Raymarine SmartPilot S1000 User manual

SmartPilot
S1000 Autopilot
Installation Guide
Document Number: 87040-1
Date: December 2004
87040_1.book Page 1 Wednesday, December 22, 2004 12:32 PM

Welcome to the Raymarine S1000 Autopilot
Congratulations on having bought a Raymarine S1000 Autopilot. This state-of-the-art
product is specifically designed to be easily integrated with your boat’s steering system, and
enable you to automatically control the steering.
The S1000 Autopilot is intended for use in:
• HC5345, HC5347, HC5348, and HC5358 SeaStar steering systems.
• Systems with HC4600, HC4645, HC4647, HC4648, and HC4658, BayStar steering rams.
• Systems with Hynautic K6 steering rams.
SeaTalk®is a Registered Trademark of Raymarine
All other trademarks used in this document are acknowledged.
© Copyright Raymarine UK Limited 2004
Existing hydraulic steering system
Buzzer
Pump control
S1000 Autopilot System
S100 Remote
Course
computer
Autopilot
pump
D7501-1
S100REMOTE
MODE
STANDBY PILOT
GPS input
The S100 requires
GPS data (SeaTalk or
NMEA compatible),
to operate correctly
Alarm
87040_1.book Page 2 Wednesday, December 22, 2004 12:32 PM

S1000 Autopilot Installation Guide 1
Connect the autopilot pump
to your existing steering system.
Bleed the steering system.
Secure the autopilot pump.
Fit the course computer.
1.
2.
3.
4.
Fit miscellaneous items
5.
Make electrical connections
6.
Carry out post installation checks
7.
In-line power switch Buzzer
Installation overview
D7583-1
Page 9
Page 12
Page 16
Page 17
Page 18
Page 21
Page 28
S100 Remote
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2 S1000 Autopilot Installation Guide
This guide
Before starting to install your S1000 Autopilot, please take time to read this guide. In particu-
lar, please take note of the safety and electromagneticcompatibility (EMC) information at the
end of this guide.
WARNING:
This product must be installed and operated in accordance with the
Raymarine instructions provided. Failure to observe this could
result in personal injury, damage to the boat and/or poor product
performance.
The installation procedures are described in a rational sequence, but because of variations in
boat design, space available etc, you may need to adapt the sequence to suit your particular
circumstances.
Before you start fitting your S1000 Autopilot, we recommend you:
•Unpack your S1000 Autopilot and check that all parts are present.
•Plan your S1000 Autopilot installation so that you fit the components in the best possible
locations.
Important note
The S1000 Autopilot must receive position information from a suitable GPS in
order to function correctly. GPS systems compatible with SeaTalk or N EA or
both, are suitable. If you need advice as to which GPS to use, please contact
your Raymarine dealer.
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S1000 Autopilot Installation Guide 3
What you need
Elbow fitting, x 4
'T' fitting x 2
High pressure
steering hoses
(x 2)
Low pressure
transparent
bleeding hose
Straight fitting x 2
Nitrile gloves
Autopilot Pump
Anti-vibration mounts x 2
Course Computer
Wrench 12 mm AF x 19 mm AF
In-line power
switch
Drill 3.4 mm
Cable Tie x 10
D7330-1
S100 Remote & 2 x cradles 1 pint (0.5 liter)
hydraulic fluid
Belt clip assembly
Fill cups
Buzzer
Parts supplied
S100 REMOTE
MODE
STANDBY PILOT
Ground lead
Data cable
Power cable
Drain cups
Lanyard
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4 S1000 Autopilot Installation Guide
D7331-1
Tools & materials required
Screwdriver,
No. 2 Pozidriv
Screwdriver,
medium,
flat blade
Screwdriver,
small,
flat blade
Countersink
bit
Pencil
Drill
Absorbent,
disposable wipes
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S1000 Autopilot Installation Guide 5
Planning
In order to make the installation as trouble free as possible, we strongly recommend you
spend adequate time planning the best locations for your autopilot components. This is
particularly important when considering the position of the autopilot pump, as hydraulic
hoses are supplied in fixed lengths, so there are some limitations on the positioning of the
autopilot pump with respect to the boat’s helm pump.
If you have internet access, please view the installation video on line at www.raymarine.com.
Before you disturb your hydraulic steering system, we strongly recommend that you consult
the manufacturer and read the steering system manuals.
5˚ 5˚
D7552-1
5˚ 5˚ 5˚ 5˚ 5˚ 5˚
At least 3 ft (1 meter)
Locating the course computer
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6 S1000 Autopilot Installation Guide
R
e
s
e
v
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r
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o
B
l
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S
c
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d
Port
Port
R
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s
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o
B
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S
c
r
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d
Port
Port
D7350-1
Autopilot pump to be lower
than helm pump
No sharp bends, kinks or
chafing of tube
Locating autopilot pump
Provide protection
from physical
damage.
Mount pump location either
horizontally or with connector end up.
Do not mount pump with connector
end down.
Install in a dry location.
Do not fit in engine compartments, near
fuel tanks or in any other area where fuel
vapor is likely.
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S1000 Autopilot Installation Guide 7
Port
Port
B
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S
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R
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Using the hydraulic hoses
D7553-1
Three, pre-assembled hydraulic hoses are supplied. Two of these are dark-colored, high
pressure steering hoses and the third is a transparent low-pressure hose.
The transparent hose is intended to help you check for air bubbles when bleeding the
system and must be used only to connect the autopilot pump reservoir to the lower
connector on the helm pump. It must NOT be used anywhere else in the system.
Port
Port
B
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Port
Port
B
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8 S1000 Autopilot Installation Guide
Tapered thread
Thread for hose
connection
Sealing hydraulic joints
Do not apply sealant to
hose connection thread
Note: The hydraulic fittings supplied with the autopilot pump have sealant pre-
applied to the tapered threads. You only need you to apply sealant to any extra
joints you may obtain. The recommended sealant for doing this, is Loctite 542.
Do not use sealing tape on any part of a hydraulic system, as this can disintegrate
and the resulting particles can cause blockages in the hydraulic system.
CAUTION:
D7545-1
2.
3.
1.5 turns
D7546-1
From hand tight, use a wrench to tighten the joint a
further 1.5 turns. This should make it leakproof.
To change the orientation of the joint to align it with the
hose, further tighten the joint, to a maximum of one
further turn, until the joint is facing the required
direction.
1.
Hand tighten
CAUTION:
Do not exceed 13 ft/lbs
(17.6 Nm) torque.
CAUTION:
Do not exceed 13 ft/lbs (17.6 Nm) torque. DO NOT
EXCEED 2.5 TURNS in total, from hand tight.
Installing tapered thread fittings
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S1000 Autopilot Installation Guide 9
Installation procedures
1. Connecting the autopilot pump
O
Port
Port
B
r
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S
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R
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R
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B
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S
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Port
Port
1. 2.
Secure the required hydraulic joints
(elbow or straight) into the autopilot
pump, as described under Fitting
hydraulic joints.
CAUTION:
Do not use the transparent hose for connecting any part of the steering
system other than between the autopilot pump reservoir and the lower
connector on the helm pump.
Connect hydraulic hoses to autopilot
pump. Ensure the transparent hose is
connected to the reservoir connector.
WARNING:
Do not allow hydraulic fluid to come into contact with your skin. Wear the
protective nitrile gloves provided when working with hydraulic fluid.
WARNING:
A sudden release of pressure from a hydraulic system could result in personal
injury. Before disconnecting any part of a hydraulic steering system, safely
release any pressure in accordance with the manufacturer’s instructions.
WARNING:
The autopilot pump is not suitable for use in the vicinity of engines, fuel
tanks or in any other area where fuel vapor is likely to be present.
Connecting the autopilot pump, sheet 1
D7345-1
Port
connector
Starboard
connector
Reservoir
connector
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10 S1000 Autopilot Installation Guide
0
D7483-1
5.
Remove & retain the plug from the
helm pump lower port and drain the
fluid into one of the cups provided.
Discard the drained fluid in
accordance with local regulations.
6.
Label the port ram hose to aid future
reassembly, then disconnect both ram
hoses & straight connectors from the
helm pump.
Remove & retain the helm pump
breather cap.
4.
Set steering to dead ahead
and do not move it until
instructed.
3.
7.
Using the Fitting hydraulic joints procedure, fit 'T'
connectors to the helm pump port (P) and
starboard (S) connectors, and a straight connector
to the helm pump lower connector.
Connecting the autopilot pump, sheet 2
D7483-1
5.
Remove & retain the plug from the
helm pump lower port and drain the
fluid into one of the cups provided.
Discard the drained fluid in
accordance with local regulations.
6.
Label the port ram hose to aid future
reassembly, then disconnect both ram
hoses & straight connectors from the
helm pump.
Remove & retain the helm pump
breather cap.
4.
Set steering to dead ahead
and do not move it until
instructed.
3.
7.
Using the Fitting hydraulic joints procedure, fit 'T'
connectors to the helm pump port (P) and
starboard (S) connectors, and a straight connector
to the helm pump lower connector.
Connecting the autopilot pump, sheet 2
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S1000 Autopilot Installation Guide 11
Port
Port
B
r
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S
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R
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Port
Port
B
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9. Re-connect the ram hoses to the
appropriate helm pump 'T' connectors.
10. Connect the transparent hose from autopilot pump reservoir hose to the
straight connector at the helm pump lower connector.
This completes the connection
of the autopilot pump.
Now bleed the steering system.
to steering
ram
Port
Port
B
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S
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D7484-1
Connecting the autopilot pump, sheet 3
8. Connect hydraulic steering hoses from
autopilot pump Port and Starboard
connectors to the Port and Starboard
connectors on the helm pump, so that
Port connects to Port, and Starboard
connects to Starboard .
87040_1.book Page 11 Wednesday, December 22, 2004 12:32 PM

12 S1000 Autopilot Installation Guide
2. Bleeding the steering system
WARNING:
Do not allow hydraulic fluid to come into contact with your
skin. Wear the protective nitrile gloves provided when
working with hydraulic fluid.
Connecting the autopilot pump will introduce air into the steering system, making it feel
‘spongy’and ‘lumpy’to operate. To return the steering system to smooth operation, use the
procedure given here to bleed the air from the system.
Por t
Port
B
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S
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Bleed procedure, sheet 1
2.
Loosen autopilot pump
bleed screw 2 full turns
2.
Top up helm pump with hydraulic fluid
D7336-1
87040_1.book Page 12 Wednesday, December 22, 2004 12:32 PM

S1000 Autopilot Installation Guide 13
Port
Port
B
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S
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R
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Port
Port
B
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Bleed procedure, sheet 2
D7339-1
4. SLOWLY turn the wheel counter-clockwise and observe
the bubbles in the transparent tube. Keep the helm
pump reservoir topped up while doing this. Keep
turning the wheel counter-clockwise until there are no
more bubbles i.e. so the hydraulic fluid in the
transparent tube is clear.
3. Using a suitable screwdriver, turn the
autopilot pump shaft so that the flat on the
shaft is toward the PORT side of the pump
87040_1.book Page 13 Wednesday, December 22, 2004 12:32 PM

14 S1000 Autopilot Installation Guide
Port
Port
B
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S
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R
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Port
Port
B
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S
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Bleed procedure, sheet 3
6. SLOWLY turn the wheel clockwise and observe the bubbles
in the transparent tube. Keep the helm pump reservoir
topped up while doing this. Keep turning the wheel
counter-clockwise until there are no more bubbles i.e. so
the hydraulic fluid in the transparent tube is clear.
D7337-1
5. Using a suitable screwdriver, turn the autopilot
pump shaft so that the flat on the shaft is toward
the starboard (STBD) side of the pump
87040_1.book Page 14 Wednesday, December 22, 2004 12:32 PM

S1000 Autopilot Installation Guide 15
Por t
Port
B
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S
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Bleed procedure, sheet 4
8. Turn the autopilot pump bleed screw, fully clockwise, and hand-tighten it.
7. Top up the hydraulic fluid.
9. Replace the helm pump breather cap.
D7486-1
This completes the
bleed procedure.
Now secure the pump.
Correct fluid level
Helm pump
87040_1.book Page 15 Wednesday, December 22, 2004 12:32 PM

16 S1000 Autopilot Installation Guide
3. Securing the pump
3. 4.
D7488-1
Slide the anti-vibration mounts onto
the pump bracket feet, then secure
the pump with the screws provided.
Countersink pilot holes to prevent
damage to the mounting surface.
The autopilot pump should now be secure.
Now fit the course computer.
Port
Port
B
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Securing the pump
1. 2.
Drill two 1/8" (3.4 mm) pilot holes
for the fixing screws
Place the pump at the intended
location and mark holes for the
fixing screws.
Port
Port
B
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S
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S1000 Autopilot Installation Guide 17
4. Fitting the course computer
D7338-1
Securing course computer
1. 2.
4.
3.
Mark holes for fixing screws. Drill two 1/82" (3.4 mm) pilot holes
for fixing screws
Partially screw in the screws provided,
then slot the course computer onto the
screws, and tighten screws.
Countersink pilot holes to prevent
damage to the mounting surface.
The course computer is now secure.
87040_1.book Page 17 Wednesday, December 22, 2004 12:32 PM

18 S1000 Autopilot Installation Guide
5. Fitting miscellaneous items
D7607-1
Buzzer
1. 2.
4.
3.
Mark holes for fixing screws. Drill two (3.4 mm) pilot holes.
18
/
"
Secure the buzzer with the screws
provided.
Countersink pilot holes to prevent
damage to the mounting surface.
Locating
Securing
D7504-2
Fitting batteries in S100 Remote
2 x AAA batteries (supplied).
When replacing, use only high-quality
alkaline, AAA size batteries.
87040_1.book Page 18 Wednesday, December 22, 2004 12:32 PM