Onwa KAP-833 User manual

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KAP833KAP833
OPERATOR'S MANUAL
KAP-833KAP-833
Autopilot

Warning!
Automatic pilots are designed to be a navigational aid. As an automatic steering
aid, an autopilot can alleviate the boredom of hand steering.
This allows the operator of the vessel time to attend to other duties, keep a more
accurate check of navigation duties or just relax and enjoy the trip.
HOWEVER, THE AUTOPILOT SHOULD NOT BE LEFT SOLELY IN CHARGE
OF THE VESSEL AND AN ADEQUATE WATCH SHOULD BE MAINTAINED
AT ALL TIMES.
IT IS NOT RECOMMENDED THAT THE AUTOPILOT BE USED WHILE
NAVIGATING IN RESTRICTED WATERWAYS AS WATER CURRENTS,
WIND CHANGES OR RADIO TRANSMITTER INTERFERENCE MAY AFFCT
VESSEL COURSE SUFFICIENTLY TO ENDANGER YOUR OWN OR OTHER
VESSELS.

Introduction
The KAP-833 autopilot is a hybrid of digital and analogue technology to give
the best of both worlds - excellent steering characteristics with digital compass
display, keypad course input, GPS and gyro interfaces, and much more, in solid
metal case.
The KAP-833 Autopilot controls the vessel steering through mechanical drive,
reversing pump set ,solenoid valves or relays.
The compass must be installed in a place free of magnetic interference, and
connected to the autopilot via the cable supplied.
The rudder feedback must be attached to the rudder in such a way that it can
accurately measure the position of the ships rudder. This must also be
connected to the autopilot via the cable supplied.
Provision has been made for two hand remote, panel remote, steering lever
or steering wheel stations. These are very robust units, which will not be
adversely affected by water. The abilities they provide are somewhat different
from the main control panel. See the Operation section of this manual for details.
For more in formation on installation of your KAP-833 autopilot, see the
Autopilot Installation section of this manual.
For more information on using your KAP-833 autopilot, see the Autopilot
Operation section of this manual.

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Autopilot Operation
1-1
1-2
1-3
1-4
1-5
Overview of Operation
Standby Mode
Auto Mode
Power Steering Mode
GPS Mode
Alarms
Stopwatch Timer Alarm
Angle Off Course Alarm
No GPS Data Alarm
2-1
2-2
2-3
Remote Unit Operation
Control function setting
4-1
4-2
4-3
Weather
Counter-Rudder
Rudder (Rudder Ratio) Control
Compass Calibration
6-1
6-2
6-3
6-4
6-5
6-6
6-7
6-8
6-9
6-10
6-11
7-1
7-2
7-3
Connection Tests
Adjustments
Fuse Protection
Commissioning Checks
Installation of Main Unit
Installation of Compass
Installation of Rudder Feedback
Installation of solenoid
Installation of Motor
Installation of Remote Units
NMEA Connection
External Alarm Installation
PORT Wiring Diagram
System Configuration with optional items
Installation Dimension
Autopilotlot Installation
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3
4
5
7
7
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8
9
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Autopilot OperationAutopilot Operation
Overview of Operation
The following is a brief list of the capabilities of the KAP-833 autopilot. Each
described in more detail in a separate chapter.
Note: Power to the KAP-833 is supplied via Weather control. Turn the knob
control in a clockwise direction to apply power to the KAP-833; this will
initially put the KAP-833 into Standby mode.
Standby Mode
The digital display shows the current magnetic heading.
The autopilot will not apply any steering control.
Auto Mode
The autopilot will maintain your vessel on any desired magnetic course.
This course can be set from the control panel by dialling up a course
change with the course knob, entering a course from the keypad, or
recalling a stored course with the PRESET button.
Power Steer
The rudder angle may be controlled by the course knob on the main
panel or from one of the remote steering stations.
GPS Mode
When receiving information from a GPS unit, the autopilot can steer a
vessel to a precise latitude and longitude.
Stopwatch Timer Mode
A timer can be set for 1 to 60 minutes. When the time expires, an alarm
will sound. Uses include timing of trawling runs, or a reminder to check
for anchor drag at set periods during a storm.
Remote steering stations
Two of these may normally be fitted (eg on each side of the bridge),
allowing adjustment of the autopilot course, or direct control of the rudder
(power steering). An optional third steering lever may be connected to
the control unit, subject to a special order at time of delivery.
Rudder Ratio, Weather and Counter Rudder
These controls customise the KAP-833 for your vessel. They may also
be used to adjust steering for varying sea conditions.
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1

Turn Weather control knob clockwise to switch KAP-833 on to Standby mode.
In this mode
The Main and Standby lights are on
The motor clutch is disengaged
No steering control output is generated
The commercial watch alarm is turned off (if enabled)
The digital display shows the vessels current magnetic course
Possible alarms
Stopwatch timer alarm
If the option of Electric steering is enabled, this mode may not be
available and the unit will go direct to power steer on turn on.
Standby Mode
2
2

Engaging Auto steering mode
When in Standby Mode and the AUTO key is pressed, a beep will
sound and the adjacent yellow light will be turned on.
The autopilot will lock on to the heading indicated.
Disengaging the Autopilot
Press the Standby button. A beep will sound and the vessel will return to
manual steering (Standby Mode). The AUTO light will be turned off and
STANDBY light turned on.
Course Adjustment
Pressing the port (red) or stbd (green) arrow keys will cause a one degree
course change in that direction. The display will change to indicate the
new course-to-steer.
Rotating the course-change knob will change the course-to-steer by one
degree for each click .
Entering a course from the keypad, and pressing GOTO will change the
course-to-steer to the bearing entered.
Auto Mode
3
3

Engaging Power Steering Mode
Press the Power button. A beep will sound and the adjacent light will come
on. The rudder will move to the centre position.
Setting the rudder angle
The angle of rudder applied depends on the amount of rotation of the
course knob.
The maximum angle of rudder is controlled by the internal and external rudder
limit settings.
Power Steering Mode
4
Rotating the course control knob clockwise will move the rudder to
starboard. Rotating the course control knob anticlockwise will move the
rudder to port.
For information on power-steering with a remote unit (eg: Electric Wheel or
Steering Levers), see the section on remote units.
If your vessel requires counter-rudder while steering in auto mode, you may wish
to set the counter rudder control 1 (ie: disabled) while using power-steer.
4

Disengaging GPS Mode
Setting up your GPS unit
Because there are a great variety of GPS units that will work with this
autopilot, the following is a guide only. For more information, consult your
GPS manual.
The GPS unit must be set up to output NMEA0183 data on a pair of
wires which are connected to the GPS In terminal connections inside the
KAP-833. The data generated must include at least on of the following.
GPS Mode
5
For use when interfaced to a GPS generating NMEA 0183 data output. While in
auto mode this allows the autopilot to be directed by the GPS, enabling automatic
heading changes and eliminating the effects of wind and tide.
The digital display indicates the course-to-steer, which will be the bearing
between the origin and destination waypoints, plus a factor to correct for the
current cross-track-error (XTE).
Pressing the Auto key will set the KAP-833 to Auto Mode.
Pressing the Standby key will return the pilot to Standby.
The APA sentence.
The APB sentence.
The BOD and XTE sentences.
If only the XTE data sentence available, the pilot can steer in a restricted
manner. See later in this section.
5
When in any mode, press the GPS key. A beep will sound and the
adjacent yellow light will be turned on.
The vessel will begin turning from its current course to the course
requested by the GPS unit, at a maximum rate of 10 degrees per second.
If no GPS data is being received by the KAP-833, the autopilot will lock
onto the course of the vessel at the time that GPS Mode was engaged, and
the No GPS Data alarm shall sound.
Engaging GPS Mode

The GPS unit must then be commanded to go to a waypoint, or to follow
a line joining two or more waypoints (called a route).
This unit will then send information to the autopilot from which can be
calculated the course-to-steer. If several waypoints are linked together into
a single route, and the GPS unit is set to auto-sequence between them,
and an arrival zone of more than 0.1 NM (Nautical Miles) is set so that
the GPS can detect when the vessel has reached a waypoint, then the
KAP-833 will be able to steer from each waypoint to the next without
intervention.
If only the XTE information is available from your GPS unit then your
vessel must be on track, and heading in the correct direction before
engaging the GPS mode, and the auto-sequencing feature is not available.
Remember:
Prior to engaging GPS mode, a route must be programmed into the GPS
for the Autopilot to follow.
No GPS Data Alarm
If the autopilot is not receiving valid information while in GPS Mode, the
No GPS Data alarm will sound, and the GPS light will blink. This could
be caused by:
Incorrect wiring of the GPS to the KAP-833.
Incorrect data output from the GPS unit.
No route set up or selected in the GPS unit.
No location fix at the GPS unit.
See also Alarms in the Operation section of this manual.
The bearings generated by the GPS unit must correspond to the bearings the
KAP-833 is receiving from its magnetic compass. The greater the difference
between these bearings, the less accurate will the be GPS Mode steering.
Ensure that the GPS unit has the correct magnetic correction factor.
Ensure that the KAP-833 compass is correctly aligned and installed.
6

A number of conditions will cause alarms to sound. In some cases, lights on the
control panel will also blink. Each alarm has a different beep pattern (except
stopwatch and commercial watch alarm). The external alarm output may also be
turned on by some of these alarms; this does not have a beep pattern .
Stopwatch Timer Alarm
This alarm indicates that the time set by the user has expired.
Alarm pattern is 0.2 second on, 0.2 second off until reset.
The external alarm output is turned on 1 minute after the internal alarm
commences. Note that a suitable piezo buzzer must be attached to this
output. This is not supplied with the KAP-833 but is available as an option.
Angle Off Course Alarm
The alarm pattern is 0.2 seconds on, 0.2 seconds off when vessel is more
than the set number of degrees from course-to-steer. The off-course
light blinks on and off at the same rate as the audible alarm. The angle at
which this alarm sounds can be set to any desired limit (including
completely disabled).
.
1
2
2
2
An alarm will sound if the vessel has deviated from its desired course by more
than a set number of degrees. This can be caused by a number of steering faults,
any of which require attention by the crew.
The angle at which this alarm sounds may be set to any value between 1 and 180
degrees.
To set the off-course alarm angle
Enter the desired angle in degrees from the keypad, and then press the
off-course button.
Angle Off Course
2
AlarmsAlarms
22
7
To examine the current off-course alarm angle
When no digits entered from the keypad, press the off-course button. The
currently set alarm angle (in degrees) will be displayed for two seconds.
When the allowable angle is exceeded, the off-course alarm will sound and the
off-course light will flash. When the vessel is brought on to its correct course
again, the alarm will cease.
Changing to power-steer or standby modes will cancel the alarm.
The default value for the off-course angle (ie the one set when the KAP-833 is
turned on) is 30 degrees.
Note that the alarm will sound if a large course change is entered (eg from
keypad, preset course or course change knob). This alarm will cease as soon as
the vessel completes its course change. The alarm may also sound when changing
from one section of a GPS route to another, and will cancel itself when the
course change is completed.
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No GPS Data Alarm
The alarm sounds 0.2 seconds on, 0.2 seconds off if the autopilot is not
receiving valid information from the GPS. The GPS light blinks on and
off at the same rate as the audible alarm.
3
23 2
8

To engage AUTO Mode - Panel or Hand Remote and Steering Lever.
Course Adjustment
When AUTO mode is engaged, turning the Remote knob (or lever) will alter
the course to steer. This change will be reflected on the digital heading
display. If the remote AUTO mode was engaged with remote knob at centre,
the course can be changed to port or stbd by 90 degrees.
To disengage AUTO Mode
Either move the remote switch to Off (which also disengages the autopilot)
or press the desired mode key on the KAP-833 main panel (Auto, GPS,
Power or Standby).
Remote Unit OperationRemote Unit Operation
33
The Panel and Hand Remotes come with a 3-way switch for selecting POWER,
Off or AUTO features.
The Steering Lever can be supplied with or without a 3 way switch. When the
switch is fitted, the Steering Lever is used in the same way as a Panel or Hand
Remote. When supplied without a switch, the Lever is used as an Electric Wheel.
The Electric Helm or Steering Lever (without switch) are dash mounted units and
control rudder angle by manually turning the wheel or moving the lever.
Ensure the Remote Switch is Off and knob (or lever) is set to centre. Move
the remote switch from Off to AUTO.
9

To engage Power Steer Mode
Ensure the remote unit switch is set to Off, and the remote dial (or steering
lever) is set to centre. Change the remote switch to the Power position.
The remote dial (or steering lever) now acts as the helm, giving control
over the movement of the rudder. The maximum rudder angle is controlled
by the rudder limit adjustment on the KAP-833 main panel.
t
To disengage Power Steer Mode
Return The rudder to centre before switching to Off.
Electric Helm or Steering Lever
The KAP-833 can be customised to accept input from an electric helm
(steering wheel) or Steering Lever to provide electric steering in place of,
or in addition to, manual steering. The KAP-833 is programmed to suit a
customer's needs. For full electric steering, Power Steer mode will
automatically be selected at turn-on. For manual steering plus electric
steering, Power Steering must be selected manually on the KAP-833 unit.
In both of these options, the course-change knob on the KAP-833 has no
effect in Power mode.
The Remote Operation can be modified by the Installing Technician as listed
in special modes section of this manual.
10

The main power switch is incorporated in this variable control. When in the OFF
position no power is applied to KAP-833. By turning this in a clockwise direction
from the OFF position, the switch applies to the KAP-833.
This setting is used for adjusting the autopilot response to varying sea conditions
and varying vessel capabilities. The weather value sets the desired accuracy of the
vessel steering. A high weather setting will cause the vessel to steer very
accurately but may cause excessive use of the steering.
In good weather, set this control to a high value, but ensure that the drive lights
do not flicker continuously. This will give the straightest possible course.
In poor weather, reduce this setting to prevent over-working the steering.
Rotating this control fully anti-clockwise will turn off power to the KAP-833
autopilot.
Weather
1
4
Control function settingControl function setting
44
11

In some vessels, changing course requires a large amount of rudder to be applied
initially, and then a smaller amount of rudder in the REVERSE direction to stop
the vessel from swinging beyond its desired course. This is called counter-rudder.
The KAP-833 autopilot has this feature built-in. A counter-rudder setting of 1
gives no counter-rudder steering, suitable for light and manouverable vessels. If
you find your ship over-steering when under autopilot control, increase the
counter-rudder setting by a couple of steps, and see if the next course change
behaves better.
Once the correct setting is found for your vessel, it should not need to be changed.
Note that when in POWER STEER mode, you may prefer to set the counter-
rudder control to 1 .
Counter-Rudder
2
4
12

This setting is used to determine the amount of rudder the vessel requires for
steering (actually, the amount of rudder angle applied for a given angle off course).
The centre position is usually suitable for most vessels, but should the vessel's
steering be sensitive or slow, adjustment maybe required.
In general, an agile vessel with a relatively large rudder or very small keel will
require a small rudder setting. A large, slow vessel may require a high value for
the rudder ratio.
This may also be adjusted according to speed - low speeds may require more
rudder angle for steering than high speeds.
A value of 1 signifies the minimum amount of applied rudder (for sensitive
steering, large rudders or low gearing ratio.)
A value of 10 signifies the maximum amount of applied rudder (for vessels
with slow steering, small rudders or high gear ratio.)
When the rudder setting is too low, turns will take an excessive amount of time
and the vessel may wander .
When the rudder setting is too high, turn will be rapid and the vessel will
oversteer.
Rudder(Rudder Ratio)Control
3
4
13

The compass supplied with your KAP-833 autopilot has been calibrated during
manufacture. This calibration will be satisfactory for almost all installations. If
you have a steel vessel, or some other factor which causes the compass to perform
poorly, the calibration procedure will adjust compass characteristics to compensate.
The calibration should only be done if the compass is known to be inaccurate.
If the KAP-833 compass display as constant offset (eg the autopilot compass
reads 3 degrees high on all bearings), simply rotate the KAP-833 compass case
to align bearings with the ships compass.. it is not necessary to re-calibrate the
compass as described below.
If the KAP-833 compass has inconsistent variation on different headings, the
following calibration procedure can be carried out. This procedure should only be
done in calm waters with adequate sea room.
1. Enter 901 by using keypad, then hold down GOTO, Press AUTO,
then release both buttons together.
2. Turn vessel slowly through two complete circles in same direction. Each
complete turn should take at least 60 seconds.
3. When the circles are complete, enter 902 by using the keypad, then
hold down GOTO, press AUTO then release both buttons together.
This completes the compass calibration. Check alignment of the KAP-833
compass by steering vessel due North (000 on ships compass) and, if necessary,
rotate outer case of the KAP-833 compass in its bracket until the heading display
reads 000.
Note: The effectiveness of the calibration is dependent upon all 3 steps being
completed. Should you wish to abort the calibration procedure at any time
during the circle turning, do not carry out step 3.
It is important to realise that on any vessel the ships compass can have heading
errors as a result of the vessels magnetic signature. These errors can be minimised
by having the ships compass swung and compensated by a licensed compass
adjuster. In any case it is highly unlikely that the ships compass and autopilot
compass will be congruent for every heading.
If you are unsure of the success of the calibration, you may return to the factory
calibration setting by entering 903 , hold down GOTO, press AUTO, then
release both buttons together.
Compass CalibrationCompass Calibration
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1
6Installation of Main Unit
Position
The KAP-833 main panel should be mounted in an accessible position, protected
from rain or salt water.
Wiring
Access for wiring must be provided. Cabling will have to be run to the rudder
feed back Unit,compass unit and steering drive system. Wiring should be kept
as far away as possible from radio aerials and aerial cables to prevent interference
to the radio, and to prevent transmitted signals from the radio influencing the pilot.
The power source for the autopilot should be fused separately from other
equipment. Maintain conventional colour coding and, if necessary, mark the
cables for ease of identification.
Connection - As per diagram labelled Connection Diagram for KAP-833.
Magnetic Effect
As a minimum amount of steel is used in the control unit. there is negligible
effect on a steering compass. Some radio interference may be caused and the
routing of cables should be considered when wiring the vessel.
Autopilot InstallationAutopilot Installation
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