This handbook contains two main parts :

Part 1: Using the ST4000+ Autopilot

Chapter 1: Introduction

Introduces the autopilot, its features and its use.

Chapter 2: Basic Operation

Covers basic autopilot operation: using Auto mode,

interpreting alarms, adjusting autopilot performance and changing the control unit lighting.

Chapter 3: Advanced Operation

Explains how to use Track and Wind Vane modes, and

display data pages.

page 1

page 3

page 19

Chapter 4: Maintenance & Fault Finding

Provides general maintenance procedures and

information to help you resolve problems you may

page 33

encounter with the autopilot

Part 2: Installing the ST4000+ Autopilot

Chapter 5: Installing the ST4000+

Explains how to install your autopilot and its components.

Chapter 6: Setting-up the ST4000+

Covers functional testing and dockside procedures after

installation, and initial sea trials.

Chapter 7: Customizing the ST4000+

Provides details on adjusting the autopilot settings to suit

your boat.

At the end of t his handbook we h ave included produ ct specifications, a glossary and index, and templates for installing different parts of the system.

page 43

page 85

page 101

Note: This handbook contains important information about installing, using and mai ntaining your new Raymarine product. To get the best from the product, pleas e read this handbook thoroughly.

x ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

Important Information

Warranty

T o register your new Raymarine product, please take a few minutes to fill out the warranty card. It is important that you complete the owner information and return the card to us 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 boa t.

WARNING: Electrical safety

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

WARNING: Calibration

W e supply this product calibrated to default settings that should provide stable p erformance for most boats. T o ensur e optimum performance on your bo at, you must complete Chapter 6: Setting-up the ST4000+ befo re use.

WARNING: Navigation aid

Although we have designed this p roduct 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 nev er replace commo n sense and navigational jud gement. Always maintain a permanent watch so you can res pond to situations as they develop.

Y our Raymarine autopilot will add a new dimension to your boating enjoyment. However, it is the skipper’s responsibility to ensure the safety of the boat at all times by following these basic rules:

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

Preface xi

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

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

• Maintain an accurate record of the boat’s position by using ei ther 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 pos itional plots. Navigation signals can pro duce significant 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 environmen t. 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 produ ct improvement may change specifications without notice. As a result, Raymarine cannot accept liability for any differences bet ween the product and the handbook.

xii ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

Part 1: Using the ST4000+

Chapter 1: Introduction 1

Chapter 1: Introduction

1 Introduction

1.1 Features

The Raymarine ST4000 Plus (ST400 0+) is a SeaT alk® compatible autopilot available in versions suitable for boats with either tiller or wheel steering systems. This autopilo t system will steer your boat to a heading automatically, accurately and reliably .

The ST4000+ has four main operating mod es:

The ST4000+ also provides the fo llowing features:

• automatic tack facility (AutoTack) in Auto and W ind V ane modes

D5460-1

Standby: autopilot off (see page 7) Auto: autopilot engaged and locked onto a heading (see page 6) Track: autopilot engaged and maintaining a track between two

waypoints created using a navigati on system (see page 20)

Wind Vane: autopilot engaged and mai ntaining a course relative

to an apparent wind angle (see page 27)

• automatic compass deviation correction

• Northerly/So utherl y heading compensation

• automatic heading deadband – seastate control

• waypoint advance feature

• setup and calibration options to optimize performance on your boat

2 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

1.2 Extended systems

The ST4000+ is compatible with all other SeaT alk instrument s. Y ou can connect it to additional fixed or handheld SeaT alk autopilot control units located at secondary steering and cont rol positions (see page 52).

1 Introduction

Y ou can also use the ST4000+ autopilot with any navigator (GPS, Decca, Loran) or wind instrument that transmits data in the internationally-accepted National Marine Electronics Association (NMEA) 0183 format.

The ST4000+ can display SeaT alk and NMEA instrument data in a user-defined selection of data pages. W hen you are using the ST4000+ to repeat inst rument data, it shows a ‘pop-up’ pilot page for 5 seconds whenever you make a change in autopilot control.

The ST4000+ can share all data transmitted from SeaT alk instruments:

• it can use wind information from a SeaT alk wind instrument for wind trim steering in W ind V ane mode without the need for a separate vane

• it can use track information from a SeaT alk navigation instrument to provide waypoint control in T rack mode

• it can use boat speed from a SeaTalk speed instrument to optimize track-keeping performance

Rudder position sensor (wheel drives only)

On wheel drive systems you can fit a rudder positi on sensor to improve the wheel pilot’s performance (see page 81). This is particularly advisable if your boat’s steering system has significant backlash, or you require optimum performance from a mechanical or cable steering system. By using the information from the rudder angle sensor , the ST4000+ will also be able to show the true rudder angle in Standby and Auto modes.

Note: You MUST add a rudder position s ensor if fitting the ST4000+ to a hydraulic steering sys tem.

Chapter 2: Basic Operation 3

Chapter 2: Basic Operation

The sections in this chapter explain how to use the basic functions on your autopilot:

Using the control unit

2.1

2.2

Summarizes the key functions and screen layout on the ST4000+ control unit.

Using Auto mode

Provides instructions for engaging/disengaging the autopilot and using Auto mode.

page 4

page 6

Adjusting autopilot performance

2.3

Making temporary adjustments to response level and

page 12

rudder gain to enhance autopilot performance.

Autopilot alarms

2.4

Describes how to recognize and respond to the

page 14

autopilot alarms.

Adjusting display and keypad lighting

2.5

Explains how to change the lighting on the control unit

page 18

display and keypad.

CAUTION: Important note for wheel drive systems

After each trip, flush inside the drive unit by inserting a hose pipe in the free slot on the back cover . This will prevent any build-up of salt on the drive ring and bearings.

2 Basic Operation

4 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

2.1 Using the control unit

Key functions

• The autopilot always powers up in S tandby mode.

• Y ou contro l the autopilot by pressing the buttons on the control

unit. The control unit confirms each button press with a short beep.

• Y ou access the main functions by pressing a single key:

• for example, when the autopilot is operating you can m ake

course changes using the

• T o access other functions you need to press two keys together:

• for example, when the autopilot is operating you make an

AutoT ack to port by pressing the

• Y ou can return to manu al steering at any time by pressing

standby and disengaging t he autopilot (see page 7).

-1, +1, -10 and +10 keys

-1 and -10 keys together

2 Basic Operation

-1 plus +1

Press for Response level

-1 plus -10

Press together for AutoTack to port

DISP

Press for Data Page

Press for 1 second for lamp control

STANDBY

Press for Standby mode

Press and hold for User and Dealer setup modes

Press for 1 second

for Rudder Gain

Course change keys

Port 1˚ Starboard 1˚

Port 10˚ Starboard 10˚

STANDBY plus AUTO

Press for Wind Vane mode Press for 1 second for Last Wind Press again to accept Last Wind

+1 plus +10

Press together for AutoTack to starboard

TRACK

Press for Track mode from Auto

Press to accept waypoint advance

Press for 1 second to skip waypoint

AUTO

Press for Auto mode Press for 1 second

for Last Heading Press again to

accept Last Heading

D3447-2

Chapter 2: Basic Operation 5

Display layout

The ST4000+ autopilot display pro vides the following information:

Variable text region (up to 9 characters/digits)

Heading indicators Distance units

Response level indicator

Autopilot mode indicators

Port and Starboard direction-to-steer indicators

Calibration mode indicator

Rudder or Steer direction indicator

(bar graph in 2˚ increments)

• If the display shows no distance unit all distances are in kilometres (Km), otherwise distances are in nautical miles (nm or statute/land miles (SM).

• The bar graph at the bottom of the screen is normally a direction-to-steer indicator (you can change this in User setup, see page 104). The information displayed on the bar graph varies according to the autopilot mode:

Autopilot mode Information displayed on bar graph

2 Basic Operation

D3316-2

)

Standby Rudder bar (only if a rudder position sensor is fitted)

Auto Heading error bar

Track Cross track error (XTE) bar, in 0.02 nm increments

Wind Vane Wind angle error bar

6 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

2.2 Using Auto mode

Engaging the autopilot (Auto mode)

1. Steady t he boat on the required heading.

2. Wheel Pilot: Engage the wheel drive clutch by rotating the clutch lever clockwise (so the lever eng ages fully onto the locating pip). Tiller Pilot: Place the pushrod end over the tiller pin. If necessary , extend or retract the pushrod using the

WARNING: Wheel drive clutch

Always reach AROUND (not through) the wheel to operate the wheel drive clutch lever .

Wheel pilot

-1, +1, -10 and +10 keys.

2 Basic Operation

Engage the clutch on the wheel pilot

Tiller pilot

Use these keys to extend or retract the pushrod

D5341-1

3. Press auto:

• in Auto mode, the display shows the locked autopilot heading

D3560-2

Chapter 2: Basic Operation 7

CAUTION:

Autopilot course control makes it easier to sail a boat, but it is NOT a substitute for good seamanship. ALWA YS maintain a permanent watch, no matter how clear the sea appears to be.

Disengaging the autopilot (Standby mode)

1. Press standby.

• in Standby mode, th e display shows the boat’s current compass heading.

2 Basic Operation

D3561-2

2. Disengage the autopilo t to return to hand steering:

• Wheel Pilot: Disengage the wheel drive clutch by rotating the clutch lever anti-clockwise (so the lever engages fully onto the locating pip).

• Tiller Pilot: Remove the drive unit from th e tiller pin. If required, retract the push rod using

-1, +1, -10 and +10 keys.

3. The last heading is memorized and can be recalled (see page 9).

CAUTION: Wheel drive systems

On wheel drive systems, always make sure that the clutch is FULL Y DISENGAGED be fore you leave the boat.

8 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

Changing course in Auto mode

In Auto mode, use the -1 and -10 (port) and +1 and +10 (starboard) keys to change the locked h eading in steps of 1° or 10°. For example: press

-10 three times for a 30° course change to port.

Port Starboard

oror

D3320-2

2 Basic Operation

Dodging obstacles in Auto mode

T o avoid an obstacle when your boat is under autopil ot control:

1. Select a course change in the appropriat e direction. For example, press

-10 three times for a 30° dodge to port.

Obstacle

Original

course

Dodge

2. When safely clear of the obstacle, you can either:

• reverse the previous course change (for example, press

three times), or

• return to the previous locked heading (

D3303-2

+10

LAST HDG)

Chapter 2: Basic Operation 9

Returning to the previous locked heading (LAST HDG)

If you have steered the boat away from the selected locked heading for any reason (for example, executing a dodge maneuver or selecting Standby), you can return to the previ ous locked heading as follows:

1. Press

auto for 1 second. The display shows the previous locked

heading (

SECOND

LAST HDG?) for 7 seconds.

D3562-2

Note: The direction-to-steer indicato r shows the direction the boat will turn.

2. T o accept the previous heading, and resume this course, press

auto within this 7 second period.

Obstacle

Resumed course

2 Basic Operation

Note: If you do not press autopilot will maintain the current heading.

Original

course

Dodge

D5431-1

auto while the display is flashing, the

10 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

Automatic tack (AutoTack)

The ST4000+ has a built in automatic tack facility (AutoT ack) that turns the boat through a pre-determined angle in the required direction. The default AutoTa ck angle is 100°, but you can adjust this in Dealer setup (see page 109).

AutoTack - Port

• to AutoTack to port: press the

• to AutoTack to starboard: press the

AutoTack - Starboard

Wind

AutoTack

angle

-1 and -10 keys together +1 and +10 keys together

Wind

AutoTack

angle

2 Basic Operation

D5399-1

Making major course changes

CAUTION:

Only make major course changes when steering MANUALL Y . This ensures that th e boat will safely clear any obstructions or other boats, and you can tak e into account the changed wind and sea conditions on the new heading before engaging the au topilot.

Large course changes which change the apparent wind direction can produce large trim changes. When a sudden tri m change occurs (for example due to weather helm or sail imbalance) there will be a delay of up to one minute before the automatic trim applies rudder to restore the locked heading.

In these situations, the autopilot will not immediately assume the new automatic heading, and will only settle onto course when the automatic trim has been fully established. T o eliminate this problem, use the following procedure to make major course changes:

Chapter 2: Basic Operation 11

1. Note the required new heading.

2. Select

standby for manual steering, so you can bring the boat to

the new heading MANUALL Y.

3. Select

auto: allow the boat to settle onto course, then bring the

boat to the final course in 1° steps using t he

Gusting conditions

In gusting conditions, the course may t end to wander slightly , particularly if the sails are badly balanced. If you take t he following precautions, the autopilot will be able to maintain competent control even in gale force conditions:

• Y o u can significantly improve course keeping by improvin g the sail balance:

• do not allow the boat to heel over excessively

• ease the mainsheet traveller to leeward to reduce heeling and

weather helm

• if necessary , reef the mainsail a little early

• In very strong winds and large seas, you should avoid sail ing with

the wind dead astern:

-1 or +1 keys

2 Basic Operation

• ideally , bring the wind at least 30° away from a dead run

• in severe conditions, you may also n eed to remove the

mainsail and sail under headsail only

12 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

2.3 Adjusting autopilot performance

During normal autopilot operation in any mode you can make temporary adjustments to:

• response level

• rudder gain

Note: You will lose these temporary changes to response level and rudder gain whenever the system is powered off then on again. You can make permanent adjustments in Dealer s etup (see page 108).

Changing the response level (AutoSeastate)

The response level controls the relationship b etween the autopilot’s course keeping accuracy and the amount of helm/drive activity .

• Response Level 1: AutoSeastate on ( Automatic deadband)

This setting causes the autopilot to gradually ignore repetitive boat movements and only react to true variations in course. This

2 Basic Operation

provides the best compromise between power consu mption and course keeping accuracy , and is the default calibration setting.

• Response Level 2: AutoSeastate off (Minimum deadband)

This setting provides the tightest course keeping possible. However, tighter course keeping results in increased power consumption and drive unit activity .

To make a temporary change to the response setting:

1. Display the

RESPONSE screen by pressing the -1 and +1 keys

together momentarily .

D3310-4

Chapter 2: Basic Operation 13

Note: If you have set up the RESPONSE screen as a default data page (see page 104) you can also access it by pressing

disp and then

scrolling through t he data pages.

2. Press

3. Press

-1 or +1 to change the response level. disp or wait for 5 seconds to return to the previous display .

Changing the rudder gain

SECOND

Decrease

rudder gain

2 Basic Operation

Increase

rudder gain

D5400-1

To make a temporary change to the rudder gain:

1. Press the rudder gain (

Note: If you have set up the (see page 104) you can also access it by pressing

-1 and +1 keys together for 1 second to display the

RUDD GAIN) screen

RUDD GAIN screen as a default dat a page

disp and then

scrolling through t he data pages.

2. Press

3. Press

-1 or +1 to change the rudder gain. disp or wait for 5 seconds to return to the previous display .

Note: See page 96 for instructions on how to check that the rudder gain is set correctly.

14 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

2.4 Autopilot alarms

Responding to alarms

The ST4000+ activates the alarms listed on the following pages:

• Unless otherwise stated, you should deal with alarms by pressing

standby to clear the alarm and return to hand steering.

• In some situations, the autopilot will raise more than one alarm. When you have dealt with the first alarm, the autopilot will display the next alarm.

SeaTalk Failure alarm (STLK FAIL)

The ST4000+ displays the SeaT alk failure message if there is a wiring fault in the SeaTalk connection.

Off Course alarm (OFFCOURSE)

2 Basic Operation

= deviation to port = deviation to starboard

D3315-2

The ST4000+ activates this alarm when the boat has been off course from the locked heading by more than the s pecified angle* for longer than 20seconds. It shows whether the deviation is to port or starboard.

Note: * You can adjust this specified al arm angle in Dealer setup (see page 109).

1. T o cancel the off course alarm, pres s

standby to return to hand

steering.

2. Check whether your boat is carrying too much sail, or whether the sails are badly balanced. Y ou can us ually significantly improve course keeping by improving the sail bala nce.

Note: The ST4000+ also clears th e alarm if the heading recovers, if you change the course, or if you change the oper ating mode.

Chapter 2: Basic Operation 15

Wind Shift alarm (WINDSHIFT)

The ST4000+ activates the W indshift alarm when it detects a change in the apparent wind angle of more than 15° (see page 29).

Large Cross Track Error alarm (LARGE XTE)

The ST4000+ activates this alarm when the cross track error exceeds

0.3 nm (see page 22).The alarm clears if the heading recovers, if you change the course, or if you change the operating mode.

Drive Stopped alarm (DRIVESTOP)

The ST4000+ activates this alarm if:

• the rudder position sensor fai ls, or

• the autopilot is unable to turn the rudder (this occurs if the weather

load on helm is too high, or if the rudder po sition sensor has passed beyond the preset rudder limits or rudder end-stops)

2 Basic Operation

Data Not Received alarm (NO DATA)

The ST4000+ activates this alarm in any of the following sit uations:

• the compass is not connected

• the autopilot is in Wind Vane mode and it has not received wind

angle data for 30 seconds

• the autopilot is in Track mode and:

• the boat has arrived at the last waypoint in th e track, or

• the autopilot is not receiving SeaT alk navigation d ata, or

• the position sensor (GPS, Loran, Decca) is receiving a low

strength signal – this will clear as s oon as the signal strength improves

The autopilot stops adjusting the heading as soon as it loses data.

Waypoint Advance alarm (NEXT WPT?)

The ST4000+ activates the W aypoint Advance alarm whenever the target waypoint numb er changes. This occurs when:

• you select automatic acquisition by pr essing

• you request waypoint advance by pr essing

track from Auto

track for 1 second in

Track mode ( with SeaT alk navigators only)

16 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

• the boat arrives at the target waypoint and the navigator accepts the next waypoint

• you activate the Man Overboard (MOB) function in T rack mode

When the alarm sounds, the pilot continues on its current heading but displays:

• the bearing to the next waypoint

• the direction the boat will turn to take up that bearing

Responding to a Waypoint Advance alarm

T o respond to a W aypoint Advance alarm:

• check that it is safe to turn onto the new track, then press accept the waypoint advance

• alternatively , you can cancel the alarm without accepting the waypoint advance by pressing: steering, or

2 Basic Operation

Note: Waypoint advance only operates if the ST4000+ is receiving valid bearing to waypoint and wa ypoint number information.

auto to retur n to Auto mo de.

standby to return to hand

track to

Low Battery alarm (LOW BATT)

The ST4000+ activates the Low Battery alarm when the supply voltage drops below 10 V (±0.5 V).

Responding to a Low Battery alarm:

T o respond to a Low Battery alarm:

• press

• start the engine to recharge the battery

standby to clear the alarm and return to hand steering

Watch alarm (WATCH)

The ST4000+ activates the W atch alarm when the autopilot is in W atch mode and the timer has reached 4 minutes.

Setting the Watch timer

T o set the Watch timer:

1. First, you must con figure the pages for display (see page 104).

2. When you have done this select Auto, Track or W ind V ane mo de.

WATCH screen as one of the data

Chapter 2: Basic Operation 17

3. Press the disp key until you see the WATCH data page:

• the watch timer will start counting

• when the timer reaches 3 minutes, the

flashing to indicate that the timer is in the last minute

• when the timer reaches 4 minutes, the ST4000+ activates the audible W atch alarm

Responding to a Watch alarm

T o respond to a W atch alarm:

• press

• press any other key to silence the alarm, reset the timer and

Note: You cannot engage Auto mode direct ly from Watch mode – pressing Auto mode, you must first exit Watch mode (see below).

Exiting Watch mode

T o exit W atch mode:

auto to silence the alarm and reset the timer to 4 minutes

perform that key’s normal function

auto will only reset the Watch timer. If you want to enter

WATCH text st arts

2 Basic Operation

• press

disp to display a different data page

standby

Shallow alarm (SHALLOW)

The ST4000+ activates the Shallow alarm if it receives a shallow depth alarm via SeaT alk:

• press

standby or disp to cancel the alarm

Man Overboard alarm (MOB)

The ST4000+ activates the Man Overboard alarm if it receives a man overboard (MOB) message from another instrument on the SeaT alk system. It displays the text the

XTE, DTW and BTW data pages.

If the autopilot is in T rack mode, it will sound the W aypoint Adv ance alarm to notify you of the change in waypoint.

MOB instead of the waypoint number for

18 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

2.5 Adjusting display and keypad lighting

Note: When the display lighting is off, the control unit still illuminates the keys at a courtesy level.

T o adjust the display and keypad ligh ting:

1. Press

disp for 1 second from any mode to access the LAMP screen

and turn on the lights.

2. Press t he settings:

disp key to cycle through the possible illumination

LAMP 3, LAMP 2, LAMP 1, OFF, LAMP 1, LAMP 2, LAMP 3

and so on.

Note:

LAMP 3 is the brightest setting.

2 Basic Operation

SECOND

D3313-3

3. The display automatically returns to the previous mode if you do not press a key for 7 seconds:

• if you press another mode key within 7 seconds you will select

the mode assigned to that key (for example: mode,

standby selects S tandby mode)

auto selects Auto

Note: You can also adjust the lighting level from any other SeaTalk instrument or control unit connected to SeaTalk.

Note: When you switch off the unit you lose any changes you have made to the lighting.

Chapter 3: Advanced Operation 19

Chapter 3: Advanced Operation

The sections in this chapter explain how to use the more advanced functions on your autopi lot:

Using Track mode

3.1

3.2

3.3

Tracking between waypoints created on navigation equipment connected to the autopilot system.

Using Wind Vane mode

Using the autopilot to maintain a course relative to the apparent wind angle.

Displaying data pages

Describes how to use data pages to display SeaTalk and NMEA information on the control unit.

page 20

page 27

page 31

3 Advanced Operation

20 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

3.1 Using Track mode

Note: You can only use Track mode if you have connecte d the ST4000+ to a suitable naviga tion system providing SeaTalk or NMEA navigation informat ion.

The ST4000+ can receive track and cross track error information from either:

• a SeaT alk navigation instrument or chartplotter (see page 52 for information on connecting to SeaT alk)

• a non-SeaT alk navigation syst em transmitting data in the NMEA 0183 format – you can connect this directly to the ST4000+ NMEA input (see page 53 for information on connecting to NMEA equipment)

In Track mode, the ST4000 + maintains a track between two waypoints created on the navigation system. The autopilot computes any course changes to keep your boat on track, automatically compensating for tidal streams and leeway .

3 Advanced Operation

Selecting Track mode

T o select Track mode, press the track key with the autopilot in Auto mode.

When you select Tr ack mode, the autopilot can acquire a track through either:

• automatic acquisition (see below), when both cross track error (XTE) and bearing to waypoint (BTW) data are available

• manual acquisition (see page 21), when only cross track error information is available

Automatic track acquisition

If cross track error and bearing to waypoint information are both available (via SeaT alk or NMEA), the autopilot can acquire a track automatically:

1. Bring the boat within 0.1 nm of track.

2. Press

3. Press

auto. The autopilot will display the current locked heading.

track to enter Track mode.

Chapter 3: Advanced Operation 21

4. W ait for th e W aypoint Advance alarm to sound. The display will show the bearing to the next planned waypoint and the di rection the boat will turn to reach this waypoint.

Note: If the boat is more than 0.3 nm from the track, the Large Cross Track Error alarm will sound ( see page 22). Press cancel the alarm, hand steer closer to t he track, press press

track.

standby to

auto and then

5. Check that it is safe to tu rn the boat onto the new course.

6. Press the

track key:

• the boat will turn onto the new course

• the display shows the new bearing to waypoint

Automatic track acquisition

From auto mode, press track to enter Track mode: Then press track again to turn boat to waypoint:

Waypoint

at 270˚

Current

heading

Waypoint

at 270˚

heading

3 Advanced Operation

Manual track acquisition

If your navigation system only provides cross track error information, you must acquire the track manually:

1. Steer the boat to within 0.1 nm of track.

2. Bring the heading to within 5° of the bearing to the next waypoint.

3. Press

4. Press

D5414-1

auto. track to enter T rack mode. The displ ay then sho ws the

locked pilot heading.

22 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

Note: Tidal streams have a far more significant effect at lower speeds

than at higher speeds. If the ti dal flow is less than 35% of the boat’s speed, you will not notice any difference in the autopilot’s performance in Track mode. However, you should take extra care during manual acquisiti on, as follows:

• Before you select T rack mode, make sur e the boat is as close as possible to track, and the dir ection made good over the gr ound is as close as possible to the dir ection of the next waypoint.

• Make positive checks of the boat’s position at r egular intervals, especially if you ar e close to potential navigational hazar ds.

Exiting Track mode

Y ou can return to either Auto or Standby mode from T rack mode by:

3 Advanced Operation

• pressing

Cross track error

Cross track error (XTE) is the distance between the current position and a planned route. The autopilot receives the cross track error information from the navigation equipment, and disp lays the XTE in nautical miles (

Actual route

auto to r eturn to Au to mode standby to return to manual steering

nm), statute miles (SM) or kilo metres.

Cross track error (XTE)

more than 0.3 nm

Waypoint 2

Waypoint 1

Planned route

D5415-1

Chapter 3: Advanced Operation 23

If the cross track error is greater t han 0.3 nm, the ST4000+ will sound the Large Cross T rack Error alarm and shows whether you are to the port

(Pt) or starbo ard (Stb) of the planned track.

T o cancel the Large Cross Track Error alarm:

• press

standby to return to hand steering, or auto to retur n to Auto mo de and ret ain the curr ent headi ng

Note: When the Large Cross Tr ack Error alarm sounds, it usuall y means that the cross tide is too gr eat for your boat’s current speed.

Tidal stream compensation

Under most conditions, Track mode will hold the selected track to within ±0.05 nm (300 ft) or better .The autopilot takes account of the boat’s speed when computi ng course changes to ensure optimum performance over a wide range of boat s peeds. In order of preference, the ST4000+ uses:

• measured boat speed (speed through water)

• if this is not available, it uses the speed over ground (SOG)

• if this is not available, it uses the cruise speed specified in Dealer

setup (see page 112)

3 Advanced Operation

Waypoint 2

Tidal component

Boat's speed over ground

Boat's speed through water

Waypoint 1

D3261-2

24 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

Waypoint arrival and advance

Arrival

As the boat arrives at the target waypoi nt the navigation aid should manually or automatically select the next target waypoint. The ST4000+ will then detect the new target waypoint number, soun d the W aypoint Advance alarm and display the W aypoint Advance screen. This shows the new bearing to the next waypoint and the direction the boat will turn to acquire the new track.

Advance

When the ST4000+ sounds the W aypoint Advance alarm, it suspends Track mode and maintains the current boat heading.T o advance to the next waypoint:

1. Check that it is safe to turn onto the new track.

3 Advanced Operation

Target

waypoint

2. Press t he

track key . This will cancel the W aypoint Advance

alarm and turn the boat towards the next waypo int.

Note: If you do not press

track to accept the Waypoint Advance, the

ST4000+ will maintain the curr ent heading and continue sounding the alarm.

Waypoint arrival and advance

Waypoint arrival Waypoint advance

Next target

waypoint at 270˚

Old target

waypoint

New target

waypoint at 270˚

D5416-1

Chapter 3: Advanced Operation 25

Note: When you reach the last waypoint in the tra ck, the NO DATA alarm will sound to i ndicate that there is no further wa ypoint information. Press

standby to return to hand steeri ng.

auto to continue on the same heading, or

Skipping a waypoint – SeaTalk navigators only

If you want to advance to the next waypoi nt before you have arrived at the target waypoint, you can s kip a waypoint by pressing 1 second. The display will then show the W aypoint Advance s creen for the next waypoint.

track for

Dodges in Track mode

When the autopilot is in Track mode you still have full control from the keypad.

Initiating a dodge maneuver

In Track mode, you can make a do dge maneuver by using the course change keys (

-1, +1, -10 or +10) to select the desired course change.

Cancelling a dodge maneuver

After you have avoided the hazard, you can cancel the dodge course change by making an equal course change in the opposit e direction.

Note: Provided the boat remains wit hin 0.1 nm of track, you do not need to steer back towards the track.

Safety in Track mode

WARNING:

T rack mode provides accurate track keeping even in complex

navigational situations. However , it is still the skipper’s responsibility to ensure the safety of their boat at all time s through car eful navigation and fr equent position checks.

3 Advanced Operation

Sailing in T rack mode assists precise navigation and removes the tasks of compensating for w ind and tidal drift. However , you MUST still maintain an accurate log with regular plots.

26 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

Confirming position at the start of a journey

At the start of a journey you must always use an easily identifiable fixed object to confirm the fix given by the navigation system. Check for fixed positional errors and compensat e for them.

Verifying computed positions

Always verify the computed position with a dead reckon ed position, calculated from the average course steered and the distance logged.

Plot frequency

• In open water , you should make plots at least every hour .

• In confined waters or when near to potential hazards, you should

make plots more frequently .

Setting waypoints

3 Advanced Operation

• Local variations in radio signal quality and changes in the tidal stream can produce deviations from the desired t rack. When setting waypoints, remember that deviations can occur.

• Thoroughly check along each track. Check up to 0.5 nm each side of the track to ensure that there are no hazards within this zone.

Note: For the waypoint advance function to work, the last four characters of adjacent waypoint names must be different.

Chapter 3: Advanced Operation 27

3.2 Using Wind Vane mode

Note: You can only use Wind Vane mode if you ha ve connected the ST4000+ to a suitabl e wind instrument/vane providing SeaTal k or NMEA wind direction inf ormation.

T o use Wind V ane mode (also known as Vane mode), the ST400 0+ must receive wind information from one o f the following sources:

• SeaT alk wind instrument, connected to the ST4000+ via SeaT alk

• NMEA wind instrument

• Raymarine wind vane connected through a SeaTalk interface box

In Wind Vane mod e the ST4000+ maintains a course relative to an apparent wind angle. It uses wind trim to eliminate the effects of turbulence and short term wind variations. This provides smooth and precise performance with minimal power consumption.

When the ST4000+ is in W ind V ane mod e it uses the fluxgate compass as the primary heading reference. As changes in the apparent wind angle occur , the ST4000+ adjusts the locked compass headin g to maint ain the or iginal app arent wind angle.

Selecting Wind Vane mode

Y ou can select W ind Vane mode from either S tandby or Auto mode:

1. Steady t he boat onto the required apparent wind angle.

2. Press

The ST4000+ will then adjust the boat’s heading to maintain the locked apparent wind angle.

standby and auto together to select Wind V ane mode and

lock the current apparent wind angle:

• the display shows the locked heading (e.g. the apparent wind angle (e.g. wind angle of 145° to port)

3 Advanced Operation

128°) along with

WIND 145P indicates an apparent

D3565-2

28 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

Exiting Wind Vane mode

Y ou can return to Auto or Standby mode from W ind Vane mode by:

• pressing

auto to r eturn to Au to mode standby to steer manually i n Standby mode

Adjusting the locked wind angle

Y ou can adjust the locked wind angle by using the -1, +1, -10 and +10 keys to change course. For example, to bear away by 10° when the boat i s on a st arboard t ack:

• press

• the autopilot will then adjust the locked heading as required to

Note: Because turning the boat affects the relat ionship between the true and apparent wind angles , you should only use this method to make mi nor adj ustments to the apparent wind angle. For maj or changes, return to Standby mode, steer onto the new heading, then reselect Wind Vane mode.

-10 to turn the boat 10° to port – the locked apparent wind

angle and locked heading will both change by 10°

maintain the new apparent wind angle

3 Advanced Operation

Returning to the previous apparent wind angle

(LAST WND)

If you have steered the boat away from the selected apparent wind angle for any reason (such as a dodge maneuver or selecting Standby mode), you can return to the previous locked wind angle:

1. Press

SECOND

standby and auto together for 1 second to display the

previous apparent wind angle (

• the

LAST WND? text alternates with the previous wind angle

LAST WND?):

and direction. The display show s the previous locked heading and indicates which direction the boat will turn

D3566-2

Chapter 3: Advanced Operation 29

2. Check that it is safe to turn onto this course.

3. T o accept this apparent wind angle, press together within 7 seconds.

Note: If you do not accept the previous wind within 7 seconds, the autopilot will lock onto the curr ent apparent wind angle.

Dodges in Wind Vane mode

When the autopilot is in W ind V an e mode you still have full control from the keypad.

Initiating a dodge maneuver

In Wind Vane mod e, you can make a dodge maneuver by using the course change keys ( change. The autopilot will adjust both the locked heading and locked apparent wind angle.

Cancelling a dodge maneuver

After you have avoided the hazard, you can reverse the previous course change, or return to the previous wind angle (

-1, +1, -10 or +10) to select the desired course

standby and auto

LAST WND?).

Wind shift alarm

If the autopilot detects a wind shift of more than 15° it will sound the wind shift alarm and display the page 15).

• T o cancel the alarm and retain the existing wind angle and new heading:

• press

• Alternatively , to cancel the alarm and return to the previous

heading, either:

• adjust the locked wind angle using the

+10 keys

• press

required heading, and press return to W ind V ane mode with the new apparent wind angle

3 Advanced Operation

WINDSHIFT alarm message (see

standby and auto together.

-1, +1, -10 and

standby to return to hand steering, steer onto the

standby and auto toge ther to

30 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

Using AutoTack in Wind Vane mode

After using the AutoT ack function (see page 10) to tack in Wind V ane mode, you may need to adjust the locked heading until you achieve the required apparent wind angle.

Note: Before you use the AutoTack function in Wind Vane mode, you must make sure that the wind vane was centered accurately at installation.

Apparent wind angle

After tacking, you may need to make minor course changes to achieve the desired apparent wind angle

3 Advanced Operation

AutoTack to Port

Operating hints for Wind Vane mode

• Always trim your sails carefully to mini mize the amount of standing helm.

• Reef the headsail and mainsail a little early rather than too late.

• In W ind V ane mode the pilot will react to long-term wind shifts,

but will not correct for short-term changes such as gusts.

• In gusty and unsteady insho re conditions, it is best to sail a few degrees further off the wind so th at changes in apparent wind direction can be tolerated.

AutoTack

angle

D4373-2

Chapter 3: Advanced Operation 31

3.3 Displaying data pages

Use the disp key to show ‘data pages’ of SeaT alk or NMEA data:

1. Press

disp to access the first data page, and press it again to cycle

through each data page in turn:

• to return to a previous data page, press

disp for 1 second

within 2 seconds of displayi ng a page

• when you cycle past the last data page, the display returns to the current autopilot mode screen (for example, Auto)

2. Select the data page you want to use as the principle display on the contro l unit:

• the current autopilot mode is shown at the left of the display

and the autopilot bar graph remains in use

• if you then select a new mode or make a course change, the

autopilot mode screen appears as a ‘pop-up’ for 5 seconds

Three data pages are set in the factory as a default (see diagram). Wi thin User setup you can select up to seven pages and control the information they display (see page 104):

• if the autopilot system cannot obtain the required information for a data page, the display will show dashes instead of a value

• the ‘direction-to-steer’ arrows relate to the data page information

• most data pages show repeated data so you cannot adjust them:

the exceptions are the

RESPONSE and RUDDER GAIN data pages

(if you have selected them for display) which you can adjust using the

Default data pages

-1 and +1 keys

Autopilot mode

Data page 2

Data page 1Data page 3

D3314-2

3 Advanced Operation

32 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

3 Advanced Operation

Chapter 4: Maintenance & Fault Finding 33

Chapter 4: Maintenance & Fault Finding

This chapter provides information abou t identifying common problems, maintaining your aut opilot system and obtaining product support:

Fault finding

4.1

4.2

4.3

This section provides a checklist to help you identify and resolve common autopilot problems.

General maintenance

This section explains how to maintain your autopilot system.

Product support

This section outlines the product support available from Raymarine worldwide.

page 34

page 36

page 40

4 Maintenance & Fault Finding

34 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

4.1 Fault finding

All Raymarine products are designed to provi de many years of trouble-free operation. W e also put them through comp rehensive testing and quality assur ance procedures before shipping.

In the unlikely event that a fault does occur with your autopilot, use the following table to help identify the problem and pr ovide a solution.

If you cannot resolve the problem yourself, refer t o the product support information on page 40.

SYMPTOM SOLUTION

The control unit display is blank

The displayed compass heading does not agree with the boat’s compass

Boat turns slowly and takes a long time to come onto course

Boat overshoots when turning onto a new course

The autopilot appears to be unstable in Track mode, or track-holding is slow

The autopilot appears to be unstable on Northerly headings in the Northern hemisphere and Southerly headings in the Southern hemisphere

No power – check the fuse/circuit breaker.

You have not corrected the compass for deviation – carry out the deviation and alignment procedures (see page 92 and page 95).

Rudder gain too low (see page 96).

Rudder gain too high (see page 96).

If tide speed exceeds 35% of boat speed, and boat speed is not available via SeaTalk, change the Cruise Speed setting in Dealer Setup to the boat’s cruising speed (see page 112).

Northerly/Southerly heading correction (AutoAdapt) is not set up (see page 111).

Display shows CAL LOCK when entering calibration

4 Maintenance & Fault Finding

Calibration lock is on – turn off the calibration protection feature is in Dealer setup (see page 108).

Chapter 4: Maintenance & Fault Finding 35

SYMPTOM SOLUTION

The autopilot will not ‘talk’ to other SeaTalk instruments

Position information not received

The autopilot will not auto advance to the next waypoint

The control unit display shows a series of rotating dashes

The control unit display shows a series of stationary dashes

The control unit display shows

NO DATA

Wheel drive: drive belt slips in Auto mode (motor operates but drive does not turn wheel)

Cabling problem – make sure all the cables are connected properly.

Navigator not transmitting the correct position data.

No bearing to waypoint information received from the navigator.

Compass deviation correction is running (see page 92).

The control unit is not receiving data – check the cabling.

The signals received by the navigator are too weak fo r reliable navigation – refer to the navigator handbook for further action. OR Wind trim data is not available – check the connection to the wind instrument.

Tighten the clutch – see page 37.

Wheel drive: drive belt drags in Standby mode

Loosen the clutch – see page 37.

4 Maintenance & Fault Finding

36 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

4.2 General maintenance

CAUTION:

The control unit , fluxgate compass, tiller drive and rudder position sensor do not contain any user serviceable parts. These products shoul d be serviced only by authorized Raymarine service technicians.

Wheel drive

Routine maintenance

After each trip, flush inside the drive unit by inserting a hose pipe in the free slot on the back cover .

Cleaning the wheel drive

CAUTION:

Do not use mineral-based solvents (such as WD40) to lubricate or clean the wheel drive as they will damage the material.

W e recommend that you complete the following st eps each season to prevent the build-up of salt on the wheel drive bearings and drive belt:

1. Remove the wheel drive from the wheel:

• remove the wheel from the pedestal

• remove the spoke clamp screws

• remove the wheel drive front cover

2. Check inside the drive un it for any signs of damage.

3. Thoroughly flus h the wheel drive interior with fresh water to remove any salt build-up on the bearings and dr ive belt.

Do not lubricate any part of the wheel d rive. It is designed to run without lubrication.

4. Replace the front cover then fit wheel drive back onto the wheel.

5. Fit the wheel and wheel drive back onto th e pedestal.

6. Clean the wheel drive case (using mild detergent if necessary), then flush thoroughly with fresh water .

4 Maintenance & Fault Finding

Chapter 4: Maintenance & Fault Finding 37

Adjusting the clutch

Y ou need to adjust the clutch if the drive belt slips in Auto mode or drags in Standby mo de. In normal use, you can tell if the clutch is slipping if the motor operates but the drive does not turn the wheel.

T o adjust the clutch, first make sure that the autopilot is in Standby mode and the clutch is disengaged. Then:

1. Use a 3 mm allen key (suppl ied) to loosen the clutch knob screw about 2 turns anti-clockwise.

2. T urn the clutch knob either 4 clicks clockwise to tighten the clutch, or 4 clicks anti-clockwise to loosen the clutch.

3. Use the allen key to re-tighten the clutch knob screw .

4. Check that the wheel still moves freely with the clutch off.

Note: If the wheel does not move freely, reduce the clutch tension by turning the clutch knob 2 clicks anti-clockwise and check again

Adjusting the clutch

Loosen the screw

5. Check the drive’s operation with the clutch engaged.

This procedure is usually suf ficient to correct a slipping or dragging drive belt. In some cases, however , you may need to repeat the steps to adjust the clutch further.

(2 turns)

Clutch knob

screw

To loosen

the clutch

(4 clicks)

Clutch knob

D5349-2

4 Maintenance & Fault Finding

To tighten

the clutch

(4 clicks)

Tighten the screw

(2 turns)

38 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

Replacing the belt

The drive belt is designed to be user serviceable. If there is insufficient adjustment to cure a slipping clutch, or if the drive belt is damaged in any way (if it is broken, frayed or st retched), you should replace the drive belt. Y ou can obtain a replacement belt from any Raymarine dealer (part number A18083). Fitting instructions are supplied with the belt.

User serviceable parts

Y ou can obtain the following 4000 mk2 wheel dri ve spare parts from your Raymarine dealer:

Part description Part number

Front cover A18074

Clutch lever A18077

Clutch knob A18078

Pedestal bracket (torque restraint) A18080

Drive belt A18083

Clutch kit (clutch eccentric and clutch roller) A18084

Single spoke clamp, screws and inserts A18089

Control unit

Routine checks

The control unit is a sealed unit. As a result, user maintenance is limited to the following routine checks:

• make sure all cable connectors are firmly attached

• examine the cables for signs of wear or damage – replace any

damaged cables

4 Maintenance & Fault Finding

Chapter 4: Maintenance & Fault Finding 39

Cleaning the display

CAUTION:

T ake care when cleaning the display . Do not wipe the display screen with a dry cloth as this could scratch the screen coating. Do not use acid, ammonia based or abrasive products.

• Never use chemical or abrasive materials to clean the control unit. If the control unit is dirty , wipe it with a clean, damp cloth.

• In certain conditions, condensation may appear inside the display screen. This will not harm the unit, and you can clear it by switching on the illumination for a short time.

EMC advice

• 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.

• T o minimize these effects and enabl e you to get the best possible performance from your Raymarine equipment, guidelines are given in the installation instructions, to enabl e you to ensure minimum interaction between dif ferent items of equipment, i.e. ensure optimum Electromagnetic Compatibility (EMC).

• Always report any EMC-related probl ems 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 g eneral this will not damage the equipment but it can lead to spuri ous resetting action, or momentarily may result in faulty operation.

4 Maintenance & Fault Finding

40 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

4.3 Product support

Raymarine products are supported by a worldw ide network of distributors and Authoriz ed Service Representatives. If you encounter any difficulti es with this product, please contact either your national distributor , service representative, or the Raymarine T echnical Services Call Center. Refer to the back cover or the W orldwide Distributor List for con tact details.

Software version

If you cannot trace or rectify the fault, contact your nearest Raymarine distributor or Service Representative, specifying:

• the product serial number , which is printed on the rear cover of the autopilot

• the software version number:

• press

SECONDS

standby for 4 seconds to display the software version

ST4000+ software version

D5334-1

4 Maintenance & Fault Finding

Part 2: Installing the ST4000+

Chapter 5: Installing the ST4000+ 43

Chapter 5: Installing the ST4000+

The sections in this chapter explain how to install and connect the components of your autopilot system:

Planning the installation

5.1

5.2

5.3

5.4

5.5

Preparation steps, tools required and EMC installation guidelines.

Control unit

How to install the surface mount and flush mount control units, and connect power, SeaTalk and NMEA.

Fluxgate compass

How to install the fluxgate compass.

Tiller drive (tiller pilots only)

How to install the 4000 tiller drive.

Wheel drive (wheel pilots only)

How to install the wheel drive.

5 Installing the ST4000+

page 44

page 48

page 55

page 59

page 70

5.6

Rudder position sensor (wheel pilot option)

How to install the optional rudder position sensor for wheel pilots.

page 81

44 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

5.1 Planning the installation

Before you start installing the autopilot s ystem, read through the relevant installation sections in this chapter .

After reading through the following EMC installation g uidelines, identify suitable locations for each part of the system:

• consider how you will run cables t o and from each component

• avoid running cables through b ilges where possible

5 Installing the ST4000+

Tools required

• avoid running cables close to fluorescent light s, engines, radio transmitting equipment etc.

T o install this autopilot system you will need the following items:

• tape measure (metric/imperial)

• pliers and cross-head/pozi-drive screwdriver

• drill and drill bits:

• 5 mm (

• 3 mm (

/32 in) for surface mount control unit

/8 in) for compass and rudder posi tion sensor

• pencil, masking tape and center punch

• sandpaper/file to smooth cut edges

• for the control unit:

• jigsaw or 90 mm hole cutter (for the control unit aperture)

• SeaT alk cables (if required – see page 52)

• extra power cable (if required - see page 52)

• for the tiller drive only:

• two-part epoxy adhesive for tiller pin and mounting socket

• installation accessories (if required – see page 61)

• drill bits as required

• appropriate power cable (see page 68) for the tiller socket

• for the wheel drive only:

• spanner for the wheel nut

• washing-up liquid (to l ubricate the spokes)

• hacksaw to cut the pedestal bracket

• 4 mm + 6 mm drill bits and 3 mm allen k ey (supplied)

Parts supplied

Use the following illustrations to check the parts supplied with your ST4000+ autopilot system.

Chapter 5: Installing the ST4000+ 45

Control unit and compass (all systems)

Control unit

No8 x 3/4 in screw (x4)

Fluxgate compass with 8 m (26 ft) cable

Gasket

COMPASSAREA

Stud (x2)

Control unit power cable 1 m (3 ft 3 in)

Compass warning label

Thumb screw (x2)

Spade connector (x12)

Control unit terminal cover

(if desired, attach to rear of control unit

after connecting all cables)

M4 x 25 mm screw

Sun cover

5 Installing the ST4000+

Also packed: Handbook, Quick Reference Card, Worldwide Distributor List

Tiller drive parts

Plug

Cable clip and screw, No 6 x 1/2 in

Mounting socket (D002)

Tiller drive

Tiller pin (D001)

D5438-1

Socket

Socket screw No 4 x 3/4 in (x2)

Optional: installation accessories if required

D5437-1

46 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

5 Installing the ST4000+

Pedestal bracket

Wheel drive parts

Wheel drive

Optional: Bulkhead/box pedestal fitting kit E15017 (if required)

Pedestal bracket

Spoke clamp (x3)

16 mm spoke

clamp insert (x3)

Clamp screw,

M5 x 16 mm (x6)

6 mm

6mm

drill bit

Power cable

4.5 m (15 ft)

12 mm spoke

clamp insert (x3)

Bracket screw,

No 10 x 3/4 in (x4)

4 mm

4mm

drill bit

3 mm

3mm

allen key

Cable clip

and screw,

No 6 x 1/2 in

D5439-1

D5439-2

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 been taken to ensure that they will perform under all conditions, it is important to un derstand what factors could affect the operation of the product.

The guidelines given here describe the conditio ns for optimum EMC performance, but it is recognized that it may not be possibl e to meet all of these conditions in all situations. T o ensure the best possible conditions for EMC performance within the constraint s imposed by any location, always ensure the maximum separation possibl e between different items of electrical equipment.

For optimum EMC performance, it is recommended that wherever possible:

Chapter 5: Installing the ST4000+ 47

• Raymarine equipment and cables connected to it are:

• At least 3 ft (1 m) from any equipment t ransmitting or cables

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

• 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 info rmation 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.

5 Installing the ST4000+

• If a suppression ferrite is attached to a cable, this ferrite should not be removed. If the ferrite needs t o be removed during installation it must be reassembled in the same position.

EMC suppression ferrites

The following illustration sh ows typical cable suppression ferrites used with 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.

48 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

5.2 Control unit

Control unit dimensions

5 Installing the ST4000+

90 mm (3.55 in)

115 mm (4.53 in)

Location

Locate the ST4000+ control unit so it is:

• within easy reach from the steering position

• viewable straight on, or with a maximum viewing angl e of 30°

• protected from physical damage

• at least 230 mm (9 in) from any compass

• at least 1 m (3 ft) from any radio/radar receivers/transmitters

The selected location should also:

• be clean, smooth and flat

• be accessible from behind (so you can secure and run cables)

• have sufficient space to accommodate the rear of the control unit

• allow at least 6 mm (

110 mm (4.33 in)

24 mm

(0.95 in)

and connectors

/4in) between adjacent control units and

instruments so you can fit their sun covers

17 mm

(0.67 in)

D3242-2

CAUTION:

The ST4000+ front cover is waterpr oof when installed according to the following instructions. However , the rear cover must be protected from water in a ventilated and drained area. Any water or water vapor in this area could cause damage by coming into contact with electrical connections or condensation by entering the contr ol unit th rough its b reathin g hole.

Chapter 5: Installing the ST4000+ 49

Mounting procedure

Control units are available in surface mount and flush mount styles.

Surface mount control units

T o fit a surface mount control unit:

1. Apply the surface mount template (supplied at the back of this handbook) to the selected bulkhead.

2. Mark the centers of the two fixing holes and the cable boss.

3. Drill two 5 mm (

4. Use a 90 mm (3.55 in) diameter cutter to drill the hole for the cable boss.

5. Peel the protective sheet from the self-adhesive gasket, then stick the gasket into position on the rear of the control un it surround.

6. Screw the fixing s tuds into the control unit.

/16in) diameter holes for the fixing studs.

5 Installing the ST4000+

7. Pass the cables (power , compass, SeaT alk etc.) through the bulkhead and connect them to the appropriate terminals (as describ ed later i n this chap ter).

8. Assemble the control unit to the bulkhead.

9. Secure the control unit with the t humb nuts provided. Hand-tighten the thumb nuts – do NOT use a wrench.

Fixing stud

Thumb nut

Cable boss

Self-adhesive gasket

D3243-3

50 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

Flush mount control units

T o fit a flush mount control un it:

1. Ensure that the intended mounting location is between 3 mm

(

/8in) and 20 mm (3/4in) thic k.

2. Apply the flush mo unt template (supplied at the back of this handbook) to the selected location. Mark the aperture into which the control unit will sit, then remove the template.

5 Installing the ST4000+

3. Use a jigsaw to cut out this aperture.

4. Peel the protective sheet from the self-adhesive gasket, then stick the gasket into position on the rear of the control unit surround.

5. Screw the two fixing studs into the threaded sockets on the rear of the control unit.

6. Pass the cables (power , compass, SeaT alk, etc.) through the bulkhead and connect them to the appropriate terminals (as described later in this chapter).

7. Place the assembled control unit, studs and gasket into the panel.

8. Locate the bracket onto the fixi ng studs and secure the assembly to the panel with the thumb-nuts. Hand-tighten the thumb nut s – do NOT use a wrench.

Aperture

cut-out

Self-adhesive

gasket

Fixing

stud

Thumb

screw

Bracket

D4585-2

Chapter 5: Installing the ST4000+ 51

Cable connectors

With the exception of the SeaT alk cables, spade connectors are used to make a ll conne ctions to th e contro l unit.

When fitting the spade connectors, make sure the connector fits securely over the blade and not between the connector and its plastic insulating cover . Incorrect fitting will give intermittent contact which will lead to faulty autopilot operation.

5 Installing the ST4000+

Power supply connection

• The autopilot requires its own dedicated power supply – it cannot source its power from SeaT alk. However , it can be used to supply power to other SeaT alk instruments.

• Y ou must fit a12 A fuse (or equivalent circuit breaker) to the +12 V supply.

Brown (+) Blue (-)

Power

cable

12 A fuse

(or equivalent

circuit breaker)

Blue (-)

Brown (+)

D3286-2

+12 V power supply

D3287-2

52 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

• As standard, we supply a 1 m (3 ft 3 in) power cable terminated

with

/4inch spade connectors.

• Y ou can extend t he power cable if required. The following table shows the minimum acceptable cable sizes:

Cable length Copper area AWG

5 Installing the ST4000+

Up to 2.5 m (8 ft) 1.0 mm

Up to 4.0m (13ft) 1.5mm

Up to 6.0 m (19.5 ft) 2.5 mm

Note: If you need to extend the cable, you MUST use the correct cable size.A lighter gauge cable might cause a voltag e drop between the supply and the control unit. This wi ll reduce the power to the drive, causing slower respons e to course changes and corrections.

SeaTalk connections

Y ou will not need any SeaT alk cables to install the standard ST4000+ autopilot system.

However, i f you want to connect your ST4000+ control unit to other SeaT alk equipment, you will need to purchase the n ecessary cables from your Raymarine dealer .

The following illustration shows the range of available SeaTalk cables.

Flat moulded plugs at each end

Part no. Type Length D284 Flat moulded plugs at each end 1 m (3 ft 3 in) D285 Flat moulded plugs at each end 3 m (9 ft 10 in) D286 Flat moulded plugs at each end 5 m (16 ft 5 in) D287 Flat moulded plugs at each end 9 m (29 ft 6 in) D288 Flat moulded plugs at each end 20 m (65 ft 6 in)

Flat moulded plug to round plug

Part no. Type Length D187 Flat moulded plug to male round plug 0.15 m (6 in) D188 Flat moulded plug to female round plug 0.3 m (12 in)

D5417-1

Chapter 5: Installing the ST4000+ 53

Typical SeaTalk connections

Autopilot control

unit (rear)

SeaTalk bus

Power supply

D3392-2

NMEA connections

5 Installing the ST4000+

ST4000+ can receive wind and navigation da ta in NMEA 0183 format for use in T rack and Wind Vane modes.

Receiving NMEA data

NMEA cabling

Connect the NMEA navigator or wind instrument to the NMEA IN terminals on the rear of the ST4000+ control unit .

Navigator or

wind instrument

with NMEA output

Data

out (-ve)

Data out (+ve)

Control unit

(rear)

(data in +ve)

Red

Blue (data in -ve)

D3374-2

54 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

Note: If you need to connect more than one item of NMEA equipment, you will need to connect one of them to the SeaTalk system using a SeaTalk/NMEA Interface (part number: E85001).

NMEA data formats

TheST4000+ can decode the following NMEA 0183 navigation and wind data:

Information NMEA 0183 data

5 Installing the ST4000+

Course Over Ground VTG, RMC, RMA

Speed Over Ground VTG, RMC, RMA

Cross Track Error APB, APA, RMB, XTE

Bearing to Waypoint APB, BWR, BWC, RMB

Distance to Waypoint BWR, BWC, RMB

Waypoint Number APB, APA, BWR, BWC, RMB

Apparent Wind Speed VWR, MWV

Apparent Wind Angle VWR, MWV

Speed Through Water VHW

Depth DBT

Water Temperature MTW

Note: The autopilot only decodes the last four characters of waypoint names. This means that the last four characters of long waypoint names must be unique for the waypoint advance function to work.

Transmitting NMEA data

Transmitting NMEA data on SeaTalk

If the ST4000+ receives any of the NMEA data shown above, and the equivalent data is not present on SeaTalk, it will transmit the data onto SeaT alk to make it available to other SeaTalk instruments:

• the ST4000+ transmits depth informat ion in the units defined by the first page in the data page rollover

• the ST4000+ always transmits water temperature in °C

Transmitting NMEA data to NMEA equipment

If you want to transmit information to NMEA equi pment, you will need to connect a SeaT alk/NMEA Interface (part number: E85001) to the SeaT alk bus to convert SeaT alk data to NMEA data.

Chapter 5: Installing the ST4000+ 55

5.3 Fluxgate compass

Location

The compass contains a self-levelling mechanism. This enables the compass to provide accurate readings with pitch and ro ll movements up to +/- 35°.

Note: The rattle that the fluxgate compass makes when shaken is normal. It is caused by the pendulum w eight hitting the inside of the case.

76 mm (3 in)

5 Installing the ST4000+

D5381-1

Fluxgate compass dimensions

Standard location

The compass is primarily designed for bel ow deck, bulkhead mounting. On steel-hulled boats y ou must mount it above deck.

T o achieve the best performance from the compass, mount it:

• as near as possible to the boat’s pitch and roll center to minimize compass disturbance

• at least 0.8 m (2 ft 6 in) away from the boat’s steering compass to prevent deviation of either compass

• away from the front third of the boat (otherwise shock motion will affect compass performance)

• away from potential sources of magnetic interference, such as: motors, drive units, loudspeakers, alternators/starters, electric cables, large ferrous objects (such as the engine, ballast, keel, gas bottles and tool boxes )

Note: Because you align the compass after ins tallation (see page 95),you can mount it so it faces i n any direction.

56 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

0.3L to 0.5L

5 Installing the ST4000+

D5401-1

Compass - recommended location for non-steel hulls

Finding the most suitable location

T o identify the best compass location on yo ur boat, start at the pitch and roll center then move the compass up and/or aft unt il you find a location with minimal magnetic disturbance.

Note: To check if the intended mounting location is free from magnetic influence, tape a handheld compass to t he chosen location, then turn the boat through 360°. The readings on the handheld compass and your boat’s main steering compass (if accurately aligned) should not differ by mo re than10° at any heading.

Steel-hulled boats

On steel-hulled boats you must mount the compass at least 1.2 m (4 ft) above the main deck or wheelhouse. Otherwise the compass will not work correctly because the hull will prevent it from sensing the Earth’s magnetic field. The following illustration shows recommended mounting positions for st eel-hulled boats.

Note: The higher above the waterline you mount the compass, t he more the boat’s pitch and roll wi ll affect compass performance.

Chapter 5: Installing the ST4000+ 57

6 ft (1.8 m)

4 ft (1.2 m)

5 Installing the ST4000+

Compass - recommended location for steel-hulls

Mounting

Fluxgate compass - orientation

CAUTION:

Y o u must mount the fluxgate compass on a vertical bulkhead, with the cable exiting at the base.

Vertical

D5383-1

5384-1

1. Hold the compass against the mounting location.

2. Mark the four mounting hol es, then remove the compass.

3. Drill four pilot holes using a 3 mm (

/8 in) drill bit.

58 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

4. Making sure the cable exits at the bottom of the compass, secure the fluxgate compass using the self-t apping screws provided (No 8 x

/4 in, pan-head).

Note: Stick the supplied warn ing label near to the compass, where it is clearly visible.

Connecting to the control unit

5 Installing the ST4000+

1. The compass is supplied with 8 m (26 ft) of cable. Route the cable to the control unit, taking into account the EMC installation guidelines (page 46).

Note: Make sure you leave some spare cable so, if necessary, you can re-position the compass to reduce deviation. If t he standard cable is not long enough, your Raymarine dealer can s upply a 10 m (30 ft) extension cable (part number: D174).

2. Connect the five cores of the cable as shown to the

Compass

terminals on the control unit.

Red

Screen

Blue Yellow Green

D3282-2

Chapter 5: Installing the ST4000+ 59

5.4 Tiller drive (tiller pilots only)

Critical dimensions

Installing the tiller dri ve involves mounting it between the tiller and a fixed point on the boat’s structure. Two dimens ions are critical for correct installation:

• Dimension A = 620 mm (24.5 in): the distance from the

mounting socket to the tille r pin. Pull out the drive pushrod to this dimension.

Note: If your installation requires a pushrod extension (see page 61) or cantilever mount (see page 65),this dimension will increase.

• Dimensi on B = 460 mm (18 in): the distance from the rudder

stock’s center line to the tiller pin.

5 Installing the ST4000+

'B' 460 mm (18 in)

468 mm (18.4 in)

38 mm (1.5 in)

'A'

620 mm (24.5 in)

44 mm (1.7 in)

'B' 460 mm (18 in)

90˚

Rudder axis

Sloping rudderstock

D5339-1

60 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

1. Clamp the tiller on t he boat’s center line and mark dimensions A and B.Use masking tape to locate the fixing points for the tiller pin and mounting socket.

Note: You can measure dimension A on either the port or starboard side of the cockpit, depending on which side you intend to mount the drive. If you select port mounting, you must correct the autopilot steering direction as described on page 86.

5 Installing the ST4000+

2. Make sure the measurements are at ri ght angles (as shown on the diagram).

3. Make sure that the drive unit is mo unted horizontally .

Basic installation

After establishing the control dimens ions A and B, you can usually mount the tiller drive directly onto the cockpit seat.

12.5 mm (0.5 in)

Installing the tiller pin (part no. D001)

1. Drill a 6 mm (1/4in) diameter hole to a depth of 25 mm (1 in) at the fixing point you have marked on the tiller .

2. Use a two part epoxy adhesive (e.g. Araldite) to fix the tiller pin in place.

3. Position the shoulder of the pin so it is 12.5 mm ( tiller surface.

Mounting socket

Tiller pin

/2in) above the

D284-2

Chapter 5: Installing the ST4000+ 61

Installing the mounting socket (part no. D002)

1. Drill a 12.5 mm (1/2in) diameter hole to a depth of 25 mm (1 in) at the fixing point you have marked on the cockpit seat.

2. If the structure at the mounti ng position is less than 25 mm (1 in) thick, reinforce the underside with plywood bonded into position.

3. Install the mount ing socket using a two part epoxy adhesive.

CAUTION:

As the tiller pilot is capable of generating high pushrod loads, you MUST:

• drill holes to the specified size and reinforce where necessary

• allow the epoxy to harden comp letely before apply a load

Installation accessories

5 Installing the ST4000+

If you are not able to install the drive unit directly onto the cockpit seat or tiller as described, use one (or a combination) of the following accessories:

• pushrod extensions

• tiller brackets

• cantilever sockets

• pedestal sockets

Pushrod extensions

If you need to increase the pushrod length (because of the distance from the mounting socket location to the center line), us e a Raymarine pushrod extensi on.

Identifying the correct pushrod extension

1. Clamp the tiller on the boat’s center line.

2. Measure dimension C.

3. Select the appropriat e pushrod extension length (and part number) using the following table.

62 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

Dimension C Pushrod extension length L Part no.

620 mm (24.5 in) Standard dimension -

648 mm (25.5 in) 25 mm (1 in) D003

673 mm (26.5 in) 51 mm (2 in) D004

699 mm (27.5 in) 76 mm (3 in) D005

724 mm (28.5 in) 102 mm (4 in) D006

5 Installing the ST4000+

749 mm (29.5 in) 107 mm (5 in) D007

775 mm (30.5 in) 152 mm (6 in) D008

D285-2

Mounting the pushrod extension

T o mount the pushrod extensi on:

1. Unscrew the end of the tiller drive’s push rod.

2. Screw the extension into the pushrod.

3. Screw the pushrod end into the pushrod extension.

Chapter 5: Installing the ST4000+ 63

Tiller brackets

If the tiller is higher or lower than the mounting socket, you can use a Raymarine tiller bracket to vary the tiller pin offset so the drive is horizontal.

Identifying the correct tiller bracket

1. Clamp the tiller on the boat’s center line.

2. Measure dimension D (if the pu shrod is above the tiller) or dimension E (if the pushrod is below the tiller).

3. Select the ap propriate b racket fr om the foll owing tab le:

Dimension D (pushrod below tiller)

25 mm (1 in) 51 mm (2 in) D009

51 mm (2 in 76 mm (3 in) D010

Dimension E (pushrod above tiller)

Bracket part no.

5 Installing the ST4000+

76 mm (3 in) 102 mm (4 in) D011

102 mm (4 in) 127 mm (5 in) D159

127 mm (5 in) 152 mm (6 in) D160

Mounting the tiller bracket

1. Position the tiller br acket on the center line of the tiller (above or below) and establish the critical dimensions A and B

Note: To measure dimension B on a b oat with a sloping r udderstock, refer to the diagram on pa ge 65.

2. Mark the centers of the two bracket mounting holes.

3. Drill two 6 mm (

/4in) diameter holes through the center line of

the tiller at the positions you have marked.

4. Attach the tiller bracket using two 6 mm (

/4in) diameter bolts,

nuts and washers.

5. Bond the fixi ng bolts in place with two part epoxy adhesive

6. When the epoxy is complet ely hardened, fully tighten the nuts.

7. Attach the tiller pin to the bracket.

64 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

5 Installing the ST4000+

D286-2

D287-2

Chapter 5: Installing the ST4000+ 65

'B'

90 degrees

D309-2

5 Installing the ST4000+

Cantilever mounting

If you need to attach the tiller drive to a vertical face (such as the cockpit sidewall), use a Raymarine cantilever socket assembly (part number D031):

• the maximum possible extensi on offset is 254 mm (10 in)

• you cut the cantilever to the exact length during mounting

Cutting the cantilever rod to length

1. Clamp the tiller on the boat’s center line.

2. Measure dimension F (actual).

3. Refer to the table to establish a cutting length for the cantilever rod – double check measurements before cutting.

4. Measure the rod from thr eaded end, then cut the cantilever rod to length L using a hacksaw . Remove any sharp edges with a file.

Dimension F Cut length L

686 mm (27 in) 51 mm (2 in)

711 mm (28 in) 75 mm (3 in)

737 mm (29 in) 102 mm (4 in)

762 mm (30 in) 127 mm (5 in)

787 mm (31 in) 152 mm (6 in)

813 mm (32 in) 178 mm (7 in)

838 mm (33 in) 203 mm (8 in)

66 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

5 Installing the ST4000+

D288-2

Mounting the cantilever assembly

T o mount the cantilever assembly:

1. T emporarily assemble t he cantilever by screwing the rod into the mounting ring.

2. Ensure the drive unit is horizontal and then mark t he location of the mounting ring and its mount ing holes.

3. Drill three 6 mm (

/4in) diameter holes at the positions you have

marked.

4. Bed the mounting r ing on a thin coat of silicon sealant.

5. Use three 6 mm (

/4in) diameter bolts, nuts and washers to attach the mounting ring to the backing plate (with the backing plate on the other side of the mounting surface, as shown above).

6. Screw the rod firmly into place.

7. Roughen the end of the cantile ver rod and the inside of the cap to provide a key . Then apply two part epoxy adhesive to the rod end and the cap.

8. Place the cap over the rod end, making sure the hole for the drive unit mounting pin faces upwards. Allow the epoxy adhesive to harden fully before applying a load.

Note: When the autopilot is not in use, you can unscrew the complete rod assembly to leave the cockpit unobstruct ed.

Chapter 5: Installing the ST4000+ 67

Pedestal socket mounting

If you need to raise the height of the drive unit mount ing socket to keep the tiller drive horizontal, use a Raymarine pedestal socket assembly.

Identifying the correct pedestal socket

5 Installing the ST4000+

D289-2

1. Clamp the tiller on the boat’s center line.

2. Establish the standard control dimensions A and B.

3. W ith the tiller drive horizontal, measure dimension G.

4. Select the appropriate pedestal socket assembly from the table.

Dimension G Pedestal socket length L Part no.

38 mm (1.5 in) Standard dimension -

76 mm (3.0 in) 38 mm (1.5 in) D026

89 mm (3.5 in) 50 mm (2.0 in) D027

102 mm (4.0 in) 64 mm (2.5 in) D028

114 mm (4.5 in) 76 mm (3.0 in) D029

127 mm (5.0 in) 89 mm (3.5 in) D030

Mounting the pedestal socket

1. Mark the mounting ring’s position on the cockpit seat or counter .

2. Ensure that control dimensions A and B are correct.

3. Mark the bolt holes on the mou nting ring and then drill three

6 mm (

/4in) diameter holes.

68 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

4. Bed the mounting r ing on a thin coat of silicon sealant.

5. Use three 6 mm (

/4in) diameter bolts, nuts and washers to attach the mounting ring to the backing plate (with the backing plate on the other side of the mounting surface, as shown above).

6. Screw the mounting socket firmly into place.

Note: When the autopilot is not in use, you can unscrew the complete rod assembly to leave the cockpit unobstruct ed.

5 Installing the ST4000+

Tiller pins

Y our Raymarine dealer can also supply the following lengths of tiller pin for other non-standard inst allations.

Description Size Part no.

Small threaded tiller pin 25 mm (1.0 in) D014

Extra length tiller pin 72 mm (2.8 in) D020

Extra length threaded tiller pin 72 mm (2.8 in) D021

Connecting to the control unit

• Connect the tiller drive to the control unit via the waterproof plug and socket (supplied).

• The plug comes ready assembled to the tiller dri ve.

• Mount the socket in the cockpit next to the tiller drive.

Cabling

1. Measure the total length of cable run from the control unit to the socket location. Use this table to identify the appropriate power cable size:

Cable length Copper area AWG

Up to 2.5 m (8 ft) 1.0 mm

Up to 4.0m (13ft) 1.5mm

Up to 6.0m (22ft) 2.5mm

2. Route the cable from the control unit to the socket location.

3. Use a suitable tool to crimp the spade receptacles (supplied) to the two cores.

4. Connect them as shown to the

Drive terminals on the control unit.

Chapter 5: Installing the ST4000+ 69

5 Installing the ST4000+

Brown Blue

D3284-2

Installing the socket

1. Apply the template (su pplied at the rear of this handbook) to the bulkhead.

2. Carefully drill a 18 mm (

(

/32in) pilot holes. Remove the template.

3. Pass the cable through the bu lkhead and attach to the socket, making sure you connect each core to the correct pin (as shown).

Rear of socket

Drive (blue) 3 stripe terminal

/32in) clearance hole and two 2.5 mm

Terminal identification stripes

Drive (brown) 2 stripe terminal

4. Attach the socket to the bulkhead us ing the two self-tapping

To the control unit

D383-5

screws. Use cable clamps to secure the drive cable at regular intervals.

70 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

5.5 Wheel drive (wheel pilots only)

The Raymarine wheel drive will fit 3, 4, 5, 6, 7 or 8 spoke wheels. It is designed to operate with steering systems with between 1 to 3.5 turns lock to lock.

Note: In the following cases, you must fit a rudder position sensor to your wheel drive system (see page 81):

• If your steering system has significant lost motion that you cannot

5 Installing the ST4000+

correct. (Any play in your boat’s steering will degrade autopilot performance, so always try to minimize this lost motion.)

• If you are installing the wheel dri ve on a hydraulic steering system.

Clamp screw, M5 x 16 mm (x6)

Spoke clamp (x3) Clamp insert (x3)

Wheel drive – main parts (see page 114 for dimensions)

Installation stages

Wheel drive front cover

Pre-drilled spoke clamp holes (x2)

Bracket screw, No 10 x 3/4 inch (x4)

Pedestal bracket

Bracket pin

Cable plug

Cable socket

Motor tube

Clutch lever

D5402-2

Installing the wheel drive involves four st ages:

1. Drilling the spoke clamp holes in the front cover .

2. Securing the wheel drive to the wheel.

3. Attaching the pedestal bracket.

4. Connecting the drive to t he control unit.

Chapter 5: Installing the ST4000+ 71

Drilling the spoke clamp holes

1. Remove the wheel drive front cover:

• the front cover is held onto the wheel drive by three ‘push-fit’

posts which sit in three sockets on the drive ring

• to remove the cover , hold the motor in one hand and use your

other hand to pull the cover up and away from the drive unit (as shown below)

5 Installing the ST4000+

D5403-1

2. Identify the appropriate sp oke clamp holes for your wheel. With the arrow at the top, refer to the following diagrams:

• the holes are numbered inside the cover (e.g. if you have a 5

spoke wheel, you need to drill the 4 locations marked with ‘

• mark the appropriate spoke clamp holes and check them by

holding the cover against your wheel

5 spokes 7 spokes

Top 2 spoke clamp holes

are pre-drilled

5’)

D5348-1a

72 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

3 or 6 spokes 4 or 8 spokes

Top 2 spoke clamp holes

are pre-drilled

5 Installing the ST4000+

Note: The wheel drive is designed to work wi th 3 spoke clamps on 4 or 8 spoke wheels. For cosmetic reasons, however, you may want to fit an extra spoke clamp to the fourth spo ke. Raymarine dealers can supply an extra spoke clamp (part number A1 8089).

D5348-1b

3. Drill the appropriat e spoke clamp holes using the larger of the supplied drill bits (6.0 mm or

/4in):

• drill from the inside, placing a piece of scrap wood under t he

cover to produce a clean exit hole

• you will need to drill 4 new hol es so the cover has 6 holes in

total (2 for each spoke clamp)

Note: The spoke clamps will cover these exit holes, so they will not be visible when the wheel drive is installed.

Piece of scrap wood

D5347-1

Chapter 5: Installing the ST4000+ 73

4. Align the cover with the wheel drive:

• the two pre-drilled holes (marked with an arrow ) must line up with their matching pair of threaded inserts on the drive ri ng (also marked with an arrow)

• make sure that the other spoke clamp holes align with their threaded inserts

Note: The cover will only fit back onto the wheel drive when you have aligned the two parts correctly.

Pre-drilled holes

(marked with arrow)

Pair of threaded inserts

(marked with arrow)

5 Installing the ST4000+

Front cover Drive unit

5. Fit the cover back onto the wheel drive:

• press the cover in the three places shown on the diagram below to push each of the posts back into its locating socket

Note: This step is easier wit h the clutch engaged.

TOP

Drive ring

D5404-1

D5405-1

74 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

Securing the wheel drive to the wheel

1. Remove the wheel from the pedestal and place it on top of the drive unit, with the front of the wheel and drive both facing up.

2. Using the wheel drive template at the end of this book , select the correct set of spoke clamp inserts for your wheel:

• measure the spoke diameter at a distance of about 135 mm

(5.3 in) from the center of the wheel

5 Installing the ST4000+

• select the appropriate set of inserts: the wheel drive is supplied

with 2 sets of 3 inserts suit able for 12 mm (

(

/8 in) diameter spokes – each insert is marked with its size

/2 in) and 16 mm

3. Fit the first spok e clamp:

• lubricate the spoke with washing-up liquid – s o you can slide

the spoke clamp along the spoke to adjust its position

• place the insert on the spoke about 135 mm (5.3 in) from the

wheel center – this distance is not critical as the wheel drive will self-center as you fit all 3 spoke clamps

• place the spoke clamp onto the insert, making sure that you

have correctly located the clamp insert in the clamp

• locate 2 of the clamp screws (M5 x 16 mm allen-head screws)

• lightly tighten the screws using the 3 mm allen key (supplied)

135 mm (5.3 in)

4. Repeat step 3 to fit the other 2 spoke clamps. As you fit each one, adjust the position of the wheel relative to the wheel drive so the holes i n the clamp line up wi th the hole s in the co ver . As you do

this, the wheel drive will self-center on the wheel.

5. After fitting all 3 spoke clamps, fully ti ghten the screws.

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Chapter 5: Installing the ST4000+ 75

Attaching the pedestal bracket

Note: If your wheel is bulkhead or box pedestal m ounted, you will need to obtain a bulkhead fitting kit (part number E1 5017) from your Raymarine dealer. Fitting instructions are supplied with the kit.

Motor tube location

Depending on the design of your pedes tal and any surrounding obstructions, you can mount the wh eel drive in one of two ways:

• Slot 1 installation: the standard position uses slot 1 on the back of

the wheel drive (the slot closest to the motor tube) so the motor tube is at the bottom to the right of the pedestal

• Slot 2 installat ion: the alternative installation uses slot 2 to

position the motor tube at the top to the left of the pedestal

Select the appropriate slot so the motor tube is clear of obstructions.

5 Installing the ST4000+

CAUTION:

If you use slot 2 and you have a pedestal-mounted compass , the drive motor may affect compass r eadings.

Slot 1 installation:

motor tube at bottom right

Slot 1

Slot 2 installation:

motor tube at top left

Slot 2

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76 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

Pedestal bracket – length and position

Note: If you are replacing an existing 4000 wheel drive, you need to: remove the old pedestal bracket, cut the new bra cket pin to the correct length (see steps 2 and 3 below), then secure it in the stand ard orientation using the exist ing pedestal holes.

1. Fit the wheel onto the pedestal , tighten the wheel nut to hold the wheel in place, and engage the wheel drive’s c lutch:

5 Installing the ST4000+

• if possible, lock the wheel in position with the appropriate slot

centered at the bottom of the wheel

• otherwise, you will find it useful t o have an assistant to hold

the wheel in position so you can locate the bracket correctly

2. Measure dimension A – the distance between the front of the pedestal and the rear edge of the drive’s front cover (see diagram):

• you may find it easiest to hold the bracket below the wheel

drive and mark dimension A directly on the pin

Cut here

10 mm

Note: If the wheel is bent or not running t rue, dimension A will change with the wheel position. Measur e the smallest distance.

3. Use a hacksaw to cut the pin 10 mm (0.4 in) LONGER than dimension A. Remove any sharp edges at th e cut end with sandpaper or a file.

4. Place the pin end in slot 1 or 2 (as required):

• to do this you may need to loosen the wheel nut so you can

slide the wheel forward slightly, place the pin end in the slot, return the wheel to its normal position and re-tighten the wheel nut

D5343-2

Chapter 5: Installing the ST4000+ 77

Note: You can install the pedestal brac ket either way up. In the standard orientation t he pin is at the bottom (below the mounting holes – see diagram). If obstructions on the pedestal prevent you from using the standard orientation, you can install the bracket so the pin is at the top (above the mounting h oles).

Standard (also for retro-fit)

Alternative

D5408-3

5. Making sure the slot is cen tral at the bottom of the drive unit

(6 o’clock position) and the pin is in the middle of the slot, carefully draw around the bracket.

5 Installing the ST4000+

6. Remove the wheel, then hold the bracket on the pedestal in the

7. Check the position and alignm ent of the pedestal bracket:

D5345-2

location you have marked.

• the bracket pin should be 154 mm (6.1 in) belo w the pedestal spindle (see the following diagram)

• the bracket pin should be aligned so it is directly below the pedestal spindle (see the following diagram)

78 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

5 Installing the ST4000+

154 mm (6.1 in)

D5346-2

8. When the pedestal bracket is correctly position ed and aligned, mark around the inside of the slots, then remove the bracket.

9. Use a center-punch to mark the center of each slot, then use the smaller supplied drill bit to drill a 4.0 mm (

/32in) diameter hole.

Note: Drill at right angles t o the pedestal surface.

10. Hold the bracket in place then lightly tighten the four cross-head screws (No 10 x correctly aligned.

11. Replace the wheel, making sure that you locate the pin in the correct slot (slot 1 or slot 2).

12. Turn the wheel with the clutch off to check that the bracket is correctly positioned and aligned.

D5344-2

/4 in). As you do this, make sure the bracket is

Chapter 5: Installing the ST4000+ 79

Note: If the wheel is bent or the wheel drive is off center, the pin will move up and down in the back plate slot. As long as t he pin does not hit the top or bottom of the sl ot, this pin movement will not affect the drive unit’s performance.

13. When you have checked alignment, fully tighten all four screws.

Connecting to the control unit

When you have attached the pedestal bracket, you need to connect the wheel drive to the control unit. The drive unit is supplied with 4.5 m (15 ft) of 2-core cable with a waterproof socket at one end.

1. Connect the socket to the plug on the wheel drive’s motor tube:

• remove the socket cover

• pull back the plug cover

• align the locking ring, plug and socket as shown b elow

5 Installing the ST4000+

Socket

Contact

Locking ring

Socket coverMotor tube

Plug

• push the plug firmly into the socket

• turn the locking ring 90° cl ockwise

CablePlug cover

(pulled back)

D5409-1

Note: To remove the plug, pull back the cover and turn the locking ring 90° anti-clockwise. If you disconnect the socket for any reason, always use the attached rubber cover to protect the socket.

• make the connection waterproof by pulling t he plug cover across so it protects the plug and socket

80 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

2. Route the cable through the pedestal (or guard rail) and back to the control unit:

• if the pedestal has a cable duct, use this for the drive cable to

make sure that it cannot foul the steering mechanism

5 Installing the ST4000+

D5338-1

3. Run the drive cable back to the control unit and connect the two cores to the

Drive t erminals as shown.

Brown Blue

D3284-2

Chapter 5: Installing the ST4000+ 81

5.6 Rudder position sensor (wheel pilot option)

If you connect the optional Raymarin e rudder position sensor (part number: M81105) to your wheel drive system, the autopilot will use the accurate rudder position information to improve performance. The ST4000+ will also use this information to show the true rudder angle in Standby and Auto modes.

Note: You must fit a rudder position sensor to your wheel dri ve system if there is significant lost motion in your steering system or if you are installing the wheel drive on a hydr aulic steering system.

The rudder position sensor connects directly to the boat’s tiller arm or quadrant. Installing the sensor involves fiv e main steps:

• ensuring correct alignment

• securing the sensor to the boat

• attaching the sensor to the tiller arm

5 Installing the ST4000+

• checking alignment

• connecting to the control unit

187 mm (7.35 in)

140 mm (5.5 in)

Ensuring correct alignment

CAUTION:

T ake care to ensure corr ect rudder sensor alignment. If the sensor is not correctly aligned, the autopilot system will not perform accurately.

Vertical alignment

60 mm (2.4 in)

70 mm (2.75 in)

D5386-1

When viewed from the front (as shown in the illustr ation below), the connecting rod should be as level as possible, so the ball-joints at each end are level. It should also remain parallel to the tiller arm’s plane of rotation at all times.

Note: If misalignment exceeds +/-5° the ball-joints will bind or fail.

82 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

Front view - rudder amidships

Ball joints (level)

Connecting rod

Parallel

Sensor arm

Rudder position sensor

5 Installing the ST4000+

Tiller arm or quadrant

Top view - rudder amidships

Aft

Min: 101 mm (4 in)

Optimum: 140 mm (5.5 in)

Max: 190 mm (7.5 in)

90˚

Parallel

Mounting base

Cable entry

60˚ 60˚

Maximum permitted travel: +/- 60˚

Minimum: 75 mm (3 in)

Maximum: 310 mm (12 in)

D5387-1

Horizontal alignment

When viewed from above (as shown in the illustration above):

• the sensor arm must be between 75 mm (3 in) and 310 mm (12 in) from the tiller arm

• with the rudder amidships, the sensor arm should be at 90° to the connecting rod and directly opposite the cabl e entry point on the sensor body

• when the rudder moves from hardover to hardo ver:

• the sensor arm and the tiller arm must remain parallel to each

other at all times

• sensor arm movement must not exceed +/- 60°: if the steering

system drives the sensor arm beyond th ese limits it will damage the rudder position sensor

Chapter 5: Installing the ST4000+ 83

Securing the sensor to the boat

Location

Mount the rudder position sensor on a sui table base alongside the rudder stock and tiller arm.

Note: If necessary, you can install the sensor upside down. If you mount the sensor in this way, you must s wap the red and green cable connections at the control unit.

Securing the rudder position sensor

1. Hold the sensor in place, mark the mount ing holes, then remove the sensor (if required, use the template supplied).

2. Drill the pilot h oles using a 3 mm (

3. Attach the sensor to the mounti ng base using the three self-tapping screws supplied (p an-head No 8 x

/8 in) drill bit.

/4 inch).

5 Installing the ST4000+

Note: To make minor adjustments to the sensor alignment, loosen the screws, rotate the sensor body, then re-tighten the screws.

Attaching the sensor to the tiller arm

Attaching the tiller pin to the tiller arm

1. For optimum performance, mount the tiller pin on the tiller arm 140 mm (5.5 in) from the rudder stock center l ine.

Note: If necessary, you can fit the tiller pin anywhere between 101 mm (4 in) and 190 mm (7.5 in) from the rudder stock. This will not affect autopilot performance, but will slightly alter the scaling of the rudder angle display shown on the cont rol unit.

2. Hold the tiller pin in place (either along or across the tiller arm), mark the mounting holes then remove the tiller pin.

3. Drill pilot holes using a 3 mm (

4. Attach the tiller pin to the tiller arm using the two self-tapping screws supplied (countersunk No 8 x nuts and lock washers.

/8 in) drill bit.

/4 inch) or suitable bolts,

84 ST4000+ Wheel & Tiller Autopilots: Owner’s Handbook

Attaching the connector rod

1. Use a hacksaw to cut the threaded connector rod to length.

2. Screw the lock nut s onto the road and then the ball-pin so ckets.

3. Press the sockets ont o the pins on the sensor arm and tiller pin.

Note: To give the precise rudder position, t he rudder sensor has a built-in spring to remove any free play in the linkage to the tiller.

5 Installing the ST4000+

Checking alignment

Move the rudder from hardover to hardover and check that at all rudder angles:

• all moving parts of the sensor remain free from any obstructions

• the sensor and connecting rod remain accurately aligned

• the ball joints do not bind

Connecting to the control unit

1. The rudder positi on sensor is supplied with 10 m (32 ft) of cable. Route the cable to the control unit, taking into account the EMC installation guidelines (page 46).

2. Connect the four cores of the cable (color for color) to the terminals on the control unit as shown.

Note: If the standard cable is not l ong enough, your Raymarine dealer can supply a 10 m (30 ft) extension cable (part number: D173).

Rudder

Blue

Red

Green

Screen

D3283-3

Chapter 6: Setting-up the ST4000+ 85

Chapter 6: Setting-up the ST4000+

When you have installed the system, you need to check that the system is wired correctly and set up to suit your t ype of boat.

The sec tions in th is chapte r provide instructio ns for the followin g post-installation procedures:

Functional test

6.1

This consists of a few basic tests to confirm that you have connected the system correctly.

page 86

Check rudder sensor operation (if fitted)

6.2

This is necessary if you have fitted an optional rudder

page 90

position sensor (wheel drives only).

Initial sea trial

6.3

The purpose of the initial sea trial is to swing the compass (and align the heading), and check autopilot

page 91

operation and rudder gain.

Autopilot calibration techniques

6.4

This explains how to optimize the autopilot set-up for

page 98

your boat.

Note: You can perform further cu stomization after the sea tr ial, as described in Chapt er 7: Customizing the ST4000+.

6 Setting-up the ST4000+

Raymarine autopilot + ST4000+ Owner's Handbook Manual

Specifications and Main Features

Frequently Asked Questions

User Manual