Raymarine 150/400 User manual

Type 150/400
Autopilot
System
Installation Guide
Document number: 81173-3
Date: June 2001
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ii Type 150/400 Autopilot System: Installation Guide
Autohelm,HSB(HighSpeedBus), SailPilot,SeaTalkandSportPilot
are registered trademarks of Raymarine Ltd.
Raymarine,AST(AdvancedSteeringTechnology),AutoAdapt,
AutoLearn, AutoRelease, AutoSeastate, AutoTack, AutoTrim,
FastTrim, GyroPlus,RayGyro,RayPilotand WindTrimare
trademarks of Raymarine Ltd.
Handbook contents © Raymarine Ltd 2001.
81173_3.book Page ii Thursday, June 7, 2001 11:51 AM

Preface iii
Contents
About this handbook ............................................................v
Important Information ........................................................vi
Warranty .....................................................................................vi
Safety notices .............................................................................vi
EMC conformance ....................................................................vii
Handbook information ..............................................................vii
Step 1: Check the Installation Kit ............................................1
1.1 Readthishandbook ...................................................................1
The autopilot system – corepackcontents ................................1
The autopilot system – other key components .......................... 3
The autopilot system – extendedsystems ................................. 3
1.2 Obtaininstallationtools ............................................................4
1.3 Checkpartssupplied .................................................................4
Step 2: Check Locations ............................................................6
2.1 Identifysuitablelocations .........................................................6
2.2 EMCinstallationguidelines .....................................................7
Step 3: Install the Course Computer .......................................9
3.1 Select the location ...................................................................10
Suitablelocations ....................................................................10
Unsuitablelocations................................................................ 11
Orientation .............................................................................. 11
3.2 Secure the course computer ....................................................12
3.3 Removethe connector cover ...................................................12
Connectingcables to the terminals .........................................14
Using thefuses ........................................................................ 14
3.4 Attach thepower cables ..........................................................15
Step 4: Install the Compass ....................................................17
4.1 Select the location ...................................................................18
4.2 Mountthe compass .................................................................20
4.3 Connect tothe coursecomputer ..............................................20
4.4 Connecting SeaTalk or NMEA compasses .............................21
Step 5: Install the Rudder Position Sensor ...........................22
5.1 Rotary rudder position sensor - installation ............................22
Introduction ............................................................................22
Ensuring correct alignment .....................................................23
Securing the sensor to theboat ................................................24
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iv Type 150/400 Autopilot System: Installation Guide
Attaching thesensor to thetiller arm ...................................... 24
Checkingalignment ................................................................25
Connectingtothecoursecomputer.........................................25
5.2 Linear rudder position sensor - installation ............................. 26
Introduction ............................................................................26
Mounting ................................................................................26
Step 6: Install the Drive Unit ..................................................28
Step 7: Install the Control Unit ..............................................29
Step 8: Clamp the Cables ........................................................30
Step 9: Integrate the System .................................................31
9.1 Connecting SeaTalk equipment ..............................................32
Possiblesystems .....................................................................32
9.2 Connecting NMEA equipment ...............................................36
Course computer NMEA inputs/outputs ................................ 36
ControlunitNMEAinputs .....................................................38
SeaTalk/NMEAinterface .......................................................38
Connectingseveral items of NMEAequipment ..................... 38
9.3 Connecting optionalcomponents ...........................................40
GyroPlusyawsensor ..............................................................40
Handheldremotes ................................................................... 40
Externalalarm .........................................................................40
Windvane (sail boats) ............................................................. 40
Off switch ............................................................................... 41
Other manufacturers’driveunits ............................................41
9.4 Setting-upthe autopilot ...........................................................42
Maintenance ........................................................................ 43
Regular checks ...........................................................................43
Fault-finding ..............................................................................43
Servicing ....................................................................................43
EMC, servicing and safety guidelines ....................................44
Product support ..........................................................................44
Specifications ...................................................................... 45
Control unit functionality ..........................................................46
Glossary ................................................................................ 47
Index ..................................................................................... 49
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Preface v
About this handbook
Welcome tothe installationguide forthe Raymarine Type 150/400
autopilot system. This autopilot system will steer your boat to a
headingautomatically, accuratelyand reliably.
This handbook explains howto install the parts provided with
Type 150,Type 150G, Type 400and Type 400G autopilotsystem
core packs. The installation process involves the following steps:
At the end ofthis handbook wehave also included:
•maintenance information
•productspecifications
•glossary and index
•installation template
•thewarranty statement
Note:This handbook containsimportant information about the
installationandmaintenanceofyournewRaymarineproduct.Toget
the best from the product, pleaseread thishandbook thoroughly.
1Check the Installation Kit page 1
2Check Locations page 6
3Install the Course Computer page 9
4Install the Compass page 17
5Install the Rudder Position Sensor page 22
6Install the Drive Unit page 28
7Install the Control Unit page 29
8Clamp the Cables page 30
9Integrate the System page 31
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vi Type 150/400 Autopilot System: Installation Guide
Important Information
Warranty
To registeryournew product,pleasetakea fewminutestofilloutthe
warrantycard.Itisimportantthatyoureturnthecardtothefactoryto
receive full warranty benefits.
Safety notices
WARNING: Product installation
Thisequipment mustbe installed andoperatedin accordance
withtheinstructionscontainedinthishandbook.Failuretodoso
couldresultinpoorproductperformance,personalinjury
and/ordamageto yourboat.
Because correctperformance of the boat’s steering is critical for
safety,weSTRONGLYRECOMMENDthatanAuthorized
RaymarineService Representativefits thisproduct.Youwill
only receive full warranty benefits if youcan show thatan
Authorized Raymarine Service Representative hasinstalled or
commissioned thisproduct.
WARNING: Electrical safety
Makesurethepowersupplyisswitchedoffbeforeyoumakeany
electrical connections.
WARNING: Calibration
Wesupplythisproductcalibratedtodefaultsettings.To ensure
optimum performance on your boat, this product MUST be
calibratedbeforeuse.DoNOT usetheproductuntilit hasbeen
calibrated using the instructions supplied.
WARNING: Navigation aid
Althoughwehavedesignedthisproducttobeaccurateand
reliable,many factors can affectitsperformance. Asaresult,it
shouldonlybeusedasanaidtonavigationandshouldnever
replacecommonsenseandnavigationaljudgement.Always
maintainapermanentwatchsoyoucanrespondtosituationsas
theydevelop.
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Preface vii
Your Raymarine autopilot will adda new dimension to your boating
enjoyment.However, itistheskipper’s responsibility to ensure the
safety of the vessel at all times by following these basic rules:
•Ensure that someone is present at the helm AT ALL TIMES, to
take manual control in an emergency.
•Make sure that all membersof crew know how to disengage the
autopilot.
•Regularlycheckforotherboatsandanyobstaclestonavigation–
nomatterhowcleartheseamayappear,adangeroussituationcan
develop rapidly.
•Maintain an accurate record ofthe boat’spositionby usingeither
anavigationaid or visualbearings.
•Maintaina continuousplotof your boat’spositionon a current
chart.Ensurethat the locked autopilot heading willsteer the boat
clear of all obstacles. Make proper allowance fortidal set –the
autopilot cannot.
•Evenwhenyourautopilotislockedontothedesiredtrackusinga
navigationaid,alwaysmaintainalogandmakeregularpositional
plots. Navigation signals can produce significant errorsunder
some circumstances and the autopilot will not be able to detect
these errors.
EMC conformance
All Raymarine equipment andaccessories are designedto the best
industrystandards for use in the recreational marine environment.
The design and manufacture of Raymarine equipment and
accessories conform to the appropriate Electromagnetic
Compatibility(EMC)standards,butcorrectinstallationisrequiredto
ensure that performance is not compromised.
Handbook information
To the best of our knowledge, the information in thishandbook was
correct when it wentto press. However, Raymarine cannot accept
liabilityforanyinaccuraciesoromissionsitmaycontain.Inaddition,
ourpolicyofcontinuousproductimprovementmay change
specifications without notice. As aresult, Raymarine cannotaccept
liability for any differences between the productand the handbook.
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viii Type 150/400 Autopilot System: Installation Guide
Key components
Other
equipment
Typical
drive units
Options
External GyroPlus
yaw sensor
Active
compass
Rotary
drive
Hydraulic
pump
Linear drive
Wind
vane
External
alarm
SeaTalk
handheld remote
D5191-2
NMEA
equipment
SeaTalk
equipment
Rudder
position sensor
Standard
fluxgate
compass
Control
unit
Course
computer
Drive
unit
Type 150/400 autopilot system
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Step 1: Check the Installation Kit 1
Step 1
Step 1: Check the Installation Kit
The first step isto get ready for installation by:
•reading through all installation steps
•obtainingthe necessary installation tools
•checkingthe parts supplied
WARNING: Product installation
Thisequipmentmustbeinstalledandoperatedinaccordance
withtheinstructionscontainedinthishandbook.Failuretodoso
couldresultinpoorproductperformance,personalinjury
and/ordamagetoyourboat.
Becausecorrectperformanceofthe boat’s steeringiscriticalfor
safety, we STRONGLY RECOMMEND that an Authorized
RaymarineServiceRepresentativefitsthisproduct.Youwill
onlyreceivefullwarranty benefitsif you can showthatan
Authorized RaymarineService Representativehas installedor
commissionedthis product.
1.1 Read this handbook
To prepare for the system installation, read through the following
informationandtherestofthishandbooktofamiliarizeyourselfwith
the autopilot system and how to install it.
The autopilot system – core pack contents
Course computer
The course computer lies at the heart ofthe autopilot system. It
processes informationfromthesensorsin the system(e.g. rudder
position and compass) so it cansteer the boat using thedrive unit:
•itcontains a microprocessor, electronic circuitry to control the
driveunitanda poweramplifierforthedrivemotor.
•it is the central distribution point for the autopilot system, with
terminals to take power from the boat’s distributionpaneland
inputs/outputsforallother autopilotcomponents
•ithasinputs/outputsforSeaTalkandNMEAsoyoucanconnectit
to Raymarine and other manufacturer’sequipment.
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2 Type 150/400 Autopilot System: Installation Guide
Step 1
*Note: The Raymarine GyroPlus yaw sensor measures the boat’s yaw (its rate of turn). The autopilot
system uses this information to enhance course keeping in adverse weather and sailing conditions (such
as sailing downwind in following seas). The Type 150G and Type 400G course computers contain a
built-in GyroPlus yaw sensor as standard. The Type 150 and Type 400 course computers do not contain
a built-in GyroPlus, but have the option of an external GyroPlus or dealer-fitted internal GyroPlus.
CAUTION:
Beforeinstalling the course computer and drive unit, check that
theyarethe correctvoltageforyourboat’ssupply.
Compass
The compass is the direction sensor for the autopilot system. It
provides the course computer with precise information about the
boat’s heading.
Raymarine supplies a standardfluxgatecompassfor the autopilot
system.
Rudder position sensor
Therudderpositionsensor(orrudderreference transducer)provides
the course computer with the exact position of the boat’s rudder.
Course computer versions
Version Supply voltage Drive unit compatibility Built-in
GyroPlus*?
Type 150 12 V All Raymarine Type 1 12 V drives and pumps
(including 12 V Constant Running pump). No
Type 150G 12 V All Raymarine Type 1 12 V drives and pumps
(including 12 V Constant Running pump). Yes
Type 400 12 V or 24 V
All Raymarine 12 V and 24 V Type 1, Type 2 and
Type 3 drives and pumps. Drive voltage must be
matched to boat’s supply voltage.
No
Type 400G 12 V or 24 V
All Raymarine 12 V and 24 V Type 1, Type 2 and
Type 3 drives and pumps. Drive voltage must be
matched to boat’s supply voltage.
Yes
ÍFor course computer installation information, see page 9
For course computer specifications, see page 45
ÍFor more information, see page 17
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Step 1: Check the Installation Kit 3
Step 1
Raymarine produces twoalternative types of rudder sensor:
•the rotary rudder position sensor is suitable for all steering
systems(apartfrom ‘bullhorn’style hydraulicoutboards)
•the linearrudder position sensor is specifically designedfor
‘bullhorn’stylehydraulicoutboardsteering systems
The autopilot system –other key components
Drive unit
The drive unit translates instructions fromthe course computerinto
rudder movement, so the course computer can steer the boat.
Raymarineproducesawiderangeofdriveunitstosuitdifferenttypes
ofsteeringsystems.
Control unit
The control unit is the yourinterface with the autopilot system. You
can useit to:
•engage and disengage the autopilot
•adjust the boat’s course when the autopilotis engaged
•viewinformationabouttheautopilotsystem’sstatusandperform
a range of otherfunctions
Raymarine produces a range of controlunits to suitdifferentboats
anduser requirements.
The autopilot system –extended systems
Aroundthese key components of theautopilot system, youcan
extendthe systemby addingoptionssuchas:
•connectionsto additionalcontrol units,SeaTalk equipment or
othermanufacturers’equipment(viaNMEA)
•a GyroPlus yawsensor (if youhave a Type150 or Type 400
course computer without abuilt-inGyroPlus)
ÍFor more information, see page 22
ÍFor more information, see page 28
ÍFor more information, see page 29
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4 Type 150/400 Autopilot System: Installation Guide
Step 1
•handheld remotes (the ST600Rfull-function remote controlor
the SeaTalk handheld remote control)
•pushpitor masthead wind vanes (for sail boatswithout a suitable
wind instrument)
•anexternal alarm (through an E85001interface)
1.2 Obtain installation tools
To install the core pack you will need the followingitems:
•tapemeasure (metric/imperial)
•screwdrivers:
•cross-head/pozi-drive
•flat-bladed(largeandsmall)
•drill and 3 mm drill bit
•centerpunch, pencil and masking tape
•fortherudderpositionsensor:
•hacksaw
•small adjustable spanner
•bolts,nuts and lockwashers(ifrequiredfor tiller pin)
•for the course computerpower supply:
•suitablepowercable(seepage 16)
•suitable fuse/circuit breaker (see page 16)
Note:You will also needthe tools andequipment required to install
the control unitand drive unit. Forfull details, referthe information
supplied with control unit and drive unit.
1.3 Check parts supplied
Use the diagram on the following page to check the partssupplied.
CAUTION:
Beforeyoustartinstallingthecoursecomputer, check that itis
thecorrectvoltage for your boat’spowerandyourdrive unit.
ÍFor more information about extended systems, see page 31.
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Step 1: Check the Installation Kit 5
Step 1
Type 150/400
Autopilot
System
Installation
Guide
Worldwide
Distributors
!
COMPASS AREA
D5377-1
Course computer
Course computer components
Core pack –parts supplied
Ferrite
(for power cable)
Cable clamp Tie-wrap (for cable clamp)
No8 x 3/4 inch pan-head
self-tapping screws (x5):
•2 for course computer
•3 for cable clamp
No8 x 3/4 inch pan-head self-tapping screws (x3)
for rudder position sensor
No8 x 3/4 inch countersunk self-tapping screws (x2)
for tiller pin
No8 x 3/4 inch pan-head
self-tapping screws (x4)
Compass
warning label
Installation Guide
(includes warranty
documents and
fitting templates)
Worldwide
Distributor List
Fluxgate compass
with 8 m (26 ft) cable
Compass components Rudder position sensor components
Rudder position sensor
with 10 m (32 ft) cable
Connecting rod (M6), nuts (M6 x2)
and ball-pin sockets (x2)
Tiller pin
Note: This illustration shows the parts supplied with Type 150, 150G, 400 and 400G autopilot core packs.
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6 Type 150/400 Autopilot System: Installation Guide
Step 2
Step 2: Check Locations
2.1 Identify suitable locations
AfterreadingthefollowingEMCinstallationguidelines(seepage 7),
identify suitable locations for each part of the system.
Course computer location:
•mount vertically on aflat bulkhead belowdecks
•dry, protected and well-ventilated
•free from high operating temperatures and excessive vibration
Compass location:
•mount vertically, with cable exiting at thebase
•as near as possible to the boat’s pitchand roll center
•atleast 0.8 m (2 ft 6 in)away from the boat’s steering compass
•in the back two-thirds of the boat
•awayfrompotentialsources of magnetic interference
ÍFor more information, see page 10
ÍFor more information, see page 18
D5378-1
Typical locations
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Step 2: Check Locations 7
Step 2
Rotary rudder position sensor location:
•suitablebase alongside the rudderstock and tiller arm.
•so the ball-joints at each end of the connecting rod are level
•sothe sensor arm is between 75 mm (3 in) and 310 mm(12 in)
from the tiller arm
Drive unit and control unit locations
Refer to the information supplied with these units to identify suitable
locations.
Cabling:
•consider how you will runcables to and from each component
•avoid running cables through bilgeswhere possible
•avoidrunningcablesclose to fluorescentlights,engines, radio
transmitting equipment etc.
Note:Whencuttingcablestolength,werecommendthatyouinclude
aloopofextracablesoyoucancutandstripthecablesa fewtimesin
the future (if necessary).
2.2 EMC installation guidelines
All Raymarine equipment andaccessories are designedto the best
industrystandards for use in the recreational marine environment.
Their design andmanufacture conforms to the appropriate
Electromagnetic Compatibility (EMC) standards, but correct
installation is required to ensure that performance is not
compromised. Although every effort has been taken to ensure that
they willperform under all conditions, it is important tounderstand
what factors couldaffect the operation of the product.
Theguidelinesgivenheredescribethe conditionsforoptimumEMC
performance, butit is recognized that it may notbe possible to meet
all of these conditions in all situations. To ensure the best possible
conditionsfor EMC performance withinthe constraintsimposed by
anylocation,alwaysensurethemaximumseparationpossible
betweendifferentitemsofelectrical equipment.
ÍFor more information, see page 23
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8 Type 150/400 Autopilot System: Installation Guide
Step 2
For optimumEMC performance, we recommend that wherever
possible:
•Raymarine equipment and cables connected toit are:
•At least3 ft (1 m)from any equipment transmitting or cables
carryingradio signalse.g.VHFradios,cablesandantennas.
Inthe case of SSBradios, increases thedistance to 7 ft (2 m).
•More than7 ft (2m) fromthe path of a radar beam. Aradar
beam can normally be assumed to spread 20degrees above
andbelow the radiating element.
•The equipment is supplied from a separate battery from that used
for engine start.Voltage dropsbelow 10 V, and starter motor
transients,cancausetheequipmenttoreset.Thiswillnotdamage
theequipment, but may cause the loss ofsome informationand
maychange the operatingmode.
•Raymarine specified cables are used. Cutting and rejoining these
cables can compromise EMC performance andmust be avoided
unless doing so is detailed in the installation manual.
•Ifasuppressionferriteisattachedtoacable,thisferriteshouldnot
beremoved.Iftheferriteneedsto beremovedduringinstallation
it mustbe reassembledin the same position.
Suppression ferrites
This following illustration shows typical cablesuppression ferrites
usedon Raymarine equipment.Alwaysuse the ferrites suppliedby
Raymarine.
Connections to other equipment
If your Raymarine equipment is to be connectedto other equipment
usingacablenotsuppliedbyRaymarine,asuppressionferriteMUST
always be attached to thecable near to theRaymarine unit.
D3548-2
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Step 3: Install the Course Computer 9
Step 3
Step 3: Install the Course Computer
Installing the course computerinvolves these tasks:
Course computer - main parts
3.1 Select the location page 10
3.2 Secure the course computer page 12
3.3 Remove the connector cover page 12
3.4 Attach the power cables page 15
D5413-2
Mounting lug
Keyhole slot
Suppression ferrite
Cables for autopilot
system components
and power
Cable clamp
Tie-wrap
Mounting screws,
No 8 x 3/4 in (x5)
Main cover
Connector
cover
Connector
cover catch
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10 Type 150/400 Autopilot System: Installation Guide
Step 3
3.1 Select the location
Suitable locations
Thecoursecomputerisdesignedtobemountedonaverticalandflat
bulkhead below decks. Select a location that is:
•dry, protected and well-ventilated
•freefrom highoperating temperatures
•freefrom excessivevibration
•non-metallic
•accessible for cableroutingand sufficiently largeto secure the
cable clamp under the computer
On sailboats, we also recommend mounting the course computer
acrossthe boaton a transverse bulkhead.
Notes:
1. If the only possible location has ametallic surface, you must
insulate the base of course computer so it is notearthed.
2. When selecting the mounting location, also refer to the EMC
installationguidelines(onpage 7).
Course computer –installation dimensions
277 mm (10.9 in)
288 mm (11.3 in)
307 mm (12.1 in) 70 mm
(2.8 in)
D5260-1
195 mm (7.7 in)
min 50 mm (1.9 in)
(recommended)
cable clearance:
min 50 mm (1.9 in)
(recommended)
26 mm
(1.0 in)
133 mm (5.2 in) 133 mm (5.2 in)
Keyhole slots
for No 8 screws
(pan-head)
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Step 3: Install the Course Computer 11
Step 3
Unsuitable locations
WARNING:
ThecoursecomputerisNOT designedto bemountedin engine
compartments.
DoNOT install the course computer:
•where there might be flammable vapors(such as in anengine
room or compartment, or in a fuel tankbay)
•where there is water splash or spray from bilges or hatches
•where it is at riskfrom physical damage from heavy items (such
ashatchcovers,tool boxes,etc.)
•where it might be coveredby other equipment
Orientation
CAUTION:
You MUST mountthecoursecomputersoitislevel and within
+/- 10°ofthe vertical.
The Type 150G and Type 400G course computers containa built-in
GyroPlus yaw sensorthatwillNOTworkcorrectlyif youmount the
computerin any other orientation. This orientation alsomaximizes
the air flow to cool the course computer andprovides optimum
resistance to drippingwater.
Note:Type150GandType400Gcoursecomputersaresuppliedwith
a temporary‘Mount vertically’label stuck to the case. Remove this
label after installation.
±10˚
level
D5379-1
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12 Type 150/400 Autopilot System: Installation Guide
Step 3
3.2 Secure the course computer
Follow these stepstosecure the coursecomputer:
1. Hold the coursecomputer in place against themounting location
so you can mark the centre of the keyhole slots:
•thesemarksshould beleveland288mm (11.3in) apart
•removethecoursecomputerthendrillthe two pilot holes
usinga 3 mm (1/8in) drill bit
2. Screwthe supplied self-tappingscrews(No8x3/4in, pan-head)
into the holes, so the head of each screw is at least 6 mm (1/4in)
fromthe surface.
3. Place the keyhole slots over the screwheads,thenmovethe
course computerdown, so the screw heads are at thetop of the
keyholeslots.
4. Tighten the screwsto hold the course computer securely against
themounting surface.
3.3 Remove the connector cover
To removethe connector cover:
•unlockthe cover:
•use a flat-bladedscrewdriver or small cointo rotate the catch
1/4turn(90°)in eitherdirection–untilyouheara click andthe
slot is horizontal
•lift off thecover
1 2 3 4
6mm
minimum
D5196-1
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