Cetrek Propilot 725 User guide

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PROPILOT 725 INSTALLATION & SERVICING MANUAL
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 (Draft)
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
807-252-10-96

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PROPILOT 725 INSTALLATION & SERVICING MANUAL
CONTENTS
THE SYSTEM ................................. 5
System Accessories ............................ 5
A Brief Overview ............................. 5
INSTALLING YOUR PROPILOT 725 ................ 7
Before you Start .............................. 7
Suggested Procedure .......................... 7
Distribution Box .............................. 8
Compass Sensor ............................. 8
Autopilot Control ............................. 9
Rudder Feedback Unit ......................... 9
Drive Units ................................ 10
Big Ship Links .............................. 11
Good Wiring Practice ......................... 11
Connecting the Autopilot ...................... 13
INSTALLATION SCHEMATIC ..................... 14
INSTALLING OPTIONAL EQUIPMENT ............. 16
Cetrek Equipment ........................... 16
Navigators ............................... 16
NMEA 0180 ............................... 18
NMEA 0182 & 0183 .......................... 18
NMEA 0183 ............................... 18
Windvane Equipment ......................... 19
Gyro Equipment ............................ 19
PROPILOT 725 FRONT PANEL (KEY) FUNCTIONS .... 20
INSTALLATION SETTINGS ...................... 22
Rudder Phasing ............................. 22
Motor Phasing .............................. 22
Rudder Feedback Unit Offset .................... 23
Compass Alignment .......................... 23
Reset .................................... 23
To Exit Installation Settings ..................... 23
Compass Variation ........................... 24
Compass Damping........................... 24

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PROPILOT 725 INSTALLATION & SERVICING MANUAL
Settings for Optional Equipment .............. 24
Windvane Interface Format ..................... 24
Wind Trim ................................. 25
Navigator Interface Format ..................... 25
Navigator Gain ............................. 25
External Alarm .............................. 26
Gyro Compass Control ........................ 26
Gyro Type or Gyro Ratio ....................... 27
CONFIGURING YOUR PROPILOT 725 ............. 28
The Settings Explained ...................... 28
Counter Rudder ............................. 28
Trim ..................................... 29
Rudder Ratio Gain ........................... 29
Rudder Deadband ........................... 30
Rudder Limit ............................... 30
Max Turn Rate .............................. 30
Power Steer Gain ............................ 30
Auto-deviation ............................. 31
Preset Configurations ....................... 31
Installing a Preset Configuration .................. 32
Adjusting Individual Configuration Settings .......... 33
SEA TRIALS ................................. 34
Checks at the Dockside ........................ 34
Checks at Sea .............................. 35
Automatic Deviation Correction ............... 36
SYSTEM DESCRIPTION ......................... 38
Block Diagram of Distribution Box ................ 38
The Distribution Box in Detail ................... 38
Fuses and Maximum Ratings .................... 38
Changing Software Eproms ..................... 39
Switches .................................. 39
TROUBLESHOOTING GUIDE .................... 41
General Principles and Cautions .................. 41
Faults .................................... 41
ERROR AND FAULT MESSAGES .................. 44
INDEX

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PROPILOT 725 INSTALLATION & SERVICING MANUAL
The System

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PROPILOT 725 INSTALLATION & SERVICING MANUAL
The System
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 (930 725) for the helmsman to control
the autopilot.
•aRudder Feedback Unit (930 807) to provide rudder position
information.
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:
• Dodge and Course Change remote controls.
• Power steer remote controls.
• Rudder Position Indicators and Repeaters.
• Compass Repeaters.
• External Audible Alarms.
• Windvane Sensors.
•ANavigator.
•AGyro Compass.
•Asecond station Autopilot Control.
A Brief The Distribution Box is the heart of the system and everything
Overview 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.

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PROPILOT 725 INSTALLATION & SERVICING MANUAL
Installing your Propilot 725
Hole positions 113 x 238 mm (4.45" x 9.37")
Cut-out for back 110 x 237 mm (4.33" x 9.33"), corners 13 mm (0.51") x 45º
NOTE: Also allow adequate clearance for cable connections to ensure cables
are not unduly stressed.
930 618 Distribution Box Dimensions
Propilot 725 Dimensions

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PROPILOT 725 INSTALLATION & SERVICING MANUAL
Installing your Propilot 725
INSTALLING YOUR PROPILOT 725
Before you Before commencing the installation of your new pilot please carry
Start 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?
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.
Suggested We suggest that the following procedure will allow you to install
Procedure 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.
• 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.
• Connect the heavy duty supply, see the Drive Unit
Caution!
All exposed moving
parts must be
sufficiently guarded to
prevent accidental
damage to persons or
clothing

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PROPILOT 725 INSTALLATION & SERVICING MANUAL
Installing your Propilot 725
information for fuse ratings.
Distribution This is the heart of the system and must be installed in a DRY,
Box 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.
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.

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PROPILOT 725 INSTALLATION & SERVICING MANUAL
Installing your Propilot 725
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 ‘electronically’ 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 This should be installed in a position convenient for the
Control helmsman to operate it.
These units must be flush mounted to maintain their
weatherproof quality.
If the front panel of this unit is removed the gasket must be
replaced to maintain the watertight seal. To order the gasket
quote part number 132-150.
Rudder The Rudder Feedback Unit is connected directly to the Rudder
Feedback Unit 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 electronically.
This procedure is described later, in the Installation Settings.

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PROPILOT 725 INSTALLATION & SERVICING MANUAL
Installing your Propilot 725
The rudder amidships position of the Rudder Feedback Unit can
be mounted up to 10º out. As mentioned this can then be
compensated for electronically, see Installation Settings.
For commercial vessels it is best to use the 930-801 Heavy Duty
Rudder Feedback Unit.
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.
The heavy duty supply should be fused according to the drive
unitfitted: 930 403, 404, 415 30A Antisurge
930 413, 414 20A Antisurge
Hydraulic Drive units connect into existing manually operated