Raymarine Rotary Drive User manual

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Any reference to Raytheon or
RTN in this manual should be
interpreted as Raymarine.
The names Raytheon and RTN
are owned by the
Raytheon Company.

Rotary Drive
Installation Guide
Drives covered:
M81135 Type 1 Rotary Drive 12 V
M81136 Type 2 Rotary Drive 12 V
M81137 Type 2 Rotary Drive 24 V
Document number: 81174-3
March 2001

2 Rotary Drive - Installation Guide
Important information
Safety notices
WARNING: Product installation
Thisequipmentmustbeinstalledandoperatedinaccordance
withtheinstructionscontainedinthishandbook.Failuretodoso
couldresultinpoorproductperformance,personalinjuryand/
ordamagetoyourboat.
Because correctperformance of the boat’ssteering is critical for
safety,weSTRONGLYRECOMMENDthatanAuthorized
RaymarineServiceRepresentativefits thisproduct.
WARNING: Navigation aid
Althoughwehavedesignedthisproducttobe accurateand
reliable,many factorscan affectits performance. Asaresult,it
should onlybeusedasanaidto navigationandshouldnever
replacecommonsenseandnavigationaljudgement.Always
maintainapermanentwatchsoyou canrespondtosituationsas
theydevelop.
EMC conformance
All Raymarine equipment and accessories aredesigned tothe best
industrystandardsfor use in the recreational marine environment.
The design and manufacture of Raymarine equipment and
accessories conform totheappropriate Electromagnetic
Compatibility(EMC)standards,butcorrectinstallationisrequiredto
ensure that performance is not compromised.
Handbook information
To the bestof our knowledge, the information in this handbook was
correct when it went to press. However, Raymarine cannot accept
liabilityforanyinaccuraciesoromissionsitmaycontain.Inaddition,
ourpolicyofcontinuousproductimprovementmaychange
specifications withoutnotice. Asaresult, Raymarine cannot accept
liabilityfor any differences between the product and the handbook.
©RaymarineLtd2001.

Rotary Drive - Installation Guide 3
Introduction
Product description
Welcometothe installationguideforthe Raymarine rotarydrive.
This product is intended tooperate the boat’s steering mechanism as
part ofa Raymarine autopilot system. It is designedfor steering
systemsthatcanbedrivenfromthehelmpositionthroughachainand
sprocket(for example: cable androdsteering systems).
The outstanding design of the Raymarine rotary driveunit provides
smooth,powerfulautopilot-controlledsteeringwith quietoperation.
The mainparts ofthe drive are:
• a rugged electric motor, that drives a precision epicyclic gearbox
viaa high tensiledrive belt
• anelectromagneticclutch thattransmitshigh torque loads
without slipping
Figure 1: Main parts of the rotary drive
Contents
Thisguidecontains:
1Product specifications page 4
2Installation instructions page 5
3Maintenance information page 15
D5082-1
Clutch cable
Motor cables
Mounting foot
Drive shaft
Motor, gearbox
and clutch assembly

4 Rotary Drive - Installation Guide
Specifications
Drive dimensions
Figure 2: Drive dimensions
Drive specifications
Table 1: Drive specifications
Performance
(at nominal voltage)
Type 1 (T1)
M81135 (12 V)
Type 2 (T2)
M81136 (12 V)
M81137 (24 V)
Maximum boat
displacement
10,000 kg
(22,000 lb)
20,000 kg
(44,000 lb)
Peak output torque 20 Nm
(180 lb.in)
34 Nm
(300 lb.in)
Maximum shaft speed 33 rpm 33 rpm
Recommended hardover
to hardover time (no load)
10 sec 10 sec
Power consumption
(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

Rotary Drive - Installation Guide 5
Installation instructions
Parts required
To install thisdrive you will need:
•Partssupplied:
•rotarydrive
•mountingfoot
•spacing shims (x3)
•Additional parts:
•suitable securing bolts andlock washers/lock nuts (see
page 9)
•suitable sprockets and grubscrews for drive andsteering
system(see page 9)
•thread-lockingcompound
•suitable drive chain (see page 9)
•suitable cable and electrical connectors for the drive motor
andclutch (seepage 13)
Note:Makesureyouhaveobtainedtheseadditionalpartsbeforeyou
startinstallation.
Other information (applies to Types 1 and 2)
protected for use in engine compartments
CE approvals - conforms to:
89/336/EC (EMC), EN60945:1997
94/25/EC (RCD), EN28846:1993
Table 1: Drive specifications (contd)

6 Rotary Drive - Installation Guide
Installation steps
WARNING: Electrical safety
Make sure you have switched off thepower supply before you
start installingthis product.
Followthesestepsto installyourrotarydriveunit:
Ï
Ï
Ï
1. EMC installation guidelines
All Raymarine equipment and accessories aredesigned tothe best
industrystandardsfor use in the recreational marine environment.
Theirdesignandmanufacture conformstothe appropriate
Electromagnetic Compatibility(EMC) standards,butcorrect
installation is required to ensure that performance is not
compromised.Although every effort hasbeen taken to ensure that
they willperform under all conditions, it isimportant to understand
whatfactorscould affectthe operationoftheproduct.
TheguidelinesgivenheredescribetheconditionsforoptimumEMC
performance, butit is recognized that it may not be possible to meet
all of these conditions in all situations. To ensure the bestpossible
conditionsfor EMC performance withinthe constraintsimposedby
any location, always ensure the maximum separation possible
between different items of electrical equipment.
For optimumEMC performance, itis recommendedthat wherever
possible:
•Raymarine equipment and cables connected toit are:
1Consult the EMC installation guidelines. page 6
2Mount the drive. page 8
3Connect to the course computer. page 13
4Complete the post-installation check. page 15

Rotary Drive - Installation Guide 7
•Atleast3 ft(1 m)from anyequipmenttransmittingorcables
carryingradiosignalse.g. VHFradios,cablesand antennas.
In the case ofSSB radios, the distance should beincreased to
7ft(2m).
•More than7 ft(2 m)fromthepath ofa radarbeam. A radar
beam can normally be assumed to spread 20 degrees above
andbelow the radiatingelement.
•Theequipmentissuppliedfrom a separatebattery from that used
forenginestart. Voltagedropsbelow10 V,andstartermotor
transients,cancausetheequipment toreset.Thiswill notdamage
theequipment,butmay cause thelossof some informationand
maychangethe operatingmode.
•Raymarine specified cablesare used. Cutting andrejoining these
cables can compromiseEMC performance andmustbe avoided
unless doing so is detailed in the installation manual.
•Ifasuppressionferriteisattachedtoacable,thisferriteshouldnot
beremoved.Iftheferriteneeds tobe removed during installation
it must be reassembled in the same position.
Suppression ferrites
The following illustration shows typicalcablesuppression ferrites
usedwithRaymarineequipment.Alwaysusethe ferritessuppliedby
Raymarine.Thisproducthasferritesmountedinternally.
Figure 3: Typical suppression ferrites
Connections to other equipment
If your Raymarine equipment is to be connected to other equipment
usingacablenotsuppliedbyRaymarine,asuppressionferriteMUST
always be attached to the cable near tothe Raymarine unit.
D3548-2

8 Rotary Drive - Installation Guide
2. Mounting the drive
Mountingthedriveinvolvesfourmainsteps:
•securingthe driveto the boat
•connectingthe drive to thesteering system
•ensuring correctsprocket alignment and chain tension
•completing a steering check
Securing the drive
Mounting location
Before you secure the drive to your boat, you must first check the
suitability of the mounting location.
CAUTION:
Consulttheboatmanufacturerifyouhaveanydoubtaboutthe
strengthorsuitabilityofthemountinglocation.
•Structuralstrength:
•This drive produces a considerable amount of force, soyou
must mount it on a solid structure (i.e. a substantial frame
member) in the boat.In some cases you mayneed to build a
special frame to mount the drive unit.
•Topreventexcessnoiseandvibration,donot attach this drive
to any structuresthat supportcabins.
•Drive orientation:
•The drive canbe mounted on a vertical or horizontal surface.
•If necessary, you can rotate the mounting foot through 90
degreesto providea more convenientmountingposition(as
shownin Figure 7). To dothis: remove the four screws
securing the mountingfootto the drive unit, rotate the
mounting foot, then replacethe screws.
•Additionally,thedrivemayfaceeitherwayasyoucancorrect
thesteeringdirectionby reversingthe polarity of themotor
connections at the course computer (see Figure 8).
•Generalposition:
•Referto the EMCinstallationguidelines(page 6)
•Make sure the drive will be accessible for future servicing.

Rotary Drive - Installation Guide 9
•Environment:
•This drive is not waterproof, so youshould mount it in adry
location,clearofany bilge water.
Mounting bolts
Attachthemountingfoot withtwostainlesssteelM12(1/2 inch) bolts
andlocknuts/lockwashers.
Note:Before finally tighteningthe boltsyou must check sprocket
alignment(see page 12)andchaintension(seepage 12).
Note:Always mountthe drive assecurelyaspossible to make sure it
performs reliably and the chain remainscorrectly aligned.
Connecting to the steering system
The rotary drive isconnected to the steering system by achain drive
betweena sprocketonthe drive and a sprocketon theboat’ssteering
shaft.
Note:Most steeringgear manufacturers supply specialautopilot
drive attachments, andmany includethis asstandard. Contact your
steering gear manufacturerformore information.
When you have checked with the steering gear manufacturer about
how andwhere youcan attach theautopilot chainto the boat’s
steeringsystem,youneed to:
•determine the sprocketand chainsizes
•attach andalign the sprockets and chain
•tensionthe chain correctly
Determining the sprocket and chain sizes
Chain size
Recommended chainsize: standard3/8 inch pitch.
Sprocket sizes
To determine the sprocket sizes required at the steering shaft and
rotary drive:
•countthenumberoftimesthesteeringshaftturnswhenyoumove
therudderfrom hardover tohardover

10 Rotary Drive - Installation Guide
•use Figure 4to determine the sprocket sizes required atthe
steering gear shaft (steering sprocket) and at the rotary drive
(drivesprocket)by:
•reading upfromthenumber ofsteeringshaftturns(onthe
horizontalaxis)until you reach the line for Type 1 or Type 2
drive(as appropriate)
•readingacross(totheverticalaxis)toidentifytheappropriate
steering and drive sprocket sizes from the table on the left
•for example, if the steering shaft turns twice when the rudder
moves from hardover to hardover you willneed (as indicated by
the dotted lines on Figure 4):
•a13toothdrivesprocketand38toothsteeringsprocketifyou
havea Type1 rotary drive
•a15toothdrivesprocketand57toothsteeringsprocketifyou
havea Type2 rotary drive
Figure 4: Rotary drive sprocket sizes
Note:The sprocket sizes in Figure 4 provide good steering
performanceformostboats.Ifyouthinkyourboatmayhaveunusual
steeringcharacteristics,contactRaymarine’sTechnicalServices
Call Centeror an Authorized Service Representative for advice.
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
123456
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

Rotary Drive - Installation Guide 11
Obtaining the steering sprocket
Obtain the appropriate sized steeringsprocketfrom the steering
systemmanufacturer.
Obtainingthedrivesprocket
Your Raymarinedealer can supply the following drivesprockets
(suitablefora 3/8inchpitch chain):
•13 tooth: part number M81182
•15 tooth: part number M81183
•17 tooth: part number M81184
•19 tooth: part number M81185
•25 tooth: part number M81186
CAUTION:
Tostopthe drivesprocketrotatingonthedriveshaft,theshaft
hasa 1/8inch square projection (a woodruff key) thatfitsintoa
notch(orkeyway)atthe centreofthesprocket.Ifyouuseanon-
Raymarinedrivesprocket,itsboreandkeywaydimensionsmust
fallwithin therangesspecified in Figure 5forit tolock correctly
tothedriveshaft.
Figure 5: Sprocket bore and keyway dimensions
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

12 Rotary Drive - Installation Guide
Attaching drive and steering sprockets
Note:Eachsprocketmustbekeyedandthenscrewedtotheshaftwith
agrubscrewsecuredwiththread-locking compound.
Checking sprocket alignment and chain tension
Aligning drive and steering sprockets
Both sprockets must be accurately aligned to run in thesame plane
whenviewedfromtheside.Checkforcorrectalignmentbyholdinga
straight edge between the edge ofthe sprockets (see Figure 6).
Figure 6: Sprocket alignment
Adjusting the chain tension
Adjustthechaintensionuntilitisjusttight,sothereisminimallost
motionbetweenthe drive sprocketandthe rudder stock.
Note:Ifthechaintensionisnotsetcorrectly,theresultinglostmotion
will impair steering performance.
To adjust chain tension:
•Drives mountedhorizontally: place asmany of the supplied
shims as necessary under the mounting foot (see Figure 7).
•Drives mounted vertically:use the slots inthe mounting foot to
movethe drive upordown (see Figure 7).
D5085-1
Side view End view
Steering sprocket
Drive
sprocket
Steering sprocket
Drive
sprocket

Rotary Drive - Installation Guide 13
Figure 7: Adjusting chain tension
Steering check
Whenyouhavetensioned thechaincorrectly,turnthesteeringwheel
fromhardovertohardovertocheckthatthechainandsprocketsmove
freelyand arecorrectly aligned.
WARNING:
Keepclear ofmovingsteering systems atall times.Protect
movingpartsfromaccessduringnormaluse.
3. Connecting to the course computer
WARNING: Electrical safety
Makesurethepowersupplyisswitchedoffbeforeyoumakeany
electricalconnections.
The rotary drivehas electrical connectionsfor:
•drive motor: twosingle-core cables: red and black
•clutch: a two-core cable with red (+) and blue (-) cores
D5086-1

14 Rotary Drive - Installation Guide
Followthesesteps toconnectthe rotary drive tothe coursecomputer:
1. Measure the totaldistance ofcable runfrom thedrive unitto the
coursecomputer:
•use Table 2 to identify theappropriatemotor cable size
•use atleast1.5mm2(16AWG)coppercablefor the clutch
2. Join these cables to the drive cables using appropriate electrical
connectorsor junctionboxes at the correct power rating.
3. Routethecablesbacktothecoursecomputer,takingintoaccount
theEMC installationguidelines(seepage 6).
4. Connect the cables tothe coursecomputer (see Figure 8):
•CLUTCH terminals:redcore to+ve, blue core to -ve.
•MOTOR terminals:at this stage youcanconnect eithermotor
cable to either terminal. You will checkthese connections
after installing the rest of the autopilot system.
Table 2: Recommended cable sizes
Cable length
(drive to course computer)
Cable gauge
(AWG)
Copper area
(mm2)
Type 1 drive
up to 3m (10ft)
up to 5m (16ft)
up to 7m (23ft)
up to 10m (32ft)
up to 16m (52ft)
14
12
10
8
6
2.5
4
6
10
16
Type 2 drive 12V
up to 5m (16ft)
up to 7m (23ft)
up to 16m (52ft)
10
8
6
6
10
16
Type 2 drive 24V
up to 3m (10ft)
up to 5m (16ft)
up to 10m (32ft)
up to 16m (52ft)
12
10
8
6
4
6
10
16

Rotary Drive - Installation Guide 15
Figure 8: Course computer connections
4. Post installation checks
Check the following points after installing the drive:
1. Is the drive secured to a substantial structure on the boat?
2. Haveyouusedsuitablesteeringanddrivesprocketsfor the boat?
3. Arethe driveandsteeringsprocketsin linewhenviewedside-on?
4. Have yousecurelylockedbothsprocketstothe shafts?
5. Have youtensioned the chain correctly?
6. Are the motor andclutch cables correctly routed and securely
connected to thecourse computer?
7. Completeahand-steering check: Do the chain andsprockets
move freely andin correct alignment from hardover to hardover?
Note:When you have installed the entire autopilot system, you will
needtocompleteanautopilotsteeringcheck.Refertothecontrolunit
handbook formore details.
Maintenance
On a regular basis:
•checkall connectionsandmountingsaresecure
•check chain and sprockets are correctly aligned and tensioned
•lightlygrease sprockets and chain
•check cables forsigns ofwear ordamage
Note:If this drive is used heavily, we recommend thatit is serviced
every two years by a Raymarine Authorized Service Representative.
+–+–12
+– AB–+
–
–
D5080-1
lk CLUTCH MOTORPOWER
Type 100/300 course computer
MOTORPOWER
OFF
SWITCH SOLENOID CLUTCH
Type 150/400 course computer

16 Rotary Drive - Installation Guide
Raymarine Ltd
Anchorage Park
Portsmouth, Hampshire
England PO3 5TD
Telephone [phone]
Fax [phone]
www.raymarine.com
Raymarine Inc
22 Cotton Road, Suite 280
Nashua
NH 03063-4219, USA
Telephone [phone]
Fax [phone]
www.raymarine.com
Raymarine Technical Services Call Center
UK: [phone] or
[phone] ext. 1083
USA: [phone] or
1-800-539-5539 ext. 2333
EMC servicing and safety guidelines
•Raymarineequipmentshouldbeservicedonly byauthorized
Raymarine service technicians. They will ensure that service
procedures/replacement parts used will not affect performance.
There are no user serviceable parts in any Raymarineproduct.
•Someproductsgeneratehighvoltages,so never handlecablesor
connectors when poweris being supplied to the equipment.
•When powered up,all electrical equipment produces
electromagnetic fields. Thesecan cause adjacent piecesof
electrical equipment to interact with one another, with a
consequent adverse effect on operation. In order to minimize
these effects and enable youto get thebest possible performance
fromyour Raymarine equipment, guidelines aregiven in the
installationinstructions, to enable you to ensure minimum
interaction between different items ofequipment, i.e. ensure
optimum Electromagnetic Compatibility (EMC).
•AlwaysreportEMC-relatedproblemstoyournearestRaymarine
dealer.Weusesuchinformationtoimproveourqualitystandards.
•In someinstallations, it maynotbe possible to prevent the
equipmentfrombeingaffected by external influences. In general
this will not damage the equipment but it can lead to spurious
resetting action, ormomentarily may result in faulty operation.
Product support
Raymarine products are supported by a worldwide networkof
distributorsand AuthorizedService Representatives.Ifyou
encounter anydifficulties with this product, please contacteither
yournationaldistributor, or your service representative, orthe
RaymarineTechnicalServices Call Center.