NORTHROP GRUMMAN naviguide 4000 Manual

Sperry Marine
Head Office and Freight: Woltmanstrasse 19, D-20097 Hamburg, Germany
Correspondence Address: P.O. Box 10 47 09, D-20032 Hamburg, Germany
Tel.: ++49-40-299 00-0, Fax: ++49-40-299 00-298, E-mail Service: [email protected]
7-120 056336
User, Installation and Service Manual
NAVIGUIDE 4000
Manual Steering System
with NAVINET 4000 Steering Control Network
Rev. AA, 08 Jan 2004

056336 Rev. AA NAVIGUIDE 4000
Copyright © Northrop Grumman Sperry Marine, Hamburg, 2004
This document contains proprietary information of
Northrop Grumman Sperry Marine, Hamburg, Germany.
Any reproduction or publication of this document or any portions thereof without the prior
written consent of Sperry Marine is expressly prohibited.
Subject to alteration without notice.
Revision Record
Rev. Date Remarks
AA 08 Jan 2004 initial release

NAVIGUIDE 4000 056336 Rev. AA
Contents
1 Description
1.1 Introduction ............................................................................................................1–1
1.2 System Components..............................................................................................1–2
1.2.1 Steering Control Unit ......................................................................................1–2
1.2.2 Steering Mode Selector / NFU Tiller...............................................................1–2
1.2.3 Mechanical Mode Switch................................................................................1–2
1.2.4 FU Hand Wheel ..............................................................................................1–3
1.2.5 NFU Override Unit ..........................................................................................1–3
1.2.6 Bus Interface Units (BIUs) ..............................................................................1–4
1.2.7 NAVINET 4000 Steering Control Network......................................................1–6
1.2.8 NAVIPILOT 4000 Control and Display Unit (CDU).........................................1–7
1.3 Example System Configurations............................................................................1–8
1.3.1 FU / NFU Manual Steering for Single Rudder ................................................1–8
1.3.2 FU / NFU Manual and Autopilot Steering for Single Rudder ..........................1–9
1.3.3 FU / NFU Manual and Autopilot Steering for Single Rudder (SPS)..............1–10
1.3.4 Dual FU / NFU Manual Steering for Single Rudder......................................1–11
1.3.5 Dual FU / NFU Manual and Autopilot Steering for Single Rudder................1–12
1.3.6 FU / NFU Manual Steering for Dual Rudders ...............................................1–13
1.3.7 Dual FU / NFU Manual Steering for Dual Rudders.......................................1–14
1.4 Technical Data .....................................................................................................1–15
1.4.1 Steering Control Unit (SCU) .........................................................................1–15
1.4.2 SCU Daughter PCBs....................................................................................1–17
1.4.3 Bus Interface Units (BIUs) ............................................................................1–18
2Operation
2.1 General Concepts ..................................................................................................2–1
2.1.1 Steering Control Operations ...........................................................................2–1
2.1.2 Engaging / Disengaging Bus Steering............................................................2–2
2.1.3 Control Transfer between Steering Positions .................................................2–3
2.2 Operating the Bus Interface Units..........................................................................2–7
2.2.1 Control Keys ...................................................................................................2–7
2.2.2 Display Screens..............................................................................................2–8
2.2.3 Power-Up Sequence ....................................................................................2–13
2.2.4 Adjusting the BIU Display Brightness ...........................................................2–14
2.3 Operating Procedures..........................................................................................2–15
2.3.1 Engaging / Disengaging Bus Steering..........................................................2–15
2.3.2 Selecting the Steering Mode ........................................................................2–16
2.3.3 Transferring Control between Steering Positions .........................................2–19
2.3.4 Synchronous / Independent Rudder Control ................................................2–36
2.3.5 Overriding Bus Steering (NFU Override)......................................................2–38
2.3.6 Overriding Auto/Ext. Steering Modes (FU Bus Override).............................2–42
2.3.7 Overriding Auto Steering Mode according to ABS .......................................2–44

056336 Rev. AA NAVIGUIDE 4000
ii
3 Errors and Alarms
3.1 Audible Warnings from the BIUs ........................................................................... 3–1
3.1.1 Single Beep: Invalid action............................................................................. 3–1
3.1.2 Three Short Beeps: Takeover Alarm.............................................................. 3–1
3.1.3 Four Long Beeps: Takeover Reminder Alarm................................................ 3–1
3.2 System Alarms ...................................................................................................... 3–2
3.2.1 Handling System Alarms with the SAM.......................................................... 3–2
3.2.2 List of Alarm Codes and Messages ............................................................... 3–4
4 Installation
4.1 Mechanical Installation .......................................................................................... 4–1
4.1.1 Mounting the System Components................................................................ 4–1
4.1.2 Adjustment of Steering Gear Feedback Units................................................ 4–1
4.2 Electrical Installation.............................................................................................. 4–2
4.2.1 Wiring............................................................................................................. 4–2
4.2.2 NAVINET 4000 Steering Control Network ..................................................... 4–2
4.3 SCU Jumper Configuration.................................................................................... 4–4
4.4 DC Daughter PCB Jumper Settings ...................................................................... 4–5
5 System Configuration
5.1 Configuring the Bus Devices ................................................................................. 5–1
5.1.1 Configuring Steering Positions....................................................................... 5–1
5.2 Configuring the Steering Gear Control .................................................................. 5–3
5.2.1 Configuring Bang-Bang Steering Control....................................................... 5–3
5.2.2 Configuring Analogue Steering Gear Control................................................. 5–6
6 Configuring the Steering Control Unit
6.1 SCU Setup Menu................................................................................................... 6–1
6.1.1 Accessing the SCU Setup.............................................................................. 6–1
6.1.2 SCU Setup: Overview .................................................................................... 6–3
6.1.3 SCU Setup: Serial Interface......................................................................... 6–11
6.1.4 SCU Setup: Analogue Interface................................................................... 6–12
6.1.5 SCU Setup: Ports......................................................................................... 6–15
6.1.6 SCU Setup: Relays ...................................................................................... 6–25
6.1.7 SCU Setup: Steering Gear........................................................................... 6–28
6.1.8 SCU Setup: ABS Override ........................................................................... 6–37
6.1.9 SCU Setup: Helm Advisor............................................................................ 6–38
6.1.10 SCU Setup: Service Interface ...................................................................... 6–38
6.1.11 SCU Setup: CAN Interface........................................................................... 6–38
6.1.12 SCU Setup: Main Mode Switch.................................................................... 6–39
6.1.13 SCU Setup: Alarm Conditions...................................................................... 6–39

NAVIGUIDE 4000 056336 Rev. AA
iii
7 Configuring the Bus Interface Units
7.1 BIU Setup Menus...................................................................................................7–1
7.1.1 Setup Menu Access Codes ............................................................................7–1
7.1.2 Entering the Setup Mode................................................................................7–2
7.1.3 Navigating the Setup Menus ..........................................................................7–3
7.1.4 Selecting Parameter Settings .........................................................................7–4
7.1.5 Toggling Parameters On or Off ......................................................................7–5
7.1.6 Editing Characters/Numbers ..........................................................................7–6
7.2 Setup of FU Control Units (3-Key-Units)................................................................7–7
7.2.1 Functional Configuration (Setup 358).............................................................7–7
7.2.2 Basic Configuration (Setup 600)...................................................................7–11
7.2.3 General CAN Setup and Service Information (Setup 610) ...........................7–21
7.3 Setup of 6-Key-Units............................................................................................7–23
7.3.1 Functional Configuration (Setup 358)...........................................................7–23
7.3.2 Steering Position Selector Basic Configuration (Setup 600) ........................7–26
7.3.3 Steering Mode Selector Configuration Options (Setup 600) ........................7–30
7.3.4 Dual Rudder Sync Selector Configuration Options (Setup 600)...................7–35
7.3.5 Steering Alarm Module Configuration Options (Setup 600) .........................7–40
7.3.6 General CAN Setup and Service Information (Setup 610) ...........................7–44
8 Service Information
8.1 SCU Main PCB ......................................................................................................8–1
8.1.1 Location of Diagnostic LED Indicators and Socketed ICs ..............................8–1
8.1.2 List of Diagnostic LED Indicators....................................................................8–2
8.1.3 List of Socketed ICs........................................................................................8–2
8.2 Solenoid Daughter PCBs .......................................................................................8–3
8.2.1 Location of Diagnostic LED Indicators on Daughter PCBs.............................8–3
8.2.2 List of Diagnostic LED Indicators....................................................................8–3
Appendix
App. A Tables
App. B Drawings

056336 Rev. AA NAVIGUIDE 4000
iv

NAVIGUIDE 4000 056336 Rev. AA
1.1: Introduction Page 1–1
1 Description
1.1 Introduction
The NAVIGUIDE 4000 Manual Steering System is a Follow-Up (FU) steering con-
trol system for marine applications. The system uses the NAVINET 4000 Steering
Control Network for communications between the central Steering Control Unit
(SCU) and a number of modular control units called Bus Interface Units (BIUs).
The BIUs provide the controls required at the respective steering positions, such
as FU rudder control, steering mode and position selection, dual rudder sync con-
trol and system status information.
The modular design of the system allows for straightforward installation on all
types of vessels and to all classification society requirements.
Use of the NAVINET 4000 Steering Control Network greatly reduces cabling com-
plexity and cost compared to conventional point-to-point wiring.
The NAVIGUIDE 4000 Manual Steering System may be combined with the NAVI-
PILOT 4000 Heading Control System, to add automatic steering capabilities. In
this case, the complete system is referred to as a SteerMaster™ Control System.
Next to the Auto mode (heading control), the NAVIPILOT 4000 provides Nav and
Track steering modes in conjunction with compatible GPS, Electronic Chart or
Track-Keeping systems.
NAVIGUIDE 4000 and SteerMaster™ control systems may also receive and ex-
ternal analogue control voltage (±10 V). This allows external systems to control
the rudders through a connection to the SCU. Many types of systems including DP
and Track Control systems will produce the required control voltage and may be
interfaced using the external connection.

056336 Rev. AA NAVIGUIDE 4000
Page 1–2 1.2: System Components
1.2 System Components
1.2.1 Steering Control Unit
The Steering Control Unit (SCU) contains an FU
control amplifier and all of the system’s in- and
output interfaces.
Each SCU may be equipped with up to two
daughterboards providing the required inter-
faces to the vessel’s steering gear.
The available daughterboards include inter-
faces to conventional AC or DC solenoid valves
(bang-bang), proportional solenoid valves, and
an analogue I/O board offering two isolated out-
puts (rudder order or error signals, ±10 V).
Two Steering Control Interface Units may be combined to provide dual FU control
for a single rudder steering gear or single FU control for a dual rudder steering
gear. Four Interface Units may be combined to provide dual FU control for dual
rudder steering gears.
1.2.2 Steering Mode Selector / NFU Tiller
The Steering Mode Selector / NFU Tiller is
located at the main steering position and se-
lects between NFU and secondary (bus)
steering modes. In NFU steering mode, the
integrated NFU tiller actuates the solenoid
valves directly.
In bus steering mode, a Steering Mode Se-
lector Bus Interface Unit (see 1.2.6.3) is used to select between the steering
modes available under bus control (e.g. “FU”, “Auto”, “External” etc.).
If so configured, the NFU tiller may be used to override the bus steering mode by
moving the tiller from the midship’s detent. The override capability may be enabled
for all bus steering modes or for specific modes only.
1.2.3 Mechanical Mode Switch
Instead of the Steering Mode Selector / NFU
tiller and Steering Mode Selector Bus Inter-
face Unit, a conventional mechanical mode
switch may be installed at the main steering
position.
A mechanical mode switch selects directly
between the available steering modes, in-
cluding NFU. A separate NFU tiller is used to actuate the solenoid valves in NFU
steering mode.

NAVIGUIDE 4000 056336 Rev. AA
1.2: System Components Page 1–3
1.2.4 FU Hand Wheel
FU hand wheels provide follow-up control in the FU bus
steering mode.
One hand wheel (the main helm) may be connected di-
rectly to the Steering Control Interface Unit(s).
Additional hand wheels may be used in combination with
FU Interface/Display Units to provide FU control at re-
mote steering positions via the NAVINET 4000 Steering
Control Network.
1.2.5 NFU Override Unit
The NFU Override Unit allows to quickly
override bus steering mode and assign con-
trol to the associated NFU Override tiller.
Override mode is activated by moving the
override tiller from the midship’s detent. The
tiller remains in control of the rudder until the
operator cancels the override mode („forced
override“). The override capability may be enabled for all bus steering modes or
for specific modes only.

056336 Rev. AA NAVIGUIDE 4000
Page 1–4 1.2: System Components
1.2.6 Bus Interface Units (BIUs)
1.2.6.1 FU Mini-Wheel/Display Unit
The FU Mini-Wheel/Display Unit (FMW) is a bus FU
steering control interface. At the unit currently in com-
mand, the mini wheel’s position is translated into FU
rudder commands and transmitted to the Steering Con-
trol Interface Unit(s) via the bus. The rudder order and
the actual rudder angle are presented as bar graphs on
the unit’s display.
In SynchroHelm™ systems, units not in command
move their mini-wheels in synchronization with the unit
in command.
1.2.6.2 FU Interface/Display Unit / Wheel Control Unit
In combination with the FU handwheel connected di-
rectly to the SCU(s) at the main steering position (the
main helm), the FU Interface/Display Unit (FID) acts as
an actual rudder and steering position status display.
In combination with remote FU handwheels, the FID
acts as a bus follow-up steering control interface. If the
unit’s steering position is in command, the handwheel’s
position is translated into an FU rudder order and trans-
mitted to the connected SCU(s). The rudder order and
the actual rudder angle are presented as bar graphs on the unit’s display.
In SynchroHelm™ systems, the unit is referred to as Wheel Control Unit (WCU).
In addition to the functions described above, the WCU also controls the Synchro-
Helm™ drive which, when the unit is not in command, moves the hand wheel in
synchronization with the unit in command.

NAVIGUIDE 4000 056336 Rev. AA
1.2: System Components Page 1–5
1.2.6.3 Steering Mode Selector Unit
The Steering Mode Selector Unit (SMS) selects be-
tween the available bus steering modes.
When SMSs are used, one SMS will be located at the
main steering position. Additional SMSs may be in-
stalled at other steering positions.
1.2.6.4 Steering Position Selector
The Steering Position Selector (SPS) transfers bus
steering control between the available steering posi-
tions.
When SPSs are used, one SPS will always be located
at the main steering position. Additional SPSs may be
installed at other steering positions.
An SPS may select between up to four steering posi-
tions. If more than four steering positions are present,
multiple SMSs are cascaded.
1.2.6.5 Dual Rudder Sync Selector
The Dual Rudder Sync Selector (DRS) selects between
synchronous and independent control of the rudders in
a dual rudder system.
The DRS is typically installed on wing steering positions
and is used in conjunction with two FU Mini-Wheel/Dis-
play Units or two FU Interface/Display Units with sepa-
rate FU Mini-Wheels.
1.2.6.6 Steering Alarm Module
The Steering Alarm Module (SAM) allows to view and
acknowledge the active alarms from all steering sys-
tem units connected to the bus.

056336 Rev. AA NAVIGUIDE 4000
Page 1–6 1.2: System Components
1.2.7 NAVINET 4000 Steering Control Network
The NAVIGUIDE 4000 SCU and the connected bus interface devices (BIUs and
NAVIPILOT 4000 CDUs) communicate through the NAVINET 4000 Steering Con-
trol Network, using the NMEA 2000 communications protocol.
NAVINET 4000 is is a CAN (Controller Area Network) bus, supporting a maximum
bus length of 160 metres. The internal bus power supply of the SCU supports up
to 10 devices or „nodes“. If more than 10 nodes are contained in the system, an
external bus power supply must be provided.
1.2.7.1 NAVINET 4000 connection board
The NAVINET 4000 connection board is a
passive component which serves to splice
the drop cables to the individual bus units
(nodes) into the bus backbone.
1.2.7.2 NAVINET 4000 bus backbone cable
NAVINET 4000 requires a bus backbone cable which is approved for compatibility
with the requirements of the CAN bus according to IEC 61126-3.
At the time of writing of this manual, the only approved type of cable is:
Lapp 2705250 Unitronic Bus DeviceNet™ Trunk cable,
manufactured by U.I.Lapp, Schultze-Delitsch Str. 25, D-70565 Stuttgart, Ger-
many.
As the backbone cable is shipyard/owner supply, it must be verified at installation
that the abobe mentioned type of cable is provided. Bus communications will not
operate reliably over other types of cable.

NAVIGUIDE 4000 056336 Rev. AA
1.2: System Components Page 1–7
1.2.8 NAVIPILOT 4000 Control and Display Unit (CDU)
When a NAVIPILOT 4000 Control and Dis-
play Unit (CDU) is added to the NAVIGUIDE
4000, the complete system is referred to as a
SteerMaster™ Control System.
Next to the Auto mode (heading control), the
NAVIPILOT 4000 provides Nav and Track
steering modes in conjunction with compati-
ble GPS, Electronic Chart or Track-Keeping systems. Operation and installation of
the NAVIPILOT 4000 Heading Control System is described in a separate manual,
Sperry Marine USA document JA19-8039x.
Within a SteerMaster™ Control System, a NAVIPILOT 4000 CDU acts as a bus
interface device and communicates with the SCU via the bus. Multiple CDUs may
be installed within the system and a given steering position may be equipped with
more than one CDU.
At the time of writing of this manual, the NAVIPILOT 4000 CDU is the only bus in-
terface device capable of accessing the SCU configuration setup. A CDU will
therefore also be provided with a manual steering system, but will not be perma-
nently connected to the bus.

056336 Rev. AA NAVIGUIDE 4000
Page 1–8 1.3: Example System Configurations
1.3 Example System Configurations
1.3.1 FU / NFU Manual Steering for Single Rudder
Fig.1–1 shows a basic FU / NFU manual steering system (F/NN).
Three steering positions are present, Main Bridge (the main steering position),
Port Wing and Stb. Wing (the remote steering positions). Selection between steer-
ing modes and steering positions is made at the same time using a manual steer-
ing mode selector switch.
The operator at the Main Bridge selects between modes „NFU main“, „FU main“
and „Remote“.
When „Remote“ is selected, an offer to take over control goes out to all remote de-
vices. An operator at a remote position may then take over, which completes con-
trol transfer to „Remote“. Between the remote positions, control may now be freely
transferred.
At any time, the operator at the Main Bridge may take control back to the main
steering position by selecting the „NFU main“ of „FU main“ steering mode.
Fig. 1–1:
example F/NN
system
TAKE
OVER
Steering
Gear
Pumps
Port Wing Main Bridge Stb. Wing
SCU
SAM
NAVINET 4000 Steering Control Network

NAVIGUIDE 4000 056336 Rev. AA
1.3: Example System Configurations Page 1–9
1.3.2 FU / NFU Manual and Autopilot Steering for Single Rudder
Fig.1–2 shows an FU / NFU manual and autopilot steering system (F/NN-AP).
This system uses the Steering Mode Selector / NFU Tiller in conjunction with a
Steering Mode Selector Unit (SMS). The operator at the Main Bridge selects be-
tween „NFU“ and „Secondary“ (bus steering) modes with the Steering Mode Se-
lector / NFU Tiller.
When „Secondary“ is selected, the operator at the main steering position may
choose „FU“, „Auto“ and „Remote“ steering modes with the Steering Mode Selec-
tor Unit.
When „Remote“ is selected, an offer to take over control goes out to all remote de-
vices. An operator at a remote position may then take over, which completes con-
trol transfer to „Remote“. From the active remote position, control may be offered
to any other steering position, including the Main Bridge.
At any time, the operator at the Main Bridge may take control back to the main
steering position by selecting the „FU“ or „Auto“ steering mode at the Steering
Mode Selector Unit or by selecting „NFU“ at the Steering Mode Selector / NFU
Tiller.
Fig. 1–2:
example
F/NN-AP
system
TAKE
OVER
Steering
Gear
Pumps
Port Wing Main Bridge Stb. Wing
SCU
SMS
NAVINET 4000 Steering Control Network

056336 Rev. AA NAVIGUIDE 4000
Page 1–10 1.3: Example System Configurations
1.3.3 FU / NFU Manual and Autopilot Steering for Single Rudder (SPS)
Fig.1–3 shows an F/NN-AP system which uses Steering Position Selector Units
(SPS) to select the active bus steering position.
The SPS at the main steering position will not offer a „Remote“ bus steering mode.
Instead, an offer to take over control can be sent to a specific remote position us-
ing the SPS. An operator at that position may then take over, which completes
control transfer. Using the SPS at the active remote position, control may be of-
fered to any other steering position, including the Main Bridge.
At any time, the operator at the Main Bridge may force control back to the main
steering position by selecting the „FU“ or „Auto“ steering mode at the Steering
Mode Selector Unit or by selecting „NFU“ at the Steering Mode Selector / NFU
Tiller.
Fig. 1–3:
example
F/NN-AP
system with
SPSs
TAKE
OVER
SMS
TAKE
OVER
SPS
TAKE
OVER
SPS
Steering
Gear
Pumps
Port Wing Main Bridge Stb. Wing
SCU
NAVINET 4000 Steering Control Network
TAKE
OVER
SPS

NAVIGUIDE 4000 056336 Rev. AA
1.3: Example System Configurations Page 1–11
1.3.4 Dual FU / NFU Manual Steering for Single Rudder
Fig.1–4 shows a basic dual FU / NFU manual steering system (FF/NN).
In contrast to the F/NN system, the FF/NN system contains two SCUs, each of
which is controlling a separate steering gear pump.
During normal operation, one of the SCUs will become the bus master and control
all bus communications. The other SCU will become a slave unit. In case of failure
of the master unit, the slave will assume the master role, thus ensuring redun-
dancy of the system.
Fig. 1–4:
example
FF/NN
system
Port Wing Main Bridge Stb. Wing
SCU 1
SAM
SCU 2
Steering
Gear
Pump 1
Steering
Gear
Pump 2
NAVINET 4000 Steering Control Network

056336 Rev. AA NAVIGUIDE 4000
Page 1–12 1.3: Example System Configurations
1.3.5 Dual FU / NFU Manual and Autopilot Steering for Single Rudder
Fig.1–5 shows a basic dual FU / NFU manual and autopilot steering system (FF/
NN-AP).
Steering mode selection and control transfer procedures are the same as for the
F/NN-AP system described in 1.3.2.
Redundant dual FU/NFU control is provided in the same manner as in the FF/NN
system described in 1.3.4.
Fig. 1–5:
example
FF/NN-AP
system
Port Wing Main Bridge Stb. Wing
SCU 1 SCU 2
Steering
Gear
Pump 1
Steering
Gear
Pump 2
NAVINET 4000 Steering Control Network
SMS
TAKE
OVER

NAVIGUIDE 4000 056336 Rev. AA
1.3: Example System Configurations Page 1–13
1.3.6 FU / NFU Manual Steering for Dual Rudders
Fig.1–6 shows a FU / NFU manual steering system for dual rudder control. This is
basically the F/NN system described in 1.3.1, but with all rudder control facilities
present in twofold.
The hand wheel at the Main Bridge provides synchronous FU control of the port
and stb. rudders.
Each remote steering position is equipped with two FU Mini-Wheel/Display Units
and a Dual Rudder Sync Selector. Once control is transferred to a remote steering
position, the operator may switch from the „Synchronous“ to the „Independent“
mode to control the port and stb. rudders independently.
During normal operation, one of the SCUs will become the bus master and control
all bus communications. The other SCU will become a slave unit. However, in
case of failure of one SCU, the associated rudder can no longer be controlled in
the bus steering modes.
Fig. 1–6:
example FU/
NFU steering
for dual
rudders
Port Wing Main Bridge Stb. Wing
Por t
SCU
SAM
Stb.
SCU
Port
Steering
Gear
Pumps
Stb.
Steering
Gear
Pumps
NAVINET 4000 Steering Control Network
DRSS DRSS

056336 Rev. AA NAVIGUIDE 4000
Page 1–14 1.3: Example System Configurations
1.3.7 Dual FU / NFU Manual Steering for Dual Rudders
Fig.1–7 shows a Dual FU / NFU manual steering system for dual rudder control.
For each of the port and stb. rudders, two SCUs are provided, each of which is
controlling a separate steering gear pump.
In case of failure of one of the SCUs, the remaining SCU at the same side takes
over control of the associated rudder, thus ensuring redundancy of the system.
Fig. 1–7:
example dual
FU/NFU steer-
ing for dual
rudders
Port Wing Main Bridge Stb. Wing
Por t
SCU 1
Port
Steering
Gear
Pump 2
Port
Steering
Gear
Pump 1
NAVINET 4000 Steering Control Network
SAM
Stb.
SCU 1
Por t
SCU 2
Stb.
SCU 2
Stb.
Steering
Gear
Pump 2
Stb.
Steering
Gear
Pump 1
DRSS DRSS