AUTOHELM Z219 User manual

Z219 ST80 Active Wind Transducer Service Procedures
D2720-1
ST80 Active Wind Transducer
ST80ActiveWindServiceProcedures 83067-1 1
Z219

CE MARKING OF EQUIPMENT/REPLACEMENT PARTS
WARNING
If the Autohelm equipment under repair, test, calibration, installation or
setting to work carries the European CE mark, only parts and compo-
nentssuppliedorapprovedforsuchusebyAutohelmshouldbeusedin
order to maintain compliance with the relevant CE requirements.
Incorporation, use or attachment, by any means, of parts or components
not supplied for or not approved for such use by Autohelm or, if supplied
or approved for use by Autohelm, not properly fitted in accordance with
instructionspublished,providedorrecommended byAutohelm,may
cause the equipment to malfunction and, in particular, to become unsafe
or to no longer meet the relevant CE requirements. In these circum-
stances,RaytheonMarineEuropeLtdexcludesliabilitytothefullestextent
permissible in law for any loss or damage including any liability for its
contribution to such loss or damage by its negligent acts or omissions .
ST80 Active Wind Transducer
2 ST80ActiveWindServiceProcedures 83067-1
Z219

Contents 1. Description ....................................................................5
2. Operation ......................................................................5
3. Disassembly...................................................................6
4. Assembly .......................................................................7
5. Functional Test ...............................................................9
5.1 Preliminary Inspection ........................................................9
5.2 Test Equipment ..................................................................9
5.3 Functional Test Flowchart................................................. 10
6. Spares Numbers ..........................................................11
7. Circuit Description .......................................................12
7.1 Power Supplies................................................................12
7.2 External Signals ...............................................................13
SeaTalk............................................................................... 13
Anemometer....................................................................... 13
Wind Vane ...........................................................................13
Connector Signals (Main PCB) ..............................................14
SeaTalk Cable ................................................................... 14
PL1 (Wind Vane) ................................................................14
PL2 (Anemometer) ............................................................ 14
7.3 Signal Processing............................................................15
Microprocessor...................................................................15
Autohelm ASIC .................................................................... 15
8. PCB Details..................................................................17
8.1 PCB Layout ..................................................................... 17
8.2 PCB Component Lists ......................................................19
Anemometer PCB, Components......................................... 19
Vane PCB, Components.....................................................19
Main PCB, Surface Mount Components, component side ....19
Main PCB, Conventional Components, component side .......19
ST80 Active Wind Transducer
ST80ActiveWindServiceProcedures 83067-1 3
Z219

Main PCB, Surface Mount Components, underside..............19
Main PCB, Conventional Components, underside.................20
Illustrations
Figure 1 Exploded View...............................................................8
Figure 2 Test Equipment Connection............................................9
Figure 3 Block Diagram ............................................................ 16
Figure 4 Component Layout......................................................17
Figure 5 Circuit Diagram........................................................... 18
ST80 Active Wind Transducer
4 ST80ActiveWindServiceProcedures 83067-1
Z219

1. Description
This section of the Maintenance Manual covers the servicing procedures
for the ST80 Active Wind Transducer, Product Code Z219.
The transducer measures wind speed and direction using an anemometer
cupassembly and a windvane,each mounted on independentshaftsat
either end of a pod containing electronic circuitry.
Electronicsignals generatedbyan opto-electric integratedcircuitand a
mechanical interrupter coupled to a shaft on which a cup assembly ro-
tates.When the cups are drivenbythe wind the generated signalsare
convertedintodatarepresentingwindspeed.
The wind vane rotates on a shaft to which a magnet is attached. Hall effect
integrated circuits detect the position of the magnet in two orthagonal
axes, and the output signals of the circuits are converted to data repre-
senting the position of the wind vane.
Position and speed data are broadcast on the SeaTalk bus at one - second
intervals, thus becoming available to other elements of the system.
Parametersdefining upper and lower limitsofwind speed and angle, both
true and apparent, can be entered (through other elements of the system)
tocause alarmsto begenerated whena specifiedlimitisexceeded.
Alarms are also broadcast on the SeaTalk bus at intervals of one second
while the alarm condition exists.
2. Operation
Thereare nooperationalactivities requiredtoprepare theActiveWind
Transducer for servicing.
ST80 Active Wind Transducer
ST80ActiveWindServiceProcedures 83067-1 5
Z219

3. Disassembly
Referto Figure 1,ExplodedView.
When handling any of the PCBs, linen or other suitable material (
not nylon)
gloves should be worn if an anti - static mat and grounding strap are not
used.If glovesarenotavailable, handle thePCB by theedges only.
1. Releasethe grubscrews(12) holdingthewind vane(1)and anemom-
eter cup assemblies (11). Back the screws just enough to free the
assemblies without allowing the nuts (4) to fall out. Remove the vane
andcupassemblies
2. Pulltheanemometer head (10) out of the main body (8) andunplugthe
ribbon cable (5) from PL1. To release the cable, lift the top bar of the
connectorandslipthecable free(see detailin Figure1)
3. Pullthe wind vanehead (2) outofthe main body(8) and unplugthe
ribbon cable (5) from PL1. To release the cable, lift the top bar of the
connectorandslipthecablefree(SeedetailinFigure1)
4. Slidethe PCB (7)out of themainbody through thetop (wind vaneend)
5. To release the PCB, unsolder the SeaTalk cable (6) from the contact
pads(seedetailonFigure1).
ST80 Active Wind Transducer
6 ST80ActiveWindServiceProcedures 83067-1
Z219

4. Assembly
Referto Figure 1,ExplodedView.
When handling any of the PCBs, linen or other suitable material (
not nylon)
gloves should be worn if an anti - static mat and grounding strap are not
used.If glovesarenotavailable, handlethePCB bytheedges only.
1. SoldertheSeaTalkcable(6) tothemainPCB(7)contactpads(see
detail, Figure 1 for cable colours and connections)
2. Lift the top bars of main PCB connectors PL1 and PL2 and insert the
ribboncables(5). Press the bars down tosecurethecables (see detail
in Figure 1). For both connectors on the PCB, the coloured side of the
cable faces the centre of the PCB
3. Slidethe PCB intothe main body (8)fromthe top (windvane end),
threading the lower ribbon cable through as the PCB enters. The PCB
is tapered and fits narrow end first
4. CheckthattheO-rings(3)ontheanemometer(10)andwindvane(2)
heads are not damaged, distorted or loose and are free of grease and
dirt.Replaceorcleanas necessary
5. Plugthelower ribbon cable (5) into PL1 of the anemometer PCB(9)
(see detail in Figure 1), ensuring that the cable is not twisted. The
coloured side of the cable faces the outer edge of the board
6. Push the anemometer head (10) into the main body (8), ensuring that
thehead isfullyhome andtheribbon cable(5)is nottwisted
7. Plugthe lowerribboncable (5)intoPL1 ofthewind vanePCB(4) (see
detail in Figure 1), ensuring that the cable is not twisted. The coloured
side of the cable faces the outer edge of the board
8. Pushthewind vane head (2) into themainbody,ensuringthat the head
isfullyhome and the ribbon cable (5)isnottwisted
9. Fit the cup assembly (11) to the lower shaft and the wind vane (1) to the
upper shaft. Insert and tighten the grub screws (12). Check that the
vane and cups rotate freely in both directions.
ST80 Active Wind Transducer
ST80ActiveWindServiceProcedures 83067-1 7
Z219

1. Wind vane
2. Wind vane head
3. 'O' ring (2 off)
4. Nut
5. Ribbon cable
6. SeaTalk cable
7. Main PCB
8. Body
9. Anemometer head
10. Cup assembly
Ribbon connector detail
Open
position
Closed
position
Red Screen
Yellow
4
1
11
2
3
PL1
5
5
7
PL1
PL2
PL1
9
3
10
11
4
D2711-1
8
6
Figure1ExplodedView
ST80 Active Wind Transducer
8 ST80ActiveWindServiceProcedures 83067-1
Z219

5. Functional Test
5.1Preliminary Inspection
Beforetesting,inspecttheequipmentforphysicaldamage(crackedor
broken case, bent/corroded/burnt connector pins, etc.). Clean off any
grease, dirt or deposits in or on the equipment.
Check for signs of water ingress. Check for damage to the pod PCB, in
particular, overheating on the power supply input pinsandPCBtracks.
5.2 Test Equipment
4
D2712-1
+
+
1352
1. Known good ST80 wind head
2. Daisychain cable
3. Power cable
4. 5A Fuse/circuit breaker
5. 12V 5A power supply
6. ST80 Active wind
transducer under test
6
Figure2TestEquipmentConnection
ST80 Active Wind Transducer
ST80ActiveWindServiceProcedures 83067-1 9
Z219

5.3Functional TestFlowchart
CONNECT POWER AND SWITCH ON.
SET APPARENT WIND SPEED
N
Y
OK
CHANGE PCB
& RESTART
POWER OFF; END OF TEST
CHECK DISPLAY SHOWS ZERO
SPEED, NOT BLANK OR DASHES
00.0
N
Y
OK
CHECK CONNECTING
CABLES
ROTATE ANEMOMETER, CHECK
LCD RESPONDS BY INDICATING
A WIND SPEED
N
Y
OK
OK
N
Y
OK
OK
ROTATE WINDVANE, CHECK
INSTUMENT POINTER FOLLOWS
VANE MOVEMENTS
KTS
app
CHECK CONNECTING
CABLES
CHECK CONNECTING
CABLES & RETRY
N
N
Y
Y
CORRECT FAULT
& RESTART
CORRECT FAULT
& RESTART
CHANGE PCB
& RESTART
CORRECT FAULT
& RESTART
CHANGE PCB
& RESTART
ST80 Active Wind Transducer
10 ST80ActiveWindServiceProcedures 83067-1
Z219

6. Spares Numbers
Item Cat. No. Part No. Comments
30m Extension
Cable D252
50m Extension
Cable D253
Anemometer Pod
Sub-Assembly Q140 9
Vane Pod
Sub-Assembly Q141 2
PCB Sub-Assembly Q142 7
Anemometer W062 10
Vane W063 1
Arm Sub-Assembly W064 8
ST80 Active Wind Transducer
ST80ActiveWindServiceProcedures 83067-1 11
Z219

7. Circuit Description
Refer to Figure 3, Block Diagram and Figure 5, Circuit Diagram.
Two sensor PCBs (round boards) feed the main PCB. Interconnection and
elements on the round boards are shown in the bottom right corner of
theblock diagram.
One sensor (anemometer) detects rotation of the wind cups and produces
a pulse train which is used to calculate the wind speed. The other sensor
(wind vane) detects the rotation of a magnet attached to the wind vane
shaft from which the wind angle is calculated.
The main PCB processes signals from the sensors and interprets mes-
sages from other system elements. SeaTalk sentences containing wind
speed, wind angle and alarm conditions are generated for transmission on
theSeaTalkbus.
7.1PowerSupplies
Anominal 12Vsupplyenters theunit viathe redlead ofthe SeaTalkcable.
VaristorV1placedacrossthesupplyand0V(blackleadoftheSeaTalk
cable) provides protection against power surges and voltage spikes.
DiodeD1,similarlyplacedacrossthesupplyand0V,provideslimited
protection against lightning strikes.
The input supply is routed as follows:
1. Through reverse protection diode D4 to IC1, a regulator which pro-
vides +5V (Vcc) to the circuitry on the PCB. The output of diode D4
(nominally12V) is sent through diodeD6to ASIC IC5, as signalVHELD
2. Through diode D3 as signal 12V to regulator IC2 (or alternative fit 8V
regulator IC9).
RegulatorIC2 (or alternative fit8Vregulator IC9) provide an8Vsupply to
digital - to - analogue convertor IC8. The sensor PCBs (wind vane and
anemometer)aresupplied with 8V through PL1 andPL2.
Reverse diode D5 ensures a floating 0V for the circuitry by isolating the
incoming0V.
ST80 Active Wind Transducer
12 ST80ActiveWindServiceProcedures 83067-1
Z219

7.2External Signals
SeaTalk
SeaTalk signals carried bytheyellow lead of theSeaTalkcable are routed
directlyto theAutohelm ASICIC5.
DiodeD2placedacrossthedatalineand0Vprovideslimitedprotection
against lightning strikes.
Incomingsignals areconverted by theASIC from SeaTalkduplex line
format to SeaTalk DATA IN format for the microprocessor.
Outgoing signals from the microprocessor are converted from SeaTalk
DATA OUT format at CMOS voltage levelsto SeaTalk format at 12Vlevel by
theASIC.
Anemometer
Pulsesare generated by opto -electricintegrated circuit IC3, at arate
dependenton wind speed, by theactionof an opto - interrupteronthe cup
mounting shaft at the lower end of the assembly.
The output of IC3 is fed via PL1 (round board) and PL2 (main PCB) to
comparator IC3a which uses the reference voltage produced by resistors
R8 and R9 to provide a clean input to microprocessor IC7.
WindVane
Hall effect sensors IC1 and IC2 on the round board at the top end of the
assembly detect the position of a magnet mounted on the wind vane shaft.
The resulting analogue voltages (sine and cosine, representing orthagonal
two-axis sensing) are fed via PL1 (round board) and PL1(mainPCB)to
comparatorsIC3band IC3d.
The microprocessor sets up bits 1 to 10 on the input of digital - to - ana-
logue convertor IC8, which produces a reference voltage at the output
(VREF).VREF is fedvia IC4a tocomparatorsIC3c (cosine), IC3b(sine) and
IC3d(VTEST).
When the reference voltage and the inputs from the Hall Effect sensors
are matched, the outputs of the comparators change state and, as the
microprocessor knows the digit pattern set up to cause this change, the
position of the magnet in relation to the sensors can be calculated.
Atestsignal (VTEST) is produced by comparatorIC3d.
ST80 Active Wind Transducer
ST80ActiveWindServiceProcedures 83067-1 13
Z219

7. Circuit Description
Refer to Figure 3, Block Diagram and Figure 5, Circuit Diagram.
Two sensor PCBs (round boards) feed the main PCB. Interconnection and
elements on the round boards are shown in the bottom right corner of
theblock diagram.
One sensor (anemometer) detects rotation of the wind cups and produces
a pulse train which is used to calculate the wind speed. The other sensor
(wind vane) detects the rotation of a magnet attached to the wind vane
shaft from which the wind angle is calculated.
The main PCB processes signals from the sensors and interprets mes-
sages from other system elements. SeaTalk sentences containing wind
speed, wind angle and alarm conditions are generated for transmission on
theSeaTalkbus.
7.1PowerSupplies
Anominal 12Vsupplyenters theunit viathe redlead ofthe SeaTalkcable.
VaristorV1placedacrossthesupplyand0V(blackleadoftheSeaTalk
cable) provides protection against power surges and voltage spikes.
DiodeD1,similarlyplacedacrossthesupplyand0V,provideslimited
protection against lightning strikes.
The input supply is routed as follows:
1. Through reverse protection diode D4 to IC1, a regulator which pro-
vides +5V (Vcc) to the circuitry on the PCB. The output of diode D4
(nominally12V) is sent through diodeD6to ASIC IC5, as signalVHELD
2. Through diode D3 as signal 12V to regulator IC2 (or alternative fit 8V
regulator IC9).
RegulatorIC2 (or alternative fit8Vregulator IC9) provide an8Vsupply to
digital - to - analogue convertor IC8. The sensor PCBs (wind vane and
anemometer)aresupplied with 8V through PL1 andPL2.
Reverse diode D5 ensures a floating 0V for the circuitry by isolating the
incoming0V.
ST80 Active Wind Transducer
14 ST80ActiveWindServiceProcedures 83067-1
Z219

7.2External Signals
SeaTalk
SeaTalk signals carried bytheyellow lead of theSeaTalkcable are routed
directlyto theAutohelm ASICIC5.
DiodeD2placedacrossthedatalineand0Vprovideslimitedprotection
against lightning strikes.
Incomingsignals areconverted by theASIC from SeaTalkduplex line
format to SeaTalk DATA IN format for the microprocessor.
Outgoing signals from the microprocessor are converted from SeaTalk
DATA OUT format at CMOS voltage levelsto SeaTalk format at 12Vlevel by
theASIC.
Anemometer
Pulsesare generated by opto -electricintegrated circuit IC3, at arate
dependenton wind speed, by theactionof an opto - interrupteronthe cup
mounting shaft at the lower end of the assembly.
The output of IC3 is fed via PL1 (round board) and PL2 (main PCB) to
comparator IC3a which uses the reference voltage produced by resistors
R8 and R9 to provide a clean input to microprocessor IC7.
WindVane
Hall effect sensors IC1 and IC2 on the round board at the top end of the
assembly detect the position of a magnet mounted on the wind vane shaft.
The resulting analogue voltages (sine and cosine, representing orthagonal
two-axis sensing) are fed via PL1 (round board) and PL1(mainPCB)to
comparatorsIC3band IC3d.
The microprocessor sets up bits 1 to 10 on the input of digital - to - ana-
logue convertor IC8, which produces a reference voltage at the output
(VREF).VREF is fedvia IC4a tocomparatorsIC3c (cosine), IC3b(sine) and
IC3d(VTEST).
When the reference voltage and the inputs from the Hall Effect sensors
are matched, the outputs of the comparators change state and, as the
microprocessor knows the digit pattern set up to cause this change, the
position of the magnet in relation to the sensors can be calculated.
Atestsignal (VTEST) is produced by comparatorIC3d.
ST80 Active Wind Transducer
ST80ActiveWindServiceProcedures 83067-1 15
Z219

IC1 +5V
0V
12V
12V HELD
IC5
REGULATOR
D2713-1
IC7
D4
D3
ASIC
RESET
W'DOG
R-C TIMING
COMPONENTS
12V HELD
IC6
EEPROM
XL1
12MHz
CRYSTAL
D5
(V1)
MICROPROCESSOR
12V
D6
IC2
+8V
REGULATOR
IC4b
REF TO IC3a, IC3d
OUT1
OUT2
(MSB) BIT1
BIT2
BIT3
BIT4
BIT5
BIT6
BIT7
BIT8
BIT9
(LSB) BIT10
VREF
IC4a
PL2
PL1
D2
D1
REGULATOR
(ALTERNATIVE FIT)
(IC9)
12V
0V
12V
0V
D/A CONVERTOR
IC8
R2
R1
PL1
MAIN PCB
PCB INTERCONNECTION
COMPARATORS
ANEMOMETER MAIN PCB WIND VANE
PL1 PL2 PL1 PL1
IC1
IC2
IC3
SeaTalk BUS
VTEST
SINE
COSINE
REF
1
2
3
4
0V
8V
NC
1
2
3
4
8V
0V
8V
SINE
COSINE
0V
IC3
8V
SINE
COSINE
0V
PL1
IC3
0V
8V
O/P IC1
IC2
ANEMOMETER WIND VANE
ROUND PCBS
RED BLACK YELLOW
+12V 0V SeaTalk
SOLDERED CONNECTIONS
RED
BLACK
YELLOW
+12V
0V
SeaTalk
DATA SeaTalk
CABLE
SeaTalk DATA IN
SeaTalk DATA OUT
RESET
W'DOG
POWER FAIL
P3.1
P3.0
RST
P1.4
P3.5
P1.1
P3.3
XTAL
P3.2
P3.4
P1.5
P1.0
SCL
SDA
P3.7
P3.6
P2.7
P2.6
P2.5
P2.4
P2.3
P2.2
P2.1
P2.0
+
0V
8V
ANEMOMETER
OUTPUT
+
+
+
+
a
d
b
c
+5V
R8
R9
0V
+
0V R11
R10
Figure3BlockDiagram
Signalflow is left to right except where indicated
ST80 Active Wind Transducer
16 ST80ActiveWindServiceProcedures 83067-1
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8. PCB Details
8.1 PCB Layout
D2714-1
Taken from Drawing No: 4288-009
Issue: E Date: 07.02.96
Taken from Drawing No: 4288-011
Issue: C Date: 01.02.96 Taken from Drawing No: 4288-007 Issue: L Date: 10.09.96
Anemometer PCB
Component Side
Underside
Vane PCB
Component Side
Underside
Main PCB
Conventional
Components,
componet side
Surface Mount
Components,
componet side
Conventional
Components,
underside
Surface Mount
Components,
underside
Figure4ComponentLayout
ST80 Active Wind Transducer
ST80ActiveWindServiceProcedures 83067-1 17
Z219

D2715-1
Figure5CircuitDiagram
ST80 Active Wind Transducer
18 ST80ActiveWindServiceProcedures 83067-1
Z219

8.2 PCB Component Lists
Anemometer PCB, Components
D3955-1
Taken from Drawing No: 4288-009 Issue: E Date:07.02.96
Vane PCB, Components
D3956-1
Taken from Drawin
g
No: 4288-011 Issue: C Date:07.02.96
MainPCB,SurfaceMount Components,component side
D3957-1
Taken from Drawin
g
No: 4288-007 Issue: L Date:10.09.96
MainPCB,ConventionalComponents, component side
D3958-1
Taken from Drawin
g
No: 4288-007 Issue: L Date:10.09.96
MainPCB, Surface MountComponents,underside
D3959-1
Taken from Drawin
g
No: 4288-007 Issue: L Date:10.09.96
ST80 Active Wind Transducer
ST80ActiveWindServiceProcedures 83067-1 19
Z219

MainPCB, Conventional Components,underside
D3960-1
Taken from Drawin
g
No: 4288-007 Issue: L Date:10.09.96
ST80 Active Wind Transducer
20 ST80ActiveWindServiceProcedures 83067-1
Z219