Cetrek PROPILOT 700 Datasheet

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PROPILOT 700 INSTALLATION & SERVICING MANUAL
807-007-5-96
PROPILOT 700
(With 618700 Software)
Installation and
Servicing Manual

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PROPILOT 700 INSTALLATION & SERVICING MANUAL
807-007-5-96
WELCOME
All of us at Cetrek would like to welcome you to the world
of Cetrek Propilot Systems.
Your Safety THE USE OF AN AUTOPILOT DOES NOT AVOID THE
NEED FOR NORMAL WATCHKEEPING.
EMC DIRECTIVE 89/336/EEC
This product has been designed to be compliant with the
above Directive.
Maximum performance and compliance with the EMC
Directive can only be ensured by correct installation. It is
strongly recommended that the installation conforms with
the following Standards:
SMALL CRAFT - ELECTRICAL SYSTEMS:
a) ISO 10133 - Extra Low-Voltage DC Installations
b) ISO 13297 - Alternating Current Installations
ISO - International Standards Organisation
The information contained in this manual is believed to be accurate at
the time of going to print but no responsibility, direct or consequential,
can be accepted by Cetrek Ltd for damage resulting from the use of
this information. Cetrek Ltd reserve the right to make changes
without notice to any of its products. © Cetrek Ltd 1996

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CONTENTS
THE SYSTEM ................................... 6
System Accessories ............................ 6
A Brief Overview .............................. 6
INSTALLING YOUR PROPILOT 700.................. 7
Before you Start .............................. 7
Suggested Procedure ........................... 7
Distribution Box............................... 8
Compass Sensor .............................. 8
Autopilot Control ............................. 9
Rudder Feedback Unit .......................... 9
Drive Units ................................. 10
Good Wiring Practice .......................... 11
Connecting the Autopilot ....................... 13
INSTALLATION SCHEMATIC ...................... 14
INSTALLING OPTIONAL EQUIPMENT............... 16
Cetrek Equipment ............................ 16
Navigators ................................. 16
NMEA 0183 ................................ 18
PROPILOT 700 FRONT PANEL FUNCTIONS .......... 19
INSTALLATION SETTINGS ........................ 20
Compass Alignment ........................... 20
Rudder Phasing .............................. 20
Rudder Feedback Unit ......................... 20
Motor Phasing .............................. 20
CONFIGURING YOUR AUTOPILOT ................. 21
Preset Configurations .......................... 21
Installing a Preset Configuration .................. 22
Rudder Limit ................................ 22
Rudder Deadband ............................ 22
Counter Rudder .............................. 22
Trim ...................................... 23
Navigator Interface Format ...................... 23
Navigator Gain .............................. 24
Power Steer Gain ............................. 24
Compass Damping ........................... 24
Auto-deviation .............................. 24
To Exit .................................... 24
SEA TRIALS ................................... 25
Checks at the Dockside ........................ 25
Checks at Sea ............................... 26
Automatic Deviation Correction .................. 27
SYSTEM DESCRIPTION .......................... 29
Block Diagram of Distribution Box ................. 29
Fuses and Maximum Ratings ..................... 29
Changing Software Eproms ..................... 30
Switches ................................... 30
TROUBLESHOOTING GUIDE ..................... 31
General Principles and Cautions .................. 31
Faults ..................................... 31
ERROR AND FAULT MESSAGES ................... 34
INDEX

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PROPILOT 700 INSTALLATION & SERVICING MANUAL
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The System

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PROPILOT 700 INSTALLATION & SERVICING MANUAL
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THE SYSTEM
A basic system consists of the following:
•aDistribution Box (930 618) to collect, process and
output information.
•aCompass Sensor (930 577) to provide heading
information.
• an Autopilot Control (930 700) for the helmsman to
control the autopilot.
•aRudder Feedback Unit (930 807) to provide rudder
position information.
•aConnection Cable (930 276) between the Propilot 700
cable and the Distribution box.
The system also requires a Drive Motor (hydraulic or
mechanical) to activate the vessel’s steering system.
SYSTEM ACCESSORIES
Your system may have some of these accessories as well:
• Power steer remote controls.
• Rudder Position Indicators and Repeaters.
• Compass Repeaters.
•ANavigator.
•Asecond station Propilot 700 Control.
A Brief The Distribution Box is the heart of the system and every
Overview thing connects to this. It contains the computer section that
reads the data from the sensors, i.e. the rudder position
from the Rudder Feedback Unit, the vessel’s heading from
the Compass. It reads the helmsman’s orders from the
Autopilot Control or a Navigator, then calculates, using the
sea state and configuration settings and moves the rudder,
via the Drive Motor to maintain a course.
The Distribution Box contains customised software (618700
V1.0) for connecting a Propilot 700 system.
A link is fitted between Port B and power on the Windvane
Port. The switch on the Light Duty Supply must be located
near the Propilot 700 control.
The System

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PROPILOT 700 INSTALLATION & SERVICING MANUAL
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PROPILOT 700 DIMENSIONS
Note: also allow adequate clearance for cable connections
to ensure cables are not unduly stressed.
930 618 DISTRIBUTION BOX DIMENSIONS
Installing Your Propilot 700

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INSTALLING YOUR PROPILOT 725
Before you Before commencing the installation of your new pilot please
Start carry out the following initial checks:
• that the correct items have been delivered ?
• that the units are undamaged ?
• that the correct voltage drive unit has been supplied ?
• if using a Mechanical Drive Unit, that the correct chain and
sprocket is available ?
• if you are using a hydraulic pump, that you have the correct
size fittings available to connect the pump ?
• that you have the correct type of hydraulic fluid to top up the
steering system once the pump is installed ?
• that you have a power cable of a suitable gauge to supply
power to the system?
• that you have a Circuit Breaker of suitable size for your
system? A Light Duty Switch is required near the Propilot 700.
If you find an error please contact the supplier of the
product immediately.
Before the drilling or cutting of any holes takes place, please
consider the exact location and cable routing that is
required for each unit. Please read this installation section
and any installation information supplied with your units
before you install the system.
Caution! All exposed moving parts must be sufficiently guarded to
prevent accidential damage to persons or clothing.
Suggested We suggest that the following procedure will allow you to
Procedure install the system encountering the least problems.
• Read this section then select the best positions for the units.
• Install the Distribution Box.
• Install the Autopilot Control and route the cable to the
Distribution Box.
• Install the Compass Sensor and route the cable to the
Distribution Box.
• Install the Rudder Feedback Unit and route the cable to the
Distribution Box.
• Install the drive unit. Route the cable to the Distribution Box.
• Route the light and heavy duty power supplies to the
Distribution Box.
Installing Your Propilot 700

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• Then proceed to connect all the cables to the Distribution Box
as per the Installation Schematic.
Finally:
• Connect the light duty supply fused at 5 amps, via the Light
Duty Switch.
• Connect the heavy duty supply, see the Drive Unit information
for fuse ratings.
Distribution This is the heart of the system and must be installed in a
Box DRY, accessible position.
Ideally the box should be positioned so that the heavy duty
power supply cables from the batteries to the distribution
box and from the distribution box to the drive unit are kept
to a minimum length. This is particularly important on
sailing vessels where often you are operating on batteries
which are not fully charged.
If the distribution box has to be installed in the engine room
please ensure that the area is properly ventilated to avoid
high ambient temperatures and abnormal condensation
levels.
Compass The Compass Sensor needs to be carefully located. The
Sensor optimum position is to mount it on a convenient (vertical)
bulkhead, as low and as close to the centre line of the boat
as possible. On fast vessels, it is advisable to fit the compass
sensor at least half way back along the centre line.
On steel vessels it is necessary to mount the sensor 2 to 3
metres above the superstructure or to use a Gyro or Pick-off
coil system working from the vessel’s main steering
compass.
The compass sensor must be installed away from sources of
magnetic interference, such as:
Radios, RDF, Depth Recorders, etc: at least 1 metre clearance
Power cables carrying more than 0.5 amp: at least 1 metre clearance
Radar Magnetrons: at least 3 metre clearance
Ship’s engines, large mass steel (soft iron) etc: at least 1 metre clearance
Also, do not install the compass in a position where
magnetic material i.e. tool boxes, drink cans, chain etc. may
be stowed at any time.
Installing Your Propilot 700

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PROPILOT 700 INSTALLATION & SERVICING MANUAL
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Check the proposed location with a hand bearing compass.
This will indicate whether there is a large deviation that
may cause problems. Switch on any electrical equipment
that may cause deviation and check the hand-bearing
compass to see if there has been any change on heading. If
a change is observed the Sensor should not be installed in
this position as the compass heading may not reflect the
true heading of the craft, therefore making autopilot
control inaccurate.
Once the Compass Sensor is installed the transit screw in
the base of the unit should be shortened or removed.
The compass does not have to physically align with the
bow of the vessel because it will be manually aligned later
during the Installation Settings.
The Automatic Deviation Correction routine is explained
later in the Sea Trials section.
Further instructions on the location of the compass sensor
are included with each compass sensor despatched from
Cetrek’s factory.
Autopilot In the interest of safety there must be an autopilot control
Control within reach of the helmsman AT ALL TIMES.
This should be installed in a position convenient for the
helmsman to operate it.
Rudder The Rudder Feedback Unit is connected directly to the
Feedback Unit Rudder Arm, which may be a tiller, quadrant or tie bar, of
the steering system. It may be necessary to construct a
mounting base for this unit.
As the steering gear is often exposed and in an area which
is used for stowage, ensure that the Rudder Feedback Unit
cannot be jammed by ropes, buckets, fenders etc.
You can mount the Rudder Feedback Unit on either side of
the Rudder Stock as changing the “Phasing” so that the
Feedback Unit indicates Port and Starboard correctly is
done manually in the Distribution Box. This procedure is
described later, in the Installation Settings.
Installing Your Propilot 700

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The rudder amidships position of the Rudder Feedback Unit
must be accurately centred.
Drive Units Mechanical Drive Units connect into existing mechanical
steering systems.
The size and position of a Rotary Drive Unit should have
been specified when originally ordering the Pilot System.
The unit will have to be positioned to align with the
sprocket which will be fitted to the existing mechanical
steering system. It is essential to ensure that a strong
mechanical mounting is provided for these units as
considerable loads are developed when under use.
Installing Your Propilot 700

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The heavy duty supply should be fused according to the
drive unit fitted:
930 403, 404, 415 30A Antisurge
930 413, 414 20A Antisurge
Hydraulic Drive units connect into existing manually
operated hydraulic steering systems. Hydraulic pumps
should be mounted on a rigid base to avoid unnecessary
vibration and noise.
The heavy duty supply should be fused according to the
drive unit fitted:
930 100,101,130,132,135,160,161,162 30A Antisurge
930 110,111,155,170,171,172,180,182 20A Antisurge
930 146 10A Antisurge
930 102,112 (Continuous Running Pumps) 5A Antisurge
For other continuously running pumps use a fuse rating of
a suitable size for the solenoids.
For either system it is acceptable to use a Fused switch or a
Circuit breaker. Changing the Phasing to reverse the
rotation of the motor is explained later in the Installation
Settings.
Good Wiring Having decided on the location and position of each unit it
Practice is essential to check the cable runs to ensure that there are
no problems.
All cable runs should be kept as clear as possible from other
cables carrying RF (radio frequency), pulsed signals or heavy
currents (such as winches etc.). At least 3 ft. clearance is
advised. Take particular care to ensure the maximum
clearance from radio transmitting aerials.
If it is necessary to extend any of the cables, the same type
of cable must be used and the screens must be connected.
Screened cables should be earthed at the Distribution Box
using the clamping bars provided.
If it is necessary to extend the Drive Unit cables, they should
be extended using a heavy duty cable, by the shortest
possible route, to avoid unnecessary power loss.
Installing Your Propilot 700

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PROPILOT 700 INSTALLATION & SERVICING MANUAL
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If the vessel has a “clean” earthing system (ie using a dyna
plate or similar system) then the case of the Distribution Box
may be connected to it using a heavy duty cable or copper
strip, this will usually improve RFI rejection.
Note: The negative of the battery system is not normally a
clean earth and the case of the Distribution Box should
not under any circumstances be connected to it.
All DC supply cables should be kept as short as possible,
and should be taken from the battery via a switch/fuse or
circuit breaker of a suitable rating for the system being
installed.
Two separately switched and fused power supplies must be
connected to the Distribution Box. The first is for the light
duty primary supply for the electronic control system. The
second is for the heavy duty supply for the drive unit.
IMPORTANT: The Light Duty Suppy Switch must be located close to
the Propilot 700, to turn the autopilot on and off.
Avoid running power and motor supply cables together or
in the same conduit with control and compass cables to
help reduce the risk of interference.
It is good practice to cleat all cables to fixed points at no
less than 0.5 m (18") spacing and where cables pass
through bulkheads, protect the cable with a suitable
grommet or sleeve.
Connecting All the connections for the system are made to the PCB in
the Autopilot the Distribution Box which is clearly marked to make
connections easy and straightforward.
Spare plugs are supplied for the connection of navigators
etc. Additional ones are available from your Cetrek
distributor.
Installing Your Propilot 700

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KEY TO THE COLOUR CODING OF CABLES
R Red Rouge Rot Rojo
B Blue Bleu(e) Blau Azul
BK Black Noir(e) Schwarz Negro
BN Brown Marron Braun Marron
V Violet Violet(te) Violett Violeta
G Green Vert(e) Grun Verde
W White Blanc(he) Weiss Blanco
GY Grey Gris(e) Graua Gris
Y Yellow Jaune Gelb Amarillo
O Orange Orange Orange Naranja
NC No connection Pas de lien Kein anschluss No conectar
The Installation Schematic on page 14 shows the location
of the connectors on the PCB and the relevant cable
connections.
Caution! Incorrect wiring (e.g. reverse polarity) can cause
irreparable damage to some equipment and is not
covered by the Cetrek warranty agreement.
Installing Your Propilot 700

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Installation Schematic

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WARNINGS
i) Do not connect or disconnect wiring with power applied.
ii) Ensure cable screens are suitably connected.
iii) Always check colour codes before applying power. Older units may have plugs
incorrectly wired for use with the 930 618 unit.
NOTES
1. Motor Connections Ensure L4 is in the ‘PWM’ position. The 930 618 can be
connected with any of the drives that Cetrek supplies. Phasing can be reversed
manually in the Distribution Box once the system is installed. See “Installation
Settings” for further details.
2. Motor Supply The Heavy Duty Motor Supply and Light Duty Supply must be run
independently. Fuse the Light Duty at 5 amps, the switch must be located close
the Propilot 700. See “Drive Units” in the Installing Section for the Heavy Duty
fuse rating.
3. Solenoid Drives Should be connected as shown in the diagram below. Links L1 &
L3 must be cut, L4 must be moved to the ‘Spool’ position. Also ensure that
adequate diode protection is fitted to the Spool Valves to prevent reverse spikes
damaging the FET’s in the 930 618. A suitable diode is IN5401 or equivalent.
Cetrek units 930 102, 930 112 have this protection built in.
4. Set SW1, 2 and 3 to OFF for 930 700. Ensure the 618700 Links between Port B
and power on the Windvane Port are fitted.
5. If the C-net Compass (930 383) is used as a Compass Repeater DO NOT connect
the white wire to this unit.
It is advisable to check your C-net Compass Manual for details of the connectons
into the Compass unit.
6. Navigator Input: Set SW7, for NAV1, ON for single wire output, OFF for two wire
output.
7. Set SW5 & SW6 to ON for 930 807 and to OFF for 930 801. There is no
connection for the brown wire on the 930 801. If connecting a 930 319 Rudder
Indicator, follow instructions supplied with the unit for phasing, regardless of the
Rudder Feedback phasing.
Installation Schematic

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INSTALLING OPTIONAL
EQUIPMENT
Cetrek Your Cetrek equipment will have Installation and Operation
Equipment Instructions with each individual unit as is appropriate for
the equipment. The Installation Schematic in this manual
covers the wiring connections of optional equipment.
Non Cetrek equipment will usually interface with your
Autopilot if you follow these instructions.
Navigators The autopilot can be controlled with data received from a
radio navigator (Sat Nav, Loran, Decca or GPS) which has a
compatible output format.
The marine industry has generally adopted the data output
formats as specified by the National Marine Electronics
Association of North America (NMEA). Your autopilot will
only accept NMEA 0183 for autopilot control:-
In order for the navigator to output the required
information, it first has to be programmed with your
required destination or waypoints. The basic information
used for autopilot control is:-
• Cross track error. This is expressed in units of one
hundredth of a nautical mile (60ft.) and whether the
error is to port or starboard of track.
• Alarm condition. This indicates if information received
from the navigator is valid.
• Heading to the next waypoint.
• Next waypoint Number.
In order to get full use of the interface facility from your
equipment, it is important to understand the principles of
control used. It would of course be very simple to use the
heading to the next waypoint calculated by the navigator.
However, this would be a dangerous method to use when
in the proximity of land as a stray tidal offset could put the
vessel in a position when it will run aground.
Installing Optional Equipment

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The use of Cross Track Error to control the autopilot
heading enables the vessel to be held on track to the next
waypoint. The autopilot is actually controlled by its own
compass output and the Cross Track Error information is
used to calculate the Trim required to keep your craft on
track.
When the waypoint is reached (provided the navigator is
programmed for the next waypoint) Cross Track Error
would not be sufficient information to turn the vessel on to
the next track. To do this it is necessary for the navigator to
output the heading to the next waypoint and indicate that
a new waypoint has been selected. Because of this, the
operation when waypoints are reached will depend on the
type of data received from your navigator.
NMEA 0183 The Autopilot is capable of processing the following NMEA
0183 messages. To obtain full use of the interface at least
one message containing Cross Track Error, Heading to
Waypoint and Waypoint number must be present in the
data received from the Navigator.
MESSAGE CROSS TRACK HEADING TOWAYPOINT WIND
ERROR WAYPOINT NUMBER ANGLE
APA üüü -
APB üüü -
BOD - üü -
BWC - üü -
XTE ü---
RMB üüü -
VWR - - - ü
üIndicates that the data should be present in the given
message according to the NMEA 0183 specification.
Installing Optional Equipment

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However, please note that not all navigator manufacturers
provide all the data required by a given message.
A navigator can be connected to the Distribution Box using
the NAV1 port.
If the Navigator has a single wire output then connect it to
the terminal marked ‘SIG+’. Switch SW7 to ON.
If the navigator has a two wire output then connect the
positive signal to the ‘SIG+’ terminal and the negative
signal to the ‘SIG-’ terminal. Switch SW7 to OFF.
The Installation Settings explain how to select the gain
values.
Installing Optional Equipment

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Propilot 700 Front Panel Functions
PROPILOT 700 FRONT PANEL FUNCTIONS
KEY PRIMARY FUNCTION SECONDARY FUNCTION
>Dodge to Starboard Increases Configuration Menu Settings
<Dodge to Port Decreases Configuration Menu Settings
< > Changes function of Dodge keys
between Dodge and Course Change
KNOB1. Pre-Selecting A Course (in Standby Mode)
2. Course Change (in Autopilot Mode)
AUTO 1. A 2 2 6 Select Autopilot Mode Course Change - in conjunction
2. P 2 2 6 Power Steer Selected with Course Selector Knob.
OFF 1. Return to Standby from Drive Mode None
2. Return from Background Menu
NAV 1. } 1 4 Cross Track Error display
2. N 2 2 6 Selects Nav Control & shows
heading being followed
ADJ Selects Sea State Settings: Press and hold ADJ Key on Power up to
r u Rudder select Configuration Settings:
r e Response (Use < or > to change values)
Shows Rudder Position, eg: 1. CONF <or > to give:
Pr:02 Port Rudder, or DISP
Sr:00 Starboard Rudder, or SdIS
Stop Rudder Limit PLAN
2. r L Rudder Limit
3. r d Rudder Deadband
4. C r Counter Rudder
5. t r Trim
6. n G Navigator Gain
7. P G Power Steer Gain
8. C d Compass Damping
9. C L r Deviation Correction

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INSTALLATION SETTINGS
There are four installation settings which are as follows:
• Rudder phasing of the Rudder Feedback Unit.
• Motor phasing.
• Rudder Feedback Unit offset.
• Magnetic Compass Alignment and Damping.
After Powering up, see Sea Trails, Checks at the Dockside.
Compass Check the heading agrees with an accurate magnetic
Alignment compass or transits. If an adjustment is required a manual
adjustment can be carried out. Make a note of the amount
of adjustment needed.
Remove the Compass Sensor front cover, then loosen the
clamp holding the coil base. The Coil Base has a printed
scale. Move the coil base clockwise to increase the heading
display, or anti-clockwise to decrease the heading display.
Check that the heading display now agrees with an
accurate magnetic compass or transits. Tighten the clamp
and refit the front cover.
Rudder Rudder Phasing is carried out to ensure the rudder
Phasing indication corresponds with the direction steered.
Connect the wires from the Rudder Feedback Unit inside
the Distribution Box. When Dockside Checks are
performed, in Standby, if the rudder indicator displays the
opposite direction to the rudder movement, reverse the
930 807 Red and Black wires.
Rudder The Rudder Feedback Unit must be centred accurately using
Feedback Unit the midship markings and Rudder Angle Template to ensure
the rudder is amidships when travelling in a straight line.
Motor Phasing Motor Phasing is carried out after Rudder Phasing to ensure
the polarity of the motor moves the rudder to Port and
Starboard correctly.
Connect the wires from the Motor Drive inside the
Distribution Box. When Dockside Checks are performed, in
Autopilot Mode, if the rudder moves continuously in one
direction, switch off immediately, then reverse the Motor
OUTPUT 1 and 2 wires.
Installation Settings