Raymarine PowerPilot User Manual

Distributed by

Any reference to Raytheon or

RTN in this manual should be

interpreted as Raymarine.

The names Raytheon and RTN

are owned by the

Raytheon Company.

Installation & Operating Handbook

Nautech Limiied, Anchorage Park, Portsmouth

Telephone [phone], Telex 86384 NAUTEC G.

Hampshire, PO3

STO,

England.

CONTENTS

Page

1. General Description

1.1.1 Course Computer

1.1.2

Control Unit

1.1.3 Fluxgate Compass
1 .1.4 RuddepReference Transducer

1.1.5

Auxiliary Alarm

1 .1.6 Radio Navigation Interface

Hydraulic Drive Units

1.2

1.2.1 Type 0 Hydraulic Drive

1.2.2 Type 1 Hydraulic Drive

2. Installation

2.1 .l Course Computer

2.1.2 Control Units and Radio
Navigation Interface

2.1.3 Fluxgate Compass

2.1.4 Rudder Reference Transducer

2.1.5

Accessories
Hydraulic Drive Unit

2.2

2.2.1 Type 0 Installation

2.2.2 Type 1 Installation

2.3 Cabling and Power Supplies

2.3.1 Signal Cabling

2.3.2 DC Power Supplies

3. Operation

3.1

Basic Principles

3.2 Controls

3.2.1 Fixed Control Unit

3.2.2 Hand Held Control Unit

3.2.3 Operating Mode Indication
and Course Display

3.2.4

Off-Course Alarm

Functional Test Procedures

3.3

3.3.1 Setting Up

3.3.2 Functional Test Procedure

3.3.3 Drive Unit Test Procedures

10
11

12
13
13
14
14
15

17

2
3
3
3
4 8.
4
4

5
5

10.

5
6

7

7
9

17
18
18
19

20
21
21
21
21
22

6.

Maintenance
Fault Location Procedure 27

7.
Warranty, After Sales

Service
U.K. Service Centres 30

9.
Overseas Representatives 31

26

28

4.

Sea Trials

First Sea Trials

4.1

Rudder Control Adjustment

4.2

5. Operating Hints

5.1

Unsatisfactory Steering
Performance

23

23

24

25

25

1. GENERAL DESCRIPTION

Congratulations on choosing the

Autohelm

outstanding self steering capability for a

wide range of modern powercraft

equipped with hydraulic steering.

The PowerPilot uses microprocessor
based technology and easy to use control
pads to give you total command under

autopilot control without the need for
constant adjustments.

The

world’s largest producer of Marine
autopilots with Technical Advice, Service

and Support ready to help you get the
most from your Autohelm.

PowerPilot.

PotierPilot

It offers

is manufactured by the

FLUX GATE

The PowerPilot is modular and designed
for easy installation with flexibility to cope
with the variation of individual craft and
owner specifications. It is supplied as
standard with the course computer, one
control unit, fluxgate compass, hydraulic
drive unit, and rudder reference
transducer. The basic

PowerPilot can be extended to suit

individual requirements. The basic system
is illustrated below in Figure 1.

Autohelm

1.1 .l Course Computer

The course computer houses the
microprocessor, electronic control circuitry
and power amplifier to drive the hydraulic

pump.

The course computer is splash proof
only and must be mounted in a dry and
protected position.

1 .1.2

Control Unit

The six button control unit is fully
waterproof and is mounted close to the
steering position. It is designed for surface
mounting, or alternatively can be bracket
mounted if required (bracket mounting kit
Cat. No. D105).

A second control unit (Cat. No. 2054)
and a hand held control unit (Cat. No.

2056) can be added to the system. The
hand held control unit is fitted with a 6m

(19ft) wander lead and plugs into a

bulkhead mounted waterproof socket.

288mm

(11.4in)

I

II

Fig. 1 BASIC SYSTEM

2

1.1.3 Fluxgate Compass

The fluxgate compass has been especially

developed for marine application. The
compass contains a gimbal mechanism to
permit accurate readings with pitch and
roll movements up to
is bulkhead mounted below decks and
connects directly to the course computer.

t40°.

The compass

92mm

(3.6in)

z
”
”

3

1.1.4 Rudder Reference
Transducer

The rudder reference transducer provides
the course computer with a precise
rudder position. It is mounted on a
suitable base adjacent to the rudder
stock. The interconnecting cable connects
directly to the course computer connector
unit.

1.1.5 Auxiliary Alarm (Cat. No. 2035)

The autopilot is provided with an

automatic off course alarm system which
sounds from all control units and provides
sufficient audible warning under most
conditions. In cases where a high power
alarm is necessary, an auxiliary alarm can
be fitted. The auxiliary alarm is connected
to the main connector unit via a two
core cable.

1.1.6 Radio Navigation Interface

(Cat. No. 2057)
The PowerPilot can be interfaced to any

Loran, Decca or Satellite Navigation

receiver having a suitable cross track error
output to NMEA0180/0182/0183. The
radio navigation interface computes the
course adjustments to enable the

PowerPilot to steer to a selected waypoint.

The unit is waterproof and designed for
surface mounting (normally adjacent to
the Loran/Satellite Navigation receiver). If
required the unit can be bracket mounted
using the bracket mounting kit
(Cat. No. D104).

4

-1

82Smm

(3.2%)

213mm (8.37in)

1.2 HYDRAULIC DRIVE UNITS

The PowerPilot is available with one of
two hydraulic drive units, depending on
the size of the vessel and the
displacement of the ram.

The vessel size and displacement
recommendations given below apply to
directly driven steering systems. When a
power steering system is fitted the vessel

1.2.2 Type 1 Hydraulic Drive

The hydraulic drive unit consists of a
precision gear pump with integral valve
block driven by a continuously rated servo
motor. The pump drive motor is connected
directly to the course computer which also
regulates peak pump pressure and
eliminates the need for end stroke limit
switches.

size and displacement recommendations
can be ignored.

1.2.1 Type 0 Hydraulic Drive

The type 0 hydraulic drive unit consists of
a twin cylinder piston pump powered by a
small but powerful reversing electric
motor.

The high volumetric efficiency of the
piston pump provides precise control,
with the twin pistons offering smoother
and quieter operation than would be
found with a single cylinder design.

Descriotion Size

Maximum Vessel Size 8m
Maximum Vessel

Displacement 3000 Kq (6600
Maximum Ram Capacity
Minimum Ram Capacity
Regulated Peak Pressure
Peak Flow Rate (Unloaded) 490cdmin (30inYmin1

Power Consumption
(Typical Averaqe)

km

Type

Double Ended (Balanced)

(26ft)

13Occ (8.0ina)

5Occ (3in’)

30 bar (450lb

1.5-2.5 amps

Ibs)

in?)

Description Size

Maximum Vessel Size 1 lm (36f~)
Maximum Vessel

Displacement 5500 Kg (12000
Maximum Ram Caoacitv 23Occ (14in’)
Minimum Ram Capacity
Reaulated Peak Pressure

Peak Flow Rate
(Unloaded)

Poher Consumption

(Typical Average)
Ram Type

I-

13Occ (8inj)

50 bar (75ODs.i)

11

OOcdmin)

(67inYmin

3.5-6 amps

Single or Double Ended

(unbalanced or balanced)

190mm (7.5in)

Ibs)

w

2.

INSTALMTION

WARNING

The Autohelm PowerPilot requires correct
installation if it is to provide accurate safe
self steering. Whilst designed for simple
installation we strongly recommend that
the system should be installed

professionally or alternatively professional
advice be obtained if you intend to install
the system yourself.

The manufacturers can accept no
liability for any claims arising from
incorrect installation or product useage.

2.1.1 Course Computer

Mounting Position - Below Deck
The course computer should be positioned

in use we strongly recommend the use of a
protective cover (optional extra
Cat. No.

in a dry protected area of the vessel free
from high operating temperatures and
excessive vibration. It can be mounted in
any attitude. Care must be taken to allow
at least

15mm

(6in) clearance all round to
aid heat dissipation from the power
amplifier in the unit. Do not mount in the
engine room.

WARNING

Safe operation of the PowerPilot requires
that the control unit be mounted within
easy reach of the helmsman when in the
normal steering position. Position the
control unit to ensure this requirement is
met.

DO NOT position the course computer

so that it will:

l

Receive any direct water splash/spray

(from Bilge/Hatch etc).

l

Be liable to physical damage from heavy

items.

0

Be covered by other equipment or

Mounting Instructions

The unit is attached with reusable positive
locking pads. In most cases, the pads may
be stuck directly onto the mounting
surface.

l

onboard gear.

l

Be close to major sources of

transmitted energy (Generators/S%

radios, Aerial Cables etc).

Mounting Instructions

l

Remove Terminal box lid (Fig. 2).

l

Unscrew two internal thumb retaining

l

nuts (Fig. 2).

l

Unplug terminal box and mounting

spine.

l

Position terminal box and mounting
spine in correct location, mark off and
pilot drill for the 5 self tapping screws
supplied (Fig. 3).

l

Screw terminal box and mounting spine
into place.

l

Plug course computer unit to terminal
box. Retighten thumb retaining screws.

The course computer is now ready for
wiring (see 2.3).

DlOl).

Using the template supplied, select the
control unit position, mark off and drill
the

17mm (5/8in)

hole for the

interconnect cable.

Attach the positive-lock pads to the rear

of the control unit (Fig. 4).

2.1.2 Control Units

Mounting Position

be mounted close to the steering stations.
The unit is fully water-proof and suitable
for external location. If the control unit is
permanently exposed when the boat is not

-

Control units must

l

Thoroughly clean the mounting surface

with alcohol (or equivalent) and allow

to dry.

7