Raymarine M81135 User manual

Rotary Drive
Installation instructions
English
Date: 11-2006
Document number: 81174-5-EN
© 2006 Raymarine UK Limited
M81135: Type 1 Rotary Drive 12 V
M81136: Type 2 Rotary Drive 12 V
M81137: Type 2 Rotary Drive 24 V

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Important information
Safety notices
EMC conformance
All Ray arine equip ent and accessories are designed to the best industry standards for use
in the recreational arine environ ent. The design and anufacture of Ray arine
equip ent and accessories confor to the appropriate Electro agnetic Co patibility (EMC)
standards, but correct installation is required to ensure that perfor ance is not co pro ised.
Handbook information
To the best of our knowledge, the infor ation in this handbook was correct when it went to
press. However, Ray arine cannot accept liability for any inaccuracies or o issions it ay
contain. In addition, our policy of continuous product i prove ent ay change
specifications without notice. As a result, Ray arine cannot accept liability for any
differences between the product and the handbook.
WARNING
roduct installation
This equipment must be installed in accordance with the instructions
contained in this handbook. Failure to do so could result in poor product
performance, personal injury and/or damage to your boat.
Because correct performance of the boat’s steering is critical for safety,
we STRONGLY RECOMMEND that an Authorized Raymarine Service
Representative fits this product.
WARNING
Navigation aid
When this product is used within a navigation system, it is only an aid to
navigation. It’s accuracy can be affected by many factors, including equipment
failure or defects, environmental conditions and improper use or handling. It is
the user’s responsibility to exercise common prudence and navigational
judgements. This product should not be relied upon as a substitute for such
prudence and judgement. Always maintain a permanent watch so that you can
respond to situations as they develop.
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Waste Electrical and Electronic Equipment Directive
The Waste Electrical and Electronic Equip ent (WEEE) Directive requires the
recycling of waster electrical and electronic equip ent. Whilst the WEEE
Directive does not apply to so e of Ray arine’s products, we support its policy
and ask you to be aware of how to dispose of this product.
The crossed out wheelie bin sy bol, illustrated above, and found on our products signifies
that this product should not be disposed of in general waste or landfill.
Please contact your local dealer, national distributor or Ray arine Technical Services for
infor ation on product disposal.
Warranty
To register your new Ray arine product, please take a few inutes to fill out the warranty
card. It is i portant that you co plete the owner infor ation and return the card to receive
full warranty benefits. Alternatively you can register your product on line at:
www.raymarine.com
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Introduction
roduct description
Welco e to the installation guide for the Ray arine rotary drive. This product is intended to
operate the boat’s steering echanis as part of a Ray arine autopilot syste . It is designed
for steering syste s that can be driven fro the hel position through a chain and sprocket
(for exa ple: cable and rod steering syste s).
The outstanding design of the Ray arine rotary drive unit provides s ooth, powerful
autopilot-controlled steering with quiet operation.
The ain parts of the drive are:
• a rugged electric otor, that drives a precision epicyclic gearbox via a high tensile drive
belt
• an electro agnetic clutch that trans its high torque loads without slipping
Figure 1: Main parts of the rotary drive
Contents
This guide contains:
1
Product specifications page 7
2
Installation instructions page 8
3
Maintenance infor ation page 18
D5082-1
Clutch cable
Motor cables
Mounting foot
Drive shaft
Motor, gearbox 
and clutch assembly
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Specifications
Drive dimensions
Figure 2: Drive di ensions
Drive specifications
Table 1-1: Drive specifications
erformance
(at no inal voltage)
Type 1 (T1)
M81135 (12 V)
Type 2 (T2)
M81136 (12 V)
M81137 (24 V)
Maxi u boat displace ent 10,000 kg
(22,000 lb)
20,000 kg
(44,000 lb)
Peak output torque 20 N
(180 lb.in)
34 N
(300 lb.in)
Maxi u shaft speed 33 rp 33 rp
Reco ended hardover to har-
dover ti e (no load)
10 sec 10 sec
Power consu ption
(typical average)
24-48 W 60-84 W (12 V)
72-120 W (24 V)
274 mm (10.8 in)
195 mm
(7.7 in)
256 mm (10 in)20 mm (0.8 in)
184 mm
(7.2 in) 60 mm
(2.4 in)

60 mm
(2.4 in)

D5087-1
2 slots to accept 
12 mm (0.5 in) bolts
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Installation instructions
arts required
To install this drive you will need:
• Parts supplied:
• rotary drive
• ounting foot
• spacing shi s (x3)
• Additional parts:
• suitable securing bolts and lock washers/lock nuts (see page 12 )
• suitable sprockets and grub screws for drive and steering syste (see page 12 )
• thread-locking co pound
• suitable drive chain (see page 12 )
• suitable cable and electrical connectors for the drive otor and clutch (see page 16 )
Note: Make sure you have obtained these additional parts before you start installation.
Other information (applies to Types 1 and 2)
protected for use in engine co part ents
CE approvals - confor s to:
89/336/EC (EMC), EN60945:1997
94/25/EC (RCD), EN28846:1993
Table 1-1: Drive specifications (Continued)
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Installation steps
Follow these steps to install your rotary drive unit:



1. EMC installation guidelines
All Ray arine equip ent and accessories are designed to the best industry standards for use
in the recreational arine environ ent.
Their design and anufacture confor s to the appropriate Electro agnetic Co patibility
(EMC) standards, but correct installation is required to ensure that perfor ance is not
co pro ised. Although every effort has been taken to ensure that they will perfor under all
conditions, it is i portant to understand what factors could affect the operation of the
product.
The guidelines given here describe the conditions for opti u EMC perfor ance, but it is
recognized that it ay not be possible to eet all of these conditions in all situations. To
ensure the best possible conditions for EMC perfor ance within the constraints i posed by
any location, always ensure the axi u separation possible between different ite s of
electrical equip ent.
For optimum EMC perfor ance, it is reco ended that wherever possible:
• Ray arine equip ent and cables connected to it are:
WARNING
Electrical safety
Make sure you have switched OFF the power supply before you start
installing this product.
1
Consult the EMC installation guidelines. page 9
2
Mount the drive. page 11
3
Connect to the course co puter. page 16
4
Co plete the post-installation check. page 18
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• At least 3 ft (1 ) fro any equip ent trans itting or cables carrying radio signals
e.g. VHF radios, cables and antennas. In the case of SSB radios, the distance should be
increased to 7 ft (2 ).
• More than 7 ft (2 ) fro the path of a radar bea . A radar bea can nor ally be
assu ed to spread 20 degrees above and below the radiating ele ent.
• The equip ent is supplied fro a separate battery fro that used for engine start. Volt-
age drops below 10 V, and starter otor transients, can cause the equip ent to reset. This
will not da age the equip ent, but ay cause the loss of so e infor ation and ay
change the operating ode.
• Ray arine specified cables are used. Cutting and rejoining these cables can co pro ise
EMC perfor ance and ust be avoided unless doing so is detailed in the installation
anual.
• If a suppression ferrite is attached to a cable, this ferrite should not be re oved. If the fer-
rite needs to be re oved during installation it ust be reasse bled in the sa e position.
Suppression ferrites
The following illustration shows typical cable suppression ferrites used with Ray arine
equip ent. Always use the ferrites supplied by Ray arine. This product has ferrites ounted
internally.
Figure 2: Typical suppression ferrites
Connections to other equipment
If your Ray arine equip ent is to be connected to other equip ent using a cable not
supplied by Ray arine, a suppression ferrite MUST always be attached to the cable near to
the Ray arine unit.
D3548-2
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2. Mounting the drive
Mounting the drive involves four ain steps:
• securing the drive to the boat
• connecting the drive to the steering syste
• ensuring correct sprocket align ent and chain tension
• co pleting a steering check
Securing the drive
Mounting location
Before you secure the drive to your boat, you ust first check the suitability of the ounting
location.
•Structural strength:
• This drive produces a considerable a ount of force, so you ust ount it on a solid
structure (i.e. a substantial fra e e ber) in the boat. In so e cases you ay need to
build a special fra e to ount the drive unit.
• To prevent excess noise and vibration, do not attach this drive to any structures that
support cabins.
•Drive orientation:
• The drive can be ounted on a vertical or horizontal surface.
• If necessary, you can rotate the ounting foot through 90 degrees to provide a ore
convenient ounting position (as shown in Figure 6 ). To do this: re ove the four
screws securing the ounting foot to the drive unit, rotate the ounting foot, then
replace the screws.
• Additionally, the drive ay face either way as you can correct the steering direction by
reversing the polarity of the otor connections at the course co puter (see Figure 2 ).
•General position:
• Refer to the EMC installation guidelines ( page 9 )
• Make sure the drive will be accessible for future servicing.
CAUTION
Mounting location
Consult the Boat Manufacturer if you have any doubt about the strength or
suitability of the mounting location.
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12
• Environment:
• This drive is not waterproof, so you should ount it in a dry location, clear of any bilge
water.
Mounting bolts
Attach the ounting foot with two stainless steel M12 (
1
/
2
inch) bolts and lock nuts/lock
washers.
Note: Before finally tightening the bolts you ust check sprocket align ent (see page 14) and chain
tension (see page 15).
Note: Always ount the drive as securely as possible to ake sure it perfor s reliably and the chain
re ains correctly aligned.
Connecting to the steering system
The rotary drive is connected to the steering syste by a chain drive between a sprocket on
the drive and a sprocket on the boat’s steering shaft.
Note: Most steering gear anufacturers supply special autopilot drive attach ents, and any include
this as standard. Contact your steering gear anufacturer for ore infor ation.
When you have checked with the steering gear anufacturer about how and where you can
attach the autopilot chain to the boat’s steering syste , you need to:
• deter ine the sprocket and chain sizes
• attach and align the sprockets and chain
• tension the chain correctly
Determining the sprocket and chain sizes
Chain size
Reco ended chain size: standard
3
/
8
inch pitch.
Sprocket sizes
To deter ine the sprocket sizes required at the steering shaft and rotary drive:
• count the nu ber of ti es the steering shaft turns when you ove the rudder fro har-
dover to hardover
• use Figure 3 to deter ine the sprocket sizes required at the steering gear shaft (steering
sprocket) and at the rotary drive (drive sprocket) by:
• reading up fro the nu ber of steering shaft turns (on the horizontal axis) until you
reach the line for Type 1 or Type 2 drive (as appropriate)
• reading across (to the vertical axis) to identify the appropriate steering and drive
sprocket sizes fro the table on the left
• for exa ple, if the steering shaft turns twice when the rudder oves fro hardover to
hardover you will need (as indicated by the dotted lines on Figure 3 ):
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13
• a 13 tooth drive sprocket and 38 tooth steering sprocket if you have a Type 1 rotary
drive
• a 15 tooth drive sprocket and 57 tooth steering sprocket if you have a Type 2 rotary
drive
Figure 3: Rotary drive sprocket sizes
Note: The sprocket sizes in Figure 3 provide good steering perfor ance for ost boats. If you think
your boat ay have unusual steering characteristics, contact Ray arine’s Technical Services Call Center
or an Authorized Service Representative for advice.
Obtaining the steering sprocket
Obtain the appropriate sized steering sprocket fro the steering syste anufacturer.
Obtaining the drive sprocket
Your Ray arine dealer can supply the following drive sprockets (suitable for a
3
/
8
inch pitch
chain):
• 13 tooth: part nu ber M81182
• 15 tooth: part nu ber M81183
• 17 tooth: part nu ber M81184
• 19 tooth: part nu ber M81185
• 25 tooth: part nu ber M81186
17
19
25
15
13
17
15
13
17
15
13
15
13
Steering sprocket Drive sprocket
76
76
57
57
57
38
38
38
25
25
25
25
25
12 3 4 5 6
1
2
3
4
5
6
7
Number of steering shaft turns (hardover to hardover)
Chain reduction ratio
Rotary drive - sprocket sizes
Type 1
Type 2
D5083-1
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14
Figure 4: Sprocket bore and keyway di ensions
Attaching drive and steering sprockets
Note: Each sprocket ust be keyed and then screwed to the shaft with a grub screw secured with
thread-locking co pound.
Checking sprocket alignment and chain tension
Aligning drive and steering sprockets
Both sprockets ust be accurately aligned to run in the sa e plane when viewed fro the
side. Check for correct align ent by holding a straight edge between the edge of the
sprockets (see Figure 5 ).
CAUTION
Drive sprocket
To stop the drive sprocket rotating on the drive shaft, the shaft has a
1
/
8
inch square projection (a woodruff key) that fits into a notch (or keyway)
at the centre of the sprocket. If you use a non-Raymarine drive sprocket,
its bore and keyway dimensions must fall within the ranges specified in
Figure 4 for it to lock correctly to the drive shaft.
9.46 mm – 9.61 mm
(0.3725 in – 0.3785 in)
3.22 mm – 3.24 mm
(0.127 in – 0.1275 in)
15.89 mm – 15.9 mm
(0.6256 in – 0.6275 in)
19 mm
(0.75 in) 12.7 mm
(0.5 in)
grub screw
D5084-1
bore
keyway
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Figure 5: Sprocket align ent
Adjusting the chain tension
Adjust the chain tension until it is just tight, so there is ini al lost otion between the drive
sprocket and the rudder stock.
Note: If the chain tension is not set correctly, the resulting lost otion will i pair steering perfor ance.
To adjust chain tension:
• Drives ounted horizontally: place as any of the supplied shi s as necessary under the
ounting foot (see Figure 6 ).
• Drives ounted vertically: use the slots in the ounting foot to ove the drive up or down
(see Figure 6 ).
D5085-1
Side view End view
Steering sprocket
Drive
sprocket
Steering sprocket
Drive
sprocket
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Figure 6: Adjusting chain tension
Steering check
When you have tensioned the chain correctly, turn the steering wheel fro hardover to
hardover to check that the chain and sprockets ove freely and are correctly aligned.
3. Connecting to the course computer
The rotary drive has electrical connections for:
• drive otor: two single-core cables: red and black
WARNING
Moving parts
Keep clear of moving steering systems at all times. rotect moving parts
from access during normal use.
WARNING
Electrical safety
Make sure you have switched OFF the power supply before you start
installing this product.
D5086-1
81174_4.book Page 16 Tuesday, October 29, 2013 11:42 AM

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• clutch: a two-core cable with red (+) and blue (-) cores
Follow these steps to connect the rotary drive to the course co puter:
1. Measure the total distance of cable run fro the drive unit to the course co puter:
• use Table 1-1 to identify the appropriate otor cable size
• use at least 1.5
2
(16 AWG) copper cable for the clutch
2. Join these cables to the drive cables using appropriate electrical connectors or junction
boxes at the correct power rating.
3. Route the cables back to the course co puter, taking into account the EMC installation
guidelines (see page 9 ).
4. Connect the cables to the course co puter (see Figure 2 ):
• CLUTCH ter inals: red core to +ve, blue core to -ve.
• MOTOR ter inals: at this stage you can connect either otor cable to either ter i-
nal. You will check these connections after installing the rest of the autopilot syste .
Table 1-1: Reco ended cable sizes
Cable length
(drive to course co puter)
Cable gauge
(AWG)
Copper area
(
2
)
Type 1 drive
up to 3 (10ft)
up to 5 (16ft)
up to 7 (23ft)
up to 10 (32ft)
up to 16 (52ft)
14
12
10
8
6
2.5
4
6
10
16
Type 2 drive 12V
up to 5 (16ft)
up to 7 (23ft)
up to 16 (52ft)
10
8
6
6
10
16
Type 2 drive 24V
up to 3 (10ft)
up to 5 (16ft)
up to 10 (32ft)
up to 16 (52ft)
12
10
8
6
4
6
10
16
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Figure 2: Course co puter connections
4. ost installation checks
Check the following points after installing the drive:
1. Is the drive secured to a substantial structure on the boat?
2. Have you used suitable steering and drive sprockets for the boat?
3. Are the drive and steering sprockets in line when viewed side-on?
4. Have you securely locked both sprockets to the shafts?
5. Have you tensioned the chain correctly?
6. Are the otor and clutch cables correctly routed and securely connected to the course
co puter?
7. Co plete a hand-steering check: Do the chain and sprockets ove freely and in correct
align ent fro hardover to hardover?
Note: When you have installed the entire autopilot syste , you will need to co plete an autopilot
steering check. Refer to the control unit handbook for ore details.
Maintenance
On a regular basis:
• check all connections and ountings are secure
• check chain and sprockets are correctly aligned and tensioned
• lightly grease sprockets and chain
• check cables for signs of wear or da age
Note: If this drive is used heavily, we reco end that it is serviced every two years by a Ray arine Au-
thorized Service Representative.
+– +– 12
+– AB–

+
–
–
D5080-1
lk CLUTCH MOTORPOWER
Type 100/300 course computer
MOTORPOWER
OFF
SWITCH SOLENOID CLUTCH
Type 150/400 course computer
81174_4.book Page 18 Tuesday, October 29, 2013 11:42 AM

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EMC servicing and safety guidelines
• Ray arine equip ent should be serviced only by authorized Ray arine service techni-
cians. They will ensure that service procedures/replace ent parts used will not affect per-
for ance. There are no user serviceable parts in any Ray arine product.
• So e products generate high voltages, so never handle cables or connectors when power
is being supplied to the equip ent.
• When powered up, all electrical equip ent produces electro agnetic fields. These can
cause adjacent pieces of electrical equip ent to interact with one another, with a conse-
quent adverse effect on operation. In order to ini ize these effects and enable you to
get the best possible perfor ance fro your Ray arine equip ent, guidelines are given
in the installation instructions, to enable you to ensure ini u interaction between dif-
ferent ite s of equip ent, i.e. ensure opti u Electro agnetic Co patibility (EMC).
• Always report EMC-related proble s to your nearest Ray arine dealer. We use such
infor ation to i prove our quality standards.
• In so e installations, it ay not be possible to prevent the equip ent fro being affected
by external influences. In general this will not da age the equip ent but it can lead to
spurious resetting action, or o entarily ay result in faulty operation.
roduct support
Ray arine products are supported by a worldwide network of distributors and Authorized
Service Representatives. If you encounter any difficulties with this product, please contact
either your national distributor, or your service representative, or the Ra marine Technical
Services Call Center.
81174_4.book Page 19 Tuesday, October 29, 2013 11:42 AM

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www.raymarine.com