AUTOHELM Z155 User manual

ST3000 Autopilot
ST3000 Autopilot Service Manual 83004-2 1
Warning
CE Marking of Equipment/Replacement Parts
IftheAutohelmequipmentunderrepair,test,calibration,installationorsettingtoworkcarriestheEuropeanCEmark,
onlypartsandcomponentssuppliedorapprovedforsuchusebyRaytheonshouldbeusedinordertomaintain
compliancewiththerelevantCErequirements.
Incorporation,useorattachment,byanymeans,ofpartsorcomponentsnotsuppliedforornotapprovedforsuchuseby
Raytheonor,ifsuppliedorapprovedforusebyRaytheon,notproperlyfittedinaccordancewithinstructionspublished,
providedorrecommendedbyRaytheon,maycausetheequipmenttomalfunctionand,inparticular,tobecomeunsafeor
tonolongermeettherelevantCErequirements.Inthesecircumstances,RaytheonMarineEuropeLtdexcludesliability
tothefullestextentpermissibleinlawforanylossordamageincludinganyliabilityforitscontributiontosuchlossor
damagebyitsnegligentactsoromissions.
Z155,ST3000 Autopilot
ServiceManual
D296

ST3000Autopilot
2ST3000 Autopilot Service Manual 83004-2
Chapter 1. Before Dismantling
Beforedismantlingtheautohelm ST3000checkthe phaseof the autopilot (If
PCBcondition allows)by driving thepilot, in standbymode,withthe course
change keys.
+10key –10key
Aftfacingactuator Clockwiseactuatorrotation Anticlockwiseactuatorrotation
Forwardfacingactuator Anticlockwiseactuatorrotation Clockwiseactuatorrotation
Allnewspares PCBs arefactory settooperatethe pilotwiththe driveunit
facingaft.A replacement PCB foran installationwith thedrive unit facing
forwardrequiresresetting.
To reset theoperating sense press the +1° and -1° course keys togetherfor
5 seconds.
Theunit beepsfor10seconds toconfirm changeoverandthe displayshows
thenewsetting, either‘Port’(actuatorsprocketfacingforward)or‘Starb’
(actuatorsprocketfacingaft’).
Theautopilot maybe calibrated tto suita particularvessel.Note the
calibrationsettings andset up thenewPCB if required.
Ifthe sparesPCB contains softwareof ahigher issuethan beforethen the
relevantOperating Supplement mustbesupplied when theequipment is
returnedto thecustomer.
Note: ReplacementPCBsrequiresettinguptoST3000.
Referto Autopilottype selection on page3 forinstructions.

ST3000 Autopilot
ST3000 Autopilot Service Manual 83004-2 3
Chapter 2. Special Functions
Display test
Adisplaytest feature includedin ST3000softwarechecksthat the display
assemblyhas beenre-fitted correctly.Displaytest is switchedon by
momentarily pressing the-1° and+10° keystogether
Thedisplayscrolls allfourcharactersthrough from0to 9andthen displays
eachannotation.This sequencecontinuesuntil eitherthe‘Standby’or‘Auto’
keyis pressedorthe unitis powered down.
Autopilot type selection
TheAutohelmrangeof cockpitpilots allcontain thesame softwarebuteach
pilotruns adifferentprogram.This iscontained withinthe same chipbut
needsto beselected asfollows:
1. Pressthe -10° and+1° degreekeysuntilthe displayshowsthepilot type
number(Approximately5seconds)
2. Pressthe -10°and +1°degree keysagain untilthe display flashes the
pilottype number(Approximately5 seconds)
3. Selectthe correct pilottype usingthe +1°and-1° degreekeys
4. Savethesetting bypressing the-10° and+1° degree keysuntil the
normalStandbydisplayappears (Approximately 2 seconds)
Note:ChangingAutopilottype willclear allcalibrationsettings.
Display of software code
The softwarecode ofthe pilotcan be displayedas follows:
1. Switchthe pilotto standbymode
2. PresstheStandbykeyuntilthe displayshowsPfollowedbyanumber.
(Approximately 10 seconds)
Thenumberindicates theversion of softwarefitted,e.g.P0 6indicates
Version6software
Calibration lockout
Tostop access to compass linearisation andcalibration functions on the
ST3000 autopilot:
1. Pressthe -1°and Standbykeysfor10 secondsuntil thedisplayshows
CALON(orCALOFF)
2. TogglebetweenCALON andCAL OFF usingthe -1°and+1° keys
3. Storethe selectedsetting bypressingthe -1°and Standby keysfor10
seconds,whenthe controlhead returns to normaloperation.
Anyattemptto linearise thecompass orenter calibrationwhen the lockout
functionis enabled will resultin thedisplayshowing Cal Off.In thiscondition
theuser cannot changeanysettings.

ST3000Autopilot
4ST3000 Autopilot Service Manual 83004-2
Chapter 3. Functional Test
Overall function
Change motor.
Restart.
Change faulty
item(s). Restart.
Connect actuator to
Control Head and apply
power to unit
Hold unit vertical.
Rotate it in clockwise
direction; check actuator
rotates anti-clockwise
(STBD set up) or
clockwise (PORT set up)
Check fluxgate
(SECT 5.6)
No
Yes
OK Change PCB.
Restart.
Unit beeps, and shows 3000
and then displays a magnetic
heading, with flashing 'C'
Press & Hold +10 key.
Check motor runs.
OK No
Yes
Press & Hold -10 key.
Check actuator runs.
Disconnect power and
remove drive module.
Disconnect motor spade
terminals and apply 10V DC
to motor terminals. Check
motor runs. (See Figure 3).
OK
Press AUTO and check
display shows 'A'
followed by a heading.
OK
Change PCB.
Restart.
OK
No
Yes
Change motor.
Restart.
No
Yes
OK
Hold unit vertical, rotate
it an anti-clockwise direction;
check actuator rotates
clockwise (STBD set up) or
anti-clockwise (PORT set up)
OK
Unit OK
No
Yes
No
Yes
OK No
Yes
Change PCB.
Restart.
Change fluxgate.
Restart.
No
Yes
OK
Reverse 10V on motor.
Check motor runs.
Check motor connections
and wires.
OK
Change PCB.
Restart.
No
Yes
No
Yes
D4103-1

ST3000 Autopilot
ST3000 Autopilot Service Manual 83004-2 5
Fluxgate compass assembly
Removethefluxgate assembly(see Figure2).
Thecompass can becheckedwith a DVM asfollows:
Connectmeteracross Resistance
1and2 <10ohms
3and5 < 5ohms
3and4 < 5ohms
1and3 Opencircuit
D4104-1
12345
No connection
Figure1. Fluxgateelectricalconnections

ST3000Autopilot
6ST3000 Autopilot Service Manual 83004-2
Chapter 4. Disassembly/Assembly
SeaTalk Deck Plug
Screw (x2)
Pin carrier
Plug pin screw (x3)
Plug pin (x3)
Metal sleeve (x3)
Brown wire
Blue wire
Yellow
wire
Plug body
Cable
clamp
Cable
seal
Clamp
nut
Cable assembly
(3016-104)
D4107-1
Assemble sleeve to wire.
Pinch sleeve with pliers. Insert
sleeve into plug pin and tighten
screw to retain. Cut off excess
metal sleeve to prevent short
circuit.
Repeat process for remaining
wires.
Electrical connections
Wirecolour Description
Brown +12Vnominalsupply
Blue 0Vsupply
ST3000 Autopilot Display Unit
Spare parts list
Theitem numbersreferto Figure2:ST3000Autopilotdisplayunit.
Item SpareDescription Part No. Comments
– ControlHead Q056 Completehead
LCDkit, including Q053
4 LCDsurround
5 LCD
6 Elastomer
7 Diffuser
8 Reflector
27 Lockingwedge(x5)
9 PCBassembly Q044 LCDnotincluded
13 Fluxgateassembly M022
30 SeaTalkdeckplugassembly D326

ST3000 Autopilot
ST3000 Autopilot Service Manual 83004-2 7
Notes: A. Keypads come bonded to facia on later units. B. Ensure that the fluxgate loom is formed around the outside of the rear case pillar. Failure to do so may result in the gimbal action being impaired and the autopilot performance degraded. C. Early production units have a spacer (29) which is effectively replaced by using 4 wedges (27) on later units.
1 29 (Note C) 4 5 6 7 8 9 27 (x4)
2 (x6)
(Note A) 3 (x6) 28
10 14
16 17 18 19
20
15 (x4)
21 22 23 24 25 26
Note B
1. Facia 2. Keypad (x6) 3. Actuator (x6) 4. LCD surround 5. LCD 6. Elastomer connector 7. Diffuser 8. Reflector 9. PCB 10. Seal 11. Gimbol support (x2) 12. Gimbol support screw (x2) 13. Fluxgate assembly 14. Rear case 15. Case screw (x4) 16. Fluxgate ground
Insert wedge (27) as shown to secure display bezel leg
Wedge (27)
PCB (9)
Display bezel (4)
Early units Later units
Important: The fluxgate loom in some
early units is wired differently.
17. Fluxgate drive 18. Fluxgate sense B 19. Fluxgate sense common 20. Fluxgate sense A 21. SeaTalk data (yellow) 22. Shield (screen - black sleeve) 23. +12V supply (brown) 24. Ground (blue) 25. Motor (black) 26. Motor (red) 27. Wedge (x4) 28. Shim 29. Spacer (early units only) 30. SeaTalk deck plug assembly
11(x2)12 (x2)13
D4101-1
30
Figure2:ST3000Autopilotdisplayunit

ST3000Autopilot
8ST3000 Autopilot Service Manual 83004-2
ST3000 Drive Actuator
Spare parts list
Theitem numbersreferto Figure3:ST3000Autopilotdriveactuator.
Item SpareDescription Part No. Comments
– ST3000drivemodule Q45 Completedrive
ST3000Gearbox/Drive
assembly, including Q102
1 Pin
2 Clutchflange
3 Gearboxhousing
4 Seal
2,1 Clutchflange&pin H006 AlsopartofQ102
7 Motor Q101
10 Pod H001
Motor replacement
Ifthe gearboxisnoisywhen themotor is replaced,removemotor,rotate
gearboxa smallamount, and refit.

ST3000 Autopilot
ST3000 Autopilot Service Manual 83004-2 9
D4102-1
Pip Blue (M2) Brown
(M1)
Blue (M2) Brown (M1)
Red dot
1 2 3 4 5 76
8 9 10
17 16 15
11 12 13 14
1. Pin 2. Clutch flange 3. Gearbox housing 4. Seal 5. Flux ring 6. Location screw 7. Drive motor 8. Cap 9. Seal
10. Pod 11. Shroud 12. Grip 13. Seal 14. Location ring 15. Receptacle 16. Socket 17. 'O' ring
Note: Connect a 10v dc supply to the actuator plug and measure the running current of the drive unit. < 2A - Drive healthy > 2A - Drive faulty
Figure3. ST3000DriveActuator

ST3000Autopilot
10 ST3000Autopilot Service Manual 83004-2
Chapter 5. PCB Details
D4108-1
Figure4: CircuitDiagram