Nexus Autopilot R-1600 User manual

http://nex / /Autopilot/dig_auto.tif
- Course Processor R-1600 -
Installation and Operation Manual
Autopilot
English

AUTOPILOT English
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English AUTOPILOT
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This manual is written for NX2 Autopilot version 1.00
Edition: May 2012

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1!Welcome aboard! ................................................................................................... 6!
1.1!Capabilities ......................................................................................................... 6!
1.2!Principle of operation .......................................................................................... 6!
1.3!Components ....................................................................................................... 7!
1.3.1!Autopilot instrument ..................................................................................... 7!
1.3.2!Course Processor R-1600............................................................................ 7!
1.3.3!Rudder Angle Transmitter ............................................................................ 7!
1.1.1!Compass transducer .................................................................................... 7!
1.1.2!Pumpset ....................................................................................................... 7!
1.1.3!Linear Drive.................................................................................................. 8!
1.3.4!Solenoid Valve Drive.................................................................................... 8!
1.4!Registering this product ...................................................................................... 8!
1.5!About this manual ............................................................................................... 8!
2!Installation of instrument ...................................................................................... 9!
2.1!Installing the instrument.................................................................................... 10!
2.1.1!Installing instrument to the Server.............................................................. 11!
3!First start............................................................................................................... 12!
3.1!Initialising the instrument in a Nexus Network .................................................. 12!
3.2!Re-initialising the instrument............................................................................. 12!
4!Operation .............................................................................................................. 13!
4.1!Instrument overview.......................................................................................... 13!
4.1.1!Instrument display ...................................................................................... 13!
4.1.2!Instrument pages and functions ................................................................. 13!
4.1.3!Instrument modes ...................................................................................... 13!
1.1.4!Instrument power on/off ............................................................................. 14!
4.2!How to use the push-buttons ............................................................................ 14!
4.2.1!MODE ........................................................................................................ 14!
4.2.2!LEFT .......................................................................................................... 14!
4.2.3!RIGHT ........................................................................................................ 14!
4.2.4!SET ............................................................................................................ 14!
4.2.5!OFF ............................................................................................................ 14!
4.2.6!Tack ........................................................................................................... 14!
4.2.7!Setup mode................................................................................................ 15!
4.2.8!Lighting....................................................................................................... 15!
5!Function ................................................................................................................ 16!
5.1!Standby mode................................................................................................... 16!
5.2!Autopilot mode.................................................................................................. 16!
5.2.1!Activate automatic steering ........................................................................ 16!
5.2.2!Turn off automatic steering ........................................................................ 16!
5.2.3!Automatic steering by compass ................................................................. 16!
5.2.4!Automatic steering by navigator................................................................. 17!
5.2.5!Automatic steering by wind ........................................................................ 17!
5.2.1!Auto Tack and Auto Gybe .......................................................................... 18!
5.2.2!Power steering ........................................................................................... 19!
5.2.3!Dodging and returning to last automatic steering function......................... 19!
6!Setup ..................................................................................................................... 20!
6.1!Setup mode ...................................................................................................... 20!
6.1.1!The setup mode is divided into 4 setup groups.......................................... 20!

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6.1.2!How to access setup mode ........................................................................20!
6.1.3!How to change a setting.............................................................................20!
6.1.4!How to return to previous mode .................................................................20!
6.1.5!Factory default settings ..............................................................................20!
6.2!Lighting setup group [Lit]...................................................................................21!
6.3!Autopilot setup group [P]...................................................................................21!
6.3.1!P0, Return [RET] ........................................................................................21!
6.3.2!P1, Rudder [RUD].......................................................................................21!
1.1.5!P2, Damping of compass heading [SEA] ...................................................22!
6.3.3!P3, Counter Rudder [CRD].........................................................................22!
6.3.4!P4, Damping of wind [WSE] .......................................................................22!
6.3.5!P5, Automatic Trim Calibration [ATC].........................................................23!
6.3.6!P6, Adaptive Control [ADC]........................................................................23!
6.3.7!P7, Automatic Pilot Calibration [APC] ........................................................23!
6.3.8!P8, Rudder Speed [RRS] ...........................................................................23!
6.3.9!P9, Rudder angle limit [LIM] .......................................................................23!
6.4!Alarm setup group [A] .......................................................................................24!
6.4.1!A0, Return [RET] ........................................................................................24!
6.4.2!A1, Pilot Course Alarm [PCA].....................................................................24!
6.4.3!A2, Timer watch alarm [TMR].....................................................................24!
6.4.4!A3, Cross Track Error alarm [XTA].............................................................24!
6.4.5!A4, Push-button beep [KEY] ......................................................................24!
6.5!Compass setup group [C] .................................................................................25!
6.5.1!C0, Return [RET]........................................................................................25!
6.5.2!C1, Magnetic heading [MAG] .....................................................................25!
6.5.3!C2, Local magnetic variation [VAR]............................................................25!
6.5.4!C3, Auto-deviation [Auto DEV] ...................................................................25!
6.5.5!C4, Check auto-deviation [Auto CHK] ........................................................26!
6.5.6!C5, Clear auto-deviation [Auto CLR] ..........................................................26!
6.5.7!C6, Adjust compass alignment [ADJ] .........................................................26!
7!Maintenance..........................................................................................................28!
7.1!Instrument maintenance ...................................................................................28!
7.2!Drive unit maintenance and inspection schedule..............................................28!
8!Fault finding ..........................................................................................................29!
8.1!General .............................................................................................................29!
8.2!Symptom - Cause - Action ................................................................................29!
8.3!Nexus Network error messages with cause and remedy..................................32!
9!Installation of Course Processor ........................................................................34!
9.1!Installation general............................................................................................34!
9.2!Installation alternatives .....................................................................................34!
9.3!Wire thickness...................................................................................................34!
9.4!Course Processor .............................................................................................35!
9.4.1!Location of Course Processor ....................................................................35!
9.4.2!Installing Course Processor........................................................................35!
9.4.3!Connecting Course Processor....................................................................36!
9.4.4!Safety switch ..............................................................................................37!
9.4.5!NMEA connections.....................................................................................37!
9.5!Rudder angle transmitter...................................................................................38!

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Rudder Feedback Installation Notes....................................................................... 38!
9.6!Pumpset............................................................................................................ 39!
9.7!Linear drive ....................................................................................................... 39!
9.8!Solenoid valve controlled pumpset................................................................... 41!
9.9!Other Accessories ............................................................................................ 41!
10!Dockside Testing................................................................................................ 42!
10.1!Preparations ................................................................................................... 42!
10.2!Dockside First Start ........................................................................................ 42!
10.3!How to remove air from system ...................................................................... 42!
11!Sea Trials ............................................................................................................ 43!
11.1!Preparations ................................................................................................... 43!
11.2!Compass calibration ....................................................................................... 43!
11.3!Automatic Pilot Calibration [APC] ................................................................... 43!
12!Fine tuning .......................................................................................................... 45!
13!Specifications ..................................................................................................... 47!
13.1!Technical Specifications ................................................................................. 47!
13.1.1!Autopilot instrument ................................................................................. 47!
13.1.2!Course Processor R-1600........................................................................ 47!
13.1.3!Rudder Angle Transmitter ........................................................................ 47!
13.2!Nexus Network specification........................................................................... 48!
13.3!Accessories .................................................................................................... 48!
13.3.1!Autopilot instrument ................................................................................. 48!
13.3.2!Nexus Remote Control instrument ........................................................... 48!
13.3.3!Nexus analog Rudder Angle indication instrument .................................. 48!
13.3.4!Nexus Multi Control instrument with Server............................................. 48!
13.3.5!NFU jog lever ........................................................................................... 49!
14!Warranty.............................................................................................................. 50!

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1 Welcome aboard!
Thank you for choosing a Nexus Autopilot. Through this manual we would like to help
you install and operate your Nexus product. We are convinced that you will appreciate
the useful functions. To get the most out of your Nexus product, please read through
this manual carefully before you start your installation. If you see us at a show, please
stop by and say hello.
Good luck and happy boating!
1.1 Capabilities
Accuracy, reliability and simplicity of use, are key features of the Nexus microprocessor
controlled Autopilot. Whether the need is for minimised fuel consumption, improved
navigational accuracy or simply more enjoyable yachting, the Nexus Autopilot is the
right navigational aid to provide precision steering under all sea conditions. Due to the
very stable HPC compass, the built in Rate sensor and automatic trim feature, this
Autopilot is suitable for sailing and powerboats. User adjustable settings make it
possible to fine tune each boat, yet factory default settings and automatic calibration
allow simple operation with minimal operator input.
The Nexus Autopilot is capable of operating either as a "Stand Alone" Autopilot, or as a
"Network" application by connecting it to the Nexus Network. Many options are
available, including GPS and wind transducers, Nexus Remote Control instrument and
other Nexus digital and analog instruments.
The Autopilot Course Processor R-1600 is designed for sailing and power boats from
25 ft. (11 m.) to over 160 ft. (50 m.), depending on drive units used. Hydraulic drive
units provide precise control with low power consumption. Connection can also be
made to solenoid valves of electro-hydraulic steering systems, allowing use on very
large boats. Hydraulic linear drives provide powerful and accurate control when
connected to mechanical steering systems and also provide independent hydraulic
steering for added safety.
Power steering through the instrument’s push-buttons may be used to avoid heavy
wheel effort when manoeuvring. Alarms for off course, off track or watch alarm are
included with provision for an optional external alarm buzzer.
1.2 Principle of operation
Any difference between the set and actual course, is compared along with rate of
change and trends in change*, to drive the pumpset motor or solenoid valve. The,
rudder is moved as necessary to return the boat back on course. The sensitivity to
course errors and amount of correction are user adjustable to suit different boats under
various sea conditions.
NB * (PID control, terminology as known by control technicians,
P = proportional part, I = integral part and D = derived part)

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Factory default settings and automatic calibration, establish a basis for normal steering
and may be further fine tuned if necessary. During set up routines, the compass is
automatically compensated and installation errors such as reversed rudder feedback
and reversed pumpset wiring or piping are automatically diagnosed and corrected.
During this routine also the rudder speed is automatically optimised. This greatly
reduces installation set up and sea trials time while eliminating possible Autopilot
malfunction.
1.3 Components
1.3.1 Autopilot instrument
Control and display of all Autopilot functions are provided by the Autopilot instrument. It
is waterproof and may be mounted below or above deck. Multiple Autopilot instruments
can be connected and the Autopilot may be activated by pressing the push-buttons of
any instrument.
1.3.2 Course Processor R-1600
The Course Processor contains the course computer and pumpset motor drive circuitry
and acts as a centre for interconnecting wiring. It is splash proof and should be located
centrally to minimise lengths of wiring. The powerful microprocessor in the Course
Processor accepts heading information direct from an electronic compass or NMEA
compass wind transducer, navigators and compares this against the course set by the
instrument and rudder.
1.3.3 Rudder Angle Transmitter
The Rudder Angle Transmitter provides the Autopilot with accurate rudder position
information. It is mounted near the rudder shaft and connected to the tiller arm or
quadrant with an adjustable ball joint linkage.
1.1.1 Compass transducer
No Autopilot can steer better than the compass stability will allow. The Nexus compass
excels in this characteristic, where the liquid dampening provides for stability even at
high speeds in heavy seas. The high gimbaling angle, eliminates compass disturbance
with boat heeling or rolling. The compass provides a stable heading reference for the
Autopilot and should be bulkhead mounted below deck near the centre of pitch and roll
for maximum stability. Construction is splash proof. The Autopilot Course Processor or
the Nexus Server can re-transmit the compass heading on the NMEA output port to
receivers such as radars, plotters, compass repeaters etc.
1.1.2 Pumpset
Various sizes and types of pumpsets can be mounted into a hydraulic steering system.
The pumpset only operates when carrying out a rudder command. When the boat is on
course, the pumpset motor stops. A variable speed motor drive adjusts optimal rudder
speed and provides for minimum power consumption and maximising of rudder
positioning accuracy.

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1.1.3 Linear Drive
A hydraulic linear drive is used to drive the tiller arm or quadrant of mechanical steering
systems. The linear drive is driven by a pumpset. The linear drive provides a cleaner
installation, being entirely below deck, and delivers more torque to the rudder than
wheel driven units. In case the mechanical steering should fail, the linear drive will
provide a back-up hydraulic steering.
1.3.4 Solenoid Valve Drive
On larger boats the main hydraulic steering may be fitted with solenoid valve controlled
power steering. In this case the Autopilot does not need to be supplied with a pumpset
since the Nexus Course Processor output can be reconfigured with its board mounted
DIP switch to provide drive for steering solenoids or relays having coil voltages of 12 or
24 VDC.
1.4 Registering this product
Please take time to fill in the warranty cards and return them to your national distributor.
By returning the warranty card, it will assist your expert distributor to give you prompt
attention. Keep your proof of purchase. Also, your details are added to our customer
database so that you automatically receive new product catalogues when they are
released.
1.5 About this manual
•Each time a push-button is referred to in this manual, the push-button name will
appear in bold and CAPITAL letters, e.g. MODE.
•Unless otherwise stated, the push-button presses are momentary.
•Each time a function is mentioned in the text, it will be in brackets and in the same
format, where possible, as displayed, e.g. [HDG] for HeaDinG.
•With the word navigator we mean a GPS, Loran or Decca instrument.
•Which instrument is navigating? By the term navigating, we mean the active
instrument in which the waypoint memory is used for navigation to calculate the
navigation data, i.e. BTW, DTW etc. There can only be one instrument on the Nexus
Network which is keeping the waypoints in memory, but the waypoints can be
reached from all instruments.
Note! We have put in a lot of effort, in order to make this manual correct and complete.
However, since we have a policy of continuous improvement, some information may
differ from the product functions. If you need further information, do not hesitate to
contact your national distributor.

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2 Installation of instrument
• The installation includes 6 major steps:
1. Read the installation and operation manual.
2. Plan where to install the transducers and instruments.
3. Run the cables.
4. Install the transducers and instruments.
5. Take a break and admire your installation.
6. Learn the functions and calibrate your system.
Before you begin drilling ... think about how you can make the installation as neat
and simple as your boat will allow. Plan where to position the transducers, Server
and instruments. Think about leaving space for additional instruments in the future.
•A few ”do nots” you should consider:
−Do not cut the cables too short. Allow extra cable length at the Server so it
can be disconnected for inspection without having to disconnect all
attached cables.
−Do not place sealant behind the display. The instrument gasket eliminates
the need for sealant.
−Do not run cables in the bilge, where water can appear.
−Do not run cables close to fluorescent light sources, engine or radio
transmitting equipment to avoid electrical disturbances.
−Do not rush, take your time. A neat installation is easy to do.
•The following material is needed:
Wire cutters and strippers.
Small and large Philips and small flat head screw driver.
Hole saw for the instrument clearance hole 63 mm (2½").
5 mm (1/4") drill for the mounting holes.
Plastic cable ties
If you are doubtful about the installation, obtain the services of an experienced
technician.