Simrad TP10, TP30, TP20 Service Manual

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TILLERPILOT

TP10, TP20 & TP30

SERVICE MANUAL

Issue 4.0 17/09/03 SIMRAD

Simrad Margate Ltd

Star Lane, Margate, Kent CT9 4NP,UK

Telephone +44 (0) 1843 290290

Facsimile +44 (0) 1843 290471

E-Mail : productsupportmargate@simrad.com

CONTENTS

1 INTRODUCTION

1.1 Electronic PCBs

1.2 Mechanical Components

2 OPERATION

3 ASSEMBLY INSTRUCTIONS

4 MECHANICAL ASSEMBLY DRAWINGS

5 CIRCUIT DESCRIPTIONS

6 CIRCUIT DIAGRAMS

6.1 Circuit Schematics

6.2 Component Lists and Layouts

7 PROGRAMMING AND CONFIGURATION

8 FAULT FINDING

8.1 Common User Faults

8.2 Common Technical Faults

9 SPARE PARTS DETAIL

9.1 Spares

9.2 Service Aids

9.3 Accessories

10 TECHNICAL NOTES

The technical data, information and illustrations contained in this publication were to the best of our knowledge correct at the time of going to print. We reserve the right to change specifications, equipment, installation and maintenance instructions without notice as part of our policy of continuous development and improvement. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form, electronic or otherwise without prior permission from Simrad Margate Ltd. No liability can be accepted for any inaccuracies or omissions in the publication, although every care has been taken to make it as complete and accurate as possible.

Tiller Pilot TP10, TP20 & TP30

Section 1

Introduction

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1 INTRODUCTION TO THE TP10, TP20 AND TP30 TILLERPILOT

The TP10, TP20 and TP30 Tillerpilots combine highly sophisticated electronics with advanced software and powerful mechanical drive to provide accurate and reliable steering performance under a variety of different conditions with minimal current consumption.

TP10 – is suitable for tiller steered sailing yachts up to 10M (34 Ft) in length.

TP20 – offers the same facilities as the TP10 and is fully compatible with the Navico Corus

instrument system to provide a complete navigation system. Options offered include connection to an external compass, wind sensor or navigational receiver together with additional remote control facilities.

TP30 – offers the same facilities as the TP20 with an improved re-circulating ball screw drive and is suitable for tiller steered sailing yachts up to 12.8M (42 Ft) in length.

The main components of the Tiller Pilot are listed below:

Electronics PCBs

Early versions

TP10 PCB (TP10 only) TP30 PCB (TP 20 & TP30)

Current Versions. The same PCB is used for all products. The wiring loom carrying the NMEA data is left disconnected in the TP10.

TP10 / 20 / 30 Re-engineered PCB (Common to all)

Mechanical Components

General Assy : TP10 General Assy : TP20 General Assy : TP30

Tiller Pilot TP10, TP20 & TP30

Section 2

Operation

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2 OPERATING SIMRAD

This Service Manual only contains operating instructions for those features of the Simrad Tiller Pilot range that are not normally available to the end user. For details of normal operation please refer to the appropriate Simrad Instruction Manual.

Tiller Pilot TP10, TP20 & TP30

Section 3

Assembly Instructions

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3 ASSEMBLY INSTRUCTIONS

General Assembly : TP10

Motor and Drive Assembly. The Bottom Case Assembly is supplied fitted with appropriate

cables. Refer to detail in Drawing Number E03504 and insert the Push Rod Seal E00747, which has a taper inner bore, into the case with the larger bore of the seal facing outwards. Fit “O” Ring 190026, spacer E02870 and End Cap E02495 and push home. Fit Retainer E03084 and secure with 2 screws 200002 to hold the end cap, ensuring it is pushed fully in when the two screws are tightened. Using a small brush, grease the ‘trough’ area and the bore which houses the seal, “O” ring and spacer. Insert the Drive Assembly E03264 ensuring that the bearing slots into the bearing housing and the drive belt 280027 is fitted around the pulley. Insert the Motor Assembly E02788 fitted with front and rear Motor Mounts E02502 and E02503 ensuring that the blue wire is uppermost, the motor sits snugly into the bottom of the retaining slot and the drive belt is engaged over the motor drive pulley. Check that the motor, belt and drive screw assembly move freely. Fit Bearing Clamp E02497 on two Nylon Spacers 200115, one on each screw 200137, into the case bottom and secure the bearing with the two screws. Refer to the sketch below and check that the belt tension is within +/- 3mm.

Fit the Tiller Connector E02607 into the end of the Push Rod E02522 and screw in, finger tight.

Hall Effect PCB. Fit the Hall effect PCB onto the 2 pillars using 2 nylon washers 200037 as spacers between the pillars and the PCB, and 2 screws 200139. Ensure that the separation distance between the Magnets (E03208), seated in the 71 Tooth Pulley (E02505), and the Hall Effect Devices (140010) does not exceed 1mm.

Main PCB. Feed the power, motor and feedback leads through the 2 grommets 190036 and the appropriate grommet in the PCB Assembly cover and solder the connections to the PCB. Refer to drawing and push PCB Assembly firmly onto the four bosses in the PCB Cover E02680. Clip the compass Assembly E02637 into the Drilled PCB Cover E02680, it can only be fitted one way round, ensuring that the lugs on the compass assembly line up with the 2 holes in the PCB cover and push in. Refer to drawing E03504 and ensuring that the wires from the compass to the connector lay over the PCB, insert plug into the socket on the PCB. Ensure all wires are clear of, and not fouling the PCB cover seal, and position the PCB Cover complete with the PCB and compass into the Case Top Assembly E02612. Screw down the PCB cover with 6 screws 200139 and fully tighten. Position the two grommets into case top, and push home into the two slots. Wrap the ‘Wits” fixing 200196 around the cable loom, and using a screw 200139 fix into the top cover.

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Main Seal. Fit the pivot pin into the square section at the rear of the prepared bottom case ensuring that the pin hangs out of the case with the notch on the pivot facing towards the operating rod of the tillerpilot. Fold the metal pin into its recess in the lower case. Position the Case Seal E02498 onto the case bottom ensuring it is pushed fully into the grooved housing. Carefully lift the case seal from around the area of the pivot pin and using a cotton bud apply Dow Corning 1205 Primer 260029 to the case. Fill a small hypodermic syringe with Dow Corning 3140 Silicone sealant 260001 and run a small bead of sealant completely around the case seal in the area of the square as shown below.

Refit the seal onto the case.

Final Assembly. Carefully position the case top onto the bottom ensuring that the case seal is correctly located all round, squeeze the top and bottom halves of the case together, and fit the 10 screws 200088. Tighten down evenly all round in the sequence shown below:

Post Assembly Test. Remove the Tiller Connector E02607 and push the Tillerpilot Test Syringe Part No. TP-SRY over the end of the Push Rod E02522. Depress the syringe piston and release, the piston should return to its original position indicating that the integrity of the case seal has not been compromised during fitting. Remove the Test Syringe and refit the Tiller Connector.

General Assembly : TP20

Refer to Drawing No. E03505. Assembly is identical to the TP10 with the following exceptions:

Case Bottom. The case bottom includes a third wiring (communications) loom to carry NMEA and CANBUS data.

PCB Cover E02681. The PCB Cover is drilled with a third access point and grommet to accept the NMEA and CANBUS data leads.

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General Assembly : TP30

Refer to Drawing No. E03506. Assembly is identical to the TP20 with the following exception:

Drive Assembly E02618. The Drive Assembly employs a re-circulating ball screw. The assembly is held in place by the metal mounting plate sitting in the mounting slots in both top and bottom cases and drive belt tension is adjusted by the inclusion of spacing shims E02754 as required.

Tiller Pilot TP10, TP20 & TP30

Section 4

Mechanical Assembly Drawings

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4 MECHANICAL ASSEMBLY DRAWINGS

General Assembly : TP10 E03504 General Assembly : TP20 E03505 General Assembly : TP30 E03506

Tiller Pilot TP10, TP20 & TP30

Section 5

Circuit Descriptions

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5 CIRCUIT DESCRIPTIONS

Tillerpilot Common PCB Assembly

Introduction. The PCB Assembly is a common item to all Wheelpilots and Tillerpilots. However,

when the PCB is used in the TP10 or WP10 those components concerned with NMEA and CANBUS data are present but not in use, these components are highlighted in Red on the Circuit Diagram Drawing No. E03372.

Supply and Regulation. The Tiller Pilots are designed to work from a 12 V source. Protection against incorrect polarity is provided by D1 and D4. Capacitors C1and C3 are used as reservoirs to hold up the supply voltage and reduce any supply dips. Protection against over-voltage spikes is provided by Resistor R2 and Zener Diode ZD1 and Regulator REG1 provides a 5V regulated supply. Transient Voltage Suppresser TVS1 protects the MOSFET drive transistors, TR10 to TR13, from voltage spikes greater than +16V.

Microprocessor. Light Emitting Diodes LED1 to LED4 are driven from the microprocessor IC2 Ports P0.0 and P0.2 to P0.4 and turn OFF when the line goes HIGH via the transistor switches TR2 to TR5. When the transistors are off, resistors R32, R34, R36 and R38 provide a low current path for the LEDs to provide low level night illumination. The Audio Resonator AR1 is self resonating and switches ON when Port P0.5 goes HIGH via the transistor switch TR1 and resistors R59 and R60. The control key lines on Ports P4.0 to P4.4, normally pulled to +5V via resistors R7 to R11, are “scanned” by the microprocessor to detect if any of the switches have been operated and pulled the line LOW.

NMEA Data In. NMEA data is optically isolated by IC5 and then fed into Port P2.4 of the microprocessor. Transistors TR6, TR7 and TR8 and components D6, D7, D8, R17, R18 and R19 form a switch, protected from high voltages, driven from Port P0.1 of the microprocessor. The switch is used to apply the synchronisation pulse (HR200_SYNC) to the NMEA line for products employing a Hand (Remote) Controller.

CANBUS Data. CANBUS data in and out is driven by IC3 directly to and from Ports P2.1 and P2.0 respectively.

NB. Components shown in RED on the circuit diagram, Drawing No. E03372, are not in circuit when the PCB is used with WP10 or TP10. The cable loom to connect them is absent from these products.

Configuration Links. The Links, L1, L2 and L3, are used to configure the Microprocessor to either Wheelpilot or Tillerpilot operation and to model versions 10, 20 or 30 in accordance with the table below:

1 Model Link 1 Link 2 Link 3 TP 10 N / C N / C N / C WP 10 N / O N /C N / C TP 20 N / C N / C N / O TP 30 N / C N / O N / O WP 30 N / O N / O N / O

LEGEND N / C Normally Closed (soldered)

N / O Normally Open (unsoldered)

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Microprocessor Reset. Integrated Circuit IC6 is an integrated reset generator for the microprocessor which produces a reset LOW pulse of approximately 50mS duration at switch on and whenever a 5v supply failure occurs. In addition to the reset provided by IC6, the microprocessor has a built in watchdog timer which will create a reset if a software crash occurs for any reason.

Non-Volatile Memory (NVM). Integrated Circuit IC3 provides 1Kbit of E

memory for the retention

of important data after power down.

Fluxgate (Compass). Two anti-phase signals are provided from microprocessor Ports P1.7 and P1.6. These signals are buffered by TR15 and TR16 to provide a higher current drive to the excitation coil of the fluxgate. A reference voltage level of +2 volts is provided by R46 and R53 decoupled by C53. The 2 coils, mounted at right angles, provide output signals proportional to the sine and cosine of the Earth’s magnetic field. These signals are fed via the electronic switch IC9, to 2 dual slope integrating analogue to digital converters IC7 and IC 8 plus associated components. The outputs of the comparator IC7 are fed to the microprocessor Ports P1.4 and P1.5 which provide input capture facilities. Accurate timing of the conversion is kept by the microprocessor to provide simultaneous precision analogue to digital conversion of both sine and cosine signals to avoid errors created by multiplexing the inputs.

Motor Drive. The motor drive signals (MDRIVE_A and MDRIVE_B) are generated from the microprocessor at Ports P0.7 and P0.6, these lines being LOW when there is no drive and HIGH to drive. The drive outputs control IC10 and IC11 which are comparators set at threshold levels of +4V and +1V produced by the resistor network R71, R72 and R73. The comparators invert the signals and provide the current to switch the MOSFETs in stages which prevents both P and N channel MOSFETs on the same side of the “H-bridge” configuration, (i.e. TR10 and TR11 or TR12 and TR13), being partially switched on at the same time. When there is no drive, both N-channel MOSFETs TR11 and TR13 are switched on giving a direct short across the motor to the 0V line thus providing active braking

EMC. Capacitors with values of 100pF, 100nF and 1nF are extensively used to decouple noise from switched data lines. Two A.C. coupled connections labelled “CHASSIS” , routed via capacitors C63 and C64, were provided for interconnection to the internal metalwork for EMC purposes. Tests have confirmed that connection is not required.

Hall Effect PCB.

Introduction. The Hall Effect PCB is a generic item which can be used for both Tillerpilots TP10,

TP20 and TP30 and Wheelpilots WP10 and WP30. For Tillerpilots, the Hall Effect devices are mounted vertically into the PCB and horizontally for Wheelpilots. The circuit diagram for the Hall Effect PCB is given in Drawing No. E03182.

Feedback. Two Hall Effect sensors HE1 and HE2 are mounted on the Hall Effect PCB and sense the rotation of 2 small bar magnets mounted 180

apart in the pulley wheel. This produces a quadrature feedback output, at logic levels, FB1 and FB2. The PCB is powered from the host unit +5V regulated supply, the line being filtered by C1, and signals FB1 and FB2 are fed back to the microprocessor via pull-up resistors on the host unit PCB.

Tiller Pilot TP10, TP20 & TP30

Section 6

Circuit Diagrams

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6 CIRCUIT DIAGRAMS

Circuit Schematics

Common PCB Circuit Diagram E03372 Hall Effect PCB Circuit Diagram E03182

Component Lists and Layouts

Common PCB Assembly Detail E03178

Hall Effect PCB Assembly Detail E03184

Early Version WP10 / TP10 Assembly Detail E03181 Early Version WP30 / TP20/30 Assembly Detail E03178 (Pre Iss. 6)

Tiller Pilot TP10, TP20 & TP30

Section 7

Programming and Configuration

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7 PROGRAMMING AND CONFIGURATION

This Service Manual only contains programming and configuration information for those features of the autopilot which are not normally available to the end user. For details of normal programming and configuration please refer to the appropriate user manual.

Tiller Pilot TP10, TP20 & TP30

Section 8

Fault Finding

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8 FAULT FINDING

Common User Faults. Common user faults are included in the Diagnostics

Guide included in the user manual.

Common Technical Faults. None yet identified.

Tiller Pilot TP10, TP20 & TP30

Section 9

Spare Parts Detail

9 SPARE PARTS DETAIL

Spares Packs

TPPK1 TP10 / 20 MECHANICAL ASSEMBLY TPPK2 TP10 TOP CASE TPPK3 TP20/30 BOTTOM CASE TPPK4 TP10 PCB CASE TPPK5 WITHDRAWN TPPK6 FLUXGATE ASSEMBLY TPPK7 MOUNTING PIN, CUP AND CONNECTOR TPPK8 MOTOR ASSEMBLY TPPK9 FEEDBACK KIT TPPK10 DRIVE BELT TPPK11 CASE SCREW PACK TPPK12 PUSH ROD SEAL PACK TPPK13 CASE SEAL PACK TPPK14 TP100 TOP CASE TPPK15 GREY BOTTOM CASE TPPK16 TP20 TOP CASE TPPK1 7 TP20/30 PCB CASE TPPK18 WITHDRAWN TPPK19 WITHDRAWN TPPK20 TP30 TOP CASE TPPK21 COMMON PCB ASSEMBLY TPPK22 TP30 MECHANICAL ASSEMBLY TPPK23 TP300CX TOP CASE TPPK24 TP200CX TOP CASE TPPK25 TP10 BOTTOM CASE

9.2 Accessories

TB30 TILLER BRACKET 30mm TB60 TILLER BRACKET 60mm TB90 TILLER BRACKET 90mm TB120 TILLER BRACKET 120mm PB30 PEDESTAL BRACKET 30mm PB60 PEDESTAL BRACKET 60mm PB90 PEDESTAL BRACKET 90mm CB1 CANTILEVER BRACKET PRE30 PUSH ROD EXTENSION 30mm PRE60 PUSH ROD EXTENSION 60mm PRE90 PUSH ROD EXTENSION 90mm PRE120 PUSH ROD EXTENSION 120mm PRE150 PUSH ROD EXTENSION 150mm PRE300 PUSH ROD EXTENSION 300mm

9.3 Service Aids

TP-SRY TILLERPILOT TEST SYRINGE

Tiller Pilot TP10, TP20 & TP30

Section 10

Technical Notes

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10 TECHNICAL NOTES

PS 139 Identification of Tillerpilot variants PS 140 Improved bonding of drive pulley to motor drive shaft PS 173 Positioning of Feedback PCB PS 174 Re-engineered Main PCB

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Technical Note

FOR THE ATTENTION OF THE SERVICE MANAGER

NUMBER : PS 139

PRODUCT : Tillerpilot – TP100 / TP200CX /

TP300C / TP300CX / TP10 / TP20 / TP30

SUBJECT : Identification of Variants

DATE : 1 October 1999

There are a number of variants of Tillerpilots currently in use which, though similar in appearance, are built and operate differently. Positive identification is therefore essential when ordering spare parts to ensure that the correct item is dispatched.

The main aids to identification are:

1. Lack of a Hall Effect PCB indicates Back emf, earliest, version.

2. Hall Effect PCB with microprocessor mounted in socket indicates intermediate version.

3. Hall Effect PCB with surface mount microprocessor indicates latest version.

A table of variants identified by serial number and drawings, General Assembly, PCB Assembly and Circuit Diagram, to aid identification of the different PCBs, is given below:

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TILLERPILOT VARIANTS. The Tillerpilot variants can be conveniently divided into 3 groups:

1. Feedback produced from the motor back emf.

2. Feedback produced from a Hall Effect PCB.

3. Introduction of Surface Mount microprocessor (SMu)

TP100 Back emf

TP200CX Back emf

TP300C Back emf

TP300CX Back emf

TP100 Hall Effect

TP200CX Hall Effect

TP300CX Hall Effect

TP200CX SM u

TP300CX SM u

u No. E02517 E02520 E02520 E02520 E03190 E03189 E03189 E03398 E03398

Man from Start Start Start MK3143 PE8818 PB1484 OD6415 Not Yet In Production Ser No. to PE8818 PB1483 MI2954 OD6414 Continue Continue Continue

Gen Assy E02587 Not Issued E02616 E02616 E03299 E03262 E03300

PCB Assy E02515 E02518 E02518 E02518 E03181 E03178 E03178

Cct Diag E02549 E02550 E02550 E02550 E03179 E03176 E03176

TP10 SM u

TP20 SM u

TP30 SM u

u No. E03398 E03398 E03398

Man from OL7635 OL1384 OL7190 Ser No. to Continue Continue Continue

Gen Assy E03504 E03505 E03506

PCB Assy E03181 E03178 E03178

Cct Diag E03371 E03372 E03372

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Technical Note

FOR THE ATTENTION OF THE SERVICE MANAGER

NUMBER : PS 140

PRODUCT : Tillerpilot – TP100 / TP200CX /

TP300C / TP300CX / TP10 / TP20 / TP30

SUBJECT : Improved bonding of drive pulley

to motor drive shaft.

DATE : 1 October 1999

The 20 Toothed Pulley Part No. E02839 is a push fit onto the motor drive shaft, see sketch below, and the bonding is enhanced with Loctite 270 Part No.

260025. Instances have occurred where the bonding has weakened resulting in reduced drive efficiency or operational failure. An improved bonding adhesive Loctite 638 Part No. 260063 has been identified and approved for use. All Tillerpilot repairs should be carried out using the new adhesive.

The new bonding agent has been used in the manufacture of all Tillerpilots with the alphabetic prefix PC, 1 March 1999, and subsequent serial numbers. The Product Support Department should be informed of any units found to be slipping post production date 1 March 1999.

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Issue 4.0 22/09/03 SIMRAD

Simrad TP10, TP30, TP20 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual