NorthStar Explorer AP380 User manual

www.northstarnav.com
Explorer AP380
Autopilot
Installation and Operation Manual

3
Northstar Explorer AP380 System Installation and Operation Manual
FCC Statement
Note: This equipment has been tested and found to comply with the limits for a Class B digital device,
pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against
harmful interference in a normal installation. This equipment generates, uses and can radiate radio
frequency energy and, if not installed and used in accordance with the instructions, may cause harmful
interference to radio communications. However, there is no guarantee that interference will not occur in
a particular installation. If this equipment does cause harmful interference to radio or television reception,
which can be determined by turning the equipment off and on, the user is encouraged to try to correct
the interference by one or more of the following measures:
Reorient or relocate the receiving antenna.
Increase the separation between the equipment and receiver.
Connect the equipment into an output on a circuit different from that to which the receiver is
connected.
Consult the dealer or an experienced technician for help.
A shielded cable must be used when connecting a peripheral to the serial ports.
IMPORTANT SAFETY INFORMATION
Please read carefully before installation and use.
DANGER
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards, Obey all safety messages that follow this symbol to
avoid possible injury or death.
!
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury
CAUTION
!
CAUTION indicates a potentially hazardous situation which, if not avoided,
could result in minor or moderate injury.
CAUTION
CAUTION used without the safety alert symbol indicates a potentially
hazardous situation which, if not avoided, may result in property damage.
DISCLAIMER: It is the owner’s sole
responsibility to install and use the instrument
and transducers in a manner that will not cause
accidents, personal injury or property damage.
The user of this product is solely responsible for
observing safe boating practices.
BRUNSWICK NEW TECHNOLOGIES INC. AND ITS
SUBSIDIARIES AND AFFILIATES DISCLAIM ALL
LIABILITY FOR ANY USE OF THIS PRODUCT IN A
WAY THAT MAY CAUSE ACCIDENTS, DAMAGE OR
THAT MAY VIOLATE THE LAW.
Governing Language: This statement,
any instruction manuals, user guides and
other information relating to the product
(Documentation) may be translated to, or
has been translated from, another language
(Translation). In the event of any conflict
between any Translation of the Documentation,
the English language version of the
Documentation will be the official version of the
Documentation.
This manual represents the Explorer AP380
as at the time of printing. Brunswick New
Technologies Inc. and its subsidiaries and
affiliates reserve the right to make changes to
specifications without notice.
Copyright © 2006 Brunswick New Technologies
Inc. Northstar™ is a registered trademark of
Brunswick New Technologies Inc.

4Northstar Explorer AP380 System Installation and Operation Manual
Installation Contents
Important ................................................................................................................................................5
1 Introduction ..........................................................................................................................................6
1-1 A typical Explorer AP380 system installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-2 Using the Explorer AP380 system with other instruments . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Explorer AP380 system hardware ...........................................................................................................8
2-1 What comes with your Explorer AP380 system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-2 Other parts required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Installation............................................................................................................................................9
3-1 Installation sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-2 Installation guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-3 Installing the MCU600 (Main Control Unit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-4 Installing the power supplies and steering drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-5 Installing the RFU (rudder feedback unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-6 Installing the Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3-7 Installing the Gyro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3-8 Installing the Explorer AP380 display unit and other instruments . . . . . . . . . . . . . . . .23
4 Dockside setup..................................................................................................................................... 27
4-1 Start dockside setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
4-2 Calibrating the rudder feedback unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
5 Sea trials.............................................................................................................................................. 28
5-1 Calibrating the compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
5-2 Aligning the compass and the rudder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Appendix A - Specifications - MCU600...................................................................................................... 29
Appendix B - Specifications - AP380 Display............................................................................................. 30
Appendix C - User data ............................................................................................................................ 31
Operation Section .................................................................................................................................. 34

5
Northstar Explorer AP380 System Installation and Operation Manual
Important
It is the owner’s sole responsibility to install and use the instrument and transducer/s in a manner
that will not cause accidents, personal injury or property damage. The user of this product is solely
responsible for observing safe boating practices.
The choice, location, and installation of all components in any AP380 system is critical. If installation is
not correct, the unit can not perform at its designed potential. If in doubt, consult your Northstar dealer.
Ensure that any holes that cut are in a safe position and will not weaken the boat’s structure. If in doubt,
consult a qualified boat builder.
Using the Explorer AP380 system :
The Explorer AP380 system is intended as an aid to save a helmsman from having to steer for long
periods of time, not as the main means of steering the boat.
The Explorer AP380 system is not intended for use in extreme weather, in adverse conditions or in
water near other boats, dangerous waters or land.
The Explorer AP380 system can not control the boat better than a helmsman. In adverse conditions
steer the boat manually.
Never leave the helm unattended. Keep a watch at all times. The helmsman should always monitor
the course of the boat and the Explorer AP380 system and be ready to resume steering the boat
manually.
The performance of the Explorer AP380 system can be affected by the failure of a part,
environmental conditions, improper installation and use.

6Northstar Explorer AP380 System Installation and Operation Manual
To verify that the Explorer AP380 system is
operating correctly, perform sea trials (see
section 5).
Cleaning and maintenance
Clean the parts of the Explorer AP380 system with
a damp cloth or mild detergent. Avoid abrasive
cleaners, petrol or other solvents.
Do not paint any part of the Explorer AP380
system except for the cables.
1 Introduction
Using this manual
This manual describes how to install and set up
the Explorer AP380 system. Refer to the Explorer
AP380 Operation Section for information on how
to operate the Explorer AP380 display unit.
To install a Explorer AP380 system, you must
perform installation, dockside setup and sea trials
(see sections 3, 4 and 5).
To fully set up a Explorer AP380 system after
a part has been changed or if a problem is
suspected, perform dockside setup and sea trials
again (see sections 4 and 5).
Manual helm
GPS
NMEA
SPEED
WIND
Display
unit
Light duty
Heavy duty
12 V DC
Power supply
Gyro
Compass
MCU600
NavBus
Clutch drive
(optional)
Parts supplied with Explorer AP380 system
Other parts required
Optional parts
Rudder
feedback
unit
Rudder
Power switch or
switches and
power protection
Rudder
control
Key
1-1 A typical Explorer AP380 system installation
Optional instruments
Note: Above shows typical installation
only. Please refer to the information
supplied with your drive for further
information.
More
display
units
Steering
drive

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Northstar Explorer AP380 System Installation and Operation Manual
1-2 Using the Explorer AP380 system with other instruments
1-2-1 Using other instruments
The Explorer AP380 system can use data from
these instruments:
GPS: A GPS or chartplotter, such as a Northstar
Explorer 500 series chartplotter must be
connected to the Explorer AP380 system for the
AP380 to operate in GPS mode (see the Explorer
AP380 Operation Section).
Note: GPS must be via NMEA input.
WIND: A wind instrument, such as a
Northstar WIND series, must be connected
to the Explorer AP380 system for the AP380
to operate in WIND mode (see the Explorer
AP380 Operation Section).
SPEED: A speed instrument, such as:
Northstar’s SPEED with a paddlewheel
speed sensor
or a GPS or chartplotter, such as
Northstar’s Explorer 500 or Explorer 660
series can be connected to the Explorer
AP380 system to increase steering
accuracy.
Note: The speed from a paddlewheel sensor is
the speed that the boat is moving through the
water. The speed from a GPS is the speed over
the ground. If there is a water current then these
two speeds will be different. If the Explorer AP380
system is connected to an instrument with a
paddlewheel sensor and to a GPS, then the
Explorer AP380 system will automatically use the
speed from the paddlewheel sensor instrument.
1-2-2 NavBus
NavBus is a Northstar proprietary system that
allows systems of multiple instruments to be
built using a single set of transducers. When
instruments are connected by NavBus:
If you change the units, alarms or calibration
in one instrument, then the values will
automatically change in all other instruments
of the same type.
Each instrument can be assigned to a group
of instruments, called a NavBus group (see
NavBus group in the Setup > Comms menu, in
the Explorer AP380 Operation Section).
If you change the backlight in an instrument
in group 1, 2, 3 or 4 then the backlight
will automatically change in the other
instruments in the same group. If you change
the backlight in an instrument in group 0
then no other instruments are affected.
If an alarm sounds, mute it on any instrument
which can display that alarm.
For more information, refer to the NavBus
Installation and Operation Manual.
Note: GPS must be via NMEA input.
NavBus and the Explorer AP380 system
The Explorer AP380 system will automatically
work with additional Explorer AP380 displays.
The Explorer AP380 system can receive wind
data from Northstar’s WIND over NavBus.
The Explorer AP380 system can receive speed
data from Northstar’s SPEED over NavBus.
1-2-3 NMEA
NMEA is an industry standard, but is not as
flexible as NavBus as it requires dedicated
connections between instruments. The Explorer
AP380 system has one NMEA input port and one
port that can be configured to be an input or an
output (See Explorer AP380 Operation Section).
Explorer AP380 system NMEA inputs
GPS: The Explorer AP380 system can receive
NMEA GPS data from a compatible GPS or
chartplotter, such as Northstar’s Explorer 500
series chartplotter:
XTE (from APA, APB or XTE sentences) is
required for the Explorer AP380 system to use
GPS mode
BRG (from APA sentences) and BOD (from APA
or APB sentences) are optional and improve
performance
COG (from VTG sentences) is optional and can
be displayed.

8Northstar Explorer AP380 System Installation and Operation Manual
2 Explorer AP380 system hardware
MCU600 (Main Control Unit)
Gyro, with 10 m
(33 ft) attached cable
Protective cover for
display unit
Explorer AP380 Display unit
Compass, with 10 m
(33 ft) attached cable
WIND: The Explorer AP380 system can receive
NMEA wind data from a compatible wind
instrument:
True or apparent wind direction (from MWV
sentences) is required for the Explorer AP380
system to use Wind mode.
SPEED: The Explorer AP380 system can
receive NMEA speed data from a compatible
paddlewheel or GPS instrument:
SOG (from VTG sentences) is optional and
improves performance.
Note: If the Explorer AP380 system is connected
to a Northstar series wind or speed instrument
using NavBus, then the Explorer AP380 system will
automatically receive and use the wind or speed
data, and the NMEA connection need not be wired.
2 mm (#14) twin
stranded cable for high
current wiring
RFU - Rudder feedback unit
2-1 Whatcomeswith yourExplorer AP380 system
Explorer AP380 system NMEA outputs
The NMEA 2 port can be configured to be an
input or to be output:
either heading (HDG & HDT) and rudder
angle (RSA) at once per second
or heading (HDG) at ten times per second
(see NMEA mode in the Setup > Comms menu, See
Explorer AP380 Operation Section).
Documentation
• Warranty
• Display unit mounting template
• This Installation/Operation
manual
Additional hardware
• Mounting hardware
• Cable cover
• Strain relief
• Spare fuses

9
Northstar Explorer AP380 System Installation and Operation Manual
The recommended installation sequence is:
1 Read this manual and the documentation
that comes with the other parts.
2 Plan the installation: select where the
equipment and wiring will be installed (see
section 3-2).
3 Install the MCU600 (see section 3-3).
4 Install the steering drive and wire the heavy
duty and light duty power supplies
(see section 3-4).
5 Install the rudder feedback unit
(see section 3-5).
6 Install the compass (see section 3-6).
3 Installation
3-1 Installation sequence
7 Install the gyro (see section 3-7).
8 Install the display unit and any other marine
instruments that will be used with the
Explorer AP380 system (see section 3-8).
9 Carry out the dockside setup
(see section 4).
10 Carry out the sea trials (see section 5).
If you are unsure where a part should be
installed, mount and wire the part temporarily,
without cutting holes in the boat. After the sea
trials have been completed, install and wire the
part permanently.
Power supply: The Explorer AP380 system
requires two power supplies, both nominally 12
V DC:
A heavy duty supply for the steering drive
A light duty supply for the Explorer AP380
system electronics and display unit; this
supply also powers any additional display
units and other instruments.
The power supplies require one or two switches
and fuses or circuit breakers (see section 3-4).
Steering drive: The Explorer AP380 system can
power a hydraulic pump, constantly running
pump set, hydraulic linear drive or mechanical
drive rated at 12 V DC and up to 20 A.
Rudder linkage: To link rudder to rudder
feedback unit (see section 3-5).
For wiring, see Select Wire Table in section 3-4-2.
External beepers or lights (optional ):
The external output is switched to ground,
30 V DC and 250 mA maximum. If the beepers
and lights require more than 250 mA total, fit a
relay.
Other marine instruments (optional): Wind,
speed or GPS instruments can be connected (see
section 1-2).
Other parts: For systems of several instruments,
wiring and connectors are required. Northstar
junction boxes can simplify wiring several
Northstar instruments together (see section 1-2
or the NavBus Installation and Operation Manual).
Coupling connectors and 10 m (33 ft) extension
cables are available to extend the rudder
feedback unit, compass or gyro cables. Do not fit
more than one extension cable to each unit.
For more information, consult your
Northstar dealer.
2-2 Other parts required
Correct installation is critical to the performance
of the unit. It is vital to read this manual and the
documentation that comes with the other parts
before starting installation.
The MCU600 is not waterproof. Mount the
unit in a dry place.
The Explorer AP380 system display unit is
waterproof.
The compass, gyro and rudder feedback
unit are completely waterproof.
Ensure that any holes that you cut will not
weaken the boat’s structure. If in doubt, consult
a qualified boat builder.

10 Northstar Explorer AP380 System Installation and Operation Manual
3-2 Installation guide
This is a general guide for locating and wiring the parts of the Explorer AP380 system. The instructions
for a particular part may have additional requirements.
3-2-1 Location guide
Do not mount any part where it can be used
as a handhold, where it will interfere with the
operation of the boat or where it might be
submerged.
Do not mount any part where it will interfere
with launching or retrieving
the boat.
Do not mount any part within 0.5 m (20”) of
the plane of a radar antenna.
Mount the compass and gyro:
At least 1 m (3 ft) away from sources of
electrical signals or noise, such as the
batteries, high-current cables, other boat
cables, engines, fluorescent lights, power
inverters, radio or radar transmitters and
antennas.
At least 1 m (3 ft) away from equipment
containing a magnet, such as a compass
or speaker.
3-2-2 Wiring guide
The Explorer AP380 system has two kinds of
cables:
The heavy-duty power supply and steering drive
usually require high-current cables:
Select the wire gauge from the wire size table
(see section 3-4-2).
Fit high-current cables at least 1 m (3 ft) away
from other electronic devices in
the boat.
Keep the cables as short as possible.
Twin 2 mm (#14) cable is supplied with the
Explorer AP380 system and can be used for
the high current cable if its gauge is suitable.
All the other cables are low-current:
Fit low-current cables at least 1 m (3 ft) away
from sources of electrical signals or noise,
such as the high-current cables, other boat
cables, engines, fluorescent lights, power
inverters and radio or radar transmitters and
antennas.
If the cable for the rudder feedback unit,
compass or gyro is too long, do not shorten
the cable; instead coil the cable up near the
main control unit.
The cable for the rudder feedback unit,
compass or gyro can be extended by
adding a 10 m (33 ft) extension cable and
coupling connector. Do not fit more than one
extension cable to each unit.
When fitting any type of cable:
Do not crush, pinch or strain the cable.
Secure the cable at regular intervals.
Ensure no connectors or exposed terminals
are in the bilge.